Sulfuric acid dewpoint monitoring and moisture leak detection measurement system

Are you involved in the sulfuric acid manufacturing industry and searching for a reliable solution to detect moisture ingress into your process gas? Look no further than Ecosystems Europe!
For years, the industry has been struggling to find a maintenance-free solution for detecting moisture in their sulfuric acid manufacturing process. Moisture can be introduced to the gas during a process upset, and if left undetected, it can lead to corrosion, weak acid vapor, and potentially hazardous situations.

Ecosystems Europe has collaborated with industry experts to develop a commercially available permanently installed sulfuric “acid dew point” monitor that is the solution to this problem. The monitor continuously measures the acid dew point, which is the temperature at which sulfuric acid vapors begin to condense into liquid form. When moisture is present in the process gas, the acid dew point temperature increases, indicating a leak or moisture ingress into the gas stream.

Ecosystems’ innovative solution is the result of decades of frustration in the industry, with previous attempts at acid dew point meter technology failing to meet the industry’s criteria for simplicity and durability. After multiple attempts, Ecosystems and the sulfuric acid industry collaborated to develop a probe that operates “above dew point cycle.” This means that the probe operates in the duct at a temperature higher than the process gas dew point but low enough to detect an increase or step change in the process gas dew point.

The Ecosystems sulfuric “acid dew point” monitor is designed to operate in a standard acid plant process gas condition without maintenance or failures for a year, meeting the industry’s criteria for simplicity and durability. It is permanently installed, providing continuous monitoring and early indication of moisture ingress into the process gas, allowing producers to monitor trends and take necessary action to prevent equipment damage or hazardous situations.

Moisture in the process gas can condense on process equipment surfaces and is generally indicative of several conditions, including drying tower malfunction, contamination in sulfur feed, waste heat boiler tube leaks, economizer tube leaks, superheater tube leaks, and sulfur gun steam jacket leaks. The presence of moisture and weak acid vapor in the gas stream is detrimental to equipment health and can cause extreme corrosion, leading to costly equipment repairs and potential safety hazards.

Moreover, the presence of moisture in the process gas can lead to the formation of hydrogen gas, which can create an explosion hazard. Ecosystems’ sulfuric “acid dew point” monitor provides early indication of moisture ingress, preventing the formation of hydrogen gas and ensuring a safe and efficient process.

Don’t let moisture in your process gas cause equipment damage or potentially hazardous situations. Contact Ecosystems Europe today to learn more about their permanently installed sulfuric “acid dew point” monitor and start monitoring your process gas with confidence.

Breen flow

Many copper and metal smelters face a unique challenge in their production process: the formation of SO3 gas, as an unwanted byproduct of the formation of SO2. The SO3 will form weak sulfuric acid with the water that is present in the gas. SO3 and weak acid are a nuisance and must be removed and treated, which is costly. However, the SO3 can also be necessary to maintain the efficiency of the hot electrostatic precipitator. Therefore, controlling the formation of SO3 is a valuable element of process improvement.

This is where Ecosystems Europe’s acid dew point measurement comes in. By measuring and controlling the sulfuric acid dew point in the smelter off-gases, our technology helps manipulate the sulfation air and minimize weak acid production. This results in significant cost savings for the smelter by reducing the need for costly SO3 removal operations. Our technology provides a direct and critical closed-loop control process that helps optimize process parameters such as air distribution at the burner, concentrate blend and distribution, sulfation air and draft control, ultimately leading to more efficient production and cost savings.

Don’t wait until it’s too late to optimize your production process and minimize costs. Contact us today to learn more about how our innovative technology can benefit your copper or other metal smelting operations. Let Ecosystems Europe help you achieve greater efficiency and profitability in your production process.

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