The Contact process incorporates Three Basic Operations, each of which corresponds to a distinct Chemical Reaction.

First Sulphur in the feed stock is oxidized (burned) to Sulphur Dioxide (SO2) S + O2 ---------> SO2 The resulting Sulphur Dioxide is fed into a process unit called Converter where it is catalytically oxidized to Sulphur Trioxide (SO3).This is a reversible process. SO2 + O2 ---------> SO3

Finally the Sulfur Trioxide is absorbed in 98% Sulfuric Acid Solution SO3 + H2SO4 ---------> H2 S2O7

This Oleum can be diluted to any further extent which is 98.5% by weight H2 S2O7 + H2O --------> All are exothermic reactions Overview of the process Molten Sulphur is pumped (using a heated pump and lines) to burners in a furnace, where it meets dried air from the Turbo-blower (fan). Where roasted Sulphur ores are used rather than elemental Sulphur, fluidized beds or rotary roasters are used in the furnace. Spent Sulfuric Acid from other production processes may also be decomposed to provide SO2 gas. The gas produced (containing around 11% or so of SO2) is passed through a heat recovery boiler then filtered before being passed to the converter. Vanadium catalyst beds in the converter encourage the reaction of SO2 with Oxygen to produce SO3 (Sulphur Trioxide).The reaction is exothermic, and the gas passes through several heat exchangers as it makes its way down the converter, controlling the temperatures at each catalyst bed to obtain optimum speed and efficiency of the conversion. The converter operates at temperatures over 400C (750F), and is usually brick-lined. In the double absorption process, gas from part-way down the converter is cooled, then passes through an inter pass absorber before being reheated and sent back to the final stage of the converter. 2 H2SO4

After the final stage, the gas passes through another heat recovery exchanger then to a final absorber. In the absorbers the SO3 laden gas is passed through 98% to 99% Sulfuric Acid, increasing the concentration of the acid. The acid circulates back to a tank, where it is diluted with water (or dilute acid) then the excess drawn off as product. The process is again exothermic, and the acid is cooled as it circulates. Absorbers are usually lined with acid-resistant brick. DCDA process:

In the double contact process, a primary conversion efficiency of 80% to 93%, depending on the arrangement of the contact beds and of contact time, is obtained in the primary contact stage of a converter preceding the intermediate absorber. After cooling the gases to approximately 190C in a heat exchanger, the sulphur trioxide already formed is absorbed in the intermediate absorber in sulfuric acid with a concentration of 98.5 to 99.5% by weight. The intermediate absorber is preceded by an oleum absorber if required. The absorption of the sulphur trioxide brings about a considerable shift in the reaction equilibrium towards the formation of SO3, resulting in considerably higher overall conversion efficiencies when the residual gas is passed through one or two secondary contact beds. The sulphur trioxide formed in the secondary stage is absorbed in the final absorber. The different raw materials sulphur, non-ferrous ores and pyrites. In general, SO2 feed gases containing up to 12 Vol% SO2 are used for this process. The conversion efficiency in new plants can reach about 99.6% as a daily average in the case of sulphur burning.

Next page Let us start with a simplified block diagram by assuming complete conversion in each reactor and with no side products. /*flowchart continues*/

1. SULPHUR PITS & FILTER Sulphur pit is a RCC Rectangular Structure. Steam coils are inserted along the borders of it. These are zigzag in shape in order to increase the surface area. A pressure of 5.5kgf/cm2 is used in the pit. Sulphur Filter has a hydraulic mechanism. Sulphur Transfer Pump transfers MOLTEN SULPHUR from Pre coat Pit/Clean Pit to the Furnace. Pre coat Pit has a material called FILTER AID (made of Perlite). Pre coat pit has pure Sulphur. Double walled pipes are used for the transportation of Sulphur which is in molten state Diagram 2 Controlled feeding is done in order to maintain the Viscosity of Sulphur which is most manageable at 130-140 degrees Celsius 2. AIR BLOWER AND DRYING TOWER Nylon filter mesh is used to remove dust from air. Air is obtained by using motor driven Centrifugal Air Blower. Flow Rate-29500 Nm3/hr;1495-3750 rpm;Blower-800 horsepower Delivers air at a pressure of 3750 mm of water column In drying tower air is dried using concentrated H2SO4 which is cooled and recirculated. Packing is done to maximize the contact of air and the molten Sulphur. Moist free air contains minute acid droplets out of drying tower called as MIST which is removed in the MIST ELIMINATOR TOWER which contains CONCENTRIC CANDLES. Diagram 3 Increase in delta P across the candles signifies their saturation after which they should be neutralized using Caustic Soda. Output Temperature of Air in this process is 985 degrees Celsius

