Sulfuric Acid

H₂SO₄ · 98.08 g/mol

H₂SO₄

Ore processing, synthesis

Molecular Weight

98.08 g/mol

State

Liquid

Catalyst

Vanadium Pentoxide (V₂O₅

Reactor

Multi-bed adiabatic conv

Sulfuric Acid molecular structure — 2D structure

Olefinverbund Integration

Inputs

**Sulfur** (Feedstock), **Oxygen** (Feedstock), **Water** (Feedstock)

→

Product

Sulfuric Acid

→

Outputs

Phosphoric Acid, Ammonium Sulfate, Hydrochloric Acid, Hydrogen Fluoride

Chemistry & Engineering

Reaction	`S + O₂ → SO₂; SO₂ + 0.5O₂ → SO₃; SO₃ + H₂O → H₂SO₄`
Thermodynamics	All steps highly exothermic
Catalyst	Vanadium Pentoxide (V₂O₅) for Contact Process
Reactor class	Multi-bed adiabatic converter with intercooling
Note	Waste heat generates significant high-pressure steam for power.

Applications

Ore processing and metal extraction
Fertilizer production (phosphoric acid, ammonium sulfate)
Battery electrolyte
Chemical synthesis intermediate
Water treatment
Etching and cleaning

Extraterrestrial Production Pattern

Extract sulfur from lunar volcanic deposits or Martian sulfate minerals
Combust sulfur: S + O₂ → SO₂
Catalytic oxidation (V₂O₅ catalyst): 2SO₂ + O₂ → 2SO₃
Absorption in water: SO₃ + H₂O → H₂SO₄
Concentration and storage in closed-loop reactors

Reaction Diagram

S + O2 -> SO2; 2SO2 + O2 -> 2SO3; SO3 + H2O -> H2SO4

Unit Operations

Process steps following chemical engineering unit operation principles

#	Operation	Description
1	Sulfur Melting	Melt solid sulfur at 120-150°C
2	Combustion	Burn sulfur in dry air at 1000°C → SO₂
3	Gas Cleaning	Remove dust and impurities from SO₂ gas
4	Catalytic Oxidation	Convert SO₂ → SO₃ over V₂O₅ catalyst (Contact Process)
5	Absorption	Absorb SO₃ in 98% H₂SO₄ (oleum formation)
6	Dilution	Dilute oleum with water to desired concentration

S88 Batch Control Model

ISA-88 BatchML schema — simplified for educational purposes

<?xml version="1.0" encoding="UTF-8"?>
<!-- ISA-88 Batch Control Model for Sulfuric Acid -->
<!-- Educational schema - simplified for demonstration -->
<BatchML xmlns="http://www.wbf.org/xml/B2MML-V0600">
  
  <ProcessCell ID="SULFURIC_ACID_PLANT_CELL">
    <Description>Process cell for Sulfuric Acid production</Description>
    
    <Unit ID="SULFURIC_ACID_PLANT">
      <Description>Main synthesis unit</Description>
      
      <!-- Equipment Modules -->
      <EquipmentModule ID="MELTER">
        <Description>Melter</Description>
      </EquipmentModule>
      <EquipmentModule ID="BURNER">
        <Description>Burner</Description>
      </EquipmentModule>
      <EquipmentModule ID="SCRUBBER">
        <Description>Scrubber</Description>
      </EquipmentModule>
      <EquipmentModule ID="CONVERTER">
        <Description>Converter</Description>
      </EquipmentModule>
      <EquipmentModule ID="ABSORBER">
        <Description>Absorber</Description>
      </EquipmentModule>
      <EquipmentModule ID="DILUTION_TANK">
        <Description>Dilution Tank</Description>
      </EquipmentModule>
    </Unit>
  </ProcessCell>
  
  <MasterRecipe ID="SULFURIC_ACID_PLANT_RECIPE">
    <Description>Master recipe for Sulfuric Acid</Description>
    <ProductID>SULFURIC_ACID</ProductID>
    
    <UnitProcedure ID="SULFURIC_ACID_PLANT_UP">
      <Description>Unit procedure for synthesis</Description>
      
      <Operation ID="OP_01">
        <Description>Operation 1</Description>
        <Phase ID="MELT">
          <Description>Melt phase</Description>
          <PhaseLogic>
            <Step ID="STEP_1"><Action>Initialize</Action></Step>
            <Step ID="STEP_2"><Action>Execute</Action></Step>
            <Step ID="STEP_3"><Action>Complete</Action></Step>
          </PhaseLogic>
        </Phase>
      </Operation>
      
      <Operation ID="OP_02">
        <Description>Operation 2</Description>
        <Phase ID="COMBUST">
          <Description>Combust phase</Description>
          <PhaseLogic>
            <Step ID="STEP_1"><Action>Initialize</Action></Step>
            <Step ID="STEP_2"><Action>Execute</Action></Step>
            <Step ID="STEP_3"><Action>Complete</Action></Step>
          </PhaseLogic>
        </Phase>
      </Operation>
      
      <Operation ID="OP_03">
        <Description>Operation 3</Description>
        <Phase ID="CLEAN">
          <Description>Clean phase</Description>
          <PhaseLogic>
            <Step ID="STEP_1"><Action>Initialize</Action></Step>
            <Step ID="STEP_2"><Action>Execute</Action></Step>
            <Step ID="STEP_3"><Action>Complete</Action></Step>
          </PhaseLogic>
        </Phase>
      </Operation>
      
      <Operation ID="OP_04">
        <Description>Operation 4</Description>
        <Phase ID="OXIDIZE">
          <Description>Oxidize phase</Description>
          <PhaseLogic>
            <Step ID="STEP_1"><Action>Initialize</Action></Step>
            <Step ID="STEP_2"><Action>Execute</Action></Step>
            <Step ID="STEP_3"><Action>Complete</Action></Step>
          </PhaseLogic>
        </Phase>
      </Operation>
      
      <Operation ID="OP_05">
        <Description>Operation 5</Description>
        <Phase ID="ABSORB">
          <Description>Absorb phase</Description>
          <PhaseLogic>
            <Step ID="STEP_1"><Action>Initialize</Action></Step>
            <Step ID="STEP_2"><Action>Execute</Action></Step>
            <Step ID="STEP_3"><Action>Complete</Action></Step>
          </PhaseLogic>
        </Phase>
      </Operation>
      
      <Operation ID="OP_06">
        <Description>Operation 6</Description>
        <Phase ID="DILUTE">
          <Description>Dilute phase</Description>
          <PhaseLogic>
            <Step ID="STEP_1"><Action>Initialize</Action></Step>
            <Step ID="STEP_2"><Action>Execute</Action></Step>
            <Step ID="STEP_3"><Action>Complete</Action></Step>
          </PhaseLogic>
        </Phase>
      </Operation>
    </UnitProcedure>
  </MasterRecipe>
  
</BatchML>

Process CellPhysical grouping of all production equipment

UnitMajor equipment performing the synthesis

Equipment ModulesIndividual devices: reactors, columns, absorbers

PhasesLowest control level: REACT, SEPARATE, PURIFY

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