Engineering, modernisation and operational support for hydrochloric acid regeneration plants
Diovis provides engineering support for new hydrochloric acid regeneration plants and for the modernisation and operation of existing installations. We work with spray-roasting and fluidised-bed technologies, independently of the original equipment manufacturer.
Discuss your project Request a technical assessmentSpent acid in, regenerated acid and iron oxide out
Spent pickling liquor is concentrated in the venturi before entering the reactor, where iron chlorides are converted into hydrogen chloride and iron oxide. The hydrogen chloride is absorbed in water to produce regenerated hydrochloric acid, which is returned to the pickling line. Iron oxide is recovered as a separate output.
Simplified spray-roaster flow. Fluidized-bed plants differ in reactor design and oxide handling.
Spray roaster or fluidized bed
We advise on the choice; we don’t sell one process.
| Spray roaster | Fluidized bed | |
|---|---|---|
| Iron oxide product | Fine powder, a saleable raw material for ferrites and pigments | Dense granules, easy to handle and reuse in steelmaking |
| Typical fit | Carbon-steel pickling where oxide quality is a revenue stream | Where a dense, low-dust oxide is preferred |
| Acid recovery | A well-run plant returns more than 99% of the acid to the pickling line, and the oxide becomes a product instead of waste. | |
From basic engineering to training
Basic engineering
Mass and energy balances, layout, specifications and guarantee figures for new plants.
Revamp & debottlenecking
Capacity, recovery rate, oxide quality and emissions, phased to protect production.
Structures in acid atmosphere
Foundations, steel structures and acid-proof floors, assessed by a civil engineer.
Operator training
For operators and maintenance staff, in English or German.
Operating issues and areas for assessment
On ageing plants the same patterns come back. This is where we look first.
| What you see | Where we look first |
|---|---|
| Rising acid loss | Absorber packing and temperature, rinse-water balance, regenerated-acid concentration, leaks in tanks and piping |
| Off-spec iron oxide | Roaster temperature profile, burner condition, spray-nozzle wear, residence time, chloride in the oxide |
| Stack HCl or dust rising | Absorber efficiency, scrubber circulation and pH, cyclone wear and dust carry-over, droplet separators |
| Fuel consumption creeping up | Burner tuning, refractory damage, false air into the roaster and ducts, pre-concentrator performance |
| Unplanned stops | Nozzle blockages, deposits on fans, corrosion of pumps and valves, structures and foundations in acid atmosphere |
What you get, and what we need from you
An honest picture of what the plant really does today, against what it was designed to do.
Request a technical assessment- Initial data review. You send operating data: DCS trends, acid and oxide lab results, stack measurements, maintenance log and the original design figures.
- Gap analysis. We compare actual against design and send you a first view of where the losses are.
- On site. Inspection of equipment, refractory, ducts and structures, with targeted measurements.
- Your report. A ranked list of bottlenecks, each with estimated cost, benefit and urgency.
Components selected for your operating conditions
We specify and source spare parts and critical components for acid regeneration plants. Using your drawings, component datasheets or an existing part as a reference, we assess material suitability and technical compatibility with your operating conditions.
Specifications are developed in accordance with applicable standards and agreed project requirements. Components are sourced from qualified manufacturers.
You receive a quotation stating the technical scope, country of origin and delivery lead time.
Request a quotationComponents we specify
Please include available drawings or datasheets, material, quantity and operating conditions.
Independent review of modernisation proposals
We provide an independent technical and commercial review of modernisation proposals, covering the scope of work, proposed solutions, performance guarantees, exclusions and pricing.
- Does the proposed scope address your plant’s actual needs?
- Are the guaranteed performance figures measurable and verifiable at acceptance?
- Which exclusions could lead to additional work or cost?
- Is the price consistent with the proposed scope of work?
Stack figures you can defend
Stack HCl, particulates and plume: we trace emissions back to absorber, scrubber and roaster operation, and give you the engineering measures and the technical explanation behind your stack figures. Compliance measurements stay with your accredited laboratory.
What isn’t measured doesn’t exist, for the regulator, the bank or the plant director.Anna Smolyanaya, Founding Partner
Plan the revamp. Don’t wait for the failure.
A planned revamp costs a fraction of an emergency repair, and the whole cold-rolling route depends on the pickling line.