11/18/21, 3:23 PM Stick Test

Sulphuric Acid on the WebTM Technical

Manual DKL Engineering, Inc.

Knowledge for the Strong Acid System - Troubleshooting

- Stick Test
Sulphuric Acid May 23, 2014

Industry
Introduction

A stick test is a qualitative test used to troubleshoot the operation of a dry or absorber tower and its
Sulphuric Acid on the mist eliminators.  The test basically consists of inserting a wooden stick in the gas flow exiting the
Web tower.  Any acid particles impacting the stick will leave a dark spot on the surface of the wood.  The
quantity and size of the spots will provide an indication of the tower and mist eliminator performance. 
Introduction
General A large number of small spots (< 5 mm diameter) on the stick will indicate problems with the mist
Equipment Suppliers
eliminator, typically re-entrainment of acid.
Contractor
Instrumentation
Industry News A uniform darkening of a dry stick will indicate the presence of high SO3
concentrations.  The
Maintenance moisture present in the wood reacts with the unabsorbed SO3 from the absorber tower causing the
Acid
Traders
uniform darkening.
Organizations
Fabricators
Conferences A stick test that results in a heavily spotted or black wet stick indicates a case of severe gas
Used
Plants bypassing, mist eliminator flooding, high inlet loadings, etc.  These problems are serious and should
Intellectual
Propoerty be addressed immediately before long-term damage to downstream equipment occurs.
Acid
Plant Database
Market
Information
Library
Ideally, a stick test should be performed far enough downstream from the tower in a straight  
horizontal section of stainless steel duct.  The stick should be inserted vertically in the gas stream.  
Stick tests performed too near the tower exit can be affected by the turbulent flow conditions of the
Technical Manual gas as it exits the tower.   The presence of an elbow at the tower exit can further complicate the test
 
results.
Introduction
General
Definitions Acid condensing on the walls of the duct can affect the stick test if this acid is re-entrained into the
Instrumentation gas stream.  Sulphate formation on the inside walls of a carbon steel duct can also affect the stick
Plant Safety test.
Metallurgial
Processes
Metallurgical
This procedure is general in nature and as such should be adapted to the specific conditions and
Sulphur Burning
Acid Regeneration
procedures existing at the site at the time the operation is performed.
Lead Chamber
Technology
Gas Cleaning
Contact
Strong Acid
Acid Storage
Loading/Unloading
Transportation
Sulphur
Systems Safety
Liquid SO2
Boiler Feed Water Personnel shall wear as a minimum SO2 respirators, protective goggles, face shield, clothing and
Steam Systems
Cooling Water
gloves.  Stick tests performed on towers where the tower is operating under pressure will be
Effluent Treatment hazardous due to the process gas (containing SO2, SO3/Acid mist) that will escape when the valve is
Utilities open.
Construction
Maintenance
The location of stick test valve is often high up where access may be difficult.  Ensure that suitable
Inspection
Analytical Procedures
access is provided (either permanent or temporary).  Safety harnesses may be required if a falling
Materials of Construction hazard is present.
Corrosion
Properties Equipment and Supplies
Vendor Data

The following equipment will be required:

DKL Engineering, Inc.
1"x1" square light coloured wood sticks (typically pine) long enough to span across the entire
Handbook of Sulphuric Acid
Manufacturing duct.
Order
Form Some form of stopper or plug to minimize the flow of gas out of the valve.
Preface
Contents
Stopwatch or timer
Feedback
A full bore valve (minimum 2" diameter) is required in the tower outlet duct.  Safe access to the valve
Sulphuric Acid Decolourization is also required.  A ball valve is recommended since it can be opened and shut quickly.
Order Form
Preface Procedure
Table of Contents

1.       Decide on the length of time to perform the stick test.  A 2 to 3 minute test is typical.
Process Engineering Data
Sheets - PEDS 2.       Ensure that all safety equipment is being worn.
Order Form
Table of Contents 3.       Quickly open the stick test valve.  Stand off to the side of the valve to avoid being hit by any
Introduction liquid, sulphate, etc. that may be in the valve.

Bibliography of Sulphuric Acid 4.       Immediately insert the stick so that it spans across the entire duct.  Ensure that the stopper or
Technology plug is in place to minimize the gas that exits through the valve.  The stick will need to be held
Order Form in place to prevent it from moving.
Preface
Contents 5.       When the allotted time is reached, quickly remove the stick and close the valve.
6.       Immediately examine the stick and record the observations.
Sulphuric Acid Plant
Specifications 7.       Perform additional stick tests as required based on the results of previous tests.   The insertion
  time can be varied based on previous results.
The following operating conditions should be noted whenever a stick test is performed:
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11/18/21, 3:23 PM Stick Test
Gas flow or plant capacity
Acid conditions in the tower (temperature, concentration, flow)
Gas temperature exit the tower
Mist eliminator pressure drop
Any visual observations at the time of the test (stack appearance, view through tower sight
glasses)

After many tests are performed, a 'database' of sticks will be available for each tower representing
various operating conditions and problems.   Typical sticks should be retained for future comparisons.

Stick Test Device

Performing stick tests on towers that are operating under pressure can be hazardous due to the gas
that escapes from the open valve.  Some operators attempt to reduce the flow gas by stuffing pieces
of cloth around the stick.  A simple device constructed of rubber gaskets can greatly improve the
safety of performing stick tests.  An opening the shape and size of the stick is cut into the centre of
the gasket.  The opening is slightly smaller than the dimensions of the stick.  Two or three gaskets are
used to ensure a good seal around the stick.  The gaskets are mounted on the stick test valve using a
standard flange.

Stick Test Device - Rubber gaskets and CPVC

mounting flange

Stick test valve

Stick test device mounted on valve

Stick test valve and device with stick inserted

A test of the device indicated a large reduction in the amount of gas leaking out of the open valve
providing for improve operator safety.

Video
 
Hanging Candle Stick Test

When a stick test reveals that there is carry over of acid droplets it is difficult to determine which candle
is causing the problems.  Sight glasses in the tower give a limited field of vision and are often dirty to the
point where nothing can be seen inside the tower.  Even during an internal inspection of the tower it is
sometimes difficult to locate the problem.

A stick test can be performed inside the tower by placing sticks across the top of candles in the standing
position.  The plant blower is operated for a short time blowing air through the plant.  When the sticks
are examined it may be possible to determine which candle is bypassing and even if a gasket is leaking.

The following picture shows acid droplets that have impacted on a stick.  The pattern clearly shows that
acid was being sprayed by a gasket leak from an adjacent candle.

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11/18/21, 3:23 PM Stick Test

This picture shows acid droplets that have impinged on a stick place over the outlet of the candle.

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