Sulfuric Acid
Technology Specialist

Sulfuric Acid — H₂SO₄

World-Class Sulfuric Acid Plant Commissioning, Refractory Curing & Steady-State Operations

1,500–3,000 MTPD
Typical Capacity
4-Pass Converter
Catalyst Beds
> 99.7%
Conversion Rate
1.2 t/t Acid
Steam Generation
Process Flow Technology

Interactive DCDA Process Flow Diagram

Explore the double-contact double-absorption (DCDA) sulfuric acid production loop. Click on any process unit to view key chemical reactions, asset configurations, and Kafaah's engineering audit guidelines.

Sulfuric Acid Production — DCDA Process Flow DiagramInteractive PFD illustrating a modern double-contact double-absorption sulfuric acid plant featuring a sulfur melter, waste heat boiler, 4-pass V₂O₅ converter, interpass tower, and final absorption tower.Air Drying Tower98% H₂SO₄ circulationDry AirSulfur Melter & FilterSolid S → Liquid S (135–145°C)Molten SulfurSulfur Burner (Combustor)S + O₂ → SO₂ | Exothermic (~1000–1100°C)Waste Heat Boiler (WHB)Cooling gas to ~420°C | High-P SteamSO₂ Gas FeedV₂O₅ Converter (Passes I, II, III)Pass I: SO₂ → SO₃ (~60-65% conversion)Pass II & III: Inter-pass cooling recoveryAccumulated Conversion Rate: ~95%Critical Catalyst ZoneRich SO₃ GasInterpass Absorber98% H₂SO₄ counter-currentUnreacted SO₂ LoopV₂O₅ Converter (Pass IV)Final equilibrium conversion to >99.7%Residual SO₃ GasFinal Absorber TowerRemaining SO₃ scrubbedExhaust StackCompliant tail gas ventAcid Cooling & DilutionHeat exchangers + Trim water98.4% H₂SO₄ Storage TanksProduct dispatch & distribution↑ Click any process node above to view technical audit parameters.

Interactive Optimization Advisor

Click on any process block in the diagram to inspect technical configurations, key reactions, and Kafaah's specialized engineering recommendations.

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