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Investigation of Chemical Kinetics of Pyrite Ore Roasting for Production of Sulphuric Acid

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Investigation of Chemical Kinetics of Pyrite Ore Roasting for Production of Sulphuric Acid The University of Dodoma University of Dodoma Institutional Repository http://repository.udom.ac.tz Natural Sciences Doctoral Theses 2019 Investigation of chemical kinetics of pyrite ore roasting for production of sulphuric acid Hiji, Morris Hiji, M. (2019). Investigation of chemical kinetics of pyrite ore roasting for production of sulphuric acid http://hdl.handle.net/20.500.12661/1956 Downloaded from UDOM Institutional Repository at The University of Dodoma, an open access institutional repository. INVESTIGATION OF CHEMICAL KINETICS OF PYRITE ORE ROASTING FOR PRODUCTION OF SULPHURIC ACID MORRIS HIJI DOCTOR OF PHILOSOPHY THE UNIVERSITY OF DODOMA OCTOBER, 2019 INVESTIGATION OF CHEMICAL KINETICS OF PYRITE ORE ROASTING FOR PRODUCTION OF SULPHURIC ACID BY MORRIS HIJI A THESIS SUBMITTED IN FULFILMENT OF THE REQUIREMENTS FOR THE DOCTOR OF PHILOSOPHY THE UNIVERSITY OF DODOMA OCTOBER, 2019 DECLARATION AND COPYRIGHT I, MORRIS HIJI, declare that this thesis is my own original work and that it has not been presented and will not be presented to any University for a similar or any other degree award. Signature ------------------------------------------ No part of this thesis may be reproduced, stored in any retrieval system, or transmitted in any form or by any means without prior written permission of the author or the University of Dodoma in that behalf. If transformed for publication in any other format shall be acknowledged that, this work has been transmitted for degree award at the University of Dodoma. i CERTIFICATION The undersigned certify that they have read and hereby recommend for an acceptance by the University of Dodoma a thesis entitled: Investigation of chemical kinetics of pyrite ore roasting for production of sulphuric acid in fulfilments of the requirements for the degree of doctor of philosophy of the University of Dodoma. Prof. SAID A. VUAI Signature: Date (SUPERVISOR) Prof. JUSTIN W. NTALIKWA Signature: Date (SUPERVISOR) ii ACKNOWLEDGEMENT I would like to express my deepest appreciation to all who helped me to complete this study. First of all, I have to appreciate the guidance given by my supervisors Prof. S.A. Vuai and Prof. J.W. Ntalikwa. I am indebted for their valuable intellectual input, mentoring and encouragement in achieving the required task. Thank you very much! I am very grateful to University of Dodoma Administration for financing this study and providing moral support. I would like to mention few of the staff: Prof A.M. Ame, the former Director of Graduate Studies and the current Deputy Vice Chancellor - Planning, Finance and Administration; Ms. S.I.A. Sawasawa, Director of Human Resources and Administration and Dr. M.I. Hamis, the Director of Graduate Studies. Furthermore, I am very grateful to crucial role performed by the staff of Geological Survey of Tanzania, for providing necessary materials and permission to use their equipment such as XRF, AAS and CS analyser machines. I would also like to mention few of them: Prof. A. Mruma, Chief Executive Officer; Ms. A.K. Rutaihwa, former Director of Mineral Resources Laboratory and Export Permit Directorate and managers Mr. H.I. Gombera and Mr. M. Makongoro. I would like also to express my sincere gratitude to the College of Natural and Mathematical Sciences of University of Dodoma, particularly the chemistry laboratory. I got useful technical assistance and cooperation during laboratory work from all technicians and scientists. iii I will not be fair enough if I could not mention the contribution of the following: Mr. H. Mditi, the former Resident Mines Officer of Merelani and staff in general for supplying the pyrite samples used in this study. I would also like to mention metallurgist engineer, Mr. B. Semboja for his valuable expertise in the area of extractive metallurgy. Last but not least, I express my sincerely appreciation to the College of Earth Sciences, School of Mines and Petroleum Engineering and Department of Mining and Mineral Processing Engineering. I would like to mention former college principal, Prof. W.S. Mwegoha and dean, Dr. G. G. Kombe for providing valuable comments and feedback which helped me to shape the proposal. As host, they assisted me in many ways. iv DEDICATION I am real indebted to my family members for full support I got from them through the entire-turbulent PhD journey. I convey special dedication to my wife Happiness; she showed enormous courage when study was complex and uncertain. I dedicate this work to my lovely children: Daniel, Abigail, Agatha and Anna-Paula who was born when I was fighting in the jungle. May God bless them! I can only show my heartfelt dedication by bible verse: Psalm 116 1 I love the LORD, for he heard my voice; he heard my cry for mercy. 