H2SO4

1. Under the supervision of
Dr. Barnali Mandal
Assistant Professor
Department of
Chemical Engineering
University of Calcutta
Presented by
Anindita Poddar
Roll Number-
T98/JFT/174156
(B.Tech 7th semester,
Chemical Engineering)
ChE - 709
University of Calcutta
Date-17/03/2021
INPLANT TRAINNING REPORT
ON THE INDUSTRIAL PRODUCTION OF
SULPHURIC ACID

2. ABSTRACT
 Detailed designing of a four stage adiabatic catalytic bed reactor
for a H2SO4 plant.
 Plant capacity 1500 TPD
 Feed is at 1 atm and 410 degree centigrade.
 DCDA process is used to produce H2 SO4
 Process achievable conversion is 99.8 %
 Comprise mainly basic parts of manufacturing plant, their
material and energy balances, heat duty of heat exchangers.

3. INTRODUCTION
 Sulfuric Acid is a colorless highly corrosive strong mineral acid.
 Historical name : Oil of Vitriol
 Molecular weight :98.08
 Molecular formula: H2SO4
 Melting point: 10.5 degree C
 Boiling point: 340 degree C
 Solubility: Completely miscible with water.

4. Uses of Sulphuric Acid
Fertilizer Production 56%
11% Agricultural Chemistry
23% Other Applications
11% Manufacture of Chemicals

5. 1. Used for production of fertilizers like urea, single
superphosphate and N.P.K assisting to increase the
agricultural output of the country
Fertilizer Industry.
2.
Used for manufacturing of pigmente . Graphene
titanium (vi) oxide and barium tetraoxosulphate (vi)
for use in plant and dyes.
Paints / pigment industry.
Textile industry.
3.
Used as a dehydrating agent in the nitration of
compounds used for making explosives.
Explosive industry
4.
Used in synthesis of phenol and alkylation of
isobutane.
Organic chemical industry
5.
Used for purification of crude oil and in the
manufacture of artificial silk.
Petroleum/Textile Industry
APPLICATION /USAGE

6. SULPHURIC ACID - WORLD MARKET

7. DCDA PROCESS :
Double Contact Double Adsorption Process
It is also called Contact Process.
Highly used as yield obtained is high.
More economical and preferable over chamber process.

8. Chemical Reactions:
Produce Sulphur dioxide:
S (l) + O2 (g)→SO2 (g) Δ H= -298.3 kJ
Oxidies SO2 to SO3:
V2 O5
SO2 (g) + ½ O2 (g) SO3 (g) Δ H= -98.3 Kj
Adding excess O2 to the sulfer dioxide in the presence of
Vanadium pentoxide.
Formation of H2 SO4:
SO3 (g) + H2 O(l) → H2 SO4 (l) ΔH= -130.4 kJ

9. Fig: Double Absorption Contact Process
The process flow sheet:

10. 1.Combustion Chamber
2.Converters
3.Absorbers
4.Heat Exchangers
The four stage catalytic reactor
Contact Process Equipments:
Total Pressure = 1 atm
Feed composition (Mole
Percent)
SO2 10
O2 11
N2 79
Overall Conversion = 99.8 %.
Fig: Four Stage Catalytic Reactor for Contact Process
Specification:

11. MATERIAL BALANCE:
Assumptions:
Complete burning of S
99.8% Conversion of S02 to SO3
Overall absorption of SO2 in process is 100%
 Humidity of entering air is 65% at 300 degree C
COMBUSTION
CHAMBER
S+O2 →SO2
Sin = 610.596
Airin =610.596
O2 in = 915.894
O2 out = 671.656
S O2 0ut =610.596
COMBUSTION CHAMBER BALANCE

12. FIRST THREE CATALYTIC BEDS(OVERALL BALANCE)
1st + 2nd + 3rd C.B
SO2 (g)+1/2 O2↔SO3 (g)
SO2 in = 610.596
PRIMARY
ADSORPSTION
TOWER
4th Catalytic
Bed
O2 in = 671.656
O2 out =376.433
SO2 out=20.15
SO3out=590.446
PRIMARY ABSORPTION
TOWER
SO3 (g)+H2 O(l)→H2 SO4
S O3 in =236.178
SO2 in=8.06
O2 in =150.573
H 2O in
H2SO4formed=236.178
O2 to 4th bed
PRIMARY ADSORPTION TOWER BALANCE

13. FOURTH CATALYTIC BED BALANCE
FOURTH CATALYTIC BED
SO2(g) +1/2 O2(g)→SO3 (g)
SO2 in =20.15
O2 in=376.433
SO3 in=354.268
SO2 out = 1.221
O2 out =366.969
SO3 in= 373.197
SO2 reacted =18.929
O2 reacted =9.464
FINAL ADSORPTION TOWER BALANCE
FINAL ADSORPTION TOWER
SO3 (g)+H2 O(l)→H2SO4 (l)
SO3 in=373.197
SO2 in=1.221
O2 in=366.969
H2SO4 formed=373.197
Total H2SO4 formed=
(Primary+Final)=609.375

