CA2451712C - In situ sulphur remelter - Google Patents
In situ sulphur remelter Download PDFInfo
- Publication number
- CA2451712C CA2451712C CA002451712A CA2451712A CA2451712C CA 2451712 C CA2451712 C CA 2451712C CA 002451712 A CA002451712 A CA 002451712A CA 2451712 A CA2451712 A CA 2451712A CA 2451712 C CA2451712 C CA 2451712C
- Authority
- CA
- Canada
- Prior art keywords
- sulphur
- heating element
- melting
- pipes
- condensate
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
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- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 title claims abstract description 171
- 239000005864 Sulphur Substances 0.000 title claims abstract description 161
- 238000011065 in-situ storage Methods 0.000 title description 2
- 238000010438 heat treatment Methods 0.000 claims abstract description 108
- 238000002844 melting Methods 0.000 claims abstract description 93
- 230000008018 melting Effects 0.000 claims abstract description 93
- 239000007787 solid Substances 0.000 claims abstract description 12
- 238000009826 distribution Methods 0.000 claims abstract description 7
- 238000007599 discharging Methods 0.000 claims abstract description 5
- 238000000605 extraction Methods 0.000 abstract description 5
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 abstract description 4
- 239000006227 byproduct Substances 0.000 abstract description 2
- 239000003345 natural gas Substances 0.000 abstract description 2
- 238000013461 design Methods 0.000 description 13
- 238000000034 method Methods 0.000 description 9
- 239000000155 melt Substances 0.000 description 8
- 238000006073 displacement reaction Methods 0.000 description 6
- 241000196324 Embryophyta Species 0.000 description 4
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 4
- 229910052782 aluminium Inorganic materials 0.000 description 4
- 230000008901 benefit Effects 0.000 description 4
- 238000010276 construction Methods 0.000 description 4
- 238000012546 transfer Methods 0.000 description 4
- 239000007788 liquid Substances 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- 230000008569 process Effects 0.000 description 3
- 229910052717 sulfur Inorganic materials 0.000 description 3
- 239000011593 sulfur Substances 0.000 description 3
- 239000003638 chemical reducing agent Substances 0.000 description 2
- 239000003517 fume Substances 0.000 description 2
- 230000005484 gravity Effects 0.000 description 2
- 230000006872 improvement Effects 0.000 description 2
- 238000005096 rolling process Methods 0.000 description 2
- 238000003860 storage Methods 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 239000000725 suspension Substances 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- 244000208734 Pisonia aculeata Species 0.000 description 1
- 230000006978 adaptation Effects 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 238000009412 basement excavation Methods 0.000 description 1
- 230000008602 contraction Effects 0.000 description 1
- 230000007812 deficiency Effects 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 238000010348 incorporation Methods 0.000 description 1
- 230000007257 malfunction Effects 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 238000011084 recovery Methods 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 230000000087 stabilizing effect Effects 0.000 description 1
- 239000011800 void material Substances 0.000 description 1
Classifications
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
- F28D7/00—Heat-exchange apparatus having stationary tubular conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall
- F28D7/0041—Heat-exchange apparatus having stationary tubular conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits for only one medium being tubes having parts touching each other or tubes assembled in panel form
-
- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
- C01B17/00—Sulfur; Compounds thereof
- C01B17/02—Preparation of sulfur; Purification
- C01B17/0221—Melting
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28B—STEAM OR VAPOUR CONDENSERS
- F28B1/00—Condensers in which the steam or vapour is separate from the cooling medium by walls, e.g. surface condenser
Landscapes
- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Organic Chemistry (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Inorganic Chemistry (AREA)
- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Production Of Liquid Hydrocarbon Mixture For Refining Petroleum (AREA)
- Processing Of Solid Wastes (AREA)
- Manufacture And Refinement Of Metals (AREA)
Abstract
Sulphur is produced as a by-product during the extraction of natural gas from the earth and is usually stored in solidified form in large blocks near the extraction location. In order to conveniently transport quantities of sulphur, it may be melted. The present invention provides a heating element for use in a solid sulphur remelter, the heating element comprising a series of mutually spaced melting pipes forming a heating plane, a top steam header pipe and a bottom condensate header pipe at respective ends of the melting pipes and communicating therewith, the top steam header pipe having an inlet for receiving steam therein for distribution into the melting pipes and the bottom condensate header pipe being adapted for collecting condensate and discharging of the condensate through an outlet formed therein and a hot nose pipe attached adjacent and in front of the bottom condensate header pipe and having a steam inlet and a condensate outlet for melting sulphur in front of the bottom condensate header pipe.
Description
IN SITU SULPHUR REMELTER
The present invention relates generally to an apparatus and method for melting block sulphur.
Sulphur is produced as a by-product during the extraction of natural gas from the earth and is usually stored in solidified form in large blocks near the extraction location. in order to conveniently transport quantities of sulphur, it may be melted.
The following patents are considered to be of general relevance to the subject matter of the present invention and are not believed to anticipate or render the present invention obvious, whether taken alone or in any combination.
United States Patent No. 4,203,625 (Ellithorpe) entitled Apparatus for sulfur melting by lateral displacement of heating element. This patent discloses an apparatus and method for melting block sulphur. The apparatus comprises a steam heating element for applying heat to the sulphur, pivotally attached to a carriage which moves on rails of a trailer. The heating element is advanced by a counter-weight and the melted sulphur runs down pipes for collection.
United States Patent No. 4,050,740 (Ellithorpe) entitled Method of and apparatus for melting block sulphur. This patent describes an apparatus and method for melting block sulphur in which a steam heating element is placed on top of the sulphur which then runs down into a collection trough.
United States Patent No. 4,597,609 (Deszynski et al.) entitled Method of melting sulphur. Deszynski et al teach a method and apparatus for melting block sulphur in which a steam heating element is applied to the top of a block. The heating element is inclined such that, as the sulphur melts, it flows into a collection area where it is drawn away.
United States Patent No. 4,651,817 (bugger et al.) entitled Heat exchange apparatus useful for melting sulphur. bugger et al. discloses a steam lance useful for melting sulphur. The main use envisaged is that of melting solid sulphur underneath a sulphur tank rail car containing molten sulphur. As the sulphur melts, the thrust provided to the tip of the lance causes the tip to advance. Condensate formed during the heat exchange is removed without having the water contact the melted sulphur.
Canadian Patent No. 1,091,430 (Potts) entitled Apparatus for the efficient deployment and operation of in situ sulfur block remelting Equipment. Potts describes the use of melters suspended by cables overtop of block sulphur. The cables are moved across the top of the block by dollies allowing for accurate displacement control.
The use of both electric and steam heating means is discussed.
The present invention may be considered an improvement upon the Applicant's United States Patent No. 4,203,625 and corresponding Canadian Patent No.1,064,224 which teach a remelter comprising a box shaped top steam header connected to a series of vertical pipes, which are arranged in two parallel, offset rows, connected to a box shaped bottom condensate header. An insulated backing panel is located behind the vertical pipes. The melted sulphur runs down the outside of the vertical pipes and is collected in a gutter at the back of the bottom header. These elements are constructed of a standard size to provide for interchangeability and a set of elements is arranged
The present invention relates generally to an apparatus and method for melting block sulphur.
Sulphur is produced as a by-product during the extraction of natural gas from the earth and is usually stored in solidified form in large blocks near the extraction location. in order to conveniently transport quantities of sulphur, it may be melted.
The following patents are considered to be of general relevance to the subject matter of the present invention and are not believed to anticipate or render the present invention obvious, whether taken alone or in any combination.
United States Patent No. 4,203,625 (Ellithorpe) entitled Apparatus for sulfur melting by lateral displacement of heating element. This patent discloses an apparatus and method for melting block sulphur. The apparatus comprises a steam heating element for applying heat to the sulphur, pivotally attached to a carriage which moves on rails of a trailer. The heating element is advanced by a counter-weight and the melted sulphur runs down pipes for collection.
United States Patent No. 4,050,740 (Ellithorpe) entitled Method of and apparatus for melting block sulphur. This patent describes an apparatus and method for melting block sulphur in which a steam heating element is placed on top of the sulphur which then runs down into a collection trough.
United States Patent No. 4,597,609 (Deszynski et al.) entitled Method of melting sulphur. Deszynski et al teach a method and apparatus for melting block sulphur in which a steam heating element is applied to the top of a block. The heating element is inclined such that, as the sulphur melts, it flows into a collection area where it is drawn away.
United States Patent No. 4,651,817 (bugger et al.) entitled Heat exchange apparatus useful for melting sulphur. bugger et al. discloses a steam lance useful for melting sulphur. The main use envisaged is that of melting solid sulphur underneath a sulphur tank rail car containing molten sulphur. As the sulphur melts, the thrust provided to the tip of the lance causes the tip to advance. Condensate formed during the heat exchange is removed without having the water contact the melted sulphur.
Canadian Patent No. 1,091,430 (Potts) entitled Apparatus for the efficient deployment and operation of in situ sulfur block remelting Equipment. Potts describes the use of melters suspended by cables overtop of block sulphur. The cables are moved across the top of the block by dollies allowing for accurate displacement control.
The use of both electric and steam heating means is discussed.
The present invention may be considered an improvement upon the Applicant's United States Patent No. 4,203,625 and corresponding Canadian Patent No.1,064,224 which teach a remelter comprising a box shaped top steam header connected to a series of vertical pipes, which are arranged in two parallel, offset rows, connected to a box shaped bottom condensate header. An insulated backing panel is located behind the vertical pipes. The melted sulphur runs down the outside of the vertical pipes and is collected in a gutter at the back of the bottom header. These elements are constructed of a standard size to provide for interchangeability and a set of elements is arranged
2 one above the other on a mast (for example: 4 elements each 10 feet high, used for a 40 foot high sulphur block). The element modules are positioned one above the other to attain the required height for a particular sulphur block. The sulphur callected from the upper elements is directed through a downspout to the collection system of troughs.
The sulphur from the lower element is raised by an Archimedes screw and discharged into the same collecting trough. The vertical pipes and the front wall of the box headers are constructed of the same thin wall material resulting in an even melt rate by all parts of the unit. All melting occurs in the primary zone at the front of the element.
Shortcomings of this design include the following:
- The elements are expensive to build because of the box header design and the fact that a 40 foot unit requires four elements. Also the box header's incorporation of the thin front wall poses problems in complying with the pressure vessel code, a problem that is costly to overcome.
- The elements are not particularly rugged since mid span support is not included.
- The collecting trough system employs gravity flow to a sulphur collecting sump or pit which requires the excavation of pits adjacent to the sulphur blocks, which in turn may cause problems with general drainage of rain water from the site.
- Retracting the elements after each advance requires simultaneous operation of the hydraulic pullback cylinder while unwinding the winch.
