State of the Art Gas Absorption

Technologies
May 5, 2009 1
CANSOLV TECHNOLOGIES INC.
www.cansolv.com


CANSOLV SO
2
SCRUBBING SYSTEM:
Review of Commercial Applications
for Smelter SO
2
Emissions Control

Presented at:
The Southern African Institute of Mining & Metallurgy

ZAMBIA


By: Valrie Lveill, Eng.




State of the Art Gas Absorption
Technologies
May 5, 2009 2
Outline
1. Overview of CTI;
2. Description of the SO
2
technology;
3. Review of commercial applications;
4. Integration to smelter emissions management.


State of the Art Gas Absorption
Technologies
May 5, 2009 3
Corporate Profile
Cansolv Technologies Inc. (CTI) founded in 1997
Headquarters in Montreal, Canada
Technology acquired from Union Carbide
Cansolv Technologies Shenzhen (CTS) founded in 2004
Chinese subsidiary for Sales/Marketing & Procurement in Asia
Acquisition by Shell Global Solutions in December 2008
Chemical Initiatives appointed agents for Africa 2009


State of the Art Gas Absorption
Technologies
May 5, 2009 4
Corporate Profile
SO
2
Technology
9 Cansolv SO
2
Scrubbing units in operation;
5 Cansolv SO
2
Scrubbing units to start-up in 2009;
5 Cansolv SO
2
Scrubbing units to start-up in 2010;
CO
2
Technology
3 Cansolv CO
2
Capture demo plants in detailed engineering
Successful demonstration in 6 piloting campaigns
State of the Art Gas Absorption
Technologies
May 5, 2009 5
CANSOLV

SO
2
Scrubbing System
A regenerable SO
2
absorption process
Similar to H
2
S/CO
2
amine treater units
Aqueous diamine absorbent is highly selective for SO
2

Pure, water- saturated SO
2
byproduct
Robust, easy to operate process with low emissions
Handles gas with varying SO
2
concentrations
High tolerance for dust and SO
3
/acid mist in gas


State of the Art Gas Absorption
Technologies
May 5, 2009 6
Cansolv

SO
2
SCRUBBING SYSTEM Integrated Configuration for Smelting Applications with
new acid converter for SO
2
by-product
Lean Amine
Tank
Condensate
Caustic
Treated Offgas to stack
< 200 ppmv SO
2
APU
Makeup
Water
Smelter Offgas
SO
2
Content: 0.1% to 15%
Quenched
Offgas
Prescrubber Effluent
Rich Amine
Lean Amine
SO
2
product gas, 99.99%
basis, dry
(constant flowrate)
SO
2
Stripper
Tower
APU Effluent
Rich Amine
Tank
Treated Offgas to stack
< 50 ppmv SO
2
Acid Plant Tail Gas
SO
2
Content: 0.5%
Constant flowrate of
H
2
SO
4
to storage
Dilution air
Main SO
2
Absorber
Tower
AP SO
2
Absorber
Tower
SINGLE ABSORPTION
ACID PLANT
Constant
Flowrate and SO
2
Content
Cansolv

SO
2
SCRUBBING SYSTEM Integrated Configuration for Smelting Applications with
new acid converter for SO
2
by-product
Lean Amine
Tank
Condensate
Caustic
Treated Offgas to stack
< 200 ppmv SO
2
APU
Makeup
Water
Smelter Offgas
SO
2
Content: 0.1% to 15%
Quenched
Offgas
Prescrubber Effluent
Rich Amine
Lean Amine
SO
2
product gas, 99.99%
basis, dry
(constant flowrate)
SO
2
Stripper
Tower
APU Effluent
Rich Amine
Tank
Treated Offgas to stack
< 50 ppmv SO
2
Acid Plant Tail Gas
SO
2
Content: 0.5%
Constant flowrate of
H
2
SO
4
to storage
Dilution air
Main SO
2
Absorber
Tower
AP SO
2
Absorber
Tower
SINGLE ABSORPTION
ACID PLANT
Constant
Flowrate and SO
2
Content
Cansolv

