Fall Winter 2017

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COVERING BEST PRACTICES FOR THE INDUSTRY

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ASARCO’s copper plant investment yields two-for-one: cleaner air and longer life Page 7

IN THIS ISSUE > > > > Phosphate production in North America likely to trend down PAGE 10 Reduced turnaround frequency is hard on acid cooling equipment PAGE 26 Detecting moisture leaks by measuring process gas dew point PAGE 30

COVERING BEST PRACTICES FOR THE INDUSTRY

Sulfuric Acid T

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ASARCO’s copper plant investment yields two-for-one: cleaner air and longer life Page 7

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IN THIS ISSUE > > > > Phosphate production in North America PAGE 10

FROM THE PUBLISHER On the Cover … 7 Upgrade to capture nearly 100 percent SO 2 emissions underway at ASARCO copper smelter. Departments 4 Industry Insights News items about the sulfuric acid and related industries 14

Lessons Learned Case histories from the sulfuric acid industry

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Product News News items about sulfuric acid products and services

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Faces & Places Covering sulfuric acid industry events

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Calendar of Events

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FEATURES & GUEST COLUMNS

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Phosphate production in North America likely to trend down

EDITOR April Kabbash

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Experience zero leaks with a true knife gate valve

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Fall protection in the workplace

EDITOR April Smith

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Do small modular acid plants fit in a world of mega plants?

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Acid proofing: where art meets industry

MARKETING ASSISTANT Tim Bowers

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Downstream sulfuric acid plants benefit from WESP technology

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Pressure grouting between steel shells & brick linings/membranes of lined

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Reduced turnaround frequency is hard on acid cooling equipment

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Fifteen acid towers in Africa

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Detecting moisture leaks by measuring process gas dew point

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Collaboration the cornerstone at 2017 Sulfuric Acid Roundtable

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Central Florida AIChE hosts 40th International Phosphate Fertilizer &

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Eco Services’ training tradition raises new engineers

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Sulfuric Acid Today adds technology seminar to conference repertoire

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INDUSTRY INSIGHTS WASTE HEAT RECOVERY BOILERS SUPERHEATERS ECONOMIZERS

SNC-Lavalin awarded contract for engineering and licensing services at the Dorogobuzh project

MONTREAL—SNC-Lavalin recently announced that it has been awarded a contract by Novgorodskiy GIAP, a subsidiary of Acron Group, for the development of engineering design packages and licensing services for a fertilizer project located in the Smolensk region of the Russian Federation. The scope of the contract includes providing pilot tests and engineering services, including the development and delivery of basic engineering packages, as well as working documentation for the construction of fertilizer facilities, which include production plants for sulfuric acid, phosphoric acid, and granulated NPK at the Dorogobuzh site. SNC-Lavalin will also provide assistance during the procurement, construction, commissioning, and start up phases of the project. The services will be led and primarily executed out of the company‘s offices in Brussels. “We are honored to have been awarded this contract,” said SNC-Lavalin President, Mining & Metallurgy, José J. Suárez. “This new contract award is testament to our recognized expertise and of our ability to support our clients globally in multiple sectors. We look forward to working with GIAP on this important project.” For more information, please visit www.snclavalin.com.

Zhejiang Petroleum & Chemical Co. awards DuPont contract for MECS® sulfuric acid regeneration unit

OpƟmus delivered its Įrst sulfuric acid plant waste heat recovery system in 1996. Across the power and process industries, we’ve produced more heat recovery boilers, HRSGs, superheaters, and economizers than any acƟve company in the USA. OpƟmus and its Chanute Manufacturing plant have a longͲstanding repͲ utaƟon for highͲquality workmanship and onͲƟme performance. CusͲ tomers trust our unique manufacturing experƟse and have conĮdence in our quality control and comprehensive project execuƟon. x x x

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WILMINGTON, Del.—Zhejiang Petroleum and Chemical Co. (ZPC) in China has awarded and signed contracts for the engineering, technology license, and proprietary equipment for a MECS® sulfuric acid regeneration (SAR) unit, licensed by DuPont Clean Technologies. ZPC is constructing a greenfield refinery and petrochemical project on Dayushan Island, just off the coast of eastern China, near Shanghai and Ningbo. The $15 billion project is the largest privately-led petrochemical and refining project in China’s history. The project will be executed in two phases with the first phase coming online in late 2018. After completion, the complex will have a refining capacity of 40 million tonnes per year, or 800,000 barrels per day. The MECS® SAR unit for the ZPC petrochemical complex will have a capacity to regenerate 858 metric tons of spent sulfuric acid. Furthermore, the MECS® SAR unit is designed to meet the Chinese Ministry of Environmental Protection’s current emission requirements for SO2, NOx and sulfuric acid mist. Jason Hartman, global market specialist for the MECS® SAR technology, said, “China’s Ministry of Environmental

Protection has enacted some of the most stringent point source emission requirements in the world. DuPont Clean Technologies is uniquely positioned to meet these new standards through enhancements to our MECS® SAR technology. These enhancements include the MECS® Vectorwall™ furnace, DynaWave® scrubbing, and Brink® mist eliminators. When built, the SAR unit at ZPC’s petrochemical complex will achieve world-class environmental emissions, reliability and on-stream time.” MECS® SAR technology is the leading technology for sulfuric acid regeneration on the market. This reliable, dry gas technology produces the desired sulfuric acid products for upstream alkylation, acrylonitrile, and methyl methacrylate unit performance. Reliability, on-stream time, and emission performance are the most important considerations when selecting SAR technology. Since the SAR unit supplies fresh sulfuric acid products to upstream units, MECS® SAR plants are designed for a high on-stream time to avoid disrupting the upstream unit’s operation and production schedule while also providing noxious emission abatement in compliance with local and country environmental requirements. For more information, please visit www.dupont.com.

Southern Peru Copper Corp. appoints Jacobs as EPC provider for its no. 1 acid plant

DALLAS—Jacobs Engineering Group Inc. was selected by Southern Peru Copper Corp. (SPCC) to provide engineering, procurement, and construction (EPC) services for its no. 1 acid plant upgrade project. SPCC operates one of the world’s largest copper smelting/refinery facilities in Ilo, Peru, which is located approximately 600 miles south of Lima. Under the terms of this lump sum EPC contract, Jacobs will perform modifications to the existing acid plant, decreasing its sulfur dioxide (SO2) emissions while increasing sulfuric acid production capacity through the use of Jacobs’ proprietary Chemetics sulfuric acid technology. “Our successful relationship with Southern Peru Copper Corporation spans more than 20 years,” said Jacobs Mining & Minerals and Specialty Chemicals Senior Vice President and General Manager Andrew Berryman. “We will provide our innovative Chemetics acid plant technology for this project, complementing the two existing plants our teams previously executed at the site, to further reduce SO2 emissions.” In addition to the no. 1 acid plant project, Jacobs is performing a feasibility study for SPCC in Lima for its power distribution system that will enable the company to support future demand. Jacobs is one of the world’s largest and most diverse providers of full-spectrum technical, professional, and construction serSulfuric Acid Today Fall/Winter 2017

vices for industrial, commercial, and government organizations globally. The company employs over 54,000 people and operates in more than 25 countries around the world. For more information, please visit www.jacobs.com.

Yidu Xingfa Chemical awards contract to DuPont

WILMINGTON, Del.—Yidu Xingfa Chemical Co. Ltd. has awarded DuPont Clean Technologies contracts for the engineering and technology license for a 3,600 MTPD MECSÂŽ MAX3™ sulfuric acid plant. This project will make the Xingfa sulfuric acid plant one of the largest in China. Xingfa is expanding its existing site, located in the Hubei province near Yichang city, with the aim of roughly doubling the phosphate fertilizer capacity. The new MECSÂŽ MAX3™ sulfuric acid plant will process 1,200,000 tons of sulfuric acid per year, as well as support the production of an additional 400,000 tons per year of phosphoric acid, 400,000 tons per year DAP and 35,000 tons per year of potassium phosphate monobasic. The new MECSÂŽ MAX3™ sulfuric acid plant will enable the Xingfa site to meet or exceed the Chinese Ministry of Environmental Protection’s strict emission requirements which govern the location in the sensitive Yangtze river basin area. “DuPont Clean Technologies is very pleased to be providing its proprietary MECSÂŽ MAX3™ technology for Xingfa’s expansion project to enable the company to become one of the most efficient fertilizer producers in China. This MAX3™ sulfuric acid plant is not only a significant step for both DuPont and Xingfa, but also for the sulfuric acid industry,â€? said Eli Ben-Shoshan, president of DuPont Clean Technologies. “Never before has sulfuric acid technology delivered more value to the end user. MAX3™ not only offers sulfuric acid plants savings in water usage, time and money, but it also allows them to recover more energy while achieving bestin-class emission levels,â€? Ben-Shoshan said. For more information, please visit www. dupont.com.

Teck Trail’s new acid plant under construction

TRAIL, B.C., Canada—Construction on the new $174-million acid plant at Teck Trail Operations is underway. Hil-Tech Contracting and CIMS were awarded the contracts for demolition and site prep; the primary equipment supplier is the same company used for the previous build. “The project is progressing on schedule,� said Community Relations Leader Catherine Adair. “The main equipment supplier for the project will be the same supplier as the No. 1 acid plant, completed in July 2014, as the new plant will be a replica of the previously constructed plant.� Teck estimates approximately 650,000 hours of construction labor will be required to complete the build, which equates to about Sulfuric Acid Today ‹ Fall/Winter 2017

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INDUSTRY INSIGHTS 160 jobs during construction. “Contractor selection for foundation work, mechanical, structural, and electrical work is currently underway,� Adair said. “And other smaller contracts will be selected throughout the construction.� The No. 2 acid plant is scheduled to become operational in the summer of 2019. Over the last 20 years Teck has made significant investments to improve environmental performance at the Trail smelter, which is one of the largest zinc and lead smelting and refining operations in the world. “The new acid plant represents an important investment in the ongoing sustainability and long-term future of Trail Operations,� Adair added. “The new plant will significantly improve operating reliability and flexibility, reducing downtime and maintenance costs.� For more information, please visit www. teck.com.

Koch Knight acquires DURO Brand corrosion-proof line

($67 &$1721 2KLRÂł.RFK .QLJKW //& a world leader in corrosion solutions with FDSDELOLWLHV LQ VWDWH RI WKH DUW FHUDPLFV DQG plastic materials manufacturing, as well as acid resistant construction and engineering, recently announced its intent to purchase the '852ÂŒ SURGXFW OLQH DVVHWV RI 0HPSKLV 7HQQ EDVHG Fuzion Technologies, Inc. ´7KH '852 SURGXFW OLQH UHSUHVHQWV DQ expansion of products that we can provide to the corrosion UHVLVWDQW PDUNHW DQG H[SDQGV RXU FXVWRPHU EDVH LQ D YDULHW\ RI LQGXVWULHV LQFOXGLQJ JOREDO LQVWDOOHUV Âľ VDLG 0DWWKHZ 7KD\HU YLFH SUHVLGHQW RI .RFK .QLJKW ´&RPELQHG ZLWK .RFK .QLJKW¡V FDSDELOLWLHV DQG PDUNHW SUHVHQFH ZH IHOW WKLV ZDV DQ H[FHOOHQW ILW DQG ORRN IRUZDUG WR RIIHULQJ these products to our new and existing customers.â€? .RFK .QLJKW LV SDUW RI .RFK &KHPLFDO Technology Group, LLC, a diverse group of companies serving refiners and chemical companies, municipalities, pulp and paper, pharmaceutical, food and dairy, automotive, utility, and other process industry customers. .RFK .QLJKW¡V SURGXFWV DQG VHUYLFHV DUH widely used in corrosive chemical processing HTXLSPHQW DQG KLJK WHPSHUDWXUH 92& DEDWHPHQW applications. Fuzion Technologies, Inc. LV RQH RI $PHULFD¡V OHDGLQJ UHIUDFWRU\ SURGXFWV FRPSDQLHV $IWHU WKH VDOH RI WKH '852ÂŒ SURGXFW OLQH )X]LRQ ZLOO FRQWLQXH to provide a full range of refractory materials for a wide variety of industries, including cement and lime, iron, steel, paper and pulp, chemical, glass, energy, aluminum, and other non-ferrous metal industries. )UHHSRUW %ULFN 'LYLVLRQ SXUFKDVHG WKH '852ÂŒ SURGXFW OLQH IURP +DUELVRQ :DONHU LQ $OO PDQXIDFWXULQJ RI WKH '852ÂŒ SURGXFW OLQH ZLOO EH PRYHG WR .RFK .QLJKW¡V (DVW &DQWRQ 2KLR ORFDWLRQ IURP WKH 3LWWVEXUJK DUHD ZKHUH '852 EULFNV KDYH EHHQ PDQXIDFWXUHG IRU WKH SDVW \HDUV For more information, please visit www. kochknight.com. T PAGE 5

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Cover Story

ASARCO’s copper plant investment yields two-for-one: cleaner air and longer life By: April Smith

Replacing Hayden’s five existing converters with three larger capacity versions will reduce SO2 emissions at the smelter.

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Sulfuric acid plant upgrades are underway and will be completed by the end of 2018.

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$6$5&2 ZDV HVWDEOLVKHG LQ DV $PHULFDQ 6PHOWLQJ DQG 5HĂ€QLQJ &RPSDQ\ DQG ZDV D FRQVROLGDWLRQ RI VHYeral lead-silver smelting companies. The facility at Hayden KDV EHHQ LQ SURGXFWLRQ VLQFH ZKHQ LW EHJDQ SURFHVVLQJ FRSSHU RUH IURP WKH DGMDFHQW 5D\ PLQH ZKLFK IHHGV WKH +D\GHQ VPHOWHU WR WKLV GD\ ,Q WKH IDFLOLW\ UHFHLYHG D major upgrade, including the installation of its present sulfuric acid plant. Further modernizations to the Hayden smelter DQG FRQFHQWUDWRU RFFXUUHG LQ DQG ,Q *UXSR 0H[LFR SXUFKDVHG $6$5&2 DQG WKH FRPSDQ\ QRZ RSHUDWHV DV D ZKROO\ RZQHG VXEVLGLDU\ 7RGD\ $6$5&2 LV DQ LQWHJUDWHG FRSSHU PLQLQJ VPHOWLQJ DQG UHĂ€QLQJ RSHUDWLRQ ZLWK DSSUR[LPDWHO\ HPSOR\HHV FRPSDQ\ZLGH DQG DERXW DW +D\GHQ ,Q DGGLWLRQ WR WKH +D\GHQ FRPSOH[ $6$5&2¡V $UL]RQD RSHUDWLRQV LQFOXGH three mines, two of them with solvent extraction/electrowinQLQJ SODQWV 7KH FRPSDQ\ DOVR UXQV WKH $PDULOOR &RSSHU 5HĂ€QHU\ LQ 7H[DV ZKLFK UHĂ€QHV DQRGHV IURP +D\GHQ WR FRSSHU FDWKRGH WKHQ WR URG DQG FDNH IRU VDOH WR FXVWRPHUV

Joe Wilhelm, left, general manager for Hayden Operations Steven Gasser, right, Hayden-operations smelter manager.

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Capturing emissions during conversion

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One of three new larger converters installed at Hayden’s copper smelter, giving the plant greater control of emissions. PAGE 7

Cover Story

Hayden’s acid plant produces about 575,000 short tons of sulfuric acid annually, which is used in the ASARCO leaching operations or is sold on the open market.

,W¡V EHHQ D PXOWL \HDU HQGHDYRU ZKLFK LQFOXGHG VHFXULQJ initial engineering contractor Gas Cleaning Technologies LQ DQG Ă€QDOL]LQJ FRQVHQW GHFUHH QHJRWLDWLRQV IRU HPLVVLRQV DEDWHPHQW ZLWK WKH (3$ LQ 8QGHU WKH (3$ DJUHHPHQW WKH SODQW ZLOO LPSURYH LWV 622 emissions capture from SHUFHQW WR SHUFHQW The primary mechanism for reaching this goal is to reSODFH WKH VPHOWHU¡V FRQYHUWHUV ZKHUH PROWHQ FRSSHU LV KHDWed at very high temperatures to separate out iron and other LPSXULWLHV 7KH H[LVWLQJ Ă€YH IW GLDPHWHU FRQYHUWHUV ZLOO EH UHSODFHG ZLWK WKUHH IW GLDPHWHU FRQYHUWHUV HDFK ZLWK DERXW WLPHV WKH FDSDFLW\ RI WKH RULJLQDOV *UHDWHU FDSDFLW\ DIIRUGV WKH SODQW WKH Ă H[LELOLW\ WR UXQ RQO\ D VLQJOH FRQYHUWHU DW D WLPH UDWKHU WKDQ WKH WZR FRQYHUWHUV LW KDG EHHQ FRQFXUrently operating. Fewer converters running mean fewer rollRXWV IRU VNLPPLQJ DQG UHFKDUJH ZKLFK LQ WXUQ WUDQVODWHV WR IHZHU RSSRUWXQLWLHV IRU IXJLWLYH JDV HPLVVLRQV $GGLWLRQDOO\ ODUJHU ODGOHV FXELF IHHW LQVWHDG RI FXELF IHHW ZLOO EH LQVWDOOHG WR UHGXFH WKH QXPEHU RI KRW PHWDO WUDQVIHUV $VLGH IURP WKH FRQYHUWHUV WKHPVHOYHV D PDMRU IHDWXUH RI WKH XSJUDGH LV D QHZ YHQWLODWLRQ V\VWHP WR EH FRQVWUXFWHG DERYH WKH FRQYHUWHUV WR FDSWXUH IXJLWLYH HPLVVLRQV 7KH V\VWHP FRQVLVWV RI EUDQG QHZ GXFWLQJ DQG KRRGLQJ LQFOXGLQJ primary, secondary, and tertiary off-gas capture systems. The QHZ FRQYHUWHUV ZLOO DOVR EH Ă€WWHG ZLWK DQ HOHFWURVWDWLF SUH-

The new wet gas cleaning system at Hayden’s acid plant improves particulate capture and eliminates a 1970s-era system that was a source of SO2 emissions.

FLSLWDWRU (63 WR UHPRYH VROLGV IURP WKH FRQYHUWHUV¡ RII JDV The off-gas collected at the converters is then ducted to the IDFLOLW\¡V VXOIXULF DFLG SODQW ZKHUH WKH FRQWDLQHG 622 is used in the production of sulfuric acid.

Wet gas handling at the acid plant

$FKLHYLQJ JUHDWHU WKDQ SHUFHQW 622 capture also reTXLUHG XSJUDGHV WR WKH IDFLOLW\¡V 673' VXOIXULF DFLG SODQW ´7KH FRQVHQW GHFUHH VHWV D FRPELQHG HPLVVLRQV OLPit throughout all stages of the process, including the acid SODQW Âľ VDLG 'DYLG 9DOGH] +D\GHQ VXSSRUW PDQDJHU ´7KH FRPELQHG HPLVVLRQV KDYH WR PHHW RQH OLPLW DW WKH VWDFN H[LW Âľ 7KH GRXEOH FRQWDFW GRXEOH DEVRUSWLRQ WHFKQRORJ\ plant provides all the sulfuric acid used in copper leaching at $6$5&2 IDFLOLWLHV ZLWK DQ\ H[WUD DFLG SURGXFHG VROG H[ternally. The acid plant can process up to 120,000 standard FXELF IHHW SHU PLQXWH 6&)0 VPHOWHU JDV DW D VWUHQJWK RI XS WR SHUFHQW 622 GU\ EDVLV 7KH XSJUDGHV XQGHUZD\ DW WKH IDFLOLW\ ZLOO UHWDLQ WKH VDPH JDV KDQGOLQJ FDSDFLW\ EXW PRUH HIĂ€FLHQWO\ LQFUHDVH WKH 622 concentration in the gas stream. $ NH\ DVSHFW RI WKH XSJUDGH LQYROYHV UHSODFLQJ WKH V HUD JDV FOHDQLQJ VHFWLRQ RI WKH DFLG SODQW ZLWK D QHZ VFUXEELQJ system that improves particulate capture from off-gas streams. 7KH SDUWLFXODWHV IURP WKH VFUXEELQJ SURFHVV DUH YDOXDEOH EHFDXVH WKH\ FRQWDLQ FRSSHU DQG FDQ EH UHSURFHVVHG IRU IXUWKHU PHWDO H[WUDFWLRQ ´:H PDNH E\SURGXFWV IURP DOO WKDW VFUXEELQJ ZDWHU Âľ H[SODLQHG 9DOGH] ´EHFDXVH LW LV KLJK LQ FRSSHU Âľ But the procedure for separating the water from particulate was time consuming and represented another source

RI HPLVVLRQV ´:H XVHG WR SXPS WKH XVHG VFUXEEHU ZDWHU WR VRODU GU\LQJ EHGV RXW LQ WKH RSHQ ,W WRRN IRUHYHU WR JHW the material ready for reuse or VDOH Âľ 9DOGH] VDLG 7KH HTXLSPHQW IRU WKH V\VWHP LQFOXGHV D QHZ VFUXEEHU SDFNHG JDV FRROLQJ WRZHU WKLFNHQHU Ă€OWHU SUHVV DQG GU\HU 7KH VFUXEEHU LV FRXSOHG ZLWK D GLVHQJDJHPHQW VHSDUDWRU YHVVHO WR IDFLOLWDWH JDV David Valdez, HaydenDQG EORZGRZQ OLTXLG VWUHDPV %ORZGRZQ IURP WKH VFUXEEHU support manager. DQG WKH UHVW RI WKH VFUXEELQJ system is pumped continuousO\ WR WKH QHZ WKLFNHQHU WR WKLFNHQ VROLGV IURP SHUFHQW WR DSSUR[LPDWHO\ SHUFHQW E\ ZHLJKW 7KH XQGHUĂ RZ IURP WKH WKLFNHQHU LV SXPSHG WR D FXELF IRRW FDSDFLW\ Ă€OWHU SUHVV WR UHPRYH WKH PDMRULW\ RI WKH OLTXLG ´:H JHW WKH VROLGV WR SHUFHQW PRLVWXUH FRQWHQW UHDG\ WR EH SXW EDFN LQ the mix to process again or sell to another metals extraction IDFLOLW\ Âľ 9DOGH] VDLG

Improving acid contact side

To tamp down on another part of the process that generates fugitive emissions, the plant will also install a new, larger capacity preheater. Historically, regulating processing temperDWXUHV DQG UHKHDWLQJ GXULQJ VWDUWXS LQ SDUWLFXODU KDYH EHHQ UHVSRQVLEOH IRU PRVW RI WKH 622 HPLVVLRQV DW WKH DFLG SODQW ´2XU ROG SURFHVV LQYROYHG VWDUWLQJ XS RQH EHG DW D WLPH ZLWK HDFK EHG KHDWLQJ XS WKH QH[W Âľ H[SODLQHG 6WHYHQ *DVVHU +D\GHQ RSHUDWLRQV VPHOWHU PDQDJHU ´%XW WKLV PHWKRG WRRN WRR ORQJ UHOHDVLQJ WRR PXFK 622 WR EH FRPSOLDQW ZLWK WKH QHZ UXOHV :LWK WKH QHZ FRQVHQW GHFUHH ZH FDQ¡W GR WKDW DQ\PRUH :H KDYH WR SUHKHDW DOO WKH EHGV DW WKH VDPH WLPH â€? 6R HDUO\ QH[W \HDU WKH WHDP ZLOO LQVWDOO D 125$0 (QJLQHHULQJ DQG &RQVWUXFWRUV /WG GHVLJQHG SUHKHDWHU FDSDEOH RI GHOLYHULQJ SUHKHDWHG JDV WR HDFK FRQYHUWHU EHG LQGHSHQGHQWO\ 7KH GHVLJQ ZLOO HQDEOH RSHUDWRUV WR KHDW DOO WKH EHGV concurrently, which reduces startup time and thus fugitive emissions. The larger preheater is designed to operate at fullĂ RZ FDSDFLW\ DQG KLJK SURFHVV JDV WHPSHUDWXUHV

Improvements to towers: Drying, Final, and Cooling

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Rendering of new converter upgrade at ASARCO’s Hayden, Ariz., copper smelter.

