APROJECTREPORT

On

MANUFACTURI
NG ASPECTSOFSULPHURI
CACI
D

SUBMI
TTEDBY GUI
DEDBY

Hi
renI
tal
i
ya(
140280105018) PROF.S.
R.SHAH

Ji
garJagat
iya(
140280105019) CHEMI
CALENGG.DEPT.

Jai
minPandya(
140280105020) L.
DCOLLEGEOFENGG.

Vi
j
ayJet
hva(
140280105021) AHMEDABAD.

L.D.COLLEGEOFENGI NEERI
NG
CHEMICALENGINEERI
NGDEPARTMENT
NAVRANGPURA,AHMEDABAD
 CONTENTS

CONTENTS I
II

CHAPTER1 I
NTRODUCTI
ON

1.
1 I
NTRODUCTI
ONTOSULPHURI
CACI
D

1.
2 PHYSI
CALPROPERTI
ES

1.
3 CHEMI
CALPROPERTI
ES

1.
4 Mar
ketofsul
phur
icaci
d

CHAPTER2 Sul
phur
icaci
dMANUFACTURI
NGPROCESSES

2.
1LeadChamberPr
ocess

2.
2Cont
actpr
ocessandi
tsdevel
opment
.
Chapt
er3:
PROCESSSELECTI
ON

3.
1 Compar isonbet
weent
heLeadChamberPr
ocessandt
he
Cont
actPr
ocess
3.
2 Pr
ocesssel
ect
ion

3.
3 Est
abl
i
shi
ngofpr
oduct
ionpr
ocess

3.
4 Concl
usi
on:Bl
ockdi
agr
am ofsel
ect
edpr
ocess
Chapt
er4MASSBALANCEAROUNDEQUI
PMENT
4.
1 Sul
furmel
ter
.
i
i
4.
2 Ai
rconsumpt
ion
4.
3 Fur
nace
4.
4 El
ect
rost
ati
cpr
eci
pit
ator
4.
5 SO2Dr
yer
4.
6 Conv
ert
er
4.
7 I
nter
medi
ateabsor
pti
ont
ower(
IAT).
4.
8 Mai
nabsor
pti
ont
ower-MAT.
4.
9 Scr
ubber
4.
10 Ol
eum st
oraget
ank
4.
11 Ol
eum di
str
ibut
ionheader
4.
12 Di
l
uti
ont
ank.

i
i
i
1.
1Int
roduct
ion
SulfuricAci d[7664- 93- 9],H2SO4, i
scol orless, v i
scousl i
qui dhav ingspeci f
icgr av i
tyof
1.8357andanor malboi li
ngpoi ntofappr oxi mately274 C. I t
sanhy dr i
de,sul fur
tri
oxide[ 7446- 11- 9],SO3,i sal soal iqui d,hav i
ngspeci ficgr avit
yof1. 857anda
normalboi lingpoi ntof44. 8 C.Sul furi
caci di sbyf arl ar
gestpr oducedchemi cal
commodi ty
.I tissol dorusedcommer cial l
yi nanumberofdi f f
erentconcent rations,
i
ncludi ng78wt%,93wt%,96wt%,98- 99wt%,100%,andasv ari
ousol eums,i .e.
fumi ngsul furicaci d[ 8014- 95- 7],H2SO4+SO3.St abili
zedandunst abili
sedl iquidSO3
areitemsofcommer ce.
Sulfuricacidhasmanydesi rabl epr opertiest hatleadt oi tsusei nawi dev arietyof
applicati
ons, i
ncludi ngpr oduct ionofbasi cchemi cals,steel,copper ,fer
ti
lizers,fibers,
plastics,gasol ine,expl osives,el ectronicchi ps,bat t
eries,andphar maceut i
cals.I t
typi
cal l
yi slesscost l
yt hanot heraci ds; i
tcanber eadilyhandl edi nsteelorcommon
all
oyatnor malcommer cialconcent rations.I tisav ailableandr eadil
yhandl edat
concent rati
ons>100wt%( oleum) .Sul furicaci di sast rongaci d;itreactswi t
hmany
organi c compounds t o produce usef ulpr oduct s.Sul furi
c aci df orms a sl ightly
solublesal torpr eci pitatewi thcal cium oxi deorhy dr
oxi de,thel eastexpensi veand
mostr eadilyav ailabl ebase.Thi si susef ulpr oper t
ywheni tcomest odi sposingof
sulfuricacid.Concent r
at edsul furicaci disal soagooddehy drat i
ngagentandunder
someci rcumst ancesi tfunct i
onsasanoxi dizingagent .

Hi
stor
y
Sulfur i
caci dhasbeenani mpor tanti tem ofcommer cesi ncet heear l
yt omi ddle
th th
1700s.I nt he18 and19 cent ur ies, itwaspr oducedal mostbychamberpr ocess, i
n
whichoxi desofni trogenar eusedashomogeneouscat alystsf ort heoxi dationof
sulfurdi oxi de.Thepr oductmadebyt hispr ocessi sofr atherl owconcent rat i
on.Thi s
i
snothi ghenoughf ormanyoft hecommer cialusesoft he1990s.Thechamber
process i st heref or e consi der ed obsol etef orpr imar ysul fur i
c aci d pr oduct i
on.
Howev er,mor er ecent ly,modi ficat iont ot hechamberpr ocesshav ebeenusedt o
producesul f
uricaci df rom met allur gical off-gasesi nsev eral Eur opeanpl ant s.
Duringt hef i
rstpar toft he20thcent ur y ,thechamberpr ocesswasgr adual l
yr epl aced
byt hecont actpr ocess.Thepr imar yi mpet usf ordev elopmentoft hecont actpr ocess
camef rom aneedf orhi ghst r engt haci dandol eum t omakesy nt heticdy esand
organi cchemi cal s.Thecont actpr ocessempl oyingpl atinum cat aly stsbegant obe
t
h
usedonal argescal el at ei nt he19 cent ur y
,t hepaceofi tsdev el
opmentwas
accel erateddur i
ngWor ldWarIi nor dert opr ov i
deconcent r
atedmi xt uresofsul furi
c
andni tri
caci dforexpl osi vespr oduct ion.
In1875,apaperbyWi nkl erawakenedi nt eresti nt hecont actpr ocess,f irstpat ented
i
n1831.Wi nkl
ercl ai medt hatsuccessf ulconv er sionofSO2 t oSO3 coul donl ybe
achiev edwi t
hst oi chiomet ry ,undi lut edr atiosofSO2andO2.Al thougher roneous, thi
s
beli
efwaswi delyaccept edf ormor et han20y ear sandwasempl oy edbyanumber
off irms.Meanwhi l
e,ot herGer manf irmsexpendedat remendousamountoft i
me
andmoneyonr esear ch.Thecul mi nat edi n1901wi thKni etsch sl ect urebef oret he
GermanChemi calSoci et yr eveal ingsomeoft hei nvest igat i
onscar ri
edoutbyt he
Badi sche Ani l
ine- und- Soda- Fabr ik.Thi sr evealed t he abandonmentofWi nkler
s
theor yandf urtherdescr ibedpr inci plesnecessar yf orsuccessf ulappl i
cat i
onoft he
cont actpr ocess.
In1915,anef f
ect ivev anadi um cat aly stf ort hecont actpr ocesswasdev elopedand
usedbyBadi schei nGer many .Thi st ypeofcat aly stwasempl oy edi nt heUni ted
Statesst ar ti
ngi n1926andgr adual l
yr epl acedpl atinum cat alystsov erthenextf ew
decades.Vanadi um cat aly stshav et headv i
v
ant agesofexhi bitingsuper i
orr esist ance
topoi soni ngandhi ghr el ativeabundantandi nexpensi ve,compar edt opl at i
num.
AfterWor l
dWarI I, thet y picalsi zeofi ndi v i
dualcont actpl ant sincr easeddr amat icall
y
i
nt heUni tedSt atesandar oundt hewor ldinor dert osuppl yt her api dlyi ncreasi ng
demandsoft hephosphat ef ert
ilizeri ndust ry.Thel argestsul f
urbur ningpl ant sasof
themi d-1990spr oduceappr oximat ely3300met ri
ct onsaci dperday .Pl antsusi ng
sulfuri nt heot herf or ms,especi allySO2 fr om smelti
ngoper at i
ons( metall
urgical
plants),henceal soi ncr easedi nsi ze.Onemet al
l
urgicalplanthasbeenbui ltt o
produce3500met ri
ct onsaci dperday .
Anot hersi gnifi
cantchangei nthecont actprocessoccur r
edin1963,whenBay erAG
announced t he firstl arge-scal
e use oft he double-contact( double absorpti
on)
process( 4-7).Int hispr ocess,SO2 gast hathasbeenpar ti
all
yconv ertedtoSO3 by
catalysisiscool ed,passest hr
oughsul f
uri
caci dtoremov eSO3,r eheated,andt hen
passedt hr oughanot heroneort wocat aly
stbeds.Thr ought hesemeans,ov er al
l
conv ersions can be i ncreased f r
om about98% t o > 99.7%,t hereby reducing
emi ssionsofunconv ertedSO2 emi ssions,mostpl ant
sasoft hemi d-1990sut i
lize
doubl e-absor pt
ion.An ear lyU. S.pat entdi scl
osed the gener alconceptoft his
processbutappar ent l
ywasnotr educedt opr act
iceatthatti
me.
Sul
fur
icAci
dMar
ket
Sul
furi
cacidi spr oducedmor ethananyot herchemi cali
nt hewor l
d.I
nWest ern
Europein1997ov er19mi ll
iontonswer eproduced,t
het ot
alproducti
onworld-
wide
bei
ngest i
mat edatar ound150mi ll
iontons.Abouthalfofthi
sout puti
sproducedin
NorthAmer i
ca,West ernEuropeandJapan.
Table1:Wor l
dPr oductionandConsumpt ion
InMill
iontonsH2SO4 1992 1993 1994 1995 1996 1997
Worldsul f
uricacidproduct
ion 145. 132. 137. 148. 151. 155.
7 5 9 9 3 6
Worldsul f
uricacid 147. 132. 138. 150. 153. 157.
consumpt ion 1 8 8 1 3 5

Theout putofsulfuri
cacidatbasemetalsmel t
erstodayrepr
esentsabout20%ofall
acidpr oduct i
on.Whereasin1991smelteraci
dpr oduct
ionamount edto27.
98mi l
l
ion
tons,itiscal cul
atedthatt
heoutputinthefol
lowingdecadewi l
lhavegrowntoreach
44.97mi lli
ontonsin2001.Smelteraci
dwillbemor ethan25%ofwor l
dsul
fur
icacid
product i
oncompar edtosome18%i n1991.
Table2: Producti
onofSulfur
icAcidint
heCount ri
esoftheEuropeanCommuni t
y
I
nMi l
li
ontonsH2SO4 1992 1993 1994 1995 1996 1997
Bel gium/Luxembourg 1.83 1. 53 1. 51 2.17 2. 06 2.16
6 5 5 4 7 0
Finland 1.35 1. 36 1. 37 1.37 1. 47 1.57
1 1 3 6 9 0
France 3.13 2. 51 2. 22 2.38 2. 26 2.24
2 5 7 2 3 2
Ger many 3.80 3. 51 3. 38 3.53 3. 97 3.49
0 5 0 0 8 6
Uni tedKingdom 1.56 1. 26 1. 22 1.29 1. 19 1.20
8 9 5 3 6 5
Spai n 2.42 2. 17 2. 34 2.26 2. 78 2.81
0 6 8 5 6 0
Sweden 0.56 0. 49 0. 51 0.48 0. 62 0.63
7 7 8 5 0 0
Nor way 0.58 0. 56 0. 58 0.60 0. 59 0.66
7 4 5 9 4 6

Sulfuri
caci disproducedi nallthecount r
iesofEur opewi t
hthemaj orproducers
beingGer many,Spain,France,Belgium andI t
aly
.Thesear ecountr
iesaccount i
ngfor
70%oft hetot
alEuropeanpr oduction. v
Thesul fur
icaci
dmar ketinI ndi
aispr oj
ectedtoexhibi
taCAGRof3. 35%dur i
ng2016-
2025,onaccountofi ncreasingferti
li
zerproducti
onint hecountr
y.Westr egionwas
themaj ordemandgener atorforsulfur
icacidinIndi
aov erthepastf ewyears,owing
topr esenceofmaj orf erti
li
zerandchemi calproducingcompani esint hi
sr egi
on.
Furthermore,l
eadingmanuf actur
erssuchasHi ndal
coI ndust
ri
esLt d.AndPar adeep
Phosphat eLt d.,hav eani nstal
l
edpr oducti
oncapacityof1, 670and660t housand
tons, respectively.
InIndi a,thereareabout140Sul furicAcidPlants(130Sulfurbased&10Smel terGas
based)wi t
hAnnualI nstal
ledCapaci tyofabout12Mi l
l
ionMT.Asi nsomepl aces,
ther ear emor et hanonest r
eam/ unitwithsomecommonf aci
li
tiestheseplantsare
situatedi n131l ocations.Itmaybeobser vedthatabout25%oft heinstal
l
edcapaci t
y
i
sl ocat edinPar adeep( Ori
ssa)onl yconsisti
ngof2pl ants(4streams/ uni
ts)
.
Tabl e3: Capaci t
y -
wisenumberofpl antscanbecat egori
zedasbel ow
Installed Capacit
y NumberofPl ants %
(MT/ Day)
Upt o50 18 12.9
51- 100 45 32.1
101- 200 40 28.6
201- 300 17 12.1
301- 500 5 3.6
501- 1000 9 6.4
1001- 2000 4 2.9
Abov e2000 2 1.4
Tot al 140 100.0

Thecur rentannual productionofSulf

uricAci
di sabout5.5Mi l
li
onMT, againstt he
i
nst al
l
edcapaci tyof12Mi l
l
ionMT/ Annum fr
om Sulfurbasedaswel l
asSmel terGas
basedpl ants.Someoft hepl antshavebeencloseddownduet ovari
ousr easons.I t
i
sl ear
ntt hatmanycapt i
v eplant
shavebeencl oseddownduet onon-
viabil
ityoft he
mai nplant,vi
z.SingleSuperPhosphat eetc.
,whi l
emer chantpl
antshavecl osed
downduet opoordemand.ThedemandofSul fur
icAcidisfull
ymetbyt hecur rent
production,astheinst al
ledcapacityi
smor ethandoubl ethedemand.Gener al
Ov
erv
iew
Fi
gur
e2:
Gener
alDi
agr
am ofSul
fur
icAci
dPr
oduct
ion.

Uses
Thel argestsi ngleusei sint hef erti
li
zerindustry
.Most lyi
npr oductionofphosphor i
c
aci
d, thisint urnusedt omanuf acturefert
ili
zerssuchast r
ipl
esuper phosphat e,mono
anddi ammoni um phosphat es.I tisal sousedf orproducingsuper phosphat eand
ammoni um sul fate.
Used as an aci dic dehy drati
ng r eaction medi um in or ganic chemi caland
petrochemi calpr ocessesi nvolvingsuchr v
ei
acti
onsasni t
rati
on,condensat ion,and
dehy drati
on,aswel lasinoi lrefining,i
nwhi chiti susedforr efi
ning,al kyl
ati
on,and
purif
icationofcr ude-oil
distil
lates.
I
nt hei norganicchemi calindust r
ye. g.i
nt heproductionofti
tanium di oxidepigments,
hydrochlor i
caci d, andhydrouor icacid.
I
nt hemet alpr ocessingindust r
ye. g.forpickli
nganddescal ingst eel,forleachi
ng
copper ,
uranium,andv anadium or esinhy dromet al
lur
gicaloreprocessi
ng,andinthe
preparati
onofelectrol
yticbathsf ornonf err
ous-met alpur
ifi
cati
onandpl at
ing.
Cer t
ainwoodpul pingpr ocessesi nt hepaperi ndustryrequir
esul f
uri
cacid,usedin
texti
leandchemi calfi
berpr ocessesandl eathertanni
ng
Inpr oducti
onofexpl osives,deter gents,batteri
es,plasti
cs,dyes,pharmaceuti
cals,
sil
icate for toothpaste,adhesi ves,r ubbers,edi ble oil
s,l ubri
cants and the
manuf actur
eoff oodacidssuchasci tr
icacidandl acti
cacid.

vi
i
Proper
ti
es
ChemicalPr
oper
ti
es
1.Dehy
drat
ingagent

Hasagr
eataf
fi
nit
yforwat
erandt
her
eact
ioni
sext
remel
yexot
her
mic.

Al argeamountofheati sproduceduet ofor

mationofmonoand
dehydrates(H2SO4.
H2OandH2SO4. 2H2O)onmixi
ngacidwi
thwater
.So
whileprepari
ngdilut
esolut
ionsofH2SO4 theaci
dshouldbeaddedto
waterslowlywithconst
antsti
rr
ing.Neveraddwatert
otheaci
d.

Usedf
ordr
yingal
mostal
lgases,
exceptNH3andH2S.

I
tscor
rosiv
eacti
ononskinisalsoduet odehy
drat
ionofski
nwhi
ch
t
henburnsandpr
oducesi
tchi
ngsensat
ion.

Duet
odehy
drat
ingpr
oper
ty,
itchar
ssugart
ogi
vecar
bon.

C12H22O11 12C+11H2O
Al so,paper,st
arch,woodetc.arecharr
edbyconc.H2SO4 duetothe
remov alofwat er
.Itisalso used i
nr emovi
ng wat
erfr
om v ari
ous
substancessuchasoxali
cacidandformicaci
d.

COOH-
COOH H2O+CO+CO2

2.Oxi
disi
ngagent

GivesO2 onst
rongheat
ing,hotconc.H2SO4al
soact
sasanoxi
disi
ng
agent.

3. Pi
ckl
i
ngagent

Finds appl
i
cat
ion i
n pickl
ing i
n whi
ch lay
ers ofbasi
c oxi
des ar
e
removedbefor
eelect
roplat
ing,
enamel
ing,
galvani
zi
ngandsol
deri
ng.

4.Aci
dicnat
ure

St
rongdibasicaci
dandf or
mst woseriesofsal
tswi
thal
kal
i
s.These
- -
2
ar
ebisul
fates(HSO4)andsul
fat
es(SO4 ).

Phy
sical
Proper
ti
es
Forsul f
uricacid
Mol ecularWei ght,
gm/mol e 98.08
Appear ance Wat erwhi t
eslight
lyvi
scousli
quid
Normal Boil
i
ngPoi nt,
C 290
Normal Boil
i
ngPoi nt,
C 10
Densi t
y,g/mL 1.
840( l
iquid)
Solubil
ity vii
isci
Mi bl
ewi thwateri
nallpr
oporti
ons
Viscosityat20 C 26.7cP
Aqueoussul furi
cacidsoluti
onsaredef
inedbyt hei
rH2SO4cont enti
nweightpercent
terms.
Anhy drous( 100%)sul f
uricacidsometi
mesr ef er
redt oasmonohy dr
ate,
whi ch
meanst hatitisthemonohy drat
eofSO3.
Dissolveanyquant i
tyofSO3, for mingoleum ( fumingsul
furicacid
).
Thephy si calproper t
iesofsul furicacidandol eum ar
edependentonH2SO4andSO3
concent rat i
ons, temper ature,andpr essure.
ForSul f
urTr i
oxide
Mol ecularWei ght ,gm/ mol e 80
Criti
calTemper at ure,C 217.8
a
Criti
calPr essure, kPa 8208
Criti
calDensi ty,g/ cm3 0.630
TriplePoi ntTemper atur e,-phase, C 16.8
TriplePoi ntPr essur e, -phase, kPaa 21.13
Nor mal Boi li
ngPoi nt,C 44.8
Mel ti
ngPoi nt,C 16.8
Transiti
onTemper ature,
C -183.0
Densi t
y, -phase, g/cm3
Liqui dat20 C 1.9224
Sol i
dat- 10 C 2.29
-
1
Coef fi
cientoft her mal expansi onat18 C, C 0.002005
b
Li
qui dHeatcapaci ty,at30 C,kJ/ (
kg.K) 3.222
b
Heatoff or mat i
onofgasat25 C,kJ/mol -395.76
b
Freeener gy offor mat i
onofgasat25 C,kJ/mol -371.07
b
Entropyofgas, at25 C, kJ/ (
mol .K) 256.8
Heatofdi l
ution, kJ/kgb 2.110
Heatoff usi on,kJ/ kgb
322.4
150.7
92.11
Heatofsubl imat ion,MJ/ kgb
0.8518
0.7269
0.7029
Heatofv apor i
zat i
on, -l
iduid,MJ/ kg 0.5843
Diffusi
oni nai r
, at80 C, m/ s 0.000013
Li
qui ddi electri
cconst ant,at18 C 3.11
Electri
cconduct ivity negli
gible

i
x
2.
1 EXI
STI
NGPROCESSROUTESFORSULFURI
CACI
DPRODUCTI
ON
Whensummi
ngupt
her
evi
ewofl
i
ter
atur
e,i
tcoul
dbenot
edconcl
usi
vel
ythatov
eral
l
,
t
her
ear
etwomai
npr
ocessesf
ormanuf
act
ureofSul
fur
icaci
dthatar
eadopt
edat
pl
ant
sacr
osst
hegl
obeasment
ionedbel
ow.

