Operating Instructions of Sulfur Furnace Post (Bolivia)

.
I. Post Tasks
1.
SO2

Atomize liquid sulfur coming from sulfur melting post with sulfur gun, sufficiently burn with dry air
coming from blower fan in sulfur furnace, produce high-temperature SO2 with a certain concentration,
and provide for conversion post after being cooled down with boiler.

2.

Control and adjust each operation indicator of the post in order to conform to requirements.

3.

Take charge of startup and shutdown operation as well as deal with abnormality.

4.

Complete safety production of the post and coordinating work with other posts.

.
II. Main Equipment of the Post (omitted)

.
III. Operation Indicators
1. S + O2 = SO2 +Q

Main Chemical Reaction Formula: S + O2 = SO2 +Q

2.

Operating Control Indicators

S/N Names of Indicators Unit Control Range
1 10001020 SO2 )
Outlet Temperature of Sulfur Furnace 10001020 (Subject to SO2
Concentration)
2 SO2 % 8.510.5
SO2 Concentration of Sulfur Furnace Outlet
3 Temperature of Liquid Sulfur 135--145
4 Pressure of Liquid Sulfur MPa 0.4
5 400--450
Outlet Temperature of the First Waste Heat
Boiler
6 MPa 0.40.5
Liquid Sulfur Insulation Steam Pressure

4
IV. Startup
1. Baking Furnace

Every time when a sulfur furnace or waste heat boiler is built or overhauled, the brick work and fire-
proof casting materials inside shall be baked first and then put into operation after being qualified. The
purpose is to remove the water and guarantee the service life of equipment. Generally speaking, baking
sulfur furnace and boiling out shall be conducted at the same time.

Necessary Conditions of Baking Furnace (including Boiling Furnace)

a.
DCS

All the pipelines and valves from air inlet of sulfur furnace to induced draft fan are well installed; all
measuring instruments are well installed and pass debugging test, and those required are connected to
DCS system.

b.

Oil (gas) supply system is installed, and oil (gas) gun passes debugging test.

c.

Clean up the boiler system. Water supply system is in good conditions and passes pressure test.

d. 0#

Prepare materials including cokes, firewood, 0# diesel (or natural gas) for furnace baking.

(3) Operating Procedures of Furnace Baking

a.
Open up manhole of sulfur furnace, start up outlet valve of MP boiler, and switch off induced draft fan.

b. 24 200 36

First up, bake the furnace with coke fired furnace, and then bake the furnace with firewood 24 hours
later till the temperature reaches 200. Keep such temperature for 36 hours, and then stop baking the
furnace with firewood. Clean up furnace tank, and prepare to bake the furnace with diesel (or natural
gas).

c.

Start up the first air inlet valve of sulfur furnace and the atmospheric valve in front of the furnace,
connect induced draft fan, and start up blower fan and control air output as required.

d.

Induce fire inside sulfur furnace, start up control valve in front of oil (gas) nozzle, and spray oil (gas) to
furnace to burn.

e.

Adjust air output and the amount of oil (gas) sprayed to let air and oil (gas) burn sufficiently, and
control the temperature of furnace tank.

f.

Strictly control the temperature of sulfur furnace according to temperature rise curve.

g. 200 10

After the temperature of furnace baking reaches 200 and stays at 200 for 10 hours, start boiling
out operation according to procedures.

h.

Start up and shut down high-temperature side-line valve of boiler at a regular basis, and bake the
pipeline lining.

i.

After furnace baking finishes, shut down oil (gas) spray valve first, and then stop induced draft fan.
Shut down first air inlet valve.

j.

After the furnace cools down naturally, enter the furnace to inspect, clean up and repair.

4 Furnace Baking Temperature Rise Curve Reference Table

hr hr
Temperature () Time of Temperature Rise (hr) Cumulative Time (hr)
--80 24 24
80--150 9 33
150 48 81
150--200 5 86
200 36 122
200--350 15 137
350 48 185
350--450 10 195
450 24 219
450--600 10 229
600 24 253
600--900 20 273
900 24 297

Notes to Furnace Baking

a.

Conduct ventilation before ignition under any circumstances; shut down fire before shut down air.
Prevent explosions due to oil (gas) accumulation.

b.

Slowing control temperature, and postpone the time of temperature rise when necessary. Boiler may
make sounds when its at the peak of expansion, when insulation must be conducted.

c.

Often check the temperature of furnace wall, and make sure the exhaust vents on furnace wall are
unblocked.

d.

Conduct insulation for sulfur furnace in case of power failure or equipment faults.

e.

Furnace shall be sealed and cooled down naturally after furnace baking finishes. No cooling down with
cool air is allowed.

2. Temperature Rise of Sulfur Furnace

Raise the temperature of sulfur furnace according to temperature rise with diesel (natural gas) furnace
baking procedures which are as follows:

a. 10 250 6

Temperature rises to 250 within 10 hours and stays at 250 for six hours;
b. 30/h 600 6

Temperature rises to 600 at 30/h and stays at 600 for six hours;

c. 30/h 900, 6

Temperature rises to 900 at 30/h and stays at 900 for six hours;

2 150

At this moment, the temperature of each section of converter shall rise above 150 with electric
furnace. High-temperature combustible gas may be directly blown into each section of converter and
controlled according to the requirements for conversion temperature rise.

