Sulphuric Acid Plant Converter Replacement Projects

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

In Memory of
Grigory Lwow
1942 – 2014
18/02/2018 Slide 2 © Copyright 2015, Chemetics Inc. All rights reserved.

Presentation Outline
 Main Factors to Consider

 Technology change
 Fabrication Strategy
 3 Case Studies
 Project 1 – Canada
 Project 2 – USA
 Project 3 – Brazil
 Conclusions

Converter Replacement Projects in General…
 Largest piece of process equipment in acid plant

 Traditional discussions when replacing a Converter
 Space constraints
 New foundation vs. existing foundation
 Technology change
 Materials of construction
 Internal heat exchangers and/or superheater
 Fabrication Strategy – modular Converter approach
 Opportunity for capacity increase
 Replace aging equipment
 Preheater evaluation
 New ducting
 Catalyst
 Shutdown time for tie-in

Technology Change
Stainless Steel
Carbon Steel Stainless Steel Converter with
bricklined Converter Internal Exchangers
Converter
Bed # 1
Bed # 1
Bed # 2
Bed # 2
Bed # 4
Bed # 3
Bed # 3
Bed # 4

Technology Change
Diffusion of Innovation Principle
Enthusiasts Visionaries Pragmatists Conservatives Skeptics

Technology Change
Stainless Steel Converters with Internal Exhangers
Diffusion of Innovation Principle
Enthusiasts Visionaries Pragmatists Conservatives Skeptics

Fabrication Strategy
 Converters rarely can be

shipped in 1 piece
3 options:
 On site “stick build” fabrication
(raw plate supply – 100% on
site fabrication)
 On site “knock-down”
fabrication (cut, rolled, bevelled
pieces done in shop and
supplied to field – > 75% on site
fabrication)
 Modularize fabrication (> 80%
shop fabrication & < 20% on
site fabrication)

Recent Case Studies
 2011 – Project 1 – Canada

 2013 – Project 2 – USA
 2014 – Project 3 – Brazil

Project 1 – Canada
 1100 mtpd metallurgical acid plant

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

Project 1 – Canada – Chemetics® Scope of Work
 EPS
 Engineering
 Complete basic and detailed engineering
 All disciplines
 Procurement
 Modular Converter supply
 13.3m diameter Converter (3+1 configuration)
 14 months (12 months fabrication w/5 months installation overlap)
 Gas/gas exchanger supply
 All materials supply
 Field Services
 Construction advisory services
 Mechanical check-out
 Commissioning advisory services












Xstrata Nickel




Project 2 – USA
 1800 mtpd sulphur burning acid plant

 Equipment reached end of service life
 Frequent gas leaks
 Plant shutdowns for repairs
 Project
 Internal gas exchangers to reduce ducting costs
 Construct new Converter next to operating plant
 Supply Converter in modules to reduce construction costs and overall
project schedule
 Tie-in during 19 day general maintenance shutdown
 All new catalyst

Project 2 – USA – Chemetics® Scope of Work
 EPS
 Engineering
 Complete basic and detailed engineering
 All disciplines
 Procurement
 Modular Converter supply
 11.7m diameter Converter (3+1 configuration)
 Accelerated schedule
 14 months (12 months fabrication w/3 months installation)
 Site Services

Project 2 – USA

Project 2 – USA

Project 2 – USA

Project 2 – USA

Project 2 – USA

Project 2 – USA

Project 2 – USA

Project 2 – USA

Project 2 – USA

Project 2 – USA

Project 2 – USA

Project 2 – USA

Project 2 – USA

Project 2 – USA

Project 2 – USA

Project 2 – USA

Project 3 – Brazil
 1400 mtpd sulphur burning acid plant

 Equipment reaching end of service life
 Frequent ducting gas leaks
 Frequent plant shutdowns for repairs
 Project
 New Internal exchanger and Superheater to reduce ducting costs
 Replace Inter and Final economizers
 Replace almost all plant ducting
 Size converter for increased plant capacity 1600 mtpd
 Construct new (knock down) Converter next to operating plant
 Tie-in during general maintenance shutdown
 Re-use old catalyst and combine with new catalyst
Project 3 – Brazil – Chemetics® Scope of Work
 E+S
 Engineering
 Basic engineering – all disciplines
 Detailed engineering – proprietary equipment and ducting
 Field Services
 Project
 11.85m diameter Converter (3+1 configuration)
 Built on-site – some large pieces shipped to site
 12 months (7 months pre-fabrication w/5 months installation)

Chemetics® Sulphur Burning Acid Plant Converter
Bed # 1
Bed # 2
Bed # 4
Bed # 3

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

Reheat Exch.