Modeling of new wet gas cleaning system at Hayden’s sulfuric acid plant. PAGE 8

The 2,000 STPD double-contact, double-absorption, 3+1 technology plant provides all the sulfuric acid used in copper leaching at ASARCO facilities.

VIP International replaced the inlet gas elbow to the drying tower with a NORAM-designed brick lined mild steel elbow. Sulfuric Acid Today ‹ Fall/Winter 2017

Challenges

1RW VXUSULVLQJO\ D SURMHFW RI WKLV VFRSH SURYLGHG WKH +D\GHQ WHDP ZLWK LWV IDLU VKDUH RI KXUGOHV 7KH ÀUVW RI WKHVH ZDV LGHQWLI\LQJ WKH JRDOV DQG PHDVXUHV WR DFKLHYLQJ (3$ compliance. ´:H FRXOGQ·W GR DQ\WKLQJ XQWLO ZH KDG DQ DJUHHPHQW ZLWK WKH 'HSDUWPHQW RI -XVWLFH DQG WKH (3$ µ VDLG :LOKHOP ´:H ZRUNHG IRU IRXU \HDUV IURP WR QHJRWLDWLQJ with the government to get a consent decree agreement. It WRRN D ORQJ WLPH EXW ZH·UH SOHDVHG ZLWK WKH RXWFRPH µ $QRWKHU KXJH FKDOOHQJH KDV LQYROYHG VFKHGXOLQJ WKH construction. The team had to determine which aspects RI WKH UHWURÀW UHTXLUHG VKXWGRZQ DQG ZKLFK FRXOG EH SHUIRUPHG ZKLOH RSHUDWLQJ 7KHQ WKH WHDP KDG WR ZRUN RXW H[DFWO\ KRZ WR SHUIRUP WKH UHWURÀW ZKLOH RSHUDWLQJ ´,W·V OLNH SXWWLQJ WRJHWKHU D MLJVDZ SX]]OH µ VDLG 9DOGH] ´6FKHGXOing the transition to new converters from the old converters KDV EHHQ GLIÀFXOW $OVR ZH·UH WHPSRUDULO\ UXQQLQJ WKH QHZ VFUXEELQJ V\VWHP ZLWK SDUW RI WKH ROG F\FORQHV XQWLO WKH QHZ (63 RSHUDWLRQ EHJLQV µ 7KH +D\GHQ FRPSOH[ DV D ZKROH HPSOR\V DERXW SHRSOH ZLWK ZRUNLQJ DW WKH VPHOWHU 6LQFH ZKHQ FRQVWUXFWLRQ EHJDQ WKHUH KDYH EHHQ URXJKO\ FRQWUDFWRUV ZRUNLQJ DW WKH IDFLOLW\ DQG WKLV WUHQG LV H[SHFWHG WR FRQWLQXH IRU WKH QH[W WR PRQWKV 7KURXJKRXW DOO WKH FRQVWUXFWLRQ KRZHYHU SURMHFW VDIHW\ KDV EHHQ H[HPSODU\ ´7KH FRQWUDFWRUV DQG RXU SODQW SHUVRQQHO KDYH EHHQ H[WUHPHO\ VXFFHVVIXO ZLWK VDIHW\ µ :LOKHOP VDLG ´$OO RI RXU contractors and Hayden employees are outstanding.”

Future at Hayden

Per the consent decree timeline, the completion date IRU WKH SURMHFW LV \HDU HQG ,Q WHUPV RI WKH XSJUDGH·V LPSDFW JRLQJ IRUZDUG WKH WHDP DQWLFLSDWHV D VOLJKW XSWLFN LQ FRVWV ´:H·OO QHHG PRUH HOHFWULFLW\ WR GULYH WKH QHZ YHQWLODWLRQ IRU WKH FRQYHUWHUV µ :LOKHOP H[SODLQHG ´+RZHYHU HPSOR\PHQW ZLOO UHPDLQ DERXW WKH VDPH µ KH VDLG ´DQG ZH will produce 4 percent more sulfuric acid.” $QG WKHQ WKHUH·V WKH LPSDFW WR WKH SHRSOH RSHUDWLQJ WKH SODQW ´, WKLQN LW ZLOO EH DQ HDVLHU SODQW WR UXQ µ VDLG *DVVHU ´EHFDXVH ZH·OO EH UXQQLQJ DW WKH VDPH SURGXFWLRQ OHYHO DV Sulfuric Acid Today Fall/Winter 2017

Hayden’s upgrades Wet gas cleaning

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The acid plant’s new EvapTech-designed cooling tower provides better temperature control and monitoring.

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VIP International installs new MECS ®-designed tubesheet in the acid plant’s final tower.

Preheating

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Tower improvements Drying Tower

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Vacuuming old ceramic packing, VIP International prepares for loading new 3” ceramic saddles from APT in the acid plant’s drying tower.

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Final Tower WRGD\ EXW ZLWK RQO\ RQH FRQYHUWHU DW D WLPH UDWKHU WKDQ RSHUDWLQJ WZR FRQYHUWHUV FRQFXUUHQWO\ QHDUO\ DOO WKH WLPH $QG ZH·OO KDYH IHZHU FUDQH PRYHPHQWV IRU WUDQVIHU RI PHWDOV µ :LOKHOP VSHDNV RI WKH VHQVH RI VHFXULW\ HPSOR\HHV KDYH EHHQ IHHOLQJ EHFDXVH DQ LQYHVWPHQW LQ WKH SODQW PLUURUV DQ LQYHVWPHQW LQ WKHLU IXWXUH WRR ´2I FRXUVH HYHU\RQH ORYHV WKH VKLQ\ QHZ HTXLSPHQW µ KH VDLG ´%XW SHRSOH VHHP KDSS\ LQ D GHHSHU VHQVH WKDW WKH FKDQJHV ZH·UH PDNLQJ UHÁHFW JUHDWHU MRE VHFXULW\ µ The changes, in fact, put the facility in good standing to continue running through 2040, the present projected life RI WKH 5D\ PLQH DQG OLNHO\ PXFK ORQJHU 3OXV RSHUDWLQJ DW QHDUO\ SHUFHQW 622 FDSWXUH UDQNV +D\GHQ DPRQJ WKH ELJ OHDJXHUV ´+RZ PXFK EHWWHU FDQ \RX JHW WKDQ SHUFHQW UHFRYHU\"µ :LOKHOP VDLG ´7KDW·V ZKDW WKH EHVW VPHOWHUV LQ WKH ZRUOG GR DQG WKDW·V ZKDW ZH·OO EH GRLQJ WRR µ T

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Cooling Tower

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PAGE 9

Cover Story

cooling tower that cools water used in acid heat exchangers. 6RPH RI WKH FKDQJHV DGGUHVVHG LVVXHV ZLWK OHDNV DQG GLVtortion, which are not surprising considering how long the SODQW KDV EHHQ UXQQLQJ ´:H·YH JRWWHQ \HDUV RI VHUYLFH RXW RI WKLV SODQW µ VDLG *DVVHU ´<RX·YH JRW WR NHHS XS ZLWK WKH PDLQWHQDQFH WR FRQWLQXH WR UXQ HIÀFLHQWO\ DQG LQ FRPSOLance,” he said. 7KH GU\LQJ WRZHU UHFHLYHG D QHZ 0(&6® GLVWULEXWLRQ V\VWHP DORQJ ZLWK GHPLVW SDGV DW WKH WRZHU·V H[LW ´2XU ROG V\VWHP ZDV IURP DQG ZH ZHUH KDYLQJ LVVXHV ZLWK PLVW FDUU\RYHU µ 9DOGH] H[SODLQHG 7KH WHDP DOVR UHSODFHG WKH ROG OHDG LQOHW JDV HOERZ ZLWK D 125$0 GHVLJQHG EULFN OLQHG HOERZ The team also installed a new EvapTech-designed FRROLQJ WRZHU WR FRRO WKH LQWHUSDVV DQG ÀQDO WRZHU DFLG VWUHDPV 7KH WZR FHOO GHVLJQ ZLWK YDULDEOH VSHHG IDQV RIIHUV EHWWHU WHPSHUDWXUH FRQWURO DQG WKH LQOLQH S+ DQG FRQGXFWLYLW\ PHWHUV SURYLGHV EHWWHU PRQLWRULQJ /LNH WKH GU\LQJ WRZHU WKH ÀQDO WRZHU LQWHUQDOV ZHUH UHSODFHG WR DGGUHVV PLVW FDUU\RYHU 0(&6® Inc.-designed HTXLSPHQW ZDV XVHG LQFOXGLQJ D =H&RU® = 8QLÁR® disWULEXWLRQ V\VWHP UHSODFHPHQW WXEHVKHHW DQG QHZ PLVW eliminator candles. 2WKHU PDLQWHQDQFH RQJRLQJ RYHU WKH ODVW IHZ \HDUV included piping, which the team has replaced in all three towers, and shoring up the four-pass converter, installed in

Feature

MARKET OUTLOOK

Phosphate production in North America likely to trend down By: Fiona Boyd, director, Acuity Commodities

3HQGLQJ PHUJHU DQG DFTXLVLWLRQ DFWLYity in the phosphate fertilizer industry will result in potential further production UDWLRQDOL]DWLRQ LQ 1RUWK $PHULFD H[WHQGLQJ D WUHQG VHHQ RYHU WKH ODVW \HDUV $W WKH VDPH WLPH WKHUH ZLOO EH DQ LQFUHDVH LQ JOREDO SURGXFWLRQ FDSDFLW\ PRVW QRWDEO\ LQ 0RURFFR DQG 6DXGL $UDELD ZKLFK FRXOG IXUWKHU LPSDFW 1RUWK $PHULFDQ RSHUDWLRQV SDUWLFXODUO\ ZLWK 8 6 EDVHG 0RVDLF Company having an ownership interest in offshore assets. This article will review how sulfurEDVHG VXOIXULF DFLG SURGXFWLRQ LQ 1RUWK $PHULFD KDV GHFOLQHG LQ FRUUHODWLRQ ZLWK D downtrend in phosphoric acid production while sulfur production firmed primarily on an increase in refining capacity in the 8QLWHG 6WDWHV %HIRUH WKHUH ZHUH DW OHDVW active phosphate fertilizer production sites LQ WKH 8QLWHG 6WDWHV 0DQ\ RI WKHVH ZHUH RSHUDWHG E\ FRPSDQLHV WKDW DUH QR ORQJHU in existence, such as Texasgulf, which EHFDPH SDUW RI 3RWDVK&RUS 3&6 $FXLW\ HVWLPDWHV E\ WKH ODWH V VXOIXU FRQsumption to support sulfuric acid production for the phosphate sector was at least 11 million tons per year. %\ KRZHYHU $FXLW\ HVWLPDWHV DQQXDO FRQVXPSWLRQ GHFOLQHG WR PLO-

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ANOTECTIONÂŽ

The trusted Anodic Protection solution

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million tons in 2015, representing a loss of 3 million tons. Phosphoric acid consumes WKH HTXLYDOHQW RI URXJKO\ WRQ RI VXOIXU per tonne of acid produced. $V GRPHVWLF GHPDQG IRU VXOIXU ZDV under pressure amid the consolidation of the industry, there was a shift occurring LQ WHUPV RI VXOIXU SURGXFWLRQ DV ZHOO 8 6 production shifted from on-purpose from Frasch mining to more produced through crude refining and natural gas processing. $V DQ LQGLFDWLRQ LQ 8QLWHG 6WDWHV *HRORJLFDO 6XUYH\ 86*6 GDWD UHIOHFWV MXVW XQGHU PLOOLRQ WRQV RI VXOIXU ZHUH SURGXFHG LQ WKH 8QLWHG 6WDWHV ZLWK DURXQG SHUFHQW EHLQJ SURGXFHG WKURXJK FUXGH UHILQLQJ ZLWK WKH EDODQFH IURP QDWXUDO JDV processing. This compares to 2011, when SURGXFWLRQ ZDV MXVW RYHU PLOOLRQ WRQV reflecting almost 1 million tons of growth in the following five years. /RRNLQJ IRUZDUG $FXLW\ GRHV QRW H[SHFW 8 6 SURGXFWLRQ WR FRQWLQXH WR LQFUHDVH DV VRPH UHILQHUV ZLOO EHFRPH more inclined to a lighter crude slate to WDNH DGYDQWDJH RI WKH ERRP LQ VKDOH GHYHORSPHQW LQ UHFHQW \HDUV $FXLW\ H[SHFWV WKLV ZLOO FRXQWHUEDODQFH UHILQHULHV WKDW PDNH changes to utilize more heavy crude with a few projects currently underway, most QRWDEO\ LQ WKH 0LGZHVW 0HDQZKLOH ZH expect production from natural gas proFHVVLQJ WR EH XQGHU GRZQZDUG SUHVVXUH DV VRXU JDV UHVHUYHV DUH ZRUNHG WKURXJK DQG QRW UHSODFHG RZLQJ WR WKH ERRP LQ VKDOH with a similar trend occurring in Canada. 6WLOO ZLWK DQ RXWORRN IRU UHODWLYHO\ VWDEOH SURGXFWLRQ VXOIXU SURGXFHUV DUH QDWXUDOO\ QHUYRXV DERXW DQ\ IXUWKHU SRWHQtial rationalization in the phosphate industry. Those concerns were intensified when &DQDGLDQ FRPSDQLHV 3&6 DQG $JULXP DQQRXQFHG D PHUJHU RI HTXDOV H[SHFWHG WR FORVH ODWH WKLV \HDU WR EH NQRZQ DV 1XWULHQ $V SDUW RI WKH PHUJHU WKH SRWHQWLDO rationalization of phosphoric acid producWLRQ FDSDFLW\ DW $JULXP¡V H[LVWLQJ RSHUDWLRQV DW 5HGZDWHU $OEHUWD WKH RQO\ DFWLYH phosphate site in Canada, was identified DV D V\QHUJ\ 3&6 ZLOO VXSSO\ LWV H[FHVV phosphoric acid to the Canadian operations LQVWHDG RI VXSSO\LQJ LW WR RIIVKRUH PDUNHWV such as India, as it does today. In addition,

at the time of writing, the companies were VWLOO ZRUNLQJ ZLWK WKH 8 6 )HGHUDO 7UDGH Commission to resolve final issues related WR VXSHUSKRVSKRULF DFLG 63$ DQG QLWULF DFLG $V D UHVXOW $JULXP FRXOG EH UHTXLUHG WR VHOO 8 6 DVVHWV IRU LWV PHUJHU ZLWK 3&6 to progress. The assets include its phosphate facility at Conda, Idaho, as well as D QLWULF DFLG IDFLOLW\ LQ 2KLR 7KH &RQGD plant receives around 540,000 tons per \HDU RI VXOIXULF DFLG VXSSO\ IURP WKH 5LR 7LQWR .HQQHFRWW FRSSHU VPHOWHU LQ 8WDK $JULXP DOVR SURGXFHV VXOIXU EDVHG DFLG WR use onsite at Conda to support phosphoric acid production with annual sulfur consumption estimated at 140,000 tons. With some domestic suppliers wary of significant exposure to domestic phosphate fertilizer producers as well as the QHHG WR EDODQFH WKH PDUNHW RIIVKRUH VXOIXU H[SRUW DFWLYLW\ RXW RI WKH 8 6 *XOI &RDVW increased. But there too, suppliers had significant exposure to the phosphate fertilL]HU PDUNHW DV WKH SULPDU\ PDUNHWV VHUYHG E\ WKH UHJLRQ DUH 0RURFFR DQG %UD]LO ,Q 0RURFFR WKH ODUJHVW EX\HU LV 2&3 DQG ZKLOH LWV VXOIXU FRQVXPSWLRQ UHTXLUHPHQWV continue to grow as it adds additional phosphate fertilizer production capacity, so WRR GRHV JOREDO VXOIXU SURGXFWLRQ PHDQLQJ JUHDWHU DYDLODELOLW\ IRU WKH ODUJH FRQVXPHU ,Q %UD]LO 9DOH LV WKH ODUJHVW VXOIXU FRQVXmer, importing at least 1.2 million tons per \HDU DFFRXQWLQJ IRU DURXQG SHUFHQW RI KLVWRULF DQQXDO LPSRUWV 1RZ PDUNHW SDUWLFLSDQWV DUH EUDFLQJ IRU DQ\ LPSDFW IURP 0RVDLF¡V SHQGLQJ DFTXLVLWLRQ RI 9DOH¡V fertilizer assets in Brazil in a deal that is H[SHFWHG WR FORVH E\ WKH HQG RI WKH \HDU If it moves forward, it will mean Mosaic will remain the largest sulfur consumer in 1RUWK $PHULFD DQG ZLOO DVVXPH UHVSRQVLELOLW\ IRU SXUFKDVLQJ IRU LWV %UD]LOLDQ operations, with its largest source of supply WKH 8 6 *XOI &RDVW In a longer term view, there is also the potential for rationalization in the United 6WDWHV DV RIIVKRUH SKRVSKDWH IHUWLOL]HU SURGXFWLRQ JURZV $V PHQWLRQHG 0RURFFR DQG 6DXGL $UDELD LV ZKHUH WKH FXUUHQW growth is. The growth here will result in Continued on page 12

Sulfuric Acid Today ‹ Fall/Winter 2017

Why Gamble with Your Maintenance Dollar?

