Sulfuric Acid Absorber Sump Segmentation for Concentration Control
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Solution Overview
Problem
Existing methods for producing sulfuric acid and oleum face challenges in achieving uniform acid concentrations, leading to increased energy and material costs due to the need for separate absorbers and drying towers.
Innovation Solution
A process and plant design that separates the gas purification sump into two sections, allowing for concentration adjustment within the sump and eliminating the need for a separate collecting tank, with controlled liquid levels to prevent mixing and using counter-current flow for efficient acid concentration adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a uniform dilution or concentration and subsequent division of the product is used, then the process is simpler, but it cannot achieve different desired concentrations for different applications
Solution Approach 1:
The absorber sump is divided into two separate sections: a first section for concentrating sulfuric acid by absorbing SO3 from the gas phase, and a second section for diluting the concentrated acid with water or steam to achieve the desired final concentration. This segmentation allows different concentration adjustments in different sections to meet different application requirements.
Solution Approach 2:
Different regions of the absorber sump are assigned different functions with different acid concentrations: the first section maintains high concentration (98-99.5% H2SO4) for effective SO3 absorption, while the second section operates at lower concentration (93-98% H2SO4) for product delivery. This local differentiation enables both concentration requirements to be satisfied simultaneously.
2Manufacturing precision
If separate absorbers or drying towers are used for different concentrations, then the desired concentrations can be achieved, but energy and material costs increase
Solution Approach 1:
The patent combines the functions of multiple absorbers or drying towers into a single absorber with a multi-section sump. The first section performs SO3 absorption to concentrate the acid, while the second section performs dilution with water or steam. This merging eliminates the need for separate units, reducing energy consumption and material costs while maintaining precise concentration control.
Solution Approach 2:
The absorber sump is designed to perform multiple functions within a single structure: concentration of sulfuric acid in the first section and dilution to desired product concentration in the second section. This multi-functionality replaces what would traditionally require separate dedicated units, reducing overall system complexity and operational costs.
3Productivity
If the sulfuric acid concentration is maintained at a certain minimum for sufficient drying, then drying efficiency is ensured, but the final product concentration may not match the desired concentration
Solution Approach 1:
The absorber sump is segmented into a first section for SO3 absorption (maintaining minimum 98% concentration for drying efficiency) and a second section for controlled dilution to achieve the exact desired final concentration (93-98%). This segmentation allows the drying function and product specification function to be decoupled.
Solution Approach 2:
The first section of the absorber sump performs the preliminary action of absorbing SO3 to concentrate the sulfuric acid to the minimum required concentration (98-99.5%) needed for sufficient drying efficiency. Subsequently, the second section performs the final concentration adjustment by dilution, ensuring both drying efficiency and final concentration accuracy are achieved.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the production of sulfuric acid or oleum at desired concentrations in a single plant with reduced energy and material costs, achieving efficient acid concentration adjustment and minimizing sulfur dioxide emission.
Implementation Method 1
the water containing gas is conducted inside a drying tower, wherein the moisture from said gas is absorbed by the acid
Implementation Method 2
an exothermic reaction of the SO 3 with the water bound by the sulfuric acid will occur according to the reaction equation: SO 3 + H 2 O → H 2 SO 4
Implementation Method 3
an exothermic reaction of the sulfuric acid with SO 3 takes place according to the reaction equation: SO 3 + H 2 SO 4 → H 2 S 2 O 7
Data Source
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AI summary
A process for the production of liquid acid, comprising the steps of: (i) feeding liquid acid with a first concentration into a gas purification; (ii) passing a gas through the gas purification such that a second concentration of the liquid acid is reached; (iii) withdrawing the liquid acid from the sump of the gas purification, where in the gas purification sump is divided by a partition wall into a first and a second section. The concentration of the liquid acid collected in the first section is adjusted to the first concentration. The liquid acid with the first concentration from the first section is at least partially fed back into step (i)and the liquid acid with the second concentration collected in the second section is at least partially withdrawn as product.