- Sulphur fumes and vapors are emitted from the area of the remelter elements to a great extent.
Certain field modified designs of the remelter described in US Patent No.
4,203,625 have been used, however, these designs suffer various deficiencies, certain of which are detailed as follows:
The sulphur from the lower element is raised by an Archimedes screw and discharged into the same collecting trough. The vertical pipes and the front wall of the box headers are constructed of the same thin wall material resulting in an even melt rate by all parts of the unit. All melting occurs in the primary zone at the front of the element.
Shortcomings of this design include the following:
- The elements are expensive to build because of the box header design and the fact that a 40 foot unit requires four elements. Also the box header's incorporation of the thin front wall poses problems in complying with the pressure vessel code, a problem that is costly to overcome.
- The elements are not particularly rugged since mid span support is not included.
- The collecting trough system employs gravity flow to a sulphur collecting sump or pit which requires the excavation of pits adjacent to the sulphur blocks, which in turn may cause problems with general drainage of rain water from the site.
- Retracting the elements after each advance requires simultaneous operation of the hydraulic pullback cylinder while unwinding the winch.
- Sulphur fumes and vapors are emitted from the area of the remelter elements to a great extent.
Certain field modified designs of the remelter described in US Patent No.
4,203,625 have been used, however, these designs suffer various deficiencies, certain of which are detailed as follows:
3 -Use of U-bend connections between the headers and the vertical pipes.
-Great disparity in the wall thickness of the various components which melt the sulphur. The result is that the element advances into the block at the rate of the slowest component. Further to this is the fact that the force applied to advance the element must be kept relatively small so as not to overload and damage the slowest melting part of the element. Moreover, unless the steam pressure is kept low, the thinner areas of the element can overheat the sulphur, causing it to become viscous .
The disparities in wall thickness reduce the overall melt rate of the element.
-Use of a jacketed sump box of heavy plate construction which melts slowly thus reducing the advance rate of the entire element, -Use of a round steam header connected through U-bends to the single row of vertical pipes which discharge condensate through U-bends into a complex shaped bottom header, comprised of a box shape and a half round pipe.
-The force which advances the unit has to be reduced so as not to overload the slowest melting section.
-When operated at elevated steam pressures the sulphur, due to its long contact time from running the length of the vertical pipes, is overheated to a viscous state, further impeding the remelt operation.
-The sump box, which has a thick wall plate steam jacket, melts slowly through the sulphur.
The condensate recovery from the bottom header is poor.
- The mounting system fails to provide for thermal expansion of the element.
According to an aspect of the present invention there is provided a heating element for use in a solid sulphur remelter, the heating element comprising a series of mutually spaced melting pipes forming a heating plane; a top steam header pipe and a bottom
-Great disparity in the wall thickness of the various components which melt the sulphur. The result is that the element advances into the block at the rate of the slowest component. Further to this is the fact that the force applied to advance the element must be kept relatively small so as not to overload and damage the slowest melting part of the element. Moreover, unless the steam pressure is kept low, the thinner areas of the element can overheat the sulphur, causing it to become viscous .
The disparities in wall thickness reduce the overall melt rate of the element.
-Use of a jacketed sump box of heavy plate construction which melts slowly thus reducing the advance rate of the entire element, -Use of a round steam header connected through U-bends to the single row of vertical pipes which discharge condensate through U-bends into a complex shaped bottom header, comprised of a box shape and a half round pipe.
-The force which advances the unit has to be reduced so as not to overload the slowest melting section.
-When operated at elevated steam pressures the sulphur, due to its long contact time from running the length of the vertical pipes, is overheated to a viscous state, further impeding the remelt operation.
-The sump box, which has a thick wall plate steam jacket, melts slowly through the sulphur.
The condensate recovery from the bottom header is poor.
- The mounting system fails to provide for thermal expansion of the element.
According to an aspect of the present invention there is provided a heating element for use in a solid sulphur remelter, the heating element comprising a series of mutually spaced melting pipes forming a heating plane; a top steam header pipe and a bottom
4 condensate header pipe at respective ends of the melting pipes and communicating therewith; the top steam header pipe having an inlet for receiving steam therein for distribution into the melting pipes and the bottom condensate header pipe being adapted for collecting condensate and discharging of the condensate through an outlet formed therein; and a hot nose pipe attached adjacent and in front of the bottom condensate header pipe and having a steam inlet and a condensate outlet for melting sulphur in front of the bottom header.
According to another aspect of the present invention there is provided a heating element for use in a solid sulphur remelter, the heating element comprising a series of mutually spaced melting pipes forming a melting plane; a top steam header pipe and a bottom condensate header pipe at respective ends of the melting pipes and communicating therewith; the top steam header pipe having an inlet for receiving steam therein for distribution into the melting pipes and the bottom condensate header pipe being adapted for collecting condensate and discharge of the condensate through an outlet formed therein; and intermediate gutters mutually vertically spaced behind the melting pipes for collecting sulphur which passes between the melting pipes, the intermediate gutters communicating with a collection area for allowing flow of sulphur thereto, the intermediate gutters being fixed to the melting pipes and providing support thereto.
According to another aspect of the present invention there is provided an adjustable heating element for use with a solid sulphur remelter for melting a transverse band of contaminated sulphur ahead of a main heating element, the adjustable heating element comprising a series of mutually spaced melting pipes forming a melting plane smaller than a melting plane of the main heating element and for disposition in front of the main heating element; the melting pipes having an inlet for receiving steam therein, and an
According to another aspect of the present invention there is provided a heating element for use in a solid sulphur remelter, the heating element comprising a series of mutually spaced melting pipes forming a melting plane; a top steam header pipe and a bottom condensate header pipe at respective ends of the melting pipes and communicating therewith; the top steam header pipe having an inlet for receiving steam therein for distribution into the melting pipes and the bottom condensate header pipe being adapted for collecting condensate and discharge of the condensate through an outlet formed therein; and intermediate gutters mutually vertically spaced behind the melting pipes for collecting sulphur which passes between the melting pipes, the intermediate gutters communicating with a collection area for allowing flow of sulphur thereto, the intermediate gutters being fixed to the melting pipes and providing support thereto.
According to another aspect of the present invention there is provided an adjustable heating element for use with a solid sulphur remelter for melting a transverse band of contaminated sulphur ahead of a main heating element, the adjustable heating element comprising a series of mutually spaced melting pipes forming a melting plane smaller than a melting plane of the main heating element and for disposition in front of the main heating element; the melting pipes having an inlet for receiving steam therein, and an
5 outlet for discharge of condensate; the adjustable heating element being adjustable to be positioned adjacent a transverse band of contaminated sulphur for enhanced remelting thereof.
According to another aspect of the present invention there is provided a modular heating element for use in a solid sulphur remelter, the heating element comprising one or more heating element modules detachably mountable along the heating element; each module comprising a series of mutually spaced melting pipes defining a melting plane; the series of melting pipes having an inlet for receiving steam and an outlet for the discharge of condensate.
According to another aspect of the present invention there is provided a remelter for use in melting solid sulphur comprising a support tower for carrying a heating element; means for supporting the heating element in an at least approximately upright disposition; means for collapsing the heating element from its upright disposition into a substantially horizontal portion on a carriage for transportation; and means of advancing the remelter along a ground surface towards the solid sulphur including a hydraulic cylinder, a directional control valve and a pressure compensated variable displacement pump.
According to another aspect of the present invention there is provided a heating element for melting a transverse band of contaminated sulphur, the heating element comprising a series of mutually spaced melting pipes stacked vertically and defining a melting plane;
the melting pipes having an inlet for receiving steam therein, and an outlet for discharge of condensate; whereby the series of melting pipes are effective for melting the transverse band of contaminated sulphur upon contacting a sulphur block containing the transverse band.
Embodiments of the invention will now be described, by way of example, with reference to the accompanying drawings, in which:
According to another aspect of the present invention there is provided a modular heating element for use in a solid sulphur remelter, the heating element comprising one or more heating element modules detachably mountable along the heating element; each module comprising a series of mutually spaced melting pipes defining a melting plane; the series of melting pipes having an inlet for receiving steam and an outlet for the discharge of condensate.
According to another aspect of the present invention there is provided a remelter for use in melting solid sulphur comprising a support tower for carrying a heating element; means for supporting the heating element in an at least approximately upright disposition; means for collapsing the heating element from its upright disposition into a substantially horizontal portion on a carriage for transportation; and means of advancing the remelter along a ground surface towards the solid sulphur including a hydraulic cylinder, a directional control valve and a pressure compensated variable displacement pump.
According to another aspect of the present invention there is provided a heating element for melting a transverse band of contaminated sulphur, the heating element comprising a series of mutually spaced melting pipes stacked vertically and defining a melting plane;
the melting pipes having an inlet for receiving steam therein, and an outlet for discharge of condensate; whereby the series of melting pipes are effective for melting the transverse band of contaminated sulphur upon contacting a sulphur block containing the transverse band.
