Criteria are presented to describe some of the features incorporated into the plant. Understanding sulfur content in alkylate from sulfuric. Flow diagram of a wet process phosphoric acid plant cont. This method starts with diluted sulfuric acid, which you boil to make concentrated sulfuric acid. This is the safest and easiest method of making sulfuric acid at home. Contact information 504 4319511 phone 888 5319511 toll free. Saturation of the gases and elimination of the coarse and fine particulate matter, 2. We also offer a comprehensive range of service solutions to support you throughout your plants lifecycle. But, mecs offers the client more than just catalyst. It includes systems for continuous emissions monitoring, process control as well as for air quality monitoring. 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.
A flowsheet of a typical sulfuric acid manufacturing plant is shown in figure. Energy recovery metallurgical acid plant energy recovery typical locations for energy recovery com 2010, vancouver, canada, october 36, 2010 44 the outlet of the cold and cold reheat exchangers is the typical location for energy recovery in a metallurgical sulphuric acid plant. Mist formation is usual also when the sulfuric acid plant is set on run. This is because the claus reaction, which is employed to convert h 2s to elemental sulphur, is exothermic, and thewaste heat from the process can be recovered as hp and lp steam. This guide focuses on the most important systems, processes, and practices that account for the bulk of energy consumption. Private and confidential for use by dow chemical company only sulfuric acid supplydemand 5 2016 global production 264 million tonnes mt acid produced through the burning of elemental sulfur predominantly used in the manufacturing of fertilizers pyrites are iron sulphide ores burned to produce acid, largely limited to china. Our engineers deliver high value customized spent acid recovery units to regenerate fresh sulfuric acid for refineries or chemical processing plants. 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.
The majority of this heat is recovered as steam and often used to generate electricity. This report contains a detailed design proc edure of a plant to manufacture sulfuric acid from. Before entering the stainless steel converter, the gas temper. Smelter acid will be more than 25% of world sulphuric acid production compared to some 18% in 1991. Analysis of concentrating solar power with thermal energy. To help reduce the environmental impact of plants and processes, we have developed several gamechanging innovations. Us2061922a1 method for producing hydrogen and sulphuric. The storage and transfer of phosphoric acid is the same for all the acids and does not depend on the method of production. Mecs is known for its proven sulfuric acid catalyst portfolio and catalyst designs based on practical experience and extensive plant knowledge.
Final project aai final sulfuric acid sulfur scribd. Sulfuric acid is a sulfur oxoacid that consits of two oxo and two hydroxy groups joined covalently to a central sulfur atom. In order to achieve high levels of mass and energy utilization efficiency, most processes involve the use of recycle. Watersaving options for sulphuric acid plants saimm. Sulfuric acid also known as oil of vitriol, battery acid, and king of chemicals produced using contact process used in the manufacture of fertilizers, explosives, dyes, petroleum products, lead. These form a mathematical model of relationships between the various plant units and process streams. Energy efficiency and cost saving opportunities for. Manual for sulfuric acid contact process louisiana state university. Appendix a constraint equations for sulfuric acid process. Sulphuric acid production references 6 umweltbundesamt vienna, 2017 energy flow chart of a double contact double absorption plant burning elemental sulphur source. The effect of these malfunctions on so emissions is illustrated by the data. A pilot plant to produce biodiesel from high free fatty. Cooling tower ph control represents the single largest acid use at most power plants.
The developed model provides an explicit relation between so 2 conversion ratio and gas temperature, which is denoted as the heatup path of the converter. Cooling of the gases, condensation of the metallic fumes and reduction of the moisture content, 3. This software is used for design of new plants as well as for simulationanalysis of existing plant performance. That being the case, theres a strong driver to minimize or eliminate sulfuric acid use in cooling towers.