VIP INTERNATIONAL 6638 Pecue Lane, Baton Rouge, LA 70817 (225) 753-8575 www.vipinc.com

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Experience zero leaks with a true knife gate valve ([WHUQDO OHDNV IURP YDOYHV GXULQJ YDOYH F\FOLQJ DUH FRPPRQ SUREOHPV for plant operators around the world. 7KHVH OHDNV FDQ KDYH GLVDVWURXV FRQVHTXHQFHV FRQWDPLQDWLQJ WKH HQYLURQPHQW DQG HQGDQJHULQJ ZRUNHUV ZLWK KD]DUGRXV materials, resulting in major down time for the company. Delta IndustrialÂŒ NQLIH JDWH YDOYHV SURYLGH ]HUR OHDNDJH LQ SODQWV ZLWK difficult process applications, helping WR VROYH WKLV SUREOHP ´7KH LVRODWLRQ LV YHU\ LPSRUWDQW EHFDXVH LW HQVXUHV VDIH and consistent plant operation, minimizes downtime, and provides lowest total RZQHUVKLS FRVW Âľ VD\V -RKQ $EERWW :HLU 0LQHUDOV JOREDO SURGXFW PDQDJHU IRU valves. ´2XU FXVWRPHUV FDQ LQVWDOO 'HOWD ,QGXVWULDO YDOYHV LQWR SUREOHP DUHDV VHFXUH LQ WKH NQRZOHGJH WKDW WKH\ ZLOO DFKLHYH long term performance and minimize harm to their people, their plant, and their HQYLURQPHQW Âľ VD\V $EERWW 3URWHFWLQJ the environment and trying to prevent KD]DUGRXV PDWHULDOV KDUPLQJ ZRUNHUV LV of prime importance for sites around the world. Weir Minerals¡ 'HOWD ,QGXVWULDOÂŒ guided shear gate valves are designed to UHSHDWHGO\ FORVH DQG SURYLGH EL GLUHFWLRQDO ]HUR OHDNDJH LVRODWLRQ QR PDWWHU ZKDW the process fluid may contain. ´2XU NQLIH JDWH YDOYHV HQVXUH QRWKing will come past the closed valve, even DEUDVLYH VOXUU\ RU ZKHQ RSHUDWLQJ XQGHU KLJK WHPSHUDWXUHV Âľ $EERWW VD\V 7KLV LV D significant feature of the Delta IndustrialÂŒ valves, and one that provides numerRXV LPSRUWDQW EHQHILWV WR WKH FXVWRPHU providing some insight into why Weir

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History of Delta Industrial Valves

'HOWD ,QGXVWULDO 9DOYHV ,QF ZDV IRXQGHG LQ DQG EHJDQ GHVLJQLQJ DQG PDQXIDFWXULQJ KLJK TXDOLW\ NQLIH JDWH YDOYHV LQ UHFRJQL]LQJ WKH XUJHQW UHTXLUHPHQWV ZLWKLQ WKH PDUNHW IRU D VXSHULRU SURGXFW 7KH FRPSDQ\ LV DQ HVWDElished leader in the valve industry, and ZLWK WKH EDFNLQJ RI :HLU 0LQHUDOV ZLOO FRQWLQXH WR SDYH WKH ZD\ LQ KLJK TXDOLW\ NQLIH JDWH YDOYHV IRU LWV FXVWRPHUV In July 2015, Delta Industrial was DFTXLUHG E\ :HLU 0LQHUDOV ZKLFK ZDQWHG WR LQFUHDVH LWV PDUNHW SUHVHQFH LQ KDUG URFN PLQLQJ Ril sands, pulp and paper DQG SRZHU LQGXVWULHV E\ H[SDQGLQJ WKH FRPSDQ\¡V SRUWIROLR RI YDOYH SURGXFWV $OZD\V VWULYLQJ WR SURYLGH WKH EHVW SRVVLEOH VHUYLFH WR LWV FXVWRPHUV ZKLOH increasing efficiency and reducing costs, Weir Minerals relocated the MichiganEDVHG 'HOWD ,QGXVWULDOÂŒ valves manufacturing operations to its LewisÂŽ pumps and YDOYHV PDQXIDFWXULQJ IDFLOLW\ LQ 6W /RXLV Missouri. The state-of-the-art manufacturLQJ IDFLOLW\ LQ 6W /RXLV KDV GHVLJQHG DQG manufactured LewisÂŽ pumps and valves for over 125 years. LewisÂŽ pumps are NQRZQ LQWHUQDWLRQDOO\ LQ WKH VXOIur, sulfuric acid, and phosphoric acid industries ZLWK HTXLSPHQW LQVWDOOHG LQ PRUH WKDQ countries worldwide. ´7KH GHFLVLRQ WR PRYH ZDV QHFHVVLWDWHG E\ WKH VXEVWDQWLDO H[SDQVLRQ SODQV RI Delta Industrial over the next two years. In addition, the relocation offers improved

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an increase in supply for major fertilL]HU LPSRUW PDUNHWV VXFK DV ,QGLD 7KLV LV OLNHO\ WR PDNH WKH SKRVSKDWH IHUWLOL]HU H[SRUW EXVLQHVV PRUH FRPSHWLWLYH ZKLFK WKH PDUNHW KDV EHHQ VHHLQJ WKLV year and which could ultimately result LQ UDWLRQDOL]DWLRQ ZLWK KLJKHU FRVW 8 6 RSHUDWLRQV YXOQHUDEOH )XUWKHUPRUH 0RVDLF KDV D SHUFHQW RZQHUVKLS VWDNH LQ WKH :D¡DG $O 6KDPDO SURMHFW LQ 6DXGL $UDELD ZKLFK EHJDQ WR UDPS XS LQ WKH VHFRQG TXDUWHU %RWK WKH 6DXGL YHQWXUH DQG LWV SHQGLQJ WDNHRYHU RI 9DOH¡V DVVHWV FRXOG LPSDFW 0RVDLF¡V RSHUDWLRQV LQ WKH 8QLWHG 6WDWHV DV WKHVH VLWHV KDYH DQ assumed lower cost of production and DUH FORVHU WR PDUNHWV LW FXUUHQWO\ VHUYHV ZLWK 8 6 H[SRUWV VXFK DV %UD]LO DQG India. When preservation of domestic phosphate reserves is also considered, it PAGE 12

PDNHV ORQJ WHUP UDWLRQDOL]DWLRQ DSSHDU LQFUHDVLQJO\ OLNHO\ 7KH 8QLWHG 6WDWHV LV DOUHDG\ EHLQJ LPSDFWHG E\ WKH JURZWK in offshore phosphate production with a surge in imports of finished phosphates LQWR WKH FRXQWU\ IURP PDUNHWV VXFK DV Morocco in recent years. Acuity Commodities was created in 2016 by Fiona Boyd and Freda Gordon to provide clarity on the global sulfur and sulfuric acid markets. Acuity offers independent price assessments and analysis to help industry stakeholders make business decisions. At present, Acuity offers three pricing reports, %ULHILQJ 6XOSKXU %ULHILQJ 6XOSKXULF $FLG and 5HJLRQDO %ULHILQJ 86 DQG Canada. For more information, please visit www.acuitycommodities.com. T

Weir Minerals’ Delta Industrial™ guided shear gate valves are designed to repeatedly close and provide bi-directional, zero leakage isolation no matter what the process fluid may contain. John Abbott, Weir Minerals global product manager for valves.

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The Delta Industrial™ advantage

1RW DOO NQLIH JDWH YDOYHV DUH WKH VDPHÂłPDQ\ DOORZ IRU OHDNDJHV WKDW FDQ leave plant operators exasperated. When DVNHG ZKDW PDNHV 'HOWD ,QGXVWULDOÂŒ NQLIH gate valves different from many others on WKH PDUNHW $EERWW VD\V ´7KHLU FRQVWUXFWLRQ SURYLGHV ]HUR OHDNDJH WR H[WHUQDO HQYLURQPHQWV GXH WR WKHLU XQLTXH WUDQVverse seal design. Couple this with Delta ,QGXVWULDO¡V ORQJ KLVWRU\ LQ WKH GHVLJQ DQG production of valves and it consistently SURYHV WR EH RQH RI WKH KLJKHVW SHUIRUPLQJ valves in these heavy duty applications.â€? :KLOH PDQ\ GLIIHUHQW W\SHV RI NQLIH JDWH YDOYHV KDYH EHHQ GHVLJQHG DQG PDQXIDFWXUHG VLQFH WKH V WKH\ KDYH DOO KDG serious limitations. The Delta IndustrialÂŒ VKHDU JDWH YDOYH GHVLJQ FRPELQHG ZLWK LWV XQLTXH VHDWLQJ DUUDQJHPHQW HQVXUHV exceptional pipeline isolation and zero OHDNDJH WR WKH DWPRVSKHUH UHVXOWLQJ LQ performance customers can rely on every time the valve operates. 7KLV XQLTXH NQLIH JDWH YDOYH GHVLJQ LV FDSDEOH RI RIIHULQJ WKH KLJKHVW SHUIRUmance in the most severe applications where solids are in solution, suspension, or ERWK 7KLV PDNHV LW WKH ZRUOG¡V SUHPLXP isolation valve for scaling applications ZKHUH WUDGLWLRQDO YDOYHV DUH LQRSHUDEOH GXH to cementation or precipitation of solids. ´:KDW¡V JUHDW DERXW RXU 'HOWD ,QGXVWULDO NQLIH JDWH YDOYHV LV WKDW WKH\ even operate in clear solutions, an area ZKHUH WUDGLWLRQDO NQLIH JDWH YDOYHV DUH QRW DSSURSULDWH Âľ VD\V $EERWW

Customer benefits

7KH FRPSDQ\ FDQ GHVLJQ DQG EXLOG a tailored valve solution for customers ZLWK VSHFLDO UHTXLUHPHQWV SURYLGLQJ D

XQLTXH VROXWLRQ IRU VSHFLILF DSSOLFDWLRQV The valve manufacturing process employs tight tolerances and minimum clearances WR HQVXUH UHOLDEOH SHUIRUPDQFH DQG WKH longevity of the highly engineered prodXFW VR FXVWRPHUV EHQHILW IURP FRQVLVWHQW performance and lower maintenance, as well as reduced downtime and increased productivity.

Applications and projects

´7KH 'HOWD ,QGXVWULDO YDOYH LV GHVLJQHG WR ZRUN LQ VHYHUH VHUYLFH DSSOLcations, providing customers from a range of sectors superior performance at high SUHVVXUHV Âľ VD\V $EERWW 'HOWD ,QGXVWULDOÂŒ valves perform well in applications that LQYROYH DEUDVLYH VOXUULHV VXFK DV IHUWLOL]HU SODQWV $Q HODVWRPHU VHDW LV UHWDLQHG E\ D precisely machined groove to position it at the edge of the guided gate and chisel tip. 7KLV DOORZV WKH YDOYH WR VHDO HTXDOO\ ZHOO from either flow direction and without regard to pressure differential, whether LQ YDFXXP VHUYLFH RU IXOO $60( UDWLQJ SUHVVXUH DQG PDNHV WKH 'HOWD ,QGXVWULDOÂŒ valve ideal for pump isolation. The full port design also helps protect the sealLQJ VXUIDFHV IURP HURVLYH DQG DEUDVLYH flows while allowing maximum volumes at minimum pressure losses.

The future for Delta Industrial™ valves

The team at Weir Minerals is curUHQWO\ ZRUNLQJ RQ FRPSOHPHQWLQJ WKHLU UDQJH RI $60( UDWHG YDOYHV ZLWK GHYHORSPHQWV FXUUHQWO\ EHLQJ WHVWHG WKDW will provide enhanced performance in KLJK SUHVVXUH DSSOLFDWLRQV ´:H DUH DOO YHU\ H[FLWHG DERXW WKH SURGXFW GHYHORSment and new design innovations to help our customers and cannot wait to see these XQIROG Âľ VD\V $EERWW For more information, please visit www.minerals.weir. T Sulfuric Acid Today ‹ Fall/Winter 2017

World-class Technology for Worldwide Markets We deliver a wide range of products and services, from engineering studies through to full EPC projects for the Sulphuric Acid Industry

Products & Services: Acid Plants ƒ ƒ ƒ ƒ ƒ

Sulphur Burning Metallurgical Spent Acid Regeneration Acid Purification & Concentration Wet Gas

Proprietary Equipment ƒ ƒ ƒ ƒ ƒ ƒ ƒ

Converter Gas-Gas Exchanger Acid Tower (brick lined and alloy) Acid Cooler Furnace SARAMET® piping & acid distributor Venturi Scrubber

Technical Services ƒ ƒ ƒ ƒ ƒ ƒ

Turnaround inspection Operations troubleshooting Process optimization Feasibility studies CFD (Fluent) analysis FEA (Ansys) study

Chemetics Inc. (headquarters)

Chemetics Inc. (fabrication facility)

Suite 200 – 2930 Virtual Way Vancouver, BC, Canada, V5M 0A5 Tel: +1.604.734.1200 Fax: +1.604.734.0340 email: chemetics.info@jacobs.com

2001 Clements Road Pickering, ON, Canada, L1W 4C2 Tel: +1.905.619.5200 Fax: +1.905.619.5345 email: chemetics.equipment@jacobs.com

www.jacobs.com/chemetics

Chemetics Inc., a Jacobs company

Department

LESSONS LEARNED: Case histories from the sulfuric acid industry

Mist-erious acid carryover Proper tower performance is integral to the successful operation of a sulfuric acid plant. Well-designed towers can increase plant uptime, improve production FDSDELOLWLHV UHGXFH HPLVVLRQV DQG ORZHU maintenance costs. Poorly-designed towers can have the opposite impacts. 3HUIRUPDQFH GLIIHUHQFHV FDQ EH LOOXVWUDWHG ZLWK HIĂ€FLHQF\ FXUYHV

Fig. 2: Illustration of re-entrainment in an absorption tower.

Fig. 1: Mist collection efficiency.

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About MECS

VWDFN HPLVVLRQV DQG RU HTXLSPHQW GDPDJH How can re-entrainment vary so ZLGHO\" 2QH SRVVLEOH DQVZHU LV WKDW QRW DOO PLVW

eliminators use drainage media to prevent re-entrainment. Thus, the presence of a drainage layer as well as the design details associated with the drainage layer have a VLJQLĂ€FDQW LPSDFW RQ UH HQWUDLQPHQW DQG overall element performance. 7KH WKHRU\ EHKLQG WKH LPSDFW RI SURSer drainage media design is fairly wellNQRZQ WKH FROOHFWLQJ PHGLD FDSWXUHV PLVW from the gas stream, and the drainage media SURYLGHV RSHQ SDWKZD\V IRU FROOHFWHG OLTXLG WR GUDLQ YHUWLFDOO\ GRZQZDUGV WR WKH ERWWRP RI WKH HOHPHQW 7KH RSHQ OLTXLG SDWKZD\V

Fig. 3: Illustration of effective drainage media.

LQ WKH GUDLQDJH OD\HU VXSSUHVV OLTXLG Ă€OP IRUPDWLRQ DQG Ă€OP EXUVWLQJ XOWLPDWHO\ SUHventing re-entrainment. /DE WHVWLQJ ZDV FRQGXFWHG WR HYDOXDWH the performance of different mist eliminator drainage media on acid mist re-entrainment in a controlled environment. 5HVXOWV LQGLFDWH WKDW D GUDLQDJH OD\HU¡V FDSDELOLW\ WR SUHYHQW UH HQWUDLQPHQW LV D FRPSOH[ IXQFWLRQ RI PDQ\ YDULDEOHV VXFK DV Ă€EHU GLDPHWHU GHQVLW\ SHUPHDELOLW\ RULentation, etc.

Figure 4: Laboratory test results for drainage layer optimization.

For 40 years ErgonArmor has been a leader in providing high performance lining solutions, such as, acid brick, mortars, coatings and corrosion-resistant systems for demanding applications in severe corrosion and chemical environments. With an extensive portfolio of long-lasting, chemical-resistant products designed for sustained immersion in aggressive chemical and slurry applications, ErgonArmor can provide the right solution for your corrosion concerns.

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PAGE 14

Though many drainage layers were tested, only 3 results are shown Fig. 4 for the VDNH RI VLPSOLFLW\ ,Q )LJ 'UDLQDJH /D\HU $ EOXH OLQH LV D JRRG FKRLFH IRU PLQLPL]LQJ UH HQWUDLQPHQW EHFDXVH LWV RYHUDOO HIÀFLHQF\ DV VKRZQ RQ WKH < D[LV LV KLJKHU WKDQ PDQ\ other designs, particularly for larger particle VL]HV DV VKRZQ RQ WKH ; D[LV WKLV LV LQdicative of low re-entrainment. By contrast, 'UDLQDJH /D\HU & JUHHQ OLQH ZRXOG EH D poor choice for minimizing re-entrainment, DV LWV RYHUDOO HIÀFLHQF\ IRU ODUJHU SDUWLFOH sizes is worse than using no drainage layer DW DOO UHG OLQH Though it is not surprising that different drainage layer designs may have different performances, it is somewhat surprising to see that poorly designed drainage layers can produce results that are even worse WKDQ XVLQJ QR GUDLQDJH OD\HU DW DOO 0(&6Ž %ULQNŽ Mist Eliminators utiOL]H D ELFRPSRQHQW GHVLJQ ZLWK VRSKLVWLFDWHG GUDLQDJH WHFKQRORJ\ VXSSRUWHG E\ \HDUV RI UHVHDUFK DQG ÀHOG H[SHULHQFH This results in a drainage layer that reduces re-entrainment, achieving lower exit PLVW HPLVVLRQV DQG EHWWHU RYHUDOO WRZHU performance.

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About DuPont Clean Technologies

DuPont Clean Technologies applies real-world experience, history of innovation, SUREOHP VROYLQJ VXFFHVV DQG VWURQJ EUDQGV to help organizations operate safely and with the highest level of performance, reliDELOLW\ HQHUJ\ HIĂ€FLHQF\ DQG HQYLURQPHQWDO integrity. The Clean Technologies portfolio LQFOXGHV 675$7&2ÂŽ DON\ODWLRQ WHFKQRORJ\ for production of clean, high-octane gasoline; IsoThermingÂŽ hydroprocessing technology for desulfurization of motor fuels; 0(&6ÂŽ sulfuric acid production and regenHUDWLRQ WHFKQRORJLHV %(/&2ÂŽ DLU TXDOLW\ FRQWURO V\VWHPV IRU )&& Ă XH JDV VFUXEELQJ DQG RWKHU UHĂ€QHU\ VFUXEELQJ DSSOLFDWLRQV 0(&6ÂŽ DynaWaveÂŽ technology for sulfur recovery tail gas-treating solutions; and a FRPSUHKHQVLYH VXLWH RI DIWHUPDUNHW VHUYLFH and solutions offerings. Learn more about DuPont Clean Technologies at www.cleantechnologies.dupont.com.

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Department

PRODUCT NEWS Spiral™ packing provides increased performance

$FLG 3LSLQJ 7HFKQRORJ\ $37 KDV EHHQ VXSSO\LQJ HQJLQHHUHG SURGXFWV WR WKH FKHPLFDO LQGXVWU\ VLQFH DQG FHUDPLF SURGXFWV VLQFH 6SLUDOÂŒ SDFNLQJ LV the latest innovation, next generation, mass WUDQVIHU SDFNLQJ 6SLUDOÂŒ SDFNLQJ ZDV GHYHOoped to match the mass transfer efficiency RI WKH 1RUWRQÂŒ LQFK VDGGOH EXW ZLWK KDOI of the pressure drop. In new construction, this low pressure drop feature can allow for smaller diameter towers. For existing towers, it can provide an increase in flow capacity or an immediate energy savings at current operating capacity. 6SLUDOÂŒ SDFNLQJ¡V XQLTXH VKDSH DQG KLJK TXDOLW\ $PHULFDQ PDGH FHUDPLF ZLOO allow for easy installation with fewer ceram-

Spiral™ packing consists of high-quality, American made ceramic.

LF FKLSV WR FOHDQ XS EHIRUH VWDUW XS :KHQ LQVWDOOHG 6SLUDOÂŒ ZLOO QRW ´QHVWÂľ WRJHWKHU OLNH WUDGLWLRQDO VDGGOH VKDSHG SDFNLQJ This design feature creates larger individual voids which are vertically aligned within the 6SLUDOÂŒ SDFNLQJ EHG ,Q IRXOLQJ FRQGLWLRQV LW¡V DQWLFLSDWHG WKLV YHUWLFDO DOLJQPHQW RI void space will minimize fouling and allow for longer run times. $37 LV RQH RI WKH ZRUOG¡V OHDGLQJ WRZHU SDFNLQJ VXSSOLHUV DQG VSHFLDOL]HV LQ engineered products for the sulfuric acid LQGXVWU\ $37 KDV VXSSOLHG LWV FHUDPLFV to numerous operating plants and major projects worldwide, involving hundreds of SDFNHG WRZHUV For more information, please visit www.acidpiping.com.

MECS DuPont marks 30 years of scrubber technology

)RU \HDUV 0(&6 FXVWRPHUV KDYH YDOXHG WKH UHOLDELOLW\ RI WKH '\QD:DYHŽ 5HYHUVH -HW 6FUXEEHU JDV FOHDQLQJ WHFKQROogy employed in their sulfuric acid plants. &HOHEUDWLQJ WKUHH GHFDGHV RI OLFHQVLQJ WKLV WHFKQRORJ\ WKH JOREDO 0(&6 '\QD:DYHŽ WHDP JDWKHUHG ODVW 6HSWHPEHU DW 0(&6 KHDGTXDUWHUV LQ 6W /RXLV 0R WR UHYLHZ WKH extensive range of successful installations. 7KH WHFKQRORJ\¡V IOH[LELOLW\ DOORZV IRU a fully customized solution. DynaWaveŽ is WKH RQO\ ZHW VFUXEELQJ SURFHVV WKDW FDQ XVH a variety of reagents to perform multiple WDVNV ZLWKLQ WKH VDPH YHVVHO 7KH V\VWHP can remove multiple types of acid gases and particulates, as well as perform hot gas TXHQFKLQJ DQG LQ VLWX R[LGDWLRQ The DynaWaveŽ 5HYHUVH -HW 6FUXEEHU IHDWXUHV DQ RSHQ GXFW ZKHUH VFUXEELQJ OLTXLG is injected through a non-restrictive reverse jet nozzle, counter current to the dirty inlet JDV 7KH OLTXLG FROOLGHV ZLWK GRZQ FRPLQJ

The unique spiral shape prevents nesting, a common problem with traditional packing.

Typical DynaWaveÂŽ Reverse Jet Scrubber system offered by MECS DuPont.

