INDIVIDUAL REPORT
DESIGN OF A PLANT TO MANUFACTURE SULFURIC ACID FROM SULFUR
1.1 INTRODUCTION
The properties of Sulfuric acid vary depending upon its concentration. Direct contact of Sulfuric acid with
anything from tissues (e.g. skin and flesh), metals, to stones will lead to their degradation while a more
acidic concentration will lead to their degradation in the form of corrosion.
This project highlights the design of a plant for manufacturing Sulfuric acid.
from Sulphur, with focus on process selection, economic viability, safety
considerations and environmental impact.
1.2 Process Selection
The Contact Process delivers higher purity and concentration of sulfuric acid than the traditional Lead
Chamber Process. It also exhibits lower operating costs due to the use of vanadium pentoxide catalyst,
which is more efficient and cost effective than platinum.
1.3 Applications of Sulfuric acid
Sulfuric acid has many uses in industrial processes, including the following:
Phosphoric Acid Production: This is the "wet method" to make phosphoric acid through the reaction
of rock phosphate with sulfuric acid, which results in calcium sulfate and hydrogen
fluoride, mainly used in fertilizers.
Iron and Steel Manufacturing: Sulfuric acid removes rust and oxidation from steel. Spent acid is
regenerated in SAR units for the production of fresh sulfuric acid with minimal cost.
Aluminum Compounds: Used to make aluminum sulfate for paper production and aluminum hydroxide
for water treatment. Ammonium sulfate is one of the major nitrogenous fertilizers and a by
product of ammonia in steel plants, which is produced by the reaction between ammonia and
sulfuric acid.
1.4 Raw material selection
Sulfuric acid is manufactured mainly from sulfur known as brimstone which
is usually obtained from regions of volcanic activity and hot springs or salt domes. It is
for this reason that 62% of world production of sulfuric acid is by this method. Sulfur is often obtained as
a by-product of petroleum refining. In metal smelting, sulfuric acid is used in various metal extraction
processes, such as copper and nickel, in "roasting." The
sulfur contained in these processes is converted to sulfur dioxide (SO₂), which is then transformed into
sulfuric acid. Smelter gases, rich in sulfur dioxide, contribute to about 26% of global sulfuric acid
production. A number of smelting plants utilize sulfuric acid regeneration units that recycle smelter
gas back into acid for the plant's operations.
1.5 Process equipment design consideration and selection
1.5.1 Contact process
Contact process can be divided into the following main steps. Among these main steps, several sub
process are used to optimize the manufacturing process.
1. Combining of Sulfur and oxygen;
2. Purifying Sulfur Dioxide in the purification unit;
3. Adding excess of oxygen to Sulfur Dioxide in presence of catalyst vanadium oxide;
4. High concentrated Sulfuric acid is added to Sulfur Trioxide , as a result Oleum is produced
5. Water is added to Oleum and 98% Sulfuric acid is formed.
Basic chemical reactions associated with this process are as follows:
1. S(l) + O2(g) - > SO2(g)
2. SO2(g) + ½ O2(g) < - > SO3(g) Δ = -99 kJ/mol
3. SO3(g) + H2SO4(l) - > H2S2O7(l)
4. H2S2O7(l) +H2O(l) - > 2H2SO4(l)
1.5.2 Establishing of production process
The previous chapter and sections have given an account of the findings from the review of literature
with regards to the available production processes and auxiliary aspects surrounding Sulfuric acid
production. What follows is the suggested process flow of the manufacture of Sulfuric acid indicating
minor variations possible and additional justifications for each specific selection.
Block diagram of selected process:
Based on features of available processes that had been identified during the review of literature and based
on above justifications, a block diagram depicting the process flow for the production of Sulfuric acid is
given below.
Figure 1.5 Complete block diagram of selected process
CHAPTER 2
ECONOMIC ANALYSIS
2.1 Economic analysis of design and evaluation
Cost estimation in the design of a chemical
plant plays an important role in feasibility study and the selection of manufacturing
process. The estimation is done regarding two kinds of capital: Fixed Capital - to erect a fully
functional plant, and Working Capital - to keep the plant in operation. Total
investment = Fixed Capital + Working Capital Early in the design, a rough financial proposal is put
forward; at this stage, the capital cost estimate can only be considered accurate to ±30%.
