How is sulfuric acid prepared in a chemical plant? What are it's dangers and what is it used for?

Answer 1

It's made in contact process:
Sulfuric acid is produced from sulfur, oxygen and water via the contact process.

In the first step, sulfur is burned to produce sulfur dioxide.

(1) S(s) + O2(g) → SO2(g)

This is then oxidised to sulfur trioxide using oxygen in the presence of a vanadium(V) oxide catalyst.

(2) 2 SO2 + O2(g) → 2 SO3(g) (in presence of V2O5)

Finally the sulfur trioxide is treated with water (usually as 97-98% H2SO4 containing 2-3% water) to produce 98-99% sulfuric acid.

(3) SO3(g) + H2O(l) → H2SO4(l)

Note that directly dissolving SO3 in water is impractical due to the highly exothermic nature of the reaction. Mists are formed instead of a liquid. Alternatively, the SO3 is absorbed into H2SO4 to produce oleum (H2S2O7), which is then diluted to form sulfuric acid.

(3) H2SO4(l) + SO3 → H2S2O7(l)

Oleum is reacted with water to form concentrated H2SO4.

(4) H2S2O7(l) + H2O(l) → 2 H2SO4(l)

Uses:

Sulfuric acid is a very important commodity chemical, and indeed a nation's sulfuric acid production is a good indicator of its industrial strength.[3] The major use (60% of total worldwide) for sulfuric acid is in the "wet method" for the production of phosphoric acid, used for manufacture of phosphate fertilizers as well as trisodium phosphate for detergents. In this method phosphate rock is used, and more than 100 million tonnes is processed annually. This raw material is shown below as fluorapatite, though the exact composition may vary. This is treated with 93% sulfuric acid to produce calcium sulfate, hydrogen fluoride (HF) and phosphoric acid. The HF is removed as hydrofluoric acid. The overall process can be represented as:

Ca5F(PO4)3 + 5 H2SO4 + 10 H2O → 5 CaSO4·2 H2O + HF + 3 H3PO4

Sulfuric acid is used in large quantities in iron and steel making principally as pickling-acid used to remove oxidation, rust and scale from rolled sheet and billets prior to sale into the automobile and white-goods business. The used acid is often re-cycled using a Spent Acid Regeneration (SAR) plant. These plants combust the spent acid with natural gas, refinery gas, fuel oil or other suitable fuel source. This combustion process produces gaseous sulfur dioxide (SO2) and sulfur trioxide (SO3) which are then used to manufacture "new" sulfuric acid. These types of plants are common additions to metal smelting plants, oil refineries, and other places where sulfuric acid is consumed on a large scale, as operating a SAR plant is much cheaper than purchasing the commodity on the open market.

Ammonium sulfate, an important nitrogen fertilizer is most commonly produced as a by-product from coking plants supplying the iron and steel making plants, Reacting the ammonia produced in the thermal decomposition of coal with waste sulfuric acid allows the ammonia to be crystalised out as a salt (often brown because of iron contamination) and sold into the agro-chemicals industry.

Another important use for sulfuric acid is for the manufacture of aluminium sulfate, also known as papermaker's alum. This can react with small amounts of soap on paper pulp fibres to give gelatinous aluminium carboxylates, which help to coagulate the pulp fibres into a hard paper surface. It is also used for making aluminium hydroxide, which is used at water treatment plants to filter out impurities, as well as to improve the taste of the water. Aluminium sulfate is made by reacting bauxite with sulfuric acid:

Al2O3 + 3 H2SO4 → Al2(SO4)3 + 3 H2O

Sulfuric acid is used for a variety of other purposes in the chemical industry. For example, it is the usual acid catalyst for the conversion of cyclohexanoneoxime to caprolactam, used for making nylon. It is used for making hydrochloric acid from salt via the Mannheim process. Much H2SO4 is used in petroleum refining, for example as a catalyst for the reaction of isobutane with isobutylene to give isooctane, a compound that raises the octane rating of gasoline (petrol). Sulfuric acid is also important in the manufacture of dyestuffs.

