Proses Wsa 1

WSA & SNOXTM technology for the production of
sulfuric acid in power plants
Presented by Patrick Polk
January 17, 2013
Agenda
WSA process
SNOXTM process
Economics compared with limestone scrubbing
Wet gas Sulfuric Acid (WSA)

95-99.97% of the sulfur content is recovered
Sulfur is recovered as concentrated sulfuric acid of
commercial grade
No waste products
Exothermic process
Simple lay-out
First reference in 1980
Over 115 references
WSA configuration
Export steam
Cleaned gas
Steam drum
BFW
Combustion
air blower
Feed
gases
Combustor
SO2 Converter
Waste heat
boiler
Tail gas
treatment unit
1st and
2nd
Interbed
coolers
Fuel gas
for start-up
Cooling
air blower
Reaction:
H2S, H2SO4, etc + O2 SO2 + H2O
Process
gas cooler
Reaction:
SO2 + 0.5 O2 SO3
Reaction:
SO3 + H2O H2SO4 (g)
WSA
condenser
Acid
cooler
Reaction:
H2SO4 (g) H2SO4 (liq)
Sulfuric
acid
product
CW
WSA applications
Refineries
SAR, Amine off-gas, SWS off-gas, Claus tail gas
Coal Gasification
Rectisol, Selexsol acid gas treatment
Metallurgical and mineral industry

Smelter off-gas
Power Plant
Boiler flue gas
Coking, Viscose, Petrochemical, etc.
SNOX = WSA + NOx removal

SNOXTM flue gas treatment
increases thermal efficiency
and reduces CO2 emission
when using high sulfur coal
or petcoke for power generation
Boiler with SNOXTM for high sulfur coal or

petcoke
Steam BFW
Fuel gases
H2S - gas
SWS - gas
Stack
Excess air
390
Reactor
NO+NH3 N2
100
Cooling
air
0.2-0.4%
SO2
SO2 SO3
ESP
WSA
condenser
410
Boiler
210225
GGH
230-245
SO3+H2O
Combustion air
WHB
H2SO4 Vap
Td
195-210
190-200
C.W.
petcoke
RFO
3-6% S
Product acid
95% H2SO4
SNOXTM birds eye view

SO2 converter
Stack
SCR reactor
Gas/gas heat
exchanger
WSA condensers
Flue gas
blowers
Cooling air
blowers
ESPs
Hot air return
Flue gas inlet
Additional heat recovered in SNOXTM plant

Catalytic SO2 oxidation:
SO2 + O2 SO3
+ 1.34 BTU/lb S
Gas phase SO3 hydration:

SO3 + H2O H2SO4 (gas)
+ 1.31 BTU/lb S
Acid condensation:
H2SO4 (gas) 95% H2SO4 (liquid)
+ 0.80 BTU/lb S
Total reaction heat recovered by converting the SO2 in the flue gas to 95%
H2SO4 at 200C is 3.45 BTU per lb sulfur in the fuel or 0.17 BTU per lb fuel with
5% S.
Additional heat recovered by cooling the flue gas from typically 185C (365F)
with WFGD to 100C (212F) with SNOXTM is 0.57 0.70 BTU per lb fuel.
With SNOX dirtier is greener

With 5 % sulfur in coal or petcoke and SNOXTM as FGD:
Steam production is 5% higher compared to current

alternatives. This corresponds to a 5% reduction of CO2
emission at the same steam production.
Replacing limestone FGD (CaCO3 + SO2 +O2
CaSO4 + CO2) reduces CO2 emission by 2% compared
to wet limestone FGD and by 4 - 5% compared to
burning the fuel in a CFB boiler (CaCO3 CaO + CO2).
Cost of flue gas desulfurization

TOTAL COST (CAPEX + OPEX) OF
FLUE GAS DESULFURIZATION
$/kWh
Normal coal
Heavy Residue
Petcoke
Limestone
scrubber
SNOXTM
SULFUR IN FUEL
Comparison of operating costs

Basis: Petcoke
300 MW electric power
Unit: USD per year
Income:
Sales of sulfuric acid at $30/t
Costs:
Limestone at $20/t
Ammonia at $300/t
Waste disposal at $20/t
Additional petcoke consumption at $40/t
Total costs
Net operating income
Downshot
PC boiler
with SNOXTM
CFB boiler
with SCR DeNOx
and limestone FGD
3,600,000
0
600,000
0
0
600,000
7,500,000
240,000
12,000,000
400,000
20,000,000
+ 3,000,000
20,000,000
WSA/SNOXTM references (location)

