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Manufacture of sulphuric acid 2017
1. INTRODUCTION
1.1 PLANT HISTORY

FACT, India‟s first large scale fertilizer unit setup in 1943. In 1947, FACT
Udyogomandal started production of Ammonium Sulphate with an installed capacity of 10,000
MT Nitrogen. FACT became a Kerala state public sector enterprise on 15th August 1960 and 21st
November 1962, the government of India became the major shareholder.
FACT Engineering and Design Organisation was set up on 24th July 1965 to meet the emerging
need for indigenous capability in vital areas of engineering, Design and consultancy for
establishing large and modern fertilizer plants.
The cochin division of FACT, the 2nd production unit was set up at Ambalamedu and the 1st
phase was commissioned in 1973. As a diversification plans from the traditional field of
fertilizers and chemicals, 50000 TPD caprolactam plant at Udyogomandal was commissioned in
1990.
1.2 COMPANY PROFILE

Fertiliser and Chemicals Travancore(FACT), is a fertilizer and chemical manufacturing
company in Kochi, Kerala, India was incorporated in 1943. The company has 2 production units
– Udyogomandal Division (UD) and Cochi Division (CD). The main products of the company
are factomfos, ammonium sulphate, ammonium phosphate, caprolactam, Sulphuric acid and
other complex fertilizers. Gypsum, Nitric acid and soda ash are major by products.
In 1996, a 900 TPD Sulphric Acid plant is proposed to be set up at Ambalamedu to utilize the
under capacity of the phosphoric acid plant.
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1.3 ABOUT SULPHURIC ACID

The production of sulphuric acid has come to be accepted throughout the world as a reliable
barometer of industrial activity. Its universal use has made it indispensable, in the widest sense
of the world, in chemical and process industries.
Sulphuric acid is a strong acid i.e. aqueous solution its largely changed to hydrogen ions and
sulfate ions. Each molecules gives 2 hydrogen ions and thus sulphuric acid is dibasic acid.
Sulphuric acid is a multipurpose product and finds its application as a dehydrating agent,
catalyst, active reagent in chemical processes, solvent and absorbent etc. It is used in process
industries from very dilute concentrations, for PH control of saline solution to strong fuming
acids used in the dye, explosives and pharmaceutical industries, in grades of less exacting
specifications for use in steel, heavy chemical and super phosphate industries.
1.4 HISTORICAL DEVELOPMENTS:

The origin of the first suphric acid is unkown but it was mentioned as far back as the tenth
century. The preparation by burning sulfur with saltpeter was first described by valentinus in the
fifteenth century. In the eighteenth and nineteenth centuries, it was essantiaally and entirely
produced by chamber process, in which oxides of nitrogen were used as homogeneous catalysts
for the oxidation of sulfur dioxide. The product made by this process were of rather low
concentration ( typically 60 baume or 77 to 78% H2SO4) not high enough for many commercial
uses.
The contact process was first discovered in 1831 by Phillips, as Englishman whose patent
included the essential features of the modern contact process namely the passing of the mixture
SO2 over a catalyst followed by absorption of SO3 in 98-99% H2SO4. Later it was demonstrated
that excess of oxygen in the gaseous mixture for conact process was advantageous. The contact
process has been improved in all details and at the current scenario is one of the low cost
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industries and is almost wholly automatic continuous process for the manufacture of sulphuric
acid.
In 1915, an effective vanadium catalyst for the contact process was developed and used by
Badische in Germany. This type of catalyst was employed in the United states starting in 1926
and gradually replaced the platinum catalyst over the next few decades. Vanadium catalyst have
the advantages of superior resistance to poisoning and of being relatively abundant and
inexpensives compared to platinum.
Another significantct change in the contact process occurred in1963, when Bayer AG announced
the first large scale use of Double Contact Double Absorption process and granted several
patents. In this process the SO2 gas that has been partially converted to SO3 by catalyst cooled,
passed through suphuric acid to remove SO3, reheated and then passed through another one or
two catalysts bed. By this means the overall coversions can be increased from 98 up to 99.5-
99.8% thereby reduced emissions of uncoverted SO2 to the atmosphere.
1.5 Uses of sulphric acid

The large amount of sulfuric acid is used to make posphoric acid, used in turn To make the
phosphate fertilizers, calcium dihydrogenphosphate and amonium phosphates. It is also used to
make ammonium sulfate.
1 st qtr 52% : phosphate fertilizers
2nd qtr 16% : metal processing
3rd qtr 12% : fibres
4th qtr 8% : hydrochloric acid
5th qtr 6% : paints and pigments
6th qtr 4% : pulp and paper
7th qtr 2% : others
3
2%
4%
6%
1st Qtr
8% 2nd Qtr
3rd Qtr
52% 4th Qtr
12% 5th qtr
6th Qtr
7th Qtr
16%
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1.6 PRODUCTION OF SULPHURIC ACID:
1.7 PHYSICAL AND CHEMICAL PROPERTIES:
Appearance : clear oily liquid
Odor : odorlees
Solubility : miscible with water, liberates much heat
Specific gravitiy : 1.84((98%), 1.40(50%), 1.07(40%)
Ph : 0.1 N solution = 0.3;
0.1N solution= 1.2;
0.01N solution=2.1.
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Boiling point of H2SO4 : 280 0 C
Boiling point of sulfur : 444 0 C
Melting point of H2S04 : 3 0C
Melting point of SULFUR : 112 0 C
Flash point of sulfur : 2050 C
Molecular weight of sulfur : 32
Molecular weight of H2SO4 : 98
2. METHODES OF PRODUCTION:
1. LEAD CHAMBER PROCESS
2. CONTACT PROCESS
2.1 LEAD CHAMBER PROCESS:
This is an old process and was intoduced in europe in the near the middle of 18th century. This
method uses the nitrogen oxides as oxygen carrying catalysts for the conversion of sulfur
dioxide to sulfur trioxide. The reactions which produce the sulfur trioxide and sulfuric acid take
place within the huge lead chambers. Chamber process produced acid of concentration less than
80%. The major disadvantages includes the limitation in quality and cancentration of the acid
produced. All known new plants uses the contact process although some older chamber process
plants may still in use.
2.2 CONTACT PROCESS:

In the contact process, the sulfur dioxide is converted to sulfur trioxide by the use of metal oxide
catalyst. Platinum was once widely used as catalyst but because of its excessive first cost and
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susceptibility to poisoning, it has been largely replaced by vanadiumpentaoxide. The vannadium

pentaoxide is dispersed on a porous carrier in a pellet form.
2.3 ADVANTAGES OF THE V2O5 CATALYST

1. Relatively immune to poisons
2. Low initial investment
3. Replacement of catalyst is easy
4. It has large surface area
2.4 DISADVANTAGES OF V2O5 CATALYST:

1. As a catalyst it is less active and requries high oxygen or so2 to give economic
conversion
2. Requries larger converters and thus higher initial investment
In contact process the overall coversion is 98.5% thereby reduced emissions of

