Magazine of The Sulfuric Acid Today Spring/Summer 2015

COVERING MAINTENANCE SOLUTIONS FOR THE INDUSTRY
Sulfuric Acid
T
www.H 2S0 4Today.com
Spring/Summer 2015
Mosaics New Wales Plant:

bringing a world-class legacy
st
into the 21 century Page 7
IN THIS ISSUE > > > >
Global sulfuric acidsupply and

demand outlook PAGE 12
Vertical pump sealing options: packing

seals vs. mechanical seals PAGE 14
Improving plant performance using

state-of-the-art MECS catalysts PAGE 24
Address Service
Requested
Keystone Publishing
P.O. Box 3502
Covington, LA
70434
PRST STD
U.S. PSTG
PAID
GPI
Sulfuric Acid
COVERING MAINTENANCE SOLUTIONS FOR THE INDUSTRY
Sulfuric Acid
T
www.H 2S0 4Today.com
Spring/Summer 2015
Mosaics New Wales Plant:

bringing a world-class legacy
into the 21st century Page 7
Vol. 21 No. 1
IN THIS ISSUE > > > >
Covering Maintenance Solutions for the Industry
FROM THE PUBLISHER
Address Service
Requested

state-of-the-art MECS catalysts PAGE 24
Keystone Publishing
P.O. Box 3502
Covington, LA
70434
PRST STD
U.S. PSTG
PAID
GPI
ON THE COVER
Mosaic Co.s New Wales

Plant in Mulberry, Fla.
upgrades its five sulfuric
acid plants with latest
technology.
DEPARTMENTS
4

Spring/Summer 2015
Global sulfuric acidsupply and

demand outlook PAGE 12
Vertical pump sealing options: packing
seals vs. mechanical seals PAGE 14
Industry Insights
News items about the
sulfuric acid and related
industries
28 Lessons Learned

Case histories from the
sulfuric acid industry
41 Faces & Places

Covering sulfuric acid
industry events
42 Calendar of Events

Upcoming industry events
Dear Friends,
Welcome to the Spring/Summer 2015 issue of Sulfuric
Acid Today magazine. We have dedicated ourselves to
covering the latest products and technology for those in
the industry, and hope you find this issue both helpful and
informative.
I recently returned from the 10th Chilean Sulfuric
Acid Roundtable, organized by Holtec Ltda. Consulting &
Technologies in Punta Arenas, Chile. I was struck, as I always
am at events like this, by the global nature of our industry. The
knowledge base at a global event is often awe-inspiring, as is
the willingness of attendees to share that knowledge with each
other.
As we send this issue to press, I am gearing up for another
great information-sharing event, our 2015 Sulfuric
Acid Roundtable. This years Roundtable will be
held March 23-26 at Streamsong Resort in Central
Florida. As of press time, we have a record number
of producers registered to attend. 105 producers from
45 manufacturing sites and five countries will gather
for three days of keynote addresses, panel discussions
and presentations, new technology developments and
networking opportunities. The events 28 co-sponsors
from around the globe will also be on hand to answer
questions and join in the discussions. I hope to see you
there. If you would like more information about the
event, please visit www.acidroundtable.com.
We hope that this issue of Sulfuric Acid Today
will provide you with some innovative technologies
or assistance with your profession. In this issue are
Sincerely,
Kathy Hayward
FEATURES &
GUEST COLUMNS
PUBLISHED BY
Keystone Publishing L.L.C.
PUBLISHER
Kathy Hayward
several articles regarding the latest technology available to

the sulfuric acid industry. Be sure to read such articles as:
Vertical pump sealing options: packing seals vs. mechanical
seals (page 14), Upgrades to sulfuric acid equipmentan
evolutionary tale (page 16), Saint-Gobain NorPro ceramic
technology provides proven reliability (page 20), Improving
plant performance using state-of-the-art MECS catalysts
(page 24), WESPs prove versatile in acid plant operations
(page 30), Advancements in sulphur: new hybrid gun and
predictive modeling (page 32) and Cylindrical superheaters
for high temperature and high pressure service (page 34).

I would like to welcome our new and returning Sulfuric
Acid Today advertisers, including Acid Piping Technology
Inc., Andronaco Industries, Beltran Technologies, CECO
Filters, Central Maintenance & Welding, Chemetics Inc., El
Dorado Metals Inc., Haldor Topse A/S, Kimre, Koch Knight
LLC, MECS Inc., NORAM Engineering & Constructors,
Optimus, Outotec, Powell Fabrication & Manufacturing,
Roberts Company, Saint-Gobain NorPro, Sauereisen, Siemens,
Southwest Refractory of Texas, Spraying Systems Co.,
Southern Environmental Inc., Sulphurnet, VIP International
and Weir Minerals Lewis Pumps.
We are currently compiling information for our Fall/
Winter 2015 issue. If you have any suggestions for articles or
other information you would like included, please feel free
to contact me via e-mail at kathy@h2so4today.com. I look
forward to hearing from you.
12
Global sulfuric acid 2014 in review and outlook
EDITOR
April Kabbash
14
Vertical pump sealing options: packing seals vs. mechanical seals
ASSISTANTEDITOR
April Smith
16
Upgrades to sulfuric acid equipmentan evolutionary tale
18
PPE: The final answer to worker protection
18
Jon Quarles retires from Acid Piping Technology
20
Saint-Gobain NorPro ceramic technology provides proven reliability
24
Improving plant performance using state-of-the-art MECS catalysts
26
The worlds first live observations of sulfuric acid catalysis
29
Roberts continues to expand offerings
30
WESPs prove versatile in acid plant applications
32
Advancements in sulfur spraying: new hybrid gun and predictive modeling
34
Cylindrical superheaters for high temperature and high pressure service
36
When secondary containment linings and coatings are primary
38
Sulphurnet offers complete melting and purification solutions
38
Matthew J. Thayer joins Koch Knight as vice president of sales and marketing
40
Industry converges in Chile for tenth sulfuric acid roundtable
MARKETING ASSISTANT
Connor Chapman
DESIGN & LAYOUT
Mailing Address: P.O. Box 3502

Covington, LA 70434
Phone: (985) 893-8692
Fax: (985) 893-8693
E-Mail: kathy@h2so4today.com
www.h2so4today.com
SUBSCRIPTIONS
U.S. Plant Personnel Complimentary
U.S. Subscription $39 per year (2 issues)
Internatl Subscription $59 per year (2 issues)
Subscribe Online: www.h2so4today.com
14
16
40
De
ep
pa
ar t m e
D
en
ntt
INDUSTRY INSIGHTS
WASTEHEATRECOVERY
BOILERS
SUPERHEATERS
ECONOMIZERS
Opmusdelivereditsrstsulfuricacidplantwasteheatrecoverysystem
in1996.Acrossthepowerandprocessindustries,weveproducedmore
heatrecoveryboilers,HRSGs,superheaters,andeconomizersthanany
acvecompanyintheUSA.
OpmusanditsChanuteManufacturingplanthavealongstandingrep
utaon for highquality workmanship and onme performance. Cus
tomers trust our unique manufacturing experse and have condence
inourqualitycontrolandcomprehensiveprojectexecuon.
50yearsofmanufacturingexperience
99%lifemeonmedeliveryperformance
20yearsexperienceinSulfuricAcidwasteheatrecoveryequipment
Ph:9184919191
www.opmustulsa.com
Email:info@opmustulsa.com
PAGE 4
Topse part of consortium

to develop large-scale
fertilizer plant in Tanzania
LYNGBY, DenmarkA consortium consisting of Haldor Topse A/S, the German

company Ferrostaal Industrial Projects
GmbH, and the Pakistani industrial enterprise Fauji Fertilizer Company Ltd, is
going to develop a large-scale fertilizer
complex in Tanzania together with the
state-owned Tanzania Petroleum Development Corporation.
The project is currently the largest
investment project in Tanzania with an
investment sum of more than $1 billion.
The fertilizer complex is expected to be
on-stream in 2019/20, producing 1.3 million tonnes of fertilizer per year for both
the local and international market. Agriculture in Tanzania will stand to benefit in
particular. The sector makes up approximately one third of Tanzanias gross domestic product, with more than 75 percent
of the population working in the agricultural sector. It is expected that 5,000 direct
and indirect jobs will be created during
the construction and operating period.
The consortium is providing support through the entire project development, including financing, technology and
product-offtake as well as construction,
maintenance and operation of the plant.
As part of this, Topses role will be to
deliver license, engineering, hardware and
catalysts for the fertilizer plant, which will
be located in the South of Tanzania, in the
Mt. Wara area, where there are existing
port facilities and connections to a future
natural gas grid.

The consortium emerged as the winner of a tender carried out by the Tanzanian government in 2013 and is currently
in exclusive negotiations with gas suppliers regarding the supply of gas for the fertilizer complex. Furthermore, Tanzanian
shareholders and off-takers will also play a
significant part in the further development
and realization of the project.

We believe the plant will leave a positive footprint in Tanzania, enabling the
country to monetize its huge gas reserves
and in the process create jobs and boost
agricultural productivity, said Bjerne S.
Clausen, Chief Executive Officer at Topse. From Topsoes perspective, the project is also extremely interesting. Not only
does it represent a substantial contract
value on its own terms, it also holds the
potential of becoming a long term steady
source of income due to our planned coownership of the plant.
For more information, please visit
www.topsoe.com.
Siemens to supply steam

turbine generator units to
Kazakhstan
ERLANGEN, GermanySiemens has received an order for the supply of two steam
turbine generator units for the Balkhash
coal-fired power plant in Kazakhstan. The
EPC contractor is a Korean joint venture
consisting of Samsung C&T and Samsung

Engineering Co. Ltd. The operator and
end customer for the plant is the Balkhash
Thermal Power Plant Joint Stock Company. The two turbines will be used primarily for power generation in the plant,
although the plant is also designed for cogeneration of heat and power for flexible
generation of district heating. Commissioning is scheduled for summer 2019.

The Balkhash coal-fired plant is located on the shore of Lake Balkhash, one
of the largest lakes in central Asia, in eastern Kazakhstan. Siemens scope of supply for the order includes two SST5-6000
steam turbines, each with an electrical
generating capacity of 660 megawatts, and
two generators of type SGen5-3000W, including control systems and all auxiliary
and ancillary systems. This plant is characterized by its particularly high fuel efficiency thanks to co-generation of heat and
power.

We are very pleased that Samsung
is putting its trust in Siemens. Thanks to
our efficient and reliable technology, this
project is contributing to sustainable, environmentally friendly generation of power
and heat. Erecting a very modern, highly
efficient power plant in Kazakhstan with
Samsung is a milestone for Siemens, said
Wilfried Ulm, head of the Steam Turbines
Business Unit within Siemens Power and
Gas.

Thanks to our excellent cooperation
with Siemens on the Balkhash Thermal
Power Plant project, we are confident that
we will successfully execute this project
together with our experienced partner,
said YongHoon Hwang from Samsung
Joint Venture.

More information, please visit www.
energy.siemens.com.
Haldor Topse signs

contract for new fertilizer
plant in Slovakia
LYNGBY, DenmarkTopse A/S has

signed contracts with Technip and Duslo
s.a. of Slovakia for a new ammonia plant
that will be constructed adjacent to an existing fertilizer complex in aa, a town
located 65 kilometers from Bratislava, the
capital of the Slovak Republic.

As part of the project, Haldor Topse
will supply licensing and basic engineering as well as proprietary catalyst and
equipment for the ammonia plant, while
Technip has been awarded the contract to
develop EPC for the new plant. The plant
is expected to go on-stream in early 2018
and will be designed to meet a daily production capacity of 1,600 MTPD. Consequently, the new plant is set to become
an important part of the local economy of
Slovakia by providing economic growth
as well as a reliable source to downstream
urea and ammonium nitrate that can benefit productivity in the agricultural sector.

The new ammonia plant will be designed based on the latest proprietary Haldor Topse technology, namely the Hal-
Sulfuric Acid Today Spring/Summer 2015
dor Topse Exchange Reformer (HTER)

technology that ensures an efficient and
reliable conversion of the feedstock, which
improves plant economics significantly
and minimizes the environmental impact
of the plant.
From a technical perspective, the
HTER consists of a number of catalystfilled tubes installed in a refractory lined
shell located in parallel with the main reformer and using the waste heat available
from the secondary reformer. In this way
the layout not only reduces the size of the
main reformer and its natural gas fuel consumption, but also minimizes steam generation from the plant.
The project in Slovakia is unique
because it represents the first entirely
new ammonia plant to be built in Europe
over the last decades, said Per Bakkerud,
group vice president in Topses Chemical
Business Unit. The ammonia industry is
highly competitive and even the slightest
changes in performance can impact the
bottom line significantly. Improvements in
production technology such as HTER are
paving the way for improved production
economics. This applies to new plants, but
is also relevant when it comes to revamps
of older plant facilities in Europe. In fact, a
revamp with an HTER can enhance capacity in an existing plant up to 25 percent.

Over the past 75 years, Haldor Topse
has earned a reputation for being a highly
trusted supplier to the global ammonia
industry. The companys industry-leading
solutions ensure reliable and safe operation
with the highest utilization and the lowest possible energy consumption. Topse
continuously works to optimize its customers ammonia production and ensure they
achieve the lowest total cost of ownership.
From new plants to revamps, the company
can help increase capacity and flexibility,
both in relation to feedstock and co-production of other chemicals, creating the
foundation for optimal day-to-day operation and long-term success.
www.topsoe.com.
Outotec to revamp and

upgrade the Potrerillos
copper smelter and
sulfuric acid plant for
Codelco
ESPOO, FinlandOutotec has been

awarded a contract to revamp and upgrade
the Potrerillos copper smelter and sulfuric
acid plant of Codelco Salvador Division
in northern Chile, in order to comply with
the new Chilean environmental regulations that take effect in 2018. The deal is
valued at approximately EUR 64 million,
of which one third has been booked in
Outotecs third quarter order intake and
the rest in the fourth quarter 2014 order intake. Outotecs scope of delivery includes
detailed engineering of the revamp, equipment supply and technical assistance dur-
Department
INDUSTRY INSIGHTS
ing the construction and commissioning
and start up of the smelter and acid plant.
Equipment deliveries will include, among
other things, gas collecting hoods for the
existing converters, revamp of the dry
electrostatic and wet precipitators and gas
ducts, a catalytic converter and an effluent
treatment plant with additional water management plant equipment.
This is a good example of how
Codelco and Outotec work together, combining their efforts to secure business
sustainability and the necessary care of
the environment in a profitable way, says
Kimmo Kontola, head of Outotecs Americas region.
Through advanced technology, we
can extend the life cycle of our customers
facilities. Specialized technical services
are always part of a long-term business
relationship with our customers, providing added value beyond equipment supply, says Robin Lindahl, head of Outotecs
Metals, Energy & Water business area.
www.outotec.com.
Solvay sells sulfuric acid

supplying Eco Services
segment to CCMP Capital
Advisors
NEW YORKCCMP Capital Advisors

LLC (CCMP), headquartered in New
York, has acquired the sulfuric acid-producing Eco Services business unit of Brussels-based Solvay SA. CCMP said that the
Eco Services unit, headquartered in New
Jersey, will continue to manufacture fresh,
high purity sulfuric acid products. The unit
had 2013 revenues of $357.1 million and
CCMP has completed its acquisition for
$890 million. The sale forms part of Solvays strategy to achieve higher growth and
greater returns.

Headquartered in Cranbury, N.J., the
sulfuric acid virgin production and regeneration business recycles spent sulfuric acid and supplies it to refineries in the
West Coast, Midwest, the Gulf of Mexico
and Canada. The Eco Services company
caters to mining, water treatment and other
chemical processing segments, from its six
manufacturing plants. In July 2014, Solvay
and CCMP signed an agreement for the
acquisition transaction. Eco Services has
a market-leading position and generates
stable cash flows, but its business profile
differs from Solvays strategic ambitions,
says Solvay CEO Jean-Pierre Clamadieu.
CCMP Capital is committed to working
with the management team to make the
investments necessary to support the longterm growth of the business.
CCMP is focused on equity investments of about $500 million in North
American and European markets, and primarily invests in consumer/retail, industrial, energy and healthcare sectors.

For more information, please visit www.
solvay.com or www.ccmpcapital.com. q
PAGE 5
Partners, Professionals,
Problem-Solvers...Check.
When it comes to exceeding the qualifications to perform
your plants turnaround or outage, CMW tops the list:
Safety: CMWs MOD rate for 2014 is 0.65. Results exhibit the difference between talk and
action. CMW has a company wide behavior-based training system that drives safety at every
level of the organization. With over 100 turnarounds under our belt, we are proud of our
dedication to keeping our employees safe.
Scheduling: CMW has a dedicated scheduling/planning division with decades of

experience in developing project master schedules that have consistently removed hours,
if not days, of wasted time and resources. From work scope outlines to complete project
tracking through Microsoft Project and/or Primavera, CMW will deliver the master schedule
that makes a difference.
Fabrication: CMWs ASME code shop has the S and U stamps along with the NBIC R
stamp for all your fabrication requirements. Our state-of-the-art 75,000 square foot facility
has produced hundreds of sulfuric pieces of equipment such as converters, heat exchangers,
pressure vessels, acid towers, ducts, expansions joints, and much more for whatever your
specific requirements may be.
Field Installation: CMW has an impeccable reputation for expert quality workmanship
and finishing on time and on budget. Our field crews are some of the best in the business
and our close to 50 years of making sure your plant is back on line provides the confidence
you need in making your contractor decision.
Maintenance: CMW believes in full service for your sulfuric acid plant. Our maintenance
crews ensure that your plant operates at peak efficiency on a daily basis while also providing
the best preparation for all outage related work.
Check us out at www.cmw.cc

For detailed capabilities, scan the QR Code
or go to: http://www.cmw.cc/additionalinfo.aspx
Toll-free in the USA: (877) 704-7411

International: (813) 737-1402
ALABAMA OFFICE
2090 Schillinger Road Ste A Mobile, AL 36695
251-378-5471
FLORIDA OFFICE
2620 East Keysville Road Lithia, FL 33547
813-737-1402
LOUISIANA OFFICE
5240 Gateway Drive Geismar, LA 70734
225-673-5452
Cover Story
Mosaics New Wales Plant: bringing a

world-class legacy into the 21st century
The worlds population is estimated
to be about 7 billion people, with another
150,000 people born every day. Combine
those statistics with limits on farmable
land, and you get a powerful demand for
productive soil. Understanding these forces,
strategic planners at Mosaic Co., the worlds
largest producer of phosphate fertilizer, are
investing billions of dollars in the companys phosphate- and potash-based fertilizer operations, including the flagship New
Wales phosphate facility in Mulberry, Fla.

The New Wales plant was built in 1975
as a state-of-the-art facility and at the time
was the largest phosphate fertilizer complex
in the world. Before Mosaic purchased it,
the facility was owned by IMC Global Inc.,
which operated several plants in Florida
and Louisiana. IMC Global had a long history dating back to 1909, and grew to be a
major player in both phosphate and potash
fertilizers.

Mosaic began operating in 2004, as a
merger between IMC Global and another
internationally recognized leader in industrial fertilizers, Cargill Crop Nutrition.
Cargill Crop Nutrition began in the 1960s
as a division of Cargill, Inc., a leading agribusiness company. From there, the division
grew to be one of the worlds top producers
of phosphate and nitrogen fertilizers.
Today Mosaic, headquartered in
Plymouth, Minn., leads the industry in
worldwide phosphate production at 11 million tons annual capacity and is a major
global producer of potash at over 10 million tons. To achieve these volumes, the
company employs nearly 9,000 individuals
to work in over a dozen large-scale mining
and production facilities and multiple distribution centers and offices worldwide.

