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Sulphuric Acid on the WebTM Technical Manual DKL Engineering, Inc.

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Sulphuric Acid on the Web

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Contact Section - Stacks - Troubleshooting
January 18, 2003

Introduction
Moisture in SO2 Gas or Air
        Poor drying
        Moist air leakage
        Poor acid distribution
        Insufficient acid circulation
        Channelling in tower
        Splash or spray from distributor
        Failure or plugging of entrainment separators
        Flooding of tower
Mist Formed at Absorber Inlet
        Cooling in SO3 cooler or economizer too great, too fast or localized
Absorber Tower Operating Conditions
        Acid temperature too high or too low
        Acid strength too high or too low
        Insufficient acid flow
Oleum Tower Operation
        Mixing of hot bypass gas and cold exit gas
Sulphur Burning Plants
       Steam or water leaks
        Oxides of nitrogen in gas
        Sulphur quality
Metallurgical Plants

        Mist leaving ESP's
        Niter in the gas

Introduction

The appearance of an acid plant stack is an indication to the general public of how well a plant is being operated.  The expectation is that the stack should be clear without any visible emissions.  Anything being emitted from a stack automatically, rightly or wrongly, gives the perception that a pollutant is being emitted to the environment.

Therefore, the appearance of the acid plant stack is one of the key factors in maintaining good public relations.  The following is a general guide to troubleshooting stack problems.  As you can see, the cause of a poor stack may be some problem in the operation of the plant well upstream in the process.

Moisture in SO2 Gas or Air

Poor drying

Moist air leakage

Poor acid distribution

Insufficient acid circulation

Channelling in tower

Splash or spray from distributor

Failure or plugging of entrainment separators

Flooding of tower

Mist Formed at Absorber Inlet

Cooling in SO3 cooler or economizer too great, too fast or localized

Absorber Tower Operating Conditions

Acid temperature too high or too low

Acid strength too high or too low

Insufficient acid flow

Packing settled

Oleum Tower Operation

Mixing of hot bypass gas and cold exit gas

Sulphur Burning Plants

Steam or water leaks

Oxides of nitrogen in gas

Sulphur quality

Metallurgical Plants

Mist leaving ESP's

Niter in the gas