WO2020163944A1

WO2020163944A1 - Systems, methods, and devices for granularization of molten process material

Info

Publication number: WO2020163944A1
Application number: PCT/CA2020/050174
Authority: WO
Inventors: Seyedbahador Zafarsadeghian
Original assignee: Seyedbahador Zafarsadeghian
Priority date: 2019-02-14
Filing date: 2020-02-08
Publication date: 2020-08-20
Also published as: CA3033791C; CA3033791A1

Abstract

Systems, methods, and apparatuses for producing granular particles in greater thermal uniformity are provided. The system comprises a hollow drum rotatably mounted on a frame and oriented for rotation along a longitudinal axis, a circumferential surface of the hollow drum comprising a plurality of lifting blade panels having one or more heat exchange extensions and at least one lifting blade extending inwardly for creating a curtain of falling granular particles during rotation. A process fluid conduit having a plurality of process fluid nozzles for spraying a process fluid inside the hollow drum is provided where the process fluid nozzles are spaced along the process fluid conduit in two or more particle formation segments. The at least two particle formation segments further comprises: a particle generation segment and at least one particle enlargement segment; a cooling fluid conduit having a plurality of cooling fluid nozzles for spraying a cooling fluid from locations corresponding to each of the particle formation segments.

Description

SYSTEMS METHODS AND DEVICES FOR

GRANULARIZATION OF MOLTEN PROCESS MATERIAL

RELATED APPLICATION

[0001] The present application is an International Patent Application which claims benefit of priority to Canadian Patent Application serial number: 3,033,791, filed February 14, 2019 and entitled “SYSTEMS, METHODS, AND DEVICES FOR

GRANULARIZATION OF MOLTEN PROCESS MATERIAL”, the disclosure of which is hereby fully incorporated by reference.

FIELD OF THE DISCLOSURE

[0002] The present invention relates to equipment, machines, systems methods and process to solidify molten sulphur other process materials to form granular particles.

BACKGROUND

[0003] Sulphur is being solidified in different shapes such as granule, pastille and prills, so it can be easily transported, stored and used as a commercial commodity. The acceptable criteria to evaluate solid sulphur were published by Sulphur Development Institute of Canada (SUDIC). Characteristics like size distribution, purity, compaction, friability, moisture content and so forth are clearly defined in those criteria. Production of sulphur through solidification method shall meet SUDIC standard.

[0004] Different patents relevant to Sulphur solidification method including granulation, pastillation and prills are published so far such as:

• Shirley proposed in U.S. Pat. No. 4,213,924 subject matter relating to the use of a horizontal cylinder rotating around its longitudinal axis, to produce sulphur in the granular shape.

• Tse proposed in U.S. Pat. No. 4,272,234 subject matter relating to the generation of sulphur seeds in a cylinder rotating around its longitudinal axis. • Mathur proposed in U.S. Pat. No. 4,507,335 subject matter relating to the use of larger droplets of a sprayed liquid sulphur to generate sulphur seeds particles in a cylinder rotating around its longitudinal axis.

• De Paoli proposed in U.S. Pat. No. 5,435,945 subject matter relating to the generation of sulphur seeds by passing a sprayed sulphur through sprayed water or solidify sprayed sulphur in a cylinder rotating around its longitudinal axis.

• Lang proposed in U.S. Pat. No. 9,028,729 & U.S. Pat. No. 8,691, 121 subject matter relating to the generation of solid sulfur seeds by formation a cooling liquid and settling in thereafter in a tank. The tank may be a spiral-dewatered tank that has a screw conveyor at the bottom of the tank that moves the seeds to a granulating drum

• Pyke proposed in Canadian. Pat. No. 2,729,462 and in US Pat. App. No. 13/001,443 subject matter relating to a granulator with a rotatable drum having distinct zones for seed generation and product growth.

• De Paoli proposed in U.S. Pat. No. 8,425,811 subject matter relating to a rotatable drum having distinct zones for seed generation and product growth. The seed generation zone has an intense water spray pattern for each sulphur spray nozzle with intersecting water sprays to solidify molten sulphur and create seeds. Sulfur seeds may be produced by spraying liquid molten sulfur from a sulfur spray nozzle into a moving stream of liquid.

[0005] However, more efficient granular sulphur generation, with tighter size distribution, better material reclamation, and more resilient processing equipment than that current available are required to meet SUDIC requirement. It would be desirable to control the size distribution and production rate of seed and granular sulphur in a manner that corresponds directly to enlargement requirements to enable sulphur granules to be produced in a single pass thru continuous enlargement process through a granulation drum without separate facilities to provide seed generation. Furthermore, screening and recycling of undersize and oversize granules will be eliminated.

[0006] Undersized and oversized granules, as well as the production failure to reclaim and mitigate damage from such undersize and oversized granules (including, e.g., dust), as well as other by-products, can impact processing and increase processing cost. Accordingly, there is a need for a system that provides processing management characteristics that can address these and other processing issues.

[0007] Further, existing processing equipment and processes associated with the conventional sulphur solidification equipment and the related process generally lack the ability to control and/or implement heat transfer from processing equipment, including but not limited to the drum body into which potentially high volumes of high temperature process fluids are introduced. Moreover, cooling processes are often designed to address cooling at a“micro”, or particle level, which may often mean that the overall temperature inside the drum, as well as post-introduction materials, can be associated with uncontrolled heat accumulation. This in turn results in an increase of the temperature of the drum body, or in some cases, operation of the drum at less than optimal level (too high or too low), and consequently affects the rate and the quality of the production of granular particles, the creation of dust or other by-products, the reclamation of unused processing, cooling, and/or other materials, and other factors.

[0008] Another shortcoming of existing granular particle generation systems is that there is generally an insufficient exhaust air filtering rate. This can impact the ability to minimize problematic emissions and/or reclaim processing, cooling, and other material from exhaust streams. Moreover, exhaust streams are generally limited by the rate at which filtering and/or reclamation can occur. This can be a serious problem frequently seen in the sulphur solidification units using granulation drums, and can result in excessive emissions released into the environment, or a reduction in the rate at which exhaust is streamed through the drum (or other equipment), or unwanted deposition of material from the exhaust stream onto certain equipment within the granularization system.

[0009] In some cases, dust from process material, including but not limited to sulphur, sticks to exhaust fan impeller blades making them unbalanced. This problem causes vibration and damage to exhaust fan bearings and coupling. Indeed, other pieces of equipment may experience unwanted deposition resulting from lack of heat control (of, for example, the inputs, outputs, and equipment of granularization systems) or reduced exhaust flow rates or other processing characteristics.

[0010] Some process material may also impact the integrity of certain materials used, because of physical impact or chemical degradation. For example, sulphur process material may lead to an acidic operating environment. Formation of the drum with integrated lifting blades or other features by way of welding can lead to loss of structural integrity over time and alternative means of drum formation may be required.

[0011] This background information is provided to reveal information believed by the applicant to be of possible relevance. No admission is necessarily intended, nor should be construed, that any of the preceding information constitutes prior art. Moreover, other disadvantages and shortcomings may exist that the subject matter disclosed herein may address.

SUMMARY

[0012] The following presents a simplified summary of the general inventive concept(s) described herein to provide a basic understanding of some aspects of the invention. This summary is not an extensive overview of the invention. It is not intended to restrict key or critical elements of the invention or to delineate the scope of the invention beyond that which is explicitly or implicitly described by the following description and claims.

[0013] A need exists for better thermal control and material management in association with granular particle production technology, including but not limited to, aspects relating to granule formation and growth, by-product reduction and reclamation, and equipment manufacture, that overcome some of the drawbacks of known techniques, or at least, provides a useful alternative thereto. Some aspects of this disclosure provide examples of such thermal control and material management in association, granular particle production technology.

[0014] In accordance with one aspect, there is provided a system for producing granular particles in thermal uniformity, said system comprising: a hollow drum rotatably mounted on a support frame and having a first end and an opposed second end oriented for rotation along a longitudinal axis, a circumferential surface of the hollow drum comprising a plurality of lifting blade panels having one or more heat exchange extensions extending outwardly from the circumferential surface, each of said lifting blade panels further comprising at least one lifting blade extending inwardly from said circumferential surface for creating a falling curtain of the granular particles during rotation of said hollow drum; a process fluid conduit extending in the hollow drum having a plurality of process fluid nozzles for spraying a process fluid, said process fluid nozzles spaced along said process fluid conduit in two or more particle formation segments, the at least two particle formation segments comprising: a particle generation segment in which the processing nozzles located therein are configured to spray process fluid droplets having a first size for forming the granular particles when cooled; and at least one particle enlargement segment in which the processing nozzles located therein are configured to spray the process fluid for coating said granular particles from other particle formation segments; a cooling fluid conduit extending in the drum having a plurality of cooling fluid nozzles for spraying a cooling fluid from locations corresponding to each of the particle formation segments, said cooling fluid nozzles configured to spray the cooling fluid so as to intersect said sprayed process fluid; a dryer for introducing a drying gas into said hollow drum for flushing dust into an exhaust air stream; an exhaust outlet for exhausting said exhaust air stream; and a particle outlet for allowing the egress of said granular particles.

