Sulfuric Acid Production from H2S Gases
Sulfuric Acid Production Costs Report | Issue D | Q2 2024
Report Details |
180 kta United States-based plant | Q2 2024 | 107 pages |
This report presents a cost analysis of a 180 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 recovering hydrogen sulfide gases to generate sulfuric acid in the United States. In this process hydrogen sulfide is initially burned, forming sulfur dioxide and water. The sulfur dioxide is then converted to sulfur trioxide, The sulfur trioxide reacts with the water previously generated and yields sulfuric acid.
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 Schematic
The process under analysis comprises three major sections: (1) Reaction; (2) Electricity Generation; and (3) Off-gas treatment.
Reaction. The reaction occurs in three major steps: Initially, the hydrogen sulfide gas is incinerated in a burner, yielding sulfur dioxide (SO2) and water. Since it is necessary to remove oxides of nitrogen (NOx) in order to comply with environmental requirements, the sulfur dioxide-rich stream is fed to Selective Catalytic Reduction (SCR) reactor, in which NOx content reacts with ammonia to generate nitrogen and water. The NOx free sulfur dioxide gas is oxidized to sulfur trioxide (SO3) in the presence of a sulfuric acid catalyst. While this reaction is exothermic, there is intermediate cooling between stages, in order to favor the SO2/SO3 equilibrium. The effluent from the converter is cooled to a temperature that allows the reaction of sulfur trioxide with water, yielding Sulfuric Acid. The acid is condensed and concentrated by countercurrent contact with hot off-gas.
Electricity Generation. In this section, high-pressure steam generated throughout the reaction is transformed into low-pressure steam in a back-pressure turbine driving a generator, for electricity generation.
Off-gas treatment. Off-gas from sulfuric acid condensation upstream is passed through a scrubber, where residual sulfur dioxide is removed by a caustic wash. The cleaned gas is sent to atmosphere while weak acid solution is recovered.
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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
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Details: 100 kta United States-based plant | Q2 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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