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S-312_WSA_process
13/09/2007
14:09
Page 80
WSA PROCESS
Meeting industry
demands
Jens K. Laursen and Frands E. Jensen of Haldor Topse A/S give an
overview of the process principles of the WSA process for sulphur
recovery, providing industry examples from a variety of applications.
Application
The WSA process is applied in all industries where removal of sulphur is an issue.
Typical applications include:
Refinery and petrochemicals
H2S-containing gases from amine units
Sour water stripper gases
Regeneration of spent sulphuric acid
from alkylation
Treatment of stack gases from boilers
fired by heavy residues and petroleum
coke
Cellulose industry
H2S and CS2 containing gases in viscose fibre plants
Power industry
Flue gases from combustion of high-sulphur fuels. Both sulphur oxides and NOx
are removed.
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Salient features
stack
gas
blower
SO2
converter
H2S gas
incinerator
Metallurgical industry
Off-gases from metal sulphide roasters
(Mo, Zn, Pb, Cu, and other)
Coal based industry
H2S, NH3 and HCN containing gases in
coking plants
H2S, NH3 and HCN containing gases
from coal gasification
blower
interbed coolers
air
WSA
condenser
gas
cooler
steam
system
superheated steam
acid
cooler
product acid
S-312_WSA_process
13/09/2007
14:09
Page 82
WSA PROCESS
Process principles
feed gas
feed gas
preheater
SO2
converter
interbed
cooler
natural
gas
start-up/
support
burner
stack gas
feed gas
preheater
boiler
blower
salt circulation
system
gas
cooler
air
salt
tank
WSA
condenser
salt
pump
acid cooler
product acid
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S-312_WSA_process
13/09/2007
14:09
Page 83
WSA PROCESS
Oxidation
SO2 + /2 O2 SO3
Hydration
Condensation
DeNOx
NO + NH3 + /4 O2 N2 + /2 H2O
+ 518 kJ/mole
+ 99 kJ/mole
+ 101 kJ/mole
3
+ 69 kJ/mole
+ 410 kJ/mole
boiler
blower
petcoke
WSA
condenser
air
flue gas
filter
flue gas
blower
air preheater
heat
exchanger
support
heat
NH3
acid cooler
product acid
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S-312_WSA_process
13/09/2007
14:10
Page 84
WSA PROCESS
Plant B
Spent acid
H2O, wt-%
H2SO4, wt-%.
Hydrocarbons, wt-%
4
90
6
Acid gas
H2S, vol-%
91
91
SWS gas
NH3, vol-%
H2S, vol-%
53
47
100
330
98
25
125
400
98
45
195
Typical performance
Spent acid, t/d
Acid production, t/d
Acid concentration, wt-%
Steam production, t/h
Cooling water consumption, m3/h
60,000
1.40 3.75
Typical performance
Acid production, t/d
Acid concentration, wt-%
Cooling water consumption, m3/h
170
98
57
OMV, Austria
Fuel
Sulphur in fuel, wt-%
Flue gas vol., Nm3/h
SO2 in flue gas, mg/Nm3
Petcoke, residue
5-7
1,200,000
10,000
residue
4
820,000
7,000
Typical performance
Acid production, t/d
Acid concentration, wt-%
440
94-95
220
94-95
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S-312_WSA_process
13/09/2007
14:10
Page 85
WSA PROCESS
TM
Conclusion
TM
Catalysts
The SO2 conversion catalysts applied in the
WSA and SNOX processes are the Topsoe
VK-series catalysts. The catalysts are based
on vanadium pentoxide and sodium and
potassium pyrosulphates on a diatomaceous earth silica carrier material and specially adapted for moist gases. The Topsoe
VK-series of catalysts will cover all relevant
process conditions and make it possible to
select the best catalyst or combination of
catalysts for a given performance specification. They are also widely used in conventional dry sulphuric acid plants.
The SCR DeNOx catalyst is one of the
Topse DNX series catalysts, a corrugated
monolithic catalyst based on titanium, tungsten and vanadium as active materials.
TM
TM
85