Computational model of large-capacity molten sulphur combustion spray efficacy and process efficiency

Abstract

The use of precision spray injectors with advanced technology nozzles in the combustion of molten sulphur represents an active and growing field. The efficient combustion of large volumes of molten sulphur is a clear requirement in the phosphate industry. Spraying Systems Company, along with our industry partners, has conducted significant research in the laboratory as well as in full-scale industrial settings to arrive at optimized process solutions for this application. Additionally, computational models have been developed to allow for the assessment and optimization of the sulphur combustion efficacy. Over the past decade there have been rapid advancements in computer and software technologies for simulation of complex applications. These strides have allowed for more complex simulations at reasonable cost, such as the design of spray injectors with stress analysis coupled with fluid dynamics and heat transfer. This paper presents the results of a detailed spray injection modelling study demonstrating the scale-up of the spray solution as well as the 100% spray combustion requirement at these elevated sulphur flow capacities. Through the use of the models developed here, the sulphur combustion was improved beyond that which was possible using experimental results.