Over 50,0 Acid Re 00 sis

ta Bricks nt

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Now Manufacturing and Stocking Acid Resistant Brick At Koch Knight LLC, our goal is to provide engineered solutions by focusing on speciďŹ c customer needs. By applying our extensive experience in the industry and on-going product development, Koch Knight has developed brick lining materials capable of providing reliable service in the most demanding corrosive applications. Whatever your corrosive application, Koch Knight has the acid-proof solution. East Canton, Ohio (USA) - Baytown, Texas (USA) Santiago, Chile - Parramatta, Australia - Seoul, Korea - Istanbul, Turkey Visit us on the web: kochknight.com | Phone: +1 (330) 488-1651

PAGE 16

JDV WR FUHDWH D ]RQH RI H[WUHPH WXUEXOHQFH with a high rate of mass transfer. The clean, water-saturated gas continues through the VFUXEEHU YHVVHO WR PLVW UHPRYDO GHYLFHV 7KH OLTXLG UHYHUVHV GLUHFWLRQ DQG UHWXUQV WR WKH YHVVHO VXPS WR UHF\FOH EDFN WR WKH reverse jet nozzle. Currently, over 300 DynaWaveÂŽ scrubbing systems have been installed worldwide. For more information on DynaWaveÂŽ technology, visit www.dynawavescrubber.com. T

Convening at MECS headquarters in St. Louis, Mo., the global MECS DynaWaveÂŽ team celebrated the 30-year anniversary of DynaWave ÂŽ technology. In the front row, from left, are: Yves Herssens, Deli Schleiffarth, Steve Meyer, Jill Hankins, Dan McLaws, Paul Wibbenmeyer, and Scott Meyer. In the second row, from left, are: Hugo Amaral, Tom Schnepf, John Horne, Kirk Schall, and Andy Ness. In the third row, from left, are: Marcelo Barrientos, Larry Paschke, Bei Weng, Sara Safariyeganeh, David Ketler, and Gerald Ellington. In the back row, from left, are: Filip Jennes, Steve Puricelli, Philippe Goossens, Grace Wei, and Allen Gu.

Sumitomo plans sulfuric acid tank terminal on U.S. West Coast TOKYO—Sumitomo Corp. has agreed on a land-lease agreement with the Port of Stockton, Calif., via Sulphuric Acid Trading Company, Inc., a company of Sumitomo Corp.’s wholly-owned subsidiary Interacid Trading S.A., with plans to construct a new sulfuric acid tank terminal at that port. The terminal will be equipped with a 30,000-ton sulfuric acid tank, diluting facilities, and freight car/truck shipping facilities with construction expenses expected to total about two billion yen. Construction is scheduled to begin by the end of 2017, and operation should start in early 2019. The Port of Stockton, the intended construction site, is a key import/export port located about 100

km east of San Francisco Bay, annually handling four million tons of cargo, primarily fertilizer, grain, cement, steel materials, and coal. West Coast demand for sulfuric acid is expected to increase in the future, particularly for agricultural, mining, and industrial use, and the Port of Stockton offers good access to consumers. The terminal will be the only sulfuric acid receiving terminal on the West Coast, and Sumitomo Corp. will seek to sell more than 200,000 tons of sulfuric acid per year to customers through SATCO, which will be running the terminal. For more information, please visit www.sumitomocorp.co.jp. T

Sulfuric Acid Today ‹ Fall/Winter 2017

Sulfuric acid catalyst

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Feature

Fall protection in the workplace

By: Darwin Passman, Safety Director, VIP International

:KHQ \RX WKLQN DERXW LQGXVWU\ LQFLGHQWV LQYROYLQJ IDOOV GRQ·W RQO\ FRQVLGHU accidents involving falls from one level to DQRWKHU 2WKHU IDOO LQFLGHQWV LQFOXGH ZDONLQJ ZRUNLQJ VXUIDFHV IDOOV RQ WKH VDPH level, and falls through an existing opening. These potential hazards are found on DOO VLWHV :LWK D OLWWOH NQRZOHGJH DQG SURSHU SUHFDXWLRQV WKHVH ULVNV FDQ EH PLQLPL]HG :DONLQJ ZRUNLQJ VXUIDFHV LQFOXGH slips, trips, and falls on the same level. 6OLSV RFFXU DQ\WLPH WKHUH LV D ORVV RI IULFWLRQ EHWZHHQ D SHUVRQ·V IHHW DQG WKH ZDONing surface. When there is enough friction, ZDONLQJ VXUIDFHV SURYLGH UHVLVWDQFH 7KLV NHHSV \RXU IHHW XQGHU WKH FHQWHU RI EDODQFH ZKLOH ZDONLQJ 3LFWXUH \RXU VLGHZDON LFLQJ over as you leave your home. The change from normal friction to almost no friction causes a dramatic fall as your feet literally IO\ RXW IURP XQGHU \RXU ERG\ 7KLV IDOO ZRXOG EH FDWHJRUL]HG DV VOLSSHU\ PDWHULDOV RQ D ZDONLQJ VXUIDFH 6OLSSHU\ IORRU VXUIDFHV LQFOXGH VPRRWK floors or floors worn smooth over time. :DONLQJ RQ D JUDYHO ZDONZD\ WKHQ VWHSSLQJ onto a smooth-finished concrete surface has enough change in friction to cause a fall.

PAGE 18

,PSURSHU IRRWZHDU IRU WKH ZDONLQJ surface environment may cause slips, trips, RU HQWUDSPHQWV +DUG OHDWKHU VROHV OLNH those found on dress shoes, are not compatLEOH ZLWK VPRRWK VXUIDFHV DQG PD\ FDXVH D IDOO :KHQ ZRUNLQJ LQ DQ LF\ HQYLURQPHQW LPSURSHU IRRWZHDU FDQ LQFOXGH WKH DEVHQFH of ice cleats on your shoes. If you find yourself on a slippery surface and you cannot avoid the area, do the IROORZLQJ ³ 7DNH VPDOO VWHSV VKRUWHU WKDQ \RXU foot length. ³ 3RLQW \RXU WRHV RXWZDUG IRU D ZLGHU PRUH VWDEOH EDVH RI VXSSRUW ³ 7XUQ JUDGXDOO\ WR PDLQWDLQ EDODQFH ³ .HHS ERWK KDQGV IUHH DQG GR QRW SXW WKHP LQ \RXU SRFNHWV Trips happen when your foot collides ZLWK DQ REMHFW FDXVLQJ \RX WR ORVH EDODQFH and eventually fall. Common causes of WULSSLQJ DUH REVWUXFWHG YLHZ SRRU OLJKWLQJ FOXWWHU LQ WKH ZDONZD\ XQFRYHUHG FDEOHV RU piping, uneven steps, and a gravel or stone ZDONLQJ VXUIDFH How do you prevent falls due to slips DQG WULSV" *RRG KRXVHNHHSLQJ LV RQH RI WKH most important preventive measures. Clean

XS RU DW OHDVW PDUN VSLOOV WKDW RFFXU DQG PDLQWDLQ D FOHDU ZDONZD\ 6HFXUH WDUSV PDWV HWF LQ ZRUNLQJ ZDONLQJ DUHDV WR HOLPLQDWH WULS SRLQWV &RYHU FDEOHV SLSHV DQG HOHFWULFDO FRUGV WKDW FURVV ZDONZD\V DQG PDNH VXUH DOO ZRUNLQJ DQG ZDONLQJ areas are well lit. Proper footwear with soles in good shape will assist in mainWDLQLQJ WKH SURSHU IULFWLRQ WR WKH ZDONLQJ surface. )DOOLQJ WR D ORZHU OHYHO E\ IDU KDV the highest percentage of fatalities in our LQGXVWU\ 2I IDWDO IDOOV WR D ORZHU OHYHO WKH KLJKHVW QXPEHU ZHUH IURP D URRI IROORZHG E\ D ODGGHU VFDIIROG DQG QRQ PRYLQJ vehicles. 7R ZRUN RQ D ODGGHU VDIHO\ WKH ´7KUHH 3RLQWV RI &RQWDFWµ UXOH PXVW EH IROORZHG $W DOO WLPHV GXULQJ DVFHQW GHVFHQW DQG ZRUNLQJ WKH FOLPEHU PXVW IDFH WKH ODGGHU and have two hands and one foot, or two feet and one hand in contact with the ladder steps, rungs, or side rails. With three points RI FRQWDFW LW LV XQOLNHO\ D IDOO ZLOO RFFXU DV a result from the loss of any one point. Use D WRZOLQH RU WRRO EHOW VR \RXU KDQGV DUH IUHH when ascending or descending the ladder. Do not overreach or lean away from the FHQWHU RI WKH ODGGHU DV WKLV ZLOO GHVWDELOL]H WKH ODGGHU DQG FDXVH D ORVV RI EDODQFH , highly recommend using a fall restraint and retrieval system when entering a confined space to access a lower level. 6FDIIROG VDIHW\ EHJLQV ZLWK HOLPLQDWing the potential fall hazard, if practical IRU WKH SURMHFW $ FRPSOHWH VFDIIROG DOVR NQRZQ DV D JUHHQ WDJJHG VFDIIROG FRXSOHG ZLWK XVLQJ D VWDLUZD\ V\VWHP WDNHV FDUH RI that. $ FRPSOHWH VFDIIROG ZLWK D ODGGHU system reduces the fall hazard when an employee is ascending or descending the VFDIIROG )ROORZLQJ WKH ´7KUHH 3RLQWV RI &RQWDFWµ UXOH IXUWKHU UHGXFHV WKH ULVN RI IDOOLQJ ,Q VRPH FDVHV LW PD\ EH SUXGHQW WR VHFXUH D VHOI UHWUDFWLQJ OLIHOLQH DERYH WKH scaffold ladder. Employees would connect WKH OLIHOLQH WR WKH ´'µ ULQJ RQ WKHLU KDUQHVV while ascending and descending, eliminatLQJ WKH SRVVLELOLW\ RI D IDOO $Q LQFRPSOHWH VFDIIROG DOVR NQRZQ DV a yellow-tagged scaffold, creates specific safety concerns. In some cases employees DUH UHTXLUHG WR EH ´WLHG RIIµ ZKLOH ZRUNing on the scaffold. They must have two ODQ\DUGV RQ WKHLU KDUQHVV DQG RQH PXVW EH attached to the scaffold at all times. Permanent structures in plant facilities DUH GHVLJQHG DV D VDIH ZRUNLQJ VWUXFWXUH 6RPHWLPHV GXULQJ WXUQDURXQGV WKHVH VWUXFtures are modified temporarily to accomPRGDWH PDLQWHQDQFH QHHGV RU DQ HTXLSment installation. This may create an RSHQLQJ LQ WKH GHFN RU WKH UHPRYDO RI D guardrail. When this occurs, it is no longer D VDIH ZRUNLQJ VWUXFWXUH )ORRU KROH FRY-

HUV RU WHPSRUDU\ UDLOLQJV PXVW EH LQ SODFH ZKHQ QR ZRUN LV EHLQJ SHUIRUPHG DW WKH RSHQLQJ :KHQ ZRUN LV EHLQJ SHUIRUPHG D IDOO DUUHVW RU IDOO UHVWUDLQW V\VWHP PXVW EH LQ SODFH DQG DOO DIIHFWHG ZRUNHUV PXVW EH DOHUWHG DERXW WKH QHZ KD]DUGV IRU WKH DUHD DQG WKH 33( UHTXLUHG ,W·V FULWLFDO WKDW WKH 6DIH :RUN 3HUPLW DGGUHVVHV WKH WHPSRUDU\ RSHQLQJV DQG VDIHW\ UHTXLUHPHQWV )DOOV IURP QRQPRYLQJ YHKLFOHV IODWEHG WUDLOHU RU YDFXXP WUXFN DUH RIWHQ WKH result of not using three points of contact or not having a fall restraint system while RQ WKH YHKLFOH $ IDOO UHVWUDLQW V\VWHP VLPSO\ SUHYHQWV WKH HPSOR\HH IURP EHLQJ DEOH WR IDOO RII WKH YHKLFOH EHFDXVH WKH V\VWHP limits the distance the employee can travel. 'XULQJ LQ WKH 8QLWHG 6WDWHV DORQH WKHUH ZHUH RYHU IDWDOLWLHV DV D UHVXOW RI IDOOV ,Q -DQXDU\ RI 26+$ EHJDQ WKH LPSOHPHQWDWLRQ RI WKH )LQDO 5XOH WR XSGDWH *HQHUDO ,QGXVWU\ :DONLQJ :RUNLQJ 6XUIDFHV DQG )DOO 3URWHFWLRQ 6WDQGDUGV The rule incorporates advances in technolRJ\ DQG LQGXVWU\ EHVW SUDFWLFHV WR SURYLGH HIIHFWLYH DQG FRVW HIILFLHQW ZRUNHU SURWHFWLRQ 7KH WLPHOLQH IRU WKH UXOH LV ³ (QVXUH H[SRVHG ZRUNHUV DUH WUDLQHG LQ IDOO KD]DUGV E\ 0D\ ³ (QVXUH ZRUNHUV XVLQJ IDOO SURWHFWLRQ HTXLSPHQW DUH WUDLQHG E\ 0D\ 2017. ³ ,QVSHFW DQG FHUWLI\ SHUPDQHQW DQFKRUDJHV IRU GHVFHQW V\VWHPV E\ 1RY 2017. ³ ,QVWDOO IDOO DUUHVW V\VWHPV RQ QHZ IL[HG ODGGHUV RYHU IHHW E\ 1RYHPEHU 2017. ³ ([LVWLQJ IL[HG ODGGHUV RYHU IHHW must have cage, well, and personal fall arrest system, or ladder safety system E\ 1RYHPEHU ³ 5HSODFH FDJHV DQG ZHOOV XVHG DV IDOO SURWHFWLRQ ZLWK ODGGHU VDIHW\ RU SHUsonal fall arrest systems on all fixed ODGGHUV RYHU IHHW E\ 1RYHPEHU The common sense approach to protection from slips, trips, and falls is WR EH DZDUH RI \RXU VXUURXQGLQJV 7KH GHJUHH DSSURDFK WR DZDUHQHVV LV NH\ <RX PXVW EH DZDUH RI ZKDW LV DURXQG \RX EHORZ \RX DQG DERYH \RX 3ODQQLQJ \RXU ZRUN XVLQJ HLWKHU DQ HVWDEOLVKHG VWDQGDUG RSHUDWLQJ SURFHGXUH RU WKH MRE VDIHW\ DQDO\sis tool can assist with identifying hazards SULRU WR SHUIRUPLQJ WKH MRE $ IULHQG RI mine is a pilot and he has a saying that PDNHV D ORW RI VHQVH ´,I \RX·UH QRW WZR VWHSV DKHDG RI WKH SODQH \RX·UH JRQQD FUDVK µ 6R PDNH VXUH \RX VWD\ WZR VWHSV DKHDG For more information, please contact Darwin Passman, Safety Director, VIP International, at darwin@vipinc.com or (252) 753-8575. T Sulfuric Acid Today ‹ Fall/Winter 2017

Beltran Wet Electrostatic Precipitators:

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Feature

Do small, modular acid plants fit in a world of mega plants?

By: Nelson P. Clark, Alexandre C. Bastida, Bruno B. Ferraro, and Vitor A. Sturm, Clark Solutions, São Paulo, Brasil

6XOIXULF DFLG SODQWV JHW ELJJHU DQG ELJJHU 7KLUW\ \HDUV DJR D 73' DFLG SODQW FRXOG EH FDOOHG D ODUJH SODQW 1RZDGD\V SODQWV DV ELJ DV 73' DQG 73' DUH EHFRPLQJ FRPmon. In our current scenario, is there space for small 100-250 73' DFLG SODQWV" While large smelting and IHUWLOL]HU FRPSOH[HV DUH UHTXLUHG to produce large amounts of acid either for pollution control purposes or as raw material, small consumers still struggle with ORJLVWLFV DQG VXSSO\ UHOLDELOLW\ $ VPDOO DFLG FRQVXPHU LQ %UDVLO .DOLXP 0LQHUDomR FKRVH WR EXLOG LWV RZQ VXOIXU EXUQLQJ SODQW LQVWHDG RI EX\LQJ DFLG 'XH to the remote plant location, the FRPSDQ\ DFTXLUHG D 073' PRGXODU VNLG PRXQWHG SODQW

The plant &ODUN 6ROXWLRQV GHVLJQHG WKH 073' VXOIXU EXUQLQJ VLQJOH DEVRUSWLRQ K\GURJHQ SHUR[LGH WDLO JDV VFUXEEHU DFLG SODQW 'XH WR WKH ORJLVWLFV RI WKH .DOLXP VLWH WKH FRPSDQ\ GHFLGHG WR EXLOG WKH SODQW RQ PRGXODU VNLGV ZKLFK ZRXOG EH SODFHG RQ FLYLO EDVLV and tied to each other at the site. The plant consists of these PRGXOHV VNLGV HDFK RQH ZLWK the dimensions of a 40-foot stanGDUG FRQWDLQHU RU VPDOOHU ³$ VXOIXU PHOWLQJ DQG ILOWHULQJ VNLG &RQVLVWV RI WKH VXOIXU PHOWing and filtering areas and was designed to melt and filter up to PHWULF WRQV SHU KRXU RI VROLG sulfur. ³$Q DLU GU\LQJ VNLG &RQVLVWV RI a high silicon stainless steel pump WDQN GU\LQJ WRZHU DQG SLSLQJ ³$ FRPSUHVVLRQ DQG VXOIXU EXUQLQJ VNLG $Q DLU EORZHU IROORZHG E\ D KRUL]RQWDO IL[HG VSUD\ JXQ UHIUDFWRU\ OLQHG EXUQHU IROORZHG E\ WKH ZDVWH KHDW ERLOHU 6DWXUDWHG VWHDP LV SURGXFHG DW EDU IRU XVH DW VLWH RSHUDWLRQV ³$ 1R FRQYHUWHU VNLG *DVHV IURP WKH ZDVWH KHDW ERLOHU DUH admitted on a computerized fluid G\QDPLFV GHVLJQHG REORQJ FRQverter with two passes separated E\ D VXSHUKHDWHU ³$ 1R FRQYHUWHU VNLG *DVHV from the first converter are admitWHG RQ WKH 1R FRQYHUWHU ZKLFK PAGE 20

shares the same dimensions as WKH 1R FRQYHUWHU &RROLQJ RI JDVHV JRLQJ WR SDVV 1R LV PDGH E\ GLOXWLRQ DLU )URP SDVV 1R the gases are cooled to 220 C on D ERLOHU HFRQRPL]HU EHIRUH EHLQJ DGPLWWHG LQWR WKH 623 DEVRUSWLRQ VNLG ³$ 623 DEVRUSWLRQ VNLG Consists of a highly resistant austenitic stainless steel tower, pump WDQN DQG SLSLQJ V\VWHP ³7ZR ERLOHU VNLGV 7KHVH ERLOers are placed after conversion SDVVHV WR SURGXFH VWHDP DW EDU ³$Q +222 VFUXEELQJ VNLG 7KH VLQJOH DEVRUSWLRQ DUUDQJHPHQW does not allow conversions higher WKDQ SHUFHQW 7KH UHPDLQLQJ XQFRQYHUWHG 622 is driven to a SODVWLF K\GURJHQ SHUR[LGH VFUXEEHU ZKHUH WKH DFLG JDV UHDFWV DQG turns into sulfuric acid. The acid produced is consumed as dilution in the plant. 7KH DUHD UHTXLUHG IRU .DOLXP·V DFLG SODQW LV PLQLPDO With very open space for maintenance and operation access, and ODUJH DLVOHV EHWZHHQ VNLGV WKH WRWDO DUHD UHTXLUHG E\ WKH SODQW LV VPDOOHU WKDQ VTXDUH PHWHUV

Fig. 1: Plant arrangement.

Production and consumption figures

The plant features a few interesting aspects, such as the production of low pressure steam, ZKLFK .DOLXP·V SURFHVV UHTXLUHV DQG ZRXOG RWKHUZLVH EH SURGXFHG E\ EXUQLQJ IXHO %HFDXVH WKH SODQW LV D VLQJOH DEVRUSWLRQ SODQW ZLWK D WDLO JDV VFUXEEHU WKH SURFHVV FRQsumes H222 DV D VFUXEELQJ DJHQW WR SURGXFH ZHDN DFLG (PLVVLRQV DUH EHORZ SSP ZLWK WKLV arrangement and the plant can turn-down up to 70 percent as there is no interpass circuit to

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DIIHFW WKH WKHUPDO EDODQFH $Q LQWHUHVWLQJ DSSURDFK EHLQJ HYDOXDWHG JLYHQ WKH QHHG for low pressure steam, is the XVH RI &ODUN 6ROXWLRQV· SDWHQWed indirect heat recovery sysWHP 6DIHKU® 2Q 6DIHKU®, strong SHUFHQW KRW DFLG DW GHJUHHV & LV XVHG WR DEVRUE WKH 623 at the tower. This acid, due to the heat of reaction, heats up to 220 degrees C and is cooled RQ D 66 KHDW H[FKDQJHU E\ KHDWLQJ &ODUN 6ROXWLRQV· SURSULHWDU\ IOXLG &6 The fluid is totally inert to acid and water, so in the event of DQ DFLG OHDN LQWR WKH V\VWHP WKHUH LV QR ULVN RI SURGXFLQJ GLOXWH DFLG DQG WKXV QR ULVN RI FDWDVWURSKLF FRUURVLRQ LQLWLDWHG E\ D OHDNDJH In fact, as there is neither dilution QRU KHDWLQJ RI WKH DFLG WKH OHDN will not increase as it normally

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does in heat exchangers, and the plant can even operate with an DFLG OHDN LQWR WKH IOXLG DOORZLQJ programmed decisions on when DQG KRZ WR VKXW GRZQ 1R HPHUgency shut-downs will happen. 6DIHKU® helps to increase WKH VWHDP JHQHUDWLRQ E\ DOPRVW 40 percent, and for each ton of DFLG 6DIHKU® can produce up to 0.50 additional tons of steam. Besides increasing steam producWLRQ 6DIHKU® actually reduces the UHTXLUHPHQW IRU FRROLQJ ZDWHU LQ a conventional tower.

