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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 embedded during the design and construction phases of the dry suction stage, leading to numerous operational challenges down the line. One major issue was the poor quality of the socket connections on both the acid pipe of the dry suction tower and the connecting pipe of the circulation tank. The space between the equipment body and the outlet pipe was not properly sealed with acid-resistant glue, which resulted in acid leakage occurring at these joints less than half a year after the system went into operation.
Despite multiple repairs using acid-resistant cement, the problem remained unresolved, and both the tower body and the circulation tank suffered varying degrees of corrosion. Acid dripping from the tower also caused repeated burns to the operators at the acid production station, often forcing the entire system to shut down for maintenance.
Another critical flaw was the small diameter of the acid tank in the circulation system—only 150mm. This design limitation became problematic whenever the acid pump suddenly stopped or electrical failures occurred. In such cases, the acid generation pipe couldn’t release 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 circulation tank and the entire dry suction tower.
To address this issue, the acid-generating pipe was replaced with a larger 300mm pipe. However, this replacement disrupted the integrity of the ceramic tiles inside the circulation tank, creating new maintenance concerns.
Additionally, the dry acid absorption process relied on cast iron pipe coolers. Before installation, the individual tube pressure tests were not conducted as required; instead, only a group pressure test was performed after installation. This made it difficult to detect leaks, and the single-tube pressure test’s purpose was not fulfilled. Once the system was operational, the cast iron acid cooler frequently leaked, significantly disrupting the continuous production of sulfuric acid.
At times, leaks went undetected for long periods, allowing acidic water to enter the 377mm circulating cooling water return pipeline. As a result, the sewage pump and related pipelines were rapidly corroded, further complicating the maintenance process and increasing operational costs.