Group 2 - Design Project 1

Final Report 2 Design Project 1 (CPB30703)
Student Name Student ID

1 MUHAMMAD FARHAN BIN MOHD FOZI 55213119183
2 ANIS FARHANA BIN MOHD ASWANI 55213119109
3 NUR AFIFAH BINTI KHAIRUR YUSHA 55213119161
4 TUAN NUR ATHIRAH BINTI TUAN MAHMOOD 55213119160
PRODUCTION BASIC: THE PRODUCTION OF SULPHURIC ACID
(230,000 MTA)
CRITERIA EVALUATION
VERY POOR GOOD VERY GOOD EXCELLENT
TOTAL
1.0 INTRODUCTION (10%) – Process Description POOR 3-4 5-6 7-8 9-10
1. Description about the selected process (from Part 1)
2.0 PROCESS FLOW DIAGRAM (40%) – (All) VERY POOR GOOD VERY GOOD EXCELLENT
TOTAL
1. Process flow diagram must contain the elements: stream number, ID of POOR 9-16 17-24 25-32 33-40
equipment, pumps, compressors, expansion valve, heat exchanger,
storage tanks.
3. Include stream information table located in the bottom of PFD. It must
contain information about stream number, flow rate of the stream (mass flow
rate and molar flow rate of component and total), enthalpy of stream,
temperature and pressure of stream.
3.0 MASS BALANCE (40%) – Student 1 VERY POOR GOOD VERY GOOD EXCELLENT
TOTAL
POOR 9-16 17-24 25-32 33-40
1. Method of calculation and detailed calculation.
2. Assumption must be stated clearly, with justification if necessary.
3. All details and calculation must be presented and explained (e.g.
reaction equation, conversion, selectivity, designed composition of
distillate/bottom product of column, vaporization rate, degree of separation,
etc).
4.0 SOFTWARE MASS (40%) – Student 2 VERY POOR GOOD VERY GOOD EXCELLENT
TOTAL
1. Mass Balance of the process simulated with software (Excel, Aspen POOR 9-16 17-24 25-32 33-40
HYSYS, Aspen Plus, ChemCAD).
2. Simulates all equipment and streamline.
3. Report generated compared with manual mass balance calculation.
VERY POOR GOOD VERY GOOD EXCELLENT
5.0 ENERGY BALANCE (40%) – Student 3 TOTAL
POOR 9-16 17-24 25-32 33-40
1. Method of calculation and detailed calculation.
2. Assumption must be stated clearly, with justification if necessary.
3. Amount of heat generated by system and/or heat required by system
must be clearly state (e.g. heat generated by reactor that require to be
cooled, or heat release by condenser/heat required by reboiler in
distillation column, etc.)
6.0 SOFTWARE ENERGY BALANCE (40%) – Student 4 VERY POOR GOOD VERY GOOD EXCELLENT
TOTAL
POOR 9-16 17-24 25-32 33-40
1. Energy Balance of the process simulated with software (Excel, Aspen
HYSYS, Aspen Plus, ChemCAD)
2. Simulates all equipment and streamline
3. Report generated compared with manual energy balance calculation
7.0 REFERENCES, NEATNESS (10%) ALL - VERY POOR GOOD VERY GOOD EXCELLENT
TOTAL
All of the supporting data must be according to according to relevant POOR 3-4 5-6 7-8 9-10
standard code of practice (e.g. physical, chemical, thermodynamic
properties). Sources of references are valid and cited in the report. Written
according to format, tidy and properly attached
Criteria % STUDENT 1 STUDENT 2 STUDENT 3 STUDENT 4
1.0 Introduction (All) 10
2.0 Process Flow Diagram (All) 40
3.0 Mass Balance (Student 1) 40
4.0 Software Mass Balance (Student 2) 40
5.0 Energy Balance (Student 3) 40
6.0 Software Energy Balance (Student 4) 40
7.0 References & Neatness (All) 10
TOTAL 100
UNIVERSITI KUALA LUMPUR
MALAYSIAN INSTITUTE OF CHEMICAL AND BIOENGINEERING TECHNOLOGY
(MICET)
CPB 30703 | PLANT DESIGN PROJECT 1
DR KELLY TONG TAU LEN
REPORT 2: PRODUCTION OF SULPHURIC ACID (230,000 MTA)
SEMESTER JULY 2021
NAME NO ID
MUHAMMAD FARHAN BIN MOHD FOZI 55213119183
ANIS FARHANA BINTI MOHD ASWANI 55213119109
NUR AFIFAH BINTI KHAIRUR YUSHA 55213119161
TUAN NUR ATHIRAH BINTI TUAN MAHMOOD 55213119160
1
TABLE OF CONTENT
TABLE OF CONTENT .......................................................................................................... 2
1.0 INTRODUCTION ........................................................................................................ 4
1.1 The Process Selection ............................................................................................ 5
1.2 Objectives ............................................................................................................... 5
2.0 PROCESS FLOW DIAGRAM .................................................................................... 6
3.0 MASS BALANCE ...................................................................................................... 9
3.1 Molecular Weights ................................................................................................ 10
3.2 Mass Balance Calculations ................................................................................... 10
3.2.1 Molar Flowrate of Product, 230,000 MTA (98.5% w/w H2SO4) (1.5% w/w
H2O). 11
3.2.2 H2SO4 Distribution Header ............................................................................. 12
3.2.3 Tower Absorption Distribution Header ........................................................... 14
3.2.4 Dilution Tank .................................................................................................. 15
3.2.5 Oleum Distribution Header ............................................................................. 17
3.2.6 Oleum Tank ................................................................................................... 20
3.2.7 Final Absorption Tower (FAT) ........................................................................ 23
3.2.8 Scrubber ........................................................................................................ 26
3.2.9 Economizer 2 ................................................................................................. 27
3.2.10 Converter 4 ................................................................................................ 28
3.2.11 Heat Exchanger 2....................................................................................... 31
3.2.12 Heat Exchanger 1....................................................................................... 32
3.2.13 Interpass Absorption Tower ........................................................................ 33
3.2.14 Economizer 1 ............................................................................................. 36
3.2.15 Converter 3 ................................................................................................ 37
3.2.16 Converter 2 ................................................................................................ 40
3.2.17 Waste Heat Boiler 2 ................................................................................... 43
3.2.18 Converter 1 ................................................................................................ 44
2
3.2.19 Electrostatic Precipitator (ESP) .................................................................. 47
3.2.20 Waste Heat Boiler 1 ................................................................................... 49
3.2.21 Furnace ...................................................................................................... 50
3.2.22 Sulfur Melter ............................................................................................... 53
3.2.23 Air Distribution Header ............................................................................... 54
3.2.24 Air Dryer ..................................................................................................... 55
3.2.25 Air Blower ................................................................................................... 57
3.3 Software Mass Balance ........................................................................................ 58
3.3.1 Simulation Mass Balance (Microsoft Excel) ................................................... 58
3.3.2 Percentage Different in Manual and Excel Calculation of Mass Balance ........ 63
4.0 ENERGY BALANCE ................................................................................................ 65
4.1 Standard Enthalpies of Formation ......................................................................... 65
4.2 Specific Heat Capacities (at constant pressure, Cp) ............................................. 66
4.3 Boiling and melting points ..................................................................................... 67
4.4 Energy Balance Calculation .................................................................................. 68
4.4.1 Reactive Energy Balance ............................................................................... 68
4.4.2 Non- Reactive Process .................................................................................. 91
4.5 Software Energy Balance (Microsoft Excel) ........................................................ 117
4.5.1 Simulation Energy Balance (Reactive) ......................................................... 117
4.5.2 Simulation Energy Balance (Non-Reactive) ................................................. 126
4.5.2 Percentage Different in Manual and Excel Calculation of Energy Balance ... 136
5.0 REFERENCES ....................................................................................................... 137
3
1.0 INTRODUCTION
The raw materials used in this company are solid sulphur and oxygen gas to produce
concentrated liquid sulphuric acid as the main product. Sulphuric acid, H2SO4 also called as
oil, vitriol, hydrogen sulphate or battery acid, which is dense, colourless, oily, corrosive liquid
and consider as one of the most important commercial chemicals for industry usage. It has
wide application usage such as car battery acid, certain detergents and sometimes called the
“the blood of chemical industry’, because of the fact it is used in the number of key syntheses
(Standen, 2021).
Sulphuric acid is a very reactive chemical and can dissolves most metals as it is concentrated
strong acid that oxidizes, dehydrates or sulfonates most organic compound. Sulphuric acid
can be produced naturally even though it can be extremely harmful. Most of anthropogenic
sources can release of sulphur into atmosphere and emissions associated with specific
volcanoes, and sulphuric acid aerosols from an eruption can persist in the stratosphere for
many years (Mpinga, Eksteen, Aldrich, & Dyer, 2015). Dilute acid will be formed as constituent
of acid rain with the reaction of sulphuric trioxide and rainwater to form sulphuric acid and
sulphur dioxide dissolved in rainwater to form sulphurous acid (H2SO3), and is then oxidized
to form sulfuric acid, which leads to acid rain.
However, pure sulfuric acid can be produced industrially by several type of processes.
Two types of common process used in industry which are contact process or chamber process
by the combustion of sulphur dioxide and oxygen gas (Davenport, King, & Rogers, 2006).
These two processes have different flow of process and equipment used to produce pure
sulphuric acid. Hence, the process chosen for SOCHEMIE Berhad considered on the quality
of the product with high acid concentration in the range of 98% to 99.9% in contact process.
Recall also that the output concentration of the final product in Lead Chamber Process is more
dilute acid content compared to process contact with 62%-78% of acid concentration. The
specification product is significant in terms of the demand of Sulfuric Acid with various
manufacturing industry such as increase in demand for fertilizer and metals processing
such as Copper and Nickel as more acid needs to be produced to cater for higher levels
of metal processing.
4
1.1 The Process Selection
The process selected for the SOCHEMIE Berhad company is the double contact
double absorption process. This process is slightly same process as single contact process
which the Contact Process is starting with the material which clean, dry sulphur dioxide (SO2)
gas by burning molten sulphur with oxygen gas. Contact process apply converter for oxidising
sulphur dioxide into sulphur trioxide with the presence of vanadium oxide as catalyst. Sulphur
trioxide then contacted and dissolved in concentrated Sulphuric Acid to produce Oleum
(H2SO4). The Oleum can be reacted with water to produce high concentration of Sulphuric
Acid (ESA & EFMA, 2000).
Furthermore, the double contact process is presence of double reactive-absorption

tower which is intermediate and final and four or more converter beds in catalytic reactor. The
Le Chatelier's principle indicates that resending the unreacted SO2 and the product SO3 back
to the column, (following intermediate absorption of SO3) the equilibrium of the conversion
reaction becomes more forward biased, thereby converting more SO2. The unconverted SO2
of the product stream from catalytic bed can be reduced as the SO2 and SO3 will be channel
to the intermediate catalytic bed reactor and absorber twice to achieve further absorption and
conversion. Hence, enhance the oxidation of SO2 to about 99.5% conversion to SO3 or higher
in the final absorption tower and an acid concentration in the range 98-99%.
1.2 Objectives
1. To construct a process flow diagram with stream number, ID of equipment, flow

sheet that contain information about flow rate of stream (mass flow rate and molar
flow rate of component and total), enthalpy of stream, temperature and pressure of
stream.
2. To simulate methanol process with software (MS Excel).
3. To compare report generated from software with the manual material/energy
balance.
5
2.0 PROCESS FLOW DIAGRAM
H-101 B-101 P-101 JB-10 DE-101 WHB-1 FG-101 R-101 WHB-102 R-102 E-101 E-102 R-103 E-103 E-104 T-101 R-104 E-105 T-102 TT-101 TT-102 J-101
Melter Furnace Filter Air Blower Air Dryer Waste Heat Electrostatics Catalytic Bed Waste H eat Catalytic Bed Condenser Heat Catalytic Bed Heat Heat Inter-pass Catalytic Bed Heat Fat Absorption Acid pump Dilution Centrifugal
Boiler 1 precipitator Reactor 1 Boiler 2 Reactor 2 1 Exchanger 1 Reactor 3 Exchanger 2 Exchanger 3 Absorption Reactor 4 Exchanger 4 tower Tank Tank Pump 1
Tower
J-102 TE-101 JC-101 T-103 FG-101 FG-102 FG-103 FG-104
Centrifugal Cooling Compressor Scrubber Air Absorption H2SO4 Oleum
Pump 2 Tower (Tower) Distribution Distribution Tank Distribution Tank Distribution Tank
420°C
1 atm
FG-101
430°C 9
R-101
1 atm
8 629°C
1 atm Gas Waste
1120°C WHB-101
1 atm 10
40 26
7 Dust
mps Collector WHB-102
Sulphur B-101
Sulphur (solid) 30°C (Molten)
1 atm
Fuel R-102
1 2 550°C
1 atm 11 T-103
430°C 90°C Waste
135°C 12 1 atm water
1 atm
1 atm 19
H-101 20
38 90°C
R-103 1 atm
13 E-103
37 E-102 430°C 32
18
1 atm 14 25
495°C 15 FG-102
1 atm
FG-101
21 500°C
6 1 atm
450°C
1 atm E-104
22 160°C 33
R-104 1 atm
DE-101
16
E-105
T-101
5 130°C 17
1 atm
23
Air
T-102
3 4
TT-101
P-101 JB-101 24
30
29
28
27
J-101 39 FG-103
Water J-102
30°C
1 atm
35 34
Concentrated
Sulphuric Acid
TT-102
31 36
FG-104
Figure
Figure 2.1: 2.2: Flow
Process Steamtable Information
Diagram at Stream
of Sulphuric 1 to Stream
Acid Production with20.
Steamtable Information.
6
Table 2.1: Steamtable Information at Stream 1 to Stream 20.
Number of Stream
FLOWRATE (kmol/hr)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
H2SO4 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 189.51 1263.39 0 0
H2S2O7 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1073.88 0 0 0
S 1525.81 1510.55 0 0 0 0 216.18 218.34 2.16 2.16 2.16 2.16 2.16 2.16 2.1618 2.16 0 0 2.16 2.16
H2O 0 0 653.15 653.15 653.15 0 0 0 0 0 0 0 0 0 0 0 0 105.4 0 0
SO2 0 0 0 0 0 0 1294.37 1294.37 1294.37 310.12 310.12 244.99 244.99 220.49 220.4942 220.49 0 0 220.49 220.49
SO3 0 0 0 0 0 0 0 0 0 984.25 984.25 1049.38 1049.38 1073.88 1073.877 1073.88 0 0 0 0
H2S 17.29 17.29 0 0 0 0 17.29 17.29 17.29 17.29 17.29 17.29 17.29 17.29 17.2941 17.29 0 0 17.29 17.29
O2 0 0 7.53 7.53 5261.96 5261.96 398.81 398.81 398.81 1142.98 1142.98 1110.42 1110.42 1098.17 1098.171 1098.17 0 0 1098.17 1098.17
N2 0 0 19823.32 19823.3 19823.32 19823.32 15165.83 15165.83 15165.83 19823.32 19823.32 19823.32 19823.32 19823.32 19823.32 19823.32 0 0 19823.32 19823.32
CO2 0 0 7.53 7.53 7.53 7.53 776.46 776.46 776.46 778.23 778.23 778.23 778.23 778.23 778.2329 779.23 0 0 778.23 778.23
Total Molar Flowrate

1543.1 1527.84 25745.96 25746 25745.96 25092.81 17868.94 17868.94 17654.93 23058.36 23058.36 23025.8 23025.8 23013.55 23013.55 23013.55 1263.39 1368.78 21939.68 21939.68
(kmol/hr)
Temperature (ᴼC) 30 135 14 14 15 143 1120 430 420 629 430 550 430 495 187 160 87 187 90 98
Pressure (atm) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Enthalphy (KJ/mol) 2828.43 -92835.93 119569 88173.39 48518.49 -99150.32
7
Table 2.2: Steamtable Information at Stream 21 to Stream 40.
Number of Stream
FLOWRATE (kmol/hr)
21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
H2SO4 0 0 0 38.658 0 0 228.17 2647.46 2647.46 3953.76 2098.949 252.667 1399.32 1399.316 0 699.633 0 0 1534.46 0
H2S2O7 0 0 0 214.009 0 0 1287.89 999.08 999.08 0 0 0 0 0 0 0 0 0 288.81 0
S 2.16 2.16 2.16 0 2.16 2.16 0 0 0 0 0 0 0 0 0 0 0 0 0 214.01
H2O 0 0 0 0 0 0 0 0 0 0 175.102 21.078 116.74 116.736 463.91 58.366 0 0 0 0
SO2 220.49 4.32 4.32 0 4.32 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
SO3 0 216.17 216.17 0 2.16 2.16 0 0 0 0 0 0 0 0 0 0 0 0 0 0
H2S 17.29 17.29 17.29 0 17.29 17.29 0 0 0 0 0 0 0 0 0 0 0 0 0 0
O2 1098.17 990.09 990.09 0 990.09 990.09 0 0 0 0 0 0 0 0 0 0 4025.66 1236.3 0 0
N2 19823.32 19823.32 19823.32 0 19823.32 19823.32 0 0 0 0 0 0 0 0 0 0 15165.83 4657.49 0 0
CO2 778.23 778.23 778.23 0 778.23 778.23 0 0 0 0 0 0 0 0 0 0 5.76 1.77 0 0

21939.68 21831.59 21831.59 252.667 21617.58 21613.26 1516.05 3646.54 3646.54 3953.76 2274.05 273.745 1516.05 1516.052 463.91 757.999 19197.25 5895.56 1823.27 214.01
(kmol/hr)
Temperature (ᴼC) 298.0263 500 130 87 90 40 87 87 187 143 70 187 187 70 30 70 143 143 87 87
Pressure (atm) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Enthalphy (KJ/mol) 14257.86 -60625 -31925.36 1315780
8
3.0 MASS BALANCE
The mass balance was produced for a plant running in steady state (with 0% accumulation
assumed), on a one-hour basis, for a plant operating in steady state.
Mass in + mass generated = mass out + mass consumed + losses
Prior to the mass balance calculation, several set of parameters or information that would be
considered as variables were identified from the literature review for future benefits. To make
the statistics as accurate as feasible, the provision was assigned individually for equipment
where it was considered relevant and as a whole for all other equipment.
Table 3.1: List of variables used in constructing mass and energy balance in MS Excel and
calculations.1
No. Parameter Figure Unit
1. No of working months per year 11 Months/year
2. No of working days per month 25 Days/month
3. No of working hours per day 12 Hours/day
4. Sulphur melting process efficiency 100% w/w
5. Percentage removal of sulphur dust from 99% w/w
mainstream in dust collector of ESP
6. Degree conversion of sulphur burner 90% v/v
7. Degree conversion: catalytic bed reactor 4 98% v/v
8. Degree conversion: catalytic bed reactor 1-3 95% v/v
beds
9. Excess air supplied to the converter 10% 10% v/v
10. Absorption efficiency in IPAT 100% w/w
11. Excess Sulphuric Acid supply to IPAT 0% w/w
12. Absorption % SO3 in FAT 99% w/w
13. Absorption % SO3 in IPAT 100% w/w
14. Concentration of product Sulphuric Acid 98.5% w/w
15. Outlet Ratio of Stream 34 to Stream 36 2:1 -
16. Ratio of Outlet Stream 28 to Stream 39 2:1 -
17. Ratio of Inlet Stream 30 to Stream 27 2.6:1 -
18. Ratio of Inlet Stream 17 to Stream 24 5:1 -
9
3.1 Molecular Weights
Molecular weight of each component is used to convert the mass-based material flow rates to
molar flow rates in the mass and energy balance. The molecular weights of components were
obtained as shown.
Table 3.2: Molecular weights of species involved in the process (Perry, Green, & Maloney,
1997)
Species Molecular Weight (kg/kmol)

Sulfur 32
Sulfur Dioxide 64.063
Sulfur Trioxide 80.058
Oleum 178
Sulfuric Acid 98
Water 18.015
Hydrogen Sulfide 34.08
Oxygen 31.999
Nitrogen 28.013
Carbon Dioxide 44.01
3.2 Mass Balance Calculations
The basic source of raw material for the process is Sulphur, which the sulphur was obtained
from other local company. Other than that, air is needed as well as the raw material to produce
high concentrated sulphuric acid. The information below shows the production rate of
SOCHEMIE Berhad and assumption of plant operation per hours and annually.
Production Rate Sulphuric Acid : 230,000 MTA (98.5% w/w H2SO4) (1.5% w/w H2O).
Assumption of plant operation : The plant operates 11 months yearly for 25 days
hours annually monthly and 12 hours daily.
10
3.2.1 Molar Flowrate of Product, 230,000 MTA (98.5% w/w H2SO4) (1.5% w/w H2O).
• 98.5% w/w x 230,000 MTA = 226,550 MTA

• 1.5% w/w x 230,000 MTA = 3,450 MTA
H2SO4
𝑘𝑔 𝑘𝑔
226,550 MTA x 1000 = 226,550,000
𝑀𝑇 𝑦𝑟
𝑘𝑔 𝑘𝑔 𝑘𝑚𝑜𝑙 𝑚𝑜𝑛𝑡ℎ𝑠 𝑘𝑚𝑜𝑙

= 226,550,000 / 98.08 = 2,309,849.103 / 11 = 209,986.282
𝑦𝑟 𝑘𝑚𝑜𝑙 𝑦𝑟 𝑦𝑟 𝑚𝑜𝑛𝑡ℎ
𝑘𝑚𝑜𝑙 𝑑𝑎𝑦𝑠 𝑘𝑚𝑜𝑙 ℎ𝑟𝑠 𝒌𝒎𝒐𝒍

= 209,986.282 / 25 = 8,399.45 / 12 = 699.95
𝑚𝑜𝑛𝑡ℎ 𝑚𝑜𝑛𝑡ℎ 𝑑𝑎𝑦𝑠 𝑑𝑎𝑦𝑠 𝒉𝒓𝒔
H2O
𝑘𝑔 𝑘𝑔
3,450 MTA x 1000 = 3,450,000
𝑀𝑇 𝑦𝑟
𝑘𝑔 𝑘𝑔 𝑘𝑚𝑜𝑙 𝑚𝑜𝑛𝑡ℎ𝑠 𝑘𝑚𝑜𝑙

= 3,450,000 / 18.01 = 191,560,2443 / 11 = 17,414.568
𝑦𝑟 𝑘𝑚𝑜𝑙 𝑦𝑟 𝑦𝑟 𝑚𝑜𝑛𝑡ℎ
𝑘𝑚𝑜𝑙 𝑑𝑎𝑦𝑠 𝑘𝑚𝑜𝑙 ℎ𝑟𝑠 𝒌𝒎𝒐𝒍

= 17,414.568 / 25 = 696.583 / 12 = 58.049
𝑚𝑜𝑛𝑡ℎ 𝑚𝑜𝑛𝑡ℎ 𝑑𝑎𝑦𝑠 𝑑𝑎𝑦𝑠 𝒉𝒓𝒔
Flow of the Process:
→ Blower → Air Dryer

→ Melter→ Furnace → Waste Heat Boiler 1 → Electrostatic Precipitator →
Converter 1 → Waste Heat Boiler 2 → Converter 2 → Heat Exchanger 1 → Converter 3 →
Heat Exchanger 2 → Precooler → Inter-Pass Absorption Tower → Converter 4 → Final
Absorption Tower → Oleum Tank → Oleum Distribution Header → Dilution Tank → H2SO4
Distribution Header → H2SO4 Storage Tank.
11
3.2.2 H2SO4 Distribution Header
Liquid Stream 34
(To Tower Absorption Distribution)
F2, Molar Flowrate

= 1516.052 kmol/hr
Molar Fraction (kmol/kmol)
x2, Sulphuric Acid, H2SO4
= 0.923 kmol/kmol
y2, Water, H2O
= 0.077 kmol/kmol
Liquid Stream 31 Molar Flowrate (kmol/hr) Liquid Stream 36

