Theoretical prediction of sulfuric acid condensation rates in boiler flue gas

Prediction of acid condensation has a critical role in designing heat exchangers to recover water vapor from power plant flue gas. Rates of mass transfer for condensation of sulfuric acid vapors onto heat exchanger tubes were theoretically investigated and a computer program for numerical simulations of sulfuric acid (H2SO4) condensation in a flue gas condensing heat exchanger was developed. Governing equations based on mass and energy balances for the system were derived to predict variables such as flue gas exit temperatures, cooling water outlet temperatures, and molar fractions and condensation rates of water and sulfuric acid vapors. The associated equations were solved using an iterative solution technique and a one dimensional finite difference method with forward differencing. The Controlled Condensation Method (EPA Method 8B) was applied to experimentally obtain concentration profiles of sulfuric acid vapor in flue gas along downstream in the system. Predicted results of sulfuric acid vapor condensation were compared with empirical data for model validation, and the discrepancy is analyzed in terms of measurement and computation uncertainties. It is found that from both modeling and test results sulfuric acids as well as water vapors are reduced and separated in condensing heat exchanger due to mass transfer with condensation in flue gas. The modeling methodology described here is applicable to theoretical prediction of sulfuric acid and water condensation in full scale flue gas condensing heat exchanger applications.