“Production Of Sulphuric Acid”

A Training Report Submitted To

Chhattisgarh Swami Vivekanand Technical University,Bhilai(C.G.)

Inpartial fulfillment of the award of degree

BACHELOR OF TECHNOLOGY
In
CHEMICALENGINEERING
Under the Guidance of
Mr. ABHISHEK SATAPATHY
PARADEEP PHOSPHATE LIMITED, PARADEEP
Submitted By-
SAMBIT KUMAR DASH

DEPARTMENTOFCHEMICALENGINEERING
RAIPURINSTITUTEOFTECHNOLOGY

Signature of Candidate Signature of process

Chemist

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 INDEX

● ACKNOWLEDGEMENT

● PREFACE

● CERTIFICATE

● DECLARATION

● PROFILE OF PLANT

● ABSTRACT

● INTRODUCTION

● SULPHUR MELTING AND FILTERING

● FORMATION OF SULPHUR DIOXIDE

● CONVERSION OF SULPHUR DIOXIDE TO SULPHUR TRIOXIDE

● ABSORPTION OF SULPHUR TRIOXIDE IN SULPHURIC ACID

● START –UP TAIL GAS SCRUBBING

● USES OF SULPHURIC ACID

● CONCLUSION

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 ACKNOWLEDGEMENT

I Take this opportunity to express my profound gratitude and deep regards to

my guide for his guidance, monitoring and constant encouragement throughout

the course of this thesis. The blessing, help and guidance given by him from

time to time shall carry me a long way in the journey of life on which I’m about

to embark. Iwould like to express my profound gratitude to Mr. Sumit Senapati

(general manager) for giving me an opportunity to take up the internship

training at Paradeep Phosphate Limited, Paradeep.

I am obliged to staff members of Paradeep Phosphate Limited, Paradeep for the

valuable information provided by them in their respective field. I’m grateful for

their cooperation during the period of assignment.

WITH REGARDS SAMBIT KUMAR DASH

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 PREFACE

I have completed the tranning assigned to me for one month in Paradeep Phosphates

Limited, Paradeep. I was assigned to Sulphuric acid plant by Mr. Lingaraj Dash,

DGM system. This Plant consists of 9 different sections. Due to this I got a brief

overview of processes involved in every section. This report is a detailed overview of my

understanding of the processes involved in this plant.

I believe that an internship is a bridge between the theory of the classroom to the

practical working of an industry. This internship has been a great opportunity for me to

understand the actual working of the industry, which not only enriched me professionally

but also helped me grow personally as well. This experience has been humbling and has

helped me understand where I lack and need to improve. This has also been motivating,

and meeting the hardworking employees has been an enlightening experience. The career

path I would be selecting for myself is quite influenced from my internship as I have had

a great opportunity to practically see how chemical industry sector is working and

evolving. I have summarized my overall experience, with my learning and challenges

faced as an intern.

SAMBIT KUMAR DASH

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 SUMMER INTERNSHIP COMPLETION
CERTIFICATE
Dt: 15/Aug/2024

TO WHOM IT MAY CONCERN

This is to certify that Sambit kumar dash has successfully completed an internship with

Paradeep Phosphate Limited as an Intern in the Sulphuric Acid Plant production

Department from 01/July/2024 to 14/Aug/2024 .

They have worked on the Sulphuric Acid plant under the supervision and guidance of mr.

Abhishek Thakur. During the internship, he/ she has gained several learnings such as

Learning and developed considerable skills, including .

Besides showing high comprehension capacity, managing assignments with the utmost

expertise, and exhibiting maximal efficiency, he has also maintained an outstanding

professional demeanor and showcased excellent moral character throughout the

internship period.

I hereby certify his / her overall work as excellent to the best of my knowledge.

Wishing him/ her the best of luck in his future endeavors.

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 DECLARATION

I hereby declare that the information I have gathered during the period of field work

report is authentic, which is to be completed as per the rules of RAIPUR

INSTITUTE OF TECHNOLOGY, C.G for the degree of Bachelor of Technology in

Chemical Engineering.