Overall benefits 7KH RYHUDOO EHQHILWV RI VPDOOHU PRGXODU DFLG SODQWV LQFOXGH ³6WHDP DQG VLGH SURGXFWV 6WHDP LV D E\ SURGXFW RI WKH SURFHVV WKDW FDQ EH D YHU\ YDOXDEOH DVVHW 7KH WDLO JDV VFUXEEHU

Fig. 2: Typical Safehr® flow arrangement.

FDQ DOVR EH GHVLJQHG WR SURGXFH RWKHU E\ SURGXFWV VXFK DV DPPRnium sulfate and sodium sulfate, among others. ³5HGXFHG WUDQVSRUW FRVWV Transportation, especially in places with limited infrastrucWXUH LV UHGXFHG ERWK LQ WHUPV RI WKH DPRXQW RI WUDQVSRUW as well as the inherent transport ULVN $FLG VSLOOV DUH PRUH GDQJHUous and harmful than solid sulfur spills. —6PDOOHU VWRUDJH UHTXLUHPHQW 6XOIXU FDQ EH VWRUHG LQ RSHQ RU enclosed piles and consumed DV UHTXLUHG ZKLOH DFLG UHTXLUHV ODUJH WDQNV ³6DIHU FRQVWUXFWLRQ 7KH PRGular design concept eliminates ULVNV LQKHUHQW WR VLWH FRQVWUXFWLRQ 0RGXOHV DUH VKRS IDEULFDWHG under much more stringent safety conditions. ³4XDOLW\ FRQVWUXFWLRQ 0RGXOHV DUH VKRS IDEULFDWHG DQG WHVWHG JXDUDQWHHLQJ D VXSHULRU TXDOLW\

Conclusion

Even though acid plants are JHWWLQJ ELJJHU DQG ELJJHU VPDOO modular acid plants will continue to find applications for those customers who need 50-250 MTPD RI DFLG DQG FDQ EHQHILW IURP WKH steam or power generated in such plants. For more information, please visit www.clarksol.com. T Sulfuric Acid Today ‹ Fall/Winter 2017

6RXWKZHVW 5HIUDFWRU\ EDVHG LQ $OYLQ 7H[DV LV D OHDGLQJ SURYLGHU RI DGYDQFHG EULFN lining systems for industrial applications. This fall, the company is performing four simultaneous acid plant projects in addition WR QXPHURXV EXLOGV DQG FRQVXOWDWLRQV LQ RWKHU LQGXVWULHV 7KHVH SURMHFWV LQFOXGH ³ 'HVLJQLQJ DQG FRQVWUXFWLQJ D QHZ SHUFHQW DFLG WRZHU RQ WKH 7H[DV *XOI &RDVW XVLQJ 6WHXOHU DFLG PDWHULDOV LQVWDOOLQJ SLHFHV RI EULFN LQ days. ³ %XLOGLQJ D EULFN IRRW E\ IRRW DFLG VWRUDJH GUXP³DOVR XVLQJ 6WHXOHU DFLG PDWHULDOV³DW WKH FRPSDQ\¡V VWDWH RI WKH DUW 7H[DV IDFLOLW\ ZLWKLQ a 30-day turnaround. ³ 3ODQQLQJ GHVLJQ DQG PDWHULDO LQVWDOlation for a major 35-day outage on a complete acid train to maintain and LQVSHFW DQ DFLG SODQW¡V IXUQDFH ERLOHU SUH KHDWHU WRZHUV DQG SXPS WDQNV &UHZV ZLOO EH ZRUNLQJ DURXQG WKH FORFN

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S E T T I N G A H I G H E R S TA N D A R D F R O M D E S I G N T O I N S TA L L AT I O N , E X P E C T T H E B E S T I N A C I D P R O O F I N G A N D R E F RA C T O R Y L I N I N G S Y S T E M S F R O M S O U T H W E S T R E F RA C T O R Y.

(281) 824 9342

Sulfuric Acid Today ‹ Fall/Winter 2017

INFO@SWR-US.COM

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PAGE 21

Feature

Downstream sulfuric acid plants benefit from WESP technology By: Gary Siegel, Marketing Director, Beltran Technologies, Inc.

Industrial-grade sulfuric acid, still the most widely used industrial chemical in the world, continues to be sourced primarily (about 70 percent) as a nondiscretionary byproduct from the roasting, smelting, and refining of nonferrous metals. The rest comes from natural gas processing, electric power generation, and spent acid regeneration. These industries are usually heavy emitters of particulates, sulfur and nitrogen oxide gases, and sulfuric acid mists, among other pollutants. They are also subject to increasingly strict environmental regulations. When concentrations of sulfur dioxide from these operations exceed five to seven percent of exhaust-gas volumes, a common and cost-effective solution is the incorporation of a downstream sulfuric acid manufacturing plant. Owners of these facilities can capitalize on the high industrial market value of purified sulfuric acid, while achieving greater operating efficiencies and easier regulatory compliance. However, cost-effective sulfuric acid manufacturing UHTXLUHV WKH PD[LPXP SRVVLEOH UHPRYDO RI Ă€QH SDUWLFXODWHV and other impurities from input gas streams to protect catalyst beds and other components, and to prevent the formation of “blackâ€? or contaminated acid. The one technology that is EHFRPLQJ DOPRVW XQLYHUVDOO\ VSHFLĂ€HG IRU WKLV SXUSRVH LV WKH Wet Electrostatic Precipitator (WESP). )RU HQJLQHHUV DQG SODQW GHVLJQHUV LQ WKH Ă€HOG RI JDV cleaning, several operational goals stand out: Âł DFKLHYLQJ WKH KLJKHVW OHYHO RI SDUWLFOH FROOHFWLRQ HIĂ€FLHQF\ — cleaning greater volumes of source gases, with faster throughput speeds. — achieving the greatest reductions in costs related to capital investment, operating cost, energy consumption, equipment maintenance, and long-term equipment replacement. To help sulfuric acid plants and other industries achieve these goals, the engineering staff at Beltran Technologies, Inc., in New York have continuously improved the basic :(63 GHVLJQ E\ UHVHDUFKLQJ DQG HQJLQHHULQJ D VSHFLĂ€F W\SH of advanced, innovative WESP technology which offers SURYHQ VXSHULRU SHUIRUPDQFH DQG HIĂ€FLHQF\ WKH %HOWUDQ :HW Electrostatic Precipitator. WESP systems can vary greatly in design, materials, JDV Ă RZ UDWHV DQG GXUDELOLW\ DV ZHOO DV FROOHFWLRQ HIĂ€FLHQF\ It is therefore important for engineers to recognize the key differences among these various systems. A well operated WESP can clean complex gaseous emissions of particulates and acid mists down to submicron scale (PM 2.5) with up

Beltran’s proven WESP technology, employed at Hindustan Zinc’s sulfuric acid plant in India captures submicron particulates from gaseous emissions with up to 99.9 percent efficiency.

WR SHUFHQW HIÀFLHQF\ DQG YHU\ ORZ HQHUJ\ GUDLQ³IDU superior to other equipment. Primarily targeted at capturing submicron-scale particulate matter, saturated sulfuric acid aerosols, and condensable organic chemicals, the Beltran WESP utilizes DTXHRXV à XVKLQJ QR]]OHV WR FOHDQ WKH FROOHFWLRQ VXUIDFHV 7KH captured particles are cleansed from the collection surfaces by recirculating water sprays. Residues, including aqueous sulfuric acid, are extracted for further use or disposal. The cleaned gas is ducted to downstream equipment or to the stack, depending on the application. The engineering of the advanced Beltran WESP systems makes them uniquely versatile over a broad range of industries, applications, operating conditions, and gas chemistries. This adaptability is critical to metallurgical and SHWUROHXP UHÀQLQJ RSHUDWLRQV ZKHUH VRXUFH JDVHV FDQ EH highly variable. Taking advantage of the inherently low pressure drop of WESPs, Beltran’s staff devised a multistage system of ionizing rods bristling with star-shaped discharge points. These are encased within square or hexagonal tubes to maximize collection surface area and minimize overall space requirements. The unique electrode geometry generates a FRURQD ÀHOG WR WLPHV PRUH LQWHQVH WKDQ WKDW RI FRQYHQWLRQDO wet or dry electrostatic precipitators resulting in greater particle migration velocity and adhesion. The multistage FKDUJLQJ FRQÀJXUDWLRQ DOVR DYRLGV FRURQD TXHQFKLQJ GXH WR KLJK SDUWLFOH GHQVLWLHV DQG DVVXUHV PD[LPXP FRURQD ÀHOG

The WESP system installed at Southern Peru Copper’s sulfuric acid plant helps the company achieve reduced costs in capital investments, energy consumption, and equipment maintenance. PAGE 22

strength with a minimum of energy load. A persistent challenge for traditional dry-operating precipitators is the re-entrainment of particles from the collection surfaces back into the gas stream due to the use of mechanical or acoustical rapping units. Beltran’s design uses D YHUWLFDO à RZ DQG FRQWLQXRXV DTXHRXV à XVKLQJ RI :(63V WR greatly minimize this problem. By eliminating the need for rappers, Beltran WESPs also reduce the higher cost and energy drain imposed by that equipment. For industries that generate RLO\ RU VWLFN\ UHVLGXHV WKH DTXHRXV à XVKLQJ DOVR SUHYHQWV particle build-up, and overcomes electrostatic resistivity and back-sparking on the WESP collection surfaces. Other critical features to look for in the advanced Beltran WESP equipment are sophisticated electronic controls linked WR D FORVH FRXSOHG JDV à RZ PDQDJHPHQW V\VWHP 7KHVH can optimize operating parameters such as gas velocity, saturation, temperature, corona intensity, etc., to achieve PD[LPXP HIÀFLHQF\ A major threat to the cost-effectiveness of a WESP is corrosion of equipment caused by the harsh chemical components of treated gases. To prevent premature deterioration, Beltran Technologies WESP systems are FRQVWUXFWHG ZLWK DGYDQFHG SURWHFWLYH PDWHULDOV VXFK DV ÀEHU reinforced plastics (FRP) or high nickel-chromium alloys. The high-voltage insulators are continuously purge-air cleaned to further reduce maintenance costs. For more information, please visit www. beltrantechnologies.com. T

At Mopani Copper Mines in Zambia, Beltran’s WESP system cleans large volumes of source gases with fast throughput speeds. Sulfuric Acid Today ‹ Fall/Winter 2017

Feature

Pressure grouting between steel shells & brick linings/membranes of lined strong acid vessels By: Bruce Luke, International Area Sales Manager, ErgonArmor

The use of chemical-resistant brick and membrane lining systems has been accepted as a well-proven and cost-effective corrosion protection system for carbon steel vessels used in the production of sulfuric acid. Plant design life is typically 15-20 years, but repairs to the linings over the last few years of the life of the plant are not unexpected, especially in units that are being operated at or beyond the original design parameters. The challenge is to develop a method of facilitating a repair to a lining in an operating plant, which can be performed only from the outside of the vessel. When a lining shows signs of needing a repair, the proper method to address such a repair is to execute it from the inside. The proper repair consists of first removing the brick lining and membrane, repairing the steel, and reinstalling the lining. The methodology outlined here is designed to execute from the outside of the equipment of an operating plant. Although there are significant limitations to this method, it can often be used to repair leaking towers, gas inlet nozzles, pump tanks, etc., and will be suitable as a short-term fix, allowing the unit to continue operating until a more substantial repair can be performed.

Introduction

Carbon steel has been a material of choice for the fabrication of vessels used in the production of sulfuric acid plants for many years. Although carbon steel offers many desirable features, it must be protected a the combination of chemical species and thermal environments. The proven design that has historically been used employs a combination lining, consisting of a 1/8-inch trowel-applied barrier of an asphaltic mastic-based membrane, which is further protected by an overlay of either red shale or fire clay acid brick. The masonry lining is laid up with full troweled-side, back, and bed mortar joints using a halogen-free, acid-cured potassium silicate mortar. The combination of the membrane and the brickwork provides an excellent lining system. The mastic membrane serves to keep oxygen and the chemical species from coming into direct contact with the steel, and the brick/mortar provides insulation, mechanical protection, and creates a stagnation condition for any chemicals that penetrate the brick masonry, thus allowing the membrane to perform satisfactorily. The thickness of the brick lining must be designed to reduce the membrane sur-

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PAGE 24

face temperature to below 140 degrees F (60 degrees C) under all possible operating, upset, shutdown, and seasonal conditions.

Background

Over time, brick linings become permeated by the chemical species, and hence the ultimate barrier for corrosion protection is the mastic membrane. Should the membrane itself be penetrated, which is possible after many years of operation, small pinholes in the steel will result. Additionally, through repeated thermal cycling, a void may develop between the brick lining and the membrane/steel shell. The installation of a welded patch on the steel from the outside will temporarily address the leak. However, the problem of trying to fill the void between the brickwork and the shell or steel patch is not addressed. This method also does not address the underlying issue of attempting to cut off the path for the chemical species to reach directly to the steel shell, and reseal the membrane from the inside. So, the injection of filler material from the outside of the vessel is desired. The first choice of material to try to use for injection was the mastic membrane. However, there are logistical problems with this. First of all, the mastic membrane is a solvent-based material and requires the evaporation of the solvent to dry. If the solvent can’t evaporate, the mastic will not dry or provide a corrosion barrier as intended. While this is not a problem during new construction, it is not possible to achieve this if used for in situ injection grouting, and the injected mastic membrane never achieves its full physical properties when used in this fashion. Secondly, the mastic membrane is of a consistency that does not easily lend itself to pumping, and it is not possible to fill all voids, especially small cavities, by utilizing this material.

Repair methodology

A technique has been developed that uses a variation of the chemical-resistant mortar formulations as a grouting mixture. To explain this variation, a basic understanding of the setting mechanism used in these mortars is necessary. The mortar most commonly used for this construction is generically described as a twocomponent halogen-free chemically setting inorganic potassium silicate mortar. The composition is of graded silica filler with a water soluble silicate binder. This mixture becomes a solid mortar by the gellation of the soluble liquid component, bonding together into a solid mass with the crushed silica component. Very early formulations relied simply on an air setting mechanism for this to take place. With later formulations the gelling action is accelerated by the addition of an acid-based hardener component. The formulating goal with this reaction is to match the amount of reactive acid hardener to the Baumé of the potassium

Ergon Refining, Inc., Vicksburg, Miss.

silicate solution. This balance must be achieved within the formulating parameters of a trowelable brick mortar. It must provide a work life, set time, and handling properties consistent with the bricklayer’s method of construction used in chemical-resistant, masonry linings. The parameters for a pressure injection grout mixture are significantly different. Whereas a brick mortar must be of a creamy, buttery consistency, the requirement for pressure grouting is for a much wetter, almost soupy consistency. The problem with achieving this goal is the reactive hardener component, which is blended in with the powdered filler. This mixture is designed to react with the potassium silicate solution when mixed in a creamy texture. By altering the reactivity of the components, and substituting a more reactive filler component (which is designed to be used as a brick mortar with a more reactive potassium silicate solution) a mixture that is suitable for pressure grouting can be achieved. This combination of products is marketed by Corrosion Engineering, a Division of ErgonArmor. Whereas brick mortars are typically formulated to be used in a mix ratio of 2.5:1 by weight of powder to solution, a more suitable ratio for pressure grouting is on the order of 1.75:1. If normal brick mortar components were to be used in this ratio, the mix would essentially be “under-hardened” and a very slow set, if any at all, would occur. By modifying the mixture as described earlier, a satisfactory set is achieved, even with a very wet mixture. After premixing the specially modified grout, the grout is injected under pressure through welded, threaded nipples that have been previously attached to the shell as required.

Conclusions

Although pressure injection of a potassium silicate-based grout is not meant as a permanent repair to leaking equipment, it does provide a cost effective and practical means of repairing leaking towers from the outside. By doing so, the acid plant operator will be able to keep a plant in service until it is possible to schedule a more convenient time to do a more permanent repair. For more information, contact Curtis Harvey, ErgonArmor national sales manager, at curtis.harvey@ergon.com or 404308-2551. T Sulfuric Acid Today Fall/Winter 2017

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Feature

Reduced turnaround frequency is hard on acid cooling equipment By: R. Barry Krentz, President, Mercad Equipment, Inc.

%DFN LQ WKH V DFLG SODQWV HQMR\HG D PRQWK IUHTXHQF\ IRU WKHLU DQQXDO WXUQarounds. The main reason for shutdowns ZDV WR VFUHHQ FDWDO\VW EHFDXVH SUHVVXUH drop in the first pass of the converter was JHWWLQJ WRR KLJK 2I FRXUVH WKHUH ZHUH RWKHU maintenance items to deal with too, and all WKHVH WKLQJV FRXOG EH HDVLO\ VFKHGXOHG RYHU D FDUHIXOO\ SODQQHG WZR ZHHN VKXWGRZQ That yearly shutdown was also when DFLG FRROHUV JRW D JRRG FOHDQLQJ XVXDOO\ E\ K\GUR EODVWLQJ WKH ZDWHU VLGH WR HOLPLQDWH PLQHUDO EXLOG XS DQG WXEH EORFNDJH FDXVHG E\ FRROLQJ WRZHU GHEULV WKDW VRPHWLPHV accumulates. By cleaning away this waterside material, the operation immediately reduced the water pressure drop, increased water flow, and returned the cooler effiFLHQF\ WR OLNH QHZ RSHUDWLRQ 7KDW XVXDOO\ translated into 15-20 percent extra cooling DELOLW\ DQG WKH SRVVLELOLW\ RI HYHQ KLJKHU than-design production rates. )DLOLQJ WR UHPRYH WXEH EORFNDJHV leaves serious situations that jeopardize

PAGE 26

Acid Inlet Debris

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when chloride ions are in the water. The RQO\ ZDWHU WKDW GRHV 127 KDYH FKORULGHV is demineralized water of steam condensate. Even glacial water has some minerals DEVRUEHG DV LW UXQV GRZQ WKH YDOOH\V LQ streams and rivers from the mountains, DQG ,·YH KHDUG LW VDLG WKDW DV OLWWOH DV ppm Cl- LV HQRXJK WR HYHQWXDOO\ FUDFN WKH KRW VWUHVVHG WXEHV DIWHU VRPH PRQWKV RI EORFNHG FRROLQJ ZDWHU IORZ $QRWKHU SRWHQWLDO VLWXDWLRQ IURP KRW WXEH ZDOO WHPSHUDWXUHV FDXVHG E\ EORFNHG WXEHV LV DFLG VLGH JHQHUDO FRUURVLRQ 2WKHU SDUWV RI WKH H[FKDQJHU VXFK DV EDIIOHV VKHOO DQG QR]]OHV DUH WKLFNHU WR JLYH PRUH FRUURVLRQ DOORZDQFH EHFDXVH WKH\ DUH QRW EHLQJ FRROHG %XW WXEHV DUH WKLQ ZLWK OLWWOH FRUURVLRQ DOORZDQFH EHFDXVH ZH NQRZ that the effect of the cooling water will furWKHU UHGXFH FRUURVLRQ RI WKH WXEH VXUIDFHV +RZHYHU ZKHQ D EORFNDJH VWRSV WKH ZDWHU IORZ WKH WXEH ZDOO WHPSHUDWXUH ULVHV WR WKH DFLG WHPSHUDWXUH DQG WXEH VXUIDFHV VXIIHU the same higher corrosion rate as the other non-cooled parts of the vessel. Fortunately, not all is lost, as the anodic protection system further reduces corrosion rates HYHU\ZKHUH LQ WKH FRROHU 1HYHUWKHOHVV WKH overall corrosion rate is accelerated on the EORFNHG WXEHV 0LQHUDO GHSRVLWLRQ VFDOH DOVR LQFUHDVHV FRUURVLRQ UDWHV 7KLV LV D EDUULHU to heat transfer and results in the water and acid temperatures getting further and further away from each other, i.e. heat transfer is dropping off. Hotter acid is more FRUURVLYH QRW RQO\ IRU WKH DFLG FRROHU EXW also every material in the entire acid loop. Pumps, valves, tower structures, piping, SXPS WDQNV³DOO WKHVH VWDUW WR FRUURGH IDVWHU ZLWK KRWWHU DFLG FLUFXODWLQJ .HHSLQJ the heat exchanger clean is very important IRU WKH ELJ SLFWXUH $FLG VLGH GHEULV LQ FRROHUV KDSSHQV YHU\ LQIUHTXHQWO\ EXW ZKHQ LW VKRZV XS LW

Acid Inlet Tube Bundle

FDQ FDXVH VHULRXV FRUURVLRQ LVVXHV 'HEULV LV XVXDOO\ OLPLWHG WR WRZHU SDFNLQJ DQG DFLG EULFN DFFXPXODWLQJ DW WKH DFLG LQOHW WXEH EXQGOH RI WKH FRROHU DOWKRXJK JDVNHWV GR RFFDVLRQDOO\ VKRZ XS ,·YH HYHQ VHHQ D PHWDO IODW ILOH O\LQJ DFURVV WKH WXEHV RQ a horizontal cooler. Believe it or not, the points on the file were still sharp enough to XVH³REYLRXVO\ WKH DFLG IORZ DGHTXDWHO\ grounded the file to the vessel and the DQRGLF SURWHFWLRQ ZDV ZRUNLQJ ZHOO 6R DQ LQVSHFWLRQ RI WKH DFLG LQOHW DUHD RI DQ DFLG FRROHU QHHGV WR EH GRQH every turnaround, especially if you have noticed higher amperage and alarms from the anodic SURWHFWLRQ FRQWUROOHU 7KH SUREOHPV ZLWK DFLG VLGH GHEULV DUH SUHVVXUH GURS DQG WXUEXOHQFH ZKHUH WKH KRW DFLG HQWHUV ,I SHUFHQW RI WKH RSHQ DUHD EHWZHHQ WKH WXEHV LV EORFNHG WKHQ WKH UHPDLQLQJ RSHQ DUHD KDV an acid velocity of twice the design. This DOVR FUHDWHV ORFDOL]HG WXUEXOHQFH DURXQG WKH EORFNDJH &RROHUV DUH VDIH DW IW VHF DFLG velocity and 3.5 ft/sec is the upper limit. *RRG OXFN ZLWK D SHUFHQW EORFNHG EXQGOH WKDW VHHV IW VHF YHORFLW\ 7KLV LV ZKHQ \RX start to see a significant increase in amperDJH GHPDQG 5HPHPEHU ZLWK DQRGLF SURWHFWLRQ ´+LJK $PSV +LJK &RUURVLRQµ DQG ´/RZ $PSV /RZ &RUURVLRQ µ /HVV IUHTXHQW WXUQDURXQGV GR QRW DOORZ for cleaning of reference electrodes or the inspection of sacrificial cathodes. Larger diameter cathodes can give you a longer life DQG ZRUN ZHOO LQ RXU H[SHULHQFH ([WUD HOHFtrodes can give the E&I maintenance perVRQQHO VRPH DGGHG IOH[LELOLW\ IRU NHHSLQJ things running smoothly. However, without these components performing properly you will have issues with your corrosion control V\VWHP ZKHQ LW VWRSV ZRUNLQJ SURSHUO\ \RX PD\ RQO\ KDYH ZHHNV RU PRQWKV EHIRUH LW·V time for a new cooler. For more information, please visit www.mercad.com. T Sulfuric Acid Today ‹ Fall/Winter 2017

Non-intrusive flow and concentration of Sulfuric Acid and mass flow of Molten Sulfur

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PIOX S

f No piping and valving f 100% clamp-on

f For hazardous area locations (FM approved)

f No media contact - No risk of leaks

f Monitor your Total Sulfur Consumption

f No process Shut-Downs for installation

f Increase your Plant Up-Time

f No bypass needed

f Balance your Processes

PIOX® S - the evolution of flow and concentration measurement in sulphuric acid production. PIOX® S is used by many of the world’s largest sulfuric acid plants for production and process control monitoring.

www.piox-s.com www.flexim.com Contact us for a free trial measurement!

