SULPHURIC ACID
[CODE NO.0386]
Sulfuric acid is one of the most important compounds made by the chemical industry. It is used to make, literally, H2SO4, hundreds of compounds needed by almost every industry.
Sulphuric acid forms the basis of so many of the most important heavy chemical used by the industries that it may well be regarded as the foundation on which the main structure of the heavy chemical industries . It is hard to find any branch of economy in which either sulphuric acid or products made from it are not used . It is universally acknowledged that the extent of manufactures of H2SO4 is a sure index of the state of the industrial life of a country. It would be rather appropriate to say that country's economy depends upon the consumption of the sulphuric acid.
There is hardly any important industry which is not directly or indirectly dependent to some extent on sulphuric acid, one of its derivatives or it salts. The versatile use of sulphuric acid has cripped in to almost all industrial fields and have gained enough popularity after second world war. The amount consumption and production of sulphuric acid in the country is proportional to the economic growth of the country. This industry takes the target there of industrial market. It is obvious that although fertilizer and chemical take up the targets proportion of the acid produced and reset to this stands Rayon and steel industry.
The sulphuric acid is the only acid which has thousands of uses in form of acid, salts and derivatives interestingly enough the uses of sulphuric acid starts with english alphabets 'a' and ends at 'z' . The 'A' alphabet indicates the use as an acid, 'B' indicates use is in battery, 'C' in chemical industry 'D' drugs , 'E' as explosives, 'F' forfeiting, 'G' galvanizing, 'H' as herbicides, I as insecticides, J as joint cleaning , and so on (I as leather industry, M as metallurgical industry O as Oil refining etc.,)
The conception of sulphuric acid is lacking behind in cooperation to western world. Inspite of versatile use and application the exact demand of sulphuric acid is not properly surfaced. If the country has to raise the economic condition then this industry should be manifold.
Sulphuric acid a strong acid, is an oily, viscous water white non volatile liquid. It absorbs water from the atmosphere. It is made in large volume by the chemical industry. The acid has a corrosive action on the skin, a drop of it on the skin causes a severe burn. The acid is used as a solvent, a dehydrating agent, a reagent in chemical reactions or processes as catalyst, an absorbent etc. The concentrated acid is usually stored in steel tanks. The dilute acid may be stored in lead lined or plastic tanks. It is used in very dilute concentrations and as strong fuming acid. It is often recovered and refused. After use in some phases of the explosives, petroleum and dye industries, it is often recovered in a form unsuitable for re-use in that industry but suitable for use in another industry. It is a versatile, useful acid has been called the work horse of chemical industry.
COST ESTIMATION
Plant Capacity : 100.00 MT./day
land & Building (10000 Sq.Mtr) : Rs. 7.58 Cr
Plant & Machinery : Rs. 7.20 Cr
Working Capital for 2 Months : Rs. 3.57 Cr
Total Capital Investment : Rs. 19.17 Cr
Rate of Return : 20%
Break Even Point : 62%
INTRODUCTION
USES AND APPLICATION
USES OF SULFURIC ACID.
