For the majority of the licensors of sulphuric acid processes represented on the market, CS builds burners and combustion chamber systems for the combustion of liquid sulphur, with or without a downstream waste heat boiler.
CS supplies burners and combustion chamber systems for the following applications and processes:
- Sulphuric acid production by dry and wet processes
- Caprolactam production
- SO2 production for pulp & paper, food industry and chemical industry.
By using the CS ultrasonic atomiser nozzles, coupled with the high-turbulence burner systems of the SWP and SWB series, up to 19% SO2 can be achieved with minimal combustion chamber dimensions, depending on the application.
The finer the droplets and the better the turbulence with the combustion air, the more efficient and faster the burnout can be. Major advantages of ultrasonic technology in sulphur combustion are the low required sulphur pre-pressure, as well as the individually adjustable atomisation angle (which also significantly influences the flame shape). Applications from 100kg/h up to 20to/h per burner system have been realised.
Waste sulphuric acid regeneration plants (SAR) are similar in design to classic sulphuric acid production plants. The residual acid is injected (atomised) into a combustion chamber and thermally split at 950-1200°C. The supporting fuels used are oil and natural gas as well as H2S, liquid sulphur and other sulphuric acids. In addition to oil and natural gas, the supporting fuels used are H2S, liquid sulphur and other residue fuels with a high thermal value.
CS is one of the world's market leaders for burners and nozzle systems, as well as complete combustion chamber packages.
The SWP series burners used can be supplied in heat-resistant materials or completely lined on the inside, depending on requirements. The patented ultrasonic nozzles of the JULIP series used for acid injection are made of the highest quality corrosion-resistant materials, including ceramic materials. In combination with the very special atomisation technology, where the acid is only atomised outside the nozzles, much longer service lives can be achieved in comparison to conventional 2-substance nozzles. In addition to the optimised design of the combustion chamber by using built-in swirl elements, the robust design of the burners and wear-free nozzle systems are the most significant advantages for the thermal splitting of waste acid.
H2S is used at some refineries, in the same way as liquid sulphur, for direct sulphuric acid production. In the majority of cases, a wet process is used.
CS has many years of experience in designing and supplying such burners and combustion chamber systems for the most common licences on the market. The burners we use are from the SWP series. In order to prevent the sulphidation of H2S lances and nozzles, which starts at the high back radiation temperatures, the burners are designed as CERAMICS systems, which allows extremely long service lives to be achieved. If preferred, the downstream waste heat boiler from CS can also be supplied.
Most of the H2S gas produced during the purification of natural gas and crude oil is converted into liquid sulphur using the Claus process and then transported for further processing.
CS can also use Claus gas at low pressure by using the pressure loss-optimised SWP burner series. This represents a great savings potential, especially in the case of retrofitting/upgrading existing Claus plants, but also in new plants. The burner systems known on the market for the thermal Claus stage have an average of 50% more pressure loss over the burner system and combustion chamber.
In order to guarantee the high sulphur conversion rates required, CS relies on its experience in the field of lean gas combustion and also uses highly efficient swirl boosters between the flame area and the reaction area of the combustion chamber in combination with the specially developed swirl burner.