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MECS INC.

MECS INC. Meeting EPA Consent Decree Compliance with DynaWave Scrubbing. Presented by Larry Paschke. Background/History. Headquarters - St. Louis, Missouri Global Business 250 Employees 75 Years - Monsanto/MECS designed and constructed over 800 chemical and cogeneration projects

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MECS INC.

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  1. MECS INC.

  2. Meeting EPA Consent Decree Compliance with DynaWave Scrubbing Presented by Larry Paschke.

  3. Background/History • Headquarters - St. Louis, Missouri • Global Business • 250 Employees • 75 Years - Monsanto/MECS designed and constructed over 800 chemical and cogeneration projects • 1969: MECS formed • 2005, Management Buyout from Monsanto and MECS Inc. formed.

  4. MECS Inc. Capabilities • Design and supply air pollution control products • DynaWave Scrubbers • Brink Mist Eliminators • Design and build sulfuric acid plants • Supply proprietary products to the sulfuric acid industry • Specialty alloys • Catalyst • Tower internals

  5. Important Issues To Be Addressed • Performance • SO2 Removal • SO3 Removal • PM Removal • Other Consideration/Effluent Treatment • Applications • FCCs • SRUs

  6. SO2 Removal

  7. SO2 Removal • Mass Transfer • Gas/Liquid Contact Mechanism • Total L/G (gpm / 1000 acfm) • Reagent Kinetics • Caustic • Soda Ash • Lime • Limestone

  8. DynaWave Scrubber

  9. SO2 Mass Transfer / Reagent

  10. Reagent Reactivity Operating Cost Caustic Most reactive Highest cost Soda Ash Very Reactive Moderate Cost Magnesium Hydroxide Moderately Reactive Moderate Cost Lime Less Reactive Lower Cost Limestone Least Reactive Lowest Cost Reagent Overview

  11. Reagent Costs

  12. Reagent Reaction Products • Caustic Soluble Salt • Soda Ash Soluble Salt • Trona Soluble Salt • Lime Insoluble Solid • Limestone Insoluble Solid

  13. Run 1 Run 2 Run 3 Ave SO2 Inlet (lb/h) 1.87 1.80 1.90 1.86 SO2 Outlet (lb/h) 0.02 0.01 0.02 0.017 Outlet ppmvd 0% O2 5.11 3.87 5.57 4.85 SO2 % Removal 98.9 99.4 98.9 99.1 Navajo Test Data Pilot Plant Full Scale Installation CEM measures < 1 ppmvd 0% O2 corrected

  14. ParticulateRemoval

  15. Particulate Matter • Size Distribution of catalyst fines (PSD) • Gas side pressure drop used by scrubber • Smaller particles require more pressure drop

  16. < 0.1 microns 0.1 Wt% < 0.3 microns 4% < 1.0 microns 35% < 1.5 microns 54% < 3.0 microns 75% > 20 microns 6% Particulate Removal Typical FCC PSD

  17. Example: 25” wc required for 90% particulate removal

  18. Run 1 Run 2 Run 3 Ave PM Inlet (lb/h) 1.15 2.39 0.78 1.44 PM Outlet (lb/h) 0.01 0.01 0.01 0.01 PM % Removal 99.1 99.6 98.7 99.1 Navajo Test Data Pilot Plant Full Scale Installation Reduction of PM by 93%

  19. SO3/Acid MistRemoval

  20. SO3 Removal Mechanism(NOT the same as SO2) • Opacity • Diffraction of light waves by particles • Hydrolyzed to H2SO4 liquid droplets • 0.4 micron size • Not absorbed, mechanical removal • Gas side pressure drop required

  21. Example: 40” wc gas pressure drop required to remove 90% of SO3

  22. Other ConsiderationsEffluent Treatment

  23. CODChemical Oxygen Demand • Measured as mg O2 / liter solution or ppm • Convert sodium sulfite/bisulfite salts to sulfate salts • Forced oxidation to sodium sulfate • O2 to S ratio • Residence time • Air dispersion

  24. CODChemical Oxygen Demand • Typical COD target range 50 to 200 ppm • Consider “pre-existing” COD in makeup water • Two oxidation methods • In-Situ • Ex-Situ

  25. DynaWave ScrubberIn-Situ Oxidation

  26. Effluent Rate Requirements • Set by dissolved solids concentration • Salt concentrations up to 20 wt% • Low effluent rate to waste water treatment desirable

  27. Effluent Rates 20% 15% % salts 10% 5% 0 20 40 60 80 100 gpm Assumes 1000 lb/h SO2 removed

  28. Other ConsiderationsMaterials of Construction

  29. Alloy Approx. Relative Cost Chloride Limit ppmw* 316L 1.0 300 Duplex RA-2205 1.3 20,000 AL6XN 3.3 +30,000 Hastelloy C-276 6 +100,000 Materials of Construction • Considerations • Inlet temperature • Wet / dry interface • Chlorides * By Rolled Alloys.

  30. DynaWave Scrubber Reaction zone: AL6XN Hastelloy Duplex 2205 Vessel: Duplex 2205 316L stainless

  31. Sources of Chlorides • Caustic • Make-up Water • FCC Off Gas

  32. Monsanto DynaWave Scrubber

  33. On-Line Reliability • Minimal mechanical equipment • Withstands upset conditions- • Large catalyst carryover to scrubber • Abrasion/pluggage design considerations • Large Reverse Jet nozzles

  34. Monsanto Refinery Experience

  35. Navajo Installation30,000 BPD FCC

  36. DynaWave in SRU • Very cost competitive versus conventional technology • Designed to meet • 100 ppmvd SO2, corrected to 0% O2 • 100 mg/L COD • Less than 10% opacity • Handles high sulfur loadings during off ratio and SRU bypass cases

  37. Conclusion • DynaWave Applications • FCC, SRU, Calciner, S-Zorb • Compliance Help with • Consent Decrees • MACT II • Lower capital and operating costs • Proven Experience

  38. Thank you.

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