Sulphuric Acid

Ballestra designs and supplies Sulfuric Acid production plants, technical or battery grade, based on the Ballestra proprietary technology and/or Monsanto license (on case by case basis).

Plants are studied in full compliance with the safety and environmental principles, as per international standards and are developed taking into consideration the Ballestra's experiences of over 35 years activities in design and supply of SO3 generation plants (over 500 plants supplied worldwide).

Ballestra's technology has been developed taking into consideration the necessity to guarantee flexibility, reliability and low operating cost, while maintaining the best quality standard as guaranteed by the ISO 9001 certification.

A wide range of plants capacities are envisageable, from small size (24TPD) for local or very specific applications to big industrial production units (400 TPD and more).

Ballestra design foresees the following configuration:

Single SO3 adsorption, with or without heat recovery system.
Double SO3 adsorption, with heat recovery system.
The main units composing the plant are the following:

Air drying.
Sulphur melting and dosing system.
Sulphur combustion.
SO2 to SO3 conversion unit.
SO3 adsorption unit (double or single adsorption).
Exhaust gases treatment system.
Heat recovery (optional)

The raw material is solid Sulphur (liquid Sulphur can also be used, avoiding the Sulphur melting section), which is melted into the plant and fed to the Sulphur furnace together with dried air. Dried air is produced by dehydration system which uses H2SO4 as the dehydrating agent. Gaseous SO2 is the result of the Sulphur combustion with oxygen. SO2 is then converted to SO3 by a catalytic reaction with oxygen. SO3 is absorbed using water in order to produce 98.5 wt % sulfuric acid (99 wt % in case of double SO3 absorption).

TThe SO3 absorption can be done by single stage or double stage or latter: in the latter, the overall plant yield is improved and it is not necessary to install an exhaust gas scrubber to remove the SO2 (also small quantity of SO3 and acid mist) present in the gases released to the atmosphere. The installation of the gas treatment ensures that the SOx traces in the exhaust gases always remain within the permitted limits, according to the most stringent international standards.

TSteam can be produced by the heat recovery system and it can be used directly in the plant in particular for the Sulphur melting unit and for the (steam) driver of the air blower. For large plants also an electric unit power generation, can be foreseen.

TH2SO4 PRODUCTION
PLANT BLOCK DIAGRAM AND OVERALL MATERIAL BALANCE


Single SO3 Absorption