A sulfuric acid plant was designed and built for reliably producing a saleable product from the recovered so 2. Exergy analysis of an industrial sulphuric acid plant william ruiz civetta1, ricardo vasquez padilla2. Exergy analysis of an industrial sulphuric acid plant. Even though the thermodynamic solubility of sulfuric acid in alkylate is negligible at process conditions, the c4 alkylate samples contained. In the wet gas sulphuric acid wsa process, residual. Sulfuric acid plant emissions during startup, shutdown, and. Hence it is important to find practical solutions to evaluate and optimize the energy performances in this process type. Feature improving plant performance using stateoftheart.
Exposure to sulfuric acid mist can cause other health problems. A 50gallon batch pilot plant has been built which can process high free fatty acid feedstocks using an acid catalyzed pretreatment followed by an alkalinecatalyzed transesterification. 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. Environmental protection agency office of air and waste management. The total solution also includes highly skilled service and support. Assessment of energy performances of a sulfuric acid production. April 2, 2015 the fate of energy resources australia hangs in precarious balance with majorityowner rio tinto growing increasingly uncertain about the competitive economics and investment risk of a lifesustaining underground expansion at australias most productive uranium project, the ranger mine. Optimum overall system behaviour requires a balance between reaction velocity. The plant designed was primarily based on the sulfur based effluents that are currently disposed from the ceylon petroleum corporation refinery at 25 mtpd were to be completely regenerated in the form of sulfuric acid by installing a manufacturing plant.
Spent acid recovery process and plant design dupont. The product of sulphuric acid manufacture is liquid acid, 93 to 98% h2so4, 2 to 7% h2o. An option exists to use sulfuric acid produced by several nearby refineries. The material balance is the fundamental tool of chemical engineering. In regions where energy costs are low, it may be more economical to burn more fuel and reduce the capital cost of the plant. The two last units are not major contributers to the energy system and are therefore not included in the model.
Energy recovery is extremely important in the economics of new sulphuric acid plants. Sulfur, as followed by group 01 as per the allocations of ch 4202 comprehensive design. The group was able to reveal from the mass and energy balance that the. Process heat recovery and digitalisation in sulphuric acid. Sulfur based thermochemical energy storage for solar power tower general atomics ga german aerospace center dlr.
Apply the energy balance relating catalyst weight and temperature. Exergy balance the exergy balance for any equipment is given by bejan 1966, campos et al. When all of the candidate designs have been optimized, the best design can be selected. With the energy transition in motion, and in light of increasing emission controls and government legislation, obtaining this license is set to become even more of a challenge. Water balance and low so2 concentrations are problems faced by acid. Analyser cabinet emitter receiver fibre optic cable stack power supply. In a few cases, this spent acid may be safely disposed or used in other processes, but. Sulfuric acid production in a pyrometallurgical process, gas from the gascleaning section enters the sulfuric acid plant via the drying tower, where most of the humidity is removed in order to minimize the potential for corrosion inside the plant. It is a single contact acid plant because it has only one h2so4 making step. Metallurgical acid plants gas cleaning systems there are four main duties to be performed by the gas cleaning system of a metallurgical sulphuric acid plant. The absorption of so 3 has a low yield so that the gas has to be recycled to the sulfuric acid plant to avoid environmental contamination. Box 16200, fi00076 aalto, finland fcg design and engineering, osmontie 34, fi00601 helsinki, finland.
Figure 7 the process flow diagram for dtrain sulfuric acid plant. Workers in sulfuric acid plants can also be exposed to the acid. Here, pilot plant and commercial c3 and c4 alkylates were examined for sulfur content, acid content, and emulsion formation. Surplus ammonia is a byproduct from the onsite urea production plant.
Sulphur plants produce valuable energy universul consulting. Doublecontact acid plants collect from 98 to more than 99 percent of the so2, emitting about 500 parts per million ppm so2. Material and energy balance chapter 6 material and. Plant design for sulfuric acid manufacture1 free download as. Plant design for sulfuric acid manufacture1 sulfur dioxide. 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. One of the most powerful and important tool of process integration is exergy analysis. Further the oleum formed reacts with water to form sulfuric acid 98 percent.
