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Product Information & Production Process
The sulfuric acid factory uses solid sulfur as the main raw material. The production line adopts a sulfur burning process combined with Double Conversion Double Absorption (DCDA) technology. The system includes four catalytic conversion stages and two absorption stages to improve sulfur utilization and control SO₂ emissions.
Main Technical Parameters
| Plant Type | Sulfur Burning Sulfuric Acid Factory |
| Production Capacity | 100,000 t/a |
| Annual Operating Time | 8,000 hours |
| Product Concentration | 98.1%–98.5% H₂SO₄ |
| Conversion Process | Double Conversion Double Absorption |
| SO₂ Conversion Rate | ≥99.8% |
| Steam Recovery Pressure | 3.82MPa |
| Steam Production | Approx. 15 t/h |
Raw Material Requirements
| Sulfur Content | ≥99.9% |
| Ash Content | ≤0.001% |
| Water Content | ≤0.01% |
| Carbon Content | ≤0.03% |
* Temperature Control: The sulfur melting system maintains liquid sulfur temperature at 135–148℃ through steam heating before entering the sulfur combustion section.
Main Equipment Configuration
1. Sulfur Melting and Filtration Unit
Solid sulfur is melted and filtered to remove impurities before combustion. Includes: Sulfur feeding equipment, Dynamic sulfur melting tank, Liquid sulfur filtration machine, Purified sulfur storage tank, Sulfur transfer pump.
2. Sulfur Burning Unit
The liquid sulfur enters the sulfur furnace through mechanical atomization equipment and reacts with dried air to generate SO₂ gas. Furnace outlet temperature: approx. 1050℃. Gas temperature after heat recovery: approx. 420℃. The high-temperature gas enters the waste heat recovery system before catalytic conversion.
3. SO₂ Conversion Unit
The conversion section adopts a four-stage catalytic converter with a "3+1" configuration. Process: SO₂ generation → First catalytic conversion → First absorption → Second catalytic conversion → Second absorption. The SO₂ conversion rate reaches ≥99.8% through controlled reaction temperature and catalyst bed operation.
4. Drying and Absorption Unit
The drying and absorption system includes: Drying tower, Fuming acid tower, First absorption tower, Second absorption tower, Acid circulation tank, Acid circulation pump, Acid cooler. Uses approx. 98.3% circulating sulfuric acid for moisture removal and SO₃ absorption.
5. Waste Heat Recovery System
Integrates heat recovery equipment: Waste heat boiler, High-temperature superheater, Low-temperature superheater, Heat pipe economizer. Recovered heat converted into: Steam pressure: 3.82MPa, Steam output: approx. 15t/h. Used for sulfur melting, equipment heating, or external supply.
Application Fields
Chemical Manufacturing
Chemical raw material and process medium.
Fertilizer Production
Phosphate fertilizer and phosphoric acid processing.
Metal Processing
Metal pickling, surface cleaning, and mineral treatment.
Battery Manufacturing
Electrolyte preparation in lead-acid batteries.
Mining Industry
Mineral processing requiring acid treatment.
Frequently Asked Questions
1. What is the production capacity of this sulfuric acid factory?
The standard design capacity is 100,000 tons per year, calculated as 100% H₂SO₄ output. The capacity can be adjusted according to requirements.
2. What technology does the sulfuric acid factory use?
The factory uses sulfur burning technology with Double Conversion Double Absorption (DCDA) process, including sulfur combustion, catalytic conversion, and two-stage SO₃ absorption.
3. What sulfuric acid concentration can this plant produce?
The factory produces industrial sulfuric acid with a concentration of 98.1%–98.5% H₂SO₄, complying with GB534-2014 standards.
4. How does the plant recover energy?
The system recovers heat from sulfur combustion and conversion reactions through waste heat boilers, superheaters, and economizers to generate 3.82MPa superheated steam.
5. Can the sulfuric acid factory be customized?
Yes. The production capacity, equipment configuration, utility system, and additional product units can be adjusted according to raw materials, energy conditions, and final product requirements.
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