Li Zhenglai's high-efficiency sulfide sprayer strengthens the production line of sulfur incinerators. 

What is a sulfonator? Why is it called the "throat" of the sulfur acid production facility? 

In the sulfuric acid production plant, liquid sulfur is atomized by the sulfur spray gun (referred to as "sulfur gun") and then enters the sulfur incinerator for combustion, generating sulfur dioxide gas. It can be said that the sulfur gun is the "throat" of the entire plant's raw material supply - its atomization performance and manufacturing quality directly determine whether the plant can operate safely, environmentally friendly, and economically for a long period. 

However, the sulfone gun is also a "minor key equipment": There are very few manufacturers in the market that truly understand the sulfuric acid production process and focus on the research and development of sulfone guns. Many enterprises lack awareness of how the performance of the sulfone gun will affect the damage to the production facility. According to statistics, the unplanned shutdown incidents of sulfuric acid production facilities due to sulfone gun problems account for more than 30%, and its failure rate is even higher than that of operating pumps, static equipment leakage and electrical instrument failures. This article will sort out the core pain points of the traditional sulfone gun and interpret the upgrade solutions, helping enterprises achieve cost reduction, efficiency improvement and long-term development. 

I. Six fatal points of the traditional sulfur gun 

Most sulfuric acid production facilities have long been constrained by traditional sulfurylators. The six core issues are interrelated and continuously pose production safety hazards: 

1. Poor atomization effect: The liquid sulfur is not atomized sufficiently, resulting in the accumulation of liquid sulfur at the bottom of the sulfur incineration furnace. The unburned residual sulfur forms a large amount of sublimated sulfur, which enters the converter along with the process gas and will cause catalyst poisoning and deactivation. 

2. Gun barrel thermal deformation: There is a significant temperature difference between the upper and lower parts of the gun barrel. This causes uneven expansion of the metal due to heat, resulting in thermal stress exceeding the material's yield strength within the barrel. This can lead to permanent deformation. 

3. Frequent blockage of nozzles: The liquid sulfur filter has insufficient filtering capacity. The sulfur corrodes the sulfur pipeline, generating iron sulfide impurities. These impurities are carried along with the liquid flow into the sulfur gun, eventually causing blockage of the atomization nozzles. 

4. Leakage of heating steam: Failure of the welds on the gun body or damage to the insulation jacket causes steam to leak into the sulfur incineration furnace. The steam then condenses in the economizer, generating a large amount of cold acidic water, resulting in severe corrosion of the first absorption acid separator and a larger and more prolonged tailing of the chimney smoke. 

5. Maintenance costs soar: The detachment of refractory bricks in the sulfur incinerator and the deactivation of catalysts in the converter have led to a significant increase in maintenance costs. 

6. Dual risks of production suspension and environmental protection: Unplanned shutdowns result in significant economic losses. Additionally, during the maintenance of the sulfur gun, the high-temperature smoke from the sulfur incinerator leaked out, further exacerbating safety and environmental risks. 

Harmful consequences of poor atomization 

For the entire process system 

The desiccant tower demister is coated with the sublimated sulfur that is blown back. 

The oxidation of sulfur can cause the catalyst to become poisoned, significantly reducing its service life. 

During the driving phase, the SO₂ emissions exceeded the standard, resulting in significant environmental protection pressure. 

The concentration inside the furnace is unbalanced, causing the catalyst to overheat and become deactivated. 

Regarding the main body of the sulfur incinerator 

The insulation layers such as refractory bricks in the sulfur incinerator will be severely damaged. The outer steel shell will be continuously eroded by high temperatures, causing the furnace bricks to collapse and fall off, and significantly shortening the maintenance and repair cycle of the equipment. 

II. Li Zhenglai High-Efficiency Sulfur Gun | Systemic Solutions for the Six Major Pain Points 

1. Regarding the issues of "poor atomization effect + sharply rising maintenance costs": The two-stage Laval dual-stage atomization technology ensures complete combustion. 

The Li Zhenglai sulfur gun adopts the Lavarel structure derived from rocket engines and innovatively designs a two-stage Lavarel atomization technology. The uniformity of the atomization effect is significantly improved compared to traditional sulfur guns. 