[0015] In accordance with another aspect, there is provided a dust separator for collecting from an exhaust stream dust generated from a granular particle generation system, said dust comprising the same process material as said generated granular particles, the dust separator comprising: a separator chamber having a top end and a bottom end, said separator chamber comprising at least a frusto-conical portion tapered towards said bottom end; a separator exhaust inlet in fluid communication with a provided exhausted stream for feeding the exhaust stream into the separator chamber near said top end in a direction that is substantially tangential to an outer wall of the separator chamber; an exhaust impeller component for increasing a volumetric flow rate of the exhaust through the separator exhaust inlet; and a recaptured process fluid outlet located near the bottom end. [0016] In accordance with another aspect, there is provided a method for generating granular particles comprising: rotating a hollow drum having a first end and an opposed second end lying along a longitudinal axis of rotation, said hollow drum having a circumferential surface comprising a plurality of lifting blade panels having one or more heat exchange extensions extending outwardly from said circumferential surface, each of said lifting blade panels further comprising at least one lifting blade extending inwardly from said circumferential surface; spraying a process fluid from a plurality of process fluid nozzles for spraying the process fluid, said process fluid nozzles spaced along a process fluid conduit in two or more particle formation segments, the at least two particle formation segments comprising: a particle generation segment in which the processing nozzles located therein are configured to spray process fluid droplets having a first size for forming the granular particles when cooled; and at least one particle enlargement segment in which the processing nozzles located therein are configured to spray the process fluid for coating said granular particles from other particle formation segments; spraying a cooling fluid inside the drum from a plurality of cooling fluid nozzles fed by a cooling fluid conduit extending in the hollow drum, said cooling fluid nozzles located along said cooling fluid conduit at locations corresponding to each particle formation segment, said cooling fluid nozzles configured to spray cooling fluid so as to intersect said sprayed process fluid; creating a curtain of falling particles from said lifting blades inside the hollow drum during rotation; introducing a drying gas into the hollow drum along said longitudinal axis to flush dust into an exhaust air stream; and removing the exhaust air stream through an exhaust outlet and said granular particles from a particle outlet.

[0017] Thermal control and/or uniformity may improve a number of outcomes relating to the generation of granular particles from a process fluid, including but not limited to process fluids that are cooled during such generation to change from a liquid or gaseous to form solid granular particles. Control and/or maintenance of thermal properties of the process fluid and/or the processing means significantly reduces the variability of certain product characteristics. Such product characteristics may include size, shape, time for generation, dust or other by-product generation, density, integrity, lifetime, as well as other characteristics known to be useful in downstream uses of granular particles (including but not limited to those made of sulphur). [0018] Moreover, uniformity in granular particle generation may reduce certain by products, such as unwanted dust, making outputs of such process cleaner and/or easier to manage. Reclamation of such dust or other by-products also becomes easier through the use of thermal management, as well as other in association with managing certain other processing characteristics, such as but not limited to pressure, purity, and volumetric flow rate) in association with processing equipment. Such reclamation reduces input costs, not only by eliminating waste, but also maintains equipment in an advantageous manner. This means less downtime for equipment cleaning or replacement, and/or equipment degradation. Degradation can occur when certain materials contact processing equipment; this can be, for example, through chemical (e.g. corrosion or other reactions) or physical degradation (high speed and/or repeated collision with equipment, and/or friction damage), as well as physical changes to moving equipment, such as fans or impellers, due to product build-up that can negatively impact processing operations.

[0019] The subject matter provided herein addresses a number of shortcomings associated with the prior art, including but not limited to those indicated above. In one embodiment, a number of lifting blades are made from aluminum panels; in some embodiments, the panels themselves may substantially form the surface of the drum. In some embodiments, the lifting blade panels may be bolted together along their lateral sides, and the joining angles are manufactured such that a specific number of panels, when joined together, will form a cylindrical drum. The drum in some embodiments is configured to rotate completely or substantially horizontally around its longitudinal axis. In some embodiments, the drum is inclined downward from a first end, associated with granule generation, to a second end, associated with formed granules and a location for granule egress.

[0020] In some embodiments, each blade has fins projected from the outer surface of the drum to provide additional heat transfer surface during solidification process. Other heat exchange structures and/or variants thereof may be used; for example, a different number of fins or even non-fin structures may be used. [0021] In some embodiments, the body of cyclone filter may be fully or partially jacketed and thereby heated by steam or another heat-supply means. Due to the tangential direction of the exhaust entry vector (relative to the outer circumference of the cyclone filter body), the sulphur dust particles are pushed towards interior wall of cyclone due to centrifugal force. During this process, because of the spiral and conical shape of the cyclone body, a turbulent flow inside cyclone is created so that exiting dusts approach to the interior wall of cyclone through centrifugal force. The sulphur dust particles are melted gradually as they hit the hot surface inside the cyclone and accumulate in the basin at the bottom of the cyclone. The dust free exhaust air now can enter into the atmosphere through the exhaust stack. Embodiments hereof may reduce the burden of exhaust fan cleaning (e.g. maintenance by an operator requiring stoppage of the granularization system due to the need to stop the system to disassemble and/or clean the exhaust fan), as well as reduction of vibration of exhaust fan and thereby extending the life of the overall system and/or components thereof. In such embodiments, a steam line may be connected to the bottom of the exhaust fan in order to heat the body of the exhaust fan. Hot steam keeps the temperature of exhaust fan body higher than melting point of sulphur to thaw all sulphur dusts which stuck to impellers of exhaust fan. The molten dust may then be collected and returned to the process material reservoir.

[0022] In some embodiments, the lifting blades are made from aluminum sections that are bolted together instead of using a welding operation. Welding materials in the environment inside drum can lead to structural weakness or loss of integrity; this may be due to, for example, acidic or basic environments (which may impact joining materials used in welding), and/or the repeated physical collision against bonded lifting blade panels.

[0023] In some embodiments, initial seed particles may be used; such seed particles may be, in some preferred embodiments, only required to start up the equipment and commence the process. In such embodiments, when the system is turned off, some granular sulphur will remain inside and may be used as seed for the next start-up. In other embodiments, sprayed droplets of molten process material may initiate the particle generation and growth process and, in such embodiments, no seed particles are used. [0024] In some embodiments, the size of granular particles is adjustable or influenced through some controllable factors; these include drum residence time, drum rotation and drum circumference (and/or other factors contributing to, inter alia , curtain vs. non-curtain residence time), input material content and characteristics (including purity, flow rate, pressure, and temperature), spraying characteristics (droplet and/or ligament size, spray velocity, spray direction (absolute and relative to other fluid spray), and ambient temperature and pressure.

[0025] In some embodiments, sulphur dust (or dust from other process materials) on the exhaust fan impellers may cause the impeller to be unbalanced and create excessive vibration. Steam jacketing the exhaust fan re-melts the sulphur dust and minimizes issues associated with the disassembly and cleaning the exhaust fan impellers.

[0026] In some embodiments, the steam jacketed cyclone filter elevates the surface of the cyclone filter to improve dust removal/reclamation from exhaust air. Moreover, the frusto-conical shape ensures that centrifugal force is maintained (or at least improved related to a cylindrical cyclone filter) as the air moves toward the discharge end of the cyclone filter.

[0027] In some embodiments, the form and the aluminum material of lifting blades bring heat transfer that results in fast cooling of generated seed particles and helps particles (including both seed particles or partially grown particles) to be coated in a more uniform and/or controlled ambient temperature within the drum.

[0028] Embodiments may further comprise process material drains, which may also be temperature-controlled (e.g. through the use of steam jackets), associated with some or all of the process elements, including the drum, filters, fluid headers, and process fluid nozzles to collect residual process fluid. This may maximize efficient use of process material, reduce of loss of process material, and prevent the creation of lumps of process material inside the granulation drum or other process elements.

[0029] The devices, systems and methods disclosed herein may be custom designed to achieve various types of products beyond granulated sulphur particles. Other process materials known to persons skilled in the art as appropriate for granularization, or the coating of granular particles, may be used in association with the present disclosure.

