SNOX™ technology solves SO2, NOx and dust challenge for ENI

“The plant achieved an average reliability factor of 99% over ten years of operation”

WSA plant helps Sokolovská Uhelná meet emission standards

“Our WSA unit has been in operation for over 25 years and has exceeded our expectations for reliability, emission levels and sulfuric acid, which is a very good product to sell!”

TOPGUN

Operating conditions, catalyst activity and equipment like heat exchangers and the converters impact sulfuric acid plant performance.

Tip the scales - get more from your sulfuric acid catalyst expenses with VK38+

Selecting the right catalysts for a SO2 converter has always been about balancing expenses and gains. The new VK38+ helps create that balance – and more.

COST-EFFECTIVE BOOST OF PLANT PERFORMANCE WITH NEW LEAP5™ CATALYSTS FOR SO2 OXIDATION

The profitability of sulfuric acid production is closely related to the production rates achievable within SO2 emission limits. The optimal operating conditions of a plant depend strongly on the plant configuration, catalyst volumes and catalyst activities, and as SO2 emission limits are tightened, more active sulfuric acid catalysts are required to maintain the desired production rates.

New Improved dust protection catalyst

The introduction of the first dust protection catalyst, VK38 in the shape of 20 mm rings in the 1970ies, provided invaluable savings for sulphuric acid plants suffering from pressure drop build-up as a result of dust present in the feed gas. Industrial experience from more than 60 installations shows prolonged production campaigns by minimum 50-75% and thereby, a reduction of time consuming and expensive shutdowns for catalyst screening as well as significant savings in blower energy over time

VK38+: Innovating on existing catalyst solutions

Exploring a new catalytic solution for improving efficiency and energy balance in sulfuric acid plants

Understanding dynamics and emissions during sulfuric acid converter startup

Increased attention on emissions during startup of sulfuric acid plants calls for better understanding of the dynamics of the plants and the phenomena controlling the emissions of SO2 and acid mist.

Dynamic simulations Sulfuric acid

Sulfuric acid plants often encounter transient phenomena such as emission spikes during unsteady operation. Emission spikes and related phenomena can be understood and predicted by considering the sulfur content of the V2O5-based catalyst used in sulfuric acid converters.

The profitable way to sulfuric acid

Profit margins are slim in the sulfuric acid business, and plants that want to succeed need feedstock flexibility, high conversion rates, low energy consumption and high reliability. They also have to meet increasingly strict limits on SO2 emission

High activity at low temperature

VK-7XX LEAP5™ is the latest catalyst developed on the basis of the unique LEAP5™ techology. It is optimized for operation in converted strong gasses at 370-440°C/700-825oF, which is typical for the final passes of single-absorption plants

Troubleshoot, Monitor & Plan Ahead

Managing a sulfuric acid plant can be challenging on the best of days, but what happens when real trouble arises? Sudden changes in pressure drops or emissions may force a decrease in production or even a full shutdown for repairs. And even when everything is working, catalyst activity changes over time – and so should a plant’s operating conditions.

Guizhou Kailin sulfuric acid plants combat dust to eliminate unplanned downtime and improve Opex

The Guizhou Kailin Fertilizer company had two sulfuric acid plants in Guizhou, China that were experiencing similar problems. A severe pressure drop build-up over the first catalyst bed was increasing energy costs and eating away at margins. Dust was forcing the plant to shut down for unplanned screening maintenance and catalyst replacement.

Design with so2 emissions of less than 400 mg/nm3 (140 ppm) in a 3+1 layout

The commencement of the new legislation of SO2 emission from the current 960 mg/Nm3 to the new target of 400 mg/ Nm3 (140 ppm) for sulfuric acid industry has forced the industry to place much focus on finding the best technology in order to comply with the new SO emission standard. The new Line B, commissioned in March 2010, was forced to comply with the new SO2 emission standard of 400 mg/Nm3 (140 ppm) corresponding to 99.9% conversion at full load.

Design with SO2 emissions of less than 400 MG/NM3 (140 PPM) in a 3+2 layout

Weifang Ensign Industry CO., Ltd. is an enterprise which mainly takes starch-based raw materials to produce citric acid series products and alcohol series products. Weifang operates a 3+2 sulfuric acid plant based on a design capacity of 1050 MTPD

Reduce SO2 emissions - Less than 100 PPM SO2 in the stack

In 1997, VK69 was installed in the fourth pass of a large 1460 MTPD sulphuric acid plant in Asia. The plant burns elemental sulphur and the four-bed converter has intermediate absorption after the third pass.