I honestly express that the information is not collected with any commercial intention

and motive. The sole motive is to gather knowledge about the Paradeep Phosphates

Limited Industry and prepare the field report. Thus, the objective of collecting

information is for academic purpose.

I also specially thank to Mr. Lingaraj Dash (DM, HR and Admin)

For giving me the opportunity to do the Internship Training and also for his extended

cooperation to make this training a success.

Signature Of Student

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 PROFILE OF THE PLANT

Founded in 1981, Paradeep Phosphates Limited (PPL) is India's third-largest

producer of non-urea fertilizer and the second-largest producer of Di-Ammonium

Phosphate (DAP). The company has a proven track record of achieving robust

financial results. Having an annual turnover of about Rs. 5,000 crores, the company

manufactures, trades, distributes, and sells various types of complex fertilisers. This

includes DAP, a total of three types of NPK (NP-10, NP-12, NP-20), Zypmite,

Phosphogypsum, and Hydroflorosilicic Acid (HFSA). Additionally, the company

engages in the trading, distribution, and sales of Muriate of Potash (MOP),

Ammonia, Specialty Plant Nutrients (SPN), and City Compost. The fertilisers are

marketed under the brand names 'Jai Kisaan - Navratna' and 'Navratna'.

The primary promoters of the company, ZuariMaroc Phosphates Private Limited

(ZMPPL) holds 80.45% of the equity share capital of the Company, with the

remaining shares held by the Government of India. The OCP group is one of the

world's major producers of phosphate rock, measuring approximately 70% of global

reserves, and currently has revenues exceeding US$6.3 billion. OCP is 95%owned by

the Moroccan government. ZACL, a leading company in the agribusiness vertical of

theAdventzGroup,holds 40.23% of the equity shares in Paradeep Phosphates

Limited. As a company, ZACL is engaged in the production, distribution, and sale of

a wide range of fertilisers such as DAP, Urea, and several grades of NPK.

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 The raw materials used by PPL come from various countries such as Morocco,

Jordan, Qatar and Saudi Arabia. For several raw materials, such as Phosphate Rock,

Ammonia and Sulphur, the company benefits from long-term supply agreements. In

the process of processing phosphate rock, phosphorus is produced, which is one of

three main nutrients commonly used in fertilizer (the other two are nitrogen and

potassium). It is estimated that India has negligible reserves of phosphorus and is

therefore dependent on foreign importation of phosphate rock or phosphoric acid.

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 ABSTRACT

The art of producing sulfuric acid is one of the oldest techniques of chemistry.

The preferred process in modern day industry for its production is the contact

process. This involves the conversion of 80; into S0 in the presence of a

catalytic mass, such as vanadium oxide, and a source of oxygen. While the

eificiency of this procedure has been developed considerably over the many

years of its use, great incentive remains to reduce the high operating and

investment cost of the process.

In the operation of the conventional contact process using sulfur as the source

of S0 it is considered necessary to dry the air or other source of oxygen prior

to combustion in a burner. The gases leaving the burner are then cooled down

to a range of about 400-500 C. by heat exchangers or steam-producing boilers.

When the source of S0 bearing gas is sulfuric acid sludge, spent alkylation

acid, or any other sulfur source which yields water on decomposition, the

combustion gases leaving the burner must be cooled down to about ambient

temperature using high capacity heat exchange equipment. This step removes

moisture by condensation and the gases are then further dried, usually by

scrubbing with strong sulfuric acid.

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 INTRODUCTION
Elemental sulphur is a bright yellow, crystalline solid at room temperature. Sulphuric

acid is one of the most important material upon which our industrial society depends.

Sulphuric acid is the most common acid that is used in various chemical experiments.

It is a strong inorganic acid. The chemical formula of sulphuric acid is H2SO4H2SO4.