1.Leadchamberpr
ocess

2.Cont
actpr
ocesses

Howev
er,
minorv
ari
ati
onswi
thi
nthesemai
ntwopr
ocessesal
soexi
st.Fur
ther
,ther
e
ar
eal
soot
herpr
ocesseswhi
char
enotaspopul
ari
nthei
ndust
ry,ast
het
opt
wo
pr
ocesseswer
e,suchas,

H2O2pr
ocess
Act
ivat
edCar
bonpr
ocess
Asf
arast
hecont
actpr
ocessi
sconcer
nedt
hel
i
ter
atur
erev
iewpoi
ntedout3
di
ff
erentpr
ocessest
hatar
ebasedont
hegener
aloper
ati
ngpr
inci
pleoft
hecont
act
pr
ocess.

1.Si
ngl
econt
actpr
ocess
2.Doubl
econt
actpr
ocess
3.WetCont
actPr
ocess(
WCP)

2.
2 LeadChamberPr
ocessandi
tsdev
elopment
As ment
ioned undersect
ions abov
e,t
his was a cr
uci
aldev
elopmenti
nthe
dev
elopmentofv
iabl
epr
oduct
ionpr
ocessesf
orSul
fur
icaci
d.JohnRoebuckand
SamuelGar
dneri
ntr
oducedamet
hodt
opr
oducet
heSul
fur
icaci
dinl
eadl
i
ned
chamber
s..

Ty
pical
stepsandr
eact
ionsoft
hel
eadchamberpr
ocessar
easf
oll
ows(
Lloy
d,2011)
.

Step1-Burni
ngofKNO3(
pot
assi
um ni
tr
ate/
nit
er/
sal
tpet
er)andSul
furi
nlead
chambers:

Sul
furi
soxi
dizedbyKNO3 andpr
oducesSul
fur
Tri
oxi
de.I
twor
ksasanoxi
dizi
ng
agentandpr
ovi
desoxy
gent
other
eact
ion:

6KNO3(
s)+7S(
s)-
--
--
>3K2S+6NO(
g)+4SO3(
g) (
2.1)

St
ep2-I
npresenceofwater
,theSul
fur
Tri
oxideconv
ert
stoSul
fur
icaci
d.
x
SO3(
g)+H2O(l
)--
--
->H2SO4(aq) (
2.2)
Thi
sbat
chpr
ocesswast
heor
igi
nall
eadchamberpr
ocesst
hatJohnRoebuckand
SamuelGar
dneri
ntr
oducedat1746.Att
hatt
imenoai
rwasi
ntr
oducedt
othel
ead
chamber
sdur
ingt
her
eact
ion.Lat
ert
hecont
inuousaddi
ti
onofai
rwassuggest
edby
Cl
ementandDesor
mes.I
naddi
ti
ont
othatatabout1806t
heydef
inedt
heact
ionof
KNO3i
nthel
eadchamber
s.

I
n1835,
thepr
ocessofr
ecov
eri
ngNi
tr
ogenf
rom Ni
tr
ogenMonoxi
dewasi
ntr
oduced
byJosephGayLussac.Thi
spr
ovedt
obev
eryi
mpor
tantf
orr
educt
ionofKNO3asa
sour
ceofNi
tr
ogen.Ther
eact
ionsr
ecov
eri
ngNi
tr
ogenwasmor
eimpor
tantt
oli
mit
t
heusageofKNO3.Thi
swasoneoft
heeconomi
cal
l
yimpor
tantf
act
orst
hatmade
t
heLeadChamberpr
ocessmor
eat
tract
ivet
hen.KNO3bei
ngexpensi
ve,
themat
eri
al
costr
educedduet
oreducedamountofKNO3.Ther
ecov
eryr
eact
ionsar
efol
l
ows,

Step3-Pr
oducedni
tr
ogenoxi
der
eact
sOxy
geni
npr
esenceofwat
er,
giv
ingNi
tr
ous
acid.

4NO(
g)+O2(
g)+2H2O(
l)-
--
--
>4HNO2(
l) (
2.3)

St
ep4-Pr
oducedNi
tr
ousaci
dreactwi
thSul
fur
Dioxi
def
orpr
oduceSul
fur
icaci
das
t
hemai
npr
oduct
.Inaddi
ti
ont
heNi
tr
ousOxi
def
ormedwoul
dber
eusabl
e.

4HNO2(
l)+2SO2(
g)-
--
--
>2H2SO4(
aq)+4NO(
g) (
2.4)

Due t
hisi
mpr
ovementoft
he pr
ocess,r
equi
rementwasl
i
mit
edt
otoppi
ngup
KNO3 Ni
tr
ogen amount
. Fur
thert
headdedt
othel
eadchamberpr
ocess
dev
elopment
s wer
e oper
ati
ng costandt
he
r
educedwi
tht
hem.

Moder
nLeadChamberPr
ocess
St
ep1-Sul
furandKNO3i
sbur
nti
ntheSul
furbur
nerandt
heKNO3bur
ner
.SO2i
s
pr
ovi
dedt
othel
eadchamber
sint
woway
s

1.
Bur
ningofel
ement
alSul
furwi
thai
randpr
oduci
ngSO2.

2.
Bur
ningofSul
furcont
aini
ngor
es

Theheatener
gyr
equi
redt
omel
ttheSul
fur
xa
indKNO3r
esul
tsi
nthef
inal
productof
o
SO2,NO2andNObei
ngatat
emper
atur
eov
er1000 C.

Thebur
ningofSul
furdonei
noneoft
woway
sasi
ndi
cat
edbel
ow:
xi
i
 1.
Mel
ti
ngt
heSul
furi
naSul
fursmel
terandpumpi
ngt
hemol
tenSul
fur
i
ntot
he r
eact
ort
o be spr
ayed f
rom t
he t
op.Ai
rst
ream i
spr
ovi
ded
count
ercur
rentt
ooxi
diz
eSul
fur
.

2.Sul
fur
isbur
ntdi
rect
lyt
oreactwi
thai
rint
heSul
furbur
nerandt
he
r
esul
tantSO2st
ream i
stakenast
heout
putoft
her
eact
or.

Ni
tr
ogencanal
sobepr
ovi
dedi
ntwoway
s:

1. Decomposi
ti
onofni
terathi
ght
emper
atur
einpr
esenceoft
heaci
d.

2. Ai
roxi
dat
ionofAmmoni
atoNi
tr
icOxi
dei
nthepr
esenceacat
aly
st.

St
ep2Next
,thepr
oduct
sfr
om t
hebur
ner
sar
efi
l
ter
ed.Themoder
nchamber
pr
ocesshast
hreemai
ntower
s:

1. Gl
owert
ower

2. Leadchamber
s

3. Gay
-Lussact
ower

HotSO2gasi
sent
eredf
rom t
hebot
tom oft
hegl
owert
owerandt
heNi
tr
ogenoxi
de
gasesareenter
edf r
om theupandaresettof
lowascount
ercur
rentl
i
quidfl
ow.In
thi
stowertheoxidesofNit
rogenar
eremovedfr
om t
heSulf
uri
caci
d.Atthatr
eact
or
SO2i
smi
xedandr
eact
edwi
thSul
fur
icaci
dwi
thNOandNO2.Thi
shast
hef
oll
owi
ng
f
eat
ures:

Concent
rat
ionoft
hechamberaci
dandst
ri
ppi
ngofNi
tr
ogenOxi
desf
rom t
he
l
i
qui
dtot
hegasi
soccur
redatt
hist
ower
.Concent
rat
ionoft
hechamberaci
d
i
sachi
evedf
rom t
heev
apor
ati
onofwat
erf
rom t
heaci
d.Thi
sisowi
ngt
othe
hotgasesent
eri
ngt
hegl
owert
ower
.Thehotgasev
apor
atesaconsi
der
abl
e
amountofwat
eri
nthechamberaci
d.Theconcent
rat
ionoft
heaci
dout
put
wor
ksoutt
obeabout62-
68%Sul
fur
icaci
daccor
dingt
oli
ter
atur
e.
SomeamountofSO2r
eact
swi
tht
hehotai
rcont
aini
ngO2andi
soxi
dizedt
o
SO3.Thepr
oducedSO3i
sdi
ssol
vedi
ntheaci
dbei
ngpr
oducedi
nthegl
ower
tower.
Thedissol
vedNit
rogenOxidei
sstr
ippedfr
om t
heaci
dandi
sconv
eyedal
ong
xi
i
i
theoutl
etgasst
ream oft
heglowertower
.
St
ep3-Thi
sout
letgasst
ream i
sconv
eyedt
othel
eadchamber
swhi
chgi
vest
he
pr
ocessi
tsname,
wher
eini
tisf
ir
stsett
oreactwi
thwat
er(
int
hel
eadl
i
nedr
ooms)
.
Att
hel
eadchamber
sther
eact
ionmi
xissubj
ectt
oaser
iesofr
eact
ions.Duet
othi
s
compl
exi
tyt
her
ear
eusual
l
ythr
eet
otwel
vel
eadchamber
sinser
ies.Thegasi
sset
t
opasst
houghal
lleadchamber
s.Thef
ormedaci
discondensedont
hewal
l
sand
col
l
ect
edont
hef
looroft
hel
eadchamber
s.Thi
sfor
medaci
dcal
l
edt
hechamber
aci
d.

St
ep4-Af
tert
hel
eadchamber
s,t
hegasesar
esentt
otheGay
-Lussact
ower
.Iti
s
essent
ial
l
yar
eact
orwher
eanyt
racesofaci
dcont
ainedgasesar
ewashedof
f.
Fur
ther
,int
hist
owert
he ni
tr
ous v
itr
iolf
orms f
rom t
he r
eact
ion ofr
emai
ning
Sul
fur
Dioxi
desandNi
tr
ogenOxi
des.Thi
sni
tr
ousv
itr
iolcanbeusedi
nthegl
ower
t
ower
.Inaddi
ti
ont
othatt
hewast
egasessepar
atedf
rom t
heGay
-Lussact
ower
mustt
reatbef
orebei
ngpur
gedt
otheat
mospher
e.

Cool
edaci
dst
eamscanbeobt
ainedf
rom t
hegl
owert
owerwhi
chwasci
rcul
ated
f
rom t
hegl
owert
owert
otheGay
-Lussact
ower
.Thi
sist
hef
inalpr
oductwhi
chhas
78%concent
rat
edSul
fur
icaci
d.

8
Fi
gur
ePr
ocessf
lowoft
heLeadChamberPr
ocess

Anal
ter
nat
ivemechani
sm andr
eact
ionsf
ort
heSul
fur
icpr
oduct
ioni
nthel
ead
chamberhadbeenpr
oposedbyLungeandBer
xi
v l
.

8 Imagesour
ce:
htt
p:/
/chemt
ips.
blogspot
.com/
2011/
11/
lead-
chamber
-pr
ocess-
lead-
chamber
.ht
ml
xv
St
ep1-TheSul
furshoul
dbur
ntof
orm Sul
fur
Dioxi
deast
hest
art
ingst
ep.The
pr
oducedgasi
sdi
rect
edt
otheGl
owert
ower
.

S+O2-
--
--
>SO2

St
ep2-Ther
eact
ionwi
thNi
tr
ousf
umesduet
opr
esenceofH2OandNO2

NO2+SO2+H2O--
---
>HOSO2.NO(OH)
St
ep
3 -Theoxi
dat
ionsofHydroxyni
tr
oSul
fur
icaci
d

2HOSO2.NO(
OH)+O- -
--
->2HOSO2.
NO2+H2O
St
ep -TheNitr
osul
furi
caci
d
4 isomer
ized

2HOSO2.
NO2-
--
-->2HOSO2.
ONO

St
ep5-TheSul
fur
icaci
dfor
medbyNi
tr
osul
fur
icaci
dandNi
tr
ousaci
disf
ormedasa
by
product
.

HOSO2.
ONO+H2O-
--
--
>HNO2+H2SO4

St
ep6Al
ter
nat
ivest
ep5.

2HOSO2.
ONO+SO2+2H2O-
--
--
>H2SO4+2HOSO2.
NO(
OH)

Themi
xi
ngofgasaf
fect
sthepr
ocessef
fi
ciencyi
nthel
eadchamberpr
ocess.The
i
mpl
ement
ati
onofpackedt
ower
sdonebyGai
l
lar
d-Par
ri
shandPet
ersonhasbeen
consi
der
edasagoodi
mpr
ovementi
nthi
spr
ocess.
Cont
actpr
ocess

Dev
elopment
Ref
ersect
ion1.
1.2f
ort
hedev
elopmentoft
hecont
actpr
ocess,i
tsev
olut
ionand
gener
alr
easons f
or i
ts pr
efer
ence ov
er ot
her pr
ocesses.I
n gener
al,when
consi
der
ingt
hecapaci
tymor
ethanacent
urysi
ncei
tsdev
elopment
,wecansee
expandedpr
oduct
ionpl
ant
swhi
chhav
eov
ert
he5000met
ri
ctonsperdayar
eint
he
pl
ant
swi
thagl
obalcl
i
ent
ele.Thi
sincr
easecanbeat
tr
ibut
edt
othei
ncr
easi
ng
demandf
ort
heSul
fur
icaci
dduet
ovar
iousaspect
s,t
hemor
erecentofwhi
chhas
beenaddressedi
nsect i
on1.3basedonthef i
ndingsofthel
i
ter
aturerev
iew.Al
so
xvi
l
argerequipment
,reducedgasstrengt
handi ncr
easinggasf
low rat
escouldwell
hav
eaf
fect
edt
hiski
ndofi
mpr
ovementoft
hecapaci
tyi
nthecont
actpr
ocess
(
Fri
edman)
.
I
dent
if
yingi
ndi
vi
dual
steps
Cont
actpr
ocesscanbedi
vi
dedi
ntot
hef
oll
owi
ngmai
nst
eps.Amongt
hesemai
n
st
eps,
sev
eral
subpr
ocessar
eusedt
oopt
imi
zet
hemanuf
act
uri
ngpr
ocess.

1.Combi
ningofSul
furandox
ygen;
2.Pur
if
yingSul
fur
Dioxi
dei
nthepur
if
icat
ionuni
t;
3.Addi
ngexcessof
oxy
gent
oSul
fur
Dioxi
dei
npr
esenceofcat
aly
stv
anadi
um
oxi
de;
4.Hi
ghconcent
rat
edSul
fur
icaci
disaddedt
oSul
fur
Tri
oxi
de,
asar
esul
tOl
eum
i
spr
oduced
5.Wat
eri
saddedt
oOl
eum and98%Sul
fur
icaci
disf
ormed.
Basi
cchemi
cal
react
ionsassoci
atedwi
tht
hispr
ocessar
easf
oll
ows.

S(
l)+O2(
g)->SO2(
g)
SO2(
g)+O2(
g)<->SO3(
g)=-
99kJ/
mol
SO3(
g)+H2SO4(
l)->
H2S2O7(
l)
H2S2O7(
l)+H2O(
l)->2H2SO4(
l)

Pr
ocessi
ndet
ail
Adet
ail
edaccountoft
hekeyst
agesi
nthecont
actpr
ocessf
oll
owedi
nSul
fur
icaci
d
pl
ant
sisgi
venbel
ow(
Loui
e,2005)
.

STEP1SO2Pr
oduct
ionandPur
if
icat
ion:Assumi
ngt
hatpur
if
iedel
ement
alScanbe
obt
ainedf
orourpr
ocess,
fir
stst
epi
nvol
vesspr
ayi
ngmel
tedSul
furi
ntoanexcessof
dr
yai
ratat
mospher
icpr
essur
e.Fort
hisst
ep,dr
yai
risobt
ainedbypassi
ngai
r
t
hroughaSul
fur
icaci
dbed,
adehy
drat
ingagent
.Thi
sisdonet
oav
oidaci
dmi
stand
cor
rosi
oni
ndownst
ream pi
pes(
Ref
erequat
ion)

Si
ncet
hemi
xtur
eofSul
fur
Dioxi
deandai
robt
ainedmaycont
ainv
ari
ousi
mpur
it
ies,
whi
chmustber
emov
ed;(
other
wise,i
twi
l
lleadi
ntocat
aly
stpoi
soni
ngandl
ossi
n
ef
fi
ciency
)sev
eralpur
if
icat
ionst
epsar
efol
l
owedwhi
chi
ncl
udesadust
ingt
ower
,
cool
i
ngpi
pes,
ascr
ubbi
ngt
ower
,adr
yingt
ower
,anar
seni
cpur
if
ierandt
est
ingbox.

Dur
ingt
hispur
if
icat
ion,
themi
xtur
eisi
nit
ial
l
ypassedt
hroughanel
ect
ri
cpr
eci
pit
ator
;
consist
ing ofachamberwith hi
gh el
ectri
cpotent
ialwi
res.Theel
ect
ri
cchar
ge
xvi
att
ractssolidpar
ti
cl
espr
esentinthestri
eam.Thengasmi xt
urei
sledtoawater
scr
ubberwher
eiti
scompl
etel
yfr
eedf
rom dustpar
ti
cles.
I
tthendr
iedbyaspr
ayofconcent
rat
edSul
fur
icaci
dinanot
herchambert
hrough
ar
seni
cpur
if
ierwher
eev
eryt
raceofar
seni
coxi
dei
sremov
ed.

Dur
ingt
hisf
ir
stmai
nst
ep,anexcessofai
r(Oxy
gen)ensur
est
heSul
furr
eact
s
compl
etel
y.Thecombust
ionofSul
furgener
atesal
otofheat
.Iti
snecessar
ytocool
o o
t
hegasst
ream f
rom 1000 Ct
oar
ound450 C,
theopt
imum t
emper
atur
efort
henext
st
ep.Heatexchanger
sar
eusedt
oremov
etheexcessheatandr
ecy
clet
hisheat
ener
gysoi
tcanbeusedt
oremel
tmor
eSul
furorpowert
urbi
nesf
orel
ect
ri
cit
y.

STEP2Cat
aly
ticOxi
dat
ionofSO2andSO3:Cl
ean,
drySul
fur
Dioxi
dei
sthef
eedst
ock
f
ort
hisst
age(
Ref
erequat
ion5.
12)
.Thi
sSul
fur
Dioxi
dei
smi
xedwi
thpur
if
iedai
rat
pr
essur
esl
i
ght
lyhi
ghert
hanat
mospher
ici
nacount
ercur
rentmanner
,andi
spassed
t
hroughacat
aly
stt
ower
,cal
l
ed aconv
ert
er.Thet
owercont
ainssev
erall
ayer
s
(
usual
l
y3-
4asperr
efer
redl
i
ter
atur
e)ofl
oosel
ypackedVanadi
um Pent
oxi
deor
Pl
ati
num onper
for
atedshel
ves.Thecat
aly
sti
spl
acedi
nver
ti
cali
ronpi
pesi
nsi
de
t
heconv
ert
er.Thepr
eheat
edmi
xtur
eofSul
fur
Dioxi
deandai
rfor
m Sul
fur
Tri
oxi
de
(
TheCont
actPr
ocess,
2013)
.

