3. The Production Process The Production Process · The Production Process Historically, sulfuric...
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6 The Production Process The criteria of purity and accuracy of grade are the primary goals of sulfuric acid production. The Contact Process, described here, is almost universally used to convert SO 2 to H 2 SO 4 Weak Acid Solution 93% Acid Stream SO 2 Gas Stream 98% Acid Stream SO 3 Gas Stream Acid Pumps Quench Tower: Weak acid jets remove particulate matter from hot process gasses Scrubber: Further contact with acid jets provides additional cooling and cleaning Electrostatic Precipitators: Acid mist and remaining dust particles removed Weak Acid Pump Tank 3. The Production Process Historically, sulfuric acid production was based on the Lead Chamber Process, involving the oxidation of sulfur dioxide by nitric acid and nitrogen oxides in the presence of water. This has been replaced by the Contact Process in which sulfur dioxide is oxidized by atmospheric air at high temperatures and in the presence of a vanadium pentoxide catalyst. Specifics will vary from one plant to another, but this description is provided as an overview of a typical Contact Process. The process begins with cleaning of the gas. The sulfur dioxide from smelting and roasting operations passes through a series of gas cleaning steps that ©N No o o or r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r rF F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F Falc c c c c c c c c c c c co o o o o o o o o o o o o. B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B By y y y y y y y y y y y y y y y r r r r r r r r r r r r e e e e e e e e e e e e e e e e e e e e ead d d d d d d d d d d d d d d d d d d d d d di i i i i i i i i i i i i i i i i i i i i i i i in n n n ng g g g g g g g t t t t t t t t t t t t th h h h h h h h h h h h h h h h h h h h h h h h h h h h h h h h h h h h hi i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i is s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d do o o o o o o o o o o o o o o o o o o o o o o o o o oc c c c c c c c c c c c c c c c c c c c c c c c c c c cu u u u u u u u u u u u u u u u u u u u u u u u u u u u u u u u u u u u u u u u u u u u u u um m m m m m m m m m m m m m m m m m m m m m m m m m m m m m 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p p p p p p p p p p p p p p p p p p pr r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r ro o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o od d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d d du u u u u u u u u u u u u u u u u u u u u u u uc c c c c ce e e e e e e e e a a a a a a a a a a a a a a a a a a a a a a a a a a a an n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n ny y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y p p p p p p p p p p p p p p p p p p p p p p p p p p p p p p p p p p p p p p p p p p p p p p p p p p p p p a a a a a a a a a a a a a a a a a a a a a ar r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r rt t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o of f f f f f f f f f i its co o o o o o o o o o o o o on n n n n n n n n n n n n n n of its n n n n n n n n n n n n n n n nt t t t t t t t t tent o o o o o o o o o o o o o o o o o o of f f f f f f f f f f f f f f f f f f f f f f f s o o o o o o o o o o o o o o o on n n n n n n n n n n n n n n n n n n n n n n n n n nt t t t t t t t t t te i i i i i i i i in n n n n n n n n n n n n n n n a a a a a a an n n n n n n n n n n n n n n ny y y y y y y y y y y y y y y y y y y y y y y y f f f f f f fo o o o o or r r r r rm m m m m m m m m m m m m m m m m m m m m m m m m m m m m m m o o o o o o o o o o o o o o o o o o or r r r r r r r r r r r r r r r f f f f f f f f f f f f f f f f f f f f f f fo o o o o o o o o o o o o o o o o o o o o o o o or r r r r r r r r r r r r r r a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a an n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n ny y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y y p p p p p p p u u u u u u u u u u u u u u u u u u u u u u ur r r r r r r r r r r r r rp p p p p p p p p p p p p p p p p p p po o o o o o o o o o o o o o o o o o o o o o o o o o os s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s se e e e e e e e e e e e e e e e e e e e e e e e e e e w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w wh h h h h h h h h h h h h h h h h h h h h h h h h h h h h h h h h h h h h h h h h h h h h h h h h h h h h h h h h h h h h ha a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a a at t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t ts s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s so o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o