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Abstract— An isothermal plug flow reactor for the production of The chemistry for the production of sulphuric acid is
sulphuric acid over a range of degree of conversion ,XA = 0.95 to presented thus as follows:
0.99 and reactor diameter, Di = 0.05 to 0.1m have been designed. S(s) + O2(g) → SO2(g) ------------------------------- (1)
The reactor which operates at atmospheric pressure is capable of
producing 10,000 metric tons per annum. This reactor is designed SO2(g) + 1 2 O2 ( g )
→ SO3( g ) -----------------------(2)
with hastelloy because it possesses an excellent corrosion and
SO3(g) + H2O(l) → H2SO4(l) ---------------------------(3)
sulphuric acid resistance properties. The reactor performance
models are simulated with the aid of a Computer using MATLAB
(R2007b).The results provided information for the functional The traditional methods of its production in pure form
parameters for the reactor which include; the reactor volume, could not cope with the demand [3]. The lead chamber
space time, space velocity, rate of heat generation per unit volume process and the contact process have been used to produce the
of reactor, pressure drop, and length of reactor. The relationship acid in commercial quantity. The lead chamber process
between these parameters and the degree of conversion are produces acid of very low grade, both in purity and
presented graphically.
concentration. However, the contact process produces acid of
Index Terms—About four key words or phrases in alphabetical high concentration and purity but the process of its
order, separated by commas. manufacture is very expensive. This process utilizes very
expensive catalyst –Vanadium pent oxide. As a result the acid
I. INTRODUCTION from this process is equally expensive.
The advancements in the chemical engineering profession has Hence, to ensure availability and affordability of the
brought to the fore the discovery of various chemicals product with acceptable quality, there is need to look for
compounds, which in a very large way affects or touches alternative methods of its production.
everyone in one way or the other every day. One of such Substantial works have been done and documented on the
chemical compounds that have found notable application is kinetics of sulphuric acid production [4]. Literatures have
sulphuric acid. Sulphuric acid also known as oil of Vitriol is a shown that direct dissolution of sulphur trioxide in water to
dense, colourless, oily, corrosive liquid having a density of produce the acid is not done due to very high heat of reaction
1.84g/cm3, a molecular formular of H2SO4 and a molar mass occasioned in the process. Instead sulphur trioxide is
of 98.08g/mol. It is miscible with water in all proportions absorbed in concentrated sulphuric acid to form oleum, and
giving an exothermic reaction. This acid is a very important subsequently diluted with water to form sulphuric acid of
chemical commodity and was probably known before 16th 98%-100% concentration.
century [1]. It was prepared by Johnann Van Helmont [2], by Although the production of sulphuric acid is eminent and
destructive distillation of green vitriol (ferrous sulphate) and known globally. Related literatures have shown that
by burning sulphur. Sulphuric acid was also produced by numerous treaties have been written and published on it
Nordhausen from green vitriol but was expensive. A process [Green wood et al, 1984] . The purpose of this research is to
for its synthesis by burning sulphur with potassium nitrate was investigate into past works on the development of
first used by Johann Glauber in the 17th century and performance models for reactor types for the production of
developed commercially by Joshua Ward in England in 1746 sulphuric acid, and to specifically identify and develop
[3]. It was superseded by the lead chamber process which was appropriate performance models for the areas that are
invented by John Roebuck in 1746. [3]. Sulphuric acid was deficient in past work.
manufactured by the lead chamber process until the However, little or no known published work had been
mid-1930s, but this process has been replaced by the contact recorded for the development of performance models for the
process involving the catalytic oxidation of sulphur dioxide production of the acid using semi-batch reactor, continuous
using vanadium pent oxide (V2O5) as catalyst. stirred tank reactor, and plug flow reactor. This present work
is aimed at addressing this seemingly neglected area.
Manuscript Received on August 2014.
Prof. M. F. N Abowei, Department of Chemical, Petrochemical II. KINETICS ANALYSIS
Engineering, Rivers State University of Science & Technology, Port
Harcourt , Nigeria. The reaction mechanism as presented in equation (3)
T. O. Goodhead, Department of Chemical, Petrochemical Engineering, showed chain reaction characteristics [1]. Gibney and ferracid
Rivers State University of Science & Technology, Port Harcourt , Nigeria.
reported on the photo-catalysed oxidation of SO32- by
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(dimethyl-glyoximato) (SO3)23- and its Substituting equation (7) into (6) results in
(Co(dimethyl-glyoximato) (SO3)32. [5] - RA = (CA) C BL2 K 2 2
1 1 1
DL 2 ……………………... (8)
The work showed that the reaction
Previous reports—Octave levenspiel 1999—showed that
SO3 + H 2O
→ H 2 SO4 the amount of SO3 (CA) and steam (CBL) that have reacted in a
is described as irreversible bimolecular chain reaction. bimolecular type reaction with conversion XA is CAO XA.