Yanggu Xiangguang copper takes new approach to meet emissions standards of 70 PMM SO2

The Chinese government has been tightening SO2 emissions regulations for years. In many regions, the targets are now set at 70 PPM. While some plants depend on conventional catalysts and scrubbers, Xiangguang Copper in Shandong Province wanted a long-term approach. the contacted Topsoe to find a catalyst solution to help them comply with stricter emission controls,

Reduced SO2 emissions - Less than 100 PPM SO2 in the stack

Yunnan Chihong Zinc & Germanium Co., Ltd’s head office is located in Qujing City, Yunnan Province. The company mainly focuses on mining, mineral processing, import and export business and domestic trade of lead, zinc and germanium series productions. The company operates five sulfuric acid plants, all based on off-gasses from zinc/lead smelting. Two of the plants are located in Qujing, two in Huize and one in Hulunbeier. All five plants are operating with Topsoe VK catalysts.

Nuova Solmine cuts SO2 emissions by 50%, complying with emissions regulations without reducing production

Nuova Solmine, a sulfuric acid plant in Scarlino, Italy, had been operating with SO2 emissions averaging about 280 PPM. When new regulations capped emissions at 224 PPM; the plant had to make a choice: reduce production of sulfuric acid, resulting in loss of profit, or find a way to reduce emissions without cutting production.

With Topsoe's Leap5™ catalyst, Australia's Incitec Pivot increased production & reduced emissions

Incitec Pivot's sulfuric acid at Mount Isa, Australia needed more sulfuric acid than they could produce, but transport of sulfur or sulfuric acid to the company's outback location was expensive.

Industrial experience with testing of catalyst samples

A sulphuric acid plant based on off-gas from processing of metal ores faced increased SO2 emissions in the stack. The plant manager contacted Topsoe for advice and recommendations. The plant is a double absorption plant with one catalyst bed located after the intermediate absorption tower (IAT).

Topsoe helps Rio Seco eliminate unplanned shutdowns

After about 2½ years of operation, the Rio Seco sulfuric acid plant in Peru, which uses a Topsoe Wet gas Sulfuric Acid (WSA) process, was confronted with a couple of critical unplanned shutdowns caused by steam leaking into the process gas. This resulted in damage to part of the catalyst in the SO2 converter, along with big, costly delays before the unit could be brought back to operation.

New improved dust protection catalyst for sulphuric acid plants

Topsoe has developed a new improved dust protection catalyst in the size of a 25 mm daisy in the proven VK catalyst formulation.

VK69 Proven performance

Topsoe introduced the caesium-promoted VK69 catalyst in 1996. VK69 is optimised for operation in the last passes of double-absorption sulphuric acid plants. At these conditions VK69 shows a very significant activity advantage compared to regular catalysts.

Proven SO2 emissions reduction in high temperature environments

Topsoe’s VK-701 LEAP5™ is optimized for operation in converted strong gasses at 410-460°C/770-895°F, which is typical for the 3rd pass of 3+1 double-absorption plants. At these conditions, VK-701 shows significant activity advantages compared to existing potassium and cesium-promoted catalysts.

Tip the scales: get more from your sulfuric acid catalyst expenses with 38+

Selecting the right catalysts for a SO2 converter has always been about balancing expenses and gains. The new VK38+ helps create that balance – and more.

Increased acid production and reduced pressure-drop with vk38+

The installation of VK38+ has not only allowed us to burn more sulfur and increase production, but also to reduce the pressure-drop across the unit with the same level of emissions

Molymet group successfully operates five units for lean SO2 gas from molybdenum roasters

“In 2010, Chile was hit by an earthquake with a magnitude of 8.8 on the Richter scale. Upon inspection of the condenser glass tubes of Topsoe’s plant, it was verified that none of these had been damaged, and the plant were able to resume production after minor repairs.

From waste to clean energy: The acid path to reducing CO2 emissions

Case study explores environmental benefits of the WSA process to capture waste heat, enhance energy efficiency, and reduce the refinery carbon footprint

Tipping the scales with VK38+

VK38+ is a new potassium-promoted catalyst from Topsoe that has been proven to have higher activity than any other catalyst, regardless of which converter bed it is used in.