Review the fundamentals of the sulphuric acid process, plant design and operation. Acid plants must be built and operated so that liquid sulphuric acid is not produced in. This fact sheet is one in a series of summaries about hazardous substances and their health effects. For economical operation of sulphuric acid plant should be minimum 250 mtday. The evolution of acid plant design has been more about materials of construction than anything else. This is because the claus reaction, which is employed to convert h 2s to elemental sulphur, is exothermic, and thewaste heat from the. Restraints for the global sulphuric acid market include stringent government regulations that are restricting its use, and high raw material prices. From the moment an acid plant is first started it begins to corrode and its days are numbered. Materials of construction corrosion properties vendor data. Manual for sulfuric acid contact process louisiana state university.
The long response times make it difficult for operations to run these units at the optimum acid consumption. If the pfd doesnt contain any data about the flow rates, it is called a qualitative flowsheet, while if the flow rates are involved the pfd is called a combined flowsheet in which qualitative information and quantitative data are combined on the basis of one flowsheet. Ca3po42 3h2so4 6h2o 2h3po4 3caso4 2h2ov 1 in order to make the strongest phosphoric acid possible and to decrease evaporation costs. This report contains a detailed design procedure of a plant to manufacture sulfuric acid from sulfur, as followed by group 01 as per the allocations of ch 4202 comprehensive design project09 batch. Material balance involves calculations the quantities of all materials that enter and. Complete process flow diagram for for production of sulphuric acid by single absorption process. If the pfd doesnt contain any data about the flow rates, it is called a qualitative flowsheet, while if the flow rates are involved the pfd is called a combined flowsheet in which qualitative information and quantitative data are combined on.
Symphos 2015a, 3rd international symposium on innovation and technology in the phosphate industry process heat recovery and digitalisation in sulphuric acid plants. The material and energy balance in a plant design is necessary because this fixes the relative flow rates of different flow streams and temperatures in the flow sheet. Material and energy balance chapter 6 material and. Design of a sulfuric acid production plant engineering essay. The reaction which takes place may be represented as follows. Process heat recovery and digitalisation in sulphuric acid plants. Sulphur plants produce valuable energy use it wisely. Design of a plant to manufacture sulfuric acid from sulfur. Preparation of sulphuric acid by contact process with examples.
The integrated energy recovery, from conversion and. We also offer a comprehensive range of service solutions to support you throughout your plants lifecycle. Appendix a constraint equations for sulfuric acid process. Conventional acid resistant gaskets may not be able to withstand attack by so3.
For more information, call the atsdr information center at 18884228737. Nearly 75% of h2so4 now produced in india is used for the manufacture of chemicals and fertilizers. Pdf optimization studies in sulfuric acid production. Sulphuric acid plant fundamentals sulphuric acid on the. Plant design for sulfuric acid manufacture1 sulfur dioxide. Process heat recovery and digitalisation in sulphuric acid. Sulphuric acid these corrosion data are mainly based on results of general corrosion laboratory tests, carried out with pure chemicals and water solutions nearly saturated with air the corrosion rate can be quite different if the solution is free from oxygen. Table 2 production of sulphuric acid in the countries of the european community sulphuric acid is produced in all the countries of europe with the major producers being germany, spain, france, belgium and italy.
This report contains a detailed design proc edure of a plant to manufacture sulfuric acid from sulfur, as followed by group 01 as per the allocations of ch 4202 comprehensive design project09. It is used to convert isobutane and lowmolecularweight alkenes primarily a mixture of propene and butene into alkylate, a high octane gasoline component. Many processes of sulphuric acid production have been developed according to the large number of sources of raw materials so2, and their specific. The material neither enters nor leaves the vessel system, as shown below. Sulfuric acid manufacturing process of sulfuric acid. Recovery, are the best examples for hugo petersens aim in making sulphuric acid plants more efficient. The products are two immiscible aqueous acids, aqueous sulphuric acid light phase and a mixture of hydrogen iodide, iodine and water, referred to as hi x heavy phase. Sulfuric acid alternative spelling sulphuric acid, also known as oil of vitriol, is a mineral acid composed of the elements sulfur, oxygen and hydrogen, with molecular formula h 2 so 4.