uncoverted SO2 to the atmosphere. Because of less emission of SO2, most new plants are
now utilize contact process.
2.5 SELECTION OF METHODS :
2.6 CONTACT PROCESS
In the contact process the sulfur dioxide is converted to sulfur trioxide by the use of
vannadium pentaoxide catalyst. And then sulfur trioxide is react with water to form
sufuric acid and the concentration of the sulfuracid is 98.5%.
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3. PROCESS DESCRIPTION :
The basic features involved in the manufacture of sulphuric acid by the contact process be
summarized as
a. The combustion of sulphur with air to produce a gas mixture of sulphur dioxide and
oxygen in the desired as
S + O2 SO2
b. Catalytic oxidation of sulphur dioxide to sulphur trioxide
SO2 + 1/2O2 SO3
c. The absorption of sulphur trioxide with water 98.5% sulphuric acid to produce sulphuric
acid
H2O + SO3 H2SO4
Plant description
3.1 Sulphur handling
Sulphur from sulphur godown is feed to either of the two sulphur feed hoppers by means
of pay loader. Sulphur from both the bins is taken to the sulphur charging bin by
conveyors. Sulphur from the bin is taken to melting pit by conveyor.
3.2 Sulphur melting
The raw materials sulphur used in the process may contain moisture and impurities such
as ash and bitumen. But it should be free from arsenic, selenium and tellurium. The
moisture may lead to corrosion in the process and also loss of sulphuric acid as mist
through the exit stack of the plant. The solid impurities if not removed, would be caught
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in the catalyst layers and gradually increase the pressure drop. The solid sulphur is fed
into the melting pit. Where it is melted by heat given by the steam coils. The steam coils
are fed with saturated steam at 6.0 kg/cm2g. The molten sulphur is kept in agitation with
the help of an agitator. From the melting pit the molten sulphur overflows into the
mixing pit. Which is also provided with steam coils and an agitator. The steam coils in
the mixing pit, precoat pit, and clean sulphur pit are fed with saturated steam at 3.5
kg/cm2g to maintain sulphur at its optimum temperature. The remaining moisture in the
sulphur if any is evaporated in the pit. Sulphur from the mixing pit flows into the precoat
pit through an opening at the bottom between the mixing and precoat pits. Sulphur from
the precoat pit is pumped to a sulphur filtter by pump. The sulphur filtter is a precoating
type pressure leaf filtter. The precoat pit is provided for the purpose of mixing precoat
material with molten sulphur. Precoat pit is also provided with steam coils and agitator
for keeping precoat material in good suspension. The filtered sulphur goes to clean
sulphur pit . sulphur in the clean sulphur pit is pumped to the luro burner mounted on the
sulphur combustion furnace through in-line filter. In-line filter serves as a precaution to
remove last traces of impurities that might have escaped the main sulphur filter.
3.3 Sulphur combustion
The sulphur combustion furnace consist of horizontal steel cylindrical shell linedinside
the bricks. Sulphur from the clean pit is sprayed by luro burner into the furnace where it
is burnt in the presence of dry air to form gas containing 12.0% sulphur dioxide by
volume. A major quantity of heat evolved due to exothermic reaction is used for steam
production in the heat exchanger 1. Gas enters the super heater for cooling .
3.4 Conversion
3.5 First stage
. This part is diluted with dry air to bring down the SO2 concentration to about 10% and
the temperature to about 430 deg C. conversion of sulphuric dioxide to sulphur trioxide is
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accomplished in the converter with the aid of vanadium pentoxide catalyst loaded in 4
layers. The conversion of sulphur dioxide to sulphur trioxide is an exothermic reaction in
order to obtain maximum conversion certain temperatures Gas leaving super heater is
taken for coversion for acid production. This gas contains 12% SO2 by volume and is
about 500deg c at the inlet of each catalyst bed must be maintained. These temperatures
are maintained by cooling the gas between the beds. The gas exit first layer having the
temperature about 600 deg C is cooled in the economizer 3 to about 430 deg C. The
reation heat after the second and third layers is removed by heating the gas going to the
fourth layer in the intermediate heat exchanger and final heat exchanger respectively.
3.6 Second stage
To obtain a coversion efficiency of over 99.5% the sulphur trioxide content of the gas
after the third pass is removed in the intermediate absorption tower. The sulphur trioxide
free gas from the intermediate absorption tower enters the fourth bed catalyst after
picking up the required heat from final heat exchanger and intermediate heat exchanger .
The final coversion takes place in the fourth bed of catalyst raising the total percentage of
conversion to 99.5% the gas exit fourth layer catalyst is cooled in the economizer 2 and
led to the final absorption tower.
3.7 Acid system
The turbine driven main air blower draws atmosphere air through an air filter and pushes
the air required for the plant through the Air Drying Tower. Where it is dried by means of
98.5% suphuric acid. The air flows from the bottom to the top while acid is uniformly
distributed from top. The sulphuric acid absorbs the moisture in air, gets diluted. Mist
eleminators are provided at top of Air drying tower, intermediate and final absorption
tower, gas scrubbing tower of so2 plant. While IAT and GST have candle type mist
eleminator ADT has polygon type and FAT has wire mesh pad type mist eleminator.
Circulation of acid to the ADT, IAT, FAT is done by circulation pumps. Temperature of
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acid inlet to the same towers is controlled by coolers. The coolers are of trombone type
and cooling water is sprayed on the coolers using water chests to cool the acid. The acid
from the towers flows to the respective acid pump tanks from where it is pumped by
circulation pumps back to the towers through the coolers. Concentration of the drying and
absorbing acid is maintained by inlet transfer of acid and by addition of dilution water to
the IAT and FAT acid pump tanks.
3.8 Waste heat recovery
Demineralaised water from the D.M storage tank is pumped by D.M water
pump to the deaerator. Demineralaised water is deaerator by using low pressure steam.
This deaerated water is pumped by the boiler feed water pumps to the steam drum
through economizer 1, 2& 3 to maintain water level in the steam drum. Steam is
generated by the natural circulation of water between the steam drum and heat exchanger.
Saturated steam from the steam drum passes through the super heater where its
temperature is raises to 400 deg C. The exhaust steam from the super heater is used for
melting, jacketing of sulphur lines. Balance exhaust steam is exported.
3.9 Acid production
The product (98.5% sulphuric acid) is bled off IAT circulation system from the discharge
of the acid circulation pump. It is cooled in the product acid cooler and taken to the
storage tank
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4 MATERIAL BALANCE:
4.1 REACTION INVOLVED
S + O2 SO2
SO2 + ½ O2 SO3
SO3 + H2O H2SO4
BASIS: 175 TPD of 98.5% sulfuric acid.
No of moles of H2SO4 in 175 T = 175 × 1000/24
=1758.928 Kg/hr
=1758.928/98
= 74. 404kmol/hr
Theoretical sulphur required:
One mole sulphur produces one mole H2SO4
No of moles of sulphur required for 175 TPD of 98.5% H2SO4 = 74.404 kmol/hr
Molar flow rate of air to the air drying tower= 718.610 kmol/hr
Theoretical O2 = 74.404 kmol/hr
% excess air = 95%
O2 supplied by air = theoretical O2 ( 1 + % excess/100)
= 74.404 ( 1 + 95/100 )
= 145.088 kmol/h
N2 in supplied by air = 545.806 kmol/h
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4.2 EQUIPMENT : AIR BLOWER
FIGURE 1:
H2O=27.88 kmol/hr
N2= 545.806kmol/hr
O2= 145.088kmol/hr
H2O=27.88 kmol/hr
N2= 545.806kmol/hr
O2= 145.088kmol/hr
Inlet to air blower
Mass flow rate of air from blower = 20839.7 kg/hr
Molar flow rate of air from blower = 718.610 kg/hr
Molar flow rate of water in inlet air =27.88 kmol/hr
Molar flow rate of N2 in inlet air = 545.806 kmol/hr
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Molar flow rate of O2 in inlet air = 145 .088 kmol/hr
Volumetric flow rate of N2 in inlet air = 545.806 × 22.44
= 12247.88 m3/hr
Volumetric flow rate of O2 in inlet air = 145.088 × 22.44
= 3255.77 m3/hr
Table 1:
Outlet from the blower:
component Molar flow rate Mass flow rate kg/hr Volumetric flow rate
kmol/hr m3/hr
moisture 27.88 501.84
Nitrogen 545.806 15282.568 12247.88
Oxygen 145.088 4642.816 3255.77
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4.3 EQUIPMENT : AIR DRYING TOWER
FIGURE 2:
N2= 545.806kmol/hr
O2= 145.088kmol/hr
H2SO4=5175.57 kmol/hr
H2O= 429.10kmol/hr
H2SO4=5254.39kmol/hr
H2O= 456.98 kmol/hr
H2O=27.88 kmol/hr
N2= 545.806kmol/hr
O2= 145.088kmol/hr
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Inlet to air drying tower
Moisture(H2O) in air = 27.88 kmol/hr
Nitrogen (N2) = 545.806 kmol/hr
Oxygen (O2) = 145.088 kmol/hr
H2SO4 mass flow rate = 514930.22kg/hr
Mass flow rate of 98.5% H2SO4 = 514930.22 × 0.985
= 507206.266 kg/hr
Molar flow rate of H2SO4 = 507206.266 ÷ 98
= 5175.57 kmol/hr
Mass flow rate of H2SO4 = 507206.266 kg/hr
Molar flow rate of H2O in acid = 429.10 kmol/hr
Mass flow rate of H2O = 7723.8 kg/hr
Outlet from air drying tower
Molar flow rate of H2SO4 = 5175.57 kmol/hr
Molar flow rate of H2O in acid = 429.10+ 27.88
= 456.98 kmol/hr
Molar flow rate of N2 = 545.806 kmol/hr
Molar flow rate of O2 = 145.088 kmol/hr
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Table 2 : outlet from the air drying tower
component Mass flow rate kg/hr Molar flow rate Volumetric flow rate
kmol/hr m3/hr
H2SO4 507206.266 5175.57
H2O IN ACID 7723.8 429.10
Nitrogen 15282.568 545.806 12247.88
Oxygen 4642.816 145.088 3255.77
4.4 EQUIPMENT: FURNACE

FIGURE :3
N2= 545.806kmol/hr
O2= 70.684kmol/hr
SO2=74.404kmol/hr
S=74.404 kmol/hr
ffuFURNACE
N2= 545.806kmol/hr
O2= 145.088kmol/hr
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Reaction : S + O2 SO2
Inlet to sulphur combustion furnace:
Molar flow rate of O2 in = 145.088 kmol/hr
Mass flow rate of sulfur = 2380.928 kg/hr
Molar fliow rate of sulfur = 74.404 kmol/hr
Molar fliow rate of N2 = 545.806kmol/hr
Inside the sulfur combustion furnace:
74.404 kmol/h of sulfur combine with 74.404 kmol/h of O2 to give 74.404 kmol/h of SO2
Molar flow rate of O2 remaining = 70.684 kmol/h
Outlet from sulphur combustion furnace:
Molar flow rate of SO2= 74.404 kmol/hr
Molar flow rate of N2= 545.806 kmol/hr
TABLE 3: outlet from the furnace
component Mass flow rate Molar flow rate Volumetric flow rate
kg/hr kmol/hr m3/hr
SO2 7291.59 74.404 1669.62
O2 2261.88 70.684 1586.14
N2 15282.568 545.806 12233.69
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4.5 EQUIPMENT: FIRE TUBE BOILER
FIGURE : 4
N2= 545.806kmol/hr
H2O= 362.5kmol/hr O2= 70.684kmol/hr
SO2=74.404kmol/hr
STEAM
N2= 545.806kmol/hr
O2= 70.684kmol/hr
SO2=74.404kmol/hr
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In fire tube boiler hot gas out from the furnace is cooled to desired temperature.
TABLE 4: Outlet from the fire tube boiler
component Mass flow rate kg/hr Molar flow rate kmol/hr
SO2 7291.59 74.404

O2 2261.88 70.684
N2 15282.568 545.806
4.6 EQUIPMENT : SUPER HEATER
FIGURE 5 :
CONVERTER
N2= 545.806kmol/hr
O2= 70.684kmol/hr
STEAM FROM STEAM DRUM
SO2=74.404kmol/hr
N2= 545.806kmol/hr
O2= 70.684kmol/hr
SUPER HEATED STEAM
SO2=74.404kmol/hr
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TABLE 5:
Outlet from the super heater
component Mass flow rate kg/hr Molar flow rate kmol/hr
SO2 7291.59 74.404
O2 2261.88 70.684
N2 15282.568 545.806
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4.7 EQUIPMENT : converter
FIGURE 6 :
N2= 545.806kmol/hr
O2= 35.268kmolhr
SO2=3.571kmol/hr
N2= 545.806kmol/hr
O2= 70.684kmolhr SO3=70.833kmol/hr
SO2=74.404kmol/hr
N2= 545.806kmol/hr
O2= 33.554kmolhr
SO2=0.143kmol/hr
SO3=74.361kmol/hr
N2= 545.806kmol/hr
O2= 48.363kmolhr
SO2=29.762kmol/hr
SO3=44.642kmol/hr
N2= 545.806kmol/hr N2= 545.806kmol/hr

