- Mani Babu P

Objective of Study:
The basic objective of the study is to maximize yield of

carbon disulfide by optimizing furnace inputs and conditions Assumptions: Sulphur feeding from godown is 100% pure with no impurities. The heat losses through furnace are only through conduction, convection and uniform throughout furnace. The temperature of feed may vary to some extent.

Approach:
There are two approaches to the problem To decrease production of hydrogen sulfide and To optimize energy requirements. - Removal of Hydrogen is difficult

Areas of Energy Requirements:

Energy requirements after feeding to furnace: (Inside the

furnace) To heat molten sulfur from 1250C to 4440C Phase change at 4440C To heat molten sulfur from 4440C to 7500C Endothermic Reaction both main and side reaction Heat losses Energy requirements before feeding to furnace: (outside the furnace) Sulfur from 250C to 1250C Charcoal from 250C to 1250C

Method of solving:
Step-1: To calculate total energy requirements for the

reaction to occur. Step-2: To calculate Heat losses Step-3: To calculate Excess energy supplied

Reactions:
Major Reaction:

C(s) + S2 (g) CS2 (g) --- (1) H = 1950 KJ/kg Side Reaction: H2 (g) + S (g) H2S (g) --- (2) H= 131.9 KJ/kg When reactants are at 250C and products are at 7500C

Calculations
Let sulfur feed per day = 5500 Kg = 229.17 Kg/hr Let charcoal feed = 250 Kg/ 4hr= 62.5 kg/hr Let return sulfur = 5% input = 275 Kg/day

= 12.5 Kg/hr Let total energy supplied = 200 KW/hr Let volatile material = 5% of charcoal = 3.125 Kg/hr Let off gasses temperature = 2250C Let shell temperature = 700 C Now to calculate all the energy requirements mentioned above Copying all the calculations looks clumsy I only hope I will have a board here.

End results
Total Energy requirements without heat losses from

furnace QR Heat losses from furnace QL Energy supplied QT Net excess energy supply QE

= 408137 KJ/hr = 179748 KJ/hr = 720000 KJ/hr = QT (QR + QL ) = 132115KJ/hr = 36.698 KW Therefore energy which we can save is 36.698 KW under these conditions

Practical Observations
Sl.no Furnace No Time to Age of Input (kgs/day) Power (KWH) Return sulfur Off gasses % Temp (0C) collect 12 lts Furnace (mins) 1 2 3 4 5 6 7 1 2 1 6 5 5 5 12 47 112 28 10** 28* 40 (days) 93 70 14 23 12 28 31 5760 5220 5800 5800 5800 5800 5800 180 190 221 228 195 218 227 45.4 12.8 4.9 19.3 54.2 41.7 13.5 260 208 220 139 106 220 152

Results of observations
Calculations are made on the same way explained

above with the help of excel and documented.

Sl. No Furnace No Return Sulfur (%) Power supplying Excess Power wastage (KW) Excess Power wastage

(KW)

(10KW
tolerance)

1 2 3 4 5 6 7

1 2 1 6 5 5 5

45.4 12.8 4.9 19.3 54.2 41.7 13.5

180 190 221 228 195 218 227

98.67 47.69 47.57 86.7 147.3 126.8 72.61

88.67 37.69 37.57 76.7 137.3 116.8 62.61

Loss Incurring:
This loss is calculated after excluding 5% return sulfur

and 10kw excess power. And assumed that all 7 furnaces are running on that particular day and results follow the above table data. Net excess power supplying per hour = sum of excess power of all 7 furnaces per hour = 557.34 KW/hour Total loss per day is = 557.34*24 = 13376.16 KW/day If the furnace run 365 days then loss = 13376.16*365 = 4882298.4 KW
incurring per year ~ Rs. 2.27 crores

Let the cost of 1 unit electricity is Rs.4.66. Hence total loss

Recommendations
The first serious recommendation is to assess the return sulfur

every day if possible every shift. If it is found to be high adjust the feed rate and power to minimize it. Maintain optimum height of charcoal bed within certain tolerance limit prescribed above. Decrease the feed of sulfur to the furnace as its age increases. Dont decrease it by convention. Alter the feed and assess the return to obtain optimum feed. Optimum feed of sulfur should be given depending upon charcoal bed level. Excess supply of sulfur will results in increased return as pressure inside the furnace increases and pushes the sulfur vapors outside the furnace without reacting with charcoal.

Contd..
There should be proper brick lining in order to avoid heat

losses from the furnaces. Before completion of every cycle of furnace check the areas on the furnace where temperature is shooting up and adjust/replace bricks to avoid heat losses. It is also observed that heat losses from furnace increases as age of furnace increases. This might be basically due to continuous heating of bricks which damages the molecular structure of bricks, thereby increasing strain in them. Hence decrease the feed and also power input with age. The furnace should be run for an optimum period. Exceeding the limit may also damage brick lining and bricks even. This can be assessed by shell temperature of furnace and return sulfur.

Contd..
Maintain the sulfur feed lines such that sulfur feed pokes nearest to

electrode so that maximum heat is available to convert in to vapors and to attain reaction temperature. Increase the number of electrodes from two to four so that heat transfer will be uniform throughout furnace. In case of our equipment the heat transfer from electrode at the center to wall is less as inner diameter is 2.01 meters. Judging productivity based on Input sulfur feed, Power supply, return sulfur, furnace shell temperature and off gas temperature together would give accurate results and judging base on any one or few parameters may give absurd results. Charcoal should contain low ash content as the removal of slag inside the furnace is batch process it stagnates inside and leads to wastage of power.

Contd..
Always maintain adequate amount of charging for charcoal. If charging of coal is less increase the power supply and decrease the feed of sulfur for certain period
Optimum bed level should increase with increase in age of furnace as the level of slag inside the furnace increases.

Maintain low feed during the startup of furnace as it requires adequate time to heat enter charcoal and to attain reaction temperature.

Thank You