(From Dilution Tank) X2, Sulphuric Acid, H2SO4 (To H2SO4 Storage Tank)
= 1399.316
F3, Molar Flowrate
F1, Molar Flowrate Y2, Water, H2O
= 757.999 kmol/hr
= 2274.051 kmol/hr = 116.736
= 0.923
= 0.923
y3, Water, H2O
y1, Water, H2O
= 0.077
= 0.077
Molar Flowrate (kmol/hr)
Molar Flowrate (kmol/hr) H2SO4 DISTRIBUTION
X3, Sulphuric Acid, H2SO4
X1, Sulphuric Acid, H2SO4 HEADER
= 699.633
= 2098.949
Y3, Water, H2O
Y1, Water, H2O
= 58.366
= 175.102
Information Provided: (Green Highlight)
• Outlet Ratio of Stream 34 to Stream 36: 2 :1, Thus the molar flowrate for Stream 34 is
1516.052 kmol/hr.
• Outlet molar fraction and molar flowrate for Sulphuric Acid, H2SO4 and Water, H2O at
stream 36.
12
NON-REACTIVE PROCESS
• Overall Balance
F1 = F2 + 757.999 kmol/hr
F1 = 1516.052 kmol/hr + 757.999 kmol/hr
F1 = 2274.051 kmol/hr
Inlet:
• Stream 31 Inlet Sulphuric Acid, H2SO4 Molar Flowrate
X1 = (2274.051 kmol/hr) (0.923 kmol/mkol)

X1 = 2098.949 kmol/hr
• Stream 31 Inlet Water, H2O Molar Flowrate
Y1 = (2274.051 kmol/hr) (0.077 kmol/kmol)

Y1 = 175.102 kmol/hr
• Stream 34 Outlet Sulphuric Acid, H2SO4 Molar Flowrate
X2 = (1516.052 kmol/hr) (0.923 kmol/mkol)

X2 = 1399.316 kmol/hr
• Stream 34 Outlet Water, H2O Molar Flowrate
Y2 = (1516.052 kmol/hr) (0.077 kmol/mkol)

Y2 = 116.736 kmol/hr
13
3.2.3 Tower Absorption Distribution Header
Liquid Stream 32 (To FAT)
F2, Molar Flowrate

= 273.745 kmol/hr

= 0.923
y2, Water, H2O Liquid Stream 18
Liquid Stream 33 = 0.077 (To IPAT)
(From H2SO4 Distribution Header) Molar Flowrate (kmol/hr)
X2, Sulphuric Acid, H2SO4 F3, Molar Flowrate
F1, Molar Flowrate
= 252.667 = 1368.78kmol/hr
= 1516.052 kmol/hr
Y2, Water, H2O
= 21.078 Molar Fraction (kmol/kmol)
= 0.923 kmol/kmol
= 0.923
Y1, Water, H2O
y3, Water, H2O
= 0.077 kmol/kmol
= 0.077
Molar Flowrate (kmol/hr) TOWER
X1, Sulphuric Acid, H2SO4 ABSORPTION
= 1399.316 DISTRIBUTION
= 1263.39
Y1, Water, H2O HEADER
Y3, Water, H2O
= 116.736
= 105.40
Absorption Header is used to distribute the concentrated sulphuric acid to two absorption
tower which are Interpass Absorption Tower and Final Absorption Tower. Therefore, the ratio
between stream 18 and stream 32 is, 5 : 1 of concentrated sulphuric acid.
14
3.2.4 Dilution Tank
Liquid Stream 35
Water, H2O
Liquid Stream 39
F2, Molar Flowrate
(From Oleum Distribution) Liquid Stream 31
= 464.615 kmol/hrs
(To H2SO4 Distribution Tank)
F1, Molar Flowrate
= 1809.439 kmol/hr
F3, Molar Flowrate

Molar Fraction (kmol/kmol) = 2274.051 kmol/hr
= 0.84
z1, Oleum, H2S2O7
DILUTION TANK x3, Sulphuric Acid, H2SO4
= 0.16 = 0.923
y3, Water, H2O
= 0.077
= 1519.929
Z1, Oleum, H2S2O7 X3, Sulphuric Acid, H2SO4
= 289.510
= 2098.949
Y3, Water, H2O
= 175.102
Main Reaction:
H2S2O7 (ℓ) + H2O (ℓ) → 2H2SO4 (ℓ)____________________ξ1
(Oleum) + (Water) (Sulphuric Acid)
In the Dilution Tank H2SO4 Production occurs using process water. This gives 98.5% pure
H2SO4.
• Stream 31, Outlet molar fraction and molar flowrate for Sulphuric Acid, H2SO4 and
Water, H2O.
• Stream 39 Inlet Molar Fraction for Sulphuric Acid and Oleum.
o x1, Sulphuric Acid, H2SO4 = 0.84 kmol/kmol
o z1, Oleum, H2S2O7 = 0.16 kmol/kmol
15
REACTIVE PROCESS (EXTENT OF REACTION)
• Oleum, H2S2O7 Balance
0 = Z1 (Oleum) - 1ξ
0 = (F1*0.16) - 1ξ
ξ = 0.16F1
• Sulphuric Acid, H2SO4 Balance
X3 (H2SO4 out) = X1 (H2SO4) + 2ξ

2098.949 kmol/hr = (F1*0.84) + 2ξ
2098.949 kmol/hr = 0.84F1 + 2(0.16F1)
F1 = 1809.439 kmol/hr
ξ = 0.16 (1809.438 kmol/hr) = 289.510 kmol/hr
• Water, H2O Balance
Y3 (H2O out) = F2 - 1ξ
175.102 kmol/hr = F2 - 1ξ
175.102 kmol/hr = F2 – 289.510 kmol/hr

F2 = 464.615 kmol/hrs
Inlet:
➢ Stream 35 Inlet Sulphuric Acid, H2SO4 Molar Flowrate
X1 = (1809.439 kmol/hr) (0.84 kmol/kmol)

X1 = 1519.929 kmol/hr
➢ Stream 35 Inlet Oleum, H2S2O7 Molar Flowrate
Z1 = (1809.439 kmol/hr) (0.16 kmol/kmol)

Z1 = 289.510 kmol/hr
16
3.2.5 Oleum Distribution Header
Liquid Stream 30 (From Air Dryer)
F2, Molar Flowrate

= 3920.451 kmol/hr

= 1.0
Molar Flowrate (kmol/hr) Liquid Stream 39
Liquid Stream 27 X2, Sulphuric Acid, H2SO4 (To Dilution Tank)
(From Oleum Tank) = 3920.451 kmol/hr
F3, Molar Flowrate
F1, Molar Flowrate
= 1809.439 kmol/hr
= 1507.866 kmol/hr

= 0.84
= 0.15 OLEUM
z3, Oleum, H2S2O7
z1, Oleum, H2S2O7 DISTRIBUTION
= 0.16
= 0.85 HEADER
= 1519.929
= 226.180
Z3, Oleum, H2S2O7
Z1, Oleum, H2S2O7 Liquid Stream 28
= 289.510
= 1281.686 (To Air Dyer)
F4, Molar Flowrate

= 3618.878 kmol/hr

= 0.73
y4, Oleum, H2S2O7
= 0.27
= 2626.702 kmol/hr 17
Z4, Oleum, H2S2O7
= 992.176 kmol/hr
Oleum header is used to distribute the Oleum to necessary location especially to Air
Dyer for drying process and return back. It is assumed that no reaction occurs in Oleum
Distribution Header. Oleum was calculated for drying based on the idea that both Sulphuric
Acid and Oleum has the ability of absorbing moisture from a system. In order to ensure
complete absorption of water (and thus reaction) it was assumed that Oleum needs to be
added in excess, and a variable in the form of excess Oleum was added.
OIeum, H2S2O7.
• Inlet Molar Fraction for Stream 27.
o x1, Sulphuric Acid, H2SO4 = 0.15 kmol/kmol
o z1, Oleum, H2S2O7 = 0.85 kmol/kmol
• Inlet Molar Fraction for Stream 30.
o X2, Sulphuric Acid, H2SO4 = 1.0 kmol/kmol
• Ratio of Outlet Stream 28 to Stream 39 = 2:1
• Ratio of Inlet Stream 30 to Stream 27 = 2.6:1
• Overall Balance
F1 + F2 = 1809.439 kmol/hr + F4
• Stream 28 Outlet F4, Total Molar Flowrate
Ratio of outlet Stream 28 to Stream 39 = 2:1

𝑆𝑡𝑟𝑒𝑎𝑚 28 2.00 𝑆𝑡𝑟𝑒𝑎𝑚 28
= = = = Stream 28 = 3618.878 kmol/hr
𝑆𝑡𝑟𝑒𝑎𝑚 39 1.00 1809.439 𝑘𝑚𝑜𝑙/ℎ𝑟
F4 = 3618.878 kmol/hr
From overall balance,
F1 + F2 = 1809.439 kmol/hr + 3618.878 kmol/hr

F1 + F2 = 5428.317 kmol/hr
18
• Stream 30 Inlet F2, Total Molar Flowrate
Ratio of Inlet Stream 30 to Stream 27 = 2.6:1

Total inlet stream 30 and stream 27 = 5428.317 kmol/hr
𝑆𝑡𝑟𝑒𝑎𝑚 30 2.6
5428.317 kmol/hr = = = 3920.451 kmol/hr
1507.866 kmol/hr
F1 = 1507.866 kmol/hr
F2 = 3920.451 kmol/hr
X1 = F1*x1
X1 = 226.180 kmol/hr
➢ Stream 27 Inlet Oleum, H2S2O7 Molar Flowrate
Z1 = F1 – X1
Z1 = 1507.866 kmol/hr - 226.180 kmol/hr
Z1 = 1281.686 kmol/hr
X1 + X2 = X3 + X4
226.180 kmol/hr + 3920.451 kmol/hr = 1519.929 kmol/hr + X4
X4 = 2626.702 kmol/hr
Since, F4 = 3618.878 kmol/hr

Z4 = F4 – X4
Z4 = 3618.878 kmol/hr - 2626.702 kmol/hr
Z4 = 992.176 kmol/hr
Hence,
x4 = 2626.702 kmol/hr / 3618.878 kmol/hr = 0.73 kmol/kmol
z4 = 1.00 kmol/kmol - 0.73 kmol/kmol= 0.27 kmol/kmol
19
3.2.6 Oleum Tank
Liquid Stream 17
Liquid Stream 24
(from IPAT)
(From FAT)
F1, Molar Flowrate F2, Molar Flowrate

= 251.311 kmol/hr = 1256.55 kmol/hr
Molar Fraction (kmol/kmol) OLEUM TANK Molar Fraction (kmol/kmol)

x1, Sulphuric Acid, H2SO4 x2, Sulphuric Acid, H2SO4
= 0.15 = 0.15
z1, Oleum, H2 S2O7 z2, Oleum, H2S2O7
= 0.85 = 0.85
Molar Flowrate (kmol/hr) Molar Flowrate (kmol/hr)
X1, Sulphuric Acid, H2SO4 X2, Sulphuric Acid, H2SO4
Liquid Stream 27
= 37.697 = 188.483
(To Oleum Distribution Header)
Z1, Oleum, H2S2O7 Z2, Oleum, H2S2O7
= 213.614 F3, Molar Flowrate = 1068.072
= 1507.866 kmol/hr
=0.15
z3, Oleum, H2S2O7
= 0.85
= 226.180
Z3, Oleum, H2S2O7
= 1281.686
20
Oleum tank is used to receive the oleum from Interpass Absorption Tower (IPAT) and Final
Absorption Tower (FAT).

OIeum, H2S2O7.
• Stream 17, Inlet molar fraction for Sulphuric Acid, H2SO4 and OIeum, H2S2O7.
x1 = 0.15 kmol/kmol
z2 = 0.85 kmol/kmol
• Ratio of Inlet Stream 17 to Stream 24 = 5:1
• Overall Balance
F1 + F2 = F3
• Stream 17 Inlet F2, Total Molar Flowrate
Ratio of Inlet Stream 17 to Stream 24 = 5:1

Total inlet stream 17 and stream 24 = 1507.866 kmol/hr
𝑆𝑡𝑟𝑒𝑎𝑚 17 5.00 1256.55 kmol/hr
1507.866 kmol/hr = = = 251.311 kmol/hr
F2 = 1256.555 kmol/hr
F1 = 251.311 kmol/hr
X2 = F2*x2
X2 = 188.483 kmol/hr
Hence,
Z2 = F2 – X2
Z2 = 1256.555 kmol/hr - 188.483 kmol/hr
Z2 = 1068.072 kmol/hr
21
X1 + X2 = X3
X1 + 188.483 kmol/hr = 226.180 kmol/hr
X1 = 37.697 kmol/hr
Hence the molar fraction H2SO4, x1

x1 = 37.697 kmol/hr/251.311 kmol/hr
x1 = 0.15 kmol/kmol
However, the molar fraction H2S2O7, z1

z1 = 1.0 kmol/kmol – 0.15 kmol/kmol
z1 = 0.85 kmol/kmol
The molar flowrate H2S2O7, Z1

Z1 = 0.85 kmol/kmol x 251.311 kmol/hr
Z1 = 213.614 kmol/hr
22
3.2.7 Final Absorption Tower (FAT)
Gas Stream 25 (To Scrubber)
F4, Molar Flowrate
= 21577.171 kmol/hr
a4, Sulfur Dioxide, SO2 = 0.0002
b4, Sulfur Trioxide, SO3 = 0.0001
Gas Stream 23 c4, Sulphur, S = 0.0001
(From Converter 4) d4, Hydrogen Sulfide, H2S = 0.0008

e4, Oxygen, O2 = 0.0458
F1, Molar Flowrate
n4, Nitrogen, N2 =0.9170
= 21790.784 kmol/hr
g4, Carbon Dioxide, CO2= 0.0360 Liquid Stream 32
Molar Flowrate (kmol/hr) (From Absorption Distribution Header)
A4, Sulfur Dioxide, SO2 = 4.315
a1, Sulfur Dioxide, SO2 = 0.0002 F2, Molar Flowrate
B4, Sulfur Trioxide, SO3 = 2.158
b1, Sulfur Trioxide, SO3 = 0.01 = 273.745 kmol/hr
C4, Sulphur, S = 2.158
c1, Sulphur, S = 0.0001
D4, Hydrogen Sulfide, H2S = 17.262
d1, Hydrogen Sulfide, H2S = 0.0008 Molar Fraction (kmol/kmol)
E4, Oxygen, O2 = 988.234
e1, Oxygen, O2 = 0.0453 x2, Sulphuric Acid, H2SO4
N4, Nitrogen, N2 = 19786.266
n1, Nitrogen, N2 = 0.908 = 0.923
G4, Carbon Dioxide, CO2 = 776.778
g1, Carbon Dioxide, CO2 = 0.0360 y2, Water, H2O
Molar Flowrate (kmol/hr) = 0.077
A1, Sulfur Dioxide, SO2 = 4.315 FINAL Molar Flowrate (kmol/hr)
B1, Sulfur Trioxide, SO3 = 215.771 ABSORPTION X2, Sulphuric Acid, H2SO4
TOWER (FAT) = 252.667
D1, Hydrogen Sulfide, H2S = 17.262 Y2, Water, H2O
E1, Oxygen, O2 = 988.234 = 21.078
Liquid Stream 24 (To Oleum Tank)
N1, Nitrogen, N2 = 19786.266
F3, Molar Flowrate
= 251.311 kmol/hr
= 0.150
z3, Oleum, H2 S2O7
= 0.850
= 37.697 23
Z3, Oleum, H2S2O7
= 213.614
Final Absorption Tower is used to recover the SO2 produced from Converter 4th at stream 23
reactor and to emit the unwanted gaseous compound present in the process stream. 99% of
SO3 present in the feed is considered removed by 98.5% concentrated sulphuric acid as
oleum.
Main Reaction:
SO3 (g) + H2SO4 (ℓ) → H2S2O7 (ℓ)____________________ξ1
(Sulphur Trioxide) + (Sulphuric Acid) → (Oleum)

Oleum, H2S2O7.
• Molar Fraction of Tail gaseous.
• Stream 32, Inlet Molar Fraction for Sulphuric Acid H2SO4 and Water, H2O.
• SO3 gas absorption/conversion = 99%
• All other gas removed at the main absorption tower of scrubber.
• No reaction between SO3 and H2O
• Oleum, H2S2O7 Balance.
Z3 (H2S2O7 OUT) = Z2 (H2S2O7 IN) + 1ξ
213.614 kmol/hr = 0 + 1ξ
ξ = 213.614 kmol/hr
• Sulphur Trioxide Balance, SO3 Balance.
B4 (SO3 OUT) = B1 (SO3 IN) - 1ξ
B4 = B1 - 213.614 kmol/hr ------ 1
Since, SO3 gas absorption/conversion = 99%
𝐵1−𝐵4
0.99 =
𝐵1
24
0.99B1 = B1 – B4
B4 = 0.01B1 ------ 2
Simultanously: 2 -> 1
0.01B1 = B1 - 213.614 kmol/hr
B1 = 215.771 kmol/hr
B4 = 215.771 kmol/hr - 213.614 kmol/hr ------ 1
B4 = 2.158 kmol/hr
• TAIL GAS FROM FAT
Total Molar Flowrate, F4

B4 = F4 x b4
2.158 kmol/hr = F4 x 0.0001 kmol/kmol
F4 = 21577.171 kmol/hr
A4 = 0.0002 kmol/kmol x 21577.171 kmol/hr = 4.315 kmol/hr

C4 = 0.0001 kmol/kmol x 21577.171 kmol/hr = 2.158 kmol/hr
D4 = 0.0008 kmol/kmol x 21577.171 kmol/hr = 17.262 kmol/hr
E4 = 0.0458 kmol/kmol x 21577.171 kmol/hr = 988.234 kmol/hr
N4 = 0.9170 kmol/kmol x 21577.171 kmol/hr = 19786.266 kmol/hr
G4 = 0.0360 kmol/kmol x 21577.171 kmol/hr = 776.778 kmol/hr
• SO3 TO FAT
All other gas is not reacted and removed at the scrubber.

Total Molar Flowrate, F1 = 21790.784 kmol/hr
a1 = 4.315 kmol/hr / 21790.784 kmol/hr = 0.0002 kmol/kmol
b1 = 215.771 kmol/hr / 21790.784 kmol/hr = 0.01 kmol/kmol
c1 = 2.158 kmol/hr / 21790.784 kmol/hr = 0.0001 kmol/kmol
d1 = 17.262 kmol/hr / 21790.784 kmol/hr = 0.0008 kmol/kmol
e1 = 988.234 kmol/hr / 21790.784 kmol/hr = 0.0453 kmol/kmol
n1 = 19786.266 kmol/hr / 21790.784 kmol/hr = 0.908 kmol/kmol
g1 = 776.778 kmol/hr / 21790.784 kmol/hr = 0.0356 kmol/kmol
25
3.2.8 Scrubber
In this process, SOx gaseous especially SO2 and acid mist released as the residue of
air from the FAT and including SO3. These gaseous is hazard to environment due to its
properties which can give impact such as acid rain and public health. A scrubbed is used to
minimize the effect of dangerous gaseous from releasing to atmosphere. The tail gas from the
FAT will be treated by contacting with process water to dissolve the hazardous gaseous.
Gas Stream 25 (From FAT) Gas Stream 26 (To Chimney)
= 21577.171 kmol/hr = 21570.698 kmol/hr

a4, Sulfur Dioxide, SO2 = 0.0002 Molar Fraction (kmol/kmol)
b4, Sulfur Trioxide, SO3 = 0.0001 c2, Sulphur, S = 0.0001
c4, Sulphur, S = 0.0001 d2, Hydrogen Sulfide, H2S = 0.0008
d4, Hydrogen Sulfide, H2S = 0.0008 SCRUBBER e2, Oxygen, O2 = 0.0453
e4, Oxygen, O2 = 0.0458 n2, Nitrogen, N2 = 0.908
n4, Nitrogen, N2 =0.9170 g2, Carbon Dioxide, CO2 = 0.0360
g4, Carbon Dioxide, CO2= 0.0360 Molar Flowrate (kmol/hr)
Molar Flowrate (kmol/hr) C2, Sulphur, S = 2.158
A4, Sulfur Dioxide, SO2 = 4.315 D2, Hydrogen Sulfide, H2S = 17.262
B4, Sulfur Trioxide, SO3 = 2.158 E2, Oxygen, O2 = 988.234
C4, Sulphur, S = 2.158 N2, Nitrogen, N2 = 19786.266
D4, Hydrogen Sulfide, H2S = 17.262 G2, Carbon Dioxide, CO2 = 776.778
E4, Oxygen, O2 = 988.234

N4, Nitrogen, N2 = 19786.266
26
3.2.9 Economizer 2
The SO3 gas feed from the Converter 4th reactor will be passed through to Economizer 2 to
cooled down the gas produced and then through the Final Absorption Tower (FAT) where the
produced SO3 is absorbed. The cooled down of temperature gas is to ensure the efficiency of
absorption process in optimum condition.
Information:
• No reaction occurs in the economizer
• Only changes of temperature.
Gas Stream 22 (From Converter 4) Gas Stream 23 (To FAT)
= 21790.784 kmol/hr = 21790.784 kmol/hr
Molar Fraction (kmol/kmol) Molar Fraction (kmol/kmol)
a1, Sulfur Dioxide, SO2 = 0.0002 a2, Sulfur Dioxide, SO2 = 0.0002
b1, Sulfur Trioxide, SO3 = 0.01 b2, Sulfur Trioxide, SO3 = 0.01
c1, Sulphur, S = 0.0001 ECONOMIZER 2 c2, Sulphur, S = 0.0001
d1, Hydrogen Sulfide, H2S = 0.0008 d2, Hydrogen Sulfide, H2S = 0.0008
e1, Oxygen, O2 = 0.0453 e2, Oxygen, O2 = 0.0453
n1, Nitrogen, N2 = 0.908 n2, Nitrogen, N2 = 0.908
g1, Carbon Dioxide, CO2 = 0.0360 g2, Carbon Dioxide, CO2 = 0.0360
A1, Sulfur Dioxide, SO2 = 4.315 A2, Sulfur Dioxide, SO2 = 4.315
B1, Sulfur Trioxide, SO3 = 215.771 B2, Sulfur Trioxide, SO3 = 215.771
C1, Sulphur, S = 2.158 C2, Sulphur, S = 2.158
D1, Hydrogen Sulfide, H2S = 17.262 D2, Hydrogen Sulfide, H2S = 17.262
E1, Oxygen, O2 = 988.234 E2, Oxygen, O2 = 988.234
N1, Nitrogen, N2 = 19786.266 N2, Nitrogen, N2 = 19786.266
G1, Carbon Dioxide, CO2 = 776.778 G2, Carbon Dioxide, CO2 = 776.778
27
3.2.10 Converter 4
Gas Stream 21 Gas Stream 22

(From Heat Exchanger 2) (To Economizer 2)

= 21898.816 kmol/hr = 21790.784 kmol/hr

c1, Sulphur, S = 0.0001 b2, Sulfur Trioxide, SO3 = 0.01
d1, Hydrogen Sulfide, H2S = 0.0008 c2, Sulphur, S = 0.0001
e1, Oxygen, O2 = 0.05 d2, Hydrogen Sulfide, H2S = 0.0008
n1, Nitrogen, N2 = 0.9035 e2, Oxygen, O2 = 0.0453
CONVERTER 4 n2, Nitrogen, N2 = 0.908
g1, Carbon Dioxide, CO2 = 0.0355
Molar Flowrate (kmol/hr) g2, Carbon Dioxide, CO2 = 0.0360
A1, Sulfur Dioxide, SO2 = 220.086 Molar Flowrate (kmol/hr)
C1, Sulphur, S = 2.158 A2, Sulfur Dioxide, SO2 = 4.315
D1, Hydrogen Sulfide, H2S = 17.262 B2, Sulfur Trioxide, SO3 = 215.771
E1, Oxygen, O2 = 1096.120 C2, Sulphur, S = 2.158
N1, Nitrogen, N2 = 19786.266 D2, Hydrogen Sulfide, H2S = 17.262
G1, Carbon Dioxide, CO2 = 776.778 E2, Oxygen, O2 = 988.234
N2, Nitrogen, N2 = 19786.266
28
In this process there are four V2O5 catalyst filled packed bed type converter. Converter
4 is the last converter in process reaction to produced SO3. First three units are connected in
series while the fourth reactor is the extra reactor where it used to convert SO2 that recovered
from IPAT mainly about 10% of feed from the top reactor. For mass balance calculations, the
first three stages of converter are considered as single unit as the gas passed through several
heat exchanger and economizers to optimize the temperature. Hence, there is no mass
change while passing through the heat exchanger.
Main Reaction:
SO2 (g) + 1/2O2 (g) → SO3 (g)____________________ξ1
(Sulphur Dioxide) + (Oxygen) → (Sulphur Trioxide)

