GREEN ANODE PLANT - Alcircle.com

ALUMINIUM TECHNOLOGY

GREEN ANODE PLANT

BUSS ChemTech AG (BCT) offers the full scope of complete turnkey Green Anode Plant and existing Green Anode Plant upgrades with associated technology enhancements resulting in production improvements.

Our knowhow is based on over 60 years of experience within the aluminium industry focusing on dedicated anode production processes. We have developed ourselves to become a strong and reliable partner thanks to our many years of experience in innovat-ing the process.

YOUR MAIN ADVANTAGES■■ Low Green Anode Plant OPEX■■ Fully continuous production

As a single source contractor with extensive process experience we provide you with contin-uously improved and fully dedicated proprietary and key equipment.

PROCESS PHILOSOPHYOur compact and modular process concept based on a fully continuous process flow allows flexibility with improved cost efficiency. The re-duced amount of required equipment, the use of proven quality equipment connected with a dedicated process design, leads to remarkable advantages beyond the traditional process standards.

This leads to the following advantages:■■ Compact design, short conveying distances■■ Continuous raw material “just in time” process with considerably reduced material segregation

■■ Fully continuous and well-known BCT Horizontal Paste Line (HPL) for the most homogeneous paste preparation

■■ Unique Anode Forming process with a high production availability with significantly reduced maintenance cost

■■ BCT’s fully customized Plant Controlling System (SCADA)

DRY MATERIAL HANDLINGThis process includes the feed from the raw material storage up to screening and crushing of calcined pet coke as well as recycling of an-ode scrap for classification of different frac-tions. The throughput of the fine milling process is adjustable and continuous. The compact design with short conveying distances with the reduced process steps improves the overall plant availability further. The efficient butt recy-cling and green scrap recycling process com-pletes the dry material handling package.Your main benefits:

■■ Compact just-in-time in process material supply/storage

■■ Less material in process without segregation■■ Fully continuous operation with adjustable throughput regulation

■■ Reduced noise level

ANODE PASTE PREPARATION The paste preparation process consists mainly of coke preheating, mixing/kneading and paste cooling. Our famous and continuously en-hanced proprietary BCT Paste Kneader and BCT Coke Preheater is known as the most ad-vanced solution within the paste preparation

segment. The easily controllable horizontal pro-cess flow with the improved and proven knead-ing process geometry ensures a highly homo-geneous paste preparation for top anode quali-ty. The horizontal paste cooling process with the accurately controlled and efficient hurling and whirling process, rounds up BCT’s well-known Horizontal Paste Line (HPL).

Your main benefits: ■■ Compact design, reduced building size■■ A fully horizontal process flow, no gravity influence

■■ Homogeneous paste preparation with reduced pitch content

■■ High Green Paste density

ANODE FORMING BCT re-introduced the hydraulic anode press as the new application in cooperation with partner (Laeis GmbH) known as a global leader in in-dustrial pressing technology. This new system gap keeps the previously known advantages of a hydraulic anode press compared to a vibro compacting forming technology. Additionally, further improvements closed the gab respec-tively and outperforms the vibro compactor technology on major features.

BCT Green Anode Plant

BUSS ChemTech AG • Hohenrainstrasse 12A • 4133 Pratteln 1 • Switzerland Tel. +41 61 825 64 62 • Fax +41 61 825 67 37 • [email protected]

www.buss-ct.com www.kresta-industries.com

GREEN ANODE PLANTALUMINIUM TECHNOLOGY

AL/010/1-13

YOUR MAIN BENEFITS■■ Low maintenance, high process availability■■ Improved anode density and densification■■ Fewer rejects, high anode dimension accuracy

■■ Low paste pressing temperature, lower emissions

■■ Fast mold change, low noise

SERVICES & RESPONSIBILITIESWe are providing you the full scope of project services to guarantee you a smooth project completion. Our scope of services includes but is not limited to:

■■ Initial feasibility study■■ Basic and Detail Engineering■■ Project Management■■ State of the Art Technology / Process design ■■ Customized Equipment- and Plant supply ■■ Plant installation & Plant commissioning■■ Process and Plant Performance Guarantees ■■ Training of your personnel■■ Ongoing customer service support after project handoff

■■ Plant modernization upgrades & capacity enhancement project

■■ Single source responsibility

BCT is committed to provide you with the best solution for your specific requirements to ensure you have the competitive edge in the market.

BCT Green Anode Plant

FLUORINE TECHNOLOGY

ANHYDROUS HYDROFLUORIC ACIDFROM FLUOROSILICIC ACID

Buss ChemTech is recognized as the world leading technology supplier for fluorine chemicals. We are able to of-fer our clients guaranteed operating plants:

Our process technology for fluorine chemi-cals is the result of over fifty years of con-tinuous development linked to direct ex-perience of the design and construction of industrial scale plants.

