Plant Design for Sulfuric Acid Manufacture(1)
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Transcript of Plant Design for Sulfuric Acid Manufacture(1)
![Page 1: Plant Design for Sulfuric Acid Manufacture(1)](https://reader033.fdocuments.us/reader033/viewer/2022061105/543e48a9afaf9fb40a8b5160/html5/thumbnails/1.jpg)
PLANT DESIGN FOR SULFURIC ACID MANUFACTURE
CHU492 PROJECT Harshadul Faseem.P Minas. VP Muhammed Dhanish
Guide: Dr.Lity Alen Varghese
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CONTENTS
• Objective• Process• Plan• Mass balance• Further steps
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OBJECTIVES
• Design a plant for manufacturing sulfuric acid with a capacity of 1000 tones/day of 98% sulfuric acid
• Optimization of processes
• Maximize the heat recovery
• Reduce the emission of sulfur dioxide
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PROCESS• Lead chamber process• Contact process
• Single absorption• Double absorption (DCDA)
Among these the DCDA process is the most modern process which has got increased yield and reduces stack emission of SO2
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The DCDA process• Raw Materials
• Molten Sulfur• Air• Water
• Reactions
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Process Flow Chart
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PLAN• The whole project has been divided to seven
different stagesStage Work
1 Identification of the best process
2 Mass balance and heat balance of the selected process
3 Design of heat transfer equipments (two heat exchangers, two waste heat boilers)
4 Design of mass transfer equipments ( two absorption columns and drying tower)
5 Design of four stage catalytic converter and burner
6 Selection transport equipments (pumps and blower)
7 Optimization and cost analysis
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MASS BALANCE
• Assumption• Complete burning of S in the burner• 99.8 % conversion of SO2 to SO3 in the reactor
• Overall absorption of SO3 in the process is 100%• 40% excess oxygen is provided • Humidity of entering air is 65% at 300 C
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Simplified flowchart for mass balance
Dryer
Burner
Reactor Absorption column
Absorption column
Tank 1 Tank 2Molten sulfur
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Calculation• Product = 1000 tones/day of 98% H2SO4
• Taking basis of 1hr operation • Primary estimations:
SUBSTANCE AMOUNT (kmole)
Final product :H2So4 416.67
Equivalent SO3 required 416.67
So2 needed (SO3/0.998) 417.502
O2 required 626.25
O2 supplied (40% excess) 876.75
Total amount of dry air 4175.01
N2 present 3298.26
Moisture present 110.98
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Drying tower
2141.23 kmole98% H2SO4
2251 kmole97% H2SO4
4285.99 kmoleMoist air DRYER
4175.013 kmoleDry air
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The Burner
BURNER3298.26 kmole N2
876.75 kmole O2
417.502 kmoleMolten sulfur
417.502kmole SO2
459.248 kmole O2
3298.26 kmole N2
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Reactor (4 stage catalytic converter)
Stage % conversion1 74.02 18.43 4.34 3.1Overall conversion
99.8
417.502kmole SO2
459.248 kmole O2
3298.26 kmole N2
13.778 kmole SO2
257.385 kmole O2
403.724 kmoleSO3
3298.26 kmole N2
First three stages
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Inter-pass absorber
Absorber 1
13.778 kmole SO2
257.385 kmole O2
403.724 kmoleSO3
3298.26 kmole N2
13.778 kmole SO2
257.385 kmole O2
158.01 kmoleSO3
3298.26 kmole N2
2450.718 kmole98 wt% H2SO4
2450.718 kmole100 % H2SO4
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Reactor (fourth stage)
13.778 kmole SO2
257.385 kmole O2
158.01 kmoleSO3
3298.26 kmole N2
0.835 kmole SO2
250.91 kmole O2
170.95 kmoleSO3
3298.26 kmole N2
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Final absorber
Absorber 2
0.835 kmole SO2
250.91 kmole O2
170.95 kmoleSO3
3298.26 kmole N2
0.835 kmole SO2
250.91 kmole O2
3298.26 kmole N2
1709.6 kmole98 wt% H2SO4
1709.6 kmole100 % H2SO4
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Final absorber circulating tank
Tank 2
1709.6 kmole100 % H2SO4
1709.6kmole98 wt% H2SO4
189.95 kmole98 wt% H2SO4
189.95 kmolewater
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Inter pass absorber circulating tank
Tank 12251 kmole97% H2SO4
2141.23 kmole98% H2SO4
462.25 kmole98% H2SO4
2450.718 kmole100 % H2SO4
2450.718 kmole98 wt% H2SO4
189.95 kmole98 wt% H2SO4
161.32 kmolewater
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FURTHER STEPS
• Energy balance• Equipment design and selection• Optimization and cost analysis
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Reference
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THANK YOU