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Talking about the replacement of acid-producing tube in the preparation of sulfuric acid
In the production of sulfuric acid within a factory, several hidden risks were introduced during the design and construction of the dry suction stage, which have caused numerous issues in the ongoing operations. One of the main problems lies in the poor quality of the socket joints of the acid pipes in the dry suction tower and the connecting pipes of the circulation tank. The space between the equipment body and the outlet pipe was not properly sealed with acid-resistant glue, leading to acid leakage at these connections just a few months after the system went into operation. Despite multiple repairs using acid-resistant cement, the issue remained unresolved, and both the tower body and the circulation tank suffered varying degrees of corrosion. Acid dripping from the tower also posed a serious risk to the workers at the acid production station, often resulting in system shutdowns.
Another issue was the small diameter of the acid tank in the circulation tank, which was only 150mm. This design flaw became apparent whenever the acid pump failed or there was an electrical outage. In such cases, the acid generation pipe could not drain the acid quickly enough, causing significant overflow from the circulation tank. This not only led to the loss of valuable sulfuric acid but also severely damaged the foundation of the tank and the entire dry suction tower.
The problem was partially resolved by replacing the acid-generating pipe with a larger one (300mm), but this change disrupted the integrity of the ceramic tiles inside the circulation tank, creating new maintenance challenges.
Additionally, the dry acid absorption process relied on cast iron pipe coolers for cooling. However, during installation, the pressure test was not conducted on individual tubes as required; instead, a group test was performed after installation. This made it difficult to detect leaks effectively, and the single-tube pressure test's purpose was not fulfilled. After commissioning, the cast iron cooler frequently leaked acid, which significantly affected the continuity of sulfuric acid production. In some cases, leaks were not detected in time, allowing acidic water to enter the circulating cooling water system. As a result, the 377mm return water pipeline corroded rapidly, and the sewage pump and associated pipelines also suffered severe damage.