Material Balance

Assumptions

1) Complete burning of S in the burner.

2) 99.8% conversion of SO2 to SO3 in the reactor.
3) Overall absorption of SO3 in the process 100%.
4) 40% excess oxygen is provided.
5) Humidity of entering air is 70% at 30°C.

Basis: 10 k mol/hr of elemental Sulphur.

Assuming 100% conversion of Sulphur to SO2

S + O2 SO2

1
SO2 + O2 SO3
2

Total SO2 provided = 10 k mol

Total O2 required = 15 k mol

Some Oxygen must be taken in excess:

Assuming 40% Excess O2,

Total O2 required= 15x 1.4 = 21 k mol

Dry air coming in = (21 x 100)/21 = 100 k mol = 2900kg(molar mass of air = 29)

Assuming, at 25oC and 70% relative humidity from psychometric chart = 0.0189kg water/kg dry
air

Therefore, water entering with dry air = 0.0189 x 2900 = 54.81kg = 3.045 k mol

Total wet air entering = 3.045 + 100 = 103.045 =103.045 k mol

6.1: Drying Tower:

Q (Dry air) 100 k mol

R (98%H2SO4 for
Dryer)

P (wet Air)

103.045 k mol

S (Wet 97%H2SO4 after absorbing moisture)

Fig: 1.1 Drying Tower

Assumption:-

1) All the water vapour is completely removed from wet air.

2) The concentration of 98% recycled acid decreases to 97%.

Calculation:

Overall material balance:

P + R= Q + S

As water is being removed from the incoming air to make it dry, the 98% acid being recycled
decreases in concentration to say 97%

Making a balance for H2O:

 548.1 + 0.02R= 0.03S

0.02R–0.03S = - 54.81 --------------------- (1)

Making a balance for H2SO4,

0.98R = 0.97S

0.98R-0.97S=0 ---------------------- (2)

Solving (1) & (2) we get R=5316.57 Kg S=5371.38 Kg

Materials In Materials Out

K mol % K mol %
Component Kg Component Kg
Wet Air 103.045 Dry Air 100
Dry 53.1657+5.9073 2954.81 Wet 531.657+89.523 2900
H2SO4 H2SO4
5316.57 5371.38
Total 162,1 Total 162.18
8271.38 8271.38

Table: 1.1 Material Balance of Drying Tower

1.2 Sulphur Burner

Sulphur (10 K mol)

Dry Air (100 k mol) SO2

 Fig: 1.2 Sulphur Burner

The Combustion takes place inside the burner where Sulphur is oxidized to Sulphur Dioxide

Moles of Sulphur coming in = 10 k mol = 320 kg

Moles of O2 coming in = 21 k mol = 672 kg

Assuming 100% conversion of Sulphur (S) to (SO2)

S + O2 SO2

SO2 formed= 10 k mol = 640 Kg

O2 leaving = 21-10=11 k mol = 352 kg

N2 coming in and going out (unchanged) = (79 x 21)/21 = 79 K mol = 2212 kg

Materials In Materials Out

K Kg Component K mol Kg
Component mol
S 100 320 SO2 10 640
O2 210 672 O2 11 352
N2 79 2212 N2 79 2212
Total 110 3204 Total 100 3204

Table: 1.2 Material Balance of Sulphur Burner

1.3: Monsanto four stage Reactor

Outlet1

Inlet 2

Outlet 2

Inlet 3

Outlet 3

Inlet 4

Outlet 4

Fig: 1.3 Monsanto Four Stage Reactor

As cited in the reference by author Norman Shreve the conversion in each stage of Monsanto
converter is given as follows:-
Stage % conversion
1 74.0
 2 18.4
3 4.3
4 3.1
Overall conversion 99.8

Table: 6.3.1 Conversion in the reactor (4 stage catalytic converter).

Conversion of SO2 to SO3 takes place according to following reaction.

SO2 + 1/2 O2 SO3

In The First Bed Of Catalyst 74% Conversion Is Attained:

SO3 formed = 0.74 x 10 =7.4 k mol.

SO2 remained = 10 – 7.4 = 2.6 k mol.
O2 remained =11 – (1/2 x 7.4) = 7.3 k mol
N2 remained = 79 K mol.
Materials In Materials Out
Component K mol Kg Component K mol Kg
SO3 7.4 592
SO2 10 640 SO2 2.6 166.4
O2 11 352 O2 7.3 233.6
N2 79 2212 N2 79 2212
Total 100 3204 Total 96.3 3204

Table: 1.3.2 Material Balance for 1st bed in the reactor.

In The Second Bed of Catalyst 18.4% Conversions Attained:-

SO3 formed = 0.184 x 10 = 1.84 K mol.

SO2 remained = 2.6 – (0.184 x 10) =.76 k mol.

O2 remained = 7.3 – (0.184x100/2) = 6.38 K mol.

N2 remained = 79 K mol.

Materials In Materials Out

K Kg % Component K Kg %
Component mol mol
SO3 7.4 592 SO3 9.24 739.2
SO2 2.6 166.4 SO2 0.76 48.64
O2 7.3 233.6 O2 6.38 204.16
N2 79 2212 N2 79 2212
Total 3204 Total 3204
96.3 95.38

Table: 1.3.3 Material Balance for 2nd bed in the reactor.

In The Third Bed of Catalyst 4.3% Conversion Is Attained:-

SO3 formed = 0.43 x 10= .43 K mol.

SO2 remained =.76 – (0.43 x 10 ) = .33 K mol.

O2 remained = 6.38 – (0.43 x 10) =6.165 K mol.

N2 remained = 79 K mol.

Materials In Materials Out

K mol Kg % K mol Kg %
Component Component
 SO3 .76 48.64 SO3 9.67 773.6
SO2 9.24 739.2 SO2 .33 21.12
O2 6.38 204.16 O2 6.165 197.28
N2 79 2212 N2 79 2212
Total 3204 Total 3204
95.38 95.165

Table: 1.3.4 Material Balance for 3rd bed in the reactor.

1.4 First Absorber:-

(SO3=4.0458k mol
SO2=.33k mol
O2=6.165k mol
N2=79k mol)

98% H2SO4

Inlet from 3rd stage converter

(SO3=9.67k mol
SO2= .33k mol
100% H2SO4
O2 =6.165k mol
N2=79k mol
Fig:1.4 First Acid Absorber

After the passage through the 1st stage or after the 1st contact, the gases are let in the 1st absorber
where the absorption of SO3 takes place. After that the gases are returned back to the 4th stage of
the converter for 2nd contact:-
According to the reaction
1
SO2 + 2 O2 ⇌ SO3
(PSO3 )
Kp = ⁄ (PSO )(PO )2
2 2

Rewriting the expression for Kp in terms of mole Fractions and total pressure for the equation-

2SO2 + O2 2SO3, we get

N x n2 SO3
Kp =
n2 SO3 x nO2 x P
Where,
n = Number of moles of each component.
N= Total moles.
P = total pressure.
By rearranging, we get.
n2 SO2 x nO2 x Kp x P
n2SO3 =
N
Assumptions:-
After absorption the remaining gases enters the fourth stage at 427°C, Kp =257 is taken from
Dryden.
.332 x 6.165 x 257 x 1
n2SO3 =
.33+6.165+nSO3
3
⟹n SO3 + 6.495 n2SO3 = .332 x 6.165 x 257
⇒ n2SO3 = 4.0458

∴ 4.0458 of SO3 came out unreacted from the 1st absorber and amount of SO3 i.e. absorbed.

