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Sulphuric Acid on the WebTM Technical Manual DKL Engineering, Inc.

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Acid Plant Database  October 6, 2017

Owner AdvanSix  
Location 905 East Randolph Road
Hopewell, Virginia
Background Formerly Honeywell 
Website www.advan6.com
Type of Plant Sulphur Burning
Gas Source Elemental Sulphur
Plant Capacity
Emissions SO2: 4 lbs/ton (3-h rolling average)
        2 lbs/ton (12 month rolling average)
        264 lb/h
        200 tons/year
Acid Mist: 0.15 lb/ton
                2.2 lb/h
                8.2 tons/year
Visible Emissions: <10% opacity
Status Operating
Year Built
Remarks Oleum Produced
General The AdvanSix Hopewell facility is one of the world’s largest single-site producers of caprolactam, the primary feedstock in the production of nylon polymer used in carpet fibers, plastics and films. It also produces a wide range of chemical intermediates, including Nadone® cyclohexanone, Naxol® cyclohexanol, sulfuric acid, specialty oximes, ammonia and carbon dioxide. The site is also a global leader in the development and production of ammonium sulfate fertilizers, which it sells under the Sulf-N®brand for both crop and turf applications.
References Title V Air Permit PRO50232 - DEQ Virginia
News October 25, 2016 - Fire and police crews in Hopewell responded to a chemical leak at the Honeywell Plant in Hopewell Tuesday night.  Officials tell 8News that the leak was reported at around 10:30 p.m. The leak was quickly contained inside the plant, although remnants of a sulfuric acid cloud remained over Route 10 for close to an hour.  Route 10 was temporarily closed but has since reopened.  Officials say there is no longer a threat to the surrounding community as crews continue to investigate the cause of the leak.

May 12, 2016
- Honeywell is spinning off its $1.3 billion Resins and Chemicals business into a new publicly-traded company named AdvanSix Inc. Honeywell's products are used in the manufacture of paints, coatings, engineered plastics, packaging, and other items. The deal is expected to be completed by early 2017.Erin Kane will serve as AdvanSix's president and CEO. Kane has served as vice president and general manager of the Resins and Chemicals business since October 2014.“Our $1.3 billion Resins and Chemicals business enjoys a leading position in the industries it serves and a global cost advantage. It is favorably positioned to continue to achieve global growth as a standalone enterprise, with added flexibility to make capital investments that enhance its offerings and service to customers,” said Honeywell Chairman and CEO Dave Cote.When finalized, AdvanSix will immediately rise to one of the leading producers of nylon 6, a polymer resin used to produce engineered plastics, fibers, filaments, and films for electronic components, carpets, and industrial packaging. AdvanSix will also produce chemical intermediates, including: phenol to make resins for wood products; acetone, used as a solvent to make paints, inks, coatings and other materials; Naxol cyclohexanol used in making lacquers, varnishes and shellac; Nadone cyclohexanone, used in paints and printing inks; and methyl ethyl ketoxime (MEKO), an anti-skinning agent for air drying paints and coatings.“Following the spin-off, Honeywell and AdvanSix will each have a more focused business and be better positioned to invest more in growth opportunities and execute strategic plans best suited to its respective business. The transaction will create added value for our shareowners, who will receive AdvanSix shares tax-free in addition to the Honeywell shares they already own,” Cote added. 

January 29, 2015 - A 100,000-gallon sulfuric acid tank at the Honeywell plant in Hopewell ruptured just before noon yesterday from being over pressurized, causing an evacuation of Honeywell employees to a shelter.  Honeywell spokesman Peter Dalpe stated that the incident involved a tank that was not in service at the time. The tank was being cleaned for inspection, according to Dalpe, when the top flipped off the tank and ruptured.  Initial media reports stated that the incident was an explosion, which Honeywell spokesman Peter Dalpe denied.  “First, to clarify: There was no fire and this was not (an) explosion, which is (a) violent event. A tank ruptured causing a sound,” Dalpe stated in an email.  Honeywell’s emergency response teams responded immediately at around 11 a.m. when the incident occurred. The emergency was cleared by 12:17 p.m and the evacuation was lifted. There were no reported injuries.  Hopewell Fire Chief Donald Hunter said the fire department responded to the incident to help suppress the vapors that were released. Hunter said Honeywell personnel put water in the tank as a preventive measure.  “The vapors that were there were controlled by them (Honeywell) by water spray and it did not leave the general area, it stayed inside their facility,” Hunter said.  Honeywell has tested the air to assure residents that no sulfuric acid has been released.  “Sensors in the plant and testing done in the immediate area of the incident showed no detectable levels of sulfuric acid in the air,” Dalpe stated.  In November of 2014, a chemical spill at Honeywell was allegedly responsible for killing hundreds of fish in the nearby Gravelly Run creek. Bill Hayden, a spokesperson for the Department of Environmental Quality, said ammonium carbonate was released into the creek.  It’s not the first incident at the Honeywell plant.  The chemical caprolactam poured out of a truck on Route 10 in Chesterfield County in October of 2013, which closed the road down for several hours. The truck driver had been traveling from the Honeywell plant in Hopewell to the plant in Chesterfield. Lt. Jason Elmore of the Chesterfield Fire and EMS said the chemical was not an environmental or personal hazard.  Honeywell was charged with a $3 million fine by the Justice Department and the Environmental Protection Agency in April 2013 for violating Clean Air Act limits on nitrogen oxide, benzene and other volatile organic compounds. Honeywell then agreed to a series of environmental upgrades for the Hopewell plant estimated at $66 million aiming to reduce “harmful air pollutants.” An agreement was filed in the U.S. District Court for the Eastern District of Virginia.  A statement from Honeywell at the time said the company did not admit to any of the alleged violations and is “committed to the highest standards of environmental compliance and sustainability at every one of our facilities.”

MTPD - Metric Tonne per Day           STPD - Short Ton per Day
MTPA - Metric Tonne per Annum      STPA - Short Ton per Annum
SA - Single Absorption
DA - Double Absorption

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