The New Wales facility, though no longer the largest fertilizer plant on the globe,
is well-positioned to continue its worldclass legacy. As a proven high-volume, lower-cost performer among Mosaics phosphate facilities, the company has invested
hundreds of millions of dollars to keep New
Wales world-class as it moves into the 21st
century.

Additional steam supply for the high

efficiency steam injection system is
generated by an LLP Boiler which recovers
additional heat from the HRS acid to
generate 15 psig steam.
The last of the 5 stacks is replaced during

the 45-day 01 Plant turnaround that started
in January 2015.
Much of this investment you can plainly

see. Walk through New Wales sulfuric acid
operations today and you will witness the
progress of a major capital investment plan
that, when completed, will have replaced
every major component of all five sulfuric
acid plants. You will also notice two new
heat recovery systems (HRS) and two new
steam turbine-generators, one installed in
2009 and the other one last year.
Putting the Continuous in

Continuous Improvement
For all of New Wales tangible

enhancements, equal focus has been placed
on improving the sulfuric acid departments
processes and organizational structure. In
fact, New Wales has been analyzing every
aspect of its sulfuric acid department: operations and maintenance, OEE, maintenance
reliability and mechanical integrity, asset
management, staffing, role definitions and
training, safetyand more. Getting and
keeping New Wales at world-class performance levels through this century means
creating a continuous improvement culture
and committing to supporting it for the long
term. Not a once-and-done process, but a
cyclical one: analyze your process, refine
your process, do your process. Repeat.
A key contributor to New Wales
refining its organizational practices is the
installation of a dedicated Continuous
Improvement (CI) group. Because the
CI groups singular focus is to optimize
the facility, it can objectively help problem solve across departments. Ky Phan,
Continuous Improvement Manager at New
Wales, puts it this way. The only skin
I have in the game is to help the plant
improve. And sometimes it takes an objective group to get all the right experts from
the different teams together to get to the

root of the problem.
And often it takes the CI groups
focused approach to hone in on the issues
amid all the activity involved with operating five acid plants, three generators and
multiple utility systems. There is a lot
going on in a plant this size with the different groups always looking at safety, cost,
production, quality, environmental and so
forth, Phan says. The CI groups job is to
penetrate beyond these routine activities to
help identify root causes, facilitate solutions
and drive them to closure with long-term
solutions rather than temporary fixes.

Much of what we do sounds simple;
and it is, Phan continues. But the problems are never really simple. There are
always multiple causes that take time and
discipline to resolve. With three years at
New Wales under his belt, Phan and his
team have earned recognition as a valueadd component of the facility. But it wasnt
always that way.

New Wales has seen a lot of improvement plans come and go over the years,
says Phan. In the past, a team would spend
months doing reviews to improve OEE,
maintenance reliability, turnaround management, costs, safety, workflow, etc. Then
the commitment to support the recommendations would disappear as soon as the
company moved on to a new area of focus.
Lots of good work was done to identify and
solve problems, but there wasnt the essential organizational support to maintain the
solutions for the long term.

But all that has changed since Mosaic
took over and implemented this CI effort.
The CI team has helped us tremendously, says Keith Willis, Sulfuric Acid Area
Manager. Theyve helped us get better
organized, stay focused and maintain
the discipline to follow our procedures.
Theyve put the systems and the metrics in
place. Theyve gotten the operators recognition from management for being an integral
part of the process. Theyve helped clearly
define all the roles in this facility and how
everyone at all levels contributes to the
overall plant and corporate goals.
The CI teams influence includes
another important dimensionmanagement support. Beyond the tools to help
the plant identify its problems, says Willis,
now for the first time the CI group can
really deliver the management support
whether that is capital funding, staffing, or
organizational standards and policiesin
a way that has not been seen in the past at
New Wales.

Its been rewarding to see that Mosaic
recognizes the value of continuous improvement, Willis says, and has made the longterm commitment to ensure the continuous
part of continuous improvement is there.
Sustaining capital
investments
Mosaics long-term commitment is

also evidenced by the capital investments it
has been making to the New Wales facility.
And with five acid plants, that means a lot
of capital. As the sulfuric acid plant equipment originally installed in the mid-1970s
began approaching 25 years service life,
a long term capital equipment replacement
plan became imperative.

When the plan was first being developed, a process analysis was conducted
to optimize the performance of each new
piece of equipment, as opposed to simply
replacing old assets with new. Steam turbine
and blower efficiencies were improved; cast
iron grid and post converters were upgraded to stainless steel radial flow designs;
and carbon steel brick-lined acid towers
with cast iron distributors became alloy
towers with high efficiency distributors,
low pressure drop structured packing, and
the latest mist elimination technology with
concentric auto-drain candle designs. All
of the heat exchange equipment designs,
from boilers to economizers, to gas-gas
heat exchangers, to acid coolers have been
optimized as well.
Its been a long program, but the
results have been exceptional, says Jim
Dougherty, New Wales Process Engineer.
These upgrades not only returned all
of the assets to their original operational
integrity, but have also increased production capacity and improved energy recoveries. On top of that, the plants also operate
with even lower emission rates than the
original designs did.

Why not just fix the equipment? Its all
part of Mosaics long-term philosophy.
Mosaic believes in the phosphate
business, and is investing heavily for the
future, says Chris Hagemo, Assistant
Facility Manager at New Wales. We are
deploying significant capital to not just fix
what we have, but to make things better.
Well get 20 to 30 more years of solid performance out of this equipment.
The equipment replacement count is
impressive: 5 each of major components
such as furnaces and converters; 10 waste
heat boilers; 15 acid towers; 18 acid coolers
and 25 super heaters and economizers. And
when you include the more routine equipment like pump tanks and stacks, the grand
total exceeds 90 pieces of major equipment.
Super-sized turnarounds
With all the new capital equipment
and the heat recovery installations, New

Wales has been experiencing the most
complex turnarounds in its history. The
turnarounds here are the largest Ive seen
PAGE 7
Cover Story
Chris Hagemo
Chris Pearson
Installation of new 4A/C economizer

4A superheater installed at 02 Plant. The
equipment was designed by MECS/DuPont
and fabricated by Optimus.
in my 25-year career, says Willis. The

coordination between the project group, the
operations group and the engineering group
has to be spot on. And while were doing a
turnaround on one of the acid plants, were
still operating four other plants and three
generators.
A normal New Wales turnaround
used to take two weeks, and might include
screening catalyst, a little maintenance on
acid distributors and brick refractory, water
blasting acid coolers, cleaning boiler and
heat exchanger tubes and maybe replacing
a gas duct or two. Then, when the capital
equipment replacement funding started
coming in, things changed. Weve had
to reinvent how turnarounds are handled
here, Hagemo says. How weve choreographed outages from staffing, planning
and logistics is a testament to the hard work
and efforts of the entire sulfuric team.
When we first started executing the
equipment replacement plan, replacing just
one piece of equipment, such as an acid
cooler or a gas-gas heat exchanger, was a
big task. Each time, we had to figure out
the best way to do the work for each piece
of equipment, recalls Dougherty. Then
things began to accelerate. We moved on
to bigger scale equipment, like furnaces and
acid towers, and then ultimately the first
converter change-out. That was a really big
deal for us28 days.

But the work intensified even further.
So much so, recalls Capital Projects Manager Atusa Amiri, that it is hard to remember what a turnaround with only one or two
equipment replacements was even like. We
progressed to multiple project turnarounds,
like a new converter with an acid tower and
two gas-gas heat exchangers. After so many
PAGE 8
Dennis Sisco
of these, Amiri continues, the norm became replacing 3-5 pieces of equipment every turnaround. We had to find a way to get
ahead of the game. Ultimately we ended up
with a 10-year sulfuric acid capital equipment plan to lay out which equipment made
the most sense to change together based on
New Wales 5-year capital funding plans.
I was developing and securing funding for
projects 3-4 turnarounds into the future, all
while executing 3-5 piece turnarounds every 6 months.

For the sulfuric operations and maintenance group, the frequency and duration
of the turnarounds compounded the complexity further. We were doing these big
turnarounds every six months and many of
them were nearly a month long, explains
Willis. So that means we were almost always either working on turnaround prep, in
turnaround, or in the post-turnaround demobilization stage. Eventually we got to the
point where turnaround mode was the only
mode we had.
Fortunately, says Hagemo, by the
time we started getting into these multiple
equipment turnarounds, we had already developed enough experience performing single-equipment replacements that the larger
projects came down to proper planning and
coordination.

The turnaround complexity ultimately
peaked in 2014 with back-to-back turnarounds installing 5 pieces of equipment
during each outage plus heat recovery system (HRS) conversions, and the commissioning of a 30 megawatt (MW) turbine
generator in between. Finally, the most recent turnaround spanned 45 days and consisted of 9 major equipment replacements
a furnace, two waste boilers, drying tower
doghouse and mist eliminators, two economizers, a superheater and two acid coolers.
Were looking forward to getting back to
those easy 2-3 equipment turnarounds
again, says Willis.
Managing turnarounds
hitting the bulls eye
With the scope of the turnarounds and
all the different groups wanting to perform

capital replacements, maintenance reliability and traditional turnaround work during
the same outage time, Operations Turnaround Coordinator Keith Eldridges role
became more critical than ever. I coordinate the logistics of all these teams coming
together, Eldridge says. So I developed a
plot plan to track all the different contractors coming in for all the various projects.
Who is coming in when, when is a certain
contractor available, what equipment are
they bringing, what crane size are they us-
Jim Gruber
ing, will it fit, what roadways are we closing

for those 12 concrete trucks coming in, is
there enough parking, how do we give access to the 300 additional people moving in
and out, do we hire a full-time person to direct traffic, how much waste are we generating, how are we handling that and so forth.

These turnarounds became complex,
but they still had to execute perfectly. Its
like having to hit the bulls eye every time,
Eldridge says. But, hey, thats what were
aiming for.
Helping him hit that bulls eye are
two dedicated planners, Mosaics Jai Jairam, and Central Maintenance and Weldings Walter Brown. I spend nearly all of
my time here at New Wales planning and
scheduling turnarounds, says Brown. Together with Mosaic, Brown has taken the
best practices from past turnarounds and
developed a New Wales-style turnaround
planning system that uses templates and an
optimized sequence of procedures. Brown
also combines all the contractors schedules and gets daily contractor updates,
which he includes in the master schedule
and redistributes.

Tracking progress is critical, Brown
says. In order to try to bring things in,
you have to know whether youre getting
behind. People need interim goals on their
way to achieving the end goal. It used to be
wed have just the one end date. Then the
tasks in the middle would keep slipping out
farther until youd push the end date.

Given the significant price tag associated with each super-sized turnaround, New
Wales has also been working diligently to
extend the time between outages. The original turnarounds back in 1975 took place every 9 months driven by the need to screen
the old pellet style catalyst. Then, with the
advent of low pressure drop ring catalyst,
a 24-month operating cycle became commonplace. Eventually they were increased
to 30 months. But even the 30-month cycle
is under scrutiny as the team considers
the feasibility of extending to a reliable
36-month operating cycle.
Weve looked at the economics of
taking just a few days to do a simple turnaroundscreen catalyst and maybe check
distribution levels in the towers, says Hagemo. But even that bit of work can cost
$2.5-3 million, so we found it makes better
financial sense to extend another 6 months
and save half a million dollars.
Pushing turnaround cycles even further means the diligent every-day operating paradigm of continuous improvement
is even more important. Longer operating
cycles means we have to run the plants even
better in between, says Hagemo. Proactive maintenance reliability is critical.
Kristi Farrell

We are in this culture now of finding
sustainable solutions to reduce expenses,
improve performance and improve reliability, Hagemo continues. Were questioning historical operating paradigms. And
weve been successful. When we went to
a 30-month turnaround cycle, folks were
saying, you cant run an HRS plant past
24 months, but we did. Well see whether
we can continue in the long-term, but well
keep searching for those bottle necks and
stretching ourselves as long as we can.

Although the New Wales team with its
five acid plants executes turnarounds every
6 months, for Mosaic as a whole, its an even
bigger story. In central Florida, Mosaic now
operates a total of 17 sulfuric acid plants,
all of which share the same contractors
during turnarounds. With this many plants
and a limited set of qualified local contractors, coordinating all of the acid plant turnarounds has become a monumental task.
In front of that task is Turnaround
Maintenance Advisor Dennis Sisco, also
known locally as the turnaround guy.
A huge proponent of planning, Sisco has
formalized a Mosaic-wide turnaround
management program and helps facilitate execution of that process at all of the
sites, particularly the sulfuric acid plants.
A central theme to his work is sharing information.

Weve looked at all the sites, capturing what theyre doing well and what they
can improve, and taking that from site to
site, so that everybody gains from the tribal
knowledge of all the teams, says Sisco.
A common issue Sisco has noticed
throughout has been too few quality contractors to perform all the work at Mosaics
17 acid plants. And the contractors they are
using are stretched to capacity.
This year, were conducting nine
sulfuric acid turnarounds, Sisco says. A
record for Mosaic. And if were using the
same contractors for all of them, the crews
get worn out. Were looking into ways of
requiring them to take time off every so
often, rotating crews, and even rotating
contractors so we dont burn out any particular contractor and get better, safer performance overall.
Securing safety
priority #1
Given all the considerations regarding turnarounds, there is one area that has
risen above all otherssafety. The safety
turnaround management plan is fully integrated to the plants planning process from
day one all the way through to the final
turnaround audits, explains New Wales
Manager for Health, Safety and Security,
Joe Alderdice. All the contractors for the
Cover Story
Ky Phan
Joe Alderdice
major projects provide a detailed safety

plan as part of the bidding process and the
quality of these plans is critical to contractor selection. Once all the contractors are
selected, the plans for each contractors
job are integrated into an overall safety
plan that becomes the core of all of the
other turnaround planning activities. This
approach becomes all the more critical as
the turnarounds became longer and more
complicated.
As important, if not more important
than these critical planning tasks are the
activities Mosaic has developed over the
years to establish a direct point of contact
with every contract employee in every
turnaround every day. A pre-turnaround
safety meeting is held between Mosaic
and the contractor management and supervisory teams, explains Alderdice. On
day one of the turnaround, a kick-off
meeting is held that is attended by every
contract employee to set the tone for the
turnaround. Demonstrations are set up for
safety focus areas specific to the activities
for that particular turnaround or lessons
learned from previous turnarounds. Then
at least one member of the sulfuric area
operations or maintenance staff attends
each individual contractors daily toolbox
meeting to establish a safety contact point
with every single contract employee every
single day of the turnaround. The Mosaic
safety team holds a daily meeting with all
of the contractors lead field supervisors
and field safety supervisor (each contractor
is required to provide its own field safety
supervisor). The daily turnaround planning
and coordination meeting includes all of
the other contract foreman and begins with
safety discussions that include review of
all of the daily audits and observations to
ensure that everyone is aware of all of the
safety activities going on.

Emergency communications is another part of the safety planning. Contract
field safety supervisors are provided with
Mosaic plant radios and are required to
have a system in place to notify all of
their field foremen immediately with a
single call or text in case of emergency.
The final contact point takes place during
the job safety walkthrough that takes place
between the operations personnel and the
crew performing each job as part of the
standard safe work permitting procedures.
By integrating contractors into the
process, New Wales is building important
relationships. Every contract employee
out in the field knows they can bring
up an issue, and well follow through,
says Maintenance Supervisor Barry Brown.
Our goal is to avoid a reoccurrence of a
significant near miss or incident. So if it
takes an extra three days or an extra three
Atusa Amiri
weeks to get the job done safely, thats what

we are going to do. Safety is number one.

The improved relationships have been
earning dividends. Now the contractors
will come up to us and challenge us to
examine their work, along with the work of
other contractors and Mosaic employees, to
see if we can find things that might cause
incidents, says Brown. It used to be theyd
get nervous when we approached them.
Now they want to talk to not only us about
what theyre doing, but to other contractors
as well. This new culture has created an
atmosphere where they all feel comfortable
talking to each other about safety.
You can actually feel it when you
walk around the turnaround areas, agrees
Alderdice. Everybody is coordinating and
communicating better, and looking out for
each other as well.
And the results of all these efforts?
Despite the New Wales sulfuric acid
department executing some of the most
complex and dangerous turnarounds in its
history, there has not been a recordable
injury during a turnaround since 2008.
Thats 14 consecutive turnarounds without a single injury in any one of them,
says Hagemo. Of all that has been accomplished in these sulfuric plant turnarounds,
this safety performance is what we all take
the most pride in.
Jai Jairam

With the investment in capital equipment and plans to continue extending operating cycles to 36-months and possibly
beyond, the performance of the supervisors
and operators who actually run the plants
becomes even more critical. The standards
required to operate three HRS units and
maintain top performance of a sulfuric acid
plant over a 36-month operating cycle without any hiccups are higher than ever before.
Recognizing that having the proper
talent is crucial to the success of any
operation, Phans Continuous Improvement
group was instrumental in getting additional headcount to do the work, but not
before conducting a comprehensive analysis
of plant roles and goals. Our task was to
really understand whos doing what and
who needs to be doing what, says Phan.
So we interviewed a lot of people and
asked a lot of very specific questions, like,
What are your key performance indicators? How is success in your job measured?
What are your goals? Whats working well
for you? Whats not working well?
The analysis identified all the tasks
necessary to achieve the plants goals and
when compared to the tasks that were currently being performed, there were many
tasks left unassigned. The analysis also
identified that the employees were performing their jobs very well, but there simply
wasnt enough employees to complete all
the tasks.
It was the specificity of Kys group
being able to document all the roles and
responsibilities that are needed to get us
where we want to go, and identify all the
standard work within those roles, explains
Willis. That became the blueprint that we
used to compare against our existing staff.
We were able to clearly show management
exactly where our staffing fell short, and we
got the additional headcount we needed, he
says. Its unusual to see headcount added,
Willis continues, but thats the leverage the
CI group brings to the tablethe ability to
get the necessary support from the highest
levels. And these days, Mosaic management
has been following through and delivering
the goods to us every time.
Another critical aspect that came out
of the evaluation was a lack of consistency in the training of the operators. Each
operator was performing his best, but sometimes assigned tasks were under-defined or
incompletely understood. These differences in understanding and performance
levels, explains Sulfuric Acid Production
Coordinator Rod Dexter, were a result
of inconsistent training practices within
the department. So, based on standard
work tasks and roles evaluations, a new
The sulfuric acid process engineering team

includes, from left, Theresa Rowe, Crystal
Alonso and Superintendent Nicole Christiansen.
Plant Operations/Maintenance team members

are, left to right, Drew Evans, Ricky Carlson,
Keith Willis, Rod Dexter, Chris Thomas, Barry
Brown, Doug Simmons and Keith Eldridge.
Operations staffing and

training
Jim Dougherty
training program was developed from the

ground up. And all of the operators went
through it, Dexter recalls, from those
with 25 years of sulfuric experience to the
ones who never set foot in the acid plant.
And everyone came away with the exact
same understanding of all of the roles and
responsibilities of each operating position
in the department, the same standard work
definitions and exactly what performance
levels were expected for each task.

