MECS® Metallurgical Sulfuric Acid Process
MECS® provides premier technology, engineering and equipment for metallurgical off-gas sulfuric acid plants. Our off-gas metallurgical process generates quality sulfuric acid, using technologies that set the standard for performance, reliability, energy recovery, and emissions reduction.
Our expert engineers leverage over two centuries of combined experience acquired by MECS® and DuPont in building over 1000 acid plants worldwide, as well as in building and operating 10 DuPont sulfuric acid plants. Our experts can design a cutting-edge metallurgical acid plant to recover and regenerate quality sulfuric acid for your organization, while meeting stringent pollution requirements and increasing your efficiency and cost-effectiveness. Our processes and plant designs feature breakthrough MECS® technologies, many of which have revolutionized performance, cost controls, and quality for the sulfuric acid industry.
MECS® Metallurgical Process Description
Off-gas from essentially any continuous or semi-continuous metallurgical process that contains SO2 gas is pulled through the primary MECS® DynaWave® Jet Scrubber, where it is cleaned and cooled to its adiabatic saturation temperature by recirculation of weak acid. Next, the gas is cooled in the high-efficiency MECS® ZeCor® Tower , to a point where the moisture level is reduced to the amount required in the product acid. Depending on the level of impurities in the feed gas, a final DynaWave® Jet Scrubber may be used. The final stage of gas cleaning is a MECS® Wet Electrostatic Precipitator (WESP), which removes both liquid and solid particulate matter, to prevent corrosion and fouling in the acid plant. The gas is then pulled through the high-efficiency ZeCor® Drying Tower, where remaining water vapor is removed. A MECS® Brink® Mist Eliminator provides efficient acid mist removal for the protection of the main compressor. The dry, clean gas is then compressed and introduced to the converter system.
In the contact section of the plant, the gas flows through three passes of MECS® GEAR™ and Cesium Catalyst , as well as their respective cooling equipment, and is then absorbed with 98% sulfuric acid (H2SO4) in the Interpass absorption tower. The lean SO2 gas flows through another Brink® Mist Eliminator to remove fine mist particles, protecting downstream equipment. The clean gas is then reheated and enters the converter to complete the fourth conversion pass of SO2 to SO3 using MECS® Super Cesium Catalyst SCX-2000, to achieve the highest possible conversion. The resulting SO3 is absorbed in 98% H2SO4 in the ZeCor® Final Absorbing Tower. Brink® Mist Eliminators are installed in the final tower to ensure the stack gas will meet acid mist environmental regulations.
A Commitment to Innovation and Quality
Our focus and commitment to technology development are primary drivers for our business. MECS® design and technical service offerings are supported by a team of expert chemical and mechanical engineers, as well as state-of-the-art Research and Development facilities and staff. We are focused on continuing to achieve new performance gains, and to solve crucial plant operations bottlenecks. Our expert engineers can custom-design your sulfur burning acid plant to meet your specific application and environmental requirements. Our innovative solutions deliver consistently superior quality, emissions control, energy recovery, and efficiency, using technologies that typically reduce maintenance and lifecycle costs.
INFORMATION & IDEAS
ZeCor® Alloy Tech Bulletin
Read the DuPont Sustainable Solutions (DSS) ZeCor® technical bulletin to learn more about our ZeCor® Alloy corrosion-resistant and high-performance metal.
Acid Coolers Technical Brochure
Download the MECS® engineered alloy products technical bulletin to get more information on the benefits and uses of our innovative FilmGARD®-5 Anodic Protection System offering.
Zecor® Piping System Information
MECS® ZeCor®-Z piping systems set the leading standard on prevention of leaks. The ultra-low corrosion rate of ZeCor-Z results in reduced maintenance costs. Read the brochure to learn more.
MECS® UniFlo® Technical Bulletin
Read the MECS® UniFlo® acid distributor technical bulletin to learn more about the uses and benefits of our ZeCor®-Z and ZeCor®-310M corrosion-resistant family of alloys in this application.
USES AND APPLICATIONS
MECS® Brink® Packaged Mist Elimination Systems
Discover how our mist elimination systems meet emission regulations in fuming acid, organic, asphalt and metalworking mist and oil smoke applications.
Brink® TowerGARD® Mesh Pads
See how TowerGARD® Mesh Pads from MECS® yield 50% turndown ratios or higher for sulfuric acid plants, significantly boosting corrosion resistance.
DUPONT PRODUCTS & SERVICES
- MECS® Sulfuric Acid and Environmental Technologies
DuPont Operator Training Simulators (OTS)
We combine our technical expertise and owner/operator experience with our world-class safety culture to deliver a high-impact training program for your operators and engineers. By leveraging the power of DuPont’s high-fidelity dynamic process simulators students learn valuable troubleshooting and response skills in a realistic environment that models “cause and effect” relationships across the entire.