A sizeable sulfuric acid plant represents the world-leading design and engineeri

MECS® Sulfuric Acid and Environmental Technologies

MECS® Sulfuric Acid and Environmental Technologies

MECS® has provided best-in-class sulfuric acid plant processes, clean technologies, and specialty products to a wide distribution of industries for over 80 years. Our proprietary solutions are engineered to perform and built to last.

MECS® is the global leader in sulfuric acid plant design and technology licensing for the phosphate fertilizer, oil refining, metal smelting, and numerous other industries. Our expert engineers apply the centuries of combined experience MECS® and DuPont have acquired in building over 1000 acid plants worldwide, as well as in producing and safely handling numerous compounds in our own facilities.

MECS® offers solutions for a wide range of markets, including power, ferrous metals, cement, titanium dioxide, coal gasification, and chemical processes, with a special focus on the chlorine and organic chemicals segments. Our world-class gas cleaning products control air emissions. Our custom-engineered heat exchange products recover energy for the chemical process industry. And our unique process technology enhances value for oil refineries.

Engineered to Perform and Built to Last
At the core of our technical expertise are our commitment to quality and our reputation for proven product innovation. Expert MECS® consultants can customize our technical services and proprietary technologies to achieve new performance gains for your organization. We can help you meet and exceed regulatory requirements or solve crucial plant operating bottlenecks. Our solutions can help you increase process reliability and energy efficiency, even as you lower your operating and maintenance costs.

Our experts bring a practical approach to plant evaluations, troubleshooting, and new technology solutions. A high percentage of MECS® personnel — in process, design and solution engineering, as well as project and product management — have previous plant operating, maintenance and start-up experience. Our design engineering group features all the disciplines needed to create world-class process-related technology. To this end, we employ state-of-the-art tools such as 3D CAD and CFD. Backed by nearly 100 years of experience, our expert consultants can work closely with your team to analyze, recommend, engineer and implement a custom solution for your specific needs.

World-Leading Sulfuric Acid Plant Processes
MECS® has a long and successful history in providing proven and reliable solutions to the sulfuric acid industry. Our solutions feature breakthrough technologies, many of which have revolutionized performance, quality and cost-effectiveness for the sulfuric acid industry. We offer complete processes and plant designs for sulfur burning, metallurgy, spent acid recovery, and wet gas sulfuric acid recovery (SULFOX).

DynaWave® Wet Gas Scrubbers
DynaWave® is the only wet gas scrubbing process that can use a variety of reagents and accomplish multiple functions — including SO2 acid gas absorption, quenching, particulate removal, and oxidation — all in one scrubber. A unique, high-performance environmental technology, DynaWave® has been implemented by MECS® in over 300 solutions worldwide, in various industries.

Brink® Mist Eliminators for Air Emissions Control
MECS® offers the industry’s broadest range of products designed to remove virtually any type of mist from any gas stream, including elusive submicron-sized aerosol mists. Thousands of our systems have been installed in hundreds of applications: from sulfuric acid to asphalt manufacturing, plastic extrusions, metalworking, and beyond.

Innovative Heat Exchange Technologies
MECS® gas-to-gas heat exchanger technology offers one of the most efficient means on the market for recovering heat from energy-consuming applications in a wide range of industries. Our flexible and modular fully welded plate heat exchangers (MECS-ThermoZ™)  or non-welded “floating” plate units (OCAP™) have delivered results in fertilizer, refining, non-ferrous metals, general chemicals, and coal gasification installations, as well as many others. For the sulfuric acid industry, we also offer a flexible and modular fully welded plate heat exchanger, MonPlex II™.

ZeCor® Engineered Alloys and Other Specialty Products
We revolutionized the sulfuric acid industry with a full line of corrosion-resistant equipment in our cost-effective ZeCor® family of alloys, exclusively available from MECS®. All of our specialty products, from high-performance alloys to innovative tower packing, join distinctive materials with MECS® process and design expertise, to deliver solutions that keep plants operating safely and smoothly.

High-Performance Catalyst for Sulfuric Acid Plant Applications
The high quality of MECS® catalyst derives from our research and development to balance and optimize the key attributes of activity, pressure drop, hardness, and service life. MECS® has the complete technical expertise, proven catalyst performance, and overall sulfuric acid plant production knowledge to specify the proper type of catalyst to maximize value for your sulfuric acid plant.

Sulfuric Acid Plant Services and Solutions
Whether you’re considering an acid plant expansion, or seek to improve plant reliability or optimize plant operation, our Global Engineered Solutions (GES) professionals are an integral extension of the MECS® sulfuric acid technology teams. GES complements MECS® design and engineering expertise by providing existing sulfuric acid facilities with a comprehensive suite of offerings, including process-critical equipment, ongoing reliability, operability, environmental, and safety services and support.

DUPONT SUSTAINABLE SOLUTIONS (DSS) IS A CATALYST FOR TRANSFORMATION

  • What solutions can our experts customize for your business?