SO
2
SCRUBBING SYSTEM Integrated Configuration for Smelting Applications with
new acid converter for SO
2
by-product
Lean Amine
Tank
Condensate
Caustic
Treated Offgas to stack
< 200 ppmv SO
2
APU
Makeup
Water
Smelter Offgas
SO
2
Content: 0.1% to 15%
Quenched
Offgas
Prescrubber Effluent
Rich Amine
Lean Amine
SO
2
product gas, 99.99%
basis, dry
(constant flowrate)
SO
2
Stripper
Tower
APU Effluent
Rich Amine
Tank
Treated Offgas to stack
< 50 ppmv SO
2
Acid Plant Tail Gas
SO
2
Content: 0.5%
Constant flowrate of
H
2
SO
4
to storage
Dilution air
Main SO
2
Absorber
Tower
AP SO
2
Absorber
Tower
SINGLE ABSORPTION
ACID PLANT
Constant
Flowrate and SO
2
Content
State of the Art Gas Absorption
Technologies
May 5, 2009 7
Amine Characteristics
Amine developed for oxidised environments
Oxidation degradation losses per year < 2% of annual
inventory
Very low amine volatility (ppb levels)
Amine in salt form undetectable losses with treated gas
High tolerance for dust ingress
High tolerance for strong acid ingress
State of the Art Gas Absorption
Technologies
May 5, 2009 8
SO
2
Product Management
SO
2
by-product is high purity
99.9% SO
2
dry basis, balance composed of traces of CO
2
, N
2
, O
2

Food grade quality SO
2
product demonstrated

SO
2
product handling:
Return to new/existing sulphuric acid plant;
Return to existing sulphur recovery unit;
Compress and liquefy;
Convert to bisulfite

State of the Art Gas Absorption
Technologies
May 5, 2009 9
How CTI Customers Handle By-Product
Liqu. SO
2
, 1
SO
2
Safe, 1
H
2
SO
4
, 11
Sulfur, 8
Byproduct
processed
in New
Facilities, 7
Byproduct
processed
in existing
facilities,
14
By-Product
Profile
State of the Art Gas Absorption
Technologies
May 5, 2009 10
Commercial Units Metallurgical and Acid Plant Applications
Application Location Flow
(Nm
3
/hr)
By-Product Feed SO
2

Conc.
SO
2

Emissions
Status
SARP Acid Plant N/S
America
40,000 H2SO4
(existing)
5,000 ppm 15 ppm Operating
(s/u 2002)
Lead Smelter Asia-Pacific 34,000 H2SO4
(existing)
0.1 12.5% 90 ppm Operating
(s/u 2005)
Copper Anode
Furnace
Asia-Pacific 43,000 H2SO4
(existing)
0.09 2% 50 ppm Operating
(s/u 2007)
Catalyst
recovery roaster
N/S
America
48,000 Liquid
SO2/Bisulfite
(new)
9100 ppm 100 ppm Operating
(s/u 2008)
Sinter Machine
(secondary)
Asia-Pacific 350,000 H2SO4
(existing)
2400 ppm 140 ppm Start-up
Sinter Machine
(primary)
Asia-Pacific

2 x 510,000 H2SO4
(new)
800 ppm 40 ppm Start-Up
Lead Smelter +
AP
Asia-Pacific 83,000 H2SO4
(new)
0.1 8% 140 ppm Construction
(s/u 2009)
State of the Art Gas Absorption
Technologies
May 5, 2009 11
Active Projects Non ferrous and Acid Plant Applications
Application Location Flow
(Nm
3
/hr)
By-
Product
Feed SO
2

Conc.
SO
2

Emissions
Status
Copper
Smelter
Furnace
Asia-
Pacific
95,000 sulphur
(new)
15-30% 250 ppm Engineering
Nickel Smelter
Converter +
Furnace
N/S
America
100,000 H2SO4
(existing)
0.1 3% 200 ppm Engineering
(piloting
campaign 2007)
Lead Sinter
Machine
Asia-
Pacific
265,000 H2SO4
(new)
1 2% 200 ppm Engineering
(piloting
campaign 2008)
Copper
Smelter
Converters
N/S
America
600,000 H2SO4
(existing)
4,000 ppm 200 ppm Engineering
Fertilizer Acid
Plant
N/S
America
160,000 H2SO4
(existing)
5,000 ppm 20 ppm Engineering
State of the Art Gas Absorption
Technologies
May 5, 2009 12
SARP Acid Plant Tail Gas
Single absorption
Replace alkali scrubbing
process
Modular Plant
Absorber retrofit (FRP)


State of the Art Gas Absorption
Technologies
May 5, 2009 13
Lead Smelter Offgas
Batch anode furnace
Load levelling design
0.1 12% SO
2

Constant SO
2
production
SO
2
recycle to existing acid
plant
Main acid plant feed is roaster


State of the Art Gas Absorption
Technologies
May 5, 2009 14
Co-gen boiler flue gas
965,000 Nm
3
/hr
5 absorbers, 1 regenerator
New sulphuric acid plant
Single absorption with
Cansolv APTG