Cat
aly
ticoxi
dat
ionofSO2i
sar
ever
sibl
epr
ocess,whi
chdependsonsev
eralf
act
ors
suchast
hecor
rectcat
aly
st,t
emper
atur
eand pr
essur
e.Pl
ati
num wasf
ormer
ly
empl
oyed asacat
aly
stf
ort
hisr
eact
ion,buti
snow consi
der
ed suscept
ibl
eto
poi
soni
ng byar
seni
cimpur
it
iesi
ntheSul
furf
eedst
ockand i
tiscompar
ati
vel
y
expensi
ve,v
anadi
um (
V)oxi
de (
V2O5)i
s now hi
ghl
y pr
efer
red i
n commer
cial

pr
oduct
ions.K2Omaybeusedasapr
omot
ert
oenhancet
heact
ivi
tyoft
hecat
aly
st.

Themechani
sm f
ort
hecat
aly
ticact
ionoccur
sint
wost
eps:
5+
St
ep1:
Oxi
dat
ionofSO2i
ntoSO3byV :

5+ 2- 4+
2SO2+4V +2O 2SO3+4V
4+ 5+
St
ep2:Oxi
dat
ionofV backi
ntoV byoxy
gen(
cat
aly
str
egener
ati
on)
:
4+ 5+ 2-
4V +O2 4V +2O

Sev
eral
fact
orsar
etakeni
ntoaccountwhenconsi
der
ingt
heopt
imum pr
essur
eand
t
emper
atur
efort
hiscat
aly
sis
xvi
i
i
Equi
li
bri
um Consi
der
ati
ons:
Tomaxi
mizet
hey i
eldt
hef
oll
owi
ngmeasur
esar
e
adopt
ed:
 *Suppl
yofexcessoxy
gen

*Appl
yhi
ghpr
essur
e(duet
o1.
5:1r
ati
o)

*Appl
ylowt
emper
atur
es(
asr
eact
ioni
sexot
her
mic)

Ki
net
icConsi
der
ati
ons:
Deal
swi
thcat
aly
ticusage,
appl
i
cat
ionofhi
ght
emper
atur
e
andpr
essur
e.

Ener
gyConsi
der
ati
ons:
Mini
mizi
ngener
gyuse(
thuscost
)i
ncl
udesdeal
i
ngwi
tht
he
f
oll
owi
ng.

*Appl
yi
ngat
mospher
icpr
essur
e(ashi
gh-
pressur
econt
ainer
sar
eexpensi
ve)

*Opt
imi
zi
nguseofcat
aly
sts,
orj
ust
if
yingi
fcat
aly
stsar
eneededascostof
r
esear
chi
ng,
produci
ngandusi
ngt
hem ar
ehi
gh

*Heatr
ecov
eryf
rom exot
her
micr
eact
ions(
combust
ionofSul
fur
)

Accor
dingt
otheLeChat
eli
er'
spr
inci
ple,atal
owert
emper
atur
e,ahi
ghpr
essur
e
shoul
dbeusedt
oshi
ftt
hechemi
calequi
l
ibr
ium t
owar
dst
her
ight
,hencei
ncr
easi
ng
t
heper
cent
agey
iel
d.Howev
er,
tool
owt
emper
atur
esal
soar
enotr
ecommended,
as
i
twi
l
llowert
hef
ormat
ionr
atet
oanuneconomi
call
evel
.Hencet
oincr
easet
he
r
eact
ionr
ate,hi
ght
emper
atur
es(
450
C)ar
emai
ntai
nedi
nthegasst
ream l
i
neby
t
heheatexchanger
sint
hepr
evi
ouspr
ocessi
ngsect
ion.

Hi
ghpr
essur
ewoul
dfav
ourt
hef
orwar
dreact
ion.Dat
agat
her
edf
rom l
i
ter
atur
e
poi
ntsoutt
hati
tisnotpossi
blet
obui
l
daci
dresi
stantt
ower
s,whi
chcanwi
thst
and
hi
ghpr
essur
es.Apr
essur
eof760-1520mm ofHgi
sused.Excessofoxy
geni
s
necessar
y,asi
twoul
dfav
ourt
hef
orwar
dreact
ion.Thus,a5:
1ai
r:SO2r
ati
oisused

(
essent
ial
l
y1:
1O2:
SO2)cr
eat
inganexcessofoxy
gen.Whi
l
emai
ntai
ningabov
e
condi
ti
onsandi
nthepr
esenceofv
anadi
um pent
oxi
de,
aconv
ersi
onr
ateof96%can
beobt
ainedbyt
hispr
ocess,
accor
dingt
oli
ter
atur
e.

STEP3Absor
pti
onofSO3:
TheSul
fur
Tri
oxi
def
rom t
hef
inal
cat
aly
stbedi
sdi
ssol
ved

i
n98%Sulfur
icaci
dintheabsorpt
iontower.Theacidisspray
edov ertheSO3and
xi
x
pr
oducesanoil
yli
qui
dcal
ledOleum.(Referequat
ions5.13)
.Thisi
spr ef
erabl
eov
er
di
rect
lydi
ssol
vi
ngSul
fur
tri
oxi
dei
nwat
erast
hisf
ormsSul
fur
icaci
dmi
sts,
duet
othe
l
argeheatofdi
ssol
uti
on(
130kJ/
mol
),whi
char
ehar
dtocont
rolanddi
ff
icul
tto
coal
esce.I
naddi
ti
on,
iti
sdi
ff
icul
tto
xx
separ
atet
heSul
fur
icaci
dgasf
rom ot
her
ssuchasni
tr
ogenoncei
tispr
oducedi
n
gaseousf
orm.

STEP4Conv
ersi
onofOl
eum t
oH2SO4:I
ndi
l
uti
ont
anks,wat
eri
smi
xedwi
thOl
eum
t
opr
oduce98%Sul
fur
icaci
d(18M)
.(Ref
erequat
ion5.
14)

Ol
eum i
sreact
edwi
thwat
ert
ofor
m concent
rat
edH2SO4.Theav
erageper
cent
age
y
iel
d oft
hisr
eact
ion i
s consi
der
ed t
o be ar
ound 30%.I
tis sol
d ei
theras
concent
rat
ed(
98%)ordi
l
utedaci
d.

3.
1PROCESSSELECTI
ON

Compar
isonbet
weent
heLeadChamberPr
ocessandt
heCont
actPr
ocess

Economi
caspect
s
Pr
oductqual
i
tyand concent
rat
ion:I
twasi
ndi
cat
ed undersect
ion 1.
5thatt
he
concent
rat
ionoft
hef
inalpr
oductf
rom t
hecont
actpr
ocessi
sabout98% Sul
fur
ic
aci
d.Recal
lal
sot
hatt
heout
putconcent
rat
ionoft
hef
inalpr
oducti
nLeadChamber
Pr
ocessi
smor
edi
l
uteaci
dcont
entof62%-
78%.Ther
easonf
ort
hisdi
ff
erencecan
beat
tri
but
edt
otheCat
aly
ticact
ivi
tyofV2O5 whi
chdel
i
ver
sani
mpr
essi
ve99.
5%
conv
ersi
oni
nthecat
aly
ticconv
ert
eri
nthecont
actpr
ocess.Ofcour
sei
tshoul
dbe
bor
nei
nmi
ndt
hatr
egar
dlessoft
hequal
i
tyachi
evedwi
thi
nthepr
ocess,
impur
it
iesi
n
r
aw mat
eri
als wi
l
laf
fectt
he ul
ti
mat
e pur
it
y.Maj
ordi
sadv
ant
ages i
nthe Lead
Chamberpr
ocessi
nter
msofpr
oduct
ivi
tyt
husi
ncl
udet
hel
i
mit
ati
onsi
nthr
oughput
,
qual
i
ty and concent
rat
ion oft
he aci
d pr
oduced wi
thr
espectt
othe Cont
act
Pr
ocess.
Cur
rent
lymostendusesofSul
fur
icaci
dar
efort
hehi
ghconcent
rat
edf
orm.
Thusi
nter
msofpr
oductcapaci
tyandconcent
rat
ion,t
hecont
actpr
ocessi
samor
e
at
tr
act
iveopt
ion.
Oper
ati
ngcost
:Theoper
ati
ngcostast
henamei
mpl
i
esi
sdr
ivenbyt
her
equi
rement
s
t
hatar
euni
quet
othepr
ocess.I
n chemi
calpr
ocessesoper
ati
ng pr
essur
eand
t
emper
atur
eoccupi
esasi
gni
fi
cantpor
ti
onoft
his.Fort
hecont
actpr
ocessi
twas
st
aredundersect
ion1.
5.2t
hathi
ghpr
essur
esf
avourt
hef
orwar
dreact
ioni
nthe
cat
aly
tic conv
ert
er (
i.
e. SO3)
. Howev
er,l
arger pr
essur
es and t
emper
atur
es
aut
omat
ical
l
yincr
ease t
he pl
antoper
atxg
i
nxicost
.For
tunat
elyhowev
er,t
his hi
gh
pr
essur
erequi
rementonl
yamount
sto1-
2at
mint
hecont
actpr
ocesswher
eiti
s
suf
fi
cientt
oachi
evet
hedesi
re99.
5%conv
ersi
on.I
not
herwor
ds,atpr
essur
esonl
y
sl
i
ght
lyabov
etheat
mospher
ic,
themar
ginal
pressur
eri
sei
ssuf
fi
cientt
oobt
aint
he
xxi
i
t
argety
iel
d,andsi
ncet
heoper
ati
ngpr
essur
erequi
rementi
snotabnor
mal
l
yhi
gh,
costofequi
pmentar
elowert
hanwhatcoul
dhav
ebeenexpect
ed.
Ener
gyconsumpt
ion:Ener
gyconsumpt
ionf
orSul
furbur
ningi
ssamef
ort
het
wo
pr
ocessbecausei
nourcaseel
ement
alsul
furwi
l
lbepr
ocur
edt
opr
oducesul
fur
di
oxi
de.I
ntheol
dleadchamberpr
ocesshowev
er,t
her
ear
eot
herr
eact
ionst
o
pr
oduceni
tr
ogenoxi
des.Soi
tcoul
dbegener
all
yst
atedt
hatt
hel
eadchamber
pr
ocessr
equi
remor
eener
gyf
orbur
ningofKNO3.Thebur
ningst
epi
sinanycase,

t
hemai
nener
gyconsumi
ngst
ep.I
nthemoder
nleadchamberpr
ocess,
SO2i
ssentt
o
t
hegl
owert
ower
.Thatmeanst
hei
nit
ialst
epoft
hebot
hpr
ocessesi
ssame.I
n
addi
ti
ont
othi
sthough,i
nthel
eadchamberpr
ocess3t
o12l
eadchamber
sar
e
oper
atedasconv
ert
orswhi
chov
eral
lconsumehi
gherener
gyamountt
opr
ovi
deand
ci
rcul
atet
hegasesandot
herl
i
qui
daci
dsf
ort
hel
eadchamber
s.
I
nthecont
actpr
ocesst
her
eisaspeci
fi
ccol
umnasconv
ert
erandev
eni
nthecase
oft
hedoubl
econt
actdoubl
eabsor
pti
oncont
actpr
ocess,onl
yfew addi
ti
onalgas
conv
eyi
ngl
i
nesar
eneeded.Thecont
actpr
ocesst
her
efor
econsumesl
essener
gy
amounti
nter
msofgasandl
i
qui
dci
rcul
ati
onut
il
it
iesoft
hepl
ant
.Thi
sadv
ant
agei
s
duet
othef
actt
hatt
hecont
actpr
ocessi
scompactandl
essofgasci
rcul
ati
onneeds
t
hant
hel
eadchamberpr
ocessandt
hismat
terbecausemor
egasconv
eyi
ngr
equi
re
mor
epumpsandai
rbl
ower
s
Asf
arasheatemi
ssi
onandheatr
ecov
erysy
stemsar
econcer
ned,t
het
womai
n
pr
ocessesar
emost
lyequal
owi
ngt
othef
oll
owi
ngr
easons:
o
Cont
actpr
ocess-Sul
furbur
ningst
epneedov
er1000 Candt
hecat
aly
tic
o
conv
ersi
on st
ep needs 450 Ct
o oper
atei
nthe opt
imum r
ange.The
cat
aly
tic conversi
on st
ep and absorpti
on st
ep bot
h gener
ate heat
.It
fol
l
owst hatthisheatcoul
dber ecovered.Thehi
ghtemperat
ureinvol
ved
cer
tai
nlymakest heheathi
gh

qual
i
ty
heat
;theexactquant
it
iescoul
dbeest
abl
i
shedaf
terconduct
inga
pi
nchanal
ysi
s.
LeadChamberPr
ocess-Thet
emper
atur
erequi
rementi
nKNO3 andS
burni
ng
o
exceed1000 Candt
hatheatr
equi
rementmi
ghtbemor
ethant
hecont
act
pr
ocessr
equi
rement
.Inf
air
nesshowev
er,moder
nleadchamberpr
ocess
al
sosendSO2 tot
hegl
owert
owerwhi
chcanbal
anceoutt
heener
gy
xxi
consumpt
ion. ii
Est
abl
i
shi
ngofpr
oduct
ionpr
ocess
Thepr
evi
ouschapt
erandsect
ionshav
egi
venanaccountoft
hef
indi
ngsf
rom t
he
r
evi
ewofl
i
ter
atur
ewi
thr
egar
dst
otheav
ail
abl
epr
oduct
ionpr
ocessesandauxi
l
iar
y
aspect
ssur
roundi
ngSul
fur
icaci
dpr
oduct
ion.Al
soi
ncl
udedwer
ethej
ust
if
icat
ions
onpr
ocesssel
ect
ionf
ocusi
ngonoper
ati
onalaspect
saswel
laseconomi
cand
saf
etyconsi
der
ati
ons,outofav
ail
abl
epr
ocessesel
abor
atedunderchapt
er5.What
f
oll
owsi
sthesuggest
edpr
ocessf
lowoft
hemanuf
act
ureofSul
fur
icaci
dindi
cat
ing
mi
norv
ari
ati
onspossi
bleandaddi
ti
onal
just
if
icat
ionsf
oreachspeci
fi
csel
ect
ion.

Uni
t1:
Sul
furbur
ning
Assumi
ng 100% pur
e sul
furcan be obt
ained f
rom t
he CPC;t
her
e ar
etwo
t
echnol
ogi
calmet
hodsf
ort
hepr
oduci
ngSul
furDi
oxi
def
rom el
ement
alSul
fur
.Bot
h
casesr
equi
real
agerheatcont
entt
omel
ttheSul
fur
.Theor
eti
cal
l
ythet
emper
atur
e
o
mustbeov
er1000 C.
Opt
ion1:Sul
furcanbedi
rect
lybur
nti
ntheSul
furbur
nerwi
thpr
esenceofdr
y
ai
rbyappl
yi
ngheat
.Int
hiscase,
thesul
furmel
ti
ngandcont
actwi
tht
heai
ris
per
for
medi
nthesamespace.A not
abl
edi
sadv
ant
agei
sther
educt
ionof
ef
fi
ciency i
nthe ev
entofa t
emper
atur
e dr
op due t
o an oper
ati
onal
mal
funct
ion,
hazar
doranyot
heraber
rat
ion.

Fi
gur
e1.
7Si
mul
taneousmel
ti
ngandbur
ningofSul
fur

Opt
ion2:Themel
ti
ngofSul
furi
sper
for
medsepar
atel
ywi
thoutcont
actoft
he
ai
rforoxi
dat
ioni
ntoSO2.Themol
tenSul
furi
ssuppl
i
edt
oar
eact
or(
spr
ayed)
al
ongwi
thacount
ercur
rentf
low ofdr
yai
rtoenabl
etheoxi
dat
ionr
eact
ion
andpr
oduceSul
furDi
oxi
de.Thecompr
omi
seoft
argetef
fi
ciencyst
ateabov
e
i
slessl
i
kel
ytooccuri
nthi
sconf
igur
ati
on.

xxi
v
 Fi
gur
eSepar
atemel
ti
ngandbur
ningofSul
fur

Opt
ion2i
sthussel
ect
edbyconsi
der
ingt
heconst
antef
fi
ciencyofSul
furoxi
dat
ion
t
hati
soper
ati
onal
l
ymor
efav
orabl
e wi
thl
essv
ari
ati
on on t
he composi
ti
on of
pr
ocessmat
eri
al.

Uni
t2:
Airdr
ying
Ther
equi
redpr
ocessai
rwher
everr
equi
redi
nthepr
ocessi
ssuppl
i
edbyoneuni
t.
Theai
rmustbef
il
ter
edanddr
iedsi
nce,i
fai
rsuppl
yiscont
ami
nat
edwi
thdust
,
moi
stur
eet
c.,t
hepoi
soni
ngoft
hecat
aly
sti
spossi
ble,whi
chcancauseanot
abl
e
r
educt
ioni
ntheconv
ersi
onef
fi
ciencyandhi
ghut
il
it
ycostdur
ingt
heoper
ati
onot
her
t
hanext
racostofr
epl
acementofcat
aly
st.
Hi
gh concent
rat
ed H2SO4 (
i.
e.f
ini
shed pr
oduct
)can beused i
ntheor
yfort
his
pur
pose,howev
er,Ol
eum i
spr
efer
red.Par
tl
ybecauseusi
ngt
hef
ini
shedpr
oduct
st
ream (
orpr
edi
l
uti
onSul
fur
icst
ream)agai
nforupst
ream oper
ati
onswher
edi
rect
cont
actwi
l
lbemadewi
thupst
ream pr
oduct
swasnotr
egar
dedasappr
opr
iat
e
al
toget
herandpar
tl
ybecauseOl
eum hasahi
gherabi
l
ityt
oabsor
bmoi
stur
eduet
o
i
tsmor
econcent
rat
edf
orm.Basedont
hisnot
ion,Ol
eum wi
l
lbesel
ect
edast
he
dehy
drat
ingmedi
um.