= 9.67 – 4.0458
= 5.6242 x 80 k mol.
= 449.936 kg.
SO3 absorbed by 98% H2SO4 (H2O + SO3 ⟶ H2SO4)
Let ‘W’ be the weight of 98% H2SO4 used in the absorption tower.

W x 0.02
SO3 absorbed by acid = ( ) x 80 kg.
18
=0.0889 W kg.

Total weight of 100% acid formed = W + 0.0889 W = 1.0889 W kg.

Kg. of SO3 absorbed by W kg = 1.0889 W – W

= 0.0889 W
But, we know
0.0889 W = 449.936
⇒ W = 5061.147357 kg.
∴ Weight of 100% acid = 1.0889 w =5511.083357.

Materials In Materials Out

K mol Kg % K Kg %
Component Component mol
SO3 9.67 773.6 SO3 4.0458 323.664
SO2 .33 21.12 SO2 .33 21.12
O2 61.65 197.28 O2 6.165 197.28
N2 79 2212 N2 79 2212

98% (50.61147357+ 100% 56.2355 5511.083357

H2SO4 5.62497063) 5061.147357 H2SO4
=56.23497063
Total 151.3999706 8265.147357 Total 1457.76 8265.14735

Table: 1.4 Material Balance for 1st absorber

1.5 Second Contact:

Fourth Stage Reactor:-

In the 4th stage (2nd contact) 99.8% conversion of SO2 to SO3 is completed.

Inlet

(SO3 = 4.0458 K mol

(SO3 = 4.3558 K mol Outlet SO2 = .33 K mol

SO2 = 0.02 K mol O2 = 6.165 K mol

O2 = 6.01 K mol N2 =79 K mol)

N2 = 79 K mol)

Fig: 1.5 4th stage reactor

SO2 left = .33 – 10 x 0.031 = 0.02

3.1
SO3 formed = x 10 = .31
100

SO3 in the outlet = 4.0458 + .31 = 4.3558 K mol.

O2 used = 6.165 – (0.5 x .31) = 6.01 K mol.

Materials In Materials Out

Component K mol Kg Component K mol Kg
 SO3 4.0458 323.664 SO3 4.3558 348.464
SO2 .352 21.12 SO2 0.02 1.28
O2 6.165 197.28 O2 6.01 192.32
N2 79 2212 N2 79 2212
Total 89.5628 2754.064 Total 893.858 2754.064

Table: 1.5 Material Balance for 4th stage in the reactor.

1.6 Final Absorber: - (the gases after 2nd contact enters the final absorber where complete
absorption of SO3 takes place)

Exit Gases

98 % recycle H2SO4

(SO3 = 348.464 kg

SO2 = 1.28 kg

O2 = 192.32 kg

N2 = 2212 kg ) 100% H2SO4

Fig: 1.6 Final Absorber

Amount of SO3 to be absorbed = 348.464 kg

Let, ‘W’ be the kg of 98% H2SO4 used.

0.02 x W
SO3 absorbed = ( ) x 80 = 0.0889 W
18
Amount of 100% H2SO4 formed = W + 0.0889W

= 1.0889 W

Since, 0.0889 W = 348.464

⇒ W = 3919.730034 kg.

∴ Amount of 100% H2SO4 = 1.0889 x 3919.730034 = 4268.194034 kg

Materials In Materials Out

K mol Kg K mol Kg
Component Component
SO3 4.3558 348.464 SO3 0 0
SO2 0.02 1.28 SO2 0.02 1.28
O2 6.038125 192.32 O2 6.038125 192.32
N2 79 2212 N2 79 2212
98% (39.19730034+ 100% 43.55300035 4268.194034
H2SO4 4.355255593) 3919.730034 H2SO4
= 43.55255595
Total 132.9664809 6673.794034 Total 128.6111253 6673.794034

Table: 1.6 Material balance for Final Absorber.

1.7 Final Circulation Tank: - from the final absorber acid moves on to the circulating tank.

100 % H2SO4 98% H2SO4

A2 R2
 TT

98% H2SO4 P W2 make up water

(Dilution water)

Fig: 1.7 Final Circulation Tank

Overall material balance: -
A2 + W2 = P + R2
⇒ W2 – P = A2 – R2
⇒ W2 – P = 4268.194034 – 3919.730034
⇒ W2 – P = 348.4 64 kg

Amount of H2SO4 required for dilution of 100 % H2SO4 (4268.194034 kg) to H2SO4.
2
= 4268.194034 x
98
= 87.10600069 kg.
∴ W2 = 87.10600069 kg
A2 + W2 = P + R2
⇒ 4268.194034 + 87.10600069 = P + 3919.730034
⇒ P = 435.5700007
Materials In Materials Out
K mol Kg % K mol Kg %
Component Component
100% acid 43.55300035 4268.194034 98% 43.55255593 3919.7.30034
H2SO4
Water 4.839222261 87.10600069 recycle
98%
H2SO4 4.839666174 435.5700007
to tank
Total 48.39222576 4355.300035 Total 48.3922226 4355.300035
 Table: 1.7 Material Balance for Final Circulation tank

1.8 Interpass Tank: - (Acid from the inter pass absorber enters the inter pass circulating tank.)

100% H2SO4 from 1st 98% recycle to 1st absorber

Absorber A1 = 5511.083357kg R1 =5061.147357kg
To product stream
P W1 make up water
(Dilution H2O)
to drying tower
R = 5316.57kg

97% H2SO4 from drying 98% H2SO4 from

Tower, S =5371.38 kg tank 2, T = 435.5700007kg

Fig: 1.8 Interpass Tank

Overall material balance: -
W1 + T + A1 +S = P + R + R1
⇒ W1 + 435.5700007 + 5511.083357 + 5371.38 = P + 5316.57 + 5061.147357
⇒ P – W1 = 940.3160007
Water balance: -
W1 +435.5700007 x 0.02+5371.38x0.03 =P x 0.02 + 5316.57 x 0.02 + 0.02 x 5061.147357
⇒ W1 + 169.8528 = P x 0.02 + 207.5543471
⇒ W1 – P x 0.02 = 37.7015471

Solving, P = 997.9770896 kg, W1 = 57.66108889 kg

Materials In Materials Out

Component K mol Kg % Component K mol kg %
100% 56.23554446 5511.083357 98% 56.23497063 5061.147357
H2SO4 H2SO4 to
(tank 1) recycle
Make-up 3.203393382 57.66108889 98% 59.073 5316.57
H2 O H2SO4 to
drying
tower
97% 62.118 5371.38 98% 11.08863433 997.9770896
H2SO4 H2SO4 to
from product
drying
tower
98% 48.39666674 5355.700007
H2SO4
from tank
2
Total 126.396605 11375.69445 Total 126.396605 11375.69445

Table: 1.8 Material Balance for Interpass Tank.