• Stream 22, Outlet molar fraction and molar flowrate for Sulphur Trioxide, SO3 and other
gases.
• SO2 gas absorption/conversion for Converter 4 = 98%
• All other gas excepted SO2 and O2 is not reacted.
• There is zero inlet molar flowrate of SO3 .
• Sulphur Trioxide, SO3 Balance
B2 (SO3 OUT) = B1 (SO3 IN) + 1ξ
215.771 kmol/hr = 0 + 1ξ
ξ= 215.771 kmol/hr
• Sulphur Dioxide, SO2 Balance
A2 (SO2 OUT) = A1 (SO2 IN) - 1ξ
4.315 kmol/hr = A1 - 215.771 kmol/hr

A1 = 220.086 kmol/hr
29
• Oxygen, O2 Balance
E2 (O2 OUT) = E1 (O2 IN) – 1/2ξ
988.234 kmol/hr = E1 - ½ (215.771 kmol/hr)

E1 = 1096.120 kmol/hr
Molar Fraction of Stream 21

a1 = 220.086 kmol/hr / 21898.816 kmol/hr = 0.01
c1 = 2.158 kmol/hr / 21898.816 kmol/hr = 0.0001
d1 = 17.262 kmol/hr / 21898.816 kmol/hr = 0.0008
e1 = 1096.120 kmol/hr / 21898.816 kmol/hr = 0.05
n1 = 19786.266 kmol/hr / 21898.816 kmol/hr = 0.9035
g1 = 776.778 kmol/hr / 21898.816 kmol/hr = 0.0355
30
F3, Molar Flowrate
= 22978.878 kmol/hr

3.2.11 Heat Exchanger 2 Gas Stream 12
(From Converter 2)
c3, Sulphur, S = 0.0001
d3, Hydrogen Sulfide, H2S = 0.0008
e3, Oxygen, O2 = 0.0482
Gas Stream 20
n3, Nitrogen, N2 = 0.861
(From Heat Exchanger 1) Gas Stream 21
(To Converter 4)
F1, Molar Flowrate Molar Flowrate (kmol/hr)
A3, Sulfur Dioxide, SO2 = 244.54 F2, Molar Flowrate
= 21898.816 kmol/hr
B3, Sulfur Trioxide, SO3 = 1043.527 = 21898.816 kmol/hr
Molar Fraction (kmol/kmol) C3, Sulphur, S = 2.158

D3, Hydrogen Sulfide, H2S = 17.262 Molar Fraction (kmol/kmol)
E3, Oxygen, O2 = 1108.347 a2, Sulfur Dioxide, SO2 = 0.01
c1, Sulphur, S = 0.0001
N3, Nitrogen, N2 = 19786.266 c2, Sulphur, S = 0.0001
G3, Carbon Dioxide, CO2 = 776.778 d2, Hydrogen Sulfide, H2S = 0.0008
e1, Oxygen, O2 = 0.05
e2, Oxygen, O2 = 0.05
g1, Carbon Dioxide, CO2 = 0.0355 Heat
Molar Flowrate (kmol/hr) Exchanger 2
F4, Molar Flowrate C2, Sulphur, S = 2.158
= 22978.878 kmol/hr D2, Hydrogen Sulfide, H2S = 17.262
E1, Oxygen, O2 = 1096.120
E2, Oxygen, O2 = 1096.120
N1, Nitrogen, N2 = 19786.266
Molar Fraction (kmol/kmol) N2, Nitrogen, N2 = 19786.266
a4, Sulfur Dioxide, SO2 = 0.106 G2, Carbon Dioxide, CO2 = 776.778
c4, Sulphur, S = 0.0001
e4, Oxygen, O2 = 0.0482
g4, Carbon Dioxide, CO2 = 0.0338 Gas Stream 13
Molar Flowrate (kmol/hr) (To Converter 3)
E4, Oxygen, O2 = 1108.347 31
N4, Nitrogen, N2 = 19786.266
F3, Molar Flowrate
= 22966.742 kmol/hr
3.2.12 Heat Exchanger 1 a3, Sulfur Dioxide, SO2 = 0.096 Gas Stream 14
a3, Sulfur Trioxide, SO3 = 0.0465 (From Converter 3)
c3, Sulphur, S = 0.0001
e3, Oxygen, O2 = 0.0477
(From IPAT) (To Heat Exchanger 2)
g3, Carbon Dioxide, CO2= 0.0338
= 21898.816 kmol/hr = 21898.816 kmol/hr
c1, Sulphur, S = 0.0001 c2, Sulphur, S = 0.0001
E3, Oxygen, O2 = 1096.120
N3, Nitrogen, N2 = 19786.266
Molar Flowrate (kmol/hr) Heat Molar Flowrate (kmol/hr)
A1, Sulfur Dioxide, SO2 = 220.086 Exchanger 1 A2, Sulfur Dioxide, SO2 = 220.086
F4, Molar Flowrate
= 22966.742 kmol/hr
c4, Sulphur, S = 0.0001
e4, Oxygen, O2 = 0.0477
g4, Carbon Dioxide, CO2= 0.0338
Gas Stream 15 (To Economizer 1)
E4, Oxygen, O2 = 1096.120
N4, Nitrogen, N2 = 19786.266 32
3.2.13 Interpass Absorption Tower
Gas Stream 19 (To Heat Exchanger 1)
F4, Molar Flowrate

= 21898.816 kmol/hr

Gas Stream 16 c4, Sulphur, S = 0.0001
(From Economizer 1) d4, Hydrogen Sulfide, H2S = 0.0008

e4, Oxygen, O2 = 0.05
F1, Molar Flowrate
= 22966.742 kmol/hr
g4, Carbon Dioxide, CO2 = 0.0355 Liquid Stream 18
Molar Flowrate (kmol/hr) (From Absorption Distribution Header)
a1, Sulfur Dioxide, SO2 = 0.096 F2, Molar Flowrate
b1, Sulfur Trioxide, SO3 = 0.0465 = 1368.78kmol/hr
c1, Sulphur, S = 0.0001
E4, Oxygen, O2 = 1096.120
d1, Hydrogen Sulfide, H2S = 0.0008 Molar Fraction (kmol/kmol)
N4, Nitrogen, N2 = 19786.266
n1, Nitrogen, N2 = 0.8615 = 0.923
g1, Carbon Dioxide, CO2= 0.0338 y2, Water, H2O
Molar Flowrate (kmol/hr) = 0.077
A1, Sulfur Dioxide, SO2 = 220.086 INTERPASS Molar Flowrate (kmol/hr)
B1, Sulfur Trioxide, SO3 = 1068.072 ABSORPTION X2, Sulphuric Acid, H2SO4
TOWER (FAT) = 1263.39
D1, Hydrogen Sulfide, H2S = 17.262 Y2, Water, H2O
E1, Oxygen, O2 = 1096.120 Liquid Stream 17 (To Oleum Tank) = 105.40
N1, Nitrogen, N2 = 19786.266 F3, Molar Flowrate
G1, Carbon Dioxide, CO2 = 776.778 = 1256.55 kmol/hr
= 0.15
z3, Oleum, H2S2O7
= 0.85
= 188.483 33
Z4, Oleum, H2S2O7

= 1068.072
Interpass Absorption Tower (IPAT) is used to recover the SO3 present in the output line of first
three bed reactor. All SO3 present in IPAT feed, is considered removed by 98.5% concentrated
sulphuric as oleum.
Main Reaction:
SO3 (g) + H2SO4 (ℓ) → H2S2O7 (ℓ)____________________ξ1
(Sulphur Trioxide) + (Sulphuric Acid) → (Oleum)

Oleum, H2S2O7
• Stream 18, Inlet Molar Fraction for Sulphuric Acid H2SO4 and Water,
• SO3 gas absorption/conversion = 100%
• All gaseous other than SO3 is not reacted and directed flow through stream 19.
• No reaction between SO3 and H2O.
• All available H2O reacts with Oleum and produces H2SO4.
• Oleum, H2S2O7 Balance
Z3 (H2S2O7 OUT) = Z2 (H2S2O7 IN) + 1ξ

1068.072 kmol/hr = 0 + 1ξ
ξ = 1068.072 kmol/hr
• Sulphur Trioxide Balance, SO3 Balance
B4 (SO3 OUT) = B1 (SO3 IN) - 1ξ

0 = B1 – 1068.072 kmol/hr
B1 = 1068.072 kmol/hr
34
• SO3 TO IAT
All other gas is not reacted and directed flow through Stream 19.
b1 = 1068.072 kmol/hr / 22966.742 kmol/hr = 0.0465kmol/kmol
e1= 1096.120 kmol/hr / 22966.742 kmol/hr /hr = 0.0477 kmol/kmol
35
3.2.14 Economizer 1
The SO3 gas feed from the Converter 3th reactor will be passed through to Economizer 1 to
cooled down the gas produced and then through the Interpass Absorption Tower (IPAT) where
the produced SO3 is absorbed by sulphuric acid as oleum. The cooled down of temperature
gas is to ensure the efficiency of absorption process in optimum condition.

• No reaction occurs in the economizer
(From Heat Exchanger 1) (To IPAT)

= 22966.742 kmol/hr = 22966.742 kmol/hr

n1, Nitrogen, N2 = 0.8615 ECONOMIZER 1 n2, Nitrogen, N2 = 0.8615
g1, Carbon Dioxide, CO2= 0.0338 g2, Carbon Dioxide, CO2= 0.0338
36
3.2.15 Converter 3

(From Heat Exchanger 2) (To Heat Exchanger 1)

= 22978.878 kmol/hr = 22966.742 kmol/hr

CONVERTER 3 n2, Nitrogen, N2 = 0.8615
g1, Carbon Dioxide, CO2 = 0.0338 g2, Carbon Dioxide, CO2= 0.0338
N 1, Nitrogen, N2 = 19786.266 N2, Nitrogen, N2 = 19786.266
37
Main Reaction:
SO2 (g) + 1/2O2 (g) → SO3 (g)____________________ξ1

gases.
• SO2 gas absorption/conversion for Converter 3 = 10 %
A2 (SO2 OUT) = A1 (SO2 IN) - 1ξ
220.86 kmol/hr = A1 - 1ξ
SO2 gas absorption/conversion for Converter 3 = 10 %

𝐴1−𝐴2
0.10 =
𝐴1
kmol
A1− 220.086
hr
0.10 = = 0.1A1 = A1 – 220.086 kmol/hr
𝐴1
A1 = 244.54 kmol/hr
220.086 kmol/hr = 244.54 kmol/hr - 1ξ
1ξ = 244.54 kmol/hr - 220.086 kmol/hr = 24.454 kmol/hr
B2 (SO3 OUT) = B1 (SO3 IN) + 1ξ
1068.072 kmol/hr = B1 + 1ξ
B1 = 1068.072 kmol/hr - 24.454 kmol/hr

B1 = 1043.527 kmol/hr
38
E2 (O2 OUT) = E1 (O2 IN) – 1/2ξ
1096.120 kmol/hr = E1 - ½ (24.454 kmol/hr)

E1 = 1096.120 kmol/hr +12.227 kmol/hr = 1108.347 kmol/hr

b1 = 1043.527 kmol/hr / 22978.878 kmol/hr = 0.0454 kmol/kmol
e1 = 1108.347 kmol/hr / 22978.878 kmol/hr = 0.0482 kmol/kmol
39
3.2.16 Converter 2

(From Waste Heat Boiler 2) (To Heat Exchanger 2)

= 23011.38 kmol/hr = 22978.878 kmol/hr

n1, Nitrogen, N2 = 0.8598 CONVERTER 2 n 2, Nitrogen, N2 = 0.861
g1, Carbon Dioxide, CO2 =0.0338 g2, Carbon Dioxide, CO2 = 0.0338
40
Main Reaction:
SO2 (g) + 1/2O2 (g) → SO3 (g)____________________ξ1

gases.
A2 (SO2 OUT) = A1 (SO2 IN) - 1ξ
244.54 kmol/hr = A1 - 1ξ
SO2 gas absorption/conversion for Converter 3 = 21 %

𝐴1−𝐴2
0.21 =
𝐴1
kmol
A1− 244.54
hr
0.21 = = 0.21A1 = A1 – 244.54 kmol/hr
𝐴1
A1 = 309.544 kmol/hr
244.54 kmol/hr = 309.544 kmol/hr - 1ξ
1ξ = 309.544 kmol/hr - 244.54 kmol/hr = 65.004 kmol/hr
B2 (SO3 OUT) = B1 (SO3 IN) + 1ξ
1043.527 kmol/hr = B1 + 1ξ
B1 = 1043.527 kmol/hr - 65.004 kmol/hr

B1 = 978.523 kmol/hr
41
E2 (O2 OUT) = E1 (O2 IN) – 1/2ξ
1108.347 kmol/hr = E1 - ½ (65.004 kmol/hr)

E1 = 1140.849 kmol/hr

a1 = 309.544 kmol/hr / 23011.38 kmol/hr = 0.0134
b1 = 978.523 kmol/hr / 23011.38 kmol/hr = 0.0425
c1 = 2.158 kmol/hr / 23011.38 kmol/hr = 0.0001
d1 = 17.262 kmol/hr / 23011.38 kmol/hr = 0.0008
e1 = 1140.849 kmol/hr / 23011.38 kmol/hr = 0.0496
n1 = 19786.266 kmol/hr / 23011.38 kmol/hr = 0.8598
g1 = 776.778 kmol/hr / 23011.38 kmol/hr = 0.0338
42
3.2.17 Waste Heat Boiler 2
The waste heat boiler has the similar principle as heat exchanger in order to change the
temperature of gas. The SO3 gas feed from the Converter 1st reactor will be passed through
to Waste Heat Boiler 2 to cooled down the gas produced by industrial water. The cooled down
of temperature gas is to ensure the efficiency of conversion process in optimum condition at
converter 2. The primary function of the waste heat boiler is to utilize the gas hot products to
generate steam, which can be utilized within the end users production process.

• No reaction occurs in the waste heat boiler
(From Converter 1) (To Converter 2)

= 23011.38 kmol/hr = 23011.38 kmol/hr

WASTE HEAT
BOILER 2
g1, Carbon Dioxide, CO2 =0.0338 g2, Carbon Dioxide, CO2 =0.0338
43
3.2.18 Converter 1
Gas Stream 38
(Dried Air)
F2, Molar Flowrate

= 5877.552 kmol/hr

(From ESP) Molar Fraction (kmol/kmol) (To Waste Heat Boiler 2)
e2, Oxygen, O2 = 0.2097
F1, Molar Flowrate n2, Nitrogen, N2 = 0.7900 F3, Molar Flowrate
= 17623.09 kmol/hr g2, Carbon Dioxide, CO2 =0.0003 = 23011.38 kmol/hr
Molar Fraction (kmol/kmol) E2, Oxygen, O2 = 1232.523 Molar Fraction (kmol/kmol)
a1, Sulfur Dioxide, SO2 = 0.0731 N2, Nitrogen, N2 = 4643.266 a3, Sulfur Dioxide, SO2 = 0.0134
c1, Sulphur, S = 0.0001 G2, Carbon Dioxide, CO2 = 1.763 b3, Sulfur Trioxide, SO3 = 0.0425
e1, Oxygen, O2 = 0.0226 d3, Hydrogen Sulfide, H2S = 0.0008
n1, Nitrogen, N2 = 0.8593 e3, Oxygen, O2 = 0.0496
g1, Carbon Dioxide, CO2 = 0.044 n3, Nitrogen, N2 = 0.8598
Molar Flowrate (kmol/hr) g3, Carbon Dioxide, CO2 =0.0338
A1, Sulfur Dioxide, SO2 = 1288.067 CONVERTER 1 Molar Flowrate (kmol/hr)
C1, Sulphur, S = 2.158 A3, Sulfur Dioxide, SO2 = 309.544
D1, Hydrogen Sulfide, H2S = 17.262 B3, Sulfur Trioxide, SO3 = 978.523
E1, Oxygen, O2 = 397.588 C3, Sulphur, S = 2.158
N1, Nitrogen, N2 = 15143 D3, Hydrogen Sulfide, H2S = 17.262
G1, Carbon Dioxide, CO2 = 775.015 E3, Oxygen, O2 = 1140.849
N3, Nitrogen, N2 = 19786.266
44
Conversion efficiency decrease with the temperature of the bed. As a result, top bed of
converter 3 shows the smallest conversion rate due to the accumulation of heat in gas stream
coming from the converter 1 and 2. According to the stoichiometric, air is supplied with 10%
(V/V) excess to achieve an effective conversion. Other tracer gases are neglected and only
O2 required to convert SO2 into SO3. No changes were considered in these gases as their
thermal stability is very high.
Main Reaction:
SO2 (g) + 1/2O2 (g) → SO3 (g)____________________ξ1

gases.
• All other gas excepted SO2 and O2 is not reacted, and other available gas are thermally
stable under these operating conditions.
• Air is supplied 10% excess to achieve effective conversion.
• 5% of V2O5 catalyst are to be regenerated at the end of each year because of the
sulphur dust present in the SO2 feed.
• Initial Inlet molar flowrate, SO3 is zero.
B3 (SO3 OUT) = B1 (SO3 IN) + 1ξ

978.523 kmol/hr = 0 + 1ξ
ξ = 978.523 kmol/hr
A3 (SO2 OUT) = A1 (SO2 IN) - 1ξ
309.544 kmol/hr = A1 - 1ξ
45
A1 = 309.544 kmol/hr + 978.523 kmol/hr
A1 = 1288.067 kmol/hr
• D2 (O2 OUT) = D1 (O2 IN) – 1/2ξ
1142.98 kmol/hr = D1 + D2 - ½ (978.523 kmol/hr)

D1 + D2 = 1140.849 kmol/hr + ½ (978.523 kmol/hr)
D1 + D2 = 1630.1105 kmol/hr
Ratio of oxygen stream 38 to oxygen stream 9: 3.1 : 1
𝑆𝑡𝑟𝑒𝑎𝑚 38 (𝑂2) 3.1 1232.523 𝑘𝑚𝑜𝑙/ℎ𝑟
= = 1630.1105 kmol/hr =
𝑆𝑡𝑟𝑒𝑎𝑚 9 (𝑂2) 1.0 397.588 𝑘𝑚𝑜𝑙/ℎ𝑟
Thus, the total molar flowrate of air, F2:

E2 = e2*F2
1232.523 kmol/hr = 0.2097 kmol/kmol x F2
F2 = 5877.552 kmol/hr
F2, Nitrogen = 0.7900 kmol/kmol x 5877.552 kmol/hr = 4643.266 kmol/hr

G2, Carbon Dioxide = 0.0003 kmol/kmol x 5877.552 kmol/hr = 1.763 kmol/hr
Hence, nitrogen and carbon dioxide in stream 38 and stream 9 is not reacted.
N1, Nitrogen = N3 – N2
N1 = 19786.266 kmol/hr - 4643.266 kmol/hr
N1 = 15143 kmol/hr
G1, Carbon Dioxide = G3 – G2

G1 = 776.778 kmol/hr - 1.763 kmol/hr = 775.015 kmol/hr

a1 = 1288.067 kmol/hr / 17623.09 kmol/hr = 0.0731
c1 = 2.158 kmol/hr / 17623.09 kmol/hr = 0.0001
d1 = 17.262 kmol/hr / 17623.09 kmol/hr = 0.0001
e1 = 397.588 kmol/hr / 17623.09 kmol/hr = 0.0226
n1 = 15143 kmol/hr / 17623.09 kmol/hr = 0.8593
g1 = 775.015 kmol/hr / 17623.09 kmol/hr = 0.044
46
3.2.19 Electrostatic Precipitator (ESP)
Gas Stream 9
(Clean SO2 with Flue gas to
Gas Stream 8
Converter 1)
(Flue gas from furnace)

= 17836.732 kmol/hr = 17623.09 kmol/hr

ESP
Solid Stream
(Dust Collected)
A1, Sulfur Dioxide, SO2 = 1288.067 F2, Molar Flowrate A3, Sulfur Dioxide, SO2 = 1288.067
C1, Sulphur, S = 215.8 = 213.642 C3, Sulphur, S = 2.158
E1, Oxygen, O2 = 397.588 Molar Fraction (kmol/kmol) E3, Oxygen, O2 = 397.588
N1, Nitrogen, N2 = 15143 c1, Sulphur, S = 1.0 N3, Nitrogen, N2 = 15143
G1, Carbon Dioxide, CO2 = 775.015 Molar Flowrate (kmol/hr) G3, Carbon Dioxide, CO2 = 775.015
C1, Sulphur, S = 213.642
47
Electrostatic Precipitator is an air cleaner which a particulate collection device that
removes particles from a flowing gas (such as air or flue gas) using the force of an induced
electrostatic charge. Electrostatic precipitators are highly efficient filtration devices that
minimally impede the flow of gases through device and can easily remove fine particulate
matter such as dust and smoke from the air stream. In this process, sulfur dioxide gas with
flue gas that is leaving from furnace with other unburned particles such as unburned sulphur.