Uni
t3:
Gascl
eani
nguni
t(SO2)
Thi
sisoneoft
hepoi
ntsi
nthepr
ocessf
rom wher
eexi
sti
ngpr
ocessesdev
iat
efr
om
eachot
her
.Thesul
furdi
oxi
det
hathadbeencr
eat
edf
rom bur
ningmol
tensul
furi
ndr
y
ai
rwi
l
lcont
ainashpar
ti
cleset
c,whi
chmustber
emov
edi
nor
dert
oensur
ethef
lawl
ess
operabi
l
ityofdownstr
eam uni
tssuchast heheatexchangersandtheconv ert
erunit
whichother
wisecoul
dbecompromisedi
fpa x
rx
t
icul
atemat
terfoul
sheatexchangersorin
v
thecaseoft heconvert
eruni
t-mightevenaf fectt
hecatalyt
icperf
ormanceoft he
cat
aly
st.Ther
efor
eanearper
fect
xx
vi
eff
ici
encyi
stobeexpect
edfr
om thecleani
nguni
t.Thel
it
eratur
erev
iewrev
eal
ed
sever
alopt
ionst
hatcoul
dbeusedthatareusedel
sewhereingascl
eani
ng
9
oper
ati
ons.
1.
BagFi
l
ter
2.
Elect
rost
ati
cPr
eci
pit
ator
3.
Scr
ubber
4.
Cycl
one
Opt
ion 1:Whi
l
e bag f
il
ter
s ar
e a common f
orm ofgas cl
eani
ng,t
he i
ntense
o
t
emper
atur
es(
~1000 C)i
nvol
vedmakemostbagf
il
ter
simpr
act
ical
.A sur
veyof
speci
fi
cat
ionsofav
ail
abl
ebagf
il
ter
sshowedt
hatev
ent
hosedesi
gnedspeci
fi
cal
l
y
f
orhi
gh t
emper
atur
e oper
ati
ons ar
e notexpect
ed t
o oper
ate as f
ari
nto hi
gh
t
emper
atur
esast
hosei
nourcase.Thi
s,coupl
edwi
tht
hehi
gherpowerconsumpt
ion
cost
sinv
olv
ed i
n pul
l
ing t
he f
lue gas t
hrough t
he f
abr
icf
il
ter
s,t
he f
requent
mai
ntenancer
equi
redi
nsol
enoi
dval
vest
hatar
einpl
acet
ohandl
ethef
low of
compr
essedai
r,andt
hef
requentdet
eri
orat
ionofbags(
andt
heassoci
atedcostof
r
epl
acement
)makebagf
il
ter
sal
essdesi
rabl
echoi
ce,al
l
owi
ngexami
ningofot
her
opt
ions.
Opt
ion2:I
nascr
ubber
,thedustpar
ti
clesar
eabsor
bedt
oanot
herphasesuchas
l
i
qui
d.Forpar
ti
clesi
zesofpar
ti
clesasmi
nut
easdustpar
ti
cles,t
hesepar
ati
on
ef
fi
ciencydependsont
hepr
oper
ti
esoft
hel
i
qui
d.Fur
therwhenusi
ngwetscr
ubber
s
o
abov
e1000 C,
thei
ntenset
emper
atur
ewi
l
lcauset
heev
apor
ati
onoft
hel
i
qui
dsused
i
nthescr
ubber
swhi
chhast
hepossi
bil
i
tyofpoi
soni
ngoft
hecat
aly
stdownst
ream.
Thi
swoul
dal
sopr
ovi
det
heneedt
ohav
eaddi
ti
onalequi
pmentsuchascool
ers,as
wel
lasdr
yer
stoagai
ndr
ytheSul
furDi
oxi
dest
ream bef
orei
tissentt
otheconv
ert
er.
Opt
ion3:I
nthecaseofacy
clonei
tisquest
ionabl
east
owhet
heri
twoul
dbe
compat
ibl
ewi
tht
hepar
ti
clesi
zei
nvol
ved.Fur
ther
,nonot
abl
einst
anceswer
efound
dur
ingt
hel
i
ter
atur
esur
veywher
ecy
clonesar
eusedov
erel
ect
rost
ati
cpr
eci
pit
ator
s.
Opt
ion4:El
ect
rost
ati
cpr
eci
pit
ator
sar
esai
dtoachi
evegoodef
fi
ciencyi
nremov
ing
t
hesmal
l
estdustpar
ti
cleswi
thl
eastaf
fectf
rom i
ntenset
emper
atur
es.Noneoft
he
i
ssuesi
nbagf
il
ter
sappl
yint
hecaseofel
ect
rost
ati
cpr
eci
pit
ator
swhi
char
eal
so
cheaperanddur
abl
ethant
heot
herf
il
ter
inguni
tsment
ionedabov
e.Thi
sist
her
efor
e
chosenast
hemedi
um f
orgascl
eani
ng.
xx
Not
e:Thet
emper
atur
eoft
heout
l va
etSO2st
eii
mfr
om t
hef
il
ter
inguni
tisar
ound1000
0
C .Thecat
aly
ticconv
ert
ert
hati
sdi
rect
lydownst
ream howev
er,needst
o be
mai
ntai
nedar
ound
9
Anotewort
hyfeat
ureofthi
sstream t
hatmayhav etobeborneinmindwhen
contempl
ati
ngthemostsuitabl
eoperationofgascl
eani
ngisthatt
hetemper
atur
eint
he
o
str
eam i
sinthenei
ghborhoodof1000C

xx
vi
i
i
 o
450 Ct
omeetopt
imum equi
l
ibr
ium condi
ti
ons.Aheatexchangerar
rangementmay
be needed t
o bot
h coolt
his st
ream and al
so mai
ntai
nthe i
nletSO2 st
ream
o
ar
ound450 C.Aheatex
changeri
sal
soneededt
ocooldownt
heCat
aly
ticconv
ert
er
because t
he r
eact
ion i
s exot
her
mic.Thi
s can be achi
eved byt
he usi
ng heat
exchanger
stot
hest
ream l
i
neswhi
chconnectt
hei
nter
medi
ateabsor
pti
ont
ower
and t
he cat
aly
tic conv
ert
er.Wher
e ener
gyi
ntegr
ati
on v
ia heatr
ecov
eryi
s not
possi
ble,aboi
l
eruni
tmayber
equi
redt
obei
nst
all
edwhi
chmaybeany
wayneeded
f
ormel
ti
ngSul
furatt
heout
set
.

Uni
t4:
Cat
aly
ticconv
ert
er
Thecat
aly
ticconv
ert
eri
sthe4st
agepackedbedusual
l
yinpl
acei
nthei
ncont
act
pr
ocess.Ther
eact
ioni
ntheconv
ert
eri
sexot
her
micr
eact
ionwher
etemper
atur
eri
se
o
i
sexpect
ed.Howev
er,mai
ntai
ningt
he450 Ct
emper
atur
eisessent
ialt
omai
ntai
n
t
hemaxi
mum conv
ersi
onar
oundt
heopt
imum equi
l
ibr
ium condi
ti
on(
othert
han
mai
ntai
ningpr
essur
ear
oundt
he1-
2at
m).

Fi
gur
e1.
9Cat
aly
ticconv
ersi
onofSO2t
oSO3

Sel
ect
ionofcat
aly
st

Thecat
aly
ticact
ionobv
iousl
ypl
aysamaj
orr
olei
ntheconv
ersi
onst
epi
nbot
hlead
chamberpr
ocessandt
hecont
actpr
ocessandi
tsv
ari
ati
ons.TheuseofPl
ati
num f
or
the puropose ofcatal
ysi
s has t
wo main disadv
ant
ages,even t
hough i
thas a
xxi
sati
sfactor
ylevelofact
ivi
ty.Mai
nlyt
hisha
xstodowi t
hitshi
ghcostofacquisi
ti
on,
andt
hushast
heef
fectofi
ncr
easi
ng
xx
x
thecapi
tal
costandoper
ati
ngcost(
thel
att
erhast
odowi
tht
her
egul
armai
ntenance
needed)
.
Secondl
yPl
ati
num cat
aly
stshav
eal
owert
hreshol
dfori
nact
ivat
ionbypoi
soni
ng.

Vanadi
um (V)Oxide as a possi
ble candi
dat
ef orcatalysi
s ofSul f
uri
c aci
d
manufact
uri
ng(
oxi
dati
onofSulfurDi
oxide)hasbeenunderconsider
ati
onsincet
he
t
h
begi
nni
ngoft
he20 cent
ury
.Incompar
ison,
V2O5hast
hef
oll
owi
ngadv
ant
ages.

Rel
ati
vel
ylowt
endencyt
opoi
soni
ngf
rom cont
ami
nat
ion.
Thel
owercostofacqui
sit
ionandoper
ati
on.Thel
att
eri
sduet
olowercostof
r
epl
acementowi
ngt
othel
esserdegr
eeofpoi
soni
ng.
Ov
eral
l
,abet
teropt
iont
obeusedi
nlar
gescal
epr
oduct
ionpl
ant
s.
Owi
ngt
other
elat
ivel
yhi
ghereconomi
cfeasi
bil
i
tyofVanadi
um (
V)Oxi
de,i
twi
l
lbe
sel
ect
edast
hecat
aly
ticmedi
um f
ort
hepr
oposedpr
ocess.I
tmustal
sobest
ated
t
hatdur
ingt
hel
i
ter
atur
erev
iew,
thi
scomponenthadbeenr
efer
redi
nmanycasesas
asui
tabl
eopt
ion,whi
chal
soi
mpl
i
edt
heappar
entmer
it
sV2O5 hol
dsov
erot
her
candi
dat
esf
orcat
aly
sis.

Uni
t5:
Int
ermedi
ateabsor
pti
ont
ower
:
Thei
nter
medi
ateabsor
pti
ont
oweri
sinser
tedt
othesel
ect
edpr
ocesst
oachi
evet
he
hi
ghconv
ersi
onef
fi
ci
encyi
ntheconv
ersi
onofSO2 t
oSO3asj
ust
if
iedunderDCDAi
n
sect
ion6.
2.Thepr
oducedSO3i
sfedt
omai
nabsor
pti
ont
ower
.Sul
fur
icaci
dmustbe
f
edf
rom st
oraget
anksandt
heout
letst
ream ofOl
eum i
ssentt
othei
rdesi
gnat
ed
st
oraget
anks.

xx
xi

Fi
gur
eInt
ermedi
ateabsor
pti
ont
oweri
ncr
easi
ngov
eral
lconv
ersi
on
 3
6

xx
xi
i
 Desi
gnofapl
antt
omanuf
act
ureSul
fur
icaci
dfr
om Sul
fur

Uni
t6:
Mai
nabsor
pti
ont
ower
SO3r
eact
swi
thSul
fur
icaci
dandpr
oducesOl
eum.Theusual
absor
pti
ont
oweri
nthe
cont
actpr
ocessi
stobesel
ect
ed.Theexot
her
micabsor
pti
onmi
ghtr
equi
reaheat
exchangert
obei
nst
all
edt
omai
ntai
nthet
emper
atur
eoft
heabsor
pti
onpr
ocesst
o
pr
eventexcessi
vef
ormat
ionofSul
fur
icmi
stt
hatoncef
ormed,
wil
lbecar
ri
edov
erby
i
nthef
luegas.

Fi
gur
e1.
11Mai
nabsor
pti
ont
ower

1.
7.3.
7Uni
t7:
Fluegast
reat
ment
Fl
uegasf
rom t
hemai
nabsor
pti
ont
owercont
ainsoxi
desofsul
fur(
andpossi
bly
oxi
des ofni
tr
ogen cont
ain due t
o hi
gh t
emper
atur
e dur
ing Sul
furmel
ti
ng and
bur
ning)
.Ar
equi
redt
oscr
ubberi
srequi
redt
otr
eatf
luegaspr
iort
odi
schar
ge(
fl
ue
gasdesul
fur
izat
ion)

Uni
t8:
Oleum t
ank
Ol
eum pr
oducedi
nthepl
antr
equi
reshol
dingt
ank.Thet
ankscanbeusedast
he
st
art
ingpoi
ntofdi
str
ibut
ionofOl
eum f
orai
rdr
yinguni
t,whi
l
ethet
anksar
etobef
ed
f
rom mai
nandi
nter
medi
ateabsor
pti
oncol
umns.

Uni
t9:
Dil
uti
ont
ank
Ol
eum i
sconv
ert
edt
oSul
fur
icaci
dint
hedi
l
uti
ont
anks.Thef
low r
ateofwat
eri
s
dependentontherequi
redconcent
rat
iona
xxndOl eum coll
ecti
ngflow r
ate.These
tankscanalsobeusedtoequali
zet x
hepri
i
oiucedf
d inalsul
fur
icaci
dconcentr
ati
on.
TheSul
fur
icaci
dst
reamsf
edt
omai
nandi
nter
medi
ateabsor
pti
ont
oweror
igi
nat
es
f
rom t
he t
ank.Tanks shoul
d cont
ain agi
tat
orst
ofaci
l
itat
e pr
opermi
xi
ng and
homogeni
zat
ion.Thef
inal
productf
rom di
l
uti
ont
anksshoul
dbe

3
7

xx
xi
v
 Desi
gnofapl
antt
omanuf
act
ureSul
fur
icaci
dfr
om Sul
fur

98%Sul
fur
ic.Heatexchanger
smaybei
nst
all
edt
ocapt
ureheatemi
tt
eddur
ing
di
l
uti
oni
frequi
red.

Concl
usi
on:
Blockdi
agr
am ofsel
ect
edpr
ocess
Basedonf
eat
uresofav
ail
abl
epr
ocessest
hathadbeeni
dent
if
ieddur
ingt
he
r
evi
ewofl
i
ter
atur
eandbasedonabov
ejust
if
icat
ions,
abl
ockdi
agr
am depi
cti
ng
t
hepr
ocessf
lowf
ort
hepr
oduct
ionofSul
fur
icaci
disgi
venbel
ow.
Fi
gur
e;Compl
etebl
ockdi
agr
am ofsel
ect
edpr
ocess
MANUFACTUREOFSULFURI
AGRAM:
PROPOSEDBLOCKDI D
CACI

xx
xv

3
8
4.
1MassBal
ance
Themassbal
ancewaspr
epar
edf
ort
hepl
antoper
ati
ngunderst
eadyst
ate(
andt
hus
zer
oaccumul
ati
onassumed)wi
thaonehourbasi
s.

(
1.1)

Dur
ingt
hepr
epar
ati
onoft
hebal
anceasetofpar
amet
erst
hatwoul
dhav
etobe
consi
der
edasv
ari
abl
eswer
eident
if
iedf
orf
utur
ebenef
it
.Pr
ovi
sionswer
eal
l
ocat
ed
i
ndi
vi
dual
l
yforequi
pmentwher
etheyar
edeemedsi
gni
fi
cantandov
eral
lpr
ovi
sion
f
oral
lot
her
stomaket
hef
igur
esasr
eal
i
sti
caspossi
ble.

xx
xvi
Tabl
e3.
3Li
stofv
ari
abl
esusedi
nconst
ruct
ingmassandener
gybal
ancei
nMSExcel
2010
(Ext
ract
eddir
ect
ly)

Defaul
t
# Parameter Fi
gur
e Uni
t fi
gure
1 Maximum Sulfurinputl
oadi
ntotheplant 35 MT/day 35
Operat
ionalcapacit
yasapercentageofmaxi
mum
2 capaci
ty 100% w/w 100%
3 Operat
ionalSulf
urinputl
oad(Fr
om #1and#2) 35 MT/day 35
4 Noofwor ki
ngday spermonth 25 days 25
5 Noofwor ki
nghour sperday 24 hour
s 24
6 Loadofunconver
tedH2Si ntheSulf
uri
nput( %tot
ali
nput
) 1% w/
w 5%
7 Percentagepr
ovi
sionforl
ossesduri
ngmeltingofSul
fur 1% w/
w 1%
8 Remov al%ofmoistur
einair(i
nthemainairdry
er) 100% w/
w 99%
9 Percentagepr
ovi
sionforl
ossesduri
ngburningofSul
fur 1% w/
w 1%
10 Percent ageremov alofmoi st
ureinSO2bySO2dr yer 100% w/
w 99%
Percent ageremov alofSul furdustf r
om mainstream i
n
dust
11 coll
ect or 99% w/w 99%
12 Degr eeofconv ersi
on: Sulfurburner 99% v/
v 99%
16 Degr eeofconv ersi
on: catalyti
creactorbed4( fr
om top) 99.
5% v/
v 99.
5%
Degr eeofconv ersi
on: catalyti
creactor1-3beds( f
rom
17 top) 93.
3% w/
w 93.
3%
Deg.ofconv ersion:cat.react orbed4( f
rom top)-New
18 Value 96.
0% w/w 96.
0%
19 ExcessAi rSuppliedtot heConv ert
er 10.
0% v/
v 10.
0%
20 Absor ptionEffi
ciencyi nIntermedi ateAbsor
pt i
onTower 100.
0% w/w 100.
0%
21 ExcessSul f
uricSuppl i
edt oI AT 0.
0% w/w 0.
0%
22 Mat eri
al ContentPer centagedi rectedtoIAT 90.
0% w/w 90.
0%
23 Absor
pti
on%SO3i
nmai
nabsor
ber 99% v
/v 99%
24 Absorption%SO3i nint
.abosorber 99% v/
v 99%
25 Overal
l provisi
onf orl
ossesdownst ream ofSul
furburner 3% w/w 3%
Percentageofexcessai rinai
rstream i
ntomaindryerfor
26 Combust i
onoff uel 20% v
/v 10%
Percentageofexcessai rinai
rstream i
ntomainairdryer
for
27 Sul
furbur ning 10% v
/v 10%
28 Percentageofexcessai rinai
rstream i
ntoconvert
er 10% v
/v 10%
PercetageofSul furDioxidepresentgasoutl
etl
inefrom
29 fur
nace 11% v/
v 18%
30 Concent r
ationofpr oductSulf
uricacid 99% w/w 98.
5%
31 Chainlengthofcombust ionfueloil 50 Catoms 50
C /
H
at
om
32 C:
Hrat
ioofcombust
ionf
uel
oil 10.
204 s 10.
204
xx
kg
xvi
Abs.
humi
dit
yfi
gur
etoest
imat
ewat
erv
apo
iurcont
enti
n
i
nlet (H2O/
dry
0.
0271
33 ai
rstr
eam 3 air
) 0.
02713
34 Per
centageofH2S04fr
om theH2SO4Tank 98.
5% w/ w 98.
5%
35 Per
centageofH2Ofrom t
heH2SO4Tank 1.
5% w/w 1.
5%
 Percent
ageofExcessOl
eum sentt
omai
nai
rdr
yerand
SO2
36 dry
er 0.
0% w/
w 0.
0%

84

xx
xvi
i
i
Ener
gyBal
anceandut
il
it
yrequi
rement
s
I
dent
if
yingandquant
if
yingcomponent
sint
heener
gybal
ance:I
nagener
alsense
ener
gycanbeent
eredi
ntoauni
tfr
om i
tsi
nput
s-pr
ocessorut
il
it
y(i
.e.bymass
t
ransf
erf
rom pr
ocessl
i
nesorbyheatt
ransf
erf
rom ut
il
it
yli
nes)ori
nthef
orm of
wor
kdone(
wor
kdoneagai
nstpr
essur
ewher
eoper
ati
ngpr
essur
eint
heuni
tisnot
at
mospher
icbutsi
gni
fi
cant
lyabov
eorbel
ow i
t,orshaf
twor
kinv
olv
edi
nmi
xi
ngor
pumpi
ng)
.Si
nce al
luni
ts oft
he pr
oposed pl
ant(
mel
ter
,fur
nace,conv
ert
er,
absor
pti
oncol
umns,di
l
uti
ont
ankset
c)ar
eoper
atedunderat
mospher
iccondi
ti
ons,
wor
kdoneagai
nstpr
essur
e(pr
essur
evol
umewor
k)wasconsi
der
edasnegl
i
gibl
e
whencompar
ingt
oener
gyt
ransf
erv
iaheatandmasst
ransf
er.Howev
er,
itshoul
dbe
not
edt
hatasf
arast
heener
gyi
nthepr
ocessf
low i
sconsi
der
edt
heener
gyi
nput
f
rom t
hesewi
l
lonl
ybeapor
ti
onoft
heamountt
hati
sconsi
der
edast
her
emai
nder
oft
heef
fi
ciencyr
ati
ng,
andf
ori
nst
ance,
onl
yaf
ract
ionoft
heener
gyt
hati
simpar
ted
t
oaf
lui
d dur
ing pumpi
ng wi
l
lremai
n wi
thi
n si
nce t
he bal
ance i
sli
kel
yto be
consumeddur
ingt
ranspor
t,whi
chwasany
wayi
tspur
pose.

