High-Efficiency Sulfur Gun-Li Zheng Lai

High-Efficiency Sulfur Gun

LGS4 Series High-Efficiency Sulfur Gun:

· Atomization Adjustment Ratio Flow 1:3 Pressure 1:3 for Complete Combustion

· Gun Body Leakage Rate Insulation Steam and Liquid Sulfur Leakage <0.1% /5 years

· Gun Body Deflection High-Temperature Continuous Use Deflection <1°/3 years

· Atomization Particle Size Liquid stream atomization particle size 75% >20μm

Product Description

Overview: As a critical component in sulfuric acid production units, the atomization performance and quality of sulfur guns directly impact the long-term safe, environmentally sound, and economical operation of the entire facility. Statistical data indicates that over 30% of unplanned shutdowns in sulfuric acid plants are attributable to sulfur gun malfunctions, with failure rates significantly exceeding those of pumps, static equipment leaks, and electrical/instrumentation faults during operation. Sulfur gun failures often trigger severe secondary issues such as economizer corrosion, system blockages from sublimated sulfur, demister clogging in drying towers, severe fan vibration, and massive corrosive gas leaks from sulfur incinerators. These problems inflict substantial economic losses and prolonged shutdowns on enterprises. Recognizing the critical importance of sulfur guns to plant operations, Lizhenglai Technology has consistently focused on their R&D. Addressing the harsh operating conditions, we have resolved key challenges facing sulfur guns, including atomization, bending, clogging, and leakage. Our independently developed LGS4 series high-efficiency sulfur guns, representing Lizhenglai Technology's fourth-generation high-performance models, incorporate four core technologies: solid cone atomization with stratified combustion, uniform temperature distribution within the gun body, straight-through flow acceleration, and high-diameter pressure-bearing butt welding. These innovations effectively resolve atomization, bending, clogging, and leakage issues. This ensures continuous operation without shutdowns due to flare nozzle failures during extended service cycles, thereby preventing economic losses for enterprises.

Four Core Technologies of the LGS4 Series High-Efficiency Flare Nozzles

Layered Atomization Technology

Solid-core atomization with stratified combustion produces a rotating solid-cone flame, enabling layered combustion of sulfur mist. This effectively prevents oxygen deficiency at the flame tip caused by surface detonation in hollow-cone flames, eliminating sublimated sulfur generation, flame retreat, and overheating in sulfur incinerators.Accelerated forced atomization effortlessly handles low-load demands during startup. Simultaneously maintains operation without overheating at loads exceeding 120%. Zero Liquid Sulfur Dripping 100% of liquid sulfur combusts within the furnace airspace, ensuring no sublimed sulfur clogs the dryer tower wire mesh mist eliminator during startup/shutdown, preventing increased fan vibration, and guaranteeing SO₂ emissions remain within limits during startup to avoid smoke incidents. This ensures safe and environmentally compliant plant startup.

Gun Body Temperature Equalization Technology: The sulfur injection device is installed inside the sulfur incinerator, where the gun body experiences thermal expansion under high-temperature conditions. The 310S stainless steel material used for the gun body has a coefficient of thermal expansion of approximately 16.6 × 10⁻⁶ (1/°C). According to the expansion formula h1=h0(1+a*ΔT), considering the lance body length typically ranges between 2 and 3 meters, the external operating temperature of the sulfur incinerator is approximately 400°C, while it rises to about 900°C after shutdown. Calculations based on this formula indicate the lance body expands by approximately 10 to 15 millimeters after shutdown. If the internal insulation steam distribution within the lance body is uneven, causing temperature differences between the upper and lower sections, the expansion rates on both sides will also differ. This disparity can lead to upward bending of the lance body. To address this issue, we independently developed a lance body uniform temperature technology. This technology ensures a uniform 360° temperature distribution across the lance body, maintaining consistent expansion rates regardless of whether the sulfur incinerator is operating or shut down. This effectively prevents lance body bending.

Large Flow Path Direct-Pass Technology: The sulfur lance is a core piece of equipment in the facility, and its service life must align with the planned operational cycle of the plant. Due to the use of carbon steel in liquid sulfur pipelines or storage tank areas, corroded iron sulfide may fall into the liquid sulfur and be transported to the sulfur gun, causing blockages during operation. This can lead to plant shutdowns or reduced production. The high-efficiency sulfur gun nozzle employs large-flow-channel straight-through technology (flow area: 376 mm²) and is equipped with an anti-clogging cone, enabling effective passage of iron sulfide without blockage. This ensures reliable operation throughout the high-efficiency sulfur gun's service life. The nozzle is fabricated from ultra-low-iron alloy wear-resistant materials, effectively preventing corrosion caused by iron-sulfur reactions at high temperatures. This design significantly enhances the nozzle's durability and longevity.

High-Diameter Pressure Welding Technology: The unit frequently shuts down due to steam or liquid sulfur leaks from the sulfur gun, which is manufactured using triple-layer jacketed pipe welding. Operating in high-temperature environments, each jacket layer has a different diameter. Thermal expansion concentrates stresses at welded joints—the weakest points. Minor defects like slag inclusions, porosity, or hydrogen cracks cause stress concentration, leading to weld failure and subsequent steam or liquid sulfur leakage. Thus, effective welding technology is the sole solution to prevent sulfur gun leaks. The welds in the high-efficiency sulfur lance within the sulfur incinerator employ high-diameter pressure welding technology. Utilizing 99.999% high-purity argon for full shielding, it achieves single-sided welding with double-sided formation—a high-quality welding technique. Combined with 100% non-destructive testing of the welds, this effectively eliminates welding defects and design flaws, ensuring the high-efficiency sulfur lance is durable and long-lasting.

Product Features: