UPCT- sulfuric acid DCDA Method
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Sulfuric acid is a colorless, oily liquid with the molecular formula H2SO4. It is produced via the contact process, which involves three steps: burning sulfur to produce sulfur dioxide, oxidizing the sulfur dioxide to form sulfur trioxide, and hydrating the sulfur trioxide to produce sulfuric acid. Vanadium pentoxide is used as the catalyst for the oxidation reaction. Major engineering challenges in the process include designing multistage converters for the exothermic oxidation reaction and improving heat transfer for the hydration reaction. Sulfuric acid has many industrial uses including fertilizer production, explosives manufacturing, and making detergents and plastics.
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Most modern ammonia processes are based on steam-reforming of natural gas or naphtha.
The 3 main technology suppliers are Uhde (Uhde/JM Partnership), Topsoe & KBR.
The process steps are very similar in all cases.
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1) Direct conversion at plant sites which uses electric furnaces to reduce phosphate rock with coke and produce elemental phosphorus and carbon monoxide, then oxidizes and hydrates it to form phosphoric acid.
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3) Blast furnace process which uses a blast furnace to reduce phosphate rock and coke to produce calcium silicate slag and phosphorus pentoxide gas, then condenses the gas to form phosphoric acid.
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This document discusses catalytic reforming and hydrocracking processes. It provides details on:
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- Hydrocracking breaks down heavier hydrocarbon molecules into simpler molecules like gasoline and kerosene using hydrogen and catalysts at high pressures.
- Both processes upgrade petroleum fractions through chemical reactions like cracking, isomerization and hydrogenation to produce more valuable products like gasoline and jet fuel.
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The ammonia manufacturing process involves 6 key steps:
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4) Water is removed by condensation.
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As of the beginning of the 20th century, H2/CO-mixtures were used for syntheses of hydrocarbons and then, as a consequence, also called synthesis gas.
Haber and Bosch discovered the synthesis of ammonia from H2 and N2 in 1910 and the first industrial ammonia synthesis plant was commissioned in 1913.
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The document summarizes the process for producing ammonia from natural gas and/or naphtha. Key steps include:
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The document describes the process for manufacturing nitric acid (HNO3) using Chile saltpeter. Chile saltpeter contains sodium nitrate (NaNO3), potassium nitrate, and sodium chloride. In the process, a mixture of Chile saltpeter and sulfuric acid is heated in a cast iron retort. The vapors produced are cooled and condensed to collect concentrated HNO3. Any uncondensed vapors are scrubbed with water to collect dilute HNO3. The key reaction is between sodium nitrate and sulfuric acid to produce sodium bisulfate and nitric acid.
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There are three main types of evaporators: natural circulation, forced circulation, and film evaporators. Natural circulation evaporators include evaporating pans, evaporating stills, and short tube evaporators. Forced circulation evaporators use pumps to circulate the liquid through a heated tube bundle. Film evaporators spread the liquid as a thin film over a heated surface, including wiped film, long tube climbing film, and long tube falling film evaporators. Each type has distinct construction features and advantages for different applications in concentrating liquids and removing solvents.
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This document summarizes a new process for converting coal to ammonia using Kellogg Brown & Root's (KBR) Transport Reactor Integrated Gasifier (TRIG) technology. The process involves:
1. Gasifying coal using KBR's TRIG technology to produce syngas. The syngas is then purified through steps like acid gas removal.
2. Compressing the purified syngas and feeding it into an ammonia synthesis loop to produce ammonia using a conventional KBR ammonia process.
3. Recovering the ammonia produced and refrigerating it for storage or transport.
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This document describes an ammonia plant with three urea plants. It summarizes the key details of each plant including their commissioning dates, capacities, and revamp history. It then provides details on the ammonia and urea production processes, including descriptions of the main units involved at each stage of production from natural gas feedstock to the final urea product. Process diagrams and pictures are included to illustrate the key components and flow of materials through the plant.
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- 1. UPCT Sulfuric Acid (DCDA) Yash Suryakant Shimpi-190110105064
- 2. The Properties of Sulfuric Acid ◦ Chemical Name- Sulfuric Acid ◦ Molecular Formula- 𝐻2𝑆𝑂4 ◦ Molecular Weight- 98.07 gm/mole ◦ Appearance- Colourless to dark brown, oily liquid ◦ Odour- Odourless ◦ Melting point- 10 ˚ C ◦ Boiling point- 337 ˚ C ◦ Density- 1.84 g/ml at 20 ˚ C
- 3. DCDA Process ◦ The process can be divided into 3-processes : 1. Burning of Sulfur in presence of excess of air. 2. Oxidation of 𝑆𝑂2 gas into 𝑆𝑂3 gas. 3. Hydration of Sulfur trioxide.
