Sulfuric acid dilution systems may be referred to as a sulfuric acid in-line-mixing system or an in-line-blending system. These systems dilute 98% or 93% sulfuric acid to lower strengths. Dilution water (city water, RO water, or DI water) is mixed with strong acid to produce any strength lower than the strong acid.
A large amount of heat can be generated during the dilution. Dilution temperatures can be high enough to boil the sulfuric acid. Many manufacturers use very expensive graphite or silicon carbide heat exchangers requiring special piping materials and insulation to protect the workers from very high temperatures.
Powell has a unique design that allows for much lower temperatures and lower-cost materials. Typical product temperatures are in the range of 95° to 105°F.
In a system where the sulfuric acid product strength is 10% or lower, the sulfuric acid can be diluted with water without the need for a heat exchanger.
Many systems can be constructed using polyethylene fusion welding pipe and fittings. 98% of sulfuric acid would typically use PTFE lined pipe and fittings. Other materials can be used depending on the purchasing company’s specifications.
Allen Bradley or Siemens PLC’s are typically used depending on the customer’s preference. VPN devices are supplied to allow Powell to connect to the system via the internet for troubleshooting and programming.
In most cases, a plate and frame heat exchanger is used for cooling. Cooling water is usually provided by a cooling tower system. Chilled water from air-cooled or water-cooled packages can be supplied for special applications.