Sulphonation Plant-Continuous SO3 Multitube Falling Film Sulphonation Reactor

• Condition: New
• Automation: Automatic
• After-sales Service: Engineers Available to Service Machinery Overseas
• Tube Material: SS316L
• Shell Material: SS304
• Capacity: 0.5tph-10tph
• Model NO.: 03R1
• Operation Flexibility: 55%-115%
• Transport Package: Nude Packing by Sea
• Specification: 1 tube - 240 tubes
• Trademark: WEI XIAN
• Origin: China

Product Description

Product Description

WEIXIAN Reactor adopts multi-tube falling film type.
The capacity range is from 1 tube to 240 tubes (0.5t/h - 10t/h). Since 1995, WEIXIAN has supplied hundreds of reactors, including two world's largest 7.5t/h 180-tube reactors. Benefiting from the reliability improvements and main components' manufacturing and design improvements, the performance of WEIXIAN's new generation reactor is notably superior to the other similar type reactors.
 

Detailed Photos

REACTION TUBE
Special manufacturing processes are applied such as high-precision cold rolling and annealing, which make sure the inner and outer surfaces'finish degree of each tube reaches Level Ra0.4 (like mirror) with high consistency.

There is no weld on the entire 6-meter Reaction Tube, shallow leakage at reaction initial part can be avoided, and the reliability is greatly improved.

TUBE SHEET
16% thickness increased for Tubesheet 1, 2 & 3 ,improved rigidity and reduced the deformation,therefore the sealing effect of SO3 is much better.

Organic Material Distribution Chamber height is increased by 25%,this is very meaningful for organic materials distribution in big capacity reactors, especially for 6t/h - 10t/h reactors.

DISTRIBUTION HEAD AND SO₃ NOZZLE
With the design optimization of Reaction Tube, SO₃ Nozzle and Distribution Head,the pressure drop of organic materials flowing through the gap is increased by 13.3%, which enhances the flow-distribution-self-balancing ability and extend reactor washing interval.

COMBINED COMPRESSING SCREW HEAD
With one set of  fluororubber O ring added,it avoids the screw thread getting corroded by SO₃ effectively.  The upper O ring is also fluororubber.

All Screw Heads' surface are processed by nitriding treatment (featured in blackish exterior),which improves the anti-corrosion performance and wear-resisting ability dramatically. Therefore, the Screw Head will never get rusted and unable to open.
 

The sealing structure between SO3 and Organic Materials

 

Product Parameters

 

ITEM	VALUE
Place of Origin	Nanjing City , Jiangsu Province, China
Brand Name	WEI XIAN
Main Products	LABSA
	SLES
	SLS
	AOS
	HABSA
	MES
	Other anionic surfactants
Marketing Type	New
Warranty	1 Year
Core Components	Reaction Tube
	Tube sheet
	Distribution head
	SO3 nozzle
	Combined compressing screw head
	Various gaskets
Applicable Industries	Chemical Manufacturing Plant
Standard Compliant	GB standard, ASME Standard, CE/PED Standard
Product Type	Key equipment for sulphonation production line
Core Competency	New generation SO3 multitube falling film reactor
Strong Point	Active matter in LABSA >= 97%
	Dioxane content in SLES can be undetectable level
	Wide operation flexibility: from 55% to 115% nominal capacity
	Reactor calibration easily reach ±1.5% deviation
	extended washing interval
Video outgoing-inspection	Provided
Machinery Test Report	Provided

Detailed Technical Advantages of WEIXIAN Sulfonator :

1. Organic material distribution system in the head of reactor
 
After calibration, the flow deviation reaches ±1.5%. The distribution head and nozzles are one-time clamped processed and formed by a CNC machine to ensure that the tolerance of major dimensions reaches ± 0.005mm, and minor dimensions ± 0.01mm.
 
2. Finish degree of reaction tube inner wall
 
Reaction tubes are applied high precision cold rolling and annealing, processed under a 1040ºC vacuum condition to remove inter-molecular stress. Those treatments make sure the inner and outer surfaces' finish degree of each tube reaches level Ra0.4 (like a mirror); the deviation of the inner and outer diameter of the reaction tube is controlled at less than ± 0.02mm.
 
3. The welding and flaw detection method of the distribution head and the reaction tube
 
High-frequency welding + argon arc welding are applied in the welding between the distribution head and the reaction tube. The welding form is fillet welding. The flaw detection method is nondestructive testing. For each tube, we applied 0.6Mpa hydrostatic test and endoscopic exploration for weld formation and inner pipe accuracy testing.
 