State of the Art Gas Absorption
Technologies
May 5, 2009 15
Key Advantages in Smelter Applications
1. Suitability to treat variable and dilute (<5%)
SO
2
loads
2. Flexibility in gas cleaning design
3. Manage SO
2
from multiple sources at a single
site
State of the Art Gas Absorption
Technologies
May 5, 2009 16
1. Treats Variable & Dilute SO
2
Load
Load levelling design
Vary lean amine flow to SO
2
absorber
Constant rich amine flow to regenerator
Larger amine inventory
Maintain SO
2
emissions
Decouple variable nature of smelter gas from sulphuric acid
production
SO
2
product & Sulphuric acid production are continuous at
constant flowrate
Eliminates need to burn sulphur to strengthen AP feed
Design capacity based on average smelter SO
2
load
State of the Art Gas Absorption
Technologies
May 5, 2009 17
Load Levelling
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
0 50 100 150 200 250
Time (hours)
S
O
2

F
l
o
w
r
a
t
e

(
k
g
/
h
r
)
Offgas SO2 Load (Cansolv inlet) SO2 Product (Cansolv outlet)
State of the Art Gas Absorption
Technologies
May 5, 2009 18
2. Flexibility in gas cleaning design
Amine has high tolerance for
dust and SO
3
ingress
Optimise between gas cleaning
and amine purification
Reduced gas cleaning increases
amine purification required
Capital/operating cost
advantages often favour amine
purification
State of the Art Gas Absorption
Technologies
May 5, 2009 19
2. Flexibility in gas cleaning design
Wet acid mist removal
Plant Dry gas
[SO
3
]
SO
3
/ mist wet
pre-treatment
SO
3
Removal
Efficiency
Inlet [SO
3
]
to Cansolv
APU Salt
Removal
Coal-fired co-gen
boilers
43 ppmv None 0% 40 ppmv

Ion Exchange
Oil Refinery FCCU 22 ppmv High DP dynamic
scrubber
88% 3 ppmv

Electrodialysis
Incinerated SRU
Tail Gas
1500 ppmv Brownian candle
mist eliminators
99% 20 ppmv

Electrodialysis
SARP Tail Gas 200 ppmv None 0% 200 ppmv

Ion Exchange
Lead Smelter + AP 110 ppmv None 0% 110 ppmv

Ion Exchange
Copper Anode
furnace
170 ppmv None 0% 170 ppmv

Ion Exchange

State of the Art Gas Absorption
Technologies
May 5, 2009 20
3. Manage SO
2
from multiple sources at a
single site
Multiple absorbers may be used with a single regenerator
Several secondary sources: furnaces, converters
Acid plant tail gas has low SO
2
load vs. smelter
Leverage existing Cansolv plant to minimise capex
State of the Art Gas Absorption
Technologies
May 5, 2009 21
Cansolv

SO
2
SCRUBBING SYSTEM Integrated Configuration for Smelting Applications with
new acid converter for SO
2
by-product
Lean Amine
Tank
Condensate
Caustic
Treated Offgas to stack
< 200 ppmv SO
2
APU
Makeup
Water
Smelter Offgas
SO
2
Content: 0.1% to 15%
Quenched
Offgas
Prescrubber Effluent
Rich Amine
Lean Amine
SO
2
product gas, 99.99%
basis, dry
(constant flowrate)
SO
2
Stripper
Tower
APU Effluent
Rich Amine
Tank
Treated Offgas to stack
< 50 ppmv SO
2
Acid Plant Tail Gas
SO
2
Content: 0.5%
Constant flowrate of
H
2
SO
4
to storage
Dilution air
Main SO
2
Absorber
Tower
AP SO
2
Absorber
Tower
SINGLE ABSORPTION
ACID PLANT
Constant
Flowrate and SO
2
Content
Cansolv

SO
2
SCRUBBING SYSTEM Integrated Configuration for Smelting Applications with
new acid converter for SO
2
by-product
Lean Amine
Tank
Condensate
Caustic
Treated Offgas to stack
< 200 ppmv SO
2
APU
Makeup
Water
Smelter Offgas
SO
2
Content: 0.1% to 15%
Quenched
Offgas
Prescrubber Effluent
Rich Amine
Lean Amine
SO
2
product gas, 99.99%
basis, dry
(constant flowrate)
SO
2
Stripper
Tower
APU Effluent
Rich Amine
Tank
Treated Offgas to stack
< 50 ppmv SO
2
Acid Plant Tail Gas
SO
2
Content: 0.5%
Constant flowrate of
H
2
SO
4
to storage
Dilution air
Main SO
2
Absorber
Tower
AP SO
2
Absorber
Tower
SINGLE ABSORPTION
ACID PLANT
Constant
Flowrate and SO
2
Content
State of the Art Gas Absorption
Technologies
May 5, 2009 22
Thank you!