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Production Process of Sulphuric Acid can be simplified by the Attached Block flow sheet

Production Process of Sulphuric Acid( H2SO4)

Sulphuric Acid ( H2SO4)

EFIC and its Subsidiary Company SCFP manufactures Commercial Grade Sulphuric Acid ( H2SO4with 98.5 % concentration ) through sealed contract process .

EFIC and its Subsidiary Company SCFP has five production lines :-

-Two lines in Kafr El Zayat with production capacity up to 540 Ton / day
(175,000.0 TPY)

-Two lines in Assuit with production capacity up to 640 Ton / day
(205,000.0 TPY)

-One line in SCFP with production capacity up to 1200 Ton / day
(420,000.0 TPY)

Sulphuric Acid ( H2SO4)
Sulphuric Acid ( H2SO4) Commercial Grade is :-

–Colorless

–Oily Liquid

–Density 1.847 MTon / m3

Raw Sulphur required imported from

–Saudi Arabia

–Iran

–Russia

Raw Sulphur Transported from Ports to the Plant Sites by lorry .

Raw Sulphur :-

Conveyed to the first portion of Sulphuric Acid Plant(Sulphur Melter) .

Where:-

It is melted using steam coils ( with 6.5 barg -165.0 C°) neutralized by lime , treated by adding pre –coating aid , then filtered using liquid Sulphur Filter equipped with vertical leaf filter able to guarantee an output pure liquid Sulphur with less than 20 ppm ash content to be placed into clean Sulphur Tank with a capacity (200 MTon) 48 hrs operation for the Acid Plant with Full Load.

The Liquid Sulphur pumped through a steam Jacketed Pipe Lines to Sulphur Combustion Furnace.

The Sulphur Combustion Furnace is of horizontal design and is directly connected with a horizontal Waste Heat Boiler "WHB" ( Fire Tube Construction ).

The liquid Sulphur injected inside the combustion furnace through Sulphur burner which is readily adjustable over a range of 40 –110 % of design capacity It is designed to ensures rapid and homogenous atomization of liquid Sulphur followed by evaporation

. The subsequent total Oxidation / Combustion of the Sulphur with the Inlet Dry Air takes place almost instantaneously producing SO2gas, which is exothermic reaction and raise gases temp. up to 1050 C◦in the Furnace.

SO2gaswith1050CopassthefiretubeWasteHeatBoilertoachievethefollowingtwopurposes.
–ReducetheSO2Gastemperaturetobe475Coasrequiredinthesequenceprocess.
–Generate asteam used in:

Providing the steam required in the Acid Plant
Travel to the Power House to drive steam turbine This generate the majority of EFIC' sand SCFP's internal electricity requirements.

SO2 gas issent to the Converter where it passes over Three beds equipped with catalyst Vanadium Penta Oxide (V2O5) which converts 92% of the SO2 gas into SO3 gas to be sent to the Pre- Absorption Tower (PAT) where SO3 absorbed and the remaining SO2 backed to the Fourth Converter Bed to satisfy the 99.7% Conversion efficiency and then the Converted SO3 sent to the Final Absorption Tower (FAT) , which name as Double Absorption System.

The Gases has to pass through set of Air Pre-heater , Gas to Gas Heat Exchanges, Economizer , Super Heaters to maximize the benefit of the generated heat in the different beds.

That For Heating :-

* The Inlet Dry Air to the Combustion Furnace

* Super heating the generated steam

* Boiler Feed Water via Economizer

* Returned SO3from PAT to the 4thBed

Absorption Towers :

As Mentioned above The Converted SO3 after three converter beds absorbed in a Pre–Absorbing Tower (PAT) and the remaining converted SO3 after leaving the fourth bed absorbed in a final Absorbing Tower (FAT).

Where :-

SO3 passed in the towers in counter current to the sprayed cooled concentrated Sulphuric acid 98.5 % where the SO3 absorbed by the acid, and by adding process water an additional Concentrated Acid produced. Because this process exothermic, the generated heat cause the circulating acid to be heated and accordingly the Acid has to be cooled down in an Anodic Protection Acid Cooler .

The Absorption Towers equipped with a ceramic packing to increase the contact surface between the SO3 gas and sprayed acid .

Also equipped with mist eliminator to prevents cabbing of any mist drops from the towers.

The high conversion efficiency in the converter and the Double Absorption Towers Design together with the heat Balance in the acid plants guarantee a Tail gases emission from the stack is much less than the Environmental requirements

Ex. The Environmental Requirements for tail gases from the stack

SO2≤1500 mg/Nm3

SO3≤100.0mg/ Nm3

EFIC and SCFP plants gas emissions

SO2<1000 mg/Nm3

SO3< 80.0 mg / Nm3

Note : for each 1 MTon of Sulphuric acid produced:

Approx : 1.20 Ton of Superheating Steam produced,( 35bar,400C°)
and hence : 248.0 KW generated.

Acid Storage Tanks :

The produced acid (HSO498.5%) stored in acid storage tanks made from carbon steel , EFIC and SCFP has a 14 storage tanks with capacity up to approximately 50000 MT on Conc . Acid

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