The most beneficial portion of the new
training program was the custom-designed
computer simulation model of the New
Wales sulfuric acid plants developed by
MECS/DuPont. The simulators have been
invaluable not only in terms of abbreviating learning time, Willis explains, but
especially in terms of the confidence that
the operators developed in their abilities
because they have actually run the plant
and troubleshot every possible failure scenario on the simulator. The simulator is
essential training for the chief operators as
it gives them the ability to learn and make
mistakes on the simulator, whereas in the
past these learning mistakes were made on
the actual plants. The training supervisor
works in the background and can input scenarios for every failure that has occurred in
the 40-year history of New Wales, Willis
says.
Production
Coordinator
David
Sheffield worked with the MECS/DuPont
development team to get every detail of
the actual plant operations modeled. The
simulator ended up being so good, says
Sheffield, that I challenged any operator
to take a double blind test whether they
were operating the simulator or a real plant.
So far, nobody has taken me up on it. The
only complaint the operators have about
transitioning from the simulator to the real
plant is that they no longer have the simulators pause button. But when you get right
down to it, Sheffield says, there really
isnt anything the plant can throw at them
that they havent already experienced on the
simulator.
An additional benefit to the simulator is that field operators can use it to
learn how a chief operator runs the plant.
Understanding what the chiefs need from
field operators improves the performance
of the field operators as well as prepares
them to develop into chief operators.
The training program has proved a
resounding successand in sharp contrast
to the manner in which operators have
historically learned their jobs. The training we used to have was school of hard
knockslearn as you go, says Dexter, but
now our training process is world-class.
Were taking guys who have never set foot
in an acid plant before and turning them
PAGE 9
Cover Story
into chief operators in six months. In the

past, an operator would have to be in the
job for six years before youd even consider
making him chief.
Maintenance reliability
Mosaic has also been investing in

other areas of New Wales organizational structure to keep the facility running
world-class. Maintenance reliability, maintenance workflow, plant automation, process control engineers and advanced process controls are all areas that have been
supported to a degree never before seen at
New Wales. The concept of staying ahead
has been a major focus for the maintenance
organization over the last several years.
From a mainly reactive strategy, the work
has shifted to a strongly proactive strategy. Were finding issues before problems
manifest, explains Chris Pearson, Facility
Maintenance Manager. Were finding
issues earlier on the failure curve so we
can address them sooner, quicker and more
cost effectively.
Another significant piece of the philosophy is employing an asset management
program for the plant. Every piece of
equipment will have a spare parts program,
a cataloguing system for all the specifications, as well as a preventative and predictive maintenance program, Pearson says.
Another significant piece of a good asset
management strategy is spares management. We are systematically reviewing
typical failure modes of each of our existing
assets to ensure we have the right spares
cataloged, documented in the BOM and,
where required, stocked in the store room,
Pearson says. With several major capital
expansion project currently underway, it is
important that we develop a spares management strategy long before commissioning
the new assets.

The main goal of a proactive reliability model is to improve overall equipment
effectiveness (OEE) to insure the assets are
available to run whenever operations needs
them to run and they are capable of running
at full capacity.
The changes have been on a revolutionary scale. It wasnt too many years ago
that our maintenance strategies were mostly
reactive. Now we have a staff of reliability
experts who are dedicated to the development of proactive strategies for all major
assets, said Pearson.
The field plant maintenance organization is also coming up to speed. Our
entire group, from planners, schedulers and
supervisors, right down to the mechanics
in the field, went for a week-long training
on root-cause analysis, thinking about why
something might fail, and even anticipating
a failure so you can avoid it altogether,
says Brown. You never heard of sending
mechanics to this type of training before.
The old culture around here was operations
ran it until it failed and then maintenance
fixed it. Were not doing that anymore
with mechanics out in the field having the
training theyve hadwere staying way
ahead of it now.
PAGE 10
The improved reliability program

has also benefited turnaround planning.
Maintaining comprehensive health analysis on all the equipment makes defining
the turnaround scope much more precise,
says Sisco. We can identify, with specificity and hard data, what maintenance needs
to be done and which pieces of equipment have outlived their usefulness. This
specific data presented in a standardized
format has been essential in securing the
necessary funding to properly maintain
the asset value of the New Wales sulfuric
acid plants. And getting the budget commitment to turnarounds early on, Sisco
continues, has allowed earlier turnaround
planning, which was essential to the success
of the complex acid plant turnarounds over
the past five years.
Chief plant operator Vance Governor at the

04 Plant DCS workstation in the New Wales
central control room.
Opportunity capital
projectsthe game
changers
With the capital equipment replacement program well under way and the operations and maintenance teams reorganized
and focused on optimizing existing acid
plant assets, Mosaic management turned
its attention to identifying capital projects
that could deliver improvements on a game
changing scale. The opportunities targeted
were energy recovery/power generation and
raw material supply, the two areas of sulfuric acid operations that have the biggest
impact on reducing operating costs and
increasing revenue generation for the New
Wales complex.

The first energy recovery and cogeneration project was completed in 2009.
The scope included the addition of two
heat exchangers into the existing acid plant
systems and a new turbine-generator (TG).
The two heat exchangers recover additional
heat from the IPA circuit at the 02 plant and
from the original HRS unit located in the
03 plant to pre-heat boiler feed water. The
additional steam generated is used to drive
a 30 MW generator that was relocated from
a plant site that had been shut down in the
early years of Mosaic and re-designed to fit
the steam system at New Wales.

The next energy recovery opportunity
was the retro-fit of two acid plants with
MECS heat recovery systems (HRS) and
the installation of a fourth turbine generator. This project was commissioned in the
summer of 2014. The MECS HRS was
02 Plant HRS system with steam injection

was commissioned in June 2014.
Production Coordinator David Sheffield

demonstrates
the
process
controls
simulator developed by MECS/DuPont for
the New Wales standard and HRS retrofitted
acid plants.
Process
Controls
Specialist
Chris
Sutherland demonstrates the use of mobile
technology for instrumentation system field
maintenance.
ordered with the latest steam injection

system design to generate even more steam
than the traditional HRS design. Putting
steam into a gas system duct prior to an
acid tower goes against everything operations has learned about running a sulfuric
acid plant, but the system really performs.
says Willis. The steam injection controls
automatically adjust to plant rate changes so
it is almost as simple as just turning it on or
off when you start up or shut down the acid
plant. This 30 MW TG runs exclusively off
of steam generated in the two HRS systems
and gives New Wales the ability to not only
supply its own 60 MW base load, but also
supply the power requirements of Mosaics
largest mine processing plant and export
power to the local utility company.

Installing all of this new capital equipment presented challenges not only in the
coordination of the turnaround executions,
but during the engineering design phases as
well. Given all the new equipment going
in, the engineering design teams had to
keep a close eye on how each new component would affect the entire acid plant
A 3-D model image of New Wales Sulfur

Melter targeted to be operational by the end
of 2015.
design, says New Wales Energy Project

Manager Kristi Farrell. With the many different engineering contractors, we had a lot
of drawings that all had to mesh together.
And because the energy project had such
a great impact to the design, it just made
sense to 3-D model the entire plant.
This 3-D modeling has made the
designs much more understandable and
easy for everyone to evaluate. Trying to
put a bunch of individual drawings together,
its really difficult to visualize how all the
designs integrate as a system. But we can
take the 3-D model and show it to the operations and maintenance folks and get their
feedback on the spot, Farrell explains. 3-D
modeling had been used for many years
for individual equipment projects, but with
the size of 2014 HRS project and the five
sustaining capital projects happening at
the same time, it was necessary to model
the entire acid plant in order to ensure that
all of the individual project designs integrated into the existing plant equipment.
After these experiences, 3-D modeling has
become the standard for all of the sulfuric
acid plant projects. Because of their readability, the models have become broadly
used across the plant to evaluate ergonomics, develop repair plans, maintenance
planning and scheduling. Most importantly,
operations can use them for equipment
lockout planning and permitting, giving
them the ability to show the work crew
exactly the equipment location where they
will be working and how the equipment has
been prepared to be safely worked on.

The other game changing project is the
installation of a sulfur melting facility at the
New Wales site. With Mosaic being the
worlds largest producer of phosphate fertilizers, it stands to reason that we are also
the worlds largest consumer of sulfur, says
Director of Raw Materials Procurement
Hermann Wittje. We consume 4.5 million tons of sulfur annually in our process.
That large volume leads to unique concerns
about supply security for this essential raw
material.
Sulfur used for fertilizer production
generally comes in two forms, molten sulfur
and prilled sulfur (reformed solid granules).
Sulfur is a by-product of petroleum refineries and natural gas production facilities.
With the advent of the new reserves of lowsulfur content shale gas and oil currently
being mined in the United States, the North
American sulfur supply is expected to progressively tighten. World supplies, however,
The high efficiency HRS designs at New Wales

include a heater and pre-heater to recover
additional energy from the high temperature
acid and pre-heat HRS boiler feed water.
The HRS systems teflon lined acid dilution

vessel.
ated at the New Wales facility adds no

CO2 emissions.
Moving into the digital age
Committed to continuously improving, New Wales has many other projects

under development that will help ensure
its world class operating status well into
the future. One of the first areas being
targeted is automation. Optimizing plant
performance at New Wales entails keeping up with the technological advances
available to the industry. Several years ago,
New Wales upgraded the 1970s generation
Digital Control System (DCS), but it ended
up being greatly underutilized until a team
of automation technicians were employed to
focus on utilizing the new systems to their
fullest extent.
The plant was already automated, says Drew Evans, Electrical &
Instrumentation (E&I) Supervisor, but we
had a lot of work making it perform well.
During the DCS modernization, the
E&I group also combined the two old control rooms into a single location from which
all five acid plants are run and also installed
dual servers to the controls network to
create the redundancy necessary for 100
percent uptime. Process Controls Specialist
Chris Sutherland is currently completing
the terminal server installations to allow the
integration of mobile devices (iPads) to the
control system networks.
In addition to these terminal servers, explains Sutherland, we are installing
plant-wide industrial WiFi that will allow
the new sulfur melter to be tied back in
to the control network to increase operator productivity and flexibility. Ultimately
security protocols will be developed that
will allow integration into the Mosaic networks to provide remote monitoring of the
controls system from mobile devices off the
plant site as well as more integrated access
to real-time management data, operating
procedures and documents.
The new sulfur melter plant was
designed and staffed based on the flexibility
afforded to an operator from the integration
of the traditional DCS systems with the latest mobile devices. The new facilities operators will be able to monitor and control their
plants operation from the mobile device
out in the plant, looking at the same DCS
screens they see in the control room. They
can keep an eye on the equipment and watch
the process changes made from their mobile
device happen right before their eyes.

The maintenance reliability group will
enjoy similar efficiencies as a pilot program
using iPads gets underway. This will be
a paperless system, says Pearson, where
a mechanic can walk up to an asset, and,
using his mobile device, input readings,
record inspection results and even order
parts for any necessary repairs that will be
ready for him by the time he goes to the
warehouse to pick them up.
New Wales process engineering team is also driving improvements
for the future. These are exciting times
for the process engineering team, says
Process Engineering Superintendent Nicole
Christiansen. We are able to do a lot more
than routine support with our active participation in commissioning and startup of the
HRS and TGs. This type of participation
provides great experiences for our team.
We have been spending a lot of time in
evaluating the best options for the National
Ambient Air Quality Standard (NAAQS)
and have also endeavored on energy optimization type projects with advanced process
controls and improved steam balancing.
Process Engineer Crystal Alonso is
working on another project that implements
advanced process controls (APC) to help
manage steam and power generation. The
APC system will be custom designed using
fuzzy logic that actually teaches itself
how to maximize steam and power generation from the data it collects monitoring the
plants while they are in operation, Alonso
explains. Initially the APC will be developed for the sulfuric acid plant and generators; then, once this base system is in place,
it will be expanded to incorporate other
areas of the fertilizer complex that impact
power generation.
The New Wales fertilizer complex
uses one million pounds per hour of steam
to evaporate and concentrate phosphoric acid for the manufacture of fertilizer,
Alonso continues. The expanded APC
model will be used to maximize phosphoric
acid concentration in the reactor, increase
evaporator operating efficiencies and cleaning cycles, and manage acid tank farm
inventories to balance out the instantaneous
evaporator loadingall of this to maximize
the amount of steam available for co-generation. The model will be further expanded
to include fertilizer production planning
since the different fertilizer products require
different concentrations of phosphoric acid,
which changes the steam demand on the
evaporators. Ultimately, the mine processing plants, which rely on power generated at
New Wales, will be included in the model
to determine the best operating rates and
outage schedules between the complexes
all with the goal of maximizing the power
generation at New Wales.

To support the plants existing automation team, Theresa Rowe is taking on a new
role as Process Controls Engineer. Initially
we will start with the existing DCS process
controls, clean up the alarm systems and
tune up all of the control loops to make
life easier for the plant operators, Rowe
explains. Then well move on to developing the higher level process control schemes
to better operate all of the plants systems
and fully utilize the capabilities of the APC
system that Crystal (Alonso) is working on.

The advancements in automation and
process controls provide great contrast to
the way things used to be at New Wales.
The first superintendent I worked for once
told me about the original sulfuric acid
plants built in the 1960s at Mosaics South
Pierce site, recalls Dougherty. There
were no automated controls at all, and the
control panel consisted of motor run lights,
start/stop buttons and a few chart recorders
for the furnace and converter temperatures.
The only process variable controlled from
inside the control room was the acid dilution water. There was a water pipe that
came through the back wall to a rotometer
and a valve monitor to adjust the flow.
Everything else was manual valves and gas
dampers out in the field and hand written
paper log sheets.
By the time these new process controls, automation and APC projects are
completed, Dougherty says, the way we
will operate the plants wouldnt even be
recognizable to acid plant operators of past
generations. And todays operators wouldnt
be able to run the plants to the standards we
expect without them.
Moving toward the future
With a strong belief in its future and

a commitment to its goals, Mosaics New
Wales sulfuric acid team has accomplished
more in the past five years than in the previous 20 years. At the core of this success has
been a willingness to take a continuousimprovement approach, looking at every
area of the business for ways to improve.
No stone was left unturned. With each new
improvement, the sulfuric acid plants provide an ever greater contribution to the New
Wales bottom line and Mosaics future success, and continue to maintain their world
class status for the 21st century. q
PAGE 11
Cover Story
are set to expand significantly. Most of the

rest of the worlds sulfur is traded in the
solid prilled form. Mosaic has, in the past,
predominantly used molten sulfur in its
Florida phosphate operations. However, as
the world sulfur markets change, Mosaic
needs to tap into this expanding world supply of sulfur to assure cost efficiency and
supply security.

This project will enable Mosaic to use
a combination of molten and prilled sulfur,
Wittje continues, and ensure an economical and reliable new supply source to fulfill
our obligation to remain a low cost producer
of phosphates for years to come.
In addition to the supply chain flexibility and commercial advantages that
the melter will bring to Mosaic, the New
Wales facility will now have a substantial
portion of its sulfur coming through the
melter, which comes with a filtration system. Since our current sulfur supply comes
from many varied sources, we have had
little or no control of the quality of sulfur we
receive, says Wittje. Having direct control
of the sulfur quality means opportunities
to reduce the rate of catalyst bed fouling
caused by impurities that come in with the
sulfur. This will be critical to our efforts to
extend the acid plant operating cycles to 36
months and beyond.

The project is already under construction and targeted to be operational prior
to the end of 2015. The sulfur melter
will be the largest in the world when it is
completed, but the facility design has been
optimized for compactness, operational
flexibility, as well as world-class safety and
environmental considerations. By utilizing
a modular approach, the project delivery
method has also been tailored to meet
business objectives as well as to minimize
impact during construction on a site that
is very active right now, explains Project
Manager Thomas Dombroski.
Devco, a Tulsa, Oklahoma based engineering and construction firm, has been
awarded a project for a turnkey sulfur melting plant including sulfur truck unloading,
storage and melting systems. The original project was to melt the sulfur at the
Port of Tampa, but applying the continuous
improvement principles and value stream
mapping, it was determined that it was actually better to melt the sulfur at New Wales.
New Wales already has steam and
power available, explains Jim Gruber,
Materials Handling Operations Manager,
who will be running the new melter. So
there is a substantial reduction in the capital investment requirements not having to
build a natural gas combustion unit and
boiler to generate steam. Operating costs
will also be lower because the electricity
requirements will be provided by power
that is generated from energy recovered
from the sulfuric acid plants. This is a
big cost savings in comparison to purchasing power from the utility company.
But best of all, Gruber continues, there
is zero environmental impact from the
melter from a carbon footprint standpoint
because the steam and electricity gener-
Feature
MARKET OUTLOOK
Global sulfuric acidsupply and demand outlook
By: Fiona Boyd, Argus Media
In 2014, Argus estimates around 239
million tons of sulfuric acid were produced
on a global basis, of which around 147

million tons, or 62 percent, was produced
through the burning of elemental sulfur. The
majority of sulfur-based acid is produced at

plants located close to end-use fertilizer
production and for industrial applications
including metallurgical leaching.

Around 72 million tons, or 31 percent,
of sulfuric acid was produced as involuntary

and generally unwanted by-product of the
smelting industry, through the smelting of

non-ferrous base metals like copper, nickel,
lead and zinc. This is what makes up the

majority of merchant sulfuric acid traded
in the market.

The remaining 20 million tons,
or 7 percent, of global sulfuric acid

production was through pyrite roasting
in China. Roasting of pyrites has been
eliminated in most other regions because

of environmental concerns surrounding the
process.

A minimal amount of acid is produced
from spent acid regeneration. This process

involves the regeneration of acid produced
within an oil refinery which is then
processed off-site before being sent back

in purified form to the refiner to be used in
the production of refined products.

By 2020, Argus has forecast global
sulfuric acid production to reach 256
million tons, with around 162 million tons,

or 63 percent, to be produced through
sulfur burning. Production from base

metals smelting will account for 74 million
tons, or 30 percent, while the remaining 20

million tons, or 7 percent, will be produced
through pyrite roasting in China.

As the forecast volumes reflect,
sulfuric acid production from elemental
sulfur will account for a larger proportion

of total production than it has in the past.
Drivers for this include the benefit of

creation of by-product energy through the
cogeneration process. A surplus of sulfur is

forecast to emerge in 2015 following tight
supply from 2010-2014. The emergence of a
sulfur surplus will result in lower operating

costs for sulfur-based producers. As a
result, operations that require significant
amounts of sulfuric acid are opting to

develop internal sulfur-based production
PAGE 12
capacity rather than rely on purchasing
seen in the Philippines and South Korea.
of supply in some regions. For example, in
by supply from the merchant market, it is
from the merchant market.
In terms of demand, consumption of
sulfuric acid closely matches production.

Since sulfuric acid is liquid, storage ability
and transportation methods are limited.
Essentially for this reason, the market must

balance itself.

Looking ahead, demand for sulfuric
acid to support fertilizer production will
increase because of the need to produce
more products to help feed a growing

population with improving dietary needs.
In 2015 and beyond, new sulfur-based
sulfuric acid capacity to support fertilizer

production is being added in China,
Indonesia, Malaysia, Morocco, Turkey,

Saudi Arabia and Brazil.

Industrial demand for sulfuric acid
is widespread for the so called king of
chemicals, with over 250 applications

identified according to The Sulfur Institute
(TSI). Major industrial uses include
metal leaching, caprolactam production,

feed-grade phosphates, hydrofluoric acid
production, titanium dioxide production,
pulp and paper production, water treatment
and ethanol production.

Ore leaching represents the largest
non-fertilizer consumption sector. As an
indicator of the importance of the metal

leach sector, Chile is the largest importer of
sulfuric acid to support copper production.
Its imports in 2005 were around 340,000
tons, before increasing significantly to

close to over 1 million tons by 2008 and
peaking at just over 3 million tons in 2012.

New
sulfur-based
sulfuric
acid
capacity to support metal leaching

commenced operations in Mexico in 2014
and additional capacity is planned for

Cuba for 2016 startup. This follows an
increase in sulfur-based production since

2011 to support metal leaching in Chile,
Madagascar and Papua New Guinea.

