Sulfur Dioxide Oxidation Using Oxygen-Enriched Air

Solution Overview

Problem

Sulfuric acid production plants face limitations in increasing sulfur dioxide conversion to sulfur trioxide due to heat exchanger capacity constraints and increased pressure drop and reduced residence time with higher gas flow rates, leading to incomplete oxidation and emissions of unreacted sulfur dioxide.

Innovation Solution

Replacing a portion of atmospheric air with oxygen in the sulfur dioxide-containing feed stream before entering the catalytic converter, either before the initial stage or subsequent stages, to maintain optimal reaction temperatures and increase conversion efficiency while managing heat generation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the volumetric gas flow rate of the gas mixture entering the catalytic converter is increased to increase production, then productivity is improved, but the pressure drop across the catalyst increases and fan capacity becomes limited

Engineering Contradiction:

Improveproduction capacityVSAvoidpressure drop

Core Design Contradiction:

ProductivityVSStress or pressure

Solution Approach 1:

The patent changes the compositional parameters of the gas mixture by replacing atmospheric air with oxygen-enriched air or pure oxygen. This parameter change allows for reduced total gas volume while maintaining adequate oxygen supply for the oxidation reaction, thereby reducing pressure drop across the catalyst while preserving productivity.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If the volumetric gas flow rate of the gas mixture entering the catalytic converter is increased to increase production, then productivity is improved, but the residence time in the catalytic converter decreases leading to lower conversion efficiency

Engineering Contradiction:

Improveproduction capacityVSAvoidconversion efficiency

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent changes the compositional parameters of the gas mixture by replacing atmospheric air with oxygen-enriched air or pure oxygen. This parameter change allows for reduced total gas volume while maintaining adequate oxygen supply for the oxidation reaction, thereby reducing pressure drop across the catalyst while preserving productivity.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If the amount of sulfur dioxide entering the catalytic converter is increased to increase production, then productivity is improved, but more heat is generated and the heat exchanger capacity becomes insufficient

Engineering Contradiction:

Improveproduction capacityVSAvoidheat removal capacity

Core Design Contradiction:

ProductivityVSLoss of energy

Solution Approach 1:

The patent changes the compositional parameters of the gas mixture by replacing atmospheric air with oxygen-enriched air or pure oxygen. This parameter change allows for reduced total gas volume while maintaining adequate oxygen supply for the oxidation reaction, thereby reducing pressure drop across the catalyst while preserving productivity.

Inventive Principle:

Principle #35Parameter changes

4Productivity

If the amount of sulfur dioxide entering the catalytic converter is increased to increase production, then productivity is improved, but the temperature control becomes difficult and reaction completeness is limited by equilibrium

Engineering Contradiction:

Improveproduction capacityVSAvoidreaction temperature control

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

The patent changes the compositional parameters of the gas mixture by replacing atmospheric air with oxygen-enriched air or pure oxygen. This parameter change allows for reduced total gas volume while maintaining adequate oxygen supply for the oxidation reaction, thereby reducing pressure drop across the catalyst while preserving productivity.

Inventive Principle:

Principle #35Parameter changes

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 enhances the capacity of the catalytic converter, maintains efficient conversion of sulfur dioxide to sulfur trioxide, and reduces emissions by optimizing gas mixture composition and temperature control within the converter.

Implementation Method 1

catalytically oxidizing at least a portion of the sulfur dioxide from the sulfur dioxide feed stream for producing sulfur trioxide

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 2

The oxidation of sulfur dioxide in the converter is an exothermic reaction and therefore, increasing the amount of sulfur dioxide entering the converter will result in more heat being generated

Methodology Applied

Scientific EffectExothermic reaction: Exothermic Reaction

Data Source

PatentUS20240351879A1Process and apparatus for preparing sulfur trioxide from sulfur dioxide

Publication Date: 2024.10.24 MESSER IND USA INC

AI summary

A process for the catalytic conversion of sulfur dioxide to sulfur trioxide to increase sulfuric acid regeneration from a spent sulfuric acid stream or other sulfur-containing stream includes replacing at least a portion of the atmospheric air typically used to oxidize sulfur dioxide to sulfur trioxide with oxygen by introducing oxygen-enriched air and/or pure oxygen feed streams into the process. A related apparatus for use in the process is also provided for catalytic conversion of sulfur dioxide to sulfur trioxide.