The conversion tower adopts vertical SS304 stainless steel packed structure with a temperature resistance of 700°C.   It is featured in stable conversion rate, flexible operation and temperature control, and maintenance-free. Four-layer packed tower, each layer is filled with V₂O₅ catalyst, which is a combination of low-temperature and medium-temperature catalysts, which can not only maintain the advantage of low light-off temperature but also ensure a conversion rate greater than 98%. This feature greatly improves the start-up preheating efficiency and shortens the preheating time.   There are corresponding thermometer interfaces on the top and bottom of each bed to precisely control the temperature and ensure the conversion efficiency. Each bed has a manhole for on-site catalyst loading.

The heat-pipe exchanger has high heat transmission efficiency. The equipment also has a compact structure, and small thermal side flow resistance. Its structure is safe, reliable, and better than the heat exchanger of other structures, and the damage of a single (or few) heat pipe will neither affect the overall performance of the equipment nor affect the plant production. The waterway is outside the flue, so it requires no shut down for replacement and overhaul. Design life is 10 years plus. This equipment is used in combination with the start-up pre-heater, which produces steam before cold start-up, external steam supply is no needed.   The recovery rate is 100kg sulfur burning generates 250kg steam. The first/second stage recovery of exhaust gas generates steam, and the third stage recovery produces hot water with efficiency of 36.5%, 44.2% and 67.3% respectively.

Our Control System adopts Siemens, ABB, Supcon, Hollysys, Honeywell or equivalent brands. We adopt on-site instruments from international brands, such as massflow meter from Emerson; dewing point meter from Michelle; pH meter from Mettler Toledo; transimitter from YOKOGAWA etc.,Major electrical components are all internationally famous brands such as SIEMENS, SCHNEIDER, or ABB.   The whole plant will be fully automatically controlled at a high level. We have in-house engineers for the programming and configuration. Remote operation parameter adjusting can be realized, if get the permission from the owner.  

The sulfuric acid plant and sulphonation plant share a common sulfur melting system. After sulfur melting, the sulfur is transported to the sulfur burning furnace through a sulfur pump and burned with dry air. The dry air is dehumidified by 98% sulfuric acid in the drying absorption tower, achieving a dew point of minus 40 degrees. Then, the main blower sends the dry air to the sulfur furnace for combustion.   After combustion, SO2 is converted once through a conversion tower to produce SO3 gas. Afterwards, SO3 is absorbed by 98% sulfuric acid in the primary absorption tower, and the exhaust gas after absorption returns to the secondary conversion. The heat from the primary conversion will be transferred to the exhaust gas from the second conversion, and after the second conversion, the conversion rate can reach 99.98%. Afterwards, SO3 undergoes secondary absorption, and the exhaust gas undergoes alkaline washing in the scrubber before finally being discharged into the atmosphere. In the early stages of start-up, the scrubber will operate at full capacity to absorb a larger amount of sulfur dioxide from the initial start-up. Under normal operation, qualified discharge can be achieved without passing through the scrubber. The exhaust gas can meet the emission standards in any country under any operating conditions.   The process for energy recovery mainly involves using fire-tube boilers to recover the combustion heat generated by sulfur combustion, as well as the reaction heat generated by the first part and secondary conversions of the converter, and generate steam. Steam can be used for sulfur melting in sulfuric acid and sulphonation plants. Meanwhile, a portion of the steam can also be used for lithium bromide refrigeration in sulphonation units. The remaining steam can be used in other nearby unites. The total heat recovery rate will reach over 80%.  

In addition to focusing on technology, we also attach great importance to technical services and training for customers. No matter where our customers are in the world, we can respond to their needs and problems within 10 hours. Technicians can be dispatched to anywhere in the world within 72 hours. Thanks to the reliability of the plant, WEIXIAN sulphonation plant can achieve an operation rate of 330 days / year. All plants have one-year guarantee period. Meanwhile, we will advise customers to purchase our standard spare parts kit to facilitate the timely replacement of vulnerable parts; the spare parts kit shall be provided at the cost price.     WEIXIAN’s technical services are including:   1. Free technical consultation. 2. Feasibility study in the early stage of the project. 3. Quotation and proposal of turnkey sulphonation plant and equipment. 4. Renovation and revamp of old sulphonation plant. 5. Design and engineering of customized turnkey sulphonation plant and equipment. 6. Installation of the plant. 7. Remote or on-site technical supports and commissioning. 8. Training of the buyer's technical personnel. 9. Other technical services related to sulphonation.