THIS RESULTS IN■■ Plant capacities and product specifications tailored to your requirements

■■ Critical equipment manufactured to strictly controlled specifications

■■ Prolonged plant life and high productivity

RANGE OF SERVICES■■ Conceptual design■■ Feasibility studies and plant assessments■■ Basic and detail engineering ■■ Process automation■■ Materials or total plant supply■■ Project management,■■ Commissioning and start-up■■ After sales service

AHF PLANTHydrofluoric acid is an important intermediate for inorganic and organic fluorine compounds, such as aluminium fluoride, cryolite, uranium hexafluoride, fluorocarbons and fluoropoly-mers.

The key process technology is the production of anhydrous hydrofluoric acid from readily availa-ble feed stocks such as fluorosilicic acid. Con-centrated fluosilicic acid is decomposed in the presence of sulphuric acid according to the following reaction:

H2SiF6+SiF4(aq)+H2SO4 →2SiF4(g)+2HF(g)+H2SO4(aq)

Capacity 10,000 MTPY; Fujian Wengfu Lantian, Hubei, PRC

H2SO4Absorption

SiF4Generation HF Generation

Vent Scrubbing

HF Purification

HF Stripping

SiO2Generation

Concentrated H2SO4

AHF

Off-Gas

SiO2 Dilute H2SO4

DiluteH2SiF6

Processwater

SiF4 Gas

SiO2 Filtration

The reaction produces silicon tetrafluoride gas and hydrogen fluoride. The latter remaining mainly absorbed in the sulphuric acid.

This acid is distilled to produce hydrofluoric acid.

The by-product sulphuric acid is dilute at a con-centration of 70% to 75%. This acid is pumped back to the phosphoric acid plant to be fed to the reaction system.

Silicon tetrafluoride gas is cleaned in absorption columns to remove hydrogen fluoride and flows forward to the silicon tetrafluoride concentra-tion system where it is absorbed in fluorosilicic acid.

SiF4 gas is absorbed and reacts according to the following overall exothermic reaction:

5SiF4+2H2O →2H2SiF6+2SiF4+SiO2 (Hydrate)

A by-product of this system is silica.

Vent gas from the silicon tetrafluoride concen-tration system is cleaned of hydrogen fluoride and flows to the Central Absorption System before emission to the atmosphere.


www.buss-ct.com www.kresta-industries.comFL/010/1-13

FLUORINE TECHNOLOGY ANHYDROUS HYDROFLUORIC ACID FROM FLUOROSILICIC ACID

KEY FEATURES■■ High profitability■■ Zero cost raw materials■■ Minimum hold-up AHF in the plant■■ High quality anhydrous hydrofluoric acid■■ Reliability in operation■■ Environmental and high safety record

AHF SAFETY STORAGE

AHF is stored at a low temperature in a double containment system with pressure control and safety instrumentation.

The main storage system consists of three AHF Storage Tanks within the AHF Storage Contain-ment Tank. The stored acid can be re-circulat-ed by the AHF Circulating Pump, through the AHF Circulating Cooler, and cooled down to below -5 °C.

HF Storage, Sao Paulo Brazil

AHF Plant; Capacity 20,000 MTPY; Wengfu Group, PRC

Utilities for AHF Plant(per metric ton of aluminium fluoride)Steam 11 bar 5,500 kgSteam 6 bar 430 kgProcess water 5 m3

Cooling water circulation 357 m3

Electric power 235 kWhChilled water 3.2 x 106 KJ

EXPECTED PRODUCT SPECIFICATION(per metric ton of aluminium fluoride)HF 99.985 % wt. minH2SO4 0.004 % wt. maxH2O 0.008 % wt. maxH2SiF6 0.001 % wt. maxSO2 0.001 % wt. maxP2O5 0.001 % wt. max

Raw Materials(per metric ton of aluminium fluoride)Fluorosilicic Acid(FSA calculated as 100 % H2SiF6)

1,600 kg

Sulphuric acid(calculated as 100% H2SO4)

30,000 kg

Potassium Hydroxide 14 kg

The gas inside the outer containment is contin-uously dried in the AHF Containment Air Dryer. The HF content in the containment is monitored online.

The vent gas flows to the Central Absorption.

EXPECTED CONSUMPTION FIGURES

FLUORINE TECHNOLOGY

ANHYDROUS HYDROFLUORIC ACID FROM FLUORSPAR

Buss ChemTech is recognized as the world leading technology supplier for fluorine chemicals.

We are able to offer our clients guaranteed operating plants:

Our process technology for fluorine chemicals is the result of over fifty years of continuous development linked to direct experience of the design and construction of industrial scale plants.

The key process technology is the production of anhydrous hydrofluoric acid from readily availa-ble feed stocks such as fluorspar. Hydrofluoric acid is an important intermediate for inorganic and organic fluorine compounds, such as alu-minium fluoride, cryolite, uranium hexafluoride, fluorocarbons and fluoropolymers.

