Sulphur Melter | Sulphur Melting process in sugar processing industry
Specifications for sulphur | Steam Requirement and E-melt system in sulphur melting
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1 Specifications for sulphur | Steam Requirement and E-melt system in sulphur melting
o 1.1 Abstract of Sulphur Melting :
o 1.2 Steam Requirement of Sulphur melting Process:
1.2.1 Example:
o 1.3 Electrical Vapouriser System – (E-melt)
1.3.1 Features of E-Melt System :
1.3.2 Some Important things in E- Boiler or E-melt
Abstract of Sulphur Melting :
1. Sulphur molecular formula “ S “ and it has an atomic number and atomic weight are 16 &
32.06 gm/mol respectively. It melt at 114oC temperature. It vaporizes at 444oC temperature when
heated with air. Sulphur is available in the form of Granular, Rock Sulphur & Roll Sulphur. It is bright
yellow, free from dart. Its density is 2.07 gm/cm -3 at 20 °C.
2. Specifications requirement
Sr. No. Parameters Requirements
1. Elemental sulphur (%by mass ) 99.50
2. Moisture content,max (%by mass ) 0.15
3. Ash, max (%by mass ) 0.20
3. SO2 gas is produced by burning of sulphur with atmospheric air
4. Sulphitation is the process of purification of cane juice by employing milk of lime and sulphur
dioxide gas.
5. Sulphur melt is feed to sulphur bunners along with air to produce sulphur dioxide gas. So sulphur
maintained in liquid state in sulphur melter by using steam coils immersed in sulphur. It steam
temperature used for steam coil is 145 to 150oC (pressure around 4.5 to 6 kg/cm2)
6. Sulphur Melter is a rectangular M.S. fabrication. It has three compartments for separation of
settling and floating impurities. The compartments are designed with underflow and overflow
arrangements, so that the impurities settle-down and float-up, through proper retention time.
7. Holding capacity of this melter is approximately 24hrs. Each compartment has its own steam coil
with inlet and outlet arrangement.
1 liter of sulphur melt = 1.77 Kg of sulphur.
9. The molten sulphur is pumped from the melter to the furnace through a steam jacketed delivery
line, which consists of one molten sulphur header with four isolation valves which are also steam
jacketed, two for re-circulation of melt and one each for the two pumps outlets. The header is
connected to the steam jacketed delivery line, which goes up to the top of the furnace for the melt to
be injected into the furnace through a molten sulphur gun.
10. It is very important to maintain the temperature of steam jacketed line within 140-150 oC for free
flow of the melt.
11. For sulphur melting process generally using 7ata steam from boiler.
Steam Requirement of Sulphur melting Process:
Heat required for sulphur melting = Weight of the sulphur to be melted in kg x ( Specific heat of the
sulphur x Temperature rise of sulphur + Latent heat of the melting
Q = M x [ (ΔT x Cp) + λ]
Q= Heat required for sulphur melting in Kcal /kg
M = Weight of the sulphur to be melted in kg
ΔT = Temperature of the granular sulphur and molten sulphur in oC
Cp = Specific heat of the sulphur in Kcal/kg/ oC
λ = Latent heat of the melting in Kcal/ Kg
Example:
Take 5000TCD plant
Sulphur requirement 0.07 % on cane (Maximum)
M = Sulphur quantity requirement = 3500kgs
ΔT = 140 to 25 oC
Cp = 0.174Kcal/kg
λ= 9.4 Kcal/kg
Q = 102935Kcal
Latent heat of the steam = 489 Kcal/kg
Steam Required for melting = 210kg/hr ( Actual this is requirement for the day but melter holding
capacity always having for 24hours so it is to be consider per hour)
Steam % Cane for sulphur melting = 0.10%
But in practical point of view extra taken due to radiation losses, venting losses etc. it is consider as
0.15 to 0.2% on cane (Depend on steam line length from boiler to sulphur melter)
While using E- melt system power requirement
1 KW = 864Kcal
Power required for melting of Sulphur = 102935 / 864 = 120Kw ( Actual this power requirement
is per day but steam required for continuously to maintained liquid state so the power vary from 60
to 120KWH )
Electrical Vapouriser System – (E-melt)
High pressure steam at 8 Kg/cm2 must be bled from the turbine or the Boiler PRDS system and
brought over long distance to the Sulphur Burners through pipelines for melting of Sulphur. While
transporting steam for this purpose, a lot of energy is lost due to condensation by radiation and
convection. Electrical vapourisers (E-Melt) is one of the solution to overcome this problem in sugar
mills.
