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The SO2 to SO3 conversion process in a sulphation or sulphonation plant is a critical stage in producing surfactants (like LABSA, SLES) and sulphuric acid. It involves the catalytic oxidation of sulfur dioxide (
) into sulfur trioxide (
) using a vanadium catalyst, typically as part of a contact process.
1. Sulfur Burning and Gas Generation
- Process: Liquid sulfur is burned with dry, dehumidified air (dew point up to -60°C) in a sulfur burner.
- Output: This generates a hot gas stream containing and oxygen ().
- Control: A mass flow meter and variable frequency drive (VFD) are used for precise sulfur measurement to ensure stable concentration.
2. Catalytic Conversion (
to
)
- Mechanism: The gas passes through a converter packed with a catalyst, usually vanadium pentoxide (), where it is oxidized to.
- Reaction: (Exothermic reaction).
- Temperature Control: The conversion occurs in multiple stages, typically at temperatures ranging between 400°C and 600°C. The converter has multiple catalyst beds with intermediate cooling (heat exchange) to keep the temperature optimal and shift the equilibrium toward production.
- Efficiency: Modern plants often use a double-contact process (intermediate absorption) to achieve conversion rates exceeding 99%.
3. Cooling and Gas Conditioning
- Cooling: Following the converter, the hot gas is cooled down in ancooler.
- Equipment: Specialized coolers (e.g., tube-type) are used, which may adopt a floating type design to avoid corrosion from high temperatures.
- Waste Heat Recovery: The heat removed in this stage is frequently used to produce steam or hot water for other units (e.g., sulfur melting, air drying).
4. Sulphonation/Sulphation Unit
- Application: The cooled gas is then fed directly into a sulphonation or sulphation reactor (e.g., falling film reactor) to react with organic feedstocks.
Features of Modern Conversion Plants
- Self-Sufficient Heat Management: Many modern plants, such as those from WEIXIAN, use waste heat recovery for startup pre-heating, eliminating the need for external steam.
- Anti-Corrosion Design: coolers often use protective insulation at the inlet and special materials to extend the life of equipment, protecting against high-temperature corrosion.
- High-Temperature Catalyst: Modern vanadium catalysts are designed for high efficiency and high-temperature stability.
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Web results
sulphonation plant SO2 SO3 conversion technology
WEIXIAN (Nanjing) Science Technology co., ltd
https://www.njweixian.com › sulphonation-plant-so2-so3...
WEIXIAN (Nanjing) Science Technology co., ltd
https://www.njweixian.com › sulphonation-plant-so2-so3...
Liquid sulfur goes to the sulfur burner by precise measurement and fully combusts with dry air to generate SO₂; after cooling, SO₂ gas goes to the converter ...Read more
Sulphonation Process-Unit 01 Sulfur Burning and SO₂/SO₃ ...
YouTube · WEIXIAN NANJING SCIENCE TECHNOLOGY CO.,LTD
1.8K+ views · 2 years ago
YouTube · WEIXIAN NANJING SCIENCE TECHNOLOGY CO.,LTD
1.8K+ views · 2 years ago
Features: SO₂ cooler adopts inlet end insulation protection and floating type design, which avoids intergranular corrosion of stainless ...
Sulfonation and Sulfation Processes
Chemithon Enterprises
https://www.chemithon.com › Technical_papers
Chemithon Enterprises
https://www.chemithon.com › Technical_papers
PDF
In the sulfonation process, the liquid SO3 is metered from the storage tank into a steam heated vaporizer where it is evaporated and mixed into the dried air ...Read more
36 pages
US1716498A - Process for conversion of so2 to so3
Google Patents
https://patents.google.com › patent
Google Patents
https://patents.google.com › patent
the basist'or calculations will be the volume and the percentage strength of sulfur dioxide -gas which must be handled per unit of time to give the tonnage of ...Read more
The Double Contact Process For Sulfuric Acid Production
Taylor & Francis Online
https://www.tandfonline.com › doi › pdf
Taylor & Francis Online
https://www.tandfonline.com › doi › pdf
by W Moeller1968Cited by 44 — In the usual contact plants 97-98% of the SO2 is oxidized to SO3 while the remaining 2 - 3 % nonoxidized SO2 are emitted. The stack gas generally contains ...Read more
Sulphonation and Sulfuric Acid Combined Manufacturing ...
LinkedIn · WEIXIAN NANJING SCIENCE TECHNOLOGY CO., LTD
30+ reactions · 2 years ago
LinkedIn · WEIXIAN NANJING SCIENCE TECHNOLOGY CO., LTD
30+ reactions · 2 years ago
After combustion, SO2 is converted once through a conversion tower to produce SO3 gas. Afterwards, SO3 is absorbed by 98% sulfuric acid in ...Read more
Easily Understanding the SO2 to SO3 Equilibrium Curve in ...
Gsatto
https://gsatto.com › mastering-the-contact-process
Gsatto
https://gsatto.com › mastering-the-contact-process
Nov 25, 2025 — The entire process hinges on respecting the limitations set by the SO2 to SO3 Equilibrium Curve. By breaking the conversion into discrete, ...Read more
Pilot plant performance of a SO2 to SO3 oxidation catalyst ...
ScienceDirect.com
https://www.sciencedirect.com › article › abs › pii
ScienceDirect.com
https://www.sciencedirect.com › article › abs › pii
by E Alvarez2000Cited by 28 — The catalyst reached a SO2 to SO3 conversion of 60 vol.% after 200 h in operation at the pilot plant. When this catalyst is further treated for another 100 h at ...Read more
Optimal Design of Catalytic Conversion of SO2 to SO3 via ...
Avestia
https://jmids.avestia.com › PDF
Avestia
https://jmids.avestia.com › PDF
PDF
by F Agin2025Cited by 2 — Abstract - This study explores the use of machine learning and multi-objective optimization to improve the catalytic conversion.Read more
22 pages
SO2-to-SO3 Conversion in Smelting | PDF | Sulfur Dioxide
Scribd
https://www.scribd.com › document › Catalytic-Role-of...
Scribd
https://www.scribd.com › document › Catalytic-Role-of...
This technical article examines the catalytic role of process dust in converting SO2 to SO3 in flash smelting heat recovery boilers.Read more