Ther
efor
e,i
nor
dert
opr
oper
lyi
dent
if
ytheener
gycont
entofast
ream,aper
cent
age
oft
heener
gycont
enti
nputbymasst
ransf
erwast
akenast
hatofener
gyt
ransf
erby
wor
ktr
ansf
erf
oreachuni
t.Thi
sappr
oachwast
akenpar
tl
ysi
ncet
heexactener
gy
cont
enti
nthest
ream duet
owor
kdonecoul
dnotbequant
if
ieddi
rect
lywi
thout
knowl
edge ofpowerr
ati
ngs oref
fi
cienci
es ofpumps,compr
essor
s,f
ans t
hat
pr
ovi
desuchener
gyt
ofl
uidsatt
hisst
agewher
eequi
pmentspeci
fi
cinf
ormat
ion
coul
dnotbev
eri
fi
ed.Whenassumi
ngt
hispr
ovi
sion,
alar
gerpr
ovi
sionwasassumed
f
oruni
tswher
esuchwor
kimpar
ti
ngequi
pmentwoul
dobv
iousl
ybepr
esentsuchas
t
heai
rdr
yer(
aircompr
essor
s),
fur
nace(
fans,
slur
rypumps)
,di
l
uti
ont
anks(
agi
tat
ors)
et
c.Thepr
ovi
si
onsofener
gyal
l
ocat
edar
egi
veni
nthet
abl
ebel
ow (
ext
ract
ed
di
rect
lyf
rom MSExcel
flowsheet
):

xx
xi
x
 8
5

xl
 Tabl
eAl
l
owancef
orwor
kdoneasaf
racti
onofener
gyt
ransf
erbyi
nputmasst
ransf
eri
n
eachuni
t

WORKDONEALLOCATI
ONS
Equi
pment Al
l
ocati
on(%ofi
nletener
gy)
Melt
er 2%
Ai
rDryer 5%
HeatExchanger
s 1%
Fur
nace 5%
SO2dryer
s 3%
WasteHeatBoi
l
er 2%
Catal
yti
cConverter 2%
Absorpti
onColumns 2%
Oleum Stor
agetanks 0.
5%
Sulf
uri
cacidstoraget
anks 1%
Dil
uti
ontanks 2%

Quant
if
yingener
gyt
ransf
erbymasst
ransf
er:Theener
gybal
ancewasdonewi
tht
he
obj
ect
iveofev
aluat
ingt
heut
il
it
yrequi
rement
soft
heuni
tinmi
nd.Thi
sisbecause
whenev
aluat
ingt
heener
gycont
entatuni
tinl
etsandout
let
sint
ermsoft
hei
r
ent
hal
piesatt
her
elev
antt
emper
atur
eswi
thr
espectt
other
efer
encest
ateof
st
andar
dtemper
atur
eandpr
essur
e(STP)
,thedef
ici
torsur
plusofener
gyobt
ained
(
aft
erpr
ovi
dingf
orl
osses)r
efl
ect
stheut
il
it
ydut
y.Wher
eli
ter
atur
eonexi
sti
ngpl
ant
s
doesnoti
ndi
cat
eforauni
tthatut
il
it
iesar
eli
kel
ytobeneeded,t
hei
mbal
anceof
ener
gywasal
l
ocat
edasal
oss-t
hatcoul
dbej
ust
if
iedi
nter
msoff
ugi
ti
veemi
ssi
ons
ofgaset
c.

Whent
heabov
eist
akeni
ntoaccount
,ener
gybal
anceexpr
essi
onf
orauni
tint
he
pr
oposedpl
antoper
ati
ngatst
eadyst
atewasconsi
der
edasshown.

I
tist
henetdi
ff
erencear
isi
ngoutofener
gygener
atedandconsumedt
hatshoul
dbe
consi
der
edwhenev
aluat
ingut
il
it
yloads.I
tisi
mpor
tantt
onot
ethatt
hispol
i
cyonl
y
y
iel
dsaccur
ater
esul
tsonl
ywhent
hisi
sdonewi
tht
hemi
ndsett
hatut
il
it
ydut
ies(
Eg:
wher
therornott
ost
eam j
acketorcoolauni
t)ar
eunknown.Aspr
evi
ousl
ypoi
nted
outt
heener
gybal
ancei
sdone,
toget
herwi
thl
i
ter
atur
eonoper
ati
ngt
emper
atur
est
o
ev
aluat
eandj
ust
if
yut
il
it
yneeds.
xl
i
Ref
erencest
ate:Whenconst
ruct
ingt
heener
gyf
low sheet
,theener
gyati
nputand
out
putperuni
tcont
entofmat
eri
alt
oanyuni
twascal
cul
atedbypl
aci
ngSTPas
r
efer
ence.
xl
i
i
Supposet
her
efer
encei
stakenasst
andar
dtemper
atur
eandpr
essur
e(STP)
.Then:
(

Wher
e:

=Ent
hal
pyoff
ormat
ionofspeci
esatt
emper
atur
eT(
wit
hrespectt
oSTP)

=St
andar
dent
hal
pyoff
ormat
ionofspeci
es(
i.
e.atSTP)

Thei
ntegr
ati
ont
ermi
ncl
udedr
efl
ect
stheadj
ust
mentt
hathast
obemadet
othe
st
andar
dent
hal
pywheni
thast
obeconsi
der
edatanel
evat
edt
emper
atur
e.Thi
s
coul
dbev
iewedast
hei
ncr
ement
alr
isei
nent
hal
pysi
ncei
tisdef
inedt
hat
:

Henceequat
ion1.
4makesper
fectsensesi
ncei
tist
hei
ncr
ement
ali
ncr
easei
n
ent
hal
pyt
hati
sbei
ngev
aluat
edasshown:
(
1.6)

Equat
ion1.
4repr
esent
edacasewi
thnophasechangeoccur
ri
ng.I
fonewer
eto
occuratt
emper
atur
e(say
).Then:

I
nthi
smannert
heener
gycont
entpr
esenti
neachst
ream wasquant
if
iedonaper
uni
tmat
eri
albasi
s(i
nthef
orm of
speci
fi
cent
hal
pies(
kJ/
kmol
))
,so t
hatt
he
cal
cul
ati
oncoul
dbemadesi
mpl
er.Onceobt
ainedf
oreachspei
cesi
nast
ream
(
processl
i
ne)t
het
otalent
hal
pypr
esenti
nthel
i
newi
thr
espectt
oar
efer
ence
ent
hal
pywasobt
ainedasshown:

xl
i
i
i
 Themol
arf
lowr
atewasobt
ainedf
rom t
hemassbal
ance.Dur
ingt
hemassand
ener
gybal
ance,
thepr
oper
ti
esment
ionedabov
ewer
eev
aluat
edi
nuni
tsgi
venbel
ow:

Tabl
e:Theuni
tsbywhi
chmai
npr
oper
ti
esofthepr
ocessf
lowhav
ebeengi
veni
nthemassand
ener
gybal
ance

Pr
oper
ty Uni
tofpr
oper
tyused
Massf
lowr
ate MT/
hr
Mol
arf
lowr
ate kmol
/hr
Ent
hal
py(
Speci
fi
cent
hal
py)atT(
wrtSTP)kJ/
kmol
Speci
fi
cheatcapaci
ty kJ/
kmol
K
Ener
gyf
lowr
ate kW
Ul
ti
mat
econsol
i
dat
ionofener
gybal
ancef
oreachuni
t:Theener
gybal
ancef
oreach
uni
twi
l
lbeshownonast
ream byst
ream basi
sandt
heener
giesi
ntoandoutofauni
t
v
iapr
ocessandut
il
it
yst
reamswi
l
lbet
otal
edf
ir
st.Secondl
ytheener
gycont
entent
ered
aswor
kdoneaccor
dingt
othepol
i
cyment
ionedabov
ewi
l
lbet
akeni
ntoaccount
,andi
t
woul
dbeassumedt
hatmuchoft
hisener
gywoul
dbeconsi
der
edf
rom t
heout
letsi
de
asener
gyl
osses.Wi
tht
hisar
rangement
,thebal
anci
ngf
igur
ewhent
hei
nputi
stot
aled
agai
nstt
heout
putwoul
dbecomet
hebal
ancef
igur
e,asshown-t
husadef
ici
tinener
gy
att
heout
leti
stobesuppl
i
ed(
asst
eam et
c.)andasur
plusi
nener
gyatt
heout
leti
sto
ber
emov
ed(
ascool
i
ngwat
eret
c).I
nthi
smannerut
il
it
ydut
iescoul
dbedet
ermi
ned,
andasampl
epr
epar
ati
oni
sshownbel
ow.

Tabl
e3.
6Sul
furmel
terener
gybal
ance

I
N OUT
o o
St
ream T(C) Ener
gy(
kW) Stream T(C) Ener
gy(
kW)
(10)MOLTEN
(9)SULFURINPUT 30 -
1.86SULFUR 150 31.
29
Util
i
ties(
Steam j
acket
) 33.15Losses 150 0.
04
Wor kdone(pumping,
agi
tat
or) 0.04

TOTAL 31.
32TOTAL 31.
32

Bal
anci
ngener
gyr
equi
rement
sinuni
tswi
thr
eact
ingsy
stems:
Theabov
ear
rangement
wasdi
spl
ayedsl
i
ght
lydi
ff
erent
lywhent
hespeci
esunder
goachemi
cal
react
ionwi
thi
na
uni
t.Thenasperequati
on1.2,
thegener
ati xl
onaindconsumpti
onofener
gy(dr
ivenby
v
generat
ionandconsumpti
onofspeci
es)mustbeincludedi
nthebal
ancei
norderto
r
econci
l
etheout
letener
gycont
entwi
tht
heener
giesi
nthei
nlet
s.Theener
gyr
eleasedi
n
f
ormat
ionofspeci
esand
xl
v
t
heener
gyconsumedi
nreact
antspeci
eswi
thi
ntheuni
tscanbei
sol
ateddur
ing
t
hedet
ermi
nat
ionofspeci
esbyspeci
esener
giesi
nagi
venst
ream.Thi
sappr
oach
hasbeenusedf
ort
heener
gybal
ancei
ntheSul
furf
urnace,
dry
ers,
cat
aly
tic
conv
ert
er,
absor
pti
oncol
umnsandt
hedi
l
uti
ont
ank.

Tabl
e:SO2Dr
yerener
gybal
anceext
ract
eddi
rect
lyf
rom MSExcel

I
N
o
St
ream T(C) Ener
gy(
kW)
PARTI
ALLYCOOLEDSULFURDI
OXI
DEWI
THFLUEGAS 350 -
3,636.
71
OLEUM FORSO2DRYER 40 -
14,
103.
70
Ener
gyrel
eased(gen.ofSul
fur
icaci
d) -
496.
06
Workdone(pumps,vac.Pumps/ej
ect
ors) 532.
21

TOTAL -
17,
704.
25

OUT
o
St
ream T(C) Ener
gy(
kW)
FI
LTEREDDRI
EDSULFURDI
OXI
DETOPREHEATER 350 -
4,208.
24
OLEUM RETURNTOHEADER 40 -
14,
390.
44
Energyconsumed(
react
ionofOl
eum andWat
er) -
279.
44
Excessheattober
emoved(Cool
ingj
acket
) 216.
62
Losses 957.
23

TOTAL -
17,
704.
25

St
ream nami
ngconv
ent
ion
I
nor
dert
ouni
quel
yident
if
yeachst
ream,anami
ngconv
ent
ionwasused.Thi
s
conv
ent
ionhasal
sobeenusedi
nthenextchapt
ersasaf
orm ofsummar
izi
ngf
low
r
esul
ts.Theconv
ent
ionmai
nlyseekst
odi
vi
depr
ocessst
reams(
ormat
eri
alst
reams)
andut
il
it
yst
reams.Apr
efi
xMS
wasusedt
odenot
ethef
ormer
,whi
l
eUS
wasused
t
odenot
ethel
att
er.

Est
imat
ionofphy
sical
andchemi
cal
proper
ti
es

Boi
l
ingandmel
ti
ngpoi
nts
Nor
malboi
l
ingandmel
ti
ngpoi
ntswer
erequi
redi
ntheener
gybal
ancet
ocal
cul
ate
t
hespeci
fi
cent
hal
piesofspeci
espr
esenti
nast
ream atagi
vent
emper
atur
e.

xl
v
i
 Desi
gnofapl
antt
omanuf
act
ureSul
fur
icaci
dfr
om Sul
fur

Tabl
e:Boi
l
ingPoi
ntsofspeci
esi
nvol
vedi
nthepr
ocess(
Sinnot
t,Coul
son&Ri
char
dson'
s
Chemi
cal
Engi
neer
ingVol
ume6(
Chemi
cal
Engi
neer
ingDesi
gn)
,1999)
o
Speci
es Nor
mal
Boi
l
ingpoi
nt(C)
Sul
fur
*(TheEl
ementSul
fur
) 445
Sul
furDi
oxi
de -
10.
2
Sul
furTr
ioxi
de 44.
8
Ol
eum*(
Oleum,
Sul
furTr
ioxi
de,
andSul
fur
ic 138
Aci
d)
Sul
fur
icAci
d*(
Nor
mal
Boi
l
ingPoi
nts-Sul
fur
ic337
Aci
d-Wat
ersy
stem,
2008)
Wat
er 100
Hy
drogenSul
fi
de -
60.
4
Ox
ygen -
183
Ni
tr
ogen -
195.
8
Car
bonDi
oxi
de -
78.
5
I
naddi
ti
ont
otheabov
e,Sul
fur
,bei
ngasol
i
datr
oom t
emper
atur
eismel
teddur
ing
oper
ati
on,whi
chr
equi
redt
heknowl
edgeofi
ts,mel
ti
ngpoi
nt,whi
chwasext
ract
ed
o
f
rom l
i
ter
atur
etobeat115 C(
TheEl
ementSul
fur
)

Mol
ecul
arwei
ght
s
Mol
ecul
arwei
ghtofeachcomponenti
susedt
oconv
ertt
hemassbasedmat
eri
al
f
low r
atest
omol
arf
low r
atesi
ntheener
gybal
ance.Themol
ecul
arwei
ght
sof
component
swer
eobt
ainedasshown.

Table3.
9Mol
ecularweight
sofspeci
esinvolv
edintheprocess(Si
nnott
,
Coul
son&Richardson'
sChemical
Engineeri
ngVolume6( Chemical
Engi
neer
ingDesi
gn),1999)

Speci
es Mol
ecul
arwei
ght
Sul
fur 32
Sul
furDi
oxi
de 64.
063
Sul
furTr
ioxi
de 80.
058
Ol
eum 178
Sul
fur
icAci
d 98
Wat
er 18.
0
x1
l5
v
Hy
drogenSul
fi
de i
34.
0i
8
 Desi
gnofapl
antt
omanuf
act
ureSul
fur
icaci
dfr
om Sul
fur

Ox
ygen 31.
999
Ni
tr
ogen 28.
013
Car
bonDi
oxi
de 44.
01

St
andar
dent
hal
piesoff
ormat
ion
The r
efer
ence st
atef
orcal
cul
ati
on ofener
gyi
nputwas t
aken t
o be st
andar
d
0
t
emper
atur
eandpr
essur
eSTP.i
.e1at
m and25 C.Thusi
nor
dert
oobt
aint
hei
nput
and out
putener
gycont
entwi
thr
espectt
othe abov
eref
erence,t
he st
andar
d
ent
hal
piesoff
ormat
ionofeachspeci
eswer
erequi
redt
obeobt
ained.

18
Tabl
eSt
andar
dEnt
hal
piesoff
ormat
ionofspeci
esi
nvol
vedi
nthepr
ocess(
Per
ry,
1999)

Speci
es St
andar
dEnt
hal
pyofFor
mat
ion(
kJ/
mol
)
Sul
fur 0.
00
Sul
furDi
oxi
de -
296.
81
Sul
furTr
ioxi
de -
394.
93
Ol
eum (
Ener
gyBal
anceofAl
kyl-
683.
92
ar
ylsul
fonat
epr
oduct
ionpl
ant
)
Sul
fur
icAci
d -
810.
40
Wat
er -
285.
84
Hy
drogenSul
fi
de -
19.
96
Ox
ygen 0.
00
Ni
tr
ogen 0.
00
Car
bonDi
oxi
de -
393.
51

Lat
entheat
soff
usi
onandev
apor
ati
on
When cal
cul
ati
ng ener
gycont
entofeach componenti
n a st
ream ata gi
ven
t
emper
atur
ewi
thr
espectt
o acer
tai
nref
erence,cer
tai
ncomponent
smayhav
e
phasechangi
ngt
emper
atur
eshal
fwayi
nbet
weent
hest
ream t
emper
atur
eandt
he
r
efer
ence.Thus,t
hesai
dcomponent
sener
gycont
entwoul
dhav
etoi
ncl
udet
hei
r
l
atentheatoff
usi
onorv
apour
izat
ion.Forspeci
essuchasNi
tr
ogen,
Oxy
gen,
Car
bon
Di
oxi
de,
Hydr
ogenSul
fi
deorSul
furDi
oxi
de,
thi
sisn
tthecase,
asal
loft
hem ar
ever
y
st
abl
egases.Forot
her
showev
er,
thel
atentheatf
igur
eswer
erequi
redt
ober
efer
red.

18 xl
v
Si
mil
artoTable1.2,
theref
erencegi
ven
ih
i
ieredoesnotappl
ytospeciesmar
ked
wi
thanast
eri
sk,whoseboil
ingpoi
ntswereobt
ainedfr
om dif
fer
entref
erences,
whi
ch
ar
ecit
edwherenecessar
y.
 Desi
gnofapl
antt
omanuf
act
ureSul
fur
icaci
dfr
om Sul
fur

Tabl
e3.
11Lat
entHeat
sofspeci
esinv
olv
edinthepr
ocess(Si
nnott
,Coul
son&Richar
dson'
s
Chemical
Engi
neer
ingVol
ume6( Chemi
calEngi
neer
ingDesi
gn)
,1999)
19

Speci
es Lat
entHeat
s(kJ/
kmol
)
Sul
fur
* Fusi
on(
Lat
entHeat1,
254.
4
ofMel
ti
ngof some
commonmat
eri
als)
Vapor
izat
ion(
Flui
ds-48,
320
Lat
ent Heat of
Ev
apor
ati
on)
Sul
furTr
ioxi
de Vapor
izat
ion 40,
679
20
Ol
eum* Vapor
izat
ion 56,
000
Sul
fur
icAci
d* Vapor
izat
ion 56,
000
(
Sul
fur
icAci
d,2008)
Wat
er Vapor
izat
ion 40,
683

3.
1.4.
5Speci
fi
cheatcapaci
ti
es(
atconst
antpr
essur
e:Cp)
Speci
fi
cheatcapaci
ti
esofsubst
ances,par
ti
cul
arl
yfort
hoseofgases,v
arywi
th
t
emper
atur
e,t
hough somet
imes assumed ot
her
wise. Var
iat
ions ar
e most
ly
cor
rect
edbypr
esent
ingspeci
fi
cheatcapaci
tyasaf
unct
ionoft
emper
atur
e.Si
ncea
r
angeoft
emper
atur
eshav
etobedeal
twi
th,i
twasi
ngener
alr
egar
dedt
hatt
he
f
unct
ioni
sappl
i
cabl
e.I
nor
dert
oev
aluat
etheener
gycont
entoft
hesubst
ance
under
goi
ngat
emper
atur
echanget
heabov
efunct
ionswer
eint
egr
ated.

21
Tabl
e3.
12Speci
fi
cHeatCapaci
ti
esofspeci
esi
nvol
vedi
nthepr
ocess(
Per
ry,
1999)

Speci
es Temp. Speci
fi
cHeatcapaci
ty(
kJ/
kmol
K)
o
r
ange(C)
22
Sul
fur 25-
95
95-
115

19
Simil
artoTable1.2,thereferencegivenher edoesnotappl ytospeciesmar ked
withanasteri
sk,whoseboi l
ingpointswer eobtainedf r
om dif
fer
entr ef
erences,which
arecit
edwher enecessary.
20
Duet ounavail
abil
i
tyoflatentheatdat aregardingOleum,ithadt obeassumedt hat
Latentofofevaporati
onofSul f
uricacidcanr easonablybeestimatedast hatofOleum as
well. xli
21
Simil
artoTable1.2,thereferencegivenhxeredoesnotappl ytospeciesmar ked
withanasteri
sk,whoseboi l
ingpointswer eobtainedf r
om dif
fer
entr ef
erences,which
arecit
edwher enecessary.
22
SinceSulf
urinitsvapourformi sseldom regarded,specif
icheatcoeffici
ent
sf ort
hat
parti
cul
arrangewer enotfoundinl i
terat
ure.Thusi twasassumedt hatSulf
urvaporbehaves
inamannert hati
ssi mil
artothatofi t
smostcommongaseousoxi dewhi chisSO2
4.
1.1 MASSBALANCE
Thebasi
csour
ceofr
awmat
eri
alf
ort
hepr
ocessi
sSul
fur
,tobesour
cedf
rom Cey
lon
Pet
rol
eum Cooper
ati
onRef
iner
ysi
tuat
edatSapugaskanda,wher
eiti
saby
product
.
f
igur
esacqui
redf
rom t
heCPC wi
thr
egar
dst
otheexactquant
it
yofSul
furt
hati
s
usual
l
ypr
oducedperdaywast
henscal
edupt
o35t
onsofSul
fur
.Itwasassumedt
hat
aci
dSul
furi
srecei
vedi
nit
sel
ement
alf
orm wi
thahi
ghpur
it
y.