Novo Inter Economizador
Novo Economizador Final
Novo Conversor 3:1 (11.85 m Ø x 21.45 m H)

– Super Aquecedor Interno
– Tocador “Inter Reheat” Interno














Retrofit References – Last 20 years
Startup Country Beds SS Internal Heat New Modular

Converter Exchangers Foundation
2015 Confidential 4 Yes Yes (2) Yes Yes
2014 Canada 4 Yes Yes (2) Yes Yes
2014 Brazil 4 Yes Yes (2) Yes No
2013 USA 4 Yes Yes (1) Yes Yes
2012 Canada 4 Yes Yes (1) Yes Yes
2010 UK 4 Yes No Yes No
2006 USA 4 Yes Yes (1) Yes No
2006 Canada 4 Yes No Yes No
2000 Sweden 5 Yes Yes (1) Yes No
1999 RSA 4 Yes No No No
1999 Netherlands 1 Yes Yes (1) Yes No
1995 USA 4 Yes Yes No No

Conclusions
 Most common solutions in Converter replacement projects

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

Thank you for your attention.
Questions?

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of this document shall be reproduced in any form nor used in any manner without express prior
permission and applicable acknowledgements. No trademark, copyright or other notice shall be altered or
removed from any reproduction.

Disclaimer
This Presentation includes and is based, inter alia, on forward-looking information and statements that
are subject to risks and uncertainties that could cause actual results to differ. These statements and this
Presentation are based on current expectations, estimates and projections about global economic
conditions, the economic conditions of the regions and industries that are major markets for Jacobs
Engineering Group Inc. (including subsidiaries and affiliates) lines of business. These expectations,
estimates and projections are generally identifiable by statements containing words such as “expects”,
“believes”, “estimates” or similar expressions. Important factors that could cause actual results to differ
materially from those expectations include, among others, economic and market conditions in the
geographic areas and industries that are or will be major markets for Jacobs’ businesses, oil prices,
market acceptance of new products and services, changes in governmental regulations, interest rates,
fluctuations in currency exchange rates and such other factors as may be discussed from time to time in
the Presentation. Although Jacobs Engineering Group Inc. believes that its expectations and the
Presentation are based upon reasonable assumptions, it can give no assurance that those expectations
will be achieved or that the actual results will be as set out in the Presentation. Jacobs Engineering
Group Inc. is making no representation or warranty, expressed or implied, as to the accuracy, reliability or
completeness of the Presentation, and neither Jacobs Engineering Inc. nor any of its directors, officers or
employees will have any liability to you or any other persons resulting from your use.
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Sulphuric Acid Plant

Converter Replacement Projects

© Copyright 2015, Chemetics Inc. All rights reserved.

18/02/2018 Slide 2 © Copyright 2015, Chemetics Inc. All rights reserved.

 Main Factors to Consider

18/02/2018 Slide 3 © Copyright 2015, Chemetics Inc. All rights reserved.

 Largest piece of process equipment in acid plant

18/02/2018 Slide 4 © Copyright 2015, Chemetics Inc. All rights reserved.

18/02/2018 Slide 5 © Copyright 2015, Chemetics Inc. All rights reserved.

Diffusion of Innovation Principle

Enthusiasts Visionaries Pragmatists Conservatives Skeptics

18/02/2018 Slide 6 © Copyright 2015, Chemetics Inc. All rights reserved.

Diffusion of Innovation Principle

Enthusiasts Visionaries Pragmatists Conservatives Skeptics

18/02/2018 Slide 7 © Copyright 2015, Chemetics Inc. All rights reserved.

 Converters rarely can be

18/02/2018 Slide 8 © Copyright 2015, Chemetics Inc. All rights reserved.

 2011 – Project 1 – Canada

18/02/2018 Slide 9 © Copyright 2015, Chemetics Inc. All rights reserved.

 1100 mtpd metallurgical acid plant

18/02/2018 Slide 10 © Copyright 2015, Chemetics Inc. All rights reserved.

18/02/2018 Slide 12 © Copyright 2015, Chemetics Inc. All rights reserved.

18/02/2018 Slide 13 © Copyright 2015, Chemetics Inc. All rights reserved.

18/02/2018 Slide 14 © Copyright 2015, Chemetics Inc. All rights reserved.

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18/02/2018 Slide 28 © Copyright 2015, Chemetics Inc. All rights reserved.

 1800 mtpd sulphur burning acid plant

18/02/2018 Slide 29 © Copyright 2015, Chemetics Inc. All rights reserved.

18/02/2018 Slide 30 © Copyright 2015, Chemetics Inc. All rights reserved.

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 1400 mtpd sulphur burning acid plant

18/02/2018 Slide 49 © Copyright 2015, Chemetics Inc. All rights reserved.

18/02/2018 Slide 50 © Copyright 2015, Chemetics Inc. All rights reserved.

SO2 from Cold

18/02/2018 Slide 52 © Copyright 2015, Chemetics Inc. All rights reserved.

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