Electrical vapourisers are also particularly suited for use during the start-up of the factory when the
steam supply is erratic and because of which, during this period there is a problem in steady
operation of Sulphur Burner system.
Features of E-Melt System :
1. While using this system the melting process is completely isolated from the main boiler of the
factory. So while boiler unexpected stoppage time it will not effect the sulphur melting process.
2. The E-Melt system can be added on to the existing Sulphur melting system with only minimal
modifications.
3. Common system for the complete Sulphur station
4. Can switch to factory steam in case of system breakdown, without disrupting the generation of
So2
5. Effects considerable amount of energy saving,
6. Easy to install & can be located close to the point of use
Some Important things in E- Boiler or E-melt
a) Water Feed (Pump) Control and Low Water : Cutoff automatically maintains correct water level
and shuts Off the vapourizer when the water level in the vapourizer drops below safe limits.
b) Gauge glass arrangement is to be done for E- boiler to know water level in boiler
c) Pressure Gauge provided for visual indication of steam pressure in the vapouriser.
d) Pilot Light visually indicates when vapouriser control circuit energized and the vapouriser is
operating.
e) Condensate Return system for recovery of condensate from melt system to vapourizer allows as
feed results in negligible water loss and make up requirement.
f) PID Control with electronic solid state relay tor maintaining vapour temperature and pressure
accurately.
g) DM water (1st body condensate water) arrangement to be done for makeup water.
h) Steam coils oulet line valves is to be gate type valves.
i) Out line (return condensate line) header to be having minimum 3″ to 4″ dia at the collecting point.
j) Drain line with valve (1/2”) to be provided for oulet condensate line before the valve (To remove
air lock)
k) Inlet and oulet steam lines, pump header and delivery lines insulation made to be perfect.
l) One drain line is to be provide for return condensate line just before the E – boiler inlet line valve.
Some Related Articles
Flocculants Used in Sugar Processing | Flocculant Dosing Calculation. | Role of Flocculants in Sugar
Industry | Flocculant Dosing Online Calculator.
Juice Defecator and Juice Sulphitor Design Criteria | Online Calculator
Juice Sulphitation Process | Methods of Sugar Cane Juice Sulphitation
Concepts of Juice Defecation Process and its Mechanization | Meaning of sugar cane juice defecation
| Methods takes place in juice defecation
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Categories: Clarification, Juice Defication/Sulphitation, Lime and Sulphur Station / 16
Responses / by siva alluri
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16 thoughts on “Sulphur Melter | Sulphur Melting process in sugar processing industry”
Prem Kumar.S
(December 18, 2017 - 11:50 pm)
Reply
Nice siva,it is helpful for me
siva alluri
(December 19, 2017 - 1:28 pm)
Reply
Thank you prem
Manjunath p
(March 17, 2018 - 9:30 pm)
Reply
Really a good article with ample information……
siva alluri
(March 23, 2018 - 4:58 pm)
Reply
Thank you Mr. manjunath
gurursharan kumbar
(July 29, 2018 - 7:28 am)
Reply
plate type heat exchange is very good practice & steam saving
siva alluri
(July 29, 2018 - 2:49 pm)
Reply
Thank you Mr.gurursharan kumbar
S. R. Sahane
(July 22, 2020 - 9:44 am)
Reply
Sir , I Didn’t understand how you calculated a steam required to melt 3500 kg Sulphur to melt, which
is whole day consumption & your answer is 210 kg per hour steam quantity.
Sulphur for melting quantity shall be 159 kg per hour.
siva alluri
(July 23, 2020 - 4:39 am)
Reply
Yes this is actual consumption per hour. But if stop the steam again it will be solidify within one hour
so steam provided continuously throughout day and also condensation losses is more. According to
this we considered it is hourly requirement
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