Sul
furmel
ter
Basi
s:1hour

Assumpt
ions:

Rawmat
eri
ali
srecei
vedasel
ement
alsul
fur
.

Loadofunconv
ert
edHy
drogenSul
fi
dei
ntheSul
furi
nputasa
per
cent
ageoft
otal
inputl
oadi
s1%.

El
ement
alSul
fur
MELTER
Molt
enSul
fur(
MS-
(
MS-
01) 03)

Sul
furl
ossesdur
ingmel
ti
ng(
MS-
02)

Fi
gur
e3.
1Inl
etandout
letst
reamsf
rom t
heSul
furMel
ter
Themassf
lowsofst
reamsnumber
edar
egi
veni
nor
derbel
ow:

SULFURI
NPUT(
MS01)
Speci es Fl
owRat
e(MT/
hr) w/
w( %)
Sulf
ur 1.
4438 99.
00
Sulf
urDi oxide 0.
0000 0.
00
Sulf
urTr ioxide 0.
0000 0.
00
Oleum 0.
0000 0.
00
Sulf
ur icAcid 0.
0000 0.
00
Wat er 0.
0000 0.
00
Hydr ogenSul fi
de 0.
0146 1.
00
Oxygen 0.
0000 0.
00
Nitr
ogen 0.
0000 0.
00
CarbonDi oxide 0.
0000 0.
00
TOTAL 1.
4583 100.
00

Sol
i
dsulf
urshoul
dbeheat
edandmel
tedatf
ir
st.Fort
hispur
pose,
semi
-under
ground
mel
ter
& set
tl
eri
sused.Thi
sisasemi
-under
groundpi
tmadeofr
einf
orcedconcr
etewi
thst
eam
heat
ercoi
l
.Onesi
deoft
hepi
tismel
ter
,wher
est
eam heat
ercoi
l
sandanagi
tat
orar
e
equi
ppedandsol
i
dsul
furi
sdumpedi
ntoi
t.Apumpi
sfi
tt
edt
otheot
herendoft
heset
tl
er
t
opumpupt
hemol
tensul
fur
.

I
tisal
soassumedt
hatper
cent
agepr
ovi
sionf
orl
ossesdur
ingmel
ti
ngofSul
furi
s1%.

LOSSESDURI
NGMELTI
NG(
MS02)
Speci
es Fl
owRat
e(MT/
hr) w/
w(%)
Sulf
ur 0.
0144 99.
00
Sulf
urDi oxi
de 0.
0000 0.
00
Sulf
urTr i
oxide 0.
0000 0.
00
Oleum 0.
0000 0.
00
Sulf
ur i
cAcid 0.
0000 0.
00
Wat er 0.
0000 0.
00
Hydr ogenSulf
ide 0.
0001 1.
00
Oxygen 0.
0000 0.
00
Nitr
ogen 0.
0000 0.
00
Car
bonDi
oxi
de 0.
0000 0.
00
TOTAL 0.
0146 100.
00
MOLTENSULFUR(
MS03)
Speci es Fl
owRat
e(MT/
hr) w/
w( %)
Sulf
ur 1.
4293 99.00
Sulf
urDi oxide 0.
0000 0.00
Sulf
urTr ioxide 0.
0000 0.00
Oleum 0.
0000 0.00
Sulf
ur icAcid 0.
0000 0.00
Wat er 0.
0000 0.00
Hydr ogenSul f
ide 0.
0144 1.00
Oxygen 0.
0000 0.00
Nitr
ogen 0.
0000 0.00
Car
bonDi
oxi
de 0.
0000 0.
00
TOTAL 1.
4438 100.
00

Ai
rconsumpt
ion
Anai
rbl
oweri
sinst
all
edbef
oreDr
yingTowerandcombust
ionai
rtoSul
furFur
nacei
s
sentbyt
hisbl
ower
.Mul
ti
-st
agedt
urbot
ypeandt
hemat
eri
alcanbecar
bonst
eel
.Fl
ow
v
olumeshal
lbecal
cul
atedf
rom pr
oduct
ioncapaci
tyofaci
d.Pr
essur
eshal
lbet
het
otalof
dr
aftr
esi
stanceofeachequi
pment
,ductandor
if
icef
orf
lowr
atemeasur
ement
.Usual
l
y,
pr
essur
eshal
lbe25-30kPaf
orsi
ngl
econt
actand30-35kPaf
ordoubl
econt
actpr
ocess.
Ef
fi
ciencyoft
hebl
oweri
susual
l
yashi
ghas6
l
i5% ormor
e.Most
ly,bl
oweri
sdr
ivenby
st
eam t
urbi
neandt
hest
eam i
sfr
om wast
eheatboi
l
erofsul
fur
icaci
dpl
anti
tsel
f.
Ai
rint
akef
rom bl
ower
Assumpt
ions:

Dr
iedai
rSt
ream consi
stsofonl
y79%Ni
tr
ogenand21%Oxy
gen.

Chosenabsol
utehumi
dit
yfi
gur
etoest
imat
ewat
erv
aporcont
enti
ninl
et
ai
rSt
ream i
s0.
027125kg(
H2O/
dryai
r)
.
Per
cent
ageofexcessai
rinai
rSt
ream i
ntoconv
ert
eri
s10%.
Per
cent
ageofexcessai
rinai
rSt
ream i
ntomai
nai
rdr
yerf
orSul
furbur
ning
i
s10%.
Per
cent
ageofexcessai
rinai
rSt
ream i
ntomai
ndr
yerf
orCombust
ionof
f
uel
is20%.
Theai
rispr
oper
lyf
il
ter
edbef
oreent
eri
ngt
hebl
owersot
hatonl
ythegasi
s
cont
aini
ngt
heSt
ream.

AI
R(MS04)
Speci
es FlowRat
e(MT/
hr) w/
w(%)
Sulf
ur 0.
0000 0.
00
Sulf
urDi oxi
de 0.
0000 0.
00
Sulf
urTr i
oxide 0.
0000 0.
00
Oleum 0.
0000 0.
00
Sulf
ur i
cAcid 0.
0000 0.
00
Wat er 0.
3766 2.
64
Hydr ogenSulf
ide 0.
0000 0.
00
Oxygen 2.
9153 20.
45
Nitr
ogen 10.
9670 76.
91
Car
bonDi
oxi
de 0.
0000 0.
00
TOTAL 14.
2588 100.
00

Cal
cul
ati
onSt
eps:

Amountofsulf
urconsumedinfur
nace =1.
4009MT/
hr
Sorequi
redoxygen(
sincemol.Wei
ghti
s
same) =1.4009MT/
hr
= MT/
hr*
1.
Requi
redexcessoxy
gensuppl
y 1.
4009 1
=1.
541Mt
/hr l
i
i
24 =
Requi
redf
uel
rat
e 0.
1926 MT/
hr
25
Sorequi
redoxygenforf
uel =0.
6031MT/
hr
Tot
alrequi
redoxygenfl
owrat
eforf
urnace = MT/hr
 2.
1440
26 =
Oxy
genr
equi
redf
orconv
ert
er 0.
7712 MT/
hr
24
Ref
ersect
ion3.
3.2f
orcal
cul
ati
onofr
equi
redf
uel
cont
ent
25
Ref
ersect
ion3.
2.3f
orcal
cul
ati
onmet
hodol
ogy

Tot
aloxy
genneeded =2.
9153MT/
hr
SoNit
rogeninf
lowrat
e =2.
9153*
(79/
21)
=10.
967Mt
/hr
Absol
utehumidit
y
27
est
imati
on (
Humi
dit
yrat
ioofai
r) = 0.
027125 kg
(
H2O/
dryai
r)
13.
882
Sowat
ercont
ent =3 *
0.027125
=0.
3766MT/
hr
14.
258
Sot
otal
airi
nfl
owr
ate =8 MT/
hr

3.
2.2.
2Mai
nai
rdr
yer
I
fH2Oexi
stsi
ncombust
iongas,t
hiswi
l
llat
elycombi
newi
thSO3andf
ormv
eryf
ine

H2SO4mi
st,
whi
chshal
lcausemanyt
roubl
esi
ndownst
ream equi
pment
.Ther
efor
e,H2O
i
nthecombust
ionai
rshoul
dbeabsor
bedandr
emov
ed.TheDr
yingt
oweri
sli
kel
ytobe
apackedcol
umn.Conv
ent
ionalt
ypei
sacy
li
ndr
icalcar
bonst
eelt
owerl
i
nedwi
thaci
d-
pr
oofpor
cel
ainbr
ick.Col
umnpacki
ngi
sal
sopor
cel
ainandsuppor
tedbyaci
d-pr
oof
por
cel
ainbr
ickbarorgr
id.Thought
her
ear
emanyt
ypesofpacki
ng,SuperI
ntal
l
ox
Saddl
e(SI
S),whi
chhashi
ghper
for
manceandl
owpr
essur
edr
op,i
swi
del
yusedl
atel
y.
SI
Shassomesi
zes,i
.
e.1i
n.,2i
n.,3i
n.Ast
hesi
zei
ncr
eases,pr
essur
edr
opl
ower
sbut
r
elat
ivesur
facear
eadecr
eases.

Assumpt
ions:

Per
cent
ager
emov
ali
ntot
almoi
stur
einai
ris99%.

Ol
eum i
nfl
ow(
MS-
05)
Dr
iedai
r(MS-
07)
DRYER
Ai
rfr
om bl
ower(
MS-
04) Wet
tedol
eum out
fl
ow(
MS-
06)
l
i
ii
 Fi
gur
e3.
2Inl
etandout
letst
reamsf
rom t
heMai
nAi
rDr
yer

Sect
ion3.
3.12shoul
dber
efer
redf
orcal
cul
ati
onofOl
eum f
lowr
ater
equi
red.

26
Si
mplestoi
chi
ometr
ygi
ves1.
4009/2=0.
7712MT/
hrsi
ncemol
ecul
arwei
ght
s
ofSandO2aresame.
27 o
Assuminganambi
entt
emper
atur
eof30C

OLEUM FORAI
RDRYI
NG(
INFLOW)(
MS05)
Speci es Fl
owRat
e(MT/hr
) w/
w( %)
Sulf
ur 0.0000 0.
00
Sulf
urDi oxide 0.0000 0.
00
Sulf
urTr ioxide 0.0000 0.
00
Oleum 3.7206 5.
72
Sulf
ur icAcid 61.3623 94.
28
Wat er 0.0000 0.
00
Hydr ogenSul fi
de 0.0000 0.
00
Oxygen 0.0000 0.
00
Nitr
ogen 0.0000 0.
00
CarbonDi oxide 0.0000 0.
00
TOTAL 65.0829 100.
00

WETTEDOLEUM FROM AI
RDRYI
NG( OLEUM RETURN)
(MS06)
Speci
es Fl
owRat
e( MT/hr
) w/w(
%)
Sulf
ur 0.
0000 0.
00
Sulf
urDi oxi
de 0.
0000 0.
00
Sulf
urTr i
oxide 0.
0000 0.
00
Oleum 0.
0000 0.
00
Sulf
ur i
cAcid 65.
4591 100.
00
Wat er 0.
0000 0.
00
Hydr ogenSulf
ide 0.
0000 0.
00
Oxygen 0.
0000 0.
00
Nitr
ogen 0.
0000 0.
00
Car
bonDi
oxi
de 0.
0000 0.
00
TOTAL 65.
4591 100.
00

l
i
v

FI
LTEREDDRI
EDAIR(MS07)
Speci
es FlowRate(
MT/hr
) w/
w(%)
Sul
fur 0.
0000 0.
00
Sul
furDi
oxi
de 0.
0000 0.
00
 Sulf
urTr i
oxi
de 0.
0000 0.
00
Oleum 0.
0000 0.
00
Sulf
ur i
cAcid 0.
0000 0.
00
Wat er 0.
0000 0.
00
Hydr ogenSul
fi
de 0.
0000 0.
00
Oxygen 2.
9153 21.
00
Ni
tr
ogen 10.
9670 79.
00
Car
bonDioxi
de 0.
0000 0.
00
Designofapl
antt
omanuf
act
ureSul
fur
icaci
dfr
om Sul
fur

TOTAL 13.
8823 100.
00

3.
2.3 Fur
nace

Mol
tensul
furi
scombust
edi
nSul
furf
urnaceandf
ormsSO2.Gast
emper
atur
e
r
eaches1,
050 1,
100.Most
lyt
her
ear
ehor
izont
al,cy
li
ndr
icalshapef
urnaces.
Sul
furi
ssuppl
i
edt
ooneendt
hroughsul
furbur
nerwi
thdr
yai
randcombust
edi
nit
.
Combust
edgasgoesoutf
rom t
heend.Mol
tensul
furi
sspr
ayedbyspeci
albur
ner
andcombust
sasf
inepar
ti
cle.Usual
l
yspr
ayi
ngmedi
aisnotusedandt
hesul
furi
s
spr
ayedbypumppr
essur
e.Combust
ionai
rispr
evi
ousl
ydr
iedi
nDr
yingTowerand
suppl
i
edt
othef
urnace,ar
oundsul
furbur
ner
.Att
heendoft
hebur
ner
,aspr
ayi
ng
noz
zlei
sat
tached.

Assumpt
ions:

1.Per
cent
agepr
ovi
sionf
orl
ossesdur
ingbur
ningofSul
furi
s1%.
2.Degr
eeofconv
ersi
oni
nSul
furbur
neri
s99%.
3.Per
cent
ageofSul
furDi
oxi
depr
esenti
ngasout
letl
i
nef
rom f
urnacei
s
11%.(
Dav
enpor
t&Ki
ng,
Sul
fur
icaci
dmanuf
act
ureanal
ysi
s,cont
rol
and
opt
imi
zat
ion)
4.Theni
tr
ogengasi
nthei
nletai
rSt
ream i
snotmaki
nganyr
eact
ioni
n
t
hef
urnace.
5.Fueloi
l#4usedf
orcombust
ioni
sa50-
50bl
endof#2and#6oi
l
.
(
Lit
erat
uremer
elyi
ndi
cat
est
hat#4i
sabl
endof#2and#6andt
hatt
he
exactpr
opor
ti
ondependsont
heappl
i
cat
ion(
Fuel
Oil
).
)
6.Thecont
entofOxy
genandNi
tr
ogeni
nher
ent
lypr
esenti
nthef
ueloi
li
s
negl
i
gibl
ecompar
edt
otheamountpresentint
heenteri
ngair
str
eam.
vLossesdur
l ingbur
ning(MS-11)

Mol
tedsul
fur(
MS-
03)
 FURNACE
(
MS-
12)
Dr
iedai
r(MS-
08)
Fl
uegaswi
th (MS-
so2 12)
Fuel
inf
low(
MS-
10)
Fi
gur
e3.
3Inl
etandout
letst
reamsf
rom t
heSul
furFur
nace

FI
LTEREDDRI
EDAI
RTOFURNACE(
MS08)
Speci es Fl
owRat
e(MT/
hr) w/
w( %)
Sulf
ur 0.
0000 0.
00
Sulf
urDi oxide 0.
0000 0.
00
Sulf
urTr ioxide 0.
0000 0.
00
Oleum 0.
0000 0.
00
Sulf
ur icAcid 0.
0000 0.
00
Wat er 0.
0000 0.
00
Hydr ogenSul f
ide 0.
0000 0.
00
Oxygen 2.
1440 21.
00
Nitr
ogen 8.
0657 79.
00
Car
bonDi
oxi
de 0.
0000 0.
00
TOTAL 10.
2097 100.
00

MOLTENSULFUR(MS03)
Speci
es FlowRate(
MT/hr
) w/
w(%)
Sulf
ur 1.
4293 99.
00
Sulf
urDi oxi
de 0.
0000 0.
00
Sulf
urTr i
oxide 0.
0000 0.
00
Oleum 0.
0000 0.
00
Sulf
ur i
cAcid 0.
0000 0.
00
Wat er 0.
0000 0.
00
Hydr ogenSulf
ide 0.
0144 1.
00
Oxygen 0.
0000 0.
00
Nitr
ogen 0.
0000 0.
00
Car
bonDi
oxi
de 0.
0000 0.
00
TOTAL 1.
4438 100.
00

SULFURDI
OXI
DEWI
THFLUEGAS&DUST(MS
l
vi
12)
Speci
es Fl
owRat
e(MT/hr
) w/
w( %)
Sul
fur 0.
0142 0.
12
Sul
furDi
oxide 2.
8045 23.
71
Sul
furTr
ioxide 0.
0000 0.
00
 Oleum 0.
0000 0.
00
Sulf
ur i
cAcid 0.
0000 0.
00
Wat er 0.
0199 0.
17
Hydr ogenSul
fi
de 0.
0143 0.
12
Oxygen 0.
2406 2.
03
Nitr
ogen 8.
0657 68.
20
Car
bonDi
oxi
de 0.
6670 5.
64
TOTAL 11.
8261 100.
00

Cal
cul
ati
ons:

Ref
ersect
iononSul
furf
urnacei
nchapt
er3f
ort
hecal
cul
ati
onoff
uelf
lowr
ater
equi
red.I
n
or
dert
ocal
cul
atet
heout
letf
lowr
atesoff
luegasest
hatgoal
ongsi
det
hepr
oducedSul
fur
Di
oxi
de,
ani
deaoft
hemol
ecul
arf
ormul
aoft
hef
ueloi
lhadt
obedet
ermi
nedi
nor
derf
ort
he
st
andar
dcombust
ioncal
cul
ati
ont
obedoneandav
aluef
ort
hemol
ecul
arwei
ghtoft
heoi
l
hadt
obei
ncl
udedf
ort
hemol
ebal
ance.Howev
er,l
i
kemanypopul
arpet
rochemi
cal
sthe
f
ueloi
linquest
iont
oo,wasf
oundt
ocont
ainami
xtur
eofhy
drocar
bons.I
nthi
sbackdr
op
t
hemol
ecul
arf
ormul
awast
akennotasapr
eci
sef
ormul
a,butasar
ati
obet
weenCar
bons
t
o Hy
drogen t
o Oxy
gen.I
tshoul
d al
so be poi
nted outt
hatt
he st
andar
d combust
ion
cal
cul
ati
on met
hodol
ogywasappl
i
ed her
eregar
dlessoft
headded compl
exi
tyi
nthi
s
scenar
io,si
nce t
he Fueloi
lwhi
ch i
s used as a combust
ion f
uelher
eis nota pur
e
hy
drocar
boncompr
isi
ngofonl
yCar
bonandHy
drogen,
butcont
ainssomeOxy
gen,
Nit
rogen
andpossi
blySul
fur
.Consi
der
ingt
hesei
ssuesassumpt
ions#5and#6hadt
obemade.

Oncet
hemol
ecul
arf
ormul
awasappr
oxi
mat
edi
nthi
smanner
,li
ter
atur
efi
ndi
ngsaboutt
he
chai
nlengt
hsoff
ueloi
l
swer
eusedt
odev
elopt
heC:
Hrat
iowhi
l
eassumi
ngt
hatwhat
ever
Ox
ygent
hati
spr
esenti
nher
ent
lyi
snegl
i
gibl
ewi
thr
espectt
othequant
it
yofOxy
gent
hati
s
needed.Ot
her
wise t
he combust
ion cal
cul
ati
on woul
d hav
e been hi
ghl
y compl
i
cat
ed.
St
andar
dchai
nlengt
hsof#4wasgi
vent
ovar
yfr
om 20-
70andi
nsomesour
ces12-
70.
Taki
ngt
hisi
ntoaccountandt
hepr
evi
ousassumpt
ion(
assumpt
ion#5,whi
chi
tsel
fwas
basedonl
i
ter
atur
e)t
hechai
nlengt
hwast
akenas50Car
bons(
FuelOi
l
)(Spei
ght&Ar
joon,
2012)
.