THIS RESULTS IN■■ Plant capacities and product specifications tailored to your requirements

■■ Critical equipment like the Prereactor manu-factured to strictly controlled specifications


RANGE OF SERVICES■■ Fluorspar reactivity tests■■ Conceptual design■■ Feasibility studies and plant assessments■■ Basic and detail engineering ■■ Process automation■■ Materials or total plant supply■■ Project management■■ Commissioning and start-up■■ After sales service

FLUORSPAR DRYING PLANTFluorspar is delivered to the plant complex with a residual humidity of up to 10% wt. The residual humidity after drying does not exceed 0.1% wt.

The drying is carried out in a flash dryer. The fluorspar is then transported by conveyors to the Fluorspar Silo.

AHF PLANTGaseous hydrofluoric acid is produced by the reaction of sulphuric acid with dry fluorspar in the Prereactor and this reaction is completed in an indirectly heated rotary kiln.

The reaction can be represented by the follow-ing equation:

CaF2 + H2SO4 →CaSO4 + 2 HF

This reaction is endothermic, and so it requires a continuous input of heat for its completion. Dry fluorspar flows from a storage silo through

a feed scale to the Prereactor. Liquid reagents, oleum and sulphuric acid, are pumped from stock tanks through preheaters to the reaction section.

Gaseous crude hydrofluoric acid flows to a se-ries of gas cleaning equipment, condensation and distillation to purify the HF to anhydrous hydrofluoric acid.

Hot solid calcium sulphate residues are re-moved and neutralised at the opposite end of the HF Reactor. Anhydrite is sold to the building industry for use as floor levelling material, building blocks and as retarder in the cement industry.

Tail gases leave the plant after final cleaning in the Central Absorption Section before emission to atmosphere.

KEY FEATURES■■ High quality anhydrous hydrofluoric acid■■ Reliability in operation■■ Environment and high safety record■■ Use of fluorspar containing high impurity levels

■■ Sale of anhydrite as building raw material

AHF Plant; Capacity 30,000 MTPY; Mexichem, UK

AHF Plant; Prereactor Capacity 53,000 MTPY; Gulf Fluor, Abu Dhabi



FLUORINE TECHNOLOGY

FL/020/1-13

ANHYDROUS HYDROFLUORIC ACID FROM FLUORSPAR



AHF SAFETY STORAGEAHF is stored at a low temperature in a double containment system with pressure control and safety instrumentation.

The main storage system consists of three AHF Storage Tanks within the AHF Storage Contain-ment Tank. The stored acid can be re-circulat-ed by the AHF Circulating Pump, through the AHF Circulating Cooler, and cooled down to below -5 °C.Utilities for AHF Plant

(per metric ton of anhydrous hydrofluoric acid)Steam 12 bar (abs) 160 kgSteam 6 bar (abs) 360 kgProcess water 0.7 m3

Cooling water circulation 30 m3

Electric power 220 kWhChilled water 2.5 x 106 KJFuel 6.8 x 106 KJ

EXPECTED PRODUCT SPECIFICATION(per metric ton of anhydrous hydrofluoric acid)HF 99.985 % wt. minH2SO4- 0.004 % wt. maxH2O 0.008 % wt. maxH2SiF6 0.001 % wt. maxSO2 0.001 % wt. maxP2O5 0,001 % wt. max

Raw Materials(per metric ton of anhydrous hydrofluoric acid)Fluorspar(calculated as 97 % CaF2)

2,165 kg

Sulphuric acid / oleum(calculated as 100% H2SO4)

2,600 kg

Calcium hydroxide 40 kg

Hydrofluoric Acid from Fluorspar Page 1/2 Buss ChemTech AG

Hydrogen Fluoride (HF)

reaction

HF Purification / Liquefaction

Vent Scrubbing

Oleum (SO3)

Off-Gas

AHF

Process water

Fluorspar (CaF2)

Anhydrous HF (AHF) Storage

SiF4 gas

Central Absorption

Waste Water Neutralization

Waste Water

Anhydrite

CaO/Ca(OH)2

CaF2 + H2SO4 + Heat --> 2HF + CaSO4

Sulphuric Acid (H2SO4)

Filter cake

The gas inside the outer containment is contin-uously dried in the AHF Containment Air Dryer. The HF content in the containment is monitored online.

The vent gas flows to the Central Absorption.

FLUORINE TECHNOLOGY

HIGH BULK DENSITY ALUMINIUM FLUORIDE FROM HYDROFLUORIC ACID FROM FLUORSPAR

Buss ChemTech is recognized as the world leading technology supplier for fluorine chemicals.

We are able to offer our clients guaranteed operating plants:

Aluminum fluoride is used by aluminum pro-ducers to lower the melting point of electrolytes in the smelting process and increase produc-tion efficiency.Our process technology for fluorine chemicals is the result of over fifty years of continuous development linked to direct experience of the design and construction of industrial scale plants.

