Sulfuric Acid

Knight Material Technologies can provide sulfuric acid manufacturers assistance in solving mass transfer and operational problems in the gas cleaning, drying and absorption towers. We have helped customers increase their tower’s capacity and improve gas-liquid distribution while providing longer service life with lower pressure drop.

From simple tower packing and internal change-outs to complex tower upgrades with high-efficiency tower packing to complete new design and construction, we offer a complete turnkey package from a single system supplier.

Select a numbered area on the image to learn more.

1.Multi-Point Trough Distributors

Liquid Distributors deliver continuous and precise distribution of acid for optimum absorption efficiency, minimum mist generation and maximum service life of downstream equipment in sulfuric acid plants.

Corrosion resistant alloy Liquid Distributors reduce installation, maintenance, and lifecycle costs. They have significantly lower lifecycle costs than conventional designs in cast iron.


FLEXISADDLE® Ceramic Random Packing

This is the most widely used random, mass transfer media on the market today. Its unique form provides a highly effective surface area and a low resistance to the air flow for mass and heat transfer optimization. Due to its high quality, it provides economic value for applications worldwide:

  • Random packing is a spray catcher that removes large acid droplets before the candles
  • Available in various sizes
  • Void spaces from 69%-77%


Flexeramic® Ceramic Structured Packing

Structured media with geometrically arranged corrugated sheets offering superior operation over saddle random media. Our proprietary media designs provide greater resistance to fouling than random or monolithic media:

  • Reduce bed depth
  • Minimize plugging
  • Maximize gas distribution in the bed
  • Increase capacity in the unit
  • Reduce fuel costs
  • Lower pressure drop
  • Utilize entire bed instead of a fraction
  • Uniform gas distribution

4. Cross Partition Rings

Cross Partition Rings Used with Random Packing

Rings with a cross-shaped septum have a high resistance to acids (>99.6%), virtually no water absorption (<0.5%) and a resistance to at least 10 heat cycles. Ceramic rings have high throughput and low pressure drop. This reduces the energy costs for pushing a gas mixture through the column and increasing the tower efficiency.


Knight-Ware® KPS Self-Supporting Dome and Packing Support

Our Self-Supporting Domes provide more than 60% open area before the tower packing is installed, offering a significantly increased open area over standard grid bar designs and providing:

  • Reduced pressure drop
  • Less maintenance
  • Ease of retrofit and new construction applications

6. DURO Acid Brick®

Duro® Acid Brick and Chemical-Resistant Mortar

Our bricks maintain corrosion resistance in high-temperature and strong acid concentration environments, conforming to ASTM 279 specifications. DURO® brick is manufactured in standard and custom shapes and sizes. Our proprietary mortars are formulated to bond our brick lining systems to meet most corrosion requirements. We offer a variety of mortar types and formulations to service most strong acid and high temperature process environments.

7. PTFE (Polytetrafluoroethylene)

PTFE (Polytetrafluoroethylene) Duply Liner

PYROFLEX® Duply lining consists of PYROFLEX® membrane with a PTFE overlay. The PTFE overlay is installed on top of the PYROFLEX® to provide an additional layer of protection and acid resistance.


Pyroflex® Acid-Resistant Membrane

PYROFLEX® Acid-Resistant Membrane is a flexible, uniformly thick sheet membrane used as an acid-resistant barrier between acid-resistant brick and corrosion prone carbon steel. PYROFLEX® is fused directly to a properly cleaned and primed surface without the use of an adhesive to provide a continuous, uniform lining with no joints. It also acts as an expansion-absorbing material between the masonry and the steel or concrete shell.

9. Carbon Steel Shell

In direct contact with acid, the Carbon Steel Shell, that constitutes the main structure of the tower, is not resistant to acid attack, progressively deteriorates and therefore requires protection.


Markets and Applications


Quench Vessels  |  Drying Towers  |  Intermediate Towers  |  Inter-Pass Absorption Towers  |  Final Absorption Towers  |  Pump Tanks  |  Phosphoric Acid Reactor  |  Surface Protection

Request a Quote