For example, the extent of process heat recovery is a tradeoff between the cost of energy and the cost of heat exchangers usually expressed as a cost of heat exchange area. Product which is to be manufactured is assumed to have strength of 98% acid. Following this step, the sulfur dioxide is converted to sulfur trioxide, using a catalyst. The first method, path approach, is shown for a simple a to 2b reaction. Respirator selection must be based on known or anticipated exposure levels, the hazards of the product and the safe working limits of the selected respirator.
Sulfuric acid is a useful acid to have on hand for a variety of home chemistry projects. 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. A single absorption acid plant with a sodium scrubber plant y was studied during a loss of ph control in the sodium scrubber, specific gravity variations, and evaporator plugging in the reclaiming system. Production of sulfuric acid using double contact double absorption process, complete description. As well, clean gas is required to prevent plugging of catalyst beds and. The final product contains 2224% of so 3 dissolved in sulfuric acid, and the theoretical purity is 105% since it is possible to generate more sulfuric acid just by adding water. Epa 450277019 control of sulfuric acid mist emissions from. This is because the claus reaction, which is employed to convert h 2s to elemental sulphur, is exothermic, and thewaste heat from the process can be.
We have our own technology specially designed and developed to increase the efficiency and costeffectiveness of sulfuric acid plants. From hot and wet gas cleaning to the sulfuric acid plant and acid production, we use our proven expertise to develop the most technologically. The wet sulfuric acid process wsa process is one of the key gas desulfurization processes on the market today. Dedicated acid tank and cooler for final absorption tower. This energy is recycled by the plant and can even be sold to other plants for use in chemical manufacture.
Material and energy balance chapter 6 material and energy. Reduction of these emissions could be attained by washing with water or ammonium hydroxide in a scrubber. Reducing cooling tower acid usage key concepts and concerns. A sulfuric acid plant is primarily comprised of a central catalytic so 2 converter, so 3 sulfur. Ammonium sulfate crystallizers for fertilizer production. The invention relates to a method for producing gaseous hydrogen and strong sulphuric acid 97100 wt% simultaneously from sulphur dioxide gas and water. Pdf design of a plant to manufacture sulfuric acid from.
The sulfuric acid process is highly exothermic and the heat recovery is a substantial part of the process. The head of outotecs metals, energy, and water business, kalle harkki, reassured ocp that the plant would be built safely. Process heat recovery and digitalisation in sulphuric acid plants. It is this that permits additional so2 oxidation in the next catalyst bed. Assessment of energy performances of a sulfuric acid. Outotecs sulfuric acid technology has proven to be one of the. Mar, 2015 two methods are shown for computing a change in enthalpy when there are reactions. Sulphuric acid plants, process, heat recovery, herostm, outotec. Sulphuric is an engineering software package for design and simulation of plants producing sulphuric acid, oleum, liquid so3, chlorosulphonic acid etc. For economical operation of sulphuric acid plant should be minimum 250 mtday. The business today, under veolias ownership, continues to be the benchmark for sulfuric acid plant operations and services.
Energy flow chart of a double contact double absorption plant burning elemental sulphur 1,000 td. Outotec to build sulfuric acid plant to moroccos ocp. The electric utility sulfuric acid plant aragon 1986. Basics types of acid plants metallurgical acid plants basic reactions catalyst conversion single vs. An advanced process analysis system is a powerful tool for use by process and plant engineers to perform comprehensive and indepth evaluations of economic, environmental. Corporate headquarters intermediate chemical producer. Review the fundamentals of the sulphuric acid process, plant design and operation. Oleumsulfuric should be used to chemically induce moisture removal. Mecs offers worldclass knowledge of sulfuric acid, innovative technologies and proprietary products for the entire acid plant. Pdf production of sulfuric acid engr sajid chaudhary. Water balance the water balance for a conventional 2000 td sulphurburning acid plant, based on evaporative cooling, is given in table ii. Nuberg epc has been providing plant design, engineering, technology and turkey solutions to the sulfuric acid industry for 20 years. Since the danish catalyst company haldor topsoe introduced and patented this technology in the late 1980s, it has been recognised as an efficient process for recovering sulfur from various process gasses in the form of commercial quality sulfuric acid h 2 so 4, with simultaneous. Spent sulphuric acid regeneration sar process s everal chemical processes utilise concentrated sulphuric acid as a catalyst or dehydrating agent, in which the acid becomes spent.