THIS RESULTS IN■■ Plant capacities and products specifications tailored to your requirements

■■ Critical equipment like the AlF3 Reactor manufactured to strictly controlled specifica-tions


RANGE OF SERVICES■■ Fluorspar reactivity tests■■ Conceptual design■■ Feasibility studies and plant assessments■■ Basic and detail engineering ■■ Process automation■■ Materials or total plant supply■■ Project management,■■ Commissioning and start-up■■ After sales service

FLUORSPAR AND ALUMINIUM HYDROXIDE DRYING PLANTSFluorspar and aluminium hydroxide are deliv-ered to the plant complex as a wet cake. Drying is carried out in flash dryers before transport to the respective user.

AHF PLANTHydrogen fluoride is produced by the reaction of sulphuric acid with fluorspar in the Prereactor and this reaction is completed in an indirectly heated rotary kiln.

The reaction can be represented by the follow-ing equation:

CaF2+H2SO4 ➝CaSO4+2HF

Dry fluorspar, oleum and sulphuric acid flow to the Prereactor where the reaction begins and is completed in a rotary kiln.

Hydrogen fluoride flows through gas cleaning equipment, is condensed and distilled to pro-duce anhydrous hydrofluoric acid.

Solid calcium sulphate residues are removed from the HF Reactor, neutralised and is sold to the building industry for use as floor levelling material, building blocks and as retarder in the cement industry.

Tail gases flow to the Central Absorption Sec-tion before emission to atmosphere.

AHF SAFETY STORAGEThe storage system consists of AHF Storage Tanks within the AHF Storage Containment Tank at a low temperature and atmospheric pressure.

AHF Plant; Capacity 53,000 MTPY; Gulf Fluor, Abu Dhabi




FLUORINE TECHNOLOGY

FL/040/1-13

HIGH BULK DENSITY ALUMINIUM FLUORIDE FROM HYDROFLUORIC ACID FROM FLUORSPAR

ALF3 PLANTAluminium fluoride is produced by reacting dried aluminium hydroxide with the hydrofluoric acid gas in a fluidized bed reactor. The reaction can be summarized as follows:

Al(OH)3 + 3 HF →AlF3 + 3 H2O

Al(OH)3 is conveyed to the Al(OH)3 Silo from where it is fed into the AlF3 Reactor.

AHF is evaporated and superheated and fed to the lower bed of the reactor.

Aluminium fluoride is fed from the lower bed of the reactor through a product cooler to storage.

Fine solids transported out of the AlF3 Reactor with the gas stream are recovered in cyclones and solids from them flow to the product stream.

Tail gases from the process flow to the Central Absorption Section.

Aluminium fluoride product is fed to bulk trans-port tankers or bag filling plant.

Utilities for AHF/AIF3 Plant (per metric ton of aluminium fluoride)Steam 12 bar (abs) 200 kg Process water 3 m3

Cooling Water Circulation 110 m3

Electric power 165 kWhChilled water 1.8 x 106 KJFuel 4.9 x 106 KJ

EXPECTED PRODUCT SPECIFICATION (per metric ton of aluminium fluoride)AIF3 90 % wt. minSO4 0.004 % wt. maxSiO2 0.025 % wt. maxP2O5 0.005 % wt. maxFe2O3 0.020 % wt. maxNa2O 0.050 % wt. max

CaO/Ca(OH)2

Process water

Off-Gas Dust Filtration

CaF2 + H2S04 + Heat => 2HF + CaSO4

Off-Gas Dust

Filtration

Off-Gas

Anhydrite

Off-Gas Dust Filtration

Waste Water

Aluminium Fluoride product

CaF2 for disposal

AHF product

AI(OH)3 + 3 HF => AIF3 + 3 H2O

Fluorspar (CaF2)

Off-Gas Dust

Filtration

Aluminium Hydroxide (AI(OH)3)

Sulphuric Acid (H2S04)

Oleum (S03)

Hydrogen Fluoride (HF) Prereaction,

Reaction

Anhydrite (CaS04)

Neutralization, Transport and

Storage

Aluminium Fluoride

(AIF3) Reaction

HF Purification / Liquefaction

Anhydrous HF (AHF) Storage

Vent Scrubbing

Central Absorption

Waste Water Neutralization

Transport Storage

Condensation & Scrubbing

AHF Evaporation

Storage, Drying,

Transport

Storage, Drying,

Transport

KEY FEATURES■■ High quality aluminium fluoride■■ Reliability in operation■■ Environment and high safety record■■ Use of fluorspar containing high impurity levels

■■ Sale of anhydrite as building raw material

■■ white free-flowing solid■■ Bulk Density 1500 kg/m3

■■ Flowability Index <60 seconds for 1 kg■■ L.O.I (one hour at 550°C) 0.5% wt max.■■ Granular size < 45 µm 10% max.■■ Granular size > 150 µm 3% max.


