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www.mecsglobal.com/.../difficultapplications.asp
History
universe-review.ca/F13atom.htm
Process of burning sulfur with saltpeter was first described in the 15th century
www.georgiaencyclopedia.org/ng 1746 lead chamber process e/Multimedia.js... 1831 contact process - use of catalyst - absorption of SO3 into 98.5 % to 99 % H2SO4
Process
S (l) O2 (g) SO2 (g) SO3 (g) 1/2O2 (g) H2SO4 (l) SO2 (g) SO3 (g) H2S2O7 (l) = 298.3 kJ, 25 0C = 98.3 kJ, 25 0C H = - 130.4 kJ, 25 0C
Because sulphur is exothermic and burns in air, heat is generated and most sulphuric acid plants generate steam as a by-product.
www.engineeringnews.co.za/article/new-sulphur...
large plants can produce 1.3 tons in excess per metric ton of acid in some countries, energy from sulfuric acid plants is used in homes and offices saving ~ 35 700 tons of fuel oil per day!
S (l)
Kp =
But, rate of reaction increases with increase in temperature balance between rate of reaction and optimum conversion
Use of a catalyst:
earlier catalysts included iron oxide and platinum replaced with V2O5 (vanadium pentoxide) can last up to 20 years is used in the shape of hollow cylinders increased surface area together with good flow of gas through the catalyst How else can we optimize the conversion to SO3?
Four-pass Converter
www.britannica.com/EBchecked/topic-art/572815...
SO2 (g)
1/2O2 (g)
SO3 (g)
S (l) O2 (g) SO2 (g) SO3 (g) 1/2O2 (g) H2O (l)
SO3 (g)
H2O (l)
H2SO4 (aq) X
highly corrosive mist of sulfuric acid fumes
SO3 (g)
Steel
H2SO4 (l)
H2S2O7 (l)
98.5 99 % sulfuric acid is a good absorber of SO3 (g) lined with acid proof bricks with ceramic packing with conc acid flowing over it allows for SO3 (g) to have close contact with the conc acid
H2O (l)
H2O
Absorbing tower
concentrated acid is withdrawn and portion going back into tower is diluted with dilute H2SO4 or water
Typical flow chart for a sulfur-burning single-absorption contact sulfuric acid plant. Monsanto Enviro-Chem from Shreves Chemical Process Industries
Heart of the contact process. Discuss in terms of the equilibrium reaction, rate of reaction, rate of conversion and increased SO3 formation?
What is a furnace?
www.oup.co.uk/.../pictures/industry/furnace/ www.petrocoke.com/pics1.html
Combustion chamber where the molten sulfur is partially burned and vaporized http://www.freepatentsonl ine.com/2622007.pdf
http://www.thefreedictionary.com/_/vie wer.aspx?path=hm&name=A4heatex
Rate of heat transfer is dependent on: - temperature difference between hot and cold fluids/surfaces - surface area available for heat transfer the geometry and physical properties of a system will also influence the heat transfer system, for eg., if fluids are involved then the flowrate is important
heat exchange or transfer is used in industry to - heat or cool reactions - keep raw materials at an optimal temperature (eg., keep solid fats in a liquid state) - conserve energy (eg., re-use of steam condensate) most commonly used between liquids but may get transfer between gas and liquid or between 2 gases.
Jacketed vessel
External coil
lower surface area smaller contact area not generally used for temperature control in reactors used in low duty heating requirements, for eg., maintaining the temperature in raw material tanks or heating pipe lines
Used in reactors even if contains viscous material. High surface area for heat transfer Problem? Makes cleaning of reactor difficult and interferes with mixers in reactors
outer annulus
inner tube
Most efficient operation is achieved when inlet and outlet temperatures are as close together as possible
divides the header from the rest of the apparatus & prevents the fluid from entering the shell
www.absoluteastronomy.com/topics/Shell_and_tu...
Heart of the contact process. Discuss in terms of the equilibrium reaction, rate of reaction, rate of conversion and increased SO3 formation?
Continuous process: - runs continuously - fairly automated minimize labour - have much less material in process therefore lower chance of ruining large quantities of feedstock - more uniform operating conditions requires good quality instrumentation for concise control
- suitable for processes that are liquids or gases. Why? - entire plant cannot be shut down for maintenance shut down small sections of the plant at a time to carry out repairs and maintenance - Disadvantage very expensive to build
Batch process: - Relatively smaller quantities of feedstock are processed in individual reactors produce smaller quantities of product - Precise quantities for each batch can be weighed out accurately but temperature control can be a problem - Easier to control the reaction in a small reactor - Maintenance is easier - Disadvantage very labour intensive
Environmental Awareness
What are the main pollutants in a sulfuric acid process? Identify, on the process chart, where these pollutants would be present. Why are these regarded as pollutants? Describe in detail the methods that can be used to reduce these pollutants
Why are these regarded as pollutants? - SO2 is a throat and nose irritant and causes breathing problems if high concentrations are inhaled. - Damage to vegetation and animals - SO3 combines with water vapour in the atmosphere to form sulfuric acid mist.
Use of higher stacks: - Tall stacks help to disperse the SO2 gas higher into the atmosphere away from ground life http://sine.ni.com/cms/images/casestudies/stacks_01.jpg - Climate conditions and topography of the surrounding must be considered during emission of gases and building of stacks
Use of scrubbers: - Scrub with water (very effective in reducing 50 75 % of SO2) soda ash (produce sodium bisulfite as byproduct) lime slurries salt solutions (slightly alkaline, heated conc salt soln) http://www.thermalenergy.com.au/images/Gas
Cleaning/LandfillGas.jpg
Removal of acid mist - The smaller the mist particles the greater the visibility which results in plumes from stacks - Removal of acid mist is carried out by: Packed bed separators containing sand, coke or fibers of glass or metal which cause the particles to coalesce Wire mesh mist eliminators cause particles to coalesce when high velocity gas pass through them
http://upload.wikimedia.org/wikipedia/commons/thum b/3/31/Packedtowerex.gif/250px-Packedtowerex.gif
Porous ceramic filter tubes made up of aluminium are effective in collecting acid mist that passes through it from the top downwards Electrostatic precipitators Sonic agglomerators use sound waves to cause small particles to stick together to form a large particle which is then removed by cyclones
Most produced chemical in the US About 40 million tons produced per year (US - 1990) Cost of sulfuric acid is affected by supply & demand which is affected by the demand for the chemicals it is used to make
http://www.purchasing.com/article/talkback/227813Sulfuric_acid_prices_continue_to_decline_as_demand_dries_up.php#52758
We may judge with great accuracy the commercial prosperity of a country from the amount of sulfuric acid it consumes
1840 Liebig