The molecular formula of sulphuric acid has 2 hydrogen atoms, 1 sulfur atom, and 4

oxygen atoms. The basic concepts related to sulfuric acid, sulfuric acid formula,

sulphuric acid molecular formula, the formula of dilute sulphuric acid, structure,

chemical properties, and uses of acid, are discussed here, for your reference. Sulphuric

acid is an oily, odorless liquid, often known as sulfuric acid or H2SO4H2SO4. It's also

highly corrosive. It has been dubbed the 'King of Chemicals' due to its extensive range

of applications. We can also find it in both a combined and a free state.The acid's

boiling point is 611 K. Because of hydrogen bonding; this molecule has a more unique

boiling point and thickness.

The following is a partial list of the industries which are its consumers; agriculture ,

chemical petroleum, iron and steel ,coal products etc. Sulphuric acid has the chemical

formula H₂SO₄. There are 2 types manufacturing process.

1. Lead chamber process

2. Contact process

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 PHYSICAL PROPERTIES OF SULPHURIC ACID

Sulphuric acid was initially called “OIL OF VITRIOL” As it was initially

prepared by distilling green vitriol(FeSO4.7H2O). Also called MATTLING

ACID And also known as “KING OF CHEMICALS”. Sulphuric Acid is a

colourless, odourless, oily fluid and tastes slight sour. Since it is hygroscopic, it

absorbs moisture from atmosphere hence kept in air tight bottles. Concentrated

acid is highly corrosive in nature and chars skin black. Sulphuric Acid is heavier

than water (R.D.-1.85) at 83 OC. The boiling point of the acid is 296 oc. The

higher boiling point and thickness of this chemical is due to hydrogen bonding.

Melting point is 10 oc (colourless crystals). Pure and concentrated acid is almost

a non-conductor of electricity and dilute acid is a good conductor of electricity.

Dilution of concentrated acid is done only by addition of acid to water and not

water to acid even though heat is evolved in both cases. If water is added to the

acid: there is a sudden increase in temperature- and the acid being in bulk tends

to spurt out. If acid is added to water: the water is in bulk and the acid being

heavier settles down. The evolved heat is dissipated in the water itself and hence

the spurting of the acid is minimised. Distillation or boiling cannot be used to

concentrate sulphuric acid beyond a certain concentration(forms constant boiling

mixture at 338oc having 98% acid) .

CHEMICAL PROPERTIES OF SULPHURIC ACID

 Action of heat: on heating strongly, it underoes dissociation at 440 oc to yield

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 water and sulphur trioxide.

 Acidic properties: sulphuric acid is a strong dibasic acid. It is diprotic and

ionises in two stages in the aqueous solution. It turns blue litmus paper red and

methyl orange pink.

 Least or non-volatile acid: concentrated acid in comparison to other acid is

less volatile with a high boiling point.

 Oxidising properties: it is a strong oxidising agent due to acid on thermal

decomposition yields nascent oxygen [o] which helps in oxidation. It oxidises

non-metals, metals, inorganic compounds.

 Dehydrating properties: concentrated acid removes elements of

water(carbohydrates, organic compounds, water of crystallisation from hydrated

salts). Also acts as a drying agent to dry gases.

 Sulphuric acid occurs in free state in minute traces in hot springs.

 It is also formed near sulphide beds e.G.: By hydrolysis of iron pyrites.

 In combined form it occurs as salts in minerals such as metallic sulphates.

TYPES OF PRODUCTION OF SULPHURIC ACID

 Lead chamber process: method of producing sulphuric acid by oxidising

sulphur dioxide with moist air, using gaseous nitrogen oxides as catalysts, the

reaction taking place primarily in a series of large, boxlike chambers of sheet

lead. One of the most prevalent manufacturing procedures is the lead Chamber

process. It yields between 50 and 60 B-grade acids. We employ moist SO2 in

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 the presence of nitrogenous oxides in this process (dynamic impetus). As a

result, it reacts with oxygen in the air, forming sulphur trioxide.

 Contact process: molten sulphur is burned to form so2, which is cooled, then

oxidised usually in the presence of pellets of porous siliceous material

inpregnated with v2o5 and a potassium compound to form so3 at moderately high

temperatures and then absorbed in water to form acid. When one mole of

Sulphur trioxide is made to react with water, One mole of sulphuric acid is

formed. This is the commercial method known as the Contact process.

