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Sulphonation plant heat recovery technology focuses on capturing the significant energy released during the highly exothermic sulfur combustion and reaction processes, converting it into reusable energy—primarily medium-pressure steam (up to
steam per ton of LABSA or
sulfur burned)—using technologies like Heat-Pipe Heat Exchangers, Fire-Tube Boilers, and Plate Heat Exchangers (PHEs).
These systems reduce energy costs by up to
, making many modern plants steam self-sufficient.
Key Heat Recovery Technologies
- Heat-Pipe Heat Exchangers: Highly efficient exchangers used to recover heat from hot gas streams. They have small flow resistance, compact structures, and high reliability; failure of a single pipe does not affect overall production.
- Fire-Tube Boilers: Used to directly convert the heat from the sulfur burner (burning to) into steam.
- Plate Heat Exchangers (PHEs): Excellent for recovering low-grade heat from circulating sulfuric acid in absorption and drying towers, handling high-corrosion environments with high efficiency.
- Sulfur Burner Waste Heat Recovery (WHU): Converts hot sulfur combustion gases into steam.
- Cooler/Heat Exchanger: Recovers heat from the convertergas, often using air-cooled exchangers to generate hot water or pre-heat air for other processes.
Key Application Areas & Benefits
- Steam Self-Sufficiency: Modern systems, including a start-up pre-heater, allow plants to operate without external steam after the initial start-up.
- Sulfur Melting/Preheating: Steam generated is used to melt solid sulfur in storage tanks.
- Process Integration: Recovered heat is used for silica gel regeneration, drying, and scrubber wastewater evaporation/crystallization.
- Operational Efficiency: Heat recovery from the absorption stages can reduce cooling load and save on cooling water or air consumption.
- Environmental Compliance: Improved energy efficiency helps meet environmental standards by reducing overall plant fuel consumption.
Typical Performance Highlights
Recovery Rate: ~100kg sulfur burning generates ~250kg steam.
Fuel Savings: Over 80% reduction in thermal energy consumption.
Dioxane Reduction:
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Web results
Sulphonation plant waste heat recovery technology
WEIXIAN (Nanjing) Science Technology co., ltd
https://www.njweixian.com › sulphonation-plant-waste-h...
WEIXIAN (Nanjing) Science Technology co., ltd
https://www.njweixian.com › sulphonation-plant-waste-h...
The heat-pipe exchanger has high heat transmission efficiency. The equipment also has a compact structure, and small thermal side flow resistance.Read more
Sulphonation Plants
Technithon
https://www.technithon.com › sulphonation-plants
Technithon
https://www.technithon.com › sulphonation-plants
Our plants are offered with waste heat recovery system and Zero Liquid Discharge (ZLD). The challenges of reduction of 1,4 Dioxane have been addressed by ...Read more
Heat recovery from sulphuric acid plants for seawater ...
ScienceDirect.com
https://www.sciencedirect.com › science › article › pii
ScienceDirect.com
https://www.sciencedirect.com › science › article › pii
by A Lovato2001Cited by 9 — With plate heat exchangers (PHEs), the heat in the sulphuric acid can be recovered with negligible temperature losses and minimum space requirements.Read more
Sulphonation Plant - Sustainability
Marsina Engineering SRL
https://marsina.com › sulphonation-plant-sustainability
Marsina Engineering SRL
https://marsina.com › sulphonation-plant-sustainability
In energy management, our sulphonation plants incorporate breakthrough recovery technology, capturing and reusing thermal energy from sulphur combustion for ...Read more
Sulphonation and Sulfuric Acid Combined Manufacturing ...
LinkedIn · WEIXIAN NANJING SCIENCE TECHNOLOGY CO., LTD
30+ reactions · 2 years ago
LinkedIn · WEIXIAN NANJING SCIENCE TECHNOLOGY CO., LTD
30+ reactions · 2 years ago
The process for energy recovery mainly involves using fire-tube boilers to recover the combustion heat generated by sulfur combustion, as well ...Read more
Improving energy efficiency with the Outotec Heat ...
Metso
https://www.metso.com › ... › Mining and metals blog
Metso
https://www.metso.com › ... › Mining and metals blog
Sep 23, 2019 — The Outotec HEROS TM Heat Recovery System, first installed in 1989, generates steam using waste heat from the acid cooling process.Read more
Sulfonation and Sulfation Processes
Chemithon Enterprises
https://www.chemithon.com › Technical_papers
Chemithon Enterprises
https://www.chemithon.com › Technical_papers
PDF
Heat recovered from the SO2 and first to second pass interstage cooler can be used to generate steam in the optional heat recovery system. In state of the art ...Read more
36 pages
Sulfation plant heat recovery unit
WEIXIAN (Nanjing) Science Technology co., ltd
https://www.njweixian.com › sulfation-plant-heat-recove...
WEIXIAN (Nanjing) Science Technology co., ltd
https://www.njweixian.com › sulfation-plant-heat-recove...
Hot air firstly goes into the heat-pipe exchanger, the heat is transferred to the soft water inside, and steam of 0.4~0.6Mpa is generated.Read more
Heat recovery in acid plants
Clark Solutions -
https://clarksolutions.com.br › uploads › 2023/07
Clark Solutions -
https://clarksolutions.com.br › uploads › 2023/07
PDF
Clark Solutions SAFEHR® is a patented sulfuric acid heat recovery technology that addresses issues such as safety and corrosion in an absolutely innovative way.Read more
8 pages
The sulphuric acid plant and district heating
Alfa Laval website
https://www.alfalaval.com › media › stories
Alfa Laval website
https://www.alfalaval.com › media › stories
PDF
In this heat recovery system the acid from the absorption towers was cooled in four anodically protected shell-and-tube heat exchangers connected in parallel ...Read more
2 pages
Missing: Sulphonation technology
Scholarly articles for Sulphonation plant heat recovery technology | |
Sulphonation technology in the detergent industry - De Groot - Cited by 102 Moisture and latent heat recovery from flue gas by … - Gao - Cited by 57 Application of pinch technology for waste heat recovery … - Ataei - Cited by 3 | |