• Percentage removal of sulfur dust from the mainstream 8 in dust collector is 99%.
• Overall Balance
F1 = F2 + F3
• Sulfur, S Balance
Percentage removal of sulfur dust from the mainstream 8 in dust collector is 99%.
𝐹1−𝐹3
0.99 =
𝐹1
0.99F1 = F1 – 2.158 kmol/hr
F1= 215.8 kmol/hr
Hence, the sulfur removed from the mainstream,

F2 = F1 - F3
F2 = 215.8 kmol/hr - 2.158 kmol/hr
F2 = 213.642 kmol/hr
Molar Fraction Stream 8

a1 = 1288.067 kmol/hr / 17836.732 kmol/hr = 0.0722
c1 = 215.8 kmol/hr / 17836.732 kmol/hr = 0.0121
d1 = 17.262 kmol/hr / 17836.732 kmol/hr = 0.001
e1 = 397.588 kmol/hr / 17836.732 kmol/hr = 0.0223
n1 = 15143 kmol/hr / 17836.732 kmol/hr = 0.849
g1 = 775.015 kmol/hr / 17836.732 kmol/hr = 0.0435
48
3.2.20 Waste Heat Boiler 1

• No reaction occurs in the waste heat boiler
(From Furnace) (To ESP)

= 17836.732 kmol/hr = 17836.732 kmol/hr

WASTE HEAT
BOILER 1
N1, Nitrogen, N2 = 15143 N2, Nitrogen, N2 = 15143
49
3.2.21 Furnace
Molten state at Stream 2 Gas Stream 7
(Sulfur from Melter) (Flue gas to Waste Heat Boiler 1)

= 1521.129 kmol/hr = 17836.732 kmol/hr

FURNACE
c1, Sulphur, S = 0.9887 a3, Sulfur Dioxide, SO2 = 0.0722
Molar Flowrate (kmol/hr) d3, Hydrogen Sulfide, H2S = 0.001
C1, Sulphur, S = 1503.867 e3, Oxygen, O2 = 0.0223
Gas Stream 37
D1, Hydrogen Sulfide, H2S = 17.262 n3, Nitrogen, N2 = 0.849
(Dried Air from Air Distribution
Header)
F2, Molar Flowrate A3, Sulfur Dioxide, SO2 = 1288.067
= 19168.354 kmol/hr C3, Sulphur, S = 215.8
Molar Fraction (kmol/kmol) E3, Oxygen, O2 = 397.588
e2, Oxygen, O2 = 0.2097 N3, Nitrogen, N2 = 15143
n2, Nitrogen, N2 = 0.7900 G3, Carbon Dioxide, CO2 = 775.015
E2, Oxygen, O2 = 4019.604
N2, Nitrogen, N2 = 15143
50
Molten sulfur is combusted in Sulfur Furnace and forms SO2. Gas temperature reaches about
1,150°C to 1,100°C. Mostly there are horizontal, cylindrical shape furnaces. Sulfur is supplied
to one end through sulfur burner with dry air and combusted for reaction. Combusted gas goes
out from the end. Molten sulfur is sprayed by special burner and combust as fine particles.
Usually, sulfur is sprayed by pump pressure. Combustion air is previously dried in Drying
Tower and supplied to the sulfur furnace.
Main Reaction:
S (s) + O2 (g) → SO2 (g)____________________ξ1
(Sulphur) + (Oxygen) → (Sulphur Trioxide)

• Degree of conversion in Sulfur Burner is 90%
• The nitrogen gas in the inlet air stream is not making any reaction in the furnace.
• The content of Oxygen and Nitrogen inherently present in the fuel oil is negligible
compared to the amount present in the entering air stream.
• The fuel oil act as utilities for the combustion reaction to occur.
• The Hydrogen Sulfide is not taking any reaction in the furnace.
A3 (S OUT) = A1 (S IN) + 1ξ
1288.067 kmol/hr = 0 kmol/hr + 1ξ
1ξ = 1288.067 kmol/hr
• Sulphur, S Balance
C3 (S OUT) = C1 (S IN) - 1ξ
215.8 kmol/hr = C1 (S IN) - 1288.067 kmol/hr

C1 (S IN) = 215.8 kmol/hr + 1288.067 kmol/hr
C1 = 1503.867 kmol/hr
51
Molar Fraction at Stream 2

c1 = 1503.867 kmol/hr / 1521.129 kmol/hr = 0.9887
d1 = 17.262 kmol/hr / 1521.129 kmol/hr = 0.0113
Molar Fraction at Stream 37
Since N2, Nitrogen, N2 is 15143 kmol/hr , the total molar flowrate of stream 37 is,
N2 = f2 * F2
15143 kmol/hr = 0.79 * F2
F2 = 19168.354 kmol/hr
E2 = 0.2097 kmol/kmol x 19168.354 kmol/hr = 4019.604 kmol/hr

G2 = 0.0003 kmol/kmol x 19168.354 kmol/hr = 5.751 kmol/hr
52
3.2.22 Sulfur Melter
Sulfur melter is used to melt the sulfur from solid state into molten state at melting point
temperature. For this purpose, semi underground melter & settler is used. A pump is fitted to
the other end of the settler to pump out the molten sulfur.

• The process changes the state of sulphur from solid to molten.
• No reaction occurs in this process
• The raw material required followed with respective production rate is 48123.744 kg/hr
= 48.123 MT/hr = 158808.355 MT/yr of Sulphur.
Molten Sulphur Stream 2

Solid Stream 1
(To Furnace)
(Sulphur Input)

= 1521.129 kmol/hr = 1521.129 kmol/hr
Molar Fraction (kmol/kmol) SULFUR Molar Fraction (kmol/kmol)

c1, Sulphur, S = 0.9887 MELTER C2, Sulphur, S = 0.9887
d1, Hydrogen Sulfide, H2S = 0.0113 D2, Hydrogen Sulfide, H2S = 0.0113
53
3.2.23 Air Distribution Header
Gas Stream 38
(Dried Air to Converter 1)
F2, Molar Flowrate

= 5877.552 kmol/hr

e2, Oxygen, O2 = 0.2097
g2, Carbon Dioxide, CO2 =0.0003
E2, Oxygen, O2 = 1232.523
Gas Stream 6
N2, Nitrogen, N2 = 4643.266 Gas Stream 37
(Dried Air from Air Dryer)
G2, Carbon Dioxide, CO2 = 1.763 (Dried Air to Furnace)

= 25045.906 kmol/hr = 19168.354 kmol/hr

e1, Oxygen, O2 = 0.2097 AIR e3, Oxygen, O2 = 0.2097
n1, Nitrogen, N2 = 0.7900 DISTRIBUTION n3, Nitrogen, N2 = 0.7900
g1, Carbon Dioxide, CO2 =0.0003 HEADER g3, Carbon Dioxide, CO2 =0.0003
N1, Nitrogen, N2 = 19786.266 n3, Nitrogen, N2 = 15143
54
3.2.24 Air Dryer
F2, Molar Flowrate

Gas Stream 6 = 25045.906 kmol/hr
(Dried Air to Air Distribution
Header) Molar Fraction (kmol/kmol)
e2, Oxygen, O2 = 0.2097
g2, Carbon Dioxide, CO2 =0.0003
E2, Oxygen, O2 = 5252.127 Liquid Stream 29
Gas Stream 5
N2, Nitrogen, N2 = 19786.266 (From Oleum Distribution
(Air from Air Blower)
G2, Carbon Dioxide, CO2 = 7.514 Header)
= 25692.781 kmol/hr = 3618.878 kmol/hr

n1, Nitrogen, N2 = 0.7701 AIR DRYER
= 0.73
z3, Oleum, H2S2O7
w1, Water, H2O = 0.025
= 0.27
E1, Oxygen, O2 = 5252.127
N1, Nitrogen, N2 = 19786.266 Liquid Stream 30
= 2626.702 kmol/hr
G1, Carbon Dioxide, CO2 = 7.514 (To Oleum Distribution Header)
Z3, Oleum, H2S2O7
W1, Water, H2O = 646.874 F4, Molar Flowrate
= 992.176 kmol/hr
= 3920.451 kmol/hr

= 1.0
= 3920.451
55
If there is contain water in the air, they will combine with SO3 and form very fine H2SO4 mist
which can cause problem in downstream equipment such as corrosion and leakage of
material. Hence, water in the air will be removed and absorbed by contacting the air with the
oleum. The drying tower is likely to be a packed column. Column packing is porcelain and
supported by acid poof porcelain brick bar.

• Percentage removal in total moisture in air is 100%.
• Stream 28, Inlet molar fraction and molar flowrate for Sulphuric Acid and Oleum
• Stream 30, Outlet molar fraction and molar flowrate for Sulphuric Acid
• Stream 6, Outlet molar fraction and molar flowrate for dried air.
Main Reaction:
H2S2O7 (ℓ) + H2O (ℓ) → 2H2SO4 (ℓ)____________________ξ1
(Oleum) + (Water) (Sulphuric Acid)
X4 (H2SO4 out) = X3 (H2SO4) + 2ξ

3920.451 kmol/hr = 2626.702 kmol/hr + 2ξ
ξ = 646.8745 kmol/hr
• Water, H2O Balance
(H2O out) = W1 (H2O in) - ξ

W1 (H2O in) = 646.874 kmol/hr

e1 = 5252.127 kmol/hr / 25692.781 kmol/hr = 0.2044
n1 = 19786.266 kmol/hr / 25692.781 kmol/hr = 0.7701
g1 = 7.514 kmol/hr / 25692.781 kmol/hr = 0.0003
w1 = 646.874 kmol/hr / 25692.781 kmol/hr = 0.025
56
3.2.25 Air Blower
An air blower is installed before Drying Tower and combustion air to Sulfur Furnace and
Converter 1 is sent by this blower. Multi-Stage turbo and the material can be carbon steel.
Flow volume has been calculated based on the production rate of the process.

• Dried air stream consists of only 20.4% of O2, 77% of N2, 0.03% of CO2, and 2.5% of
H2O.
• Percentage of excess air in air stream into converter is 10%.
• The air is properly filtered before entering the blower so that only the gas is containing
the Stream.
• The raw material required followed with respective production rate is:
o Oxygen = 168,068.064 kg/hr = 168.068 MT/hr
Gas Stream 5
Gas Stream 4
(To Air Dryer)
(From Filter)

= 25692.781 kmol/hr = 25692.781 kmol/hr
Air Blower
w1, Water, H2O = 0.025 w1, Water, H2O = 0.025
W1, Water, H2O = 646.874 W1, Water, H2O = 646.874
57
3.3 Software Mass Balance
3.3.1 Simulation Mass Balance (Microsoft Excel)
Stream
18
Stream 20
Stream Stream Stream Stream

Stream Stream Stream Stream Stream
Stream 2 7 Stream Stream 15 16
8 9 10 11 12
Sulp
1 13 14 Interpass
Waste Converter waste Heat Converter Heat Converter Heat Heat
hur Melter Furnace ESP Absorption Tower Stream 32
Heat Boiler 1 Boiler 2 2 Exchanger 1 3 Exchanger Exchanger 3
Fee (IPAT)
OleumDistribution
Sream Stream Stream Tank
Stream 19
40 17
37
Sream Stream
Dust Collecter 21 Stream 33
38
Air
Distributio Centrifugal
Stream Stream
22 23 Stream 24
Pump 1
Converter Heat
FinalAbsorption Acid
4 Exchanger
Tower (FAT) Pump Stream 34
4 Stream
Stream 6 Stream
26 36
Stream Concentrated
25 Gas OleumDistribution
Scrubber Tank Sulphuric
Waste Acid
Stream
27
Stream
31
Stream
Stream 39
Air 30
Filter Air Air H2SO4
Feed Dryer Dilution Tank
Stream Stream Blower Stream Distribution
3 4 5
Stream Stream
29 Stream 35
28
Centrifugal
Pump 1
Figure 3.1: Block Flow Diagram in Excel.
58
Table 3.3: Mass Balance in Excel from Stream 1 to Stream 10.
Number of Stream
FLOWRATE (kmol/hr)
1 2 3 4 5 6 7 8 9 10
H2SO4 0 0 0 0 0 0 0 0 0 0
H2S2O7 0 0 0 0 0 0 0 0 0 0
S 1525.81 1510.55 0 0 0 0 216.18 218.34 2.16 2.16
H2O 0 0 653.15 653.15 653.15 0 0 0 0 0
SO2 0 0 0 0 0 0 1294.37 1294.37 1294.37 310.12
SO3 0 0 0 0 0 0 0 0 0 984.25
H2S 17.29 17.29 0 0 0 0 17.29 17.29 17.29 17.29
O2 0 0 7.53 7.53 5261.96 5261.96 398.81 398.81 398.81 1142.98
N2 0 0 19823.32 19823.3 19823.32 19823.32 15165.83 15165.83 15165.83 19823.32
CO2 0 0 7.53 7.53 7.53 7.53 776.46 776.46 776.46 778.23

1543.1 1527.84 25745.96 25745.96 25745.96 25092.81 17868.94 17868.94 17654.93 23058.36
(kmol/hr)
59
Number of Stream
FLOWRATE (kmol/hr)
11 12 13 14 15 16 17 18 19 20
H2SO4 0 0 0 0 0 0 189.51 1263.39 0 0
H2S2O7 0 0 0 0 0 0 1073.88 0 0 0
S 2.16 2.16 2.16 2.16 2.1618 2.16 0 0 2.16 2.16
H2O 0 0 0 0 0 0 0 105.4 0 0
SO2 310.12 244.99 244.99 220.49 220.4942 220.49 0 0 220.49 220.49
SO3 984.25 1049.38 1049.38 1073.88 1073.8773 1073.88 0 0 0 0
H2S 17.29 17.29 17.29 17.29 17.2941 17.29 0 0 17.29 17.29
O2 1142.98 1110.42 1110.42 1098.17 1098.1705 1098.17 0 0 1098.17 1098.17
N2 19823.32 19823.32 19823.32 19823.32 19823.3215 19823.32 0 0 19823.32 19823.32
CO2 778.23 778.23 778.23 778.23 778.2329 779.23 0 0 778.23 778.23

23058.36 23025.8 23025.8 23013.55 23013.5523 23013.55 1263.39 1368.78 21939.68 21939.68
(kmol/hr)
60
Number of Stream
FLOWRATE (kmol/hr)
21 22 23 24 25 26 27 28 29 30
H2SO4 0 0 0 38.658 0 0 228.17 2647.46 2647.46 3953.76
H2S2O7 0 0 0 214.009 0 0 1287.89 999.08 999.08 0
S 2.16 2.16 2.16 0 2.16 2.16 0 0 0 0
H2O 0 0 0 0 0 0 0 0 0 0
SO2 220.49 4.32 4.32 0 4.32 0 0 0 0 0
SO3 0 216.17 216.17 0 2.16 2.16 0 0 0 0
H2S 17.29 17.29 17.29 0 17.29 17.29 0 0 0 0
O2 1098.17 990.09 990.09 0 990.09 990.09 0 0 0 0
N2 19823.32 19823.32 19823.32 0 19823.32 19823.32 0 0 0 0
CO2 778.23 778.23 778.23 0 778.23 778.23 0 0 0 0

21939.68 21831.59 21831.59 252.667 21617.58 21613.26 1516.05 3646.54 3646.54 3953.76
(kmol/hr)
61
Number of Stream
FLOWRATE (kmol/hr)
31 32 33 34 35 36 37 38 39 40
H2SO4 2098.949 252.667 1399.32 1399.316 0 699.633 0 0 1534.46 0
H2S2O7 0 0 0 0 0 0 0 0 288.81 0
S 0 0 0 0 0 0 0 0 0 214.01
H2O 175.102 21.078 116.74 116.736 463.91 58.366 0 0 0 0
SO2 0 0 0 0 0 0 0 0 0 0
SO3 0 0 0 0 0 0 0 0 0 0
H2S 0 0 0 0 0 0 0 0 0 0
O2 0 0 0 0 0 0 4025.66 1236.3 0 0
N2 0 0 0 0 0 0 15165.83 4657.49 0 0
CO2 0 0 0 0 0 0 5.76 1.77 0 0

2274.05 273.745 1516.05 1516.052 463.91 757.999 19197.25 5895.56 1823.27 214.01
(kmol/hr)
62
3.3.2 Percentage Different in Manual and Excel Calculation of Mass Balance
The summary table of the percentage difference between manual and excel mass
balance calculations is shown in Table 3.7 below. The value differs slightly because
it calculated up to 4 decimal places in manual calculation and up to 7 decimal places in
simulations.
Table 3.7: Percentage Different in Manual and Excel Calculation of Mass Balance.
Total Molar Flowrate (kmol/hr)

Streamline
Manual Calculation Excel Calculation Percentage Different (%)
1 1521.129 1543.10 1.4444
2 1521.129 1527.84 0.4412
3 25692.781 25745.96 0.2070
4 25692.781 25745.96 0.2070
5 25692.781 25745.96 0.2070
6 25045.906 25092.81 0.1873
7 17836.732 17868.94 0.1806
8 17836.732 17868.94 0.1806
9 17623.090 17654.93 0.1807
10 23011.380 23058.36 0.2042
11 23011.380 23058.36 0.2042
12 22978.878 23025.8 0.2042
13 22978.878 23025.8 0.2042
14 22966.742 23013.55 0.2038
15 22966.742 23013.55 0.2038
16 22966.742 23013.55 0.2038
17 1256.550 1263.39 0.5443
18 1368.780 1368.78 0.0000
19 21898.816 21939.68 0.1866
20 21898.816 21939.68 0.1866
21 21898.816 21939.68 0.1866
22 21790.784 21831.59 0.1873
23 21790.784 21831.59 0.1873
24 251.3110 252.66 0.5396
25 21577.171 21617.58 0.1873
63
Streamline Total Molar Flowrate (kmol/hr)
Manual Calculation Excel Calculation Percentage Different
26 21570.698 21613.26 0.1973
27 1507.866 1516.05 0.543
28 3618.878 3646.54 0.7644
29 3618.878 3646.54 0.7644
30 3920.451 3953.76 0.8496
31 2274.051 2274.05 0.0000
32 273.745 273.74 0.0000
33 1516.052 1516.05 0.0001
34 1516.052 1516.05 0.0000
35 464.615 463.91 0.1520
36 757.999 757.99 0.000
37 19168.354 19197.25 0.1507
38 5877.552 5895.56 0.3064
39 1809.439 1823.27 0.7644
40 213.642 214.01 0.1723
64
4.0 ENERGY BALANCE
4.1 Standard Enthalpies of Formation
The reference state for calculation of energy input was taken to be standard temperature and
pressure STP 1 atm and 25°C based on property table. The standard enthalpies of formation
of each species were obtained in order to calculate the input and output energy content.
Table 4.1: Standard Enthalpies of formation of species provided involved in the process
(Perry et al., 1997)
Species Standard Enthalpies of Formation

(kJ/mol)
Sulfur 0.00
Sulfur Dioxide -296.90
Sulfur Trioxide -395.18
Oleum -683.92
Sulfuric Acid -907.51 (aq)
Water -285.84 (l)
-241.83 (g)
Hydrogen Sulfide -19.96 (g)
Oxygen 0.00
Nitrogen 0.00
Carbon Dioxide -412.9 (l)
-393.5 (g)
65
4.2 Specific Heat Capacities (at constant pressure, Cp)
Specific heat capacities of substances, particularly for those of gases, vary with temperature,
though sometimes assumed otherwise. Variations are mostly corrected by presenting specific
heat capacity as a function of temperature. Since a range of temperatures have to be dealt
with, it was in general regarded that the function is applicable. In order to evaluate the energy
content of the substance undergoing a temperature change the above function were
integrated.
Table 4.2: Specific Heat Capacities of species involved in the process.(Perry et al., 1997)
Species Temp range Specific Heat Capacity (kJ/mol.K)

(°C)
Sulfur 0 – 95 Cp = 15.2 x 10-3 + 2.68 x10-5 T
95 - 118.85 Cp = 18.3 x 10-3 + 1.84 x10-5 T
SO2 0 – 1500 Cp = 38.91 x 10-3 + 3.904 x10-5 T – 3.104 x 10-8 T2 + 8.606 x 10-12 T3
SO3 0-1000 Cp = 48.50 x 10-3 + 9.188 x10-5 T – 8.540 x 10-8 T2 + 32.4 x 10-12 T3
Oleum, 25-178 Cp = 275.9
H2S2O7 (__) >178 Cp = 47.289 + 190.331 T – 148.13 x 10-2 T2 + 43.866 T3 – 0.74 T-2
H2SO4 10 - 45 Cp = 139.1 x 10-3 + 15.59 x10-5 T
H2O 0 – 100 Cp = 75.4 x 10-3
0 – 1500 Cp = 33.46 x 10-3 + 0.6880 x10-5 T + 0.7604 x 10-8 T2 – 3.593 x 10-12
T3
H2S 0 – 1500 Cp = 33.51 x 10-3 + 1.547 x10-5 T + 0.3012 x 10-8 T2 – 3.292 x 10-12
T3
O2 0 – 1500 Cp = 29.10 x 10-3 + 1.158 x10-5 T - 0.6076 x 10-8 T2 + 1.311 x 10-12 T3
N2 0 – 1500 Cp = 29.00 x 10-3 + 0.2199 x10-5 T + 0.5723 x 10-8 T2 – 2.871 x 10-12
T3
CO2 0 – 1500 Cp = 36.11 x 10-3 + 4.233 x10-5 T – 2.887 x 10-8 T2 + 7.464 x 10-12 T3
66
4.3 Boiling and melting points
Normal boiling point and melting point were required in the energy balance in order to calculate
the specific enthalpies of species present in a stream at a given temperature.
Table 4.3: Boiling points of species involved in the process.
Species Normal Boiling Point (°C)

Sulfur (the elemental sulfur) 445
Sulfur Dioxide -10.2
Sulfur Trioxide 44.8
Oleum 138
Sulfuric Acid 337
Water 100
Hydrogen Sulfide -60.4
Oxygen -183
Nitrogen -195.8
Carbon Dioxide -78.5
Sulfur being a solid at room temperature is melted during operation and the melting point at
115 °C.
67
4.4 Energy Balance Calculation
4.4.1 Reactive Energy Balance
4.4.1.1 Dilution Tank
Stream 35
(Liquid, 30°C, 1 atm)
Molar flowrate = 464.615 kmol total/hr
• 464.615 kmol H20 /hr
Dilution Tank
Stream 39 Stream 31
(Liquid, 75°C, 1 atm) (Liquid, 187°C, 1 atm)

Molar flowrate = 1809.439 kmol total/hr Molar flowrate = 2274.05 kmol total/hr
• 289.510 kmol H2S2O7 /hr • 2098.949 kmol H2SO4 /hr

• 1519.929 kmol H2SO4 /hr • 175.102 kmol H20 /hr
H2S2O7 (l) + H20 (l) H2SO4 (l)
References: Oleum (l, 25°C, 1 atm); Sulphuric Acid (l, 25°C, 1 atm); Water (l, 25°C, 1 atm)
Substance Input Output
nin (mol/hr) Hin (kJ/mol) nout (mol/hr) Hout (kJ/mol)
Oleum (H2S2O7) 289510 H1 - -
Sulphuric Acid (H2SO4) 1519929 H2 2098949 H3
Water (H2O) 464615 H4 175102 H5
Total
68
Step 1: Start with chemical equation
I. Oleum
4S (s) + 2H2 (g) + 7O2 2H2S2O7
II. Sulphuric acid

S (s) + H2 (g) + 2O2 2H2SO4
III. Water
1
2H2 + 2 O2 H2O
Step 2: Find H1 (Oleum, H2S2O7)
7
𝐻2 + 2𝑆 + 𝑂2 2H2S2O7
2
(l, 25°C, 1 atm) H2
(l, 75°C, 1 atm)
Ha2 Hb2
2H2S2O7
(l, 25°C, 1 atm)
References: S (s), H2 (g), O2 (g) at 25°C and 1 atm (put phase)

nin (kmol/hr) Hin (kJ/mol) nout (kmol/hr) Hout (kJ/mol)
Oleum (H2S2O7) 638.795 H1 - -
Calculation:
Heat of formation (ΔHf, H2SO4), Ha2 = -683.92 kJ/mol
ΔH(kJ/mol) - Heat Capacities, Hb2 = 275.90 kJ/mol
H1 = Ha1 + Hb1 = -683.92 kJ/mol + 275.90 kJ/mol

= -408.020 kJ/mol
69
Step 3: Find H2 (Sulphuric Acid - input)
S (s) + H2 (g) + 2O2 H2 2H2SO4
(25°C, 1 atm) (75°C, 1 atm)
Ha2 Hb2
2H2SO4
(25°C, 1 atm)
References: S (s), H2 (g), O2 (g) at 25°C and 1 atm

Sulphuric Acid (H2SO4) 121.675 H2 1399.267 H3
Find Ha2 = Heat of formation (ΔHf, H2SO4) at Table B1 in Appendix B
Calculation:
ΔH(kJ/mol) - Heat Capacities, Hb2
𝑇2
= ∫𝑇1 (𝑎 + 𝑏𝑇 + 𝑐𝑇 2 + 𝑑𝑇 3 )𝑑𝑇
𝑇2
= ∫𝑇1 (𝑎 + 𝑏𝑇 + 𝑐𝑇 2 + 𝑑𝑇 3 )𝑑𝑇
𝑏 𝑐 𝑑
= a(T2-T1) + 2 (T22 -T12) + 3 (T21 -T13) + (T24 -T14)
4
15.59 × 10−5
= 139.1 x 10-3 (75-25) + (752 - 252)
2
= 7.345 kJ/mol

= -803.975 kJ/mol
70
Step 4: Find H3 (Sulphuric Acid- output)
H3 2H2SO4
S (s) + H2 (g) + 2O2
(25°C, 1 atm) (187°C, 1 atm)
Ha3 Hb3
2H2SO4
(25°C, 1 atm)

Sulphuric Acid (H2SO4) 121.675 H2 1399.267 H3
Find Ha3 = Heat of formation (ΔHf, H2SO4) at Table B1 in Appendix B
Calculation:
By referring Table B8 in Appendix B,

