Sulphur Storage

30/10/2013

Sulphuric Acid on the WebTM

Knowledge for the

Sulphuric Acid
Industry
Sulphuric Acid on
the Web
Introduction
General
Equipment Suppliers
Contractor
Instrumentation
Industry News
Maintenance
Acid Traders
Organizations
Fabricators
Conferences
Used Plants
Intellectual Propoerty
Acid Plant Database
Market Information
Library

Technical Manual
Introduction
General
Definitions
Instrumentation
Plant Safety
Metallurgial Processes
Metallurgical
Sulphur Burning
Acid Regeneration
Lead Chamber
Technology
Gas Cleaning
Contact
Strong Acid
Acid Storage
Loading/Unloading
Transportation
Sulphur Systems
Liquid SO2
Boiler Feed Water
Steam Systems
Cooling Water
Effluent Treatment
Utilities
Construction
Maintenance
Inspection
Analytical Procedures
Materials of Construction
Corrosion
Properties
Vendor Data

DKL Engineering, Inc.

Handbook of
Sulphuric Acid
Manufacturing
Order Form
Preface
Contents
Feedback

Sulphuric Acid
Decolourization
Order Form
Preface
Table of Contents

Process Engineering
Data Sheets - PEDS
Order Form

Technical Manual

DKL Engineering, Inc.

Sulphur Systems - Sulphur Storage

November 4, 2003

Introduction
Solid Sulphur
Forms of Sulphur
Transfer of Sulphur
Bulk Storage
Liquid Sulphur
Storage Pits
Sizing
Ancillaries
Sulphur Tanks
Sizing
Insulation
Ancillaries
Sulphur Heaters

Associated Links
Sulphur Properties
Sulphur Safety
Sulphur Melting
Sulphur Filtration
Sulphur Pumps
Sulphur Piping
Sulphur Furnace
Procedures

Introduction
Large quantities of sulphur are produced, formed, stored, transported, handled, melted and
comsumed annually. The sulphur will be stored either in the solid or liquid form at some
point in the process. Proper storage methods are required to ensure the sulphur is not
contaminated, that it doesn't damage equipment (i.e. corrosion, fires, etc.) and it doesn't
harm the environment.
Solid Sulphur
The majority of sulphur that is transported around the world is done as a bulk solid. The
sulphur is often stored in the open in huge stockpiles at terminals ready to be loaded onto
ships, railcars or truck or at plant sites to be melted and used in the production of sulphuric
acid. Most sulphur stockpiles are located outdoors in open where it is exposed to wind,
rain, dust, salt air, etc. In some cases sulphur is stored indoors where some protection from
the elements is available.
Sulphur, being a brittle material, is easily degraded during handling. Losses will occur
during the loading/unloading, transportation, and storage of sulphur due to the creation of
airborne dust. Losses can be as high as 0.5% in some cases. Factors affecting how much
is lost are:
Form of sulphur being handled
Ambient conditions (i.e. wind speed and direction)
Handling methods
Shipping methods
Forms of Sulphur
Solid sulphur is produce in many forms which vary in their friability and
mechanical strength. The process used to produce bulk sulphur will affect the
amount of dust it contains and the subsequent formation of dust through
handling of the material.
Bulk sulphur produced from sulphur that has been crushed from larger pieces
will be irregular in shape and posses many sharp edges and points which will
be easily broken producing smaller particles and dust.
Slate sulphur is formed by pouring molten sulphur on a moving belt where it is
solidified into a continuous slab with a thickness of 3 to 5 mm. The sulphur
begins to break into smaller pieces when it is separated from the belt and
when sulphur is discharged from the belt at the head pulley. This process
produces irregular shaped pieces with sharp edges. Fines (less than 50 Tyler
Mesh) amount to about 3.5% by weight. Additional fines are produced through
further handling of the product.
Granulated sulphur is produced by spray coating sulphur particles to increase
their size to produce dense spherical solid granules. Small seed particles of
sulphur are introduced at the feed end of a rotating drum. The particles are
spray coated with molten sulphur as the particles move down the drum
towards the discharge. Each layer of molten sulphur that is applied is cooled
to solidification before the next coat is applied. Through repeated application

