Case Study

Sulphur

Burner Substitution

YOUR EXPERTS

FOR BURNERS

AND COMBUSTORS

• CS Introduction

• Technology

• Applications

• Sulphur combustion & revamp projects

Agenda

Thomas Bartonek

© 2019 CS Combustion Solutions

Page 3/25

Headquaters

CS China (Wholly owned enterprise)

CS Germany

Representations Partners

Moscow

Shanghai

Mumbai

Campinas

France

Fernandia, FL

Vienna

MINHANG DISTRICT

Locations

Germany

Thomas Bartonek

© 2019 CS Combustion Solutions

Page 4/25

CS Industries &

Applications

2

Sulphur

Applications

1Hazardous

Waste Incineration

4

Special Boiler &

HGG Applications

3Thermal

Oxidizers

Industries andApplications

Thomas Bartonek

© 2019 CS Combustion Solutions

Page 5/25

Engineering

• Draft of Combustion System

• Detailed Combustion Calculation

• Tailormade Solutions for client

• CFD Modeling, Optimization

• Detail Engineering

• Manufacturing

• Supervision of Erection

• Start-up and Commissioning

• After Sales Service

Thomas Bartonek

© 2019 CS Combustion Solutions

Page 6/25

OptimizationwithCFD-Simulation

Simulation of complex injection systems with several reaction zones, in operation since 2015SO2 Distribution before and after optimization, in operation since 2014, Brasil

Development of new technology, VARIEX ® Gas Injection, Patented since 2014

Thomas Bartonek

© 2019 CS Combustion Solutions

Page 7/25

Waste Liquid Lance

Gas Lance

Burner Wind Box

Gas-Ring Distributor

Waste Liquid/Water Lance

with cooling air connection

Pre Combustion

Chamber

Combustion

Chamber

OFF-Gas Injection

Modular Combustion Systems

Thomas Bartonek

© 2019 CS Combustion Solutions

Page 8/25

Atomizing medium

Liquid Waste/Fuel

Atomizing medium

Resonance Chamber

based on Hartman Generator

Exit of

Ultrasonic

field

UltrasonicNozzle

Thomas Bartonek

© 2019 CS Combustion Solutions

Page 9/25

Distributor

Flame Former

Basic body

Advantages of the ultrasonic nozzle

• Stable and calm spray pattern, smooth atomizing

• Extreme fine droplets

• Non moving parts

• Manufacturing in a wide choice of materials,

• Low wear, due to low pressure and speed

• Turn down range up to 1:7

• Use of different distributors, easy to adopt spray pattern

• Easy changeover from tulip nozzle to jet nozzle

• Cooling and cleaning effect during and after operation by atomizing

air

UltrasonicNozzle

Thomas Bartonek

© 2019 CS Combustion Solutions

Page 10/25

70 80 90 100 110 120

Variable Spray Pattern

Thomas Bartonek

© 2019 CS Combustion Solutions

Page 11/25

Acidgas Combustion

Biggest WSA plant worldwide

• horizontal firing

• 1 Master Burner:

• Acid Gas 5.550 kg/h

• Liquid Sulphur 520 – 5.000 kg/h

• Natural Gas 2.655 kg/h

• 1 Slave burner:

• Acid Gas 5.550 kg/h

• Capacity: 1.000 t/d H2SO4

• Start up 2016

Thomas Bartonek

© 2019 CS Combustion Solutions

Page 12/25

High contaminated Spent Acid:

• horizontal firing

• Spent Acid (H2SO4 60%, Tar, solid Sulphur,

metals and chlorine)

• Capacity 7MW:

• 665 Nm³/h Natural Gas

• 100 Nm³/h light ends (C2-C6 80%, CS2 20%)

• 1.600 kg/h spent Acid

• Start up 2010

SpentAcidRegeneration

Thomas Bartonek

© 2019 CS Combustion Solutions

Page 13/25

Tail Gas combustion downstream SRU:

• Horizontal firing

• Tail Gas and Amine Off Gas

• Capacity 30MW:

• 804 kg/h Fuel Gas

• 891 kg/h Amine Off Gas

• 50.997 kg/h Claus Off Gas

• Start up 2011

TailgasCombustion

Thomas Bartonek

© 2019 CS Combustion Solutions

Page 14/25

CustomizedSRU Main Burners

Features of the CS-Claus burner:

• High turbulent burner with short mixing zone

• Low pressure drop through windbox

• Extension of residence time due to internal

recirculation

• Long lifetime of gas guns due to

special ceramics

Thomas Bartonek

© 2019 CS Combustion Solutions

Page 15/25

SulphurCombustion

Plant before burner Revamp

• SO2 Production for Caprolactam

• Furnace Pressure 0,6 bar

• Sulphur throughput 8.000 kg/h each burner.

Total capacity 16 t/h Sulphur

• Approx 2-3 shut downs/year

LURO Burners

Rafractory lining

Thomas Bartonek

© 2019 CS Combustion Solutions

Page 16/25

SulphurCombustion

Plant after burner Revamp in 2011

• One instead of 2 burner

• Less downtime, faster switch from natural gas to sulphur

• Same size of combustion chamber with 25% more capacity

• Atomizing air is supplied from compressor with 150°C. It is used as

traced heating media for the sulphur in the gun.

• No rotating parts in the hot furnace, hence less wear on burner.

• Much higher turn down of nozzles and burner

• No cooling of burner during hot stop

Thomas Bartonek

© 2019 CS Combustion Solutions

Page 17/25

SulphurBurner

Burner Features

• Design Pressure Windbox 0,8 bar

• Connection Flange with refractory

inlining for hot stops

• Higher availability due to 2

Sulphur guns inside the burner.

One can be removed during

operation!

• Material partly heat resistant

stainless steel

• Wear parts are 2 nozzles each

year

Thomas Bartonek

© 2019 CS Combustion Solutions

Page 18/25

CFD for proof of TTT approach:

• High swirl for homogenious distribution

of Combustion Air (Turbulence)

• Advanced atomization for superfast

evaporation and oxidation of sulphur

droplets (Temperature)

• Reduced dimenssions for Furnace

(Time)

Sulphur Combustion

Thomas Bartonek

© 2019 CS Combustion Solutions

Page 19/25

Sulphur Combustion

Case study sulphur furnace in Brazil

CASE DIMENSIONSSTEEL

WEIGHTVOLUME

BRICK

WEIGHTCOST ESTIMATE

1D 4,6 m x

L 15,2 m~45 t 252 m3 ~ 220 t ~USD 340k

2D 4,6 m x

L 20,3 m~55 t 337 m3 ~280 t ~USD 430k

3D 3,8 m x

L 17,5 m~40 t 198 m3 ~190 t ~USD 300k

OR

IGIN

AL

DE

SIG

N 2

00

0 t/d

(19

91

)

LIC

EN

SO

R

RE

CO

ME

ND

AT

ION

˜30

00

t/d

CO

MB

US

TIO

N S

OL

UT

ION

S

PR

OP

OS

AL

~3

00

0 t/d

Thomas Bartonek

© 2019 CS Combustion Solutions

Page 20/25

VelocityDistribution

• Big recirculation zone in the

center of the combustion

chamber

• Swirl air on the outerboarder

of the chamber.

Thomas Bartonek

© 2019 CS Combustion Solutions

Page 21/25

Temperature Distribution

Temperature [K]

Thomas Bartonek

© 2019 CS Combustion Solutions

Page 22/25

SulphurRelatedProjects

•

•

•

•

•

•

•

•

•

•

•

•

• •

•

Thomas Bartonek

© 2019 CS Combustion Solutions

Page 23/25

Thank you for your attention !