Sulfuric Acid Production Plant Design
Sulfuric Acid Production Plant Design
Superiors of Tamaulipas
PLANT DESIGN
ING. JOSÉ LUIS VARGAS PÉREZ
PROJECT:
SULFURIC ACID PRODUCTION PLANT
Sulfuric acid is one of the most commonly used chemicals by the industry.
basic chemistry, with a world production of approximately 250 million
annual tons and an estimate of 285 million tons for 2020.
It is obtained from sulfur, from sulfide minerals or from effluents from the
sweetening processes of natural gas. In all cases the product
the intermediate produced is sulfur dioxide (SO2), which is transformed into
sulfuric oxide by a heterogeneous catalytic oxidation process, method
called contact. Finally, sulfur trioxide (SO3) reacts with water.
producing sulfuric acid (H2SO4), this last operation is carried out in towers
of absorption.
The industry that uses sulfuric acid the most is the fertilizer industry. Others
important applications are found in oil refining, production
of pigments, steel treatment, extraction of non-ferrous metals,
manufacture of explosives, detergents, plastics, and fibers. In many cases, the
sulfuric acid acts as an indirect raw material and rarely appears in
the final product.
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BACKGROUND
Of all the list of chemical compounds that are produced industrially, the acid
sulfuric is the product that is manufactured in the largest quantity by mass each year (not
The importance of this chemical compound reaches such a point that its production
has been used as one of the indicators of the industrial strength of a
country.
Applications
At this point, we can ask ourselves what the reason is for sulfuric acid
it is so important and we find the answer in the wide range of
applications that sulfuric acid allows, among which we can highlight:
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Production of calcium superphosphate (fertilizers).
Water purification: to produce aluminum sulfate from bauxite.
Detergents: in the sulfonation of dodecyl-benzene, which is the raw material
basic for most detergents used in the home and the
industry. 22% oleum is also used for this.
Paper Mills: In the process of producing paper pulp, e
indirectly in the use of aluminum sulfate. It is also used in
the purification of wastewater and in the treatment for drinking water.
Agro-Phytosanitary: in the production of copper sulfate.
Oil Refining: for boilers and chemical processes.
Thermal energy generation: for the treatment of boilers.
Metallurgy: for the pickling of metals.
Production of acid for electric batteries.
Aluminum sulfate production: it is used in reaction with hydroxide of
aluminum. The aluminum sulfate produced is primarily used in
water treatment, tanneries, paper production, and salts of
aluminum.
Production of chromium (II) sulfate: it is used in reaction with dichromate
of potassium and a reducing agent. Chromium sulfate is used
mainly for leather tanning (chrome tanning).
Manufacturing of organic products, paints, pigments, and rayon.
Explosives: for their great reactivity.
The three raw materials used by industries are: sulfur, air, and water.
the manufacturing of sulfuric acid is cheap, as the heat that is wasted in
one stage of the process can be used in the next stage. The main
Sulfuric acid producing companies in Chile are: CODELCO, ENAMI and La
Disputed. It should be noted that they also produce copper in parallel.
Production methods
Of the four methods for the production of sulfuric acid, there are two processes
mainly, the lead chamber method and the contact process.
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Vitriol Process
The oldest method for obtaining sulfuric acid is the so-called 'process of
"vitriol", which is based on the thermal decomposition of vitriols, which are
sulfates of various types, of natural origin.
The Persian alchemists, Jābir ibn Hayyān (also known as Geber, 721 –
815 AD), Razi (865 – 925 AD) and Jamal Din al-Watwat (1318 AD) included
vitriol in its mineral classification lists.
The first mention of the 'vitriol process' appears in the writings of Jabir ibn.
Hayyan. Then, the alchemists Saint Albert the Great and Basilius Valentinus.
they described the process in more detail. Alum and calcanthite (vitriol) were used
blue) as raw materials.
At the end of the Middle Ages, sulfuric acid was obtained in small quantities.
in glass containers, in which sulfur was burned with saltpeter in a
humid environment. The vitriol process was used on an industrial scale from the
16th century due to a greater demand for sulfuric acid.
The focus of the production was centered in the German city of Nordhausen.
that began to be called vitriol as 'Nordhausen vitriol'), where it
used iron(II) sulfate (green vitriol, FeSO4 – 7H2O) as a raw material,
which was heated, and the resulting sulfur trioxide was mixed with water to
obtain sulfuric acid (vitriol oil). The process was carried out in
galleys, some of which had multiple levels, in parallel, in order to obtain
greater quantities of vitriol oil.
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Galena used in the production of vitriol
In the eighteenth century, a more economical process for production was developed.
sulfuric acid known as the 'lead chamber process'.
Until then, the maximum concentration of acid obtained was 78%, while
that with the 'vitriol process' concentrated acid and oleum were obtained, so
this method continued to be used in certain sectors of the industry until
the emergence of the "contact process" in 1870, which allowed for the production of acid
concentrated in a cheaper way.
