Acid Regeneration Plant
Tenova role as a pole of excellence in technologies concerning efficiency of the Acid Regeneration Plant is resumed in cutting-edge technologies, named BLUEdrivenTM Technology.
A significant advantage due to the sustainable improvements in industrial efficiency and performance.
Overview
The acid regeneration process is the total recovery of metal-free chloride solutions based on the pyro hydrolysis principle. Pyro hydrolysis is the chemical conversion of metal salts using steam and oxygen at high temperatures. Operators not only recover hydrochloric acid in its free and bonded state, but also obtain high quality iron oxide, either as granules or fine powder.
Two technologies have been established:
Spray Roaster Technology
An Acid Regeneration Plant (ARP), equipped with the Spray Roaster technology, is operated at a lower temperature than the FLB, which is creating an economical benefit. A by-product is obtained as reddish powder with grain size of approximately 30 µm, which is highly demanded on the market. Many years of experience provide Tenova with specialized know-how in spray roaster technologies which enable to provide optimized, tailored, and continuously updated solutions for each customer.
Fluidized Bed Process
Under high temperature and continuous operation the process regenerates HCl acid (18%wt) and permits to sinter oxide forming grey granules up to 2 mm in size. The iron oxide granules are free of dust and contain almost no chlorides. It is mainly used be reused in the steel production (e.g. in the electric arc furnace) or sold as a by-product.
Technical data
Our Services - Acid Regeneration Plant (ARP)
- Spray Roaster or Fluidized Bed Technology
- Silica Removal Plant (SRP) designed for individual requirements
- Capacity from (500) 750 l/h up to 20.000 l/h
- Customized designed and European engineered
- Latest state of art - BLUEdrivenTM Technology
- Unique Automation algorithm for higher stability in operation and for reduction of energy consumption
- Upgrade availability for future extensions
- Long term After Sales Service & Support
- Worldwide References
What would be if you could save up to 40% of the investment costs during life time of the plant?
Under full consideration of the ARP life cycle costs, TENOVA improved the Spray Roaster Technology with a significant improvement of Operating Costs, Production Quality as well as for the Environmental Protection and health and Safety.
The economical solution is based on a balance from a global perspective.
While the main influence factors of the OPEX, are creating costs, a enhanced system can balance the system and is able to lift the plant to an economically new level.
Tenova BLUEdriven© Technology enhanced features:
- Advanced automation algorithm and remote function
- Customized burning chambers for highest efficiency
- Enhanced & maintenance free Venturi
- Failsafe over-temperature prevention safety system
- Remarkable reduction of maintenance
- Chemical & effluent free scrubber system
- Long term proven technology
- Extended, long term client support and service
Innovation
BLUEdrivenTM Technology
BLUEdrivenTM Pyrolysis
set parameters to produce high quality Fe-oxide. Here it is decided whether the by-product creates revenues or solely costs. The system is a significant improvement in the flexible configuration of nozzles while at the same time enhancing the safety of work at the reactor head is achieved.
BLUEdrivenTM Liquid Treatment
is a long-term proven maintenance-free Venturi system with special nozzle-free inlet concept. In combination with a new designed liquid distributor, which enables maintenance outside the columns, a positive effect on the safety of the personnel and efficiency of the process plant.
BLUEdrivenTM Emission Control
allows the operators to bring the plant in compliance with strict emission values. The reduction of the environmental pollution is possible due to closed circuits in exhaust gas cleaning section and reduce OPEX at the same time. There are no effluents and chemical treatment foreseen.
ZEROwaste Process
fully recycles the rinse and scrubber water and allow the chlorides to flow back into the production cycle. An increase in plant efficiency of just 0.5% will bring the operators a 50% saving in fresh acid consumption.
BLUEdrivenTM Flex Capacity
includes an integrated capacity increase of up to 50%. It is a worldwide unique capacity flexibility of an ARP allows adjustments of steel production according the demands while the operation remains uninterrupted and stable. Highlight: Lower capacity consumes direct proportionally less utilities.
Environment
Through global environmental movement, every company is requested to improve the environmental impact of its production as much as possible to meet the demands of the market. Lowered limits set by public authorities create problems, as many plants produce up to 250% higher exhaust emissions than the latest technology would allow.
Tenova BLUEdrivenTM Emission Control allows the operators to bring the plant in compliance with strict emission values as per European Union Standard.
Emission control starts at the combustion.
Tenova developed megawatt-size flameless combustion system burning any mixture of natural gas and hydrogen, up to 100% hydrogen.
A new milestone in the decarbonization of steel production: its TSX SmartBurner was developed to be installed in industrial plants with potentially zero carbon dioxide emissions, working in a full range of hydrogen and natural gas mixtures. It is the first flameless burner of a megawatts family that has been tested with 100% of hydrogen successfully.
Digital
Digital technologies are changing our world, including the way we make metals. Tenova is able to provide you with the ultimate digital technologies and cover a great variety of applications. With the purpose of making access to these innovations easier, Tenova offers modular and scalable digital packages, each focusing on specific requirements. These modules can be structured and customized to help you reach your goals.
Tenova adVISOR
Your remote mentor on site, guiding you through our experts ‘remote support, interactive documentation and the use of artificial intelligent algorithms on real time automation data.
Tenova EDGE
An innovative, customized and highly secure solution: Tenova EDGE, the gateway for seiting the opportunities offered by the Internet of Things.
Customized system
Our steps to a customized system solution that meets all our customers’ requirements
Our stages on the way to a customized system solution that meets all our customers’ requirements.
Meeting both our customers’ requests and the relevant process requirements is our utmost priority during the conceptualisation and execution of every single plant. Each ARP is unique; no plant requirements are the same as any other. By employing innovative methods, modular systems and cutting-edge technologies, we guarantee the highest levels of profitability.
Our process know-how, which we keep continually up to date, informs the work of our development, engineering and commissioning teams and ensures that your plants operate reliably and reduce significantly unforeseen interruptions.
Tenova broad portfolio and our international presents on 5 continents allows us to offer the majority of services in-house, which ensures best value for money and planning predictability for our customers.
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