Commodity Production Costs Report
Sulfuric Acid Production from H2S Gases
Sulfuric Acid Operating Costs & Plant Construction Costs
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.
Key reference(s): ?
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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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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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 from Spent Acid (Double-Contact Process)
This report presents the economics of spent sulfuric acid regeneration via double-contact double absorption process. The spent acid is first decomposed in a furnace to sulfur dioxide, which is oxidized to sulfur trioxide. Finally, it is fed to the absorption process for producing sulfuric acid. The economic analysis performed is based on a plant constructed in the United States.
Details: 150 kta United States-based plant | Q3 2024 | 107 pages | Issue E | From $799 USD
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Laurolactam from Cyclododecane (Oximation with Hydroxylamine)
This report presents the economics of Laurolactam production from cyclododecane in the United States. Initially, cyclododecane is oxidized to cyclododecanol. Subsequently, the cyclododecanol obtained is dehydrogenated to cyclododecanone. Then, the cyclododecanone is submitted to an oximation reaction with hydroxylamine. Finally, the cyclododecanone oxime produced is converted to laurolactam by Beckmann rearrangement.
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