𝑇2
= ∫𝑇1 (𝑎 + 𝑏𝑇 + 𝑐𝑇 2 + 𝑑𝑇 3 )𝑑𝑇
70
= ∫25 (𝑎 + 𝑏𝑇 + 𝑐𝑇 2 + 𝑑𝑇 3 )𝑑𝑇
𝑏 𝑐 𝑑
= a (T2-T1) + 2 (T22 -T12) + 3 (T21 -T13) + (T24 -T14)
4
15.59 × 10−5
= 139.1 x 10-3 (187-25) + (1872 - 252)
2
= 25.211 kJ/mol
= -786.109 kJ/mol
71
Step 5: Find H4 (Water- input)
1
H4 H2O
2H2 + O2
2
(30°C, 1 atm)
(g, 25°C, 1 atm)
Ha4 Hb4
H2O
(25°C, 1 atm)
References: H2 (g), O2 (g) at 25°C and 1 atm

Water (H2O) 755.527 H4 116.732 H5
Find Ha4 = Heat of formation (ΔHf, H2O) at Table B1 in Appendix B
Calculation:
Heat of formation (ΔHf, H2O), Ha4 = -285.84 kJ/mol

𝑇2
= ∫𝑇1 (𝑎 + 𝑏𝑇 + 𝑐𝑇 2 + 𝑑𝑇 3 )𝑑𝑇
30
= ∫25 (𝑎 + 𝑏𝑇 + 𝑐𝑇 2 + 𝑑𝑇 3 )𝑑𝑇
𝑏 𝑐 𝑑
= a (T2-T1) + 2 (T22 -T12) + 3 (T21 -T13) + (T24 -T14)
4
= 75.4 x 10-3 (30-25)

= 0.377 kJ/mol
= -285.463 kJ/mol
72
Step 6: Find H5 (Water- output)
1
H5 H2O
2H2 + O2
2
(l, 187°C, 1 atm)
(g, 25°C, 1 atm)
Ha5 Hb5
H2O
(l, 25°C, 1 atm)

Water (H2O) 755.527 H4 116.732 H5
Find Ha5 = Heat of formation (ΔHf, H2O) at Table B1 in Appendix B
Calculation:
Heat of formation (ΔHf, H2O), Ha5 = -285.84 kJ/mol

𝑇2
= ∫𝑇1 (𝑎 + 𝑏𝑇 + 𝑐𝑇 2 + 𝑑𝑇 3 )𝑑𝑇
70
= ∫25 (𝑎 + 𝑏𝑇 + 𝑐𝑇 2 + 𝑑𝑇 3 )𝑑𝑇
𝑏 𝑐 𝑑
= a (T2-T1) + 2 (T22 -T12) + 3 (T21 -T13) + (T24 -T14)
4
= 75.4 x 10-3 (187-25)

= 12.215 kJ/mol

= -273.625 kJ/mol
73
Step 7: Find Q
References: Oleum (l, 25°C, 1 atm); Sulphuric Acid (l, 25°C, 1 atm); Water (l, 25°C, 1 atm)
Oleum (H2S2O7) 289510 -408.020 - -
Sulphuric Acid (H2SO4) 1519929 -803.975 2098949 -786.109
Water (H2O) 464615 -285.463 175102 -273.625
Total = ∑ninHin = ∑noutHout
= -1472741180 = -1697914984
Find Q; = ∑noutHout -∑ninHin
= -1697914984 – (-1472741180)
= -225173804 kJ/hr
= -22.51 x 107 kJ/hr
74
4.4.1.2 Final Absorption Tower (FAT)

STREAM 32 Molar flowrate = 273.745 kmol total/hr
• 252.667 kmol H2SO4 /hr

• 21.078 kmol H2O /hr
STREAM 23 Final Absorption Tower STREAM 25
(FAT)
(Gas, 130°C, 1 atm) (Gas, 90°C, 1 atm)
Molar flowrate = 21790.784 kmol total/hr Molar flowrate = 760.471kmol total/hr
• 2.158 kmol S /hr • 2.158 kmol S /hr

• 4.315 kmol SO2 /hr • 4.315 kmol SO2 /hr
• 17.262 kmol H2S /hr • 17.262 kmol H2S /hr
• 988.234 kmol O2 /hr • 988.234 kmol O2 /hr
• 19786.266 kmol N2 /hr STREAM 24 • 19786.266 kmol N2 /hr
• 776.778 kmol CO2 /hr • 776.778 kmol CO2 /hr
• 37.697 kmol H2SO4 /hr

• 213.614 kmol H2S2O7 /hr
References: Sulphur (s, 25°C, 1 atm); Sulphuric Acid (l, 25°C, 1 atm); Oleum (l, 25°C, 1 atm);
Water (l, 25°C, 1 atm); Sulphur Dioxide (g, 25°C, 1 atm); Sulphur Trioxide (g, 25°C, 1 atm);
Hydrogen Sulphide (g, 25°C, 1 atm); Oxygen (g, 25°C, 1 atm); Nitrogen (g, 25°C, 1 atm) and
Carbon Dioxide (g, 25°C, 1 atm);

Sulphur 2158 H6 2158 H7
Oleum (H2S2O7) - - 213614 H10
Water (H2O) 21078 H11 - -
Sulphur Dioxide (SO2) 4315 H12 4315 H13
Sulphur Trioxide (SO3) 215771 H14 2158 H15
Hydrogen Sulphide (H2S) 17262 H16 17262 H17
Oxygen (O2) 988234 H18 988234 H19
Nitrogen (N2) 19786266 H12 19786266 H20
Carbon Dioxide (CO2) 776778 H13 776778 H21
75
Find Q
References: Sulphur (s, 25°C, 1 atm); Sulphuric Acid (l, 25°C, 1 atm); Oleum (l, 25°C, 1 atm);
Water (l, 25°C, 1 atm); Sulphur Dioxide (g, 25°C, 1 atm); Sulphur Trioxide (g, 25°C, 1 atm);
Hydrogen Sulphide (g, 25°C, 1 atm); Oxygen (g, 25°C, 1 atm); Nitrogen (g, 25°C, 1 atm) and
Carbon Dioxide (g, 25°C, 1 atm);

Sulphur 2158 1.811 2158 1.088
Oleum (H2S2O7) - - 213614 -408.020
Water (H2O) 21078 -273.625 - -
Sulphur Dioxide (SO2) 4315 -292.814 4315 -294.232
Sulphur Trioxide (SO3) 215771 -389.399 2158 -391.767
Hydrogen Sulphide (H2S) 17262 -16.313 17262 -17.723
Oxygen (O2) 988234 3.992 988234 1.934
Nitrogen (N2) 19786266 3.067 19786266 1.895
Carbon Dioxide (CO2) 776778 -389.384 776778 -391.002
= -529052370.6 = -384131785
Find Q;
Q= ΔH
= ∑noutHout -∑ninHin
= -384131785 – ( -529052370.6)
= 144920585.6 kJ/hr
76
4.4.1.3 Converter 4
STREAM 21 STREAM 22
4th Catalytic Bed
(Gas, 450°C, 1 atm) (Gas, 500°C, 1 atm)

• 2.158 kmol S/hr • 2.158 kmol S /hr

• 17.262 kmol H2S /hr • 215.771 kmol SO3 /hr
• 1096.120 kmol O2 /hr • 17.262 kmol H2S /hr
• 19786.266 kmol N2 /hr • 988.234 kmol O2 /hr
• 776.778 kmol CO2 /hr • 19786.266 kmol N2 /hr
• 776.778 kmol CO2 /hr
References: Sulphur (s, 25°C, 1 atm); Sulphur Dioxide (g, 25°C, 1 atm); Sulphur Trioxide (g,
25°C, 1 atm); Hydrogen Sulphide (g, 25°C, 1 atm); Oxygen (g, 25°C, 1 atm); Nitrogen (g,
25°C, 1 atm) and Carbon Dioxide (g, 25°C, 1 atm);

Sulphur 2158 H22 2158 H23
Sulphur Trioxide (SO3) - - 215771 H26
Oxygen (O2) 1096120 H29 988234 H30
Nitrogen (N2) 19786266 H31 19786266 H32
77
Find Q

Sulphur 2158 9.165 2158 10.562
Sulphur Trioxide (SO3) - - 215771 -363.738
Oxygen (O2) 1096120 13.365 988234 15.034
Nitrogen (N2) 19786266 12.692 19786266 14.242
= -86342031.12 = -72111351.53
Find Q; Q= ΔH
= -72111351.53 – (-86342031.12)
= 14230679.59 kJ/hr
78
4.4.1.4 InterPass Absorption (IPAT) (Gas, 90°C, 1 atm)
• 2.158 kmol S /hr

• 220.086 kmol SO2 /hr
STREAM 19 • 17.262 kmol H2S /hr
• 1096.120 kmol O2 /hr
• 19786.266 kmol N2 /hr
• 776.778 kmol CO2 /hr
STREAM 16 InterPass Absorption STREAM 18
(IPAT) 21\18
(Gas, 160°C, 1 atm) (Liquid, 187°C, 1 atm)
• 2.158 kmol S /hr • 1263.39 kmol H2SO4 /hr

• 220.086 kmol SO2 /hr • 105.40 kmol H2O /hr
• 1068.072 kmol SO3 /hr
• 17.262 kmol H2S /hr STREAM 17
• 1096.120 kmol O2 /hr
• 19786.266 kmol N2 /hr (Liquid, 87°C, 1 atm)
• 776.778 kmol CO2 /hr Molar flowrate = 1256.55 kmol
total/hr
• 188.483 kmol H SO /hr

References: Oleum (l, 25°C, 1 atm); Sulphuric Acid2 (l, 425°C, 1 atm); Water (l, 25°C, 1 atm);
• 1068.072kmol H2S2O7 /hr
Sulphur Dioxide (g, 25°C, 1 atm); Sulphur Trioxide (g, 25°C, 1 atm); Hydrogen Sulphide (g,
25°C, 1 atm); Oxygen (g, 25°C, 1 atm); Nitrogen (g, 25°C, 1 atm) and Carbon Dioxide (g,
25°C, 1 atm);
Oleum (H2S2O7) - - 1068072 H37
Water (H2O) 105400 H38 - -
Sulphur 2158 H39 2158 H40
Sulphur Trioxide (SO3) 1068072 H43 - -
Oxygen (O2) 1096120 H46 1096120 H47
Nitrogen (N2) 19786266 H48 19786266 H49
79
Find Q
References: Oleum (l, 25°C, 1 atm); Sulphuric Acid (l, 25°C, 1 atm); Water (l, 25°C, 1 atm);
25°C, 1 atm);
Oleum (H2S2O7) - - 1068072 -408.020
Water (H2O) 105400 -273.625 - -
Sulphur 2158 2.387 2158 1.088
Sulphur Trioxide (SO3) 1068072 -387.596 - -
Hydrogen Sulphide 17262 -15.239 17262 -17.723
(H2S)
Oxygen (O2) 1096120 4.066 1096120 1.934
Nitrogen (N2) 19786266 3.949 19786266 1.895
= -1719230871 kJ/hr = -916154078.4 kJ/hr
Find Q; Q= ΔH
= ∑noutHout - ∑ninHin
= -916154078.4- (-1719230871)
= 803076792.6 kJ/hr
80
4.4.1.5 3rd Catalytic Bed
STREAM 13 STREAM 14
3rd Catalytic Bed
(Gas, 430°C, 1 atm)

Molar flowrate = 23025.80 kmol (Gas, 495°C, 1 atm)
total/hr Molar flowrate = 23013.55 kmol total/hr
• 2.158 kmol S /hr • 2.158 kmol S /hr

• 1108.347 kmol O2 /hr • 1096.120 kmol O2 /hr
• 19786.266 kmol N2 /hr • 19786.266 kmol N2 /hr
References: Sulphur (s, 25°C, 1 atm); Sulphuric Acid (l, 25°C, 1 atm); Water (l, 25°C, 1 atm);
25°C, 1 atm);

Sulphur 2158 H51 2158 H52
Oxygen (O2) 1108347 H58 1096120 H59
Nitrogen (N2) 19786266 H60 19786266 H61
81
Find Q
25°C, 1 atm);

Sulphur 2158 8.625 2158 10.419
Oxygen (O2) 1108347 12.703 1096120 14.866
Nitrogen (N2) 19786266 12.075 19786266 14.087
= -492073661.1 kJ/hr = -443698117.4 kJ/hr
Find Q; Q= ΔH
= -443698117.4 - (-492073661.1)
= 48375543.65 kJ/hr
82
4.4.1.6 2rd Catalytic Bed
STREAM 11 STREAM 12
2nd Catalytic Bed
(Gas, 430°C, 1 atm) (Gas, 550°C, 1 atm)

Molar flowrate = 23058.36 kmol Molar flowrate = 23025.80 kmol total/hr
total/hr
• 2.158 kmol S /hr
• 2.158 kmol S /hr • 244.54 kmol SO2 /hr
• 978.523 kmol SO3 /hr • 17.262 kmol H2S /hr
• 17.262 kmol H2S /hr • 1108.347 kmol O2 /hr
• 1140.849 kmol O2 /hr • 19786.266 kmol N2 /hr
• 19786.266 kmol N2 /hr • 776.778 kmol CO2 /hr
• 776.778 kmol CO2 /hr
25°C, 1 atm);

Sulphur 2158 H64 2158 H65
Oxygen (O2) 1140849 H72 1108347 H73
Nitrogen (N2) 19786266 H74 19786266 H74
83
Find Q
25°C, 1 atm);

Sulphur 2158 8.625 2158 12.025
Hydrogen Sulphide (H2S) 17262 -4.911 17262 0.060
Oxygen (O2) 1140849 12.703 1108347 16.719
Nitrogen (N2) 19786266 12.075 19786266 15.808
= -485764600.4 kJ/hr = -397791432.1 kJ/hr
Find Q; Q= ΔH
= -397791432.1 – (-485764600.4)
= 87973168.29 kJ/hr
84
4.4.1.7 1st Catalytic Bed
(Gas, 143 °C, 1 atm)

STREAM 38
• 1232.523 kmol O2 /hr
• 4643.266 kmol N2 /hr
• 1.763 kmol CO2 /hr
STREAM 9 STREAM 10
Ist Catalytic Bed
(Gas, 629°C, 1 atm)

(Gas, 420°C, 1 atm)
Molar flowrate = 17623.09 kmol
total/hr
• 2.158 kmol S /hr
• 309.544 kmol SO2 /hr
• 2.158 kmol S /hr
• 978.523 kmol SO3 /hr
• 1288.067 kmol SO2 /hr
• 17.262 kmol H2S /hr
• 17.262 kmol H2S /hr
• 1140.849 kmol O2 /hr
• 397.588 kmol O2 /hr
• 19786.266 kmol N2 /hr
• 15143 kmol N2 /hr
• 776.778 kmol CO2 /hr
• 775.015 kmol CO2 /hr
25°C, 1 atm);
Sulphur 2.158 H77 2.158 H78

Sulphur Dioxide (SO2) 1288.067 H79 309.544 H80
Sulphur Trioxide (SO3) - - 978.523 H81
Hydrogen Sulphide (H2S) 17.262 H82 17.626 H83
Oxygen (O2) - S9 397.588 H84 1140.849 H87
Oxygen (O2) - S38 1232.523 H85
Nitrogen (N2) - S9 15143 H86 19786.266 H90
Nitrogen (N2) - S38 4643.266 H88
Carbon Dioxide (CO2) - S9 775.778 H89 776.778 H92
Carbon Dioxide (CO2) - S38 1.763 H91
85
Find Q
25°C, 1 atm);
Sulphur 2158 8.359 2158 14.474

Sulphur Trioxide (SO3) - - 978523 -353.555
Oxygen (O2) - S9 397588 12.703 1140849 19.410
Oxygen (O2) - S38 1232523 3.554
Nitrogen (N2) - S9 1514300 11.767 19786266 18.313
Nitrogen (N2) - S38 4643266 3.449
Carbon Dioxide (CO2) - 775778 -376.172 776778 -365.432
S9
Carbon Dioxide (CO2) - 1763 -388.846
S38
= -608432675.3 kJ/hr = -328173894.9 kJ/hr
Find Q; Q= ΔH
= -328173894.9 – (-608432675.3)
= 280258780.4 kJ/hr
86
4.4.1.8 Furnace
Fuel
STREAM 2 STREAM 7
Furnace
(Solid, 135 °C, 1 atm)
total/hr Molar flowrate = 17836.732 kmol
total/hr
• 1503.867 kmol S /hr
• 17.262 kmol H2S /hr • 215.8 kmol S /hr
• 1288.067 kmol SO2 /hr
• 17.262 kmol H2S /hr
STREAM 37 • 397.588 kmol O2 /hr
• 15143 kmol N2 /hr
(Gas, 80 °C, 1 atm) • 775.015 kmol CO2 /hr
total/hr
• 4019.604 kmol O2 /hr

• 15143 kmol N2 /hr
References: Sulphur (s, 25°C, 1 atm); Sulphur Dioxide (g, 25°C, 1 atm); Hydrogen Sulphide
(g, 25°C, 1 atm); Oxygen (g, 25°C, 1 atm); Nitrogen (g, 25°C, 1 atm) and Carbon Dioxide (g,
25°C, 1 atm);
Sulphur 1503867 H93 2158 H94
Sulphur Dioxide (SO2) - - 1288067 H95
Oxygen (O2) 4019604 H98 397588 H99
Nitrogen (N2) 15143000 H100 15143000 H101
87
Find Q
References: Sulphur (s, 25°C, 1 atm); Sulphur Dioxide (g, 25°C, 1 atm); Hydrogen Sulphide
(g, 25°C, 1 atm); Oxygen (g, 25°C, 1 atm); Nitrogen (g, 25°C, 1 atm) and Carbon Dioxide (g,
25°C, 1 atm);
Sulphur 1503867 1.908 2158 33.445
Sulphur Dioxide (SO2) - - 1288067 -240.971
Oxygen (O2) 4019604 1.633 397588 36.795
Nitrogen (N2) 15143000 1.602 15143000 34.685
= 31163019.54 kJ/hr = -31953429.09 kJ/hr
Find Q; Q= ΔH
= -31953429.09 - 31163019.54
= -63116448.63 kJ/hr
88
4.4.1.8 Air Dryer
(Gas, 80°C, 1 atm)

STREAM 6 total/hr
66 • 5252.127 kmol O2 /hr
• 19786.266 kmol N2 /hr
Air Dryer
STREAM 5 STREAM 29
55 1 atm)
(Gas, 30°C, 2929
Molar flowrate = 25692.781 kmol Molar flowrate = 3618.878 kmol
total/hr total/hr
• 5252.127 kmol O2 /hr • 2626.702 kmol H2SO4 /hr

• 19786.266 kmol N2 /hr • 992.176 kmol H2S2O7 /hr
• 646.874 kmol H2O /hr
STREAM 30
total/hr
• 3920.451 kmol H2SO4 /hr
References: Oxygen (g, 25°C, 1 atm); Nitrogen (g, 25°C, 1 atm) and Carbon Dioxide (g, 25°C,
1 atm); Water (l, 25°C, 1 atm); Sulphuric acid (l, 25°C, 1 atm); Oleum (l, 25°C, 1 atm);
Oxygen (O2) 5252127 H1 5252127 H2
Nitrogen (N2) 19786266 H3 19786266 H4
Water (H2O) 646874 H7 - -
Oleum (H2S2O7) 992176 H10 - -
Total
89
Find Q
References: Oxygen (g, 25°C, 1 atm); Nitrogen (g, 25°C, 1 atm) and Carbon Dioxide (g, 25°C,
1 atm); Water (l, 25°C, 1 atm); Sulphuric acid (l, 25°C, 1 atm); Oleum (l, 25°C, 1 atm);

Oxygen (O2) 5252127 0.148 5252127 1.633
Nitrogen (N2) 19786266 0.145 19786266 1.602
Water (H2SO4) 646874 0.377 - -
Oleum (H2S2O7) 992176 -408.020 - -

= -2510914953 = -3117559407
Find Q; Q= ΔH
= -3117559407- (-2510914953)
= -606644454.4
90
4.4.2 Non- Reactive Process
4.4.2.1 Scrubber
STREAM 25 STREAM 26
25v25 Scrubber 2626
(Gas, 90°C, 1 atm) (Gas, 40°C, 1 atm)

• 2.158 kmol S /hr • 2.158 kmol S /hr

• 2.158 kmol SO3 /hr • 988.234 kmol O2 /hr
• 17.262 kmol H2S /hr • 19786.266 kmol N2 /hr
• 988.234 kmol O2 /hr • 776.778 kmol CO2 /hr
• 19786.266 kmol N2 /hr
• 776.788 kmol CO2 /hr
90°C, 1 atm); Hydrogen Sulphide (g, 90°C, 1 atm); Oxygen (g, 90°C, 1 atm); Nitrogen (g, 90°C,
1 atm) and Carbon Dioxide (g, 90°C, 1 atm);
Sulphur 2.158 0(ref) 2.158 H1
Sulphur Dioxide (SO2) 4.315 0(ref) - -
Sulphur Trioxide (SO3) 2.158 0(ref) - -
Hydrogen Sulphide (H2S) 17.262 0(ref) 17.262 H2
Oxygen (O2) 988.234 0(ref) 988.234 H3
Nitrogen (N2) 19786.266 0(ref) 19786.266 H4
Carbon Dioxide (CO2) 776.778 0(ref) 776.778 H5
91
Step 1: Find H1 (Sulphur)
H1
S S
(s, 90°C, 1 atm) (s, 40°C, 1 atm)
Ha1 Hb1
S
(s, 40°C, 1 atm)
References: S (s) at 90°C and 1 atm

Sulphur 2.158 0(ref) 2.158 H1
Calculation:
ΔH(kJ/mol) - Heat Capacities, Ha1
𝑇2
= ∫𝑇1 (𝑎 + 𝑏𝑇 + 𝑐𝑇 2 + 𝑑𝑇 3 )𝑑𝑇
70
= ∫25 (𝑎 + 𝑏𝑇 + 𝑐𝑇 2 + 𝑑𝑇 3 )𝑑𝑇
𝑏 𝑐 𝑑
= a (T2-T1) + 2 (T22 -T12) + 3 (T21 -T13) + (T24 -T14)
4
2.68 × 10−5
= 15.2 x 10-3 (40-90) + (402 - 902)
2
= -0.847 kJ/mol
Hb1 =0
H1 = Ha1 + Hb1 = -0.847 kJ/mol + 0 kJ/mol

= -0.847 kJ/mol
Step 2: Find 2 (Hydrogen Sulphide)
H2
H2 + S H2S
(g, 90°C, 1 atm) (g, 40°C, 1 atm)
Ha2 Hb2
H2S
(g, 40°C, 1 atm) 92
References: S (s), H2 (g) at 90°C and 1 atm
Hydrogen Sulphide (H2S) 17.262 0(ref) 17.262 H2
Calculation:
𝑇2
= ∫𝑇1 (𝑎 + 𝑏𝑇 + 𝑐𝑇 2 + 𝑑𝑇 3 )𝑑𝑇
70
= ∫25 (𝑎 + 𝑏𝑇 + 𝑐𝑇 2 + 𝑑𝑇 3 )𝑑𝑇
𝑏 𝑐 𝑑
= a (T2-T1) + 2 (T22 -T12) + 3 (T21 -T13) + (T24 -T14)
4
1.547× 10−5 0.3012 × 10−8 −3.292 × 10−12
= 33.51 x 10-3 (40-90) + (402 - 902) + (403 – 903) + (404
2 3 4
- 904)
= (-1.676) + (-0.050) + (-0.0006) + (0.00005)
= -1.727 kJ/mol
Hb2 =0

= -1.727 kJ/mol
Step 3: Find H3 (Oxygen)
H3
O2 O2
(g, 90°C, 1 atm) (g, 40°C, 1 atm)
Ha3 Hb3
O2
(g, 40°C, 1 atm)
References: O2 (g) at 90°C and 1 atm