O2= 48.363kmolhr O2= 35.268kmolhr
SO2=29.762kmol/hr SO2=3.571kmol/hr
N2= 545.806kmol/hr
O2= 33.485kmolhr N2= 545.806kmol/hr
SO2=0.005kmol/hr O2= 33.554kmolhr
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4.7 Equipment :Converter 1st stage:
Reaction: SO2 + ½ O2 SO3
Molar flow rate of O2 in = 70.685kmol/hr
Molar flow rate of SO2in = 74.404kmol/hr
Molar flow rate of N2 in = 545.806kmol/hr
Inside the reactor :
1 mole of SO3 require 1 mole of SO2 and 0.5 mole of O2
CONVERSION IN 1ST STAGE IS 60%
SO2 reacted = 74.404×0.60 = 44.642kmol/hr
O2 required = 44.642 × 0.5 = 22.321kmol/hr
O2 remaining = 70.685 – 22.32
O2 remaining = 48.363kmol/hr
SO2 remaining =29.762kmol/hr
Outlet from coverter 1st stage
Molar flow rate of SO3 = molar flow rate of SO2 reacted
= 44.642 kmol/hr
Molar flow rate of SO2 = 29.762 kmol/hr
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TABLE 6:
OUTLET COMPOSITION OF 1ST STAGE :
Component Mass flow rate kg/hr Molar flow rate Mol %

kmol/hr
SO3 3571.36 44.642 6.7
SO2 1904.762 29.762 4.5

O2 1547.616 48.363 7.2
N2 15282.568 545.806 81.6
4.8 EQUIPMENT: ECONOMISER 3
FIGURE 7 :
ECONOMISER 3
N2= 545.806kmol/hr
N2= 545.806kmol/hr O2= 48.363kmol/hr
O2= 48.363kmol/hr SO2=29.762kmol/hr
SO2=29.762kmol/hr SO3=44.642 k mol/hr
SO3=44.642kmol/hr
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In the economizer 3 hot gas temperature is reduced to a desired temperature .
Table 7 :
Outlet from economizer 3
Component Mass flow rate kg/hr Molar flow rate Mol %

kmol/hr
SO3 3571.36 44.642 6.7
SO2 1904.762 29.762 4.5

O2 1547.616 48.363 7.2
N2 15282.568 545.806 81.6
nd
4.9 EQUIPMENT :Coverter 2 stage
Reaction: : SO2 + ½ O2 SO3
Molar flow rate of SO3 in = 44.642kmol/hr
CONVERSION IN 2nd STAGE IS 88%
1 mole of SO3 require I mole of SO2 and 0.5 mole of O2
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Outlet from the converter 2nd stage
Molar flow rate of SO3 = Molar flow rate of SO2 reacted
= 26.191 kmol/hr
Molar flow rate of SO2 = 29.762- 26.191
= 3.571 kmol/hr
Molar flow rate of O2 = 48.363- 13.095
= 35.262 kmol/hr
Total molar flow rate of SO3 = 26.191+ 44.642
= 70.833 kmol/hr
TABLE 8 :
outlet from converter 2nd stage
component Mass flow rate Molar flow rate Mol%

kg/hr kmol/hr
SO3 5666.64 70.833 10.81
SO2 228.544 3.571 0.54
O2 1128.384 35.262 5.38
N2 15282.568 545.806 83.27
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4.10 EQUIPMENT : INTERMEDIATE HEAT EXCHANGER
FIGURE 8 :
N2= 545.806kmol/hr
O2= 35.268kmol/hr
SO2=3.571kmol/hr
SO3=70.833kmol/hr
N2= 545.806kmol/hr
O2= 33.554kmol/hr
SO2=0.143kmol/hr
N2= 545.806kmol/hr
O2= 33.554kmol/hr
SO2=0.143kmol/hr
N2= 545.806kmol/hr
O2= 35.268kmol/hr
SO2=3.571kmol/hr
SO3=70.833kmol/hr
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The intermediate heat exchanger functions to cool the outlet from the 2nd stage of
For the effective temperature control and achieving higher conversion in 3rd stage of the
Coverter.
Table 9 :
Outlet from the intermediate heat exchanger

kg/hr kmol/hr
SO3 5666.64 70.833 10.81
SO2 228.544 3.571 0.54
O2 1128.384 35.262 5.38
N2 15282.568 545.806 83.27
4.11 EQUIPMENT : coverter 3RD stage
Molar flow rate of N2 in = 545.806 kmol/hr
Molar fow rate of SO3 IN = 70.833 kmol/hr
Inside the reactor :
1 mole of SO3 require I mole of SO2 and 0.5 mole of O2
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CONVERSION IN 3rd STAGE IS 96%
SO2 reacted = 3.571×0.96 = 3.428 kmol/hr
SO3 produced = 3.428 kmol/hr
Outlet from the converter 3rd stage
Molar fow rate of SO3 = Molar flow rate of SO2 reacted
= 3.428 kmol/hr
Total molar flow rate of SO3 = 70.833 + 3.428
= 74.361 kmol/hr
TABLE 10: outlet of the 3rd stage

kg/hr kmol/hr
SO3 5948.88 74.361 11.34
SO2 9.152 0.143 0.02
O2 1073.728 33.554 5.13
N2 15282.698 545.806 83.47
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4.12 EQUIPMENT : FINAL HEAT EXCHANGER
FIGURE 9 :
SO3=74.361kmol/hr
SO2=3.428kmol/hr
O2=33.554kmol/hr
N2=545.806kmol/hr
N2= 545.806kmol/hr
O2= 33.554kmol/hr
SO2=0.143kmol/hr
N2= 545.806kmol/hr
O2= 33.554kmol/hr
SO2=0.143kmol/hr
SO3=74.361kmol/hr
SO2=3.428kmol/hr
O2=33.554kmol/hr
N2=545.806kmol/hr
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The final heat exchanger functions to cool the outlet from the 3rd stage of converter for
effective temperature control and achieving higher coversion in 4th stage of the converter.
Table 11 :
Outlet from final heat exchanger
component Mass flow rate kg/hr Molar flow rate Mol%

kmol/hr
SO3 5948.88 74.361 11.34
SO2 9.152 0.143 0.02
O2 1073.728 33.554 5.13
N2 15282.698 545.806 83.47
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4.13 EQUIPMENT : Intermediate absorption tower
FIGURE 10 :
SO3=74.361kmol/hr
O2=33.554kmol/hr O2=33.554kmol/hr
N2=545.806kmol/hr N2=545.806kmol/hr
H2O=74.361kmol/hr
H2SO4=5175.5kmol/hr
H2O=429.10kmol/hr
H2SO4=0.138 kmol/hr H2SO4== 5250.069kmol/hr

H2SO4= 0.002 kmol/hr H2O= 429.10kmol/hr
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Reaction: SO3 + H20 H2SO4
Molar fow rate of SO3 IN = 74.361kmol/hr
Molar fow rate of H2SO3 IN from FAT = 0.138kmol/hr
Molar flow rate of dilusion H2O IN = 74.361kmol/hr
Molar flow rate of H2SO4 in from IAT acid cooler = 5175.57kmol/hr
Molar flow rate of H2O in from IAT acid cooler = 429.10kmol/hr
OUTPUT:
Molar flow rate of H2SO4 out = 5250.069kmol/hr
Molar flow rate of H2O out = 429.10 kmol/hr
Molar flow rate of O2 out = 33.554 kmol/hr
Molar flow rate of SO2 out = 3.428 kmol/hr
Molar flow rate of N2 out = 545.806 kmol/hr
Molar flow rate of H2SO4 recycle to tower = 5249.93 – 74.449
= 5175.57 kmol/hr
Molar flow rate of produced H2SO4 to storage :
= molar flow rate of H2SO4 out – molar flow rate of H2SO4 in
= 5250.069 – 5175.57 = 74.499 kmol/hr
33
TABLE 12: COMPOSITION OF STREAM AT BOTTOM OF TOWER

No component Molar flow rate Mole %
1 H2SO4 5250.069 kmol/hr 92.44
2 H2O 429.10kmol/hr 7.56
TABLE 13: COMPOSITION OF STREAM AT TOP OF TOWER
NO component Molar flow rate Mole %

1 SO2 3.428kmol/hr 0.59
2 O2 33.554kmol/hr 5.76
3 N2 545.806 kmol/hr 93.65
4.14 EQUIPMENT : Coverter 4TH stage
34
Inside the reactor
1 mole of SO3 requires 1 mole of SO2 and 0.5 mole of O2
CONVERSION IN 4TH STAGE IS 96%
SO2 remaining = 0.005kmol/hr
SO3 produced = 0.138 kmol/hr
Outlet from converter 4th satge
35
TABLE14 : outlet of the 4th stage

kmol/hr
SO3 11.04 0.138 0.02
SO2 0.32 0.005 -
O2 602.73 33.485 5.78
N2 15282.568 545.806 94.2
4.15 EQUIPMENT : ECONOMISER 2
FIGURE 11 :
SO3=0.138kmol/hr
SO2=0.005kmol/hr
O2=33.485kmol/hr
N2=545.806kmol/hr
H2O
SO3=0.138kmol/hr
SO2=0.005kmol/hr
O2=33.485kmol/hr
N2=545.806kmol/hr
36
TABLE 15 : OUTLET OF THE ECONOMISER 2

kmol/hr
SO3 11.04 0.138 0.02
SO2 0.32 0.005 -
O2 602.73 33.485 5.78
N2 15282.568 545.806 94.2
37
4.16 EQUIPMENT : FINAL ABSORPTION TOWER
FIGURE 12 :
SO3=0.138kmol/hr
SO2=0.005kmol/hr
O2=33.485kmol/hr
N2=545.806kmol/hr SO2=0.005kmol/hr
O2=33.485kmol/hr
N2=545.806kmol/hr
H2O= 429.10 kmol/hr
H2O= 428.96 kmol/hr
38
Reaction: SO3 + H20 H2SO4
Molar fow rate of SO3 IN = 0.138kmol/hr
Molar flow rate of 98.5% H2SO4 in from FAT ACID cooler = 5157.57 kmol/hr
Molar flow rate of H2O in = 429.10 kmol/hr
Inside the reactor:
1 mole of H2SO4 requires 1 mole of H2O and 1 mole SO3
Moles of H2SO4 produced by absorption in H2O = moles of SO3 absorbed
= 0.138 kmol/hr
Moles of H2O remaining = 429.10 – 0.138
= 428.96 kmol/hr
Outlet final absorption tower:
Molar flow rate of H2SO4 out = 5175.57 + 0.138
= 5175.708 kmol/hr
Molar flow rate of H2O out = 428.96 kmo/hr
Molar flow rate of O2 out = 33.485kmol/hr
Molar flow rate of SO2 out = 0.005kmol/hr
39
Molar flow rate of N2 out = 545.806kmol/hr
TABLE 16: COMPOSITION OF STREAM AT BOTTOM OF TOWER
No component Molar flow rate Mole %
1 H2SO4 5175.708 92.35

