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Sulphuric Acid on the WebTM Technical Manual DKL Engineering, Inc.

Knowledge for the Materials of Construction - Sulphur Furnace

Sulphuric Acid November 8, 2002

Industry
Introduction Associated Links
Shell
Refractory Brick Lining Sulphur Burning
Sulphuric Acid on the Sulphur Furnace
Insulating Brick
Web Fire Brick Sulphur Systems
Castable
Introduction
Standards
General
Equipment Suppliers
Contractor
Instrumentation Introduction
Industry News
Maintenance A sulphur furnace is exposed to high temperatures from the combustion of
Acid Traders sulphur to sulphur dioxide. The materials of construction must be capable of
Organizations
withstanding temperatures as high as 1200ºC (2192ºF).
Fabricators
Conferences
Used Plants Shell
Intellectual Propoerty
Acid Plant Database The furnace shell is generally carbon steel. The specific grade of steel will vary
Market Information
depending on the expected operating shell temperature (i.e. Cold Shell or Hot
Library
Shell design). For cold shell design A36 steel will be adequate. For hot shell
designs A515 Gr. 70, A516 Gr. 70 or A285 Gr. C may be used. The selection of
Technical Manual material will be a function of maximum operating temperature of the shell,
design pressure and availability and cost of the material.
Introduction
General
Definitions
If the shell can see extreme low temperatures an impact tested steel may be
Instrumentation required.
Plant Safety
Metallurgial Processes Back to top
Metallurgical
Sulphur Burning
Refractory Brick Lining
Acid Regeneration
Lead Chamber
Technology The brick lining serves two purposes:
Gas Cleaning
Contact
reduce temperature at shell
Strong Acid
Acid Storage
Loading/Unloading protect shell from corrosive gases and liquids
Transportation
Sulphur Systems The above is achieved by using both refractory brick and insulating brick.
Liquid SO2
Multiple layers are typical for mechanical reasons and to eliminate a direct leak
Boiler Feed Water
path to the shell. For most furnaces a 343 mm (13½”) layer of refractory
Steam Systems
Cooling Water
(insulating and fire brick) is adequate to maintain shell temperatures at
Effluent Treatment acceptable levels. When the furnace operating temperature is higher, increased
Utilities thickness (457 mm (18”)) of refractory brick will be necessary.
Construction
Maintenance Refractory brick comes in standard brick sizes regardless of the supplier.
Inspection
Standard brick dimensions are 9” x 4½” x 2½” and 9” x 4½” x 3”. Other sizes
Analytical Procedures
Materials of Construction
and shapes are available as standard.
Corrosion
Properties Back to top
Vendor Data

Insulating Brick
DKL Engineering, Inc.
Insulating brick is generally applied between the steel shell and the exposed
Handbook of Sulphuric Acid layer of fire brick. As its name implies its purpose is to reduce heat transfer and
Manufacturing
insulate the shell from the hot process gases. Insulating brick should conform to
Order Form
Preface
ASTM C155 – Standard Classification of Insulating Firebrick which covers heat
Contents insulating materials known as insulating firebrick. Insulating bricks are classed
Feedback according to their bulk density and the behaviour in the reheat change test
conducted at the specified temperature. Eight groupings are defined in the
Sulphuric Acid Decolourization specification:
Order Form
Preface
Table of Contents Reheat Change,
Bulk Density Not
Group Not more than 2%
Greater Than
Process Engineering Data No. when tested at °F
lb/ft³ (g/cm³)
Sheets - PEDS (°C)
Order Form

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Table of Contents
Introduction 16 1550 (845) 34 (0.54)

Bibliography of Sulphuric Acid

20 1950 (1065) 40 (0.64)
Technology
Order Form 23 2250 (1230) 48 (0.77)
Preface
Contents
26 2550 (1400) 54 (0.86)
28 2750 (1510) 60 (0.96)
Sulphuric Acid Plant
Specifications
30 2950 (1620) 68 (1.09)
32 3150 (1730) 95 (1.52)
33 3250 (1790) 95 (1.52)
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Fire Brick

Fire brick provides protection from the high operating temperatures in the
furnace and are more resistant to mechanical damage and chemical attack than
insulating brick. Fire bricks are composed of various combinations of alumina
and silica containing materials. The chemical composition can vary from almost
100% alumina and little silica to 100% silica and little alumina. Fire bricks are
classified into two broad categories; fireclay and high-alumina bricks. Fireclay
brick are classified based on physical propeties while high-alumina bricks are
classified primarily on alumina content.

Modulus of
Alumina
PCE Rupture
Class Type Content
(min) (MPa/psi)
(% Al2O3)
(min)
Fireclay
Brick

Regular 33 4.14 / 600

Spall
Super-duty 33 4.14 / 600
Resistant
Slag
33 6.89 / 1000
Resistant

Regular 31ln$
Spall
High-duty 31ln$ 3.45 / 500
Resistant
Slag
31ln$ 8.27 / 1200
Resistant

Semi-silica 2.07 / 300

Medium-duty 3.45 / 500

Low-duty 4.14 / 600

High-
Alumina
Brick

50 34 50 ± 2.5

60 35 60 ± 2.5

70 36 70 ± 2.5

80 37 80 ± 2.5

85 85 ± 2.0

90 90 ± 2.0

99 97 (min)

Typically, a super duty (a fireclay refractory having an Orton pyrometric cone

equivalent above 33) fire brick is used containing 45 wt% or greater alumina
content.

Bulk density of refractory materials ranges from 2.19 to 2.24 g/cm³.

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Castable

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Castable refractory may be used in parts of the sulphur furnace design. Areas
where castable refractory may be used are the front of the furnace where the
sulphur gun and nozzles are located, manways, sightglasses, etc. The castable
refractory is held in place by anchors which are resistant welded to the shell.

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Standards

ASTM Test Method for Load Testing Refractory Brick at High

C16 Temperatures

ASTM Standard Test Methods for Apparent Porosity, Water Absorption,

C20 Apparent Specific Gravity, and Bulk Density of Burned Refractory
Brick and Shapes by Boiling Water

ASTM Test Method for Pyrometric Cone Equivalent (PCE) of Fireclay and
C24 High-Alumina Refractory Materials

ASTM Standard Classification of Fireclay and High-Alumina Refractory

C27 Brick

ASTM Test Method for Reheat Change of Refractory Brick

C113

ASTM Test Methods for Cold Crushing Strength and Modulus of Rupture
C133 of Refractories

ASTM Standard Test Methods for Size, Dimensional Measurements, and

C134 Bulk Density of Refractory Brick and Insulating Firebrick

ASTM Standard Classification of Insulating Firebrick

C155

ASTM Standard Test Methods for Reheat Change or Insulating Firebrick

C210

ASTM Standard Test Methods for Apparent Porosity, Water Absorption,

C800 Apparent Specific Gravity, and Bulk Density of Burned Refractory
Brick and Shapes by Boiling Water

ASTM Standard Test Method for Bulk Density and Volume of Solid
C914 Refractories by Wax Immersion

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