As indicated, there will also be an
increase in sulfuric acid produced through

smelting, adding additional supply to the
merchant market. In 2014, new capacity
came on stream in Serbia and in Chile
(through roasting of arsenic concentrates).
In 2015 and beyond, new capacity will start

up in China, Zambia, Namibia and most
likely Indonesia, and expansions will be
On the other hand, there will be a loss
Australia the Mount Isa smelter is slated

to be closed in 2017, although there is
the potential this could be extended. At
the same time, the Port Pirie smelter will

expand its production capacity in 2017,
helping counterbalance some of the loss

from Mount Isa.

In the United States, PotashCorp
(PCS) will curtail sulfur-based sulfuric

acid production at its Geismar, La., facility
While there is an increase in sulfuric
acid demand forecast that would be met
most significant in the Latin American

region and would effectively alter trade
flows there. New leach projects in Chile

will require sulfuric acid, but at the same
time some facilities are forecast to close.
This will ultimately reduce Chiles overall

import requirements, but a change in Peru
will mean it will have less sulfuric acid
to supply Chile. Historically, Peru has
in the second quarter 2015. This will result
supplied around 1 million tons per year to
merchant market to fulfill demand rather
Peru supplied Chile with 1.1 million tons,
is expected to tighten supply in the U.S.
Southern Copper is expected to commence
in the need for acid to be purchased in the
Chile to support copper leaching. In 2014,
than use internally-produced product. This
or 52 percent, of its import volume. In 2017,
Gulf coast region and allow for a higher
operation of its Tia Maria copper project in
volume of offshore imports. This marks

the second closure by PCS, who idled
capacity at its White Springs, Fla., facility

in July 2014. Then in late 2014, Mississippi
Phosphates idled production of phosphate
fertilizer and associated sulfur-based
sulfuric acid at its Pascagoula operation.

The PCS closure at White Springs and
the Mississippi Phosphates closure are not

expected to have a significant impact on
the traded sulfuric acid market, as acid was
Peru, which will consume around 720,000
tons per year of sulfuric acid after ramping

up. As a result, Peru will have less to
supply to Chile. Although Chiles overall

requirements will be lower, it will mean
demand for sulfuric acid from alternative
markets, such as South Korea and Japan,

will remain intact.

As this article has examined, there are
several factors impacting the outlook for
produced on-site for internal consumption.
the sulfuric acid market in terms of both
consumption in the United States. In
the end, the market will have to balance
regular importer of sulfuric acid from
for sulfuric acid. In the event demand does
expected need for import material to cover
to be reduced in order to keep product
It will, however, result in reduced sulfur
losses and gains in supply and demand. In
addition, Mississippi Phosphates was a
itself because of the limited storage options
offshore sources, mainly Europe, but the
not keep pace with supply, prices will have
the Geismar closure should counterbalance

that loss of demand.

Meanwhile, by-product sulfuric acid
production will increase in the United

States with the 2016 start up of the
Mississippi Power project, which will
create sulfuric acid through a gasification
process. In 2017, Freeport-McMoran will

expand smelter capacity at its Miami,
Ariz., facility.
moving.
Argus
Media
publishes
weekly
global reports on sulfur and sulfuric acid

as well as reports on fertilizer-related
products including nitrogen, ammonia,
potash and phosphate. North Americanspecific publications for both fertilizers
and the sulfur/sulfuric acid markets are
also available. Argus also offers consulting
In Canada, which supplies around
services, including single-client studies and
to the United States, a loss of production
acid supported by our proprietary supply
in 2017-2018, although the exact loss in
on Argus and its portfolio of fertilizer
subject to change.
com/fertilizer. q
2 million tons per year of sulfuric acid
presentation service for sulfur and sulfuric
is forecast from two smelting operations
and demand model. For more information
volume is unquantified at present and
publications, please visit www.argusmedia.
Feature
Vertical pump sealing options:

packing seals vs. mechanical seals
By: Martha Villasenor, Area Manager, Weir Minerals Lewis Pumps
Weir Minerals Lewis Pumps verti-
by-pass in the shaft column. Through this

by-pass component, the circulating fluid
cal pumps, used in molten sulfur, sulfuric
lubricates the wetted bearing(s) and then
acid and oleum applications, are typically
returns to the tank or suction side of the
installed with a packed stuffing box. This
pump. This arrangement prevents liquid
type of sealing arrangement works well
pressurization at the stuffing box.
because the packing is exposed only to the

In the sulfur and sulfuric acid induspressure inside the vessel and the pumped
tries, the wide use of pumps manufactured
fluid never reaches the top of the stuffing
by Weir Minerals Lewis Pumps is due, in
box. Another feature of these pumps is a
part, to their reputable trouble-free vertical
packing seal design. In molten sulfur applications, the pump design prevents leakage
and solidification of product that inherently
occurs when using a horizontal pump. In
sulfuric acid applications, the packing has
to prevent hazardous fumes from being released into the atmosphere. One method of
preventing emission of fumes is to induce
a slight vacuum on the acid tanks. It is important to keep the vacuum on the tank to
a minimum to keep moist atmospheric air
from entering the system as this could lead
Fig. 1: Weak acid formed by moist air
entering with acid fumes. Dry-air/nitrogen
to the entrance of moist air in the pump/
10798_SAU_SAT_0208_R1:Layout
1 2/19/08 3:45 PM Page 1
purge
was not used.
tank, which can then cause build-up of
Polymer Concretes for Infrastructure Longevity
Temperature Environment
Chemical Environment
Physical Environment
Delivering Ultimate Corrosion Protection

Within 48 hours after pouring, Sauereisen polymer concrete delivers unparalleled
strength, durability and chemical resistance. It exhibits five times the compressive
strength of standard concrete. Like a brick lining, Sauereisen castables hold up to the
most aggressive process environments, but at a fraction of the installation time and cost.
Call Sauereisen for a solution thats fast and made to last.
p: 412.963.0303 email: questions@sauereisen.com

P i t t s b u r g h , PA 1 5 2 3 8 U . S . A w w w . s a u e r e i s e n . c o m
PAGE 14
Dry Air
1/4 NPT
Pipe Union
SCHEMATIC ONLY
Fig. 2: Fume
containment
arrangement.
iron sulfate and highly corrosive weak acid

(Fig. 1).

When using the deep stuffing box arrangement, it is recommended to use dry
air or nitrogen at 2-5 SCFM at a pressure of
2-3 Psi (15-25 kPa) above the tanks pressure, in order to eliminate fume emissions
from the deep stuffing boxes. Emissions
can be eliminated when tank pressures
are higher than atmospheric pressure. The
fume containment arrangement, as shown
in Fig. 2, prevents the acid fumes from being emitted to the environment and also
prevents moist atmospheric air from entering the pump.
There are certain conditions under
which the packing arrangement is not adequate. One such condition is when the
pressure in the pump tank or tower exceeds
atmospheric pressure and the pressure rating of the packing. Pressure on the packing
is not to exceed 60 inches of water column
(2.53 Psi gauge). Many acid plants have
higher tower pressures that qualify for a
mechanical seal rather than the packing arrangement. However, before changing out
all of the deep stuffing box arrangements
for the higher pressure accommodating
mechanical seals, keep in mind that mechanical seals present their own challenges.
Some of the most common issues are: sensitivity to installation errors; damage due
to improper handling; lack of resistance
to thermal shock; high cost; more time
consuming to replace; gas cooling/gas lubrication required to prevent damage; and
susceptibility to mechanical damage due to
misalignment, cavitation, shaft deflection
or shaft run out.
Weir Minerals Lewis Pumps has
multiple mechanical seal options, such as
single mechanical seal graphite or tungsten
carbide. Still another common option is a
cartridge dual mechanical seal kit. Other
seal options have been provided, depending
Tank Pressure
(PT)
Note: Location of dry air connection shown is applicable to
Pump Sizes 7HR through 10H only. Dry air connection
on all other pump sizes is located on Stuffing Box (part
of Ball Bearing Housing).
on the application and requirements. For

any of these options, using clean dry air or
nitrogen for cooling the seal is necessary.
The pressure of the air or gas needs to be
2-3 Psig above the maximum tank pressure.
Gas lubrication will need to be provided to
the seal at all times, otherwise sulfuric acid
fumes can damage the seal components.

When selecting appropriate mechanical seal materials that are chemically
compatible with the different acid concentrations and temperatures, the pump
design must be done within seal and pump
manufacturer tolerances and guidelines. It
is recommended that Weir Minerals Lewis
Pumps determine the selection and design
of the pump and mechanical seal. When
using a mechanical seal, shaft deflection
and run out are key factors that have to be
considered to ensure trouble free operation
of the pump and long, useful life of the mechanical seal.
In summary, Weir Minerals Lewis
Pumps vertical pumps can be used in most
applications with just the packed stuffing
box arrangement. Molten sulfur and standard sulfuric applications are mainly handled with this type of seal set-up. The vertical pump design prevents product from
reaching the stuffing box. Weir Minerals
Lewis Pumps recommends the installation
of the fume containment dry air purge, as
illustrated in Fig. 2, to prevent air entrainment and fume emissions. For applications
where the differential pressure on the packing is greater than 2-3 Psig above atmospheric pressure, the packing seal arrangement will not be an option. The higher
pressures will demand that a mechanical,
gas-lubricated seal be integrated within the
pump to handle the additional pressures.
For further information, please contact Martha Villasenor of Weir Minerals Lewis Pumps at martha.villasenor@
weirminerals.com or (314) 272-6218. q
World-class Technology
for Worldwide Markets
We deliver a wide range of products and services, from engineering
studies through to full EPC projects for the Sulphuric Acid Industry
Products & Services:

Acid Plants
Sulphur Burning
Metallurgical
Spent Acid Regeneration
Acid Purification & Concentration
Wet Gas
Proprietary Equipment
Converter
Gas-Gas Exchanger
Acid Tower (brick lined and alloy)
Acid Cooler
Furnace
SARAMET piping & acid distributor
Venturi Scrubber
Technical Services
Turnaround inspection
Operations troubleshooting
Process optimization
Feasibility studies
CFD (Fluent) analysis
FEA (Ansys) study
Chemetics Inc.
(headquarters)
Chemetics Inc.
(fabrication facility)
Suite 200 2930 Virtual Way

Vancouver, BC, Canada, V5M 0A5
Tel: +1.604.734.1200 Fax: +1.604.734.0340
email: chemetics.info@jacobs.com
2001 Clements Road

Pickering, ON, Canada, L1W 4C2
Tel: +1.905.619.5200 Fax: +1.905.619.5345
email: chemetics.equipment@jacobs.com
www.jacobs.com/chemetics
Chemetics Inc., a Jacobs company
Feature
Upgrades to sulfuric acid equipmentan evolutionary tale

By: Guy Cooper, NORAM Engineering and Constructors Ltd.
In the beginning

In the mid-1700s, sulfuric acid
was made in lead-lined wooden vessels through the reaction of sulfur
dioxide, steam and nitrogen oxides
in what was called the lead chamber
process. In the 1900s the contact
process became prominent with the
use of a vanadium pentoxide catalyst. This process still forms the basis for sulfur dioxide oxidation and
the production of sulfuric acid.
In the past 50 years, sulfuric
acid technology has progressed with
three major improvements:
Materials of construction.
From carbon steel and cast iron to
stainless steels and high-silicon alloys for acid systems.
Process. From single absorption to double absorption, lowgrade heat recovery and SO2 scrubbing systems
New equipment designs.
Radial flow gas exchangers, stainless steel converters with improved
catalysts and anodically protected
acid coolers.
Lets take a look at improvements made to the converter, the gas
exchanger, and the acid system.
Converter
The dark ages:

The proverbial heart of a sulfuric acid plant is the converter. Pre1980, converters had thick carbon
steel shells, heavy cast iron grids,
and posts and brick-lining in bed
one and sometimes in bed two to
keep shell temperatures appropriate
for carbon steel.

The thick shells were required
to accommodate the strength reduction of carbon steel at the high
operating temperatures. High temperature oxidation caused carbon
steel flaking and subsequent fouling
of downstream equipment, requiring metallizing of the first pass.
However, the aluminum used in the
metallizing would often flake off,
requiring periodic reapplication.
Converter catalyst support with

cast iron post and grids.
PAGE 16
A three-catalyst bed configuration was typical, as most of the

early acid plants were single contact,
single absorption (SCSA). Catalyst
activities were much lower than today and the pellet shape of catalyst
created a high bed pressure drop.
The age of enlightenment:

The use of stainless steel in the
1980s revolutionized everything.
This was especially pronounced
in the design of stainless steel converters. Weldable metal that had
good mechanical strength at temperatures up to 1,200 degrees F (650
degrees C) improved the converter
designs with thinner walls, sealed
division plates, internal exchangers,
better internal support systems and
reduced maintenance. Instead of
resisting thermal expansion, some
new converter designs embraced it,
by allowing the shell to grow radially without causing any significant
stress to the structure through the
use of curved blooper (or dished)
plates and sliding vessel supports.
NORAMs stainless steel post design allows the use of the full crosssectional area of the converter bed,
avoiding the area lost to a core support. The posts can also be used to
support an internal gas exchanger.
Catalyst conversion:
Catalyst also improved by
leaps and bounds. Cylindrical pellets with high pressure drop and
relatively modest conversion gave
way in the 1970s to rings, and in the
1980s rings morphed into what various vendors refer to as stars, ribbed
or daisy-shaped rings. In addition
to shape improvements with lower
pressure drop and an extended surface, the late 1980s saw the use of
cesium-promoted catalyst. This
metal additive reduced the catalyst
strike temperature, improving the
equilibrium and conversion, and
went a long way toward serious
emission reductions.
New NORAM converter with catalyst

support posts and internal hot
exchanger.
Double absorption adoption:

During the 1970s and 80s,
double absorption arrived on the
scene, partly in response to the U.S.
Clean Air Act of 1970. With the
addition of an extra converter bed,
exchangers and another absorption
system, emissions plummeted from
thousands to hundreds of ppm SO2.
Different configurations were used
including two beds before the new
interpass tower followed by one bed
after the interpass tower; and this
is known as a 2:1 double contact
double absorption (DCDA) system.
Similarly, there are 3:1, 2:2, and 3:2
configuration systems with the 3:1
being the most common DCDA
system today. Double absorption allowed some plants to increase their
SO2 strength to the first pass from
7-8 percent to 11-12 percent, resulting in higher temperatures in the
converter and hot exchanger. This
further compounded the requirement for the use of stainless steel for
these components.
Gas to gas heat

exchangers
The heat is on:

Over the past thirty years, gasto-gas exchanger designs have improved tremendously. Advancement
has come in materials of construction and in the process design.
Stainless takes over:
In the good old days, hot exchangers, which see among the
hottest temperatures in the plant,
would be made out of carbon steel
for the shell and the hot first pass
gases would flow through tubes
impregnated with aluminum (also
known by the trade name Alonized). As with its use in converters,
hot exchangers are now only fabricated from 304-type stainless steel.
Stainless steels high temperature
strength and corrosion resistance
make it an easy choice for this service. Even for cold exchangers, especially replacements, most clients
select stainless steel for its corrosion
resistance and to help reduce sulfate
fouling.
Radial flowcircular is logical:

In the early days, gas exchangers had shells crammed full of
tubes. After all, shells are expensive
and why not fill them up with tubes?
That design may work well in the oil
and gas industry, but for an industry
dealing with large volumes of low

pressure, high temperature, corrosive and sometimes condensing
gases, there is a better way.
Technology providers developed the radial-flow gas exchanger,
which had no tubes in the center
of the shell bundle and the periphery, and the gas flowed radially
between the outer and inner shell
portions. This arrangement greatly
increases the shell-film coefficient
since all the tubes are in cross flow.
Compared to double-segmental
shell configuration, the radial flow
exchanger can have over twice the
heat transfer coefficient. And that
means fewer and more efficient
tubes, as well as greater thermal and
mechanical symmetry.
address condensation with moderate success, including sacrificial

heat exchanger, bimetallic tubes and
thicker tube walls to allow more
corrosion resistance.
In the 1990s, NORAM
(through CECEBE) patented the radial-flow, hot-sweep feature, where
a portion of the hot shell gas is internally directed to the cold tubesheet.
A warm tubesheet prevents condensation, is dry and sulfate-free. The
hot-sweep feature is also used in
SO3 coolers to greatly reduce the air
flow necessary to keep the cold end
above the dew point. For preheaters, turning a hot sweep to a cold
sweep can significantly improve the
thermal efficiency of the preheat exchanger.
Keeping the cold exchanger hot:

Cold exchangers can get cold.
Too cold. Especially in the zone of
the exchanger where the cold SO2
gas is in thermal contact with the
cool SO3 gas. In this area, condensing can occur; and for carbon steel
exchangers, sulfate formation can
clog the shell and the tubes. Various approaches have been tried to
Acid systems
Installation of new NORAM

RFTM gas heat exchanger.
Demolition of old singlesegmental gas heat exchanger.
Large diameter towers:

Early towers were carbon steel
and brick lined, with small size
packing, and were often installed
in increasing sizes from bottom to
top. Pall, Raschig and cross partition rings were common packing
materials prior to 1970. Old towers
often featured low irrigation rates,
cast iron trough acid distributors
and mesh pads for mist elimination.
With the small-size packing, large
diameter towers were required to
keep the pressure drop from getting
too high.
The towers were brick lined
and some designs offered flat floors
to support the brick arches needed
for the Aludur beam packing supports. After some years, acid leaks
would develop on the tower bottom,
caused by lining failure from the
high point loads of the brick arches
on the floor. The top tower shell section above the bricking was fabricated from carbon steel plate and the
inevitable acid mist would result in
large sulfate formation fouling the
top of the acid tower.
Musical coolers:

The acid piping systems at that
time were cast iron and the early-day
acid coolers were cast iron pipe sections with an external water-spray.
These coolers were called cascade
coolers or, because they looked like
a musical instrument with their convolutions, trombone acid coolers.
They were prone to corrosion leaks
requiring frequent acid plant shutdowns.
NORAM SX SMART distributor

with external clean out ports.
SX trough-type distributor.
NORAM SX acid cooler.
NORAM acid cooler with anodic

protection.
percent pressure drop of the conventional 3-inch standard saddles.

This allows increased gas throughput or less energy consumption for
the same gas flow.

Distributors are now using long
lasting high silicon alloy in a trough
or a pipe format. The NORAM
pipe distributor permits distributor
cleanout from outside of the tower,
negating the need for tower entry to
remove chips. For mist elimination,

mesh pads in absorbing towers have
been replaced with candles such as
Brownian diffusion or impaction,
and mist removal is now down to
the submicron level.

