Dynamic modeling and process optimization of an industrial sulfuric acid plant

Kiss, Anton A.; Bîldea, Costin Sorin; Grievink, Johan

doi:10.1016/j.cej.2010.01.023

Cited by 39 publications

(24 citation statements)

References 42 publications

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“…The individual bed

{SO}_{2}

conversion ratio relative to the feed

{SO}_{2}

into each bed is obtained if

X_{{SO}_{2}}^{in}

indicates the

{SO}_{2}

inlet concentration into the corresponding bed, and the overall converter

{SO}_{2}

conversion ratio for each bed relative to the feed

{SO}_{2}

into the converter is obtained if

X_{{SO}_{2}}^{in}

indicates the

{SO}_{2}

inlet concentration to the first bed of a converter. The overall converter

{SO}_{2}

conversion ratio relative to the feed

{SO}_{2}

into the overall converter is usually referred to in the available literature …”

Section: Dynamic Modellingmentioning

confidence: 99%

“…Under these assumptions, a dynamic model can be developed based on mass and energy balances:

\frac{ρ_{g} V_{g}}{M_{g}} \frac{{dX}_{{SO}_{2}}}{dt} = \frac{ρ_{g} Q^{in}}{M_{g}} (X_{{italicSO}_{2}}^{italicin} - X_{{italicSO}_{2}}) - false(1 - \frac{1}{2} X_{{SO}_{2}} false) r,

(ρ_{g} c_{p, g} V_{g} + ρ_{italiccat} c_{p, cat} V_{italiccat}) \frac{dT}{dt} = ρ_{g} c_{p, g} Q^{in} (T^{italicin} - T) + false(- Δ H false) r,

where r (mol/min) indicates the consumption rate of

{SO}_{2}

. The reaction kinetics for

{SO}_{2}

oxidation have been extensively studied and the available expressions for the reaction rate are mostly from the lab test results, for example:

r = ρ_{cat} K_{1} \frac{X_{{SO}_{2}} X_{O_{2}} - \frac{1}{K_{p}} X_{{SO}_{3}} X_{O_{2}}^{1 / 2} P_{t}^{- 1 / 2}}{22.414 {false(P_{t}^{- 1} + K_{2} X_{{SO}_{2}} + K_{3} X_{{SO}_{3}} false)}^{2}},

…”

Section: Dynamic Modellingmentioning

confidence: 99%

“…Sulphuric acid plants are remarkably important in the modern process industry due to the wide applications of sulphuric acid products, e.g., fertilizers, metallic ore leaching, and petroleum . Capable of capturing sulphur dioxide in the off‐gas, a sulphuric acid plant is also the key to achieve the reduction of

{SO}_{2}

emissions in metal production and has become an essential part of many smelters.…”

Section: Introductionmentioning

confidence: 99%

“…Active research has been carried out for modelling various

{SO}_{2}

converters, such as periodic flow reversal reactors for

{SO}_{2}

oxidation and trickle‐bed

{SO}_{2}

reactors . Dynamic modelling and optimization of

{SO}_{2}

oxidization and sulphuric acid plants have been investigated . Process start‐ups have been modelled for an industrial

{SO}_{2}

converter.…”

Section: Introductionmentioning

confidence: 99%

See 3 more Smart Citations

Dynamic modelling and simulation of the sulphur dioxide converter in an industrial smelter

Zhang

Shang

2019

Can J Chem Eng

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Sulphuric acid plants have been widely used in industrial smelters to reduce sulphur dioxide (SO2) emissions to the atmosphere. The catalytic SO2 converter, where SO2 is oxidized to sulphur trioxide (SO3), is the key unit and determines the performance of a sulphuric acid plant. In this paper, a dynamic model is built based on mass and energy conservation for the SO2 converter in an industrial smelter. The derived model is compared with industrial measurement and a very good fit is obtained. A key variable of high industrial interest, SO2 conversion ratio, is defined and explored in modelling the SO2 converter, and thus the resulting model is of important industrial values. Based on the derived model, simulations are run to investigate the system dynamics and effects of process variables.

show abstract

“…The individual bed

{SO}_{2}

conversion ratio relative to the feed

{SO}_{2}

into each bed is obtained if

X_{{SO}_{2}}^{in}

indicates the

{SO}_{2}

inlet concentration into the corresponding bed, and the overall converter

{SO}_{2}

conversion ratio for each bed relative to the feed

{SO}_{2}

into the converter is obtained if

X_{{SO}_{2}}^{in}

indicates the

{SO}_{2}

inlet concentration to the first bed of a converter. The overall converter

{SO}_{2}

conversion ratio relative to the feed

{SO}_{2}

into the overall converter is usually referred to in the available literature …”

Section: Dynamic Modellingmentioning

confidence: 99%

“…Under these assumptions, a dynamic model can be developed based on mass and energy balances:

\frac{ρ_{g} V_{g}}{M_{g}} \frac{{dX}_{{SO}_{2}}}{dt} = \frac{ρ_{g} Q^{in}}{M_{g}} (X_{{italicSO}_{2}}^{italicin} - X_{{italicSO}_{2}}) - false(1 - \frac{1}{2} X_{{SO}_{2}} false) r,

(ρ_{g} c_{p, g} V_{g} + ρ_{italiccat} c_{p, cat} V_{italiccat}) \frac{dT}{dt} = ρ_{g} c_{p, g} Q^{in} (T^{italicin} - T) + false(- Δ H false) r,

where r (mol/min) indicates the consumption rate of

{SO}_{2}

. The reaction kinetics for

{SO}_{2}

oxidation have been extensively studied and the available expressions for the reaction rate are mostly from the lab test results, for example:

r = ρ_{cat} K_{1} \frac{X_{{SO}_{2}} X_{O_{2}} - \frac{1}{K_{p}} X_{{SO}_{3}} X_{O_{2}}^{1 / 2} P_{t}^{- 1 / 2}}{22.414 {false(P_{t}^{- 1} + K_{2} X_{{SO}_{2}} + K_{3} X_{{SO}_{3}} false)}^{2}},

…”

Section: Dynamic Modellingmentioning

confidence: 99%

{SO}_{2}

emissions in metal production and has become an essential part of many smelters.…”

Section: Introductionmentioning

confidence: 99%

“…Active research has been carried out for modelling various

{SO}_{2}

converters, such as periodic flow reversal reactors for

{SO}_{2}

oxidation and trickle‐bed

{SO}_{2}

reactors . Dynamic modelling and optimization of

{SO}_{2}

oxidization and sulphuric acid plants have been investigated . Process start‐ups have been modelled for an industrial

{SO}_{2}

converter.…”

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Dynamic modelling and simulation of the sulphur dioxide converter in an industrial smelter

Zhang

Shang

2019

Can J Chem Eng

View full text Add to dashboard Cite

show abstract

“…Dynamic models for entire plants have been developed previously in the fields of CO 2 capture (Bui et al, 2014), gasification (Pérez-Fortes et al, 2009) or cracking units (Berreni and Wang, 2011). Recently, the same methodology has been successfully adopted for the minimization of SO x emissions of a sulfuric acid plant (Kiss et al, 2010), but many issues are still unresolved to extend it to other chemical and oil & gas areas. In tail gas units, for instance, such as Claus processes, there is the need to characterize complex kinetics to get a reliable prediction of the dynamic behavior of the plants.…”

Section: Introductionmentioning

confidence: 99%