Sulphuric acid plant modernization projects: Project execution strategy and use of improved technologies

摘要

To continue successful operation, all sulphuric acid plants will eventually need upgrades, even with good equipment designs. The plant will have to execute projects to achieve higher performance, and to solve issues caused by the deterioration of certain pieces of equipment. Drivers for plant upgrades may include: (1) need to replace end-of life equipment, (2) requirement to meet more stringent environmental regulations, (3) new energy recovery targets, or (4) need to increase gas handling or acid production capacities. Moreover, some acid plant components may need upgrading or replacement due to the age and mechanical conditions of the equipment, or when they are found to be a bottleneck in the plant. NORAM specializes in engineering strategies for upgrading plants. These modernization strategies are best conceived as part of a long term plan. Upgrade factors include: process and mechanical engineering considerations, budgetary constraints, turnaround planning, duration of plant shutdown, lost production, technical risk, mechanical conditions of existing equipment, space availability, shipping restrictions, permitting, logistic considerations, as well as the time required for fabrication and installation of major equipment. NORAM provides improved sulphuric acid plant technologies and equipment that can be utilized in plant upgrades. NORAM's designs are used to improve the plant performance and reliability, while achieving the objectives set by the client. A recent case study is presented, where a final acid tower was replaced in a Chilean sulphuric acid plant This paper also reviews other recent plant modernization projects in terms of their unique challenges, project execution strategy, and the use of modern technology in existing plants.