Control the liquid level of MP boiler and boiling out operation.

After conversion temperature rise finishes, cut off oil (gas) supply and shut down blower fan;
disassemble oil (gas) gun, assemble sulfur gun, unseal blind flange, adjust relevant valves, and prepare
for sulfur spray startup.

3. Sulfur Furnace Startup

Adjust the high-temperature side-line valve and outlet valve of MP boiler to a certain degree; open up
the first air inlet valve of sulfur furnace and shut down the atmospheric valve in front of the furnace.

Shut down sulfur spray valve in front of the furnace, and check liquid sulfur temperature, and
insulation steam pressure. Start up fine sulfur pump.

3 600

Start up blower fan and control air output. Control the amount of sulfur sprayed with sulfur spray
valve. The outlet temperature of sulfur furnace shall be controlled at around 600 to assist conversion
post in catalyst pre-saturation operation.

Constantly observe the burning of liquid sulfur inside sulfur furnace, and adjust air output and the
amount of sulfur sprayed according to conversion temperature till they meet the requirements.

4. Startup after Short-term Shutdown

350 500
800
When the temperature of each conversion section is higher than 350 and when the temperature of
sulfur furnace is higher than 500, its unnecessary to raise the temperature of sulfur furnace and
converter, but directly start up blower fan and spray sulfur to burn. Initially the furnace temperature
shall be controlled at around 800, and then gradually adjust air output and the amount of sulfur
sprayed till they meet the requirements.

.
VI. Shutdown
1. Short-term Shutdown

Shut down sulfur pump and blower fan; drain residual sulfur inside sulfur pipe and conduct insulation
for sulfur pipe and sulfur furnace.

2. Long-term Shutdown

SO2 8.5%

Operate system at low load (SO2 concentration is 8.5%), and rise the temperature of each conversion
section; stop sulfur pump according to the liquid level of fine sulfur tank; stop secondary air, reduce air
output as much as possible, and start hot air blowing; increase air output after hot air blowing
finishes, and start cool air blowing.

.
VI. Notes to Normal Operation
1.

Check sulfur pipe heat tracing insulation steam pressure and drainage to ensure liquid sulfur
temperature. When the system is in short-term stop, heat tracing steam of sulfur gun shall keep
circulation; when necessary, unload sulfur gun to prevent damage. If there is sulfur in sulfur pipe heat
tracing steam drainage, consider the sulfur leakage of sulfur pipe jacket and it shall have emergency
shutdown.

2. 0.4MPa

Liquid sulfur pressure of sulfur gun shall be higher than 0.4Mpa to ensure atomization effect of liquid
sulfur. Pay attention to the burning flame and sulfur atomization in the observation furnace to prevent
producing sublimed sulfur.
3.

Adjust secondary air properly to prevent sulfur furnace temperature backwards.

4. 12

Pay attention to temperature change of sulfur furnace: (1) Prevent sulfur gun blocking and sudden
temperature drop. (2) Strictly prohibit sudden temperature rise.

5.

Check sulfur gun properly to prevent the damage of sulfur gun steam jacket and moisture into the
system.

6.

For system production, conduct ventilation first, and then sulfur spray. Stop feeding sulfur first, and
then stop feeding air. Purpose: Prevent sulfur accumulation inside the furnace. In case the blower fan
trips and sulfur pump does not, shut down sulfur pump immediately or close sulfur spray valve. In that
case, for system startup, purge with less air output at first, and then spray sulfur when the outlet
temperature of sulfur furnace begins to fall.

Operating Instructions of Dry Absorption Post (Bolivia)

.
I. Post Task
SO3

Remove the moisture in the air coming from blower fan; absorb SO3 coming from converter to prepare
sulfuric acid.

. )
II. Equipment Specification Chart (omitted)

.
III. Process Flow
93%98%
0.1g/Nm3

Humid air filtered with air filter will have pressure rise with main blower fan and go to drying tower
for drying with 93% (98%) acid, Demist acid mist with mesh demister at tower top, and feed into sulfur
furnace to burn with sulfur. Moisture in dry air shall be 0.1g/Nm 3.

93% 40

98% 60 SO3
.
. 98% 60
SO3

Drying tower, first absorption tower and second absorption tower are all packing towers. Acid
circulating pump of drying tower conveys 93% acid to dry acid cooler. Spray it in drying tower after it
cooling down to 40 and absorb moisture in air then back acid to drying circulation tank. A portion
will go to the first absorption circulation tank. The acid circulating pump of first absorption tower will
convey 98% acid to the first absorption acid cooler, and go to the first absorption tower when it is
cooled down to 60. The spray will absorb SO3 from the third converter will back acid to the first
absorption circulation tank, a portion of it will go to drying circulation tank. Add process water and
sulfuric acid mixing and then produce acid to keep concentration of acid, stable liquid level in acid
circulation tank. The acid circulating pump of the second absorption tower will convey 98% acid to the
second absorption acid cooler, and go to the second absorption tower when it is cooled down to 60.
The spray will absorb SO3 from the fourth converter. Keep acid concentration and liquid level stable by
adding water and producing acid.

