OXYSULFsulfuric acid recovery

download OXYSULF flow diagram

The OXYSULF technology is an innovative wet process to produce sulfuric acid from off-gas containing sulfur-bearing compounds. This technology pairs sustainability with guaranteed low emissions.
OXYSULF technology offers total and reliable solutions for a wide range of industrial sectors.

• Refineries and petrochemical industry
• Coal based fertilizer and chemical industry
• Natural gas processing
• Viscose industry
• Power industry
• Cokes manufacturing
• Metallurgical industry (Cu, Mo, Pb, …)

For each client and their application, a specific plant configuration is developed to achieve an optimal solution.
Plant configurations depend on feed composition and impurities.

• Type of sulfur-compounds in the feed (H₂S, CS₂, COS, SO₂, R-SH, spent acid or sulfates …)
• Concentration of sulfur-compounds in feed (low/high)
• Clean or dirty feeds
• Liquid/ gaseous feed
• Emission requirements of local authorities
• Additional sulfur burning for higher H₂SO₄ production
• Additional products are required

The basic reactions in the process are:
S, H₂S, CS₂, R-SH, H₂SO₄ + O₂ ➔ SO₂ + CO₂ + H₂O
SO₂ + O₂ ➔ SO₃

SO₃ + H₂O ➔ H₂SO₄

OXYSULF plants are easily operated and highly automated to minimize operator working time and maximum availability.
OXYSULF plants have a compact design with modular parts which means easy installations and easy integration into existing industrial plants.

• Combustion and waste heat boiler unit
• Reactor: to achieve high overall conversion, special TARDIGRAD catalysts are used (a noble metal-based catalyst for wide temperature range, low pressure drop and high conversion rate).
• Heat recovery system: uses a heat transfer fluid to achieve the maximum efficiency. Due to the exclusive design the excess heat is recovered from the reactor and from the condensation column as the acid cooler to recover it efficiently in the process or externally.
• Condensation unit: the acid condensation column is based on a new KVT proprietary design which ensures reliability, high on-stream time, and low maintenance costs. The column is made of PFA lined stainless steel which ensures the required corrosion resistance.
• Acid Management: to cool and store the acid, a special type of plate heat exchanger and PTFE- lined tubes and components are used.
• Wet electrostatic precipitator removes the sulfuric acid aerosols formed during condensation in the condensation column. The acid mist emission complies with the environment regulations.
• Tail Gas Reactor: specially applied, if very high overall efficiency or very low emissions are required.
• Scrubber units: for special requirement, several scrubber types as feed gas scrubbers to remove impurities or tail gas scrubber as NaOH or H₂O₂ scrubber maybe added to achieve an optimal plant performance.

• Robust, high-quality acid condensation column
• Guaranteed low SO₂ emission and high sulfur oxidation efficiency
• Highly efficient heat recovery system
• Guaranteed low acid mist emission
• Simple automated operation
• Compact, modular construction

Find out more about the right solution for you – OXYSULF SCU/HC/LC/SAR/MET

download OXYSULF HC_LC flow diagram

download OXYSULF HC_LC flow diagram

For high concentration gas feed OXYSULF HC is used. The process is equipped with a combustion chamber for the thermal oxidation of sulfur compounds and for sulfur combustion if a certain quantity of sulfuric acid is required. The heat recovery system is equipped with a proper waste heat boiler to recover the excess heat after the combustion chamber from the reactor and from the condensation column. Thanks to the tail gas treatment the SO₂ emissions can be kept below 200 mg/Nm₃, lower emissions are reachable depending on the individual case.

• Refineries
• Steel industry
• Power industry
• Viscose industry