Tabl
e3.
13Mol
ecul
arwei
ghtest
imat
ionoff
uel
oil
no4

l
vi
i Molecul
a
C H O+N S r
Rati
osfor#4oi
l 85.
75 12.
5 0.
75 1 weight
BasedonnoofCat
oms50 7.
289 0.
437 0.
583 635.57
Fol
l
owi
ngt
heest
abl
i
shmentoft
her
ati
osoft
hecont
entofCar
bonat
omst
oot
her
sand
l
i
nki
ngi
twi
tht
heact
ual
numberofCar
bonat
oms,
thecombust
ionequat
ioncoul
dbewr
it
ten,
keepi
ngi
nmi
ndassumpt
ion#6andt
hef
actt
hatexcessai
ris20% wi
thr
espectt
othe
combust
ionoft
hef
uel
oil
.
( )

Asi
mpl
emol
ebal
anceofOxy
genandNi
tr
ogeny
iel
ds:

and

Fr
om t
abl
e2.
1abov
e,x=50y
=7.
289gi
vesA=10.
364andB=233.
822

28
Requi
redf
uel
flowr
ate:
0.1926MT/
hr

Thus,
nooff
uel
mol
es=192.
6/635.
57=0.
303kmol

Fr
om abov
e,si
nceexcessOxy
genandNi
tr
ogenmol
esar
e10.
364/
moloff
ueland
233.
822mol
off
uel
respect
ivel
y,

I
nthe same manner
,Ni
tr
ogen and Car
bon Di
oxi
de quant
it
ies f
orcombust
ion
r
equi
rement
swer
eobt
ained.Ox
ygenr
equi
rementf
orbur
ningofSul
furcoul
dbe
quant
if
iedbasedont
heoxi
dizat
ionofSul
furwi
tha10% excessal
l
ocat
edanda
si
mpl
emol
ebal
anceofOxy
gent
oobt
ain1.
5409MT/
hr(
i.
e.1.
4009MT/
he*110%-
si
ncemol
ecul
arwei
ghtofSul
furandOxy
genar
esame)
.

3.
2.4 El
ect
rost
ati
cpr
eci
pit
ator
El
ect
rost
ati
cai
rcl
eaneri
sapar
ti
cul
atecol
l
ect
iondev
icet
hatr
emov
espar
ti
clesf
rom
af
lowi
nggas(
suchasai
r)usi
ngt
hef
orceofani
nducedel
ect
rost
ati
cchar
ge.
El
ect
rost
ati
cpr
eci
pit
ator
sar
ehi
ghl
yef
fi
cientf
il
tr
ati
ondev
icest
hatmi
nimal
l
yimpede
t
hef
lowofgasest
hrought
hedev
ice,andcaneasi
l
yremov
efi
nepar
ti
cul
atemat
ter
suchasdustandsmokef
rom t
heai
rSt
ream.I
nthi
spr
ocess,sul
furdi
oxi
degasi
s
l
eav
ingt
hef
urnacewi
thf
luegasandot
herunbur
nedpar
ti
clessuchasunbur
ned
car
bonpar
ti
clesf
rom f
uel
ssomef
lyash,
unbur
nedmi
ner
alset
c.

Assumpt
ions:

Per
cent
ager
emov
alofSul
furdustf
rom mainStr
eam i
ndustcol
l
ect
ori
s99%
l
vii
i
Cl
eangas(
MS-
14)
Fl
uegasf
rom bur
ner(
MS-
12)
 ELECTR:
PRECIPI
TATOR
Dust
col
lected
(MS-13)

28 Ref
ersect
ion3.
2forcal
cul
ati
onoff
uel
quant
it
yneeded

Fi
gur
e3.
4Inl
etandout
letst
reamsf
rom t
heEl
ect
rost
ati
cpr
eci
pit
ator

CLEANSULFURDI
OXI
DEWI
THFLUEGAS(
MS14)
Speci es Fl
owRat
e(MT/
hr) w/
w( %)
Sulf
ur 0.
0001 0.00
Sulf
urDi oxide 2.
8045 23.74
Sulf
urTr ioxide 0.
0000 0.00
Oleum 0.
0000 0.00
Sulf
ur icAcid 0.
0000 0.00
Wat er 0.
0199 0.17
Hydr ogenSul f
ide 0.
0143 0.12
Oxygen 0.
2406 2.04
Nitr
ogen 8.
0657 68.28
Car
bonDi
oxi
de 0.
6670 5.
65
TOTAL 11.
8121 100.
00

DUSTCOLLECTED(
MS13)
Speci
es Fl
owRate(
MT/hr
) w/
w(%)
Sulf
ur 0.
0140 100.
00
Sulf
urDi oxi
de 0.
0000 0.
00
Sulf
urTr i
oxide 0.
0000 0.
00
Oleum 0.
0000 0.
00
Sulf
ur i
cAcid 0.
0000 0.
00
Wat er 0.
0000 0.
00
Hydr ogenSulf
ide 0.
0000 0.
00
Oxygen 0.
0000 0.
00
Nitr
ogen 0.
0000 0.
00
Car
bonDi
oxi
de 0.
0000 0.
00
TOTAL 0.
0140 100.
00

3.
2.5 SO2Dr
yer
Thisi
sasimpl
yabsor
pti
ontowerwhichi
susedtoremovet
hemoist
urecont
aini
ngin
thesulf
urdi
oxi
destr
eam sentfrom ESPl
i
xuni
t.I
fthi
sgasstr
eam enter
edt othe
downst
ream pr
ocesseswi
thoutdr
ying,i
twi
l
lul
ti
mat
elyl
eadt
opr
ocessf
ail
uresdue
t
o cat
aly
stpoi
soni
ng i
nsi
de t
he r
eact
ors bywat
er.So i
tis agai
n pur
if
ied by
cont
act
ingwi
thol
eum,whi
chwaspr
oducedonsi
te.Theol
eum i
sint
roducedf
rom
t
het
opandgasi
ssentf
rom bot
tom.Thel
eav
ingst
ream i
scont
aini
ngonl
ydr
ysul
fur
di
oxi
degas.

Assumpt
ion:
Per
cent
ager
emov
alofmoi
stur
einSO2bydr
yeri
s100%.

10
4

l
x
 Desi
gnofapl
antt
omanuf
act
ureSul
fur
icaci
dfr
om Sul
fur

Dr
iedgas(
MS-
18) Ol
eum i
nfl
ow(
MS-
16)
SO2
DRYER
Wett
edol
eum out
fl
ow(
MS-
17)
So2+f
luegasf
rom ESP(
MS-
14)

Fi
gur
e3.
5Inl
etandout
letst
reamsf
rom t
heSul
furDi
oxi
deDr
yer

MS-
14r
efer
stot
hest
ream whosef
lowt
abl
ewasgi
venundert
hepr
evi
oussect
ion.
Ot
herst
ream masscomposi
ti
oni
sgi
venbel
ow.Thecal
cul
ati
onofpr
eci
seOl
eum
f
lowr
ater
equi
redwi
l
lbeaddr
essedi
nsect
ion2.
11

OLEUM FORSO2DRYER(
MS16)
Speci
es Fl
owRat
e(MT/
hr) w/
w(%)
Sul
fur 0.
0000 0.
00
Sul
furDi
oxi
de 0.
0000 0.
00
Sul
furTr
ioxi
de 0.
0000 0.
00
Ol
eum 0.
1961 3.
14
Sul
fur
icAci
d 6.
0488 96.
86
Wat
er 0.
0000 0.
00
HydrogenSul
fi
de 0.
0000 0.
00
Oxygen 0.
0000 0.
00
Nit
rogen 0.
0000 0.
00
Car
bonDi
oxi
de 0.
0000 0.
00
TOTAL 6.
2449 100.
00
OLEUM RETURNTOHEADER(
MS17)
Speci
es Fl
owRat
e(MT/
hr) w/
w(%)
Sulf
ur 0.
0000 0.
00
Sulf
urDi oxi
de 0.
0000 0.
00
Sulf
urTr i
oxide 0.
0000 0.
00
Oleum 0.
0000 0.
00
Sulf
ur i
cAcid 6.
2648 100.
00
Wat er 0.
0000 0.
00
Hydr ogenSulf
ide 0.
0000 0.
00
Oxygen 0.
0000 0.
00
Nitr
ogen 0.
0000 0.
00
Car
bonDi
oxi
de l
xi 0.
0000 0.
00
TOTAL 6.
2648 100.
00

105
 DRYSULFURDI
OXI
DE(
MS18)
Speci es Fl
owRat
e(MT/
hr) w/
w( %)
Sulf
ur 0.
0001 0.00
Sulf
urDi oxide 2.
8045 23.78
Sulf
urTr ioxide 0.
0000 0.00
Oleum 0.
0000 0.00
Sulf
ur icAcid 0.
0000 0.00
Wat er 0.
0000 0.00
Hydr ogenSul f
ide 0.
0143 0.12
Oxygen 0.
2406 2.04
Nitr
ogen 8.
0657 68.40
Car
bonDi
oxi
de 0.
6670 5.
66
TOTAL 11.
7922 100

3.
2.6 Conv
ert
er
I
nthedesi
gn t
her
ear
efourV2O5 cat
aly
stsf
il
led packed bed t
ypeconv
ert
ers.
Cl
eaned&f
il
ter
edai
rst
oget
herwi
thSO2pr
oduced,
aresuppl
i
edt
otheconv
ert
erst
o
pr
oduceSO3.Fi
rstt
hreeuni
tsar
econnect
edser
iesandt
hef
our
thr
eact
ori
susedt
o

conv
ertSO2r
ecov
eredf
rom I
nter
medi
ateAbsor
pti
onCol
umn(
IAT)mai
nlyandabout
10%off
eedf
rom t
het
opr
eact
ors.Formassbal
ancecal
cul
ati
onsi
ntheconv
ersi
on
uni
t,t
hef
ir
stt
hreer
eact
orbedsoft
heconv
ert
erar
econsi
der
edasasi
ngl
euni
t,
t
houghmat
eri
ali
sdi
rect
edt
hroughHeatexchanger
sateachst
age.Thi
smet
hod
wasused,
ast
her
eisnoanymasschangewhi
l
eheatexchangi
ng.

Howev
er,anexpl
odedv
iew oft
her
eact
orshav
enotbeeni
ndi
cat
edbutt
hemai
n
out
putl
i
neshav
ebeencal
cul
atedconsi
der
ingi
tasaoneuni
t.

Assumpt
ions:

I
tisassumedt
hatonl
ySO2conv
ersi
oni
staki
ngpl
acei
nther
eact
orsasal
l
ot
herav
ail
abl
egasesar
ether
mal
l
yst
abl
eundert
heseoper
ati
ngcondi
ti
ons.
5%ofV2O5Cat
aly
star
etober
egener
atedatt
heendofeachy
earbecauseof
t
heSdustpr
esenti
ntheSO2f
eed.

SO2 f
ed i
ntot
he conv
ert
eri
sreact
ed wi
thi
nthe f
ir
st3 beds wi
th an ov
eral
l
conv
ersi
on ef
fi
ciencyof93.
25%.Thi
sis cal
cul
ated as f
oll
ows consi
der
ing t
he
conv
ersi
onef
fi
ci
encyofeachbed(
from t
opt obot
tom)
.
l
xi
i
st
Conv
ersi
onof1 bed=(
1*40%)

10
 6

l
xi
i
i
 nd
Conv
ersi
onof2 bed=[
1-(
1*40%)
]*55%

Conv
ersi
onof3r
dbed={
1-(
1*40%)-[
1-(
1*40%)
]*55%}
*75%

Ov
eral
lConv
ersi
onEf
fi
ciency=93.
25%

Conv
ersi
onef
fi
ci
encydecr
easeswi
tht
het
emper
atur
eoft
hebed.Asar
esul
t,t
op
bedshowst
hesmal
l
estconv
ersi
onr
ateduet
oaccumul
ati
onofheati
nthegas
st
ream comi
ngf
rom t
hebot
tom beds.

Accor
ding t
othest
oichi
omet
ri
crat
iosO2 r
equi
red t
o conv
ertSO2 i
nto SO3 i
s
cal
cul
ated and ai
ris suppl
i
ed wi
th 10% (
V/V)excess t
o achi
eve an ef
fect
ive
conv
ersi
on.

Ot
hert
racergasesar
enegl
ect
edandonl
yO2,
H2S,
CO2andN2ar
eaccount
edi
nthe
massbal
ance.Nochangeswer
econsi
der
edi
nthesegasesast
hei
rther
malst
abi
l
ity
i
sver
yhi
gh.
t
h
Al
sobyl
i
ter
atur
e,wef
oundt
hatonl
y05-10%oft
hef
eedi
sdi
rect
edt
o4 Cat
aly
st
bedt
oconv
ertt
heunr
eact
edSO2 (
Dav
enpor
t& Ki
ng,Sul
fur
icaci
dmanuf
act
ure
anal
ysi
s,cont
rolandopti
mizat
ion)
.Hence,itwasdecidedt o di
rect90% ofthe
conv
ert
edmat er
ialf
rom t
op3bedst oInt
ermedi
ateAbsorpt
ionTower .Remai
ning
t
h
10%i
sint
roducedt
othe4 bedwhi
chhas94%conv
ersi
onef
fi
ciencyandout
puti
s
t
hendi
rect
edt
omai
nabsor
pti
ont
owerf
orf
urt
herpur
if
icat
ion.

Fi
l
ter
eddr
iedai
r(MS-
09)

So2f
eed(
MS-
18) CONVERTER SO3t
oM.
A.T(
MS-
21)

Unconv
ert
edso2Fr
om I
AT(
MS-
20) Par
ti
all
yconv
ert
edso2t
oI.
A.T(
MS-
19)

Fi
gur
e3.
6 I
nletandout
letst
reamsf
rom conv
ert
er

l
xi
v
 107

l
xv
 DRYSULFURDI
OXI
DE(
MS18)
Speci
es Fl
owRat
e(MT/hr) w/
w(%)
0.000
Sul
fur 1 0.
00
2.804
Sul
furDi
oxi
de 5 23.
78
0.000
Sul
furTr
ioxi
de 0 0.
00
0.000
Ol
eum 0 0.
00
0.000
Sul
fur
icAci
d 0 0.
00
0.000
Wat
er 0 0.
00
0.014
Hy
drogenSul
fi
de 3 0.
12
0.240
Oxy
gen 6 2.
04
8.065
Ni
tr
ogen 7 68.
40
0.667
Car
bonDi
oxi
de 0 5.
66
TOTAL 11.7922 100

FI
LTEREDDRI
EDAI
RTOCONVERTER(MS
09)
Speci es Fl
owRat
e(MT/
hr) w/
w( %)
Sulf
ur 0.
0000 0.
00
Sulf
urDi oxide 0.
0000 0.
00
Sulf
urTr ioxide 0.
0000 0.
00
Oleum 0.
0000 0.
00
Sulf
ur icAcid 0.
0000 0.
00
Wat er 0.
0000 0.
00
Hydr ogenSul fi
de 0.
0000 0.
00
Oxygen 0.
7712 21.
00
Nitr
ogen 2.
9013 79.
00
CarbonDi oxide 0.
0000 0.
00
3.
672
TOTAL 6 100.
00

UNCONVERTEDSULFURDIOXI
DE
RETURN(
MS20)
Species Fl
owRate(MT/
hr) w/
w( %)
Sulf
ur lxv 0.
0001 0.00
Sulf
urDioxide i 0.
1704 1.58
Sulf
urTrioxide 0.
0000 0.00
Oleum 0.
0000 0.00
Sulf
uricAcid 0.
0000 0.00
Wat er 0.
0000 0.00
 HydrogenSul
fide 0.
0129 0.
12
Oxygen 0.
2754 2.
56
Nit
rogen 9.
6940 90.
15
CarbonDioxi
de 0.
6003 5.
58
TOTAL 10.
7531 100.
00

PARTI
ALLYCONVERTEDSULFURDI
OXI
DE(
MS19)
Speci
es Fl
owRat
e(MT/
hr) w/
w(%)
Sulf
ur 0.
0001 0.
00
Sulf
urDi oxi
de 0.
1704 1.
30
Sulf
urTr i
oxide 2.
3537 17.
96
Oleum 0.
0000 0.
00
Sulf
ur i
cAcid 0.
0000 0.
00
Wat er 0.
0000 0.
00
Hydr ogenSulf
ide 0.
0129 0.
10
Oxygen 0.
2754 2.
10
Nitr
ogen 9.
6940 73.
96
Car
bonDi
oxi
de 0.
6003 4.
58
TOTAL 13.
1067 100.
00

SULFURTRI
OXIDE(
MS21)
Speci es Fl
owRate(
MT/hr
) w/
w( %)
Sulf
ur 0.
0001 0.00
Sulf
urDi oxide 0.
0076 0.06
Sulf
urTr ioxide 0.
4887 3.92
Oleum 0.
0000 0.00
Sulf
ur icAcid 0.
0000 0.00
Wat er 0.
0000 0.00
Hydr ogenSul f
ide 0.
0143 0.11
Oxygen 0.
3126 2.51
Nitr
ogen 10.
9670 88.04
Car
bonDi
oxi
de 0.
6670 5.
35
TOTAL 12.
4573 94.
65

I
nter
mediat
eabsor
pti
ontower(
IAT)
I
ATisusedtor
ecovert
heSO3presenti
ntheout
putl
i
neoff
ir
stt
hreer
eact
orbeds.

Al
lSO3pr
esenti
ntheI
ATf
eed,
isconsi
der
edr
emov
edby98.
5%Concent
rat
ed
Sul
fur
icasol
eum. l
xv
i
i
Assumpt
ions:

I
ATi
sconsi
der
edasani
deal
absor
pti
onuni
t.
(100%Ef
fi
ciency
)
NoExcessH2SO4pr
ovi
ded
 Al
lav
ail
abl
eH2Or
eact
swi
thOl
eum andpr
oduceH2SO4

l
xv
i
i
i
 Sul
fur
icf
lowr
ater
equi
redf
ort
hisabsor
pti
onpr
ocessi
scal
cul
atedusi
ngSO3and
Sul
fur
icr
eact
ionr
ati
os.I
tisf
oundt
hat90.
95%concent
rat
edol
eum canbepr
oduced
f
rom t
heI
AT.
t
h
Remai
ningSO2,
O2,
CO2,
H2SN2,
whi
chi
sdi
rect
edt
o4 cat
aly
stbedi
sfur
ther
r
eact
edt
oobt
ainmor
eSO3y
iel
d.

Par
ti
all
yconv
ert
edso2t
oIAT(
MS-
19)

I
ATol
eum out
let(
MS-
23) H2SO4(
98.
5%)i
nfl
ow(
MS-
I
.A.
T 22)

Unconv
ert
edso2f
rom I
AT(
MS-
20)

Fi
gur
e:I
nputandout
putst
reamsf
rom t
hei
nter
medi
ateabsor
pti
ont
ower

MS-
19andMS-
20wasputi
nthepr
evi
oussect
ion.

98%SULFURI
CFORMAI
NABSORPTI
ON
Speci
es Fl
owRat
e(MT/
hr) w/
w(%)
Sul
fur 0.
0000 0.
00
Sul
furDi
oxi
de 0.
0000 0.
00
Sul
furTr
ioxi
de 0.
0000 0.
00
Ol
eum 0.
0000 0.
00
Sul
fur
icAci
d 0.
5922 98.
50
Wat
er 0.
0090 1.
50
Hy
drogenSul
fi
de 0.
0000 0.
00
Oxygen 0.
0000 0.
00
Nit
rogen 0.
0000 0.
00
Car
bonDi
oxi
de 0.
0000 0.
00
TOTAL 0.
6012 100.
00

l
xi
x
 OLEUM FROM I
NT.ABSORBER(
MS23)
Speci
es Fl
owRat
e(MT/
hr) w/
w(%)
Sul
fur 0.
0000 0.
00
Sul
furDi
oxi
de 0.
0000 0.
00
Sulf
urTr
ioxi
de 0.
0000 0.
00
Oleum 4.
8027 90.
95
Sul
fur
icAci
d 0.
4781 9.
05
Water 0.
0000 0.
00
HydrogenSul
fi
de 0.
0000 0.
00
Oxygen 0.
0000 0.
00
Ni
tr
ogen 0.
0000 0.
00
Car
bonDi
oxi
de 0.
0000 0.
00
TOTAL 5.
2808 100.
00

Mai
nabsor
pti
ont
ower-MAT
t
h
Mai
nabsor
pti
ont
oweri
susedt
orecov
ert
heSO2pr
oducedf
rom t
he4 r
eact
orand
t
oemi
ttheunwant
edgaseouscompoundspr
esenti
nthepr
ocessst
ream.99% of
SO3pr
esenti
nthef
eedi
sconsi
der
edr
emov
edby98.
5%concent
rat
edSul
fur
icaci
d
asOl
eum.

