Detailed Project Report on sulphuric acid

SULPHURIC ACID
[CODE NO.0386]  


Sulfuric acid is one of the most important compounds made by the chemical industry.  It is used to make, literally, H2SO4, hundreds of compounds needed by almost every industry.

Sulphuric  acid  forms  the basis of so many   of  the  most important heavy chemical used by the industries that it may well be  regarded  as the foundation on which  the main  structure  of the heavy chemical industries . It is hard to find any branch  of economy   in which either sulphuric acid  or products  made  from it are not used . It is universally acknowledged that the  extent of  manufactures  of H2SO4  is a sure index of the state  of  the industrial life of a country.  It would be rather appropriate to say that country's economy depends upon the consumption of the sulphuric acid.

There is hardly any important industry which is not directly or indirectly dependent to some  extent  on  sulphuric acid,  one of its derivatives or it salts. The versatile  use  of sulphuric acid has cripped in to almost all industrial fields and have gained enough popularity after second world war.  The amount consumption and production of sulphuric acid in the country is proportional  to  the  economic growth  of  the  country.   This industry takes the target  there of  industrial market.  It  is obvious  that  although  fertilizer  and  chemical  take  up  the targets proportion of the acid produced and reset to this stands Rayon and steel industry.

The sulphuric acid is the only acid which has thousands of uses in form of acid, salts and derivatives interestingly  enough the  uses  of sulphuric acid  starts with english  alphabets  'a' and ends at 'z' . The 'A' alphabet indicates the use as an  acid, 'B'  indicates use is in battery, 'C'  in  chemical industry  'D' drugs , 'E'  as explosives, 'F' forfeiting, 'G' galvanizing, 'H' as herbicides, I as insecticides, J as joint cleaning , and so on (I  as  leather industry, M as metallurgical  industry O  as  Oil refining etc.,)

The  conception  of  sulphuric  acid  is  lacking  behind   in cooperation  to  western  world.  Inspite  of  versatile  use   and application  the   exact demand of sulphuric acid is  not  properly surfaced.  If the country has to raise the economic condition  then this industry should be manifold.

Sulphuric acid  a strong acid, is an oily, viscous water white non  volatile liquid. It absorbs water from the atmosphere. It is made in large volume by the chemical industry. The acid has a corrosive action on the skin, a drop of it on the skin causes a severe burn. The acid is used as a solvent, a dehydrating agent, a reagent  in  chemical  reactions  or  processes  as  catalyst, an absorbent  etc. The concentrated acid is usually stored  in steel tanks.  The dilute  acid may be stored in lead  lined  or  plastic tanks. It is  used in very dilute concentrations  and  as  strong fuming acid. It is often recovered and refused. After  use in  some phases of the explosives, petroleum and dye industries, it is often recovered  in  a form unsuitable for re-use in  that  industry  but suitable for  use in another industry. It is a  versatile, useful acid has been called the work horse of chemical industry.


COST ESTIMATION

Plant  Capacity                                              :   100.00 MT./day                      
land & Building  (10000 Sq.Mtr)                :    Rs. 7.58  Cr
Plant & Machinery                                         :    Rs. 7.20  Cr
Working Capital for 2 Months                     :    Rs. 3.57  Cr
Total Capital Investment                             :    Rs. 19.17 Cr
Rate of Return                                               :    20%
Break Even Point                                          :    62%