.
IV. Technological Operation Indicators
1. SO3 + H2O = H2SO4 + Q

Main Chemical Reaction Formula: SO3 + H2O = H2SO4 + Q

2. 0.1g/NM3

Outlet Moisture of Drying Tower 0.1g/NM3

3. 9496%( 93.594.5) 9898.8%

Concentration of dry acid is 9496% (93.594.5% when necessary); acid concentration of first and
second absorption towers is 9898.8%

4. 4060

Temperature of Acid Fed to Drying Tower 40; Temperature of Acid Fed to First Absorption Tower
and Second Absorption Tower 60

5. 14018099.95%

Air Inlet Temperature of First Absorption Tower and Second Absorption Tower: 140180,
Absorbance: 99.95%

6. PH6.5 cl-50ppm P0.25MPa T40

Cooling Water of Acid Cooler: PH6.5 cl-50ppm P0.25MPa T40

.
V. Startup

(I) Preparation for Startup after Long-term Shutdown

1.

Check if all equipment, pipelines and valves are in good conditions; test the amount of acid lifted of
each tower respectively; wash towers, spit acid and feed acid; determine the current of acid pump.
2. 98%

Feed 98% acid sufficiently to each acid circulation tank. After being informed of conversion
temperature rise, start up drying pump, first absorption pump and second absorption pump as required.
Open up cooling water valve of acid cooler and start up water pump.

3.

During temperature rise of converter, control acid concentration and acid temperature.

(II) Normal Startup

98%

After temperature rise of converter finishes and being informed of startup, start up drying pump, first
absorption pump and second absorption pump, and control the amount of acid to feed the tower. When
acid concentration rises, feed water and acid into the tank, and control acid concentration; when acid
temperature rises, adjust the amount of circulating cooling water of acid cooler, and control acid
temperature; when the liquid level of circulation Tank rises, open up acid production valve to produce
98% acid constantly and steadily, and control liquid level.

.
VI. Shutdown

(I) Long-term Shutdown

1.

Raise acid concentration and liquid level of circulation tank to a certain degree, and hot air and cool air
blowing to converter shall be accompanied.

2. 97.5%
92.5%

When blowing hot air and cool air, all three towers need acid lift, and acid concentration needs to be
analyzed once every hour, which may not be lower than 97.5% (dry acid concentration higher than
92.5%).

3.

After system shutdown, if acid tank level allows, stop the pump and cooling water; drain residual acid,
and shut down relevant valves.
4. 0 97%

If ambient temperature is lower than 0, acid concentration shall be controlled at around 97% to avoid
crystal accumulation.

(II) Short-term Shutdown

Control liquid level of acid tank, and stop pumps after system shutdown; there is no need to stop pumps
if nothing needs to be repaired.

.
VII. Causes and Treatment of Abnormal Phenomena

1 1
2 2
3 3
4 4
1 1
2 2
3 3
4 4

PH 1 1
2 2
1 1
2 2
3 3
1 1
2 2
3 3
4 4

Abnormal Causes Treatment

Phenomena
Chimney smokes 1. Too high or too low of acid 1. Adjust acid concentration
concentration 2. Increase lift volume or overhaul acid
2. Insufficient lift volume of acid pump or acid tank liquid level is too low
pump 3. Shutdown for overhaul
3. Acid distribution is uneven 4. Shutdown for inspection and overhaul
 4. Moisture into the system
Acid 1. Decrease of gas concentration
concentration 2. Decrease of conversion rate
decreases 3. Excessive watering
4. Inaccurate acid concentration
analysis
Acid pump trips Fault of electrical equipment or
acid pump
PH value of 1. Leakage of acid cooler
cooling water 2. Cooling water is acidic itself
value
Acid temperature 1. Leakage of acid cooler
is too high 2. Water temperature is too high
3. Insufficient of cooling water
Current of acid 1. Fault of ampere meter
pump drops 2. Turn down the pump outlet
valve
3. Pump suction inlet blocked
4. Fault of acid pump
1. Adjust gas concentration or decrease
watering
2. Adjust conversion temperature
3. Decrease watering
4. Overhaul acid concentration analyzer or
medicament
Emergency System Shutdown
1. Shutdown for overhaul
2. Alkali addition or water displacement
1. Shutdown for overhaul
2. Handle after identifying cause
3. Increase cooling water
1. Inspect and maintenance
2. Open outlet valve
3. Shutdown for cleaning up
4. Shutdown for overhaul

.
VIII. Safety Precautions
1.

Operate by holding certificates. When working with acid, wear acid-poof equipment.

2.

When inspecting and repairing equipment, relieve pressure, exhaust all the spent acid, clean enough
and hang safety warning sign.

3. 36V

When working in towers and tanks, wear personal protection equipment and use 36V safety lamps.
Ventilate first and somebody shall monitor outside.

4.

Steel acid storage vessel. Conduct hot work analysis before hot work.