14. ENERGY BALANCE:
LAW OF CONSERVATION ENERGY:
Energy can neither be created nor be destroyed, it can only be
changed from one form to another.
HEAT BALANCE :
The energy or heat coming into a process in the inlet
materials plus any net energy added to the process is equal to the energy leaving
in the materials.
∑HR + (-∆H⁰
298 ) + q = ∑HP …(1)
Where,
∑HR =The sum of enthalpies of all materials entering the reaction process
(-∆H⁰
298 )= Standard heat of reaction at 298K and 101.32KPa
q= Net heat or heat added to the system
∑HP = The sum of enthalpies of all materials leaving the reaction process.

15. NET ENTHALPY CHANGE AT CATALYTIC BED:
The temperature dependency of the heat capacity
C⁰P = a+ bT+ CT2 +… …(2)
ΔH⁰RT = T∫298 ∑ (ni C⁰Pi) ReactantdT + ΔH⁰298 +298∫T ∑ (ni C⁰pi) ProductsdT
…(3)
Where,
ΔH⁰RT is the standard heat of reaction at temperature T (⁰K)
ΔH⁰RT = ΔH⁰298 +298∫T ( ∑ (niC⁰Pi) Products -∑ (ni C⁰Pi) ReactantsdT
…(4)
Enthalpy change,
∑H = ΔH⁰RT – ΔH⁰298 = ( ∑ ai ni )(T–298) + ((∑ bi ni)/2)(T2 – 2982)
+... …(5)

16. Enthalpy change between T1 K and T2 K
∑H = ( ∑ ai ni )(T1 –T2 ) + ((∑ bi ni)/2)(T1
2 – T2
2 ) + …
…….(6)
Standard heat of reaction at 298 K (ΔH⁰298 ) from heat of formation,
ΔH⁰298 = [ ∑ (ni ΔH⁰f) ] Products– [ ∑ (ni ΔH⁰f )]Reactant
Where,
[ ∑ (ni ΔH⁰f) ]Product = standard heat of formation of products
and,
[ ∑ (ni ΔH⁰f )]Reactant = standard heat of formation of reactants

17. FIRST CATALYTIC BED
Fig: ENTHALPHY BALANCE OVER FIRST CATALYTIC BED
Enthalpy in
(∑HR )=19880.838KW
Enthalpy out
(∑HP ) =31229.197KW
Enthalpy to be removed
(q)= -1065.99KW
Standard heat of reaction at 298K
(∆H⁰298 )=-12414.358KW

18. SECOND CATALYTIC BED
Enthalpy in
(∑HR )=22917.5705KW
Enthalpy to be removed
(q)= -529.504KW
Enthalpy out
(∑HP ) =25474.992KW
Standard heat of reaction at 298K
(∆H⁰298 )=-3O86.926KW
Fig: ENTHALPHY BALANCE OVER SECOND CATALYTIC BED

19. THIRD CATALYTIC BED
Enthalpy to be removed
(q)= -11.2604KW
Enthalpy in
(∑HR )=21728.873KW
Enthalpy out
(∑HP ) =22439.106KW
Standard heat of reaction at 298K
(∆H⁰298 )=-721.493KW
Fig: ENTHALPHY BALANCE OVER THIRD CATALYTIC BED

20. FOURTH CATALYTIC
BED
Enthalpy to be removed
(q)= -1.689KW
Enthalpy in
(∑HR )=19197.066KW
Enthalpy out
(∑HP ) =19715.176KW
Standard heat of reaction at 298K
(∆H⁰298 )=-519.799KW
Fig: ENTHALPHY BALANCE OVER FOURTH CATALYTIC BED

21. HEAT LOAD FOR HEAT EXCHANGERS:
Enthalpy change
First bed
outlet
Second bed
inlet
875K to 711K ∆H1 =-9303.2204KW
Second bed
outlet
Third bed
inlet
771K to 705K ∆H2 =-3746.1182KW
Third bed
outlet
Fourth bed
inlet
717K to 700K ∆H3 =-839.760KW
Heat load required between
beds
Temperature change
∑H = ( ∑ ai ni )(T1 –T2) + ((∑ bi ni )/2)(T2
1– T2
2) + …

22. REFERENCES:
1.Levenspiel, Octave, (1999). Chemical Reaction Engineering,
Third Edition
2.Fogler, H.S., 1999. Elements of chemical reaction engineering,
Third edition
3. Douglas k. Louie, (2005).Handbook of Sulphuric Acid Manufacturing ,
Second Edition
4. Bhatt, B.I., Vora, S.M., 1996. Stoichiometry. Third edition. Mc-Graw
Hill, New Delhi.