[0030] Other aims, objects, advantages and features of the invention will become more apparent upon reading of the following non-restrictive description of specific embodiments thereof, given by way of example only with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE FIGURES

[0031] Several embodiments of the present disclosure will be provided, by way of examples only, with reference to the appended drawings, wherein:

[0032] Figure 1 shows a schematic process flow diagram (PFD) of the granulation process in accordance with an aspect of the instant disclosure;

[0033] Figure 2a shows an isometric view of a granulation system in accordance with a first aspect of the instant disclosure;

[0034] Figure 2b shows a side view of the granulation system in accordance with the first aspect of the instant disclosure;

[0035] Figure 2c shows a front view of the granulation system in accordance with the first aspect of the instant disclosure;

[0036] Figure 2d shows a top plan view of the granulation system in accordance with the first aspect of the instant disclosure;

[0037] Figure 2e shows a longitudinal cross-sectional view of the granulation system of Figure 2d;

[0038] Figure 3a shows an isometric view of a granulation drum in accordance with a second aspect of the instant disclosure;

[0039] Figure 3b shows an isometric view of the granulation drum in accordance with a second aspect of the instant disclosure;

[0040] Figure 3c shows a side view of the granulation drum in accordance with a second aspect of the instant disclosure; [0041] Figure 3d shows a front cross-sectional view of the granulation drum of Figure 3c;

[0042] Figure 3e shows a top plan view of the granulation drum in accordance with a second aspect of the instant disclosure;

[0043] Figure 3f shows a longitudinal cross-sectional view of the granulation drum of Figure 3e;

[0044] Figure 3g shows an isometric view of a circumferential structure of the granulation drum in accordance with a second aspect of the instant disclosure;

[0045] Figure 3h shows a cross-sectional view of a lifting blade panel in accordance with an aspect of the instant disclosure;

[0046] Figure 4a shows a schematic top plan view of a granulation drum in accordance with the second aspect of the instant disclosure, showing associated exemplary fluid inputs and input directions;

[0047] Figure 4b shows a schematic longitudinal cross-sectional view of the granulation drum of Figure 4a, showing associated exemplary fluid inputs and input directions;

[0048] Figure 4c shows a side view of sulphur and water headers of the granulation drum in accordance with aspects of the instant disclosure;

[0049] Figure 4d shows a cross-sectional view of the granulation drum shown in Figure 4b, showing spray pattern and granule curtain in process;

[0050] Figure 4e shows a front detail view of spray patterns from nozzles in headers in accordance with an aspect of the instant disclosure;

[0051] Figure 5a shows a detailed isometric view of a steam -jacketed cyclone in accordance with an aspect of the instant disclosure;

[0052] Figure 5b shows a side cross-sectional view of a steam -jacketed cyclone in accordance with an aspect of the instant disclosure;

[0053] Figure 5c shows a side cross-sectional view of a steam -jacketed cyclone in accordance with an aspect of the instant disclosure; [0054] Figure 5d shows a top plan cross-sectional view of a steam -jacketed cyclone in accordance with an aspect of the instant disclosure;

[0055] Figure 5e shows a cut-away isometric view of a steam -jacketed cyclone in accordance with an aspect of the instant disclosure;

[0056] Figure 6a shows an isometric view of a steam -jacketed exhaust fan in accordance with an aspect of the instant disclosure;

[0057] Figure 6b shows an isometric view of a steam -jacketed exhaust fan in accordance with an aspect of the instant disclosure;

[0058] Figure 6c shows a side view of a steam -j acketed exhaust fan in accordance with an aspect of the instant disclosure;

[0059] Figure 6d shows a front view of a steam -jacketed exhaust fan in accordance with an aspect of the instant disclosure;

[0060] Figure 6e shows a top plan view of a steam -jacketed exhaust fan in accordance with an aspect of the instant disclosure;

[0061] Figure 6f shows a cross-sectional side view of the steam -jacketed exhaust fan of Figure 6e; and

[0062] Figure 6g shows a cross-sectional detailed view of the coupling from an impeller motor to an impeller in the steam -jacketed exhaust fan from Figure 6f.

DETAILED DESCRIPTION

[0063] The subject matter disclosed herein presents a process for producing generally spherical small particles which herein after is called“granule” or“product” by coating seed particles with process material, or in a fluid form, process fluid. Here, for better understanding, molten sulphur is considered as process fluid, while urea, bentonite fertilizers and/or a wide range of other liquefied substances can be also used as process material.

[0064] In general, the subject matter disclosed herein relates to systems, methods, and devices for producing granular particles from a molten process material. In embodiments, various aspects of the subject matter relate to maintaining thermal characteristics, including thermal uniformity and minimum temperatures within process stages and on and within processing equipment. The management of thermal characteristics, among other things, promotes improved manufacturing outcomes, materials reclamation, and equipment maintenance outcomes (e.g. improved lifetime, reduced maintenance costs, and reduced downtime).

[0065] In one aspect, there is provided a system for producing granular particles from a molten process material, the system comprising a hollow drum in which the molten process material is introduced for forming into granular particles. While many of the exemplary embodiments disclosed herein relate to the processing of molten sulphur to create granular sulphur particles, other process materials may be used in the formation of granular particles thereof. Molten process material is introduced via one or more spray nozzles into the interior of a rotatable drum, which is oriented for rotation along a longitudinal axis thereof. The drum has a circumferential surface of the hollow drum comprises a plurality of lifting blade panels; each lifting blade panel comprises lifting one or more blades which run substantially along the longitude direction of the drum and extend inwardly substantially along the radius of the drum circumference; the extension direction of the lifting blades may deviate slightly from the radial direction, and they may be flat along the radial direction, or convex or concave on the lifting side. The at least one lifting blade extending inwardly from said circumferential surface is for creating a curtain of falling granular particles during rotation of said hollow drum; as the drum rotates, the lifting panels lift granular particles around the circumference of the drum until the lifting blade is oriented in a downward facing direction sufficient for granular particles in the drum to slide of the lifting blade and fall into the interior space of the drum. This results in a“curtain” of granular particles falling from the blades. The panels further comprise of one or more heat exchange extensions extending outwardly from the circumferential surface, generally away from the drum, thereby providing significantly additional surface area to facilitate heat transfer from the drum surface. As molten sulphur (or other process material) is sprayed into the interior of the drum, the ambient temperature can exceed optimal heat levels, particularly as the granular particles grow in size and number along the drum.

[0066] In some embodiments, the heat exchange extensions are integral with the lifting panels, which are in direct contact with the hot granular particles and the air, vapour, and fluids inside the drum, and therefore provide effective heat transfer. In some embodiments, the heat exchange extensions are not integral with the lifting panels, but may be attached in other ways to the exterior of the drum.

[0067] In some embodiments, the system further comprises a process fluid conduit extending along the interior of the hollow drum. The conduit has a plurality of process fluid nozzles for spraying a process fluid into the interior of the drum. The process fluid nozzles are spaced along said process fluid conduit in two or more particle formation segments. The first segment may be a particle generation segment in which the processing nozzles located therein are configured to spray small diameter process fluid droplets for forming granular particles when cooled; in these and other embodiments, the process may utilize in the first segment“seed” particles, which are pre-existing particles of sulphur, in which case the first zone may be a particle enlargement segment, or both a particle generation segment and a particle enlargement segment. Inside the drum, there is at least one particle enlargement segment in which the processing nozzles located therein are configured to spray process fluid for coating granular particles that have already been formed, and are either arriving from other particle formation segments or are already in the current segment (e.g. continue to be coated, or are seed particles).

[0068] Embodiments will further comprise a cooling fluid conduit extending in the drum for spraying a cooling fluid that cools the sprayed molten process material such that it cools below the melting point of the process material and becomes solid, including segments wherein process fluid is for generating particles and coating particles. The cooling fluid may be water, demineralized water, or other fluids that will not react with the process fluid, and generally has a much lower melting point than the process fluid. The cooling fluid conduit comprises a plurality of cooling fluid nozzles for spraying the cooling fluid from locations corresponding to each of the particle formation segments, and in general the cooling fluid nozzles are configured to spray cooling fluid so as to intersect said sprayed process fluid.

[0069] The system may further comprise a dryer for introducing a drying gas, often air, into said hollow drum for flushing dust into an exhaust air stream. The dryer may or may not heat or cool the drying gas to a desired temperature. Typically, at a location of the drum distal from the inlet of the drying gas, there is an exhaust outlet for exhausting said exhaust air stream, which is in fluid communication with a cyclone filter or other type of filter. A particle outlet, generally located at the end distal from the particle formation segment (or in embodiments using seeds, the first particle growth segment), is provided for allowing the egress of said granular particles. A support structure is generally provided, which is configured to support the rotatable drum and other components. A drum rotator is generally located on such structure as well. The support structure may be configured, optionally, to change the incline of the axis of the drum.

[0070] In some embodiments, as part of the system or as a stand-alone device, there is provided a dust separator to collect dust from an exhaust stream coming from particle generation systems. The dust separator is typically in the form of a cyclone-type filter comprising a separator chamber having a top end and a bottom end: the exhaust stream is directed, generally through the use of an exhaust impeller (although a fan or pump can be used), to flow into the first end so that the direction of flow of the exhaust is substantially perpendicular to the axis and tangential to the circumference of the separator, resulting in a spiral gas flow from the inlet end to the outlet end. At least a portion of the separator chamber in a frusto-conical shape tapering towards the outlet end of the filter. Accordingly, the centrifugal force of the exhaust hitting or pushing against the separator chamber wall is higher than would otherwise be the case in a cylindrical separator chamber as the circumference of the chamber as the gas spirals from the inlet to the outlet decreases. The collision of the dust in the exhaust causes the collection of the process material against the wall and gravity forces it to a process material outlet located at the bottom of said chamber. In some embodiments, the filter is equipped with a heating process fluid jacketing component to ensure that the wall of the separator chamber is maintained at a temperature close to or above the melting temperature of the process material. In such embodiments, the process material liquifies and is collected via a recaptured process fluid outlet located at the bottom of the separator. The recaptured process fluid outlet may be connected to the process material reservoir, wherein the recaptured process material can be re-used in the formation of granular particles.

