Presentation - COBRAS 2015

1. Heat recovery – efficiency at any price?
Sebastian Brechtel
Product & Strategy Manager

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Agenda
• Efficiency – General terms
• Automotive fuel consumption – „Clean diesel“
• Thermal efficiency in acid plants
• Financial efficiency - ROI
• Facing real life
• Take care of your cash cows
• HEROS heat recovery system design
• Getting digital support
10/26/20152

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Efficiency – General terms
10/26/20153
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Removal or conversion efficiency
Operational efficiency
Energy efficiency

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Efficiency – Automotive fuel consumption
10/26/20154
Standard
operation

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10/26/20155
Standard
operation
Efficiency – Automotive fuel consumption

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10/26/20156
loss
Best
operation
Standard
operation
Efficiency – Automotive fuel consumption

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10/26/20157
loss
Standard
operation
Best
operation
Efficiency – Automotive fuel consumption

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10/26/20158
loss
Standard
operation
Best
operation
Too small particle filter
Efficiency – Automotive fuel consumption

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Thermal efficiency – Waste heat recovery in
sulfuric acid plants (sulfur burner)
10/26/20159
Sulphur
Melting
1%
34%
10%
Intermediate
Heat Exchanger
Evaporator
Economizer
Final Absorber
Acid Coolers
Tail Gas
3%
11%3%
Sulphur
98%
Electric
Energy
2%
Blower
Drying
Tower
Air
Acid Coolers
6%
23% 9%
1%
Steam
57.5%
Acid Cooling
39%
Intermediate
Absorber
Waste Heat
Boiler
Converter
Tray No.1
Converter
Tray No.2
Converter
Tray No.3
Converter
Tray No.4
Sulphur
Combustion
Furnace
Production
Acid
0.5%
Steam
Superheater

10. © Outotec – All rights reserved
Thermal efficiency – Waste heat recovery in
sulfuric acid plants (sulfur burner)
10/26/201510
Sulphur
Melting
1%
34%
10%
Intermediate
Heat Exchanger
Evaporator
Economizer
Final Absorber
Acid Coolers
Tail Gas
3%
11%3%
Sulphur
98%
Electric
Energy
2%
Blower
Drying
Tower
Air
Acid Coolers
6%
23% 9%
1%
Steam
57.5%
Acid Cooling
39%
Intermediate
Absorber
Waste Heat
Boiler
Converter
Tray No.1
Converter
Tray No.2
Converter
Tray No.3
Converter
Tray No.4
Sulphur
Combustion
Furnace
Production
Acid
0.5%
Steam
Superheater

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10/26/201511
Financial efficiency – Return on Investment
(ROI)

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10/26/201512
?
Financial efficiency – Return on Investment
(ROI)

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Financial efficiency – Return on Investment
(ROI)
10/26/201513
Design basis for a financial efficiency calculation
Plant capacity 4500 mtpd H2SO4 (as 100wt%)
Plant location Europe
Plant type Sulphur burning, 3+1
Utility concept
“Over the fence” – purchase of electricity, cooling water,
demin water and LP steam. Sale of HP and LP steam.
Financial concept
Plant cost fully financed by a commercial loan: interest
rate 6%, depreciation based on a 20 year period.

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ROI – HEROS heat recovery system
10/26/201514
0
0.2
0.4
0.6
0.8
1
1.2
1.4
0 1 2 3 4
CumualativeROI
Operational years
HEROS
$$

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ROI - SAP and HEROS™
10/26/201515
0
0.2
0.4
0.6
0.8
1
1.2
1.4
0 2 4 6 8 10 12 14
CumualativeROI
Operational years
SAP
HEROS
$$
$$

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Facing real live – Failure scenarios
10/26/201516
Heat recovery (HR) failure scenarios
Short term failure Long term failure
Failure mode Acid pump failure Boiler leakage with
weak acid scenario
HR shutdown duration 3 days 3 months
Additional cost
[% of initial investment]
3% 20%
$$
$$