5.

When having a lab analysis, we shall not put water into sulfuric acid, but put sulfuric acid into water
slowly.
6.

Do not let acid contact with skin. If the skin is spilled with acid, immediately wash with large amount
of clean water and see the doctors when serious.

7.

Timely overhaul the acid leakage of equipment and hang danger signs.

8.

Lubricate acid pump. In case an acid pump is tripping and cant be started up, the system must have
emergency shutdown.

Operating Instructions of Boiler Post (Bolivia)

.
I. Post Task
1.

Well manage all electric appliances, instruments and mechanical equipment in waste heat boiler
system.

2.

Strictly control all technological operation indicators, guarantee boiler water quality and steam quality
to ensure safe and economic operation of boiler and steam piping network;

3.

As an important component of sulfur burning and conversion post, the operation indicators of waste
heat boiler system shall conform to the overall technological requirements for sulfur burning and
conversion.

.
II. Process Flow
104

Convey demi. water being treated to waste heat boiler drum with MP water supply pump (convey to
de-aerator, heat up to 104 with LP steam till de-oxidation is qualified).
 1020 425 3.0MPa255

1020 high temperature furnace gas from sulfur furnace is cooled down to 425 by waste heat
boiler, and produce saturated steam of 3.0MPa, 255.

3.0MPa.255 0.6MPa

The produced MP saturated steam of 3.0MPa, 255 will be lowered to 0.6MPa LP pipe network
through spray de-superheating decompression.

For safe operation of boiler, conduct regular and continuous blow-down of boiler; set a dosing vehicle
to add TSP solution into boiler drum and treat with boiler water.

.
III. Main Equipment (omitted)

.
IV. Technological Operation Indicators

S/N Names of Indicators Unit Indicators Range
1 MPa 2.63.0
Operating Pressure of Boiler Drum
2
Liquid Level of Boiler Drum Above Centerline
3 MPa 3.8
Boiler Feed-water Pressure
4 mol 3
Boiler Feed-water Hardness
5 s/cm 10
Feed-water Conductivity
6 PH Feed-water PH Value 8.59.8
7 Boiler Water Hardness mol 3
3-
8 PO4 mg/L 215
3-
Boiler Water PO4 Value
9 PH Boiler Water PH Value 911
10 mol 0.21.2
Total Alkalinity of Boiler Water
11 s/cm 100
 Boiler Water Conductivity

.
V. Boiling Out
1.

Boilers newly-built or overhauled shall be boiled out, namely removing oil stain and rust on water side
with chemical solution.

2.

Boiling out and baking sulfur furnace (temperature rise) will proceed synchronously.

3. 200 10

When the temperature of baking sulfur furnace reaches 200 and stays at 200 for 10 hours,
operation according to boiling out curve and requirements.

4.

During pressure rise, conduct thermal fastening of pressure parts with bolts.

.
VI. Hydraulic Pressure Test on Boiler
1. ...

Check all equipment, electrical equipment, instrument and valve are well installed for use. Remove
safety valve and seal blind plate.

2. .

The feed water system will water washing from economizer to boiler body pipeline. Remove flow
orifice plate and valve body of throttle before washing. Washing qualified will subject to boiler water
transparency.

3.

After washing, main feed water valve will inflow water to steam drum slowly. when the steam drum
level reaches to normal water level, stop water inflow and observe water-level fluctuation of the steam
drum. If variation occurs, find out reasons and then eliminate it.

4.

Close import and export valve of level gauge, and continue to inflow water to steam drum until normal
outlet water of atmospheric valve and draining valve on super-heater pipeline. Close atmospheric
valve, draining valve and then the boiler system begin to boost.

5.

Pressure rise operation should be done slowly. The speed of pressure rise and test pressure will proceed
according to the installation instructions of waste heat boiler.

6. 0

After passing hydraulic pressure test, slowly open up blow-down valve to relieve pressure. When the
pressure falls to 0, open up atmospheric valve and draining valve on super-heater pipeline, as well as
the inlet and outlet valves of liquid level gauge, control liquid level at normal water level.

.
VII. MP Boiler Startup
1.

Start up the atmospheric valve of MP boiler drum, shut down main steam valve of drum, and start up
MP water feed pump to feed water into boiler drum till it reaches low water level. Inform system for
temperature rise.

2. 0.2MPa

It can confirm that the air is discharged out of the drum when drum pressure reaches 0.2MPa, then the
atmospheric valve of drum may be closed a little bit. Pressure of MP boiler starts to rise slowly.

3. 1.0MPa 0.4MPa
1.0MPa 0.8MPa

Pressure rise of boiler system shall be conducted strictly according to pressure rise curve that pressure
rise per hour shall be less than 0.4MPa under 1.0MPa, and less than 0.8MPa above 1.0MPa. The speed
of pressure rise may be adjusted with the atmospheric valve of drum.

4. 1.0MPa

When drum pressures increases to 1.0MPa, open up the atmospheric valve of LP sub-cylinder, debug
temperature and pressure reduction device for water spray, slightly open up main steam valve, and feed
steam to LP sub-cylinder. When we can confirm that the air is completely discharged from LP sub-
cylinder, we may close the atmospheric valve a little bit and feed steam to LP pipe network.