Embodiments of the invention will now be described, by way of example, with reference to the accompanying drawings, in which:
6 Figure 1 is a perspective view of an apparatus according to an embodiment of the present invention in place next to a block of sulphur;
Figure 2A is a side view of a trailer, carriage and support tower of an apparatus according to an embodiment of the present invention;
Figure 2B is an isometric view of a trailer, carriage and support tower of an apparatus according to an embodiment of the present invention where the support tower is in an erected position;
Figure 2C is an isometric view of a trailer, carriage and support tower of an apparatus according to an embodiment of the present invention where the support tower is in a collapsed position;
Figures 3 and 4 show broken-away views taken in cross-section through rollers of the carriage of an apparatus according to an embodiment of the present invention;
Figure 5 is a side view of a heating element as part of an apparatus according to an embodiment of the present invention;
Figure 6 is an isometric broken-away view of part of a front portion of a heating element as part of an apparatus according to an embodiment of the present invention;
Figure 7 is broken-away view of part of a back portion of a heating element as part of an apparatus according to an embodiment of the present invention;
Figures 8A and 8B are top views of a sulphur sump pump in place within an apparatus according to an embodiment of the present invention;
Figures 8C and 8D are side views of a sulphur sump pump in place within an apparatus according to an embodiment of the present invention;
Figure 9 shows a hydraulic control circuit of an apparatus according to an embodiment of the present invention;
Figures 1 OA and 1 OB are partially transparent top and side views of a top steam header pipe as part of an apparatus according to an embodiment of the present invention;
Figure 2A is a side view of a trailer, carriage and support tower of an apparatus according to an embodiment of the present invention;
Figure 2B is an isometric view of a trailer, carriage and support tower of an apparatus according to an embodiment of the present invention where the support tower is in an erected position;
Figure 2C is an isometric view of a trailer, carriage and support tower of an apparatus according to an embodiment of the present invention where the support tower is in a collapsed position;
Figures 3 and 4 show broken-away views taken in cross-section through rollers of the carriage of an apparatus according to an embodiment of the present invention;
Figure 5 is a side view of a heating element as part of an apparatus according to an embodiment of the present invention;
Figure 6 is an isometric broken-away view of part of a front portion of a heating element as part of an apparatus according to an embodiment of the present invention;
Figure 7 is broken-away view of part of a back portion of a heating element as part of an apparatus according to an embodiment of the present invention;
Figures 8A and 8B are top views of a sulphur sump pump in place within an apparatus according to an embodiment of the present invention;
Figures 8C and 8D are side views of a sulphur sump pump in place within an apparatus according to an embodiment of the present invention;
Figure 9 shows a hydraulic control circuit of an apparatus according to an embodiment of the present invention;
Figures 1 OA and 1 OB are partially transparent top and side views of a top steam header pipe as part of an apparatus according to an embodiment of the present invention;
7 Figures 11A and 11B are top and side views of a bottom condensate header pipe as part of an apparatus according to an embodiment of the present invention;
Figures 12A and 12B are top views of a bottom condensate header pipe and a pickup tray as part of an apparatus according to an embodiment of the present invention;
Figures 13A and 13B are top and side views of intermediate gutters as part of an apparatus according to an embodiment of the present invention;
Figures 14A and 14B are side views of a hot nose pipe as part of an apparatus according to an embodiment of the present invention;
Figure 15 is another side view of a hot nose pipe and a bottom condensate header pipe as part of an apparatus according to an embodiment of the present invention;
Figure 16 is an isometric view of a mounting bracket as part of an apparatus according to an embodiment of the present invention;
Figure 17 is a perspective view of a prior art apparatus in place next to a block of sulphur;
Figure 18 is an isometric view of a trailer, carriage and support tower of a prior art apparatus where the support tower is in an erected position;
Figure 19 is an isometric broken-away view of part of front portion of the heating element as part of a prior art apparatus;
Figure 20 is a side view of a remelter according to an embodiment of the present invention;
Figure 21 is side broken-away view of part of a remelter according to an embodiment of the present invention;
Figure 22 is a front broken-away view of part of a remelter according to an embodiment of the present invention;
Figure 23 is a front broken-away view of part of a remelter according to an embodiment of the present invention;
Figures 12A and 12B are top views of a bottom condensate header pipe and a pickup tray as part of an apparatus according to an embodiment of the present invention;
Figures 13A and 13B are top and side views of intermediate gutters as part of an apparatus according to an embodiment of the present invention;
Figures 14A and 14B are side views of a hot nose pipe as part of an apparatus according to an embodiment of the present invention;
Figure 15 is another side view of a hot nose pipe and a bottom condensate header pipe as part of an apparatus according to an embodiment of the present invention;
Figure 16 is an isometric view of a mounting bracket as part of an apparatus according to an embodiment of the present invention;
Figure 17 is a perspective view of a prior art apparatus in place next to a block of sulphur;
Figure 18 is an isometric view of a trailer, carriage and support tower of a prior art apparatus where the support tower is in an erected position;
Figure 19 is an isometric broken-away view of part of front portion of the heating element as part of a prior art apparatus;
Figure 20 is a side view of a remelter according to an embodiment of the present invention;
Figure 21 is side broken-away view of part of a remelter according to an embodiment of the present invention;
Figure 22 is a front broken-away view of part of a remelter according to an embodiment of the present invention;
Figure 23 is a front broken-away view of part of a remelter according to an embodiment of the present invention;
8 Figure 24 is a front broken-away view of part of a remelter according to an embodiment of the present invention;
Figure 25 is a side view of a modular sulphur remelter element according to an embodiment of the present invention;
Figure 26 is a front broken-away view of part of a modular sulphur remelter element according to an embodiment of the present invention;
Figure 27 is a front broken-away view of part of a modular sulphur remelter element according to an embodiment of the present invention; and Figure 28 is an isometric view of part of a modular sulphur remelter element according to an embodiment of the present invention.
Figures 17 to 19 illustrate a prior art apparatus (described in Applicant's U.S. Patent No.
4,203,625) adjacent a block of sulphur P67 comprising a heating element P11, held by a support tower P12 which itself is mounted on a carriage P14 which itself is mounted on a trailer P15. The heating element P11 is advanced by a counter-weight P48.
As seen from Figure 19, a box shaped top steam header pipe P73 connects to a series of vertical pipes P71, which are arranged in two parallel, offset rows, connected to a box shaped bottom condensate header pipe P74. The vertical pipes P71 communicate at opposite ends thereof with the hollow interiors of the top steam header and the bottom condensate header pipes P73 and P74. The top steam header pipe P73 has a steam inlet pipe P75 for supplying steam thereto from a vertical steam supply pipe P76. The bottom condensate header pipe P74 communicates through an outlet pipe P77 with a vertical discharge pipe P78, which is similarly connected to the bottom condensate header of each of the other heater sections. The bottom condensate header pipe has a flat top surface P80 which is rearwardly inclined and provided with upstanding side walls P81, so that molten sulphur melted by the vertical pipes P71, when the apparatus is in use, will flow to the rear of the flat top surface P80, and thence into a
Figure 25 is a side view of a modular sulphur remelter element according to an embodiment of the present invention;
Figure 26 is a front broken-away view of part of a modular sulphur remelter element according to an embodiment of the present invention;
Figure 27 is a front broken-away view of part of a modular sulphur remelter element according to an embodiment of the present invention; and Figure 28 is an isometric view of part of a modular sulphur remelter element according to an embodiment of the present invention.
Figures 17 to 19 illustrate a prior art apparatus (described in Applicant's U.S. Patent No.
4,203,625) adjacent a block of sulphur P67 comprising a heating element P11, held by a support tower P12 which itself is mounted on a carriage P14 which itself is mounted on a trailer P15. The heating element P11 is advanced by a counter-weight P48.
As seen from Figure 19, a box shaped top steam header pipe P73 connects to a series of vertical pipes P71, which are arranged in two parallel, offset rows, connected to a box shaped bottom condensate header pipe P74. The vertical pipes P71 communicate at opposite ends thereof with the hollow interiors of the top steam header and the bottom condensate header pipes P73 and P74. The top steam header pipe P73 has a steam inlet pipe P75 for supplying steam thereto from a vertical steam supply pipe P76. The bottom condensate header pipe P74 communicates through an outlet pipe P77 with a vertical discharge pipe P78, which is similarly connected to the bottom condensate header of each of the other heater sections. The bottom condensate header pipe has a flat top surface P80 which is rearwardly inclined and provided with upstanding side walls P81, so that molten sulphur melted by the vertical pipes P71, when the apparatus is in use, will flow to the rear of the flat top surface P80, and thence into a
9 collection gutter P82, which extends horizontally along the rear of the bottom condensate header pipe P74. The collection gutter P82 communicates with a vertical downspout P83, which is common to all of the heater sections and is arranged, in use, to discharge the molten sulphur downwardly into a trough or the like (not shown). The sulphur collected from the upper elements is directed through the downspout to the collection system of troughs. The sulphur from the lower element is raised by an Archimedes screw and discharged into the same collecting trough.
Turning now to the present invention with reference to Figures 1 through 16, a block sulphur melting apparatus 1 illustrated in the drawings comprises an elongated rectangular melter or heating element 2 which is shown in an erected position of at least approximately upright disposition in FIGS. 1, 2A, and 2B. The heating element 2 is supported at the rear side of a support tower indicated generally by reference numeral 3, which is in the form of a framework, and the support tower 3 is pivotally supported by means of pivot connections 4 (FIG. 2A) on the rear end of a subframe or carriage, which is indicated generally by reference numeral 5.
The subframe or carriage 5 is movably supported, as will be described in greater detail hereinafter, on the rear end of the chassis of a mobile platform or trailer indicated generally by reference numeral 6, and is extensible and retractable, in the longitudinal direction of the trailer 6 to and from the rear end of the trailer 6, between the retracted position, in which the carriage 5 is shown in FIGS. 1, 2B, and 2C and an extended position as shown in FIG. 2A, in which the carriage 5 is pivoted outwardly beyond the rear end of the trailer 6. Crawler tracks 6a may be provided as a means to horizontally displace the trailer.
More particularly, the carriage 5 comprises opposed longitudinal vertical side walls 7 in the form of rectangular lattice frames, which are connected at the corners thereof by transverse members 8, the pivot connections 4 being provided at the rearmost uppermost corners of the side walls 7. Alternatively, the side walls 7 may be connected to one another by lattice structures.
The carriage 5 is movably supported on a track formed by a pair of parallel rails which are indicated generally by reference numeral 9 and which extend longitudinally along the trailer 6. Each of the side walls 7 is provided with three pairs of rollers 10 to 12 co-operating with the respective rail 9.
As can be seen more clearly from FIGS. 3 and 4, each rail 9 comprises an I-beam 13 having an upper flange providing at its top an upper running surface 14 and at its underside a lower running surface 15.
The roller 10, which is shown in FIG. 3, rollingly engages the upper running surface 14, and is rotatable on a journal 16 projecting from one end of a tubular member extending transversely of the carriage 5.
FIG. 4 shows the rollers 11 and 12 and, as will be seen, these rollers comprise a vertically spaced pair of rollers in rolling engagement with the upper and lower rolling surfaces 14 and 15, respectively. The rollers 11 and 12 are rotatably journalled on respective stub shafts 18 and 19 projecting laterally from the carriage 5 at the lower, front corner thereof.
Since the rollers 10 as shown in FIG. 2A, are located approximately one-third of the length of the carriage 5 from the front end of the latter at which the rollers 11 and 12 are provided, the arrangement of the rollers 10 to 12 and the two I-beams 13 enables the carriage 5 to be moved rearwardly from the rear end of the trailer 6 while remaining in its horizontal position, i.e. without tilting at the rear of the trailer 6.
At each side of the carriage 5, there is provided a lifting mechanism in the form of a hydraulic cylinder, indicated generally by reference numeral 20, for pivotally raising the heating element support tower 3, and therewith the heating element 2, about the horizontal common axis of pivotation of the pivotal connections 4 into the erected, operational position. Each hydraulic cylinder 20 is pivotally connected at one end thereof to the respective side wall 7 of the carriage 5 by a pivot connection 21 and at its other end to a respective side of the support tower 3 by a pivot connection 22.
Each mast support 20a is pivotally connected at the top end to the respective side of the support tower 3 and is pivoted until it aligns with its respective connection point on the side wall of the carriage 5 whereupon it is attached with a pin connection.