Raw Materials (per metric ton of aluminium fluoride)Fluorspar 1540 kgSulphuric acid / oleum (calculated as 100% H2SO4)

1850 kg

Aluminium hydroxide(calculated as 100% wt Al(OH)3

1030 kg

Calcium hydroxide 30 kg

AlF3 Plant; Capacity 60,000 MTPY Gulf Fluor, Abu Dhabi

REACTION TECHNOLOGY

DYNAMIC PHOSGENE GENERATION

Dynamic phosgene generation: the safe way to production.

Phosgene is a very versatile raw material commonly used in the production of phar-maceuticals and other organic compounds. Reactions using phosgene produce high purity products with high yields. However, phosgene’s reactivity and toxicity make it a particular hazard and as such, regulatory authorities impose stringent safeguards on its storage, transportation and use. Alterna-tive reagents, like thionylchloride or phos-phorylchloride, however, pose even greater risks.

Buss ChemTech AG (BCT) has developed a unique system for the dynamic production of phosgene that avoids the liquefaction or stor-age of phosgene and incorporates features that safeguard the health and well-being of person-nel and the environment.

DYNAMIC PHOSGENE GENERATORS BCT offers phosgene generators with capaci-ties up to 13,000 kg/h (28’600 lbs/h) using CO and Cl2 as the starting materials. Their flexible operation allow for an operating range of 10 to 100 % of nameplate capacity. For batch applications, the units can be put in “idle” after the reaction cycle comes to an end. Restarting the unit is simple and it only requires a few minutes to again produce high quality phos-gene. Furthermore, the plant can serve multi-ple consumers.

The highly flexible design is just one of the many outstanding attributes of BCT’s phosgene production technology. And for clients who do not own the safety absorption equipment that satisfy the regulations of the local authorities, Buss ChemTech can offer an absorption unit together with the generator.

SAFETYHigh safety is understandably of paramount importance. Therefore, zero compromise is made. Additional reliability plays an im-portant role in BCT’s intrinsically safe(r) ap-proach■■ No storage of liquefied phosgene■■ Low pressure operation with very small gaseous phosgene hold up

■■ Double containment with continuous air purging

■■ Double jacketed piping with continuous air purging

■■ Phosgene detectors in the purge gas stream■■ Independent ISD logic■■ Continuous monitoring of off gas ■■ All relevant welds 100 % x-ray inspected ■■ Heat transfer fluid recirculation and indirect water cooling

■■ Fully compliant to regulatory requirements

RELIABLE PERFORMANCE■■ Microprocessor auto feedback control with on-demand phosgene generation

■■ Automatic control between 10 and 100 % of rated output

■■ In-line product analysis for quality assurance■■ Total validation of design and construction for quality assurance

■■ Auto-control of start-up and shut-down■■ Robust and reliable design with minimal maintenance requirements

■■ Low CO excess (max. 2 vol-%) leading to potential savings

■■ More than 20 years experience in building phosgene generators

■■ Extensive know-how of phosgene catalysts■■ Superb phosgene product quality■■ <50 wt-ppm residual Cl2■■ 20 to 80 wt-ppm CCl4 (depending on catalyst used)


www.buss-ct.com www.kresta-industries.comRT/010/1-13

Reaction Technology Dynamic Phosgene Generation

Purge air

CO

CL2

Off-gas

Product

absorption Vent system

Safetyabsorption to atmosphere

NaOH recovery

Raw materialGenerator Phosgenation

SAFE PHOSGENE GENERATION AND PHOSGENATION

PHOSGENATIONBuilt on 25 years of experience delivering tech-nology and equipment for the safe and econom-ical production of phosgene, Buss ChemTech can also provide the technology for your down-stream phosgenation reaction:The Buss Loop® Reactor sets new standards for safe and efficient production of phosgene derivatives. It delivers the highest possible mass transfer and thus minimises the need for excess phosgene, which is a benefit to the safety

and economy of the process. It is designed to deal with the extreme hydraulic and thermal characteristics of the phosgenation process to achieve high yields with excellent selectivity. This often eliminates otherwise required down-stream purification facilities.

Ideally, the phosgenation plant is connected via double jacketed pipe from the phosgene gener-ator, so that safety and reliability is also extended

to the phosgenation step. As an example of our commitment to both, our design includes fully automatic control of the plant with hard-wired emergency shutdown systems. Also, the phos-genation facility is placed within a safety con-tainment shell which is purged with air and continuously monitored against leakage.

The purged air is sent to the safety absorption for neutralisation prior to being released into the atmosphere. The off gas from the plant is sent to process absorption for destruction prior to the incineration of non-destructible compo-nents. Minimising phosgene hold-up by maxim-ising reaction rate and plant performance is the mission of our design engineers.

Using our own test centre, we can optimise or develop phosgenation processes for and with our clients.

Our long-term experience with handling highly toxic and hazardous materials, our extensive scale-up know-how and proven safety philoso-phy results in an intrinsically safe industrial plant design which includes full process and performance guarantees.

