Who has the best renovation plan

1 By using a turbine to directly drive the blower, high efficiency is achieved from an energy utilization perspective, and it is possible to avoid the need for motors, generators, and power distribution equipment, resulting in lower investment costs. However, external medium-pressure steam is required during startup, and steam must also be supplied during normal operation; therefore, large integrated enterprises should give priority to using turbines to directly drive blowers. 2 However, if there is no external medium-pressure steam available during startup, and it is necessary to use a startup fan (with an electric motor as the power source to drive the centrifugal blower) before switching to the fan used in normal production operation (a blower driven by a steam turbine), I believe it is better to use a high-power electric motor to drive the blower. The existing fan motor can be modified to have variable frequency speed control; steam can be supplied during normal production, while a separate steam turbine generator should be used.

I support this plan; the technology is mature.

Theoretically, using a steam turbine for drive is a good solution as it saves energy. But in practice, variable frequency is the better option. Driven by steam, it experiences large fluctuations and instability, which causes many difficulties in the operations related to conversion and dry absorption processes, thus affecting production.

German motors are of very high quality; it would be a shame not to use them. Moreover, since their power is relatively high, measures can be taken in the electrical system to reduce reactive power. Using an inverter will affect the outlet pressure of the fan, and the impact is significant. Additionally, domestic inverters with such high power levels are not yet mature enough, so it is necessary to import inverters. In my opinion, option 1 is still to use the original motor without an inverter； If it’s truly necessary, then adding a hydraulic coupler will also serve to achieve speed control. 2. It’s best to use a back-pressure steam turbine; the steam, after being cooled, can be used for the phosphorus ammonium concentration process in your company, which yields the best energy-saving results. However, operating such a turbine presents certain difficulties. There are still some issues with the electrical control of the turbines produced by GAC Skoda. Both Yunnan Sanhuan and Jiangchuan have used them, so you might want to consult more information on this topic.

Thank you for the remarks above. I personally prefer not to use turbines, as the company’s thermal power plant already has surplus turbines that can handle the steam generated by sulfuric acid production. Furthermore, as mentioned above, motors operate more stably than turbines, which is also beneficial for future HRS upgrades. It just feels that from the perspective of energy utilization, it’s not entirely satisfactory.

Hello, you must be from Hubei Dayukou Phosphating Company. Previously, there were two sets of facilities for producing sulfuric acid from pyrite, with Series A and B. The German 3K fans are of good quality; their value is around 10 million RMB. If the process is changed to using sulfur for acid production, these devices can still be utilized effectively. However, 2680 KW is a relatively high power level for producing sulfuric acid from 300,000 tons of sulfur per year. This power level can be reduced by using variable frequency control or hydraulic couplings, which can help save electricity. Furthermore, your company has been out of production for 7 or 8 years now; I assume that the equipment and pipelines used for dry absorption conversion (towers, tanks, acid separators, low-grade cast iron pipes, etc.) also need to be modified. From what you say, it seems you still intend to carry out modifications to the HRS in the future. Currently, only Su Jinghua and Yihua in China possess this technology, and they do it by designing and putting the system into operation directly; there are not many cases of modifying HRS on existing installations in China!

Reply to chx8965: Hello, you are right. I wonder where the moderator is? I accidentally discovered Haichuan Forum on the 19th of this month, and I’m very happy. Workers in the sulfuric acid industry now have a platform for exchanging ideas, discussing matters, and sharing information; they have therefore registered as members and find great value in accessing Daily View of the Seas and Rivers. Dayukou Company resumed production in 2005, replaced the original heavy calcium carbonate with DAP, and built a new MAP plant with an annual capacity of 150,000 tons. The conversion and dry absorption units of the sulfuric acid plant are in good condition; the cast-iron pipes have been replaced with those protected by stainless steel anodes, and all the acid separators have also been replaced. Regarding HRS, it is necessary to first gain an understanding of it, conduct investigations, and make technical preparations; I believe this can be achieved in not too much time. Additionally, with the wall temperature of your sulfur incineration furnace at 200°C, isn’t the heat loss too high?

It’s currently in Jiaxing, Zhejiang; has it been converted to sulfuric acid production due to the expansion of phosphate ammonium production? The slurry method for phosphatic ammonium will make good use of the low-pressure steam in HRS; currently, sulfur costs around 5,000 yuan per ton. Should the conversion catalyst still be the original Mengmoke catalyst? Should the outlet heat exchanger in section 1 be replaced with a 304L steam/steam superheater? Should the flue gas before the first suction stage be routed to a heat pipe economizer to heat the boiler feedwater? Should the outlet of section 4 use an economizer (to heat the boiler feedwater) and a low-temperature superheater (to superheat the saturated steam) for heat exchange? The wall temperature of our sulfur incineration furnace is 200°C, in compliance with the basic design principles established by Menmoke. We have installed an aluminum-covered shelter 40 centimeters outside the circumference of the furnace to protect it from rain and snow, thereby preventing the external surface temperature of the furnace from dropping; this also serves as an indirect insulation measure. This post was last edited by chx8965 on 2008-1-27 16:58.]