1.9 Overall Plant Material Balance: -

Sulphur 98% H2SO4

O2 N2
H2SO4 plant
N2 O2
 H2O SO2

Fig: 1.9 Overall plant Material Balance

Materials In Materials Out

Component K mol Kg % Component K mol kg %
Sulphur 10 320 98% 11.08863433 997.977089
O2 21 672 H2SO4
N2 79 2212 N2 79 2212
H2 O 11.08761609 199.57708958 O2 6.038125 192.32
SO2 0.02 1.28
Total 121.0876161 340.357709 Total 96.14675933 3403.57709

Table: 1.9 Overall Plant Material Balance

Energy Balance

Basis: 1 hour operation

In carrying out the energy balance, these following assumptions have been made:

a) There is no energy loss from the equipments by radiation.

b) There is no accumulation of heat.
c) All the process equipments are under atmospheric pressure.
 d) Datum temperature is 25oC.
e) Water for cooling is available at 20oC.

Chemical Data: (Ambient temperature 25oC)

Specific heats: (KJ/Kmol°K) (valid in range 250K to 500K)

Heat capacities of gases at constant pressure

Cp = a + bT + cT2 + ….

N2 = 27.034 + (5.815×10-3) T – (0.2889×10-6) T2 ------------------------1.1-1

O2 = 25.611 + (13.260×10-3) T – (4.2077×10-6) T2 -----------------------1.1.2

SO2 = 29.077 + (41.910×10-3) T – (15.8847×10-6) T2 --------------------1.1.3

SO3 = 31.208 + (80.093×10-3) T – (27.7501×10-6) T2 ---------------------6.1.4

(Ref. Narayanan K.V, Lakshmikutty B, Stoichiometry and Process Calculations )

S = 3.63 + (0.00640T)(Kcal/kmol°K) ---------------------------------------6.1.5

100% H2SO4 =1.4435 KJ/kg K

98% H2SO4 = 1.465 KJ/ kg K

97% H2SO4 = 1.4865 KJ/ kg K

H2O = 4.187 KJ / kg K

Heat of Combustion of Sulphur = - 296.77 KJ/kmol

Heat of reaction for [SO2 + ½ O2 SO3] = ∆ Hr = 96.270 KJ/gmol

Heat of dilution = 9.304 KJ/kg of H2O

Heat of vaporization of water at 25oC = 2430.96 KJ/kg (Ref. Perry R.H, Green D.W ,Chemical
Engineer’s Hand book)
2.1: Drying Tower:

Q (Dry air) (O2 + N2)

Mesh pad

R (98%H2SO4)

P (wet Air)

S (97% H2SO4)

Figure 2.1: Drying Tower

The input streams are at a temperature of 30oC (303K)

Cp O2 = 29.242 KJ/ kmol K Cp N2 = 28.769 KJ/ kmol K

Cp H2O = 4.187 KJ/ Kg K Cp 98% H2SO4 = 1.465 KJ/ Kg K

Cp 97% H2SO4= 1.4865 KJ/ Kg K Heat of dilution= 9.304 KJ/Kg

Now, Heat input

= mo2 Cp O2 ∆T + mN2 Cp N2 ∆T + mH2O Cp H2O ∆T + mH2SO4 Cp H2SO4 ∆T
= 87.675×29.242× (30-25) + 329.825×28.769× (30-25) + 228.83175×4.187× (30-25) +
(22196.67975×1.415× (30-25))

=227643.9107 KJ

Heat Generation (due to dilution) = 228.83175×9.304 = 2129.050602 KJ

Heat Output (neglecting changes in Cp values at output temperature To

= mo2 Cp O2 ∆T + mN2 Cp N2 ∆T + mH2SO4 Cp H2SO4 ∆T

= (87.675×29.242 × (To-25)) + (329.825×28.769 × (To-25)) + (22425.5115×1.4865 × (To-25))

= 45388.05062 × (To-25)

Assuming steady state and no heat loss:

The heat balance equation is given as

Input + Generation = Output

227643.9107 + 2129.050602 = 45388.05062 × (To-25)

Solving,

229772.9613
To = + 25 = 30.0624oC
45388.5062

TABLE N0 2.1

ENERGY IN ENERGY OUT

( Input + Generation )
Component Enthalpy Component Enthalpy
KJ KJ
O2 12818.96175 O2 12978.94239
N2 47443.67713 N2 48035.77422
H2 O 4790.59269 97% H2SO4 168757.7511
Heat of 2129.050602
Dilution
98% H2SO4 162590.6792

Total 29772.9613 Total 229772.4677

2.2: AIR PREHEATER

Hot gases at a temperature of 1127oC come from the Sulphur furnace. Air from the dryer is
heated to 120oC before it enters the burner in a Preheater.

Air from dryer at 3.00624oC to WHB 1

 Air to burner at 120oC hot gases from burner at 1127oC

Figure 2.2: Air preheater

Cp of components of air at 120oC (393K)

N2 = 28.16 KJ/ kmol K O2 = 29.97 KJ/ kmol K

Enthalpy input of the air = 610147.1661 KJ

Output Enthalpy = mo2 Cp O2 ∆T + mN2 Cp N2 ∆T

= 87.675×29.97× (120-25) + 329.825×28.16× (120-25) = 4285860.863KJ

Cp of Hot gas components of air at 1127oC (1273K)

N2 = 32.97 KJ/ kmol K O2 = 35.67 KJ/ kmol K SO2 =56.69 KJ/ kmol K

Input Enthalpy of the hot gases mo2 Cp O2 ∆T + mN2 Cp N2 ∆T + m SO2 Cp SO2∆T

=45.925 ×35.67×(1127-25) + 329.825×33.97×(1127-25) + 41.75×56.69 ×(1127-25) =
148288798.16KJ

Assuming no heat loss,

Heat gained by the cold air stream = 4285860.863 – 610147.1661 = 3675713.697KJ

 (Heat lost by hot gas steam)

Output Enthalpy of the Hot gas stream =1482887968.16 – 3675713.697 = 144612388.9 KJ

The heat lost is negligible compared to the heat input and Input, output Enthalpy are comparable.

