Packaged plant to dilute Sulphuric Acid
Across many industries using Sulphuric Acid, significant cost savings can be made by purchasing and transporting it in its most concentrated form and diluting locally it on-site. Sulphuric Acid however, has a great affinity for water and so the dilution process has a high exothermic heat of dilution – releasing large quantities of heat energy. This heat energy can result in the boiling of the mixture if the process is not carefully controlled.
Regardless of the proportions of the feedstocks and the final concentration, the mixture will always pass through the maximum exotherm (in excess of 145°C) at some point in the process.
Traditionally, due to the corrosive nature of Sulphuric Acid and the high process temperatures, acid dilution plants are made up of indifferent materials each with different expansion and contraction rates which ultimately lead to leaks and external corrosion issues. Typically, mixing and cooling plant use resin filled graphite, carbon, or glass for contact surfaces; these relatively fragile and expensive materials can often suffer from severe thermal shock due to the thermal cycling, leading to high maintenance costs and significant plant downtime.
Initiated more than 25 years ago we have continually pioneered the use of Thermoplastics in many blending, dilution and cooling systems taking advantage of their excellent chemical resistance.
Sulphuric Acid Dilution Systems present an additional challenge with the high exothermic heat of the dilution process. However, by utilising PVDF for the initial mixing phase, Polypropylene for the volume mixing and pumping system and HDPE for our unique internal heat exchangers we can address the corrosion, heat and subsequent cooling challenges with these three Thermoplastic materials and achieve a compact “plug and play” batch dilution design.
The batch dilution process is entirely managed through a PLC control panel to give safe and accurate control of the dilution process by monitoring the density and temperature of the solution without any manual intervention. If an alarm situation was to occur the system would initiate a close-down procedure to render the system safe.
Flexibility of the system is important and many different dilution recipes can be pre-programmed to provide a comprehensive range of concentrations.
Standard Sulphuric Acid dilution units are available in a range of models with batch capacities from 1m³ to 5m3. Larger capacity systems can be designed based on client requirements