Case Study: Sulfur Recovery – Design, Supply, Supervision
Our South American refinery client selected Quantum (QIG) because we have years of experience in designing, building and maintaining SRU furnace trains. The repair scope included burner replacement, barrel brick maintenance, and baffle wall rebuild. The refinery was not satisfied with the historical maintenance as the unit was down every 4-6 months.
The refinery’s Superclaus unit service temperature is extremely high >1593°C (>2900°F). At the client request we supplied an extra high alumina brick, high purity mortar, high temperature IFB, and ceramic fiber multi component lining. Also during cool down the choke ring collapsed and QIG faced the obstacle of no special shape availability. We were able to render a design and adapt high purity castable to fortify and replace the choke. This customer relies on QIG to specify the refractory quality because we understand lining failure/wear mechanisms, and WE KNOW WHAT WORKS. Prior refractory drawings were illegible, so after a pre-job field inspection QIG provided engineering and updated new construction prints. Thermal profiles were provided to Plant Reliability to evaluate shell temperatures of the new lining design.
QIG was able to provide material on an emergency basis. QIG coordinated and expedited deliveries to SA, then provided engineering and field installation support to meet a 5 week outage. Our customers expect us to get them back on line quickly, which was challenging given the skill set of local labor. QIG supervision met the challenge very professionally and managed local personnel to finish before the outage timetable ran out.
During the install our client was impressed that we paid attention to critical areas such as tight ring construction of the inlet head brick and elimination of large gaps by properly engineering and installing the elliptical head brick. We replaced a rudimentary plant installed Baffle Wall which had collapsed after becoming unstable. The new Baffle Wall design utilizes turbulence technology to enhance flow patterns, improve process efficiency, promote combustion air mixing, and reflect more radiant heat to better protect the tube sheet at the end of the unit. The new wall design was far more structurally stable.
Following the QIG repair/installation, the refinery Reliability Department reported a 3-year operation, the longest run of continual service in the history of its operations.