What’s the contact process?

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The contact process is a method for the industrial production of sulfuric acid. It is the industry standard for producing this chemical in the purity and volume needed for manufacturing applications ranging from batteries to fertilizer production. The use of this process dates back to the mid-1800s, when British chemists first developed it to meet the needs of the growing industrial revolution. After production in a chemical factory, the sulfuric acid is ready for shipment to manufacturers and other facilities.

There are four stages in the production of sulfuric acid with the contact process. The first involves the production of sulfur dioxide, often by combustion in a high oxygen environment. In the second stage, more oxygen is added along with vanadium oxide, which acts as a catalyst to create sulfur dioxide in the next stage. This creates a compound known as oleum which can be mixed with water to create sulfuric acid in the final stage.

Companies can use this process to generate very large volumes of sulfuric acid. Technicians strictly control conditions to keep the chemical as pure as possible. Contamination can affect the contact process or create problems with the finished chemical. For quality control purposes, the company may periodically take samples from sulfuric acid batches and test them to confirm that they are free of contaminants and ready to use. Facilities can produce a mix of chemicals and it is important to keep them all in a high state of purity.

This chemical can be dangerous. Technicians must be vigilant during the contact process and must carefully package the finished sulfuric acid to avoid injury. They use non-reactive containers to limit the risk of a problem during processing and shipping and to ensure the chemical arrives intact at a final destination. For very large shipments, companies can fill tankers or rail cars and use them to transport the finished sulfuric acid.

The basics of the contact process remain consistent, but each factory can tweak the process slightly. Different catalysts can be used and there are different ways to produce the initial sulfur dioxide. Companies also need to consider issues such as pollution potential. The unintentional release of chemicals during this process could result in the payment of fines or cleanup costs, or exposure to lawsuits by chemically injured members of the public. Measures such as wastewater filtration and tight control of manufacturing facilities help limit pollution and keep surrounding communities safe.

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