Therefore, we neglect the change in Cp due to drop in temperature,

Heat output =41.75 ×56.69×(T0-25) + 45.923×35.67×(T0-25) + 329.825×33.97 ×(T0-25)

= 152090.3616(T0-25)

Making heat balance,

144612388.9 = 152090.3616 (T0-25)

144612388.9
To = 152090.3616 + 25 = 975.832oC

Energy In Energy Out

Component Enthalpy KJ Component Enthalpy KJ
Air Input 610147.1661 Air output 4285860.863
Hot gas input 148288102.6 Hot gas output 144612388.9
Total 148898249.8 Total 148898249.8

Table 8.2
2.3: Sulphur-Melter

Solid Sulphur at 30oC Molten Sulphur at

Heat from fuel

Figure 2.3: Sulphur Heater

Cp of sulphur at 30oC = 23.32 KJ/ Kmol K

Cp of sulphur at 140oC = 26.26 KJ/ Kmol K

Enthalpy input of Sulphur = mS CpS ∆T = 41.75 ×23.32 × (30-25) = 48680.5 KJ

Enthalpy output of Sulphur = mS CpS ∆T = 41.75 ×26.26 × (140-25) = 1260808.25KJ

Therefore, heat supplied by heater = 126080.825- 4868.05 = 121212.775KJ

TABLE No. 2.3

ENERGY IN ENERGY OUT

( Input + Generation )
Component Enthalpy Component Enthalpy KJ
KJ
Sulphur 4868.05 Sulphur 126080.825
Heat 121212.775
supplied
Total 126080.825 Total 126080.825

2.4: Sulphur Burner

Sulphur at 140oC
SO2 O2 N2 at 1127oC

O2 N2 at 120oC

Heat from oil fired burner

 Fig 2.4: Sulphur Burner

S + O2 SO2 ∆ H= -70.9 Kcal/Kmol = -296.77 KJ/ kmol ----------------6.4.1

Standard heat of combustion = 296.77 KJ/ kmol
The heat of reaction at any temperature is given by (Narayanan and Lakshmikutty,
2005).
∆ HT0 = ∆ H’ + ∆ α T + ∆ (β/2) T2 + ∆(δ/3) T3 -------------------- 6.4.2
Where ∆ α, ∆ β , ∆δ are difference in coefficients of the Cp equation of the product and
the reactants
∆ H’ is evaluated from the heat of a single reaction
The specific heat of the components are represented by Cp = α + βT + δT2 ----- 6.4.3

TABLE No. 2.4.1

Component Α Β Δ
SO2 29.077 41.910 × 10-3 -15.8847 × 10-6
O2 25.611 13.260 × 10-3 -4.2077 × 10-6
S 15.19 0.02619 0

∆ α = α SO2 - α S- α O2
= 29.077 –25.611–15.19 = –11.724

∆ β = β SO2– β s- β O2
= 41.910× 10-3 - 0.02679-13.260× 10-3 = 1.86× 10-3
∆ δ = δ SO2 - δ S - δ O2
= (-15.8847) × 10-6 – 0 – (-4.2077 × 10-6) = -11.677 × 10-6
∆ HT0 = ∆ H’ -11.724T + ∆ (1.86× 10-3/2) T2 + ∆(-11.677 × 10-6/3) T3

At 298K, ∆ H2980 = -296.77 KJ/Kmol K

So, putting this in above equation and solving for ∆ H’
 ∆ H’ = -296770 –11.724 ×298 + ∆ (1.86 × 10-3/2) (298)2 – ∆(-11.677 × 10-6/3) (298)3
∆ H’ = – 300284.1694

Now, ∆ HT0 = -300284.1694 -11.724 T + ∆ (1.86 × 10-3/2) T2 + ∆(-11.677 × 10-6/3) T3

At T = 120OC = 393K,
∆ H9730 = -300284.1694 -11.724 (1400) + ∆ (1.86 × 10-3/2) (1400)2 + ∆(-11.677 × 10-6/3)
(1400)3
∆ H973 = -325.555.5321KJ/ kmol

Temperature inside the burner 1127oC, (Anderson and Wenzel, 1961)

We assume the output gas from burner to be 1127oC
Input enthalpy of air (N2 + O2) = 4285860.863 KJ
Enthalpy input of Sulphur = m Cp ∆T = 41.75 ×26.26 × (140-25) = 126080.825KJ

Heat generated due to combustion = 325.555.532 × 41.75 = 13591.26925 KJ

Heat output from burner = 41.75 ×56.69× (1127-25) + 45.925×35.67× (1127-25) +

329.825×32.97 ×(1127-25)

= 27461093.4KJ

Heat given/ generated by the burner = 27461093.4 – 4285860.863 – 126080.825 – 13531.26925

= 23035620.43 KJ

TABLE No. 2.4.2

ENERGY IN ENERGY OUT

( Input + Generation )
Component Enthalpy Component Enthalpy KJ
KJ
O2 919666.9125 O2 7508114.173
N2 3366193.95 N2 1561970.23
S 126080.825 SO2 2307637.313
Generation 13531.2925
Burner 23035620.3
Total 27461093.1 Total 11377721.72

2.5: Waste Heat Boiler 1 (WHB1)

SO2 SO2
O2 N2
N2 O2 (at 410oC)
(At 9750C)
Fig 2.5: Waste Heat Boiler

From literature (Shreve, Dryden), we know the entry point temperature to the four stages
of reactor,
1st Stage=4100C
2nd Stage=4380C
3rd Stage = 4320C
 4th Stage = 4270C
WHB1 is just before the first stage entry point. So it must absorb heat to reduce the
temperature of gases from 975.8320C to 4100C

Therefore, Cp of the component at

TABLE No. 2.5.1
Component At Input (11020C) (KJ/Kmol At Output (4100C)
K) (KJ/Kmol K)
O2 35.669 32.70
N2 33.969 30.87
SO2 56.689 50.291

Heat input = mo2 Cp O2 ∆T + mN2 Cp N2 ∆T + mso2 Cp so2 ∆T

= (45.925×35.669× (975.832-25)) +(329.825×33.969×(975.832-25)) +
(41.75×56.689×(975.832-25))
=14461308.45KJ

Heat output = mo2 Cp O2 ∆T + mN2 Cp N2 ∆T + mso2 Cp so2 ∆T

= (45.925×32.7×(410-25)) + (329.825×30.87×(410-25)) +(41.75×50.291×(410-25))
= 5306491.383 KJ
Steam is generated at 4 Kgf/cm2 and 300oC.

