Sandvik – a world leader insulphur solidification

and handling systems

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A total capability

From start to finish

At Sandvik Process Systems we can engineer total sulphur solidification andhandling systems to the strictestproduction and environmental parameters, with a typical turnkey projectcovering everything from pumping liquidsulphur from the storage tank, to loadingequipment for the end product.

At the heart of every system we deliveris the solidification unit, consisting of afeeding device and cooler.All our systemsmake use of indirect cooling, with the heat of the molten product being transferred through the steel belt by means of cooling water sprayed on theunderside of the belt.

As well as being tough and durable, thethin steel belt also has negligible heat resistance, so cooling can be preciselycontrolled to achieve the desired crystallization speed. Heat exchangersremove heat and cooling water is recycled, which means that the processand the efficiency of the plant can becontrolled accurately. In this way, both capacity and speed can be increased,highlighting Sandvik's commitment tohelping customers achieve the higheststandards of production.

Cooling tower

Sulphur solidification and handling plant

Process control

Rotoform unit – sulphur feeding end

Feeding/conveying

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Control room

Cooling section

Sulphur pastilles conveyed to stockpile

Sophisticated process control assuresproduction efficiency as well as precisemanagement control. Our turnkey capabilities encompass all ancillary equipment such as water cooling, pipingand pumping systems, preconditioning,handling, storage and packaging units.

Sulphur storage silo and truck loading system

Sandvik Process Systems is approved to DIN EN ISO 9001:2000– the international recognition ofhighest quality standards andpractices.

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The process... the product...

The perfect solution toyour particular needs

For many companies today, the efficientsolidification of sulphur is essential froman operational, handling and environmental point of view, so specifyingthe most appropriate system is vital interms of maximizing productivity and safety. Furthermore, the ability to storesulphur in a convenient solid form can also provide a valuable hedge againstshort term market fluctuations.

At Sandvik Process Systems, we havemore than 25 years' experience in delivering total turnkey solidification solutions to customers throughout theworld.These systems are designed tomeet specific requirements in terms ofcapacity, flexibility and form of end product.

Sandvik Process Systems hassupplied more sulphur solidification systems than any other manufacturer in the marketand the most widely specified ofthese is the Rotoform® system.

Rotoform unit – discharge end

Rotoform unit discharge end

RF-Unit 3

Cooling water tank or pit

Cooling water

Cooling waterreturn

Filter

Liquid sulphur

Sulphur surge tank

Sulphur pump

M

M

M

PC

RF-Unit 1

RF-Unit 2

RF-Unit 4

Bucket elevator

Conveyor

Storage silo

Truckloading

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Recent years have seen more and more sulphur solidified in the form of pastilles,the ideal shape for subsequent storage,handling and reprocessing.

We have been at the forefront of this revolution, combining the qualities of theSandvik steel belt – excellent thermal properties, flexibility and durability – withthe performance of the Sandvik Rotoform process, now widely acceptedas the industry standard for high qualitypastille production.

Sandvik pastillation plant with 4 Rotoform units and 2 truck loading stations

Rotoform unit – cooling section

Since the early 1980s, some 300+ Rotoform units have been commissionedand installed around the world for thepastillation of sulphur, and this provensuccess is the result of the unique combination of benefits provided by thistechnology.

Quality of formed sulphur• Free flowing pastilles of uniform size

and quality: ideal for subsequent handling, storage and transport.

• Premium spec. quality according to SUDIC (Sulphur Development Institute of Canada) test.

Super-efficient process• Indirect heat transfer : no contact

between product and cooling medium.• Controlled crystallization: well defined

cooling time.• Environmentally friendly: emissions

within the limits of international lawsand cooling water recycled.

• Maximum flexibility: rapid changeoverto partial operation without affectingquality.

• Quick start-up of plant.

Versatile, reliable equipment• Efficient modular system: ability to

increase capacity simply by groupingseveral identical units together.

• Reliable operation with minimal service requirements: suitable for remote areas.

• Reliable development and back-upthrough test and pilot plants.

• Worldwide service network availableat short notice.

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The proven performance of the Rotoform process

Rotoform units in a solidification plant in Sicily

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Typical data for the Rotoform 3000 process

Product

Pastille shape hemispherical, uniform

Pastille diameter 2-4 mm

Bulk density >1,150 kg/m3 loose>1,320 kg/m3 packed

Dust (<0.3 mm) as produced <0.2%

Friability stress level (acc. to SUDIC) <2%

Unit

Capacity max 6 t/h

Capacity range 70-100%

Belt area 7.5 m x 1.5 m

Floorspace requirement approx. 11.0 m x 2.0 m

Basic principle of Rotoform 3000

heatingD = 80 mm

Steel belt

Free flowing dustfree sulphur pastilles

The Sandvik Rotoformer®

The Rotoform system has undergone continual improvement over the years,leading to the development of an entire family of specialist systems. Of these,two are specifically designed to deliverpremium quality sulphur pastilles with aconsistent, hemispherical shape: the Rotoform 3000 featured here, and theRotoform HS (see over).