2 H2O 428.96 7.65
TABLE 17: COMPOSITION OF STREAM AT TOP OF TOWER
NO component Molar flow rate Mole %

1 SO2 0.005kmol/hr
2 O2 33.485kmol/hr 5.78
3 N2 545.806 kmol/hr 94.22
40
4.17 EQUIPMENT :DEAERATOR
FIGURE 13 :
STEAM
DM WATER H2O=362.5kmol/h
H2O=362.5kmol/h
41
4.18 EQUIPMENT: STORAGE TANK
FIGURE 14 :
H2SO4= 74.499 kmol/hr
Table 18 :
Composition of 98.5% H2SO4
component Molar flow rate Mol %
H2SO4 73.381 98.5

H2O 1.117 1.5
TOTAL = 74.499 100
Total molar flow rate of 98.5% H2SO4 = 74.499 kmol/hr
Mass flow rate of 98.5% H2SO4= 74.499 × 98
= 7300.902 kg/hr = 175.22 TPD
175.22 TPD of 98.5% H2SO4 is sent to storage tank.
42
5 ENERGY BALANCE :
BASIS : 1 hour of operation
TECHNICAL DATA :
REACTION : S + O2 SO2 + ΔH = 296.84 KJ/mole of sulfur
REACTION : SO2 + ½ O2 SO3 + ΔH = 99.1 KJ/mole of SO2
REACTION : SO3 + H2O H2SO4 + ΔH= 130 KJ/mole of H2SO4
Specific heat capacity of sulphur (solid) = 0.71 KJ/kg K
Specific heat capacity of sulphur (liquid) = 0.995 KJ/kg
Specific heat capacity of N2 = 26.8677 + 5.6079 × 10-3 T
Specific heat capacity of O2 = 28.20 + 6.8634 × 10 -3 T
Specific heat capacity of SO2 = 39.8412 + 15.3334 × 10 -3T
Specific heat capacity of SO3 = 50.764 + 33.9822 × 10 -3T
Specific heat capacity of H2SO4 = 1.4435 KJ/kg K
Specific heat capacity of H2O = 4.183 KJ/kgK
43
5.1 EQUIPMENT : AIR BLOWER
FIGURE 15 :
H2O=27.88 kmol/hr
N2= 545.806kmol/hr
O2= 145.088kmol/hr
H2O=27.88 kmol/hr
N2= 545.806kmol/hr
O2= 145.088kmol/hr
Air enters the blower at a temperature of 400 C (313 K)
Mass flow rate of air from blower = 20839.69 kg/h
Quantity of moisture in air = 501.84 kg/hr
44
5.2 EQUIPMENT : AIR DRYING TOWER
Figure 16 :
N2= 545.806kmol/hr
O2= 145.088kmol/hr
583589.63KJ
0
150.4 C
H2SO4=5175.57 kmol/hr
H2O= 429.10kmol/hr
45 0 C
H2O=27.88 kmol/hr
N2= 545.806kmol/hr H2SO4=5254.39kmol/hr 4149561.533KJ
O2= 145.088kmol/hr H2O= 456.98 kmol/hr 185043.048KJ
40 0C 3843343.245 kJ 50
0
C
45
Reaction involved :
H2SO4 + H2O H2SO4 . H2O
Heat of dilution from 98.5% to 98.1 % = 19.751 KJ/kg
Mass flow rate of 98.5% dil H2SO4 = 514930.22 kg/hr
= 514930.22 × 0.985
Mass flow rate of H2SO4 = 507206.266 kg/hr
Heat evolved due to dilution = 507206.22 × 19.715
= 10017830.97 KJ/hr
Sulphuric acid enters the tower at 450C
Sulphuric acid leaves the tower at 50 0 C
Heat absorbed by sulphuric acid ,
Q1 = m CP ΔT
= 507206.266 × 1.4435 × ( 50- 40)
= 3660761.225 KJ/hr
Heat absorbed by water,
Q2 = m CP ΔT
= 7723.95 × 4.184 × ( 50 – 45) + 501.840 × 4.184 (50- 40)
= 182582.019 KJ/hr
Total heat absorbed = 3660761.225 + 182582.019
46
= 3843343.245 kJ/hr
Remaining heat = 10017830.97 - 3843343.245
= 6174487.725 kJ/hr
Number of moles of N2 in gas stream = 545.806 kmol/hr
Number of moles of O2 in gas stream = 145.088 kmol/hr
Heat capacity of N2 gas = 14667.170 + 3.060 T
Heat capacity of O2 gas = 4091.48 + 797 T
Total heat capacity of gas = 18758.650 + 0.998 T
Q = n CPΔT
6174487.725 = 18758.650 × ( T – 313) + 0.998 ( T2 – 3132)
= 150.40 C or 423.4 K
TABLE 19 : NET ENERGY BALANCE OF AIR DRYING TOWER
Component phase Temperature change Energy required

Heat of dilution - - - 10017830.97 KJ
Heat absorbed by liquid 45 to 500C 3660761.225 KJ
sulphuric acid
Heat absorbed by liquid 40 to 500 C 182582.019 KJ
water
Heat absorbed by air( gas 40 to 150.40 C 6174487.725
N2,O2)
47
5.3 EQUIPMENT: FURNACE
Figure 17 :
0
951 C
-22086083.36KJ
0
140 C N2= 545.806kmol/hr
O2= 70.684kmol/hr
S=74.404 kmol/hr SO2=74.404kmol/hr
FURNACE
0
150.4 C
N2= 545.806kmol/hr
O2= 145.088kmol/hr
Reaction : S + O2 SO2 + 296.84 KJ/mole
Moles of SO2 produced in reaction = 74.404 kmol
Total energy produced by reaction = 296.84 × 103 × 74.404
= 22086083.36 KJ
48
No of moles of N2 = 545.806 kmol
No of moles of O2 = 70.684 kmol
No of moles of SO2 = 74.404 kmol
Heat capcity ( n CP ) of N2 = 14664.170 + 3.060 T
Heat capcity ( n CP ) of O2 = 1993 .289+ 0.485 T
Heat capcity ( n CP ) of SO2 = 2964.330 + 1.140 T
Total heat capacity = 19621.789 + 4.685 T
Total heat produced is taken by gas phase ,
22086083.36 = 19621.789 × ( T – 423 ) + 4.685( T2 – 4232 )
= 951 0 C
TABLE 20 : NET ENERGY BALANCE OF FURNACE
Component phase Temperature change Energy required
Heat of reaction - - - 22086083.36 kJ
Heat absorbed by gas 150.4 0C TO 951 0 C 22086083.36 kJ

gas phase
49
5.4 EQUIPMENT : FRIE TUBE BOILER
Figure 18 :
N2= 545.806kmol/hr
O2= 70.684kmol/hr
0 SO2=74.404kmol/hr
H2O= 362.5kmol/hr 550 C
-11714005.58KJ
STEAM
N2= 545.806kmol/hr
O2= 70.684kmol/hr
SO2=74.404kmol/hr
0
951 C
50
Number of moles of N2 = 545.806 kmol
Number of moles of O2 = 70.684 kmol
Number of moles of SO2 = 74.404 kmol
Heat capacity (nCp) of N2 = 14664.170 + 3.060 T
Heat capacity (nCp) of O2 = 1993.289 + 0.485 T
Heat capacity (nCp) of SO2 = 2964.330 + 1.140 T
The gas phase is cooled from 9510 C to 550 0 C in fire tube boiler
Heat to be removed from gas phase :
= 1921.789 ( 1224 – 823 ) + 4.685 ( 1224 2 – 823 2 )
= 11714005.58 KJ
TABLE 21 : NET ENERGY BALANCE OF FIRE TUBE BOILER
component phase Temperature change Energy required
Heat removed from gas 9510 C to 550 0 C -11714005.58 KJ

gas phase
(O2,N2,SO2)
51
5.5 EQUIPMENT : SUPER HEATER
Figure 19 :
0
430 C N2= 545.806kmol/hr
O2= 70.684kmol/hr
SO2=74.404kmol/hr
STEAM FROM STEAM DRUM
-3212531.880KJ
0
550 C
SUPER HEATED STEAM
N2= 545.806kmol/hr
O2= 70.684kmol/hr
SO2=74.404kmol/hr
52
Number of moles of N2 = 545.806 kmol
Number of moles of O2 = 70.684 kmol
Number of moles of SO2 = 74.404 kmol
Heat capacity (nCp) of N2 = 14664.170 + 3.060 T
Heat capacity (nCp) of O2 = 1993.289 + 0.485 T
Heat capacity (nCp) of SO2 = 2964.330 + 1.140 T
The gas phase is cooled from 9510 C to 4300 C in fire tube boiler
= 1921.789 ( 1224 – 703 ) + 4.685 ( 1224 2 – 703 2 )
= 3212531.880 KJ
Table 22 : NET ENERGY BALANCE OF SUPER HEATER
Heat removed from gas 9510 C to 430 0 C -3212531.880KJ

gas phase
(O2,N2,SO2)
53
5.6 EQUIPMENT : CONVERTER
Figure 20 :
0
430 C
N2= 545.806kmol/hr
N2= 545.806kmol/hr O2= 35.268kmolhr
O2= 70.684kmolhr 0
SO2=3.571kmol/hr
SO2=74.404kmol/hr 513.6 C
SO3=70.833kmol/hr
-4424022 KJ
2595528KJ
4424022 KJ
0
580.5 C
-2595528KJ N2= 545.806kmol/hr
O2= 33.554kmolhr
0 SO2=0.143kmol/hr
471 C
N2= 545.806kmol/hr SO3=74.361kmol/hr
O2= 48.363kmolhr
SO2=29.762kmol/hr 339714.8 KJ
SO3=44.642kmol/hr - 339714.8 KJ
0
440 C
N2= 545.806kmol/hr N2= 545.806kmol/hr
SO2=29.762kmol/hr -13675.8 KJ 0 SO2=3.571kmol/hr
SO3=44.642kmol/hr 450 C SO3=70.833kmol/hr
0
466 C
0
N2= 545.806kmol/hr 492 C N2= 545.806kmol/hr
SO2=0.005kmol/hr 13675.8 KJ SO2=0.143kmol/hr
SO3=0.138kmol/hr
54
5.7 EQUIPMENT : COVERTER- LAYER 1
Inlet temperature of gas phase = 430 0 C
Reaction involved :
SO2 + ½ O2 SO3 + 99.1 Kj/mol
SO3 produced = 44.642 kmol
Total heat produced due to reaction
= 99.1 × 103 × 44.642
= 4424022 KJ
No of moles of O2 = 48.363kmol
No of moles of SO3= 44.642 kmol
Heat capacity ( nCp) of N2 = 14664. 170 + 3.060 T
Heat capacity ( nCp) of O2 = 1363.83 + 0.332 T
Heat capacity ( nCp) of SO2 = 1185.754 + 0.456T
Heat capacity ( nCp) of SO3 = 2266.206+ 1.517T
The heat produced is taken up by gas phase
4424022 = 19479.960 (T – 703 ) + 5.366 ( T2 – 7032 ) = 580.5 0 C
55
TABLE 23 : NET ENERGY BALANCE : COVERTER 1 ST SATGE
Heat of reaction - - - 4424022 kJ