Heat absorbed in generating steam = 14461308.8 – 5306491.383 = 9154474.797 KJ

Saturation temperature at 4Kgf / cm2(3.92 bar) = 142.89oC
Latent heat, λs = 2135.14 KJ/Kg
Cp of steam at 300oC = 1.9703 KJ/KgoK
Cp of water = 4.187KJ/KgoK
Let, amount of water = m = amount of steam.
Q = m Cp w ΔT1 + m λs + m Cp s ΔT2
 91125465.25 = m (2917.364)
 91125465.25
 Steam generated = = 31235. 546 kg
2917.364

TABLE NO. 2.5.2

ENERGY IN ENERGY OUT

( Input + Generation )
Component Enthalpy Component Enthalpy
KJ KJ
O2 1557556.782 O2 57817.27875
N2 2250396.612 N2 391995.3634
SO2 10652955.74 SO2 80836.49613
Heat -9154474.797
absorbed
Total 5306491.383 Total 5306491.383
.

2.6: Reactor

Reaction
SO2 +1/2O2 SO3 ∆ Hr = ΔHof – ΔHoreactant
= -395.18 – (-296.90)
= -98280 J/gmol
= 96270 KJ/kmol-------6.6.1

The heat of reaction at any temperature is given by ( Narayanan and Lakshmikutty, 2005)

∆ HT0 = ∆ H’ + ∆ α T + ∆ (β/2) T2 + ∆(δ/3) T3 ----------------------6.6.2

 TABLE NO. 2.6.1
Component Α Β Δ
SO2 29.077 41.910 × 10-3 -15.8847 × 10-6
O2 25.611 13.260 × 10-3 -4.2077 × 10-6
SO3 31.208 80.093 × 10-3 -27.7501 × 10-6

∆ α = α SO3 - 1/2 α O2 - α SO2

= 31.208 – ½ (25.611) -29.077 = -10.6745

∆ β = β SO3 - 1/2β O2 - βSO2

= (80.093-1/2(13.260)-41.910) × 10-3 = 31.553 × 10-3

∆ δ = δ SO3 - 1/2 δ O2 - δ SO2

= [(-27.7501)-1/2(-4.2077)-(-15.8847)] × 10-6 = -9.76155 × 10-6

∆ HT0 = ∆ H’ -10.6745 T + ∆ (31.553 × 10-3/2) T2 + ∆(-9.76155× 10-6/3) T3 -----6.6.3

At 298K, ∆ H2980 = -98. 280 KJ/gmol

At T= 683K,
∆ HT0 = -9641.907 -10.6745(683) + ∆ (31.553 × 10-3/2) (683)2 + ∆(-9.76155× 10-6/3) (683)3
∆ H683 = -97381.74 J/gmol

Similarly,
∆ H7110 =-97197.64 KJ/ kmol
∆ H7050 =-97238.27 KJ/ kmol
∆ H7000 = -97271.64 KJ/ kmol
Reactor
2.6.a: Stage 1

SO2 N2 O2
at 4100C

SO2
O2
SO3
N2 at 6010C
Figure 2.6.a: Reactor stage1

Therefore, Heat input (at Cp values of T = 410OC)

= mo2 Cp O2 ∆T + mN2 Cp N2 ∆T + mso2 Cp so2 ∆T
= (41.75×50.291× (410-25)) + (45.925×32.7×(410-25)) + (329.825×30.87×(410-25))
 = 5306491.383 KJ

Heat of generation = 30.895×97381.74 = 3008608.857 KJ

Since the heat generated is not within considerable limits but we can’t neglect the change
in Cp values due to rise in temperature to T0 in comparison to heat input.. So we consider Cp
value at 600OC (873K).

Heat output = mo2 Cp O2 ∆T + mN2 Cp N2 ∆T + mso2 Cp so2 ∆T+ mso3 Cp so3 ∆T

=10.855×53.55×(T0 –25)+25.4775×33.98×(T0 –25)+329.825×31.89×(T0 –
25)+25.895×79.98×(T0 – 25) = 146060.1205(T0 – 25)

Therefore, making a steady state heat balance with no loss,

Input + Generation = Output

5306491.383 + 3008608.857 = 146060.1205(T0 – 25)

883151002.4
To = + 25 = 594.29oC (which is comparable to assumed
146060.1205
temperature)
TABLE NO. 2.6

ENERGY IN ENERGY OUT

( Input + Generation )
Component Enthalpy Component Enthalpy
KJ KJ
O2 808364.9613 O2 589571.2124
N2 3919953.634 N2 5987860.108
SO2 578172.7875 SO2 330919.88
Heat of 3008608.857 SO3 1406705.4
Generation
Total 8315100.24 Total 8315100.418
 2.7: Waste Heat Boiler 2 (Whb2)

The gas excluding from the first stage reactor at 590.4OC (863.4 K) is cooled to 438
O
C (711K) before it enters the 2nd Stage in the Waste heat Boiler 2 (WHB2)

SO2 SO2
O2 N2
N2 O2
SO3 at 594.2930C SO3 at 4380C

Figure 6.7: Waste Heat Balance

Cp values (KJ/Kmol K) at:
Table No 2.7.1
Component At Input (594.2930C) At Output (4380C)
(KJ/Kmol K) (KJ/Kmol K)
O2 33.98 32.90
N2 31.89 31.02
SO2 53.55 50.88
SO3 79.98 74.11

Heat input
= mo2 Cp O2 ∆T + mN2 Cp N2 ∆T + mso2 Cp so2 ∆T+ mso3 Cp so3 ∆T
= (30.4775×33.98× (594.293-25)) + (10.855×53.55× (594.273-25)) +
(329.825×31.89×(594.293-25))
+ (30.895×79.98× (594.293-25))
= 8315100.418 KJ
 Heat output = mo2 Cp O2 ∆T + mN2 Cp N2 ∆T + mso2 Cp so2 ∆T+ mso3 Cp so3 ∆T
= (30.4775×32.91× (438-25)) + (10.855×50.84× (438-25)) + (32.9825×31.02×
(438-25)) + (30.895×74.11× (438-25))
= 5813310.397KJ
Saturated steam is generated at 1.023 Kg/cm2 water at 30oC is available.
Saturation temperature = 100oC
Cp = 4.187 KJ/Kg K
λs = 7256.9 KJ/Kg
Heat absorbed = 8315100.418 KJ – 5813310.397 KJ = 2501790.021 KJ
Let, m = amount of water = amount of steam.
 2501715.876 = m Cpw (100-30) + m λs
2500439.913
Steam produced = = 1005.715 Kg
254.999
TABLE NO. 2.7
ENERGY IN ENERGY OUT
( Input + Generation )
Component Enthalpy Component Enthalpy KJ
KJ
O2 5987891.662 O2 414244.9988
N2 589574.3193 N2 4225473.83
SO2 330921.6238 SO2 227921.5666
SO3 1406712.813 SO3 945744.146
Heat
absorbed 2501715.876
Total 5813384.542 Total 5813384.542

2.6.b: Reactor
b) Stage 2 (Input temperature = 4380C,
Output temperature =T0)
SO2
O2
 N2
SO3 at 4380C