Upon removal of the pin from the connection of the mast support 20a to the side wall of the carriage 5, the mast support 20a is pivoted about its top connection with the support tower 3 until it is in a vertical position whereupon it is secured to the support tower 3, thereafter contraction of the hydraulic cylinders 20 to lower the support tower 3 by downward pivotation about the common horizontal axis of the pivot connections 4, with the carriage 5 in its forward, retracted position, the support tower 3 becomes substantially horizontally disposed, as illustrated in FIG. 2C. In this lowermost position, the support tower 3 can be secured relative to the trailer by any suitable means for transportation and/or storage.
The carriage 5, and therewith the support tower 3 and its heating element 2, can, when required, be biased rearwardly for movement rearwardly from the trailer 6 from the retracted position in which the carriage 5 is shown in FIGS. 1, 2A, and 2B to a rearwardly extended position, in which the rear end of the carriage 5 is displaced rearwardly of the rear end of the trailer 6, by means of a second hydraulic cylinder 23 as seen in FIG. 2A.
As described later in further detail with reference to FIG. 9, the element is advanced and retracted by a system comprised of the second hydraulic cylinder 23, a directional control valve V6 and a pressure compensated variable displacement pump. The force applied to the advancing element is adjusted by varying the hydraulic pressure.
The trailer 6 has, at each side thereof, a pair of ground engagement wheels 24, which can be raised or lowered relative to the trailer 6 by means of an adjustable suspension comprising a pair of bell crank levers 25. A pair of hydraulic rams 26 are pivotally connected to the respective I-beam 13 and to one end of the respective bell crank levers 25, and the other end of the bell crank levers 25 are pivotally connected to the joined lower ends of a pair of struts 27 depending from the underside of the trailer 6.
The bell crank levers 25 are operatively connected, intermediate their ends, to the ground engagement wheels 24 so that, on actuation of the hydraulic rams 26, the ground engagement wheels 24 are raised or lowered.
The trailer 6 is also provided with hydraulically actuatable front support legs 27a for stabilizing the trailer 6 when the sulphur melting apparatus is in use.
Turning now to the heating element 2 and support tower 3 with particular reference to FIGS. 5, 6 and 7. As seen from the side view of FIG. 5, the heating element 2 and support tower 3 generally comprise a top steam header pipe 28, vertical steam pipes 29, intermediate gutters 30, downspouts 31, a remelter mast or tower 32, a sulphur sump pump 34 and a sump 33.
S The system is shown isometrically in FIG. 6. In operation, when the heating element 2 is approached to a block of sulphur 66, steam is input into a round hollow top steam header pipe 28 by way of the steam inlet flanges 35. The steam then enters and passes down through the vertical steam pipes 29 until the steam reaches and enters a bottom condensate header pipe 36.
The top steam header pipe 28 may be cylindrical and directly connected by concentric reducers 42 (see FIG. 10B) to vertical steam pipes 29 which may be aligned in a single parallel row. The top steam header pipe 28 also serves as the top mount for the heating element 2. A straight connection between the top steam header pipe 28 and the bottom condensate header pipe 36 and the vertical steam pipes 29 may be used. The vertical steam pipes 29 are directly connected by concentric reducers 43 (see FIGS. 11A
and 11 B) to the bottom condensate header pipe 36 which serves as a condensate outlet.
The bottom condensate header pipe 36 may also be cylindrical. The condensate is removed from the bottom condensate header pipe 36 by large equally spaced syphons 44 so as not to allow a buildup of condensate. The bottom condensate header pipe 36 has mounting brackets 45 which incorporate a slide arrangement to allow for the thermal expansion of the heating element 2. The mounting brackets are illustrated in greater detail in Figure 16. The brackets have a channel shape which fits around a square tubing 45a which is attached to the support tower 3. The other end of the bracket 45c is attached to the bottom condensate header pipe 36. The web of the channel transmits the horizontal force to the heating element 2 while the flanges deal with the lateral forces. Loose fitting bolts or pins located in slotted holes 45b in the flanges of the channel retain the element during the retraction phase of the operation.
A thin wall tube of similar wall thickness as the vertical steam pipes 29 is used as a hot nose pipe 41 to melt a path through the sulphur in front of the bottom condensate header pipe 36. This hot nose pipe 41 has a steam inlet 46 (see FIG 14B) with several outlets 47 into the hot nose pipe 41 as well as three condensate outlets 48 to assure there is good steam distribution and no buildup of condensate in the hot nose pipe 41.
The syphon 44 allows for improved extraction of condensate from the bottom steam header pipe 36. If all parts melt at the same rate, then a greater force can be evenly distributed over the entire unit. A greater force creates a more intimate contact which increases the heat transfer rate.
Vertically spaced intermediate gutters 30 are disposed horizontally adjacent to the heating element. The intermediate gutters 30 carry the melted sulphur away from the hot vertical steam pipes 29, allowing the heating element 2 to be operated at higher steam pressures. The intermediate gutters 30 feed into downspouts 31 so that melted sulfur can flow down to the pickup tray 39. This combined with greater advancing force due to even distribution of the loading allows for more intimated contact between the vertical steam pipes 29 and the unmelted sulphur resulting in better heat transfer, and thus greater melt (advance) rate.
The intermediate gutters 30 may be attached at regular spacing down the back of the element to collect the sulphur as it melts and to provide intermediate supports for the vertical pipes. As the sulphur in front of the vertical steam pipes 29 (named primary zone) is melted it runs down the entire length of the vertical steam pipes 29 and is collected in the pick up tray 39 located at the back of the bottom condensate header pipe 36.
Some of the sulphur passes as unmelted slivers or sheets between the vertical steam pipes 29 where it contacts a backing panel BP (shown in Figure 15) which causes it to break or crumble, and fall into the void between the back of the pipes 29 and the backing panel BP located behind the vertical steam pipes 29 between the top steam header pipe 28, the intermediate gutters 30 and the bottom condensate header pipe 36.
This sulphur then falls down the space between the back of the vertical steam pipes 29 and the backing panel BP landing in the pickup tray system 39. This is where secondary melting occurs and furthertertiary melting occurs when the unmelted sulphur is flooded with the hot melted sulphur from the primary and secondary zones.
This tertiary melting occurs in the intermediate gutters 30, pickup tray 39 and sulphur sump 33. The single row design may afford general reduction in fumes and vapors released as compared to an offset double row design.
The sulphur is melted either by contact with the back of the vertical steam pipes 29 (named secondary zone) or by the flow of molten sulphur in the pickup tray 39 (named tertiary zone). The sulphur flows from the pickup tray 39 into the sump 33 where it is pumped away with the sulphur sump pump 34 (see FIG. 5). The melted sulphur which is not collected in the pickup tray 39 is collected in the cavity 49a in the sulphur base pad 49 (see FIG. 5), melted by a sump coil and then enters the sump 33 through a hole in its bottom. The sump 33 is located behind the pickup tray 39 and comprises a series of steam coils constructed of thin wall pipe and a hole in its bottom allowing inflow of all melted sulphur which is not collected in the pickup tray 39.
The apparatus of the present invention uses a single element custom built to the required height. An advantage of this configuration is low cost due to the use of few headers of simple construction, that is, of round cross-section.
Because pressure-retaining parts of the element are built entirely of commercially available round pipe and tubing, there is no difficulty in complying with the pressure code and the unit is simple and straight forward and therefore less expensive to build.
Referring now to the hydraulic control circuit illustrated in FIG. 9, it will be seen that this circuit has a reservoir R for containing a supply of hydraulic fluid and a pressure compensated hydraulic pump 50 driven by tandem variable displacement hydraulic pumps 51 and right and left hydraulic motor tracks 52 and a motor M. The pressure compensated hydraulic pump 50 has a pump inlet connected by hydraulic line 52a to the reservoir R. A fixed displacement pump is indicated by reference FDP.
Hydraulic lines 53 and 54 are connected to the outlet of the hydraulic pump FDP and the inlet of the reservoir R, respectively, and a plurality of manually actuatable control valves V, to V5 are connected in parallel across the hydraulic lines 53 and 54 by hydraulic lines 55 and 56.
Valves V, and VZ have outlets connected by hydraulic lines 56a-59 to the cylinders of the hydraulic rams 26 of the left and right wheels, respectively, of the trailer 6.
Valve V3 is connected by hydraulic lines 60 and 61 to the hydraulic rams 20 for raising and lowering the heating element support tower 3.
Valves V4 and VS are connected by hydraulic lines 62-65 to respective cylinders of the front support legs 27a.
A pressure relief valve RV is connected via hydraulic line 56 across hydraulic lines 53 and 54.
The operation of the above-described apparatus is as follows. To transport the apparatus to the vicinity of the sulphur block 66 (FIG. 1 ), the trailer 6 is towed by a truck (not shown) with the heating element support tower 3 in its collapsed position, as illustrated in FIG. 2C. The trailer 6 is then backed towards the sulphur block 66 into an appropriate position, and the ground engagement wheels 24 are raised, and the support legs 27a are lowered, so that the trailer 6 is securely stabilized on the ground. The hydraulic cylinder 20 is actuated to pivot the heating element support tower 3, and therewith the heating element 2, from its collapsed position on the trailer 6 to its upright, operational position. Steam supply pipes are then coupled to the top steam header pipe 28 and bottom condensate header pipe 36 of the heating element 2 to supply steam thereto. With the apparatus thus ready for operation, the sulphur is melted and the carriage 5 is advanced thus advancing the heating element 2, against the progressively melting sulphur block 66.
Heat applied to the sulphur block 66 from the heating element 2 melts the sulphur in the immediate vicinity of the heating element 2. More particularly, the hot nose pipe 41 firstly melts its way into the sulphur block, being the first part of the apparatus to contact the sulphur block 66, and then acts as a seal while the vertical steam pipes 29 approach and melt the sulphur block 66 so that the melted sulphur runs down the vertical steam pipes 29 for collection as hereinbefore described and is prevented from running forwardly by the sealing of the sulphur block 66 to the projecting forward edge of hot nose pipe 41. The molten sulphur may be pumped to storage tanks using the sulphur sump pump 34.
More specifically the remelting occurs as follows: as the heating element 2 advances horizontally with the top steam header pipe 28 protruding above the sulphur block 66 the front face of the vertical steam pipes 29 and the front face of the horizontal hot nose pipe 41 melt the sulphur in the primary melting zone. The slivers or sheets of unmelted sulphur, passing between the vertical steam pipes 29, crumble and break as they contact the backing panel BP where it is melted in the secondary zone. Any unmelted sulphur that gets past this zone is melted by the flow of molten sulphur which carries it through the intermediate gutter 30, downspout 31 and pickup tray 39 (tertiary zone).
The sulphur discharges from the pickup tray 39 into the sump 33 where it is pumped away by a commercially available submersible sulphur sump pump 34.