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Interdependency of Acid plant & Heat
recovery system
10/26/201517
loss loss
One
way option
Two
way option

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10/26/201518
lossloss
Plant down time
& production
loss
Fall back to
standard
operation
One
way option
Two
way option
Interdependency of Acid plant & Heat
recovery system
Shut down of heat
recovery system

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ROI - Heat recovery system (failure)
10/26/201519
0
0.2
0.4
0.6
0.8
1
1.2
1.4
0 1 2 3 4
CumualativeROI
Operational years
HR short
term failure
HR long
term failure
$$

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ROI - Heat recovery system (failure)
10/26/201520
0
0.2
0.4
0.6
0.8
1
1.2
1.4
0 1 2 3 4
CumualativeROI
Operational years
HR short
term failure
HR long
term failure
$$
??

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ROI - Sulphuric acid plant (failure)
10/26/201521
0
0.2
0.4
0.6
0.8
1
1.2
1.4
0 2 4 6 8 10 12 14
CumualativeROI
Operational years
HR short
term failure
HR long
term failure
$$

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ROI - Sulphuric acid plant (failure)
10/26/201522
0
0.2
0.4
0.6
0.8
1
1.2
1.4
0 2 4 6 8 10 12 14
CumualativeROI
Operational years
HR short
term failure
HR long
term failure
?

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HEROS design aspect: Plant Availability
10/26/201523
Advantage
Acid and HP steam production guaranteed
even if HEROS ís not in operation.
Features
Separation of hot
acid circuit from
system possible
IAT design for 100 %
capacity
Target
Failure of hot circuit must not lead to plant
shutdown

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HEROS design aspect: Safety precaution 1
10/26/201524
Advantage
Wide operational window & minimized
corrosion under off-set conditions
Feature
Material selection: stainless steel & acid
resistant bricklining (indicated in red)
Target
Limit hazard potential

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HEROS design aspect: Safety precaution 2
10/26/201525
Advantage
Minimized corrosion in case of
heat exchanger failure and emergency stop
Features
Heat exchanger
outside of acid tank
Fast isolation of acid
and water circuit
Target
Limit hazard potential

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Getting digital support
• The PORS (Plant Operability
Reliability and Safety)
system is a virtual process
expert - it is our online know-
how at plant site
• Analysis of plant operation
for potentially hazardous
situations
• Guidance and support for
plant operators
Plant Operability Reliability and Safety System
10/26/201526
PORS
Operational
Data
Process
know-how
Awareness
of key
operational
trend /
upset

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PORS system – virtual process expert
10/26/201527
Benefits
Value proposition
Improved process safety and plant availability
Features
Operator support and guidance
Process know-how delivered to site in black
box “traffic light” system
Permanent systemic process monitoring and
analysis of plant status
Risk mitigation - early detection of
developing hazards and reduction of
response time to upset conditions
Improved awareness of operators for plant
mal-operation
Improved plant availability

28. © Outotec – All rights reserved
10/26/201528
Risk mitigations for heat recovery systems
HEROS™
feature
Availability Flow Sheet Fundamental principle is that HR plant failure will not
lead to SAP plant shutdown. The hot acid circuit is
completely separated from rest of the acid plant.
Intermediate absorption tower is designed for
complete SO3 absorption at 100% plant load.
✔
Availability Material of
Construction
All vessels are acid-brick lined to minimize corrosion.
Use of Alloy 3033, which allows for wide operational
window where no brick lining is possible ✔
Safety Flow Sheet
Material of
Construction
Automation
In fail-safe mode, automatic draining of hot acid by
gravity into brick lined equipment, reducing corrosion
to minimum levels.
✔
Operability Support tools PORS system for additional high level
trending/critical process information requiring
operator action to safeguard operating plant integrity.
Operator training simulator as optional training
measure.
✔

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