The acid coolers have undergone a tremendous change from
cast-iron trombone to anodically
protected shell and tube exchangers. Conversion from cast iron
trombone coolers to anodically
protected coolers resulted in a significant increase in acid plant onstream time. And now high silicon
alloy acid coolers permit operation
without anodic protection. For the
piping systems, high silicon alloy
can replace ductile iron piping
with the benefits of light weight
and significantly higher erosion
resistance. They also remove the
need for flanges and their potential leaks.
Heat recovery systems are
available that can convert heat lost to
cooling water into low- to mediumpressure steam. New SO2 scrubbing
systems using regenerative solvents
are also gaining popularity.
Feature
NORAM SX Pump Tank and SX

Acid Towers.
The modern era:

Todays acid system has improved significantly in all areas.
High silicon alloys (SX, Zecor,
Saramet) are sometimes used for
the lower section, eliminating the
need for bricking and permitting
replacement in the same location
within a two- or three-week annual shutdown. For brick lining,
clients often request dome packing supports, which eliminate the
need for the brick support arches
and allow a dished bottom without point loads and an inherently
more reliable shape. Above the
acid distributor level, 316 stainless steel is used, which eliminates sulfate formation. This
keeps the top section nice and
clean.
Tower packing is now typically a 3-inch ceramic saddle.
Low pressure drop saddles such
as NORAMs No. 3 HPTM saddle as well as structured ceramic
packing have improved the process. With the same or better mass
transfer capability, NORAMs
No. 3 HPTM packing has only 50
HPTM low pressure saddles.
Change is good
Converters, catalysts, gas exchangers and acid systems have all

made tremendous improvements
in performance, operability and
reduced maintenance over the past
50 years. These changes have come
through material upgrades, design
improvements in equipment and
systems and new products. And as
Shrek, the famous movie ogre, said,
Change is good, Donkey.
NORAM Engineering and
Constructors Limited performs
engineering studies and supplies
better-than-average equipment
at attractive prices for sulfuric
acid plants. For more information, please e-mail sulfuric@
noram-eng.com, or call (604)
696-6910. q
Powell Sulfuric Acid Dilution System

The Powell Sulfuric Acid Dilution Systems are engineered to continuously dilute 93% or 98% sulfuric acid to any lower
strength. The systems are automatic and include pumps and cooling water systems for the safe, accurate dilution of the
concentrated acid. Systems are available for all flow rates and diluted acid strengths.
Features
Automatic Dilution
PLC Based Control System
Adjustable Batch Amounts or Flow Rates
Strong Acid and Water Supply Pumps
Skid Mounted, Fully Assembled
740 E. Monroe Road, St. Louis, MI 48880

Ph: 888.800.2310
www.powellfab.com
email: info@powellfab.com
PAGE 17
Feature
PPE: The final answer to

worker protection
By: Darwin Passman, HR/Safety Director, VIP International
The best safety practice dealing with hazards of the

workplace is called the Hierarchy of Hazard Control. There are
five types of hazard controls. They are, in order of preference:
1. Elimination: Eliminate the hazard by physically
removing it. For example, a manually operated valve may be
positioned 12 feet above ground level, requiring a ladder to
operate. Eliminate by repositioning the valve to ground level.
2. Substitution: Replace what produces the hazard with
something that does not produce a hazard. The paint industry
replaced lead-based paint with acrylic paint, thus removing the
hazard.
3. Engineered controls: Isolate hazards from exposure
to personnel. For example, ventilation at a workstation can
remove airborne contaminants from the work area.
4. Administrative controls: Change the way people work
by limiting or preventing peoples exposure to the hazards.
Administrative controls include procedure changes, employee
training signs and labels.
5. Personal protective equipment (PPE): Require workers
to use the last line of defense against a hazard. This includes
gloves, respirators, hard hats, safety glasses, high-visibility

clothing, safety footwear and chemical-protective clothing.

Despite the preference for controls noted in numbers one
through four, PPE is often the only option for successfully
completing the task. This is particularly true during a
turnaround. Performing isolations, line-breaks and confined
space entries requires extensive use of PPE during a sulfuric
acid turnaround.

Anytime there is a task with the possibility of exposure
to sulfuric acid, full body protection is the best practice. The
PPE should provide total protection from an uncontrolled
release of acid. Line breaks are a good example of a task
needing protection.

During a line break, there is a potential for an uncontrolled
release due to:
Plugged drain lines.
Valves that do not completely isolate the flow of acid.
False indication of the level of acid in a vessel.
Performing a line break on an energized line.
INDUSTRY PROFILE
Jon Quarles retires from

Acid Piping Technology
After 47 years in the sulfuric acid industry, Jon Quarles has
recently retired from his role as
Marketing Director of Acid Piping Technology. He started his career in the agricultural division of
Monsanto in 1967. In 1970, Quarles
moved to Monsanto Enviro Chem
Systems (now MECS Inc.), where
he handled marketing and service
for mist eliminators and sulfuric
acid catalyst.

After several years at MECS,
Quarles spent a year at Lewis
Pumps before Ed Knoll approached
him about working for Acid Piping
Technology, which was just getting
started. We started it together,
building the building and getting the customers and getting the
market lined up. When we started,
there were only about 5 of us. Now,
Acid Piping Technology has over
20 employees, says Quarles.

The size of the company isnt
the only change Quarles has noticed over the years. Ive seen acid
plants go from 800-1,000 tons per
PAGE 18
Jon Quarles recently retired from

Acid Piping Technology after 47
years in the sulfuric acid industry.
day to up to 3,500-4,000 tons per

day. As the plant size has grown,
so has the piping theyve used. Its
gone from 12-16 inch pipe all the
way up to 30-36 inch pipe. Mist
eliminators have improved in design, and newer, more active catalysts have been introduced.

Another big change has been
the tightening of pollution control

at the plants. SO2 emissions are
much more controlled now. Ive
seen the industry progress in many,
many ways.
Over the years, Quarles has
worked on projects around the
world, from Arizona to Morocco.
Ive probably worked on 18 or 20
plants in Morocco for OCP, Quarles says.
Even retirement wont keep
Quarles from the industry he loves,
though. Im looking forward to
working on some hobbies and
spending time with family, he
says. If I could do some consulting, too, that would be great.
Acid Piping Technology specializes in engineered products for
the sulfuric acid industry worldwide. The company maintains the
worlds largest inventory of MONDI pipe and fittings for routine or
emergency needs.
For more information, please
visit www.acidpiping.com. q

Once isolation has occurred and the line break is defined,
the nearest safety shower or water source must be identified.
The route from the line break to the water source must be
reviewed with all personnel. The water source must be safe for
human exposure, ensuring volume and pressure is sufficient
for decontamination of PPE or direct use on the skin and eyes.
Some facilities have line-break permits specifically
designed to mitigate the hazards while others use a general
work permit supplemented with a job safety analysis (JSA).
These tools will follow the Hierarchy of Hazard Control to
define the job scope, hazards involved, and mitigation or
elimination of the hazards. Mitigation is the area where PPE
is defined.

Confined spaces are another area of concern. Confined
space entries in the acid towers of a sulfuric acid plant
will always require maximum protection. This is due to
an environment with primarily concentrated acid or at a
minimum low pH liquid exposure. All facilities have confined
space permits that address the mitigation or elimination of
hazards present. Confined spaces are monitored to ensure
the atmosphere is breathable. If atmospheric hazards exist,
ventilation and/or respiratory protection is used to ensure
safe entry.

If the work involves confined space entry or line breaks,
the potential exposure is elevated. The PPE must protect
the worker against significant and probable exposure. If the
potential exposure is low, such as working on the deck of a
confined space, PPE should be defined accordingly.
Confined space entries in the converter of a sulfuric
acid plant require PPE for atmospheric protection from sulfur
dioxide, NOx and dust. The physical hazard is primarily
catalyst dust exposure to skin. PPE selection must protect
against inhalation of dust and skin exposure. High levels of
exposure may require respiratory protection with a high level
of skin protection. Low levels of exposure may only require
basic PPE for the site. When atmospheric testing reveals toxics
in the atmosphere, OSHA mandates the respiratory protection
required for the toxics.
Once PPE is defined, its crucial that all employees
receive adequate training prior to performing turnaround
work. This training should include use and limitations,
donning and doffing, decontamination of PPE and storage
or disposal of PPE. Performance-based training is also
necessary to be sure that work functions can be performed
appropriately with the PPE.

If respiratory protection is required, the employee must
receive a medical examination, pulmonary function test and
respirator fit-test in addition to other training.

If the Hierarchy of Hazard Control system dictates the
implementation of PPE, identify the best PPE for the task and
make sure the worker is medically fit and properly trained in
its use and limitations.
Finally, one of the most important components for the
safe and effective use of PPE is the mindset of the worker. Each
worker must feel comfortable and competent with the PPE
worn and the task performed. The mindset of the worker is
critical to the proper use of PPE; they should feel comfortable,
protected and confident to perform each assigned task.

For more information, please contact Darwin Passman
of VIP International at (225) 753-8575. q
Sulfuric Acid Catalyst
Unmatched emission
reduction - hit your targets
Stronger regulatory requirements for SO2 emissions are raising the bar
for many acid producers. VK-701 LEAP5 catalyst can help meet these
demanding targets. Topsoe specializes in advanced catalyst technologies
and we aim to provide the most cost efficient catalyst solution. This will
offer you significant SO2 reductions, save you energy and give you longer
turnaround cycles - we call this optimal performance.
topsoe.com
topsoe.com
Deeapta
F
urrtem e n t
Saint-Gobain NorPro ceramic technology

provides proven reliability

Since the companys start in 1859 in
Akron, Ohio, Saint-Gobain NorPro has developed into a major international supplier
of ceramic-based products. Strategically
located manufacturing facilities in Asia,
Europe and the United States maintain the
strictest product and material standards
and provide the same high quality to customers globally.
The two key materials manufactured
by Saint-Gobain NorPro for optimum durability and chemical resistance in strong
acid applications are Aludur ceramic and
Proware ceramic.
Aludur ceramic
Saint-Gobain NorPro developed Aludur

ceramic over 50 years ago to provide the
added strength necessary for large structural ceramic bodies like grid bars. This
material is three to four times stronger
than other ceramics and provides excellent corrosion resistance even at elevated
temperatures. Aludur ceramic resists all
alkalis, solvents and acids, except hydrofluoric acid. It is highly resistant to thermal
shock, which is an important characteristic
of large, monolithic ceramic parts. Aludur
ceramic became established as the industry standard for grid bar assemblies used as
packing support in traditional brick-lined
acid towers.
Aludur ceramic grid bars
Aludur ceramic bars assembled into

a support grid are the traditional means
of supporting the packing in brick-lined
sulfuric acid absorbers, dryers and other
highly corrosive applications. The use of
Aludur grid bar assemblies is widespread
in older towers and can still be favored in
new construction, especially with larger diameter towers.

The support grid is created from multiple bars placed in parallel across the tower diameter and resting on a support ledge
of acid-proof bricks along the towers brick
lining. In larger diameter towers, the bars
Proware ceramic grid blocks can be placed

above grid bars installed on 8-inch centers.
Aludur ceramic became established as the

industry standard for grid bar assemblies
used as packing support in traditional bricklined acid towers.
are also supported by intermediate spans

constructed of brick arches that rest on the
dished bottom head of the tower, keeping
the bricks in compression. Grid bar assemblies have been used in a wide range
of tower sizes with spans added to suit the
tower diameter.
Proware ceramic
overflow ->

Saint-Gobain NorPros Proware ceramic material is mechanically stronger,
less porous and considerably more chemically resistant than typical stoneware. This
tightly controlled material is much smoother, more finely-grained and vitreous than
typical stoneware and is virtually iron-free.
Proware ceramic is the standard material
for all NorPro packing products for acidic
applications.
Proware ceramic grid

blocks

Grid bar assemblies are installed using a secondary layer of packing support.
That secondary layer is typically composed
of grid blocks placed above adjacent grid
bars, which allow the bars to be installed
on 8-inch centers. This configuration provides an optimal 59 percent open area for
gas and liquid flow. Older designs often
used a more flow restrictive 6-inch centerline bar spacing with cross-partition rings.
A packing support system of Aludur grid
bars and Proware grid blocks will retain
a minimum 2-inch saddle size.
PAGE 20
Proware ceramic saddles provide better

liquid/gas contact than comparably sized
standard saddles.
Proware ceramic saddles
Ceramic packing enhances mass

transfer by providing a large area of contact
between the gas and liquid phases entering
the tower. Saint-Gobain NorPro was the
originator of the industry standard Intalox
ceramic saddle and continues to manufacture Norton saddles in acid-resistant Proware ceramic. For optimal performance,
the unique scalloped edge of the Norton
super saddle provides better liquid/gas contact and lower pressure drop than comparably sized 1 and 2 standard saddles.
Proven technology
Aludur ceramic grid bar assemblies

typically have a long service life. When repair or replacement of the original assembly
is required, Saint-Gobain NorPro can supply individual 8 or 10 bars or complete
new assemblies in the Aludur ceramic
material. Saint-Gobain NorPros adherence
to strict process and material control in our
ISO 9001:2008 certified manufacturing
sites ensures consistent physical properties
and quality. Traditional Aludur ceramic
bars, Proware grid blocks and Norton
saddles can be the immediate product solutions for acid tower repair or replacement.
www.norpro.saint-gobain.com. q
Discover
our comprehensive
portfolio
Turning sulfur into profit

Your reliable partner for efficient sulfur processes
Sulfuric acid production and sulfur recovery demand for technologies which
ensure highest levels of availability and energy-sensitive operation. With its
pre-designed turbocompressors and its reputation for reliability and efficiency,
Siemens provides the perfect solution for both production and recovery.
Siemens outstanding expertise and comprehensive research & development
have produced a technology which guarantees mechanical durability and
resistance to wear, especially under severe operating conditions. The STC-SOF,

STC-GO and STC-SOR compressor series meet and even exceed these
stringent requirements. Siemens pre-designed turbocompressors have proven
to be more efficient than conventional solutions in the longer term. Thus,
Siemens is meeting the future demands of the sulfur industry even today.
siemens.com/singlestageturbocompressors
Feature
state-of-the-art MECS catalysts
By: Sarah Richardson, Senior Catalyst Product Engineer, MECS, Inc.

Andrea Trapet, Vice President of Catalyst, MECS, Inc.

Major sulfuric acid plant producers worldwide have installed
MECS catalyst since the 1920s.
Over the past 90 years, the dedicated research and development team
at MECS, Inc. (MECS) has evolved
catalyst from pellets to energy-saving rings to low-emission cesiumpromoted catalyst. As energy savings and environmental concerns create new operational
and design challenges for sulfuric acid plants, innovations in catalyst technology provide the solution. This
article will detail the MECS catalyst portfolio of vanadium-based and cesium-promoted catalysts for sulfuric
acid, including the latest innovations, GEAR catalyst
and improved formulation cesium catalyst. The benefits
of lower SO2 emissions, increased acid production, energy savings and longer production cycles through utilization of these contemporary catalyst products will be
explored.
A rich history of catalyst

developments

Driving innovation in the sulfuric acid market since
the 1920s, MECS remains the industry leader in technology, engineering and equipment dedicated to sulfuric
acid producers needs. Major sulfuric acid plants worldwide have installed MECS catalyst and have benefited
from the technical developments offered by MECS over
the years. With a comprehensive understanding of sulfuric acid plants, MECS product innovations and customer
service offerings continue to provide benefits far beyond
that of catalyst.

Sulfuric acid catalyst history began with platinumbased catalysts, which were expensive, unreliable and
easily poisoned. Through a partnership in research and
development between various independent entities and
corporations (including MECS), a new vanadium-based
catalyst formula was developed. The first installation
of MECS catalyst occurred in 1925 when a vanadium-
based, pellet-shaped catalyst was shipped to the Monsanto Chemical Works plant in Sauget, Ill. This catalyst
remained the industry standard until the 1960s, when
MECS developed and introduced a new formula of catalyst designed specifically for the low SO2 and kinetically-hindered conditions located in beds three and four of
the standard sulfuric acid plant converter. The new catalyst provided higher activity per unit volume with the
identical catalyst dimensions and resulting pressure drop
of the existing catalyst. The advent of this new catalyst
formula in the early 1960s marked a major improvement
in the overall acid plant process.

Due to major societal concerns regarding the environment and energy consumption in the 1970s, the industry began to focus on technology and products that could
respond to these challenges. MECS offered a catalyst
solution in the form of a larger diameter pellet and then
a new type of catalyst shape, called a Raschig ring.
These catalysts lowered pressure drop across the converter and provided higher activity. In addition, MECS
focused on reducing acid plant costs by developing more
robust catalysts offering lower screening losses.

The 1990s saw an increased need for production efficiency and reduced SO2 emissions. MECS responded
to these needs with the introduction of a cesium-promoted catalyst, which took advantage of the low temperature
properties of the cesium promoter. This catalyst generated excellent SO2 conversion at bed inlet temperatures
from 55 to 75 degrees F (30 to 40 degrees C) lower than
conventional catalysts. The low temperature activation
allowed for new acid plant designs with dramatically
lower SO2 emissions as well as improving the conversion
performance of existing double and single absorption
acid plants.
MECS Catalyst Research and Development continued to innovate in the form of shape modifications and
formula enhancements. Ribbed ring catalysts, with much
lower pressure drop characteristics, as well as increased
activity offered by a larger surface area, were developed
for both the vanadium-based and cesium-promoted catalyst formulas. The ribbed ring products quickly became
MECS Sulfuric Acid Catalyst Research Laboratories, circa 1950s and present.
PAGE 24
MECS Catalyst Shapes, left to right, GEAR hexa-lobed

ring, XLP ribbed ring, LP ring, and pellet.
the industry standard due to their high performance and

low pressure drop. With these introductions, MECS offered sulfuric acid plant producers a strong portfolio of
catalyst products with benefits applicable for a multitude
of operating requirements.

With a continued focus on energy savings and performance improvement, MECS expanded their catalyst
portfolio yet again in 2011. MECS is the only catalyst
manufacturer to offer GEAR catalyst, using a unique
hexa-lobed ring shape which, combined with an improved catalyst formula, has demonstrated better conversion performance, lower pressure drop and improved
dust handling. By geometrically optimizing the catalyst
shape, GEAR catalyst offers more surface area for access to active sites than any other catalyst on the market.
In addition, when loaded into a catalyst bed, the hexalobed ring shape creates a catalyst bed configuration that
increases spacing between the catalyst rings, lowering
pressure drop significantly over other manufacturers
catalyst.
Innovative new product

introductions
An interesting extension of the unique GEAR

catalyst properties is offered for customers who would
benefit from combining the low temperature benefits of
cesium-promoted catalysts with a GEAR catalyst shape.
An example would be an existing acid plant with one of
the following challenges:

High dust contamination in the gas stream (such
as metallurgical plants or sulfur burning plants with
varying quality of sulfur in the feed)

Desire to increase throughput without increasing
pressure drop or emissions

The demonstrated superior dust handling provided by
the hexa-lobed ring shape of the GEAR catalyst, especially in pass one, inspired the addition of GEAR cesium catalyst, GR-Cs, to the MECS catalyst portfolio. Sulfuric acid
plant converters operating with lower bed-inlet temperatures have the opportunity to upgrade to GEAR cesium
catalyst for energy savings and excellent dust handling.

The most recent product enhancement developed by
MECS Catalyst Research and Development is a minor,
but high activity boosting modification to the well-established Super Cesium SCX-2000 cesium catalyst formula. This proprietary formula improvement positively
affected the SCX-2000 cesium catalyst activity, offering
customers higher performance in the fourth and fifth
Start-Up Values Normalized
PeGASys (10 months later)
411
448
448
1 Inlet SO2 (%)
10.95
10.95
Pass 1 dP (mm w.c.)
90
105
102
Pass 1 dP (mm w.c.)
70
82
92
Pass 1 dP (mm w.c.)
105
123
133
Pass 1 dP (mm w.c.)
90
105
122
Total dP (mm w.c.)
355
414
449
Plant Rate (MTPD)
catalyst allows a customer to achieve lower SO2 emissions through higher catalyst activity and better conversion or the ability to operate at a lower bed inlet temperature of 385 degrees C (725 degrees F).