Further research into the works of Erikson [6] and Huie, et al Hence equation (8) can be rewritten as
[7] established the reaction as second order reaction with rate - RA = K 2 2 DL 2 (CBO − C AO X A ) 2
1 1 1
(C A0 − C A0 X A )
constant K2 = 0.3 mole/sec. Morokuma and Mugurama,
(m − X A ) (1 − X A ) …. (9)
1 1 3 1
performed abinitio calculation and determined the energetic = K 2 2 D L 2 C A0 2 2
Where
2.1 EVALUATION OF FRACTIONAL VOLUME
CAo = Initial concentration of SO3 (moles/Vol)
CHANGE, εA
CBo = Initial concentration of H2O (moles/Vol) From equation (3), it is clear that change in volume takes
XA = Fractional conversion of SO3 (%) place as the reaction proceeds. One mole of sulphur trioxide
-RA = Rate of disappearance of SO3 (mole/ Vol/t) reacts with one mole of steam to form one mole of sulphuric
In this work, the rate expression (-RA) as in equation (4) will acid. This change in volume can be expressed in terms of
be used to develop the hypothetical plug flow reactor design
fractional change in volume of the reaction (εεA)
equations with inculcation of the absorption coefficient factor
as recommended in the works of Van-Krevelen and Hoftyzer
(1948). This is achieved by modifying equation (5) as
V XA = 1 − V XA = 0
εA =
illustrated below. The hypothetical concentration profile of
the absorption of sulphur trioxide by steam (H2O) is
represented in fig 1. V XA = 0 ------------ (10)
the bulk liquid CBL and to the second order reaction rate
For a plug flow reactor, we know, the rate of accumulation of
constant K2 for the absorption of SO3 in steam solution. Thus
A in element of volume is zero.
(K 2 DL C BL )
1
2
r= KL ………….……. (7)
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International Journal of Innovative Science and Modern Engineering (IJISME)
ISSN: 2319-6386, Volume-2 Issue-9, August 2014
FA dX A = (− R A )dVR
FA0 dX A
dVR =
(− R A ) (18)
But,
dC A
C A20 (m − X A ) (1 − X A )
1 1 3 1
− RA = = K 2
2 D 2
L
2
(dt )
Substituting for RA in equation (18) we have.
FA 0 dX A
dV R = (19)
(m − X A ) (1 − X A )
1 1 3 1
2 2 2
K 2 D L C A0
2
2 (m − X )
1
F A0 2
(21)
VR =
A
K
1
2
DL 1 C
3
2
1− X A
2 2 AO
2(m − X A )
1
4 FA0 2
(23)
LR =
1 − X A
1 1 3
Figure 3 Hypothetical Heat Exchanger πD K 2 2
i
2
DL 2
C AO 2
Unit
FA = FA0 (1 − X A ) Mathematically, Vs =
1
Ts
(1 − )
1 1
Differentiating both sides give, K 2
D 2
C
1
2 X
Vs = 2 L A0 A (25)
2 (m − X A) 1
2
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START
3.5 PRESSURE DROP
3.1.6 PRESSURE DROP ALONG REACTOR LENGTH
The pressure drop (∆p) corresponding to the designed flow READ
rate is often relatively small and does not usually impose any FA0, V0 , CA0, ∆HR,, K2, DL, M,
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ISSN: 2319-6386, Volume-2 Issue-9, August 2014
0.06
0.045
Reactant molar flow rate FA0 3.937 mol/sec
0.04
0.03
Molar ratio of reactants m 1.0to 1.5 0.94 0.95 0.96 0.97 0.98 0.99 1
CONVERSION DEGREE
Liquid phase diffusivity of SO3 DL 17 m2/Sec Figure 6 Plot of Space Time against Conversion
Degree for Isothermal PFR
Volumetric flow rate of V0 2.352x10- m3/Sec
4
reactants
34
30
Industrial reactors for the production of sulphuric acid over a 28
18
sulphuric acid resistance properties. The reactor performance
16
models were simulated with the aid of MATLAB R2007b. 14
0.94 0.95 0.96 0.97 0.98 0.99 1
The results provided information for the functional reactor CONVERSION DEGREE
parameters. These parameters include reactor volume, reactor Figure 7 Plot of Space Velocity against Conversion
length, space time, space velocity, and rate of heat generation Degree for Isothermal PFR
per reactor volume. It is the purpose of this section to present 5
7
x 10
HEAT GENERATED PER UNIT VOLUME (kJ/sec.m3)
1.6 45
1.5
PRESSURE DROP (N/m2)
40
REACTOR VOLUME (m3)
1.4
1.3
1.2 35
1.1
1 30
0.9
0.8 25
0.7
0.94 0.95 0.96 0.97 0.98 0.99 1
CONVERSION DEGREE
20
0.94 0.95 0.96 0.97 0.98 0.99 1
Figure 5 Plot of Reactor Volume against Conversion CONVERSION DEGREE
Degree for Isothermal PFR Figure 9 Plots of Pressure Drop against Conversion
Degree for Isothermal PFR
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From the results of the computation for the reactor it was 8.208E-04N/m2 and 5.90E-03N/m2 for the reactant molar
found that, if the degree of conversion, XA was 0.95, the ratio, m=1.0 and 1.5 respectively.