[0071] In some embodiments, the exhaust impeller component comprises an impeller heating element for maintaining a temperature of the exhaust impeller component at least as high as the process fluid melting point. The exhaust heating element may comprise a heating fluid jacketing system. The heating fluid may be steam although other fluids, and indeed other heating systems may be used.

[0072] In one aspect, there is provided a number of lifting blades which are made from aluminum sections that, when bolted together, form a cylindrical drum (granulator machine) that rotates horizontally around its longitudinally sloped axis. In respect of an embodiment that produces sulphur granular particles, an amount of sulphur particles is generated in the drum as initial seed and which can be used for granulation process; in some embodiments, initial seed particles, similar in size to a sulphur droplet may be added to the drum prior to start-up, however, such seeds are not required as feed granular sulphur in some embodiments. As drum rotates, a number of blades which are integral parts of each aluminum section of the drum lift up the seed particles then drop them down to create a sulphur granules curtain.

[0073] In sulphur granular particle producing embodiments, a sulphur header, having a number of nozzles mounted thereon, is provided parallel to a water header, also having spray nozzles mounted thereon, where are both installed inside a cylindrical drum rotating around its longitudinally inclined axis. Molten sulphur and de-mineralized water are simultaneously sprayed from the respective headers through a certain spraying pattern into the curtain of sulphur seeds, or, depending on the embodiment, as seed creation (wherein there may yet be no particle curtain formed). In this embodiment, the spraying pattern divides granulation drum to four zones: the seed generates in the first zone, and granule particles are coated by hot sulphur to enlarge particles in each respective zone, ultimately reaching a desired size in the final zone. In embodiments using introduced seed particles (instead of generating seed particles), existing seed particles are place in the first zone prior to operation of the system, and each zone enlarges particles arriving from the prior zone (except for the first zone, which enlarges the seed particles already located therein). In some embodiments, there is provided a process fluid collection header located directly below said process fluid conduit, said process fluid collection header comprising a header heating element for maintaining a temperature thereof above the melting point of the process fluid, and being inclined toward a process fluid collection outlet. [0074] Since the rotating granulation drum is mounted on main skid with a slight incline, granular particles initiate the generation and/or growth process at the higher end of the incline, and proceed down the slight incline toward the final zone and, thereafter, an exit is located at the second end to discharge to a collector conveyor. The drum rotation, axis incline angle, process material and cooling material flow rate, and process temperature regulation are regulated resulting in granular particles having a desired size and size distribution; in some embodiments, such size and size distribution meeting or exceeding required standards, such as those set by the Sulphur Development Institute of Canada (hereinafter“SUDIC”). Such temperature regulation is achieved in some embodiments through control of (i) inputs and their characteristics (such inputs including but not being limited to, process material, cooling fluid, and air, and their characteristics including but not being limited to temperature, pressure, and volumetric flow rate), and/or (ii) equipment temperature control elements (such as, but not limited to, heat exchange devices and heating/cooling jacketing on equipment),

[0075] In some embodiments, there is provided a steam j acketed dust separator cyclone filter for removing undesired humidity and re-melting dust in exhaust air as much as possible; in some cases, to comply with environmental regulations and/or to reclaim otherwise unused process material. An exemplary cyclone filter may be fully or partially steam jacketed such that at least a portion of the filter body is maintained at a temperature that is higher than the melting point of sulphur (or other process material). The cyclone filter is connected to exhaust fan by discharge duct. A fan creates suction inside drum to move air exiting from the drum, and containing process material (possibly as dust), to pass through the cyclone. Due at least in part to the configuration of the exhaust input flow direction relative to the cyclone filter, which is typically substantially tangential to the cyclone filter circumference at one end (generally, but not necessarily the top end of a vertically-oriented cyclone filter), circular or spiral flow occurrs inside cyclone filter. Accordingly, dust particles are propelled, due to centrifugal force, against the inner wall of the cyclone filter, and therefore contact, and often stick to the cyclone filter inner wall. Then, as the cyclone filter wall is maintained at a high temperature (i.e. above the process material melting point) the dust re-melts inside cyclone and drains downward into a sulphur buffer tank, or a receptacle in fluid connection therewith, through a steam jacketed piping. The exhaust air is then discharged from the system through an exhaust channel.

[0076] In some embodiments, a liquid process material reservoir is provided to supply liquid sulphur for the sulphur header in the granulation drum; this sulphur tank may act as a buffer tank for process material entering the granulation system, and may also be used to collect the returning sulphur that drains from the sulphur header, sulphur filter, cyclone and the sulphur piping.

[0077] In some embodiments, a process water tank is been provided to supply de mineralized water for the granulation process, which is used to feed the cooling fluid header.

[0078] In some embodiments, one or more steam jacketed sulphur pumps (horizontal or vertical) are provided to the process to pump liquid process material from the liquid process material reservoir to the granulation drum; the one or more pumps may be variable frequency drive (“VFD”) pumps so that the process material input pressure and/or volumetric flow rate can be precisely controlled.

[0079] In some embodiments, one or more vertical or horizontal, single or multi-stage pumps are provided to pump a high-pressure feed of cooling fluid, which in some embodiments is de-mineralized water from a cooling fluid tank, to provide water for the granulation drum; these one or more pumps are VFD driven so the pressure and/or flow rate of the cooling fluid can be precisely controlled.

[0080] In some embodiments, liquid sulphur filter may be provided to remove impurities from sulphur and/or to prevent nozzles from blocking. In some cases, the distance between the filter location and the granulation drum may be minimized, so it can collect impurities immediately prior to processing. In case of failure of any equipment, molten sulphur (or other process material fluid) is drained from the drum and/or process material heater back to the main process material reservoir. Accordingly, buildup of liquid sulphur inside granulation drum is minimized, thereby avoiding the creation of lump sulphur inside the granulation drum during or after operation. [0081] Process material granular particles (e.g. sulphur in some embodiments), exiting from the cylindrical drum discharge to a collector conveyor which may be directed towards a storage location. Output of the granulator is configured to comply with SUDIC standards, and therefore separation of different ranges of granular particle size is not required, or is minimized.

[0082] Referring to Figure 1, there is shown one embodiment of a granularization system in accordance with the subject matter disclosed herein, in which the process material is sulphur and the cooling fluid is de-mineralized water. In the embodiment shown in Figure 1, molten sulphur, which may comprise high purity sulphur (e.g. 99.98% degree of purity in this case) is stored in the liquid sulphur storage tank 101. De-mineralized water is also shown to be provided through a water source and stored in the Process Water Tank 102. Steam (135 °C to 140 °C and 3 barg) is shown to be provided in steam and sulphur lines. Sulphur lines consist of a core-shell pipe where sulphur goes inside the core and the steam runs in shell section to maintain the molten sulphur at a high temperature. Molten sulphur moved through the sulphur lines is pumped from liquid sulphur storage tank 101 towards granulation drum 103. Molten sulphur goes across the liquid sulphur filters 110 to remove impurities. When the differential pressure between the two sides of the filter rises so as to be detected by a differential pressure transmitter, it may indicate that the filter should be changed or cleaned.

[0083] In some embodiments, the sulphur solidification process may be generally described as being carried out in the following exemplary six stages. Exemplary and illustrative descriptions for various elements of the system and method are set out below for the following aspects thereof: Receiving of the liquid sulphur in the storage tank and pumping the sulphur out of the tank; Filtering the liquid sulphur and pumping it to the granulation drum; Pumping de-mineralized water through the water header and processing fluid nozzles for spraying it into the granulation drum for cooling sulphur particles therein; Granularization by spraying molten sulphur into the granulation drum for either or both of granular particle generation and/or particle growth; Removing humidity and dust, created inside the granulation drum via an air flow through the drum; Using the exhaust fan and filtering the exhaust by cyclone filter 104; Transferring sulphur granular particles to a storage area using a rubber belt conveyor. [0084] With reference to Figure 1, receiving and transferring liquid sulphur to the storage tank may be implemented in some embodiments as follows. Liquid sulphur is received from sulphur sources into liquid sulphur storage tank 101, wherein the temperature of liquid sulphur is maintained between 125°C to 150°C. The level of liquid sulphur inside the liquid sulphur storage tank 101 is controlled by a level transmitter. When the amount of sulphur inside the tank is decreased below the aforementioned level, the level transmitter provides a command to open the on/off valve (i.e. tank input valve), and when the liquid sulphur amount is increased above such level, the level transmitter provides a command to close the valve. The temperature of liquid sulphur storage tank 101 is measured continuously by temperature transmitter.

