CA2206747C - Gas-to-gas heat exchangers for use in sulfuric acid plants - Google Patents

Gas-to-gas heat exchangers for use in sulfuric acid plants Download PDF

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Publication number
CA2206747C
CA2206747C CA 2206747 CA2206747A CA2206747C CA 2206747 C CA2206747 C CA 2206747C CA 2206747 CA2206747 CA 2206747 CA 2206747 A CA2206747 A CA 2206747A CA 2206747 C CA2206747 C CA 2206747C
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shell
gas
aperture
space
communication
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Expired - Lifetime
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CA 2206747
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French (fr)
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CA2206747A1 (en
Inventor
Gordon M. Cameron
Eric William Evanson
Charles Guy Cooper
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Noram Engineering and Constructors Ltd
Original Assignee
Gordon M. Cameron
Eric William Evanson
Charles Guy Cooper
Cecebe Technologies Inc.
Noram Engineering And Constructors Ltd.
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Abstract

A shell and tube gas-to-gas heat exchanger for use in the manufacture of sulfuric acid by the contact process involving heat transfer between dry gases. The heat exchanger comprises (a) a shell having (i) a first shell portion defining a first shell space and a first shell first aperture and second aperture through which a first gas stream operably passes; and (ii) a second shell portion defining a second shell space and a second shell first aperture and second aperture through which a second gas operably passes; (b) a first gas inlet conduit in communication with the first shell first aperture; first gas outlet conduit in communication with the first shell second aperture; second gas inlet conduit in communication with the second shell first aperture; second gas outlet conduit in communication with the second shell second aperture; (c) baffles so located within the first and the second shell spaces as to operably direct flow of the first and the second gases within the shell spaces in radial flow across the tube bundle; (d) a divider plate extending radially across the shell which separates the first shell space from the second shell space; (e) an annular tube bundle comprising a plurality of tubes within the shell extending longitudinally and axially through the first and second shell spaces and the divider plate, and defining a tube-free central core space within the shell and an annular tube-free space between the shell and the annular tube bundle. The dual-purpose, single unit heat exchanger allows improved equalization of heat between gas flows.

Description

GAS-TO-GAS HEAT EXCHANGERS FOR USE IN
SULFURIC ACID PLANTS

FELD OF THE lNVENTION
This invention relates to gas-to-gas heat exchangers for use in sulfuric acid manufacturing plants involving heat exchange between air, sulfur dioxide and sulfur trioxide gases.

BACKGROUND TO THE INVENTION

When cold SO2-co~ il-g gases are treated to remove SO2 in a double absorption system of a contact process for sulfuric acid production, the SO2 process gas must be heated twice to catalyst inlet bed temperatures from lower temperatures These two 20 heating operations are normally carried out using heat removed from between catalyst beds of the catalytic system. The amount of heat available, the distribution of heat between the various bed exit gases, the temperatures to which gases need to be cooled, and the areas of the heat exchangers involved are dependent on gas strength.
When the process gas is dilute, the reaction heat generated by SO2 oxidation is 25 also small and only a small number of catalyst beds are needed, typically, three beds. The heat requirements, often, are such that very large exchangers may be needed to provide a high degree of heat recovery from the hot gases. This may result in possible unwanted condensation. Also, such conditions may occur in excessive areas in at least one of the reheat steps, unless means are provided to share the limited amount of high temperature 30 process heat.
When gas strengths are high, as is normally the case when oxygen is used to generate the SO2 gas stream, for example, as in flash smelting, the number of beds is increased to 4 or 5. This generates a large quantity of high temperature process heat available. SO3 gas temperatures often rise to levels which are excessive for good absorber 35 performance. In this case, there is a need to cool the SO3 gases prior to absorption and cooling is normally carried out using air or acid plant tail gas in an applop.iate number of exchangers, depending on how heat transfer between the various streams is desired.
It is, of course, possible to use extra exchangers to split heat load or cool streams, independently, but such options add significantly to cost and complexity as additional gas 5 ducting, foundation, and instrumentation are needed to service the additional equipment.
Two heat exchangers have been used, for example, to cool the gas leaving a first catalyst bed with one heating the unconverted incoming gas and the second exchanger heating gas returned to the converter from a primary absorption tower. Similarly, SO3 gas en route to an absorbing tower has been passed through both a cold heat exchanger, to effect heating 10 of SO2-cc"~ -g process gas, and an SO3 gas exchanger to heat air or plant tail gas.
However, for simplification of the double absorption process, there remains a need for simpler and less expensive equipment which is able to transfer heat from one gas stream to two separate and distinct streams or to accept heat from two separate gas streams SUMMARY OF THE INVENTION

