Acid Distributors
Efficient acid distribution is critical for the optimal performance of sulphuric acid plants. Acid distributors form the core of the drying and absorption tower system, ensuring uniform distribution of acid over the packing.
Complete contact and effective mixing of gas and acid are essential for proper operation of the towers. A well-designed acid distribution system directly impacts plant efficiency, acid quality, and equipment life.
Key Characteristics of a Good Acid Distribution System
Uniform acid distribution with full coverage of the tower area
Proper acid flow rate to ensure complete irrigation and avoid flooding
Long service life
Gentle distribution to prevent localized high-velocity gas flow
Reduced mist generation
Manufactured from corrosion-resistant materials
Easy to install, clean, and maintain
Low life-cycle cost
Restricts plugging
Advantages of Alloy Pipe Acid Distributors
Higher Efficiency
- Performance is determined by number of distribution points per m²
- Alloy distributors provide 2–4 times more distribution points than cast iron
- Ensures superior and uniform acid coverage
Low Corrosion
- Cast iron distributors corrode at rates exceeding 100 mpy, causing sulphate sludge formation
- Sludge leads to packing blockage, poor acid quality, gas channeling, and frequent shutdowns
- Alloy distributors exhibit corrosion rates below 2 mpy, ensuring clean and stable operation
Longer Life
- Service life is 2–3 times longer than cast iron distributors
- Alloy distributors inspected after 15 years of operation showed minimal corrosion and clean condition
Constant Performance
- Corrosion in cast iron enlarges orifices over time, reducing efficiency
- Low corrosion in alloy distributors maintains orifice size
- Ensures consistent distribution and performance throughout service life
Low Maintenance
- Practically zero maintenance required
- Only periodic inspection of branch pipes and main header needed to check for plugging
No Stocking of Spare Parts
- Cast iron distributors require block replacement and spare inventory
- Alloy distributors are fully weldable using conventional techniques
- No spare part stocking required
Easy to Install
- Lightweight construction
- Components can be handled and installed easily by a single person
Easy to Clean
- Branch pipes can be disconnected individually from the main header
- Simplifies cleaning during plant shutdowns
Reduced Load on Mist Eliminators
- Installed above packing for gentle acid distribution
- Minimizes high-velocity gas zones
- Reduces mist generation, pressure drop, and load on mist eliminators
Legacy / Credibility Highlight
Galiakotwala has supplied acid distributors to most major sulphuric acid plants in India, as well as to sulphuric acid plants worldwide.