Dilution of sulphuric acid

Developed over 30 years ago, we have continually pioneered the use of Thermoplastics in many blending, dilution and cooling systems to take advantage of their excellent chemical resistance.

Sulphuric Acid Dilution Systems present an additional challenge with the high exothermic heat of the dilution process. However, by utilising PVDF for the initial mixing phase, Polypropylene for the volume mixing and pumping system and HDPE for our unique internal heat exchangers we can address the corrosion, heat and subsequent cooling challenges with these three Thermoplastic materials and achieve a compact “plug and play” batch dilution design.

The batch dilution process is entirely managed through a PLC control panel to give safe and accurate control of the dilution process by monitoring the solution density and temperature without any manual intervention. If an alarm situation was to occur, the system would initiate a close-down procedure to render the system safe.

The flexibility of the system is important and many different dilution recipes can be pre-programmed to provide a comprehensive range of concentrations.

Standard Sulphuric Acid dilution units are available in a range of models with batch capacities from 1m³ to 5m³.  Larger capacity systems can be designed based on client requirements, providing your perfect Sulphuric Acid Dilution System.

Chem Resist have provided blending vessels up to 130m³ for this application using internally mounted all thermoplastic mixing eductor technology powered by a base mounted centrifugal pump eliminating the need for a large agitator and gearbox.

The blend normally comprises solid Urea prills delivered in one tonne bags and demineralised water presenting a solids handling challenge to the normal aqueous blending process. This is overcome by traditional spiral and bucket conveyor systems, delivering prills to the top of the mixing tank and the mixing eductor technology ensuring dissolution of the prills into the concentrating solution.

A solid-state densitometer records increasing density and manual refractive index measurements confirm compliance of the final solution with ISO 22241. The dissolution is aided by increasing water temperature and this facility can be provided as part of the packaged plant.

A matching storage vessel, pump and pipework allows transfer of the compliant solution and frees the blending vessel to resume production.

The plant is centrally controlled by a Siemens PLC with auto and manual modes of operation. The batch plant can be successfully manned by one operator with fork lift driving skills.

Our package can include full delivery and installation of the equipment and always provides a commissioning engineer who will complete wet and process commissioning and will train operators on-site.

Gary Smith, Sales Director at Chem Resist explains, “Using Chem Resist to manage new turnkey installations gives our customers significant benefits. These projects are often complex; using not only our products and services but local contractors and all to tight timescales. Obviously, we connect all the Chem Resist products and services to create a complete solution for customers but additionally we co-ordinate trade contractors and manage the whole timeline too. We take complete ownership of the project.”

Historically, back in the 1980’s and 90’s installation projects were managed by organisations using their own resources to individually source tanks, pipework, pumps, fume scrubbers and the installation. Today, organisations simply don’t have the resources available to manage complex capital projects with many moving parts, requiring multiple points of contact.

Gary adds, “Working with us will, in the first instance remove the need for any external consultancy, reducing project costs. If required we can also attend or chair HAZOPS as part of the project design phase. We ensure there’s always a consistent communication flow and knowledge transfer between Chem Resist and the customer. We’ll share our technical expertise with customers and guide them through complex chemical processes such as diluting, mixing & neutralising. In our many years’ experience, we’ve probably worked on a similar project, so we can draw on that and help avoid costly pitfalls and delays. Hand-in-hand with the project ownership comes responsibility, so when there are issues and things don’t go to plan, which let’s face it can happen, it’s down to us to sort everything out, which we do.”

Very simple things can give significant savings; by provide a single point of contact we simplify the whole communication process, so we’re always just one call or email away. We add value to projects, helping customers make their own internal processes safer and more efficient, which is to them priceless.

Recent Chem Resist turnkey projects include; fully automated sulphuric acid dilution and storage, caustic storage and transfer, maximising footprint to increase site storage capacity by building tall.

To discuss your next project requirements, please contact us.