Sulfuric acid conversion rate
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Colleagues, we are currently facing a technical challenge in the operation of our sulfuric acid production facility. For the first conversion stage, the inlet temperature is 415 degrees, while the outlet temperature reaches 610 degrees; the gas concentration is 6–7%. The temperatures in the other stages are also within the specified range and remain stable. According to the adiabatic temperature rise formula for sulfuric acid conversion, the conversion rate for this first stage should be over 70%. However, the analysis results show that the actual conversion rate for this stage is only 49.66%, and for the second stage it is 20.72%. The overall conversion rate is 99.9%. The sulfur dioxide content in the exhaust gas at the exit of the second absorption tower is as high as 2500 milligrams per cubic meter, which corresponds to the amount of caustic soda used by the exhaust gas desulfurization unit (about 15 packs per shift). This shows that the conversion efficiency at this level is indeed poor. We now suspect there might be an error in the conversion temperature readings, and we have asked the instrument technician to check them. However, the instrument engineer inspected the instrument modules and thermometers today, and everything appeared to be fine! Here, we would like to ask our colleagues for their assistance and answers.
Is there a leak in the heat exchanger? What kind of process do you use for conversion?
Do you know if it’s possible to reduce the ventilation volume of the converter?
“3+2 two-rotation two-suction process
How many years has your equipment been in use? If the moisture removal is not up to standard, check the No. 3 heat exchanger first
The sulfur dioxide content in the exhaust gas at the outlet of the second absorption tower is as high as 2500 milligrams per cubic meter; it’s impossible for the overall conversion rate to be 99.9%
Most importantly, with such high exhaust emissions, the conversion rate cannot be 99.9%
An exhaust gas output of 2500 is inconsistent with a conversion rate of 99.9%; one of the values must be incorrect
As a supplement, check the change in resistance over a certain period for the catalyst.
"The inlet temperature of the conversion layer is 415 degrees, while the outlet temperature reaches 610 degrees; the gas concentration is 6–7%. There is a contradiction between the gas concentration and the temperature rise – when the gas concentration is 6–7%, the temperature rise is around 140°C. It is suspected that the gas contains CO; it is recommended to conduct a gas analysis of the flue gas