Pamantasan ng Lungsod ng Maynila

College of Engineering and Technology

Department of Chemical Engineering

Production of Sulfuric Acid through Contact Process

Contact process is the current method of producing sulfuric acid in the high
concentrations needed for industrial processes. This process was patented in 1831 by
the British vinegar merchant Peregrine Phillips. This process is far more economical
process for producing concentrated sulfuric acid than the previous lead chamber
process since this process has 98% conversion unlike the lead chamber process with
80% conversion. Platinum used to be the catalyst for this reaction; however, as it is
susceptible to reacting with impurities in the sulfur feedstock, vanadium(V)
pentoxide (V2O5) is now preferred.

The process goes to several stages, namely,

Preparation of sulfur
Burning of sulfur
Purification of sulfur dioxide
Catalytic conversion
Intermediate absorption
Dilution of sulfuric acid

Equipment Layout

Dusting
Sulfur Burner
Chamber
Sulfur Reaction Furnace

Absorption Tower Catalytic Converter Washing Tower

 Pamantasan ng Lungsod ng Maynila
College of Engineering and Technology
Department of Chemical Engineering

Storage Tanks

Manufacturing Process

Preparation of Sulfur

The sulfur is first melted in a large, carbon steel

tank with heating coils. The molten sulfur is then filtered
using a carbon steel filter unit which is approximately
1.6 m diameter and 11.6 m tall. If the sulfur is delivered
as a liquid already, this process will be skipped.

Burning of Sulfur

The molten sulfur is fed to a sulfur reaction furnace and burned with oxygen
(from dried air) at about 900C. This produces sulfur dioxide (SO 2). This oxidation
 Pamantasan ng Lungsod ng Maynila
College of Engineering and Technology
Department of Chemical Engineering
produces large amount of heat that will be used to produce steam.

S(l) + O2(g) SO2(g)

Purification of Sulfur Dioxide

SO2 contains a number of impurities such as dust particles, vapors, sulfur etc.
These impurities must be removed otherwise the catalyst loses its efficiency (catalyst
poisoning).

The purification undergoes through several stages in different equipment,

Dusting Chamber

The mixture of sulfur dioxide is passed through a purifier or dusting

tower in which electric charger attract the solid particles, which are removed.
SO2 is first passed through the dust chamber where steam is spread over the
gas to remove dust particles, which settles down.

Washing Tower or Scrubbing Tower

The gas is then led into a water scrubber where it is completely freed
from dust particles and other soluble impurities.

Drying Tower

The gas is now dried by passing through drying tower where conc.
H2SO4 (dehydrating agent) is sprayed. H2SO4 removes moisture from SO2.

Catalytic Conversion

Catalytic conversion is the heart of the process in the manufacturing of sulfuric

acid. The sulfur dioxide proceeds to the converter at 400-450C and at 1-2
 Pamantasan ng Lungsod ng Maynila
College of Engineering and Technology
Department of Chemical Engineering
atmospheric pressure together with the vanadium pentoxide catalyst.
Inside the converter are four beds which works simultaneously.

The first bed in the converter converts about 63% of the sulfur dioxide into
sulfur trioxide and heat is produced. The gas stream is cooled before it passes to the
next catalyst bed. Hot gas superheats steam in the furnace boiler. The gas stream
passes through two further catalyst bed and the percentage conversion increases
about 88%. Between each stage. The hot gases should be cooled. By the third bed,
about 95% of the original sulfur dioxide has been converted to sulfur trioxide.

Conditions Necessary for Maximum Yield of Sulfur Trioxide

Oxidation of SO2 is a reversible and exothermic process in which volume

of product is less than the volumes of reactants. In order to obtain maximum
amount of SO3, according to Le-Chateliers Principle following conditions are
necessary.

Concentration:
Excess of oxygen.

Temperature:
A decrease in temperature favors reaction in forward direction. Optimum
temperature for this process is 400oC to 450oC.

Pressure:
Since volumes of reactants are greater than the product (3:2), therefore,
according to Le-Chateliers Principle a high pressure is favorable. Optimum
pressure is about 1 to 2 atmospheres.

Use of catalyst:

At low temperature, rate of reaction decreases. To increase rate of

reaction a catalyst vanadium pentoxide (V2O5) is used.

SO2(g) + O2(g) SO3(g)

 Pamantasan ng Lungsod ng Maynila
College of Engineering and Technology
Department of Chemical Engineering

A flow diagram of the Contact Process showing four beds of catalyst conversion

Absorption

Hot sulfur trioxide passes through the heat exchanger and is dissolved in
concentrated H2SO4 in the absorption tower to form oleum:

H2SO4(l) + SO3(g) H2S2O7(l)

Note that directly dissolving SO3 in water is impractical due to the

highly exothermic nature of the reaction. Acidic vapor or mists are formed instead of a
liquid.

Oleum is reacted with water to form concentrated H2SO4 (about 99%).

H2S2O7(l) + H2O(l) 2 H2SO4(l)

 Pamantasan ng Lungsod ng Maynila
College of Engineering and Technology
Department of Chemical Engineering
The unreacted SO2 gas from the top of the tower contains some
sulfur dioxide and oxygen and is fed back into the final bed of the converter at which
99.5% of the original sulfur dioxide is converted to sulfur trioxide.

Dilution of Sulfuric Acid

The 99% sulfuric acid is diluted with water to about 98% (e.g.) and this
increases the volume of the acid. The acid concentration is made by sampling.

Storage and Transportation

The sulfuric acid is stored to sulfuric acid storage tanks and is prepared to be
transported by rail or by road.

Beside sulfuric acid, this process generates a large amount of heat which is
used to produce high temperature steam and make electricity. Electricity is sold to the
National Grid.