Sulfuric Acid from Spent Acid (Wet Gas Sulfuric Acid Process)
Sulfuric Acid Production Costs Report | Issue F | Q4 2024
| Report Details |
| 150 kta United States-based plant | Q4 2024 | 107 pages |
This report presents a cost analysis of a 150 kta (kilo metric ton per annum) United States-based plant. You can add a customized cost analysis, assuming another location (country), when ordering a premium edition of this report.
Report Abstract
This report presents the economics of spent sulfuric acid regeneration via wet sulfuric acid (WSA) process in the United States. In this process, spent acid is decomposed to form sulfur dioxide and water. The sulfur dioxide is oxidized to sulfur trioxide, which is then regenerated to sulfuric acid by vapor-phase reaction with water.
The report provides a comprehensive study of Sulfuric Acid production and related Sulfuric Acid production cost, covering three key aspects: a complete description of the Sulfuric Acid production process examined; an in-depth analysis of the related Sulfuric Acid plant capital cost (Capex); and an evaluation of the respective Sulfuric Acid plant operating costs (Opex).
The Sulfuric Acid production process description includes a block flow diagram (BFD), an overview of the industrial site installations, detailing both the process unit and the necessary infrastructure, process consumption figures and comprehensive process flow diagrams (PFD). The Sulfuric Acid plant capital cost analysis breaks down the Capex by plant cost (i.e., ISBL, OSBL and Contingency); owner's cost; working capital; and costs incurred during industrial plant commissioning and start-up. The Sulfuric Acid plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.
Process Overview
Product
Sulfuric Acid. Sulfuric acid is one of the most widely used industrial chemicals, serving as a key component in fertilizer production, mineral processing, and chemical manufacturing. It is also used in the refining of petroleum and metal ores. Sulfuric acid is produced via the contact process, where sulfur dioxide is oxidized and absorbed in water. It is stored as a liquid and is crucial for processes like phosphate fertilizer production and in lead-acid batteries.
Raw Material
Spent Sulfuric Acid. Sulfuric acid has a number of large-scale essential uses in the manufacture of other chemicals. Usually, it is employed as catalyst and, despite not being consumed in these processes, it is contaminated with impurities and becomes less effective over time. Therefore, the processes that employ sulfuric acid as catalyst require that the spent acid is replaced by strong sulfuric acid. The spent acid removed from this kind of processes is the feed for the spent acid recovery processes.
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Production Process Information
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Production Process Information
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Production Costs Datasheet
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Operating Cost Details
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Production Process Information
Process Consumptions
Labor Requirements
Plant Capital Cost Summary
Operating Cost Summary
Production Costs Datasheet
Plant Capital Cost Details
Operating Cost Details
Plant Cost Breakdowns
Plant Capacity Assessment
Process Flow Diagrams
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the Sulfuric Acid production plant examined
Plant Capital Cost Details
Detailing of fixed capital (ISBL, OSBL & Owner’s Cost), working capital and additional capital requirements
Plant Cost Breakdowns
Breakdown of Sulfuric Acid process unit (ISBL) costs and infrastructure (OSBL) costs; plant cost breakdown per discipline
Operating Costs Summary
Summary presenting the operating variable costs and the total operating cost of the Sulfuric Acid production plant studied
Operating Cost Details
Detailing of utilities costs, operating fixed costs and depreciation
Plant Capacity Assessment
Comparative analysis of capital investment and operating costs for different Sulfuric Acid plant capacities
Production Process Information
Block Flow Diagram, descriptions of process unit (ISBL) and site infrastructure (OSBL)
Process Consumptions
Raw materials and utilities consumption figures, by-products credits, labor requirements
Process Diagrams
Process flow diagrams (PFD), equipment list and industrial site configuration
Other Sulfuric Acid Production Cost Reports
Sulfuric Acid from Spent Acid (Double-Contact Process)
This report presents the economics of spent sulfuric acid regeneration via double-contact double absorption process. The spent acid is first decomposed in a furnace to sulfur dioxide, which is oxidized to sulfur trioxide. Finally, it is fed to the absorption process for producing sulfuric acid. The economic analysis performed is based on a plant constructed in the United States.
Details: 150 kta United States-based plant | Q4 2024 | 107 pages | Issue E From $799 USD
The cost analyses presented in this report target a 150 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.
Sulfuric Acid Production from Tail Gas
This report presents the economics of employing hydrogen peroxide abatement to generate Sulfuric Acid from tail gas in the United States. In this process, hydrogen peroxide is used to oxidize sulfur dioxide to sulfuric acid.
Details: 100 kta United States-based plant | Q4 2024 | 107 pages | Issue G From $999 USD
The cost analyses presented in this report target a 100 kta (kilo metric ton per annum per annum) United States-based plant. For those interested in cost analyses considering other plant capacities and/or locations, Intratec offers a customized analysis as an optional feature.
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