Oxygen (O2) 988.234 0(ref) 988.234 H3
93
Calculation:
𝑇2
= ∫𝑇1 (𝑎 + 𝑏𝑇 + 𝑐𝑇 2 + 𝑑𝑇 3 )𝑑𝑇
70
= ∫25 (𝑎 + 𝑏𝑇 + 𝑐𝑇 2 + 𝑑𝑇 3 )𝑑𝑇
𝑏 𝑐 𝑑
= a (T2-T1) + 2 (T22 -T12) + 3 (T21 -T13) + (T24 -T14)
4
1.158× 10−5 −0.6076 × 10−8 1.311 × 10−12
= 29.10 x 10-3 (40-90) + (402 - 902) + (403 – 903) + (404
2 3 4
- 904)
= (-1.455) + (-0.038) + 0.001 + (-0.00002)
= -1.492 kJ/mol
Hb4 =0

= -1.492 kJ/mol
Step 4: Find H4 (Nitrogen)
H4
N2 N2
(g, 90°C, 1 atm) (g, 40°C, 1 atm)
Ha4 Hb4
N2
(g, 40°C, 1 atm)
References: N2 (g) at 90°C and 1 atm

Nitrogen (N2) 19786.266 0(ref) 19786.266 H4
Calculation:
𝑇2
= ∫𝑇1 (𝑎 + 𝑏𝑇 + 𝑐𝑇 2 + 𝑑𝑇 3 )𝑑𝑇
94
70
= ∫25 (𝑎 + 𝑏𝑇 + 𝑐𝑇 2 + 𝑑𝑇 3 )𝑑𝑇
𝑏 𝑐 𝑑
= a (T2-T1) + 2 (T22 -T12) + 3 (T21 -T13) + (T24 -T14)
4
0.2199 × 10−5 0.5723 × 10−8 −2.871 × 10−12
= 29.00 x 10-3 (40-90) + (402 - 902) + (403 – 903) + (404
2 3 4
- 904)
= (-1.450) + (-0.007) + (-0.001) + 0.00004
= -1.458 kJ/mol
Hb4 =0

= -1.458 kJ/mol
Step 5: Find H5 (Carbon Dioxide)
H5 CO2
C + O2
(g, 90°C, 1 atm) (g, 40°C, 1 atm)
Ha5 Hb5
CO2
(g, 40°C, 1 atm)
References: CO2 (g) at 90°C and 1 atm

Carbon Dioxide (CO2) 776.778 0(ref) 776.778 H5
Calculation:
𝑇2
= ∫𝑇1 (𝑎 + 𝑏𝑇 + 𝑐𝑇 2 + 𝑑𝑇 3 )𝑑𝑇
70
= ∫25 (𝑎 + 𝑏𝑇 + 𝑐𝑇 2 + 𝑑𝑇 3 )𝑑𝑇
𝑏 𝑐 𝑑
= a (T2-T1) + 2 (T22 -T12) + 3 (T21 -T13) + (T24 -T14)
4
95
4.233 × 10−5 −2.887 × 10−8 7.464 × 10−12
= 36.11 x 10-3 (40-90) + (402 - 902) + (403 – 903) + (404
2 3 4
- 904)
= -1.806 + (-0.138) + 0.0064 + (-0.0001)
= -1.938 kJ/mol
Hb5 =0

= -1.938 kJ/mol
Step 6: To find Q
Sulphur 2158 0(ref) 2158 -0.847
Sulphur Dioxide (SO2) 4315 0(ref) - -
Sulphur Trioxide (SO3) 2158 0(ref) - -
Hydrogen Sulphide (H2S) 17262 0(ref) 17262 -1.727
Oxygen (O2) 988234 0(ref) 988234 -1.492
Nitrogen (N2) 19786266 0(ref) 19786266 -1.458
Carbon Dioxide (CO2) 776778 0(ref) 776778 -1.938
=0 = -31859856.02
Find Q; Q= ΔH
= -31859856.02 – 0
= -31859856.02
96
4.4.2.2 Oleum Distribution
STREAM (Liquid, 87°C, 1 atm)

27
• 226.180 kmol H2SO4 /hr
• 1281.686 kmol H2S2O7 /hr
STREAM Oleum Distribution STREAM

(Liquid, 30
70°C, 1 atm) 28
Molar flowrate = 3920.451 kmol (Liquid, 87°C, 1 atm)
total/hr Molar flowrate = 3618.878 kmol
total/hr
• 3920.451 kmol H2SO4 /hr
• 2626.702 kmol H2SO4 /hr
• 992.176 kmol H2S2O7 /hr
STREAM
39
total/hr
• 1519.929 kmol H2SO4 /hr

• 289.510 kmol H2S2O7 /hr
References: Sulphuric acid (l, 70°C, 1 atm); Sulphuric acid (l, 87°C, 1 atm); Oleum (l, 87°C,
1 atm)

Sulphuric Acid (stream 30) 3920.451 0(ref) 1519.929 0.752
Sulphuric Acid (stream 27) 226.180 0(ref) 2626.702 0
Oleum (Stream 30) - 0(ref) 289.510 275.9
Oleum (Stream 27) 1281.686 0(ref) 992.176 0
Total
97
Find Q
References: Sulphuric acid (l, 70°C, 1 atm); Sulphuric acid (l, 87°C, 1 atm); Oleum (l, 87°C,
1 atm) ;
Sulphuric Acid (stream 12) 3920451 0(ref) 1519929 0.752
Sulphuric Acid (stream 27) 226180 0(ref) 2626702 0
Oleum (Stream 21) - 0(ref) 289510 275.9
Oleum (Stream 27) 1281686 0(ref) 992176 0
=0 = 81018795.61
Find Q; Q= ΔH
= 81018795.61– 0
= 81018795.61
98
4.4.2.3 Economizer 2
STREAM 22 STREAM 23
Economizer 2
(Gas, 500°C, 1 atm) (Gas, 90°C, 1 atm)

Molar flowrate = 21790.784 kmol Molar flowrate = kmol total/hr
total/hr
• 2.158 kmol S /hr
• 988.234 kmol O2 /hr • 19786.266 kmol N2 /hr
• 776.778 kmol CO2 /hr
References: Sulphur (s, 500°C, 1 atm); Sulphur Dioxide (g, 500°C, 1 atm); Sulphur Trioxide
(g, 500°C, 1 atm); Hydrogen Sulphide (g, 500°C, 1 atm); Oxygen (g, 500°C, 1 atm); Nitrogen
(g, 500°C, 1 atm) and Carbon Dioxide (g, 500°C, 1 atm);
Sulphur 2158 0(ref) 2158 H1
Sulphur Dioxide (SO2) 4315 0(ref) 4315 H2
Sulphur Trioxide (SO3) 215771 0(ref) 215771 H3
Hydrogen Sulphide (H2S) 17262 0(ref) 17262 H4
Oxygen (O2) 998234 0(ref) 998234 H5
Nitrogen (N2) 19786266 0(ref) 19786266 H6
Carbon Dioxide (CO2) 776778 0(ref) 776778 H7
Total
99
Find Q

Sulphur 2158 0(ref) 2158 - 8.748
Sulphur Dioxide (SO2) 4315 0(ref) 4315 -17.810
Sulphur Trioxide (SO3) 215771 0(ref) 215771 -25.662
Oxygen (O2) 998234 0(ref) 998234 -11.897
Nitrogen (N2) 19786266 0(ref) 19786266 -11.175
=0 = -252249862.1
Find Q; Q= ΔH
= -252249862.1 - 0
= -252249862.1
100
4.4.2.4 Heat Exchanger 2 (Gas, 255°C, 1 atm)
Molar flowrate = kmol total/hr
• 2.158 kmol S /hr

• 220.086 kmol SO2 /hr
STREAM 20
• 17.262 kmol H2S /hr
• 1096.120 kmol O2 /hr
• 19786.266 kmol N2 /hr
• 776.778 kmol CO2 /hr
STREAM Heat Exchanger 2 STREAM 13

12 1 atm)
(Gas, 550°C,
total/hr Molar flowrate = kmol total/hr
• 2.158 kmol S /hr • 2.158 kmol S /hr

• 1108.347 kmol O2 /hr • 1108.347 kmol O2 /hr
• 19786.266 kmol N2 /hr STREAM 21 • 19786.266 kmol N2 /hr
(Gas, 450°C, 1 atm)
• 2.158 kmol S /hr

• 220.086 kmol SO2 /hr
• 17.262 kmol H2S /hr
• 1096.120 kmol O2 /hr
• 19786.266 kmol N2 /hr
• 776.778 kmol CO2 /hr
References: Sulphur (s, 550°C, 1 atm); Sulphur (s, 255°C, 1 atm); Sulphur Dioxide (g, 550°C,
1 atm); Sulphur Dioxide (g, 255°C, 1 atm); Sulphur Trioxide (g, 550°C, 1 atm); Hydrogen
Sulphide (g, 550°C, 1 atm); Hydrogen Sulphide (g, 255°C, 1 atm); Oxygen (g, 550°C, 1 atm);
Oxygen (g, 255°C, 1 atm); Nitrogen (g, 550°C, 1 atm); Nitrogen (g, 255°C, 1 atm); Carbon
Dioxide (g, 550°C, 1 atm); and Carbon Dioxide (g, 255°C, 1 atm);

Sulphur (stream 13) 2158 0(ref) 2158 H1
101
Sulphur Dioxide (Stream 13) 244540 0(ref) 244540 H3
Sulphur dioxide (stream 21) 220086 0(ref) 220086 H4
Sulphur trioxide 1043527 0(ref) 1043527 H5
Hydrogen Sulphide (Stream 17262 0(ref) 17262 H6
13)
Hydrogen Sulphide (Stream 17262 0(ref) 17262 H7
21)
Oxygen (Stream 13) 1108347 0(ref) 1108347 H8
Nitrogen (Stream 13) 19786266 0(ref) 19786266 H10
Carbon Dioxide (Stream 13) 776778 0(ref) 776778 H12
Total
102
Find Q

nin (mol/hr) Hin (Kj/mol) nout (mol/hr) Hout (Kj/mol)
Sulphur (stream 13) 2158 0(ref) 2158 -3.399
Sulphur (stream 21) 2158 0(ref) 2158 4.806
Sulphur Dioxide (Stream 13) 244540 0(ref) 244540 -6.188
Sulphur dioxide (stream 21) 220086 0(ref) 220086 9.579
Sulphur trioxide 1043527 0(ref) 1043527 -9.214
Hydrogen Sulphide (Stream 13) 17262 0(ref) 17262 -4.545
Hydrogen Sulphide (Stream 21) 17262 0(ref) 17262 7.679
Oxygen (Stream 13) 1108347 0(ref) 1108347 -4.016
Oxygen (Stream 21) 1096120 0(ref) 1096120 6.332
Nitrogen (Stream 13) 19786266 0(ref) 19786266 -3.734
Nitrogen (Stream 21) 19786266 0(ref) 19786266 5.921
Carbon Dioxide (Stream 13) 776778 0(ref) 776778 -6.093
Carbon Dioxide (Stream 21) 776778 0(ref) 776778 9.303
=0 = 39292599.32
Find Q; Q= ΔH
= 39292599.32 - 0
= 39292599.32
103
4.4.2.5 Heat Exchanger 1
(Gas, 255°C, 1 atm)

• 2.158 kmol S /hr

• 220.086 kmol SO2 /hr
• 1096.120 kmol O2 /hr
• 19786.266 kmol N2 /hr
• 776.778 kmol CO2 /hr
STREAM 14 Heat Exchanger 1 STREAM 15

(Gas, 495°C, 1 atm)
Molar flowrate = kmol total/hr (Gas, 300°C, 1 atm)
• 2.158 kmol S /hr
• 220.086 kmol SO2 /hr • 2.158 kmol S /hr
• 19786.266 kmol N2 /hr • 1096.120 kmol O2 /hr
• 776.778 kmol CO2 /hr STREAM 19 • 19786.266 kmol N2 /hr
• 776.778 kmol CO2 /hr
(Gas, 90°C, 1 atm)
• 2.158 kmol S /hr

• 220.086 kmol SO2 /hr
• 17.262 kmol H2S /hr
• 1096.120 kmol O2 /hr
• 19786.266 kmol N2 /hr
• 776.778 kmol CO2 /hr

nin Hin (kJ/mol) nout (mol/hr) Hout (kJ/mol)
(mol/hr)
104
Sulphur Dioxide (Stream 15) 220086 0(ref) 220086 H5
Sulphur dioxide (stream 19) 220086 0(ref) 220086 H6
Sulphur trioxide 1068072 0(ref) 1068072 H7
Hydrogen Sulphide (Stream 15) 17262 0(ref) 17262 H8
Hydrogen Sulphide (Stream 19) 17262 0(ref) 17262 H9
Total
105
Find Q

nin Hin (kJ/mol) nout (mol/hr) Hout (kJ/mol)
(mol/hr)
Sulphur (stream 15) 2158 0(ref) 2158 -0.886
Sulphur (stream 19) 2158 0(ref) 2158 3.161
Sulphur Dioxide (Stream 15) 220086 0(ref) 220086 -9.751
Sulphur dioxide (stream 19) 220086 0(ref) 220086 7.376
Sulphur trioxide 1068072 0(ref) 1068072 -14.317
Hydrogen Sulphide (Stream 15) 17262 0(ref) 17262 -7.785
Hydrogen Sulphide (Stream 19) 17262 0(ref) 17262 7.69
Oxygen (Stream 15) 1096120 0(ref) 1096120 -6.399
Oxygen (Stream 19) 1096120 0(ref) 1096120 5.1
Nitrogen (Stream 15) 19786266 0(ref) 19786266 -5.968
Nitrogen (Stream 19) 19786266 0(ref) 19786266 4.875
Carbon Dioxide (Stream 15) 776778 0(ref) 776778 -9.512
Carbon Dioxide (Stream 19) 776778 0(ref) 776778 7.017
=0 = -40799331.20
Find Q; Q= ΔH
= -40799331.20 – 0
= -40799331.20 kJ/hr
106
107
STREAM 15 STREAM 16
Economizer 1
(Gas, 300°C, 1 atm) (Gas, 160°C, 1 atm)

Molar flowrate = kmol total/hr Molar flowrate = kmol total/hr
• 2.158 kmol S /hr • 2.158 kmol S /hr

• 1096.120 kmol O2 /hr • 1096.120 kmol O2 /hr
• 19786.266 kmol N2 /hr • 19786.266 kmol N2 /hr
Oxygen (O2) 1096120 0(ref) 1096120 H5
Nitrogen (N2) 19786266 0(ref) 19786266 H6
Total
108
Find Q

Sulphur 2158 0(ref) 2158 -2.991
Oxygen (O2) 1096120 0(ref) 1096120 -4.403
Nitrogen (N2) 19786266 0(ref) 19786266 -4.530
=0 = -110586819.7
Find Q; Q= ΔH
= -110586819.7- 0
= -110586819.7 kJ/hr
109
4.4.2.6 Waste Heat Boiler 2
STREAM 10 STREAM 11
Waste Heat Boiler 2
(Gas, 629°C, 1 atm) (Gas, 430°C, 1 atm)

• 2.158 kmol S /hr • 2.158 kmol S /hr

• 1140.849 kmol O2 /hr • 1140.849 kmol O2 /hr
• 19786.266 kmol N2 /hr • 19786.266 kmol N2 /hr
• 776.778kmol CO2 /hr • 776.778kmol CO2 /hr
Oxygen (O2) 1140849 0(ref) 1140849 H5
Nitrogen (N2) 19786266 0(ref) 19786266 H6
Total
110
Find Q
Sulphur 2158 0(ref) 2158 -5.849
Oxygen (O2) 1140849 0(ref) 1140849 -6.708
Nitrogen (N2) 19786266 0(ref) 19786266 -6.238
=0 = -157573303.8
Find Q; Q= ΔH
= -157573303.8 - 0
= -157573303.8 kJ/hr
111
4.4.2.7 ESP
STREAM 8 STREAM 9
ESP
(Gas, 430°C, 1 atm) (Gas, 420°C, 1 atm)

• 215.8 kmol S /hr • 2.158 kmol S /hr

• 397.588 kmol O2 /hr • 397.588 kmol O2 /hr
• 15143 kmol N2 /hr • 15143 kmol N2 /hr
Sulphur 215800 0(ref) 2158 H1
Oxygen (O2) 397588 0(ref) 397588 H5
Nitrogen (N2) 15143000 0(ref) 15143000 H6
Total
112
Find Q

Sulphur 1288067 0(ref) 2158 -0.266
Oxygen (O2) 15143000 0(ref) 397588 -0.330
Nitrogen (N2) 775015 0(ref) 15143000 -0.307
=0 = -5822272.23
Find Q; Q= ΔH
= -5822272.23 - 0
= -5822272.23
113
STREAM 7 STREAM 8
Waste Heat Boiler 1
(Gas, 1120°C, 1 atm) (Gas, 430°C, 1 atm)

• 215.8 kmol S /hr • 215.8 kmol S /hr

• 397.588 kmol O2 /hr • 397.588 kmol O2 /hr
• 15143 kmol N2 /hr • 15143 kmol N2 /hr
(g, 1120°C, 1 atm); Hydrogen Sulphide (g, 1120°C, 1 atm); Oxygen (g, 1120°C, 1 atm);
Nitrogen (g, 1120°C, 1 atm) and Carbon Dioxide (g, 1120°C, 1 atm);
Sulphur 215800 0(ref) 215800 H1
Oxygen (O2) 397588 0(ref) 397588 H5
Nitrogen (N2) 15143000 0(ref) 15143000 H6
Total
114
Find Q
(g, 1120°C, 1 atm); Hydrogen Sulphide (g, 1120°C, 1 atm); Oxygen (g, 1120°C, 1 atm);
Nitrogen (g, 1120°C, 1 atm) and Carbon Dioxide (g, 1120°C, 1 atm);

Sulphur 215800 0(ref) 215800 -24.819
Oxygen (O2) 397588 0(ref) 397588 -24.092
Nitrogen (N2) 15143000 0(ref) 15143000 -22.618
=0 = -435250614.2
Find Q; Q= ΔH
= -435250614.2 - 0
= -435250614.2
115
4.4.2.9 Melter
STREAM 1 STREAM 2
Melter
(Solid, 30 °C, 1 atm) (Solid, 135 °C, 1 atm)
Molar flowrate = 1521.129 kmol Molar flowrate = 1521.129 kmol
total/hr total/hr
• 1503.867 kmol S /hr • 1503.867 kmol S /hr

References: Sulphur (s, 30°C, 1 atm); Hydrogen Sulphide (g, 30°C, 1 atm);
Sulphur 1503867 0(ref) 1503867 H110
Total
Find Q
References: Sulphur (s, 30°C, 1 atm); Hydrogen Sulphide (g, 30°C, 1 atm);
Sulphur 1503867 0(ref) 1503867 1.828
Hydrogen Sulphide (H2S) 17262 0(ref) 17262 3.655
=0 = 2812161.49
Find Q; Q= ΔH
= 2812161.49– 0
= 2812161.49
116
4.5 Software Energy Balance (Microsoft Excel)
4.5.1 Simulation Energy Balance (Reactive)
4.5.1.1 Dilution Tank
Stream 35

• 463.91 kmol H20 /hr
Stream 39 DILUTION TANK Stream 31
(Liquid, 87°C, 1 atm) (Liquid, 70°C, 1 atm)

• 288.81 kmol H2S2O7 /hr • 2098.95 kmol H2SO4 /hr

• 1534.46 kmol H2SO4 /hr
• 175.10 kmol H20 /hr
H2S2O7 (l) + H2 0 (l) H2SO4 (l)
Cp coefficients (Table B2) Table B1

a b c d Tb (Celcius)
Oleum
(H2S2O7)
Sulphuric
-811.32
Acid 139.1 15.59 0 0
-285.84
Water (H2O) 75.4 - - -
Celcius atm
Reference 25 1
IN OUT
Temperature Pressure Total Hin Temperature Total Hout
nin (mol/s) Hin (kJ/mol) Pressure (atm) nout (mol/s) Hout (kJ/mol)
(Celcius) (atm) (kJ/s) (Celcius) (kJ/s)
Oleum
288.81 -1247.20 -360203.83 - - -
(H2S2O7)
sulphuric acid (H2SO4) 25°C 1 1534.46 -802.16 -1230883.97 25°C 1 2098.95 -285.46 -599172.56
Water (H2O) 463.91 -804.73 -373320.90 175.1 -282.45 -49456.47
Total In -1964408.70 Total Out -648629.03
Figure 4.1: Excel Energy Balance for Dilution Tank
117
4.5.1.2 Final Absorption Tower (FAT)
STREAM 32
• 252.667 kmol H2SO4 /hr

• 21.078 kmol H2O /hr
STREAM 23 Final Absorption Tower (FAT) STREAM 25
(Gas, 130°C, 1 atm) (Gas, 90°C, 1 atm)

• 2.16kmol S /hr • 2.16 kmol S /hr

• 17.29 kmol H2S /hr
• 990.09 kmol O2 /hr • 990.09 kmol O2 /hr
(Liquid, 87°C, 1 atm) • 19823.32 kmol N2 /hr
• 19823.32 kmol N2 /hr
Molar flowrate = 252.667 kmol total/hr • 778.23 kmol CO2 /hr
• 778.23 kmol CO2 /hr
• 38.658 kmol H2SO4 /hr
• 214.009 kmol H2S2O7 /hr

Sulphur 1.52E-02 2.68E-05 0

Sulphuric
Acid 1.39E-01 1.56E-04 -811.32
Oleum
Water
7.54E-02 -285.84
Sulphur
Dioxide 3.89E-02 3.90E-05 -3.10E-08 8.61E-12 -296.9
Sulphur
Trioxide 4.85E-02 9.19E-05 -8.54E-08 3.24E-11 -395.18
Hydrogen
Sulphide 3.35E-02 1.55E-05 3.01E-09 -3.29E-12 -19.96
Oxygen
2.91E-02 1.16E-05 -6.08E-09 1.31E-12 0
Nitrogen
2.90E-02 2.20E-06 5.72E-09 -2.87E-12 0
Carbon
Dioxide 3.61E-02 4.23E-05 -2.89E-08 7.46E-12 -393.5
Celcius atm
Reference S,H2SO4,H2O,SO2,SO3,H2S,O2,N2,CO2 25 1
IN OUT
Temperature Pressure Total Hin Temperature
nin (mol/s) Hin (kJ/mol) Pressure (atm) nout (mol/s) Hout (kJ/mol) Total Hout (kJ/s)
(Celcius) (atm) (kJ/s) (Celcius)
Sulphur 130°C 126.545 1.811 229.172995 90°C 19.361 1.088 21.064768
Sulphuric Acid
187°C 126.545 -786.11 -99478.16 19.36 -802.16 -15530.52
(H2SO4)
87°C
Oleum (H2S2O7) - - - 107.184 -1247.20 -133679.88
Water (H2O) 187°C 10.558 -273.63 -2888.93 - - -
Sulphur Dioxide
2.165 -292.81 -633.94 2.165 -294.23 -637.01
(SO2)
1 1
Sulphur Trioxide
108.266 -389.40 -42158.67 108.266 -391.77 -42415.05
(SO3)
Hydrgen Sulphide
10.827 -16.31 -176.62 10.827 -17.72 -191.89
(H2S)
130°C 90°C
Oxygen (O2) 495.877 3.99 1979.54 495.877 1.93 959.03
Nitrogen (N2) 9931.607 3.09 30658.87 9931.607 1.90 18820.40
Carbon Dioxide (CO2) 394.103 -389.38 -153457.40 394.103 -391.00 -154095.06
Figure 4.2: Excel Energy Balance for Final Absorption Tower (FAT)
118
4.5.1.3 Catalytic Bed Reactor 4
STREAM 21 STREAM 22
4rd Catalytic Bed
(Gas, 450°C, 1 atm) (Gas, 500°C, 1 atm)