If necessary, the crawler track unit 6a can be actuated to laterally adjust the carriage 5 by laterally displacing the forward end of the trailer 6 to correctly align the heating element support tower 3 relative to the sulphur block 66. In this way, a cut of uniform thickness can be ensured.
After the heating element 2 has thus been displaced rearwardly of the trailer 6 by the maximum distance, i.e. when the carriage 5 has reached the limits of its rearward travel, the carriage 5 is pulled back to its starting position by retracting the second hydraulic cylinder 23. The trailer 6 is then backed further towards the remaining unmelted portion of the sulphur block 66 by use of the crawler track unit 6a, and the process is repeated.
The crawler track unit 6a is connected to the trailer 6 by a fifth wheel attachment which can be raised and lowered to provide correct elevation of the one end of trailer 6, the other end is adjusted with the front support legs 27a and suspension. The crawler track unit 6a is equipped with brakes to allow it to act as an anchor so that it may resist the reactionary forces caused by the second hydraulic cylinder 23 pushing the heating element 2 into the sulphur block.
The above-described apparatus not only has the advantage of mobility but also provides safety for the operating personnel, who operate with the apparatus at ground level and are not required to work at a position close to the molten sulphur and the heating element. Since the flow of molten sulphur is vertically downward and since the sulphur is collected by the intermediate gutters, sulphur losses through fissures in the block are minimized and high volumes and velocities of sulphur flow are avoided. Energy efficiency is obtained as heat is transferred to the block through a minimum thickness of molten sulphur. The apparatus requires minimal permanent plant adaptation, since the steam and electrical power requirements are normally readily available at all block locations from ordinary plant operation. The use of the present apparatus is not labour intensive and does not require extraordinary skill and judgment. The operation of the apparatus may be continuous or intermittent, as required, since the apparatus is simple to start up or close down.
CONTAMINATED SULPHUR REMELTER UNIT (CSRU) When sulphur blocks are poured, they are vulnerable to being contaminated by a variety of items and causes such as moisture from snow and rain, dirt and ash from surrounding fields and process plants, and chemicals from process malfunction in the gas plant.
The modular sulphur remelter element is an attachment which can be used with both the current remelter heating elements (for instance as described herein) and the earlier remelter heating elements (as described for instance in Applicant's Canadian Patent 1,064,224).
The purpose of the unit is to melt a generally horizontal band of sulphur as the unit advances ahead of the main remelter heating element. The band of sulphur is typically contaminated with dirty ash, chemicals, or excessive moisture; all of which reduce melt rate and can damage the main remelter element. If the CSRU melt rate is slower than the main heating element then the entire unit will only advance at the rate of the slowest melting part, however, because the CSRU is separate from the main heating element its steam supply can be adjusted to suit its particular operating condition without adversely affecting the main heating element. The sulphur melted by the CSRU
is collected separately and can be disposed of, treated or reblended with the remaining sulphur.
As seen in Figures 20 and 22, the CSRU 68 is composed of a series of steam heated melting pipes 69 positioned generally vertically one above the other and each pipe having a slight incline to the horizontal along its length. There is a small vertical space between these steam heated melting pipes 69 to allow the remelted sulphur to flow between them to the collecting area. Each of the steam heated melting pipes 69 is closed at both ends. Steam is supplied to an inlet pipe 70 which penetrates the closure at the lower end of each melting pipe and extends to near the other end, thus assuring good steam circulation. The slight incline of the pipe ensures that the condensate flows to the lower end, where it is discharged through a hole in the lower closure of each melting pipe and discharges through a condensate outlet pipe 71 into a piping system which is connected to a steam trap. Figure 23 shows the steam inlet piping and Figure 24 shows the condensate outlet piping.
The steam heated parallel melting pipes 69 are attached to a backing panel such that each successively lower pipe slightly precedes the one above. There is a bottom that connects the lowest pipe to the backing panel. Referring to Figure 20, end panels and mounting brackets connect the CSRU to a trolley 72 which runs on rails 73 attached to the remelter mast 32. The unit can be moved up or down by use of winches, hydraulic cylinders or come-a-longs 74.
As the CSRU 68 advances horizontally, melting into the sulphur block, the sulphur melted by each steam heated parallel melting pipe 69 flows around the pipe and discharges into the area between the pipes and the backing panel where it is collected on the bottom. Slivers of sulphur passing between the pipes contact the backing panel where they break off and fall between the back of the pipes and the backing panel.
There the slivers are melted by contact with the back of the hot pipes as well as by the molten sulphur flowing over them. Because the unit (including the bottom) slopes slightly to the outside end (as seen in front view Figure 22), the sulphur flows to that end where it is collected and is discharged to a down spout. An example of the slope, is four vertical inches for sixteen foot long pipes. The sulphur which flows under the lowest pipe will be collected by the main heating element, therefore the CSRU 68 will have to be positioned so that the lowest pipe is in contact with the clean sulphur below the band of contaminated sulphur as seen in Figure 20.
With the steam inlet pipe discharging at the high end and because of the slope, the condensate flows to the outside end to be discharged, resulting in a good circulation of steam, without a buildup of condensate.
This arrangement has a number of advantages over previous remelter elements that have historically utilized vertical melting pipes. First, the expensive steam and condensate headers are eliminated. Second, the steam and condensate headers do not have to melt their way through the sulphur block. Third, wider remelter units can be made by simply making the melting pipes longer as opposed to the vertical arrangement where longer steam and condensate headers have to be built and additional vertical pipes installed. Fourth, the proposed design lends itself to modular constructions, thereby requiring only as many elements as are needed for the particular height of the sulphur block engaged. This is a major improvement because the headers are otherwise typically constructed as tall as practicable as a cost consideration at the expense of modularity, and the remelter heating elements extend well above the top of the sulphur block.
The design is simple and inexpensive to build and lends itself to fabrication from a variety of materials, including aluminum. Aluminum has good heat transfer properties and has been used for sulphur handling for many years.
MODULAR SULPHUR REMELTER ELEMENT
The modular sulphur remelter element was previously described as an attachment used with remelter elements including the CSRU. The purpose of the modular element is to melt horizontally through a sulphur block in much the same manner as do the previous designs, such as depicted in Figure 1. The modular element is designed to mount onto the mast of the previous design, thus employing all the features of the existing leveling and advancing systems.
Referring to Figure 25, the modular element is composed of a series of heating element modules 76 mounted vertically one above the other, up the face of the mast.
This design only uses as many modules as are required to reach the height of the sulphur block.
As seen in Figure 25, each heating element module is composed of a series of steam heated melting pipes 77 positioned generally vertically one above the other and each pipe having a slight incline to the horizontal along its length. There is a small vertical space between these steam heated melting pipes 77 to allow the remelted sulphur to flow between them to the collecting area. Each of the steam heated melting pipes 77 is closed at both ends. As with the CSRU, steam is supplied to an inlet pipe 78 which penetrates the closure at the lower end of each melting pipe and extends to near the other end, thus assuring good steam circulation. The slight incline of the pipe ensures that the condensate flows to the lower end, where it is discharged through a hole in the lower closure of each melting pipe and discharges through a condensate outlet pipe 79 into a piping system which is connected to a steam trap. Figure 26 shows the steam inlet piping and Figure 27 shows the condensate outlet piping. There is a bottom that connects the lowest pipe to the backing panel. The backing panel of each heating element module has a hook shaped flange along its top edge which hooks over a mounting rail attached to the mast. This connection allows for thermal expansion of the heating element module (both vertically and horizontally) as well as simplifies replacement of the module should it become damaged. A pair of clips prevent the module from sliding sideways or unintentionally being lifting off the mounting rail.
As the modular sulphur remelter element advances horizontally, melting into the sulphur block, the sulphur melted by each steam heated parallel heating melting pipe 77 flows around the pipe and discharges into the area between the pipes and the backing panel where it is collected on the bottom. Slivers of sulphur passing between the pipes contact the backing panel where they break off and fall between the back of the pipes and the backing panel. There the slivers are melted by contact with the back of the hot pipes as well as by the molten sulphur flowing over them. Because the unit (including the bottom) slopes slightly to the outside end as described in respect of the CSRU, the sulphur flows to that end where it is collected and is discharged to a down spout. The sulphur which flows under the lowest pipe of each module will be collected by the module below. The liquid sulphur 83, as shown in Figure 28, flows under the lowest pipe of the bottom heating element module and flows over the surface of the sloping base pad 80 to the outside edge of the melt area where it is collected.
At first appearance the sloping base pad 80 left by the bottom heating element module would appear to be a problem, however, by making each successive cut lower by the vertical distance of the slope, the overall sloping base pad 80 remains level and the added advantage is that the liquid sulphur 83 which flows under the bottom heating element module is collected in the resulting trough 81, where it can be picked up by the use of a commercial sulphur pump or Archimedes screw 82.
If only the sulphur sump pump is used, it is necessary to surround it with a steam heated coil of pipe so that it will melt a sump into the sloping base pad 80 as described in the earlier patent description. If the Archimedes screw 82 is used, then the liquid sulphur 83 can be picked up from the trough 81 without melting a sump. Because the Archimedes screw 82 has a very limited capacity to deal with head it will have to discharge into a gravity rundown system or into a holding tank where the sulphur is collected with that flowing from the upper heating element modules. A
commercial sulphur pump can be installed in the holding tank to pump away the remelted sulphur.
With the steam inlet pipe discharging at the high end and because of the slope, the S condensate flows to the outside end to be discharged, resulting in a good circulation of steam, without a buildup of condensate.
The heating element modules easily lend themselves to being built as wide as practical without a great increase in the cost of construction. A wider heating element simply requires longer pipes, whereas the previous design required more vertical pipes and more header fabrication to make a wider heating element. This feature will prove advantageous for remelting low blocks. Conversely, the taller the block, the more heating element modules (increased cost) are required, but only as many as are required to reach the top of the block, thus eliminating the common practice of making the heating element taller than needed.
The design is simple and inexpensive to build and lends itself to fabrication from a variety of materials including aluminum. Aluminum has good heat transfer properties and has been used in sulphur handling for many years.
Turning now to the present invention with reference to Figures 1 through 16, a block sulphur melting apparatus 1 illustrated in the drawings comprises an elongated rectangular melter or heating element 2 which is shown in an erected position of at least approximately upright disposition in FIGS. 1, 2A, and 2B. The heating element 2 is supported at the rear side of a support tower indicated generally by reference numeral 3, which is in the form of a framework, and the support tower 3 is pivotally supported by means of pivot connections 4 (FIG. 2A) on the rear end of a subframe or carriage, which is indicated generally by reference numeral 5.
