Sulphuric Acid PlantConverter Replacement Projects - Chemetics - COBRAS 2015

© Copyright 2015, Chemetics Inc. All rights reserved.
Sulphuric Acid Plant
Converter Replacement Projects

© Copyright 2015, Chemetics Inc. All rights reserved.26/10/2015 Slide 2
Grigory Lwow
1942 – 2014
In Memory of

Presentation Outline
 Main Factors to Consider
 Technology change
 Fabrication Strategy
 3 Case Studies
 Project 1 – Canada
 Project 2 – USA
 Project 3 – Brazil
 Conclusions
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Converter Replacement Projects in General…
 Largest piece of process equipment in acid plant
 Traditional discussions when replacing a Converter
 Space constraints
 New foundation vs. existing foundation
 Technology change
 Materials of construction
 Internal heat exchangers and/or superheater
 Fabrication Strategy – modular Converter approach
 Opportunity for capacity increase
 Replace aging equipment
 Preheater evaluation
 New ducting
 Catalyst
 Shutdown time for tie-in
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Technology Change
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Bed # 1
Bed # 2
Bed # 3
Bed # 4
Carbon Steel
bricklined
Converter
Stainless Steel
Converter
Stainless Steel
Converter with
Internal Exchangers
Bed # 4
Bed # 3
Bed # 1
Bed # 2
Slide 5

Technology Change
Enthusiasts Visionaries Pragmatists Conservatives Skeptics
Diffusion of Innovation Principle
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Technology Change
Stainless Steel Converters with Internal Exhangers
Enthusiasts Visionaries Pragmatists Conservatives Skeptics
Diffusion of Innovation Principle
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Fabrication Strategy
 Converters rarely can be
shipped in 1 piece
3 options:
 On site “stick build” fabrication
(raw plate supply – 100% on
site fabrication)
 On site “knock-down”
fabrication (cut, rolled, bevelled
pieces done in shop and
supplied to field – > 75% on site
fabrication)
 Modularize fabrication (> 80%
shop fabrication & < 20% on
site fabrication)
26/10/2015 Slide 8

Recent Case Studies
 2011 – Project 1 – Canada
 2013 – Project 2 – USA
 2014 – Project 3 – Brazil
26/10/2015 Slide 9

Project 1 – Canada
 1100 mtpd metallurgical acid plant
 Converter Diagnostic
 +25 year old carbon steel brick-lined Converter
 Equipment reaching end of service life
 Structural integrity of Converter compromised – shell thinning
 Extended plant shutdowns for major repairs
 Project
 Technology upgrade to SS Converter on new foundation
 Internal exchanger to reduce ducting costs and reduce footprint
 Replace cold and inter gas/gas heat exchangers
 Construct new Converter next to operating plant
 Tie-in during 28 day general maintenance shutdown
 Re-use old catalyst and combine with new catalyst
26/10/2015 Slide 10

Project 1 – Canada – Chemetics® Scope of Work
 EPS
 Engineering
 Complete basic and detailed engineering
 All disciplines
 Procurement
 Modular Converter supply
 13.3m diameter Converter (3+1 configuration)
 14 months (12 months fabrication w/5 months installation overlap)
 Gas/gas exchanger supply
 All materials supply
 Field Services
 Construction advisory services
 Mechanical check-out
 Commissioning advisory services
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Xstrata Nickel
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Project 2 – USA
 1800 mtpd sulphur burning acid plant
 Equipment reached end of service life
 Frequent gas leaks
 Plant shutdowns for repairs
 Project
 Internal gas exchangers to reduce ducting costs
 Construct new Converter next to operating plant
 Supply Converter in modules to reduce construction costs and overall
project schedule
 Tie-in during 19 day general maintenance shutdown
 All new catalyst
26/10/2015 Slide 29