Rotoform 3000 for sulphur pastillation

at up to 6 t/h

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Rotoform HS – patented for high capacity

The Rotoform HS is a revolutionary new solution for pastillation of liquids,developed by Sandvik Process Systems, theexpert in melt granulation.

Recognising that many companies’sulphur solidification requirements are increasing, we have developed the Rotoform HS, a high capacity system capable of processing sulphur at up to 12 t/h.

As with all Rotoform systems, the Rotoform HS depositor combines with asteel belt cooler to produce pastilles of ahighly uniform shape, stability and quality,in an environmentally friendly manner,and is ideal for low viscosity, fast cooling products.

High pastillation speed – reducedcentripetal forces due to increaseddiameter

Rotoform HS for high capacity sulphur pastillation at up to 12 t/h

Rotoform HS – depositing sulphur droplets onto a steel belt cooler

s2

r2

F2

RF HSr1

RF 3000

s1

F1

V1 V2F1 = F2V2 » V1

F1, F2 = centripetal force

s1, s2 = circumferential speed

V1,V2 = belt speedr1, r2 = depositor radius

Building on the proven strengths of the Rotoform principle – the Rotoform HS

Rotoform HSThe difference between this and thestandard Rotoform is that the RotoformHS uses a much larger rotating shell,enabling droplets to be deposited on thesteel belt without distortion at twice theprevious speeds, typically up to 120 m/min. Combine this with a belt that's twice as long (to allow the sameamount of cooling time) and the capacityof the system is up to 2.5x that of a standard Rotoform.

The Rotoform HS provides improved safety – if anything is caught betweendropformer and belt, the dropformerautomatically raises to minimise the riskof damage or injury.

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pastillation of liquid melts

Rotoform HS in working position

heating

Steel belt

D = 250 mm

In addition, this high capacity version also offers a number ofservice enhancements:• Swing-out bearing unit to allow much

easier access.• Reduction of wear parts through

elimination of rotary seals.• Dropformer now lifts into service

position pneumatically.• Easier servicing with fewer

components to check and replace.

This ensures that all the inherent benefitsof the Rotoform remain available,enabling users to produce pastilles of ahighly uniform shape, stability and quality,in an environmentally friendly manner.In short, the Rotoform delivers the bestof all worlds:

• High capacity production• Proven Rotoform technology• 8,000 hrs/year operation• Sandvik support & service• Rapid return on investment

Basic principle of Rotoform HS

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The economic andenvironmental imperative

The impact of continuous populationgrowth and attendant increases in energyconsumption are having a profound effect on the sulphur processing industry:as fossil fuels are the main source ofenergy, the emission of sulphur dioxide isof increasing environmental concern.

More intense desulphurisation is one result, as is the use of natural gas, crudeoil and coal with higher sulphur contentsas the purer energy carriers are used up.Increasingly, sulphur is arriving on themarket after passing through the Clausprocess, as well as from the desulphurisation of crude oil products.

The common denominator with all sulphur extraction is that it is obtained inliquid form, and needs transporting fromthe extraction point to the end user’splant.

This raises major logistical problems interms of potential hazards, environmentalissues and the need for complex infrastructure, but there is also an obvious solution: the solidification of sulphur into a solid, easy-to-handle form.

It’s an area in which Sandvik Process Sy-stems is an acknowledged world leader,with the resources and experienceto deliver a full turnkey plant from initialengineering and fabrication, through supply and erection including civil works,to start-up and training.

Our solidification systems are usedaround the world to maximize efficiency,productivity and profitability, and at thesame time they maintain the very higheststandards of safety and environmentalcontrol.

Successful sulphur handling

Photographs courtesy of Caltex.

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The Sandvik sulphur solidification andhandling system at the Caltex plant inCape Town, South Africa is based aroundtwo Sandvik Rotoform units.This installation was completed in 2002 and is operating to the customer’s full satisfaction.

With the capacity to operate around theclock and process up to 12 tonnes perhour, this installation can handle up to288 tonnes of sulphur a day.

As well as its high capacity and consistentproduct quality, the other major benefitof this extremely modern plant is its ability to satisfy the strict environmentalregulations required in South Africa, a keyfactor behind the customer's decision tochoose Sandvik Rotoform.

Successful sulphur handling

If you’d like more detailed information on the 300+ sulphursystems we’ve already installed,just ask.We’re ready to share ourexperience and know-how withyou.

The Sandvik sulphur solidification systemat Shantz forming plant takes liquid sulphur feed from the Caroline/Canadagas plant.

With 46 Rotoform installations and thecapacity to produce up to 6,000 tonnesper day of sulphur pastilles, this is the

largest installation of its kind in the world.Shell chose Sandvik for a number of factors including capacity, environmentalimplications such as dust and other effluents, product quality, maintenance requirements, safety and ease of operation.

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Free flowing pastilles at a Sicilian sulphur plant

Transport of sulphur pastilles in open railway cars over the Rocky Mountains

46 Rotoform units in one solidification plant at Shell/Canada