The subframe or carriage 5 is movably supported, as will be described in greater detail hereinafter, on the rear end of the chassis of a mobile platform or trailer indicated generally by reference numeral 6, and is extensible and retractable, in the longitudinal direction of the trailer 6 to and from the rear end of the trailer 6, between the retracted position, in which the carriage 5 is shown in FIGS. 1, 2B, and 2C and an extended position as shown in FIG. 2A, in which the carriage 5 is pivoted outwardly beyond the rear end of the trailer 6. Crawler tracks 6a may be provided as a means to horizontally displace the trailer.
More particularly, the carriage 5 comprises opposed longitudinal vertical side walls 7 in the form of rectangular lattice frames, which are connected at the corners thereof by transverse members 8, the pivot connections 4 being provided at the rearmost uppermost corners of the side walls 7. Alternatively, the side walls 7 may be connected to one another by lattice structures.
The carriage 5 is movably supported on a track formed by a pair of parallel rails which are indicated generally by reference numeral 9 and which extend longitudinally along the trailer 6. Each of the side walls 7 is provided with three pairs of rollers 10 to 12 co-operating with the respective rail 9.
As can be seen more clearly from FIGS. 3 and 4, each rail 9 comprises an I-beam 13 having an upper flange providing at its top an upper running surface 14 and at its underside a lower running surface 15.
The roller 10, which is shown in FIG. 3, rollingly engages the upper running surface 14, and is rotatable on a journal 16 projecting from one end of a tubular member extending transversely of the carriage 5.
FIG. 4 shows the rollers 11 and 12 and, as will be seen, these rollers comprise a vertically spaced pair of rollers in rolling engagement with the upper and lower rolling surfaces 14 and 15, respectively. The rollers 11 and 12 are rotatably journalled on respective stub shafts 18 and 19 projecting laterally from the carriage 5 at the lower, front corner thereof.
Since the rollers 10 as shown in FIG. 2A, are located approximately one-third of the length of the carriage 5 from the front end of the latter at which the rollers 11 and 12 are provided, the arrangement of the rollers 10 to 12 and the two I-beams 13 enables the carriage 5 to be moved rearwardly from the rear end of the trailer 6 while remaining in its horizontal position, i.e. without tilting at the rear of the trailer 6.
At each side of the carriage 5, there is provided a lifting mechanism in the form of a hydraulic cylinder, indicated generally by reference numeral 20, for pivotally raising the heating element support tower 3, and therewith the heating element 2, about the horizontal common axis of pivotation of the pivotal connections 4 into the erected, operational position. Each hydraulic cylinder 20 is pivotally connected at one end thereof to the respective side wall 7 of the carriage 5 by a pivot connection 21 and at its other end to a respective side of the support tower 3 by a pivot connection 22.
Each mast support 20a is pivotally connected at the top end to the respective side of the support tower 3 and is pivoted until it aligns with its respective connection point on the side wall of the carriage 5 whereupon it is attached with a pin connection.
Upon removal of the pin from the connection of the mast support 20a to the side wall of the carriage 5, the mast support 20a is pivoted about its top connection with the support tower 3 until it is in a vertical position whereupon it is secured to the support tower 3, thereafter contraction of the hydraulic cylinders 20 to lower the support tower 3 by downward pivotation about the common horizontal axis of the pivot connections 4, with the carriage 5 in its forward, retracted position, the support tower 3 becomes substantially horizontally disposed, as illustrated in FIG. 2C. In this lowermost position, the support tower 3 can be secured relative to the trailer by any suitable means for transportation and/or storage.
The carriage 5, and therewith the support tower 3 and its heating element 2, can, when required, be biased rearwardly for movement rearwardly from the trailer 6 from the retracted position in which the carriage 5 is shown in FIGS. 1, 2A, and 2B to a rearwardly extended position, in which the rear end of the carriage 5 is displaced rearwardly of the rear end of the trailer 6, by means of a second hydraulic cylinder 23 as seen in FIG. 2A.
As described later in further detail with reference to FIG. 9, the element is advanced and retracted by a system comprised of the second hydraulic cylinder 23, a directional control valve V6 and a pressure compensated variable displacement pump. The force applied to the advancing element is adjusted by varying the hydraulic pressure.
The trailer 6 has, at each side thereof, a pair of ground engagement wheels 24, which can be raised or lowered relative to the trailer 6 by means of an adjustable suspension comprising a pair of bell crank levers 25. A pair of hydraulic rams 26 are pivotally connected to the respective I-beam 13 and to one end of the respective bell crank levers 25, and the other end of the bell crank levers 25 are pivotally connected to the joined lower ends of a pair of struts 27 depending from the underside of the trailer 6.
The bell crank levers 25 are operatively connected, intermediate their ends, to the ground engagement wheels 24 so that, on actuation of the hydraulic rams 26, the ground engagement wheels 24 are raised or lowered.
The trailer 6 is also provided with hydraulically actuatable front support legs 27a for stabilizing the trailer 6 when the sulphur melting apparatus is in use.
Turning now to the heating element 2 and support tower 3 with particular reference to FIGS. 5, 6 and 7. As seen from the side view of FIG. 5, the heating element 2 and support tower 3 generally comprise a top steam header pipe 28, vertical steam pipes 29, intermediate gutters 30, downspouts 31, a remelter mast or tower 32, a sulphur sump pump 34 and a sump 33.
S The system is shown isometrically in FIG. 6. In operation, when the heating element 2 is approached to a block of sulphur 66, steam is input into a round hollow top steam header pipe 28 by way of the steam inlet flanges 35. The steam then enters and passes down through the vertical steam pipes 29 until the steam reaches and enters a bottom condensate header pipe 36.
The top steam header pipe 28 may be cylindrical and directly connected by concentric reducers 42 (see FIG. 10B) to vertical steam pipes 29 which may be aligned in a single parallel row. The top steam header pipe 28 also serves as the top mount for the heating element 2. A straight connection between the top steam header pipe 28 and the bottom condensate header pipe 36 and the vertical steam pipes 29 may be used. The vertical steam pipes 29 are directly connected by concentric reducers 43 (see FIGS. 11A
and 11 B) to the bottom condensate header pipe 36 which serves as a condensate outlet.
The bottom condensate header pipe 36 may also be cylindrical. The condensate is removed from the bottom condensate header pipe 36 by large equally spaced syphons 44 so as not to allow a buildup of condensate. The bottom condensate header pipe 36 has mounting brackets 45 which incorporate a slide arrangement to allow for the thermal expansion of the heating element 2. The mounting brackets are illustrated in greater detail in Figure 16. The brackets have a channel shape which fits around a square tubing 45a which is attached to the support tower 3. The other end of the bracket 45c is attached to the bottom condensate header pipe 36. The web of the channel transmits the horizontal force to the heating element 2 while the flanges deal with the lateral forces. Loose fitting bolts or pins located in slotted holes 45b in the flanges of the channel retain the element during the retraction phase of the operation.
A thin wall tube of similar wall thickness as the vertical steam pipes 29 is used as a hot nose pipe 41 to melt a path through the sulphur in front of the bottom condensate header pipe 36. This hot nose pipe 41 has a steam inlet 46 (see FIG 14B) with several outlets 47 into the hot nose pipe 41 as well as three condensate outlets 48 to assure there is good steam distribution and no buildup of condensate in the hot nose pipe 41.
The syphon 44 allows for improved extraction of condensate from the bottom steam header pipe 36. If all parts melt at the same rate, then a greater force can be evenly distributed over the entire unit. A greater force creates a more intimate contact which increases the heat transfer rate.
Vertically spaced intermediate gutters 30 are disposed horizontally adjacent to the heating element. The intermediate gutters 30 carry the melted sulphur away from the hot vertical steam pipes 29, allowing the heating element 2 to be operated at higher steam pressures. The intermediate gutters 30 feed into downspouts 31 so that melted sulfur can flow down to the pickup tray 39. This combined with greater advancing force due to even distribution of the loading allows for more intimated contact between the vertical steam pipes 29 and the unmelted sulphur resulting in better heat transfer, and thus greater melt (advance) rate.
The intermediate gutters 30 may be attached at regular spacing down the back of the element to collect the sulphur as it melts and to provide intermediate supports for the vertical pipes. As the sulphur in front of the vertical steam pipes 29 (named primary zone) is melted it runs down the entire length of the vertical steam pipes 29 and is collected in the pick up tray 39 located at the back of the bottom condensate header pipe 36.
Some of the sulphur passes as unmelted slivers or sheets between the vertical steam pipes 29 where it contacts a backing panel BP (shown in Figure 15) which causes it to break or crumble, and fall into the void between the back of the pipes 29 and the backing panel BP located behind the vertical steam pipes 29 between the top steam header pipe 28, the intermediate gutters 30 and the bottom condensate header pipe 36.
This sulphur then falls down the space between the back of the vertical steam pipes 29 and the backing panel BP landing in the pickup tray system 39. This is where secondary melting occurs and furthertertiary melting occurs when the unmelted sulphur is flooded with the hot melted sulphur from the primary and secondary zones.
This tertiary melting occurs in the intermediate gutters 30, pickup tray 39 and sulphur sump 33. The single row design may afford general reduction in fumes and vapors released as compared to an offset double row design.
The sulphur is melted either by contact with the back of the vertical steam pipes 29 (named secondary zone) or by the flow of molten sulphur in the pickup tray 39 (named tertiary zone). The sulphur flows from the pickup tray 39 into the sump 33 where it is pumped away with the sulphur sump pump 34 (see FIG. 5). The melted sulphur which is not collected in the pickup tray 39 is collected in the cavity 49a in the sulphur base pad 49 (see FIG. 5), melted by a sump coil and then enters the sump 33 through a hole in its bottom. The sump 33 is located behind the pickup tray 39 and comprises a series of steam coils constructed of thin wall pipe and a hole in its bottom allowing inflow of all melted sulphur which is not collected in the pickup tray 39.
The apparatus of the present invention uses a single element custom built to the required height. An advantage of this configuration is low cost due to the use of few headers of simple construction, that is, of round cross-section.
Because pressure-retaining parts of the element are built entirely of commercially available round pipe and tubing, there is no difficulty in complying with the pressure code and the unit is simple and straight forward and therefore less expensive to build.
Referring now to the hydraulic control circuit illustrated in FIG. 9, it will be seen that this circuit has a reservoir R for containing a supply of hydraulic fluid and a pressure compensated hydraulic pump 50 driven by tandem variable displacement hydraulic pumps 51 and right and left hydraulic motor tracks 52 and a motor M. The pressure compensated hydraulic pump 50 has a pump inlet connected by hydraulic line 52a to the reservoir R. A fixed displacement pump is indicated by reference FDP.
Hydraulic lines 53 and 54 are connected to the outlet of the hydraulic pump FDP and the inlet of the reservoir R, respectively, and a plurality of manually actuatable control valves V, to V5 are connected in parallel across the hydraulic lines 53 and 54 by hydraulic lines 55 and 56.
