A close-up of copper-toned metal shavings represents the MECS Metallurgical Sulf

MECS® Metallurgical Sulfuric Acid Process

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.

DUPONT SUSTAINABLE SOLUTIONS (DSS) IS A CATALYST FOR TRANSFORMATION

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    Increase reliability with clean technologies

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    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.

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  • 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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    Can Energy Management Deliver Real Savings?

  • Enhance operational performance 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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    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.

    Improve contractor safety and turnarounds

    Our Contractor Safety Management experts implement the proven practices developed in DuPont capital projects, turnarounds and supplemental labor projects worldwide. We help business owners and contractor firms reduce contractor-related injuries, labor disruptions and capital losses. We can customize a solution for your organization that helps keep your contracted projects safe, on-time and on-budget.

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    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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    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

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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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  • 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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    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

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    Randy improves all areas of the alkylation process

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DUPONT PRODUCTS & SERVICES

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    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.

DUPONT BRANDS

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INFORMATION & IDEAS

  • Clean Technologies Overview Brochure

    Read the DuPont Sustainable Solutions (DSS) Clean Technologies brochure to learn more about our focused technology-based solutions backed by real-world experience.

  • ZeCor® Alloy Packing Brochure

    Read the product and offering brochure to learn more about the features and benefits of using our ZeCor® Alloy packing support system.

  • DynaWave® Application: Cement Kilns

    To get more information on improving removal efficiency and protection against corrosion in cement kilns, please read the full bulletin on DynaWave® wet gas scrubber applications.

  • DynaWave® Reverse Jet Scrubber

    Read the short brochure to learn more about the application, features and benefits of using our DynaWave® Reverse Jet Scrubbers.

  • 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.

  • 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.

  • Ideas for a Better Cleanup

    Read the full article in Sulphur Magazine for more information on how DynaWave® wet gas scrubbers can help lower operating costs, allow greater flexibility, and lower CO2 emissions.

  • 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.

  • ZeCor® Alloy Brochure

    Download the ZeCor® Alloy technical bulletin to get more information on the benefits and uses of our corrosion-resistant and high-performance metals.

  • MECS® WavePak™ Brochure

    Read the brochure to learn more about how our MECS® WavePak™ ceramic porcelain packing can help your business increase both performance and savings.