Fixed Capital Investment
Fixed Capital Investment (FCI) encompasses the setting up of plants, which
includes equipment like furnace, catalytic converter, absorption tower, etc., land, infrastructure, and
installation or commissioning.
Working Capital Investment (WCI): covers the operation expenditure that includes raw materials
(sulfur, water), labor cost, utilities-costs for power, steam, air, etc.-consumables
(catalysts) used, operating cost, etc.
Fixed Operating Cost: Salaries, depreciation, and insurance.
Operating Variable Costs: Cost of raw materials, utilities, maintenance, waste disposal,
and replacement of catalysts.
Revenue Generation:
Product Sales: Revenue is mainly generated through the sale of sulfuric
acid, whose price depends on different purities or market situations. Other by-
products, such as oleum or sulfur dioxide, may add to revenue generation.
Market Demand: Prices depend on worldwide demand for products in
industries such as fertilizers or petroleum refining. Long-term contracts or a spot market may
influence prices
Financial Metrics:
Payback Period
The payback period measures how long it will take for the plant to recoup its initial capital investment
from operating profits.
����� ������� ����������
Payback period = ������ ��� ������
Return on Investment (ROI)
ROI measures the return generated relative to the capital invested.
��� ������
ROL = ����� ������� ���������� ×100
Net Present Value (NPV)
NPV evaluates the present value of future cash flows from the project, discounted to account for the
time value of money. The formula is:
��� ���ℎ ���� �� ���� �) −������� ����������
NPV=∑( (1+�)�
.
CHAPTER 3
FLOW SHEETING OF MASS AND ENERGY BALANCE
3.1 Mass Balance
The mass balance was prepared for the plant operating under steady state (and thus zero
accumulation assumed) with a one hour basis.
Mass in + mass generated = mass out + mass consumed + losses
3.2 Energy Balance and utility requirements
Energy can enter a unit in the form of inputs such as mass transfer from process lines, heat transfer
from utilities, or work done such as pressure work or shaft work related to mixing or pumping.
Since these units operating in the plant-melter, furnace, converter, absorption columns, etc.-are under
atmospheric conditions, it was assumed that all pressure-volume work would be negligible compared to
heat and mass transfer. It would be assumed that energy input due to work done (such as in pumping or
fluid transport) is a fraction of the total, the remainder being lost during transport. Since accurate power
ratings or efficiencies for pumps, compressors, and fans are not available at this stage, estimates
of energy content are based on mass transfer and known equipment (for example, compressors on air
dryers, fans on furnaces, agitators on dilution tanks).
Energy balance expression for a unit in the proposed plant operating at steady state was considered as
shown.
Energy in + energy generated = energy out + energy consumed +losses
Entalpy of a speciese at temotratutre T = Entalpy of formation of that speciese at temprature T
Supose that the reference is taken as standrand temperature and presure, then the specificentalpy of a
�
given speciese at T = ∆Hf = ∆Hf° + �� ��(�)��
Where:
∆Hf= Enthalpy of formation of species at temperature T (with respect to STP)
∆Hf°= Standard enthalpy of formation of species
The integration term included reflects the adjustment that has to be made to the standard
enthalpy when it has to be considered at an eleva ted temperature. This could be viewed as the
incremental rise in enthalpy since it is defined that:
dH = CpdT
�
∆Hf = ∆Hf° + ∆H(T° to T) = ∆Hf° + �° ��
T T
∆Hf = ∆Hf° + T° Cp(T)dT + Latant heat at Ts + Ts Cps(T)dT
In this manner the energy content present in each stream was quantified on a per unit material
basis (in the form of ‘specific enthalpies’ (kJ/kmol)), so that the calculation could be made
simpler. Once obtained for each speices in a stream (process line) the total enthalpy present
in the line with respect to a reference enthalpy was obtained as shown:
∑of speciese (speciese of entalpy at T × molar flow rate =
Total entalpy insteam at T with respect to STP
3.3 Utility considration
[Link] and Heat Generation: Steam for heating purposes, maintaining reaction temperatures, and
energy generation is needed. Boilers and waste heat recovery systems would come into
play with specific views related to energy efficiency, managing pressure, and temperature.
