SAP-2 MATERIAL BALANCE

Sulfuric Acid Plant Capacity = 400 TPD

Concentration of Sulfuric Acid = 98.5 %

Basis: Unit Hour Of Production

Total Acid Flow Rate = 16920.47 kg/hr

Acid On 100 % Basis = 16666.67 kg/hr
Water Present In Acid = 253.8071 kg/hr

SULFUR CALCULATION
Sulfur Present in Acid = 5442.177 kg/hr

Loss of SO2 from STACK (per TON of Acid Production) = 2 kg

Loss of SO2 from STACK = 33.33333 kg/hr
Loss of Sulfur from STACK = 16.66667 kg/hr

Assuming no loss of Sulfur in processing except STACK

Net Sulfur consumption in SAP-2 = 5458.844 kg/hr
170.5889 kgmol/hr
AIR HUMIDITY CALCULATION:

DryBulb Temperature = 38 Deg C

Wet Bulb Temperature = 28 Deg C
Relative Humidity = 45 %
Vapor Pressure of water at Dry Bulb Temp. = 100 mm HG

At Dry bulb temp and atmospheric pressure

Water present in Air = 0.041765 kgof H2O/m3 of air

At normal Condition( 1 atm , 0 deg C )

Water present in Air = 0.047579 kg of H2O/Nm3 of air

Percentage of water in air = 5.921053 % H2O

Assuming Nitrogen, Oxygen and water is present in air

Composition of Air :
N2 = 74.32237 %
O2 = 19.75658 %
H2O = 5.921053 %

Total = 100 %

Sulfur oxidation takes place in Burner

REACTION :
S + O2 ------------------------> SO2
1 mole 1mole 1 mole
 32 kg 32 kg 64 kg
BURNER CALCULATION :

Assuming 100% combustion of sulfur in burner

% of SO2 in exit gas from Burner = 11.5 %

Assuming Air coming from Drying Tower is not having any moisture
Air
N2 = 79 %
O2 = 21 %

Total = 100 %

Air Requirement = 1483.381 kgmol/hr

42780.72 kg/hr 33228.36 Nm3/hr

Composition of Gas Coming Exiting the Burner

Gas kgmol/hr kg/hr %

SO2 170.5889 10917.69 11.5

N2 1171.871 32812.4 0.79
O2 140.9212 4509.479 87.71

Total 1483.381 48239.56 100

This gas enters the Converter where SO2 is converted into SO3
REACTION :
SO2 + 1/2 O2 ………………..> SO3
1 mole 1/2 mole 1 mole
64 kg 16 kg 80 kg

FIRST BED :

Conversion in 1st Bed = 60 %

Composition of Gas coming out from 1st Bed

Gas kgmol/hr kg/hr %

SO2 68.23554 4367.075 4.7613971

SO3 102.3533 8188.265 7.1420956
N2 1172.766 32837.44 81.834235
O2 89.74457 2871.826 6.2622723

Total 1433.099 48264.61 100

SECOND BED :

Conversion in 1st Bed = 30 %

 Composition of Gas coming out from 2nd Bed

Gas kgmol/hr kg/hr %

SO2 17.05889 1091.769 1.2127603

SO3 153.53 12282.4 10.914843
N2 1171.871 32812.4 83.311363
O2 64.15625 2053 4.5610335

Total 1406.616 48239.56 100

THIRD BED :

Conversion in 3rd Bed = 5 %

Composition of Gas coming out from 3rd Bed

Gas kgmol/hr kg/hr %

SO2 8.529443 545.8844 0.6082242

SO3 162.0594 12964.75 11.556261
N2 1171.871 32812.4 83.564723
O2 59.89152 1916.529 4.270792

Total 1402.352 48239.56 100

Gas from 3rd bed goes to IAT for SO3 absorption in Acid
Assuming all the SO3 is absorbed in Acid and Gas entering the 4th pass is not having SO3

FOURTH BED:

Conversion in 3rd Bed = 4.7 %

Composition of Gas coming in 4th Bed

Gas kgmol/hr kg/hr %

SO2 8.529443 545.8844 0.6876962

SO3 0 0 0
N2 1171.871 32812.4 94.48348
O2 59.89152 1916.529 4.8288234

Total 1240.292 35274.81 100

Composition of Gas coming OUT 4th Bed

Gas kgmol/hr kg/hr %

SO2 0.511767 32.75306 0.0413956

 SO3 8.017676 641.4141 0.6485306
N2 1171.871 32812.4 94.789857
O2 55.88269 1788.246 4.5202163

Total 1236.283 35274.81 100

This 4th bed outlet gas is absorbed(100% SO3) in FAT and then passed to STACK

COMPOSITION OF STACK GAS:

Gas kgmol/hr kg/hr %

ppm
SO2 0.511767 32.75306 0.0416658 416.6579 Loss of Sulfur through the STACK
SO3 0 0 0 1.965184
N2 1171.871 32812.4 95.408612
O2 55.88269 1788.246 4.5497227

Total 1228.266 34633.4 100

MATERIAL BALANCE FOR DT, IAT & FAT:

DRYING TOWER: Drying Tower absrobs the water coming with humid air by sulfuric acid.

Acid Circulation Rate in DT = 115 m3/hr Density = 1.834

210910 kg/hr

H20 entering in DT with Air =1580.9725 kg/hr

H20 out from DT with Air = 0 mg/Nm3 of Air
0 kg/hr
Net WATER recovered from air = 1580.9725 kg/hr

Acid going to Acid Circulation Tank from Drying Tower = 212491 kg/hr

H2SO4 207746.4 kg/hr

H2O 4744.622 kg/hr

INTERMEDIATE ABSORPTION TOWER (IAT) : Acid reacts S03 to form oleum in IAT .
Oleum reacts with water to produce acid.
Assuming all the oleum formed in IAT/FAT converted to acid

H2SO4 + SO3 …………………> H2S2O7

1 mole 1 mole 1 mole
98 kg 98 kg 178 kg

H2S2O7 + H20 …………………..> 2 H2SO4

1 mole 1 mole 2 mole
178 kg 18 kg 196 kg

Acid Circulation rate to IAT = 193 m3/hr Density = 1.834

 353962 kg/hr
kg/hr
H2SO4 348652.6
H20 5309.43

SO3 entering in IAT = 162.05942 kgmol/hr SO3 out from IAT =

12964.753 kg/hr

Net H2SO4 produced in IAT = 15881.823 kg/hr

Net H20 consumed in IAT = 2917.0695 kg/hr
kg/hr %
Acid going to Acid Circulation Tank from IAT = 366926.8

H2SO4 364534.4 99.348

H2O 2392.36 0.651999

FINAL ABSORPTION TOWER :

Acid Circulation Rate to FAT = 96 m3/hr Density =
176064 kg/hr
kg/hr
H2SO4 173423
H2O 2640.96

SO3 entering FAT = 8.0176764 kgmol/hr SO3 out from FAT =

641.41412 kg/hr

Net H2SO4 produced in FAT = 785.73229 kg/hr

Net H2O consumed in FAT = 144.31818 kg/hr
kg/hr %
Acid going to Acid Circulation Tank from FAT = 176705.4

H2SO4 174208.8 98.58712

H2O 2496.642 1.412884

BALANCE ON ACID CIRCULATION TANK:

Dilution WATER added to Acid Tank = 1480.415 kg/hr

Acid taken as PRODUCT from Acid circulation tank = 16667.56 kg/hr
400.0213 TPD

NET ACID TAKEN FROM TANK = 16921.38 kg/hr

406.113 TPD
406.0914 TPD
400 TPD
6.091371 TPD

3.049633 m3/hr
ulfur through the STACK
kg of SO2 per Ton of H2SO4

y sulfuric acid.

g/ml

%
97.76714
2.232858

oleum in IAT .
ater to produce acid.
nverted to acid

g/ml
%
98.5
1.5

0 kg/hr

1.834 g/ml

%
98.5
1.5

0 kg/hr

1.480415 m3/hr

9.226486 m3/hr
 Gas kgmol/hr kg/hr %

SO2 0 0 100
N2 0 0 #DIV/0!
O2 0 0 #DIV/0!

