Third generation high efficiency sulfonate gun

Foreword

As the core component of sulfur acid making device, its operating efficiency and quality are directly related to the safety, environmental protection performance and economic benefits of the entire device. According to statistics, during the operation of sulfur acid making equipment, the proportion of unplanned shutdown caused by sulfonic gun problems is as high as more than 30%, and this failure rate significantly exceeds other factors such as machine pump failure, static equipment leakage and electrical instrument failure. What is more serious is that the failure of the sulfonate gun often leads to a series of major failures, such as the corrosion of the economizer, the sublimation of sulfur leading to system blockage, and the corrosion of the sulfur burning furnace leading to smoke leakage, etc. These consequences not only bring heavy economic losses to the enterprise, but also may lead to a long time to stop production.

In view of the key role of the sulphate gun in the sulfur acid production device, Lilly & Lilly Technology has devoted a lot of efforts to the research and development of the sulphate gun, in-depth analysis of the operating condition characteristics of the sulphate gun, and the current common problems such as bending, blocking and leakage of the sulphate gun, which seriously affect the safe operation of the device, and conducted special research. Its self-developed LGS3 high-efficiency sulfonate gun, as Lilly Technology's third generation of high-performance products, integrates three core technologies: gun body temperature technology, through flow growth technology, and high-diameter pressure butt welding technology. The application of these technologies effectively overcome the common problems such as bending, blocking and leakage in the operation of the sulfonate gun, and ensure that the device can avoid the shutdown caused by the failure of the sulfonate gun during the long operation cycle, thus providing a solid guarantee for the stable production of enterprises and reducing economic losses.

1. Unique Technology

Efficient atomization technology

High efficiency sulfonator nozzle, innovative use of through flow speed atomization technology, the fog torch presents a rotating solid cone shape, this design realizes the layered combustion of sulfur fog, effectively avoids the common surface deflagging problem of hollow cone fog, and then prevents a series of adverse consequences such as the formation of sublimed sulfur caused by front-end hypoxia, combustion lag and overtemperature of sulfur burning furnace.

The fog torch rotating solid cone nozzle technology is a unique technology independently developed based on the in-depth understanding of liquid sulfur characteristics and the accurate matching of sulfur burner structure, while drawing on the essence of rocket engine Laval nozzle technology. Through the combination of two-stage growth and fixed forced atomization, the technology uses centrifugal force and supersonic effect to force atomized liquid sulfur, ensuring that up to 75% of atomized particles are less than or equal to 20&micro. m.

The highlight of this technology is that even at a lower pressure of 0.30MPa, the highly efficient sulfonate gun can achieve excellent atomization. This high atomization capability at low pressure gives the high efficiency sulfonator a wider working flow adjustment range (up to 1:2) and working pressure adjustment range (up to 1:4). This feature enables the high efficiency sulfonator to flexibly respond to the low load demand of the device in the early stage of operation, effectively prevent the occurrence of excessive tail-discharge and smoking accidents during the start-up process of the device, thus ensuring the safe and environmental protection operation of the device.

Atomizing fluid simulation diagram

Flow pressure diagram

Gun temperature equalization technology

The gun is installed in the sulfur furnace, and the gun body is baked at high temperature, and the metal material used will have thermal expansion phenomenon. The gun body is made of 310S material, and its expansion coefficient is about 16.6*10^-6 (1 /℃), the specific calculation formula is h1=h0(1+α *Δ T). Given that the length of the gun body is roughly between 2 and 3 meters, the external ambient temperature of the gun body is about 400 ° C when the sulfur burner is running, and it rises to about 900 ° C after the shutdown.

According to the formula, the expansion of the gun body after stopping is about 10 to 15 mm. If the thermal insulation steam inside the gun body is not evenly distributed, the temperature difference between the upper and lower sides of the gun body will be significant, which will cause the expansion amount to be inconsistent, and finally make the gun body bend upward.

To solve this problem, we independently developed the gun body temperature equalization technology. The technology can ensure that the gun body is 360 % deg when the sulfur burner is running or stopped. The temperature in the range is uniform, so as to achieve the consistency of the expansion amount, and effectively avoid the occurrence of the bending phenomenon of the gun body.

Large channel through technology

As the core equipment in the device, the operation cycle of the sulfonate gun needs to match the planned operation cycle of the entire device. In view of the fact that carbon steel materials are often used in liquid sulfur pipelines and storage tank areas, these materials are prone to corrosion during use, producing iron sulfide and falling into liquid sulfur. When the liquid sulfur containing iron sulfide is transported to the gun, it may lead to blockage during operation of the gun, and then cause the device to stop or reduce production.