    Extract value with operations excellence

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    Get more from assets, materials and workers

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    Enhance operations and process safety

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    Integrate sustainable planning company-wide

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    Transfer knowledge and transform performance

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    Build skills with award-winning online employee training

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    Reduce employee incident and injury rates

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    Transform your work culture, operations and profits

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    Increase reliability with clean technologies

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    Reduce risks, maximize returns and minimize waste

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    Improve reliability and operability of alkylation technology

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  • Extract value with operations excellence

    Operational excellence can be achieved through an integrated approach that combines both organizational and technical solutions to accelerate results and deliver lasting improvements in your organization. Our experts help you operationalize customized strategies and build capabilities within your organization to sustain improvements going forward. Through our own experience, we understand how to implement these strategies in a way that includes an emphasis on cultural awareness.

    Optimize assets to boost productivity

    Effective asset management can make businesses more productive—and profitable. DuPont helps companies apply discipline and knowledge, to reduce downtime and maintenance costs while improving mechanical integrity and product quality.

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    Brian Rains

    Global Operations Excellence Practice Leader

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    Optimize assets without major capital investment

    Brian and his team work with COOs to meet growth objectives by unlocking value within their operations. They help clients optimize operations performance via a systemic approach to safety, quality, yields, assets, supply chains, energy and people.

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    The Path to Operational Excellence through Operational Discipline

  • Get more from assets, materials and workers

    DuPont Asset Productivity consultants can help your organization optimize any aspect of your operating asset-base. Our integrated management processes and systems are designed to improve the cost productivity of your workforce, infrastructure and investments. Our expert consultants can customize our solutions to help you achieve new efficiency and effectiveness, improving your productivity, revenue, profits and operational excellence.

    Strategically manage energy and cut costs

    Strategic and efficient energy management is key to business sustainability, and can deliver significant value. Our experts can customize the process and operational improvements that have worked for DuPont, as well as our proven cultural change methodologies, to help your organization get quick and lasting results. Our solutions help reduce energy costs, risks and carbon emissions, while strengthening operational excellence, profitability and competitive advantage.

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    Garrett Forsythe

    Global Solutions Architect
    Sustainable Operations

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    Garrett helps clients boost yields and savings

    As one of our operations management experts, Garrett helps clients capitalize on energy and asset efficiencies, shrinking their footprint and costs. He's already helped save millions for oil and gas clients, as well as within DuPont facilities.

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    Can Energy Management Deliver Real Savings?

  • Enhance operations and process safety

    Our Operational Risk Management and Process Safety experts draw on over 40 years of DuPont experience in managing hazards at our own facilities. Our customized solutions can help prevent safety and environmental incidents, to preserve your business continuity, capitalization and right to operate, and – most importantly – to protect precious lives. In addition, our proven processes can boost cost efficiency, productivity and quality.

    Reduce employee incident and injury rates

    As a world safety leader, DuPont experts can help you implement organizational and individual change management processes that transform your safety culture. We help your organization foster a fully-integrated commitment to safety at all levels, with practices that strengthen leadership and reduce costs. Our solutions boost morale, performance and productivity, and most importantly, help send your workers home safely every night.

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    Srinivasan Ramabhadran

    Global Leader
    Process Safety & Risk Management

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    Process safety improves with experts like Srini

    With 8 years in operations management and 17 years in safety consulting, Srini and his team of experts have helped to transform process safety performance and reduce operational risk for an international range of industries and clients.

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    Assessing Industrial Process Performance

  • Integrate sustainable planning company-wide

    Our management experts can implement sustainable strategies within the framework of your business, turning your environmental efforts into broad-based cost and competitive advantages. We catalyze your organization to help you reduce costs, effectively compete, attract investments and strengthen engagement with key stakeholders. Our customized, integrated solutions quickly achieve measurable and lasting results.

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    Davide Vassallo

    Global Practice Leader
    DuPont Sustainable Solutions

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    Davide's team helps make operations sustainable

    Davide's group helps transform our clients' operations with solutions of unsurpassed breadth. We enhance environmental management, asset productivity and energy efficiency, and also offer emissions controls and other Clean Technologies for heavy industry.

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    Maximize the Value of Your Sustainability Strategy

  • Transfer knowledge and transform performance

    Our experts offer a full range of integrated learning technologies and engaging content to help your workforce develop critical skills. From classroom training tools to e-learning solutions to tailored, on-site seminars, our blended learning solutions help you bring your organization closer to its employee-development goals. Our training experts help you assess, build, implement and extend your corporate training programs, as well as evaluate their effectiveness.

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    Rosi Torriani

    Global Solutions Architect

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    Rosi helps leaders learn in innovative ways

    With over nine years of expertise, Rosi designs leadership development programs, implementing innovative customized learning and development solutions and managing multidisciplinary teams.

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    Learning & Development Offering and Processes

  • Build skills with award-winning online employee training

    Our training experts can help your organization develop employee skills while reducing training costs and enhancing productivity. Available in more than 30 languages, our award-winning on-demand DuPont eLearning courseware incorporates advanced online training technologies and highly engaging content. Its flexible and customizable features also make it simple to manage your users, curriculum and training components from start to finish.