Heat absorbed by gas 430 0C to 951 0 C 4424022 KJ
gas phase
Figure 21 :
- 3917954.60 KJ
N2= 545.806kmol/hr
O2= 48.363kmol/hr N2= 545.806kmol/hr
SO2=29.762kmol/hr O2= 48.363kmol/hr
SO3=44.642 k mol/hr SO2=29.762kmol/hr
SO3=44.642 k mol/hr
ECONOMISER 3
0 0
580.5 C 440 C
Gas inlet : 580.5 0 C
Gas is cooled to 440 0C by deareator water
56
= 19479.960 (853.5– 703 ) + 5.366 ( 853 2 – 7032 )
= 3917954.760 KJ
Table 24 : NET ENERGY BALANCE : ECONOMISER 3
component phase Temperature Energy required

change
Heat removed gas 580.5 0 C to 440 0
- 3917954.60 KJ
from gas phase C
5.9 EQUIPMENT : CONVERTER 2ND STAGE
Inlet temperature of gas phase = 440 0C
57
Reaction involved :
SO2 + ½ O2 SO3 + 99.1 KJ/mol
= 26.191 × 99.1 × 10 3
= 2595528 KJ
Total heat capacity = 19396.767 + 8.171T
2595528 = 19396.767 ( T – 713) + 8.171 ( T2 – 7132)
T = 513.6 0 C
TABLE 25 :NET ENERGY BALANCE: COVERTER 2ND STAGE

Heat of reaction - - - 2595528 kJ
Heat absorbed by gas 440 0 C to 513.60 C 2595528 kJ
Gas phase
58
Figure 22 :
0
513.6 C
N2= 545.806kmol/hr
O2= 35.268kmol/hr
SO2=3.571kmol/hr
0 N2= 545.806kmol/hr
SO3=70.833kmol/hr 364 C O2= 33.554kmol/hr
SO2=0.143kmol/hr
- 2018203.87 KJ
N2= 545.806kmol/hr
O2= 33.554kmol/hr
SO2=0.143kmol/hr
0
466 C
0
450 C N2= 545.806kmol/hr
O2= 35.268kmol/hr
SO2=3.571kmol/hr
SO3=70.833kmol/hr
59
Gas phase inlet : 513.60 C
The gas is cooled to 450 0 C by gas from FHE
Total heat capacity = 19396.767 + 8.171T
Q = (19396.767 + 8.171T ) ΔT
= 19396.767 ( 786.6– 723) + 8.171 (786.62 – 7232)
= 2018203.87 KJ
60
TABLE 26: NET ENERGY BALANCE: IHE
componet phase Temperature change Energy required
Heat removed gas 513.50 C to 4500 C - 2018203.87 KJ

from gas phase
61
5.11 EQUIPMENT : COVERTER 3RD STAGE
Reaction involved :
SO2 + ½ O2 SO3 + 99.1 KJ/mol
= 3.428 × 99.1 × 10 3
= 339714.8 KJ
Heat capacity ( nCp) of O2 = 946.223+ 0.102 T
62
Total heat capacity = 19391.222+ 5.690T
339714.8 = 19396.767 ( T – 723) + 8.171 ( T2 – 7232)T
= 471 0 C
TABLE27 : NET ENERGY BALANCE : COVERTER 3RD STAGE
Heat of reaction - - - 339714.8 KJ
Heat absorbed by gas 450 0 C to 4710 C 339714.8 KJ

gas phase
63
5.12 EQUIPMENT : Final heat exchanger
Figure 23 :
0
471 C
SO3=74.361kmol/hr
SO2=3.428kmol/hr
O2=33.554kmol/hr
N2=545.806kmol/hr
N2= 545.806kmol/hr
0 O2= 33.554kmol/hr
77 C
SO2=0.143kmol/hr
0 - 5954301 KJ
364 C
N2= 545.806kmol/hr
O2= 33.554kmol/hr
SO2=0.143kmol/hr
0
250 C
SO3=74.361kmol/hr
SO2=3.428kmol/hr
O2=33.554kmol/hr
N2=545.806kmol/hr
64
Gas phase inlet : 471 0 C
The gas is cooled from 471 to 250 0 C by gas from IAT. Hence the heat to be removed
Heat capacity ( nCp) of O2 = 946.223+ 0.102 T
Q = ( 19391.222+ 5.690T)ΔT
Q = 19396.767 ( 774 – 723) + 8.171 ( 7442 – 7232)
Q = 5954301 KJ
TABLE 28 : NET ENERGY BALANCE OF FINAL HEAT EXCHANGER
Heat removed gas 471 0 C to 2500 C - 5954301 KJ

from gas phase
65
5.13 EQUIPMENT : INTERMEIATE ABSORPTION TOWER
Figure24:
SO3=74.361kmol/hr
SO2=3.428kmol/hr
O2=33.554kmol/hr
N2=545.806kmol/hr SO2=3.428kmol/hr
O2=33.554kmol/hr
N2=545.806kmol/hr
0
250 C
- 11098783.2 KJ
0
77 C
H2SO4=5175.5kmol/hr
H2O=74.361kmol/hr H2O=429.10kmol/hr
0
65 C
-9666930kJ
0
91 C
H2SO4=0.138 kmol/hr H2SO4=5328.889kmol/hr

H2O= 0.002 kmol/hr H2O= 429.1027kmol/hr
20765713.2 KJ
66
Reaction involved :
SO3 + H2O H2SO4 + 130 KJ/mol
Total SO3 reacting = 130 × 103 × 74.361
= 9666930 KJ
H2SO4 in = 5175.5kmol
H2SO4 produced by reaction = 74.361kmol
H2SO4 in from FAT = 0.138 kmol
H2O in = 429.10 kmol at 65 0C
H2O in from FAT = 0,002 kmol at 65 0C
H2O in for dilusion = 74.361 kmol at 32 0C
Total molar flow rate of H2O = 429.102 kmol
Heat taken by water = 354.739 × 4.184 ( 91- 65 ) + 0.002 × 4.184 ( 91- 65) + 74.361 ×
4.184(91- 32)
= 56946.389 KJ
Heat taken by H2SO4 = 5175.5 × 98 × 1.4435 ( 91- 65) + 74.361× 98× 1.4435 ( 250-
91) + 0.138 × 98×1.4435 ( 91-65)
= 20708766.8 KJ
Total heat absorbed by dilute H2SO4 98.5%
= 20708766.8 + 56946.389 = 20765713.2 KJ
67
Heat absorbed from reaction = 9666930 KJ
Total heat to be absorbed from gas phase = 20765713.2 – 9666930
= 11098783.2 KJ
Heat capacity ( nCp) of O2 = 946.222+ 0.230T
- 11098783.2 = 15616.08 ΔT + 3.292 ΔT2
- 11098783.2 = 15616.08 (T- 523) + 3.292 ( T2- 5232)
0
T = 77 C
TABLE 29 : NET ENERGY BALANCE OF IAT
component phase Temperature Energy required

change
Heat of reaction - - – 9666930kJ
Heat absorbed liquid 65 0 C to 910 -20765713.2 KJ
by dilute C
H2SO4
Heat released gas 2500 C to 770 C - 11098783.2
by gas
phase
68
5.14 EQUIPMENT : Final heat exchanger
Figure 25 :
SO3=74.361kmol/hr
SO2=3.428kmol/hr 0
O2=33.554kmol/hr 471 C
N2=545.806kmol/hr
N2= 545.806kmol/hr
O2= 33.554kmol/hr
SO2=0.143kmol/hr
0
77 C
0 5954301 KJ
364 C
N2= 545.806kmol/hr
O2= 33.554kmol/hr
SO2=0.143kmol/hr
SO3=74.361kmol/hr
0 SO2=3.428kmol/hr
250 C O2=33.554kmol/hr
N2=545.806kmol/hr
69
Actual heat available for pre- heating = 5954301 KJ
No of moles of O2 = 33.554 kmol
Total heat capacity = 15616.08 ( T – 350) + 3.292 ( T2 – 3502 )
5954301 = 15616.08 ( T – 350) + 3.292 ( T2 – 3502 )
T = 364 0C
TABLE 31 : NET ENERGY BALANCE : FHE
Heat gained by gas 77 0 C to 3640 C 5954301 KJ

inlet gas phase
70
Figure 26 :
0
513.6 C
N2= 545.806kmol/hr
O2= 35.268kmol/hr
SO2=3.571kmol/hr
SO3=70.833kmol/hr N2= 545.806kmol/hr
O2= 33.554kmol/hr
SO2=0.143kmol/hr
0
364 C
N2= 545.806kmol/hr -2018203 KJ

