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Transcript of The Dorr-Oliver FluoSolids® technology makes Technip · PDF fileDead roasting of pyrite,...
The Dorr-Oliver FluoSolids® technology makes Technipa leading provider of fluid bed systems
Dorr-Oliver FluoSolids® Systems
Engineering and technologies
2
Technip is a world leader in project management, engineering and construction for
the oil and gas industry.
With a global footprint, our talents constantly offer the most innovative technologies and
best solutions to our clients to optimize their investments and meet the world’s energy
challenges.
Our mission is to deliver safe, sustainable and quality projects across the world.
We operate in three main businesses:
Offshore
In the Offshore business, our
activities include engineering,
procurement, construction (EPC) and
installation of fixed and floating
platforms.
We use a complete range of
technological solutions to answer
the challenges faced by our clients.
We are leveraging our expertise in
full-range of offshore facilities, as
well as our strong know-how with
added-value process skills and
proprietary platform design.
Onshore
In the Onshore business, we deliver to
our clients all the experience we have
acquired for almost 60 years, combined
with a large technology solutions
portfolio. We are working on onshore
facilities that the energy sector needs, in
particular for oil and gas industry players.
Technip is one of the global leaders for
the refining business and petrochemical
units. We also reinforced our position on
project management consultancy (PMC)
activities, by leveraging our expertise in
the management of complex projects.
Subsea
In subsea hydrocarbon field
development, Technip’s activities
include the design, manufacture
and installation of rigid and
flexible subsea pipelines and
umbilicals.
Thanks to our portfolio of
technologies, industrial and
operational assets on all
continents and a state-of-the art
fleet, we offer a unique vertically
integrated model in the industry.
Technip at a glance
3Dorr-Oliver FluoSolids® Systems
50 t/d Arseno-pyrite roaster, Australia 88 t/d Arseno-pyrite roaster, Australia
1,650 t/d Phosphate rock calciner, Morocco
The Dorr-Oliver FluoSolids® technology makes Technip a leading provider of
fluid bed systems, with nearly 1,000 reference projects.
The technology was developed over a 70-year period with a wide range of
applications in the metallurgical, chemical and waste processing industries.
Dorr-Oliver FluoSolids® Systems
Technology history
The technology was developed by Dorr-Oliver starting in the early 1940s. The first commercial installation, an arseno-pyriteroaster for gold recovery, came in 1947. In 1997, the business was transferred from Dorr-Oliver to sister company KineticsTechnology International (KTI), a company specializing in furnaces and other high temperature equipment and systems. In 2000,KTI merged with Technip, who has continued to develop the technology. In 2012, Technip Stone & Webster Process Technologybecame the exclusive provider of this technology, offering modern fluidized bed systems for roasting, calcining, incineration,and a host of other applications to customers worldwide.
FluoSolids® references include:
More than 310 roaster systems for metallurgical applications, as well as sulfurdioxide and sulfuric acid manufactureMore than 100 calcining systemsMore than 270 drying systemsMore than 90 preheaters and calcine coolersMore than 200 waste incineration systems, both municipal and industrial
Main features
Chemical and thermal efficiencySimple start-up and shut-downUniform solids temperature in the bedVariable solids retention timeVertical, cylindrical design for efficient space utilizationLow operating costNo internal moving partsLong refractory lifeLow maintenance costsSimple controls
2 x 3850 MTPD nickel ore roasters, Koniambo,New Caledonia
4 Dorr-Oliver FluoSolids® Systems
The world's first commercial fluidized bed roasting system
was a FluoSolids® unit designed to treat gold-bearing
sulfide ore. The technology continued to develop under
Dorr-Oliver and now Technip to include a vast array of
roasting process applications and reactor designs.
Roaster with slurry feed
Roasting applications
Commercial FluoSolids® roasters have been designed and supplied to implement thefollowing processes:
Two-stage roasting of refractory gold ore using pure oxygen (Freeport process)CFB roasting of refractory gold oreTwo-stage roasting of gold-bearing arseno-pyrite concentrates for arsenic andsulfur removalPartial roasting of copper and nickel sulfides for sulfur control in smeltingDead roasting of pyrite, pyrrhotite, zinc, nickel and other sulfidesSulfation roasting of Cu and Cu/Co sulfides (RLE processes)Reduction roasting of iron ores and nickel laterite oresChlorination roasting of copper ores (TORCO process)
Operating Advantages
Ease of operationHigh reliabilityLow operating and maintenance costsFlexible designs for various roasting applications
Features of a FluoSolids® roaster system
FluoSolids® roaster systems incorporate the ideal combination of design features,specific to any application. Each roaster system is tailored to the specific processrequirements and solids handling characteristics. FluoSolids® systems have incorporatedthe following design features:
Cyclone, bag filter and hot ESP dust collectionDirect quench and fluid bed calcine coolers with heat recoveryFluidized feed distributors for bone dry feedSlinger-belt feeders for filter cake feedSlurry distributors and in-bed slurry injectionDirect in-bed injection of liquid, gas and solid fuelsIn-bed steam coils for temperature control and heat recoveryExhaust gas waste heat boilers
Nearly
1,000 references
worldwide
Roasting systems
5Dorr-Oliver FluoSolids® Systems
The multi-compartment FluoSolids®
reactor usually consists of a reaction bed
and one or more heat exchange beds for
heat recovery.