[0085] With reference to Figure 1, the filtering and transferring of liquid sulphur to the granulation drum, as referred to above, is implemented in some embodiments as follows, in association with the sulphur pressure pump 105 and liquid sulphur filter 110. Liquid sulphur is pumped by the sulfur pressure pump 105 before being sprayed into the granulation drum 103; it is also filtered to remove impurities prior to being sprayed. The pressure of sulphur in discharge nozzles of pumps is measured by differential pressure transmitter and displayed on the control system. Control of sulphur flow rate is affected by a flow meter and flow measurement sensors. The filter status, in terms of being full or empty, is controlled by an operator through monitoring of two-pressure indicator transmitters differential pressure calculated by software.

[0086] In some embodiments, piping has been used to circulate molten sulphur in an effort to provide a buffer for sulfur entering into the granulation drum 103. This circulation of liquid sulphur before entering it into sulphur header makes a steady state fluid while the valve of drain line is opened. When the valve of the drain line is opened, the molten sulphur is pumped into the sulphur line and goes across filter 110 then returns to the liquid sulphur storage tank 101 by the force of gravity instead of going directly towards the granulator drum 103. A filter valve provided at the bottom of the sulphur filter 110 is used to drain liquid sulphur and impurities from the filter. The remaining liquid sulphur in the piping and sulphur header may drain back into the liquid sulphur storage tank 101 by gravity, if the pump 105 is shutdown. [0087] With reference to Figure 1, the transferring and spraying of de-mineralized water into the granulation drum, as referred to above, is implemented in some embodiments as follows, in association with water tank 102 and water pump 106. De-mineralized water in the tank 102 is pumped to the granulation drum 103 by water pump 106. In order to decrease the temperature of liquid sulphur and/or the granular particles, the water is sprayed inside the granulation drum 103 via mounted nozzles on the water header. Flow meters are used to control the water flow rate. These flow meters control the water flow rate through pump speeds, which is controlled by Variable Speed Drive. Water pressure is measured by a pressure transmitter.

[0088] With reference to Figure 1, the spraying of molten sulphur into the granulation drum and granule formation, as referred to above, is implemented in some embodiments as follows, in association with the granulation drum 103. In this stage, fine particles of sulphur may be used as initial seed and added to the granulation drum 103 for initial stage start-up, or the nozzles may be configured to spray droplets that, when cooled, form initial particles. When the granulation drum rotates, these particles lift via lifting blades (a cross section of said lifting blades is shown in Figure 3h) and during the rotation, fall down to form a curtain or curtains (as shown in Figure 4d) of these particles. Liquid sulphur is sprayed into that curtain (as shown in Figure 4e) through some sulphur nozzles which are mounted on the sulphur header (as shown in Figure 4c). This process is repeated continuously during particle formation. The sulphur granules move forward towards the discharge chute, because of the slope of the granulation drum 103 and because of the drying air flow created by the exhaust fan 107.

[0089] In some embodiments, the granularization of liquid sulphur in order to form granulated sulphur may be described in some embodiments as follows: Spray water through the water nozzles inside the granulation drum; Heat transfers through granulation drum body; Cool down the falling seeds by the air flow. In embodiments, the following factors affect the transformation the liquid sulphur, with an initial temperature of 135°C to 150°C, into granulated seeds at 70°C temperatures.

[0090] With reference to Figure 4c, there is shown molten sulphur and water headers, in which separate specified lines flow out of the headers and which headers are extended inside the granulation drum 103. The sulphur header 401 and the water header 402 have different nozzles, the sulphur nozzle 403 and the water nozzle 404, each with pre determined patterns, are mounted to spray molten sulphur and water into granulation drum

103

[0091] As shown in Figure 2a, in one embodiment, the granulation drum 201 is assembled on a base skid 203; the cyclone 202 is assembled on a cyclone base 204 and in is connected to the drum via the exhaust outlet 205. Further detail of the system in accordance with this embodiment is shown in Figures 2b, 2c, 2d, and 2e.

[0092] As shown in Figures 3a through 3h, the outer surface of the granulation drum has a chain sprocket that is placed circumferentially and rotates by an electromotor 318 gearbox and a chain secured to or around a rotation drive ring 315. Motive force for rotating of the granulation drum comes from an electromotor gearbox which rotates the drive sprocket 312 of the granulation drum. The speed of rotation is controllable by variable Speed drive (VSD). At the head end of the granulation drum there is an inlet box 303 and at the opposite end (discharge end) of the granulation drum there is an outlet box 304. Both the inlet box 303 and the outlet box 304 are equipped with an access door to provide access into the granulation drum. An access hole is provided to access the header assemblies. The outlet box 304 also comprises a hatch for exhaust air duct or cyclone duct 327. The inlet box 303 has a wire mesh window 303a for intake air for the granulation drum. There are two rings encircling the granulation drum 335 and 336. These two rings help the drum to rest on four rollers 305 and facilitate the rotation by bearing the weight of the granulation drum during operation. In order to prevent undesired lateral movements during the operation, a holder ring 314 is encircled around the granulation drum so that the edge of holder ring is fixed between two pairs of holder rollers 306 on both sides of the granulation drum.

[0093] In one embodiment, the granulation drum 103 is made from thirty aluminum pieces of lifting blade panels, a cross-sectional view of an example of which is shown in Figure 3h. In some embodiments, these parts are fabricated through an extrusion processes into the pre-specified shapes. Of course, any suitable number panels may be used as determined by one of skill art so as to form a granulation drum. In the instant example, all thirty lifting blade panels may be secured to each other, in some embodiments by bolts and nuts, along the longitudinal axis of the granulation drum and sealed by gaskets (not shown) from a first panel edge 360 on a given lifting blade panel to a second edge 361 on the adjacent lifting panel. This configuration, not only because of forming the drum body from the panels themselves, as well as the use of bolting instead of welding, reduces the risk of issues associated with the welding of drum portions of the body of the granulation and may improve the efficiency of maintenance to the equipment. The edge of the lifting blade (Fig. 3h) is therefore, once sufficient lifting blade panels are secured to one another, configured to form the surface of the granulation drum 103. Outer heat exchange extensions 355 extend outwardly from the panels in order to facilitate radiation and forced convection heat transfer during the solidification operation. As the granulation drum lifting blades 350 lift granules up to a determined elevation inside the granulation drum then, due to gravity, the granules fall down and this creates a cascade of granules that resembles a curtain as shown in process in Figure 4d.

[0094] Referring to Figures 4b and 4c, sulphur and water headers 401, 402 are extended inside the granulation drum and a row of different nozzles 403, 404 are assembled on both headers. The sulphur header 401 includes two coaxial pipes (e.g. 2”x4”) and similar to the jacketed sulphur piping, hot steam flows in the annular space between the jacket (outer) pipe and molten sulphur flows in the core (inner) pipe. The water header 402 is placed under the sulphur header 401 parallel to the longitudinal axis of the granulation drum. In each header (Fig. 4c), holes have been provided in order to mount the spray nozzles. The end of the headers is closed with blind flanges and are fixed by two stands. A shelter 325 is designed to prevent granules from pouring down on the header.

[0095] As shown in Figure 4e, a spraying pattern indicates the angle and intensity of the sprays. It is also defined by the type, the size and the number of nozzles. Spraying patterns, as exemplified but not limited to those shown in Figure 4e, are a factor in manipulating important process characteristics in the granulation process. For example, different predetermined spraying patterns result in different production size distribution and characteristics. The spraying pattern can also be adjusted to meet custom requirements of production and reach the final desired product. [0096] In some embodiments, the process of granule formation inside the granulation drum may be occur in two zones: a particle generation zone (typically comprising a single segment) and particle growth zone (which may comprise of more than one particle growth segments, depending on, inter alia , the final desired size of the granular particles). The seed generation zone or segment is placed in the upstream zone inside the granulation drum located close to the head end of the granulation drum and next to the inlet box. This zone is allocated to generate seeds. The first three sulphur nozzles that are located in this zone are small-size in order to spray sulphur in the form of small droplets to form small particles or a powder. The water header 402 is also extended precisely at the bottom of the sulphur header 401 with nineteen consecutive nozzles 404 that align to the upper thirteen sulphur nozzles 403. In the seed generation zone or segment in some embodiments, three street elbows are installed on the first three water nozzles to reduce the distance between the water nozzle and the respective sulphur nozzle in order to change the angle of water spraying upward into the respective sulphur nozzle. This action results in an immediate crosswise contact of water to the hot spraying sulphur in order to decrease sulphur temperature instantly and generate seeds.

