Category: Energy Optimisation

E. Almeida and B. Ferraro of Clark Solutions discuss how regular monitoring by simple testing of the towers in sulphuric acid plants can improve the reliability and lifespan of the plant.

Economically viable production of green ammonia requires plants that can react to fluctuations in renewable power thanks to their flexible design. Casale’s Francesco Baratto, Giovanni Genova and Sergio Panza explain how new tools are helping design green ammonia plants that deliver the highest possible production at the lowest possible cost.

With climate change looming there is an increased focus on reducing the environmental footprint of the production of fertilizers. The use of renewable energy/green hydrogen is one way to make the fertilizer industry more environmentally sustainable. In this article, Rene Dijkstra of Chemetics introduces the Green Fertilizer Complex. This practical solution integrates an oxygen-based sulphuric acid plant using the Chemetics’ patented CORE-SO2™ process with a green hydrogen and ammonia facility to deliver low cost, low emission, and carbon-free phosphate (MAP/DAP) and/or sulphate (AMS) based ammonia fertilizers.

A sulphuric acid plant forms critical material and energy interfaces with other plants in several different types of chemical and metallurgical complexes. Shailesh Sampat of SNC-Lavalin discusses how the acid plant design is customised to match the product mix and the energy requirements of the complex to provide the optimum solution for energy and material requirements.

The production of syngas from hydrocarbon feedstock uses a number of catalytic steps to increase efficiency and maximise conversion while minimising energy consumption. In this article we report on the latest developments in water gas shift catalysis from Johnson Matthey, Clariant and Topsoe, and shift converter design from Casale.

Developments in sulphuric acid technology and engineering know-how are highlighted by recent project case studies from DuPont Clean Technologies, Metso Outotec and thyssenkrupp Uhde.

Nitrogen-rich wastewaters remain a major issue for fertilizer and other industries. Saipem’s new electrochemical technology, SPELL, is an important step towards the overall objective of zero industrial pollution. A complete engineering review of the technology, its alignment with all international applicable standards, and optimisation has now been concluded and the technology is ready for deployment for the removal of ammonium nitrogen from industrial waters and wastewaters. Saipem discusses the key features of SPELL and reports on the first two industrial references.

Tightening regulations and growing global competition are increasing the pressure felt by sulphuric acid plant operators to reduce emissions and improve energy output. Conservation of energy is a continuous focus for operators, and environmental communities have grown more vocal in their desire for greater emissions oversight. In this article, DuPont Clean Technologies examines simple, tried, and true tactics, as well as new products and designs that can be incorporated into existing plants to address operating efficiency and emissions and to help to prolong the life of the plant.

Chemetics describes a variety of ways to extend the life of sulphuric acid plants. Debottlenecking, emissions reduction and/or energy recovery projects require a systematic, phased approach to maximise the potential of economic and operational benefits to the owner.

MegaZonE™ is a newly introduced layered loading technology for boiling water-cooled reactors used for methanol synthesis. This new concept is one of the latest results of the long-standing collaboration between Air Liquide Engineering & Construction and Clariant Catalysts to improve the methanol process flowsheet and optimise catalyst performance in the complete reactor system.