reactor volume, VR were 6.84E-05m3 and 2.06E-05m3 when (f) From (d) – (e) above, the reactor volume, space time,
the reactant molar ratio, m = 1.0 and 1.5 respectively but reactor length and the pressure drop were greater at the upper
increase of XA resulted in increase of the reactor volume up to limits of conversion degree. While the rate of heat generation
7.965E-04m3 to 1.115E-04m3 when XA = 0.99 and m = 1.0 to per unit reactor volume decreases as conversion degree
1.5. increases.
Generally,
V. CONCLUSION (g) At the lower limits of operating condition (i.e. conversion
An isothermal plug flow reactor has been designed for the degree, XA=0.95) increase in reactor diameter has no affect on
production of ten thousand metric tons per year of sulphuric reactor volume, space time and rate of heat generation per
acid. Computer program was developed and utilized to reactor volume. While the reactor length, and the pressure
simulate the reactor performance models over a conversion drop decrease as reactor diameter increases.
degree interval of XA = 0.95 to 0.99. From the results of
computation, it is clearly established that: Similarly, at the upper limits of operating conditions (i.e.
conversion degree, XA=0.99), increase in reactor diameter has
(a) When the diameter of the reactor, Di=0.02m, degree of no affect on reactor volume, space time and rate of heat
conversion, XA=0.95,the volume of the reactor, VR are generation per reactor volume. While the reactor length and
7.20E-06m3 and 2.39E-05m3, the space time, TS are pressure drop decrease as reactor diameter increases.
3.06E-02sec and 0.1015sec, the reactor length, LR are
2.2909E-02m and 7.60E-02m, the rate of heat generation per VI. APPENDIX
reactor volume, RQ are 4.5795E07KJ/sec.m3 and
4.5795E07KJ/sec.m3 and the pressure drop, ∆P are APPENDIX 17A : ISOTHERMAL PFR(for m=1)
Di XA VR(m3) LR TS (sec) VS Rq(kJ/s ∆P
20.7851N/m2 and 68.9365N/m2 for the reactant molar ratio, (m) *10-4 (m)*10-2 (sec-1) ec.m3) (N/m2)
*107
m=1.0 and 1.5 respectively. .02 0.95 0.0720 2.2909 0.0306 32.6862 4.5795 20.7851
(b) When the degree of conversion, XA=0.99 for the same .02 0.96 0.0805 2.5614 0.0342 29.2354 4.1391 23.2385
.02 0.97 0.0929 2.9559 0.0395 25.3186 3.6219 26.8335
lower reactor diameter, as specified above, the reactor .02 0.98 0.1138 3.6209 0.0484 20.6726 2.9878 32.8642
volume, VR are 1.609E-05m3 and 1.149E-04m3, the space .02 0.99 0.1609 5.1195 0.0684 14.6177 2.1342 46.4770
0.1015sec, the reactor length, LR are 9.1636E-04m and .10 0.9 0.0720 9.1636 0.0306 32.6862 4.5795 0.3671
.10 5 0.0805 10.2455 0.0342 29.2354 4.1391 0.4104
3.0418E-03m, the rate of heat generation per reactor volume, .10 0.9 0.0929 11.8236 0.0395 25.3186 3.6219 0.4739
.10 6 0.1138 14.4836 0.0484 20.6726 2.9878 0.5804
RQ are 4.5795E07KJ/sec.m3 and 4,5795E07KJ/sec.m3 and .10 0.9 0.1609 20.4782 0.0684 14.6177 2.1342 0.8208
the pressure drop, ∆P are 3.671E-04N/m2 and 1.2E-03N/m2 7
0.9
for the reactant molar ratio, m=1.0 and 1.5 respectively. 8
0.9
(e) when the degree of conversion, XA=0.99 for the same 9
upper reactor diameter, as specified above, the reactor
volume, VR are 1.609E-05m3 and 1.149E-04m3, the space
time, TS are 6.84E-02sec and 0.4885sec, the reactor length, LR
are 2.0478E-03m and 1.4624E-02m, the rate of heat
generation per reactor volume, RQ are 2.1342E07KJ/sec.m3
and 2.1342E07KJ/sec.m3 and the pressure drop, ∆P are
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