Commodity Production Costs Report
Sulfuric Acid from Spent Acid (Wet Gas Sulfuric Acid Process)
Sulfuric Acid Operating Costs & Plant Construction Costs
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.
Key reference(s): ?
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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Professional report based on Q3 2024 economic data, ensuring timely evaluations.
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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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Other Sulfuric Acid Production Cost Reports
Sulfuric Acid from Sulfur (Single-Contact Process)
This report presents the economics of Sulfuric Acid production from sulfur in the United States. In this process, sulfur is burned to form sulfur dioxide, which is then converted to sulfur trioxide. This sulfur trioxide is converted to sulfuric acid by absorption with recirculating sulfuric acid solution in water in only one column.
Details: 1480 kta United States-based plant | Q3 2024 | 107 pages | Issue B | From $999 USD
Sulfuric Acid Production from Iron Pyrite Gases
This report presents the economics of sulfuric acid production from iron pyrite gases in the United States. In this process, iron pyrite gas is treated for undesirable compounds removal and then, sulfur dioxide contained in the gas is converted to sulfur trioxide, which passes through double-contact double absorption to generate sulfuric acid.
Details: 300 kta United States-based plant | Q3 2024 | 107 pages | Issue C | From $999 USD
Sulfuric Acid Production from H2S Gases
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.
Details: 180 kta United States-based plant | Q3 2024 | 107 pages | Issue D | From $799 USD
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Aluminum Sulfate Production
This report presents the economics of a typical Aluminum Sulfate production process from bauxite and sulfuric acid in the United States. In this process, prepared bauxite ore is subjected to reaction with sulfuric acid, producing Aluminum Sulfate.
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