Economic Considerations
The manufacture of sulfuric acid has become very competitive all over the world due to the availability of large quantities of by-product sulfuric acid from metallurgical plants based on copper pyrites, zinc pyrites, iron pyrites, etc. Moreover, many cons
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Economic Considerations
9.1
Introduction
The manufacture of sulfuric acid has become very competitive all over the world due to the availability of large quantities of by-product sulfuric acid from metallurgical plants based on copper pyrites, zinc pyrites, iron pyrites, etc. Moreover, many consumers of sulfuric acid have started using waste sulfuric acid available at a much lower price instead of the fresh acid. The spread of sulfuric acid manufacturing plants has made it uneconomical to transport the acid safely over long distances. It has thus become imperative to explore markets for the acid in nearby areas only. In many countries the plants are located inland away from ports where sulfur is not available locally. The long distances from the ports involved in these countries increases the cost of transportation of sulfur to the plant site. It is customary to use tankers having capacities of 40–60 MT to reduce the cost of transportation. However this increases the risk of leakage during transport. Special regulations are imposed by each country in order to safeguard the surrounding environment. The price of crude oil can materially affect the transportation/shipment costs of raw sulfur to the manufacturing plants which, in turn, increases the cost of manufacturing sulfuric acid from solid/molten sulfur compared to by-product acid from ferrous/non-ferrous metallurgical plants based on sulfide ores.
9.2
Options Available to Management for Improving Economic Viability
A sulfuric acid plant generally produces technical grade acid. However, plant management can explore the markets for the following products since they can realise much higher prices and they can be produced by “adding on” certain equipment as outlined below. This will improve the financial profitability of the organization.
N.G. Ashar and K.R. Golwalkar, A Practical Guide to the Manufacture of Sulfuric Acid, Oleums, and Sulfonating Agents, DOI 10.1007/978-3-319-02042-6_9, © Springer International Publishing Switzerland 2013
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9.2.1
9 Economic Considerations
Product Mix
– Technical grade sulfuric acid. – Battery grade/Analytical Reagent grade sulfuric acid: this will need PTFE lined/ glass absorption towers, special PTFE lined pumps, glass heat exchangers, etc. – Electronic grade for manufacture of electronic printed circuit boards. – 23–25% oleum: an additional absorption tower with oleum circulation pump, trombone type or PHE type oleum coolers, dedicated cooling tower, etc. – 65% oleum: in addition to the equipment required for the manufacture of 23–25% oleum, this will need a separate absorption tower, oleum circulation pump, cooling system, etc., and facilities for generation of pure SO3 vapors (by boiling 25% oleum). Certain plants produce 65% oleum by mixing 30% oleum with liquid sulfur trioxide in a controlled manner. – Liquid sulfur trioxide (SO3): needs a specially designed water-cooled condenser, a dedicated cooling tower, storage tanks, etc. – Liquid sulfur dioxide (SO2): conventional processes for manufacture of liquid su
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