Feature

Fifteen acid towers in Africa

By: Davood Faraji, Glenn Stefurak, Andrés Mahecha-Botero*, and C. Guy Cooper, NORAM Engineering and Constructors Ltd., Vancouver, Canada

125$0 UHFHQWO\ XSJUDGHG WKH DFLG V\VWHPV RI VL[ sulfuric acid plants at two important sites for one of WKH ODUJHVW IHUWLOL]HU SURGXFHUV LQ WKH ZRUOG 125$0 provided technology, engineering design, procurement, DGYLVRU\ VHUYLFHV DQG VXSSOLHG VSHFLDOL]HG HTXLSPHQW PDQXIDFWXUHG DW $;721 D 125$0 VXEVLGLDU\ $ WRWDO of 15 acid towers were supplied for these sites. Three of WKH WRZHUV ZHUH EULFN OLQHG DQG ZHUH PDQXIDFWXUHG in high-silicon alloy. The plant capacities ranged from 073' WR 073' DV SHUFHQW Z Z +2624 UHTXLULQJ WRZHUV RI DSSUR[LPDWHO\ PHWHUV LQ GLDPHWHU IW 6RPH RI WKH WRZHUV XWLOL]HG 125$0 60$57 SLSH DFLG GLVWULEXWRUV DQG DOO WKH WRZHUV XVHG 125$0

+3 FHUDPLF VDGGOH SDFNLQJ +LJK VLOLFRQ DOOR\ ZDV XWLOL]HG IRU GLVWULEXWRUV DV ZHOO DV IRU VRPH RI WKH SODQW piping. 7KH DFLG V\VWHP XSJUDGH SURMHFWV WRRN SODFH LQ WKUHH VWDJHV DV UHTXLUHG E\ WKH FOLHQW VFKHGXOH IURP 6WDJH ZKLFK WRRN SODFH IURP LQFOXGHG D EULFN OLQHG GU\ VXOIXULF DFLG WRZHU LQWHUSRVH VXOIXULF DFLG WRZHU DQG ILQDO VXOIXULF DFLG WRZHU $ KLJK VLOLFRQ DOOR\ dry sulfuric acid tower and interpose sulfuric acid tower ZHUH DOVR FRPSOHWHG DW WKLV WLPH $OO ILYH WRZHUV LQFOXGHG 125$0 +3 FHUDPLF VDGGOH SDFNLQJ 6WDJH RI WKH SURMHFW IURP LQFOXGHG WZR SODQW VWDFNV DFLG SLSLQJ WZR GU\ VXOIXULF DFLG WRZHUV and two final sulfuric acid towers. The dry towers were PDGH RI 125$0 6;ΠZLWK GU\ 7RZHU 6PDUWΠacid GLVWULEXWRUV DQG WKH ILQDO WRZHUV ZHUH PDGH RI 125$0 6;ΠZLWK 7RZHU 6PDUWΠDFLG GLVWULEXWRUV 125$0 +3 FHUDPLF VDGGOH SDFNLQJ ZDV LQVWDOOHG LQ WKH GU\ DQG ILQDO towers. The final stage of the project stretched from 2015 7KLV LQFOXGHG WKH LQVWDOODWLRQ RI WZR 125$0 6;ΠGU\ VXOIXULF DFLG WRZHUV WZR 6;Πinterpass towers, and WZR ILQDO VXOIXULF DFLG WRZHUV DOO ZLWK 60$57Πacid disWULEXWRUV DQG 125$0 +3 FHUDPLF VDGGOH SDFNLQJ 7KH DGGLWLRQ RI SODQW VWDFNV LQWHUFRQQHFWLQJ JDV GXFWLQJ DQG acid piping rounded out the project.

for innovation and excellence in the supply of proprietary HQJLQHHULQJ DQG HTXLSPHQW SDFNDJHV WR WKH FKHPLFDO pulp and paper, minerals processing, and electrochemiFDO VHFWRUV 7KH FRPSDQ\·V VL[ VSHFLDOL]HG EXVLQHVV groups have completed capital projects on five continents. 125$0 LV UHFRJQL]HG ZRUOGZLGH DV D OHDGHU LQ WKH ILHOGV of nitration, sulfuric acid, and electrochemistry. 125$0 (QJLQHHULQJ DQG &RQVWUXFWRUV /LPLWHG SHUforms engineering studies, conducts training, and supplies LPSURYHG HTXLSPHQW DW DWWUDFWLYH SULFHV IRU VXOIXULF DFLG plants. In addition to carrying out large assignments for PDMRU PXOWL QDWLRQDO FOLHQWV DQG PXQLFLSDOLWLHV 125$0 ZRUNV ZLWK HDUO\ VWDJH WHFKQRORJ\ FRPSDQLHV SURYLGLQJ HQJLQHHULQJ GHVLJQ DQG IDEULFDWLRQ VXSSRUW VKDULQJ H[SHrience in technology commercialization, and growing ZLWK WKH FRPSDQ\ DV D VWUDWHJLF VWDNHKROGHU For more information, please email: sulfuric@norameng.com, call (604) 681 2030, or visit www.noram-eng.com. T * Corresponding Author: Andrés Mahecha-Botero, Ph.D., P.Eng., andresmb@noram-eng.com, andresmb@gmail.com.

Wrap-up 7KH FRPSOHWLRQ RI WKLV SURMHFW VLJQDOV 125$0·V VXFFHVVIXO WUDFN UHFRUG LQ DFLG V\VWHP XSJUDGHV XVLQJ state-of the art acid technology and incorporating a variety of designs and materials of construction to suit the UHTXLUHPHQWV RI DFLG SODQWV ZRUOGZLGH 6LQFH 125$0 KDV EXLOW D JOREDO UHSXWDWLRQ

NORAM used state-of-the-art technology to upgrade six acid plants for a major fertilizer producer in Africa.

Both brick-lined and high silicon alloy towers were used for this project.

This acid system upgrade was completed in three phases, over the course of seven years. PAGE 28

This project involved replacing a total of 15 acid towers.

The towers, for one of the world’s largest fertilizer producers, were located on two separate sites in Africa. Sulfuric Acid Today ‹ Fall/Winter 2017

Feature

Detecting moisture leaks by measuring process gas dew point

By: Daniel T. Menniti, Breen Energy Solutions, Senior Director, Marketing and Sales, North America

6XOIXULF DFLG LV PDQXIDFWXUHG E\ R[LGL]LQJ VXOIXU GLR[LGH 622 JDV WR 623 in a converter through a catalytic oxidation process. 7KH PRVW FRPPRQ VRXUFHV RI 622 DUH ³ %XUQLQJ HOHPHQWDO VXOIXU ³ 622 off-gas from a primary process such as a copper smelter. ³ 'HFRPSRVLWLRQ RI +2622 in a spent acid regeneration process. 7KH 622 gas is passed over a catalyst in WKH SUHVHQFH RI R[\JHQ WR R[LGL]H LW WR 623. 7KH 623 JDV LV WKHQ DEVRUEHG LQWR ² percent H2624 WR IRUP ROHXP +26227 DOVR NQRZQ DV IXPLQJ VXOIXULF DFLG 7KH ROHXP LV then diluted with water to form concentrated sulfuric acid.

Acid dew point measurement in sulfuric acid production

,Q VXOIXULF DFLG SURGXFWLRQ 622 is oxidized over a solid vanadium catalyst to generate sulfur trioxide. The sulfur trioxide LV WKHQ DEVRUEHG LQ ZDWHU FRQWDLQHG LQ percent sulfuric acid to form new sulfuric DFLG 7KH 622 LV HLWKHU SURGXFHG E\ EXUQLQJ elemental sulfur or is an off-gas from other processing plants such as a copper smelter or a spent acid regeneration process. The JDV ODGHQ ZLWK 623 LQ WKH SURFHVV LV NHSW moisture free and the only time when moisture gets introduced in the gas is when there is a process upset. This is a highly XQGHVLUDEOH FRQGLWLRQ DQG FDQ EH SRWHQtially hazardous. 0RLVWXUH LQ WKH IOXH JDV ODGHQ ZLWK 623 is reflected in the acid gas dew point and is generally indicative of one of the following FRQGLWLRQV DPRQJ RWKHUV Âł GU\LQJ WRZHU PDOIXQFWLRQ Âł PRLVWXUH LQ IHHG Âł ZDVWH KHDW ERLOHU WXEH OHDNV Âł HFRQRPL]HU WXEH OHDNV Âł FOHDQLQJ V\VWHP PDOIXQFWLRQV $FLG GHZ SRLQW PHDVXUHPHQW LQ WKLV process, and to a large extent, is mostly for PRLVWXUH OHDN GHWHFWLRQ 7KH SUHVHQFH RI PRLVWXUH DQG WKHUHIRUH ZHDN DFLG YDSRU LQ WKH JDV VWUHDP LV GHWULPHQWDO WR HTXLSPHQW KHDOWK DQG FDQ FDXVH H[WUHPH FRUURVLRQ $ secondary impact of moisture in the flue gas FDQ EH WKH IRUPDWLRQ RI K\GURJHQ JDV ZKLFK can create an explosion hazard [1]. ܾܹ3 +2Üą Ń— H2ܾܹ4 ‍ܪ Ý Ü¨â€Ź2ܾܹ4 Ń— â€ŤÜąÜľÝ ܨ‏4 ‍ܪ‏2 The H2 WKXV IRUPHG DV VKRZQ LQ WKH HTXDWLRQV DERYH FDQ FUHDWH DQ H[SORVLRQ KD]DUG LQ WKH SUHVHQFH RI 22 and an ignition source.

Fig. 1: Typical moisture ingress points in a sulfuric acid manufacturing process.

Âł ZDVWH KHDW ERLOHU WXEHV Âł HFRQRPL]HU WXEHV Monitoring each of these individual SURFHVV SRLQWV VHH )LJ IRU PDOIXQFWLRQ DQG PRLVWXUH LQJUHVV EHFRPHV H[SHQVLYH DQG ODERU LQWHQVLYH ,GHDOO\ LI WKH GRZQVWUHDP SURFHVV JDV GHZ SRLQW FRXOG EH measured, it would signal a step-change response should moisture enter the upstream process. Until recently, however, the availDEOH WHFKQRORJLHV KDYH QRW EHHQ DEOH WR ZLWKVWDQG WKH KDUVK FRQGLWLRQV SUHVHQWHG E\ the application. 8QGHUVWDQGLQJ WKLV QHHG LQ HDUO\ %UHHQ (QHUJ\ 6ROXWLRQV EHJDQ GHVLJQLQJ a system that would withstand the harsh environment, as well as simplify the output to provide the desired response.

Challenges for acid dew point measurement

There are several challenges that had WR EH RYHUFRPH LQ RUGHU WR VXFFHVVIXOO\ develop an instrument that can survive in a sulfuric acid plant and provide the necessary PHDVXUHPHQW &KLHI DPRQJ WKHP DUH Âł &RPSOHWHO\ VHDOHG GHVLJQ WR LVRODWH process gases from the system internals. Âł 0XVW ZLWKVWDQG D SURFHVV SRVLWLYH SUHVVXUH RI XS WR 3VLJ W\SLFDO 3VLJ Âł +HDWHG WLS WR DOORZ RSHUDWLRQ LQ SURFHVV temperatures close to the dew point. Âł 6DIHW\ IHDWXUHV WR LVRODWH WKH V\VWHP LQ FDVH RI VHQVRU IDLOXUH EUHDFK Âł 0DWHULDO RI FRQVWUXFWLRQ GHVLJQHG WR handle high concentrations of sulfuric acid. Âł 3URFHVV PRXQWLQJ V\VWHP GHVLJQHG

to seal and allow online system removal for maintenance. The Breen Dew Point meter was originally designed for negative-pressure, comEXVWLRQ JDV SURFHVVHV 7KHVH SURFHVVHV DOORZHG IRU D SUREH V\VWHP WKDW RQO\ QHHGHG WR EH VHDOHG IURP WKH DWPRVSKHUH RQFH LW ZDV LQVHUWHG 7KH SUREH GLG QRW KDYH DQ\ SURWHFtion, nor a process to allow for a hermetically VHDOHG LQVHUWLRQ 6XEVHTXHQWO\ WKH V\VWHP was redesigned to meet these challenges. 7KH %HWD GHVLJQ FDQ EH VHHQ LQ )LJ $V WKH ILJXUH VKRZV WKH SUREH ZDV designed to insert into an operating process through a compression fitting that would prevent gases from venting into the atmoVSKHUH $IWHU VXFFHVVIXO IDFWRU\ WHVWLQJ WKH SUREH ZDV WDNHQ WR D VXOIXULF DFLG PDQXIDFWXULQJ SODQW RQ WKH 8 6 *XOI &RDVW DQG installed at the exit of the economizer on a sulfuric acid production train.

The economizer outlet location presents a process gas temperature of approximately 400 degrees F and a process gas SUHVVXUH EHWZHHQ SVL 7KH SURFHVV JDV GHZ SRLQW ZDV H[SHFWHG WR EH DW DSSUR[Lmately 250 degrees F. $IWHU LQLWLDO LQVWDOODWLRQ WKH GHZ SRLQW SUREH SURYLGHG VRXQG GHZ SRLQW UHVXOWV DV VHHQ LQ )LJ 2YHU WKH QH[W VHYHUDO ZHHNV the system successfully measured the proFHVV JDV GHZ SRLQW RQ D FRQWLQXRXV EDVLV 3HULRGLFDOO\ WKH V\VWHP ZDV DEOH WR GHWHFW an increase in process gas dew point as a result of moisture ingress into the process. 7KLV PRLVWXUH LQJUHVV ZDV VLPXODWHG E\ introducing moist plant air through the dew SRLQW VHQVRU FOHDQLQJ DLU WXEH DND ´VRRWEORZHU¾ WXEH DV VHHQ LQ )LJ While the results were encouraging, it ZDV QHDUO\ LPSRVVLEOH WR PHFKDQLFDOO\ FOHDQ the sensor in situ, as the instrument cleaning air contained trace amounts of moisture, and FRQVHTXHQWO\ UHQGHUHG WKH VHQVRU FOHDQLQJ V\VWHP LQRSHUDEOH

“Above dew point� measurement tests

Fig. 3: AbSensor-ADM-SA Rev 2 installation.

Fig. 4: Preliminary dew point measurements.

Fig. 5: System output showing increased dew point due to moisture ingress into process. Sootblower tube

,Q RUGHU WR NHHS WKH VHQVRU IUHH RI SURFHVV FRQGHQVDEOHV ORQJ WHUP DQG DOVR SURYLGH PRLVWXUH OHDN GHWHFWLRQ LW ZDV GHFLGHG WR RSHUDWH WKH V\VWHP DW DQ ´DERYH GHZ SRLQW F\FOH ¾ 7KH DERYH GHZ SRLQW F\FOH DOORZV WKH SUREH WR RSHUDWH LQ WKH GXFW DW D temperature higher than the process gas dew SRLQW EXW ORZ HQRXJK WR GHWHFW DQ LQFUHDVH or step change, in process gas dew point. 7KHUH ZHUH WZR REMHFWLYHV WKDW QHHGHG WR EH PHW GXULQJ RSHUDWLRQ LQ WKLV PRGH ³ 'HWHFWLRQ RI PRLVWXUH LQJUHVV ³ 3URYLGH D PHWKRG WR YHULI\ PHDVXUHment integrity. The system was operated in this mode ZLWK SHULRGLF FKHFN F\FOHV L H GHZ SRLQW PHDVXUHPHQWV DQG PRLVWXUH GHWHFWLRQ YLD PRLVW DLU LQWR WKH VHQVRU VRRWEORZHU WXEH 7KLV FDQ EH VHHQ JUDSKLFDOO\ LQ )LJ During this time, there were no signs of sensor fouling, or system malfunction. 7KH V\VWHP UDQ IRU VHYHUDO ZHHNV WR YHULI\ WKH SUREH LQWHJULW\ IRU WKH DSSOLFDWLRQ 7KH SUREH UDQ IRU DSSUR[LPDWHO\ GD\V DW WKH HQG RI ZKLFK LW VXIIHUHG IURP D EUHDFK LQ LQWHJULW\ DQG SURFHVV JDVHV OHDNHG LQWR WKH SUREH LQQHU WXEH DQG EDFN HQG MXQFWLRQ ER[

Moisture leak detection

$V VWDWHG WKHUH DUH VHYHUDO SRWHQWLDO sources of moisture ingress into the process JDV VWUHDP 7\SLFDO VRXUFHV LQFOXGH Âł GU\LQJ WRZHU Âł UDZ PDWHULDO IHHG VWRFN PAGE 30

Fig. 2: AbSensor-ADM-SA Rev 2 for sulfuric acid manufacturing plants. Sulfuric Acid Today ‹ Fall/Winter 2017

The system was rigorously reviewed and our engineering team identified 27 SRLQWV RI SRVVLEOH EUHHFK LQ RXU SUREH V\VWHP 7KH HQWLUH SUREH ZDV UH HQJLQHHUHG

DQG RI WKH SRWHQWLDO LQWHJULW\ EUHDFK points were eliminated. The other two were LVRODWHG LQ VXFK D ZD\ WKDW LW ZRXOG WDNH SRLQWV RI VLPXOWDQHRXV IDLOXUH IRU WKH SUREH LQWHJULW\ WR EH EUHDFKHG 7KH V\VWHP KDV EHHQ UHGHVLJQHG DQG

manufacturing completed. It should prove WR EH UXJJHG HQRXJK WR PHHW WKH DSSOLFDWLRQ FKDOOHQJHV SUHVHQWHG LQ WKH EHJLQQLQJ RI WKLV DUWLFOH $ UH LQVWDOODWLRQ RI WKH ODWHVW GHVLJQ ZDV FRPPLVVLRQHG LQ $XJXVW DQG UHVXOWV DUH VFKHGXOHG WR EH UHSRUWHG LQ 1RYHPEHU RI WKLV \HDU

Summary

The dew point measurement system KDV WKH FDSDELOLW\ WR PHDVXUH FRQWLQX-

Fig. 6: Above dew point operation.

ous process gas dew point temperatures. Understanding that the industry desires a long term, ultra low maintenance sysWHP LW DSSHDUV WKDW WKH ´DERYH GHZ SRLQW modeâ€? measurement philosophy has merit DV D PHWKRG WR GHWHFW PRLVWXUH OHDNV ZKLOH maintaining a clean and dry sensor in EHWZHHQ PRLVWXUH HYHQWV 7KLV PHWKRG DOVR allows for the in situ verification of sensor IXQFWLRQ XVLQJ D SHULRGLF V\VWHP ´FKHFN cycleâ€? outputting a measured dew point on demand. It is also important to note that WKHUH KDYH EHHQ QR SK\VLFDO JODVV VHQVRU failures during any of the test runs. For more information, please visit www.breenes.com. T $FNQRZOHGJPHQW Note [1] Information developed and presented by the Hydrogen Safety Workgroup.

Fig. 7: Mechanical breach of process gases into probe’s inner tube and junction box.

Fig. 8a: Completely sealed probe sensor tip.

Fig. 8b: The new design also includes ball valves on each air supply point.

