Process Simulation and Design of Sulfuric Acid Production via Double Contact Process

Shokry, Fathy; Osama, Ahmed; Salama, Ahmed; Reda, Amira; Noshy, Elsayed; Magdy, Maram; Elshafey, Rwan; Bassyouni, Mohamed; Zarraa, R. M.

doi:10.21608/ejchem.2025.362901.11346

Process Simulation and Design of Sulfuric Acid Production via Double Contact Process

Document Type : Original Article

Authors

¹ portfouad - portsaid

² Department of Chemical Engineering, Faculty of Engineering, Port Said University, Port Said 42526, Egypt

³ Department of Chemical Engineering, Port Said University

⁴ Petrochemical Engineering Department, Faculty of Engineering, Pharos University in Alexandria, Alexandria, Egypt.

10.21608/ejchem.2025.362901.11346

Abstract

This study examined the production of 98% sulfuric acid using the double contact process, optimized for environmental sustainability and process efficiency. The methodology involved burning sulfur to generate sulfur dioxide (SO₂), then catalytically oxidizing it into sulfur trioxide (SO₃) using vanadium pentoxide across five fixed-bed reactors. The SO₃ produced was absorbed sequentially to form sulfuric acid with intermediate and final absorption stages ensuring optimal conversion and purity. Process simulations conducted via Aspen Plus V11 focus on mass and energy balances, emphasizing energy recovery from exothermic reactions through waste heat boilers and comprehensive heat exchanger networks. The SO₃ produced was absorbed sequentially, resulting in a final sulfuric acid concentration of 98%, with an intermediate absorption efficiency of 99.5%. Process simulations conducted via Aspen Plus V11 showed a total energy recovery of 7.5 MW through waste heat boilers and heat exchanger networks, contributing to overall energy efficiency This study, highlighted key environmental strategies, including advanced emission controls such as scrubbers and neutralization pits, to effectively address the release of sulfur oxides and other pollutants. Environmental strategies included advanced emission controlled such as NaOH scrubbers, reducing SO₂ emissions to below 200 mg/m³ and mitigating acid mist emissions to less than 10 mgH₂SO₄/Nm³. Results showed that strategic process design and rigorous operational controls were crucial for maximizing production efficiency while minimizing environmental footprint, offering insights into scalable and sustainable industrial chemical production.

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