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Lead camera process
SO2NO2 NO + SO3
From the Glover tower a mixture of gases (that includes dioxide and trioxide of
sulfur, nitrogen oxides, nitrogen, oxygen, and vapor) is transferred to a
lead-coated chamber where it is treated with more water. The chamber can be
a large box-shaped space or an area in the shape of a truncated cone. The
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sulfuric acid is formed by a complex series of reactions; it condenses in the
walls and is accumulated on the floor of the chamber. There can be between three and six
cameras in series, where the gases pass through each of the chambers in
succession. The acid produced in the chambers, typically called chamber acid
fertilizer camera or acid, contains 62% to 68% H2SO4.
After the gases pass through the chambers, they are passed to a reactor.
called Gay-Lussac tower where they are washed with cooled concentrated acid
(from Glover's tower). Nitrogen oxides and sulfur dioxide
that did not react dissolve in the acid forming nitrous vitriol
used in the Glover tower. The residual gases are usually released into
the atmosphere.
Contact process
The process is based on the use of a catalyst to convert the SO2in SO3,
from which sulfuric acid is obtained by hydration.
2 SO2+ O2 2 SO3
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Contact process diagram
In the second converter, the temperature varies between 500º and 600ºC. This
select to obtain an optimal equilibrium constant with a conversion
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maximum at a minimum cost. The residence time of the gases in the converter
it is approximately 2-4 seconds.
The gases from the catalysis are cooled to about 100ºC approximately and
they pass through an oleum tower to achieve the partial absorption of SO3The gases
residuals pass through a second tower, where the SO3the remainder is washed with acid
98% sulfuric. Finally, the unabsorbed gases are released into the atmosphere.
through a chimney.
The double contact double absorption process (DCDA or Double Contact Double Absorption)
In 1960, Bayer applied for a patent for the so-called double catalytic process.
The first plant that used this process started operations in 1964.
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The gases pass again through the final absorption column,
achieving not only a high conversion rate of SO2 to SO3 (of approx.
99.8%), but also allowing for the production of a higher concentration of
sulfuric acid.
The essential difference between this process and the ordinary contact process is
in the number of absorption stages.
The biggest impetus for the current development of the contact process is focused on the
increase in the recovery and utilization of the large amount of energy produced
in the process.
In fact, a large and modern sulfuric acid plant can be seen not only
as a chemical plant, but also as a thermal power plant.
JUSTIFICATION
The lead chamber process is the older of the two processes and is
currently used to produce a large part of the acid consumed in the
fertilizer manufacturing. This method produces a relatively dilute acid.
(62%-78% H 2SO4The contact process produces a purer acid and
concentrated, but it requires purer raw materials and the use of
expensive catalysts. In both processes, sulfur dioxide (SO2) is rusty
and dissolved in water. Sulfur dioxide is obtained through incineration.
sulfur, roasting pyrites (Iron Bisulfide), roasting other non-ferrous sulfuros, or
through the combustion of hydrogen sulfide (H2S) gaseous.
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Selection of the method
We are directed towards the production of sulfuric acid from the process of
contact due to the fact that in terms of quality a product with greater
purity and concentration, percentage-wise up to 98% and at a cost
investment that makes the project's profitability feasible.
The lead chamber method was not selected because this is a process
primarily used to obtain the sulfuric acid that industries use
of fertilizers and detergents, since great purity is not required in
the product, and the market that we are going to cover with the 98% quality is
focused on oil refining, for boilers and chemical processes, and the
thermal energy generation, for the treatment of boilers.
MARKET STUDY
The following pie chart shows the global consumption of sulfuric acid in
2017
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Most sulfuric acid is generated by burning sulfur; the smelting acid
it occurs involuntarily and its economy is primarily driven
through the metal markets. The increase in the recovery of the byproduct of
sulfuric acid in foundries has had a significant impact on the industry,
what has led to increased trade in sulfuric acid (as the
By-products are not necessarily found close to acid markets.
and forces some plants to burn sulfur.
Market need
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SWOT Analysis
STRENGTHS:
OPPORTUNITIES:
WEAKNESSES:
THREATS:
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For the export and transportation of this product, it is required to comply with several
Financing
The company Noracid, owned by the Ultramar and Belfi groups, was founded in the
Year 2007 with the aim of implementing the project 'Sulfuric Acid Plant.'
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By 2020, Peru will have a maximum production of 6.7 million tons.
of sulfuric acid for a maximum consumption of 7.7 million tons, according to
the long-term projections. In any case, the difference will be much smaller than
the estimate this year could be recorded in the medium term between both
projections an increase between 2.5 million and 3 million tons.
That is why we consider that there is a large market where Peru can
to efficiently and effectively meet this demand, since our country is the
fifth exporter at the global level.
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Location
Plant distribution
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TECHNICAL STUDY
Flowchart
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Process
Aspen
PRODUCTIVITY
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Determination of production
Construction companies
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The installation of the plant equipment is of
Belfi's responsibility as well as the engineering,
supply and installation of engineering, supply and
installation of the equipment for auxiliary services.