SO2
O2
N2
SO3 at 70
Figure 2.6.b: Reactor Stage 2

Heat input (711K) = mo2 Cp O2 ∆T + mN2 Cp N2 ∆T + mSO2 Cp SO2 ∆T+ mSO3 Cp SO3 ∆T
= (30.4775×32.91× (438-25)) + (10.855×50.84×(438-25)) +
(32.9825×31.02×(438-25)) + (30.895×74.12×(438-25))
= 5813384.542KJ
Heat generated = 7.682×97197.64 = 746672.2705 KJ

Assumption, the heat generated is within considerable limits compared to the heat input.
We can neglect the changes in Cp values to rise in temperature to T0
Heat output (at Cp for 711K) = mo2 Cp O2 ∆T + mN2 Cp N2 ∆T + mso2 Cp so2 ∆T+
mso3 Cp so3 ∆T
(3.173×50.84× (T0-25)) + (26.6365×32.91× (T0-25)) + (329.825×31.02× (T0-25))
+ (38.577×74.12× (T0-25))
= 14128.42128(T0-25) KJ

Therefore, making a steady state heat balance with no loss,

Input + Generation = Output

5813384.542 + 746672.27055= 14128.42128(T0 – 25)

 6560056.813
To = 14128.42128 + 25 = 489.316 oC

TABLE NO. 2.6.b

ENERGY IN ENERGY OUT
( Input + Generation )
Component Enthalpy Component Enthalpy
KJ KJ
O2 414244.9988 O2 1327631.387
N2 227921.5666 N2 4750496.626
SO2 4225473.83 SO2 74901.28412
SO3 945744.1462 SO3 407022.7556
Generation 746672.2705
Total 6560056.812 Total 6560052.053

2.6. C: Stage 3(Input temperature = 4320C,

Output temperature =T0)

SO2
O2
N2l
SO3 l at 4320C

SO2,O2 , N2 , SO3
 Fig No 2.6.c Reactor 3rd stage

Cp value at input temperature = 4320C Cp ( KJ/Kmol K)

SO2-50.73 O2- 32.86

N2-30.98 SO3- 73.70

Now, Heat Input = mo2 Cp O2 ∆T + mN2 Cp N2 ∆T + mso2 Cp SO2 ∆T+ mSO3 Cp SO3 ∆T
(26.6365×32.86× (432-25)) + (3.173×50.73×(432-25)) + (329.825×30.98×(432-25))
+ (38.577×73.7×(432-25))
= 5737619.448 KJ
Heat generated = 1.79525× 97238.27 = 174567.0042 KJ
Heat output (neglecting change in Cp) = mo2 Cp O2 ∆T + mN2 Cp N2 ∆T + mso2 Cp so2 ∆T+ mso3
Cp so3 ∆T
(1.37775×50.73× (T0-25)) + (25.738875×32.86× (T0-25)) + (329.825×30.98×
(T0-25)) + (40.37225×73.70× (T0-25))
= 14109.08602(T0-25) KJ
Therefore, making a steady state heat balance with no loss,
Input + Generation = Output

5737619.448 + 174567.0042 = 14109.08602(T0 – 25)

59121864.52
To = 141090.8602 + 25 = 444.033oC

TABLE No. 2.6.c

ENERGY IN ENERGY OUT
( Input + Generation )
Component Enthalpy Component Enthalpy
KJ KJ
 O2 356237.0837 O2 354409.4929
N2 4158717.25 N2 4281670.185
SO2 65573.28 SO2 29287.58137
SO3 1157151.834 SO3 1246805.381
Heat of 174567.0042
reaction

Total 5912186.452 Total 5912172.642

2.6.d: Stage 4 (inlet temperature = 4270C, output temp = T0)

SO2
O2
N2
SO3 at 4270C

SO2
O2
N2
SO3 at T0
Figure 2.6.d Reactor 4th stage
 Cp value at input temperature = 4270C Cp ( KJ/Kmol K)

SO2-50.63 O2- 32.83

N2-25.96 SO3- 73.67
Heat Input = mo2 Cp O2 ∆T + mN2 Cp N2 ∆T + mso2 Cp SO2 ∆T+ mso3 Cp SO3 ∆T
= (25.738875×32.83× (427-25)) + (1.37775×50.63× (427-25)) + (329.825×30.96× (427-25))
+ (16.891215×73.67× (427-25))
= 4972949.264KJ
Heat generated = 1.29425×97271.64 = 125893.8201 KJ
Heat output (neglecting change in Cp) = mo2 Cp O2 ∆T + mN2 Cp N2 ∆T + mSO2 Cp SO2 ∆T+
mso3 Cp SO3 ∆T
= (0.0835×50.63× (T0-25)) + (25.09175×32.83× (T0-25)) + (329.825×30.96× (T0-25))
+ (18.19425×73.67× (T0-25))
= 12379.09496(T0-25) KJ
Therefore, making a steady state heat balance with no loss,
Input + Generation = Output
4972949.264 + 125893.8201= 12379.09496 (T0 – 25)
50988430.84
To = 123790.9496 + 25 = 436.891oC= 437oC

TABLE No. 2.6d

ENERGY IN ENERGY
OUT
( Input + Generation )
Component Enthalpy Component Enthalpy
KJ KJ
O2 339692.921 O2 339300.2168
N2 4104975.564 N2 42005976.343
SO2 28041.70397 SO2 1741.312451
SO3 500499.246 SO3 551295.601
Generation 125893.8201
 Total 5098724.708 Total 5098837.802

2.8: Hot Interpass Exchanger (Heat Exchanger 1)

Hot (488.317oC) T c in
2nd stage outlet

432oC
3rd stage inlet

4th stage inlet (427oC)

Figure 2.8 Hot Inter pass exchanger

Hot fluid:
Outlet gas from the stage 2 of the reactor at 488.317oC which is cooled to a temperature of
432oC and fed into stage 3 inlet

So, Q h in = 65459377.62 KJ Q h out = 57376194.48KJ

Th in = 488.317oC Th out = 432oC

Cold Fluid:

Gas from the cold inter pass exchanger at Tc in which gets heated to 427oC before entering the 4th
stage inlet

Tc out = 427oC Q c out =49732094.35KJ

Assuming no heat loss, Heat absorbed by the cold stream:

Q h in – Q h out = 65600520.55 KJ - 57376194.48KJ = 8224326.07KJ

Q c in = Qc out – 8224326.07KJ = 41505166.57 KJ

So, the heat absorbed by the cold stream is not very high compared to the input and output
streams. Change in Cp at Tc in is neglected.

