Sulfuric Acid Production Using O2-Enriched Gas Streams
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Solution Overview
Problem
The production of sulfuric acid using atmospheric air as an oxidant results in excessive process equipment size due to inert nitrogen, leading to increased costs and thermal management challenges, while the high cost of oxygen-enriched gases and excessive heat from oxidation processes pose additional issues.
Innovation Solution
Employing an O2-enriched gas stream, preferably with at least 15 vol % SO2, in contact with a catalytically active material like vanadium-based catalysts on porous silica, operating at elevated temperatures and pressures, to optimize SO2 oxidation to SO3, with recycling of process gases for temperature moderation and reduced equipment volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If atmospheric air is used as oxidant in SO2 oxidation process, then the oxidation reaction can proceed, but the process equipment size becomes excessive due to inert nitrogen
Solution Approach 1:
The patent removes inert nitrogen from the oxidation process by using oxygen-enriched air or pure oxygen instead of atmospheric air. This extraction of the harmful inert component reduces the total gas volume required for oxidation, thereby decreasing process equipment size while maintaining SO2 oxidation efficiency.
Solution Approach 2:
The patent changes the oxygen concentration parameter in the oxidation process from 21% (atmospheric air) to higher concentrations (oxygen-enriched air or pure oxygen). This parameter change reduces the total gas volume needed for oxidation, leading to smaller process equipment while maintaining or improving oxidation performance.
2Volume of stationary object
If oxygen-enriched air or pure oxygen is used to reduce process equipment size, then equipment volume decreases, but the cost of O2 becomes too high to be commercially viable
Solution Approach 1:
The patent makes the oxidation process self-sufficient by using oxygen produced as a by-product of the ammonia synthesis process (from air separation). This internal oxygen supply eliminates the need to purchase external oxygen, making the process commercially viable while maintaining reduced equipment volume.
Solution Approach 2:
The patent combines the ammonia synthesis process with the sulfuric acid production process, using the oxygen from air separation for both purposes. This merging of functions allows the system to internally supply oxygen, reducing operational costs while maintaining the benefits of reduced process equipment size.
3Productivity
If atmospheric air is used as oxidant, then the oxidation process can proceed, but excessive heat is released requiring thermal management
Solution Approach 1:
The patent removes inert nitrogen from the oxidation process, which reduces the total heat capacity of the gas stream. This allows for better temperature control and reduces the thermal management burden while maintaining high oxidation reaction rates through the use of oxygen-enriched conditions.
4Volume of stationary object
If high pressure is used to reduce gas volume, then equipment size decreases, but the complexity of process equipment increases
Solution Approach 1:
The patent removes inert nitrogen from the oxidation process, which naturally reduces the total gas volume required for oxidation. This volume reduction allows the process to operate at lower pressures, thereby reducing equipment complexity while still achieving compact process equipment size through the elimination of unnecessary inert gas handling.
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
This approach reduces process volume and costs, minimizes environmental impact, and enhances thermal efficiency by using O2-enriched gas streams from electrolysis or air separation, allowing for stable operation at higher SO2 concentrations and pressures, thus lowering equipment size and energy consumption.
Implementation Method 1
contact a material catalytically active in oxidation of SO2 to SO3
Implementation Method 2
oxidation of SO2 to SO3
Implementation Method 3
absorbing at least an amount of the produced SO3 in a stream of lean sulfuric acid
Implementation Method 4
the high amount of heat released during the oxidation process
Data Source
AI summary
A process and a process plant for conversion of SO2 to H2SO4 including a. directing a process gas stream including at least 15 vol % SO2, and an amount of O2 originating from a source of purified O2 or O2 enriched air to contact a first material catalytically active in oxidation of SO2 to SO3 under oxidation conditions involving a maximum steady state temperature of the catalytically active material above 700° C., to provide an oxidized process gas stream, wherein the material catalytically active in oxidation of SO2 to SO3 includes an active phase in which the weight ration of vanadium to other metals is at least 2:1 supported on a porous carrier comprising at least 25 wt % crystalline silica, b. absorbing at least an amount of the produced SO3 in a stream of lean sulfuric acid to provide a stream of liquid sulfuric acid.