HEALTH AND SAFETY
5. Hotspot elimination: Smaller droplet sizes and controlled atomisation angles prevented large sulphur particles from impacting the refractory, extending its lifespan and enhancing furnace safety.
Temperature distribution inside the furnace after CS revamp
4. Uneven temperature distribution: Inefficient combustion chamber dynamics and pressure atomisers caused hotspots on the furnace shell, compromising durability and safety. These issues resulted in elevated
operational costs, reduced productivity, and recurring maintenance challenges.
THE OPTIMISATION APPROACH To tackle these problems, CS Combustion Solutions implemented a four-step optimisation strategy:
1. Ultra-sonic nozzle atomisation: Replacing traditional pressure atomisers with ultra-sonic nozzles was a game-changer. Droplet size was reduced from 400 µm to 110 µm, significantly improving sulphur combustion efficiency. Smaller droplets reduced fouling in the WHB and catalyst beds while extending refractory material life.
2. Swirl bodies for enhanced combustion: Swirl bodies were integrated into the combustion system, inducing rotational motion in combustion air. This promoted better flame stability and complete combustion, particularly during startup operations when oil is also burned.
3. Single vector wall installation: Ineffective baffle walls, which failed to mix combustion air and sulphur properly, were replaced with a single vector wall. This solution ensured efficient turbulence and mixing within the chamber, preventing unreacted sulphur from reaching downstream equipment.
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4. Computational fluid dynamics (CFD) study: A detailed CFD study was conducted to simulate the proposed modifications and ensure optimal performance before implementation. This predictive step was crucial in minimising risks and validating the expected improvements.
RESULTS AND BENEFITS The optimisation delivered remarkable improvements in plant operations and efficiency:
1. A production capacity increase of 30%: The upgrades enabled the plant to achieve 3000 MTPD, incinerating 40 tonnes of sulphur per hour without compromising performance.
2. Improved maintenance flexibility: Operators could replace sulphur guns during operation, eliminating unplanned shutdowns and increasing plant availability.
3. Enhanced combustion efficiency: Swirl bodies and ultra-sonic nozzles optimised SO2
6. Cost savings and downtime reduction: Unplanned shutdowns decreased significantly owing to fewer nozzle failures and better refractory stability.
KEY LEARNINGS AND INDUSTRY INSIGHTS The African Copperbelt plant’s success demonstrates the critical role of high atomisation quality in optimising sulphuric acid production. Advanced technologies, such as ultra-sonic nozzles and swirl combustion systems, significantly improve plant efficiency and reliability. Ultra-sonic nozzles provide a quick
and effective upgrade for existing furnaces, reducing droplet size to minimise fouling and refractory wear. The results of this project also emphasise the value of CFD-based studies for validating design changes before implementation. For plants facing similar
challenges, adopting such innovative solutions can increase capacity, reduce operational costs, and enhance long-term performance.
conversion
rates, leading to complete sulphur combustion with lower emissions. Despite the increased capacity, emissions remained controlled owing to improved efficiency.
4. Pressure loss reduction: The vector wall and optimised combustion chamber design reduced pressure drops, leading to annual OPEX savings of US$160,000 on blower operations.
CONCLUSION CS Combustion Solutions’ expertise in ultra-sonic atomisation and combustion optimisation helped the plant in the African Copperbelt overcome major operational challenges. By boosting capacity, enhancing efficiency, and reducing OPEX, this case study showcases how targeted upgrades can provide significant benefits in a competitive market. As sulphuric acid demand
continues to grow, plants must adopt similar strategies to remain efficient and competitive while minimising downtime and costs.
For more information visit:
www.comb-sol.com/
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