Dynamic modelling and simulation of a sulphuric acid plant in an industrial copper-nickel smelter

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With increasingly strict regulatory requirements, the operation of a sulphuric acid plant is vital for stable smelter performance. Despite its importance, very few examples on modelling the process can be found in the literature. This project proposes to develop a detailed transient model of a sulphuric acid plant with linkages to smelter operations. The model will help to predict process behaviour and explore strategies for operational improvements as well as reducing the impact of process disturbances on the acid plant. The model will be developed based on fundamental principles in combination with industrial operating data. Simulations will be carried out to emulate existing scenarios of industrial relevance in order to calibrate the model. Additional simulations will then be used to define optimal response strategies to process upsets. It is envisioned that this model could be developed into a training simmulator for future acid plant operators.