[0097] A size enlargement zone, comprising one or more segments, is located downstream from the seed generation zone near to outlet box. This zone or segment(s) is/are configured to provide a supplementary coating operation where, for example, ten sulphur nozzles in three different sizes and types (e.g. one size per enlargement segment), spray hot sulphur on curtain of seeds, as shown in process in Figure 4d, in three consecutive segments to coat the seeds to form granules. The size of the sulphur nozzles in the granulation drum 103 become larger from the start to the end in order to provide a higher amount of sulphur in the curtain in order to reach to the desired size of granule. The rest of water nozzles that are located in the size enlargement segment(s) are used to improve the quality of production through cooling down the granules to prevent them from sticking to each other and to prevent the creation of lump of sulphur. The cooling of the granules ensures a better sulphur coating with a goal to achieve the required size. Spraying extra water increases the moisture inside the granulation drum, which may lead to producing smaller granules (i.e. undersized product), while insufficient water or improper dispersion of water may result in producing oversized granules and/or the creation of lump sulphur. [0098] In some embodiments, the intensity of spraying sulphur may be controllable, at least in part, through the sulphur pressure pump 105, which may have variable speed drive (VSD) control. Higher power in sulphur pump results in a higher flow rate in the sulphur line and this respectively increases the intensity of sulphur spray that increases the rate of production as well.

[0099] The granulation drum 103 is slightly sloped (approximately two degrees from the horizontal axis) to direct flow of products to the end of the granulation drum where they are discharged to the transfer conveyor. The slope of granulation drum 103 can be adjusted by changing the position of rollers 305. The speed of rotation of the drum, the shape of lifting blades (Fig. 3h) and rate of drying air flow can be used to control the rate of the production and rate of the product discharge.

[00100] With reference to Figure 1, removing humidity and dust created inside the granulation drum may be implemented in some embodiments as follows. Air comprising moisture and dust inside the granulation drum is pulled from drum 103 by a steam jacketed exhaust fan 107 and filtering the air by a steam jacketed cyclone filter 108. Turning to Figures 5a through 5e for further detail in respect of the dust removal in the cyclone filter, the ventilation system for this process includes a steam jacketed cyclone filter 108, a steam jacketed exhaust fan 107 (not shown in Figures 5a through 5e) and inlet air flange 504 and discharge ducts 506. The exemplary conical cyclone shown in Figures 5a, 5b, 5c, and 5e, is about four meters height and is mounted on the main skid near to outlet box. The inlet air flange 504 is connected to the cyclone duct 327 (not shown in Figures 3a through 3e) of the outlet box and the discharge duct connects the cyclone to exhaust fan. As the exhaust fan runs, air, comprising moisture and dust, from the granulation drum is pushed into the cyclone. Due to the conical body of the cyclone and the entry angle of the exhaust, a vortex flow inside cyclone creates a centrifugal force so dust hits the interior hot wall of the cyclone. The body of cyclone filter is fully jacketed and it is heated by low pressure steam, being pushed in a steam inlet nozzle 508 and out through steam outlet nozzle 509. Dust particles deviate towards the interior wall of cyclone due to the centrifugal force. The dust particles melt and stick to the wall and then accumulate in the basin at the bottom of the cyclone. The drying air, with the dust content removed, with dust removed, exits into the atmosphere through a discharge duct 506. A siphoned type self-drain jacketed line 510 is provided to keep a minimum level of sulphur inside basin as well as to prevent reverse direction of air suction. As the liquid sulphur drains to the liquid sulphur storage tank 101 by gravity, the air and humidity inside the granulation drum 103 and cyclone filter 108 enters the atmosphere through exhaust fan 107 pulling air from the discharge duct 506 located at the top of the cyclone filter.

[00101] Although most of the dust particles are removed by passing throughout the steam jacketed cyclone filter, there may still be a further decrease in the amount of dust in order to meet, for example, acceptable levels by international standards (less than 50-100 mg/m3). Even this small amount of dust, should it be deposited on and stick to the impellers of the exhaust fan 107, can create an imbalance on the fan that results in excessive vibration and, over time, equipment degradation. In order to avoid or minimize cleaning the exhaust fan, a process that would previously require an operator to stop and disassemble the exhaust fan, a steam line can be connected to the bottom of the exhaust fan to heat up the body of the exhaust fan. As shown in more detail in Figures 6a through 6f, which show the exhaust fan assembly 107 in more detail, the hot steam, input into a steam jacket integrally forming part of the exhaust fan body 622 via steam inlet 637 and drains therefrom via steam outlet 636, keeps the temperature of exhaust fan body 622 higher than melting point of sulphur to re-melt all sulphur dust that sticks to the impeller of the exhaust fan 107. The molten dusts will self-drain in to the liquid sulphur storage tank 101.

[00102] With reference to Figure 1, transferring sulphur granules to a storage area by rubber belt conveyor may be implemented in some embodiments as follows. Transferring sulphur granules to a storage area is in general implemented by a rubber belt conveyor 109. Products (e.g. sulphur granule based on SUDIC standard) that discharge from outlet box of the granulation drum are transferred to a rubber belt conveyor by an outlet chute 319.

[00103] In some embodiments, there is provided an apparatus to have thermal uniformity in a granulation drum to grow sulphur granules to the desired size by using a lifting blade with a special shape, comprising an aluminum blade that is extruded in a special sectional profile (an exemplary profile is shown in more detail in Figure 3h). The profile is configured in a“T” shape such that a blade extends from a top edge portion slightly tilted to an angle from 0 to 20° from a direction perpendicular to the upper edge, and such“T” further having two other appendages projected away from outer surface, to the opposite direction of the blade extension, to facilitate a better heat transfer.

[00104] In some embodiments, a number of above-mentioned blades may be formed or cut at a calculated length, and then connected to each other along the sides of the upper edge, side by side, around the perimeter of a circle with a known diameter to shape a hollow drum rotatable on a sloped longitudinal axis, with the upper edges substantially forming the surface of the drum. In other embodiments, they may be fastened to the interior of a pre-formed drum. Heat exchange extensions may, in some embodiments, be integral with the lifting blade panels and, in the case of drum having a surface that is not formed from the lifting blade panels and to which the lifting panels are secured, extend via openings in the surface. In other embodiments, the heat exchange extensions may be integral parts of, or secured to, the outer surface separately.

[00105] In some embodiments, the apparatus further comprises a liquid sulphur header, which may be steam jacketed. A first set of the liquid sulphur spray nozzles are associated with the header, which nozzles may comprise the particle generation segment. The nozzles and the spray emitted therefrom are configured to generate very small droplets, which in some embodiments may be powder-like when aggregated. A second set of the liquid sulphur spray nozzles are configured to be the first particle enlargement segment; the amount of liquid sulphur and the configuration and direction (actual and relative to cooling fluid nozzle spray) of the spray are configured to coat particles that are created or seeded into in the seed generation segment (i.e. small particles). A third set of the liquid sulphur spray nozzles to be used as the second particle enlargement segment; the amount of liquid sulphur and the configuration and direction (actual and relative to cooling fluid nozzle spray) of the spray are configured to coat particles that are slightly larger than those coated in prior segments. A fourth set of the liquid sulphur spray nozzles to be used as the final granule enlargement segment; the amount of liquid sulphur and the configuration and direction (actual and relative to cooling fluid nozzle spray) of the spray are configured to coat particles that are arriving from the prior, or second, particle enlargement zone. Additional or fewer segments may be utilized depending on operational and/or product requirements. [00106] In some embodiments, the apparatus further comprises a process water header that is located below the sulphur header. Other cooling fluids may be used. A first set of the cooling liquid spray nozzles to be sprayed at a higher rate intersecting the first segment of the sprayed sulphur to create seeds; the spray direction and flow rate are configured to provide an intensity of cooling to rapidly cool the small droplets quickly and preferably prior to the fluid droplets combining into larger volume droplets or ligaments. A second set of the cooling liquid spray nozzles intersecting the first particle enlargement segment of the sprayed sulphur to enlarge the sulphur seeds; the spray flow rate and direction are configured to provide a sufficient intensity of cooling to solidify the liquid coating on the seed particles prior to their combination with other liquid-sulfur-coated particles, which level of intensity being in general less than in the prior segment. A third set of the cooling liquid spray nozzles are provided that intersect the second particle enlargement segment of the sprayed sulphur to increase the size of the sulphur granules; the spray flow rate and direction are configured to provide a sufficient intensity of cooling to solidify the liquid coating on the particles arriving from the prior segment before their combination with other liquid-sulfur-coated particles, which level of intensity being in general less than in the prior segment. A fourth set of the cooling liquid spray nozzles intersecting the third particle enlargement segment of the sprayed sulphur to complete the size of the sulphur granules to the desired size; the spray flow rate and direction in this segment are configured to provide a sufficient intensity of cooling to solidify the liquid coating on the particles arriving from the prior segment before their combination with other liquid-sulfur-coated particles, which level of intensity being in general less than in the prior segment.

