Increasing production capacity of sulfuric acid plant
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Our company is requesting that the sulfuric acid production facility increase its output; we have not implemented similar plans before. Does anyone here have experience in this area? Please tell me what the key milestones for increasing production are, and what risks need to be avoided?
To see if production can be increased, ask the designers first. Typical designs include a margin of excess, which can be adjusted according to one’s own circumstances. Generally, attention is paid to whether the load on the equipment remains within a controllable range. As production increases, it is necessary to consider whether the relevant operating parameters of the equipment need to be adjusted, and whether the amount of catalyst used needs to be increased, among other things. These are personal opinions for reference only.
This post was last edited by hnfxl689 on 2015-7-24 at 17:50. In terms of increasing acid production, the margin available in the conversion fans has a significant impact, while the purification equipment offers greater flexibility in terms of its margin. It is best to conduct a systematic analysis with the designers, comparing the initial design conditions, the current operating status, and the system’s capacity reserves, before deciding on matters related to increasing production. Pay attention to the hidden aspects that arise after an increase in production, such as heat load; factors including purification heat load, dry absorption, and conversion all need to be taken into consideration. The water balance is also a point.
Increasing production will inevitably affect various indicators; it is best to have the sulfuric acid company assess the capacity of the existing equipment and develop a plan for upgrades. It is common to see sulfuric acid plants operating beyond their capacity, which leads to a sharp increase in failure rates; the equipment gets damaged, and so do the people working there.
The previous set of exhaust treatment devices can increase it by over 50%
Start with the equipment – check whether fans, heat exchangers, thermal control devices, and other similar equipment meet the requirements. If they don’t, determine which ones need to be replaced
Hehe, it’s hard to explain clearly. You just need to gradually increase the air flow rate and also gradually increase the amount of raw material used. By doing so, you can determine which equipment becomes overloaded, which process parameters can no longer be controlled, and which ones result in efficiency levels that fall below the required standards. Well, congratulations – you’ve reached a bottleneck; without making modifications to the setup, this is the maximum output possible.
To increase production, it is possible to improve the performance of sulfur incineration furnaces. What temperatures can high-alumina brick firewalls withstand? Has anyone had experience with this?
It’s not just about raising the temperature of the sulfur incineration furnace; it also involves increasing both the volume of gas and the amount of sulfur
Haha, that makes sense. Generally, people don’t spend too much time seeking out relevant designers for calculations; instead, they gradually increase the load by themselves. Once one of those components is operating at full capacity, it’s okay. Want to mention it again? Then expand the capacity and upgrade to new equipment.
To improve the gas concentration, check whether the conversion rate is satisfactory； Check whether the drum and exhaust fan have headroom, and increase the air volume. Run these two plans first, and then observe the changes in the process parameters for each section.