2. Cooling Water: This is required mainly for the cooling of process gases, sulfuric acid, and
absorption towers. The cooling towers or other systems provide cool water, and attention is paid
to water quality, efficient heat transfer, and environmental effects.
3. Compressed Air: The uses include combustion air, feeding the catalytic converter, and pneumatic
controls. Compressed air has to be energy-efficient, free of contaminant, and maintained
at constant pressure.
[Link] Supply: Water is used for cooling, dilution, and absorption. It may be raw water or treated
water. Some considerations are water treatment, efficient use, and wastewater treatment.
5. Electric Power: Power drives pumps, compressors, fans, and instrumentation. A reliable power
supply, energy-efficient equipment, and backup power systems are of essence.
6. Waste Treatment and Disposal: Wastewater, gas emissions (SOx, acid mist), and solid waste (spent
catalysts) should be properly treated. Proper treatment entails regulatory compliance and considerations
for minimizing the rate of waste generation.
7. Safety and Emergency Systems: Such as fire suppression, gas leak detection, and emergency power
systems are highly important for assurance of plant safety. Proper training and emergency procedures
are necessary.
CHAPTER 4
4.1 ENVIRONMENRAL ANALYSIS OF DESIGN
Sulfuric acid production plants cause pollution in the environment: sulfur oxides, acid mist, dust, and
waste liquids. Management should take a proper approach to minimize
emissions according to the CEA standards for environmental protection. Treatment can
be done within the plant itself before waste discharging. The poor conversion and poor absorption in
the process lead to increased emissions;
therefore, efficiency in the processing method will contribute to reducing the pollutants.
4.1.2 Sources of gaseous pollutants and mitigation of impact in design and operation
Oxides of Sulfur(SOx) and acid mist are the main forms of gaseous pollutants present in manufacture of
Sulfuric acid that can be considered as having an adverse environmental impact if not mitigated. The
absorption column and the catalytic converter can be considered as a main point of emission of Oxides of
Sulfur and possibly small quantities of acid mist (in the case of the absorption columns); since they can be
released to the atmosphere as residue air.
4.1.3 Minimizing catalytic waste
Catalytic waster could be minimized if units to regenerate V2O5 are installed in situ. A cost effective
regeneration with unused catalyst disposal process meeting environmental standards should be
recommended. The caustic leaching method is a common method that is used to recover V2O5 catalyst
in Sulfuric acid plants.
4.1.4 Liquid waste
Several possible points of discharge of liquid waste could be identified in a Sulfuric acid production plant.
It should be treated prior to disposal depending on the properties of the waste water generated since the
properties of the waste could be either highly acidic or alkali with high dissolved solids.
4.2 Minimizing enviromental Impact
Air Quality
The plant shall be provided with state-of-the-art airpollution control measures, inclusive of electrostatic
precipitators,scrubbers, and mist eliminators to
minimize the release of sulfurdioxide, sulfur trioxide, and acid.
Water Management
Wastewater will be treated beforedischarge, utilizing different methods
such as alkaline neutralization and filtration,ensuring compliance with local
environmental regulations.
Catalyst Regeneration
The plant will also use a catalystregeneration process to reduce
waste and increase the sustainability
Noise Control
To minimize noise pollution, soundproofingwalls will be fitted. Provided also are
earplugs to employees to reduce theexposure to high-noise areas.
Reference
Sulfuric Acid plant safety - Sulfur. (2003, November 3). Retrieved May 31, 2013, from
Sulfuric Acid on the web: [Link]
[Link]/techmanual/Plant_Safety/safety_sulphur.htm
Occupational Health and Safety Manual. (2004, October 12). Retrieved June 13, 2013, from
Department of Transporation and Works, New Foundland, Canada:
[Link]
Technical Information and Safe Handling Guide for Methanol. (2006, September). Retrieved
November 10, 2012, from [Link]
Resources/Health---Safety/[Link]
Sulfuric Acid Handbook. (2007, April). Retrieved June 15, 2013, from NorFalco:
[Link]
[Link]
Normal Boiling Points- Sulfuric Acid-Water system. (2008). Retrieved July 14, 2013, from
[Link]
Sulfuric Acid. (2008). Retrieved July 16, 2013, from Chemical Book:
[Link]