http://www.sulphuric-acid.com/techmanual/sulphur/storage.htm

1/5

Sulphur Storage

Order Form
Table of Contents
Introduction

Bibliography of
Sulphuric Acid
Technology
Order Form
Preface
Contents

Sulphuric Acid Plant

Specifications
Google Search

30/10/2013

of sulphur layers, a granule size of 1 to 6 mm diameter is produced. Fines

are minimal a the production stage and the round shape of the granule resist
further degradation to fines. Sulphur formed by this process will contain
approximately 0.5% by weight of fines (less than 50 Tyler Mesh).
The WetPrillTM process involves pumping molten sulphur onto a perforated
plate. The sulphur flows through the perforations in the form of droplets. The
droplets fall into an agitated water bath which solidifies and cools the sulphur
into pellets. The pellets are separated from the water in dewatering screens.
Sulphur formed by this process will contain approximately 0.2% by weight of
fines (less than 50 Tyler Mesh).
Transfer of Sulphur
The movement of bulk sulphur from production to storage to ship or truck to its
final destination requires that the sulphur be handled by various types of
equipment. The equipment used may be conveyors, screws, hoppers and
chutes just to name a few.
Rubber belt conveyors have proven to be the best means of transferring large
quantities of sulphur from one location to another. Conveyors should be
covered to minimize the escape of dust to the environment. The maximum
angle of inclination for a plain rubber belt conveyor is 18 to 20. All belts are
to be protected against the build-up of static electricity.
To minimize the amount of dust formed the free fall height from conveyors to
another conveyor, stock pile or hopper should be minimized. Covered hoppers
and flaps on the discharge and receiving belts will reduce air currents and the
amount of dust that is picked up.
Telescoping spouts should be used to direct the sulphur as close to the
stockpile, truck or ship hold as possible. The spout minimizes the height the
sulphur must fall while exposed to the wind. The spout must be grounded to
minimize the formation of static charges.
Front-end loaders are often used to transfer bulk sulphur from a stockpile to a
hopper feeding a conveyor. Standard equipment powered by diesel, gasoline,
propane, etc. are not suitable since they can be a source of ignition. Spark
arrestors must be installed on equipment and the temperature rating of the
engine and exhaust must limit the surface temperature to a maximum of
100C.
The buckets or front-end loaders are generally made of hardened alloy steels
which can produce sparks when it comes in contact with concrete. Care must
be taken when working in and around a sulphur stockpile to avoid scraping the
bucket along any concrete surface and to minimize dust formation.
Bulk Storage
Indoor storage of bulk sulphur should be provided whenever possible to
minimize losses and contamination of sulphur, however, the cost of a building
cannot always be justified. Proper ventilation will reduce the possibility of fires
or explosions due to sulphur dust. The building should be equipped with
explosion vents and doors. The building should be designed without ledges
that will allow sulphur to accumulate. A protective coating should be applied
to all exposed steel combat corrosion.
If indoor storage cannot be provided there is no choice but to store the sulphur
outdoors. A location should be selected that is shielded from the prevailing
winds. Erection of wind barriers can be considered if there is no natural
formations or barrier (i.e. trees) present in the area. The stockpile should also
be located upwind of possible sources of contamination such as ore stockpile,
crushing operations, heavily travelled dirt roads, etc.
If the sulphur is stored directly on the ground (i.e. dirt) the first 150 mm to 200
mm layer of sulphur should be considered as lost since recovery of this
sulphur would introduce too much dust and dirt into the sulphur system. An
asphalt or concrete pad should be provided which will enable 100% recovery of
the sulphur in the stockpile.
Wind losses can be minimized by spraying water onto the stockpile. Excess
water in the sulphur will result in higher steam usage in the sulphur melter
since energy will be required to evaporate the water. Excess water may also
lead to foaming in the sulphur melter. Addition of water may also increase the
formation of sulphuric acid in the sulphur stockpile which may lead to increase
corrosion in the molten sulphur handling system. The effectiveness of water
for dust control is limited by the hydrophobic nature of sulphur.
The hydrophobic nature of sulphur can be overcome by the use of special
water based chemical surfactants. The wetted particles agglomerate to each
other and larger particles making them more difficult to be picked up by the
wind. The use of these dust suppressants does cause concern as regards to
contamination of the sulphur and the effect these contaminants may have on
downstream processes. Dust suppressant chemicals may also result in the
formation of car-sul, a black, insoluble material formed by the reaction between

