The sulfuric acid dilution device is a specialized equipment used to mix concentrated sulfuric acid and water in a certain proportion to prepare dilute sulfuric acid with the required concentration. Since the dilution of sulfuric acid is a strongly exothermic reaction and has strong corrosiveness and danger, the design of the device must strictly follow safety regulations. The following is a detailed introduction to the sulfuric acid dilution device:
I. Core Components of the Device
Raw Material Storage Tanks
Concentrated Sulfuric Acid Storage Tank: The material should be corrosion-resistant (such as PP, PVC, stainless steel 316L), and it should be equipped with a level gauge and a temperature sensor.
Dilution Water Storage Tank: Usually made of stainless steel or PE material, and deionized water is required to avoid reactions with impurities.
Metering System
Flowmeter/Metering Pump: Precisely control the ratio of concentrated sulfuric acid and water (such as a mass flowmeter).
Proportioning Control Valve: Automatically control the ratio to ensure the stability of the concentration.
Mixing Reactor
Structural Design: It is preferred to adopt the method of "adding acid to water" (to avoid splashing caused by intense heat release).
Material: Resistant to high temperature and corrosion (such as glass-lined, Hastelloy or fluoroplastic lining).
Mixing System: Mechanical or static mixer to ensure full and uniform mixing.
Cooling System
Jacket Cooling: Control the reaction temperature through circulating cooling water or coolant (usually it is necessary to maintain the temperature below 80°C).
Plate Heat Exchanger: Used to quickly transfer out the heat during large-scale dilution.
Waste Gas Treatment Unit
Acid Mist Absorption Tower: Neutralize the volatilized SO3 acid mist with an alkaline solution (such as NaOH).
Exhaust System: A corrosion-proof fan ensures the safety of the operating environment.
Finished Product Storage Tank
Store the diluted sulfuric acid, and the material should match the target concentration (for example, PP or steel-lined plastic can be used for dilute sulfuric acid).
Automated Control System
PLC/DCS: Integrate temperature, flow rate and level monitoring, and realize automatic alarm and interlock shutdown.
pH/Concentration Monitoring: On-line detection of the concentration of the diluted sulfuric acid.
II. Operation Process
Startup Preparation
Check whether the equipment's sealing performance, cooling system and emergency shower device are normal.
Wear protective equipment (acid-proof clothing, face shield, acid and alkali-resistant gloves).
Dilution Process
First, inject water into the mixer, and then slowly add concentrated sulfuric acid (reverse operation is strictly prohibited!).
Control the temperature through the cooling system and stir until the mixture is uniform.
Detect the concentration on-line and adjust the ratio to meet the standard.
Safe Discharge
The waste gas is discharged up to the standard after being treated in the absorption tower.
Collect the waste liquid in the neutralization tank for treatment.
III. Safety Precautions
Anti-corrosion Design
All components in contact with sulfuric acid should be made of corrosion-resistant materials, and regularly detect the aging condition of the equipment.
Explosion-proof and Leak-proof
Install leakage detection sensors and be equipped with emergency leakage plugging tools.
Install explosion-proof electrical equipment in the device area.
Emergency Measures
Be equipped with an emergency stop button, an eyewash device and a shower device.
Store neutralizing agents (such as lime powder) on site to deal with leaks.
Operation Specifications
Single-person operation is prohibited, and two-person supervision is required.
Direct manual pouring of sulfuric acid during dilution is strictly prohibited.
IV. Application Scenarios
Industrial Field: Battery manufacturing, fertilizer production, metal pickling, wastewater treatment, etc.
Laboratory: For small-scale dilution, an explosion-proof fume hood and a special mixing container should be used.
V. Common Problems and Solutions
Problem 1: The temperature is too high during dilution
→ Increase the cooling efficiency or reduce the speed of adding acid.
Problem 2: Uneven concentration
→ Check the power of the agitator or change to a static mixer.
Problem 3: Acid mist leakage
→ Overhaul the seals and strengthen the waste gas treatment system.
VI. Equipment Selection Suggestions
Small-scale: Select integrated skid-mounted equipment with automatic control functions.
Large-scale: Customized design, integrating a DCS system and high-precision metering modules.
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