Total 0 0 #DIV/0!
 SAP-2 MATERIAL BALANCE
Sulfuric Acid Plant Capacity = 400 TPD
Concentration of Sulfuric Acid = 98.5 %

Basis: Unit Hour Of Production

Total Acid Flow Rate = 16920.47 kg/hr

Acid On 100 % Basis = 16666.67 kg/hr
Water Present In Acid = 253.8071 kg/hr

SULFUR CALCULATION
Sulfur Present in Acid = 5442.177 kg/hr

Loss of SO2 from STACK (per TON of Acid Production) = 2 kg

Loss of SO2 from STACK = 33.33333 kg/hr
Loss of Sulfur from STACK = 16.66667 kg/hr

Assuming no loss of Sulfur in processing except STACK

Net Sulfur consumption in SAP-2 = 5458.844 kg/hr
170.5889 kgmol/hr
AIR HUMIDITY CALCULATION:

DryBulb Temperature = 38 Deg C 311.15 K

Wet Bulb Temperature = 28 Deg C
Relative Humidity = 85 %
Saturated Vapor Pressure of water at Dry Bulb Temp. 6633.1193762 Pa

At Dry bulb temp and atmospheric pressure

Water present in Air = 0.0392310036 kgof H2O/m3 of air

At normal Condition( 1 atm , 0 deg C )

Water present in Air = 0.0446917294 kg of H2O/Nm3 of air

Percentage of water in air = 5.5644228667 % H2O

Assuming Nitrogen, Oxygen and water is present in air

Composition of Air :
N2 = 74.60411 %
O2 = 19.83147 %
H2O = 5.564423 %

Total = 100 %

Sulfur oxidation takes place in Burner

REACTION :
S + O2 ------------------------> SO2
1 mole 1mole 1 mole
 32 kg 32 kg 64 kg
BURNER CALCULATION :

Assuming 100% combustion of sulfur in burner

% of SO2 in exit gas from Burner = 11.5 %

Assuming Air coming from Drying Tower is not having any moisture
Air
N2 = 79 %
O2 = 21 %

Total = 100 %

Air Requirement = 1483.381 kgmol/hr

42780.72 kg/hr 33228.362674 Nm3/hr

Composition of Gas Coming Exiting the Burner

Gas kgmol/hr kg/hr %

SO2 170.5889 10917.69 11.5

N2 1171.871 32812.4 0.79
O2 140.9212 4509.479 87.71

Total 1483.381 48239.56 100

This gas enters the Converter where SO2 is converted into SO3
REACTION :
SO2 + 1/2 O2 ………………..> SO3
1 mole 1/2 mole 1 mole
64 kg 16 kg 80 kg

FIRST BED :

Conversion in 1st Bed = 60 %

Composition of Gas coming out from 1st Bed

Gas kgmol/hr kg/hr %

SO2 68.23554 4367.075 4.7613971

SO3 102.3533 8188.265 7.1420956
N2 1172.766 32837.44 81.834235
O2 89.74457 2871.826 6.2622723

Total 1433.099 48264.61 100

SECOND BED :

Conversion in 1st Bed = 30 %

 Composition of Gas coming out from 2nd Bed

Gas kgmol/hr kg/hr %

SO2 17.05889 1091.769 1.2127603

SO3 153.53 12282.4 10.914843
N2 1171.871 32812.4 83.311363
O2 64.15625 2053 4.5610335

Total 1406.616 48239.56 100

THIRD BED :

Conversion in 3rd Bed = 5 %

Composition of Gas coming out from 3rd Bed

Gas kgmol/hr kg/hr %

SO2 8.529443 545.8844 0.6082242

SO3 162.0594 12964.75 11.556261
N2 1171.871 32812.4 83.564723
O2 59.89152 1916.529 4.270792

Total 1402.352 48239.56 100

Gas from 3rd bed goes to IAT for SO3 absorption in Acid
Assuming all the SO3 is absorbed in Acid and Gas entering the 4th pass is not having SO3

FOURTH BED:

Conversion in 3rd Bed = 4.7 %

Composition of Gas coming in 4th Bed

Gas kgmol/hr kg/hr %

SO2 8.529443 545.8844 0.6876962

SO3 0 0 0
N2 1171.871 32812.4 94.48348
O2 59.89152 1916.529 4.8288234

Total 1240.292 35274.81 100

Composition of Gas coming OUT 4th Bed

Gas kgmol/hr kg/hr %

SO2 0.511767 32.75306 0.0413956

 SO3 8.017676 641.4141 0.6485306
N2 1171.871 32812.4 94.789857
O2 55.88269 1788.246 4.5202163

Total 1236.283 35274.81 100

This 4th bed outlet gas is absorbed(100% SO3) in FAT and then passed to STACK

COMPOSITION OF STACK GAS:

Gas kgmol/hr kg/hr %

ppm
SO2 0.511767 32.75306 0.0416658 416.65786049 Loss of Sulfur through the STACK
SO3 0 0 0 1.965184
N2 1171.871 32812.4 95.408612
O2 55.88269 1788.246 4.5497227

Total 1228.266 34633.4 100

MATERIAL BALANCE FOR DT, IAT & FAT:

DRYING TOWER: Drying Tower absrobs the water coming with humid air by sulfuric acid.

Acid Circulation Rate in DT = 115 m3/hr Density = 1.834

210910 kg/hr

H20 entering in DT with Air = 1485.033 kg/hr

H20 out from DT with Air = 0 mg/Nm3 of Air
0 kg/hr
Net WATER recovered from air = 1485.033 kg/hr

Acid going to Acid Circulation Tank from Drying Tower = 212395 kg/hr

H2SO4 207746.4 kg/hr

H2O 4648.683 kg/hr

INTERMEDIATE ABSORPTION TOWER (IAT) : Acid reacts S03 to form oleum in IAT .
Oleum reacts with water to produce acid.
Assuming all the oleum formed in IAT/FAT converted to acid

H2SO4 + SO3 …………………> H2S2O7

1 mole 1 mole 1 mole
98 kg 98 kg 178 kg

H2S2O7 + H20 …………………..> 2 H2SO4

1 mole 1 mole 2 mole
178 kg 18 kg 196 kg

Acid Circulation rate to IAT = 193 m3/hr Density = 1.834

 353962 kg/hr
kg/hr
H2SO4 348652.6
H20 5309.43

SO3 entering in IAT = 162.05942 kgmol/hr SO3 out from IAT =

12964.753 kg/hr

Net H2SO4 produced in IAT = 15881.823 kg/hr

Net H20 consumed in IAT = 2917.0695 kg/hr
kg/hr %
Acid going to Acid Circulation Tank from IAT = 366926.8

H2SO4 364534.4 99.348

H2O 2392.36 0.651999

FINAL ABSORPTION TOWER :

Acid Circulation Rate to FAT = 96 m3/hr Density =
176064 kg/hr
kg/hr
H2SO4 173423
H2O 2640.96

SO3 entering FAT = 8.0176764 kgmol/hr SO3 out from FAT =

641.41412 kg/hr

Net H2SO4 produced in FAT = 785.73229 kg/hr

Net H2O consumed in FAT = 144.31818 kg/hr
kg/hr %
Acid going to Acid Circulation Tank from FAT = 176705.4

H2SO4 174208.8 98.58712

H2O 2496.642 1.412884

BALANCE ON ACID CIRCULATION TANK:

Dilution WATER added to Acid Tank = 1576.355 kg/hr

Acid taken as PRODUCT from Acid circulation tank = 16667.56 kg/hr
400.0213 TPD

NET ACID TAKEN FROM TANK = 16921.38 kg/hr

406.113 TPD
406.0914 TPD
400 TPD
6.091371 TPD

3.049633 m3/hr
ulfur through the STACK
kg of SO2 per Ton of H2SO4

g/ml

%
97.8113
2.188697

o produce acid.

g/ml
%
98.5
1.5

0 kg/hr

1.834 g/ml

%
98.5
1.5

0 kg/hr

1.576355 m3/hr

9.226486 m3/hr