Multi-compartment calciner
4 x 1,500 t/d Phosphate rock calciner, USA
Calcining systems
In a typical 3-stage unit as illustrated here, hot gases from the main calciningcompartment are used to dry and preheat calciner feed. Fuel is directly injected intothe reaction compartment, where temperature and atmosphere are closely controlled.Finally, heat is recovered from hot product solids and used to preheat the fluidizingair. Auxiliary vessels, such as fluid bed spray coolers or indirect coolers may be usedto further cool product solids for ease of handling.
Applications
Multi-compartment FluoSolids® reactors have been successfully employed in thefollowing applications:
Limestone calciningCalcium and magnesium sulfite decompositionFoundry sand calciningIlmenite roastingPhosphate rock calciningFireclay calciningLime mud calcining and pelletizationAlumina and bauxite calcinationIron ore preheatingIron ore reduction (hematite to magnetite)Manganese oxide reduction
6 Dorr-Oliver FluoSolids® Systems
Combustion system Combuster, USA
The fluid bed with its homogeneoustemperature, high turbulence and longresidence time performs exceptionallywell for the combustion of sludges,waste oils, waste chemicals, solid wastesand other hazardous wastes. Totalsystems are available from feed to stackincluding ash dewatering and heatrecovery.
Features
All combustion systems are designed to specific application and process requirementsand solids handling characteristics. FluoSolids® systems for the municipal and industrialwaste sectors have these integrated features designed into each plant:
Efficient combustion with low excess airLower temperature operations for equivalent combustion resultsReduced air emissionsFlexibility of operationSimplicity of controlLower staffing requirementsLower maintenance and operating costsLower total system capital costs
Applications
Technip is the world's most qualified supplier of fluidized bed waste combustionsystems. Installation capacity ranges from 2 to 200 million BTU per hour feed input.
Municipal sludges - primary, secondaryPetroleum wastesPharmaceutical sludgePulp and paper deinking sludgeAutomobile manufacturing wasteFood wastesLivestock wasteChemical process waste
Combustion systems
Technip is a world leader in FluoSolids® combustion technology with more than
200 installations worldwide, spanning the municipal, refining, petrochemical,
food, pharmaceutical and pulp/paper industry sectors.
Circulating fluid bed (CFB) systems
7Dorr-Oliver FluoSolids® Systems
Advantages
Improved reaction kineticsGreater range of gas turndown capabilityHigher throughput per unit area
Additionalcapabilities
Circulating fluid bed
4,500 t/d CFB gold ore roaster inMali, West Africa
120 t/h sand dryer system,Sweden
Refinery waste incinerator,USA
Fluid bed dryers
Technip can design and supply fluid beddryers for a multitude of applications.Dryer systems can be configured fordirect heating, indirect heating with bedcoils, or as a dryer-cooler combination.Applications have included:
Limestone and DolomitePhosphate RockPotashSulfide concentratesSand and FluxSlag AluminaCoal and CokeUranium OrePlastics and ChemicalsCatalyst
Heat recovery & gas cleaning
High temperature exhaust gases provide the possibility of heat recovery. Techniphas provided heat recovery systems of flue gas to air, flue gas to water and flue gasto steam via water tube or fire tube waste heat boilers. Every fluid bed produces acarry-over of solids and gaseous products in the gas stream. Technip designs proprietarycyclones and venturi scrubbers for solids recovery and emission control. Dorr-Oliverhas also provided multiple component custom-designed emission trains to meetthe most stringent environmental air regulations. A plumeless stack appearance canalso be obtained using flue gas heat recovery. Special exothermic applications havecoils in the fluid bed for steam generation.
Pilot scale testing
Technip routinely conducts pilot planttesting of fluid bed processes to supportequipment design, scale-up, and processguarantees. This testing offers the followingadvantages:
Determine process feasibilityOptimize product qualityDefine gaseous emissionsProve destruction and removalefficiencyEstablish design parameters for commercial design
As gas velocities increase, more fluidized solids are carried
upward in the reactor and the boundary between the bed and
freeboard zones becomes less distinct.
A dense phase of coarse solids is created in the lower zone of the reactor followedby a dilute phase of upwardly moving particles in the upper zone. A majority of thesolids exit the reactor with the exhaust gases and are collected and re-circulated viaa cyclone.
HEADqUARTERSTechnip89 avenue de la Grande Armée75773 Paris Cedex 16 France Phone: +33 (0)1 47 78 24 00
CONTACTSTechnip Stone & Webster Process TechnologyBrent SCHIER 1430 Enclave ParkwayHouston, Texas 77077USAPhone: +1 281 848 5234Fax: +1 281 575 6653e-mail: [email protected]
Kevin O’MALLEY / Eric ECCLESTON555 West Arrow HighwayClaremont, California 91711USAPhone: + 909 447 3600Fax: + 909 447 3704e-mail: [email protected]: eeccleston@technip,com
This document is the property of Technip and is not intended to be a binding contractual document. Any information contained herein shall not result in any binding obligation on the part of Technip, orany of its affiliates, and is provided for information purposes only.Technip - Group Communications - February 2016 - Photo credits: Technip.
www.technip.com
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