Q c in = (25.738875×32.83× (Tc in-25)) + (1.37775×50.63× (T c in-25)) + (329.825×30.96× ( T c in-

25)) + (16.891215×73.67× (T c in-25))
= 12370.52056 ( T c in – 25 ) = 4150516.657

41648911.21
Tc in = + 25 = 360.517oC
123711.6775

TABLE No. 2.8

ENERGY IN ENERGY OUT

Component Heat Component Heat KJ

 KJ
Hot input 6560052.055 Hot output 5737619.448

Cold input 4150516.657 Cold output 4972949.264

Total 10710568.71 Total 10710568.71

2.9: Cold Interpass Exchanger (Heat Exchanger 2)

Cold in

Hot (443.8oC) (1st absorber top at 90oC)

3rd stage outlet

Hot out (to secondary

Economizer)
Cold out (362oC)

Figure 2.9: Cold Interpass Exchanger

Hot fluid:
Outlet gas from the 3rd stage of the reactor at 444.033oC which is cooled to a certain temperature
before entering a secondary economizer.

So, Q h in = 59121303.15 KJ Th in = 443.033oC

Cold Fluid:

Gas from the top of first absorber column at 90oC (assumed) heated to a temperature of 362oC
which then enters the hot inter pass absorber

Tc in = 90oC T c out = 360.517oC Q c out =41505199.47 KJ

We assumed the cold inlet to be at 90oC (363K)

Cp value at input temperature = 900C Cp ( KJ/Kmol K)

SO2-42.19 O2- 29.86 N2-29.10 SO3- 56.62

Q c in = (25.738875×29.86× (90-25)) + (1.37775×42.19× (90-25)) + (329.825×29.10× (90-25))
+ (16.891215×56.62× (90-25)) = 739763.5813 KJ
Now, by assuming no heat loss,
Heat gained by cold stream =4150519.947 KJ –739763.5813 KJ = 3410756.366 KJ
= Heat lost by hot stream
Qh out =5912130.315 –3410756.366 = 2501373.949 KJ
Again Q h out (at Cp value for 3rd stage inlet) =
(40.37225×73.70× (T h out-25)) + (1.37775×50.73× (T h out-25)) + (329.825×30.96× (T h out-25))
+ (25.738875×32.86× (T h out-25)) = 141090.8602 × (T h out – 25)
14102.48952 (T h out – 25) = 2501373.949
25013739.49
To = 141024.8952 + 25 = 202.371oC

TABLE 2.9

ENERGY IN ENERGY OUT

Component Heat Component Heat KJ

 KJ
Hot input 5912130.315 Hot output 2501373.949

Cold input 739763.5813 Cold input 4150519.947

Total 6651893.896 Total 6651893.896

2.10: SECONDARY ECONOMIZER ( COOLER 1)

The hot gases for cold IP Exchanger is further cooled from 201oC to 110oC (assumed) at
which it enters the bottom of the first absorption tower.

Hot gases from cold IP exchanger at 202.371oC

At To = 110oC

Figure 2.10: - Secondary Economizer

Inlet gas temperature = 202.371oC (475.371K)

Outlet gas temperature = 110oC (383K)

Cp values (KJ/kmol K) at inlet and outlet:

TABLE NO. 2.10 a
Component At Input (2040C) (KJ/Kmol At Output (1100C)
K) (KJ/Kmol K)
O2 32.86 30.07
N2 30.96 29.21
SO2 50.73 42.79
SO3 73.70 57.81

Heat input = mo2 Cp O2 ∆T + mN2 Cp N2 ∆T + mso2 Cp so2 ∆T+ mso3 Cp so3 ∆T

(40.37225×73.70× (20.2371-25)) + (1.37775×50.73×(202.371-25)) +
(329.825×30.96×(202.371-25)) + (25.738875×32.86× (202.371-25))
= 2501372.668 KJ
Heat output = mo2 Cp O2 ∆T + mN2 Cp N2 ∆T + mso2 Cp so2 ∆T+ mso3 Cp so3 ∆T
(40.37225×57.81× (110-25)) + (1.377775×42.79×(110-25)) +
(329.825×29.21×(110-25)) + (25.738775×30.07× (110-25))
= 1088087.543KJ

Heat absorbed =2501372.668KJ – 1088087.543KJ = 1413285.125KJ

Let, water temperature increase from 30oC to 80oC
m Cp w (To - 30) = 1413285.125
 m × 4.187 (80 - 30) = 1413285.125
14132851.25
Steam produced = = 567.684kg
2430.96

TABLE NO.2.10
 ENERGY IN ENERGY OUT
( Input + Generation )
Component Enthalpy Component Enthalpy
KJ KJ
O2 150016.7437 O2 65787.27756
N2 1811203.037 N2 818906.0013
SO2 12397.03698 SO2 5011.083413
SO3 527755.8503 SO3 198383.1807
Heat 1237898.968
absorbed
Total 1088087.543 Total 1088087.543

2.11:
Intermediate Absorption Tower:
Q recycles at 30oC
SO3,O2 ,N2,SO3 at 900C

Q out – 7397959.127KJ

Q gen

SO2, O2 N2 SO3
Qin – 10880875.43KJ
110oC Q (100% H2SO4)

Fig 2.11: first absorption tower

SO3 + H2O H2SO4

He at of formation of H2SO4 = - 130000KJ/ kmol
Therefore,
Q heat gen = 23.481 ×(-13000) = -3052153.0 KJ

Q recycle = 21130.29022 ×1.465× (30-25) = 154779.3759 KJ

Q in = 1088087.543

Q(100% H2SO4) = 23008.77302 ×1.4435× (T0-25)

=33213.16385(T0 -25) KJ

Making a steady state heat balance around the absorption tower

 Q in + Q gen + Q recycle = Q out + Q 100% H2SO4

1088087.543 + 3052153.0 + 154779.3759 = 739763.5813+ 33213.16385(T0 -25)

 TO = 132.0436oC

TABLE NO.2.11

INPUT + GENERATION OUTPUT

Component Heat (KJ) Component Heat (KJ)
Q in 1088087.543 Q out 739763.5813
Q recycle 154779.3759
Q gen 3052153.0 Q (100% H2SO4) 3555256.626

Total 4295019.719 Total 4295020.208

2.12: Economizer

Outlet from the fourth stage of the reactor at 436.891oC is fed into the economizer super heater
which cools it to 110oC, then it enters the bottom of the final absorbing tower.

