Category: Technology

NOx emissions from chemical processes such as steam methane reforming contribute to air pollution. The chemical industry is required to take steps to lower such emissions. Technology, developed for related industries, can be designed and optimised to reduce NOx emissions from steam methane reformers. Emission control experts can use a combination of modelling and experience to guide plant operators in recommending and designing optimum, sometimes tailor-made solutions. In this article different options are discussed including low NOx burners, selective catalytic reduction, selective non-catalytic reduction and high emissivity ceramic coatings.

Dr MP Sukumaran Nair, policy analyst and director of the Centre for Green Technology & Management in Cochin, India, discusses the ways that digitisation is improving fertilizer plant operation.

In a carbon-constrained world, carbon capture and utilisation or storage (CCUS) installed on a methanol plant is a necessary and feasible solution. The new, patented AdWinMethanol CC® technology, jointly developed by thyssenkrupp Industrial Solutions AG and GasConTec GmbH, integrates carbon capture into large-scale, natural gas-fuelled methanol production to yield a drastically reduced carbon footprint. U. Koss and W. Balthasar of GasConTec and J. Wagner of thyssenkrupp Industrial Solutions discuss how it removes CO 2 emissions in an efficient, cost effective, and environmentally friendly manner, taking advantage of the design features of AdWinMethanol ® .

Process and simulation models can be valuable tools when troubleshooting to solve operational issues in sulphur recovery units. Two examples are provided. In the first case study it is shown how a tuned model was useful in troubleshooting an SRU that was experiencing lower than expected recovery efficiency and apparent channelling in the first catalytic converter. In the second case study an SRU simulation tool is used to investigate sulphidic corrosion in a waste heat boiler.

Selecting the right catalysts for the SO2 converter in a sulphuric acid plant has always been about balancing expenses, gains, and compliance. With increasing demands for sustainability and in challenging economic times, operators need to adjust their plants to get even more from less. This has led to market demand for new catalytic solutions that offer better productivity and a lower climate footprint, all at the lowest cost possible. Catalyst design and formulations continue to evolve with Haldor Topsoe, DuPont Clean Technologies and BASF all adding new types of sulphuric acid catalysts to their portfolios.

Failure investigations, equipment design and process upgrade projects for SRUs often overlook the impact of water quality. In this article E. Nasat o of Nasato Consulting and L. Huchler of MarTech Systems explore impacts of higher heat transfer rates, control of boiler and condenser water chemistry, conventional equipment design/configurations and monitoring program designs. SRU operators can improve the effectiveness of their failure investigations by implementing a broader, more holistic approach that assesses equipment design, process conditions, operating protocols and water quality issues.

Several highly corrosion resistant materials are available today for use in handling process fluids encountered in the production of concentrated sulphuric acid. These alloys, properly selected for the operating conditions, provide the benefits of long operating life under harsh operating conditions extending the period of uninterrupted production cycles and lowering the incidence of catastrophic equipment failure. In this article, M. J. Cooke of Weir Minerals discusses materials of construction for pumps, valves and piping used in the production of sulphuric acid.

A. Bhargav and A. Krishnan of Helium Consulting Pvt. Ltd discuss how it is possible to reduce SOx emissions within the existing system setup of an oil refinery or gas plant through detailed analysis, expedited corrective actions and the use of automated algorithms in real-time, by using a digital IIoT solution to monitor, control and optimise.

Recent innovations in fertilizer granulation include thyssenkrupp’s new process for premium ammonium sulphate production. Eirich has launched new equipment for NPK granulation, while Rhewum is also offering new screening technology.

Malte Plewa, Volker Schmidt, Daniel Ávila and Enrico Rubertus of German development agency GIZ and Dr. Silke Karcher of the German Environment Ministry (BMU) discuss action on climate change from nitric acid production and the Nitric Acid Climate Action Group (NACAG) and its global initiative for mitigating emissions.