A mixture of sulfuric acid and water is sometimes used as the electrolyte in various types of lead-acid battery where it undergoes a reversible reaction where lead and lead dioxide are converted to lead(II) sulfate. Sulfuric acid is also the principal ingredient in some drain cleaners, used to clear blockages consisting of paper, rags, and other materials not easily dissolved by caustic solutions.

Sulfuric acid is also used as a general dehydrating agent in its concentrated form.

Dangers:
Laboratory hazards

The corrosive properties of sulfuric acid are accentuated by its highly exothermic reaction with water. Hence burns from sulfuric acid are potentially more serious than those of comparable strong acids (e.g. hydrochloric acid), as there is additional tissue damage due to dehydration and particularly due to the heat liberated by the reaction with water, i.e. secondary thermal damage. The danger is obviously greater with more concentrated preparations of sulfuric acid, but it should be remembered that even the normal laboratory "dilute" grade (approx. 1 M, 10%) will char paper by dehydration if left in contact for a sufficient length of time. The standard first aid treatment for acid spills on the skin is, as for other corrosive agents, irrigation with large quantities of water: in the case of sulfuric acid it is important that the acid should be removed before washing, as a further heat burn could result from the exothermic dilution of the acid. Washing should be continued for a sufficient length of time—at least ten to fifteen minutes—in order to cool the tissue surrounding the acid burn and to prevent secondary damage. Contaminated clothing must be removed immediately and the underlying skin washed thoroughly.

Preparation of the diluted acid can also be dangerous due to the heat released in the dilution process. It is essential that the concentrated acid is added to water and not the other way round, to take advantage of the relatively high heat capacity of water. Addition of water to concentrated sulfuric acid leads at best to the dispersal of a sulfuric acid aerosol, at worst to an explosion. Preparation of solutions greater than 6 M (35%) in concentration is the most dangerous, as the heat produced can be sufficient to boil the diluted acid: efficient mechanical stirring and external cooling (e.g. an ice bath) are essential.

[edit] Industrial hazards

Although sulfuric acid is non-flammable, contact with metals in the event of a spillage can lead to the liberation of hydrogen gas. The dispersal of acid aerosols and gaseous sulfur dioxide is an additional hazard of fires involving sulfuric acid. Water should not be used as the extinguishing agent because of the risk of further dispersal of aerosols: carbon dioxide is preferred where possible.

Sulfuric acid is not considered toxic besides its obvious corrosive hazard, and the main occupational risks are skin contact leading to burns (see above) and the inhalation of aerosols. Exposure to aerosols at high concentrations leads to immediate and severe irritation of the eyes, respiratory tract and mucous membranes: this ceases rapidly after exposure, although there is a risk of subsequent pulmonary edema if tissue damage has been more severe. At lower concentrations, the most commonly reported symptom of chronic exposure to sulfuric acid aerosols is erosion of the teeth, found in virtually all studies: indications of possible chronic damage to the respiratory tract are inconclusive as of 1997. In the United States, the permissible exposure limit (PEL) for sulfuric acid is fixed at 1 mg/m3: limits in other countries are similar. Interestingly there have been reports of sulfuric acid ingestion leading to vitamin B12 deficiency with subacute combined degeneration. The spinal cord is most often affected in such cases, but the optic nerves may show demyelination, loss of axons and gliosis.

Answer 2

The formula for sulfuric acid is H2SO4(aq). It could have (aq) as a subscript to instruct that it extremely is, extremely, dihydrogen sulfate in answer (in certainty what sulfuric acid is).

Answer 3

That Potter Boy said it all. He deserves an A for Chemistry.

Answer 4

http://encarta.msn.com/encnet/refpages/search.aspx?q=sulfuric+acid&Submit2=Go