SECTION 1.0
Process Overview
Double Contact Double Absorption (DCDA) process for manufacturing 98% sulphuric acid from elemental sulphur, with integrated waste heat recovery and steam generation.
1.1 Design Basis & Parameters
| Parameter | Value / Specification |
|---|---|
| Plant Capacity | 3,000 TPD (on 100% basis) to produce 98% acid on 24 hr/day basis |
| Turndown Capability | 60–110% of rated capacity |
| Annual Production | 990,000 MTPA (at 330 operating days) |
| Process Technology | DCDA (Double Contact Double Absorption) |
| Converter Configuration | 3+2 (3 beds → IAT → 2 beds → FAT) |
| SO₂ Conversion Efficiency | > 99.92% (enhanced with additional catalyst layer) |
| Sulphur Feed | Bright Yellow Elemental Sulphur (99.5% min purity) |
| Sulphur Melting Capacity | ~1,020 TPD (Ash content in output < 50 ppm) |
| HP Steam Generation | 65 bar(g), 480°C (superheated) |
| LP Steam (from HRS) | 4.5 bar(g), saturated — exported to process users |
| Power Generation (via TG) | ~30 MW (from HP steam through extraction-cum-condensing turbine) |
| Cooling Water | Supply 35°C, Return 42°C (~6,898 m³/hr) |
| Stack Emission (SO₂) | < 0.5 kg/ton H₂SO₄ |
| Acid Mist Emission | < 30 mg/Nm³ |
| Design Life | 25 years |
Note: All data provided in these PFDs is preliminary. To be confirmed based on detail engineering.
1.2 Site & Meteorological Data
| Parameter | Value |
|---|---|
| Location | Paradeep, Odisha (20°16'N, 86°37'E) |
| Seismic Zone | Zone III (IS 1893) |
| Basic Wind Speed | 50 m/s (IS 875 Part 3) |
| Max. Temperature | 45°C (design), 48°C (extreme) |
| Min. Temperature | 10°C |
| Relative Humidity | 70–95% (coastal, high corrosion zone) |
| Annual Rainfall | ~1,500 mm |
| Soil Bearing Capacity | 5–8 T/m² (piling required) |
| Flood Level | +5.5 m above MSL |
| Ambient Noise Level | < 85 dB(A) at plant boundary |
Source: SAP-C Design Basis, IS Codes, and site-specific geotechnical survey data.
1.3 Process Flow — Step by Step
Sulphur Melting & Filtration
Operating Temperature: 135–145°C
Solid bright yellow sulphur is conveyed from storage to a steam-heated melter at 135–145°C. The molten sulphur passes through Leaf Filters and Polishing Filters to remove ash and impurities (output ash < 50 ppm), then stored in a heated Molten Sulphur Tank before being pumped to the furnace.
Materials of Construction
CS with steam coils, SS 304 filter elements
Key Equipment
- Sulphur Conveying Equipment (Belt Conveyor)
- Sulphur Melter
- Leaf Filter
- Polishing Filter
- Molten Sulphur Tank
- Sulphur Feed Pumps
1.4 Process Flow Diagrams (7 Sheets)
Drawing No. I-2551FDOK-18-PFD-03-001 through 008 | Client: Paradeep Phosphates Limited | Contractor: Simon India Limited
1.5 3D Plant Model Views
Sulphur Melting & Furnace Section
Converter & WHB Section
Absorption Towers & Stack