In order to effectively deal with this problem, the high efficiency sulfonate gun adopts a large flow channel through technology (flow area of 376mm), and is specially equipped with an anti-blocking cone. This design allows the gun to easily pass through the iron sulfide and avoid clogging, thus ensuring the gun's stable use during its operating cycle.

In addition, the nozzle of the high efficiency sulfonate gun also innovatively uses gold Au composite material. This material has excellent performance in high temperature environment, can effectively isolate the reaction between iron and sulfur, prevent the formation of iron sulfide and corrosion phenomenon. This innovative design makes the nozzle more durable, further improving the overall performance and stability of the gun.

High diameter pressure welding technology

Units frequently shut down due to steam or liquid sulfur leaks from the gun, mainly due to the three-ply bushing welded construction of the gun. Due to the high temperature environment in which the gun is operated, the difference in diameter of each layer of casing leads to the stress concentration on the welding weak point after thermal expansion. If there are small defects such as slag inclusion, pores, hydrogen cracks in the welding, these stress concentrations will cause welding failure, and then cause steam or liquid sulfur leakage. Therefore, superb welding technology has become the key technical way to solve the problem of leakage of sulfonate gun.

In order to improve the performance of the sulfonate gun, high diameter pressure welding technology is adopted in the weld of the high efficiency sulfonate gun in the sulfur burning furnace, and the purity of up to 99.999% argon gas is used to protect the whole process, which realizes the exquisite process of single-side welding and double-side forming. Combined with 100% non-destructive testing of the weld, this high-quality welding technology effectively prevents welding and design defects and ensures the durability of the highly efficient gun.

Atomization testing machine

The effect of the sulfonate gun is directly related to the safe and long-term stable operation of the sulfur acid making device, so it is particularly critical to carry out strict atomization performance test on the newly manufactured sulfonate gun. Since the atomization performance of the sulfonate gun is carefully designed according to the specific properties of the sulfur burner, the relationship between the pressure and the flow rate, the pressure and the Angle of the cone, the pressure and the length of the torch, and the diameter of the torch must be measured in detail at the time of the completion of the manufacture of the sulfonate gun.

In view of the many parameters involved in the spray test of the gun, in order to ensure the accuracy of the test data, we use an advanced spray test machine, which is equipped with a multistage variable frequency pump, which can provide a working pressure range of 0~2.0MPa and a working flow rate of 0~20t/h. In terms of measuring instruments, we have selected high-quality flowmeters and pressure transmitters from Siemens brands, complemented by precise taper gauges to ensure comprehensive and accurate measurement of the parameters required for the sulfonate gun.

In addition, we are committed to providing customized R & D testing services to meet the needs of sulfur-gun testing in various fields such as sulfur acid production, waste acid cracking, hydrogen sulfide acid production, and sublimation sulfur. We promise to help customers achieve more efficient and safer production operations with professional technology and quality service.

2. High efficiency gun structure diagram

3. Product Performance

name;   Said: High efficiency sulfonate gun

Flow range: 1~5t/h; 5~10t/h; 7.5 ~ 15 t/h < / p >

Pressure range: 0.4~1.5MPa

Atomization diameter: 1.6~2.2m

Atomization Angle: 60~90°

Atomization density: 0.365 s.g /m³

Atomization length: 2.8~3.56m

Maximum operating temperature: 1100℃

4. Product Advantages

1. The large sulfur acid making device significantly reduces the number of sulfur-gun installations, thus reducing the investment cost of liquid sulfur pipeline and attached instruments, optimizing the space utilization of the sulfur-burning furnace platform, and greatly reducing the installation workload of sulfur-gun during the start-up and shutdown of the device.

2. Its efficient atomization performance not only improves the volume ratio of the sulfur burning furnace, but also ensures the non-liquid sulfur burning phenomenon at the bottom of the sulfur burning furnace, effectively protects the sulfur burning furnace from the corrosion of sublimed sulfur, and prevents the generation of sublimed sulfur in the system.

3. The device has an ultra-wide atomization adjustment range, which can flexibly adapt to the needs of large, medium and small types of devices to ensure stable atomization combustion effect.

4. By using advanced stratified combustion technology, the high efficiency sulfonate gun successfully avoids the potential risk of the furnace temperature exceeding 1150℃, thus effectively ensuring the safe operation of the device.

5. The high efficiency sulfonate gun also has the convenient function of online replacement, which provides strong support for users to achieve long-term continuous operation of the device.