5.

After startup turns normal, debug and sample the cooler. Sample steam, furnace water and feed water to
analyze their quality. Determine the discharge capacity and dosage of boiler according to analytic
results.

.
VIII. Shutdown

Stop dosing, and shut down blow-down valve and sampling valve. Control the water level of boiler
drum and maintain the pressure. Stop water spraying of temperature and pressure reduction device.

Conversion between hot and cool air blowing and slow pressure drop shall be applied to long-term
shutdown.

.
IX. Notes to Normal Operation
1.

Strictly control the water of boiler. When the boiler is shorting of water, we must have emergency
shutdown. Watering balanced and pay attention to whether feed water flow matches the steam flow.
When in normal operation, avoid to increase or decrease rapidly and do not close to the highest or
lowest water level.

2.

Complete the calibration work of safety valve pressure gage.

3.

Wash the liquid level gauge two times in every shift. Steps:

Open drain cock; close aqueous cock;

Open aqueous cock; close steam cock;

Open steam cock and close drain cock. Watch the rise of liquid level.

4.
Conduct regular and continuous blow-down operation in every shift. Supplement medicament timely
and ensure the quality of boiler water and steam.

5.

When the level of liquid level gauge cant be seen, start the operation of calling for water as follows:

1)

Close steam and liquid clocks, and open drain cock.

2)

Close drain cock and open liquid cock. If we see the liquid level, water to the drum and open
the steam cock to back to normal; if the liquid level cant be seen, we must have
emergency shutdown.

7.
2MPa

Strictly control the boiler pressure and prohibit overpressure. To reduce the condensate corrosion of
furnace gas to the tube wall of boiler, under permission condition of boiler operation pressure, control
boiler drum pressure to be larger than 2Mpa.

8.

When there is a leakage of boiler system, the principle of treatment is: on the condition that boiler
system safety is assured, avoid the steam to come into converter to protect catalyst.

X. Causes and Treatment of Abnormal Phenomena

1 1 1
2
3 2
3
4 4
5 5
2 1 1
2 2
3 3
4 4
3


S/N Abnormal Causes Treatment

Phenomena
1 Drum level 1. Fault of automatic
drops rapidly regulation of feed water
2. Fault of feed water pump
and pipe
3. Excessive blow-down
amount or blow-down valve is
not closed properly
4. Increase of boiler load
5. Explosion of boiler
2 Drum level 1. Rapidly decrease of steam
increases output volume.
rapidly 2. Inaccurate instrument
regulation loop
3. Fault of pressure transmitter
4. Big evaporation capacity
3 Great Bad boiler water quality to
fluctuation of cause priming
drum level
1. Manually adjust feed water valve position,
verify actual water level on site and inform
instrument repair.
2. Start up standby pump or have emergency
shutdown.
3. Increase the feed water volume or close
blow-down valve.
4. Increase feed water volume.
5. Emergency shutdown.
1. Turn up atmospheric valve.
2. Switch to manual adjustment.
3. Refer to other pressure gage adjustment.
4. Adjust steam volume or sulfur spraying
volume.
Improve feed water quality, or increase
medicament, increase blow-down volume to
improve feed water quality

Operating Instructions of Centrifugal Blower

.
I. Preparation for Unit Startup
1.

No grinding or scratching during hand turning of unit.

2. 3040mm

Check the oil level of lubricating oil tank to make sure that its 3040mm higher than the highest oil
level.

3.

Check the cooling water system.

4.

Check and adjust interlock device: interlock between main motor and main oil pump; interlock
between bearing temperature and main motor; interlock between oil pressure and standby oil pump;
interlock between oil pressure and main motor.

5.

Slightly open the inlet valve of blower fan, and fully open the atmospheric valve at the outlet of blower
fan.

.
II. Unit Startup
1.

Start up main oil pump, check if lubricating oil system (including high-level oil tank) is clear, and
check if oil level is normal.

2. 0.01MPa

Adjust the oil pressure of LP oil circuit at 0.01MPa.

3. 2535

Check if the lubricating oil temperature of each bearing is within 2535 , if not, cool down or heat
up such lubricating oil.

4.

Start up the main motor.

5.

Check if there is any leakage, abnormal vibration, or abnormal sound. Check oil temperature, and
adjust cooling water of oil cooler.

6.

Gradually start up the inlet valve of blower fan and gradually shut down the atmospheric valve at outlet
when the unit is operating well.

.
III. Unit Shutdown
1.

Slowly shut down the inlet valve of blower fan and main motor. Record the time assumed from
shutting down the unit to unit rotator completely stopping for comparison.

2. 20 45
Shut down the unit for 20 minutes, or shut down main oil pump when bearing temperature is lower
than 45.

3.

After main oil pump stops, shut down the inlet and outlet valves of cooling water of oil cooler, and
discharge the water accumulated inside the cooler if necessary.

.
IV. Unit Maintenance
1.

Often check if the unit has any vibration or abnormal sound.