2 Because he turned his ear to me, I will call on him as long as I live. v ABSTRACT The large-scale production of mine wastes and their secure disposal has been a problem of global importance. In this work, the mine waste from Merelani, crude overburden pyrite ore was converted into a value added chemical, sulphuric acid. XRF, XRD, AAS and modified ASTM D-2492 tests were used to investigate the mineral and chemical composition of the ore. It was revealed that the ore comprised about 60% w/w of mineral pyrite (FeS2). The evaluation of XRD pattern shows that the pyrite is of good quality according to the International Centre for Diffraction Data (ICDD). The elucidation of chemical kinetics of roasting of the ore to form a key precursor in the production of sulphuric acid, sulphur dioxide, revealed pseudo first order kinetic with respect to solid reactant in gas-solid system and optimum roasting temperature of 750° C. The activation energy (Ea) value of 15 kJ/mol was deduced from Arrhenius equation suggesting that the roasting reaction was controlled by diffusion of oxygen through the ash layer to the reacting surface. The main gaseous product of roasting crude pyrite ore was then converted into sulphuric acid, which apart from providing proper mitigation to the environment, but also serves as a social˗economic income to local people. The grade of sulphuric acid obtained was 40% w/w which is sufficient for battery acid use. The techno-economic evaluation of a small-scale plant of converting crude pyrite into sulphuric acid was done with the aid of SuperPro Designer simulator. The plant involves five major sections namely: size reduction, pyrite roasting, gas cleaning, formation of NO gas, formation of NO2 gas and acid chamber. Both the capital investment and operating cost vi were estimated by standard engineering cost estimation methods in evaluating chemical process economic viability. The economic indicators showed that the project is feasible with estimated value of NPV (3,503,000 USD), IRR 18.05% and PBP of about 3 years. Sensitivity analysis results were comparable with theory where the unit production cost decrease; the NPV and IRR increase with increasing plant production scale of maximum limit of 1.4. vii TABLE OF CONTENTS Page CERTIFICATION .................................................................................................... ii ACKNOWLEDGEMENT ....................................................................................... iii DEDICATION ........................................................................................................... v ABSTRACT .............................................................................................................. vi LIST OF TABLES ................................................................................................. xiii LIST OF FIGURES ................................................................................................ xv LIST OF PUBLICATIONS ................................................................................. xvii LIST OF ACRONYMS AND ABBREVIATIONS .............................................. xx CHAPTER ONE ....................................................................................................... 1 INTRODUCTION ..................................................................................................... 1 1.1 General Overview ........................................................................................... 1 1.2 Problem Statement ....................................................................................... 10 1.3 Objectives ..................................................................................................... 11 1.4 Hypothesis .................................................................................................... 12 1.5 Significance of the Study................................................................................ 12 CHAPTER TWO .................................................................................................... 13 LITERATURE REVIEW ...................................................................................... 13 2.1 Production of Sulphuric Acid .......................................................................... 13 2.1.1 Introduction ..................................................................................................... 13 2.1.2 Raw materials................................................................................................... 14 viii 2.1.3 Grades of sulphuric acid................................................................................... 19 2.1.4 Analytical and titrimetric methods .................................................................. 22 2.1.5 Qualitative methods .......................................................................................
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