Vanadium Oxide is used as a catalyst in this reaction.

 DCDA process: sulphuric acid is produced by double conversion (so 2 →so3)

and double absorption.

CONTACT PROCESS

The following steps are used in the contact process:

1. Melting and filtering of solid Sulphur

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 2. Formation of sulphur dioxide by burning sulphur.

3. Conversion of sulphur dioxide to sulphur trioxide.

4. Absorption of sulphur trioxide in sulphuric acid.

5. Scrubbing of the tail gas during start-up operation.

SULPHUR MELTING & FILTRATION

The solid sulphur is conveyed from the sulphur pile to the sulphur melting and

filteration system. Sulphur melting is carried out in above-ground partially

brick-lined concrete pits, containing steam coils to transfer heat to the liquid

sulphur. Agitators are installed in the melting pits to mix solid and liquid

Sulphur and improve heat transfer. The unfiltered molten sulphur is pumped

through the sulphur filters to the filtered sulphur pit.

Sulphuric acid is produced from sulphur. In the presence of air, sulphur dioxide is

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 first obtained by burning the molten sulphur. In the presence of a catalyst for

vanadium pentoxide, sulphur dioxide is then converted to sulphur trioxide.

[ MELTING AND FILTERATION (SAP A&B) ]

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 [ MELTING AND FILTERATION (SAP C) ]

FORMATION OF SULPHUR DIOXIDE

 Step 1: Preparation of sulphur dioxide:

 SO2 is prepared by burning sulphur in the presence of excess air so that the

product combines with oxygen which is helpful for the next stage.

 S(s) + O2 (g) → SO2(g)(COMBUSTION)

 The air is then drawn through the packed drying tower counter-current to a flow

of 96% of H2SO4,to remove water vapour contained in the air by the main
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 compressor.

 Sufficient acid is circulated over the tower so that the water vapour removed

does not significantly reduce the strength .

 As a result ,the process gas is cooled in a waste heat boiler which recovers the

surplus heat as high pressure saturated steam.from the waste heat boiler, the

sulphur dioxide gas flows to the first pass of the converter.

CONVERSION OF SULPHUR DIOXIDE TO SULPHUR

TRIOXIDE

 Step 2: Preparation of sulphur trioxide:

 The acid plant converter is the heart of the acid plant. In the converter, sulphur

dioxide (SO2) reacts with oxygen

 (O2) in the presence of a catalyst to form sulphur trioxide (SO3) according to

the following reaction:

 SO2 + 1/2 O2 <=> SO3(CONVERSION)

 The converter serves the following functions:

• ƒ provides single or multiple beds in which the catalyst is placed

• ƒ Provides for the distribution of gas across the catalyst bed.

• ƒ Provides for the collection of gas to exit the converter

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 FlOW CHART OF SULPHUR TRIOXIDE

FORMATION

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 GAS SECTION (SAP A & B)

GAS SECTION (SAP C)

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 BOILER SECTION (SAP A&B)

BOILER SECTION (SAP C)

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 ABSORPTION OF SULPHUR TRIOXIDE IN

SULPHURIC ACID

 The MECS® HRS™ technology uses the heat of absorption and dilution to

generate steam instead of rejecting the heat and sending it to the cooling tower.

 Step 3: Preparation of concentrated sulphuric acid:

 The sulphur trioxide formed is first made to react with concentrated sulphuric

acid. Sulphur trioxide cannot be dissolved in water directly as it leads to the

formation of fog. The product obtained after this reaction is known as oleum.

The oleum obtained is then dissolved in water to obtain concentrated sulphuric

acid.

 H2SO4 + SO3(g) → H2S2O7(l)(ADSORPTION)

 H2S2O7(l) + H2O(l) → 2H2SO4(ADSORPTION)

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 START-UP TAIL GAS SCRUBBING

 Sulfuric acid wet Scrubber systems are a diverse group of air

pollution control devices that can be used to remove gases from

industrial exhaust streams.

