Modelagem, simulação e otimização do reator para aumento de eficiência na produção industrial de ácido sulfúrico: uma perspectiva tecnológica e sustentável

Abstract

With the rapid growth of sulfuric acid production in the global industry, this work addresses the modeling, simulation, and optimization of the fixed-bed catalytic reactor used in industrial sulfuric acid production, focusing on operational efficiency, cost reduction, and mitigation of environmental impacts. The research highlights the strategic importance of H₂SO₄ as a key input in various industrial sectors, as well as its role as an indicator of economic development. Mathematical modeling tools, computational simulation, and response surface analysis were applied to define the optimal operating conditions (temperature, pressure, and inlet gas composition), evaluating conversion, temperature, and pressure profiles along the reactor. The study also includes the design of inter-stage heat exchangers, which are essential for thermal control of the highly exothermic process. The results demonstrate that the configuration of multiple catalytic beds with intermediate cooling allows SO₂ conversions above 98%, increasing SO₃ productivity with low pressure drop and high operational reliability. It is concluded that the proposed optimization represents a viable and sustainable alternative, combining technical competitiveness, energy efficiency, and environmental compliance.