SULPHURIC ACID PRODUCTION

(DCDA PROCESS)
CONTACT PROCESS

Presented By
Mr. S. S. Haral
PROPERTIES OF H2SO4:

 Molecular weight: 98.08

 Molecular formula of sulphuric acid is H2SO4
 Melting point: 10.50C
 Boiling Point: 3400C
 Solubility: Completely miscible with water with large
heat of solution. SO3 soluble in H2SO4 to give varying
percentage of oleum.
Structure:
 Safety Precautions with Sulfuric Acid
As sulfuric acid is very exothermic (when dissolving in
water), several safety precautions are taken with the
handling, storage, dilution and transportation of sulfuric
acid.
A strong acid which can corrode metals and other
materiSulfuric acid must be stored carefully in containers
made of nonreactive material (such as glass).als .
Sulfuric acid must be stored carefully in containers made
of nonreactive material (such as glass).
Always wear protective googles, gloves and a lab coat, as
concentrated H2SO4 causes serious damage to skin
 USES
 Sulfuric acid is one of the most important industrial chemicals.
 "wet method" for the production of phosphoric acid.
 For iron and steel making industry to remove oxides from the surface
of metals.
 Production of fertilizers.
 Manufacture of aluminium sulphate.
 For making hydrochloric acid.
 It is also used in petroleum refining.
 Manufacture of dyestuffs, pigments (such as titanium dioxide),
and solutions.
 Sulphuric acid is the electrolyte in lead-acid (car) batteries.
 It is also used as a general dehydrating agent in its concentrated
form.(detergents).
Methods of Manufacturing

H2SO4

CONTACT
Wet Sulphuric
PROCESS/ CHAMBER
Acid
DCDA PROCESS
Process
PROCESS
DCDA PROCESS
DCDA PROCESS…

 DCDA is Double Contact Double Absorption

Process.
 It is also called as Contact Process.
 Highly used as yield obtained is high.
 More economical and preferable over Chamber
process.
Raw Materials

 Sulphur
 Oxygen
 Water
Chemical Reactions:

 Produce Sulphur dioxide:

S (s) + O2 (g) → SO2 (g) ∆H=-70Kcal
 Oxidise SO2 to SO3:-
2SO2 (g) + O2 (g) → 2 SO3 (g) ∆H=-23kcal
 Formation of H2SO4:-
SO3(g) + H2O (l) → H2SO4 (l) ∆H=-139kJ

 H2SO4(l) + SO3(g) → H2S2O7(l)

 H2S2O7(l) + H2O(l) → 2 H2SO4(l)
FLOW DIAGRAM
 FOUR STAGES:

 Combining of sulphur and oxygen.

 Adding excess of oxygen to sulfur dioxide in
presence of catalyst vanadium pentoxide.
 Sulphur trioxide formed is added to sulfuric acid
which gives rise to oleum (disulphuric acid)
 The oleum then is added to water to form sulfuric
acid which is very concentrated
Combining of sulphur and oxygen:

 Sulphur and air are purified (drying with H2SO4)

 Formation of SO2 in burner.
 Exothermic reaction
 Removal of heat by water cooling.
 Passing of gases through gas filter for removal of
dust and impurities.

S (s) + O2 (g) → SO2 (g) ∆H=-70Kcal

Adding of oxygen to SO2

 Done in converter in two stages.

 Stage one-Temperature of 500-600°C & 30%
catalyst bed. Yield of 80% SO3.
 Cooling by heat exchanger. Temperature=300°C.
 Stage two-Temperature of 400-450. Yield of 97%
SO3.
 Catalyst used-Vanadium Oxide.
Oxidise SO2 to SO3:-
2SO2 (g) + O2 (g) → 2 SO3 (g) ∆H=-23kcal
Formation of oleum
 Hot sulphur trioxide passes through the heat
exchanger and is dissolved in concentrated H2SO4
in the absorption tower to form oleum.

H2SO4(l) + SO3(g ) → H2S2O7(l )

 Formation Of H2SO4:
 Concentrated H2SO4 is formed.
 Acid is cooled and stored in storage tanks.

 H2S2O7(l ) + H2O(l ) → 2 H2SO4(l )

 Advantages of Vanadium Pentoxide

 Good porosity
 Resistance to gases at high temperature
 Pellet form used in packed bed.
 Powder form used in fluidised bed.
 Less sensitive to poison.
 Low initial investment.
IMPORTANT QUESTIONS

 Multistage reactor used----WHY???

 Double Absorption---WHY???
 Oleum is used----Why????
WHY MULTISTAGE REACTOR??

 In stage one high reaction rate.

 Less residence time.
 Less conversion rate i.e 80%.
 Temperature increases.
 Conversion of SO2 decreases.
 To prevent backshift of reaction.
 With two stages conversion increases to 97%.
WHY DOUBLE ABSORPTION??

 Gases leaving first absorption tower have low SO3.

 Double Absorption increases yield upto 99.7%.
 High recovery rate ensured.
 Also called 3+1 configuration.
 Heat produced is used in waste heat
boilers,ecnomisers etc.
Why Oleum???
 Exothermic nature of reaction.
 Direct usage of H2O not preferrable.
 Acidic vapour or mists might be formed instead of
liquid.
 Oleum increases absorption of H2SO4.
 Advantages Of DCDA Process:

 High concentration of sulphuric acid (99.7%).

 Utilization of heat.
 Reduces stack gases elimination.
 Utilizes nearly all SO3.