2.
SULPHURIC ACID PLANT
2.1. Introduction
Sulphuric acid is a highly corrosive strong metal acid with the molecular
formula H2SO4 and molecular weight 98.079 g/mol. It is a pungent-ethereal,
colourless to slightly yellow viscous liquid that is soluble in water at all
concentrations. Sometimes, it is dyed dark brown during production to alert
people to its hazards. The historical name of this acid is “Oil of Vitriol”.
Fig-2.1: Bond structure of H2SO4
Sulphuric acid is a diprotic acid and shows different properties depending upon
its concentration. Its corrosiveness on other materials, like metals, living tissues
or even stones, can be mainly ascribed to its strong acidic nature and, if
concentrated, strong dehydrating and oxidizing properties. It is also
hygroscopic, readily absorbing water vapour from the air. Sulphuric acid at a
high concentration can cause very serious damage upon contact, since not only
does it cause chemical burns via hydrolysis, but also secondary thermal burns
through dehydration. It can lead to permanent blindness if splashed onto eyes
and irreversible damage if swallowed.
Sulphuric acid as wide range of application including in domestic acidic drain
cleaners, as an electrolyte in lead-acid batteries and in various cleaning agents.
It is also a central substance in chemical industries. It is mainly used in mineral
processing, fertilizer manufacturing, oil refining, wastewater processing and
chemical synthesis. It is widely produced with different methods such as:
Contact process, Wet Sulphuric acid process, Lead chamber process and some
other methods.
At Kesoram Rayon plant we only learned about Double Contact Double
Absorption [DCDA] process (two different plants: DCDA I and DCDA II) for
production of Sulphuric acid.
2.2. Production Process
Raw Materials: Sulphur and Oxygen (from air).
Sulphur is melted using steam at the temperature 125°C.
Molten Sulphur is pumped into Furnace and reacted with excess air at
the temperature 1000°C.
Sulphur reacts with oxygen to produce Sulphur dioxide. Again excess
oxygen reacts with Sulphur dioxide to produce trace amount of Sulphur
trioxide.
Reaction: S + O2 SO2
SO2 + O2 SO3
A Waste Heat Boiler is used to reduce the temperature from 1000°C to
440°C, which produces steam from the water that is obtained from the
water treatment plant.
The gas mixture from the furnace is passed through a packed vessel. The
packing removes Sulphur particles from the gas mixture.
The gas mixture is sent to the 1st pass of absorption tower. The hot gases
from the 1st pass is sent to the Auxiliary Boiler to produce steam and
bring down the temperature to 440°C.
The following mixture is sent to 2nd pass where the temperature of the
mixture rises to around 542°C. This hot mixture is passed through the
shell side of Hot Heat Exchanger which brings down the temperature of
this stream to 390°C.
From hot heat exchanger the mixture is sent to 3rd pass where the
temperature of the mixture again rises. To reduce the temperature it is
sent to the shell side of Cold Heat Exchanger.
This mixture is sent to the Economiser followed by Inter-Pass
Absorption Tower (I.P.A.T.) where some of the SO3 is absorbed in
H2SO4 sprayed from the top of the tower, forming Oleum (H2S2O7). This
process reduces the temperature of the gaseous stream to 32.5℃. To
increase the temperature of the stream the mixture is sent to the tube side
of cold heat exchanger followed by the tube side of the hot heat
exchanger which raises the temperature to 416℃.
Reaction: H2SO4 (l) + SO3 (g) H2S2O7 (I)
The gaseous mixture containing small amounts of SO2 and O2 is sent to
the converter again for the 4th pass which ensures 98.5% conversion of
SO2 to SO3. The gases which come out of the converter after the 4th pass
are sent to another Economiser which reduces its temperature to129℃.
This stream is sent to Final Absorption Tower (F.A.T.) where the
remaining SO3 is absorbed in H2SO4. Now the unreacted SO2 and traces
of SO3 and some S are sent to a scrubbing tower where the gases are
scrubbed with Caustic Soda. The acidic gases are absorbed in the Caustic
before releasing these gaseous mixture through a chimney to meet the
environmental regulations.
The Oleum thus produced is sent to the dilution tank where calculated
amount of water is added to it to produce the acid and to maintain the
desired concentration of 98.5%.
Reaction: H2S2O7 (l) + H2O (l) 2 H2SO4 (l)
The acid produced is then sent to Six (6) large storage tanks.
Air Air Waste
Blower Drying Furnace Heat
Tower Boiler
Sulphur Melter Strainer Hot Gas
Filter
HHE
Shelling Auxiliary
2nd Pass Converter 1st Pass in (70-
Boiler 80) % conversion
CHE CHE
3rd Pass ECONO IPAT
Shelling Tube
SO2 4th Pass HHE
FAT ECONO
Scrubber Tube
Channel
Acid Circulation Tank Cooler
Acid Storage Tank
Fig-2.2: Catalytic Converter
BLOCK DIAGRAM OF DCDA FOR
SULPHURIC ACID PRODUCTION
Fig-2.3: Acid Dilution Tank
Fig-2.4: Boiler Feed water Control Valve
Fig-2.5: Furnace
Fig-2.6: Acid Storage Tank
2.3. Industrial Uses
Sulphuric acid is a very important commodity chemical, and indeed, a nation’s
Sulphuric acid production is a good indicator of its industrial strength. World
production in 2004 was about 180 million tonnes, with the following geographic
distribution: Asia 35%, North America 24%, Africa 11%, Western Europe 10%,
Eastern Europe & Russia 10%, Australia & Oceania 7%, South America 7%.
Most of these amount is used for fertilizers particularly super phosphate,
ammonium phosphate, ammonium sulphate. About 20% is used in chemical
industries for production of detergents, synthetic resins, pharmaceuticals,
petroleum catalysts, insecticides and antifreeze, acidizing aluminium reduction,
paper sizing, and water treatment. About 6% uses are related to pigments and
include paints, enamels, printing inks, coated fabrics and paper, and the waste is
dispersed into a multitude of applications such as production of explosives,
cellophane, acetate and viscous textiles, lubricants, non-ferrous metals and
batteries.
2.4. Domestic Uses
Sulphuric acid at high concentrations is frequently the major ingredient in acidic
drain cleaners which are used to remove grease, hair, tissue paper etc. Similar to
the alkaline versions, such drain openers can dissolve fats and proteins via
hydrolysis. Moreover, as concentrated sulphuric acid has a strong dehydrating
property, it van remove tissue paper via dehydrating process as well. Since the
acid may react with water vigorously, such acidic drain openers should be
added slowly into the pipe to be cleaned.