Pyrometallurgy, sulphuric acid, sulphur dioxide abstract the raw material for sulphuric acid manufacture is clean so2 gas. Based on the growth rates of end use industries the total demand for sulphuric acid is estimated to increase from 5. The majority of this heat is recovered as steam and often used to generate electricity. Exergy analysis of an industrial sulphuric acid plant. However, iarc, the acgih and the ntp have concluded there is sufficient evidence that occupational exposure to strong inorganic acid mists containing sulphuric acid is carcinogenic or potentially carcinogenic to humans see toxicological information, section.
Chouaibi the main purpose of this study is to evaluate the energetic performances of a sulfuric acid production unit using a double absorption contact process with four conversion steps and an intermediate absorption with sulfuric acid. Material balances chapter page 6 introduction to material balance 3 7 general strategy for solving material balance problems 166 8 solving material balance problems for single units. Sulfuric acid is an important raw material used in many industrial processes, such as phosphate fertilizer production and to a much lesser extent for nitrogen and potassium fertilizers, sulfuric acid is produced by catalytic oxidation of sulfur dioxide to sulfur trioxide, which is. However, the actual consumption in dcda sulphuric acid plants generally varies from 0. Workers that use sulfuric acid may breathe in mists or have direct skin contact. Schematic of single contact, 3 catalyst bed sulphuric acid plant. We have our own technology specially designed and developed to increase the efficiency and costeffectiveness of sulfuric acid plants. The process control of a sulphuric acid plant needs good and reliable detection of gas phase so2. Metallurgical contentparting goldsilver alloy with sulphuric acidgoldzinc alloysgold, silver, and sodiumeffect of tellurium on partingparting of gold and silver commerciallythe gutzkow refining process pure silver is readily attacked by strong hot sulphuric acid of sg 1. The group was able to reveal from the mass and energy balance that the. Basic principles and calculations in chemical engineering first year by. As well, clean gas is required to prevent plugging of catalyst beds and.
Pdf design of a plant to manufacture sulfuric acid from. The general population may be exposed to sulfuric acid when breathing in ambient air or dermal contact with products containing sulfuric acid, such as the material that forms on car battery terminals or battery acid itself. Water balance and low so2 concentrations are problems faced by acid. Product which is to be manufactured is assumed to have strength of 98% acid. The sulphuric acid concentration from a sulfox plant depends on the feedstock composition. To confirm the efficiency of this process, a mass balance study is carried out on sulphuric acid plant, using a double contactdouble absorption process, this study demonstrates that this new. It is soluble in water and generally releases heat on contact. Material and energy balance chapter 6 material and energy.
Sulphuric acid production by dcda process essay 4535 words. These form a mathematical model of relationships between the various plant units and process streams. Plant will consume 865 kw the balance kw will be exported to other plants. Acid plant, figure 9 sulfacid process for removal of so2 feed gases are mixed with steam if required. Well, sulphuric acid is basically an oxidizing agent, a strong mineral acid, and a dehydrating agent. The invention relates to a condenser, having a process gas side and a heat transfer medium side said condenser being configured for feeding a hot process gas containing a condensable component to an inlet of the condensing side, and being further configured for withdrawing a cooled process gas from an outlet of the condensing side, and being even further configured for withdrawing a condensate.
Basic principles and calculations in chemical engineering. Project report on sulphuric acid manufacturing process. Smelter acid will be more than 25% of world sulphuric acid production compared to some 18% in 1991. Several places in the process needs to be monitored. The process occurs in the presence of an acid such as sulfuric acid h 2 so 4 or hydrofluoric acid hf as catalyst. Keep at rest in a position comfortable for breathing. Sulphuric acid plant fundamentals sulphuric acid short course presented by douglas louie com 2010 vancouver, canada october 36, 2010 contact information douglas louie worleyparsons canada minerals and metals 2645 skymark avenue mississauga. Nuberg epc has been providing plant design, engineering, technology and turkey solutions to the sulfuric acid industry for 20 years. Exergy analysis of an industrial sulphuric acid plant william ruiz civetta1, ricardo vasquez padilla2, antonio bula silvera3, arturo gonzalez quiroga4 1,2,3,4 department of mechanical engineering, universidad del norte, km 5 via pto colombia, barranquilla, colombia abstract this paper presents an exergy analysis of an. Assessment of energy performances of a sulfuric acid. Concentrated sulfuric acid 9398 % is used in the manufacture of fertilizers, explosives, dyes, and petroleum products. Double absorption plant water balance autothermal gas drying absorption energy recovery emissions. Typical pfd for a lime sulphuric acid recovery plant to make it more complete, material and energy balance calculations are required to indicate the flow components into each unit operations and has been excluded to. The general population may be exposed to sulfuric acid when breathing in ambient air or dermal contact with products containing sulfuric acid, such as the material that forms on.
