Smelter acid

Owing to the cycHc nature of the TBRC operation, waste heat recovery from the off-gases is not practical and the SO2 content of the gas varies with the converter cycle. In order to supply a relatively uniform flow and strength SO2 gas to a sulfuric acid plant, a system has been installed at RonnskAr whereby the SO2 from fluctuating smelter gases is partially absorbed in water. During smelter gas intermption, SO2 is stripped with air and the concentrated gas deflvered to the acid plant. 

Sulfuric acid is the most important sulfur-containing intermediate product. More than 85% of the sulfur consumed in the world is either converted to sulfuric acid or produced direcdy as such (see Sulfuric acid and sulfur trioxide). Worldwide, well over half of the sulfuric acid is used in the manufacture of phosphatic fertilizers and ammonium sulfate for fertilizers. The sulfur source may be voluntary elemental, such as from the Frasch process recovered elemental from natural gas or petroleum or sulfur dioxide from smelter operations. 

Paper Products. Paper (qv) products account for about 2% of sulfur demand. The largest single segment of demand is in the manufacture of wood pulp by the sulfite process (see Pulp). In this process, the main sulfur intermediate is sulfur dioxide, which is generally produced at the plant site by burning elemental sulfur. Some sulfur dioxide, however, is produced as a by-product at smelter operations, purified andUquefied, and shipped to the pulp mills. The sulfur dioxide is converted to sulfurous acid, and the salt of this acid is a principal component of the cooking Hquor for the sulfite process. 

Nonferrous Metal Production. Nonferrous metal production, which includes the leaching of copper and uranium ores with sulfuric acid, accounts for about 6% of U.S. sulfur consumption and probably about the same in other developed countries. In the case of copper, sulfuric acid is used for the extraction of the metal from deposits, mine dumps, and wastes, in which the copper contents are too low to justify concentration by conventional flotation techniques or the recovery of copper from ores containing copper carbonate and siUcate minerals that caimot be readily treated by flotation (qv) processes. The sulfuric acid required for copper leaching is usually the by-product acid produced by copper smelters (see Metallurgy, extractive Minerals RECOVERY AND PROCESSING). 

Sulfuric acid is the most commonly used reagent for the recovery of uranium from ores, and vanadium is often recovered as a coproduct. The sulfuric acid used is either the by-product sulfuric acid produced at smelters or sulfuric acid produced from elemental sulfur. 

Double-Absorption Plants. In the United States, newer sulfuric acid plants ate requited to limit SO2 stack emissions to 2 kg of SO2 per metric ton of 100% acid produced (4 Ib /short ton Ib = pounds mass). This is equivalent to a sulfur dioxide conversion efficiency of 99.7%. Acid plants used as pollution control devices, for example those associated with smelters, have different regulations. This high conversion efficiency is not economically achievable by single absorption plants using available catalysts, but it can be attained in double absorption plants when the catalyst is not seriously degraded. 

The cost and price of sulfuric acid depend in large part on raw material cost and on freight costs. In many areas, the deUvered cost of sulfur is the most important factor affecting sulfuric acid pricing. By-product raw material, ie, SO2, costs at smelters are essentially zero, but the remote locations of many smelters make freight costs significant. Nevertheless, the nondiscretionary nature of smelter acid means that it must be sold if the smelter is to operate. 

Metallurgical (smelter) plants and spent acid decomposition plants usually produce acid of good (low) color because the SO2 feed gases ate extensively purified prior to use. In some cases, however, and particularly at lead smelters, sufficient amounts of organic flotation agents are volatilized from sulfide ores to form brown or black acid. Such acid can be used in many applications, particularly for fertilizer production, without significant problems arising. 

In a fire-assay method used at the smelters, a weighed quantity of concentrate is mixed with sodium cyanide in a clay or porcelain cmcible and heated in a muffle furnace at red heat for 20—25 min. The tin oxide is reduced to metal, which is cleaned and weighed. Preliminary digestion of the concentrate with hydrochloric and nitric acids to remove impurities normally precedes the sodium cyanide fusion. 

Sulfur Dioxide, Spray Towers Flue gases and offgases from sulfuric acid plants contain less than 0.5 percent SO9 smelter gases like those from ore processing plants may contain 8 percent. The high-concentration streams are suitable for the manufacture of sulfuric acid. The low concentrations usually are regarded as contaminants to be destroyed or recovered as elemental siilfur by, for example, the Claus process. 

Primary Lead Smelters Primary Aluminum Reduction Plants Phosphate Fertilizer Industry Wet-Process Phosphoric Acid Plants... 

Tall stacks for SO2 dispersion have been used in the past but are no longer acceptable as the sole means of SO2 control. Acid plants have been installed at many smelters to convert the SO2 to sulfuric acid, even though it may not be desirable from an economic standpoint. 

The company manufactures lead-acid batteries at a piant in New Mexico. The company also operates a lead smelter that produces lead ingots at another location in New Mexico and ships them to the battery plant. Lead scrap from the battery plant is returned to the smelter for recovery and reuse. 

Acid deposition has been known to exist since early in the industrial age. The principle pollutants responsible for the elevated levels of acidity are the oxidized forms of sulphur and nitrogen that have been emitted as by-products from non-ferrous smelters, fossil-fueled power generating stations, and motor vehicles. The pollutants are transported substantial distances from the source areas by the atmosphere. They are deposited on receptor regions remote from the sources as acidic rain, snow, and fog or as gasses and dry particulates. 

One such process was developed by the Outokumpu Company in Finland and used in the company s zinc smelter at Kokkola. The gases are scrubbed with concentrated sulfuric acid, whereby mercury is dissolved as mercuric sulfate. After several recycling operations, the mercury concentration reaches saturation level such that crystals of mercuric sulfate form and can be removed. 

With respect to periodic reversal of flow direction, this seems to be competitive for low levels of smelter gas S02, probably under 4 vol%, at ambient temperature. If S02 is too high, thermal runaway can occur. A second, important application is to reduce S02 in the off-gas from a conventional acid plant. Use of flow reversal avoids the problem of reheating the gas leaving the first-stage absorber. 

Primary copper processing results in air emissions, process wastes, and other solid-phase wastes. Particulate matter and sulfur dioxide are the principal air contaminants emitted by primary copper smelters. Copper and iron oxides are the primary constituents of the particulate matter, but other oxides, such as arsenic, antimony, cadmium, lead, mercury, and zinc, may also be present, with metallic sulfates and sulfuric acid mist. Single-stage electrostatic precipitators are widely used in the primary copper industry to control these particulate emissions. Sulfur oxides contained in the off-gases are collected, filtered, and made into sulfuric acid. 

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