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What is the most effective way to calculate overall conversion in a sulphuric acid plant?
10 months ago

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Latest Updates Like Comment Follow Flag More RAHUL PANDYA commented in the group on How can I get a video clip of industrial sulfuric acid for possible use in a documentary production?: 98 percent Sulfuric acid is colorless. you can get the pics on the internet. Just try in Google to search. If lucky can get a video too.
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Bruce Garrett Hi Darrell. I presume you are looking to determine the overall conversion of SO2 to SO3 in the catalytic oxidation step of the process. If you have in-situ analyzers for SO2 and O2 in the stack, then you can directly calculate the conversion rate from only these two pieces of data. If you do not have one or both of these analyzers, then you will need to perform manual sampling and analysis of the stack gas to obtain the data. Once I know your exact situation, we can find the best solution. You are welcome to contact me directly, or we can continue the discussion here. Regards, Bruce Garrett
10 months ago Like 1

ting ll likes this comment by sAumil shAh I need some help to know the price and the capacity of the sulfuric acid plant equipaments.: may be you get what you want from this...
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Jos Miguel Ojeda Or One option would be simulation based on operational parameters in order to develope a conversion curve. Would it be possible Mr. Bruce Garret?? Regards, Jos Ojeda
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Bruce Garrett Jose, it is certainly possible to develop such a curve based on operational parameters but also based on the theoretical conversion of SO2 to SO3. In order to accurately determine the actual conversion, you must measure the gas composition at the outlet of the converter. Regards, Bruce Garrett
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ting ll commented in the group on I need some help to know the price and the capacity of the sulfuric acid plant equipaments.: In china, just cost only $ USD 24 million per 1000MTD of sulfur buring sulfuric acid plant. its very economy. MY company construct an...
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Geert Jamaer Geert@H2SO4.pm wrote: Darrell, a rule of thumb one can use to determine overall SO2 to SO3 conversion in a sulphuric acid plant is adding up all the temperature rises (C) over all the catalyst beds and dividing them by 29 to obtain the vol% SO2 concerted. Geert Jamaer, Operations Manager www.H2SO4.pm +32 473 425779
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Vithal Rao You must measure SO2 concentration at the inlet to 1st pass; let us say it is "x" expressed in % SO2 by volume. Also measure SO2 concentration at the outlet of Final absorption tower, let us say it is "y".expressed in %SO2 by volume. The overall conversion effeciency is calculated by the formula: Overall Eff.in %= ((x-y)/y)(20000/(200-3y) This formula can be easily derived from material balance.It is also given in Sulphuric Acid books. Example let x=11.5% SO2 , y= 0.06% SO2 (600ppm) Overall eff.in % =( (11.5-0.06)/11.5)(20000/(200-3x0.06))=99.568% The assumption in this calculation is that no quench air is used. If quench air is used the concentration "y" as measured at FAT outlet will have to be corrected to a higher value by multiplying with a factor so that it will increase by the ratio of (gas+quench)/gas. This is also a simple calculation for a chemical engineer to perform. The gas analysis should be done by Reich's test or by chromatography with suitable columns ( catalyst suppliers do the latter but don't tell you how). Do not rely on instruments (SO2 analysers). The Reich test can also be done after Interpass tower and the effeciency after 3 passes can be obtained. It is advisable to do these tests once a week. The chemist should ensure that the solutions of Iodine are fresh and their aliquot concentrations are accurate. VVR
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Bruce Garrett Thank you Dr. Rao. To repeat, you must measure the SO2 concentrations in order to accurately determine the conversion in the catalytic converter.
9 months ago Like

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Jacob Lenzi Dr. Rao how much more accurate is the Reich test verses SO2 analyzers?
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Vithal Rao Reich test is certainly reliable and accurate , if done properly , and checked for reproducibilty of results. Instruments ,SO2 analysers , if properly maintained ( they get affected due to corrosion), and calibrated against Reich test, should also be reliable. Catalyst suppliers have their own methods of SO2 analysis based on chromatography. In this method , they remove SO3 from gas and analyse SO2 in residual SO3 free gas by gas chromatography. The column for this analysis is calibrated with SO2 /air mixtures in their labs. You have to pay them to do the analysis at site and give you conversion effeciency after each converter pass and also the overall conversion effeciency. Compared to SO2 analysers which are not calibrated, Reich tests are certainly more accurate, in my view. V.V.Rao
8 months ago Like 1

Wafa Kahloul Can someone please help me and send me a link where I can find the Reich test steps??
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