Commodity Production Costs Report
Sulfuric Acid Production from Iron Pyrite Gases
Sulfuric Acid Operating Costs & Plant Construction Costs
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.
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 two major sections: (1) Gas cleaning; and (2) Double contact process.
Gas cleaning. Iron pyrite gas containing SO2 is passed through electrostatic precipitators to eliminate particulate matter and dust. The gas is subsequently cooled in heat exchangers to remove excess heat and condense any moisture. Following this cooling process, the gas undergoes countercurrent drying with concentrated sulfuric acid. Finally, the dried gas is compressed in a blower before being fed into the downstream SO2 converter.
Double contact process. In the SO2 Converter, the sulfur dioxide is oxidized to sulfur trioxide. This step occurs in four catalyst beds within a single vertical converter. The gases from the second bed leave the reactor and are directed to an Intermediate absorption step downstream in which part of the sulfur trioxide formed reacts with existing water in the recirculating sulfuric acid, forming more sulfuric acid. After this intermediate absorption step, the column off-gas is routed to the third and fourth beds for the last catalytic oxidation stages. The oxidation product is sent to the final absorption step, which is analogous to the intermediate absorption. The concentrated sulfuric acid obtained - the final product (98.5 wt% sulfuric acid) - is discharged from the final absorber circuit.
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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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