[00107] In some embodiments, the sulphur spray nozzles in each of the segments, including those described above, are located inside the drum. In some embodiments, the cooling water spray nozzles in segments in each of the segments, including those described above, are located inside the drum below the sulphur injection nozzles. In some embodiments, there is provided a shelter component to prevent particles from falling on a header or headers.

[00108] In some embodiments, the hollow drum is made of a number of aluminum blade panels that are extruded in a special sectional profile having a T shape, with the bottom of the“T” forming a lifting blade. The profile is further characterized by having one, two, or more appendages projected from outer surface of the blade (i.e. the top of the“T”) to the opposite direction of the lifting blade. During the granulation process, the drum will rotate around the sloped longitudinal axis of the drum, and the two appendages facilitate a convection heat transfer away from the drum surface, and better thermal uniformity, this feature also, eliminates the need for extra temperature control equipment (including but not limited to the sulphur pre-conditioner or sulphur cooler).

[00109] In some embodiments, a specific shape and number of lifting blade panels are configured to, when connected to each other side by side, form the perimeter of a circle with a known diameter to shape a hollow drum. The panels may be configured to have substantially similar lengths, to form a cylindrical drum that is rotatable around a level or sloped longitudinal axis.

[00110] In some embodiments, components are equipped with steam jacketed casing, or other heating mechanism (e.g. convection or resistance heating), to maintain surfaces contacting the exhaust from the granularization drum at a temperature sufficient to re-melt the sulphur dusts and/or to avoid sulphur to be deposited thereon. The components may include any ducts, filters, cyclone filters, impellers, or casings therefor. In some embodiments there is provided a blower that has a steam jacketed casing. In some embodiments, steam is used to heat up the steam jacketed blower, which facilitates the re melting of sulphur dusts that would be deposited on, and otherwise stick to, the blower casing and impeller. This reduces the likelihood of unbalance rotation to occur due to encrusted sulphur on the impeller and casing, as well as more efficient blower operation. The re-melted sulphur may be reclaimed via a drain at the bottom of the casing housing that may be connected to a buffer tank.

[00111] In some embodiments, there is provided a separation apparatus to separate, and then re-melt the sulphur dust from the process for reclamation. Exhaust gas (i.e. air comprising moisture and process material dust) is moved into the apparatus such that a vortex fluid flow is created by the air and sulphur dust mixture blown thereinto. The separation apparatus comprises a dust separator body, generally comprising a cylindrical column, at least a portion of which is frusto-conical in shape. In some embodiments, the dust separator body is steam jacketed (or heated using other heating mechanisms). In some embodiments, there is further provided a collection basin at the bottom of the dust separator body, which may, in some embodiments be steam jacketed dust separator body (or heated using other heating mechanisms), where sulphur, once melted on the interior wall of the dust separator body, drips into by way of gravity. In some embodiments, the basin further comprises a siphoned type self-drain jacketed line. In some embodiments, the jacketed basin of the dust separator has a siphoned type self-drain jacketed line for keeping a minimum level of sulphur inside the jacketed basin in order to prevent air to be suctioned in to the drain line.

[00112] In some embodiments, there is provided a leak avoidance apparatus to avoid liquid sulphur leaking from the spray nozzles when granulation is not in operation. The leak avoidance apparatus comprises a steam jacketed header that is inclined towards the first end (i.e. that closest to the particle generation segment); this is generally inclined in the opposite direction as the incline of the drum axis.

[00113] In some embodiments, there is provided a filtering apparatus to eliminate all impurities from the liquid sulphur before it enters the drum; this, inter alia , reduces the likelihood of blockage of spray nozzles orifices. The filtering apparatus comprises a steam jacketed sulphur filter having a filtering element, to capture impurities. In some embodiments, the filtering apparatus may be located closely prior to liquid sulphur header to remove all impurities from process fluid before entering to header and spray nozzles. The solid impurities may block the small orifices of the spray nozzles and accordingly this filtering decreases the frequency of the cleaning and maintenance activity and also increases the availability of the granulator.

[00114] In some embodiments, lifting blades panels have appendages that extend from the outer surface of granulation drum for more and faster heat transfer. These appendages provide more efficient heat transfer that help seeds and granules to be cooled faster. Fast cooling of seeds and granules will generally result in a better growth in the seeds and granules, consequently it speeds up the production rate and reduces energy consumption and also decrease dusts. In embodiments, the lifting blade panels may be bolted to each other to make granulation drum; this method mitigates difficulties associated with the use of welding in corrosive environment inside the granulation drum. [00115] In embodiments, the sulphur spray nozzles of the particle generation segment have orifices configured to atomize the liquid sulphur into small particles; such orifices are relatively small in general. In general, the first segment of the cooling nozzles sprays cooling water to cool down the sulphur particles at a rate fast enough that substantially all droplets discharged from the sulphur nozzles of the first segment create solid seed particles. In some embodiments, the second segment of the sulphur spray nozzles have a larger orifice size compare to the first segment. Seed particles reaching this segment are enlarged as liquid sulphur is sprayed to coat them, and the second segment of the cooling water sprays discharges cooling water to cool down the sulphur granules and the liquid coating therearound. In some embodiments, the third segment of the sulphur spray nozzles have a larger orifice size compare to the second segment, thereby configured to enlarge the granules created in the prior segment, the third segment of the cooling water sprays discharges cooling water to cool down the sulphur granules that are produced in this segment. Likewise, the sulphur spray nozzles of the fourth segment are characterized by having a larger orifice size compare to the third segment to enlarge the granules created in prior segments or nozzles. The fourth segment cooling water nozzles spray cooling water to cool down the sulphur granules that are produced in this segment and complete the granule enlargement process.

[00116] In some embodiments, the sulphur spray nozzles do not discharge the sprayed sulphur in a horizontal flat plane, instead, they are tilted to the certain angle to spray sulphur in angled or vertical planes that are parallel to each other, in order to help to avoid mixing sprayed sulphur with those sprayed from the adjacent nozzles. In some embodiments, the cooling fluid nozzles of the first segment may be relatively closer to the sulphur nozzles than the corresponding nozzles in other segments. This may be accomplished by adding two pipe elbows. Water in this segment is, in this embodiment, sprayed toward the spray field of the process fluid with more intensity, therefore, it can more efficiently generate seeds, and eliminate or reduce the need for seed particles to be added to the granulation drum from any other sources. In some embodiments, there is provided a method for generating granular particles. The method, being carried on a granulation system in accordance with the subject matter described herein, comprises of at least some of the steps described herein. A hollow drum is rotated, the drum having a first end and an opposed second end lying along a longitudinal axis of rotation. The hollow drum has a circumferential surface formed from, or otherwise comprising, a plurality of lifting blade panels having one or more heat exchange extensions extending outwardly from said circumferential surface, each of said lifting blade panels further comprising at least one lifting blade extending inwardly from said circumferential surface. Inside the rotating drum, a process fluid (i.e. a fluid process material) is sprayed from a plurality of process fluid nozzles in fluid communication with a process fluid conduit; the process fluid nozzles are spaced along the process fluid conduit in two or more particle formation segments. The at least two particle formation segments comprise a particle generation segment and at least one particle enlargement segments. In the particle generation segment, the processing nozzles are configured to spray small diameter process fluid droplets for forming granular particles when cooled. The at least one particle enlargement segment in which the processing nozzles located therein are configured to spray process fluid for coating said granular particles from other particle formation segments. Spraying a cooling fluid inside the drum from a plurality of cooling fluid nozzles fed by a cooling fluid conduit extending in the hollow drum, the cooling fluid nozzles being located along said cooling fluid conduit at locations corresponding to each particle formation segment, said cooling fluid nozzles configured to spray cooling fluid so as to intersect said sprayed process fluid. Creating a curtain of falling particles from said lifting blades inside the hollow drum during rotation. Introducing a drying gas into the hollow drum along said longitudinal axis to flush dust into an exhaust air stream. Lastly, removing the exhaust air stream through an exhaust outlet and said granular particles from a particle outlet.

[00117] Embodiments of the subject matter disclosed herein may be applicable in sulphur solidification units for oil and gas refineries and in the agricultural industries to coat sulphur granules with urea or bentonite. Indeed, it may be applied to coating any particle in a process material. Sulphur is a by-product of oil & gas refineries and also petrochemical complexes. Accordingly, the subject matter disclosed herein may be used in sulphur solidification units in petrochemical applications producing sulphur coated urea (SCU) in fertilizer plant. In such embodiments, seed particles comprising of urea particles of predetermined sizes may be used as described above, wherein resulting granular particles have a urea (or indeed other material) -based core with a sulphur coating therearound. The improvements indicated hereinabove are applicable in maintaining a tighter distribution in size variability of such granular particles, process material reclamation and filtering, and maintenance advantages, among others.

[00118] While the present disclosure describes various embodiments for illustrative purposes, such description is not intended to be limited to such embodiments. On the contrary, the applicant's teachings described and illustrated herein encompass various alternatives, modifications, and equivalents, without departing from the embodiments, the general scope of which is defined in the appended claims. Except to the extent necessary or inherent in the processes themselves, no particular order to steps or stages of methods or processes described in this disclosure is intended or implied. In many cases the order of process steps may be varied without changing the purpose, effect, or import of the methods described.

