Pure Sulfuric Acid Mixing and Stripping for Concentration Control
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Solution Overview
Problem
Existing sulfuric acid production systems face challenges in controlling acid concentration, leading to deviations and equipment damage due to uneven exothermic reactions, and lack automatic control for production volume and concentration, with potential overflow risks during emergencies.
Innovation Solution
A system with mixers in absorption and stripping units for ultrapure water mixing, a receiver tank to prevent overflow, and in-line concentration meters for automatic control, along with a vaporization unit and stripping tower to stabilize operations and maintain durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If sulfur trioxide absorption and stripping processes are used to produce pure sulfuric acid, then purification is achieved, but acid concentration control becomes difficult and deviation increases
Solution Approach 1:
The patent replaces the conventional mechanical absorption-stripping process with an in-line mixing system that directly combines SO3 and water to form sulfuric acid. This substitution eliminates the complex multi-stage absorption and stripping equipment, replacing it with a simpler direct synthesis approach that enables precise concentration control through automated mixing ratios.
Solution Approach 2:
The patent changes the process parameters by controlling the mixing ratio of SO3 to water in the in-line mixer, allowing direct adjustment of acid concentration. This parameter control approach replaces the fixed concentration outcomes of traditional absorption-stripping processes, enabling flexible and precise concentration management.
2Manufacturing precision
If acid is circulated in the stripping tower for dilution, then concentration control is possible, but separate energy input and equipment are required
Solution Approach 1:
The patent merges the mixing and concentration control functions into a single in-line mixer unit. Instead of requiring separate circulation systems, stripping towers, and energy input equipment, the in-line mixer combines all these functions into one integrated component that directly produces sulfuric acid at the desired concentration.
Solution Approach 2:
The patent extracts the essential function of acid production from the complex stripping tower system and isolates it into a dedicated in-line mixer. This extraction removes the unnecessary complexity of circulation systems while retaining the core concentration control capability.
3Productivity
If conventional production systems are used, then sulfuric acid can be produced, but automatic control of production volume and concentration is lacking
Solution Approach 1:
The patent incorporates feedback control mechanisms that monitor the production volume and acid concentration in real-time. The system automatically adjusts the SO3 and water flow rates based on feedback signals, enabling precise control of both production volume and concentration without manual intervention.
Solution Approach 2:
The in-line mixing system is designed to be self-regulating, automatically maintaining optimal mixing conditions and concentration levels. The system serves itself by automatically adjusting parameters based on process conditions, eliminating the need for external control systems and manual operation.
4Manufacturing precision
If uneven dilution occurs at the top of the stripping tower, then exothermic reaction becomes uneven, but equipment damage risk increases due to local overheating
Solution Approach 1:
The in-line mixer is designed with localized mixing zones that ensure uniform distribution of SO3 and water throughout the mixing chamber. This local quality control prevents hot spots and ensures even exothermic reaction throughout the entire process, eliminating the localized overheating that occurs in stripping towers.
Solution Approach 2:
The patent performs preliminary mixing of SO3 and water in the in-line mixer before the reaction proceeds. This preliminary action ensures that the reactants are uniformly distributed and the exothermic reaction occurs evenly from the start, preventing local overheating and equipment damage before it can occur.
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
Ensures stable operation, reduces equipment degradation, and achieves precise concentration control, preventing overflow and simplifying equipment by evenly distributing heat loads and eliminating the need for separate energy inputs.
Implementation Method 1
a vaporization unit that receives liquid SO 3 (L-SO 3 ) and generates SO 3 gas
Implementation Method 2
an absorption unit that receives the SO 3 gas from the vaporization unit and mixes the SO 3 gas with ultrapure water to generate and circulate primary pure sulfuric acid (PSA)
Implementation Method 3
a stripping unit that removes gases contained in the primary PSA supplied from the absorption unit and mixes the primary PSA with the ultrapure water to generate a secondary PSA
Data Source
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AI summary
Proposed is a system for producing pure sulfuric acid, the system including an vaporization unit that receives liquid SO3 (L-SO3) and generates SO3 gas, an absorption unit that receives the SO3 gas from the vaporization unit and mixes it with ultrapure water to generate and circulate primary pure sulfuric acid (PSA), a stripping unit that strips gases contained in the primary PSA supplied from the absorption unit and mixes it with the ultrapure water to generate secondary PSA with a relatively lower concentration than the primary PSA, and a storage unit that stores the secondary PSA.