Sulphuric acid production sulfuric acid chemical process. The metallurgical offgases must be cleaned prior to entering the contact section of the acid plant to enable the plant to produce a product acid of acceptable quality for use and sale. Alkylation units where feed compositions and rates vary require constant manipulation of the acid to control both the acid material balance and the strength of the acid that has been spent spent acid. An alkylation unit alky is one of the conversion processes used in petroleum refineries. Sulphuric acid is formed from the oxidation of so2 in the presence of h2o and activated carbon.
We will first start by addressing the question of what is sulphuric acid. Waste heat boiler to recover energy from gas leaving furnace. Best available techniques reference document on the production. We have the distinction of having installed one of the worlds largest whrs system for 2 x 3500 tpd in india and for 2400 tpd in europe for sulphuric acid plants. Basics types of acid plants metallurgical acid plants basic reactions catalyst conversion single vs. Sulphuric acid plant fundamentals sulphuric acid on the web. Sulphuric acid is the most commonly used chemical for reducing ph in water treatment, although carbon dioxide is also sometimes used under certain circumstances, particularly in conjunction with lime to increase alkalinity.
Take precautions to ensure your own safety before attempting rescue e. To measure so2 is a challenge due to the corrosive environment and high concentration of so2. It is a colorless, odorless, and viscous liquid that is soluble in water and is synthesized in reactions that are highly exothermic. Plant testing during the plant test, the data was examined and. Abstract the raw material for sulphuric acid manufacture is clean so2 gas.
Sulfuric 2520acid material 2520 balance sulfur sulfur dioxide. Sulfuric 2520acid material 2520 balance free download as pdf file. Use only pureteflon ptfe gaskets in so3 vapor and liquid lines. The first method utilizes oxidation, condensation, and absorption to produce a weak nitric acid.
The information in this database is believed to be current. A simplified reaction for the dihydrate process is as follow. The starting material for sulphuric acid manufacture is clean, dry so2, 8 to 12% in o2, n2, so2, co2, so3 gas. A final mist precipitator grants low acid mists emissions at the stack. Pdf design of a plant to manufacture sulfuric acid from sulfur. When the feedstock is h 2 s rich gas, a waste liquid or a spent acid, a preliminary oxidation section both thermal or catalytic is added to obtain the so 2 inlet stream. Optimum overall system behaviour requires a balance between reaction velocity and equi. Pyrite is also used as a raw material for sulphuric acid production. Flow diagram of a wet process phosphoric acid plant cont. With vast industry expertise, we help you select the right material to match the sulphuric acid process thereby ensuring reliable operation and uptime. These tools and technology do not necessarily, only cover one area of the acid plant, no the energy source is the sulphuric acid plant.
If breathing is difficult, trained personnel should administer emergency oxygen. During the 1st quarter of the year 2007, chemical initiatives undertook a study to up rate the sulphuric acid plant output by 10% i. Sulphuric acid production free download as powerpoint presentation. If there are any errors or omissions please notify me and i will correct the information. Sulphuric is an engineering software package for design and simulation of plants producing sulphuric acid, oleum, liquid so3, chlorosulphonic acid etc. Scrubbing systems used in phosphoric acid plants include venturi, wet cyclonic, and semicrossflow scrubbers. Sulphuric acid market global industry analysis, size and. Plant design for sulfuric acid manufacture1 free download as powerpoint presentation. Acid strength control in a sulfuric acid alkylation unit. Pdf the plant designed was primarily based on the sulfur based effluents that are. Following this step, the sulfur dioxide is converted to sulfur trioxide, using a catalyst.
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