3. FURNACE Molten Sulphur is sprayed into the furnace using the ATOMIZER GUN.

In the furnace Sulphur is oxidized to Sulphur Dioxide An excess of air is used so that the Sulphur Dioxide produced is already mixed with the Oxygen for the next stage. In the furnace the temperature is around 1000 c. Furnace is lined for the better mixing of molten sulphur and oxygen

3. WASTE HEAT BOILERS AND GAS FILTER Steam generated in boilers is utilized in heat exchangers used later in the process. Steam generated in the plant is about 2 times the final output of the plant which is used at several parts within the plant Boiler 1: The gas stream from the Furnace is sent to the heat exchanger Boiler 1 where the extra heat is utilized to convert water to steam. The temperature of the Gas Stream falls to 350-400 degrees Celsius.

Boiler 2: In the boiler 2, the amount of Steam generated is 4.25 MT/hr. Gas stream containing SO3 exits the first bed of the converter and enters the boiler. Gas stream leaving it is at a temperature of about 455c.

Gas filter: Gas filter is packed with ceramic stone of 10mm diameter. These are used to filter impurities and dust particles from the gas stream. NXT FLOW CHART DIAGRAM 5. CONVERTER There are two beds in each converter. In these converters SO2 is converted to SO3 .It is an exothermic reaction and large amount of heat is generated.

Several Catalysts such as Platinized Asbestos, Vanadium Pent oxide (V2O5) etc.; can be used V2O5 is mostly preferred as the others are easily poisoned and it is relatively cheap. Composition of the Catalyst V2O5 (6-8%), Remaining SiO2 (60-65%), K2O, Al2 O3 present. The converter is of (5-10) m length and is stainless steel construction. Minimize heat loss to maintain essentially an adiabatic reaction. The reaction is reversible and hence Le Chateliers principle can be applied to know the optimum conditions to maximize the production of SO3. They provide for the uniform flow of process gas to and from the catalyst beds. The volume of catalyst required increases as the bed number increases.

PRIMARY: Temperature of the gas entering the Primary Converter is around 450 degrees Celsius. It contains two beds of platinum or V2O5 Catalyst.

First bed: The gas stream from the first bed is sent to the Waste Heat Boiler 2 where it is cooled down to 455 degrees Celsius to produce steam. In the first bed the conversion percentage is 60-65%. Second bed: In the second bed the conversion percentage is about 80-85 % depending on the conditions used. Gas stream containing SO3 is sent to intermediate heat exchanger.(IHE) The volume of catalyst required is about 13.5 m3.

The gas stream produced in the Primary Converter contains 80-85% SO3 It is at a temperature of 543 degrees Celsius. SECONDARY:

The gas stream entering secondary converter is around 400 c. It also contains two beds of platinum or V2O5 Catalyst. Third bed:

The gas stream entering is about 420C. The gas stream leaving the third bed is at a temperature of 483 c. It is at a temperature of around 483C. The volume of catalyst required is 19.8 m3.

Fourth bed: . The gas stream entering is about 420C. The percentage conversion is about 96-98%. The gas stream leaving the bed is at 444C. It requires about 23.8 m3.

Heat Exchanger: The function of a gas-to-gas heat exchanger is to cool/heat the process gas to achieve the desired temperature for maintaining the process Conditions. The heat exchangers are required to operate over a wide range of conditions so they are equipped with gas bypasses to enable the Process temperature to be controlled. The O2/SO2 ratio is important to achieve as high a conversion rate of SO2 to SO3 as possible The gases are reheated to the ignition temperature through gas/gas heat exchangers using the heat of conversion, upstream of the converter. The reaction is exothermic, and the gas passes through several heat exchangers as it makes its way down the converter, controlling the temperatures at each catalyst bed to obtain optimum speed and efficiency of the conversion.

