Sulphur / Sulfur Solidification, Forming and handling facilities (Pastillation)
Sulphur / Sulfur Pastillation is another common method for Sulphur / Sulfur Forming & Solidification that has drawn more attention in recent years due to its low impact on the environment. Through Sulphur / Sulfur Pastillation, drops of liquid sulphur are placed on a steel belt cooler in regular rows using a liquid Sulphur / Sulfur Pastillator injector machine. The liquid sulphur loses heat as it moves on the steel belt cooler and forms into uniform hemispherical shapes called pastille.
Since water and sulphur do not come into direct contact with one another through Sulphur / Sulfur Pastillation method, pastillation entails fewer environmental difficulties than other sulphur solidification methods. Sulfur / Sulphur Pastillation is an increasingly popular choice due to its relative ease of setup and high quality end product. Another advantage of Sulfur / Sulfur Pastillator unit is its versatility; the same equipment can be used to create other products, such as Sulphur Bentonite and Urea. Some Sulphur / Sulfur Forming & Solidification plants that use ARIaNA SANAT ZAFARAN CO. pastillators can produce elemental sulphur, Sulphur Bentonite, or other chemical substances pastilles according to prevailing market demand. This versatility also accounts for increasing interest in Sulfur / Sulfur Pastillation unit in production plants around the world.
ARIaNA SANAT ZAFARAN CO. Sulfur / Sulphur pastillators have an operating capacity of 120 tonnes per day, and their modular design allows them to be integrated together to achieve higher production capacity on demand. This modularity also allows a plant to continue production when one of the units is not operational, while also enabling rapid start-up with lower capital investment costs.
Regardless of the name of the unit, whether sulfur / sulphur handling, solidification or forming unit, after degasification liquid sulphur is stored in a special tank before it is pumped through a 300-micron filter into a Sulfur / Sulphur Pastillation unit. A Sulfur / Sulphur pastillator consists of three main sections: a feeding bar and a stator (both non-moving parts), and a rotor which revolves around them. Liquid sulphur enters the feeding bar and is injected onto a moving steel belt cooler through the holes on a perforated rotor.
Synchronizing the steel belt cooler speed with the rotor is one of the most important factors affecting the shape of the pastilles and must be precisely adjusted during production to ensure a uniform product shape. When properly synchronized, the injected sulphur forms hemispherical pastilles as they cool and solidify while moving along the steel belt cooler. The belt temperature is controlled by regulating water flow and temperature sprayed on its underside. This water absorbs heat from molten sulphur and is then sent to a cooling tower and stored for reuse. Depending on plant climate, a chiller may be required. Water never comes into direct contact with sulphur in this process.
A release agent is applied as a thin layer on the steel belt cooler surface to prevent sulphur adhesion, assist in pastille removal, and ensure uniform shape. The sulphur pastilles reach approximately 60°C at the end of the belt, where they are scraped off and transported by conveyor to storage. An exhaust system above the belt prevents the spread of sulphur gases away from the unit.
| Shape | Flake |
| Size | smaller than 10 cm x 10 cm and 4 mm thickness |
| Color | Black |
| Angle of repose | <30° |
| Dust | Less than 0.4% (wt) |
| Bulk density |
Loose: Greater than 1,050 kg/m³ Agitated: Greater than 1,150 kg/m³ |
| Standards | Meets SUDIC specifications |
| Friability | Less than 2% (Stress Level II) |
| Purity | High purity (as received) |
| Moisture | Less than 0.5% (wt) |
| Others |
Low dust generation during transport Easy to re-melt Stable chemical and physical forms Low acidity Uniform size and shape |
Sulphur Bentonite
| 5 metric tonnes per hour | Capacity |
|
H: 1,900 W: 2,250 L: 33,000 |
Dimension (mm) |
| 15,500 kg | Weight |
|
Electric Power: 20kW Steam: 50 kg/h (3 barg) Water: No net water consumption |
Utility Consumption |
Other Features
- Easy to start up, shut down and operate
- Low maintenance
- Minimal spare part requirements
- Cooling water does not come in contact with pitch
- No air or water pollution associated with flake production
- Method enables water circulation
- Minimal plant footprint
- Allows rapid scaling of plant capacity by integration with additional units
- Flaker versatility also enables production of high softening point pitch, coal tar pitch, tar, sulphur, urea, etc.
