TABLE OF CONTENTS

1.0 Introduction 1.1 Background 1.2 Problem statement 2.0 Objective 3.0 Methodology 4.0 Research plan 5.0 Potential contributors 6.0 References APPENDIXES

2 2 4 5 6 8 9 10

1.0

INTRODUCTION

Sulphuric acid, H2SO4, is an extremely corrosive, colourless, oily, and odourless liquid (Sulphuric Acid MSDS, retrieved on 23rd February 2011). The raw material of producing this important chemical is sulphur, which is brought from the Kemaman Supply Base, in Kemaman, through ship from PETRONAS Penapisan in Malacca. 1.1 Background

Sulphuric acid is one of the most important materials in the chemical industry, and its production in the US alone is 90 billion lb per year in 2002 (Chernier, 2002) and it finds its uses as the electrolytes in lead acid accumulators (Masterton, 1997), to the making of titanium dioxide (by digesting ilmenite in sulphuric acid, http://www.lookchem.com/Titanium-dioxide/, retrieved on 23rd February 2011). The example of usage in United States in year 1993 is shown on Table 1.0.

Table 1.0: U.S. Consumption of 100% Sulfuric Acid by End Use, 1993 U.S. Consumption of 100% Sulfuric Acid by End Use, 1993 Metric Tons Pounds % of Total (000) (000,000) Fertilizers 27,541 60,718 72.02 Ore Processing 2,282 5,031 5.97 Petroleum Alkylation 1,550 3,417 4.05 Pulp and Paper 930 2,050 2.43 Caprolactam 800 1,764 2.09 Methyl Methacrylate 806 1,777 2.11 Aluminum Sulfate 595 1,312 1.56 Hydrofluoric Acid 436 961 1.14 Titanium Dioxide 350 772 0.92 Pigments Batteries 224 494 0.59 Cellulosic Fibers and 213 470 0.56 Plastics Iron and Steel 210 463 0.55 Industry Ammonium Sulfate 120 265 0.31 Surface-active 75 165 0.20 Ingredients Miscellaneous Uses 2,111 4,654 5.56 Total 38,243 84,313 100 Source: SRI International, Chemical Economics Handbook, 1995 (Palo Alto, CA) End-Use

1.2 Problem statement But, the productions of the materials above also have negative impacts towards the environment, if the process is not monitored well. In the production of the sulphuric acid, for example, some fugitive sulphur dioxide (SO2) and sulphur trioxide (SO3) emissions may escape into the atmosphere and become a major air pollutant. The spent acid also poses problems towards the environment, mainly the waterways, as it can alter the pH of the water, thus contributing the leaching of the minerals into the waterways. To control the pollution associated with these chemicals, a life cycle inventory (LCI) can be used. LCI is an analysis of the environmental impacts and an analysis of potential improvements. The life cycle inventory defines the materials and energy associated with a product over its life cycle which is from extraction of the raw materials, throughout its useful life, to eventual reuse, recycling or disposal at end of life. The goal of the LCI is to create a mass balance which accounts for all input and output to the overall system, from the beginning of a process to the final disposal. As a result, an inventory analysis produces a list containing the quantities of pollutants released to the environment and the amount of energy and material consumed. The results can be segregated by life cycle stage, or specific processes.

2.0

OBJECTIVE Throughout this research, it is aimed: 1. To investigate the production of the chemical inputs used, mining/chemical processes, the industrial processing, the transportation of materials and chemicals, and waste management associated with the production of sulphuric acid, that can have adverse effects on the environment, mainly to the surface water system, by changing the natural parameters. 2. To find the areas that needs improvements to make the process of manufacturing the sulphuric acid more environmentally safer.

3.0

METHODOLOGY To achieve the objectives of this study, which is to conduct a Life Cycle Inventory study, a variety of method and procedures are used. Besides that, to get the best information, one have to take it from the most veritable source, which is from the company and its supplier.

1. Firstly, a flow diagram of the processes being evaluated can be developed, as the flow diagram is a tool to map the inputs and outputs to a process or system. In the flow diagram, unit processes inside of the system boundary link together to form a complete life cycle picture of the required inputs and outputs (material and energy) to the system. For data-gathering purposes it is appropriate to view the system as a series of subsystems. Each subsystem requires inputs of materials and energy; requires transportation of product produced; and has outputs of products, co-products, atmospheric emissions, waterborne wastes, solid wastes, and possibly other releases, such as shown on the Figure 1.0.

Electricity, fuel

Transportation

Sulphur

Contact Process

Sulphuric acid

Pollutants

Figure 1.0: The simple flow diagram for the production of Sulphuric acid
6

2. Secondly, Data collection and planning should be done to complete the life cycle inventory, as an LCI data collection plan will ensure that the quality and accuracy of data meet the expectations of the decision-makers.

3. Then, Data collection will be done to collect the information on multiple input streams and many output streams. Usually only one of the outputs is of interest for the life cycle assessment study being conducted, so I need to determine how much of the energy and material requirements and the environmental releases associated with the process should be attributed, or allocated, to the production of each co-product. The needed data for this final year project will be collected during June and July 2011, by a visit to the company. The data will be recorded inside a form, and it will be verified by both of the company and its suppliers.

4. Lastly, Result evaluation and report, as the collected data will be reviewed and analyzed using simple computer program, and the results will be displayed in the final report. One of the copies will be given to the See Sen Company as agreed.

4.0

RESEARCH PLAN

5.0

POTENTIAL CONTRIBUTORS

In this study, we might be able to have a deeper insight in the production of the one of the most important materials in chemicals industry. Besides that, we can identify the stages within the life cycle of the sulphuric acid where reductions in resource use and emissions can be achieved, thus contributing to the better wellbeing of the environment. Lastly, we can monitor overall resource use, energy consumption, and environmental loading, and modifying the stages where the impact to the environment is hardest.

6.0

REFERENCES

1.

Chernier, P. Survey of Chemical Industry (3rd Edition), Boston, Kluwer Academic / Plenum Publishers

2.

Masterton, W. and Hurley, C. Chemistry: Principles and Reaction (3rd Edition), Orlando, Saunders College Publishing

3. 4.

SRI International, Chemical Economics Handbook, 1995 (Palo Alto, California) Scientific Applications International Corporation (SAIC), Life Cycle Assessment: Principles and Practice, Ohio, Environmental Protection Agency

5.

http://www.ee.iitb.ac.in/~nanoe/msds/sulphuric%20acid.pdf, retrieved on 22nd February 2011

6. 7.

http://www.lookchem.com/Titanium-dioxide/, retrieved on 23rd February 2011 http://www.eoearth.org/article/Abiotic_factor?topic=49461, retrieved on 25th February 2011

10