It is an object of the present invention to provide in a single heat exchanger the means to effect transfer of heat between a single gas stream and two separate streams in 20 which the heat transferred to or from the separate streams can be varied to suit various embodiments of use in the contact process. Thus, the invention provides a dual-purpose, single unit heat exchanger.
It is a further object to provide a single heat exchanger which enables two SO3-gas streams to be suitably cooled prior to SO3 absorption in a double absorption sulfuric acid 25 plant.
It is a yet further object to provide a single heat exchanger to effect pre-heating of two distinct SO2 process gas streams for heating the catalyst mass of catalyst beds in a catalytic converter start-up.
It is a still further object to provide a single heat exchanger which allows high 30 quality heat from a first bed to be equalized between heating incoming gas and gas from a primary absorption tower to allow a better optimization of the heat transfer surface in the overall heat.
Accordingly, in one aspect the invention provides a shell and tube gas-to-gas heat exchanger for use in the manufacture of sulfuric acid by the contact process involving heat transfer between dry gases, said heat exchanger comprising (a) a shell having (i) a first shell portion defining a first shell space and a first shell first aperture and second aperture through which a first gas stream operably passes; and (ii) a second shell portion defining a second shell space and a second shell first aperture and second aperture through which a second gas operably passes;
(b) first gas inlet conduit means in communication with said first shell first aperture;
first gas outlet conduit means in communication with said first shell second aperture;
second gas inlet conduit means in communication with said second shell first 1 5 aperture;
second gas outlet conduit means in communication with said second shell second aperture;
(c) baffle means so located within said first and said second shell spaces as tooperably direct flow of said first and said second gases within said shell spaces in radial flow across said tube bundle;
(d) a divider plate extending radially across said shell which separates said first shell space from said second shell space;
(e) an annular tube bundle comprising a plurality of tubes within said shell extending longit~l(1in~11y and axially through said first and second shell spaces and saiddivider plate, and defining a tube-free central core space within said shell and an annular tube-free space between said shell and said annular tube bundle.
Preferably, the divider plate is located mid-way between the ends of the heat exchanger.
Most preferably, the gas outlets are adjacent one another, either side of the divider plate.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the invention may be better understood, preferred embodiments willnow be described by way of example only, with reference to the accompanying drawings, wherein Fig. 1 represents a diagrammatic vertical cross-section of a heat exchanger according to the invention;
Fig. 2 represents a diagrammatic flow diagram of a double absorption sulfuric acid plant comprising a heat exchanger according to the invention;
10 Fig. 3 represents a diagrammatic flow diagram of an alternative absorption sulfuric acid plant comprising a heat exchanger according to the invention; and wherein the same numerals denote like parts.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
OF THE INVENTION

With reference to Fig. 1, this shows generally as 10, a three-gas shell-in-tube heat exchanger having a shell 12 defining a right-vertical cylinder, having a lower vestibule 14, an upper vestibule 16 and a central space portion shown generally as 18. Central 20 space portion 18 is separated from lower vestibule 14 by vestibule plate 20 and from upper vestibule 22 by vestibule plate 22, respectively. Extending longitudinally and axially of shell 12 between vestibules 14, 16 is an annular tube bundle comprising a plurality of tubes 24, which plurality defines a tube-free central core space 26 and, with shell 12, an annular tube-free space 28.
Midway longitudinally of shell 12 is a radial divider plate 30, which, with an upper portion of shell 12 and vestibule plate 22, defines an upper shell space 32, and with a lower portion of shell 12 and vestibule plate 20 defines a lower shell space 34.
Shell 12 has a tube gas inlet port 36 into vestibule 14 and a tube gas outlet part 38 from vestibule 16, such that in operation tube gas enters vestibule 14 through port 36, 30 passes through tubes 24 into vestibule 16 and out through port 38.