Hubei Dayukou Chemical Co., Ltd. – I visited it 10 years ago; it has completely changed. Now its owner is CNOOC.

The original catalyst has worn out, and Topso catalyst is now being used. Two high- and low-temperature superheaters and two economizers have been added to replace the original three tube heat exchangers. The transformation of sulfur-based acid production is in line with CNOOC’s goal of becoming an \"internationally leading green energy company.\" The company began reconstruction and renovation in 2003, with various units coming online successively in 2005. In 2007, production targets were fully met: 1.5 million tons of mineral processing products, 200,000 tons of phosphoric acid, 310,000 tons of sulfuric acid produced from sulfur, and 350,000 tons of DAP. The company’s workforce has been reduced from several thousand to less than 900 people at present.

On October 13, the high-power high-voltage frequency conversion units manufactured by Xiangfan Chuangxinyuan Energy-Saving Technology Co., Ltd. of Dali Group were successfully applied to the 1900kW sulfuric acid blower at Jiangsu Jihua Chemical Co., Ltd. The original design of the 1900kW sulfuric acid blower at Jihua Chemical Co., Ltd. called for operation at power frequency with air damper adjustment, the maximum opening degree of which was only 30%. A large amount of electrical energy was wasted on these dampers. In order to improve efficiency and reduce energy consumption, it was decided to implement speed control for this blower. After thorough evaluation, the DLHVF-2400/10B high-voltage frequency conversion unit produced by Dali Group Xiangfan Innovation Energy Electric Co., Ltd. was selected. Given the excellent energy-saving effects of budget-friendly options, users request delivery within a month in order to use energy-saving equipment as soon as possible, which poses a challenge for manufacturers of high-voltage frequency conversion devices. Through careful planning, Innovation Source Company worked overtime during the National Day holiday to complete the production of the equipment within a month. The equipment arrived at the site on October 6, 2007; installation was finished on October 9, followed by testing, and the equipment was successfully put into operation under load on October 13. Two weeks of continuous operation have proven that the device operates stably and reliably, with highly significant energy-saving effects; all technical specifications meet the requirements of the engineering design. This device has been very popular and well-received by users at their sites. Factory director Chen said that by using this device, 10,000 yuan in electricity costs can be saved in just one day; it’s practically like a small banknote printer! Transformations like this deserve to be widely promoted across the entire industry and throughout the country. Chen Xin, a technician at the factory, said: Nowadays, soft starting is used, so the starting current is much lower than the rated current; adjusting the air volume is both simple and precise.

Has your company launched Project 8632?

Not yet; the final plan still needs further evaluation.

Can’t acid production from pyrite be carried out anymore? Then advanced facilities would have to be converted back to sulfur-based acid production systems, which is unreasonable. Moreover, the cost of sulfur is currently very high. Yangfeng in the vicinity is building a 200,000-ton capacity facility for acid production from pyrite. Low-temperature heat recovery systems, as well as XuanDa’s modular systems, offer advantages when it comes to upgrading existing systems.

I fully agree with your idea; the operating conditions of steam turbines are highly variable, and starting them is very complex. As far as I know, at a company in China with somewhat inferior technology, the original design called for a turbine to drive it, but it still hasn’t been put into operation yet!

What is the total investment for a 1900KW inverter and related costs? I wonder how it’s performing at the moment? Sometimes the reports can be a bit inaccurate, and they also need to be tested through long-term online operation. How much investment is needed for a 2680KW inverter? If anyone knows, they can give a brief introduction for everyone’s reference.

The variable frequency speed control range can be considered, which will reduce the investment in inverters.

It is recommended to consider a waste heat recovery power generation project during renovations, as this can reduce energy consumption and save costs. Our company specializes in the design, construction, equipment selection, as well as investment and operation of waste heat recovery power generation projects for sulfuric acid production. In the sulfuric acid industry, the recovered waste heat is mainly used for power generation or to drive fans directly. If anyone in the sulfuric acid industry plans to implement a waste heat recovery project, they can get in touch with me at QQ: 38739249

Why the rush to renovate? Could we first consider using Wengfu mixed with sulfur? Choose the method that is cheaper.

Of course, choose the cheaper one; it’s best not to make any changes.