A novel integrated modified sulfur cycle and ammonia production process was suggested for the co-generation of sulfuric acid. Exergy analysis, heat integration, and safety assessment were conducted to investigate the feasibility and analyze the process. The exergy analysis showed that the highest exergy destruction occurred in the section with the most considerable temperature difference involved with a large flow rate. The heat integration - an economic assessment, confirmed that the total cost was estimated to be reduced by 10.9% at the minimum temperature difference of 39 °C. The failure rate contribution to the overall system was 19%, 11%, 22%, and 47% from the Bunsen section, H2SO4 concentration section, HI decomposition section, ammonia production section explosion, fire, and structural damage contributed 82%, 16%, and 2% to the overall system in terms of accident scenario. The accident cost contributed 84% and 16% of accident injury costs to the overall system, respectively. For the sectional based contribution, section 1 (Bunsen process), SA concentration, section 3, and ammonia production process contributed 45%, 29%, 19%, and 6% to the accident injury cost in the overall system, respectively. As a result of individual section failure to the whole section, failure in Bunsen process and HI decomposition led to failure in production of all the products. Failure in NH3 production section led to production in concentrated H2SO4 and H2. The failure in H2SO4 section leads to production in NH3 and diluted H2SO4 concentration. The failure in H2SO4 concentration, NH3 production, and Bunsen process and HI decomposition contributed to the higher failure rate in ascending order.

Polygeneration Sulfuric Acid Ammonia Hydrogen 3ER Analysis

Rosen MA, Energy, 35(2), 1068 (2010)
Kiss AA, Bildea CS, Grievink J, Chem. Eng. J., 158(2), 241 (2010)
Tejeda-Iglesias M, Szuba J, Koniuch R, Ricardez-Sandoval L, Ind. Eng. Chem. Res., 57(24), 8253 (2018)
Grand View Research. Application (Fertilizers, Chemical Manufacturing, Refinery, Textile), and Segment Forecasts, 2018-2025. GRV-2-68038-231-0; 2016.
Grand View Research. Application (Fertilizers, Textile, Pharmaceuticals, Refrigerants), by Region, and Segment Forecasts, 2018-2025. GRV-2-68038-207-5; 2017.
Lee B, Park J, Lee H, Byun M, Yoon CW, Lim H, Renew. Sust. Energ. Rev., 113, 109262 (2019)
King MJ, Davenport WG, Moats MS, Sulfuric Acid Manufacture Analysis, Control, and Optimization. Elsevier (2013).
Kirk O, Encyclopedia of chemical technology, John Wiley & Sons (1984).
Bicer Y, Iharahim D, Calin Z, Greg V, Frank R, J. Clean Prod., 135, 1379 (2016)
Hwangbo S, Lee S, Yoo C, Appl. Energy, 208, 195 (2017)
Orrego D, Sharma S, Oliveira S, Marechal F, J. Clean Prod., 44, 118647 (2020)
Hwangbo S, Lee S, Yoo C, Appl. Energy, 208, 195 (2017)
Zhu L, Li LL, Fan JM, Chem. Eng. Res. Des., 104, 792 (2015)
Mehrpooy M, Habibi R, J. Clean Prod., 275, 12386 (2020)
Norman JH, Besenbruch GE, Brown LC, O'Keefe DR, Allen CL, Report, General Atomics Corp (1982).
Brown LC, et al., Report, General Atomics Corp (2020).
Shin Y, Lee K, Kim Y, Chang J, Cho W, Bae K, Int. J. Hydrog. Energy, 37(21), 16604 (2012)
Kasahara S, Iwatsuki J, Takegami H, Tanaka N, Noguchi H, Kamiji Y, Onuki K, Kubo S, Int. J. Hydrog. Energy, 42(19), 13477 (2017)
Rodriguez DG, Lira CABD, Parra LRG, Hernandez CRG, Valdes RD, Energy, 147, 1165 (2018)
Ping Z, Laijun W, Songzhe C, Jingming X, Renew. Sust. Energ. Rev., 81, 1802 (2018)
Park JK, Nam KJ, Heo SK, Lee JG, Lee IB, Yoo CK, Korean Chem. Eng. Res., 58(2), 235 (2020)
Park J, Lee SY, Lee IB, J. Chem. Eng. Jpn., 52(7), 638 (2019)
Giaconia A, Caputo G, Ceroli A, Diamanti M, Barbossa V, Tarquini P, Sau S, Int. J. Hydrog. Energy, 32, 532 (2007)
Lee BJ, No HC, Yoon HJ, Kim SJ, Kim ES, Int. J. Hydrog. Energy, 33(9), 2200 (2008)
Sapute SR, Park J, Revankar ST, Adv. Chem. Eng. Res., 4, 1 (2015)
Sakurai M, Nakajima H, Onuki K, Shimizu S, Int. J. Hydrog. Energy, 25, 206 (2000)
Murphy JE, O'Connell JP, Int. J. Hydrog. Energy, 37(5), 4002 (2012)
Immanuel V, Shukla A, Int. J. Hydrog. Energy, 37(6), 4829 (2012)
Liberatore R, Lanchi M, Caputo G, Felici C, Giaconia A, Sau S, Tarquini P, Int. J. Hydrog. Energy, 37(11), 8939 (2012)
Park J, Ifaei P, H-Alawi A, Safder U, Yoo C, Int. J. Hydrog. Energy, 45(28), 14578 (2020)
Rong A, Lahdelma R, Renew. Sust. Energ. Rev., 53, 363 (2016)
Ifaei P, Safder U, Yoo CK, Energy Conv. Manag., 197, 111851 (2019)
Crowl DA, Louvar JF, Chemical process safety fundamentals and applications, Prentice Hall, New York (2011).
Ifaei P, Rashidi J, Yoo C, Energy Conv. Manag., 123, 610 (2016)
Dincer I, Rosen MA, Exergy: energy, environment and sustainable development, Newnes (2012).
Kim S, Guo J, Ahn KI, Lee JC, American Nucl. Soc., 117, 951 (2017)
Murphy JE, O'Connell JP, Fluid Phase Equilib., 288(1-2), 99 (2010)
Tripodi A, Compagnoni M, Bahadori E, Rossetti I, J. Ind. Eng. Chem., 66, 176 (2018)
Brown NR, Oh S, Revankar ST, Vierow K, Rodriguez S, Cole R, Gauntt R, Nucl. Technol., 167, 95 (2009)
Rashidi J, Yoo C, Energy, 155, 504 (2018)
Dehghani S, Sayyaadi H, Int. J. Hydrog. Energy, 38(22), 9074 (2013)
Yilmaz F, Selbas R, Energy, 140, 520 (2017)
Smith R, Chemical process design and integration, John Wiley & Sons (2005).
Kim S, Lee JC, Annals of Nuclear Energy, 139, 107248 (2020).
Turton R, Bailie RC, Whiting WB, Shaeiwitz JA, tacharyya DB, Pearson (2013).
Kim YI, National Health Insurance Statistical Year book, NHIS (2018).
SINTEF Industrial Management, Offshore Reliability Data Handbook, Norway (2002).
Athar M, Shariff AM, Buang A, Shaikh MS, Khan MI, Chem. Eng. Technol., 42(3), 524 (2019)
Mannan S, Lees' loss prevention in the process industries: hazard identification, assessment, and control, Elsevier (2012).