2. 60 25--35

Often check if the bearing temperature is lower than 60, and adjust the amount of cooling water of
oil cooler to make sure that the bearing temperature is within 25--35.

3. 80120KPa

Often check if the oil pressure of bearing lubricating oil system is within 80120KPa.

4.

Often check the level of oil tank which may not be lower than the lowest oil level.

5.

Use oil filter and analyze the quality of lubricating oil at a regular basis.

6.

Unit operation in a surging area is not allowed. The inlet valve and outlet atmospheric valve of blower
fan shall be adjusted if there is any surging.

7.

The cooling water pressure of oil cooler may not be higher than the oil pressure here. Clean up all the
pipes at water side of oil cooler at a regular basis according the quality of cooling water.

Operating Instructions of Sulfur Melting Post (Bolivia)

.
I. Post Task

Be responsible for melting solid sulfur timely and sufficiently, and conveying liquid sulfur that
conforms to technological requirements to sulfur furnace. Guarantee safety in production and prevent
sulfur fires.

.
II. Process Flow

135--145
Convey solid sulfur to rapid sulfur melting tank continuously and evenly with belt conveyer. Melt to
liquid sulfur continuously by heating up with coil steam and agitator. By controlling the amount of
solid sulfur conveyed, control the liquid level of rapid sulfur melting tank. Liquid sulfur overflows to
settling tank and fine sulfur tank, and liquid sulfur temperature shall be controlled at 135--145 .
Refined liquid sulfur will be conveyed to sulfur furnace with fine sulfur pump for burning.

.
III. Post Main Equipment (omitted)

.
IV. Main Technological Indicators

S/N Names of Indicators Unit Control Range
1 135--145
Temperature of Liquid Sulfur
2 % 80
Liquid Level of Liquid Tank
3 MPa 0.60.8
Steam Pressure of Rapid Sulfur Melting Tank
4 MPa 0.40.5
Sulfur Pipe Insulation Steam Pressure
5 MPa 0.50.6
Steam Pressure of Settling Fine Sulfur Tank

.
V. Startup
1.

Check if all equipment, pipelines and valves are well installed. Check if steam insulation and drainage
are in good conditions.

2. 0.7MPa

Convey solid sulfur to rapid sulfur melting tank through belt conveyer. Heating steam pressure of
sulfur melting tank shall be controlled at around 0.7MPa, to make sure that the solid sulfur piled is
slightly higher than heating coils.

3.
Start up stirring device and agitator to constantly feed solid sulfur to melt them.

4.

Liquid sulfur overflows to settling fine sulfur tank, adjust steam pressure, and well control liquid sulfur
temperature. Well control the liquid level of each tank, debug fine sulfur pump, and get ready to feed
sulfur to sulfur furnace.

5.

After being informed to start up, open the outlet valve of pump and start up fine sulfur pump.

6.

Constantly melt sulfur to maintain a steady liquid level of fine sulfur tank.

.
VI. Shutdown

(I) Short-term Shutdown

1.

Stop feeding sulfur, and liquid level shall be controlled above heating coils.

2.

After being informed of shutdown, stop fine sulfur pump. Shut down the outlet valve of fine sulfur
pump after the liquid sulfur inside sulfur pipe flows back.

3.

Well control the temperature of each tank.

(II) Long-term Shutdown

1.

Stop feeding sulfur to rapid sulfur melting tank, open the drainage valve at the bottom of tank to fully
consume the liquid sulfur inside the tank.

2.

Inform other posts to prepare for shutdown, and stop fine sulfur pump.

3.

After the liquid sulfur inside sulfur pipe flows back, shut down the outlet valve of fine sulfur pump.
4.

Shut down heating steam. If cleaning is needed, open up the manhole or cover board of each tank for
ventilation and cooling down.

5.

Cut off equipment power supply and master steam valve, and hang up signs.

.
VII. Safety Notes to Normal Operation
1.

Often check each heat and insulation line pipe frequently to ensure unblocked drainage and prevent
part insufficient heat tracing and liquid sulfur solidification.

2.

Check each tank liquid level to prevent liquid sulfur spill or insufficient.

3. SO2

Strengthen patrol inspection to prevent solid sulfur and liquid sulfur burning. If there is flame or smoky
(the concentration of SO2 gas is high), use water or steam to put out the fire. When solid sulfur is on
fire, use large amount of solid sulfur to put out the fire with coverage.

4.

According to the acidity of sulfur, timely add alkali to neutralize.

5.

Often check frequently and keep the vent of each tank unblocked to prevent the accumulation of
harmful gas in the tank.

6. 1

Drain residual sulfur inside sulfur pipe during short-term shutdown. Provide insulation for liquid sulfur
and sulfur pipe if possible; in case there is no steam supplied, preheat up sulfur pipe one hour before
startup to ensure the sulfur pipe in not blocked.

7.

Outlet valve of fine sulfur pump shall keep relatively stable to avoid fluctuation of back system.

8.

Because of the higher temperature of liquid sulfur and steam, we shall prevent burns in the operation.
9.

Before cleaning or overhauling the storage tank, we shall pay attention to ventilation and prevent
poisoning.