Valves V, and VZ have outlets connected by hydraulic lines 56a-59 to the cylinders of the hydraulic rams 26 of the left and right wheels, respectively, of the trailer 6.
Valve V3 is connected by hydraulic lines 60 and 61 to the hydraulic rams 20 for raising and lowering the heating element support tower 3.
Valves V4 and VS are connected by hydraulic lines 62-65 to respective cylinders of the front support legs 27a.
A pressure relief valve RV is connected via hydraulic line 56 across hydraulic lines 53 and 54.
The operation of the above-described apparatus is as follows. To transport the apparatus to the vicinity of the sulphur block 66 (FIG. 1 ), the trailer 6 is towed by a truck (not shown) with the heating element support tower 3 in its collapsed position, as illustrated in FIG. 2C. The trailer 6 is then backed towards the sulphur block 66 into an appropriate position, and the ground engagement wheels 24 are raised, and the support legs 27a are lowered, so that the trailer 6 is securely stabilized on the ground. The hydraulic cylinder 20 is actuated to pivot the heating element support tower 3, and therewith the heating element 2, from its collapsed position on the trailer 6 to its upright, operational position. Steam supply pipes are then coupled to the top steam header pipe 28 and bottom condensate header pipe 36 of the heating element 2 to supply steam thereto. With the apparatus thus ready for operation, the sulphur is melted and the carriage 5 is advanced thus advancing the heating element 2, against the progressively melting sulphur block 66.
Heat applied to the sulphur block 66 from the heating element 2 melts the sulphur in the immediate vicinity of the heating element 2. More particularly, the hot nose pipe 41 firstly melts its way into the sulphur block, being the first part of the apparatus to contact the sulphur block 66, and then acts as a seal while the vertical steam pipes 29 approach and melt the sulphur block 66 so that the melted sulphur runs down the vertical steam pipes 29 for collection as hereinbefore described and is prevented from running forwardly by the sealing of the sulphur block 66 to the projecting forward edge of hot nose pipe 41. The molten sulphur may be pumped to storage tanks using the sulphur sump pump 34.
More specifically the remelting occurs as follows: as the heating element 2 advances horizontally with the top steam header pipe 28 protruding above the sulphur block 66 the front face of the vertical steam pipes 29 and the front face of the horizontal hot nose pipe 41 melt the sulphur in the primary melting zone. The slivers or sheets of unmelted sulphur, passing between the vertical steam pipes 29, crumble and break as they contact the backing panel BP where it is melted in the secondary zone. Any unmelted sulphur that gets past this zone is melted by the flow of molten sulphur which carries it through the intermediate gutter 30, downspout 31 and pickup tray 39 (tertiary zone).
The sulphur discharges from the pickup tray 39 into the sump 33 where it is pumped away by a commercially available submersible sulphur sump pump 34.
If necessary, the crawler track unit 6a can be actuated to laterally adjust the carriage 5 by laterally displacing the forward end of the trailer 6 to correctly align the heating element support tower 3 relative to the sulphur block 66. In this way, a cut of uniform thickness can be ensured.
After the heating element 2 has thus been displaced rearwardly of the trailer 6 by the maximum distance, i.e. when the carriage 5 has reached the limits of its rearward travel, the carriage 5 is pulled back to its starting position by retracting the second hydraulic cylinder 23. The trailer 6 is then backed further towards the remaining unmelted portion of the sulphur block 66 by use of the crawler track unit 6a, and the process is repeated.
The crawler track unit 6a is connected to the trailer 6 by a fifth wheel attachment which can be raised and lowered to provide correct elevation of the one end of trailer 6, the other end is adjusted with the front support legs 27a and suspension. The crawler track unit 6a is equipped with brakes to allow it to act as an anchor so that it may resist the reactionary forces caused by the second hydraulic cylinder 23 pushing the heating element 2 into the sulphur block.
The above-described apparatus not only has the advantage of mobility but also provides safety for the operating personnel, who operate with the apparatus at ground level and are not required to work at a position close to the molten sulphur and the heating element. Since the flow of molten sulphur is vertically downward and since the sulphur is collected by the intermediate gutters, sulphur losses through fissures in the block are minimized and high volumes and velocities of sulphur flow are avoided. Energy efficiency is obtained as heat is transferred to the block through a minimum thickness of molten sulphur. The apparatus requires minimal permanent plant adaptation, since the steam and electrical power requirements are normally readily available at all block locations from ordinary plant operation. The use of the present apparatus is not labour intensive and does not require extraordinary skill and judgment. The operation of the apparatus may be continuous or intermittent, as required, since the apparatus is simple to start up or close down.
CONTAMINATED SULPHUR REMELTER UNIT (CSRU) When sulphur blocks are poured, they are vulnerable to being contaminated by a variety of items and causes such as moisture from snow and rain, dirt and ash from surrounding fields and process plants, and chemicals from process malfunction in the gas plant.
The modular sulphur remelter element is an attachment which can be used with both the current remelter heating elements (for instance as described herein) and the earlier remelter heating elements (as described for instance in Applicant's Canadian Patent 1,064,224).
The purpose of the unit is to melt a generally horizontal band of sulphur as the unit advances ahead of the main remelter heating element. The band of sulphur is typically contaminated with dirty ash, chemicals, or excessive moisture; all of which reduce melt rate and can damage the main remelter element. If the CSRU melt rate is slower than the main heating element then the entire unit will only advance at the rate of the slowest melting part, however, because the CSRU is separate from the main heating element its steam supply can be adjusted to suit its particular operating condition without adversely affecting the main heating element. The sulphur melted by the CSRU
is collected separately and can be disposed of, treated or reblended with the remaining sulphur.
As seen in Figures 20 and 22, the CSRU 68 is composed of a series of steam heated melting pipes 69 positioned generally vertically one above the other and each pipe having a slight incline to the horizontal along its length. There is a small vertical space between these steam heated melting pipes 69 to allow the remelted sulphur to flow between them to the collecting area. Each of the steam heated melting pipes 69 is closed at both ends. Steam is supplied to an inlet pipe 70 which penetrates the closure at the lower end of each melting pipe and extends to near the other end, thus assuring good steam circulation. The slight incline of the pipe ensures that the condensate flows to the lower end, where it is discharged through a hole in the lower closure of each melting pipe and discharges through a condensate outlet pipe 71 into a piping system which is connected to a steam trap. Figure 23 shows the steam inlet piping and Figure 24 shows the condensate outlet piping.
The steam heated parallel melting pipes 69 are attached to a backing panel such that each successively lower pipe slightly precedes the one above. There is a bottom that connects the lowest pipe to the backing panel. Referring to Figure 20, end panels and mounting brackets connect the CSRU to a trolley 72 which runs on rails 73 attached to the remelter mast 32. The unit can be moved up or down by use of winches, hydraulic cylinders or come-a-longs 74.
As the CSRU 68 advances horizontally, melting into the sulphur block, the sulphur melted by each steam heated parallel melting pipe 69 flows around the pipe and discharges into the area between the pipes and the backing panel where it is collected on the bottom. Slivers of sulphur passing between the pipes contact the backing panel where they break off and fall between the back of the pipes and the backing panel.
There the slivers are melted by contact with the back of the hot pipes as well as by the molten sulphur flowing over them. Because the unit (including the bottom) slopes slightly to the outside end (as seen in front view Figure 22), the sulphur flows to that end where it is collected and is discharged to a down spout. An example of the slope, is four vertical inches for sixteen foot long pipes. The sulphur which flows under the lowest pipe will be collected by the main heating element, therefore the CSRU 68 will have to be positioned so that the lowest pipe is in contact with the clean sulphur below the band of contaminated sulphur as seen in Figure 20.
With the steam inlet pipe discharging at the high end and because of the slope, the condensate flows to the outside end to be discharged, resulting in a good circulation of steam, without a buildup of condensate.
This arrangement has a number of advantages over previous remelter elements that have historically utilized vertical melting pipes. First, the expensive steam and condensate headers are eliminated. Second, the steam and condensate headers do not have to melt their way through the sulphur block. Third, wider remelter units can be made by simply making the melting pipes longer as opposed to the vertical arrangement where longer steam and condensate headers have to be built and additional vertical pipes installed. Fourth, the proposed design lends itself to modular constructions, thereby requiring only as many elements as are needed for the particular height of the sulphur block engaged. This is a major improvement because the headers are otherwise typically constructed as tall as practicable as a cost consideration at the expense of modularity, and the remelter heating elements extend well above the top of the sulphur block.
The design is simple and inexpensive to build and lends itself to fabrication from a variety of materials, including aluminum. Aluminum has good heat transfer properties and has been used for sulphur handling for many years.
MODULAR SULPHUR REMELTER ELEMENT
The modular sulphur remelter element was previously described as an attachment used with remelter elements including the CSRU. The purpose of the modular element is to melt horizontally through a sulphur block in much the same manner as do the previous designs, such as depicted in Figure 1. The modular element is designed to mount onto the mast of the previous design, thus employing all the features of the existing leveling and advancing systems.
Referring to Figure 25, the modular element is composed of a series of heating element modules 76 mounted vertically one above the other, up the face of the mast.
This design only uses as many modules as are required to reach the height of the sulphur block.
As seen in Figure 25, each heating element module is composed of a series of steam heated melting pipes 77 positioned generally vertically one above the other and each pipe having a slight incline to the horizontal along its length. There is a small vertical space between these steam heated melting pipes 77 to allow the remelted sulphur to flow between them to the collecting area. Each of the steam heated melting pipes 77 is closed at both ends. As with the CSRU, steam is supplied to an inlet pipe 78 which penetrates the closure at the lower end of each melting pipe and extends to near the other end, thus assuring good steam circulation. The slight incline of the pipe ensures that the condensate flows to the lower end, where it is discharged through a hole in the lower closure of each melting pipe and discharges through a condensate outlet pipe 79 into a piping system which is connected to a steam trap. Figure 26 shows the steam inlet piping and Figure 27 shows the condensate outlet piping. There is a bottom that connects the lowest pipe to the backing panel. The backing panel of each heating element module has a hook shaped flange along its top edge which hooks over a mounting rail attached to the mast. This connection allows for thermal expansion of the heating element module (both vertically and horizontally) as well as simplifies replacement of the module should it become damaged. A pair of clips prevent the module from sliding sideways or unintentionally being lifting off the mounting rail.
