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ExtraAcid

ExtrAcid® is the first system that recycles waste sulfuric acid under pressure using innovative patented loop systems producing high concentrated acid and process steam at the same time.

INTRODUCTION

Waste sulfuric acid from various chemical processes has to be recycled by removing water and other impurities from the acid. By dewatering the concentration rides from less than 15% to higher values of typically 98%.

Typical Acid concentration systems (SAC or SAS or dewatering systems) are separated in to lower concentration of up to 70%, medium and high concentration systems.

SYSTEM WORKS FOR ALKALINE, HF OF HCL AS WELL

BENEFITS AT A GLANCE

• Energy recovery by steam production
• Innovative patented 2 loops design
• Flexible inlet concentration
• From 5 to 98%
• Handles impurities
• Small footprint
• Optimized capex and opex

APPLICATIONS FOR ExtrAcid®

• Titanium Dioxide
• Gas drying/purification
• Nitration processes
• Mining
• High purity acids

PATENTED DESIGN

The design of the ExtrAcid® system is patented covering the process including the loops for steam production and the usage of SIC material in the required pressure and temperature ranges.

TURN ACID WATER INTO PROCESS STEAM

Well-known is that recycling by vacuum evaporation of water consumes high energy resources. Although the energy consumption has been optimized in recent years valuable energy cannot be recovered due to low temperature levels.

The innovative ExtrAcid® process system is the first that can significantly reduce the energy consumption by producing valuable process steam.

IMPURITIES

As waste sulfuric acid has many different sources it often contains organic or inorganic impurities other than water which have to be removed. Dependent on the nature of the process typical examples are HF, H₂O₂ or Fe.

It is important to know the kind and amount of the impurities before the design of the ExtrAcid® system. Some organics like H₂O₂ are decomposed into water and O₂ if the temperature is increased sufficiently. Others like HF stay in the vapor phase and can be separated this way. Some need special treatment like purification by crystallization.

ExtrAcid® can offer many solutions to this wide range of challenges. Due to the universal chemical resistance of our main material, it is suitable for HF applications, due to high temperatures it burns many organics into its elements or separates by evaporation.

PURIFICATION BY CRYSTALLISATION

• Organics mostly decomposed at high evaporation temperatures
• Purification by crystallization possible
• Can handle HF applications

ExtrAlkali:

• Revamping capability (2-3 effects to 4-5 effects)
• Payback less than 2 years for revamping
• Combined plants from 30% to 98.5%
• Flaking or Prilling options

Feature	ExtraAcid	ExtrAlkali
Process Type	Sulfuric Acid Concentration/Dewatering	Caustic Soda (NaOH) Concentration
Concentration Range	5% to 98% (Inlet: 5-50%, Outlet: 50-98%)	30% to 98.5% (typically 32% to 99%)
Temperature Range	Up to 450°C	Up to 500°C (evaporators)
Pressure Range	Up to 40 barg	Up to 20 bar (evaporators), vacuum to 10 bar
Energy Recovery	Steam production (up to 10 bar), Energy recovery ratio: 70%	25-35% energy saving in 4-step evaporation, Steam recovery
Design Features	Innovative patented 2 loops design, Pressure operation	Up to 5 effects available, 2-4 stage evaporation
Key Benefits	• Energy recovery by steam production • Flexible inlet concentration • Handles impurities (HF, H₂O₂, Fe) • Small footprint • Optimized capex and opex	• No Nickel pick up • Energy recovery by steam production • Longer life time, less maintenance • Small footprint • Optimized capex and opex
Applications	• Titanium Dioxide • Gas drying/purification • Nitration processes • Mining • High purity acids • Works for Alkaline, HF or HCl as well	• NaOH/KOH up to 99% • H₂SO₄ up to 98% (chlorine drying) • HCl up to 25% • CaCl₂ up to 72% • HF up to 40% • Works for Acid, HF or HCl as well
Material	NoMoCorr® SIC (Silicon Carbide) block heat exchangers	NoMoCorr® SIC (Silicon Carbide), PTFE for lower requirements
Flow Rates	2 up to 200 MTPD SA97 Size of 200 MTPD: 2.4m x 2.7m x 12m height (skid mounted)	Tailor-made concept, modular structure of different sizes
Special Features	• Organics mostly decomposed at high evaporation temperatures • Purification by crystallization possible • Can handle HF applications	• Revamping capability (2-3 effects to 4-5 effects) • Payback less than 2 years for revamping • Combined plants from 30% to 98.5% • Flaking or Prilling options

SIC – THE UNIVERSAL ANTI CORROSION MATERIAL

Our SIC Products are manufactured from pure directly sintered a SIC, the so called SSiC. They do no longer contain free Silicone, which may reduce the chemical resistance. SIC offers a nearly universal chemical resistance, highest thermal conductivity. Extreme surface hardness allows protection against abrasion and results in high flow rates with increased thermal efficiency. Like hardly any other corrosion resistant material, SSiC is excellently suited for extreme high temperature applications.

SIC is used as a material of choice for the following components for high temperatures. Most of them are innovatively designed in detail or generally by Wilk Graphite for the use in severe applications.

• Universal Chemical resistance
• Highest thermal conductivity
• No abrasion
• No contamination
• Extremely hard ceramic
• Low wall thickness
• Low fouling rates
• High velocities
• High thermal shock resistance

• Many designs possible
• High temperature resistance
• Low surface roughness
• No aging / no fatigue

KEY PROPERTIES

• Density > 3 120 kg/m³
• Thermal conductivity: 130 W/(m.K)
• Heat exchanger up to 450 °C and 40 barg
• Separators
• Pipes
• Compensator
• Thermowells
• Columns
• Vickers hardness: 19,2 GPa (500g load) > Tensile Strength: 210 Mpa
• Young's modulus: 420 GPa