O2= 33.554kmol/hr
SO2=0.143kmol/hr
0
466 C
0
450 C
N2= 545.806kmol/hr
O2= 35.268kmol/hr
SO2=3.571kmol/hr
SO3=70.833kmol/hr
71
Actual heat available for pre- heating = 2018203 KJ
Total heat capacity = 15616.08 ( T – 637) + 3.292 ( T2 – 6372 )
2018203 = 15616.08 ( T – 637) + 3.292 ( T2 – 6372 )
T = 4660C
Table 32 : NET ENERGY BALANCE : IHE
Heat gained by gas 364 0 C to 4660 C 2018203 KJ

inlet gas phase
72
5.16 EQUIPMENT : COVERTER 4th STAGE
Reaction involved :
SO2 + ½ O2 SO3 + 99.1 KJ/mol
= 0.138 × 99.1 × 10 3
= 13675.8 KJ
73
13675.8 = 15618.65 ( T- 739) +7.98 (T2 – 7392)
= 492 0C
Table 33 : NET ENERGY BALANCE : COVERTER 4TH STAGE
Heat of reaction - - - 13675.8 KJ
Heat absorbed by gas 466 0 C to 4920 C 13675.8 KJ

gas phase
Figure 27 :
SO3=0.138kmol/hr
0 SO2=0.005kmol/hr
492 C O2=33.485kmol/hr
7904786.44 KJ N2=545.806kmol/hr
H2O=362.5kmol/h
0 SO3=0.138kmol/hr
180 C SO2=0.005kmol/hr
O2=33.485kmol/hr
N2=545.806kmol/hr
74
Gas phase cooled from 492 0 C to 1800 C
Heat to be removed from gas
= 15618.65 ( 765- 453) +7.98 (7652 – 4532)
Q = 7904786.44 KJ
Table 34: NET ENERGY BALANCE : ECONOMISER 2
Heat removed gas 492 0 C to 1800 C -7904786.44 KJ

from gas phase
75
5.18 EQUIPMENT : FINAL ABSORPTION TOWER
Figure 28 :
SO3=0.138kmol/hr
SO2=0.005kmol/hr
O2=33.485kmol/hr
N2=545.806kmol/hr
SO2=0.005kmol/hr
O2=33.485kmol/hr
N2=545.806kmol/hr
-19880243.6 kJ
0
17940 KJ H2O= 429.10 kmol/hr
180 C
0
65 C
0
91 C
H2O= 428.96 kmol/hr
19898183.6KJ
76
Reaction involved :
SO3 + H2O H2SO4 + 130 KJ/mol
Total H2SO4 formed = 0.138
Total SO3 reacting = 130 × 103 × 0.138
= 17940 KJ
H2SO4 in = 5175.5 kmol at 65 0 C
H2SO4 produced by reaction = 0.138 kmol
H2O in = 429.10 kmol
Heat absorbed by dilute H2SO4 98.5% for change from 65 0 C to 910 C
Q = 5175.5 × 98× 1.445 ( 91 – 65 ) + 0.138 × 98× 1.445 (180- 91) + 429.10 × 18 ×4.184
( 91- 32)
= 19898183.6KJ
Heat to be removed from gas phase = 19485841.4 - 17940
= 19880243.6 kJ
77
Total heat capacity = 15611.64+3.2890T
19880243.6 = 15611.64 ( T – 453 ) + 3.2890 ( T2 – 4532)
= 70 0 C
TABLE 35 : NET ENERGY BALANCE : FAT
Heat of reaction - - – 17940 KJ

0
Heat absorbed by liquid 65 C to 910 C -19898183.6KJ
dilute H2SO4
Heat released by gas 1800 C to 70 0 C 19880243.6 kJ
gas
phase
78
6 . DESIGN OF SHELL AND TUBE HEAT EXCHANGER :
TABLE 36 : FEED PROPERTIES

SPECIFICATION UNITS SHELL SIDE TUBE SIDE
Fluid circulated - gas gas

Flow rate Kg/s 6.2 4.55
Specific heat kJ/kg 0C 0.96 1.05
Fluid(in/out) 364/466 513.6/450
0
Temperature C
vicosity cP 0.28 0.32
density Kg/ m3 0.82 0.95
Thermal W/m 0 C 0.112 0.132

conductivity
Fouling resistance m2/W 0 C 1.76 × 10-4 1.76 × 10-4
6.1 Heat duty of heat exchanger :
Shell side :
Q = mc*Cp*ΔT
=16365.498*0.96*(466-364)
= 1602509.56 KJ/h
= 445.14 KW
Tube side :
Q = mh*Cp*ΔT
=22306.328*1.05*(513.6-450)
79
= 1489616.58 KJ/h
= 413.78 KW
Temperature driving force :
LMTD = ΔT1 – ΔT2/ ln ( ΔT2 /ΔT2 )
ΔT1 = 513.6 – 466 = 47.6
ΔT2= 450 – 364 = 86
LMTD = 47.6 – 86/ ln (47.6/86)
= 64.92
For 1 shell and 2 tube passes
ΔTlm = FT * LMTD
P = ( TC2 – TC1 )/ ( Th1 – Th2 )
= ( 466 – 364 )/ (513.6 – 364 )
= 0.68
R = ( Th1 – Th2 )/ ( TC2 – TC1 )
= ( 513.6 – 450 )/ (466 – 364 )
= 0.62
From chart
FT = 0.65
ΔTlm = 0.65 * 64.92
= 42.200 C
Estimated area :
80
Q = UAΔT lm
A = Q/ UΔTlm
Let as assume over all heat transfer co- efficient = 250 W/ m2 0C
A = 413.79 × 103/ 250 × 42.20
= 39.22 m2
Tube pitch = 1.25 ( OD )
= 1.25 * 0.01905
= 0.024 m
Heat transfer area of each tube
lenth – allowance )
= 3.14 * 0.01905 * ( 4.88 – 0.05 )
= 0.2889 m2
Number of tubes required
= A/ surface area of tube
= 39.22/ 0.288
= 136
Fluid flow area:
At = /4 × (ID)2 × ( NT/NP )
= 3.14/4 ×(0.01574 )2 × (136/2)
= 0.01m2
Fluid velocity in tube :
81
V = mass velocity/ρ × At
= 4.55/ 0.95 × 0.11
= 0.48 m/s
Wall temperature :
TW = 0.5 ( ( Th1 +( TC1 + TC2/ 2 ) )
= 0.5 ( 928.60 )
= 464.3 0 C
Film temperature :
Tfilm = Twall + Th1/ 2
= 464.3 + 513.6/ 2
= 488.9 0C
6.2 Film co- efficient of shell side :
h0 De/ k = 0.36 ( Nre ) 0.55 (Npr)0.33 (ϻ/ ϻw )0.14
NRE = GS De / µ
GS = MS / AS
AS = DS C „ B/PT
Clearance C „= PT – OD
= 0.024 – 0.019 = 0.005 m
Baffle spacing B = DS
B = 0.4489 m
AS = 0.4489 * 0.005 * 0.4889/0.024
82
= 0.0498 m2
GS = 6.2/0.0498
= 124.50 kg/m2s
Equivalent diameter :
De = 4 ( PT2 - /4 (OD)2 ) ( * OD )
= 4 ( 0.0242 - /4( 0.0192 )2) ( * 0.019 )
= 0.0196 m
NRE = 124.5 * 0.019/0.2 * 10-3
= 8448.21
NPR = CP ϻ/k
= 1.05 * 0.28 * 10-3 * 1000/ 0.132
= 2.23
Let as assume (ϻ/ ϻw ) = 1 for low viscous fluids
h0 *0.0196/ 0.132 = 0.36 ( 8448.21 ) 0.55 ( 2.23)0.33
h0 = 451.73 W/ m2 0C
6.3 film heat transfer co-efficient of tube side :
hiDi/ k = 0.023( Nre ) 0.88 (Npr)0.33 (ϻ/ ϻw )0.14
NRE = Gt Di / ϻ
Gt = Mt/ At
= 4.55/ 0.01
83
= 455 kg / m2s
At = /4 × (ID)2 × ( NT/NP )
= 3.14/4 ×(0.01574 )2 × (136/2)
= 0.01 m2
NRE = 455 * 0.0157/ 0.32 * 0.001
= 22323.44
NPR = 1.05 * 0.32/ 0.112
=3
hi *0.015/ 0.124 = 0.023 ( 22323.44 ) 0.8 ( 3)0.33
hi = 766.03 W/m2 0C
hi0 = hi ( ID/OD )
= 766.03 ( 0.0157 / 0.01905 )
= 631.32 W/m2 0C
TUBE WALL RESISTANCE :
RW = D0 / 2KW ln ( D0 / Di )
= 0.0195/ 2*55 ln ( 0.01905 / 0.0157)
= 3.349 * 10-5 m2 0C / W
Rdi0 = 1.76 * 10-4
Rdo = Rdi ( D0 / Di )
= 1.76 * 10-4 * ( 0.01905/ 0.0157 )
= 2.13 * 10 -4 m2 0C / W
84
6.4 Over all heat transfer co-efficient :
U0 = ( 1/h0 + RW + Rdi0 + Rdo + 1/ hio )
= 254.60 W/m2 0C
Required heat transfer area
Ar = Q/ U0 ΔTm
= 413.9/254.60 * 42.20
=38 m2
Heat transfer area available
Aa = (OD ) * L * Nt
= 3.14 ( 0.01905 ) * 4.88 * 136
= 39.70 m2
Available heat transfer area is greater than the required heat transfer area so
Design is safe.
% excess area = Aa - Ar / Ar * 100
=( 39.70 – 38 )/38 * 100 = 4.47 %
6.5 Pressure drop in shell side :
Δps = { ( f * GS 2 * DS ) ( Nb + 1) } / ( 2 * 106 * De * S* ψS )
f fanning friction factor
GS mass velocity of shell side fluid
85
DS diameter of shell
Nb no of baffles
S specific gravity of shell side gas
F = 1.87( NRE ) -0.2
= 1.8 ( 8448.21 )-0.2
= 0.31
S = 0.53
Nb = lenth of tube/ baffle spacing
= 4.88/0.4889 = 10
Δps = { ( 0.31 * 124.5 2 * 0.4889 ) ( 10 + 1) } / ( 2 * 106 * 0.0196* 0.53* 1 )
= 1.24 < 20 kpa
Design is safe.
6.6 Pressure drop in tube side :
Δpt = { ( f * Gt2 * L * NP )/2*106 *Di* S* ψS ) + ( 2.5* NP *V2 *S )
f fanning friction factor
Gt mass velocity of tube side fluid
Di inner diameter of tube
Np no of passes
S specific gravity
V velocity
86
F = 0.72( NRE ) -0.33
= 0.72 ( 22323.44 )-0.33
= 0.03
Δpt = { ( 0.03* 4552 * 4.88* 2 )/2*106 *0.0157* 1* 1) + ( 2.5* 2 *0.482 *1 )
= 3.08< 20 kpa
Design is safe .
6.7 Design summary :
Heat duty of the heat exchanger = 413.9 KW
Area required for heat transfer = 38 m2
Area available for heat transfer = 39.5 m2
No of tubes = 136
No of passes in tube side =2
No of passes in shell side =1
Film heat transfer co-efficient in tube side = 766.03 W/m2 0C
Film heat transfer co-efficient in shell side = 451.73 W/ m2 0C
Over all heat transfer co-efficient = 254.60 W/m2 0C
Pressure drop in tube side = 3.08 kpa
Pressure drop in shell side =1.24 kpa
87
7 . Design of centrifugal pump :
Figure 29 :
Data :
Suction side :
Flow rate = 6.53 m3/h
Diameter of the pipe = 0.06 m
Geometric pipe length = 10 m
88
Discharge side :
Flow rate = 6.53 m3/h
Diameter of the pipe = 002 m
Geometric pipe length = 30 m
Density = 1000 kg/ m3
Viscosity = 0.75 cp
7.1 Determination of suction pressure :
Flow rate = area * velocity
Q= D2/4 * V
6.53/3600 = 3.14 * 0.062/4* V
V = 0.64 m/s
Total equivalent lenth = geometric lenth + lenth of the fittings
Geometric lenth = 10 m
Lenth of the fittings = 500 * 0.06 = 30 m
Total equivalent lenth = 40 m
7.2 Line pressure drop = 4fLv2/2g D
NRE = DVρ/µ
= 0.06 * 0.64 * 1000/0.75 * 0.001
= 51200
F = 0.0035 + 0.264 (NRE )-0.42
89
= 6.27 * 10-3
Δpf = ( 4 * 0.006 * 40 * 0.64 * 0.64 ) / 2 * 9.81 * 0.06
= 0.33 m
=0.33 * 10-4 *1000
= 0.03 kg/cm2
Static head = (10-4 ) * 10-4 * 1000
= 0.6 kg/cm2
Suction pressure :
System pressure = 1.0 kg/cm2
Satic head = 0.6 kg/cm2
Line pressure drop = 0.03 kg/cm2
Suction pressure = 1.63 kg/cm2
7.3 Determination of discharge pressure :
Flow rate = area * velocity
Q= D2/4 * V
6.53/3600 = 3.14 * 0.022/4* V
V = 5.77 m/s
Total equivalent lenth = geometric lenth + lenth of the fittings
Geometric lenth = 30 m
Lenth of the fittings = 600 * 0.116= 70 m
90
Total equivalent lenth = 100 m
Line pressure drop = 4fLv2/2g D
NRE = DVρ/µ
= 0.02* 5.77 * 1000/0.75 * 0.001
= 153866.66
F = 0.0035 + 0.264 (153866.66)-0.42
= 5.24 * 10-3
Δpf = ( 4 * 0.0052 * 100 * 5.77 * 5.77 ) / 2 * 9.81 * 0.02
= 176 m
=176 * 10-4 *1000
= 17.6 kg/cm2
Static head = 10 * 10-4 * 1000
= 1.0 kg/cm2
discharge pressure :
System pressure = 2.11 kg/cm2
Satic head = 1 kg/cm2
Line pressure drop = 17.64 kg/c
discharge pressure = 20.78 kg/cm2
91
7.4 differential pressure :
differential pressure = discharge pressure – suction pressure
= 20.75 – 1.63
= 19.12 kg/cm2
= 191.2 MWC
7.5 NET POSITIVE SUCTION HEAD :
NPSH = SUCTION PRESSURE – VAPOUR PRESSURE
= 1.63 – 1.05
= 0.58 kg/ cm2
= 5.8 MWC
7.6 SAFETY MARGIN :
Safety margin = (NPSH) – 0.6/ specific gravity
= 5.8 – 0.6/0.6 = 8.7 MWC
7.7 Horse power required :
HP = flow rate * ( density * differential pressure in MWC ) / 75
= 6.53/3600 * (1000 * 19.12) = 0.46 hp
7.8 Break horse power required :
BHP = HP/PUMP EFFICIENCY
92
= 0.46/ 0.6
= 0.77 hp
7.9 Motor horse power required :
MHP = BHP/ MOTOR EFFICIENCY
Motor power efficiency is 80%
= 0.77/0.8
=0.96 hp
7.10 Efficiency = HP/BHP * 100
= 0.46/ 0.77
= 60 %
93
7.11 Design summary :
Suction pressure = 1.63 kg/cm2
Discharge pressure = 20,75 kg/cm2
Differential pressure = 19.12 kg/cm2
Net positive suction head = 0.58 kg/cm2
Pump efficiency = 60 %
Horse power required = 0.46 hp
Break horse power required = 0.77 hp
Motor horse power required = 0.96 hp
94
8. process economics :
Table 37 : TOTAL PURCHASE COST OF EQUIPMENTS
equipment Cost of equipment