[00119] Information as herein shown and described in detail is fully capable of attaining the above-described object of the present disclosure, the presently preferred embodiment of the present disclosure, and is, thus, representative of the subject matter which is broadly contemplated by the present disclosure. The scope of the present disclosure fully encompasses other embodiments which may become apparent to those skilled in the art, and is to be limited, accordingly, by nothing other than the appended claims, wherein any reference to an element being made in the singular is not intended to mean "one and only one" unless explicitly so stated, but rather "one or more. " All structural and functional equivalents to the elements of the above-described preferred embodiment and additional embodiments as regarded by those of ordinary skill in the art are hereby expressly incorporated and are intended to be encompassed by the present claims. Moreover, no requirement exists for a system or method to address each and every problem sought to be resolved by the present disclosure, for such to be encompassed by the present claims. Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. However, that various changes and modifications in form, material, work-piece, and fabrication material detail may be made, without departing from the spirit and scope of the present disclosure, as set forth in the appended claims, as may be apparent to those of ordinary skill in the art, are also encompassed by the disclosure.

Claims

CLAIMS What is claimed is:

1. A system for producing granular particles in thermal uniformity, said system

comprising:

a hollow drum rotatably mounted on a support frame and having a first end and an opposed second end oriented for rotation along a longitudinal axis, a circumferential surface of the hollow drum comprising a plurality of lifting blade panels having one or more heat exchange extensions extending outwardly from the circumferential surface, each of said lifting blade panels further comprising at least one lifting blade extending inwardly from said circumferential surface for creating a falling curtain of said granular particles during rotation of said hollow drum;

a process fluid conduit extending in the hollow drum having a plurality of process fluid nozzles for spraying a process fluid, said process fluid nozzles spaced along said process fluid conduit in two or more particle formation segments, the at least two particle formation segments comprising:

a particle generation segment in which the processing nozzles located therein are configured to spray process fluid droplets having a first size for forming said granular particles when cooled; and

at least one particle enlargement segment in which the processing nozzles located therein are configured to spray said process fluid for coating said granular particles from other particle formation segments;

a cooling fluid conduit extending in the drum having a plurality of cooling fluid nozzles for spraying a cooling fluid from locations corresponding to each of the particle formation segments, said cooling fluid nozzles configured to spray said cooling fluid so as to intersect said sprayed process fluid;

a dryer for introducing a drying gas into said hollow drum for flushing dust into an exhaust air stream; an exhaust outlet for exhausting said exhaust air stream; and

a particle outlet for allowing the egress of said granular particles.

2. The system of claim 1, wherein the circumferential surface of said hollow drum is formed by joining lateral edges of the lifting blade panels.

3. The system of claim 2, wherein the lateral edges of said lifting blade panels are joined together by physical joiners.

4. The system of claim 3, wherein said physical joiners are bolts.

5. The system of any one of claims 1 to 4, wherein said longitudinal axis is inclined downward toward said particle outlet.

6. The system of any one of claims 1 to 5, wherein said process fluid is provided to said process fluid conduit from a temperature-controlled process fluid input.

7. The system of any one of claims 1 to 6, further comprising a process fluid

filtering device for filtering said process fluid prior to the input of said process fluid to the process fluid conduit.

8. The system of claim 7, further comprising a filter heating element for maintaining the process fluid in the fluid filtering device at a temperature at least as high as the process fluid melting point.

9. The system of any one of claims 1 to 8, wherein said process fluid conduit further comprises at least two sequentially-located particle enlargement segments.

10. The system of any one of claims 1 to 8, , wherein said process fluid conduit

further comprises at least three sequentially-located particle enlargement segments.

11. The system of any one of claims 8 to 10, wherein said process fluid nozzles of each particle enlargement segment are configured to enlarge granule particles produced by an adjacently-located particle formation segment.

12. The system of any one of claims 1 to 11, wherein said coolant fluid nozzles

corresponding to any particle formation segment are configured to provide cooling fluid at a rate proportional to effect cooling of the granule particles produced in the corresponding particle formation segment.

13. The system of any one of claims 1 to 12, further comprising a process fluid

collection header located directly below said process fluid conduit, said process fluid collection header comprising a header heating element for maintaining a temperature thereof above the melting point of the process fluid, and being inclined toward a process fluid collection outlet.

14. The system of any one of claims 1 to 13, wherein the system further comprises a dust separator to collect dust from said exhaust stream, the dust separator comprising:

a separator chamber having a top end and a bottom end, said separator chamber comprising at least a frusto-conical portion tapered towards said bottom end;

a separator exhaust inlet in fluid communication with said exhaust outlet for feeding the exhaust stream into the separator chamber near said top end in a direction that is substantially tangential to an outer wall of the separator chamber;

an exhaust impeller component for increasing a volumetric flow rate of the exhaust through the separator exhaust inlet; and

a recaptured process fluid outlet located near said bottom end.

15. The system of claim 14, further comprising a separator chamber heating element for maintaining a temperature of at least the frusto-conical portion of the separator chamber at least as high as the process fluid melting point.

16. The system of either one of claim 14 or claim 15, wherein said exhaust impeller component comprises an impeller heating element for maintaining a temperature of the exhaust impeller component at least as high as the process fluid melting point.

17. A dust separator for collecting from an exhaust stream dust generated from a granular particle generation system, said dust comprising the same process material as said generated granular particles, the dust separator comprising:

a separator exhaust inlet in fluid communication with a provided exhausted stream for feeding the exhaust stream into the separator chamber near said top end in a direction that is substantially tangential to an outer wall of the separator chamber;

a recaptured process fluid outlet located near the bottom end.

18. The dust separator of claim 17, further comprising a separator chamber heating element for maintaining a temperature of at least the frusto-conical portion of the separator chamber at least as high as the process fluid melting point.

19. The dust separator of either one of claim 17 or claim 18, wherein said exhaust impeller component comprises an impeller heating element for maintaining a temperature of the exhaust impeller component at least as high as the process fluid melting point.

20. A method for generating granular particles comprising:

rotating a hollow drum having a first end and an opposed second end lying along a longitudinal axis of rotation, said hollow drum having a circumferential surface comprising a plurality of lifting blade panels having one or more heat exchange extensions extending outwardly from said circumferential surface, each of said lifting blade panels further comprising at least one lifting blade extending inwardly from said circumferential surface;

spraying a process fluid from a plurality of process fluid nozzles for spraying said process fluid, said process fluid nozzles spaced along a process fluid conduit in two or more particle formation segments, the at least two particle formation segments comprising:

at least one particle enlargement segment in which the processing nozzles located therein are configured to spray said process fluid for coating said granular particles from other particle formation segments; spraying a cooling fluid inside the drum from a plurality of cooling fluid nozzles fed by a cooling fluid conduit extending in the hollow drum, said cooling fluid nozzles located along said cooling fluid conduit at locations corresponding to each particle formation segment, said cooling fluid nozzles configured to spray cooling fluid so as to intersect said sprayed process fluid; creating a curtain of falling particles from said lifting blades inside the hollow drum during rotation; introducing a drying gas into the hollow drum along said longitudinal axis to flush dust into an exhaust air stream; and removing the exhaust air stream through an exhaust outlet and said granular particles from a particle outlet.

21. The method of claim 20, wherein the circumferential surface of said hollow drum is formed by joining lateral edges of the lifting blade panels.

22. The method of either one of claim 20 or claim 21, wherein the axis is inclined toward said particle outlet.

23. The method of any one of claims 20 to 22, wherein said process fluid is provided to said process fluid conduit from a temperature-controlled process fluid input.

24. The method of any one of claims 20 to 23, wherein said process fluid is provided to said process fluid conduit from a process fluid filtering device.

25. The method of claim 24, wherein said process fluid filtering device further

comprises a filter heating element for maintaining the process fluid in the fluid filtering device at a temperature at least as high as the process fluid melting point.

26. The method of any one of claims 20 to 25, wherein the fluid process fluid conduit further comprises at least two sequentially-located particle enlargement segments.

27. The method of any one of claims 20 to 26, , wherein the fluid process fluid

conduit further comprises at least three sequentially-located particle enlargement segments.

28. The method of any one of claims 20 to 27, wherein said process fluid nozzles of each particle enlargement segment are configured to enlarge particles produced by an adjacently-located particle formation segment .

29. The method of any one of claims 20 to 28, wherein said coolant fluid nozzles corresponding to any particle formation segment are configured to provide cooling fluid at a rate proportional to effect cooling of the granule particle produced in the corresponding particle formation segment.

30. The method of any one of claims 20 to 28, further comprising a process fluid collection header located directly below said process fluid conduit, said process fluid collection header comprising a header heating element for maintaining a temperature thereof above the melting point of the process fluid, and being inclined toward a process fluid collection outlet.