INDUSTRIAL TRAINING

SULFURIC ACID –IV PLANT

GSFC LTD
Industrial Mentor:
Mr. Siddarth S Patel & SA-IV Team
Faculty Mentor:
Mr. A Srikrishnan

Submitted by:
1) Thakar Krunalbhai Rajeshbhai
15BE01050
2) Mastan Mehtab Faruk
15BE01D070
3) Dalwadi Ishita Miteshkumar
15BE01D064

(Chemical Engineering Department)

School of Technology, GSFC University
Vadodara
 INTRODUCTION
• The plant is designed to produce 98.5% Sulphuric Acid
and 29% oleum by latest Double Contact Double
Absorption process know-how from M/s Tim J. Browder
& Company, USA and implementation by M/s Dharamsi
Morarji Chemical Co. Ltd. Bombay on turnkey basis.
• The plant is designed to produce 1350 MTPD 100%
Sulphuric Acid of 98.5% concentration by weight.
• The designed rated capacities in MTPD for two different
alternatives are as under:
Name of product Alternative-l Alternative-Il
Oleum 29% by wt. - 220
Sulphuric Acid 100% by wt. 1350 1130
 Process Description
The process used is Browder's 3 + 2 DCDA (Double Contact
Double Absorption) process with air quench after the 4th
pass of Converter. Sulphur is burned to produce SO2 which
is oxidized to SOs in a five pass Converter containing
Vanadium Pentoxide (V205) catalyst. The SO3 is absorbed
using 98.5% Sulphuric Acid in Acid Absorption Towers to
produce Sulphuric Acid and using Oleum in oleum
Absorption Tower to produce 29% oleum. The five main
sections of the plant process are as under
1. Sulphur circuit
2. Air & Gas Circuit
3. Acid Circuit
4. Oleum Circuit
5. Water and Steam Circuit
PROCESS EQUIPMENT INTERLOCKS

THE MAIN CIRCUIT OF INTERLOCKS

On Tripping of P-301 (Drying Tower Acid Circulating Pump)
OR
P-302 (Interpass Absorption Tower Acid Circulating Pump)
OR
P-304 (Final Absorption Tower Acid Circulating Pump)

CR-501/CR-502 (Main Air Blower/Start up Blower) will tip

Tripping of CR-501/CR-502, Clean Sulphur Pump (P 203) and

Atmospheric Blower (CR-503 A/B) will trip.
 INTERLOCKS AND TRIPPS PROVIDED TO SA-4 PLANT IN
CASE OF EMERGENCY
1. On tripping of P-102 A/B (DM Water Pump). P-302 (IAT Acid Pump) will trip and further CR-
501/502(Main Air Blower or Start up Blower) will trip , Tripping of CR-501/CR-502, Clean
Sulfur Pump (P 203) and Atmospheric Blower (CR-503 A/B) will trip.
2. On very low level of Boiler Steam Drum, CR-501/502(Main Air Blower or Start up Blower)
will trip , Tripping of CR-501/CR-502, Clean Sulfur Pump (P 203) and Atmospheric Blower
(CR-503 A/B) will trip. And Emergency Boiler feed water Pump will start automatically.
3. On tripping of all Cooling Water Pumps (P-107, A/B/C/D /E), all three Acid Circulation
Pumps (P-301, P-302 & P-304), Product Acid Pump (P-305) and Oleum Circulating Pump (P-
401) will trip resulting into other tripping sequence.
4. Low cooling water flow in individual Acid/Oleum Cooler will cause for the tripping of
corresponding Acid or Oleum Circulating Pumps and further tripping sequence.
5. High level of Drain acid pit (D-301) will start Drain Acid Pump automatically preventing
overflow of acid .
6. Low level of Drain Acid Pit (D-301) will stop Drain Acid Pump automatically
7. Low oil pressure will start Auxiliary Oil Pump automatically, (Set pt. 0.8 Kg/cm2) Blower
/Turbine lube oil system
8. In blower lube oil system, very low oil pressure (Set pt. 0.35 Kg/cm2) will trip Ari Blower
automatically resulting into Tripping of Plant.
9. In Start up Furnace and Sulfur Furnace heating system by natural gas, flame failure
detecting device is provided stop natural gas automatically on failure of flame.
10. Also low combustion air, pressure low NG pressure (0.3 kg/cm2)( and high NG Pressure
kg/cm2) will stop the burner automatically.
 ACTIVITES DONE DURING THE
INTERNSHIP
• Visited all the sections of the plants.
• Attempted a physical demo lect on safety
• Introduced to
 latest software like SAP.
 Data Entry
 Log book
 How to take the Observations .
 Emergency Action plan etc.
• Physical activities like Isolation of Valves etc.
 FAILURE CASE LISTING FOR SA - IV
PLANTS
1. Leakage /Rupture of SO2 Yard Pipeline to Caprolactam-I near
Capro-l Warehouse
2. Leakage in 23% oleum Supply Yard Pipeline to Caprolactam-I near
Capro-l warehouse
3. Leakage in 29% oleum Supply Line to CEP near LC-AS Field Cabin
4. 23% Oleum Storage Tank Outlet Line Failure of SA-IV tanks
5. 29% Oleum Storage Tanks Outlet Line Failure of SA- Tanks
6. Fire in Sulfur Go-down/Silo of SA-IV
7. Fire in Sulfur Bin of SA-IV
8. Fire in Sulfur Melting Pit of SA-IV
9. Fire in Sulfur Muck Yard
10.Explosion /Rupture of Sulfur Furnace Shell
11.Chlorine Cylinder Outlet Nozzle Failure of SA-IV
 Fire in Sulfur Melting Pit of SA-IV
(One of the incident occurs in 2017)
Solid Sulfur is usually melted in a brick-lined tank called melting pit, D-202 of 8.8
m length, 6.8 m breadth and 2.35 m height Melting pit is underground of 1350
maximum capacity & operated at atmospheric pressure & 135-140'C temp with
steam coils. To avoid the possibility of an explosive concentration of Sulfur vapor
occurring. the temperature of the liquid Sulfur shall not exceed 154°C. If Sulfur
melting carried out under operating conditions, then liquid Sulfur burns but not
explodes Apart from the fire hazard itself, the Sulfur dioxide gas produced is
highly irritating and toxic in very small amounts.

CAUSE:- one of the labor was removing sulfur sludge of from the
outer surface of pit with the help of iron rod which is metal so due
to friction between rod and sulfur fire cause………
 EMERGENCY ACTIONS
1. Stop Sulfur charging belt.
2. Stop Agitator isolate electric supply from sub-station
3. Open steam blanketing valve to the pit.
4. Check wind direction & approach from windward side wearing
respiratory protection
5. Cordon off the area
6. Evacuate the area. Evacuation warning should be given
immediately to the plants / areas which are likely to be affected
in the downwind / surrounding area. Maximum hazard distance
should be considered for evacuation.
7. All personnel indulged in the fire fighting activity should wear fire
suits and breathing apparatus if required Fire fighting should be
done extinguisher o from fire tender.