http://www.sulphuric-acid.com/techmanual/sulphur/storage.htm

2/5

Sulphur Storage

30/10/2013

carbon and sulphur. Excessive amounts of Car-sul can lead to operating

problems in the acid plant. Dustbind S, produced by Raisio, has been used
successfully as a dust suppressant in sulphur handling.
The application of dust suppressant is usually done at transfer points within
the sulphur handing system where the possibility of the dust becoming
airborne is the greatest. These locations will typically be at discharges of
conveyors, hopper, chutes, etc.
If sulphur will be stored outdoors for extended periods of time, the stockpile
can be coated with molten sulphur which will form a crust that will prevent wind
losses.
The amount of bulk sulphur in storage should be kept to a minimum. This can
be achieved by proper scheduling of shipments. The amount of molten
sulphur in storage should be maximize which will minimize the amount of bulk
sulphur in storage.
Liquid Sulphur
At some point prior to being burned in a sulphur furnace to produce sulphur dioxide, solid
sulphur must be melted and stored. Molten sulphur must be handled and stored within a
relatively narrow range of temperatures. Too hot and the sulphur viscosity rises quickly and
the sulphur cannot be pumped. Too cold and the sulphur will solidify. Once solidified in a
storage vessel it is difficult to liquify again due to the low thermal conductivity of solid
sulphur.
Storage Pits
Sulphur storage pits are generally in-ground concrete pits with submerged
steam heaters. A portion of the pit wall will be bricked lined in the region
where the level in the pit normally fluctuates. The bricklining prevents
deterioration of the concrete wall due to the interaction between the moist
atmospheric air and sulphur at the interface. The pit is covered by a carbon
steel roof to minimize contaminants entering the stored sulphur.
If a melting section is included in the design of the pit, it should be separated
from the main storage section by a baffle wall. This will prevent solid sulphur
from damaging the pump or plugging the line or sulphur gun. The sulphur
should overflow from melting section to the main storage section. This allows
any solids to settle out prior to entering the main storage section.
Sizing
The design and size of the storage pit is determined by the plant
production rate, delivery schedule, shipment size, reliability of
delivery, quality of the sulphur and the form in which the sulphur
arrives to site. The capacity of sulphur melters and settlers may
or may not be included in the overall storage requirements.
The depth of the pit should be large enough to accommodate the
sulphur pump. Typical Lewis pump lengths are 84", 114" and
144" although standard units are available in lengths ranging
from 7' to 22'.
Ancillaries
A level instrument is generally provided in the sulphur pit for
determination of level. A bubbler type instrument is generally
suitable. A separate nozzle should be provided on the roof for
manually dipping the pit.
Pumps are generally mounted on the roof of the sulphur pit.
Sufficient support must be provided for the pump and motor.
Steam heaters are required to maintain the sulphur in the liquid
phase.
Sulphur Tanks
Sulphur tanks are generally vertical cylindrical, above ground, insulated carbon
steel tanks with submerged steam coils (see Figure 2).
Approximately 0.25 ft2 of heating surface per square foot of tank wall and roof
will be required to maintain sulphur molten and compensate for heat losses.
Detailed calculations should be carried out for each specific case. An overall
heat transfer coefficient of 20 to 25 Btu/h ft2 oF may be expected when using
75 psig steam pressure in pipe coils.
Piping should be provided to permit steam to be used to smother and tank
fires.
Sizing

http://www.sulphuric-acid.com/techmanual/sulphur/storage.htm

3/5

Sulphur Storage

30/10/2013

The design and size of the storage tank is determined by the

plant production rate, delivery schedule, shipment size, reliability
of delivery, quality of the sulphur and the form in which the
sulphur arrives to site. The capacity of sulphur melters and
settlers may or may not be included in the overall storage
requirements.
If a pump is installed in the tank, the height of the tank should be
high enough to accommodate the sulphur pump. Typical Lewis
pump lengths are 84", 114" and 144" although standard units are
available in lengths ranging from 7' to 22'.
Insulation
Insulation is required on the tank to minimize heat loss. A
minimum of 50 mm (2 inches) of insulation should be installed
on the tank. Mineral wool insulation is used for the side of the
tank and calcium silicate is used for the roof if access by
personnel is required.
Ancillaries
A level instrument is generally provided in the tank for
determination of level. A bubbler type instrument is generally
suitable. A separate nozzle should also be provided for
manually dipping the tank.
A high point vent should be installed to vent gases while the tank
is being filled and allow air to enter when the tank is being
emptied. The vent should be heat traced and insulated to
prevent solidification of sulphur in the vent pipe which could
block-off the vent.
An overflow should installed in the tank to prevent overfilling of
the tank during filling operations. The overflow should be
directed to a sulphur pit or some contamint area. The contamint
area should be kept clean as any spilled sulphur can be
recovered after it has solidified. The overflow should be size for
the maximum inflow to the tank.
Pumps can be mounted in the roof of the tank to pump sulphur
from the storage tank. However, a more common arrangement
is to drain the tank by gravity to a sulphur pit and the pump from
the pit. Level in the pit is controlled automatically using a
control valve on the drain line.
Steam heaters are required to maintain the sulphur in the liquid
phase.
Sulphur Heaters
Steam heater are
typically used in
storage tanks and
pits for heating
sulphur. A typical
steam heater used
in the industry is
the THERMO-FLO
heater (Model TF18) supplied by
Brown Fintube
Engineering Ltd.
The TF-18
provides lots of
surface area in a
compact heater.
The vertical
arrangement and
off the floor design
enables the
bottom of the tank
or pit to be easily
cleaned of
accumulated
solids. The
heaters also allow
a thermosyphon to
be setup which
assures an
efficient and higher
rate of heat
transfer.
Brown Fintube
http://www.sulphuric-acid.com/techmanual/sulphur/storage.htm

4/5

Sulphur Storage

30/10/2013

Model TF-18
Heating Surface
Headers
Tube
Fins
Weight
Displacement
Pressure Rating
Corrosion Allowance

265 ft
1" IPS Sch 80 Seamless Pipe
1" OD 10 Gauge
0.035" Steel, 1" high, 20 per tube
385 lb dry
407 lb full of water
395 lb shipping
1 ft
600 psi @ 650F
1/16"

Typical Installation in a Tank

Copyright 2005-2011 DKL Engineering, Inc., All Rights Reserved

DKL Engineering, Inc. shall not be held liable for any type of damages resulting from the use of this information. The user assumes all risk and liability in connection with the use of information contained in this and
associated web sites. The data is intended for personal, non-commercial use.

http://www.sulphuric-acid.com/techmanual/sulphur/storage.htm

5/5