- 4. Raw materials ◦ Following raw material are used in DCDA process. 1) 𝑆𝑂2 gas is obtained from various sources like, a) Sulphur burning b) Pyrites roasting containing 40- 45 % sulfur c) Metal sulfide roasting and smelting d) Sulfuric acid regeneration e) Metal sulfate roasting f) Combustion of 𝐻2𝑆 or other Sulfur-Containing gases g) Other processes.
- 5. Raw materials 2) Catalyst : For oxidation of 𝑆𝑂2 into 𝑆𝑂3 , vanadium pentoxide dispersed on porous carrier in pellet form is used. Previously Platinum was widely used. Previously Platinum was widely used, but it has several disadvantages like less conversion ratio (𝑆𝑂2and 𝑆𝑂3), poisonous, fragile, rapid heat deactivation and high initial investment, arsenic impurities. But, vanadium pentoxide is used as catalyst, because it has higher conversion ratio, less poisonous and initial low investment. Vanadium pentoxide is regenerated by following process: 1). Oxidation of 𝑆𝑂2 into 𝑆𝑂3 by 𝑉 5+ 2 𝑆𝑂2 + 4𝑉 5+ + 2 𝑂 2− 2 𝑆𝑂3 + 4 𝑉 4+ 2). Oxidation of 4 𝑉 4+ back into 𝑉 5+ by oxygen (catalyst regeneration) 4 𝑉 4++ 𝑂2 4 𝑉 5+ + 2 𝑂 2−
- 7. Process description: ◦ Burning of Sulphur in presence of excess of air: ◦ As per flow-chart, molten sulphur as a raw material is taken into storage tank and transferred in sulphur burner. Also, dry air is subjected to dry into drying tower using mixture of oleum and sulphuric acid. So, air contain 7-10% 𝑆𝑂2 gas is transferred in burner. Thereafter, liquid sulphur is burnt in excess of air temperature of 500-600 *C to form 𝑆𝑂2 gas. ◦ Oxidation of 𝑆𝑂2 gas into 𝑆𝑂3 gas: ◦ Cleaned and dried sulphur dioxide at 430*C is passed with air over catalyst pellet beds called converters. The converters consists of four bed of vanadium(V) oxide as catalyst with alkali metal sulphate promoters (mainly potassium or caesium sulphate) on silica ceramic base in cylindrical type vessels. The catalyst bed may be 8 meters in diameter and 60 cm deep. ◦ The temperature of 500-600*C and pressure is normally 2 atmospheres is maintained. Conversion temperature is strictly maintained during the reaction 500-600*C, because a conversion is reversible above 650*C and catalyst is activated at 550*C
- 8. Process description ◦ Hydration of Sulphur trioxide gas: ◦ Hot Sulphur trioxide gas is cooled up to 150*C by repeated heat exchanges. The cooled gas is then absorbed column filled with oleum and thereafter 97% Sulfuric acid. The acid strength can be adjusted by controlling the streams of 𝐻2𝑆𝑂4 to give acid of 91 to 100% 𝐻2𝑆𝑂4 with various amounts of added 𝑆𝑂3 and water. The conversion of sulphur to acid is over 99.5%.
- 9. Major Engineering problems in DCDA: 1. Design of multistage catalytical convertor for highly exothermic reaction. Earlier two stage convertor is used but nowadays the design of three or four stages rather than conventional two stage operation are developed. 2. To optimize space velocity in catalyst chamber because it deals with pumping cost or fixed charges of reactor. 3. Thin catalyst beds of 30-50cm height used to avoid above difficulties. Yield can drop due to longitudinal mixing if the convective gas velocity through the bed is low. 4. Removal of heat of absorption of 𝑆𝑂3 in acid. Pipe coolers with water dripping over external surface have been replaced by cast iron pipe with internal fins to promote better heat transfer 5. Pressure drop must be low, so, 8cm stacked packing is often used
- 10. Uses 1. The largest single use is in fertilizer industry. 2. Mostly in production of phosphoric acid, which in turn used to manufacture fertilizer such as triple superphosphate, mono and diammonium phosphates 3. Used for producing superphosphate and ammonium sulfate. 4. In manufacture of explosives, detergents and plastics 5. In production of dyes and pharmaceuticals.