oe e e e e e e e e e e e e e e e e e e ev v v v v v v ve e e e e e e e er r r r w w w w wi i i i i i i i i i it t t t t t t t t t t t t t th h h h h h h h h hou u u u u u u u u u u ut t t t t t t t t t t t t t t t th h h h he e e e e e p p p p p p p p pr r r r r r r r r r r r r r r r ri i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i io o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o or r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w w wr r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r ri i i i i i i i i i i i i i i i i i i i i i i i i i i i i i it t t t t t t t t t t t t t t t t t t t t t t t t t t t t tt t t t t t t t t t t t t t t t t t t t t te e e e e e e e e e e e e e e e e e en n n n n n n n n n n n n n n n n n n n n n n n c c c c c c c c c c c c c c c c c c c c c c c c c c c c c c c c c c c c c c c c c co o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o o on n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n ns s s s s s s s s s s s s s s s s s s se e e e e e e en n n n nt t t t t t t t t t t t t t t t t t t o o o o o o o o o o o o o o of f f f f f f f f N N N N N N N N N N N N N N N No o o o o o o o o o o o o o o o o o o o o o o o o o o o or r r r r r r r r r r r r r r r r rF F F F F F F F F F F F F F F F F F Falco. The criteria accu cu cu cu cu cura ra ra ra ra racy cy cy cy cy cy of g the primary g g g go g g lf i id d d d sulfuric acid prod d d d d d d du Th T T e Contact Pro o oc o o o o e de d d d d d d d scribed he er r r re r r r r , is al al al al al al a al al al l alm m mo m st univers sa a al a a a a ly used to to to to to to to to to to to c c c c c c c con o vert SO O O O 2 2 2 2 2 2 to H 2 SO Sc crubber: Further contact with aci a d jets provides de des e des es es des des e des d additiona a a a al c l c l c l c lc c l c l c c lc c l oo ool oo o o o o o o o ing g ng ng ng g g and cl cl cl cl l cl cl cl cl c c c ea ea ea ean e ea ea ea e e e ing ng ing ing ing ng ng ng ng g ing g ng
Transcript of 3. The Production Process The Production Process · The Production Process Historically, sulfuric...
6
The
Production
Process
The criteria of purity and
accuracy of grade are
the primary goals of
sulfuric acid production.
The Contact Process,
described here, is
almost universally used
to convert SO2 to H2SO4
Weak Acid Solution
93% Acid Stream
SO2 Gas Stream
98% Acid Stream
SO3 Gas Stream
Acid Pumps
Quench Tower:Weak acid jets removeparticulate matter fromhot process gasses
Scrubber:Further contact with
acid jets providesadditional cooling
and cleaning
ElectrostaticPrecipitators:Acid mist and remainingdust particles removedWeak Acid
Pump Tank
3. The Production ProcessHistorically, sulfuric acid production was based on the
Lead Chamber Process, involving the oxidation of
sulfur dioxide by nitric acid and nitrogen oxides in the
presence of water. This has been replaced by the
Contact Process in which sulfur dioxide is oxidized by
atmospheric air at high temperatures and in the
presence of a vanadium pentoxide catalyst.
Specifics will vary from one plant to another, but thisdescription is provided as an overview of a typicalContact Process.
The process begins with cleaning of the gas. Thesulfur dioxide from smelting and roasting operationspasses through a series of gas cleaning steps that
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Drying TowerPumpTank
Drying Tower:Clean gasses are dried by contactwith concentrated H2SO4
Converter:SO2 in the clean dry gas isconverted to SO3
HeatExchangersbetweeneach stageof conversion
Absorption Tower:SO3 is absorbed by waterin concentrated acid toform more H2SO4
Absorption TowerPump Tank
To Stack
SO2 Stripper: Air streamremoves excess SO2
To DryingTower
98%
93%96%
cool and remove almost all metallurgical dusts.The gas is then drawn through electrostaticprecipitators where acid mist and any remainingdust particles are removed. The wet gas is driedin a tower by direct contact with 93% sulfuricacid and a blower then forces the gas through aseries of heat exchangers and converter beds,where, in the presence of vanadium pentoxide,the sulfur dioxide is oxidized to sulfur trioxide.
The purpose of the heat exchangers is to utilizethe heat of reaction in the converter beds to heatthe incoming cool gas to the reactiontemperature. The SO3 gas then passes throughan absorption tower where it combines with thewater in 98% sulfuric acid to make additionalsulfuric acid.
Depending on the required product strength,acid from the absorption or drying towers can bestripped of SO2, cooled, and pumped tostorage. Some acid is exchanged between theabsorption and drying circuits to maintain acidstrength.
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