-Shell 12 has a pair of opposing gas ports 40 and 42 in communication with shell space 32 at an upper and lower part thereof, respectively. Shell 12 has a further pair of opposing gas ports 44 and 46 in communication with lower shell space 36 at an upper and lower part thereof, respectively. Ports 42 and 46 are substantially adjacent, one either 5 side of divider plate 30.
Radially disposed within shell spaces 32 and 34 is a plurality of baffle plates 48 so arranged as to operably direct gas flows within shell spaces 32 and 34 radially across tube bundle 24 This embodiment shows a co-current gas-to-gas heat transfer arrangement in 10 conjunction with a counter-current arrangement. .
Fig. 2 represents, generally as 50, apparatus and flow system of one embodiment of part of a sulfuric acid contact process manufacturing plant involving a heat exchanger according to the invention. Fig. 2 shows a conventional 4-bed, catalytic converter 52, intermediate absorption tower 54, final absorption tower 56, heat exchanger of the present invention 58, having upper shell space 58A and lower shell space 58B, associated gas pump 60, conventional heat exchangers 62, 64 and 66 and associated gas conduits. Gas flows are in the direction indicated by the arrows.
The embodiment shown in Fig. 2 provides equalization of the heat evolved in the catalyst beds between (a) cooler, incoming SO2 gas, and (b) partially converted gas returned from intermediate absorption tower 54.
Incoming SO2 gas is pumped through and pre-heated by heat exchangers 62 and 64 along conduit 68 to shell space 58A and, subsequently, conduit 70 to bed 1. Hot, partially converted gas from bed 1 is passed through conduit 72, tubes (not shown) of exchanger 58, in co-current flow to the incoming SO2 gas to bed 1, and conduit 74 to bed 2.
Further converted gas from bed 2 is cooled by exchanger 64, passed through bed 3, then cooled by exchanger 66 and passed through conduit 76 to tower 54. SO3-depleted gas from tower 54 is passed along conduit 78, pre-heated in exchanger 66 in counter-current flow and passed along conduit 80 to exchanger 58B.
From lower shell space 58B, the pre-heated gas is passed through conduit 82, through bed 4, cooler 62 and along conduit 84 to final absorption tower 56.

In this embodiment, with control of the hereinbefore described shell-side gas flows, the heat transfer to each of the two streams can be regulated such that the duty imposed on exchangers 62 and 66 can be optimized to provide substantially similar gas temperatures for the gas flows to absorption towers 54 and 56.
Fig. 3 represents a flowsheet in which two SO3 gas streams as part of the SO3 gas fed to an intermediate tower and final absorption tower are cooled in a single exchanger according to the invention.
Heat exchanger portion 58B heats air provided by pump 90 from conduit 92 and cools SO3 gas from bed 4 through conduit 94, in co-current heat transfer which m~int~in.c 10 a high tube sheet temperature. The cooled SO3 gas stream in conduit 96 mixes with cooled SO3 gas from exchanger 62 out of bed 4. The tubular air stream in exchanger portion 58A cools part of the SO3 gas out of bed 3 entering 58A through conduit 98, in counter-current flow to produce cooled SO3 gas in conduit 100 fed into intermediate absorber 54, mixed with cooled SO3 gas from bed 3 and exchanger 102 through conduit 15 104. Thus, exchanger 58 allows exchange of heat from two distinct process streams in a single unit. Variation of air and SO3 gas flows provides a wide temperature range of coolmg.
The embodiments described, hereinbefore, show a radial flow tubing layout.
However, the co-current/counter-current arrangement is applicable with tubing used in 20 association with single and double segmented baffles.
Although this disclosure has described and illustrated certain preferred embodiments of the invention, it is to be understood that the invention is not restricted to those particular embodiments. Rather, the invention includes all embodiments which are functional or mechanical equivalence of the specific embodiments and features that have 25 been described and illustrated.

Claims (3)

1. A shell and tube gas-to-gas heat exchanger for use in the manufacture of sulfuric acid by the contact process involving heat transfer between dry gases, said heat exchanger comprising (a) a shell having (i) a first shell portion defining a first shell space and a first shell first aperture and second aperture through which a first gas stream operably passes; and (ii) a second shell portion defining a second shell space and a second shell first aperture and second aperture through which a second gas operably passes;
(b) first gas inlet conduit means in communication with said first shell first aperture;
first gas outlet conduit means in communication with said first shell second aperture;
second gas inlet conduit means in communication with said second shell first aperture;
second gas outlet conduit means in communication with said second shell second aperture;
(c) bale means so located within said first and said second shell spaces as to operably direct flow of said first and said second gases within said shell spaces in radial flow across said tube bundle;
(d) a divider plate extending radially across said shell which separates said first shell space from said second shell space;
(e) an annular tube bundle comprising a plurality of tubes within said shell extending longitudinally and axially through said first and second shell spaces and said divider plate, and defining a tube-free central core space within said shell and an annular tube-free space between said shell and said annular tube bundle.
2. A heat exchanger as defined in claim 1 wherein said divider plate is essentially mid-way of said shell.
3. A heat exchanger as defined in claim 1 wherein said first gas outlet aperture and said second gas outlet aperture are adjacent said divider plate.
CA 2206747 1996-09-05 1997-06-02 Gas-to-gas heat exchangers for use in sulfuric acid plants Expired - Lifetime CA2206747C (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US70745096A 1996-09-05 1996-09-05
US08/707,450 1996-09-05

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CA2206747A1 CA2206747A1 (en) 1998-03-05
CA2206747C true CA2206747C (en) 2001-10-16

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Publication number Priority date Publication date Assignee Title
CA2703317A1 (en) * 2010-05-06 2011-11-06 Aker Solutions Canada Inc. Shell and tube heat exchangers

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