Combustion furnace 4198307
Fire tube boiler 1919883
Economizer 529784
Boiler feed storage tank 498275.57
Deaerator 887441
Super heater 264892
Converter 3921225
Intermediate heat exchanger 408156
Final heat exchanger 988940
Intermediate absorption tower 805585
Final absorption tower 688940
Air drying tower 222195
Storage tank 4621591
Acid cooler tank 509250
Pump 4243826
Total 23417850
Total purchase equipment cost = 23417850 Rs
95
8.1 Direct cost :
Installation cost
47 % of purchase equipment cost = 0.47 (23417850)
= Rs. 11006389.5
Instrumentation and control cost :
20 % of purchase equipment cost = 0.2 (23417850)
= Rs. 4683570
Piping (installed) :
30 % purchase equipment cost = 0.3(23417850)
= Rs. 7025355
Electrical(installed) :
10% of purchase equipment cost = 0.1(23417850)
=Rs.2341785
Building (including service) :
20% of purchase equipment cost = 0.2 (23417850)
= Rs. 4683570
Yard improvement :
10% of purchase cost = 0.1(23417850) = Rs. 2341785
96
Land :
=Rs.9367140
Service facilities :
=Rs.9367140
Total direct cost = Rs. 50816734
8.2 Indirect cost :
Engineering and supervision :
8.2 % of total direct cost = 0.082(50816734)
= Rs. 6626972.188
Construction expenses :
5% of total direct cost = 0.05(50816734)
= Rs. 2540836.7
Contractor fee :
11.4% of total direct cost = 0.114(50816734)
= Rs. 5793107.67
97
Contigency :
4% of total direct cost = 0.04(50816734)
=Rs. 2032669.36
Indirect cost = Rs. 16993585.92
Miscellaneous cost :
Maintenance, telephone,transport,
Postage, advertisement = Rs. 3000000
Total cost = Rs. 70810319.92
Working capital cost (per year) :
Fixed capital investment = total direct cost + total indirect cost
= 50816734 + 16993585.92
= Rs. 67810319.92
Working capital investment = 15% of fixed capital investment
= 0.15 * 67810319.92
= Rs. 10171547.99
Total capital investment = Working capital investment + fixed capital investment
= 10171547.99 +67810319.92
= Rs. 77981867.91
98
Raw material cost = Rs. 273300
Net capital investment :
Total cost + working capital cost = 70810319.92 +10171547.99
= Rs. 80981867.91
Direct production cost :
Process utilities = Rs. 5000000
Raw material cost = Rs. 273300
Maintenance = Rs. 2500000
Labour charges = Rs. 2000000
Total = Rs. 9773300
8.3 Fixed cost :
Depreciation equipment cost
10% of equipment cost = 0.1(23417850)
= Rs. 2341785
Depreciation of building
3% of building cost = 0.03(4683570)
=Rs. 140507.1
99
Local taxes
4% of net capital investment = 0.04(80981867.91)
= Rs. 3239274.71
Insurance
0.005% of net capital investment = 0.005 (80981867.91)
= Rs. 404909.33
Total = Rs. 6126476.14
8.4 Plant overhead :
Medical safety
15% of labour charge = 0.15(2000000)
= Rs. 300000
Restaurant and recreation
15% of maintenance cost = 0.15(2500000)
= Rs. 3750000
General expenses :
Advertisement
5% of manufacture cost = 0.05(9773300)
= Rs. 488665
100
Research
5% of manufacture cost = 0.05(9773300)
= Rs. 488665
Total plant overhead = Rs. 5027330
Total production cost = Rs. 11153806.14
Annual sales
Product per day = 175000 kg
Per kg of sulphuric acid = Rs. 500
Annual sales amount = Rs. 87500000
Gross profit = annual sales - Total production cost
= 87500000 - 11153806.14
= Rs.76346193.86
Net profit (25% of gross profit) = 0.25(76346193.86)
= Rs. 19086548.47
Payback period = net capital investment/ net profit
= 80981867.91/19086548.47
= 4 years 2 months.
101
9. PLANT LOCATION AND LAYOUT