SO2 , O2, N2, SO3 at 436.891o C

Steam at 100oC At 300oC

At 110oC

Figure 2.12:- Economizer

Q in = 50988378.02KJ (from 4th stage outlet)

Cp value at outlet temperature = 1100C Cp (KJ/Kmol K)

SO2-42.79 O2- 30.07

N2-28.21 SO3- 57.81
 Q out = mo2 Cp O2 ∆T + mN2 Cp N2 ∆T + mso2 Cp so2 ∆T+ mso3 Cp so3 ∆T
= 18.185465×57.81× (110-25) + 0.0835×42.79×(110-25)+25.09175×30.07×(110-25)
+329.825×29.21× (110-25) = 972703.6089 KJ

Heat absorbed =5096715.088KJ – 972703.6089KJ = 4126134.193 KJ

 m × 1.9702 × (300-100) = 4126134.193

41261341.93
Steam produced=m = 394.04
= 10471.3587 kg

TABLE NO. 2.14

ENERGY IN ENERGY OUT

( Input + Generation )
Component Enthalpy KJ Component Enthalpy KJ
O2 339141.2307 O2 64133.25841
N2 4204005.547 N2 303.702025
SO2 1740.496523 SO2 818906.0013
SO3 551827.8119 SO3 818906.0013
Heat absorbed 4126134.193
Total 972703.609 Total 972703.609

2.15:
Final Absorption Tower:

SO2
O2 Q out at 90oC
N2

41750kg of 98% H2SO4

Q rec
Q gen

at 110oC

SO2
O2
N2
SO3

Q 100% H2SO4

H2S2O7 +97% H2SO4

Figure 2.15: FINAL ABSORPTION TOWER

Q in = 972703.6089 KJ

Q out = 0.0835×42.79× (90-25) +25.09175×29.86×(90-25) +329.825 ×28.99 × (90-25)

= 672793.5513 KJ

Q gen = 18.18319 × -130000 = 2363814.7 KJ

Q recycle = 16364.87289 × 1.465 × (30-25) = 119872.6939 KJ

Q 100% H2S04 17819.71009 ×1.4435 × (T0 -25) = 257227.5515 (T0 -25) KJ

Making a steady state heat balance around the absorption tower

 Q in + Q gen + Q recycle = Q out + Q 100% H2S04

 972703.6089 + 2363814.7 + 119872.6939 = 672793.5513 + 257227.5515 (T0 -25)

257227.5515 (T0 -25) = 2783597.452

27835974.52
To = 79163.91365 + 25 = 133.215 o C

TABLE NO.2.15

INPUT + GENERATION OUTPUT

Component Heat (KJ) Component Heat (KJ)
Q in 972703.6089 Q out 672793.5513
Q recycle 119872.6939
Q gen 2363814.7 Q 100% H2S04 2783597.844

3456391.003 3456391.396
2.16: FINAL CIRCULATING TANK

98% H2SO4 at T0

100%
H2SO4

Qin
Make up H2O at 133.215oC
at 30oC (Qw)

Figure 2.16: FINAL ABSORBER CIRCULATING TANK

Q in = 363.6675529 ×4.187 × (30 -25) = 7613.38022 KJ

Q w = 17819.71009 × 1.4435 × (133.215 -25) = 2783597.844 KJ

Q gen = heat of dilution =0.9304 × 3636.675= 3383.562912 KJ

Q out = 18183.37764 × 1.465× (T0-25) = 26638.64824(T0-25)

Making a steady state heat balance of the tank

Q in + Q w + Q gen = Q out

7613.38022+ 2783597.844+ 3383.562912 = 26638.64824 (T0-25)

 26638.64824 (T0-25) = 2794594.787
27945947.87
T0 = 266386.4824 + 25 = 129.9075 o C

TABLE NO 2.16

INPUT + GENERATION OUTPUT

Component Heat (KJ) Component Heat (KJ)
Q in 7613.38022 Q out 2794593.991
Qw 2783597.844
QD 3383.562912

2794594.787 2794593.991

2.13: ACID COOLER 1

Inlet acid temperature = 129.9075 o C

Outlet acid temperature = 30oC
Inlet water temperature = 20oC
Outlet water temperature =75oC
Assuming no heat loss, making a heat balance;
 16364.87289 × 1.465 × (129.9075 - 30) = m × 4.187 × (75 -20)
23952362.34
 m water = = 10401.18216 Kg
230.285

2.12: INTERPASS ABSORBER CIRCULATING TANK ( TANK 1)

100% H2SO4 at
132.04oC
 A1 R

P W1 at 30oC

T (129.907 oC )
S
30.0624

Figure 2.12: INTERPASS ABSORBER CIRCULATING TANK ( TANK 1)

Q in = 23008.77302 × 1.4435× (132.04 -25) = 3555137.059 KJ

Q w = 240.7350461 × 4.187× (30-25) = 5039.787225 KJ

Q gen = heat of dilution = .9304 × 2407.350461 = 2239.798868 KJ

98% H2SO4 = 1818.504753 × 1.465 × (129.9075 - 25) = 279485.0635

97% H2SO4 = 22425.5115 × 1.4865 × (30.0624 - 25) = 168757.7508

Q out = 47493.52432 × 1.465 × (T0-25) = 69578.01313 (T0-25)

Making a steady state heat balance of the tank

Q in + Q w + Q d = Q out

 3555137.059 + 5039.787225 + 2239.798868= 69578.01313 (T0-25)

 9228.948375(T0-25) = 408070.3265

 T0 = 82.6440 C

TABLE 2.12

INPUT + GENERATION OUTPUT

Component Heat (KJ) Component Heat (KJ)
Q in 3555137.059 Q out 4010775.862
Q WATER 5039.787225
98% H2SO4 279485.0635
97% H2SO4 168757.7508
Heat of generation 2239.798868
Total 4010779.028 Total 4010775.862
2.17: Acid Cooler 2

Inlet acid temperature = 82.6443oC

Outlet acid temperature = 30oC
Inlet water temperature = 20oC
Outlet water temperature =75oC (Assumed)

Q acid out = (47493.52432×1.465× (82.6443-30) = 3662885.797KJ

Assuming no heat loss, making a heat balance;

36628857.97
 m water = = 10401.13011kg
4.187(75−20)

Overall Heat Balance

ENERGY IN ENERGY OUT

( Input + Generation/ absorption )
Component Enthalpy Component Enthalpy KJ
KJ
Sulphur(S) 4868.05 98% H2SO4 30520.01
Oxygen (O2) 12818.962 from Tank 1
Nitrogen (N2) 47443.677
Water(H2O) 17443.761

Generation: Nitrogen (N2) 623864.0

Dryer 2129.0506
Melter 121212.78 Oxygen (O2) 48700.58
Burner 14260780.6
Fuel 13432.264 Sulphur
dioxide 228.986225
Reactor (SO2)
Stage 1 3008608.9
Stage2 746672.27
Stage3 174567.0
Stage4 125893.82

Absorber 1 3052153.0
Tank 1 2239.7989
Absorber 2 2363814.7
Tank2 3383.5629
Absorption

WHB1 -9154817.1
WHB2 -2501790.0
Eco1 -1413285.1
Eco2 -4126134.2
Cooler 1 -3662885.8
Cooler2 -2395236.2

Total 703313.755 Total 703313.6

Overall heat loss = 703313.755-703313.6= .0155 KJ