10.

Lubricate pumps well and conduct hand turning of unit before startup.

.
VIII. Causes and Treatment of Abnormal Phenomena

1 1
2 2
3 3
4 4
5 5

1 1
2 2
3 3
4 4

Abnormal Phenomena Causes Treatment

Sulfur transportation 1. Steam pressure temperature is too high 1. Adjust steam pressure
pipeline blocked or too low 2. Dredge
2. Drainage pipeline blocked 3. Clean debris
3. Debris blocked in the pipe 4. Clean jacket and find the
4. Leakage of insulation steam jacket, leakage point to weld
flow of liquid sulfur into jacket 5. Overhaul or change the
5. Fault of fine sulfur pump pump
Liquid sulfur bubbles Leakage of steam pipe Plugging
Fine sulfur pump output 1 Sulfur transportation pipeline blocked 1. Pipeline dredge
drops 2 Fault of fine sulfur pump 2. Overhaul or change the
3 Tank liquid level is too low pump
4. Pump inlet blocked 3. Increase the liquid level
4. Clean
Floating acid on the Dilute acid produced when putting out the Add alkali to neutralize
surface of liquid sulfur fire or high moisture in the sulfur

Operating Instructions of Conversion Post (Bolivia)

.
I. Post Task
1. SO2 SO3

Convert SO2 coming from the first waste Heat boiler to SO 3 through catalysis of vanadium catalyst for
absorption post to absorb to prepare sulfuric acid.

2.

Control and adjust all equipment indicators of the post and take charge of startup and shutdown
operation, as well as deal with abnormality.

3.

Check and maintain all equipment, pipelines, electric appliances and instruments of this post.
Guarantee safety in production and sanitary environment.
.
II. Process Flow and Operation Indicators of Post
1. Process Flow

1000.SO2 9.5%
420
440 440

420

Burn dry air and atomized liquid sulfur in sulfur furnace sufficiently to produce high-temperature
furnace gas at about 1000 with 9.5% SO2. Cool down such furnace gas to 420 with MP waste heat
boiler. Then furnace gas reacts inside the first section of converter. The outlet gas of first section will be
cooled down to 440 with the primary air cooler, and then react inside the second section of
converter. The outlet gas of second section will be cooled down to 440 with hot-hot heat exchanger,
and then react in the third section of converter. The outlet gas of third section will go to the first
absorption tower after being cooled down with cold-hot heat exchanger. The gas from the first
absorption tower will be heated to 420 with cold-hot heat exchanger and hot-hot heat exchanger, and
then react in the fourth section of converter. The outlet gas of forth section will go to the second
absorption tower after being cooled down with the secondary air cooler.

2. Operation Indicators

12SO2 + O2 = 2SO3 +Q

Main Chemical Reaction Formula: 2SO2 + O2 = 2SO3 +Q

Operation Control Indicators

S/N Names of Indicators Unit Control Indicators
1 SO2 % 8.510.5
Inlet SO2 Concentration of the First
Section
2 415--420
Inlet Temperature of the First Section
3 440--445
Inlet Temperature of the Second
Section
4 430435
Inlet Temperature of the Third Section
5 420--430
Inlet Temperature of the Fourth Section
7 600
 Outlet Temperature of the First Section
8 % 99.5
Final Conversion Rate

.
III. Post Main Equipment (omitted)

.
IV. Startup
1. Preparation for Startup

Check if all equipment, pipelines, and valves are well installed and meet startup requirements.

Check oil cooling system and water cooling system of air blaster to make sure that they are standing by.

Check electric appliances and instruments.

Contact relevant posts to get ready for startup.

2. Conversion Temperature Rise

550120 30/hr
120

Initial temperature rise of converter. Shut down the butterfly valve at the air inlet of sulfur furnace, the
butterfly valve at the outlet of waste heat boiler, and its side-line valve; start up the valve at the air inlet
of first section, start up drying pump, and drip pump lifts acid; start up blower fan and electric furnace,
and adjust the air output and the number of electric furnace groups, to make the temperature at electric
furnace outlet 550, and the temperature rise at the inlet of first section and fourth section during the
first hour 120 respectively, and keep temperature rise at 30/hr. Stop lifting acid when the
temperature at the outlet of each section above 120.

2 150

40--60/hr
Temperature rise of converter. When the outlet temperature of each section is over 150 , conversion
temperature rises as the temperature of sulfur furnace rises and the pressure of boiling out rises. After
adjusting relevant valves, continuously blow the high-temperature combustible gas inside the furnace
into converter. Adjust the side-lien valve of each conversion section to control the temperature rise of
each section at 40--60/hr.

3 70

During conversion temperature rise, when the temperature at the inlets of first and second absorption
towers is 70, the first and second absorption towers start to lift acid and control acid temperature as
required.

4 450 420 350

420

When inlet temperature of first section, second section, third section and fourth section of converter
reach 450, 420, 350, and 420 respectively, conversion temperature rise finishes.