Project 2 – USA – Chemetics® Scope of Work
 EPS
 Engineering
 Complete basic and detailed engineering
 All disciplines
 Procurement
 Modular Converter supply
 11.7m diameter Converter (3+1 configuration)
 Accelerated schedule
 14 months (12 months fabrication w/3 months installation)
 Site Services
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Project 2 – USA
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Project 2 – USA
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Project 2 – USA
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Project 2 – USA
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Project 2 – USA
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Project 2 – USA
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Project 2 – USA
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Project 2 – USA
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Project 2 – USA
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Project 2 – USA
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Project 2 – USA
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Project 2 – USA
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Project 2 – USA
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Project 2 – USA
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Project 2 – USA
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Project 2 – USA
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Project 3 – Brazil
 1400 mtpd sulphur burning acid plant
 Equipment reaching end of service life
 Frequent ducting gas leaks
 Frequent plant shutdowns for repairs
 Project
 New Internal exchanger and Superheater to reduce ducting costs
 Replace Inter and Final economizers
 Replace almost all plant ducting
 Size converter for increased plant capacity 1600 mtpd
 Construct new (knock down) Converter next to operating plant
 Tie-in during general maintenance shutdown
 Re-use old catalyst and combine with new catalyst
26/10/2015 Slide 48

Project 3 – Brazil – Chemetics® Scope of Work
 E+S
 Engineering
 Basic engineering – all disciplines
 Detailed engineering – proprietary equipment and ducting
 Field Services
 Project
 11.85m diameter Converter (3+1 configuration)
 Built on-site – some large pieces shipped to site
 12 months (7 months pre-fabrication w/5 months installation)
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Chemetics® Sulphur Burning Acid Plant Converter
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Bed # 4
Bed # 3
Bed # 1
Bed # 2

Bed # 4
Bed # 3
Bed # 1
Bed # 2
Superheater
Inter Reheat
Exchanger
SO2 from
Boiler
SO2/SO3
to IAT
SO3 to
Econ. / FAT
SO2 from Cold
Reheat Exch.
Steam
Chemetics® Sulphur Burning Acid Plant Converter
Flow Path

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Novo Conversor 3:1 (11.85 m Ø x 21.45 m H)
– Super Aquecedor Interno
– Tocador “Inter Reheat” Interno
Novo Economizador Final
Novo Inter Economizador
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Retrofit References – Last 20 years
Startup Country Beds SS
Converter
Internal Heat
Exchangers
New
Foundation
Modular
2015 Confidential 4 Yes Yes (2) Yes Yes
2014 Canada 4 Yes Yes (2) Yes Yes
2014 Brazil 4 Yes Yes (2) Yes No
2013 USA 4 Yes Yes (1) Yes Yes
2012 Canada 4 Yes Yes (1) Yes Yes
2010 UK 4 Yes No Yes No
2006 USA 4 Yes Yes (1) Yes No
2006 Canada 4 Yes No Yes No
2000 Sweden 5 Yes Yes (1) Yes No
1999 RSA 4 Yes No No No
1999 Netherlands 1 Yes Yes (1) Yes No
1995 USA 4 Yes Yes No No
26/10/2015 Slide 69

Conclusions
 Most common solutions in Converter replacement projects
 New SS converter on new foundation
 Internal exchangers for space limitations and ducting costs
 Install Converter while plant is operating and then tie-in new ducting
during a general maintenance shutdown (<30 days)
 Take advantage of overall project to replace other aging equipment
 Capacity increase is common, but only if existing equipment can
perform increased capacity – project sometimes executed in phases
 Modular Converter approach to reduce construction costs (large
crane) and increase fabrication quality becoming more common
 Emission guarantee with all new catalyst or activity tested existing
catalyst
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Thank you for your attention.
Questions?
26/10/2015 Slide 71

Copyright
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removed from any reproduction.
26/10/2015 Slide 72

Disclaimer
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are subject to risks and uncertainties that could cause actual results to differ. These statements and this
Presentation are based on current expectations, estimates and projections about global economic
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Presentation are based upon reasonable assumptions, it can give no assurance that those expectations
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26/10/2015 Slide 73

Sulphuric Acid PlantConverter Replacement Projects - Chemetics - COBRAS 2015

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