Four Primary Stages of the Contact Process:
- Production of Sulphur Dioxide ($\text{SO}_2$): Burning sulphur in dry air or roasting iron pyrites: $$\text{S} + \text{O}_2 \rightarrow \text{SO}_2 \quad \text{or} \quad 4\text{FeS}_2 + 11\text{O}_2 \rightarrow 2\text{Fe}_2\text{O}_3 + 8\text{SO}_2$$
- Purification of Gas Mixture: The $\text{SO}_2 + \text{O}_2$ mixture is scrubbed through dust chambers, washed with water, dried with concentrated $\text{H}_2\text{SO}_4$, and passed through an arsenic purifier (hydrated ferric oxide, $\text{Fe(OH)}_3$) because trace arsenic impurities act as a catalytic poison!
- Catalytic Oxidation of $\text{SO}_2$ to $\text{SO}_3$ (The Core Equilibrium):
$$2\text{SO}_2(g) + \text{O}_2(g) \rightleftharpoons 2\text{SO}_3(g) + 196\text{ kJ} \quad (\Delta H = -196\text{ kJ/mol})$$
• Catalyst: Vanadium Pentoxide ($\text{V}_2\text{O}_5$) (preferred over platinized asbestos because $\text{V}_2\text{O}_5$ is cheaper and not easily poisoned by arsenic).
• Temperature: $450^\circ - 500^\circ\text{C}$ (optimum temperature; low temperature favors exothermic yield, but slows rate).
• Pressure: $1 - 2\text{ atmospheres}$ (high pressure favors forward yield, but atmospheric pressure gives $98\%$ yield safely). - Absorption of $\text{SO}_3$ in Concentrated $\text{H}_2\text{SO}_4$ to Form Oleum:
$$\text{SO}_3 + \text{H}_2\text{SO}_4(98\%) \rightarrow \mathbf{\text{H}_2\text{S}_2\text{O}_7 \quad \text{(Oleum / Pyrosulphuric acid)}}$$
Why is $\text{SO}_3$ not absorbed directly in water? Dissolving $\text{SO}_3$ in water is violently exothermic, producing a dense, choking, indestructible fog of tiny sulphuric acid droplets that cannot be condensed or collected!
- Dilution of Oleum: Oleum is mixed with a calculated quantity of water to produce pure concentrated sulphuric acid ($98\%$): $$\text{H}_2\text{S}_2\text{O}_7 + \text{H}_2\text{O} \rightarrow \mathbf{2\text{H}_2\text{SO}_4}$$