Sulphuric Acid plant presentation which help to learn something new

this contain comprehensive information to learn process of sulphuric acid

1. Sulphuric Acid Process and Market details

2. Introduction sulphuric acid is a colour less dense oily corrosive liquid produced by the reaction of sulphur trioxide with water and used in accumulators and in the manufacture of fertilizers, dyes, and explosives. Formula: H2SO4

3. Other Names of Sulphuric Acid King of compounds Oil of vitriol Dipping acid Battery acid Electrolyte acid Mattling acid Dihydrogen sulphate

4. World Production of Sulphuric Acid

5. World demand/Supply for Sulphuric Acid (Thousands of Metric Tons- 100% H2SO 4 )

6. Properties of Sulphuric Acid Highly Corrosive Non Volatile liquid Soluble in water Diprotic Acid Viscous colorless liquid Only Liquid Dense As a dehydrating Agent

7. USES

8. Fertilizers 75% of the Sulfuric Acid that is produced is used to make fertilizers such as Super phosphate Ammonium sulphate Ammonium phosphate. Rock phosphate contains insoluble Calcium Phosphate . To be made available to plants it needs to be converted to a soluble form: Ca3(PO4)2, (s) + 2H2SO4 (l) + 4H2O Ca(H2PO4)2 (s) + 2CaSO4 • 2H2O (s)

9. Top 25 Industries of Sulphuric Acid Agricultural Chemicals Aluminium Sulphate Batteries Cellophane Detergents Explosives Fertiizers Gasoline Herbicides Leather Lubricating oils Medical processes Oil additives Paper Rayon and Rubber Sugar Synthetic fibers Veternary drygs

10. Top 25 Industries of Sulphuric Acid ( Contd …) Iron and Steel Pickling Jet Fuel Kerosine Oil Water softner regeneration Water treatment Yellow pigments

11. Major Industries using Sulphuric Acid in daily routine Chemical Manufacturing Oil refinery Metal Processing The Manufacturing of Rayon The Manufacture of Lead-Acid batteries Potato Harvesting The Manufacture of medicines

12. H 2 SO 4 Manufacturing Process

13. Processes for Manufacturing of Sulphuric Acid There are three industrial processes for manufacturing of Sulphuric acid. Contact process Lead chamber process Wet Sulfuric Acid Process (WSA)

14. The Contact Process- Raw Material Sulphur (source sulphide ore etc. ) Water Air

15. Sources of SO 2 Sulphur burning Pyrites roasting Metal sulfide roasting and smelting Metal sulfate roasting Combustion of H2S or other sulfur-containing gases

16. Step-1: Burning Sulphur

17. Treatment of Burner Gas

18. Step 2: Catalytic Oxidation of Sulphur dioxide SO2 is converted to SO3 with the use of V2O5 catalyst in converter or contact chamber Sulphur dioxide is mixed with Air and passed through trays containing loosely packed porous pallets of catalysts

19. Contact Chamber

20. Purpose of Heat Exchanger The conversion of SO2 into SO3 is and exothermic reaction . It releases -197 kj per mole energy To remove this extra heat coolers or heat exchangers are adjusted on the outlets of reaction bed The temperature in the converter is maintained between 400°C and 500°C and the pressure is close to 1 atm.

21. Stage 2: Equilibrium Yield Using Le Chatelier’s principal, the equilibrium yield of sulfur trioxide will increase:  As temperature decrease. Since the reaction is exothermic a decrease in temperature will favour the forward reaction.  As pressure increases. Since there are more gas particles on the reactants the forward reaction will result in a decreased pressure.  If excess reactants are added.

22. Step 3: Abserption of Sulphur trioxide Direct reaction of SO3 with water is very exothermic which results in the formation of steam . sulphuric acid as gas is very difficult to collect .  SO3(g) + H2O(l) H2SO4(l) H= -103kjper mole  Due to this SO3 is absorbed in H2SO4 to produce oleum  SO3 (g)+ H2O (l ) H2S2O7(l)

23. Step 4: Dilution Tower Oleum is mixed with water to form Sulphuric acid H2S2O7 + H2O 2H2SO4

24. Block Diagram

25. Process Diagram- H 2 SO 4

26. Advantages/ Disadvantages of Contact Process ADVANTAGES Larger amount of sulphuric acid is manufactured High concentration of sulphuric acid is obtained as compared to all other processes Widely used DISADVANTAGES The biggest problem is that the catalyst can be poisoned if the sulfur dioxide is not fairly pure.

27. Wet Sulphuric Acid (WSA) Advantages There are little or no waste by-products produced by this process. It is also the most economic way to get rid of sulfurous waste gases. Disadvantages This process produces an acid with low concentration instead of the high concentrations that the Contact Process yields.

28. Advantages/ Disadvantages of Lead Chamber Process Advantages The original acid to be used can be obtained at any concentration. Disadvantages The acid in the chamber is between 62% and 68% sulfuric acid. This process is not used as widely as the Contact Process is today mainly because this process produces a more dilute acid than the Contact Process which yields pure sulfuric acid. The Contact Process also produces a much larger amount of sulfuric acid than the Lead Chamber Process.

29. Annual Production of Sulphuric Acid (World Wide) World: 231 million tones China: 74 million tones U.S.: 37 million tones India: 16 million tones Russia: 14 million tones Morocco: 7 million tones

30. Pakistan Industries producing Sulphuric Acid Exide Pakistan 16,500 MTPA Tufail Chemicals 20,000 TPA Siraj chemicals 75,000 TPA Ittehad Chemicals 33,000 TPA Internation Chemicals 300 MTPD Hazara fertilizers 110 MTPD Amber Chemicals 50 MTPD Akbari Chemicals 25 MTPD

31. Thanks