The GEAR and SCX-2000 innovations join the rest
of the MECS portfolio offering catalyst solutions to major sulfuric acid producers placing their confidence in
MECS technology and know-how.
Proven MECS catalyst excellence
The low pressure drop, high-performance benefits
of MECS catalyst are currently being enjoyed by the
Fluorsid II sulfuric acid plant in Italy. This plant selected
GEAR catalyst with Super Cesium SCX-2000 in the final pass for their recent new plant designed by MECS.
After a smooth start-up in 2013, MECS technicians vis-
converter size and fixed catalyst volumes, MECS knew
that Fluorsid II needed high performance catalyst. The

premium GEAR catalyst combined with high-activity
Super Cesium SCX-2000 catalyst offered exactly the required characteristics to meet Fluorsids stringent design
criteria.

Specifically, Fluorsid requested that MECS offer
them the ability to produce 10 percent more sulfuric acid
than the design capacity. After optimizing the catalyst
Fluorsid II converter pressure drop data.
converter passes. The improved formula SCX cesium
achieve higher production and lower emissions with a set
ited the plant to perform a PeGASyS (MECS proprietary

Portable Gas Analysis System) test, to evaluate the plant
performance on a pass-by-pass basis. At Fluorsid, the
PeGASyS test demonstrated that the GEAR catalyst
pressure drop after 10 months of service was lower than
typical daisy-shaped catalyst at clean pressure drop. Pass
one showed no pressure drop build-up after 10 months of
operation.
Low SO2 emissions and higher production than
name plate were also design criteria for the Fluorsid II
Plant. Fluorsid returned to MECS for their new plant design after successfully operating Fluorsid I with MECS
sulfuric acid technology for several years. For Fluorsid
II, the company wanted to maximize acid production,
minimize SO2 emission and reduce capital expenditures
by reusing the Plant I converter design. This requirement meant that there was no flexibility to add converter
passes or additional catalyst in the new plant. In order to
design using the same converter specifications as the
previous plant, Fluorsid was able to run at 110 percent

of design capacity with low pressure drop. The Fluorsid
SO2 stack analyzers showed lower SO2 emissions than

permitted, thus illustrating the ability of MECS to meet
customers unique design challenges.

MECS is known for its proven sulfuric acid catalyst
portfolio and catalyst designs based on practical experience and extensive plant knowledge. But, MECS offers
the client more than just catalyst. MECS offers world-
class knowledge of sulfuric acid, innovative technologies and proprietary products for the entire acid plant.
Local, personalized service and technical services are
also offered for troubleshooting, maintenance, training
and optimization, as well as maintenance planning support. MECS offers everything the client needs to achieve
optimal sulfuric acid plant performance.

For more information, please visit www.mecsglobal.com. q
PAGE 25
Feature
Start-Up
Feature
The worlds first live observations of

sulfuric acid catalysis
By: Kurt Christensen, Filippo Cavalca, Pablo Beato and Stig Helveg of Haldor Topse
Scientific advances depend on knowledge gained

through observation, but what do you do when you cant
observe a process youd like to advance? Take catalysis:
Its difficult to observe catalysis at work, because you cant
get inside a working reactor. You can observe the results of
a reaction, but you cant observe the reaction itself. Or at
least you couldnt until recently.

At Haldor Topse, our whole culture revolves around
knowledge. Since you cant apply knowledge unless you
have it to begin with, we spend enormous amounts of time
and money on knowledge acquisition. In fact, we invest
11 percent of our annual turnover far more than our
competitors into understanding our catalysts and the
processes theyre involved in. Since knowledge acquisition
usually starts with asking questions, we are famous for
asking a lot of them even if they seem silly or nave.

As part of our work to even further optimize our VK
catalyst for SO2 oxidation, we started thinking that there
must be some way to observe the SO2 oxidation process
directly. If we cant go to the reaction, we asked, can we
make the reaction come to us? We had pioneered some
transmission electron microscopy (TEM) techniques
that could enable us to observe a live reaction, but
we had to find a way to trigger the reaction in the
microscope and to prevent the sulfur from corroding the
microscopes objective lens and field emitter, and thus
After modifying the microscope we were able to observe the

VK catalyst working under chemically meaningful reaction
conditions.
impeding its imaging capabilities.

To solve the first problem, we developed a novel
technique for crushing a VK-type catalyst into powder
and dispersing it over micro-electro-mechanical system
(MEMS) devices, before introducing the SO2 and
O2 reactants and heating the catalyst in the electron
microscope. Then we modified the microscope to protect
it from exposure to the SO2 reactant, the SO3 product and
temperatures up to 1,100 degrees F during the reaction.
Achieving this led to the worlds first live observation of
the VK catalyst at work under chemically meaningful
reaction conditions.
In situTEM of dynamic changes of the model catalyst during

exposure to 10 mbar of 50 percent SO2and 50 percent O2(a)
at 350 degrees C (b) at 600 degrees C and (c) after cooling to
350 degrees C and reheating to 600 degrees C. The sphere
diameter is 100 nm.

Triggering the reaction in the instruments enabled us
to employ both TEM imaging and Raman spectroscopy
to study the reaction, which is especially useful since the
active phase of sulfuric acid catalysis involves a liquid
film of vanadia dissolved in pyrosulfate and distributed
dynamically throughout the carriers pore system. By
observing this dynamic behavior directly at nanometer
resolution, we are learning a great deal about the process
and our own catalyst which will lead to even more
improvements in our catalyst and process designs going
forward.

Until then, we look forward to presenting the results
of our work in detail at the 2015 AIChE Clearwater
Conference in June. We hope to see you there!

For more information, please visit www.topsoe.com. q
A Reliable Source for the Sulfuric Acid Industry

Roberts core business is to provide construction solutions,
resources and support for facility owners and managers in
the sulfuric acid industry. We strive for long-term relationships
with our customers relationships built around dependability,
responsiveness, results and more importantly, trust.
Our business is about

finding solutions for
your business.
For more information, visit www.robertscompany.com | www.ppsengineers.com
Engineering + Fabrication + Construction + Maintenance Services

PAGE 26
Department
LESSONS LEARNED
Case histories from the

By: Orlando Perez, OP & Associates Ltd. H2SO4 Consultants
Cart before the horse
Gas-gas exchangers upstream of the interpass and final

absorption towers in double contact, double absorption metallurgical and spent acid regeneration
plants are prone to sulfate blockage in the SO2 and SO3 sides. The
attendant loss in heat transfer
efficiency increases the gas temperature into the absorber towers,
thereby increasing mist formation
as well as increasing the load to
the acid coolers. In addition, it
also decreases the temperature
into the catalyst bed downstream.
The increase in pressure drop due
to the sulfate blockage not only
causes a reduction in production
capacity, but also can breach the
divider plate between catalyst
beds. The breach will cause SO3
to bypass the absorbing tower.
All these will result in an increase in stack SO2 and acid mist
emissions.

The sulfate blockage is normally the symptom of poor equipment design, improper operation
and/or non-maintenance of the
pieces of equipment upstream.
Fig. 1 shows sulfate blockage in
the shell side of a cold reheat exchanger with stainless steel tubes.
The SO2 gas passages are almost
entirely blocked. Fig. 2 shows sulfate blockage in the tube side of
a cold reheat exchanger. The inner 10 rows of tubes are entirely
blocked for SO3 gas passage.

To solve the blockage problem, some plants choose to correct the symptom rather than
address the root cause. The exchanger is replaced with some
modifications when all the sulfate removal techniques in their
arsenal have been exhausted.
Reversing the SO3 flow from the
traditional downward flow inside
tubes and changing the material
of construction to stainless steel
are some of the techniques used.
All these have proved to be inadequate and after less than three
years in operation, the plant
is back to square one. Cases in
point are shown in Fig. 3 where
SO2 gas was switched with the
traditional upward flow in the
shell side to downward flow
inside the tubes, and in Fig. 4
where SO3 gas flow was reversed
from the traditional downward
flow inside the tubes to upward
Fig. 3: Cold exchanger with SO2

flowing down inside tubes.
Fig. 4: Cold exchanger with SO3

flowing up inside tubes.
Fig. 1: Sulfate blockage on shell side.
flow inside the tubes. All these

modifications were in vain.

Fig. 5 shows a photo of the
divider plate between beds three
and four. A portion of the circumferential weld on the sidewall
cracked due to the high-pressure
drop in the cold reheat exchanger.
PAGE 28
Fig. 5: Divider plate between beds

3 and 4.
Acid-damaged catalyst
Fig. 7: Catalyst damage along

sidewall perimeter.
Taken for granted
Fig. 8: Water ingress through the

cladding of an expansion joint.
Weather protection or cladding for thermal insulation on

hot pieces of equipment, ducting and piping is the fixed asset
that is widely taken for granted in
most acid plants. Once installed,
it is forgotten. And when it gets
damaged from people stepping
on it, blown by the wind or other
causes, it rarely gets the attention
like the other pieces of equipment
in the plant do. Cladding is important in that it protects the thermal insulation from the elements,
preventing water ingress. Water
is detrimental to any thermal insulation system. With the proper
weatherproof construction design
to accommodate expansion and
contraction movements and with
the necessary flashings and seals,
ingress of water is eliminated.
However, this is not always
the case, as shown in Fig. 6 where
the cladding on the roof of a converter has been badly deformed
due to improper design, not accounting for the expansion/contraction of the cladding. In this
particular case, the water that en-
Fig. 6: Cladding on roof of converter.
the insulation contractor. Someone with know-how and experience on how the equipment operates should review the design.
Bridging the gap
Lesson learned
Do not put the cart before
the horse! Correct the root cause
of the problem first before replacing the exchanger. Replacement designs should be given due
diligence by an independent consultant who has knowledge and
experience in the operation and
maintenance of the equipment.
Weld crack along sidewall
Fig. 2: Sulfate blockage on tube side.
Sidewall
tered through the gaps ran down

the sidewall of the converter and
cooled the metal, causing condensation of acid on the catalyst along
the perimeter of the sidewall.
Fig. 7 shows the catalyst damage
caused by acid condensation.

Fig. 8 shows evidence of water ingress through the cladding
of an expansion joint due to inadequate flashing and sealing. The
Expansion joints are piping

components that are designed to
accommodate thermal and mechanical changes in the piping
system. They are usually made up
of a series of convolutions forming a bellow, which is flexible
enough to compensate for axial,
lateral and/or angular movements.
Expansion joints are often
installed where expansion loops
cannot be made due to limited
space. If properly designed, installed and maintained, piping
expansion joints should last a
long time. Their use, however, in
sulfuric acid piping should only
be the last resort as they are the
weak link in the piping system.

Fig. 10 shows an expansion
joint for a product-acid piping
that is incorrectly applied. Based
on the inspection of the piping
run and considering the operating temperature of the product
acid, the need for an expansion
joint is not required. This particular expansion joint, however,
was installed to bridge the gap
from misalignment caused by
poor pipefitting. The expansion
joint is permanently deformed
and poses a safety hazard to everyone in the area.
Fig. 9: Badly deformed and cracked

expansion joint convolution.
sudden cooling of the hot metal

badly deformed the convolution
and created cracks in the metal,
as shown in Fig. 9.
Lesson learned
Never take for granted the
cladding for thermal insulation
of hot pieces of equipment, ducting and piping. Cladding, like
any other acid plant equipment,
should be given regular inspections. When damage is found, it
should be repaired at the most opportune time. Design of the cladding should not rest entirely on
Fig. 10: Expansion joint in a

ductile iron piping system for
product acid in the cold position.
Lesson learned

Misapplication of expansion
joints can have serious consequences to the health and safety
of everyone in the area. Always
In a hurry to startup

Maintenance turnarounds in acid plants
can be very stressful. There are pressures
coming from everywhere: pressure to finish
the work on time, pressure to keep the cost
on budget, pressure to get back on line as
quickly as possible. So when an opportunity
to save time comes around, management often jumps on it. Such is the case for a spent
acid regeneration plant. Operations decided
to get a jump on starting up the plant while
work progressed in the acid circulation of
the brick-lined final absorber tower. This
particular acid plant is a 3+1 double-contact,
double-absorption unit with the catalyst beds
in stand-alone vessels. The 4th catalyst bed
is equipped with its own preheating system.
Preheating started with no acid circulation in
the final tower. Towards the end of the preheating cycle, an alarm went off in the stack
monitoring system and a visible plume was
noticed coming out of the stack. During preheating, the SO2/SO3 that was trapped in the
catalyst during the cool down process prior to
the turnaround was released when the catalyst started to liquefy. Without acid circulating in the final absorbing tower, the SO3 just
went through the packed section unabsorbed
by the acid that was held up in the packing. In

addition to creating stack emissions, putting
hot gas in a brick-lined acid tower without
the cooling effect of acid circulation is very
risky. There is very high probability of collapsing the packing support and damaging
the brick lining and packing at the bottom
section when acid circulation is turned on due
to thermal shock.
Lesson learned
During preheating of the converter
beds, ensure that the absorber towers have
acid circulation in them to absorb SO3 that
may be released when the catalyst starts to
liquefy. Also, this will eliminate the possibility of damaging or collapsing the packing support.
Disclaimer: OP & Associates Ltd.
H2SO4 Consultants is not responsible for,
and expressly disclaims all liability for,
damages of any kind arising out of use,
reference to, or reliance on any information
contained herein. Readers should take specific advice before applying any information contained in this publication.
For more information, contact Orlando Perez at 360-746-8028 or orlando.
perez@h2so4consultants.com, or visit
www.h2so4consultants.com. q
Roberts continues to expand offerings

WINTERVILLE, N.C.
Roberts, a fully integrated engineering, fabrication,
construction
and plant maintenance
company, continues to
impress customers in the
with its quick response
and quality workmanship. Recent projects
have allowed several of
Roberts clients to expand product offerings,
improve plant processes
and extend the life of
their equipment.

Mosaic, featured in
this edition, relied on
Roberts extensive experience in the industry
to provide the necessary work for several
projects. The first was a
new MECS Heat Recovery System (HRS).
Mosaic also tapped
Roberts to provide site
prep, concrete and pilings for their Micro Essentials project, one
SARAMET
Roberts recently worked

on one of Mosaics largest projects to date.
of the largest projects

Mosaic has undertaken.

Roberts quick turnaround at Rentech Nitrogen, disconnecting an
old acid converter and
installing a new, larger
converter and associated
ducting in their sulfuric
A recent job for Rentech

Nitrogen provided improved heat recovery and
less downtime.
acid plant, will allow

the company many years
of continued operation.
Improved heat recovery
and less downtime from
a system that operates
at peak performance are
just some of the benefits
of this project.
The sulfuric acid
industry continues to
rely on Roberts for its
multitude of capabilities
and vast knowledge. As
a long-time service provider, Roberts has proven
time and time again to
be reliable, efficient and
responsive. This leads
customers to return for
a variety of projects,
including new project
design, project management, plant maintenance
services and repairs, as
well as shutdowns, turnarounds and fast track
emergency response.
For more information, please visit www.
robertscompany.com. q
(Sulphuric Acid Resistant Metal)
Experience:
The first silicon SS in the sulphuric acid industry, introduced in 1982
Originally developed and patented for sulphuric acid service by Chemetics
In house metallurgists and corrosion specialists
Features and Benefits:
Fully weldable
- Eliminates most flanges
- Can be supplied in modular spools, and field welded for final fit-up
Corrosion resistant
- Long life reliability
- High velocity limits reduce line sizes
- Reduced iron in product acid
Resilient, high ductility and strength resists catastrophic failure
Chemetics stocks $5 Million inventory of plate, pipe, fittings and tubes maintained for urgent
fabrication service
Innovative solutions for your Sulphuric Acid Plant needs

Chemetics Inc.
Chemetics Inc.
(headquarters)
Vancouver, British Columbia, Canada
Tel: +1.604.734.1200 Fax: +1.604.734.0340
Pickering, Ontario, Canada
Tel: +1.905.619.5200 Fax: +1.905.619.5345
PAGE 29
Department
consult with a piping stress engineer for the

proper type and application of expansion
joints prior to installation.
Feature
WESPs prove versatile in acid plant applications
Advanced wet electrostatic precipitators demonstrate superior gas-cleaning performance

in installations around the world
By: Michael Beltran, President and CEO, Beltran Technolgies, Inc.
Advanced gas cleaning and emission

control strategies continue to evolve
in response to increasingly stringent
environmental mandates worldwide, as
well as to the increasing complexity,
toxicity and corrosiveness of industrial
exhaust and process gas streams. For
industries in which concentrations of sulfur
compounds exceed five to seven percent of
exhaust gas volumes, downstream sulfuric
acid manufacturing plants represent a
common and cost-effective solution for
cleaning these gases while capitalizing
on the reliable market values for purified
sulfuric acid, a primary industrial chemical
with hundreds of applications.
However, an efficient sulfuric acid
manufacturing process requires the
maximum possible removal from input gas
streams of fine particulates, acid mists,
condensable organic compounds and
other contaminants. This is necessary for
protecting sensitive acid plant components
from corrosion, fouling and plugging, as
well as for preventing the formation of a
black or contaminated acid end product.
Proper gas cleaning also reduces longterm costs of maintenance, operations and
Beltran engineered WESP installation at

Rockwood Pigment.
Beltran engineered WESPs installation at

Votorantim Metals.
equipment replacement.
To reduce contaminants before
entering the sulfuric acid plant, plant
owners have relied on several gas cleaning
techniques, such as cyclones, scrubbers
and mist eliminators. These systems
can control large particulates, but are
usually inefficient or ineffective on fine
particulates, acid mists or condensed
organic compounds. Therefore, owners
continue to turn to modern wet electrostatic
precipitators (WESPs), which can clean
complex gaseous emissions of particulates
and acid mists down to submicron scale
(PM 2.5) with up to 99.9 percent efficiency.

Today, advanced WESPs are designed
around a multistage system of ionizing rods
with star-shaped discharge points. These
are encased within square or hexagonal
tubes that are lined with grounded
collection surfaces. The unique electrode
geometry generates a corona field 4-5 times
stronger than that of conventional wet or
dry ESPs, propelling even submicron-size
particulates and sulfuric acid droplets
toward the collection surfaces, where they
adhere as cleaned gas is passed through.
The surfaces are intermittently cleansed of
residues by recirculating water sprays.

The cool, saturated environment in the
WESP makes the system highly effective
on condensable or oily compounds, while
the continuous aqueous flushing process
prevents re-entrainment of particles,
sticky residue build-ups and unfavorable
particle resistivity. By eliminating the need
for mechanical or acoustical rappers of
dry ESPs, the wet cleansing process also
minimizes energy and maintenance costs.
With virtually no physical or
mechanical obstruction of gas streams,
there is very little pressure drop through the
WESP, and gas velocities can be extremely
high. This enables plant engineers to use
smaller-scale, less costly equipment for
specific gas volumes and still achieve
superior collection efficiencies. The use
of smaller, simpler equipment also means
lower maintenance and energy costs.