 The term scrubber refers to pollution control devices that use liquid to

wash unwanted pollutants from a gas stream.

DIFFERENCE BETWEEN SAP A&B AND SAP C

 In SAP A&B there are 4 beds in a converter arranged from up to down

whereas in SAP C there are 5 beds arranged from down to up.

 In SAP A&B there is one boiler, one diluter, one heater and one pre-

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 heater for both sections.

 In SAP A&B the furnace is a luro burner system whereas in SAP C

the furnace is a gun system.

 In SAP A&B there are two superheaters and two

economisers(economiser-1 & economiser-2) whereas in SAP C there

are three superheaters(superheater-5a, superheater-4b, superheater-1c)

and three economisers(economiser-5a, economiser-3b, economiser-

5c).

USES OF SULPHURIC ACID

 Up to 50 per cent of this liquid manufactured is used in the production

of phosphoric acid which is in turn used to make phosphate fertilizers.

 It is used in the manufacturing of metals such as copper , zinc etc.

 5 per cent of the produced acid is used in the making of fibres.

 In Domestic Environments:

• Used in acidic drain cleaners.

• Due to its strong dehydrating property, it can be used to remove

the tissue paper.

 As a Catalyst:

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 • Used as a catalyst in the manufacturing process of nylon.

• Used in the Manheim process in the manufacturing of HCl.

• Used in petroleum refining.

SAFETY

 Aim to minimize the adverse impact of our products and activities on

the environment, maintain ecological balance and protect the bio-

diversity near our manufacturing facility.

 PPL is subjected to extensive environmental laws and regulations in

India, including regulations relating to prevention and control of water

pollution and air pollution, environmental protection, hazardous waste

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 management and noise pollution, in relation to our manufacturing

facility. These laws and regulations govern the discharge, emission,

storage, handling and disposal.

 Sulphuric acid is very dangerous and will cause severe irritation to the

skin, eyes and mucous membranes. Contact with skin is very painful

and can cause burns, contact with eyes can cause blindness. Proper

protection must be worn by anyone working with the acid. In case of

contact, flushing with plenty of water is very important.

 Fluorosilicic acid is as dangerous as sulphuric acid and similarly in case

of contact with skin and eyes, must be flushed with large amount of

water.

CONCLUSION

 Company’s product portfolio ensures Balanced Fertilisation i.e.

supply of essential plant nutrients such as N (Nitrogen), Phosphorus

(P), Potassium (K), Sulphur (S) and Zinc (Zn) for optimum plant

growth, yield and quality.

 To be efficient and achieve a great result, maintenance and production

must work together and have a common goal to focus their energy in

the same direction. That’s the unique way to produce sulphuric acid
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 with less effort.

 The results take time to appear, but when they appear based on solid

support and rigor, they will sustain for a long time.

 The industrial training at PPL, Paradeep has been a very

good learning experience for me. The knowledge of theoretical

subject is not enough for any engineering student. One has to have

the practical knowledge to remove the gap between the actual and

expected performance.

 Training helped me to know and develop various technical and

communication skills. It also gave me a lot of knowledge about the

process, its equipments and operational phases.

 The training is an important step towards us becoming

successful engineers.

 The most important lesson that I have learned is discipline,

management and co-operation. With the immense cooperation of

thePPL family not only did 1 grasp technical knowledge

regarding all the industrial issues and operations but also filled in

the gap that always existed in real while studying a theoretical

subject with the same being put into practical use.

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  Working in the Fertilizer processing plant really gives me the

honor of being a part of this beautiful family. With this I would

like to thank each and every personal I have interacted in the plant

and who have helped so deep in clearing all the problems that I

faced.

REFERENCE

1. https://www.anekantprakashan.com/sugar-factory/louh purush-sardar-

vallabhbhai-patel-sahkari-shakkar-karkhana maryadit-pandariya-

chhattisgarh/738.

2. http://ww25.lspssk.com/?subid1=20240813-1724-0635-a6a8.

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