Phosgene Generator, 2 x 12’500 kg/h units (on-site erected) Safety Absorption Section

REACTION TECHNOLOGY

ALKOXYLATION

Buss ChemTech is the worldwide leading supplier of alkoxylation technology.

Our technology is especially known for its:■■ operational safety■■ performance reliability■■ excellent product quality

Our experience with unique speciality prod-ucts, combined with our comprehensive R&D services (including in-house lab and pilot-plant facilities), enable Buss ChemTech to provide our clients with optimised pro-cess designs resulting in cost-effective and high performance solutions.

Naturally, our ethoxylation and propoxylation technology is based on the proven performance characteristics of the Buss Loop® Reactor, which achieves the highest efficiency in this, as well as other gas/liquid reactions, as compared to other alternatives. In the case of alkoxyla-tions, however, we have focused even more on the most important design aspect which does not allow compromise: safety!

SAFETYEthylene oxide (EO) is an extremely flammable liquid. It can also form explosive mixtures when it comes into contact with air. Unfortunately, the dangers of EO are often not recognized until after an accident actually takes place. And de-spite the occurance of many serious incidents, there are still stirred-tank and spray-head tech-nologies on the market which do not adequate-ly address the dangers. At Buss ChemTech, we insist on and incorporate the following minimum safety requirements in our process design:

■■ No explosive gas phase!When an ignitable gas phase is present, the potential for an explosion exists. We do not gamble. We add a nitrogen (N2) blanket and tightly control the pressure of the N2/EO mix-ture ensuring an inert (non-ignitable) atmos-phere at all times.

■■ No liquid droplets in the gas phase!“Flying” liquid droplets are to be avoided be-cause they can cause an electrostatic build-up and deflagration.

■■ Shock resistant design!To protect personnel as well as the environ-ment, our standard plant design pressure is 45 barg. In the very unlikely worst-case scenar-io, this means “shock resistance” (no release of product or chemicals, no danger for the envi-ronment, not even damage of equipment).

ALKOXYLATION PROCESSThe alkoxylation process consists of three ma-jor steps:

■■ Pre-treatment: The initiator and catalyst are metered and de-hydrated under vacuum according to the prod-uct recipe.

■■ Reaction:The EO and/or PO feed begins and is controlled by monitoring reactor conditions to ensure a safe and fast reaction. When the reaction is completed, residual oxide is cooked down to 1 ppm and 100 ppm for EO and PO, respectively.

■■ Post-treatmentThe product is neutralized and, if necessary, blended, bleached and stripped.

All three steps can be performed in one reactor (a “one-pot system”). But the most economical design in terms of room-time-yield is the “three-pot system”, where each step is per-formed in a dedicated section (see illustration).

Each of these sections is operated in batch mode and all sections can operate inde-pendently so three batches can be processed in the plant simultaneously.



Reaction Technology Alkoxylation

PRODUCTIVITY/ECONOMY■■ Very high EO dosing rates (adjusted for eco-nomic reasons to around 750 kg/h/m3)

■■ Elegant process control algorithms result in stable reaction conditions

■■ Very short cook-down times■■ High throughput■■ Constant efficiency from beginning (low reac-tor liquid level) to the end of reaction (full re-actor)

■■ Low energy consumption (much lower dis-charge head in comparison to spray head technology)

PRODUCT PORTFOLIOExtensive production technologies are available for derivatives of fatty alcohols, -acids, -amines and -esters, including alkyl phenols, castor oil, sorbitan esters, methanol, allyl alcohol, butanol, MEG, BPA, glycerine and other polyols.

The design of the Buss Loop® Reactor allows the handling of low boiling or high melting starters as well as the production of high viscous pro-ducts like high molecuar weight PEG and mPEG.

PRODUCT QUALITY (whithout stripping)Residual EO < 1 ppm

for most productsDioxane < 4 ppm

for most alcohol and alkyl phenol derivatives

Colour < 20 APHA for alcohol and alkyl phenol derivatives

PRODUCT QUALITY Raw material handling under inert conditions, effective temperature control and accurate EO dosing lead to optimized reaction conditions with a minimum of side product formation (dioxane, coloured impurities).

By recirculating the gas in the head space dur-ing cook down, extremely low concentrations of residual EO in the gas and liquid phase can be achieved within a very short period.

HIGH GROWTH RATIO DESIGN(growth ratio = end volume : minimum starting volume)

For the production of high molecular weight products, our design incorporates a small loop. This allows us to achieve growth ratios of up to 85:1 without the need for a second reactor, intermediate storage or a loss of efficiency.