APPLICATIONS
B.I.S. SPECIFICATIONS
MARKET SURVEY
INDIA SULPHURIC ACID MARKET TO GROW AT CAGR 3.35% TILL 2025
THE FOLLOWING PIE CHART SHOWS WORLD CONSUMPTION OF
SULFURIC ACID IN 2017
DETAILED EXPORT DATA OF SULPHURIC ACID
DETAILED IMPORT DATA OF SULPHURIC ACID
MANUFACTURERS/SUPPLIERS OF SULPHURIC ACID
STAGES IN CONTACT PROCESS TO MANUFACTURE SULPHURIC ACID 31
MANUFACTURING PROCESS
AIR POLLUTION CONTROL IN SULFURIC ACID PLANT
PLANT AND EQUIPMENT
TREATMENT OF BURNER GAS
PREHEATERS AND COOLERS
CONVERTER
PROCESS FLOW DIAGRAM FOR MANUFACTURE OF SULPHURIC ACID
MATERIALS OF CONSTRUCTION
HANDLING AND CONTAINERS
RAW MATERIALS SELECTION
OCCURRENCE AND SOURCES OF AVAILABILITY
PROCESS DESCRIPTION
PROCESS FLOW CHART OF SULPHURIC ACID MANUFACTURE
PROCESS OF SULPHURIC ACID MANUFACTURE
ELEMENTAL SULFUR
SULFUR BURNING
CONVERSION OF SO2 INTO SO3
ABSORPTION OF SO3
TAIL GAS SCRUBBER
PROCESS DESCRIPTION FOR SULFURIC ACID PLANT (BATTERY GRADE)
AVAILABLE TECHNIQUES
SOURCES OF SO2
SULFURIC ACID PRODUCTION
PRINCIPAL METAL SULFIDES PRODUCING SO2
STRONGER GAS PROCESSES HAVE
COMBUSTION OF SULFUR
PYRITES ROASTING
METAL SULFIDE ROASTING/SMELTING
SULFURIC ACID AS A BYPRODUCT FROM COPPER ORE SMELTERS
SULFURIC ACID AS A BYPRODUCT FROM LEAD PRODUCTION
REGENERATION OF SULFURIC ACID
SULFATE ROASTING
COMBUSTION OF SULFUR-CONTAINING GASES
TAIL GAS SCRUBBING
SULFURIC ACID PRODUCTION PROCESSES FOR NEW PLANTS
DETAILS OF CONTACT PROCESS
A BRIEF SUMMARY OF THE CONTACT PROCESS
MAKING THE SULPHUR DIOXIDE
CONVERTING THE SULPHUR DIOXIDE INTO SULPHUR TRIOXIDE
CONVERTING THE SULPHUR TRIOXIDE INTO SULPHURIC ACID
EXPLAINING THE CONDITIONS
THE PROPORTIONS OF SULPHUR DIOXIDE AND OXYGEN
THE TEMPERATURE
EQUILIBRIUM CONSIDERATIONS
RATE CONSIDERATIONS
EQUILIBRIUM CONSIDERATIONS
EQUILIBRIUM CONSIDERATIONS
TECHNIQUE APPLICABLE TO SULFURIC ACID PRODUCTION
SINGLE CONTACT PROCESS
DOUBLE CONTACT PROCESS (DOUBLE ABSORPTION)
OTHER PROCESSES FOR MANUFACTURE OF SULFURIC ACID
WET CONTACT PROCESS (WCP)
PRESSURE PROCESS
PLANT LAYOUT
SUPPLIERS OF RAW MATERIALS
SULPHUR POWDER
TESTING CHEMICALS
COMPLETE PLANT SUPPLIERS FOR SULPHURIC ACID ON TURNKEY BASIS
SUPPLIERS OF PLANT AND MACHINERY
SCRUBBER
HEAT EXCHANGER
COOLING TOWER
STORAGE VESSEL FOR OLEUM AND SULPHURIC ACID
MATERIAL HANDLING EQUIPMENTS
INSTRUMENTATION & PROCESS CONTROL EQUIPMENTS
LABORATORY EQUIPMENTS
POLLUTION CONTROL EQUIPMENTS
BOILERS
AIR COMPRESSORS
APPENDIX – A:
1. COST OF PLANT ECONOMICS
2. LAND & BUILDING
3. PLANT AND MACHINERY
4. FIXED CAPITAL INVESTMENT
5. RAW MATERIAL
6. SALARY AND WAGES
7. UTILITIES AND OVERHEADS
8. TOTAL WORKING CAPITAL
9. COST OF PRODUCTION
10. PROFITABILITY ANALYSIS
11. BREAK EVEN POINT
12. RESOURCES OF FINANCE
13. INTEREST CHART
14. DEPRECIATION CHART
15. CASH FLOW STATEMENT
16. PROJECTED BALANCE SHEET