There are two Heat Exchanger in the given manufacture process of Sulfuric Acid. Intermediate Heat Exchanger (IHE): It is used in heat exchanges in first and second beds of Primary converters. It cools down the gas to 420 c. It is a shell and plate heat exchanger.

Final Heat Exchanger (FHE): It is used in exchanging heat of gas stream and lies in between third and fourth beds of Secondary converters. It receives gas stream at a temperature of 483C and exits it at about 284C.

ABSORPTION TOWER: Absorbing towers are designed to remove sulphur trioxide from the gas. The absorption of SO3 by the circulating acid stream increases the acid concentration and through the process of dilution, the product acid is produced. Intermediate or Inter-pass Absorption tower refer to the absorber located after bed 2 in the process. The tower located before the stack is simply refer to as the Final Absorption Tower.

Intermediate Absorption Tower-

SO3 in the gases leaving the third bed is passed through Intermediate Absorption Tower where SO3 is absorbed in water to produce Sulfuric Acid. The absorption of the sulphur trioxide brings about a considerable shift in the reaction equilibrium towards the formation of SO3, resulting in considerably higher overall conversion efficiencies when the residual gas is passed through one or two secondary contact beds. The sulphur trioxide formed in the secondary stage is absorbed in the final absorber.

Majority of the products is formed here. The product leaving it is at about 65 C.

FINAL ABSORPTION TOWER In this tower SO3 from the fourth bed is absorbed into water to form Sulfuric acid. As a result mist is formed which needs to be eliminated into the BRINK MIST ELIMINATOR from the stream to avoid any problems in the flow of the STREAM.

Brink mist eliminator: Mist is inevitably formed at various points in Sulfuric Acid Plants. In the gas drying tower, as well as intermediate and final absorption towers, poorly performing mist eliminators contribute to corrosion of ducting, blowers, heat exchangers and vessels, and also to acid plant stack emissions. Brink mist eliminators excel at collecting the very difficult to remove submicron size mist particle from gas stream. The fiber bed eliminators incorporate a specially wound fiber, computer controlled quality and a patented bi-component design.

10. ECONOMISER Economizers are used to recover the useful heat in exhaust or flue gas before it is released into the atmosphere and transfer it to the steam production cycle. This increases the overall boiler thermal efficiency, resulting in more steam with less fuel. Boiler efficiency increases by approximately 1% for every 40F the flue gas is cooled. It is widely accepted in the industry that economizers provide a good return on investment and also help reduce carbon emissions. In the manufacture of sulphuric acid, it receives the heated gas stream from converters and the cooled gas stream exits it for final absorption. 12. CHIMNEY The conversion is always incomplete and is affected by number of stages in the catalytic converter, the amount of catalyst used, Temperature, Pressure and the concentration of the Reactants. Tail gas stream must contain less than 25 mg/m3 of MIST(385ppm) Sulphur Flow-452 metric tons /hour Air Flow-29500 Nm3/hr Blower current 126 A Total Storage capacity of RCF 2400 metric tones Length of the Chimney-55m. Gaseous emissions in Sulfuric Acid Industry consist of unabsorbed SO2/SO3 gases and acid mist after final absorption tower. These are let off from the main stack (Chimney).

Sulphuric Acid Storage Tank (98.5%):Initial and Final Product Storage:-

There is no air pollution problem connected with the storage, handling and shipping of sulphuric acid. Oleum and SO3 storage and handling operations, which are often linked with H2SO4 production, should be installed with a means of controlling fume emissions.

Venting should be directed towards acid tanks or scrubbing systems. Installations should be built by following the best engineering practice. The emissions can condense and solidify in cool areas so this must be very carefully guarded against to prevent over-pressurisation of storage tanks.

During storage and handling of sulphuric acid, leaks may have an impact on the soil or on waters. Precautions have to be taken in order to reduce the possibility and the gravity of these leaks.