● Key effect: 70% of the particles are smaller than 20μm, ensuring more complete combustion; 

● Burning effect inside the furnace: The sulfur combustion flame is red in color, with no localized flames or flowing liquid sulfur. 

● Solving the chain problem: Significantly reducing the accumulation of liquid sulfur at the bottom of the furnace can effectively inhibit the formation of sublimated sulfur, thereby protecting the desiccator filter and catalyst in the conversion reactor, as well as the refractory insulation layer inside the sulfur incinerator, avoiding excessive temperature deformation of the furnace shell, and ensuring the safety of the equipment while reducing maintenance costs. 

2. Regarding 【bent or deformed gun body】: Gun body is designed with integrated uniform temperature control. 

The self-developed 360° circular steam distribution ring is adopted to ensure uniform temperature distribution around the gun body, enabling complete synchronization of thermal expansion during start-up and shutdown stages. After long-term operation verification, the gun body's curvature has been stably controlled within the design allowable range, effectively eliminating the deformation caused by temperature difference stress physically. 

3. For the issue of "Frequent Blockage of Nozzles": Large-flow channel direct-through design + Anti-blockage structure (optional) 

● The spray nozzles of the entire series are equipped with a 376mm² ultra-large straight-through channel, allowing sulfuric iron impurities to pass through smoothly without getting clogged; the HC276 alloy wear-resistant nozzles are resistant to corrosion and anti-coking. 

● The LGS4-T series anti-blockage sanding gun is equipped with a cleaning port, allowing for the removal of impurities without stopping the machine. 

Overall, it can reduce unplanned stops and ensure the continuous operation of the equipment. 

4. Regarding "Steam Leakage from Insulation": High-pressure Sealing Technology 

The welds of the sulfide tubes and jacketed tubes are all welded using 99.999% high-purity argon gas protection. After welding, non-destructive testing is conducted to effectively reduce defects such as slag inclusions, pores, and cracks, meeting the pressure-bearing standards. The leakage rate is lower than the industry's conventional indicators. This reduces the risk of steam leakage entering the incinerator furnace and corroding subsequent equipment from the manufacturing source. 

5. Regarding the "production suspension and environmental protection dual risks": Comprehensive safety structure to avoid high temperatures and leaks 

● The atomization uniformity has been improved, effectively suppressing local high temperatures in the sulfur incinerator, reducing the risk of the furnace body being burned through and minimizing the generation of sublimated sulfur. 

●High-pressure welding is adopted, reducing the possibility of liquid sulfur and steam leakage; 

The anti-backup design reduces frequent start-stop operations and lowers the risk of process fluctuations during start-up and shutdown. 

III. Instantly Determine the Quality of Atomization! On-site Rapid Identification Techniques 

1. Efficient atomization (Lizhengla High-Efficiency Sulfur Gun) 

The sulfur incineration furnace is operating well. The flame is red and evenly distributed, with no phenomenon of open flame combustion. The temperature of the furnace shell remains within the safe threshold, and the on-site inspectors have no obvious risk of burns after a short period of contact. 

2. Poor atomization 

By observing the fire outlet of the sulfur incinerator through the viewing window on the bottom of the furnace, one can see liquid sulfur flowing and burning. Local intense flames are glaring, the temperature of the furnace shell is extremely high and cannot be touched, and a large amount of sulfur is precipitated outside the furnace. These are some of the intuitive signals for determining the failure of atomization. 

IV. The upgrade of the sulfuryard is an optimal solution for reducing costs and increasing efficiency in the sulfuric acid plant

Many factories pour a large amount of their budgets into large main equipment, but overlook the chain losses caused by a small scrubber gun. In fact, an efficient scrubber gun can specifically address five typical problems such as blockages, overheating, unplanned shutdowns, environmental control, and equipment wear and tear. Its long-term overall benefits usually cover the investment for the renovation. 

A high-quality sulfiding gun not only addresses the issue of "whether the spraying is good or not", but also forms the foundation for the device to operate stably for long periods, at full capacity and with low energy consumption. Currently, more than 200 Lirizhi efficient sulfiding guns are serving sulfuric acid plants all over the world. 

Li Zhenglai Technology (Chongqing) Co., Ltd. - Dedicated to solving measurement and equipment problems in the sulfuric acid industry, ensuring that your equipment operates more stably, longer, and more economically.