Design of the sulfur melting tank

I. Process calculations for the sulfur melting section: 1. The production capacity of the two sulfuric acid units is 385 tons per day; 390 tons per day is used as an estimate. The daily consumption of sulfur is 130 tons per day, while the amount of sulfur melted per hour ranges from 6.5 to 7 tons per hour； According to the \"Sulfur Workers’ Manual,\" the heat required to melt 1 kilogram of sulfur containing 1% water is 197.04 KJ/kg. 2. Two rapid sulfur melting tanks: V=16 m3 per tank ； ∮3200×1800×lower cone height 1000 (with stirrer). Area of the heating tube: F = 48–52 ㎡. 52㎡ per unit is adopted (for ∮45×368 meters per unit, large and small coils are used together to save space). Stirrer cycloidal pinwheel reducer: Model: XSLB10-17-11KW, input speed of 1000 r/min; Model: YB2-225M-6B5, 11KW. Investment: 1.5×2=3.00 million yuan. 3. Two liquid sulfur filters, F=22㎡ per unit ； Invest 350,000 yuan ； (Take F=25㎡ per unit) ； Investment: 400,000 yuan). 4. Coarse sulfur tank (with mixer; cycloidal pinwheel reducer: model XSLB10-17-11KW, input speed of 1000 r/min; three-phase asynchronous motor: model YB2-225M-6B5, 11KW, manufacturer: Changzhou Nanjiang Reducer Co., Ltd.): Volume = 23 m3 per unit, heat exchange area = 15㎡. 5. Fine sulfur tank: Volume = 9 m3 per unit, heat exchange area = 8㎡. 6. Filtration assistance tank (with mixer; cycloidal pinwheel reducer: model SBLB14-29-5.5KW, input speed of 1500 r/min): Volume = 7 m3 per unit, heat exchange area = 8㎡. 7. Liquid sulfur transfer tank: Capacity designed for 3–4 days to ensure there is sufficient liquid sulfur available in case of failures in the liquid sulfur filter, thus preventing shutdowns: Volume = 300 m3 per tank (above-ground, open-tank type). ∮7000×8000 (top cone: 800). Area of the heating tube: F = 55–60 ㎡. Use 60㎡ of heat exchange tubes with a diameter of ∮51 and a length of 376 meters. Investment cost: 8. One bucket elevator or one belt conveyor with a large inclination angle (based on a sulfur feeding rate of 7–10 tons per hour): estimated investment cost of 30,000 yuan. 10. Rough sulfur pump: 2 units, Q=10 m3/h, H=40 meters, speed 1450 r/min ； (One in use, one as backup). 11. Filter aid pump: 2 units, Q = 18 m3/h, H = 40 meters, rotation speed of 1450 r/min ； (One in use, one as backup). 12. Sulfur purification pumps: 2 units, Q = 7 m3/h, H = 30 meters, speed of 1450 r/min ； (One in use, one as backup). Total investment for 6 pumps: approximately 80,000 yuan. 【It should also be considered that the qualified sulfur solution from the filter press flows directly into the sulfur purification pump tank piping (combining main and auxiliary pipes) in front of the 40,000 and 60,000 tons/year sulfur incineration furnaces.】 13. Estimated investment for process valves and pipelines: 60,000 yuan. 14. Investment estimate for electrical instruments: 30,000 yuan. 15: Estimation of investment for heat preservation: 10,000 yuan. 16: Civil engineering investment estimate: 60,000 yuan. Total of items 1 to 16: Total investment: 10,000 yuan.

Thank you, brother upstairs. Our project is still in the quotation stage. A rapid sulfur melting tank in the form of a cylindrical cone on the ground – I had seen one when I visited a sulfuric acid plant before, but I didn’t pay much attention to it at the time. (I regret it now.) But I think that the sulfur melting capacity of these rapid sulfur melting tanks is generally not very high. The sulfur melting capacity of the tank I designed is 45 t/h; if we simply increase its size (since it’s difficult to increase the height of the tank, and there are also constraints related to the agitator), the diameter of the tank would become too large. The designed jars are thick, short, and ugly. I also hope that experts will continue to discuss this. Last edited by heartlake on 2008-10-12 at 18:14.]

Just design a few more, isn’t that it? Why must it be a single unit? Using a larger one in parallel would solve the problem.

There are already two lines, with each line having a capacity of 45 t/h. The sulfur supplied by the client is of poor quality; the filter operates for 16 hours per day, while the remaining time is used for cleaning and pre-coating

Thank you for the explanation on the second floor; I now understand much better

I suggest you stop using those fast sulfur melting tanks with a cylindrical cone-shaped bottom. I’m fed up with them – the slag removal problem is extremely troublesome, and maintenance and cleaning are dangerous tasks. It seems that the slag removal has been thought through carefully, but it is very dangerous in practice; it’s difficult to remove the slag 70% of the time. The underground version is an even worse design. At present, the flat-ground type performs well; as long as the stirrer is chosen properly, there is little sediment accumulation.

3# Heartlake: In any case, an electric heater must be installed. I saw on site that heating was done only using residual heat; without any other heating method, it’s quite troublesome to melt sulfur

Molten sulfur is in an explosion-proof area; is it difficult to design electric heating systems in such areas to ensure explosion prevention?

Liquid sulfur consumption: 45 t/h. Calculation results: Total heat required to melt sulfur: 7,367,425.5 KJ/h. Heat transfer area required for sulfur melting: 455 square meters. Steam consumption (calculated at 0.8 MP gauge pressure): 3,597 kg per hour. The residence time of liquid sulfur in the storage tank is generally around 5–8 hours, while it is about 2.5–3 hours in the refined sulfur tank. The above values are based on the calculations provided in the sulfuric acid manual issued by Nanhua Institute.

Good suggestion. Our company is also preparing to start up the sulfur melting unit.