Modelling and optimization of the sulphuric acid plant in an industrial smelter

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In the smelting of copper, nickel or other metal ores, sulphur dioxide gas is generated, which, without treatment, can cause serious environmental damages and community health issues. An efficient sulphuric acid plant is vital for smelter operations as it converts harmful sulphur dioxide gas to sulphuric acid, which has extensive applications in the chemical industry. In recent years, Ontario has significantly tightened sulphur dioxide emission requirements and major metallurgical companies are taking all necessary measures to ensure smelter operations satisfy the tightened regulations. With increasingly stringent environmental regulations, a sulphuric acid plant has to be operated such that it reduces the sulphur dioxide gas to the required emission level. Modelling of acid plants in smelters is essential in providing a sound foundation for the needed enhanced process understanding, process control and optimizations. In this project, a sulphuric acid plant at an industrial smelter will be modelled using both fundamental principles and industrial data. Based on the developed model, the impact of smelter operational changes on the acid plant and sulphur dioxide emission will be investigated. This project will generate useful and timely results, as the involved industrial company is currently taking extensive measures to achieve significant reduction in sulphur dioxide emissions.