As the modular sulphur remelter element advances horizontally, melting into the sulphur block, the sulphur melted by each steam heated parallel heating melting pipe 77 flows around the pipe and discharges into the area between the pipes and the backing panel where it is collected on the bottom. Slivers of sulphur passing between the pipes contact the backing panel where they break off and fall between the back of the pipes and the backing panel. There the slivers are melted by contact with the back of the hot pipes as well as by the molten sulphur flowing over them. Because the unit (including the bottom) slopes slightly to the outside end as described in respect of the CSRU, the sulphur flows to that end where it is collected and is discharged to a down spout. The sulphur which flows under the lowest pipe of each module will be collected by the module below. The liquid sulphur 83, as shown in Figure 28, flows under the lowest pipe of the bottom heating element module and flows over the surface of the sloping base pad 80 to the outside edge of the melt area where it is collected.
At first appearance the sloping base pad 80 left by the bottom heating element module would appear to be a problem, however, by making each successive cut lower by the vertical distance of the slope, the overall sloping base pad 80 remains level and the added advantage is that the liquid sulphur 83 which flows under the bottom heating element module is collected in the resulting trough 81, where it can be picked up by the use of a commercial sulphur pump or Archimedes screw 82.
If only the sulphur sump pump is used, it is necessary to surround it with a steam heated coil of pipe so that it will melt a sump into the sloping base pad 80 as described in the earlier patent description. If the Archimedes screw 82 is used, then the liquid sulphur 83 can be picked up from the trough 81 without melting a sump. Because the Archimedes screw 82 has a very limited capacity to deal with head it will have to discharge into a gravity rundown system or into a holding tank where the sulphur is collected with that flowing from the upper heating element modules. A
commercial sulphur pump can be installed in the holding tank to pump away the remelted sulphur.
With the steam inlet pipe discharging at the high end and because of the slope, the S condensate flows to the outside end to be discharged, resulting in a good circulation of steam, without a buildup of condensate.
The heating element modules easily lend themselves to being built as wide as practical without a great increase in the cost of construction. A wider heating element simply requires longer pipes, whereas the previous design required more vertical pipes and more header fabrication to make a wider heating element. This feature will prove advantageous for remelting low blocks. Conversely, the taller the block, the more heating element modules (increased cost) are required, but only as many as are required to reach the top of the block, thus eliminating the common practice of making the heating element taller than needed.
The design is simple and inexpensive to build and lends itself to fabrication from a variety of materials including aluminum. Aluminum has good heat transfer properties and has been used in sulphur handling for many years.
Claims (15)
PROPERTY OF PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A heating element for use in a solid sulphur remelter, the heating element comprising:
-a series of mutually spaced melting pipes forming a heating plane;
-a top steam header pipe and a bottom condensate header pipe at respective ends of the melting pipes and communicating therewith; the top steam header pipe having an inlet for receiving steam therein for distribution into the melting pipes and the bottom condensate header pipe being adapted for collecting condensate and discharging of the condensate through an outlet formed therein; and a hot nose pipe attached adjacent and in front of the bottom condensate header pipe and having a steam inlet and a condensate outlet for melting sulphur in front of the bottom condensate header pipe.
-a series of mutually spaced melting pipes forming a heating plane;
-a top steam header pipe and a bottom condensate header pipe at respective ends of the melting pipes and communicating therewith; the top steam header pipe having an inlet for receiving steam therein for distribution into the melting pipes and the bottom condensate header pipe being adapted for collecting condensate and discharging of the condensate through an outlet formed therein; and a hot nose pipe attached adjacent and in front of the bottom condensate header pipe and having a steam inlet and a condensate outlet for melting sulphur in front of the bottom condensate header pipe.
2. A heating element according to claim 1, wherein the melting pipes are at least substantially vertical when in an operating position.
3. A heating element according to claim 1 or 2, wherein the melting pipes communicate with the top steam header pipe and the bottom condensate header pipe by way of a straight connection.
4. A heating element according to any one of claims 1 to 3, wherein the bottom condensate header pipe is equipped with at least one syphon to extract the condensate therefrom.
5. A heating element according to any one of claims 1 to 4, further comprising:
-a backing panel disposed behind the melting pipes for directing sulphur which passes between the pipes down to a pickup tray disposed behind and beneath the melting pipes for collecting sulphur to be pumped away -a sump having an entrance at its bottom disposed behind the pickup tray for collecting sulphur to be pumped away which is proximate to the pickup tray.
-a backing panel disposed behind the melting pipes for directing sulphur which passes between the pipes down to a pickup tray disposed behind and beneath the melting pipes for collecting sulphur to be pumped away -a sump having an entrance at its bottom disposed behind the pickup tray for collecting sulphur to be pumped away which is proximate to the pickup tray.
6. A heating element according to any one of claims 1 to 5, further comprising:
-mounting brackets arranged between the bottom condensate header pipe and a support tower which incorporate a slide arrangement to allow for thermal expansion of the heating element.
-mounting brackets arranged between the bottom condensate header pipe and a support tower which incorporate a slide arrangement to allow for thermal expansion of the heating element.
7. A modular heating element for use in a solid sulphur remelter, the heating element comprising:
-one or more heating element modules detachably mountable along the heating element;
each module comprising:
-a series of mutually spaced melting pipes defining a melting plane;
-the series of melting pipes having an inlet for receiving steam and an outlet for the discharge of condensate.
-one or more heating element modules detachably mountable along the heating element;
each module comprising:
-a series of mutually spaced melting pipes defining a melting plane;
-the series of melting pipes having an inlet for receiving steam and an outlet for the discharge of condensate.
8. A modular heating element according to claim 7, wherein at least one module is adapted to receive steam independent of at least one other module for controlled melting through selective steam distribution.
9. A modular heating element according to claim 7 or 8, wherein each module further comprises a backing panel having a hook shaped flange along its top edge which hooks over a mounting rail attached to a support tower of the remelter.
10. A remelter for use in melting solid sulphur comprising:
-a heating element according to any one of claims 1 to 9;
-means of supporting the heating element in an at least approximately upright disposition; and -means of advancing the heating element along a ground surface towards the solid sulphur.
-a heating element according to any one of claims 1 to 9;
-means of supporting the heating element in an at least approximately upright disposition; and -means of advancing the heating element along a ground surface towards the solid sulphur.
11. A heating element for melting a transverse band of contaminated sulphur, the heating element comprising:
-a series of mutually spaced melting pipes stacked vertically and defining a melting plane;
-the melting pipes having an inlet for receiving steam therein, and an outlet for discharge of condensate.
-whereby the series of melting pipes are effective for melting the transverse band of contaminated sulphur upon contacting a sulphur block containing the transverse band.
-a series of mutually spaced melting pipes stacked vertically and defining a melting plane;
-the melting pipes having an inlet for receiving steam therein, and an outlet for discharge of condensate.
-whereby the series of melting pipes are effective for melting the transverse band of contaminated sulphur upon contacting a sulphur block containing the transverse band.
12. A heating element according to claim 11, wherein the melting pipes are slightly sloped from a horizontal position along the melting plane and the melting pipes together are inclined upwardly.
13. A heating element according to claim 12, wherein the melting pipes are in an inclined row.
14. A heating element according to any one of claims 11 to 13, wherein a backing panel and a collecting trough are disposed behind the melting pipes for collection of the sulphur.
15. A heating element according to claim 12, wherein the inlet is positioned at a lower end of each pipe but discharges in the vicinity of or at a higher end of each pipe and the condensate outlet is positioned in the vicinity or at the lower end of each pipe and the melted sulphur discharges at the lower end.
Priority Applications (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA002451712A CA2451712C (en) | 2003-02-28 | 2003-12-30 | In situ sulphur remelter |
| CA002555722A CA2555722C (en) | 2003-12-30 | 2003-12-30 | In situ sulphur remelter |
| PCT/CA2004/000255 WO2004076347A1 (en) | 2003-02-28 | 2004-02-24 | In situ sulphur remelter |
| RU2005130258/15A RU2348579C2 (en) | 2003-02-28 | 2004-02-24 | Device for onsite sulphur melting |
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA2,420,561 | 2003-02-28 | ||
| CA 2420561 CA2420561A1 (en) | 2003-02-28 | 2003-02-28 | In situ sulphur remelter |
| CA002451712A CA2451712C (en) | 2003-02-28 | 2003-12-30 | In situ sulphur remelter |
Related Child Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002555722A Division CA2555722C (en) | 2003-12-30 | 2003-12-30 | In situ sulphur remelter |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2451712A1 CA2451712A1 (en) | 2004-03-25 |
| CA2451712C true CA2451712C (en) | 2006-10-31 |
Family
ID=32231692
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002451712A Expired - Lifetime CA2451712C (en) | 2003-02-28 | 2003-12-30 | In situ sulphur remelter |
Country Status (3)
| Country | Link |
|---|---|
| CA (1) | CA2451712C (en) |
| RU (1) | RU2348579C2 (en) |
| WO (1) | WO2004076347A1 (en) |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| ITMI20061737A1 (en) * | 2006-09-12 | 2008-03-13 | Snam Progetti | PROCEDURE FOR THE TRANSPORT OF SULFUR TO LOW RISK AND TO ZERO EMISSION FROM SOLID SULFUR DEPOSITS IN BLOCKS OF CONSIDERABLE DIMENSIONS |
Family Cites Families (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CA969438A (en) * | 1974-02-06 | 1975-06-17 | Eric G. Bowman | Block sulphur melting apparatus and method |
| CA1074083A (en) | 1975-02-20 | 1980-03-25 | Ernest R. Ellithorpe | Method of and apparatus for melting block sulphur |
| CA1091430A (en) | 1975-10-24 | 1980-12-16 | Harold L. Potts | Apparatus for the efficient deployment and operation of in situ sulphur block remelting equipment |
| CA1064224A (en) | 1977-05-17 | 1979-10-16 | Western Sulfur Remelters Ltd. | Sulfur melting by lateral displacement of heating element |
| US4651817A (en) | 1982-02-05 | 1987-03-24 | Occidental Chemical Agricultural Products, Inc. | Heat exchange apparatus useful for melting sulfur |
| CA1224014A (en) | 1984-07-31 | 1987-07-14 | Andrew W. Deszynski | Method of, and apparatus for melting sulphur |
-
2003
- 2003-12-30 CA CA002451712A patent/CA2451712C/en not_active Expired - Lifetime
-
2004
- 2004-02-24 RU RU2005130258/15A patent/RU2348579C2/en not_active IP Right Cessation
- 2004-02-24 WO PCT/CA2004/000255 patent/WO2004076347A1/en active Application Filing
Also Published As
| Publication number | Publication date |
|---|---|
| RU2348579C2 (en) | 2009-03-10 |
| RU2005130258A (en) | 2006-06-10 |
| WO2004076347A1 (en) | 2004-09-10 |
| CA2451712A1 (en) | 2004-03-25 |
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| Date | Code | Title | Description |
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| EEER | Examination request | ||
| MKEX | Expiry |
Effective date: 20240102 |