Sulfuric acid plantsAcid plant play a critical role in metallurgical operationsOperation by treating SO₂-bearing off-gas, with their efficiencyEfficiency closely tied to overall plant performancePerformance. Gas quenchingGas quenching, which cools gases from 300–500 °C to 50–60 °C, presents significant designDesign and maintenance challenges due to thermal stressesThermal stress and chemical exposure. Specialized materials such as potassium silicate and furan resin mortars, along with acid-resistant bricks, are used to protect quench systems but remain susceptible to wear and corrosionCorrosion. Maintenance intervals typically range from 2 to 6 years. This study compares traditional elbow quench designsDesign with newer vertical designsDesign, highlighting that both require regular maintenance. While elbow designsDesign typically require complete replacementReplacement or major overhauls every 4 to 10 years, vertical designsDesign offer significantly longer lifespans—potentially eliminating the need for full replacementReplacement. ModularModular systems facilitate faster repairs, minimizing downtime. Proper material selectionMaterial selection and periodic maintenance can enhance system longevity. The study provides valuable insights into optimizing maintenance strategies and material choices to improve the reliabilityReliability of quench towers in metallurgical operationsOperation.