Industrial Chemistry Manufacturing of Sulfuric Acid by Lead Chamber Process and Contact Process

IIS SETYO BUDI R. DWI KRESHNA SETYA PUTRA SAYUDI BAROKAH FADJAR MULYA INNA YUSNILA KHAIRANI

LEAD CHAMBER PROCESS

Raw materials : sulfur, potassium nitrate, water Catalyst : NO2 Production Process: 1. sulfur and KNO3 are ignited in a room lined with lead foil 6KNO3(s) + 7S(s) 3K2S + 6NO(g) + 4SO3(g) 2. the floor of the room was covered with water. When the sulfur trioxide reacted with water, sulfuric acid was produced. SO3(g) + H2O(l) H2SO4(aq)

 In 1835, Joseph Gay-Lussac invented a process for recovering the nitrogen in nitrogen monoxide and recycling it to replace the saltpeter (potassium nitrate) as a source of nitrogen
4NO(g) + O2(g) + 2H2O(l) 4HNO2(l) 4HNO2(l) + 2SO2(g) 2H2SO4(aq) + 4NO(g)

Contact process
Raw materials : sulfur, iron pyrite, liquid water, water vapor, H2SO4 Catalyst : V2O5 Production process 1. preparation of SO2 can be done by burning sulfur or heating iron pyrite (FeS2) both with excess oxygen S + O2 SO2 4FeS + 11O2 2 Fe2O3 + 8SO2

2. Purification of SO2 SO2 contains a number of impurities such as dust particles, arsenous oxide, vapors, and sulfur. It should be removed. Theres dust chamber, washing tower, drying tower, Tyndall box ( test box). 3. conversion to SO3 oxidation of SO2 is carried out in contact tower where V2O5 is filled with temperature of 400-450 Celsius degree. SO2 here reacts with air (O2) to produce SO3. under above conditions, 98% SO2 is converted into SO3 2SO2 + O2 2SO3 + 45 Kcal

4. conversion SO3 to H2SO4 SO3 is not directly passed In water because a dense fog of minute particles of H2SO4 is produced. Therefore, it should be dissolved in H2SO4 to form H2S2O7 (Oleum)
SO3 + H2SO4 2H2S2O7 (oleum) oleum is now diluted with water to form H2SO4

H2S2O7 + H2O 2 H2SO4

Process diagram of contact process

Process diagram of contact process

Process diagram of contact process

Comparison between contact process and lead chamber process

WET SULFURIC ACID PROCESS

WSA process, diterapkan pada banyak industry dimana penghilangan sulfur dibutuhkan. Proses ini biasanya lebih tepat digunakan untuk memproses satu atau lebih aliran yang mengandung sulfur. Reaksi Utama pembentukan Asam Sulfat dengan Wet Sulfuric Acid adalah : Pembakaran: H2S + 1.5 O2 = H2O + SO2 Oksidasi: SO2 + O2 = SO3 (in the presence vanadium (V)oxide catalyst) Hidras : SO3 + H2O = H2SO4 (g) Kondensasi: H2SO4 (g) = H2SO4 (l) Energi yang diproduksi dari reaksi diatas digunakan untuk produksi steam. Energinya mendekati 2-3 ton steam tekanan tinggi/ton asam yang di produksi.

Cleaning

Hot air for preheating or combustion

Cooling water

Sulfurous Feed

Preheat Or Combustion

SO2 Convertion

Gas Cooling

Acid Condensation

Acid Cooling

Product

Superheating Steam

Atmospheric Air

Cooling water Return

http://en.wikipedia.org/wiki/Wet_sulfuric_acid_process

TABEL PERBANDINGAN
Suhu Konversi SO3 Biaya : : 420-440oC lebih dari 99%

: Harga plant murah karena recovery sulfur tinggi dan laju recovery panas tinggi sehingga kebutuhan cooling water rendah : V2O5

Katalis

WSA in Manufactured
Example 1: Feed-gas flow : 14,000 Nm3/h

Composition [vol %]

: 5.8% H2S, 1.2% COS, and 77.4% CO2

: 106 MTPD : 53 ton/h

SOx concentration [vol %] : 1.58% H2SO4 production Steam production

Cooling water consumption: 8 m3/ton acid (delta T = 10C) Fuel consumption Example 2: : 1,000 Nm3/h

A sulfur plant in China will be built in connection with an ammonia plant, producing 500 kilotons/annum of ammonia for fertilizer production

Sulphur recovery; (2007). The Process Principles in sulphur recovery by the WSA process.). Denmark: Jens Kristen Laursen, Haldor Topsoe A/S. Reprinted from Hydrocarbonengineering August 2007