Sulfuric Acid
Sulfuric Acid
Sulfuric Acid
ROYDIA LENSY
UNGKU MUHAMMAD ZUNURAIN
H2SO4
Contact Process
Most important process for making sulfuric acid in industry Involves 3 stages
First stage: Make sulfur dioxide gas by burning sulfur in air S (l) + O2(g) SO2 (g)
Second Stage: Convert sulfur dioxide to sulfur trioxide 2 SO2 (g) + O2(g) 2 SO3 (g) Third Stage: Convert sulfur trioxide to sulfuric acid SO3 (g) + H2O (l) H2SO3 (l)
Contact Process
Source: http://www.sfie.com.eg/EFIC%20Production%20Processes.pdf
Overall Process
MATERIAL BALANCE
PURITY: PRODUCT WHICH IS TO BE MANUFACTURED IS ASSUMED TO HAVE STRENGTH OF 98% ACID. 1000TPD implies that we have 1000 x 103 / 24 = 41666.67 Kg/Hr of Acid With 98% purity, (98 x 41666.67) / 100 = 40833.34 Kg/Hr
MATERIAL BALANCE
MOLS OF SULFURIC ACID PRODUCED SO3 REQUIRED
= 40833.34 / 98 416.667 Kmoles/Hr
SO2 REQUIRED
overall conversion of SO2 to SO3 in the reactor is 99.8% = 416.67 / 0.998 417.51Kmoles/Hr
MATERIAL BALANCE
Title
Assuming 100% combustion of Sulfur, Amount of oxygen required to convert 1Kmole of S to SO3 = 1.5 Kmoles
MATERIAL BALANCE
Dry air in = (876.76 x 100)/ 21= 4175 Kmoles/Hr At 30C, assuming 65% Relative Humidity Humidity = 0.0165 Kg water/ Kg dry air water entering with dry air = 4175 x 29 x 0.0165 = 1997.73 Kg/Hr = 110.980 Kmoles/Hr Total weight of entering air =4175 x 29 + 110.980 x 18 = 123073 Kgs
MATERIAL BALANCE
DRYING TOWER
MATERIAL BALANCE
MATERIAL BALANCE
Sulfur burner
Oxygen leaving = 876.76 417.51 = 459.25 Kmoles Nitrogen leaving =(876.76 x 79)/ 21= 3298.3 Kmoles
MATERIAL BALANCE
MATERIAL BALANCE
Sample calculation for the 2nd stage is shown as follows: Components SO2 kmoles INLET = 108.55 Kmoles
Title
OUTLET = 108.55 417.51 x 0.184 Kmoles = 31.73 Kmoles N2 O2 INLET INLET = 3298.3 Kmoles = 304.78 Kmoles
SO3
INLET
= 308.95 Kmoles
MATERIAL BALANCE
REACTOR
MATERIAL BALANCE
SO2 to SO3
Now for KP at the entering temperature of 4th stage i.e. 427C KP = 270.2
MATERIAL BALANCE
REACTOR: For the second contact we have the following details,
COMPONENTS
MATERIAL BALANCE
MATERIAL BALANCE
FINAL ABSORPTION TOWER:
Let X2 be the Kgs/hr of the acid fed in this tower, Then, 1.0 (X2 + 170.96 x 98) = 0.98 x X2 + 170.96 x 98 Again by trial and error, we have X2 = 16500 Kgs/Hr
MATERIAL BALANCE
ACID PRODUCT RECYCLE
DILUTION WATER
ACID INLET
TANK
MATERIAL BALANCE
Tank 1: Dilution water is added in the tank to bring down the
concentration to the desired 98%, and this is calculated as = 245.718 x 18 + (24080.4 x 2)/98 = 4915 Kgs/Hr Material balance around the tank is given as, Or, 24000 + A1 (24000 + 245.718 x 98 245.718 x 18) - 4915 = 0 Then, A1 = 24572 Kgs/Hr
MATERIAL BALANCE
Tank 2: Dilution water is also added in this tank to bring down the concentration to desired 98%, which is calculated as = 170.95 x 18 + (16754 x 2)/98 = 3419 Kgs/Hr Material balance around the tank is given as, Or, 16500 + A2 - (16500 + 170.95 x 98 170.95 x 18) 3419 = 0 Then, A2 = 17095 Kgs/Hr Then total amount of acid that is formed is = 41667 Kgs/Hr = 41667 x 24 =1000008 Kgs/day =1000.01 TPD
PLANT LOCATION
Industrial Area: Teluk Kalung, Kemaman Land Area: 117400 km sq ft