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Sulfuric Acid Production Plant
Industrial processing system integrating raw material preparation, combustion reaction, catalytic oxidation, acid absorption, and energy recovery into a continuous manufacturing unit.
Production Technology
The plant adopts the Double Conversion Double Absorption (DCDA) process, which is based on multiple-stage catalytic conversion and absorption. During operation, solid sulfur is first melted and purified before entering the combustion furnace. The combustion reaction produces SO₂ gas, which passes through heat recovery equipment before entering the converter.
Inside the converter, SO₂ reacts with oxygen under catalyst action to form SO₃. After two conversion stages and two absorption stages, the final acid product reaches the required concentration range. The conversion process achieves an SO₂ conversion rate of ≥99.8%, while the recovered process heat is transferred into the steam generation system.
Key System Components
Sulfur Preparation System
The sulfur preparation unit provides treated liquid sulfur for the combustion process. Solid sulfur is heated until it becomes liquid and then filtered to remove impurities. The purified sulfur is maintained at a controlled temperature before being delivered to the furnace. The preparation stage ensures stable sulfur feeding and reduces impurities entering the combustion section.
System integration: Sulfur melting equipment, Filtration unit, Storage tank, Transfer pumps, Steam heating system.
Typical operating conditions: Sulfur melting temperature: 135–148℃, Heating steam pressure: 0.4–0.6MPa.
Combustion and Gas Generation System
The combustion unit converts elemental sulfur into sulfur dioxide. Liquid sulfur is sprayed into the furnace through atomization equipment and reacts with dried air (S + O₂ → SO₂). The combustion process produces high-temperature SO₂ gas with an outlet temperature of approximately 1050℃. Before entering the conversion section, the gas passes through heat recovery equipment to reduce temperature and recover thermal energy.
Catalytic Conversion System
The catalytic conversion unit is responsible for transforming SO₂ into SO₃. The system consists of converter equipment, catalyst beds, gas heat exchangers, and temperature control devices. The plant uses a four-stage catalyst arrangement with a "3+1" conversion design. Temperature regulation between catalyst stages maintains suitable reaction conditions and supports stable conversion performance (SO₂ conversion rate: ≥99.8%).
Absorption and Acid Circulation System
The absorption section completes the conversion of SO₃ into sulfuric acid. The circulating acid system controls acid concentration, circulation flow, and absorption temperature. The finished product concentration is maintained tightly at 98.1%–98.5% H₂SO₄.
Main equipment: Drying tower, Absorption towers, Acid circulation tanks, Pumps, Acid coolers.
Waste Heat Recovery System
The production process releases heat during sulfur combustion and catalytic reactions. The plant uses recovery equipment to convert this heat into usable steam, which can be deployed for sulfur melting, heating systems, and other plant utilities.
System architecture: Waste heat boiler, Steam drum, Superheater, Economizer.
Reference parameters: Steam pressure: 3.82MPa, Steam production: approximately 15t/h.
Process Control and Automation
The plant integrates automatic monitoring and control systems to manage production conditions. The control system monitors gas temperature, acid concentration, pressure conditions, liquid level, and equipment operating status. Automatic regulation of pumps, valves, and process parameters helps maintain stable operation during continuous production.
The electrical and instrumentation system includes: Distributed control system (DCS), Field instruments, Motor control equipment, Safety monitoring devices.
Technical Data Specifications
| Parameter Name | Value / Range |
|---|---|
| Raw Material | Elemental sulfur |
| Production Capacity | 100,000 t/a |
| Product Concentration | 98.1%–98.5% H₂SO₄ |
| Process Technology | DCDA |
| SO₂ Conversion Rate | ≥99.8% |
| Operating Time | Approx. 8,000 h/year |
| Steam Recovery | Approx. 15 t/h |
| Steam Pressure | 3.82 MPa |
Engineering Scope
Process Equipment Supply
Comprehensive provision involving core structural items: Sulfur melting equipment, Combustion furnace, Converter system, Absorption towers, Heat recovery equipment, Acid storage system.
Utility System Integration
Full setup management covering plant infrastructural items: Cooling water circulation, Steam supply, Compressed air system, Electrical power supply, Instrument air system.
Environmental Management
The plant incorporates: Tail gas treatment, Acid mist control, Wastewater neutralization, Sulfur residue management.
Reference tail gas parameters: Gas volume: approximately 25,965Nm³/h, SO₂ concentration: ≤400mg/Nm³, Acid mist concentration: ≤30mg/Nm³.
Application Areas
Fertilizer Manufacturing
Sulfuric acid is used in phosphate fertilizer production, including phosphoric acid preparation and fertilizer processing systems.
Chemical Production
The plant can provide continuous acid production for chemical facilities requiring sulfuric acid as a process material.
Metal Processing
The produced acid can be applied perfectly in automated metal pickling, surface cleaning, and industrial treatment processes.
Battery & Mining
Deployed directly as electrolyte material in lead-acid battery manufacturing and mineral processing requiring controlled acid supply.
Frequently Asked Questions
1. What raw materials are required for this plant?
The primary raw material is elemental sulfur. The recommended sulfur specification includes sulfur content ≥99.9%, ash ≤0.001%, moisture ≤0.01%, and carbon ≤0.03%.
2. What production process is used?
The plant uses the sulfur combustion route with DCDA technology, including sulfur oxidation, catalytic conversion, and two-stage absorption.
3. What capacity can the plant achieve?
The reference design provides a production capacity of 100,000 tons per year. The capacity can be adjusted according to project requirements.
4. How is energy recovered during production?
Heat generated from combustion and conversion reactions is recovered through boilers and heat exchangers to produce approximately 3.82MPa steam.
5. What systems are included in a complete project?
A complete system includes process equipment, acid circulation units, heat recovery equipment, automation systems, utilities, and environmental control facilities.
Sulfuric Acid Production Plant Manufacturer
The sulfuric acid production plant combines sulfur processing, chemical conversion, absorption technology, energy recovery, and automation control into a complete industrial production system. The plant design can be adapted according to production capacity, raw material conditions, utility requirements, and environmental standards for different industrial projects.
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