• 2.158 kmol S/hr • 2.158 kmol S /hr

• 19786.266 kmol N2 /hr • 988.234 kmol O2 /hr
• 776.778 kmol CO2 /hr

a b c d Hf (kJ/mol)
Sulphur 1.52E-02 2.68E-05 0
Sulphur Dioxide (SO2) 3.89E-02 3.90E-05 -3.10E-08 8.61E-12 -296.9
Sulphur Trioxide (SO3) 4.85E-02 9.19E-05 -8.54E-08 3.24E-11 -395.18
Hydrogen Sulphide
3.35E-02 1.55E-05 3.01E-09 -3.29E-12 -19.96
(H2S)
Oxygen 2.91E-02 1.16E-05 -6.08E-09 1.31E-12 0
Nitrogen (N2) 2.90E-02 2.20E-06 5.72E-09 -2.87E-12 0.00E+00
Carbon Dioxide (CO2) 3.61E-02 4.23E-05 -2.89E-08 7.46E-12 -393.5
Celcius atm
Reference 25 1
IN OUT
Temperature Pressure Temperature Total Hout
nin (kmol/hr) Hin (kJ/mol) Total Hin (kJ/hr) Pressure (atm) nout (kmol/hr) Hout (kJ/mol)
(Celcius) (atm) (Celcius) (kJ/hr)
Sulphur 2.16 9.165 19.7964 2158 10.562 22792.796
Sulphur Dioxide (SO2) 220086 -277.28 -61024785.82 4315 -274.71 -1185369.335
Sulphur Trioxide (SO3) - - - 215771.00 -363.74 -78484112.00
Hydrogen Sulphide
450°C 1 17262 -4.10 -70774.20 500°C 1 17262 -2.04 -35179.96
(H2s)
Oxygen(O2) 1096120 13.37 14649643.80 988234 15.03 14857109.96
Nitrogen (N2) 19786266 12.69 251127288.07 19786266 14.24 281796000.37
Carbon Dioxide (CO2) 776778 -374.68 -291043181.04 776778 -372.16 -289082593.37
Figure 4.3: Excel Energy Balance for Catalytic Bed Reactor 4
119
STREAM 13 STREAM 14
3rd Catalytic Bed
(Gas, 430°C, 1 atm) (Gas, 495°C, 1 atm)
Molar flowrate = 23025.80 kmol Molar flowrate = 23013.55 kmol total/hr
total/hr
• 2.158 kmol S /hr
• 2.158 kmol S /hr
• 220.086 kmol SO2 /hr
• 244.54 kmol SO2 /hr
• 1068.072 kmol SO3 /hr
• 1043.527 kmol SO3 /hr
• 17.262 kmol H2S /hr
• 17.262 kmol H2S /hr
• 1096.120 kmol O2 /hr
• 1108.347 kmol O2 /hr
• 19786.266 kmol N2 /hr
• 19786.266 kmol N2 /hr
• 776.778 kmol CO2 /hr
• 776.778 kmol CO2 /hr

a b c d Hf (kJ/mol)
Sulphur 1.52E-02 2.68E-05 0
Sulphur Trioxide (SO3) 4.85E-02 9.19E-05 -8.54E-08 3.24E-11 -395.18
Hydrogen Sulphide
3.35E-02 1.55E-05 3.01E-09 -3.29E-12 -19.96
(H2S)
Oxygen 2.91E-02 1.16E-05 -6.08E-09 1.31E-12 0
Nitrogen (N2) 2.90E-02 2.20E-06 5.72E-09 -2.87E-12 0.00E+00
Carbon Dioxide (CO2)

3.61E-02 4.23E-05 -2.89E-08 7.46E-12 -393.5
Celcius atm
Reference 25 1
IN OUT
Temperature Pressure Temperature Pressure nout Hout Total Hout
nin (kmol/hr)Hin (kJ/mol) Total Hin (kJ/hr)
(Celcius) (atm) (Celcius) (atm) (kmol/hr) (kJ/mol) (kJ/hr)
Sulphur 2158 8.625 18612.75 2158 10.419 22484.202
Sulphur Dioxide 244540 -278.35 -68068198.08 220086.00 -274.97 -60516387.16
Sulphur Trioxide 1043527 -369.06 -385120944.04 1068072 -364.12 -388909580.86
Hydrogen Sulphide 430°C 1 17262 -4.91 -84773.68 495°C 1 17262 -2.25 -38787.71
Oxygen 1108347 12.70 14079331.94 1096120 14.87 16294919.92
Nitrogen 19786266 12.08 238919161.95 19786266 14.09 278729129.14
Carbon Dioxide 776778 -375.68 -291816851.93 776778 -372.41 -289279894.98
120
STREAM 11 STREAM 12
(Gas, 430°C, 1 atm)

2nd Catalytic Bed
total/hr (Gas, 550°C, 1 atm)
• 2.16 kmol S /hr
• 310.12 kmol SO2 /hr • 2.16 kmol S /hr
• 984.25 SO3 /hr • 244.99 kmol SO2 /hr
• 19823.32 kmol N2 /hr • 1110.42 kmol O2 /hr
• 778.23 kmol CO2 /hr

a b c d Hf (kJ/mol)
Sulphur (S) 1.52E-02 2.68E-05 0
Sulphur Dioxide
3.89E-02 3.90E-05 -3.10E-08 8.61E-12 -296.9
(SO2)
Sulphur Trioxide
4.85E-02 9.19E-05 -8.54E-08 3.24E-11 -395.18
(SO3)
Hydrogen Sulphide
3.35E-02 1.55E-05 3.01E-09 -3.29E-12 -19.96
(H2S)
Oxygen 2.91E-02 1.16E-05 -6.08E-09 1.31E-12 0
Nitrogen (N2) 2.90E-02 2.20E-06 5.72E-09 -2.87E-12 0.00E+00
Carbon Dioxide
(CO2) 3.61E-02 4.23E-05 -2.89E-08 7.46E-12 -393.5
Celcius atm
Reference 25 1
IN OUT
Tempera
Temperature Pressure Pressure nout Hout Total Hout
nin (kmol/hr) Hin (kJ/mol) Total Hin (kJ/hr) ture
(Celcius) (atm) (atm) (kmol/hr) (kJ/mol) (kJ/hr)
(Celcius)
Sulphur 2.16 8.625 18.63 2.16 12.025 25.974
Sulphur Dioxide 310.12 -278.35 -86322.52 244.99 -272.10 -66662.51
Sulphur Trioxide 984.25 -369.06 -363244.35 1049.38 -359.84 -377613.10
Hydrogen Sulphide 430°C 1 17.29 -4.91 -84.91 550°C 1 17.29 0.06 1.04
Oxygen 1142.98 12.70 14519.27 1110.42 16.72 18565.11
Nitrogen 19823.32 12.08 239366.59 19823.32 15.81 313367.04
Carbon Dioxide 778.23 -375.68 -292362.33 778.23 -369.58 -287619.80
4.5: Excel Energy Balance for Catalytic Bed Reactor 2
121
Stream 38 (Gas, 143 °C, 1 atm)

• 1232.523 kmol O2 /hr

• 4643.266 kmol N2 /hr
Stream 9 1st Catalytic Bed Stream 10
(Gas, 629°C, 1 atm)

(Gas, 420°C, 1 atm) Molar flowrate = 23011.38 kmol total/hr
total/hr
• 2.158 kmol S /hr
• 309.544 kmol SO2 /hr
• 2.158 kmol S /hr
• 978.523 kmol SO3 /hr
• 1288.067 kmol SO2 /hr
• 17.262 kmol H2S /hr
• 17.262 kmol H2S /hr
• 1140.849 kmol O2 /hr
• 397.588 kmol O2 /hr
• 19786.266 kmol N2 /hr
• 15143 kmol N2 /hr
• 776.778 kmol CO2 /hr
• 775.015 kmol CO2 /hr

a b c d Hf (kJ/mol)
Sulphur (S) 1.52E-02 2.68E-05 0
Sulphur Dioxide
3.89E-02 3.90E-05 -3.10E-08 8.61E-12 -296.9
(SO2)
Sulphur Trioxide
4.85E-02 9.19E-05 -8.54E-08 3.24E-11 -395.18
(SO3)
Hydrogen Sulphide
3.35E-02 1.55E-05 3.01E-09 -3.29E-12 -19.96
(H2S)
Oxygen 2.91E-02 1.16E-05 -6.08E-09 1.31E-12 0
Nitrogen (N2) 2.90E-02 2.20E-06 5.72E-09 -2.87E-12 0.00E+00
Carbon Dioxide
(CO2) 3.61E-02 4.23E-05 -2.89E-08 7.46E-12 -393.5
Celcius atm
Reference 25 1
IN OUT
Temperature Pressure Temperature Pressure nout Hout Total Hout
nin (kmol/hr) Hin (kJ/mol) Total Hin (kJ/hr)
(Celcius) (atm) (Celcius) (atm) (mol/hr) (kJ/mol) (kJ/hr)
Sulphur 2158 8.36 18038.72 2158.00 14.47 31226.26
Sulphur Dioxide 1288067 -278.80 -359111791.53 309544 -267.93 -82934576.20
Sulphur Trioxide 420°C - - - 978523 -353.56 -345961699.27
Hydrogen Sulphide 17262 -5.32 -91764.79 17626 3.46 60915.46
Oxygen -(S-9) 397588 12.70 5050560.36
1 629°C 1 1140849 19.41 22143879.09
Oxygen -(S-38) 143°C 1232523 3.55 4380386.74
Nitrogen (S-9) 420°C 1514300 11.77 17818768.10
19786266 18.31 362345889.26
Nitrogen (S-38) 143°C 4643266 3.45 16014624.43
Carbon Dioxide (S-9) 420°C 775778 -376.17 -291825961.82
776778 -365.43 -283859538.10
Carbon Dioxide (S-38) 143°C 1763 -388.85 -685535.50
122
4.5.1.7 Furnace
Fuel
Stream 2 Stream 7
Furnace
(Gas, 1120°C, 1 atm)
(Solid, 135 °C, 1 atm) Molar flowrate = 17836.732 kmol
Molar flowrate = 1521.129 total/hr
kmol total/hr
• 215.8 kmol S /hr
• 17.262 kmol H2S /hr Stream 37 • 17.262 kmol H2S /hr
• 397.588 kmol O2 /hr
• 15143 kmol N2 /hr
(Gas, 80 °C, 1 atm)
Molar flowrate = 19168.354 kmol • 775.015 kmol CO2 /hr
total/hr
• 4019.604 kmol O2 /hr

• 15143 kmol N2 /hr

a b c d Hf (kJ/mol)
Sulphur (S) 1.52E-02 2.68E-05 0
Hydrogen Sulphide
3.35E-02 1.55E-05 3.01E-09 -3.29E-12 -19.96
(H2S)
Oxygen 2.91E-02 1.16E-05 -6.08E-09 1.31E-12 0
Nitrogen (N2) 2.90E-02 2.20E-06 5.72E-09 -2.87E-12 0.00E+00
Carbon Dioxide (CO2)

3.61E-02 4.23E-05 -2.89E-08 7.46E-12 -393.5
Celcius atm
Reference 25 1
IN OUT
Temperatur Pressure nin Hin Total Hin Temperature Pressure nout Hout Total Hout
e (Celcius) (atm) (kmol/hr) (kJ/mol) (kJ/hr) (Celcius) (atm) (kmol/hr) (kJ/mol) (kJ/hr)
Sulphur 135°C 1503867 1.908 2869378.236 2158 33.445 72174.31
Sulphur Dioxide - - - - 1288067.00 -240.97 -310386793.06
Hydrogen Sulphide 135°C 17262 -16.14 -278539.632 17262 26.547 458254.314
1 1120°C 1
Oxygen 4019604 1.633 6564013.33 397588 36.80 14629250.46
Nitrogen 80°C 15143000 1.60 24259086.00 15143000 34.69 525234955.00
Carbon Dioxide 5751 -391.40 -2250918.40 775015 -338.01 -261961270.12
Total In 31163019.54 Total Out -31953429.09
Figure 4.7: Excel Energy Balance for Furnace
123
4.5.1.8 Interpass Absorption Tower (IPAT)
(Gas, 90°C, 1 atm)
STREAM 19 • 110.431 kmol SO2 /hr

• 10.827 kmol H2S /hr
• 550.01 kmol O2 /hr
• 9931.607 kmol N2 /hr
• 394.103 kmol CO2 /hr
STREAM 16 STREAM 18
Interpass Absorption (IPAT)
• 110.431 kmol SO2 /hr • 667.998 kmol H2SO4 /hr

• 537.817 kmol SO3 /hr • 55.728 kmol H2O /hr
• 10.827 kmol H2S /hr STREAM 17
• 550.01 kmol O2 /hr
• 9931.607 kmol N2 /hr
• 394.103 kmol CO2 /hr
• 94.909 kmol H2SO4 /hr

• 537.817 kmol H2S2O7 /hr

a b c d Hf (kJ/mol)
Sulphuric Acid
1.39E-01 1.56E-04 -811.32
(H2SO4)
Oleum (H2S2O7)
Water (H2O) 7.54E-02 -285.84

Sulphur Dioxide
3.89E-02 3.90E-05 -3.10E-08 8.61E-12 -296.9
(SO2)
Sulphur Trioxide
4.85E-02 9.19E-05 -8.54E-08 3.24E-11 -3.95E+02
(SO3)
Hydrogen Sulphide
(H2S) 3.35E-02 1.55E-05 3.01E-09 -3.29E-12 -19.96
Oxygen (O2) 2.91E-02 1.16E-05 -6.08E-09 1.31E-12 0
Nitrogen (N2) 2.90E-02 2.20E-06 5.72E-09 -2.87E-12 0
Carbon Dioxide (CO2) 3.61E-02 4.23E-05 -2.89E-08 7.46E-12 0
Celcius atm
Reference 25 1
IN OUT
Temperature Pressure Total Hin Temperature Pressure nout Hout Total Hout
nin (mol/s) Hin (kJ/mol)
(Celcius) (atm) (kJ/s) (Celcius) (atm) (mol/s) (kJ/mol) (kJ/s)
Sulphuric Acid 1263.39 -786.11 -993162.25 189.51 -802.16 -152016.39
Oleum 187°C - - - 87°C 1073.88 -1247.20 -1339343.14
Water 105.4 -273.63 -28840.08 - - -
Sulphur 2.16 2.39 5.16 2.16 1.09 2.35
Sulphur Dioxide 220.49 -291.20 -64206.69 220.49 -294.23 -64875.21
1 1
Sulphur Trioxide 1073.88 -387.60 -416231.59 - - -
Hydrogen Sulphide 17.29 -15.24 -263.48 17.29 -17.72 -306.43
160°C 90°C
Oxygen 1098.17 4.07 4465.16 1098.17 1.93 2123.86
Nitrogen 19823.32 3.95 78282.29 19823.32 1.90 37565.19
Carbon Dioxide 778.23 -388.13 -302057.52 778.23 -391.00 -304289.49
Figure 4.8: Excel Energy Balance for Interpass Absorption Tower (IPAT)
124
4.5.1.9 Air Dryer
(Gas, 80°C, 1 atm)

STREAM 6
• 5252.127 kmol O2 /hr
• 19786.266 kmol N2 /hr
STREAM 5 Air Dryer STREAM 29

Molar flowrate = 25692.781 Molar flowrate = 3618.878 kmol total/hr
kmol total/hr
• 2626.702 kmol H2SO4 /hr
• 5252.127 kmol O2 /hr • 992.176 kmol H2S2O7 /hr
• 19786.266 kmol N2 /hr
STREAM 30
• 646.874 kmol H2O /hr
total/hr
• 3920.451 kmol H2SO4 /hr

a b c d Hf (kJ/mol)
Oxygen (O) 2.91E-02 1.16E-05 -6.08E-09 1.31E-12 0
Nitrogen (N2) 2.90E-02 2.20E-06 5.72E-09 -2.87E-12 0
Carbon Dioxide
3.61E-02 4.23E-05 -2.89E-08 7.46E-12 -393.5
(CO2)
Water (H2SO4) 7.54E-02 -285.84
Sulphuric Acid
1.39E-01 1.56E-04 0.00E+00 0.00E+00 -811.32
(H2SO4)
Oleum (H2S2O7) 0.00E+00 0.00E+00 0.00E+00 0.00E+00 0.00E+00
Celcius atm
Reference 25 1
IN OUT
Temperature Pressure nin Hin Total Hin Temperature Pressure nout Hout Total Hout
(Celcius) (atm) (kmol/hr) (kJ/mol) (kJ/hr) (Celcius) (atm) (kmol/hr) (kJ/mol) (kJ/hr)
Oxygen 5252127 0.148 777314.796 5252127 1.633 8576723.391
Nitrogen 19786266 0.15 2869008.57 19786266.00 1.60 31697598.13
Carbon Dioxide 7514 -393.31 -2955353.882 7514 -391.397 -2940957.058
30°C 1 87°C 1
Water 646874 0.377 243871.50 - - -
Sulphuric Acid 2626702 -802.16 -2107022142.81 3920451 -804.73 -3154892771.88
Oleum 992176 -408.02 -404827651.52 - - -
Figure 4.9: Excel Energy Balance for Air Dryer
125
4.5.2 Simulation Energy Balance (Non-Reactive)
4.5.2.1 Scrubber
Stream 25 Stream 26
Scrubber
(Gas, 90°C, 1 atm) (Gas, 40°C, 1 atm)
• 2.158 kmol S /hr • 2.158 kmol S /hr

• 17.262 kmol H2S /hr • 19786.266 kmol N2 /hr
• 19786.266 kmol N2 /hr
• 776.788 kmol CO2 /hr

a b c d TB (celcius) Hv (kJ/mol)
Sulphur 1.52E-02 2.68E-05 444.6 83.7
Sulphur Dioxide
3.89E-02 3.90E-05 -3.10E-08 8.61E-12 -10.02 24.91
(SO2)
Sulphur Trioxide
4.85E-02 9.19E-05 -8.54E-08 3.24E-11 43.3
(SO3) 41.8
Hydrogen
3.35E-02 1.55E-05 3.01E-09 -3.29E-12 -60.3
Sulphide (H2S) 18.67
Oxygen 2.91E-02 1.16E-05 -6.08E-09 1.31E-12 -182.97
6.82
Nitrogen (N2) 2.90E-02 2.20E-06 5.72E-09 -2.87E-12 -1.96E+02
5.577
Carbon Dioxide
(CO2) 3.61E-02 4.23E-05 -2.89E-08 7.46E-12 -78 -
Celcius atm
Reference 25 1
IN OUT
Temperature Total Hin Temperature Pressure nout Hout
Pressure (atm) nin (mol/s) Hin (kJ/mol) Total Hout (kJ/hr)
(Celcius) (kJ/hr) (Celcius) (atm) (mol/hr) (kJ/mol)
Sulphur 2158 0 0 2158 -0.847 -1827.826
Sulphur Dioxide
4315 0.00 0 - - -
(SO2)
Sulphur Trioxide
2158 0.00 0.00 - - -
(SO3)
Hydrogen
90°C 1 17262 0.00 0.00 40°C 1 17262 -1.73 -29811.47
Sulphide (H2s)
Oxygen(O2) 988234 0.00 0.00 988234 -1.49 -1474445.13
Nitrogen (N2) 19786266 0.00 0.00 19786266 -1.46 -28848375.83
Carbon Dioxide
776778 0.00 0.00 776778 -1.94 -1505395.76
(CO2)
Figure 4.10: Excel Energy Balance for Scrubber
126
STREAM 22 STREAM 23
Economizer 2
(Gas, 500°C, 1 atm) (Gas, 90°C, 1 atm)
Molar flowrate = 21790.784 kmol Molar flowrate = kmol total/hr
total/hr
• 2.158 kmol S /hr
• 988.234 kmol O2 /hr • 19786.266 kmol N2 /hr
• 776.778 kmol CO2 /hr

a b c d Tb (Celcius) Hv (kJ/mol)
Sulphur 1.52E-02 2.68E-05 0 83.7
Sulphuric Acid
1.39E-01 1.56E-04 -811.32 -
Sulphur Dioxide
3.89E-02 3.90E-05 -3.10E-08 8.61E-12 -296.9 24.91
Sulphur Trioxide
4.85E-02 9.19E-05 -8.54E-08 3.24E-11 -395.18 41.8
Hydrogen Sulphide
3.35E-02 1.55E-05 3.01E-09 -3.29E-12 -19.96 18.67
Oxygen
2.91E-02 1.16E-05 -6.08E-09 1.31E-12 0 6.82
Nitrogen
2.90E-02 2.20E-06 5.72E-09 -2.87E-12 0 5.577
Carbon Dioxide
3.61E-02 4.23E-05 -2.89E-08 7.46E-12 -393.5 -
Celcius atm
Reference 25 1
IN OUT
Temperature Pressure nin Total Hin Temperature Pressure nout Hout Total Hout
Hin (kJ/mol)
(Celcius) (atm) (mol/hr) (kJ/hr) (Celcius) (atm) (mol/hr) (kJ/mol) (kJ/hr)
Sulphur 2158 0 0 2158 -8.748 -18878.184
Sulphur Dioxide
4315 0.00 0 4315 -17.81 -
(SO2)
Sulphur Trioxide
215771 0.00 0.00 215771.00 -25.66 -5537115.40
(SO3)
Hydrogen Sulphide
500°C 1 17262 0.00 0.00 90°C 1 17262 -14.27 -246397.79
(H2s)
Oxygen(O2) 998234 0.00 0.00 998234 -11.90 -11875989.90
Nitrogen (N2) 19786266 0.00 0.00 19786266 -11.18 -221111522.55
Carbon Dioxide
776778 0.00 0.00 776778 -17.23 -13383108.16
(CO2)
Figure 4.11: Excel Energy Balance for Economizer 2
127
STREAM 16
STREAM 15
Economizer 1
(Gas, 160°C, 1 atm)
(Gas, 300°C, 1 atm)
• 2.158 kmol S /hr

• 2.158 kmol S /hr
• 220.086 kmol SO2 /hr
• 220.086 kmol SO2 /hr
• 1068.072 kmol SO3 /hr
• 1068.072 kmol SO3 /hr
• 17.262 kmol H2S /hr
• 17.262 kmol H2S /hr
• 1096.120 kmol O2 /hr
• 1096.120 kmol O2 /hr
• 19786.266 kmol N2 /hr
• 19786.266 kmol N2 /hr
• 776.778 kmol CO2 /hr
• 776.778 kmol CO2 /hr

a b c d Hv (kJ/mol)
Tb (Celcius)
Sulphur 1.52E-02 2.68E-05 0 83.7

Sulphuric
Acid 1.39E-01 1.56E-04 -811.32 -
Sulphur
Dioxide 3.89E-02 3.90E-05 -3.10E-08 8.61E-12 -296.9 24.91
Sulphur
Trioxide 4.85E-02 9.19E-05 -8.54E-08 3.24E-11 -395.18 41.8
Hydrogen
Sulphide 3.35E-02 1.55E-05 3.01E-09 -3.29E-12 -19.96 18.67
Oxygen
2.91E-02 1.16E-05 -6.08E-09 1.31E-12 0 6.82
Nitrogen
2.90E-02 2.20E-06 5.72E-09 -2.87E-12 0 5.577
Carbon
Dioxide 3.61E-02 4.23E-05 -2.89E-08 7.46E-12 -393.5 -
Celcius atm
Reference 25 1
IN OUT
Tempera
Temperature Pressure Total Hin Pressure nout Hout Total Hout
nin (mol/s)Hin (kJ/mol) ture
(Celcius) (atm) (kJ/hr) (atm) (mol/hr) (kJ/mol) (kJ/hr)
(Celcius)
Sulphur 2158 0 0 2158 -2.991 -6454.578
Sulphur
220086 0.00 0 220086 -6.48 -1426817.538
Dioxide (SO2)
Sulphur
1068072 0.00 0.00 1068072.00 -9.16 -9780335.30
Trioxide (SO3)
Hydrogen
300°C 1 17262 0.00 0.00 40°C 1 17262 -5.21 -89865.97
Sulphide (H2s)
Oxygen(O2) 1096120 0.00 0.00 1096120 -4.40 -4826216.36
Nitrogen (N2) 19786266 0.00 0.00 19786266 -4.53 -89631784.98
Carbon
776778 0.00 0.00 776778 -6.21 -4825344.94
Dioxide (CO2)
Total In 0 Total out -110586819.67
Figure 4.12: Excel Energy Balance for Economizer 1
128
(Gas, 255°C, 1 atm)
• 2.15kmol S /hr
• kmol SO2 /hr
STREAM 20 • kmol SO3 /hr
• kmol H2S /hr
kmol O2 /hr
• kmol N2 /hr
• kmol CO2 /hr
STREAM 12
Heat Exchanger 2 STREAM 13
(Gas, 550°C, 1 atm)
Molar flowrate = 22978.878 kmol total/hr (Gas, 430°C, 1 atm)
2.158 kmol S /hr
244.54 kmol SO2 /hr • 2.158 kmol S /hr
1043.527 kmol SO3 /hr • 244.54 kmol SO2 /hr
17.262 kmol H2S /hr • 1043.527 kmol SO3 /hr
1108.347 kmol O2 /hr STREAM 21 • 17.262 kmol H2S /hr
19786.266 kmol N2 /hr • 1108.kmol O2 /hr1108.347 kmol O2 /hr
776.788 kmol CO2 /hr • kmol N2 /hr
(Gas, 450°C, 1 atm)
• 19786.266 kmol N2 /hr
• 776.778
• kmol CO2 /hr
• 2.158 kmol S /hr
• 220.086 kmol SO2 /hr
• 17.262 kmol H2S /hr
• 1096.120 kmol O2 /hr
• 19786.266 kmol N2 /hr
• 776.778 kmol CO2 /hr