PLANT SITE
The location of the plant can have a crucial effect on the overall profitability of a project and scope
for future expansion many factors must be considered when selecting a suitable plant. The principle factors
are:
 Location with respect to the marketing area
 Raw materials supply
 Transport facilities
 Available of suitable land
 Availability of labour
 Environmental impact and effluent disposal
 Local community considerations
 Climate
 Political and strategic consideration
RAW MATERIAL AVAILABILITY:
The source of raw material is one of the most important factors influencing the selection of
a plant site. This is particularly true if large volumes of raw material are consumed, because
location near the raw material source permits considerable reduction in transportation and
storage charge. Attention should be given to the purchased price of the raw material , distance
from the source of supply , fright or transportation expenses availability and reliability of supply
purity of the material and storage requirements.
MARkETS:
The location of markets or intermediate centers affects the cost of product distribution and
the time required for shipping. Proximity to the major markets is an important consideration in
the selection of plant site, because the buyer usually finds it advantages to purchase from nearby
sources. It should be noted that markets are needed for by products as well as major final
products.
102
WATER SUPPLY:
The process industries use large quantities of water for cooling, washing steam generation
and as raw material. The plant therefore must be located where a dependable supply of water is
available. A large river must be located where a dependable supply of water may be satisfactory
if the amount of water required is not great. The level of the existing water table can be checked
by constancy of the water table and the year-round capacity of local rivers or lakes should be
obtain. It the water supply shows seasonal fluctuations, it may be to construct a reservoir or to
several standby wells. The temperature, mineral content, silt or sand content, bacteriological
content, and cost for supply and purification treatment must be considered when choosing a
water supply.
WASTE DISPOSAL:
In recent years, many legal restrictions have been placed on the methods for disposing of
waste material from the process industries. The site selected for disposing of a plant should have
adequate capacity and facilities for correct waste disposal. Even though a given area has minimal
restrictions on pollution. It should not be assumed that this condition will continue to exist. In
choosing a plant sit, the permissible tolerance levels for various methods of waste disposal
should be considered carefully and attention should be given to potential for additional waste-
treatment facilities.
LABOUR SUPPLY:
The type and supply of labour available in the vicinity of a proposed plant site must be
examined. Consideration should be given to prevailing pay scales, restrictions on number of
hours worked per week, competing industries that can cause dissatisfaction or high turnover
rates among the workers, and variations in the skill and productivity of the workers.
ENERGY AVAILABILITY:
Power and steam requirements are high in most industrial plants, and fuel is ordinary
required to supply these utilities. Consequently power and fuel can be one major factor in the
choice of a plant site. Electrolytic processes require a cheap source of electricity and plants using
electrolytic processes are often located near hydroelectric installations.
103
If the plant requires large quantities of coal or oil, location near a source of fuel supply may be
essential for economic operation. The local cost of power can help determine whether power
should be purchased or self-generated.
CLIMATE:
If the plants is located in a cold climate, costs may be increased by the necessity for
construction of protective shelters around the process equipment, and special cooling towers or
air –conditioning equipment may be required if the prevailing temperature are high. Excessive
humidity or extremes of hot or cold weather can have a serious effect on the economic operation
of plant and these factors should be examined when selecting a plant site.
TRANSPORTATION FACILITIES:
Water, railroads and high and ways are the common means of transportation used by major
industrial concerns. The kind and amount of products and raw materials determine the most
suitable type of transportation facilities. In any case, careful attention should be given to local
freight rates and existing railroad lines. The proximity to railroad centers and possibility of
canal, river, lake or ocean transport must be considered. Motor trucking facilities are widely
used and serve as a useful supplement to rail and water facilities. If possible ,the plant site
should have access to all three types of transportation, and certainly, at least two types should be
available .There is usually need for convenient air and rail transportation facilities between the
plant and the main company headquarters, and effective transportation facilities for the plant
personnel are necessary.
FLOOD AND FIRE PROTECTION:
Many industrial plants are located along rivers near large bodies of water, and risks of flood
of flood or hurricane damage. Before selecting a plant site, the regional history of natural events
of this type should be examined and the consequences of such occurrence considered. Protection
from losses by fire is another important factor in selecting a plant location. In case of major fire,
assistance from outside fire department should be available. Fire hazards in the
104
immediate area surrounding the plant site must not be overlooked.
COMMUNITY FACTORS:
The character and facilities of a community can have quite an effect on the Location of
plant. If a certain minimum number of facilities for satisfactory living of plant personnel do not
exist, it often becomes a burden for the plant to subsidize such facilities. Cultural facilities of the
community are important to sound growth. Churches libraries, schools, civic theatres, concert
associations and other similar groups, if active and dynamic, do much to make a community
progressive. The problem of recreation deserves special consideration. The efficiency, character
and history of both state and local government should be evaluated. The existence of low taxes is
not in itself a favourable situation unless the community is already well developed and relatively
Free of dept.
105
18 19
16 17 20
21 22
15 28 13 12
23
14 8 9 10
7
1 6 11 26
4 3
5 25
27
5
24
106
Table 38 :
1 sulphur melting 17 stack
2 Sulphur storage 18 Water treatment plant
3 IAT ac id cooler 19 ADT& FAT COLLER

4 Coverter 20 Analyzing room
5 Fire tube boiler 21 ADT pump tank
6 Economizer 22 FAT pump tank
7 Transformer room 23 Blower house
8 Switch gear room 24 intermediate heat exchanger

9 Control room 25 Final heat exchanger
10 furnace 26 IAT pump tank
11 Sulphur pit 27 Suphuric acid storage
12 Air drying tower 28 Gas scrubbing tower
13 Final absorption tower
14 Water tank
15 deareator
16 Power supply
107
10. SAFETY
General
A safe and comfortable working environment is an essential part of efficient production .
operating and maintenance personnel should give careful consideration for safe practices. The
following points are given from the point of view of potential hazard involved in operating a
plant where corrosive accids and fumes are processed.
Protective equipment
Personal protective equipment is not a substitute for safe and good working conditions which
are taken care of at the design and construction stages; all the same protective equipment is must
in the plant of this type. Use of specific equipment is discussed in the following paragraphs.
Potential hazardous conditions

Sulphur
Elemental as sulphur dust is an irritant to the eyes. Muscous membranes and skin and may be
classed as muisance dust. When stored in bulk piles out of doors a wind may disseminate
sufficient dust to cause complaints of irritation. The use of dust tight eye protection and dust
respirators may be used to overcome this hazard.
Sulphur dioxide
In the normal operation of the sulphuric acid plant only very little unconverted sulphur
dioxides escapes into the atmosphere in the waste gas from the plant. But this quantity will be
more during start ups and abnormal operating conditions . control of a SO2 emission is
ordinarily an operational problem and is usually overcome by proper operating and maintenance
procedures.
Suphur dioxide is a colourless gas having a characteristics odour and having a strong irritant
action on the eyes, nose, throat and upper respiratory. Control of concentrations of SO2 to
levels which are not discomforting should prevent any significant effects in health. Proper
respiratory devices should be available for entering areas where high concentrations may
accumulate and for emergency purposes.
Sulphur dioxide and sulphuric acid

Hazards associated with handling sulphur trioxide and sulphuric acd are two types local effects
on the skin and eyes and irritation of the respiratory tract. Direct contact of concentrated H2SO4
108
on the skin is rapidly destructive to tissuses and may produce severe burns and accompanied by
shock and collapse. Contact with eyes may result severe damage or loss of sight.
In case of contact with sulphuric acid the most treatment is immediate flushingwith copious
amount of water. Safety showers/eyewash points must be inspected and ensuring to be in good
working order at all time in the plant. Personnel handling sulphuric acid must at least wear
rubber gloves and safety glass when working with sulphuric acid.
Vanadium pentaoxide
Vanadium pentaoxide catalyst is used in contact sulphuric acid plants in the converter .
personnel handling the catalyst are exposed to serious hazard. Catalyst cleaning can cause a
serious exposure when personnel are cleaning catalyst. Exposure to vanadium pentaoxide dust
produces irritation to the eyes and repiratory tract.
General safety in a sulphuric acid plant

Personnel in a sulphuric acid plant are exposed to the hazard created by contact with the
materials and equipment in the plant. They may be exposed to possibility of eye injuries
burns and physical injury. As a control on the safety of personnel, all personnel are required to
wear protective materials like goggles, jacket, pants, rubber shoes, gloves, respirator and face
masks whenever required.
Estabilished safety practices and good housekeeping in the plant will minimize the risks
against injuries. The general safety department of the factory has to lay down clear cut
procedure for the operation and maintenance of the plant. Such safety practices and procedure
have to be reviewed and updated from time to time.
109
11. Conclusion :
The various design aspects of the sulphuric acid manufacturing plant has been analysed, the cost
estimate analysis clearly indicates a good profitability from the project. The plants future
growth will be exceptional and self supportive. Use of fire tube boiler at appropriate routes help
in steam production, which can be used both for internal heating requirements and export for
power generation.
110
12. REFERENCE :
1. Bhatt B.I and Vora S.M., Stoichiometry, III edition, Tata McGraw Hill, New Delhi
1996
2. Coulson J.m., Richardson J.F., “Coulson and Richardson‟s Chemical engineering”,
Volume II, Volume VI,second edition, Butterworth Heinemann,ttMalaysia.
3. McCabe W.L., Smith J.C., Peter Harriot., “Unit Operation Of Chemical
Engineering”, IV edition, McGraw Hill Book Company, New York.
4. Perry R.H., Green D.W., “Perry‟s Chemical Engineer‟s HandBook”, VII edition
McGraw Hill Book Company, New York.
5. http:// en.Wikipedia.org/wiki/sulphuric acid
111

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Manufacture of sulphuric acid 2017

1.1 PLANT HISTORY

1.2 COMPANY PROFILE

1.3 ABOUT SULPHURIC ACID

1.4 HISTORICAL DEVELOPMENTS:

1.5 Uses of sulphric acid

1 st qtr 52% : phosphate fertilizers

2nd qtr 16% : metal processing

3rd qtr 12% : fibres

4th qtr 8% : hydrochloric acid

5th qtr 6% : paints and pigments

6th qtr 4% : pulp and paper

7th qtr 2% : others

1.6 PRODUCTION OF SULPHURIC ACID:

1.7 PHYSICAL AND CHEMICAL PROPERTIES:

Appearance : clear oily liquid

Solubility : miscible with water, liberates much heat

Specific gravitiy : 1.84((98%), 1.40(50%), 1.07(40%)

Ph : 0.1 N solution = 0.3;

0.1N solution= 1.2;

Boiling point of H2SO4 : 280 0 C

Boiling point of sulfur : 444 0 C

Melting point of H2S04 : 3 0C

Melting point of SULFUR : 112 0 C

Flash point of sulfur : 2050 C

Molecular weight of sulfur : 32

Molecular weight of H2SO4 : 98

2.1 LEAD CHAMBER PROCESS:

2.2 CONTACT PROCESS:

susceptibility to poisoning, it has been largely replaced by vanadiumpentaoxide. The vannadium

2.3 ADVANTAGES OF THE V2O5 CATALYST

2.4 DISADVANTAGES OF V2O5 CATALYST:

2. Requries larger converters and thus higher initial investment

In contact process the overall coversion is 98.5% thereby reduced emissions of

2.5 SELECTION OF METHODS :

2.6 CONTACT PROCESS

b. Catalytic oxidation of sulphur dioxide to sulphur trioxide

SO2 + 1/2O2 SO3

H2O + SO3 H2SO4

3.1 Sulphur handling

3.2 Sulphur melting

3.3 Sulphur combustion

3.5 First stage

3.6 Second stage

3.7 Acid system

3.8 Waste heat recovery

3.9 Acid production

4.1 REACTION INVOLVED

SO3 + H2O H2SO4

BASIS: 175 TPD of 98.5% sulfuric acid.

No of moles of H2SO4 in 175 T = 175 × 1000/24

Theoretical sulphur required:

One mole sulphur produces one mole H2SO4

Theoretical O2 = 74.404 kmol/hr

% excess air = 95%

O2 supplied by air = theoretical O2 ( 1 + % excess/100)

N2 in supplied by air = 545.806 kmol/h

4.2 EQUIPMENT : AIR BLOWER

Inlet to air blower

Mass flow rate of air from blower = 20839.7 kg/hr

Molar flow rate of air from blower = 718.610 kg/hr

Molar flow rate of water in inlet air =27.88 kmol/hr

Molar flow rate of N2 in inlet air = 545.806 kmol/hr