REACTION TECHNOLOGY

PROCESS DEVELOPMENT

Successful chemical process develop-ment is based on a foundation of trust:

Trust in the technology partner’s competence and trust in his confidential handling of the client’s IP. This foundation is a key factor for successful cooperation. Buss ChemTech’s clients can rest assured that their gas/liquid reaction chemistry will remain their own and that it will run under optimized conditions. We have several approaches depending on our level of know-how with a particular pro-cess and the information the client brings to the project:

Proven processWhether the plan is to replace an old reactor with the latest technology or to install an addi-tional reactor to increase capacity, we will veri-fy the suitability of the Buss Loop® Reactor for the process based on the client’s process data and will provide an estimate of the expected performance increase that could be achieved.

Tune up your (lab) processUsing process parameters developed by the client’s own efforts, most often using STR’s, Buss ChemTech can adapt the process to a Buss Loop® Reactor. Usually, a preliminary pro-cess design can be developed from the lab-scale results. If necessary, additional testing in the pilot-scale will be performed to commercial-ize the process and define guaranteed perfor-mance parameters.

Development projectsBuss ChemTech can also put its full set of ca-pabilities to work for clients with no develop-ment capacity: starting with literature and pat-ent searches, catalyst screening and lab tests. With the lab data in hand, we can design a preliminary process and proceed to testing in one of our pilot plants to confirm and optimize the necessary process parameters to design a commercial plant with process guarantees.

KEYS TO SUCCESSThe performance of an industrial plant depends on how well the process design is optimized. To aid in the development of optimized commercial processes, Buss ChemTech operates three pilot plants and a number of laboratory reactors.

All warranties for process and performance offered by Buss ChemTech are based on actual data developed in our technology center (and backed up by industrial scale performance).

THE SHORTEST PATH FROM THE LAB TO FULL-SCALE PRODUCTIONFor a proven process, five days are usually sufficient to optimize the process parameters in one of our pilot plants. Using the results from the pilot-scale, Buss ChemTech defines exten-sive process guarantees, such as yield, selec-tivity and catalyst consumption, depending on its scope of supply. This work forms the basis of our quotations and the design of the industrial plant.

Development programs to tune up your (Lab)process usually needs two to three weeks to get useful result depending on the starting point of the cooperation.

Longer-term development projects usually start from a vision and can show early success as two completely different knowledge pools are collaborating. Early success is no guaran-tee, however, that an economically successful industrial plant will be the result. Buss ChemTech will propose a phased approach which will allow the client to minimize further

costs if it becomes apparent that the project will not be ultimately successful. And depending on the client’s need and wishes, Buss ChemTech can enter the development process at whichever stage is appropriate.

SCALE-UPRegardless of scale, a Buss Loop® Reactor unit is characterized by:■■ Uniform mixing (minimizing temperature, concentration and pH gradients)

■■ Smallest gas bubble size (average size in µm-range) and thorough distribution and hence highest mass transfer

■■ Independent and virtually unlimited heat transfer capacity

These characteristics allow scale-up without changes in mixing pattern and area-to-volume ratios.

A linear scaling of temperature and concentra-tion gradients ensures optimum reaction kinet-ics for scale-up ratios of up to 1:4000.

Realization of industrial plant with comprehensive performance data

Client’s requirement

Literature, database and patent research by BCT

endClient’s decisionfor go / no go

Laboratory trialreport and proposal


Pilot testreport incl. performance data quotation for industrial plant




Reaction Technology Process Development

RT/030/1-13

DEVELOPMENT EQUIPMENT■■ Batch and continuous laboratory reactors up to 200 barg

■■ 15 liter pilot plant in Hastelloy® (50 barg, 200ºC)

■■ 15 liter pilot plant in glass for highly corrosive media (1 barg, from -20º up to 150ºC)

■■ 50 liter pilot plant in SS316 (100 barg, 280ºC)

■■ Batch and continuous filtration systems■■ Thin film evaporator

CONTINUOUS SAMPLING AND ANALYTICS■■ Online monitoring by FTIR (Fourier Transform Infrared)

■■ Large numbers of analytical tools like GC, HPLC, IR, UV/Vis

■■ For specific needs such as rectification, crys-tallization and the like, BCT can offer exten-sive know-how in collaboration with our highly experienced partners

■■ Special analytics (NMR, MS,IC) provided by our network partners

BUSS CHEMTECH – FOR A SMART INVESTMENT■■ Fast and efficient process development■■ Excellently equipped laboratories, highly ex-perienced and qualified staff

■■ Ability to demonstrate almost any multiphase reaction

■■ Full process and performance guarantees■■ Scale-up factors of up to 4000 realized■■ Reliable and reproducible process data and consumption figures guarantee the success of the investment decision

