Sulfuric Acid Recovery via Oxygen-Enriched Oxidation
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Solution Overview
Problem
Existing sulfuric acid production methods are energy-intensive, environmentally damaging, and inefficient, particularly in producing ultrapure sulfuric acid, with issues including high emissions, additional processing requirements, and challenges in achieving low metal impurity levels.
Innovation Solution
A process involving a first gas stream with oxygen and a second gas stream with sulfur dioxide is used to stabilize the oxidation reaction, reducing inert nitrogen content and optimizing oxygen use, followed by electrochemical conversion to produce ultrapure sulfuric acid.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If ambient air is used in the oxidation process, then the oxidation reaction can proceed, but the process flow volume increases and energy consumption increases
Solution Approach 1:
The patent uses oxygen-enriched air instead of ambient air for the oxidation process. This provides a higher concentration of oxygen, allowing the reaction to proceed more efficiently with smaller process flow volumes, thereby reducing energy consumption while maintaining productivity.
Solution Approach 2:
The patent changes the oxygen concentration parameter in the gas stream from ambient air (21% oxygen) to oxygen-enriched air (higher oxygen concentration). This parameter change enables the oxidation reaction to proceed with reduced inert gas content, lowering the overall process flow volume and energy requirements.
2Productivity
If ambient air is used in the oxidation process, then the oxidation reaction can proceed, but the plant volume must be expanded
Solution Approach 1:
By using oxygen-enriched air, the patent achieves more efficient oxidation reactions that require smaller reactor volumes and reduced process infrastructure, thereby avoiding the need to expand the plant volume while maintaining productivity.
Solution Approach 2:
Changing the gas composition parameter from ambient air to oxygen-enriched air reduces the total volume of gas required for the oxidation process, allowing the plant to operate with a smaller footprint without compromising reaction efficiency.
3Productivity
If waste sulfuric acid is used as sulfur-containing raw material, then the sustainability of the process increases, but additional processing is required
Solution Approach 1:
The patent converts waste sulfuric acid, which contains metal impurities, into a useful sulfur source for producing high-purity sulfuric acid. By using oxygen-enriched air oxidation, the process efficiently converts the sulfur in waste acid to sulfur trioxide, transforming a harmful waste stream into a valuable raw material while maintaining product purity through controlled oxidation.
4Device complexity
If metal impurities are present in sulfuric acid, then the production process is simplified, but the manufacturing cost increases due to thermal separation processes
Solution Approach 1:
The use of oxygen-enriched air in the oxidation process helps control metal impurity levels by providing precise oxygen control that prevents excessive oxidation of metals. This reduces the need for energy-intensive thermal separation processes while maintaining product purity, thereby reducing overall energy consumption.
Solution Approach 2:
By changing the oxidation conditions using oxygen-enriched air, the patent controls the formation of metal impurities at the source. This parameter change in the oxidation process reduces the burden on subsequent purification steps, avoiding the need for energy-intensive thermal separation while maintaining high product quality.
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 the risk of thermal runaway, decreases energy consumption, and achieves ultrapure sulfuric acid meeting SEMI C44 specifications with lower plant volume and operational costs.
Implementation Method 1
the step of producing a process stream containing sulfur dioxide from a sulfur-containing medium which includes sulfur compounds oxidizable to sulfur dioxide, by oxidation in which the sulfur-containing medium is brought into contact with a first gas stream which includes oxygen
Implementation Method 2
followed by electrochemical conversion to produce ultrapure sulfuric acid
Data Source
Figure 1
AI summary
The present invention relates to a process for the production of sulfuric acid, comprising a) the step of producing a process stream comprising sulfur dioxide from a sulfur-containing medium (11) which includes sulfur compounds oxidizable to sulfur dioxide, by oxidation in which the sulfur-containing medium (11) is brought into contact with a first gas stream (10) comprising oxygen, and b) the further processing of the process stream comprising sulfur dioxide obtained in step a) to produce sulfuric acid, characterized in that in step a) a second gas stream (9) comprising sulfur dioxide is brought into contact with the sulfur-containing medium (11) and the first gas stream (10).