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DKL Engineering, Inc.
Handbook of Sulphuric Acid Manufacturing
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Preface
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Instrumentation - Dew Point
June
4, 2006
Introduction Acid Dew Point Air Dew Point Principle of Operation Instruments |
There are two important dew points that are important in the operation of an acid plant. The most important is the acid dew point which has an impact on the life of the process equipment. The second is the dew point of instrument air.
The acid dewpoint is important to know because
excessive acid condensation will lead to increased corrosion of process
equipment. The areas in the plant where this is critical are points in the
process where the gas has been cooled close to or below its dewpoint.
These areas are:
Exit Cold Heat Exchanger to Absorber Tower (Economizers/SO3
Coolers in parallel)
Exit Cold Reheat Exchangers to Absorber Tower (Economizers/SO3
Coolers in parallel)
The dewpoint of the gas is approximately 140°C to 180°C. Knowing the
exact dewpoint of the gas can enable the acid plant to recover the maximum
amount of heat in heat recovery equipment (ie. economizers and boilers) by
cooling the gas closer to its dewpoint temperature.
A dewpoint monitor is sometimes specified for an instrument air system where the
air quality is important for the proper operation of a plant. Instances
where this is important are plant locations where the ambient temperatures are
very low (-40°C/°F). If the instrument air is not dried to the required
dewpoint, water will condense and freeze in instrument air lines resulting in
instrument failures, safety hazards, and possibly a plant shutdown.
Condensed Liquid Film - A probe is inserted into the gas stream and the detector
is gradually cooled by increasing the flow of air to the probe. As the
detector temperature falls, a point is reached where a thin film of acid begins
to condense onto its surface. Two electrodes are fused into the detector
surface, and as the acid condenses, a current begins to flow between them.
The magnitude of the current depends on the thickness of the acid film.
The air flow to the probe is adjusted until a steady current is obtained
indicating that the thickness of the film is constant. At that point the
rate of condensation of acid is equal to the rate of evaporation, and the
temperature at which this occurs is the acid dew point temperature. The
precise temperature is measured by the probe thermocouple which indicates the
temperature of the detector surface.
The following instruments are available for measuring acid dew points.
Manufacturer | Type | Model | Mounting | Remarks |
Land Combustion | Constant current through condensed liquid film | 410 A | 3" 150 lb flange with 1 1/2" swagelok fitting and PTFE compression ring | Instrument Air: 6 CFM
@ 60-100 psi Electrical: < 20 W Accuracy: +/- 4°F (2°C) over full ambient range |
Land Combustion | Constant current through condensed liquid film | 200A | 3" 150 lb flange with 1 1/2" swagelok fitting and PTFE compression ring | Identical to Model 410 A except portable |