Some examples of successful applications

Hydrogenation of an aromatic nitro compoundxx

Reaction TimePercent

360 min

100 min

STR: 150 °C, 40 bargBLR: 150 °C, 40 barg

0.1 wt%

0.01 wt%Catalyst load

0 100 200 300 4000.1 0.05 0

Hydrodehydroxylation


375 min

300 min


20 wt%

10 wt%Catalyst load

0 100 200 300 400100 80 60 40 20 0

98.2 %

96.7 %Conversion

77.4 %

83.1 %Selectivity

Oxidation


600 min

42 min

STR: 60 °C, 3.4 barBLR: 60 °C, 3.4 bar

0 200 400 6001 0.5 0

0.6 wt%


Hydrogenation of an aldehyde


360 min

100 min


6 wt%


0 100 200 300 400100 80 60 40 20 0

6 5 4 3 2 1 0

90 %

95 %Yield

Hydrogenation of an aromatic nitro compound

Hydrodehydroxylation Hydrogenation of an aldehyde

Oxidation

STR: Stirred Tank Reactor BLR: Buss Loop® Reactor

REACTION TECHNOLOGY

CATALYTIC GAS / LIQUID REACTIONS

Buss ChemTech AG is recognized as the world leading technology supplier for gas/liquid reactions.

For many gas/liquid reactions, the main challenge is overcoming mass transfer lim-itations. The Buss Loop® Reactor is the tool of choice to achieve a high gas/liquid sur-face area by vigorous and effective disper-sion of the gas into the liquid phase.

This results in one or more of the following process characteristics:■■ significantly shorter reaction time ■■ higher yield and selectivity■■ reduced catalyst consumption

We are a solution provider. Based on our proven technologies, Buss ChemTech delivers high level process design packages for your chemical plant and the necessary proprietary equipment. Together with our partner companies in the KRESTA group, we can provide you with ex-panded scope of supply and services, up to and including a turnkey plant.

OPERATING PRINCIPLES OF BUSS LOOP® REACTOR TECHNOLOGYThe Buss Loop® Reactor consists of the Reaction Mixer (gas-liquid ejector), a Reaction Vessel, a Reaction Pump and a heat exchanger. As the entire gas-liquid mass (including catalyst) is circulated through the loop, the entire volume is considered the working (reaction) volume and the whole system acts as a reactor.

■■ The Reaction Mixer is a high performance gassing tool and generates very small gas bubbles (µm range) producing very high mass transfer rates. The two-phase mixture created in the reaction mixer is then injected into the fluid of the autoclave.

■■ The autoclave of a Buss Loop ® Reactor has a simple geometry (no baffles or internal heat exchange surface so it is easy to empty and easy to clean). The two-phase mixture that “jets” into the reaction autoclave causes intensive secondary mixing, maintaining the

small bubbles created in the reaction mixer and provides additional high mass transfer reaction volume.

■■ The independent heat exchanger can be built as large as required and is not limited by the reactor’s working volume.

■■ The circulation pump produces high power input per unit volume (kW/m³). The special pump design allows pumping of liquids with high solid (catalyst) contents and high gas loads (up to 30 vol %) without cavitation.

AVAILABLE TECHNOLOGIESBuss ChemTech has developed complete pro-cesses in the areas of ethoxylation, hydrogena-tion (sugar alcohols, resin/rosin, nitroaromatic compounds) as well as for a broad range of oleochemicals (amines, nitriles, amides, chlo-rides, etc.).

OTHER EXPERTISEOver 600 reactions, including hydrogenations, oxidations, alkoxylations, alkylations and many others, have been developed and/or optimized by Buss ChemTech AG during the last several

decades for industrial scale processes, saving our clients millions. This experience is a reliable basis which can be adapted to a client’s pro-cess within a short timeframe and with minimal effort.



Reaction Technology Catalytic Gas / Liquid Reactions

DEVELOPMENTOur laboratory and pilot plant facilities are avail-able to simulate almost any industrial applica-tion and even open the door to new chemical processes.

SUMMARY:Our main focus is on plant safety, process in-tensification, reliability of scale-up and guaran-teed plant performance:■■ “Safety First” is not just a slogan for Buss ChemTech, it is our commitment to you, the environment and to our clients’ and our staff members. Performing a safety analysis during the design stage, avoiding explosive mixtures in our process design, specifying the appropriate monitoring equipment and building in safe shutdown procedures into the process control scheme, are all components of the “inherently safer design” concept we employ.

■■ Improved performance, whether through im-proved selectivity and yield, shorter reaction times or lower catalyst usage, is the goal of our research and development efforts.

■■ The design characteristics of a Buss Loop® Reactor system allow us to scale up to virtually any size reactor with confidence.

■■ Process guarantees are derived from our know-how, experience and project-specific lab and/or pilot scale testing (if necessary).

With this approach, our clients get the informa-tion they need to estimate CAPEX, OPEX and payback period - with a minimized investment (time and money).

Buss Loop® Reactor technology is generally suitable for all kinds of processes, but strongly recommended if one or more of following con-ditions apply:■■ catalytic gas/liquid reactions ■■ highly exothermic reactions■■ flexible operating volume required■■ continuous processes■■ requirement for treatment of the gas phase (condensation, absorption, etc.)

GREEN ANODE PLANT - Alcircle.com

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