3. System Startup

1 SO2 45%
SO2 600

After preparation, start up system ventilation. At initial stage, SO 2 concentration at the inlet of first
section shall be controlled between 4% and 5%, to let the new catalyst start SO 2 pre-saturation. Control
the temperature of first section bed to make it rise steadily without exceeding 600.

At the initial stage of system startup, according to inlet temperature of first and fourth sections, try as
hard as possible to start up the side-line valve of the first waste heat boiler, shut down outlet valve of
boiler and start up the number of electric furnace groups to a certain degree.

3 420
8.59.5%

When the first and second sections respond well, and inlet temperature of the fourth section is higher
than 420, gradually increase air output to make inlet air concentration of the first section between 8.5
9.5%. Then gradually decrease the heat of electric furnace, turn down high-temperature side-line
valve, start up outlet valve of boiler, and set every operating index within the required range.

4. Startup after Short-term Shutdown

1 350 500
800

When the temperature of each section of converter is higher than 350 , and when the temperature
inside sulfur furnace is higher than 500, no conversion temperature rise is needed for startup. Sulfur
may be sprayed and burned directly for conversion ventilation. The outlet temperature of sulfur furnace
may be controlled at about 800 initially. Then raise the temperature of each section to the regulated
range by adjusting electric furnaces of first and fourth sections, as well as side-line valve of each
section. Gradually increase gas flow and gas concentration after the temperature of each section
becomes good.

2 350

System needs to have temperature rise again according to temperature rise procedures if the
temperature of each conversion section is under 350.

5.
V. Shutdown
1. Short-term Shutdown

1 440

Raise the inlet temperature of each conversion section to 440 before shutdown (except for
emergency shutdown).

Shut down sulfur pump, blower fan, and inlet valve of blower fan.

Shut down side-line valve of each section, and conduct insulation for sulfur furnace and converter.

2. Long-term Shutdown

1 10--20

Raise the temperature of each conversion section 10--20 compared to the original in advance; reduce
the air output of blower fan after shutting down spraying sulfur, start up electric furnace, and blow hot
air to conversion system with dry air, self-heat of sulfur furnace preserved, and electric furnace. Lift
acid in three towers during hot blowing.

2 400

Keep the inlet temperature of first section higher than 400 , increase hot air output properly, and use
side-line valves of each section to delay temperature reduction of each section as much as possible.

3 380 SO2+SO30.03%
After the temperature of first section drops below 380, and when SO 2+SO30.03% at the outlet of
fourth section is measured, turn to cool blowing.

4 30--50/hr 80
4 93%

Shut down electric furnace during cool blowing, and gradually increase air output. The dropping speed
of inlet temperature of first section shall be regulated at 30--50/hr. When the temperature turns 80 ,
keep such temperature for four hours till cool blowing finishes. Shut down blower fan and all valves.
Dry acid concentration shall not be less than 93% during cool blowing.

.
VI. Design and Control Parameters of Each Conversion Section
%
Inlet Temperature Outlet Temperature Conversion Rate %
420 598 65
st
1 Section
440 500 88
nd
2 Section
430 445 95
rd
3 Section
430 440 995
th
4 Section

VII. Notes to Safety in Production

1.

Strictly control inlet temperature of each section and inlet gas concentration of the first section to
prevent the decrease of conversion rate, exhaust blow-down out of standard and polluting environment.

2. 600

The catalyst layer temperature may not be higher than 600 , so as to prevent from burning catalyst
and equipment.

3.

Discharge condensate acid of heat exchanger regularly.

4.

Pay attention to the resistance change of each section in the converter.

5.

When operating, strengthen the contact with each post.

.
VIII. Treatment of Abnormal Phenomena

1 1
2 2
3 3
4 4
5 5
1 1
2 2
3 3
1 1
2 2
3 3
4 4

1 1
2 2

Abnormal Causes Treatment

Phenomena
Low conversion 1. Abnormal conversion temperature 1. Adjust the temperature of each
rate 2. Too high or unstable concentration section to normal
3. Short circuit of catalyst layer and the 2. Adjust concentration
air leakage of heat exchanger 3. Handle after determining and
4. Analyze error identifying
5. Poisoning and aging of catalyst 4. Reanalysis
5. Handle after identifying
Decrease of 1. Decrease of gas concentration 1. Check blowing rate, sulfur pump
conversion 2. Unsuitable adjustment of vice-line and sulfur gun
temperature valve 2. Adjust vice-line valve
3. Instrument malfunction 3. Check instruments
Catalyst layer 1. Low inlet temperature of the first 1. Adjust inlet temperature
reaction section 2. Gas concentration
temperature 2. Too high concentration 3. Handle after identifying
moves backwards 3. Poisoning and aging of catalyst 4. Check instrument
4. Instrument malfunction
Increase of inlet Equipment at the back of blower fan or Check the resistance change of each
pressure of blower pipe blocked equipment and deal with such change
fan after identifying it
Large fluctuation 1. Too much lift volume 1. Check acid pump current
of inlet pressure of 2. Acid accumulation at the bottom of 2. Dredge lower tower acid pump or
blower fan tower or heat exchanger discharge waste acid

Yangzhou Jintao Chemical Equipment Co., Ltd.

2011-5-19

May 19, 2011