416.444.4880 admin@mercad.com Ć” www.mercad.com

Sulfuric Acid Today ‹ Fall/Winter 2017

PAGE 31

Feature

Dew point probe redesign

Feature

Collaboration the cornerstone at 2017 Sulfuric Acid Roundtable /DVW 6SULQJ VXOIXULF DFLG industry insiders pooled their FROOHFWLYH NQRZOHGJH DW WKH 6XOIXULF $FLG 5RXQGWDEOH WKDW convened in The Woodlands, near Houston, Texas. Because of WKH EHQHILWV RI H[FKDQJLQJ LQIRUmation within such a complex industry, sulfuric acid producers, consultants, and suppliers from multiple companies and locations gathered to share their expertise. 2YHU DWWHQGHHV IURP FRPSDQLHV JDWKHUHG DW 7KH :RRGODQGV 5HVRUW IURP $SULO to participate in technical discussions, presentations, and panels aimed at helping the industry as a whole produce acid efficiently, safely, and cleanly. They shared experiences, relayed comPRQ SLWIDOOV DVNHG TXHVWLRQV DQG offered suggestions. ´7KLV LV D IRUXP IRU FROODERUDWLRQ Âľ H[SODLQHG .DWK\ Hayward, conference organizer and Sulfuric Acid Today SXEOLVKHU ´7KH SDUWLFLSDQWV KDYH experiences and challenges that DUH XQLYHUVDO VR WKH\¡UH FRPing together to learn from each other, instead of trying to reinvent the wheel.â€? $V LQ SDVW \HDUV URXQGWDEOH SDUWLFLSDQWV LQFOXGHG SHUVRQQHO IURP ERWK SURGXFing acid plants and suppliers/ FRQVXOWDQWV WR WKH LQGXVWU\ 2I WKH FRPSDQLHV UHSUHVHQWHG ZHUH VXOIXULF DFLG SURGXFHUV ZKR VHQW GHOHJDWHV IURP different locations across the 8QLWHG 6WDWHV &DQDGD &KLQD 3HUX 1HZ =HDODQG DQG WKH 8QLWHG .LQJGRP 7KHVH ORFDtions included fertilizer plants, smelters, regeneration, and merchant plants. The remaining 34 companies represented were VXSSOLHUV WKDW SURYLGH HTXLSment and services to the industry. Besides participating in the technical exchange that is the cornerstone of this event, the suppliers also co-sponsored the conference, along with Sulfuric Acid Today magazine. $ YDULDWLRQ LQ WKLV \HDU¡V conference was the greater numEHU RI SUHVHQWDWLRQV IURP SURducing plants than in past years. +D\ZDUG EHOLHYHV WKH LQFUHDVH might stem from an even greater emphasis among plants on OHDUQLQJ IURP HDFK RWKHU ´,W¡V D WHFKQRORJ\ EDVHG LQGXVWU\ QRZ WKHUH¡V D ORW RI PRYLQJ SDUWV with more added all the time,â€? +D\ZDUG VDLG ´$QG IRONV NQRZ WKDW WKLV LV WKH WLPH WR VSHDN XSÂł when we have the most experiPAGE 32

ence in one room than any other time.â€? Hayward also noted that more producer presentations also EHQHILW WKH VXSSOLHU FRPSDQLHV EHFDXVH WKH\ OHDUQ PRUH DERXW the needs in the field. Producer plant panel discussions featured many topics, including acid towers; DFLG UHVLVWDQW OLQLQJV EULFNV mortars and furnace refractory; converters; heat exchangers; process gas monitoring and analyzers; sulfur handling, storage, and pit maintenance; and safety and incident reviews. Co-sponsor presentations also covered a range of topics, including mist elimination and :(63 WHFKQRORJLHV KDQGOLQJ 12[ IRUPDWLRQ HQJLQHHULQJ 622 FRQYHUWHUV PD[LPL]LQJ SDFNLQJ HIILFLHQF\ WKH EHQHILWV RI SURSHU PDLQWHQDQFH DQG 4$ 4& innovative acid resistant linings; replacing heat exchangers; thermal effects on sulfur guns; measuring process gases with optical systems; and safety concerns such as hydrogen mitigation and +$=23 UHSRUWV Though safety is always a featured topic during the roundWDEOH LW EHFDPH PRUH RI D IRFXV WKLV \HDU ´7KH GLVFXVVLRQV honed in on the importance of VDIHW\ Âľ VDLG +D\ZDUG ´SDUWLFXODUO\ WKH KD]DUG DQG RSHUDELOLW\ UHYLHZ RU +$=23 Âľ ,Q IDFW GXH to these discussions, the conference decided to create a central GDWDEDVH WR VKDUH UHSRUWV OLNH +$=23V DORQJ ZLWK LQIRUPDWLRQ on hydrogen safety. The reports will omit proprietary informaWLRQ DQG ZLOO EHFRPH DYDLODEOH through the Sulfuric Acid Today ZHEVLWH ZZZ K VR WRGD\ FRP $V LQ SDVW \HDUV WKH conference offered participants activities outside the conference URRP 6SHFLDO HYHQWV WKLV \HDU included fishing and golf tournaPHQWV DORQJ ZLWK D 7H[DV EDUEHTXH GLQQHU IROORZHG E\ FLJDU UROOLQJ DQG ZKLVNH\ WDVWLQJ 9,3 International and Weir Minerals Lewis Pumps provided their traditional Cajun dinner to welcome participants, and co-sponsor companies together with Sulfuric Acid Today hosted a casino night with door prizes. The last day of the conference featured a plant tour of Eco 6HUYLFHV¡ VXOIXULF DFLG IDFLOLW\ LQ Houston. Participants toured the SODQW E\ EXV DQG WKHQ FRQYHQHG inside the facility for refreshPHQWV DQG D TXHVWLRQ DQG DQVZHU SHULRG ´These plant tours, and

SDUWLFXODUO\ WKH FKDQFH WR DVN TXHVWLRQV DERXW ZKDW WKH\¡YH VHHQ KDYH EHFRPH D UHDOO\ YDOXDEOH SDUW RI WKH FRQIHUHQFHV Âľ +D\ZDUG VDLG ´,W¡V DQRWKHU opportunity for plant people to see other plants facing the exact same issues, and a venue to discuss common solutions.â€? The next Sulfuric Acid Roundtable will be held in central Florida at the Streamsong Resort, April 8-11, 2019. For more information, please contact Kathy Hayward at (985) 807-3868 or email kathy@h2so4today.com. T

Fiona Boyd of Acuity Commodities opened the roundtable with her insightful keynote presentation regarding the changes in supply and demand for sulfuric acid and its impact on the market.

Over 160 attendees from 63 companies gathered to share new technology, best practices, and lessons learned during the 2017 Sulfuric Acid Roundtable in The Woodlands, Texas.

The conference featured a plant tour of Eco Services’ sulfuric acid facility in Houston. Participants toured the plant by bus, and then convened inside the facility for refreshments and a question-and-answer period.

Participants were able to interact with the supporting co-sponsors during the roundtable’s exhibition time. Randy Stanfill of Weir Minerals Lewis Pumps, left, shares his company’s technology with Eugene Rawlins of JR Simplot.

Fun was had by all during the roundtable’s casino night networking function.

Co-sponsors of the event shared their company’s latest technologies with participants. Patrick Polk of Haldor Topsøe explained NOx formation and removal in sulfuric acid plants.

Tony Staton of Cornerstone Chemical, right, shares his facility’s experiences during the acid tower panel discussion. Also chairing the panel, are, from left, Xavier Paquet of Horne Smelter-Glencore, Gabriel St-Pierre of Horne Smelter-Glencore, Kieran Murray of Ravensdown Fertilizer, and Trevor Wyatt of Lucite International. Sulfuric Acid Today ‹ Fall/Winter 2017

THE ART OF ACID PROOFING

S O U T H WEST REFRACTORY DELIVERS THE HIGHEST Q U ALIT Y ACID PROOFING, REFRACTORY, INDUSTRIA L MASONRY AND FIREPROOFING WORK.

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IN FO @S WR - U S . C O M

Feature

CONFERENCE REVIEW

Central Florida AIChE hosts 40th International Phosphate Fertilizer & Sulfuric Acid Technology Conference

The International Phosphate )HUWLOL]HU DQG 6XOIXULF $FLG Technology Conference, now in its 41st year, is always a highlyanticipated industry event. Hosted DW WKH 6KHUDWRQ 6DQG .H\ 5HVRUW E\ WKH &HQWUDO )ORULGD &KDSWHU RI WKH $PHULFDQ ,QVWLWXWH RI Chemical Engineers Central )ORULGD 6HFWLRQ WKH FRQIHUHQFH EULQJV FROOHDJXHV IURP DURXQG WKH ZRUOG WR )ORULGD¡V *XOI &RDVW WR share ideas concerning chemical process technology, specifically the production of phosphoric acid, phosphate fertilizers, and sulfuric DFLG 7KLV \HDU¡V VXOIXULF DFLG SUHVHQWDWLRQV LQFOXGHG Âł ´)HDVLELOLW\ RI 6RODU 3DQHOV in Industrial Processes,â€? E\ -HQQLIHU 6 :RRGVRQ RI 0LVVLVVLSSL 6WDWH 8QLYHUVLW\ Âł ´&)' 6LPXODWLRQ WR ,PSURYH Cooling Pond Performance,â€? E\ $QJHOR 6WDPDWLRX RI Hatch. Âł ´)XPLQJ $FLGV 6SLOO 0LWLJDWLRQ 7UDLQLQJ Âľ E\ 0DUN 6DO]EUHQQHU DQG %UDG YDQ 6FRLN RI 9HROLD Âł ´8PP :D¡DO 3KRVSKDWH

3URMHFW³6XOSKXULF 3ODQWV ¾ E\ -RVHSK .HOO\ DQG 6KDLOHVK 6DPSDW RI 61& /DYDOLQ ³ ´:KDW WR 'R :KHQ <RX 5XQ 2XW RI %ORZHU ¾ E\ -RKQ :RRGURPH RI 0(&6 DuPont. $Q LQWHJUDO SDUW RI WKH FRQference in Clearwater, Fla., is the 6XOIXULF $FLG :RUNVKRS 7KLV \HDU¡V WK DQQXDO 6XOIXULF $FLG :RUNVKRS ZDV PRGHUDWHG E\ 5LFN 'DYLV RI 'DYLV $VVRFLDWHV 7KH session included presentations that were geared toward practicing engineers with various degrees of exposure to the sulfuric acid process, plant operation, and plant maintenance. Presenters included 7LQR 3UDGR RI 3UDGR $VVRFLDWHV +HUEHUW /HH RI &KHPHWLFV 5LFN 'DYLV RI 'DYLV DQG $VVRFLDWHV /HQ )ULHGPDQ RI $FLG (QJLQHHULQJ Consultants, and Jim Dougherty of Mosaic. They focused on variRXV DVSHFWV RI +$=236 LQ VXOfuric acid plants, from Process +D]DUG $QDO\VLV WR WKH SXUSRVH DQG OLPLWDWLRQV RI +$=23 VWXGLHV and the shortcomings of the system. Best practices and case stud-

ies were shared, allowing industry leaders to learn from each other RQ WRSLFV UDQJLQJ IURP WDQN OLQLQJ DQG FRQYHUWHU VWDUWXS WR (3$ UHJXODWLRQV $ OLYHO\ URXQGWDEOH discussion followed, touching on topics including shutdowns within +$=23 WKH HFRQRPLF EHQHILWV RI +$=23 DQG WKH LPSRUWDQFH RI LQFOXGLQJ WKH SODQW¡V RSHUDtions and maintenance side in +$=23 ,QIRUPDWLRQ VKDULQJ EHWZHHQ IDFLOLWLHV WR KHOS H[SDQG WKH NQRZOHGJH EDVH DURXQG WKH world, was also discussed. The Clearwater Conference LV DOZD\V DERXW PRUH WKDQ SUHsentations and panel discussions, though. Everyone spent some GRZQWLPH EHWZHHQ VHVVLRQV HQMR\LQJ WKH EHDXWLIXO *XOI &RDVW ORFDWLRQ :KLOH DWWHQGHHV ZHUH EXV\ OHDUQLQJ DERXW WKH ODWHVW DGYDQFHV in their fields, children enjoyed WKH WK $QQXDO &KLOGUHQ¡V 6FLHQFH Party, presented in partnership ZLWK WKH 0XVHXP RI 6FLHQFH DQG Industry, which included several IXQ 67(0 EDVHG DFWLYLWLHV $QG DOO attendees enjoyed family-friendly hospitality suites each night, which

Rick Davis of Davis & Associates moderated the sulfuric acid workshop on the various aspects of HAZOPS in sulfuric acid plants.

Mark Salzbrenner of Veolia shared his company’s knowledge of fuming acids spill mitigation training with participants during the sulfuric acid session of the conference.

Jim Dougherty of Mosaic Co., right, explained his company’s procedures for sulfuric acid HAZOPS. Also pictured, from left, are Rick Davis of Davis & Associates, Len Friedman of Acid & Engineering Consultants, Herbert Lee of Chemetics, and Tino Prado of Prado Associates.

Brennan Afelskie of SNC Lavalin explains his company’s sulfuric acid plant designs for the Umm Wa’al Phosphate Project in Saudi Arabia.

DIIRUGHG WKH FKDQFH WR QHWZRUN reconnect with old friends, and enjoy some great Florida cuisine.

Dates for the 2018 conference have been set for June 8-9, 2018. For more information, visit the event’s website at www. aiche-cf.org. T

Eco Services’ training tradition raises new engineers 6XOIXULF DFLG PDQXIDFWXUHU (FR 6HUYLFHV XQGHUVWDQGV WKH YDOXH RI H[SHULHQFH 6LQFH WKH FRPSDQ\ KDV RIIHUHG its junior engineers training sessions ZKHUH WURYHV RI FROOHFWLYH NQRZOHGJH JOHDQHG E\ H[SHULHQFHG VWDII DUH SDVVHG GRZQ WR WKH QHZHVW UHFUXLWV ´:H VHH RXU new engineers developing into leadership roles in the not too distant future,â€? VDLG *DYLQ )OR\G (FR 6HUYLFHV¡ +RXVWRQ &DSLWDO 3URMHFWV 0DQDJHU ´6KDULQJ DFLG industry and company specific information helps them get there.â€? (FR 6HUYLFHV KDV D ORQJ KLVWRU\ LQ sulfuric acid manufacture and spent acid regeneration technologies. The company, KHDGTXDUWHUHG LQ 7KH :RRGODQGV 7H[DV KROGV QXPEHU RQH SRVLWLRQV LQ ERWK UHJHQ VHUYLFHV DQG PHUFKDQW YLUJLQ DFLG SURGXFWLRQ LQ WKH 8QLWHG 6WDWHV :LWK D WRWDO RI HPSOR\HHV (FR 6HUYLFHV RSHUDWHV HLJKW VXOIXULF DFLG XQLWV QDWLRQZLGH ZLWK D FRPELQHG SURGXFWLRQ FDSDFLW\ RI PLOOLRQ 673' 7KURXJKRXW WKH \HDUV WKH EDVLF WUDLQLQJ format has remained the same, with seniors teaching juniors, and outside suppliers sharLQJ WKHLU H[SHUWLVH %XW WKH FRXUVH¡V GXUDWLRQ has increased to meet the learning goals as they have evolved. The latest session, held DW WKH 0DUULRWW &KLFDJR 2¡+DUH +RWHO UDQ IRU WKUHH GD\V ODVW VXPPHU IURP -XO\ PAGE 34

Thirteen junior engineers participated from DOO VL[ RI (FR 6HUYLFHV¡ PDQXIDFWXULQJ VLWHV %DWRQ 5RXJH /D %D\WRZQ DQG +RXVWRQ Texas; Dominguez and Martinez, Ca.; and Hammond, In. 7KH ILUVW GD\ NLFNHG RII ZLWK D SODQW tour of the Hammond site, which provided context for the training and was especially useful for engineers from other plants. 7KH IROORZLQJ GD\ EHJDQ ZLWK D ZHOFRPH IURP 0LFKDHO 0LODV]HZVNL +DPPRQG

senior technical group representative, and DQ H[SHULHQWLDO GLVFXVVLRQ DERXW PRWLYDWLRQ DQG GULYH IDFLOLWDWHG E\ OHDGHUVKLS development professional Brad Humphries RI 3LQQDFOH 'HYHORSPHQW *URXS 1H[W (FR 6HUYLFHV¡ VHQLRU HQJLQHHUV EHJDQ WKH NQRZOHGJH VKDUH 'DUUHO +RGJH SODQW PDQager at the Martinez facility, shared some ´OHVVRQV OHDUQHG¾ IURP KLV SODQW VR QHZ HQJLQHHUV FRXOG EHQHILW IURP WKRVH H[SHULHQFHV 5REHUW 6FKOHJHO %DWRQ 5RXJH WHFK

Participating in Eco Services’ new engineer training in Chicago are, from left to right, Mike Milaszewski, Adam Strakosch, Joe Lacasella, Kevin Cornell, Cleve Daigel, Jeff Keller, Ted Olzanski, Ryan Powell, Brad Touhey, Bert Young, Meredith Cook, Rock Demarais, Gavin Floyd, Colby Fletcher, Nicholas Ritchey, Ben Kalafut, Rob Schlegel, and Carl Yamada.

services engineer, relayed his expertise on turnaround inspections, and Gavin Floyd discussed some of his hard learned lessons, focused more specifically on engineering. $V LQ SDVW \HDUV VXSSOLHUV WR WKH sulfuric acid industry rounded out the GLVFXVVLRQV 6HYHUDO UHSUHVHQWDWLYHV IURP Chemetics discussed converters, acid coolHUV KHDW H[FKDQJHUV GLVWULEXWRUV DQG JDV exchangers. 2XWVLGH RI WKH FRQIHUHQFH URRP participants gathered to unwind and get WR NQRZ HDFK RWKHU EHWWHU 7KH\ VRFLDOized during dinners out, sampled some of &KLFDJR¡V GHHS GLVK SL]]D DQG ERZOHG D few games at a local alley. 7KH EHQHILWV RI WKLV W\SH RI SURJUDP DSSO\ EURDGO\ WR ERWK MXQLRU DQG VHQLRU engineers, and to the company as a whole. ´7KH WUDLQLQJ GHYHORSV PRUH SHUVRQDO UHODWLRQVKLSV EHWZHHQ WHFKQLFDO H[SHUWV DQG QHZO\ KLUHG HQJLQHHUV Âľ VDLG )OR\G ´,W DOVR SURPRWHV EHWWHU FRPPXQLFDWLRQ EHWZHHQ WKH QHZ HQJLQHHUV E\ OHWWLQJ WKHP PHHW LQ DQ LQIRUPDO VHWWLQJ VR WKH\ FDQ JHW WR NQRZ each other.â€? The training team regularly refines the course to ensure it remains in sync with company operating technologies and continXHV WR EH PHDQLQJIXO WR WKH HQJLQHHUV T

Sulfuric Acid Today ‹ Fall/Winter 2017

6LQFH WKH HDUO\ V WKH $XVWUDODVLD :RUNVKRS DQG WKH 6XOIXULF $FLG 5RXQGWDEOH 6$5 KDYH EHHQ EULQJLQJ sulfuric acid industry insiders together to share a wealth of technical expertise and experience. The conferences are held in resort areas where participants typically travel ORQJ GLVWDQFHV WR DWWHQG 6RRQ FRQIHUHQFH RUJDQL]HU .DWK\ +D\ZDUG ZKR UXQV WKH $XVWUDODVLD :RUNVKRS DQG 6$5 ZLOO RIIHU DQRWKHU RSWLRQ WR DFLG SURGXFHUV WKH 6XOIXULF $FLG 7HFKQRORJ\ 6HPLQDU 6$76 KRVWHG DW WKH SURGXFHU¡V facility or local conference center. ´7KH ORFDO VHPLQDU ZLOO EH VLPLODU WR WKH 6XOIXULF $FLG 5RXQGWDEOH EXW IRU MXVW RQH VXOIXULF DFLG SURGXFLQJ FRPSDQ\ Âľ H[SODLQHG +D\ZDUG ZKR DOVR SXEOLVKHV Sulfuric Acid Today ´:H FRPH WR \RX :H ZRUN DURXQG \RXU VFKHGXOH and customize the topics to fit your needs.â€? Hayward sees the local seminar concept as a way to VHUYH WKH WUDLQLQJ QHHGV RI MXQLRU HQJLQHHUV ZKRVH EXV\ ZRUN VFKHGXOHV SURKLELW WKHP IURP WUDYHOLQJ WR D FRQIHUHQFH ´2IWHQ WKH\¡UH LQ WKH PLGGOH RI D WXUQDURXQG DQG FDQ¡W JHW DZD\ Âľ +D\ZDUG VDLG ´7KLV ZD\ ZH FDQ RIIHU D RQH RU WZR GD\ 6$76 VHVVLRQ ZKHQ LW¡V FRQYHQLHQW DQG save the client some money in the process.â€? The conference itself is complimentary to producing SODQWV 7KHLU RQO\ H[SHQVH ZRXOG EH ORGJLQJ VKRXOG WKH plant choose to have employees overnight at an offsite YHQXH VXFK D ORFDO KRWHO RU FRQIHUHQFH FHQWHU /LNH D WUDGLWLRQDO URXQGWDEOH FRQVXOWDQWV DQG YHQGRUV ZKR VHUYLFH the sulfuric acid industry would cosponsor the event and would provide the training, or optionally co-train with the

