Basic & detail engineering for one combined tail gas scrubbing system for Sulphuric acid plant units A & B

About The Project

The scrubbing system is designed for continuous operation and is shared between Unit-6 and Unit-7, handling gases from one plant at a time to avoid operational issues. The system comprises a packed tower scrubber with an integral reservoir, circulation pumps, alkali preparation tank, caustic lye storage tank, ID fan, oxidation blower, and solution storage tank, among other components.

The scrubber, made of FRP, utilizes a mix of caustic solution, dissolved Na₂SO₃, and water as the scrubbing agent. Inside the scrubber, PP Pall Rings serve as packing material for effective gas-liquid contact. A pipe-type distributor ensures uniform distribution of caustic solution, while mesh pads made of PP and SS316L capture SO₂ and acid mist traces. The system includes provisions for CIP (Clean in Place) of demister pads.

The Scrubbing system is designed such that the final emission of gas will have very low content of SO₂ < 100 mg/Nm³

Scope

Scope of work will be to carry out basic & detail engineering and provide engineering documents/drawings for one combined tail gas scrubbing system for Sulphuric acid plant units A & B as detailed below:

Basic engineering

Basic engineering will cover the basic design, PFD, PID, layout and the specifications of the major equipment such as the gas scrubber, major vessels, stack, pumps, instrumentation, and electric system

Design Basis

• Design Basis shall be updated to reflect the last agreed to project basis and shall include the following information:
  • Design Conditions
  • Raw material requirements
  • Utility supply condition requirements at battery limit
  • Effluent conditions and flows
  • Specific site criteria

Process Design

• Process design and drawings required for Tail Gas Scrubbing Systems
• Process Description
• Process Flow Diagram including mass and energy balance
• Process & Instrumentation Diagrams (main control loops and instruments)
• Equipment List including equipment dimensions and capacities
• Equipment Layout for Alkali Scrubbing System
• Specifications of the major equipment such as the gas scrubber, major vessels, stack, pumps, instrumentation, and electric system

Detail Engineering

Fabricated Items

• Preparation of engineering specification sheets and engineering drawings.
• Review vendor data prepared by the selected vendors and incorporate the vendor data in appropriate drawings.
• Provide Civil load data required for civil foundation design

Bought Out items

• Preparation of enquiry & purchase specifications suitable for procurement

Piping & Ducting

• Piping line list
• Piping layout, 3 D Modelling for piping related to Alkali Scrubbing System
• Material take-off, valve schedules
• Pipe support drawings as required
• Ducting Connections for hooking up Alkali Scrubber and required duct supports
• Isometric drawings for piping with bill of materials
• Piping insulation requirements

Electrical

• Electrical load list
• Electrical Single Line diagram
• Specifications of electrical motors

Instrumentation

• Instrument List
• Specification for Instruments.
• Hook-up diagram as may be required
• I/O List
• Instrument location drawings, loop & logic diagrams
• Instrument cable schedule & material list
• Junction box schedule
• Control philosophy for operation & control of gas scrubber

Structural Engineering

• Platform & Structural Drawings as may be required for equipment, piping etc.

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