Versatile and adaptable to a wide range
of operating conditions, modern WESPs
engineered by Beltran Technologies, Inc,
of Brooklyn, NY, are currently producing
excellent results worldwide for a host
of industrial applications, including the
following examples.
31st
Oil | Gas | Fertilizers | Metallurgy | Industrial
Sulphur 2015
BOOK AT
EARLY BIRD
RATE TO SAVE
US$250
International Conference & Exhibition

9-12 November 2015, Sheraton Centre, Toronto, Canada
The worlds leading event for the sulphur & sulphuric acid markets
2015
CALL FOR PAPERS
NOW OPEN
Share operational experience and

showcase practical solutions and
new technologies
DEADLINE 11 MAY 2015
Gold sponsors:
70+
EXHIBITORS
NETWORK
WITH 600+
professionals
from the sulphur
& sulphuric acid
industries
SHARE OPERATIONAL
EXPERIENCE & INDENTIFY
SOLUTIONS
with your peers
CRU VIEW
Global updates
on the sulphur
and sulphuric acid
markets
TECHNICAL PAPERS
SULPHUR+
SULPHURIC ACID
50% DISCOUNT for

operators
ONE DAY
operator pass
FREE ACCESS
to the exhibition
Silver sponsors:
Official publications:
REGISTER TODAY AT THE EARLY BIRD RATE www.sulphurconference.com
Sulphur 2015 124mm x 150mm.indd 1
PAGE 30
06/03/2015 15:54
Metals

Brazils Votorantim Metais purchased
Companhia Paraibuna de Metais seeking
to expand production capacity and zinc
resources. As part of a campaign to
incorporate Zero Waste principles, the
company incorporated a metallurgical
sulfuric acid plant to capture and
commercialize industrial quality sulfuric
acid originating from its fluidized bed zinc

roaster. To purify the smelter emissions
entering the acid plant, Paraibuna had used
a variety of techniques, including lead mist
precipitators, which were not sufficient
to thoroughly clean the contaminated gas
streams. In addition, the equipment suffered
significant deterioration after years of
operation due to the harsh, corrosive nature
of the metallic gas stream components.
The company found a solution in a
system of wet electrostatic precipitators
(WESPs)
engineered
by
Beltran
Technologies. The Beltran precipitators
were designed for durability, using specially
formulated fiberglass-reinforced plastics
(FRP), a corrosion-resistant composite
material made of a polymer matrix
reinforced with fibers. These materials
were used in sensitive components and
housings and a special conductive FRP was
used for the WESP collector plates. At the
Paraibuna zinc smelter, the Beltran WESPs
have been operating for over 15 years at
up to 99.5 percent cleaning efficiency
on fine particulates and acid mists. The
company expects to produce 45,000 tons of
marketable sulfuric acid annually.
Chemical processing
Rockwood Pigments, a global

manufacturer of pigment products for
diversified industries, chose a Beltran
WESP system to clean process gas streams
at a sulfuric acid plant at its Easton, Pa.,
manufacturing facilities. Rockwood is
the second largest manufacturer in the
world of iron oxide and other inorganic
color pigments used by paint and coatings
producers to add vibrant, long-lasting color
to an array of materials, products and
structures.
The corrosive nature of Rockwoods
flue gases demanded that special attention
be given to the materials of construction.
The Beltran WESP was fabricated using
fiberglass reinforced plastic (FRP) and
high nickel-chromium alloys instead of
lead. Besides being extremely corrosion
resistant, FRP components are also less
expensive and easier to construct and
maintain. The electrically conductive
sections of the WESP are made from
special conductive FRP. The system
designed and engineered for Rockwood
has achieved an overall efficiency of 99.5
percent, and has resulted in greater energy
savings and lower total operating costs for
Rockwood Pigments.
Michael R. Beltran is president and
CEO of Beltran Technologies, Inc. For
more information, please contact him
at beltran@earthlink.net, or visit www.
beltrantechnologies.com. q
Feature
Advancements in sulfur
spraying: new hybrid gun
and predictive modeling
Reduce the operating pressure drop of your process, improve the

throughput of your vessels, and lower your maintenance costs by
using Kimre - the highest performing products possible.
HIGH REMOVAL EFFICIENCY LOW PRESSURE DROP LONGER FILTER
LIFE LOW OPERATING & MAINTENANCE COSTS
EASY INSTALLATION & REMOVAL SIZED TO FIT ANY VESSEL
CUSTOM DESIGNED FOR YOUR PERFORMANCE NEEDS
KIMRE CAN tACKlE ANy sulfuRIC ACId

MIst REMovAl ChAllENgE
KIMRE CANdlE fIbER bEd fIltERs
Brownian Diffusion
Candle Filter
b-goN MIst ElIMINAtoRs
Using modeling tools

to optimize spray
performance and identify
potential failures
Impaction Candle Filter
Using high efficiency media, the Kimre Candle Fiber

Bed Filter can achieve efficiencies greater than 99.9% on
particles smaller than 1 micron.
Mat and roving media allow custom designed
composite beds.
Designed to meet the specific requirements of each plant.
Kimre offers exact replacements of existing elements in
many plants.

Hydraulic nozzles have long been the
standard for spraying molten sulfur, but the
benefits of using air atomizing nozzles can
be significant. The smaller drops produced
by air atomizing nozzles typically improve
combustion and eliminate carryover
and damage to downstream equipment.
Until now, testing guns equipped with air
atomizing nozzles required purchasing
new guns to equip an entire furnace.
A new hybrid sulfur gun has been
introduced by Spraying Systems Co. The
guns can be easily converted from hydraulic
operation with WhirlJet BA nozzles to air
atomizing operation with FloMax nozzles.
In addition, the guns can be converted back
to hydraulic operation if air atomizing
performance doesnt meet expectations.
The hybrid guns offer producers an easy
and risk-free way to evaluate air atomizing
nozzles in their operations.
Combines the best features of knitted mesh and plate-type

mist eliminators.
High efficiency, low pressure drop
The most pluggage resistant mist eliminators available
The best option for drying tower mist eliminators
Easy to clean, reusable media.
Designed to meet the specific requirements of each plant.
We achieve flexibility in design by having a

broad range of options
Optimizing molten sulfur spraying

is dependent on many variables including
atomization, drop size, residence time,
placement of the gun, furnace baffle
locations and operating conditions in the
furnace. Many producers are turning to
Computational Fluid Dynamics (CFD)
modeling to improve performance.
Common studies look at both gun
placement to avoid sulfur impingement
on walls and drop size to determine the
optimal size for complete vaporization
and full combustion. Fluid Structure
CFD shows impingement with base of

combustion chamber using hydraulic
nozzle (top) and no impingement using air
atomizing nozzle (bottom).
Interaction (FSI) modeling is also gaining

rapid acceptance. One recent study looked
at the thermal and structural properties of
a sulfur gun and the effect of flow-induced
vibrations. The study validated the thermal
integrity of the sulfur gun but identified a
structural weakness that could result in gun
failure. The gun was redesigned to include
support collars to counteract the vibrations.
More information on sulfur gun
technology is available at www.
spray.com/hybridgun including the
following topics:
Animation of hybrid sulfur gun
conversion from hydraulic to air
atomizing
Presentation: Optimizing Sulfur
Spraying, Sulfuric Acid Roundtable
2013
Sulfur gun fluid interaction study

Sulfur gun and spray nozzle
overview q
MATERIALS OF CONSTRUCTION
Fiberglass Polyethylene Terephthalate (PET) Polypropylene (PP)
Polyester Roving High Temperature Polypropylene (HTPP)
PVDF Alloy 20 ETFE PFA Stainless Steel
Kimre,Inc. 744 SW 1st Street Homestead, FL. 33030

Tel: (305) 233-4249 Fax: (305) 233-8687
Web: www.kimre.com E-mail: sales@kimre.com
Hydraulic nozzles can be replaced with air atomizing nozzles on hybrid sulfur guns providing
producers with an easy and economical way to compare performance between nozzle types.
See animation at www.spray.com/hybridgun.
PAGE 32
Feature
Cylindrical superheaters for high temperature

and high pressure service
By: Mike McGuire, VP Engineering, Optimus Industries, Tulsa, Okla.

The waste heat recovery systems on sulfuric acid plants designed with technology by
MECS, Inc. (MECS) typically feature a superheater downstream of the converter first pass,
operating in high temperature, high pressure
service. These superheaters, usually designated as Superheater 1A or 1B, are required
to handle gas-side conditions around 1,150 degrees F and 7+ psig (621 degrees C and 0.49+
barg), which can induce high mechanical
stresses in the outer casing that are challenging
for the superheater to accommodate.
Because superheater heat transfer coils
themselves are a rectangular configuration, for
most units the casing that houses them is also
rectangular, with stiffened flat sidewalls and
header boxes with square corners. Particularly
on large Superheater 1A/1B units, the welded
corners where two flat casing walls intersect
are subjected to high stresses due to internal
pressure and thermal expansion. Even stainless steel casing material has relatively low
strength at design temperatures of around
1,200 degrees F (649 degrees C).
As an alternative to a rectangular-style
superheater, in 2007 Optimus developed its
first cylindrical casing design for the Superheater 1A used in the PCS Phosphates Aurora
Plant #7, the largest sulfuric acid plant in North
America. Because of the history and critical
A cylindrical-style superheater unit can

enhance a plants long-term reliability.
Optimus used computer aided engineering

to design its cylindrical casing.
nature of the superheater casing, the specifications from MECS required a cylindrical casing design and that a Finite Element Analysis
(FEA) be performed on the final design. Even
though the main body and ends of the superheater are cylindrical, the FEA is important
because the design of the gas inlet and outlet connections are very tricky and the most
susceptible to failure. At that time, the most
popular computer aided engineering (CAE)
tools for structural design were useful for rectangular casing design, but were not suited for
sophisticated FEA analysis of the cylindricalstyle casing. So, Optimus shifted to a more
versatile set of 3D modeling/CAE tools and
designed the Aurora cylindrical superheater
solely with FEA methodology. It has since become the company standard for superheater/
economizer casing design. The Optimus cylindrical superheater design has evolved over the
years with 3D FEA tools helping to find and
reduce stress concentrations more effectively
with each new Superheater 1A/B produced.

Since the PCS Aurora project, Optimus
has participated in several large capacity Superheater 1A/B replacement projects where
an old rectangular unit is replaced with a new
cylindrical superheater. Also, many RFQs for
new-build MECS sulfuric acid plants have
specified cylindrical Superheater 1A/Bs. This
is not to say a rectangular-style superheater
cannot operate reliably for 10+ yearsOptimus has used its 3D FEA methodology to
improve those, as wellbut apparently some
plant operators prefer a well-designed cylindrical unit for the high temperature/high pressure
operating conditions of the Superheater 1A/B

units.

Optimus is currently manufacturing a cylindrical Superheater 1B for the Mosaic Uncle
Sam Plant to replace an existing rectangular
unit on its E Train plant. The engineering project managers for Mosaic consulted
with MECS for the concept and specification
package of this replacement superheater. Nick
Darling, the MECS mechanical engineering
supervisor, has had an active role in recommending cylindrical superheaters in many of
these hot, high pressure applications such as
Mosaic Uncle Sam. As sulfuric acid plants
continue to get larger, MECS is recommending and specifying more and more cylindrical
stainless steel superheaters in place of the rectangular designs, says Darling. We feel that
when designed, built and installed properly,
these cylindrical superheaters are more reliable than the rectangular type, especially when
used in conjunction with MECS gas bypass
and duct design.

For plant operators with rectangular Superheater 1A/B units nearing their end of life,
it is certainly worth considering whether a
cylindrical style unit could enhance a plants
long-term reliability.
For more information, contact Optimus at
(918) 488-3202 or visit www.optimus-tulsa.com. q
Radial Flow Gas-Gas Heat Exchangers

Experience:
Introduced in 1977
Originally developed and patented by Chemetics
Industry standard best-in-class design
More than 300 in service worldwide
Features and Benefits:
Radial flow design
- Minimises differential thermal stress
- Eliminates dead flow zones to yield reduced fouling and corrosion
- High efficiency and lower pressure drop for energy savings
Typically 20+ years leak free life with minimal maintenance
Flexible configuration allows retrofit into any plant
Advanced design options to suit demanding services
Innovative solutions for your Sulphuric Acid Plant needs

Chemetics Inc.
Chemetics Inc.
(headquarters)
Vancouver, British Columbia, Canada
Tel: +1.604.734.1200 Fax: +1.604.734.0340
PAGE 34
Pickering, Ontario, Canada
Tel: +1.905.619.5200 Fax: +1.905.619.5345
Feature
When secondary containment linings and

coatings are primary
Reliable and effective means to prevent a chemical release into the environment
By: John E. Davis, Inside Sales & Marketing Specialist, Sauereisen Inc.

Its a common occurrence to turn on the
news and witness some form of hazardous
chemical release into the waterways,
ground or atmosphere. These dangerous
events have become a much greater public
concern over the last 25 years and social
media and camera phones help to keep
them in the forefront. Typically, we used
to hear about only the larger incidents that
resulted in the loss of life, environmental
impact on drinking water or large scale
effect on wildlife, such as when the Exxon
Valdez ran aground on Prince William
Sounds Bligh Reef in 1989. Now we are
hearing and seeing more of such events,
even those of a smaller scale.
New regulations and legislation have
now put the liability on the chemical
users and transporters, so that they must
take every precaution to minimize and
prevent the accidental release of hazardous
substances into the environment. The
protection of life and the environment
must be a primary concern for every
facility owner, plant engineer, operator and
Severe
degradation
to standard
portland
cement in
secondary
containment.
A completed secondary containment
area with Sauereisen Fiber-filled
Linings no. 218 & 228, a chemicalresistant epoxy-novolac system.
maintenance personnel.
There will always be human error,
accidents, leaking connections, faulty
gaskets and seal failures, but with proper
design and aggressive planning for such
incidents, these toxic releases can be
minimized. The proper design, construction
and maintenance of the secondary
containment system within an industrial
facility is paramount to containing leaks
and spills from the primary storage tanks or
vessels. The main purpose of a secondary
Sulfuric Acid
A S S O C I A T E S
Link in and join the discussion

with industry leaders, professionals
and consultants.
www.h2so4network.com
hosted by
PAGE 36
system is to contain the spill until it can

be neutralized, cleaned up and disposed
of properly. A secondary containment
structure must be designed with a high
degree of chemical resistance, although
less than that of the primary system.
Especially in older facilities, many of these
containment structures were built from
formed concrete due to cost of material and
ease of application. Concrete alone is not
a suitable material in providing effective
chemical resistance or a reliable barrier for
the permeation of most acids and chemical
concentrations. The permeation into the
concrete will cause severe degradation
and cracking, allowing the acid or caustic
substance to leach out and contaminate the
environment.
Protecting the concrete with a
chemical resistant coating or lining is an
economical way to protect these structures.
Before a lining or coating can be applied,
the concrete must be evaluated to determine
its condition and what surface preperation,
crack filling, chemical resistance and other
obstacles will need to be addressed to
assure a proper bond and a reliable finished
product. Chances are that if the secondary
pit has been in place for some time, stress
and settling cracks will have formed and
will need to be repaired with a compatible
mortar before a lining or coating can be
applied.
Today, engineers and specifiers have
a broader range of materials to choose
from depending on whether the primary
storage is an acid, solvent or caustic;
what the concentrations are; and at what
temperatures they are stored. Protective
coatings and linings can range from thin
film coatings to higher-build fiber or
flake-filled lining systems, up to thick
matte-reinforced systems. Typically all
these systems will have an epoxy, vinylester, epoxy vinyl-ester, novolac, furan or
polymer concrete chemistry. Application
methodology may be done by hand, such
as brush, roller, trowel or squeegee. But
spray applications by conventional airless spray and plural component spray are
quicker and may be more cost effective.
Reinforced matte systems do offer a higher
degree of chemical resistance, but are time
consuming applications that are typically
much more expensive. Again, keep in mind
that the corrosion protection required in
secondary containment does not have to
equal the level of protection in the primary
system. You may have a matte system in the
primary vessel but an 80 mil lining in the
secondary pit.
The degree of protection should be
enough that in the event of a small spill
the surface will be protected until a proper
cleanup can be done. However, if a spill
does cause penetration of the coating,
repairs can be completed to restore the
integrity of the coating at a cheaper cost
than removing and replacing damaged
concrete.

For extreme chemical resistance, there
are even heavier-duty linings such as furan
resin mortar/grout and brick or polymer
concretes. The carbon-filler furan is a
bonding material for acid-resistant brick
or quarry tile and is suitable to protect
concrete and steel substrates from attack
by corrosive chemicals and physical abuse.
Polymer concretes are aggregate-filled
systems with sodium silicate, epoxy, vinylester or epoxy novolac resins that are mixed
and cast like standard portland cements.
They are formulated to create a monolithic
top coat over standard cement or as a castin-place chemical resistant pump-tank pad.
Thanks to advances in materials
technology and application methodology,
the rate of application is now accelerated
while lowering overall costs. Any industrial
facility that stores larger quantities of acids
and caustics that are protected by secondary
containment will need a corrosionresistant material for the protection of
its asset. Dont let your lax protection
result in a new hashtag: #ToxicSpill
#PoorProtection #AnotherHazmatIncident
or #ShouldHaveUsedSauereisen.
With more than 115 years of
experience, Sauereisen has long provided
corrosion resistant solutions for secondary
containment rehabilitation. While this
overview focuses on thin film coatings and
medium duty linings, Sauereisen is also
a formulator of heavy-duty linings, matte
systems, furans and polymer concretes.
Sauereisen products are regularly specified
in the chemical/petro-chemical, power and
wastewater markets.
www.sauereisen.com. q
Beltran Sulfuric Acid Today Full Page Rev2 9/16/14 6:46 AM Page 1
Beltran Wet Electrostatic Precipitators:
PROVEN
GAS-CLEANING
PERFORMANCE
FOR SULFURIC
ACID PLANTS
Beltrans advanced WESP technology

captures fine particulates, acid mists
and condensed organics with maximum
efficiency and lower cost.
Save on equipment, operating and energy costs with Beltran gas-cleaning WESP
systems, proven worldwide for collection efficiency and reliable performance.
Our custom-engineered WESP designs remove even hard-to-capture submicron
particulates, sulfuric acid mists and condensed organics.
Beltran WESPs are currently producing excellent results for sulfuric acid
plants and other applications worldwide, including mining and metallurgy,
spent acid recovery, power generation, boilers, incinerators and more.
Unique electrode design and multistage systems capture flue-gas
components with up to 99.9% efficiency.
Low pressure drop supports higher gas velocities and volumes with
smaller equipment and lower costs.
Aqueous flushing system prevents particle re-entrainment, residue
build-up, resistivity.
Cool, saturated WESP is more effective on condensable,
oily, sticky contaminants.
Contaminant-free feedstock gas assures quality
end-product for acid plants.
SCAN HERE
with your
Smart Phone for more
info from Beltran
Beltran Wet Electrostatic Precipitators:

The ideal gas cleaning solution
for sulfuric acid plants.
BELTRAN
TECHNOLOGIES, INC.
Beltran Technologies, Inc.

1133 East 35th Street, Brooklyn, NY 11210
718.338.3311 Fax: 718.253.9028
info@beltrantechnologies.com
www.beltrantechnologies.com
ENGINEERING THE FUTURE IN EMISSION CONTROL TECHNOLOGY!

50 YEARS OF EXPERIENCE. MORE THAN 1000 INSTALLATIONS WORLDWIDE.
Feature
Sulphurnet
offers complete
melting and
purification
solutions

Sulphurnet is a dynamic company providing services
for the sulfuric acid industry. It was founded after a simple
observation: the world has changed. Most importantly, the
acid industry just did not keep up with new developments
and ideas. Current sulfur melting technology was outdated.
Someone needed to find a way to introduce new solutions
to customers.

Sulphurnets goal is to pioneer true turnkey service to
the sulfuric acid industry, delivering a complete melting
and purification solution. Sulphurnets full design package
includes improved melting technology in combination with
a very efficient filtration technology, protecting valuable
catalyst in the converter from fouling. Systems also meet
all the health, safety and environmental regulations and all
equipment is built above the ground, making it much easier
to maintain.

