Sulfuric Acid Production in the Copper Industry—A Review with Future Insights

This chapter delves into the production of sulfuric acid within the copper industry, focusing on two primary methods: sulfur-burning and metallurgical acid plants. It begins by outlining the fundamental processes involved in sulfuric acid manufacturing, including the oxidation of sulfur to sulfur dioxide and the subsequent conversion to sulfur trioxide. The text then compares the two types of acid plants, highlighting their respective process and mechanical limitations. Innovations such as the CORE-SO2 and CORE-S systems are introduced as solutions to overcome these limitations, offering benefits like ultra-low emissions and enhanced production capacity. The chapter also discusses the advantages of continuous converting processes over traditional batch converting methods, emphasizing their impact on equipment size, operating costs, and environmental performance. Additionally, it provides a detailed comparison of metallurgical and sulfur-burning acid plants, underscoring the unique challenges and opportunities associated with each. The conclusion underscores the potential of adopting new technologies to achieve lower emissions, higher production capacities, and more sustainable operations in the copper industry.