CHEMICAL PLANT SERVICES
Galiakotwala Engineering has been an expert in Sulphuric Acid for more than 38+ years studying issues and finding unique solutions for Acid Plants across the world.
Technical Audit & Services
We provide the following services for Sulphuric Acid Plants:
- Plant Audit
- Energy Audit
Consultancy Services
Our plant and energy audit services help sulphuric acid plants improve performance, increase capacity, reduce operating costs, enhance reliability and become more energy efficient through systematic engineering evaluation.
Our specialization is maximizing production value in sulphuric acid plants and we can help you achieve:
Advantages of a Plant Audit
Advanced Equipment
- Use of specialized Alloy to significantly enhance life of equipment
- Complete Stainless Steel Converters
- DCS based instrumentation
Reliability
- Higher on-stream availability due to improved equipment selection
- Less down-time due to reduction in material handling equipment
- Elimination of problems associated with conventional Acid Dilution systems
- Improved material selection, resulting in lower corrosion
Advantages of a Energy Audit
Energy
- Hot water generation
- High steam generation and export
- Low power consumption
- Various options to recover by-product
Low Emissions
- SO2 emissions within 0.5Kg/MT, if required
- SO3 emissions within 50ms/ mm³ in all plants
- Full conversion within 2 hours of start up from cold
Technical Services
We provide the following on site services for Sulphuric Acid Plants:
- Tube Cleaning for Heat Exchangers
- Mist Testing
- Moisture Testing Services
When does your Heat Exchanger need cleaning?
Heat exchangers in sulphuric acid plants are prone to fouling, scaling, and deposits over time due to process conditions. These deposits restrict flow, reduce heat transfer efficiency, and increase energy consumption, resulting in lower plant performance. Timely inspection and professional tube cleaning restore heat transfer efficiency, reduces pressure drop, improve reliability, and help maintain consistent production while extending equipment life and reducing operating costs.
- Has the heat transfer efficiency of your heat exchanger declined over time?
- Have you observed a significant reduction in heat exchange rates affecting overall process efficiency?
- Is there an increased pressure drop across the heat exchanger tubes?
- Are circulation pumps or associated systems consuming more energy than normal?
- Is your plant unable to achieve its target production capacity due to reduced heat exchanger performance?
Advantages of Tube Cleaning for Heat Exchangers
- Extending the lifetime of the Heat Exchanger equipment
- Reduction of electric energy consumption
- Saving of water in cooling towers
- Un-interrupted production
Challenge: Phosphoric Acid Impurities
Measurement Method
We measure sulphuric acid mist in accordance with the stipulations of US EPA Method 8 to ensure accurate and reliable results. Gas samples of known volume are collected from designated locations such as the Drying Tower (DT), Intermediate Absorption Tower (IPAT), and Final Absorption Tower (FAT). These samples are then analyzed under controlled laboratory conditions to determine the concentration of sulphuric acid mist and sulphur trioxide, enabling accurate assessment of mist eliminator performance and plant operating efficiency.then advantages are listed
Advantages of measuring
Sulphuric Acid Mist:
- To measure the performance of Mist Eliminators.
- To avoid damage to downstream equipment from Acid Mist.
Moisture Testing Services
Measurement
In the Drying Tower, Sulphuric Acid is used to remove moisture from the air. In this process, there is a possibility of moisture slippage due to a number of factors, so measurement of Moisture at the Drying Tower outlet becomes necessary.
Advantages of measurement of moisture at the Drying Tower outlet:
- To ensure the performance of the Drying Tower and internals.
- To avoid damage to catalyst and downstream equipment from Moisture present in the Outlet Gas from the Drying Tower.
Laboratory Analysis*
*Illustrations are for representation purposes only.
What Our Customers Say
“I am pleased to report that since installing the GEC BMW Type Candle Filter in our Interpass Absorption Tower (IPAT) at our Sulphuric Acid Plant in 2019, it has performed exceptionally well. We have not observed any acid condensate at the outlet of the IPAT, indicating the filter is effectively removing any impurities.”
Manager SAP Plant
Birla Copper
“We were facing mist carryover problems in the Drying Tower for a long time. We discussed the problem with the Galiakotwala Technical Services (GTS) Technical team.They studied the issue and gave the solution of an advanced Demister Pad of SX Wire Mesh for Drying Tower and solved this prolonged problem permanently.”
General Manager (Auxiliary),
Century Rayon
“Galiakotwala Engineering Company has provided us with the best solution in form of Alloy Piping to get rid of continued issues of leakage in conventional Sulphuric Acid Piping. After installation of the Alloy Piping, we observed zero leakage and significant cost savings due to reduced downtime. Since then we have changed most of our Acid Piping in both Sulphuric Acid Plants at Haldia with their low corrosion alloy.”
General Manager (Engineering),
Tata Chemicals Limited, Haldia
“We wanted to replace our old Brick-Lined Acid Towers with a newer technology due to difficulty in location and repair of leaks in these Acid Towers. GEC gave a solution of an complete Alloy Tower 7500 mm in diameter including all internals such as Distributor, Mist Eliminators, Packing and Support, etc. We are happy to note we have observed no corrosion in last 7 years and achieved 99.99% absorption efficiency.”
JSC Apatit,
Russia
“We were continuously facing excess mist generation and moisture carryover problems in FAT and DT with the conventional distributors. Galiakotwala Engineering Company (GEC) replaced conventional distributors with Alloy Distributors in 2004. Since then, there is no change in the thickness and deformation of hole sizes of the branch pipes of the distributor. We appreciate the quality of work and and the materials used by GEC even after 18 years of operation.”
Deputy General Manager (Mechanical),
Paradeep Phosphates Limited
“We are using your Vane Separators for the last 15 years and have never faced any issues in the performance or life of the equipment. We are thankful to the Galiakotwala team for designing the special type Vane Separators according to our requirement that continues to ensure our process operates.”
Sr. Manager (Mechanical),
TATA Steel
“In 1987, Galiakotwala Engineering Company (GEC) provided our first Shell and Tube Type Heat Etxchanger with the assurance of an advanced, efficient design and manufactured with a low-corrosion alloy that would extend its lifespan. Even after 30+ years of trouble-free operation, the Heat Exchangers are still functioning effectively. We are pleased to report that GEC adhered to their commitments.”
Vice President Technology
Dharamsi Morarji, Roha