Purchase of materials
MATERIAL K/M2
GRAVEL AGGREGATES 1,490.0
CERAMICS 557.0
CEMENT 192.0
PRECAST MORTAR 132.0
CAL 51.0
PRECAST CONCRETE 38.0
STEEL 35.0
WOOD 17.0
LIGHT CERAMICS 15.0
TERAZZO 14.0
GALVANIZED STEEL 13.0
PLASTER 12.0
LACQUERED ALUMINUM 2.5
ADDITIVES 4.8
PVC 2.0
ANODIZED ALUMINUM 0.5
TOTAL KG/m2 2,575.8
Turbogenerator - Siemens
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•Caldera – Alstom
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GEA/Alfa Laval Heat Exchangers
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Catalyst - BASF
LEGAL FRAMEWORK
Environmental standards
Chile, in the year 1995 issued theRegulation for the Issuance of Standards
Environmental and Emission Qualityin accordance with the provisions of articles 32 and 40 of
Law 19.300, on General Environmental Bases of 1994. The
Regulation establishes the procedure for the issuance of quality standards
environmental, considering at least the following stages: technical analysis and
economic, development of scientific studies, consultations with organizations
competent, public and private, analysis of the observations made and a
appropriate advertising. This rule also establishes the deadlines and formalities of
required compliances and the criteria for reviewing the current regulations.
Under the previous context, the available environmental regulations are organized as
continues:
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constitute a risk to the life or health of the population, defining the
levels that give rise to emergency situations.
Secondary Environmental Quality Standards: They are those that establish
the values of the concentrations and periods, maximums or minimums
permissible substances, elements, energy or combination of them, whose
presence or absence in the environment may pose a risk to the
protection or conservation of the environment, or the preservation of the
nature.
Emission Standard: It is the one that establishes the maximum allowed quantity for
OPERATIONAL STRUCTURE
From the operational point of view of environmental legislation, it is divided into the
the following categories:
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environmentally relevant regulations of a sectoral nature (Ministry of
Health, Ministry of Agriculture, Ministry of Mining, etc.), applicable to
different environmental elements (air, noise, water, soil, flora, vegetation,
fauna, archaeological, historical and cultural heritage, etc.), which
establish specific requirements or demands, generally oriented towards
preserve or conserve quality aspects of the environmental element and/or
in charge of establishing emission requirements. Additionally to the
sectoral provisions of environmental relevance mentioned above,
There are legal regulations whose specifications determine the condition.
of the design and operation of some engineering works and their activities
annexes (transport, solid waste management, materials handling and
hazardous waste, fuel management, etc.), which aims to
that as a final result of its application, the occurrence of is prevented
environmental damage, in order to ensure an environmentally friendly activity
infrastructure.
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financing contained in the contractual commitments linked to
the projects.
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National Council for Clean Production
INDUAMBIENTAL
Sustainable Development
Legislation and Environmental Policy in Chile
Water
Air
Energy
Biodiversity
Household Waste
International Trade
Industrial Waste
Clean Production
Industrial Practices
Online Environment
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It is a program from the University of Santiago de Chile that makes available
from the community of Chile and the world a new way to access information
and environmental knowledge. Given its history and development, SUMA21 is established
as a recognized program in Chile for its leadership, extensive experience and
collaboration in the development of educational resources, programs of
professional training and research in applied environmental science. The
Communication with the productive sector is carried out through this website.
that brings together IT, management, and environmental education in one reference
SUMA is a productive unit that develops and conceptualizes
environmental knowledge state of the art, and validates its own methodologies to implement
within reach of academics, students, teachers, educational institutions and
government, companies, and their professionals resources to achieve protection
environmental with sustainability.
1. RAW MATERIALS: Procurement and technical data sheet. Elemental sulfur. In this
part will mention raw materials in general, since
regardless of what they are, they receive the same treatment in
the initial part of the process. Sulfur is the main raw material of
process. It is a chemical element that is yellow in color. Chemical symbol S.
Spent sulfuric acid. This acid is referred to as spent because it has already
underwent a preliminary treatment.
2. RAW MATERIALS: Acquisition and technical data. Sulfur exists in the form
elemental in underground deposits and is extracted through a
special procedure, known as Frasch Process Procedure: It
injects superheated water through the outer tube of a formed probe
through three tubes. Compressed air and the sulfur-water mixture are injected
ascend through the intermediate tube.
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0.30 %
1960 kg/m3
4. Services: RAW MATERIALS: Procurement and technical data sheet. Water: From
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NORMATIVE FRAMEWORK ON ATMOSPHERIC POLLUTANTS.
The General Health Law establishes in its Seventh Title, 'Promotion of Health'
Chapter IV, 'Effects of the Environment on Health' (Articles 116 and following) that, in
subject of the effects of the environment on the health of the population, corresponds to the
health authorities establish norms, take measures, and carry out activities
tending to protect human health against the risks and damages that may arise
cause the conditions of the environment, as well as determine the values of
maximum permissible concentration for humans of pollutants
atmospheric. Based on the above, the Ministry of Health has issued various
Mexican Official Standards.
MEXICO
NOM-039-
SEMARNAT-1993 Sulfur dioxide and sulfur trioxide and sulfuric acid mists in
sulfuric acid production plants.
CHILE:
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BIBLIOGRAPHY
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