Sulfuric Acid Tower Restoration
05 | 06 | 2026
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Understanding the Problem
In 2015, a sulfuric acid producer requested support from Clark Solutions to resolve critical operational issues in their production line. The Intermediate Absorption Tower (IAT) was experiencing severe problems—tests on the outlet gas stream indicated acid mist was being carried downstream.
This phenomenon not only leads to economic losses due to maintenance, repairs, and equipment replacement but also suggests internal tower failures that can compromise its efficiency and structural integrity. It also poses risks to occupational safety and the environment due to leaks, infiltration, and contamination.
With this in mind, Clark Solutions performed a complete system evaluation and delivered reliable, long-term solutions efficiently.
Problem
Cause
Solution
Trough operation
Deposits, liquid flow above design, and missing downcomer extensions
Redesign and replacement of orifice plates in acid feed lines
Downcomer clogging
Sulfate buildup; large area taken by support pins; lack of downcomer extensions
Replacement of pins with reduced penetration models
Damage to candles
Excess acid exposure; damage to support beams
Installation of pedestals, internal reinforcement, and drain/sealing system repair
Gas bypass through chimney tray
Structural modifications, corrosion, removed refractory bricks, clogged drains
Drain unclogging and resizing, PTFE gasket installation
Candle overload
Leak in one of the acid distributor header joints
Repair of the cast iron header and installation of MaxiMesh® mist eliminator in the Drying Tower
Packing misdistribution
Fragmentation, fouling, and corrosion
Replacement and repositioning of packing to cover downcomers
Mist formation in Oleum tower
Lower operating temperature causing excess mist load on eliminators
Blocking of the Oleum tower
Outro problema que surgiu durante as inspeções, foi que a TAI operava com menos eliminadores de névoas que o projetado e o seu desempenho estava bastante prejudicado – os danos causados às fibras e à estrutura pela exposição excessiva ao ácido reduziram bastante a eficiência de operação.
Additionally, the IAT was operating with fewer mist eliminators than designed, and the remaining ones were heavily damaged—fiber and structure erosion from acid exposure drastically reduced operational efficiency.
To meet the client’s urgent demand, Clark Solutions manufactured 18 new FiberBed® mist eliminators within 7 days—a record time unmatched by any other supplier globally, made possible by allocating exclusive resources.
Thanks to detailed engineering and strategic planning, Clark Solutions delivered a complete, cost-effective, and long-lasting solution in just a few weeks. The tower has since operated without requiring repairs or maintenance.
What We Deliver:
Innovation, offering state-of-the-art technologies;
Continuous improvement of our processes and quality standards;
Customized solutions, with a strong focus on customer satisfaction.