Assumpt
ions:

SO2gasabsor pti
oneff
ici
ency99%
Al
lothergassesgetremovedatthemai
nabsor
pti
ont
ower
Noreacti
onbet weenSO3andH20
NoExcessH2SO4pr ov
ided

H2SO4(
98.
5%)l
i
ne(
MS-
24)

M.A.
Tol
eum out
let(
MS-
SO3t
oM.
A.T(
MS-
21) M.
A.T 25)

Tai
lgasf
rom M.
A.T(
MS-
26)
Fi
gur
e3.
8Inputandout
putst
reamsf
rom t
hemai
nabsor
pti
ont
ower

l
xx
 SULFURTRI
OXI
DE(
MS21)
Speci es Fl
owRat e(MT/
hr) w/w(%)
Sulfur 0.0001 0.00
SulfurDioxide 0.0076 0.06
SulfurTrioxi
de 0.4887 3.92
Oleum 0.0000 0.00
Sulfuri
cAci d 0.0000 0.00
Wat er 0.0000 0.00
HydrogenSul fi
de 0.0143 0.11
Oxy gen 0.3126 2.51
Nitr
ogen 10.9670 88.
04
Car
bonDioxi
de 0.6670 5.
35
TOTAL 12.4573 100.00

TAI
LGASFROM MAT(
MS
26)
Speci es Fl
owRat
e(MT/hr) w/
w( %)
Sulf
ur 0.
0000 0.00
Sulf
urDi oxide 0.
0076 0.06
Sulf
urTr ioxide 0.
0049 0.04
Oleum 0.
0000 0.00
Sulf
ur icAcid 0.
0000 0.00
Wat er 0.
0000 0.00
Hydr ogenSul fi
de 0.
0143 0.12
Oxygen 0.
3126 2.61
Nitr
ogen 10.9670 91.60
CarbonDi oxide 0.
6670 5.57
TOTAL 11.
9733 100.
00

OLEUM FROM MAI

NABSORBER(
MS25)
Speci
es Fl
owRat
e(MT/hr) w/
w( %)
0.0
Sul
fur 0.
0000 0
0.0
Sul
furDi
oxi
de 0.
0000 0
0.0
Sulf
urTr
ioxi
de 0.
0000 0
Oleum 0.
9866 90.95
9.0
Sul
fur
icAci
d 0.
0981 5
0.0
Wat
er l
xx 0.
0000 0
i 0.0
Hy
drogenSul
fi
de 0.
0000 0
0.0
Oxygen 0.
0000 0
Nit
rogen 0.
0000 0.0
 0
0.
0
Car
bonDi
oxi
de 0.
0000 0
TOTAL 1.
0847 100.
00

l
xx
i
i
3.
2.9 Scr
ubber
I
nthepr
ocesst
heSOxgasses,speci
all
ySO2andaci
dmi
stcanber
eleasedast
he

r
esi
dueai
rfr
om t
hemai
nabsor
pti
ont
oweri
ncl
udi
ngSO3 (
poorabsor
pti
on)
,SO2
(
poorconv
ersi
on)andaci
dmi
st(
duet
osul
fur
icaci
d).Thesemustpr
eventf
rom
ent
eri
ngt
heenv
ironmentduet
oit
spr
oper
ti
eswhi
chcanaf
fectt
heenv
ironmentand
al
sot
hepubl
i
cheal
th.Ascr
ubberi
susedt
omi
nimi
zet
heef
fectoft
hatbydi
ssol
vi
ng
t
hosegasesi
nwat
er.Scr
ubbi
ngsy
stem canbeOper
ateonl
yatst
art
upandshut
down.

Tr
eat
edgas(
MS-
34) Pr
ocessWat
er(
MS-
33)

Scr
ubber

Tai
lGas(
MS-
26) Wat
er+SO2(
MS-
35)

Fi
gur
e3.
9Scr
ubberi
nlet
sandout
let
s

I
nor
dert
oest
imat
ethedegr
eeofr
ecov
eryofgasesf
rom t
het
ailgast
hesol
ubi
l
ity
pr
oper
ti
eswer
eusedf
rom t
hecur
veshownbel
ow.

l
xx
i
ii 29
Fi
gure3.
10Solubil
it
ydataforSul
furTr
ioxi
deinwat
er Tai
lgasf
lowr
ateswer
e
gi
venint
heprevioussect
ion
 3.
2.10Ol
eum st
oraget
ank
Ol
eum t
anki
susedt
orecei
vet
heol
eum pr
oducedbyI
ATandMAT.

Assumpt
ions:

Nor
eact
ionoccur
sint
heOl
eum Tank

Ol
eum f
rom mai
nabsor
ber(
MS-
25) Ol
eum t
otheol
eum header(
MS-
27)
OLEUM
TANK

Ol
eum f
rom i
nt.Absor
ber(
MS-
23)

Fi
gur
e3.
113.
12I
nlet
sandout
let
sfr
om Ol
eum t
anks

OLEUM FROM MAI

NABSORBER(
MS25)
Speci es Fl
owRat
e(MT/
hr) w/
w( %)
Sulf
ur 0.
0000 0.
00
Sulf
urDi oxide 0.
0000 0.
00
Sulf
urTr ioxide 0.
0000 0.
00
Oleum 0.
9866 90.
95
Sulf
ur icAcid 0.
0981 9.
05
Wat er 0.
0000 0.
00
Hydr ogenSul f
ide 0.
0000 0.
00
Oxygen 0.
0000 0.
00
Nitr
ogen 0.
0000 0.
00
Car
bonDi
oxi
de 0.
0000 0.
00
TOTAL 1.
0847 100.
00

29
Sour
ce:
htt
p:/
/docs.
engi
neer
ingt
ool
box
.com/
document
s/1148/
sol
ubi
l
ity
-so2-
wat
er.
png

114
l
xx
i
v
 Desi
gnofapl
antt
omanuf
act
ureSul
fur
icaci
dfr
om Sul
fur

OLEUM FROM I
NT.ABSORBER(
MS23)
Speci
es Fl
owRat
e(MT/
hr) w/
w(%)
Sul
fur 0.
0000 0.
00
Sul
furDi
oxi
de 0.
0000 0.
00
Sul
furTr
ioxi
de 0.
0000 0.
00
Ol
eum 4.
8027 90.
95
Sul
fur
icAci
d 0.
4781 9.
05
Water 0.
0000 0.
00
Hydrogen
Sul
fi
de 0.
0000 0.
00
Oxy
gen 0.
0000 0.
00
Ni
tr
ogen 0.
0000 0.
00
Car
bonDi
oxi
de 0.
0000 0.
00
TOTAL 5.
2808 100.
00

OLEUM TOTHEOLEUM HEADER(MS

27)
Speci es Fl
owRate(MT/hr
) w/
w( %)
Sulf
ur 0.0000 0.
00
Sulf
urDi oxide 0.0000 0.
00
Sulf
urTr ioxide 0.0000 0.
00
Oleum 5.7893 90.
95
Sulf
ur icAcid 0.5762 9.
05
Wat er 0.0000 0.
00
Hydr ogen
Sulf
ide 0.
0000 0.
00
Oxygen 0.
0000 0.
00
Nitr
ogen 0.
0000 0.
00
Car
bonDi
oxi
de 0.
0000 0.
00
TOTAL 6.
3655 100.
00

Ol
eum di
str
ibut
ionheader
Ol
eum Headeri
susedt
odi
str
ibut
eOl
eum f
ornecessar
ylocat
ionsandt
orecei
vet
he
r
etur
nback.I
tisassumedt
hatnor
eact
ionoccur
sinOl
eum t
anks.

Oleum t
ool
eum Header(
MS- wet
tedol
eum f
rom ai
rdr
ier(
MS-
06)
27)
`
l
xx
dr
ier(
MS-
17) v

tank
Wet
tedoleum f
rom so2
Ol
eum di
str
ibut
ionheader
o
l
e
u
m
t
o
d
i
l
u
t
i
o
n
(
M
S
-
2
8)

O
l
e
u
m
t
o
a
i
r
d
r
i
e
r
(
M
S
-
0
5)
e
f
e
e

lxx
vi
 Ol
eum t
oso2dr
ier(
MS-
16)

Fi
gur
e3.
13Ol
eum headeri
nlet
sandout
let
s

OLEUM TOTHEOLEUM HEADER(

MS27)
Speci es Fl
owRat
e(MT/
hr) w/
w( %)
Sulf
ur 0.
0000 0.
00
Sulf
urDi oxide 0.
0000 0.
00
Sulf
urTr ioxide 0.
0000 0.
00
Oleum 5.
7893 90.
95
Sulf
ur icAcid 0.
5762 9.
05
Wat er 0.
0000 0.
00
Hydr ogenSul f
ide 0.
0000 0.
00
Oxygen 0.
0000 0.
00
Nitr
ogen 0.
0000 0.
00
Car
bonDi
oxi
de 0.
0000 0.
00
TOTAL 6.
3655 100.
00

Cal
cul
ati
on:Ol
eum r
equi
rementf
ordr
yingwascal
cul
atedbasedont
hei
deat
hat
bot
hSul
phur
icandOl
eum hast
heabi
l
ityofabsor
bingmoi
stur
efr
om asy
stem.I
n
or
dert
oest
imat
ethequant
it
yofdr
yingi
twasf
ir
stest
abl
i
shedt
hatatl
eastt
he
st
oichi
omet
ri
camountshoul
dbesuppl
i
ed(
i.
e.anequalmol
arf
low r
ateofwat
er
r
emov
ed)
.Oncet
hiswascal
cul
atedt
heamountofSul
fur
icaci
dgener
atedf
rom t
he
r
eact
ionbet
weenwat
erandOl
eum wasconsi
der
edandt
heamountofSul
fur
icaci
d
wascal
cul
ated based on a si
mil
arst
oichi
omet
ry.I
n or
dert
o ensur
ecompl
ete
absor
pti
onofwat
er(
andt
husr
eact
ion)i
twasassumedt
hatOl
eum needst
obe
addedi
nexcess,andav
ari
abl
eint
hef
orm ofexcessOl
eum wasaddedt
othe
cal
cul
ati
on.Fi
gur
esobt
ainedi
ntheexcel
sheetar
egi
veni
nthet
abl
esbel
ow:

lxx
vii
 WETTEDOLEUM FROM AI
RDRYI
NG(OLEUM RETURN)(
MS06)
Speci es Fl
owRate(MT/hr) w/
w( %)
0.
000
Sulf
ur 0 0.00
0.
000
Sulf
urDi oxide 0 0.00
0.
000
Sulf
urTr ioxide 0 0.00
0.
000
Oleum 0 0.00
Sulf
ur icAcid 65.4591 100.00
0.
000
Wat er 0 0.00
Hydr ogen 0.
000
Sulf
ide 0 0.00
0.
000
Oxygen 0 0.00
0.
000
Nitr
ogen 0 0.00
0.
000
CarbonDi oxide 0 0.00
TOTAL 65.4591 100.00

OLEUM RETURNTOHEADER(
MS
17)
Speci
es Fl
owRat
e(MT/hr) w/
w( %)
Sul
fur 0.
0000 0.00
Sulf
urDi
oxide 0.
0000 0.
00
Sulf
urTr
ioxide 0.
0000 0.
00
Oleum 0.
0000 0.
00
Sul
furi
cAcid 6.
2648 100.
00
Water 0.
0000 0.
00
HydrogenSul
fide 0.
0000 0.
00
Oxygen 0.
0000 0.
00
Nit
rogen 0.
0000 0.
00
CarbonDioxi
de 0.
0000 0.
00
6.
264
TOTAL 8 100.
00

OLEUM TOTHEDI
LUTI
ONTANK(
MS28)
Speci es Fl
owRat
e(MT/
hr) w/
w( %)
Sulf
ur 0.
0000 0.
00
Sulf
urDi oxide 0.
0000 0.
00
Sulf
urTr ioxide 0.
0000 0.
00
lxx
Oleum vii
i 1.
8725 27.
69
Sulf
ur icAcid 4.
8891 72.
31
Wat er 0.
0000 0.
00
Hydr ogenSul f
ide 0.
0000 0.
00
Oxygen 0.
0000 0.
00
Ni
tr
ogen 0.
0000 0.
00
Car
bonDi
oxi
de 0.
0000 0.
00
TOTAL 6.
7616 100.
00

l
xx
i
x
 OLEUM FORAI
RDRYI
NG(
MS05)
Speci
es Fl
owRat
e(MT/
hr) w/
w(%)
Sul
fur 0.
0000 0.
00
Sul
furDi
oxi
de 0.
0000 0.
00
Sulf
urTr
ioxi
de 0.
0000 0.
00
Oleum 3.
7206 5.
72
Sul
furi
cAcid 61.
3623 94.
28
Water 0.
0000 0.
00
HydrogenSul
fi
de 0.
0000 0.
00
Oxygen 0.
0000 0.
00
Nit
rogen 0.
0000 0.
00
Car
bonDi
oxi
de 0.
0000 0.
00
TOTAL 65.
0829 100.
00

OLEUM FORSO2DRYER(MS
16)
Speci
es Fl
owRate(
MT/ hr
) w/
w(%)
Sulf
ur 0.
0000 0.
00
Sulf
urDi oxi
de 0.
0000 0.
00
Sulf
urTr i
oxide 0.
0000 0.
00
Oleum 0.
1961 3.
14
Sulf
ur i
cAcid 6.
0488 96.
86
Wat er 0.
0000 0.
00
Hydr ogenSulf
ide 0.
0000 0.
00
Oxygen 0.
0000 0.
00
Nitr
ogen 0.
0000 0.
00
Car
bonDi
oxi
de 0.
0000 0.
00
TOTAL 6.
2449 100.
00

Theexcessquant
it
yofOl
eum andSul
fur
icst
ream r
efl
ect
sthei
deat
hatt
he
st
eadyst
atequant
it
yofOl
eum/Sul
fur
icaci
dpr
oducedmustbet
oppedupwi
th
pr
epr
oducedquant
it
iesf
rom st
oraget
oful
fi
ll
thi
sdemand.

3.
2.12Di
l
uti
ont
ank
I
ntheDi
l
uti
onTankH2SO4Pr
oduct
ionoccur
susi
ngpr
ocesswat
er

H2S2O7+H2O=2H2SO4
l
xx
Thi
sgi
ves98.
5%pur
eH2SO4 x
 Pr
ocesswat
erf
rom pur
if
icat
ionuni
t(MS-
29)

Oleum t
othedi
l
uti
onTankf
rom header(
MS- Sul
fur
icaci
d(MS-
30)
28) Di
l
uti
ont
ank

Fi
gur
e3.
14Di
l
uti
ont
anki
nlet
sandout
let
s

OLEUM TOTHEDI
LUTI
ONTANK(
MS28)
Speci es Fl
owRat
e(MT/
hr) w/
w( %)
Sulf
ur 0.
0000 0.
00
Sulf
urDi oxide 0.
0000 0.
00
Sulf
urTr ioxide 0.
0000 0.
00
Oleum 1.
8725 27.
69
Sulf
ur icAcid 4.
8891 72.
31
Wat er 0.
0000 0.
00
Hydr ogenSul f
ide 0.
0000 0.
00
Oxygen 0.
0000 0.
00
Nitr
ogen 0.
0000 0.
00
Car
bonDi
oxi
de 0.
0000 0.
00
TOTAL 6.
7616 100.
00

SULFURI
CACID(
MS30)
Speci es Fl
owRat
e(MT/
hr) w/
w( %)
Sulf
ur 0.
0000 0.
00
Sulf
urDi oxide 0.
0000 0.
00
Sulf
urTr ioxide 0.
0000 0.
00
Oleum 0.
0000 0.
00
Sulf
ur icAcid 6.
9509 98.
50
Wat er 0.
1059 1.
50
Hydr ogenSul f
ide 0.
0000 0.
00
Oxygen 0.
0000 0.
00
Nitr
ogen 0.
0000 0.
00
Car
bonDi
oxi
de 0.
0000 0.
00
TOTAL 7.
0568 100.
00

l
xx
H2SO4St
oraget
ank xi
 Sul
fur
icaci
dfi
nal
product(
MS-
31) 119

98%sul
fur
icaci
dfor
H2SO4St
orage mai
nabsor
ber(
MS-
24)
Sul
fur
icaci
d(MS-
30)
Tank
98%sul
fur
icaci
dfori
nt.Absor
ber(
MS-
22)

Ov
eral
lpr
ovi
sionf
orl
ossesaf
terbur
ner(
MS-
32)

Fi
gur
e3.
15Sul
fur
icst
oraget
anki
nletandout
let
s

SULFURI
CACI
D(MS30)
Speci es Fl
owRat
e(MT/
hr) w/
w( %)
Sulf
ur 0.
0000 0.
00
Sulf
urDi oxide 0.
0000 0.
00
Sulf
urTr ioxide 0.
0000 0.
00
Oleum 0.
0000 0.
00
Sulf
ur icAcid 6.
9509 98.
50
Wat er 0.
1059 1.
50
Hydr ogen
Sulf
ide 0.
0000 0.
00
Oxygen 0.
0000 0.
00
Nitr
ogen 0.
0000 0.
00
Car
bonDi
oxi
de 0.
0000 0.
00
TOTAL 7.
0568 100.
00

SULFURI
CACI
DFINALPRODUCT(MS
31)
Speci es Fl
owRate(MT/
hr) w/
w( %)
Sulf
ur 0.
0000 0.
00
Sulf
urDi oxide 0.
0000 0.
00
Sulf
urTr ioxide 0.
0000 0.
00
Oleum 0.
0000 0.
00
Sulf
ur icAcid 3.
4755 98.
50
Wat er 0.
0529 1.
50
Hydr ogen
Sulf
ide 0.
0000 0.
00
Oxygen 0.
0000 0.
00
Nitr
ogen 0.
0000 0.
00
Car
bonDi
oxi
de 0.
0000 0.
00
TOTAL xx 284
l 3.
5 100.
00
xi
i

MS-
22andMS-
24st
reamshav
ebeengi
venundersect
ions2.
7and2.
8
l
xx
xi
i
i
 Desi
gnofapl
antt
omanuf
act
ureSul
fur
icaci
dfr
om Sul
fur

3.
2.14Ov
eral
ll
osspr
ovi
sionaf
terbur
ner
Losseshav
ebeeni
ndi
vi
dual
l
ygi
veni
nthemel
terandf
urnacebutnotaf
ter
war
ds.I
n
or
dert
oaccountf
ort
hisanov
eral
llosspr
ovi
sionwi
l
lbeaddedt
oaccountf
or
l
ossesi
ntheconv
ert
er,
absor
pti
oncol
umnsanddi
l
uti
onandst
oraget
anks.

OVERALLPROVI SI
ONFORLOSSESAFTERBURNERMS-32
Speci es Fl
owRate(MT/hr
) w/w(%)
Sulf
ur 0.
0000 0.
00
Sulf
urDi oxide 0.
0000 0.
00
Sulf
urTr ioxide 0.
0000 0.
00
Oleum 0.
0000 0.
00
Sulf
ur icAcid 0.
0000 0.
00
Wat er 0.
0000 0.
00
Hydr ogenSul fi
de 0.
0000 0.
00
Oxygen 0.
0000 0.
00
Nitr
ogen 0.
0000 0.
00
CarbonDi oxide 0.
0000 0.
00
TOTAL 0.
0000 0.
00

90
 1
2
1

91