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After years of searching for cost-effective solutions to reduce sulfuric acid plant emissions, many members of the sulfur and sulfuric acid industries must still decide on the best system for their needs. These companies seek to balance the appropriate technology choice with maintaining equipment integrity and exercising strong operational discipline. The ideal solution would reduce operating costs, maximize energy recovery and improve emissions, which is exactly what the MECS® MAX3™ process sets out to do. The proprietary MECS® MAX3™ sulfuric acid plant technology simplifies the conventional sulfuric acid plant flow scheme by combining a single absorption Heat Recovery System (HRS™) plant with MECS’ SolvR® regenerative SO2 scrubbing technology, thereby eliminating equipment, cutting costs and increasing efficiency. The diagrams in this leaflet set out the different sulfuric acid plant designs available with their relative merits and drawbacks to illustrate the revolutionary differences a fully integrated MAX3™ flow scheme offers.
MECS®
MAX3TM The Three-in-One Sulfuric Acid Technology for Optimized Emissions, Energy Recovery and Operating Costs
• Combines single absorption, HRS™, SolvR® and SteaMax™ in a fully integrated and optimized flow scheme specific to a particular customer’s needs
• Minimizes SO2 emissions and maximizes energy recovery while at the same time minimizing capital and operating costs to produce the plant design delivering maximum value to the customer
MAX3™ - Sulfuric Acid Plant
THE PATH TO THE INNOVATIVE MECS® MAX3™ TECHNOLOGY
Energy Recovery• Heat recovery from strong acid system through
production of intermediate pressure steam.• Additional low level heat recovery from strong acid
by preheating treated water• Recovers >90% of available heat
SO2 Emissions• Limited to ~100 ppmv from catalyst performance
Capital and Operating Costs• Increased capital costs offset by operating cost bene-
fits of intermediate steam production and reduced cooling water consumption
Energy Recovery• Basic heat recovery from sulfur combustion and SO3 formation steps by producing high-pressure steam• Low level heat recovery from strong acid by preheating treated water• Recovers 70% of available heat
SO2 Emissions• Limited to ~100 ppmv from catalyst performance
Capital and Operating Costs• Base level capital and operating costs• No optimization of heat recovery, emissions, or costs
Double Absorption Sulfuric Acid Plant with BFW Preheating
Double Absorptionwith HRS™
THE PATH TO THE INNOVATIVE MECS® MAX3™ TECHNOLOGY
Energy Recovery• Without further integration, low-pressure steam and
cooling water use increases due to addition of SolvR®
SO2 Emissions• <20 ppmv guaranteed with actual performance near
0 ppmvCapital and Operating Costs• Capital costs are equivalent or lower than a double
absorption plant with HRS™ due to low cost skidded supply of the SolvR®
• Low pressure steam and cooling water operating costs increase, but power use decreases
Energy Recovery• Recovers additional SO3 formation heat as high
pressure steam by eliminating process gas reheating after HRS Tower
SO2 Emissions• Limited to >3000 ppmv from catalyst performance• Lower emission targets require tail gas scrubber
Capital and Operating Costs• Decreased capital costs offset by much higher operating
costs of typical tail gas scrubbers
Single Absorptionwith HRS™
Single Absorptionwith HRS™ & SolvR®
Sulfuric Acid Plant withintegrated MAX3™
MECS®
MAX3™
Copyright © 2016 MECS, Inc. All rights reserved. The DuPont Oval Logo, DuPont™, The Miracles of Science™ and all products denoted with a ® or ™ are trademarks or registered trademarks of E. I. du Pont de Nemours and Company or its affiliates.EMEA version.
www.cleantechnologies.dupont.comwww.mecs.dupont.com
Brussels, BelgiumMECS Europe/Africa BVBATel: +32-2-658 [email protected]
Moscow, RussiaTel: +7-495-797 [email protected]
Dubai, United Arab EmiratesTel: +971-4-428 [email protected]
Johannesburg, South AfricaTel: +27-11-218 [email protected]
MECS also has regional offices in Asia Pacific and the Americas.
Mumbai, IndiaMECS India Private Ltd.Tel: +91-22-6751 [email protected]
MECS Inc. (Headquarters)Chesterfield, Missouri 63017 USATel: +1-314-275 [email protected]
• High pressure steam ≥1.5 ton steam / ton acid at 45 barg, 400° C• Intermediate pressure steam ≈0.3 ton steam / ton acid at 10 barg saturated• Reduced SO2 emissions to < 20 ppmv• Reduced or maintained cooling water use equivalent to a double absorption HRS™ design• Reduced power use ~10% compared to a double absorption plant• Reduced caustic / chemical use by ~50% compared to a double absorption plant with a
tailgas scrubber (or by 95% compared to a single absorption plant with a tailgas scrubber)• Reduced or maintained overall capital cost compared to a double absorption HRS™
design with a tail gas scrubber to meet low SO2 emissions• Reduced field construction time due to modular supply of the SolvR® system
With decades of experience in designing sulfuric acid plants, MECS used its expertise to develop an integrated system for a single absorption plant with HRS™ and SolvR® that optimizes the three critical aspects of a sulfuric acid plant: energy recovery, emissions reduction, and cost: the State-of-the-Art MECS® MAX3™.
MAX3™ Summary and Benefits