4. Concentricity of three tube sheets
 
All three tube sheets are processed with the same coordinate in the machining center. Tube concentricity tolerance reaches ± 0.01mm. All three tube sheets will be stacked and fixed together according to the installation position and checked by inspection mandrel the holes one by one with concentricity deviation less than ± 0.01mm.
 
5. Sealing reliability
 
5.1 The cooling water sealing between the shell side upper section and middle&lower section
The cooling water enters into the second and third parts and exits from the third part of sulfonator. The first (upper) part has to be strictly isolated to ensure the separated circulation of chilling water (15ºC), which is crucial for better product quality, especially for AOS.
 
5.2 The two-way sealing between sulfonator upper part SO₃ and organic material
In tube sheet 1, the compressing screw head adopts a combined screw head + three combined gaskets type, which forms a reliable two-way sealing. It realizes 100% isolation of the oleum and prevents rusting and leaking.
 
5.3 The sealing of cooling water between the distribution head and shell side
Adopting a new type of sealing structure greatly improves the pressure resistance of the shell side. The shell side test pressure can be greater than 0.6Mpa, and the water is able to return with pressure. All sealing parts are made out of special fluororubber O-rings, with 100% sealing efficiency, and lifetime replacement free.
 
5.4 The sealing of cooling water between the reaction tube's lower part and the shell side
Applied fluororubber O-rings, the sealing efficiency is 100%, and lifetime replacement free.
 
6. Other Technical advantages of our sulfonator
 
6.1 Extended operation period: LABSA continuous production period reaches 40+ days;
 
6.2 70% SLES continuous production period reaches over 3 months;
 
6.3 AOS continuous production period reaches 25+ days;
 
6.4 Easy sulfonator calibration:
First start-up flow deviation is able to reach ±1.5%. The thickness of replacing gaskets are from 1.8~2.2mm (standard thickness is 2mm). Top level products quality and extended sulfonator washing interval can be ensured.
 
6.5 Yield flexibility:
LABSA capacity adjustment range 55%~115%
70% SLES capacity adjustment range 80%~140%

 

Packaging & Shipping

Company Profile

WEIXIAN is a sulphonation/sulphation technology specialized engineering company, that owns a professional engineers and technicians team dedicate for feasibility research, design and engineering, turnkey plant and key equipment supply, installation, commissioning, and other technical services. In the last 30 years, WEIXAIN has completed over 200 LABSA, SLES, SLS, AOS, HABSA, and MES manufacturing plant projects worldwide, including two world's largest 7.5tph LAS  plants. 

Since 21^st century, WEIXIAN is leading the innovation and progress of sulphonation/sulphation technology. WEIXIAN is the pioneer who introduced these technologies into the industry, such as Unit 79, Unit 69, Unit 38, Exhaust Gas Circulation Process, etc. Moreover, WEIXIAN keeps improving and perfecting the details of each key piece of equipment, such as converters, scrubbers, heat exchangers, pumps, blowers, mixers, etc. Focus comes from the love of what we are doing, as a sulphonation/sulphation technology specialized engineering company, we are confident about our technology leadership in the world market, and we are aiming to serve investors not only from Asia but also from all over the world. Choosing WEIXIAN is your most efficient solution for investing in state-of-the-art sulphonation plants.

Our Advantages

 

• Continuous SO₃ Multitube Film Sulphonation Reactor: conducts homogeneous and complete reactions, minimizing by-product generation and raw materials consumption. Designed for 15 years + serving life.
• Unit 79 Neutralization and Dioxane Stripping: invented in 2010, featured in producing undetectable level dioxane content 70% SLES, and up to 40% overproduction ability
• Unit68 Three Stage Waste Heat Recovery: realizes plant steam and hot water self-sufficiency.
• Unit 69 Reaction Heat Recovery: reduces power consumption by 15% compared to standard process.
• Unit 38 Waste Water Crystallization: realizes waste water ZERO discharge.
• Exhaust Gas Circulation Process: reduces exhaust gas discharge by 96%.
• Sulphonation reactor, Vertical Static Aging Vessel, Plate-type ESP, Floating-type SO₂Cooler, Tubular SO₃Cooler and more.

 

After Sales Service

WEIXIAN guarantees our customers that we can respond to your needs and problems within 10 hours. Thanks to the reliability of the plant, WEIXIAN sulphonation plants can achieve an operation rate of 330 days/year. All plants have a 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 include:

 

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 the 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 support and commissioning.

8. Training of the buyer's technical personnel.

9. Other technical services related to sulphonation.

 

Installation Instructions

WEIXIAN owns a professional installation team that has assisted plant owners in carrying out the installation of their plants, tank farms, etc,  professionalism, efficiency, and quality are the purposes of our service!