January 2010
1 1
3 2
11 13
1
4
1216
6 1
4 14
2 3 5
4 7 17
4
2
2 4
5 24
26
1 14
2 15
20
18
8
25
7
10 8 9
14
9 10
12
11
19
2
6
10
6
16 17
17 8
11 12
11
3
8
5
19 15 18 6 13 16
9 13
7
15
6
27
Oil refining
Coking
Gasification
Metallurgical
Viscose
Sundry applications
1 5
2223
28
12
10
3 9
3 3
WSA/SNOXTM plants references

Contracted plants:
35 in oil refining (including 4 SNOXTM)
30 in coking industry
24 in gasification
13 in metallurgical industry
7 in viscose industry
8 in other industries (including 2 SNOXTM)
SNOXTM references
Plant
Capacity
(flue gas)
Start-up
Fuel
Nordjyllandsvrket,
Denmark
1,000,000 Nm3/h
900 MM SCFD
1991
Coal
Raffineria di Gela,
Italy
1,200,000 Nm3/h
1,075 MM SCFD
1999
Petcoke + RFO
OMV Refinery,
Austria
820,000 Nm3/h
735 MM SCFD
2007
RFO + sour gas
Petrobras RNEST,
Brazil
2 x 650,000 Nm3/h
2 x 582 MM SCFD
Expected
2014
Petcoke + sour
gas
Ohio Edison, USA

(demonstration plant)
135,000 Nm3/h
121 MM SCFD
1991-96
Coal
SNOXTM Raffineria di Gela, Italy

Raffineria di Gela, Sicily, Italy
Boilers:
Fuel:
Additional fuel:
approx. 250 MWe

+ steam and heat
90% Petroleum coke
Oil and gas
Total flue gas flow: 1,200,000 Nm3/hr

1,075 MM SCFD
H2SO4 (95%):
225 t/d
SO2 removal:
96.5%
Commissioned:
1999
Left stack
emits
1,000,000
Nm3/h
SNOXTM
treated
(invisible)
flue gas
Right stack
emits (hazy)
flue gas from
the 4th boiler
before it was
connected to
the SNOXTM
plant
SNOXTM OMV, Austria

OMV Refinery, Schwechat, Austria
Boilers:
Fuel:
180 MWe
+ 1,000 t/h steam
Visbreaker residue
Additional feed:
Total flue gas flow:
Claus tail gas

820,000 Nm3/hr
735 MM SCFD
H2SO4 (94%):
225 t/d
SO2 removal:
98%
Commissioned:
2007
Eight good reasons for SNOXTM

Excellent heat recovery
Reduced CO2 emissions

No process chemicals except NH3 for SCR
No process water consumption

No production of waste solids and liquids
Valuable sulfuric acid product

Clean, proven and reliable technology
Low operating & maintenance costs.
Thank you for your attention!

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Proses Wsa 1

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WSA & SNOXTM technology for the production of

sulfuric acid in power plants

Presented by Patrick Polk

January 17, 2013

Wet gas Sulfuric Acid (WSA)

Over 115 references

Metallurgical and mineral industry

Coking, Viscose, Petrochemical, etc.

SNOX = WSA + NOx removal

Boiler with SNOXTM for high sulfur coal or

SNOXTM birds eye view

Hot air return

Flue gas inlet

Additional heat recovered in SNOXTM plant

Gas phase SO3 hydration:

With SNOX dirtier is greener

Steam production is 5% higher compared to current

Cost of flue gas desulfurization

Comparison of operating costs

WSA/SNOXTM references (location)

WSA/SNOXTM plants references

8 in other industries (including 2 SNOXTM)

RFO + sour gas

Ohio Edison, USA

SNOXTM Raffineria di Gela, Italy

approx. 250 MWe

Total flue gas flow: 1,200,000 Nm3/hr

SNOXTM OMV, Austria

Claus tail gas

Eight good reasons for SNOXTM

Reduced CO2 emissions

No process water consumption

Valuable sulfuric acid product

Low operating & maintenance costs.

Thank you for your attention!

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