SODQW¡V RZQ H[SHUWV LI GHVLUHG (LWKHU WUDLQLQJ RSWLRQ FDQ EH arranged and is up to the individual plant. ´7KH FRQVXOWDQW DQG YHQGRU NQRZOHGJH EDVH LV YDVW Âľ VDLG +D\ZDUG ´2YHU WKH \HDUV WKH\¡YH VHHQ PDQ\ GLIIHUHQW SODQWV DQG ZKHQ \RX JHW WKHP LQ D URRP WRJHWKHU \RX¡UH JHWWLQJ \HDUV RI FRPELQHG H[SHULHQFH Âľ 0DQ\ SODQWV DOVR KDYH WKHLU RZQ LQGXVWU\ H[SHUWVÂłVHQLRU OHYHO VWDII ZKR FRXOG VKDUH WKH OHVVRQV WKH\¡YH OHDUQHG RYHU WKH \HDUV ZLWK WKH QHZHVW HQJLQHHUV ´3ODQWV FRXOG XVH WKLV RSSRUWXQLW\ WR WUDQVIHU WKHLU RZQ LQ KRXVH NQRZOHGJH EDVH WR MXQLRU VWDII Âľ +D\ZDUG VDLG 7KH 6$76 LV FRPSOHWHO\ FXVWRPL]DEOH WKH SODQW chooses the time, place, and topics. Hayward will help SODQWV GHVLJQ WKH FRQIHUHQFH WKDW EHVW VXLWV WKHLU QHHGV including arranging social events in the local area, such as KRVSLWDOLW\ FRFNWDLO KRXUV WKHPHG GLQQHUV RU RWKHU RXWLQJV ´:H¡YH IRXQG WKDW ZLWK WKH 6$5 DQG $XVWUDODVLD FRQIHUHQFHV HYHQ D OLWWOH ELW RI VRFLDO WLPH JRHV D ORQJ ZD\ WR EXLOGLQJ UHODWLRQVKLSV WKDW HQFRXUDJH NQRZOHGJH VKDULQJ Âľ +D\ZDUG VDLG ´:KHQ SHRSOH JHW WR NQRZ HDFK RWKHU EHWWHU WKH\¡UH PRUH OLNHO\ WR DVN WKDW TXHVWLRQ WKH\ KHVLWDWHG WR DVN in the conference room, or contact one another later, after the conference is over.â€? +D\ZDUG ZLOO VWLOO SURGXFH WKH 6XOIXULF $FLG 5RXQGWDEOH DQG WKH $XVWUDODVLD FRQIHUHQFHV EHFDXVH WKHVH HYHQWV RIIHU D JUHDWHU FROOHFWLYH NQRZOHGJH EDVH E\ JDWKHULQJ SODQW SHUsonnel from many acid manufacturers across the country DQG DURXQG WKH JOREH ´3URGXFLQJ SODQWV VKDUH FRPPRQ goals and challenges, and so have a tremendous amount they can learn from each other,â€? Hayward explained. In

IDFW WKHUH ZDV DQ LQFUHDVH LQ WKH QXPEHU RI SURGXFHU SUHVHQWDWLRQV DW WKH 6XOIXULF $FLG 5RXQGWDEOH KHOG ODVW 6SULQJ DV FRPSDUHG WR SUHYLRXV \HDUV +D\ZDUG EHOLHYHV WKH LQFUHDVH LV EHFDXVH RI D JURZLQJ YDOXH SODFHG RQ LQIRUPDWLRQ VKDULQJ DV WKH LQGXVWU\ EHFRPHV PRUH FRPSOH[ 7KH ORFDO 6$76 VHPLQDU LV RIIHUHG DV DQ DOWHUQDWLYH WR WKH RIIVLWH FRQIHUHQFH JLYLQJ SODQWV WKH IOH[LELOLW\ WR design their own event with the date, location, and content of their choosing. For more information about offering a technology seminar at your site, contact Kathy Hayward at kathy@h2so4today.com. T

ISO-FLOW™ Trough Distributors with SWIFT-LOCK™ Experience: ‡ Next generation Orifice distributor introduced in 2011 ‡ Developed and patented by Chemetics Features and Benefits: ‡ Orifice distribution provides consistent flow to each downcomer ‡ Air gaps provide hydraulic separation and allow for easy troubleshooting ‡ Calming plates promote even distribution - Integral screens catch chips to minimize plugging and allow easy cleaning - Internal channel minimises header pipes ‡ SWIFT-LOCK™ system - Reduces distributor installation time by 50% - Simplifies tube bank installation/removal – time reduced by 90% - Eliminates 90% of nuts/bolts/washers ‡ SARAMETŽ Construction for excellent acid corrosion resistance The ISO-FLOW™ Trough Distributor is designed to be installed through tower manways and is ideal for retrofits.

Innovative solutions for your Sulfuric Acid Plant needs Chemetics Inc.

Chemetics Inc.

www.jacobs.com/chemetics

Chemetics Inc., a Jacobs company

(headquarters) Vancouver, British Columbia, Canada Tel: +1.604.734.1200 Fax: +1.604.734.0340 email: chemetics.info@jacobs.com

Sulfuric Acid Today ‹ Fall/Winter 2017

(fabrication facility) Pickering, Ontario, Canada Tel: +1.905.619.5200 Fax: +1.905.619.5345 email: chemetics.equipment@jacobs.com

PAGE 35

Feature

adds technology seminar to conference repertoire

Faces & Places Vi it ng du Visiting during n Cheme Chemetic’s c s hospitality hos t it su suite te held hel att tthe he A AICh AI ICh ChE hE C onve on nve vent ent ntio tio ion on iin n AIChE Convention Clearwater, Fla. are, from left, Herbert Lee and Boris Nesic of Chemetics, Mark Salzbrenner and Brad van Scoik of Veolia, and Bob Whitters of Chemetics. Ed Knoll of Acid Piping Technology, left, Darwin Passman of VIP International, center, and Alex Knoll of Acid Piping Technology, right, visit during a dinner hosted by Weir Minerals Lewis Pumps during the AIChE Central Florida Chapter Convention in Clearwater, Fla.

From left, Nathaniel Bepperling, Eric Betournay, and Eduardo Cabera, all of Brunswick Smelter– Glencore, enjoy a session break during the 2017 Sulfuric Acid Roundtable in The Woodlands, Texas.

Eco Services and Solvay’s Baton Rouge, La. facilities participated in United Way’s Jambalaya Jam cook-off in downtown Baton Rouge to benefit the local community. Pictured are, from left, Robert Mollier, Corey Wheat, Bruce Mayberry, Brad Touhey, Robert Musselman, Brittany Burton, and Daniel Tate.

Becky and Jack Harris of VIP International served some delicious etouffee and corn maque choux to the participants of the 2017 Sulfuric Acid Roundtable at The Woodlands Resort in Texas.

Enjoying MECS’ hospitality suite during the AIChE’s Central Florida Convention in Clearwater, Fla. are, from left, Carlos Iwaszkowiec of MECS, Eugenio Barriga of Innophos, and Jose Antonio Cabrera of Innophos.

Claude Champagne of Border Chemical, left, was the lucky door prize recipient from Brad Varnum of Central Maintenance & Welding, right, during the casino night networking function at the 2017 Sulfuric Acid Roundtable in The Woodlands, Texas..

Catching up with one another at the AIChE’s Central Florida Convention in Clearwater, Florida are, from left, Guy Cooper of NORAM Engineering & Constructors, George Wang of Acid Tech, and Nelson Clark of Clark Solutions.

Michael Garcia of Tesoro, right, tries a hand-rolled cigar at the 2017 Sulfuric Acid Roundtable in The Woodlands, Texas.

The culinary team for this year’s welcome Cajun Dinner at the 2017 Sulfuric Acid Roundtable in The Woodlands, Texas consisted of Randy Stanfill of Weir Minerals Lewis Pumps, left, Stan Miller of VIP International, center, and Hoss Maddry of VIP International. The crew prepared some delicious jambalaya, etouffee, corn maque choux, and fried fish from the day’s fishing tournament.

Participating in the golf tournament at the 2017 Sulfuric Acid Roundtable at The Woodlands Resort are, from left, Bryan Argenbright of Ramco Manufacturing, Graeme Cousland of Begg Cousland Envirotec, Corey Muller of Outotec, and Steve Shrout of Ramco Manufacturing.

Kleber Juardo of Southern Peru Copper Corp., left, visits with Robert Maciel of Chemetics in his company’s booth at the 2017 Sulfuric Acid Roundtable in The Woodlands, Texas.

Enjoying the annual Tenney & Company customer appreciation celebration at an Astros Game in Houston are, from left, Dean Raucstadt of Dow, Skip Unger of Acid Piping Technology, Paul Wibbenmeyer of MECS, Howard Tenney of Tenney & Company, Brian Lamb of MECS, Jim Cesen of Eco Services, and Steve Williams of MECS.

Weir Minerals Lewis Pumps hosted a dinner for their clients and customers att Crabby Bill’s Restaurant in Clearwaterr during the AIChE Central Florida Chapterr d Convention in Clearwater, Fla. Pictured e are, from left, Ricky Jaswal, Mick Cooke, and Randy Stanfill, all from Weir Minerals Lewis Pumps.

Enjoying En njoying o ing some om cigars c g r dur during n an evening v n n hospitalit hospitality hosp a ityy ffunction unc unc ncttio on n aatt th the he 20 2017 0177 Sulfuric Sul ulf lffu furi uri rric i Acid Roundtable are, from left, Dan Castellino and Dean Williams of Langeloth Metallurgical; Shane Gibbons of El Dorado Chemical; and George Froats, Eric Barton, and Dan Himmel of Langeloth Metallurgical.

Approximately 200 people attended the annual Tenney & Company Customer Appreciation event cosponsored by MECS, Acid Piping, and Weir Minerals Lewis Pumps during an Astros baseball game in Houston. This year’s theme, “Rock Star Customers,” was fun for all.

Networking during the welcome reception of the 2017 Sulfuric Acid Roundtable in The Woodlands, Texas are, from left, Andy Smith of Lucite, Rick Davis of Davis & Associates, Vince Goyette of PVS Chemicals, and George Volker of Lucite.

Toasting a successful day at the 2017 Sulfuric Acid Roundtable in The Woodlands, Texas are, from left, Joel Heath of Sherritt and Matt Thayer of Koch Knight LLC.

Enjoying the welcome reception of the 2017 Sulfuric Acid Roundtable in The Woodlands, Texas are, from left, Bandish Patel and Dan Vidusek of Spraying Systems Co., Clayton Cody of Dow Chemical, Deborah Hanson, David Hanson of Dow Chemical, and Chuck Munro of Spraying Systems Co.

In downtown Baton Rouge, employees from Mosaic’s Louisiana facilities participated in United Way’s Jambalaya Jam cook-off to benefit the local community. Pictured are, from left, Randy Cassio, Mike Duhe, and Cody Chauppetta.

Participants of the 2017 Sulfuric Acid Roundtable enjoyed a Cajun welcome at The Woodlands resort in Texas. Pictured are, from left, Arebel Torres of Chemtrade Logistics, Vince Chow of Teck Metals, Kate Parejko-Kompa of Teck Metals, Jesse Huebsch of Chemetics, Rick Gaethle of Chemtrade Logistics, and Zig Biernacki of Turbine Diagnostic Services.

Haldor Topsøe hosted a dinner at the Columbia restaurant during the AIChE Convention in Clearwater, Fla. Pictured are, from the left side, Michelle Navar of Mosaic, Brittany Cooley of Mosaic, Bethany Cooley of Mosaic, Emily Fliegar, Bill Goodall of Haldor Topsøe, Lian Blackwelder of Mosaic, and Nolan Blackwelder. From the right side are Sam Chidester of Haldor Topsøe, April Kabbash of Sulfuric Acid Today, Russell O’Connell of Mosaic, Patrick Polk of Haldor Topsøe, Heather Thurner, and Justin Graff of Mosaic.

Catching up during the Tenney & Company customer appreciation gathering at the Astros baseball game in Houston are, from left, Gene Tenney of Tenney & Company, Jimmy Sharp of Eco Services, and Howard Tenney of Tenney & Company.

Department

CALENDAR OF EVENTS

Phosphates 2018

March 12-14, 2018 Marrakesh, Morocco /21'21²&58 LV GHOLJKWHG WR UHWXUQ WR 0RURFFR IRU 3KRVSKDWHV DQG FHOHEUDWH the 11th event in the series. The last Phosphates Conference in Morocco, in 2012, attracted a record attenGDQFH RI RYHU SDUWLFLSDQWV $V 0RURFFR UHPDLQV D GULYLQJ IRUFH LQ JOREDO SKRVSKDWH SURGXFWLRQ WKLV VWUDWHJLF ORFDWLRQ HQDEOHV &58 WR EULQJ WRJHWKHU RQH RI WKH ZRUOG·V ODUJest audiences of phosphate mining and plant operators and engineers. &58·V 3KRVSKDWHV &RQIHUHQFH LV ILUPO\ HVWDEOLVKHG DV WKH SUHPLHU JDWKHULQJ IRU VHQLRU GHFLVLRQ PDNHUV UHSUHVHQWLQJ WKH IHUWLOizer, feed, and industrial phosphates industries. Business leaders from producers, tradHUV HQJLQHHULQJ WHFKQRORJ\ DQG HTXLSPHQW providers, and consumers, meet at this annual HYHQW WR HQJDJH LQ KLJK OHYHO QHWZRUNLQJ QHJRWLDWH EXVLQHVV FRQWUDFWV DQG VKDUH LQGXVWU\ NQRZOHGJH 3KRVSKDWHV ZLOO SURYLGH GHOHJDWHV ZLWK NH\ LQVLJKWV DQG LQ GHSWK PDUNHW LQIRUPDWLRQ DERXW SKRVSKDWHV UDZ PDWHULDOV LQWHUmediates, and finished products. The two-day SURJUDP ZLOO FRYHU NH\ FRPPHUFLDO VXEMHFWV LQFOXGLQJ FXUUHQW DQG IRUHFDVW VXSSO\ G\QDPLFV SKRVSKDWH IHUWLOL]HU FRVW RXWORRN XSGDWHV

on new projects and their anticipated impact RQ RYHUVXSSOLHG PDUNHWV DQG GHPDQG GULYHUV IURP WKH IHUWLOL]HU IHHG DQG LQGXVWULDO PDUNHWV 3KRVSKDWHV ZLOO DOVR FRQWLQXH WR grow its technical content, with a dedicated stream of technical presentations in addition WR WKH SRSXODU WHFKQLFDO VKRZFDVHV 5HJLVWHUHG attendees will have the chance to share practical experience with other operators and meet ZLWK WKH LQGXVWU\·V OHDGLQJ VXSSOLHUV RI WHFKnology and engineering solutions in the large VFDOH H[KLELWLRQ The Phosphates conference is the mustattend event for commercial and operational executives in the fertilizer, feed, and industrial phosphates industries. For more information, please visit www. events.crugroup.com/phosphates/home.

regularly attracts nearly 500 delegates from 40 countries. International attendees represent the complete copper value chain from miners to smelters, traders, and end-users. 2YHU SHUFHQW RI DWWHQGHHV DUH & OHYHO executives including all of the most influential &(2V LQ WKH FRSSHU LQGXVWU\ 7KLV PHDQV WKH QHWZRUNLQJ RSSRUWXQLWLHV DW WKH FRQIHUHQFH DUH unsurpassed and the issues discussed have a IXQGDPHQWDO HIIHFW RQ WKH IXWXUH RI FRSSHU $W the forthcoming conference there will presentaWLRQV SDQHO GLVFXVVLRQV DQG NH\QRWH VSHHFKHV ORRNLQJ DW QH[W OHYHO WHFKQRORJ\ PLQLQJ VWUDWHJLHV LQ WKH V ILQDQFLQJ WKH VFUDS PDUNHW IXWXUH GHPDQG WUHQGV HFRQRPLF DQG PDUNHW expectations. For more information, please visit www.events.crugroup.com/copper/home.

World Copper Conference 2018

CORROSION 2018

April 15-19, 2018 Phoenix, Arizona +286721³&25526,21 WKH ZRUOG·V ODUJHVW FRUURVLRQ FRQIHUHQFH DQG H[SRsition, is coming to the West Coast. Each \HDU &25526,21 ZHOFRPHV PRUH WKDQ FRUURVLRQ HQJLQHHUV VFLHQWLVWV UHVHDUFKers, technicians, asset owners, inspectors, and RWKHU SURIHVVLRQDOV IURP RYHU FRXQWULHV around the world. This comprehensive conferHQFH LV SDFNHG ZLWK WHFKQLFDO HGXFDWLRQ DQG

April 9-11, 2018 Santiago, Chile /21'21³&58·V :RUOG &RSSHU &RQIHUHQFH ZLOO EH KHOG GXULQJ &(6&2 :HHN &KLOH IURP $SULO 7KHVH SDUWQHUHG HYHQWV SURvide the most important commercial and netZRUNLQJ RSSRUWXQLWLHV LQ WKH LQGXVWU\ The three-day conference is widely regarded as the leading copper conference and

Save the Date! 2019

Sulfuric Acid

R O U N D T A B L E

April 8-11, 2019 Streamsong Resort Central Florida

NQRZOHGJH H[FKDQJH DORQJ ZLWK RSSRUWXQLWLHV to connect with industry experts and peers, focused on the prevention and mitigation of corrosion worldwide. For more information, please visit www.nacecorrosion.org.

AIChE Central Florida—2018 Clearwater Convention

June 8-9, 2018 Clearwater, Florida /$.(/$1' )OD ³(DFK \HDU PHPEHUV RI WKH $,&K( &HQWUDO )ORULGD 6HFWLRQ DQG FROleagues from all around the world gather in Clearwater Beach to share ideas concerning chemical process technology, specifically the production of phosphoric acid, phosphate fertilL]HUV DQG VXOIXULF DFLG 7KH 6KHUDWRQ 6DQG .H\ 5HVRUW LQ &OHDUZDWHU ZLOO RQFH DJDLQ EH WKH VLWH for this highly anticipated event, scheduled for -XQH 7KH VXOIXULF DFLG WHFKQRORJ\ ZRUNVKRS FKDLUHG E\ 5LFN 'DYLV RI 'DYLV $VVRFLDWHV ZLOO WDNH SODFH RQ )ULGD\ DIWHUQRRQ $V DOZD\V WKH FRQYHQWLRQ DOVR SURYLGHV D relaxing getaway with friends and family, good IRRG DQG D ORW RI IXQ 6RFLDO DQG QHWZRUNLQJ events are planned during the conference, with a little something for everyone. For more information, please visit www.aiche-cf.org. T

The Sulfur 2019 Roundic Acid table will

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Industry’s Premier Event for N ™ Networking & Sharing Best Practices™ PAGE 38

Sulfuric Acid Today ‹ Fall/Winter 2017

Turn-Key Installation For Sulphuric Acid Structured Packing Efficiency FLEXERAMIC® Structured Tower Packing provides plant operators increased absorption efficiency, increased capacity, lower pressure drop and often significantly lower energy costs of operation. This means retrofitting existing packed units with FLEXERAMIC® Structured Tower Packing will improve profitability.

Injection Tower Repair Koch Knight’s proprietary EPOXIGARD HC Injection system provides for fast repair of leaking towers and pump tanks without vessel entry. Our Injection Repair System is a proven success in multiple installations.

Acid Proof Stocked Products • FLEXERAMIC® Ceramic Structured Packing • FLEXISADDLE® Ceramic Random Packing • Ceramic Dome Support • Cross Partition Rings • Ceramic Grid Blocks • KNIGHT-WARE® Acid-Proof Ceramic Brick • DURO™ Acid Brick • PYROFLEX® PTFE DuPly Membrane • Proprietary Mortars • Supplier of Specified Third-Party Equipment > Mist Eliminators > Candles > Distributors

Over 100,000 Cu

bic Fe Ceramic et of /Plastic Packing

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| Drying Towers | Absorption Towers | | HCR | Storage Tanks | Sumps | Now Manufacturing and Stocking Shop / Field Lining

Membranes and Linings

Brick Installation

East Canton, Ohio (USA) - Baytown, Texas (USA) - Santiago, Chile - Parramatta, Australia - Seoul, Korea - Istanbul, Turkey

Visit us on the web: kochknight.com | Phone: +1 (330) 488-1651

LEWIS® PUMPS Vertical Chemical Pumps The world standard for vertical pumps and services to the sulphur chemicals industry Lewis® Pumps comprehensive product line includes: Sulphuric Acid Pumps Molten Sulphur Pumps Axial Flow Phosphoric Acid Pumps Molten Salt Pumps Sulphuric Acid Valves t Butterfly Valves t Gate Valves t Globe Valves Lewmet® Specialty Items t Dilution Pipes t Orifice Plates t Strainers Weir Minerals Lewis Pumps is known internationally in the sulphur, sulphuric acid and phosphoric acid industries with equipment installed in more than 120 countries worldwide. Founded in 1891 as Chas. S. Lewis & Co., Inc., today Weir Minerals Lewis Pumps is the recognized world leader for pumps and valves in these difficult pumping applications.

Weir Minerals Lewis Pumps 8625 Grant Rd. St. Louis, MO 63123

T: +1 314 843-4437 F: +1 314 843-7964 Email: sales.lewis@weirminerals.com

t Thimbles t Vortex Breakers

To learn more about Lewis® Pumps or Weir Minerals products, visit: www.weirminerals.com

Copyright © 2013, EnviroTech Pumpsystems, Inc. All rights reserved. LEWMET, LEWIS, and LEWIS PUMPS are registered trademarks of Envirotech Pumpsystems, Inc.; WEIR is a registered trademark of Weir Engineering Services Ltd.

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