Objectives: 7.1 Describe the contact process for the manufacture of sulphuric acid. 7.

7.2 Discuss the industrial importance of compounds of sulphur. 7.3 Assess the impact of sulphuric industry.

Sulphuric acid is produced commercially using the contact process. The raw material needed are source of sulphur dioxide, air, water and a catalyst. The main stages are: Production of sulphur dioxide Oxidation of sulphur dioxide to sulphur trioxide Hydration of the sulphur trioxide to sulphuric acid.

This can be produced by: Burning sulphur in an excess of air S(s)+O2 SO2 (g) Heating sulphide ores like pyrite in an excess air 4FeS2(s)+1102(g) 2Fe2O3(s)+ 8SO2(g)

Decomposing calcium sulphate in the presence of coke

2CaSO4(s)+C(s) 2CaO(s)+CO2(g)+2SO2(g)

A catalyst, ideally vanadium (V) oxide, is needed for this stage in the process. The oxygen is supplied by the addition of excess air to sulphur dioxide and is purified by an electrostatic precipitator.

The purified sulphur dioxide combines with oxygen in the presence of this catalyst to form the anhydride of sulphuric acid, sulphur trioxide.
2SO2(g)+O2(g)

2SO3(g)

H = -196kJ/ mol

This reaction is a reversible and the forward one is exothermic one. It would be ideal, according to Le Chateliers Principle, for the conditions of this process to be low temperature and high pressure.

2SO2(g)+O2(g) 2SO3(g) H = -196kJ/ mol

But at low temperatures the reaction rate would be too slow to be economical. And high pressures would result in the sulphur dioxide to liquefy.

Then, A catalyst is needed, to increase the rate of reaction without affecting the position of the equilibrium. Vanadium oxide is used with a temperature of about 450C to produce a fairly high yield of sulphur trioxide at an acceptable rate.

Since the reaction is exothermic, as it proceeds, the temperature of the surrounding system rises to 600C from 450C. At this temperature, the yield is reduced to approximately 70%. Thus to give a yield of about 98%, the gases are cooled to about 450C between successive layers of catalyst. A closed water circuit, is usually used as the cooling system in which energy is recovered as steam, this reducing the use of external heating. Close to atmospheric pressure is used which gives an approximate yield of 98%, although high pressure gives greater yield of sulphur trioxide in the equilibrium mixture.

A counter flow system is usually done in the industry, where water is sprayed downward over the upward flowing gas. However, because this will produce uncontrollable, toxic, hard to condense clouds of sulphuric acid, this method cannot be used. Concentrated sulphuric acid destroys skin and flesh and can cause blindness if eye is contacted.

INSTEAD, the sulphur trioxide is first dissolved in concentrated sulphuric acid to form oleum. H2SO4 (l)+ SO3 (g) H2S2O7 (l) Then is diluted with water to produce, concentrated sulphuric acid. H2S2O7 (l) + H2O (l) 2H2SO4 (l)

Uses of Sulphur: to produce sulphur dioxide to make

sulphuric acid

rubber to improve its elasticity and tensile strength

( its makes the rubber less sticky and less soluble in organic solvents)

used in the vulcanization of natural

used as fungicide and as a fumigant

Uses of Sulphur dioxide (a reducing agent): used for bleaching wool, straw and paper and as an antioxidant in food preservation. Uses of Sulphuric Acid: used in the manufacture of: fertilizers detergents car batteries high strength fibres paints pigments - petroleum refining and metallurgy

Advantages of The Contact Process: Sulphuric acid production reduces the amount of sulphur dioxide emited into the atmosphere. Emission of sulphur dioxide from the Contact Process is minimized by recycling unreacted sulphur dioxide. In addition, scrubbing tail gas with a basic solution. Recycling and regenerating Sulphuric Acid is another positive impact on the industry.

Also spent catalyst from the Contact process is either disposed in a suitably licensed landfill site or its vanadium content is recovered and recycled. Heat energy is also recycled, when heat evolved from the process is used to turn water into steam, which is in turn used to generate electricity. The environment is protected, as no Carbon dioxide is formed because fossil fuel is not used.

During production, handling and storage of sulphuric acid, there is always a risk of accidental leaks which may have a negative impact on the environment. Thus precautions and safety measures must be implemented to reduce these risk possibilities.