FIELD RESULTS
Sulfuric acid plants
direct DCS operation.
Software that autonomously optimizes and operates all 25+ DCS set points from inlet elemental sulfur flow rate to SO2 emissions.
Sulfur melting tanks →
Air blower →
Drying tower →
Burner →
Heat utilization →
Converter →
Intermediate absorption →
Cooling water distribution
Final absorption →
from
+3.2%
production increase
Built for acid plants of every kind
The one thing they share: more to give.
Years Built
1960s – 2010s
Design capacity utilization
91 – 102%
Technologies
Double contact double absorption (DCDA), single contact single absorption (SCSA), wet gas processes (WSA)
SO₂ sources:
Sulfur burning, Metallurgical, Acid Regeneration
DCS vendors
Schneider Electric, Honeywell, Yokogawa, Emerson
Production increase in TPD, plant by plant.
Production rate improved without adverse effects on other process parameters, including the NH3 consumption norm.
+62.9
+46.7
+23.7
+16.6
+16.1
+15.4
+14.8
All results are actual plant measurements taken at the acid flow meter on the line to the product tank.
Paths to higher production.
Typical production improvements from AI Software, APC and Capital projects.
PATH
AI process control
Advanced process control
Capital projects
Drying Tower Upgrade
Gas-Gas Heat Exchangers Replacement
Air Blower Retrofit
PRODUCTION INCREASE
3.2 – 4.8%
0.3 – 1.5%
3 – 8%
3 – 5%
4 – 6%
6 – 8%
AVG. ROI, MONTHS
3
9
21 – 32
21
24
32