Fig. 1 shows the features of the companys sulfur melting and purification technology.
For more information, please visit www.sulphurnet.
com. q
Fig. 1: Sulphurnets melting and purification technology.
PEOPLE ON THE MOVE
Matthew J. Thayer joins Koch Knight as

Vice President of Sales and Marketing
EAST CANTON, OhioMatthew
J. Thayer has joined Koch Knight
LLC as the new Vice President of
Sales and Marketing. He will be
based at corporate headquarters in
East Canton.
Thayer has had 30 years of
experience in roles of increasing
responsibility within the engineering, business development and sales
management areas of several companies. He comes to Koch Knight
from Air Products and Chemicals,
Inc., where he was the Global Mining Manager since 2008. Thayer
joined Air Products in 2003 in the
metallurgical group as a senior applications engineer specializing in
reactive metallurgy and thermal
spray applications.His experience
is enhanced by his Bachelors degree from Edinboro University of
Pennsylvania and a Masters degree
in Business Administration from
University of Phoenix.

Prior to his role at Air Products,
Thayer was Global Technical Direc-
Matthew J. Thayer, Vice President of

Sales and Marketing, Koch Knight
LLC
tor for AstroCosmos Metallurgical,

a division of Mersen, for 10 years.
Mersen is a global leader in the
design and fabrication of titanium,
tantalium, zirconium and nickelbased alloys as well as graphite and
silcon-carbide heat transfer equipment.

As Vice President of Sales and
Marketing, Thayer will be responsible for the overall direction and
global presence of sales and marketing initiatives.

Matthew Thayer brings a significant amount of experience in both
technical and international business
development, says Michael Graeff,
President of Koch Knight LLC. We
are excited to have him join our organization.

Koch Knight is part of the Koch
Chemical Technology Group, LLC,
a diverse group of companies serving the refining, chemical and petrochemical industries. Koch Knight
offers one-stop shopping for many
customers because of the related
product lines of its sister companies.
Diagnostic scans, combustion burners, modular mass transfer skids,
state of the art packing supports
and heat transfer products are just a
few of the many products available
from other companies within Koch
Chemical Technology Group, LLC.
For more information, please
visit www.kochknight.com. q
Fig. 1
PAGE 38
Feature
CONFERENCE REVIEW
Industry converges in Chile for tenth sulfuric acid roundtable
The Hotel Dreams in Punta Arenas,

Chile, provided a beautiful backdrop for the
2014 X Mesa Redonda de Plantas de Acido
Sulfuricothe Chilean Sulfuric Acid
Roundtable. Organized by Holtec Ltd., the
conference, now in its tenth year, was held
November 16-20. More than 125 attendees
gathered at Chiles southern tip to discuss
maintenance and operations technology.

Representatives from facilities around
the globe attended, taking advantage of
this opportunity to share information,
knowledge and best practices with others
in their field. Plant attendees included:
Acidos Y Minerales De Venezuela;
AngloAmerican; AR ZINC S.A.; Cemin
Dos Amigos Pada; Codelco Orgullo de
Todos Chuquicamata, Ministro Hales,
Salvador, El Teniente, and Ventanas; Eco
Services; ENAP Refinerias Aconcagua;
Galvani; Glencore; Haldeman Mining
Company S.A.; Industiras Basicas De
Caldas S.A.; ISUSA; Monomeros; Noracid;
Paranapanema; Pequiven; Procel; and
Southern Copper.

Event sponsors included: Acid Piping
Technology, Afla Delta LTDA, AWS,
Babcock & Wilcox, Bayer Technology
Services,
BASF,
Begg,
Cousland
Envirotec, Chemetics, Clark Koch, Drake
Specialties, DuPont MECS, GEA, Gore,
Haldor Topse, Ingal, Invenio, Koch
Knight LLC, Marco, MB Consultores
Ltda., MetalCop, Nicolaides, NORAM,
Outotec, Repin LTDA, SMA, Steuler KCH,
Sulfuric Acid Today, SNC-LAVALIN,
Sulphurnet, Tetramet, TPI, Twin Filter,
Triangle Fluid Controls Ltd., Verne,
Vorwerk y Cia. S.A., Worley Parsons and
Weir Minerals Lewis Pumps.

Events like the roundtable are a perfect
place to share information and discoveries
within the industry. Attendees enjoyed
panel discussions and presentations
covering a wide range of topics, including:
Control and inspection equipment
enforcement emission standard by Viviana
Rojas and Maria Jose Osuna of Holtec.
The roundtable included an informative

panel on safety. Panelists, from left, were
George Wang of Eco Services, Carlos Lama
of Southern Peru Copper, Claudio Diaz of
Codelco Div. Ventanas and Elio Barraza of
Noracid.
PAGE 40
More than 125 attendees gathered for the X Mesa Redonda de Plantas de Acido Sulfurico in
Punta Areans, Chile.
Dirk van der Werff of Holtec welcomes

participants to the X Mesa Redonda de
Plantas de Acido Sulfurico, held Nov. 16-20,
in Punta Arenas, Chile.
Sarah Richardson of DuPont MECS informed

participants on how to effectively manage
and reduce emissions in sulfuric acid plants
using MECS catalyst.
Convertor maintenance of SO2 gases by

Gabriel Araya of Codelco Chuquicamata.
Saving time and money with form-inplace gasket materials by Douglas Strait
of Gore.
The suitability of double absorption
and scrubbing technologies to meet new
emission standards by Guy Cooper of
NORAM.
Commercialization of MECS SolvR
regenerative SO2 technology by Steve
Puricelli of DuPont MECS.
Leakage behavior of gaskets in flanged
connections by Chett Norton of Triangle
Fluid Control.
Bayqik & sulfuric acid technology
by Lucia Fernandez of Bayer Technology
Services.
Increasing acid plant campaigns by
Claudio Diaz of Codelco Ventanas.
Hydrogen formation in sulfuric acid
plants by George Wang of Eco-Services.
Reform of truck load and dispatch in
sulfuric acid by Lucas Barcado of AR
Zinc.
Wet ESP developments by Sam Kumar
& Bob Snyder of Babcock.
Solid construction PTFE step face
Fun was had by all at the friendly soccer match between the producing plant attendees and
the events sponsors.
gaskets for improved sealing performance

in Mondi piping by Mike Shorts of
Triangle Fluid Control
Operational reliability when designing
for maintenance by Grant Harding of
Chemetics.
Improving efficiency and safety in
metallurgical acid plants by Sebastian
Brechtel of Outotec.
Waste heat recovery in sulfuric acid
plants by Claudia Araya of Holtec.
Air quality standards in sulfuric acid
plants by Kleber Jurado of Southern
Copper.
Presentation of a new sulfuric acid
production plant in Uruguay by David
Mardero of ISUSA.
How to effectively manage and reduce
emissions in sulfuric acid plants using
state-of-the-art MECS catalyst by Sarah
Richardson of DuPont MECS.
Tailor-made catalyst solutions to meet
the demands for lower SO2 emissions by
Osman Chaudhry of Haldor Topse.
A scoring system and sound
management of silica-rich stainless steels
by Axel Alfaro of TPI.
Cooler tubes and housing for sulfuric
acid by Ester Droguett of Outotec.
Sulfuric acid recirculation tank repair
by Gustavo Barreto of ISUSA.
Engineering and construction of an
absorption tower by Diego Rojas of Ingal.
Mist elimination techniques by
Alesandro Gull of AWS.
Comprehensive improvement project
gas capture and processing Potrerillos
Smelter by Manuel Roco of Codelco
Salvador.
The art of troubleshooting mist
eliminators by Graeme Cousland of Begg
Cousland Envirotec.
Improved control system for new
sulfuric acid plant by Hugo Ramirez of
ISUSA.
Master control gas management - Ilo
Smelter by Carlos Lama of Southern
Copper.
Leaks and consequences in sulfuric
acid plant by Elio Barraza of Noracid.

All work and no play makes for a dull
conference, though. With that in mind,
organizers of the Chilean Sulfuric Acid
Roundtable arranged a variety of interesting
events to complement the programming.
Fun was had by all at the biannual soccer
match between producers and sponsors,
in addition to hospitality and networking
opportunities and dinners each night.
Attendees were also treated to a tour of the
historic Punta Arenas cemetery, as well as
a trip to a local farm for a Chilean BBQ
dinner with dancers in native costumes.
The next Chilean Sulfuric Acid
Roundtable will be held in 2016. q
From left to right, Amadeo Valds of SMA, Manuel

Alvarado of Glencore and Hernab Luma of SPCC enjoyed
catching up with one another at the welcome reception of
the X Mesa Redonda de Plantas de Acido Sulfrico, held
Nov. 16-20, in Punta Arenas, Chile.
Grant Harding of Chemetics presented an

informative paper on operational reliability
when designing for maintenance during
the X Mesa Redonda de Plantas de Acido
Sulfurico in Punta Arenas, Chile.
Department
Faces & Places

Guy Cooper of NORAM Engineering
and Constructors Ltd. presented his
companys paper on the suitability
of double absorption and scrubbing
technologies to meet new emission
standards during the X Mesa Redonda
de Plantas de Acido Sulfrico in Punta
Arenas, Chile.
Kleber Jurado of
SPCC presented an
informative paper
regarding the air
quality standards in
sulfuric acid plants
during the X Mesa
Redonda de Plantas
de Acido Sulfrico in
Punta Arenas, Chile.
Claudia Araya of Holtec Ltda. spoke

about waste heat recovery in sulfuric
acid plants during the X Mesa Redonda
de Plantas de Acido Sulfrico in Punta
Arenas, Chile.
Sebastian Brechtel
of Outotec shared
his experiences
with improving
efficiency and safety
in metallurgical acid
plants during the X
Mesa Redonda de
Plantas de Acido
Sulfrico in Punta
Arenas, Chile.
Graeme Cousland of Begg Cousland Envirotec, left, and

Osvaldo Cabrera of Alfa Delta networked at the welcome
reception of the X Mesa Redonda de Plantas de Acido
Sulfrico in Punta Arenas, Chile.
Enjoying the welcome reception of the X Mesa Redonda de

Plantas de Acido Sulfrico in Punta Arenas, Chile are, from left,
Juan Herrera of Drake Specialties, Viviana Rojas of Holtec, Maria
Jose Osuna of Holtec and Claudio Diaz of Codelco Ventanas.
Diego Rojas of Ingal Ingenieria, left, and Nelson Clark

of Clark Koch enjoyed networking during the welcome
Mario Beer of MB Consultores, left, and Carlos Lama

of SPCC enjoyed the festivities during the welcome
Nelson Clark of Clark Koch, right, visited with George Wang

of Eco Services, center, and Dirk van der Werff of Holtec
at the welcome reception during the X Mesa Redonda de
Plantas de Acido Sulfrico in Punta Arenas, Chile.
A few of the participants of the X

Mesa Redonda de Plantas de Acido
Sulfrico enjoyed a day trip to the
scenic Torres del Paine National Park
in the southern Chilean Patagonia
region. Pictured from left to right,
are Alvaro Stegmann of Worley
Parsons, Osvaldo Cabrera of Alfa
Delta, Kathy Hayward of Sulfuric Acid
Today, Graeme Cousland of Begg
Cousland Envirotec, Jan Hermans of
Sulphurnet, Anabel Thomas of SNCLavalin and Orlando Perez of OP &
Associates H2SO4 Consultants.
Matthias Walschburger of Koch Knight LLC, right, visited with,

from left Andres Videla of Vorwerk y Cia, Manuel Rodriguez
of ENAP Refinerias and Eduardo Perez of ENAP Refinerias
during the welcome reception during the X Mesa Redonda de
Plantas de Acido Sulfurico in Punta Arenas, Chile.
Osman Chaudhry of
Haldor Topse, left, visits
with Jan Hermans of
Sulphurnet, center, and
Ken Black of Weir Minerals
Lewis Pumps, right, at the
welcome reception during
the X Mesa Redonda de
Plantas de Acido Sulfrico
in Punta Arenas, Chile.
PAGE 41
Department
CALENDAR OF EVENTS
OCP organizes 3rd SYMPHOS

conference
MARRAKESH, MoroccoThe third

International Symposium on Innovation
and Technology in the Phosphate Industry
(SYMPHOS) will take place May 18-20,
2015, at the Mansour Eddahbi Congress
Center
in
Marrakesh.
SYMPHOS,
sponsored by OCP, is a biennial event
dedicated to all the key players of the
phosphates and derivatives industry. This
highly technical and scientific event aims
to honor innovation, technology, trends in
upgrading processes of phosphates and
derivatives and research and development
perspectives for the phosphate sector.
SYMPHOS is also an information
exchange platform for stakeholders
operating in the mining, phosphates,
chemical processing, sulfur and sulfuric
acid production, ammonia, fertilizers,
biotechnology and phosphate materials
industries. This years event will add a focus
on biotechnology, specific fertilizers and
fertilizers of the future.
www.symphos.com.
AIChE Clearwater
Conference slated for June
CLEARWATER, Fla.Each year for the

last 38 years, members of the AIChE Cen-
tral Florida Section and colleagues from all

over the world have gathered at Clearwater
Beach to share their ideas concerning chemical process technology, specifically the
production of phosphoric acid, phosphate
fertilizers and sulfuric acid. This years conference is slated for June 5-6, 2015.

This year, there will be two sessions on
Friday afternoon. The first will be a sulfuric acid session, chaired by Rick Davis of
Davis & Associates Consulting, Inc. and
Jim Dougherty of Mosaic Co. The second
session will be a workshop on granulation
technology. To obtain PDH certification for
conference sessions, you must attend the full
session of the section for which you need
credit. You must also supply your P.E. number on or before June 5, 2015, and you must
have your attendance verified by proctors.
In addition to its technical sessions,
the Clearwater conference is known for the
beautiful Sand Key backdrop, good food,
ample social time with family and colleagues and a lot of fun. This year should
be no different, with a variety of activities
planned for attendees and their families.
For more information or to register,
please visit www.aiche-cf.org.
cessing, transportation and trade of sulfur

and sulfuric acid. Scheduled for November
9-12, 2015, at Sheraton Centre in Toronto,
the event is sure to attract industry decision
makers from around the world. Its proximity
to the sulfuric acid sector in Ontario and key
U.S. production sites make Toronto an ideal
setting for the global sulfur and acid community to meet and discuss the commercial
and technical issues shaping the industry.

Sulphur 2015 is now firmly established
as the premier industry event for the sulfur
and sulfuric acid markets, offering an annual opportunity for the industry to meet, learn
and network for over 30 years. The conference celebrated its 30th anniversary in 2014,
attracting over 600 industry professionals
from 43 countries and making it one of the
biggest gatherings in the events history.

Each year, the extensive program covers key market trends, project updates and
supply and demand forecasts in the commercial sessions, with presentations from
respected industry figures and high level
analysis from CRUs Sulphur Team.

The two day split-stream technical program showcases the latest technological developments to improve efficiency and compliance, and provides a high-level forum for
engineers from the sulfur and sulfuric acid
industries to share experiences and develop
solutions to common operational problems.
The 2015 call for technical papers is
now open. All papers should be submitted
Toronto will host Sulphur 2015
LONDONCRU is delighted to host Sulphur 2015 in Canada, one of the worlds

primary markets for the production, pro-
2016
Australasia
H SO W O R K S H O P
2
S U L F U R I C A C I D T O D AY
Jupiters Townsville
Hotel & Casino
April 4-7, 2016
for consideration by May 11, 2015.

www.crugroup.com/events/sulphur/.
Australasia Sulfuric Acid

Roundtable announced
COVINGTON, La.Sulfuric Acid Today is

happy to announce that the eighth Australasia Sulfuric Acid Workshop will take place
April 4-7, 2016. It will be held at the Jupiters
Townsville Hotel & Casino in Townsville,
Queensland, Australia.
The 2014 Workshop attracted more
than 80 participants from around the world,
and 2016 is shaping up to be an even bigger
event. As in years past, sulfuric acid insiders
will gather to attend presentations given by
event co-sponsors on a variety of topics relevant to the industry. Panel discussions and
co-sponsor booths will provide more opportunities for information sharing, while social
events will ensure that participants get to
enjoy the beautiful area while building relationships that promote beneficial business
exchanges in the future.

The Australasia Sulfuric Acid Roundtable is offered in even years in Australia and alternates with the Sulfuric Acid
Roundtable, which is offered in odd years in
the United States.
www.h2so4today.com or email kathy@
h2so4today.com. q
2016 Aus
trala
Worksho sia Sulfuric Acid
p will off
er:
Global s
u
lf
2015 and uric acid market revie
w of
outlook for
Informa
tive Co-Spo 2016
nsor prese
Insightfu
nta
l
Mainten producing plant pres tions
an c e p an e l
entations
dis
Safety p
anel and in cussions
cident revie
Co-Spon
ws
s
Network or exhibits
ing opportu
nities
Townsville, Queensland Australia

Sponsored By:
Sulfuric Acid
T
Industrys Premier Event for Networking

& Sharing Best Practices
Register On-Line Today! www.acidworkshop.com
PAGE 42

Magazine of The Sulfuric Acid Today Spring/Summer 2015

Transféré par

Informations du document

Titre original

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

Magazine of The Sulfuric Acid Today Spring/Summer 2015

Transféré par

Droits d'auteur :

Formats disponibles

COVERING MAINTENANCE SOLUTIONS FOR THE INDUSTRY

www.H 2S0 4Today.com

Mosaics New Wales Plant:

IN THIS ISSUE > > > >

Global sulfuric acidsupply and

Vertical pump sealing options: packing

Improving plant performance using

COVERING MAINTENANCE SOLUTIONS FOR THE INDUSTRY

www.H 2S0 4Today.com

Mosaics New Wales Plant:

Covering Maintenance Solutions for the Industry

FROM THE PUBLISHER

Improving plant performance using

Mosaic Co.s New Wales

Global sulfuric acidsupply and

several articles regarding the latest technology available to

Global sulfuric acid 2014 in review and outlook

Vertical pump sealing options: packing seals vs. mechanical seals

Upgrades to sulfuric acid equipmentan evolutionary tale

PPE: The final answer to worker protection

Jon Quarles retires from Acid Piping Technology

Saint-Gobain NorPro ceramic technology provides proven reliability

Improving plant performance using state-of-the-art MECS catalysts

The worlds first live observations of sulfuric acid catalysis

Roberts continues to expand offerings

WESPs prove versatile in acid plant applications

Advancements in sulfur spraying: new hybrid gun and predictive modeling

Cylindrical superheaters for high temperature and high pressure service

When secondary containment linings and coatings are primary

Sulphurnet offers complete melting and purification solutions

Industry converges in Chile for tenth sulfuric acid roundtable

Mailing Address: P.O. Box 3502

Topse part of consortium

LYNGBY, DenmarkA consortium consisting of Haldor Topse A/S, the German

Siemens to supply steam

consisting of Samsung C&T and Samsung

Haldor Topse signs

LYNGBY, DenmarkTopse A/S has

Sulfuric Acid Today Spring/Summer 2015

dor Topse Exchange Reformer (HTER)

Outotec to revamp and

ESPOO, FinlandOutotec has been

Solvay sells sulfuric acid

NEW YORKCCMP Capital Advisors

Sulfuric Acid Today Spring/Summer 2015

Scheduling: CMW has a dedicated scheduling/planning division with decades of

Check us out at www.cmw.cc

Toll-free in the USA: (877) 704-7411

Mosaics New Wales Plant: bringing a

Additional steam supply for the high

The last of the 5 stacks is replaced during

Much of this investment you can plainly

Putting the Continuous in

For all of New Wales tangible

the different teams together to get to the

Mosaics long-term commitment is

and the heat recovery installations, New

Installation of new 4A/C economizer

in my 25-year career, says Willis. The

all the different groups wanting to perform

ing, will it fit, what roadways are we closing

major projects provide a detailed safety

weeks to get the job done safely, thats what