INTRODUCTION    
USES AND APPLICATION    
USES OF SULFURIC ACID.    
APPLICATIONS    
B.I.S. SPECIFICATIONS    
MARKET SURVEY    
INDIA SULPHURIC ACID MARKET TO GROW AT CAGR 3.35% TILL 2025    
THE FOLLOWING PIE CHART SHOWS WORLD CONSUMPTION OF
SULFURIC ACID IN 2017    
DETAILED EXPORT DATA OF SULPHURIC ACID    
DETAILED IMPORT DATA OF SULPHURIC ACID    
MANUFACTURERS/SUPPLIERS OF SULPHURIC ACID    
STAGES IN CONTACT PROCESS TO MANUFACTURE SULPHURIC ACID    31
MANUFACTURING PROCESS    
AIR POLLUTION CONTROL IN SULFURIC ACID PLANT    
PLANT AND EQUIPMENT    
TREATMENT OF BURNER GAS    
PREHEATERS AND COOLERS    
CONVERTER    
PROCESS FLOW DIAGRAM FOR MANUFACTURE OF SULPHURIC ACID    
MATERIALS OF CONSTRUCTION    
HANDLING AND CONTAINERS    
RAW MATERIALS SELECTION    
OCCURRENCE AND SOURCES OF AVAILABILITY    
PROCESS DESCRIPTION    
PROCESS FLOW CHART OF SULPHURIC ACID MANUFACTURE    
PROCESS OF SULPHURIC ACID MANUFACTURE
ELEMENTAL SULFUR    
SULFUR BURNING    
CONVERSION OF SO2 INTO SO3    
ABSORPTION OF SO3    
TAIL GAS SCRUBBER    
PROCESS DESCRIPTION FOR SULFURIC ACID PLANT (BATTERY GRADE)    
AVAILABLE TECHNIQUES    
SOURCES OF SO2    
SULFURIC ACID PRODUCTION    
PRINCIPAL METAL SULFIDES PRODUCING SO2    
STRONGER GAS PROCESSES HAVE    
COMBUSTION OF SULFUR    
PYRITES ROASTING    
METAL SULFIDE ROASTING/SMELTING    
SULFURIC ACID AS A BYPRODUCT FROM COPPER ORE SMELTERS    
SULFURIC ACID AS A BYPRODUCT FROM LEAD PRODUCTION    
REGENERATION OF SULFURIC ACID    
SULFATE ROASTING    
COMBUSTION OF SULFUR-CONTAINING GASES    
TAIL GAS SCRUBBING    
SULFURIC ACID PRODUCTION PROCESSES FOR NEW PLANTS    
DETAILS OF CONTACT PROCESS    
A BRIEF SUMMARY OF THE CONTACT PROCESS    
MAKING THE SULPHUR DIOXIDE    
CONVERTING THE SULPHUR DIOXIDE INTO SULPHUR TRIOXIDE    
CONVERTING THE SULPHUR TRIOXIDE INTO SULPHURIC ACID    
EXPLAINING THE CONDITIONS    
THE PROPORTIONS OF SULPHUR DIOXIDE AND OXYGEN    
THE TEMPERATURE    
EQUILIBRIUM CONSIDERATIONS    
RATE CONSIDERATIONS    
EQUILIBRIUM CONSIDERATIONS    
EQUILIBRIUM CONSIDERATIONS    
TECHNIQUE APPLICABLE TO SULFURIC ACID PRODUCTION    
SINGLE CONTACT PROCESS    
DOUBLE CONTACT PROCESS (DOUBLE ABSORPTION)    
OTHER PROCESSES FOR MANUFACTURE OF SULFURIC ACID    
WET CONTACT PROCESS (WCP)    
PRESSURE PROCESS    
PLANT LAYOUT    
SUPPLIERS OF RAW MATERIALS    
SULPHUR POWDER    
TESTING CHEMICALS    
COMPLETE PLANT SUPPLIERS FOR SULPHURIC ACID ON TURNKEY BASIS    
SUPPLIERS OF PLANT AND MACHINERY    
SCRUBBER    
HEAT EXCHANGER    
COOLING TOWER    
STORAGE VESSEL FOR OLEUM AND SULPHURIC ACID    
MATERIAL HANDLING EQUIPMENTS    
INSTRUMENTATION & PROCESS CONTROL EQUIPMENTS    
LABORATORY EQUIPMENTS    
POLLUTION CONTROL EQUIPMENTS    
BOILERS    
AIR COMPRESSORS    

    
APPENDIX – A:

 1.      COST OF PLANT ECONOMICS      
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET