word(s) in header by

changing the Open

Sans (Headings)

Reduce emission and increase productionwith new LEAP5™ catalyst

1

Presented by Eliana Revelli

2

Air pollutionTighter regulation is expected in the future

Beijing

Sao Paulo

Source:GB269332, ELVIK BREF 2007, EPA

New Delhi

London

Los Angeles

Mexico City

3

Reduction is a worldwide trend

SO2 emission

16%Further reductions

during start-up

37%Further reductions during

daily operation

47%No further reductions and other

Future regulations on SO2 emission+ 50%

Expect further reduction

Perú

Current: 200-400 ppm

Brazil

Current: 400 ppm

Chile

Current: 400 – 600 ppm

4

Common ways to reduce your SO2 emissionWithout reducing plant output

Cs catalyst in last bed

+ Easy installation

+ Normal operation & handling

+ Cleaner start-up

+ Slightly higher production

÷ Extra CAPEX

• May require lower inlet temperature

Adding an extra bed

+ Normal operation and handling

+ Similar start-up

+ Slightly higher production

÷ Complex installation

÷ Require higher inlet pressure

÷ Extra CAPEX and extra OPEX

Cut capacity

+ No installation

+ No requirements

+ Normal operation and handling

+ Similar start-up

÷ Lower production

Tail-gas scrubber

+ Cleaner start-up

+ Normal production

÷ Complex installation

÷ Require higher inlet pressure

÷ Extra handling of scrubber products

÷ Extra CAPEX and extra OPEX

61%Catalyst Solution

26%Scrubber solution

13%Revamp or

replace de plant

5

The sulphuric acid catalystSupported liquid phase

6

The sulphuric acid catalystSupported liquid phase

7

Ambient temperature

Active phase is present as crystals

The sulphuric acid catalystSupported liquid phase

Operating conditions

Vanadium is dissolved in a pyrosulphate melt

The active phase is a liquid

8

Mechanism for SO2 oxidationVanadium (V) makes the catalyst active

(VVO)2O(SO4)4

(VVO)2O(SO4)4O2

(VVO)2O(SO4)4O

(VVO)2O(SO4)4SO3

-4

-4 -4

-4

SO3

SO2

SO2

SO3

O2

2VIVO(SO4)2 2VIVOSO4 (s)

2SO4SO2 SO3-2Main reaction

mechanism

Equilibrium reaction to VIV

9

Vanadium (V) contentTraditional catalyst technologies

0

10

20

30

40

50

60

70

80

380 390 400 410 420 430 440

Re

lati

ve

co

nte

nt

of

va

na

diu

m (

V)

[%]

Temperature [°C]Conditions: 10% SO2, 10% O2, high conversion

Traditional catalyst technologies

VK-711 LEAP5™

Why not utilize this potential?

10

Nano-scale Vanadium melt dynamicsTEM in situ recordings - Physical properties analyzed

F. Cavalca, P. Beato, J. Hyldtoft, K. Christensen, and S. Helveg (2017). Phys. Chem. C, 121, 3350−3364.

Vanadium (V)

Vanadium (IV)

Vanadium (IV)

Through optimizing the carrier structure and formulation, the Vanadium (V) content is

maximised.

11

New ways to achieve lower emissionsEven higher SO2 conversion before intermediate absorption

SO2 feed

SO3 rich gas

VK48

VK38

VK69

VK38

Equilibrium curve before intermediate

absorption

0

2

4

6

8

10

SO

2co

nce

ntr

ati

on

[%

]

Equilibrium curve after intermediate

absorption

350 400 450 500 550 600 650

Temperature [°C]

Bed 1

Bed 2

Bed 3

Bed 4

Inte

rme

dia

te

ab

sorp

tio

n

12

0

0.5

1.0

1.5

2.0

SO

2co

nce

ntr

ati

on

[%

]

380 400 420 440 460 480 500

Temperature [°C]

Bed 3 Equilibrium curve before intermediate

absorptionBed 3

Equilibrium curve after intermediate

absorptionBed 4Bed 4

SO2 feed

SO3 rich gas

VK48

VK38

VK69

VK38

Inte

rme

dia

te

ab

sorp

tio

n

+100% activity?

New ways to achieve lower emissionsEven higher SO2 conversion before intermediate absorption

13

0

50

100

150

200

SO

2co

nce

ntr

ati

on

[p

pm

]

380 390 400 410 420 430 440

Temperature [°C]

Bed 4

Bed 4

Equilibrium curve before intermediate

absorption

Equilibrium curve after intermediate

absorption

37% emission reduction

SO2 feed

SO3 rich gas

VK38

VK69

VK38

Inte

rme

dia

te

ab

sorp

tio

n

+100% activity?LEAP5™

New ways to achieve lower emissionsEven higher SO2 conversion before intermediate absorption

14

Optimizing performance at lower operating temperaturesNew VK-711 LEAP5™

1

10

100

1000

370 380 390 400 410 420 430 440 450 460 470 480 490

Re

lati

ve

act

ivit

y

Temperature [°C]

VK48

VK-701 LEAP5TM

VK59

VK-711 LEAP5TM

15

Optimised Vanadium (V) contentIntroducing LEAP5™

0

10

20

30

40

50

60

70

80

380 390 400 410 420 430 440

Re

lati

ve

co

nte

nt

of

va

na

diu

m (

V)

[%]

Temperature [°C]Conditions: 10% SO2, 10% O2, high conversion

LEAP5™

Traditional catalyst technologies

16

How does LEAP5 fit in?Without reducing plant output

Adding an extra bed

+ Normal operation and handling

+ Similar start-up

+ Slightly higher production

÷ Complex installation

÷ Require higher inlet pressure

÷ Extra CAPEX and extra OPEX

LEAP5 catalyst

+ Easy installation

+ Normal operation

+ Cleaner start-up

+ Slightly higher production

+ Reduce OPEX of any future scrubber

÷ May require lower inlet temperature

÷ Extra CAPEX

Cut capacity

+ No installation

+ No requirements

+ Normal operation and handling

+ Similar start-up

÷ Lower production

Tail-gas scrubber

+ Cleaner start-up

+ Normal production

÷ Complex installation

÷ Require higher inlet pressure

÷ Extra handling of scrubber products

÷ Extra CAPEX and extra OPEX

17

LEAP5 – Worldwide references

18

LEAP5™ can do more than reduce emissionFive advantages for acid plant operators

Reduced SO2

emissionIncreased sulfuric

acid capacityReduce scrubber

chemical consumption

Reduced plant pressure drop

Thank You