Nature of heat recovery due to the exothermal reactions taking place in a sulphuric acid plant, the recovery of process heat generated in the oxidation sections sulphur furnace converter section is commonly known. However, when reliability of supply and the energy produced by a sulphur burning. Rockefellers first oil refinery standard oil of ohio with barrels of sulfuric acid on horsedrawn wagons. Now, in the last step if we directly add water to sulfurtrioxide formed in second step,it yield sulfuric acid but the reaction is. When the acid is not concentrated enough additional mist formation could take place. The southern african institute of mining and metallurgy base metals conference 20 r.
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. From sulfur to sulfuric acid university of kwazulunatal. Sulphuric acid plant fundamentals sulphuric acid on the. Thermodynamic properties of aqueous sulfuric acid hannu sippola, and pekka taskinen department of materials science and engineering, metallurgical thermodynamics and modeling, aalto university school of chemical technology, p. Sulfur based thermochemical energy storage for solar power. Water is syphoned off and recycled through a surge cooling pond to the phosphoric acid figure 8. Double absorption plant water balance autothermal gas drying absorption energy recovery emissions. Sulphur plants produce valuable energy use it wisely. The solutions above allow to have so 2 emissions at stack within the limit of 100 ppmv equivalent to a conversion factor over 99. Very often, the design engineer will find that several designs have very close economic. Sulfur based thermochemical energy storage for solar power tower author. Based in vancouver, canada, we boost our local capabilities with support from our custombuilt fabrication facility and research lab plus other global centers of excellence in toronto, perth, moscow and santiago. The information found here will help energy and plant managers identify.
An analysis of concentrating solar power with thermal energy storage in a california 33% renewable scenario paul denholm, yihhuei wan. Symphos 2015a, 3rd international symposium on innovation and technology in the phosphate industry process heat recovery and digitalisation in sulphuric acid plants. Pdf design of a plant to manufacture sulfuric acid from sulfur. It is a colorless, odorless, and viscous liquid that is soluble in water and is synthesized in reactions that are highly exothermic. Energy resources of australia ltd era mines uranium ore and produces drummed uranium oxide at its ranger mine 260 kilometres east of darwin in australias northern territory. Production constraints given by product range, energy source and the availability of.
Alkylation of shortchain olefins with isobutane catalyzed by sulfuric acid is a common process for reformulated fuel. O emissions in nitric acid plants, a powerful greenhouse gas with a high global warming potential. 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. While it may be possible to minimize sulfuric acid usage, there are several technical and operational challenges that must be addressed. Alkylation process alkylation is the process of producing gasoline range material light olefins primarily propylene and butylene with isobutane in the presence of a highly acidic catalyst, either sulfuric acid or hydrofluoric acid. Mecs the threeinone sulfuric acid technology max3tm and. The heat recovery system of a conventional sulphuric acid plant recovers most of the heat produced during the sulphur combustion and the so 2 so 3 conversion, producing 1. A nioshmsha approved airpurifying respirator equipped with acid gasfume, dust, mist cartridges for concentrations up to 10 mgm 3.
274 1306 1 1340 1150 1211 1173 189 1183 1450 283 951 1464 203 172 1313 1037 270 947 139 217 656 947 1451 1330 468 108 1212 452 150 63 1272 1103