SO2 To SULFURIC ACID

Rameshni & Associates Technology & Engineering (RATE) specializes in treating waste gases from metallurgical processes to reduce sulphur dioxide (SO2) emissions. By converting SO2 into sulphur trioxide (SO3), we enable the production of sulfuric acid (H2SO4) in dedicated plants, helping industries meet environmental regulations while producing a valuable chemical.

Sulfuric acid is a critical feedstock for industries such as fertilizer production, ore leaching, petroleum refining, pharmaceuticals, batteries, and more.

It is produced through the contact process, where SO2 is oxidized with oxygen over vanadium-based catalysts to form SO3, which is then absorbed into water to create sulfuric acid.

Gas Cleaning

Before entering the sulfuric acid plant’s contact section, metallurgical off-gases must be cleaned to ensure high-quality acid production and protect equipment. Key contaminants, including SO3, dust, metals, mercury, and fluorides, are removed to:

Prevent catalyst plugging and pressure drop increases.
Protect against catalyst poisoning.
Reduce corrosion of plant equipment.

Converters

Converters house vanadium-based catalysts that accelerate the reaction of SO2 with oxygen to form SO3, releasing heat. These systems are designed to:

Support three to five catalyst beds for optimal reaction efficiency.
Minimize heat loss for an adiabatic (heat-retaining) process.
Ensure uniform gas flow through radial distribution.
Converters are constructed from welded stainless steel and may include internal heat exchangers to manage temperature.

Direct Cooling

Cooling systems, such as packed cooling towers and open spray towers, lower gas temperatures to protect equipment and optimize reaction conditions.

Strong Acid System

The strong acid system includes towers, packing, and acid coolers to absorb SO3 into water, forming sulfuric acid. Acid coolers manage the heat generated during this process, ensuring safe and efficient operation.