Sulphur 1.52E-02 2.68E-05 0
Sulphuric Acid
1.39E-01 1.56E-04 -811.32
Sulphur Dioxide
3.89E-02 3.90E-05 -3.10E-08 8.61E-12 -296.9
Sulphur Trioxide
4.85E-02 9.19E-05 -8.54E-08 3.24E-11 -395.18
Hydrogen Sulphide
3.35E-02 1.55E-05 3.01E-09 -3.29E-12 -19.96
Oxygen
2.91E-02 1.16E-05 -6.08E-09 1.31E-12 0
Nitrogen
2.90E-02 2.20E-06 5.72E-09 -2.87E-12 0
Carbon Dioxide
3.61E-02 4.23E-05 -2.89E-08 7.46E-12 -393.5
Celcius atm
Reference 25 1
IN OUT
Temperature Pressure nin Hin Total Hin Temperature Pressure nout
Hout (kJ/mol) Total Hout (kJ/hr)
(Celcius) (atm) (mol/hr) (kJ/mol) (kJ/hr) (Celcius) (atm) (mol/hr)
Sulphur (Stream 13) 550°C 2158 0 0 2158 -3.399 -7335.042
Sulphur (Stream 21) 255°C 2158 0 0 2158 4.806 10371.348
Sulphur Dioxide (stream

550°C 244540 0.00 0 244540 -6.19 -1513213.52
13)
Sulphur Dioxide (stream
255°C 220086 0 220086 9.58 2108203.794
21) 0.00
Sulphur Trioxide 550°C 1043527 0.00 0.00 1043527.00 -9.21 -9615057.78
Hydrogen Sulphide
550°C 17262 0.00 0.00 17262 -4.55 -78455.79
(Stream 13)
Hydrogen Sulphide 0.00
255°C 1 17262 0.00 40°C 1 17262 7.68 132554.90
(Stream 21)
Oxygen(stream 13) 550°C 1108347 0.00 0.00 1108347 -4.02 -4451121.55
Oxygen(stream 21) 255°C 1096120 0.00 0.00 1096120 6.33 6940631.84
Nitrogen (stream 13) 550°C 19786266 0.00 0.00 19786266 -3.73 -73881917.24
Nitrogen (stream 21) 255°C 19786266 0.00 19786266 5.92 117154480.99

0.00
Carbon Dioxide (stream
550°C 776778 0.00 0.00 776778 -6.09 -4732908.35
13 )
Carbon Dioxide (stream
255°C 776778 0.00 776778 9.30 7226365.73
21 ) 0
Total In 0.00 Total Out 39292599.32
Figure 4.13: Excel Energy Balance for Heat Exchanger 2
129
(Gas, 255°C, 1 atm)
• 2.158 kmol S /hr

STREAM 20
• 220.086 kmol SO2 /hr
• 17.262 kmol H2S /hr
• 1096.120 kmol O2 /hr
• 19786.266 kmol N2 /hr
• 776.778 kmol CO2 /hr
STREAM 14 STREAM 15
Heat Exchanger 1
(Gas, 495°C, 1 atm)

(Gas, 300°C, 1 atm)
• 2.158 kmol S /hr

• 2.158 kmol S /hr
• 220.086 kmol SO2 /hr
• 220.086 kmol SO2 /hr
• 1068.072 kmol SO3 /hr
• 1068.072 kmol SO3 /hr
• 17.262 kmol H2S /hr
• 17.262 kmol H2S /hr
• 1096.120 kmol O2 /hr STREAM 19 • 1096.120 kmol O2 /hr
• 19786.266 kmol N2 /hr
• 19786.266 kmol N2 /hr
• 776.778 kmol CO2 /hr
(Gas, 90°C, 1 atm) • 776.778 kmol CO2 /hr
• 2.158 kmol S /hr

• 220.086 kmol SO2 /hr
• 17.262 kmol H2S /hr
• 1096.120 kmol O2 /hr
• 19786.266 kmol N2 /hr
• 776.778 kmol CO2 /hr

Sulphur 1.52E-02 2.68E-05 0
Sulphuric Acid
1.39E-01 1.56E-04 -811.32
Sulphur Dioxide
3.89E-02 3.90E-05 -3.10E-08 8.61E-12 -296.9
Sulphur Trioxide
4.85E-02 9.19E-05 -8.54E-08 3.24E-11 -395.18
Hydrogen Sulphide
3.35E-02 1.55E-05 3.01E-09 -3.29E-12 -19.96
Oxygen
2.91E-02 1.16E-05 -6.08E-09 1.31E-12 0
Nitrogen
2.90E-02 2.20E-06 5.72E-09 -2.87E-12 0
Carbon Dioxide
3.61E-02 4.23E-05 -2.89E-08 7.46E-12 -393.5
Celcius atm
Reference 25 1
IN OUT
Temperature nin Hin Total Hin Temperature Pressure nout Hout Total Hout
Pressure (atm)
(Celcius) (mol/hr) (kJ/mol) (kJ/hr) (Celcius) (atm) (mol/hr) (kJ/mol) (kJ/hr)
Sulphur (Stream 15) 495 2158 0 0 300 2158 -0.886 -1911.988
Sulphur (Stream 19) 90 2158 0 0 255 2158 3.161 6821.438
Sulphur Dioxide
495 220086 0.00 0 300 220086 -9.75 -2146058.586
(stream 15)
Sulphur Dioxide
90 220086 0.00 0 255 220086 7.38 1623354.336
(stream 15)
Sulphur Trioxide 495 1068072 0.00 0.00 300 1068072.00 -14.32 -15291586.82
Hydrogen Sulphide
495 17262 0.00 0.00 300 17262 -7.79 -134384.67
(Stream 15)
Hydrogen Sulphide
90 1 17262 0.00 0.00 255 1 17262 7.69 132744.78
(Stream 19)
Oxygen(stream 15) 495 1096120 0.00 0.00 300 1096120 -6.40 -7014071.88
Oxygen(stream 19) 90 1096120 0.00 0.00 255 1096120 5.10 5590212.00
Nitrogen (stream 15) 495 19786266 0.00 0.00 300 19786266 -5.97 -118084435.49
Nitrogen (stream 19) 90 19786266 0.00 255 19786266 4.88 96458046.75

0.00
Carbon Dioxide
495 776778 0.00 0.00 300 776778 -9.51 -7388712.34
(stream 15)
Carbon Dioxide
90 776778 0 0.00 255 776778 7.02 5450651.23
(stream 19)
Figure 4.14: Excel Energy Balance for Heat Exchanger 1
130
STREAM 10 STREAM 11
Waste Heat Boiler 2
(Gas, 629°C, 1 atm) (Gas, 430°C, 1 atm)
• 2.158 kmol S /hr • 2.158 kmol S /hr

• 1140.849 kmol O2 /hr • 1140.849 kmol O2 /hr
• 19786.266 kmol N2 /hr • 19786.266 kmol N2 /hr
• 776.778kmol CO2 /hr • 776.778kmol CO2 /hr

a b c d Hv (kJ/mol)
Tb (Celcius)
Sulphur 1.52E-02 2.68E-05 0 83.7

Sulphuric
Acid 1.39E-01 1.56E-04 -811.32 -
Sulphur
Dioxide 3.89E-02 3.90E-05 -3.10E-08 8.61E-12 -296.9 24.91
Sulphur
Trioxide 4.85E-02 9.19E-05 -8.54E-08 3.24E-11 -395.18 41.8
Hydrogen
Sulphide 3.35E-02 1.55E-05 3.01E-09 -3.29E-12 -19.96 18.67
Oxygen
2.91E-02 1.16E-05 -6.08E-09 1.31E-12 0 6.82
Nitrogen
2.90E-02 2.20E-06 5.72E-09 -2.87E-12 0 5.577
Carbon
Dioxide 3.61E-02 4.23E-05 -2.89E-08 7.46E-12 -393.5 -
Celcius atm
Reference 25 1
IN OUT
Tempera
Temperature Pressure Total Hin Pressure nout Hout Total Hout
nin (mol/s)Hin (kJ/mol) ture
(Celcius) (atm) (kJ/hr) (atm) (mol/hr) (kJ/mol) (kJ/hr)
(Celcius)
Sulphur 2158 0 0 2158 -5.849 -12622.142
Sulphur Dioxide
309544 0.00 0 309544 -10.37 -3209352.192
(SO2)
Sulphur
978523 0.00 0.00 978523.00 -15.50 -15170042.07
Trioxide (SO3)
Hydrogen
629°C 1 17262 0.00 0.00 430°C 1 17262 -8.37 -144431.15
Sulphide (H2s)
Oxygen(O2) 1140849 0.00 0.00 1140849 -6.71 -7652815.09
Nitrogen (N2) 19786266 0.00 0.00 19786266 -6.24 -123426727.31
Carbon Dioxide
776778 0.00 0.00 776778 -10.24 -7957313.83
(CO2)
Figure 4.15: Excel Energy Balance for Waste Heat Boiler 2
131
STREAM 7 STREAM 8
Waste Heat Boiler 1
(Gas, 430°C, 1 atm)
(Gas, 1120°C, 1 atm) Molar flowrate = 17836.732 kmol total/hr
total/hr • 215.8 kmol S /hr
• 1288.067 kmol SO2 /hr
• 215.8 kmol S /hr • 17.262 kmol H2S /hr
• 17.262 kmol H2S /hr • 15143 kmol N2 /hr
• 15143 kmol N2 /hr
• 775.015 kmol CO2 /hr

Sulphur 1.52E-02 2.68E-05 0 83.7

Sulphuric
Acid 1.39E-01 1.56E-04 -811.32 -
Sulphur
Dioxide 3.89E-02 3.90E-05 -3.10E-08 8.61E-12 -296.9 24.91
Sulphur
Trioxide 4.85E-02 9.19E-05 -8.54E-08 3.24E-11 -395.18 41.8
Hydrogen
Sulphide 3.35E-02 1.55E-05 3.01E-09 -3.29E-12 -19.96 18.67
Oxygen
2.91E-02 1.16E-05 -6.08E-09 1.31E-12 0 6.82
Nitrogen
2.90E-02 2.20E-06 5.72E-09 -2.87E-12 0 5.577
Carbon
Dioxide 3.61E-02 4.23E-05 -2.89E-08 7.46E-12 -393.5 -
Celcius atm
Reference 25 1
IN OUT
Temperature Pressure nin Total Hin Temperature Pressure nout Hout Total Hout
Hin (kJ/mol)
(Celcius) (atm) (mol/s) (kJ/hr) (Celcius) (atm) (mol/hr) (kJ/mol) (kJ/hr)
Sulphur 215800 0 0 215800 -24.819 -5355940.2
Sulphur Dioxide
1288067 0.00 0 1288067 -37.32 -48074524.64
(SO2)
Hydrogen
17262 0.00 0.00 17262 -31.46 -543045.26
Sulphide (H2s)
1120°C 1 430°C 1
Oxygen(O2) 397588 0.00 0.00 397588 -24.09 -9578690.10
Nitrogen (N2) 15143000 0.00 0.00 15143000 -22.62 -342504374.00
Carbon Dioxide
775015 0.00 0.00 775015 -37.67 -29194040.04
(CO2)
Figure 4.16: Excel Energy Balance for Waste Heat Boiler 1
132
4.5.2.8 Electrostatic Precipitator (ESP)
STREAM 8 STREAM 9
ESP
(Gas, 430°C, 1 atm) (Gas, 420°C, 1 atm)
• 215.8 kmol S /hr • 2.158 kmol S /hr

• 397.588 kmol O2 /hr • 397.588 kmol O2 /hr
• 15143 kmol N2 /hr • 15143 kmol N2 /hr

Sulphur 1.52E-02 2.68E-05 0 83.7

Sulphuric
Acid 1.39E-01 1.56E-04 -811.32 -
Sulphur
Dioxide 3.89E-02 3.90E-05 -3.10E-08 8.61E-12 -296.9 24.91
Hydrogen
Sulphide 3.35E-02 1.55E-05 3.01E-09 -3.29E-12 -19.96 18.67
Oxygen
2.91E-02 1.16E-05 -6.08E-09 1.31E-12 0 6.82
Nitrogen
2.90E-02 2.20E-06 5.72E-09 -2.87E-12 0 5.577
Carbon
Dioxide 3.61E-02 4.23E-05 -2.89E-08 7.46E-12 -393.5 -
Celcius atm
Reference 25 1
IN OUT
Tempera
Temperature Pressure nin Total Hin Pressure nout Hout Total Hout
Hin (kJ/mol) ture
(Celcius) (atm) (mol/s) (kJ/hr) (atm) (mol/hr) (kJ/mol) (kJ/hr)
(Celcius)
Sulphur 1288067 0 0 2158 -0.266 -574.028
Sulphur
17262 0.00 0 1288067 -0.51 -651761.902
Dioxide (SO2)
Hydrogen
397588 0.00 0.00 17262 -0.40 -6973.85
Sulphide (H2s)
430°C 1 420°C 1
Oxygen(O2) 15143000 0.00 0.00 397588 -0.33 -131204.04
Nitrogen (N2) 775015 0.00 0.00 15143000 -0.31 -4648901.00
Carbon
1288067 0.00 0.00 775015 -0.49 -382857.41
Dioxide (CO2)
Figure 4.17: Excel Energy Balance for Electrostatic Precipitator (ESP)
133
4.5.2.9 Melter
STREAM 1 STREAM 2
Melter
(Solid, 30 °C, 1 atm) (Solid, 135 °C, 1 atm)
Molar flowrate = 1521.129 Molar flowrate = 1521.129 kmol
kmol total/hr total/hr
• 1503.867 kmol S /hr • 1503.867 kmol S /hr


Sulphur 1.520E-02 2.680E-05 444.6 83.7
Hydrogen Sulphide 3.351E-02 1.547E-05 3.012E-09 -3.292E-12 -60.3 18.67
Inlet Outlet Enthalpy Table

Celcius atm Celcius atm
Reference H2SO4 H2S 25 1 25 1
IN OUT
Substance Temperature Total Hin Temperatur Pressure nout Total Hout
Pressure (atm) nin (mol/hr) Hin (kJ/mol) Hout (kJ/mol)
(Celcius) (kJ/hr) e (Celcius) (atm) (mol/hr) (kJ/hr)
Sulphur 1503867 0.00 0.00 1503867 1.8280 2749068.8760
Hydrogen 30 1 135 1
17262 0 0 17262 3.6550 63092.6100
Sulphide
Figure 4.18: Excel Energy Balance for Melter
134
4.5.2.10 Oleum Distribution
STREAM 27 (Liquid, 87°C, 1 atm)

• 226.180 kmol H2SO4 /hr

• 1281.686 kmol H2S2O7 /hr
STREAM 30 Oleum Distribution STREAM 28

• 2626.702 kmol H2SO4 /hr
• 3920.451 kmol H2SO4 /hr
• 992.176 kmol H2S2O7 /hr
STREAM 39

total/hr
• 1519.929 kmol H2SO4 /hr

• 289.510 kmol H2S2O7 /hr

Sulphuric acid 1.391E-01 1.559E-04 340
Oleum 3.351E-02 1.547E-05 3.012E-09 ######## 18.67
Inlet Outlet Enthalpy Table

Celcius atm Celcius atm
Reference H2SO4 H2S 25 1 25 1
IN OUT
Substance Temperature Pressure nin Hin Total Hin Temperature Pressure nout Total Hout
Hout (kJ/mol)
(Celcius) (atm) (mol/hr) (kJ/mol) (kJ/hr) (Celcius) (atm) (mol/hr) (kJ/hr)
Sulphuric
70 3920451 0.00 0.00 87 1519929 0.7520 1142986.6080
Acid(stream 30)
Sulphuric
87 226180 0 0 75 2626702 0.0000 0.0000
Acid(stream 27)
1 1
Oleum (Stream
70 - - - 87 289510 275.9000 79875809.0000
30)
Oleum (Stream
87 1281686 0 0 75 992176 0.0000 0.0000
27)
Figure 4.19: Excel Energy Balance for Oleum Distribution
135
4.5.2 Percentage Different in Manual and Excel Calculation of Energy Balance
Table 4.4: Approximation Error in Calculation for Manual and Simulation for Energy Balance
Non-reactive
Equipment Enthalpy, Q (kJ/hr) Approximation
Manual Calculation Simulation Error (%)
Calculation
Scrubber -31859856.02 -3185956.02 0
Oleum Distribution 81018795.61 81018795.61 0
Economizer 2 -252249862.1 -252173012 0.03
Heat Exchanger 2 3929599.32 3929599.32 0
Heat Exchanger 1 -40799331.2 -40799331.24 0
Economizer 1 -110586819.7 -110586819.7 0
Waste Heat Boiler -157573303.8 -157573303.8 0
2
ESP -5822273.23 -5822272.23 0
Waste Heat Boiler -435250614.2 -435250614.2 0
1
Melter 2812161.49 2812161.486 0
Reactive
Dilution Tank -225173804.0 -225173804.5 0
Final Absorption 144920585.6 143654745.2 0.8
Tower
4rd Catalytic Bed 14230679.59 14250437.86 0.14
Interpass Absorption 803076792.6 803076740.8 6.45x10-6
Tower
rd
3 Catalytic Bed 48375543.65 48375543.64 2.06X10-8
2nd Catalytic Bed 88173.39 88173.38 0
1st Catalytic Bed 28025878.4 280258771.8 3.07X10-6
Furnace -63116448.63 -63116448.63 0
Air dryer -606644454.4 -606644454.1 4.94 x 10-8
Table 4.4 above shows the summary table of the differentiation between manual and
simulation calculation for energy balance by using excel software. There are some different in
the value because in of the decimal place used in manual and excel calculations.
136
5.0 REFERENCES
Davenport, W. G., King, M. J., & Rogers, B. (2006). Sulphuric acid manufacture. Nature,
115(2889), 396.
Mpinga, C. N., Eksteen, J. J., Aldrich, C., & Dyer, L. (2015). Direct leach approaches to
Platinum Group Metal (PGM) ores and concentrates: A review. Minerals Engineering, 78,
93–113. https://doi.org/10.1016/J.MINENG.2015.04.015
Perry, R. H., Green, D. W., & Maloney, J. O. (1997). 10. Transport and Storage of Fluids. In
Perry’s chemical engineers’ handbook 7th edition.
Standen, A. and K. (2021, October 4). Chemical industry | Overview, Importance, & History |
Britannica. Retrieved October 4, 2021, from
https://www.britannica.com/technology/chemical-industry
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Group 2 - Design Project 1

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Final Report 2 Design Project 1 (CPB30703)

Student Name Student ID

Criteria % STUDENT 1 STUDENT 2 STUDENT 3 STUDENT 4

1.0 Introduction (All) 10

2.0 Process Flow Diagram (All) 40

3.0 Mass Balance (Student 1) 40

4.0 Software Mass Balance (Student 2) 40

5.0 Energy Balance (Student 3) 40

6.0 Software Energy Balance (Student 4) 40

7.0 References & Neatness (All) 10

CPB 30703 | PLANT DESIGN PROJECT 1

DR KELLY TONG TAU LEN

REPORT 2: PRODUCTION OF SULPHURIC ACID (230,000 MTA)

SEMESTER JULY 2021

MUHAMMAD FARHAN BIN MOHD FOZI 55213119183

ANIS FARHANA BINTI MOHD ASWANI 55213119109

NUR AFIFAH BINTI KHAIRUR YUSHA 55213119161

TUAN NUR ATHIRAH BINTI TUAN MAHMOOD 55213119160

TABLE OF CONTENT .......................................................................................................... 2

1.0 INTRODUCTION ........................................................................................................ 4

1.1 The Process Selection ............................................................................................ 5

1.2 Objectives ............................................................................................................... 5

2.0 PROCESS FLOW DIAGRAM .................................................................................... 6

3.0 MASS BALANCE ...................................................................................................... 9

3.1 Molecular Weights ................................................................................................ 10

3.2 Mass Balance Calculations ................................................................................... 10

3.2.2 H2SO4 Distribution Header ............................................................................. 12

3.2.3 Tower Absorption Distribution Header ........................................................... 14

3.2.4 Dilution Tank .................................................................................................. 15

3.2.5 Oleum Distribution Header ............................................................................. 17

3.2.6 Oleum Tank ................................................................................................... 20

3.2.7 Final Absorption Tower (FAT) ........................................................................ 23

3.2.8 Scrubber ........................................................................................................ 26

3.2.9 Economizer 2 ................................................................................................. 27

3.2.10 Converter 4 ................................................................................................ 28

3.2.11 Heat Exchanger 2....................................................................................... 31

3.2.12 Heat Exchanger 1....................................................................................... 32

3.2.13 Interpass Absorption Tower ........................................................................ 33

3.2.14 Economizer 1 ............................................................................................. 36

3.2.15 Converter 3 ................................................................................................ 37

3.2.16 Converter 2 ................................................................................................ 40

3.2.17 Waste Heat Boiler 2 ................................................................................... 43

3.2.18 Converter 1 ................................................................................................ 44

3.2.20 Waste Heat Boiler 1 ................................................................................... 49

3.2.21 Furnace ...................................................................................................... 50

3.2.22 Sulfur Melter ............................................................................................... 53

3.2.23 Air Distribution Header ............................................................................... 54

3.2.24 Air Dryer ..................................................................................................... 55

3.2.25 Air Blower ................................................................................................... 57

3.3 Software Mass Balance ........................................................................................ 58

3.3.1 Simulation Mass Balance (Microsoft Excel) ................................................... 58

4.0 ENERGY BALANCE ................................................................................................ 65

4.1 Standard Enthalpies of Formation ......................................................................... 65

4.2 Specific Heat Capacities (at constant pressure, Cp) ............................................. 66

4.3 Boiling and melting points ..................................................................................... 67

4.4 Energy Balance Calculation .................................................................................. 68

4.4.1 Reactive Energy Balance ............................................................................... 68

4.4.2 Non- Reactive Process .................................................................................. 91

4.5 Software Energy Balance (Microsoft Excel) ........................................................ 117

4.5.1 Simulation Energy Balance (Reactive) ......................................................... 117

4.5.2 Simulation Energy Balance (Non-Reactive) ................................................. 126

5.0 REFERENCES ....................................................................................................... 137