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    Sam Ponzo

    Global Practice Leader
    Learning & Development Solutions

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    Learning leaders like Sam improve employee performance

    As Practice Leader, Learning & Development Solutions, Sam helps clients achieve sustained improvements in operational, safety and learning and development performance.

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    Accelerating Skills Development: The DuPont Approach

  • Reduce employee incident and injury rates

    As a world safety leader, DuPont experts can help you implement organizational and individual change management processes that transform your safety culture. We help your organization foster a fully-integrated commitment to safety at all levels, with practices that strengthen leadership and reduce costs. Our solutions boost morale, performance and productivity, and most importantly, help send your workers home safely every night.

    Enhance operations and process safety

    Our Operational Risk Management and Process Safety experts draw on over 40 years of DuPont experience in managing hazards at our own facilities. Our customized solutions can help prevent safety and environmental incidents, to preserve your business continuity, capitalization and right to operate, and – most importantly – to protect precious lives. In addition, our proven processes can boost cost efficiency, productivity and quality.

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    Mieke Jacobs

    Employee Safety Global Practice Leader

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    Mieke and her team help companies protect their people

    Mieke and her team help global clients achieve a fully integrated safety culture that helps motivate employees, improve performance and productivity, reduce costs and send employees home safely every night.

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  • Transform your work culture, operations and profits

    Each of our expert consultants acts as a catalyst for business transformation. We can customize our management best practices to lead your workplace and work culture to become safer, more efficient and more environmentally sustainable. Our solutions facilitate change and enhance leadership and organizational development to deliver world-class workplace safety, footprint reduction, operations and capital effectiveness, and unsurpassed energy efficiency.

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    Simon Herriott

    Global Managing Director
    DuPont Sustainable Solutions

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    Simon guides businesses, and our expert team

    Simon draws on a 25-year tenure in business leadership, strategy and organizational development to direct DSS consulting teams. He helps organizations become safer, more efficient and more environmentally sustainable.

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    The Savings of Safety

  • Increase reliability with clean technologies

    MECS® is the global leader in sulfuric acid plant design and technology licensing for the phosphate fertilizer, oil refining, metal smelting, and numerous other industries. Our expert engineers apply the combined experience MECS® and DuPont gained in building over 1,000 acid plants worldwide. MECS® offers solutions for a wide range of markets, including power, ferrous metals, cement, titanium dioxide, coal gasification, and chemical processes.

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    Steve Puricelli

    Vice President
    MECS

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    Steve helps design improved sulfuric acid plants

    An expert in sulfur recovery technologies, Steve is responsible for commercialization of new technologies and all technical aspects of sulfur management solutions. Technologies include SolvR regenerative scrubbers and DynaWave® wet scrubbers.

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    Regenerative SO2 Capture: Recovering the Future

  • Reduce risks, maximize returns and minimize waste

    Our Sustainable Operations consultants can help you strategize and prioritize initiatives and resources to optimize your operations. By customizing proven sustainability, energy efficiency, asset productivity and capital effectiveness solutions for your operations, we help you reduce risks, maximize returns and minimize waste. Our experts have delivered multimillion-dollar savings for the oil and gas, utilities, mining, chemical and transportation industries.

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    Juan Aguiriano

    President, Asia Pacific
    DuPont Sustainable Solutions

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    Juan helps businesses achieve sustainable operations

    An expert in environmental management, capital effectiveness, and energy efficiency strategies, Juan helps organizations improve return on operations while reducing their environmental footprint.

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    Achieving Sustainable Growth through Productivity Optimization

  • Improve reliability and operability of alkylation technology

    World-leading STRATCO® technology helps refiners safely produce cleaner-burning gasoline. We license sulfuric acid alkylation technology to oil refiners and customize solutions. Our technology experts can work with you to assess and determine the right solution for your refinery. We support you every step of the way, from proposal, technology evaluation, and design through equipment fabrication, startup, and training.

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    Randy Peterson

    Process Technology Manager
    Clean Technologies

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    Randy improves all areas of the alkylation process

    With over 24 years of refinery expertise, Randy specializes in all things alkylation – from startup design and unit revamp, to operator training, to test runs and troubleshooting.

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Featured

CASE STUDIES

  • PotashCorp—Aurora Facility Case Study

    Read the DuPont Sustainable Solutions (DSS) case study on the Aurora Facility to learn about the successful use of a combination of two distinct MECS® high-performance catalysts in a grass roots, large scale, new sulfur-burning acid plant in North America.

  • ZeCor® Alloys Case Studies

    Read the DuPont Sustainable Solutions (DSS)case study on how MECS® ZeCor® materials are intrinsic to CF Industries and JR Simplot plant success.

  • Kiri Dyes & Chemicals Ltd. Case Study

    Read the DuPont Sustainable Solutions (DSS) case study on Kiri Dyes & Chemicals Ltd. to learn more about how their sulfur-burning acid plant achieves low SO2 emissions using MECS® Catalyst in all converter passes.

USES AND APPLICATIONS