Sandvik capabilities in the petrochemical industry

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Sandvik steel belts around the world

Sandvik steel belt technology forms thebasis for all of our processing systemsand delivers a range of proven benefits.

• Hard and smooth surface• Temperature resistant• Corrosion resistant• Easy to clean• Endless weldable• Wear resistant• High thermal conductivity• High tensile stress resistance• Easy to repair

A number of Sandvik standard steel beltsare available for chemical processingapplications, and we can incorporate afull range of special designs to satisfyparticular requirements.

• Various grades of stainless or carbon steel.

• Various thicknesses and widths.• Side retainer and retaining strips.• Various surface finishes from cold

rolled to mirror polished.• Steel belt technology has proved a

highly efficient and economical solutionfor the petrochemical and fertilizer industries.

We offer a choice of solidification systems based on the proven performanceof steel belt technology

Economical processes for the petrochemical and fertilizer industries

• Sandvik Rotoform® process – for highquality free flowing pastilles.

• Sandvik flaking process – ideal and economical solution for high capacityrequirement of bulk products.

• Sulphur / sulphur bentonite• Paraffin wax• Pitch• Asphaltene• Bitumen

The advantages at a glance:• Efficient cooling through good contact

with the steel belt.• Very wide product viscosity range.• Very wide temperature range (feeding

temperature up to 320°C).• Easy processing of corrosive, abrasive

and sedimenting melts.• Environmentally friendly production –

virtually no exhaust air pollution;cooling water is recirculated.

• Smooth surface of the steel belt meanseasy maintenance and cleaning.

• System versatility – easy changeover todifferent products within minutes.

Our solidification processes are developedfor products like:

• for the production of oxidized bitumen in sheets/blocks

Sulphur Pitch Wax Pitch Sulphur Pitch

Oxidized bitumen: from liquid to solid – on ready-to-load pallets – in less than 15 minutes

Granulation process (flaking and pastillation)

Sheet casting process

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Sandvik Rotoform® process

M

Raw material II

Granules silo

Storage

BaggingWeighing

M

Release agent applicator

Tensioning drum(heating optional)

Water collecting tank

Reactoror mixer

Prefilter

Release agent

Cooling water

Cooling waterreturn

Product pump Fine filter Rotoformer Steel belt cooler

Exh

aust

air

Raw material I

Typical Rotoform plant

• Pastilles are solidified directly from themelt, eliminating the energy and equipment costs associated with subsequent grinding, crushing or other breaking processes.

• Pastilles are of a highly uniform shapeand stability, with practically no dustproduced.

• Pastilles are free flowing and ideal forhandling, blending, storage and furtherprocessing.

• Higher bulk density and better packingproperties than bulky flakes.

• Environmentally friendly production ascooling media (water) and product arekept apart, ensuring no possibility ofcontamination either way.

• The excellent thermal conductivity ofthe steel belt means cooling time isshort, so very little vapor or gas canget into the atmosphere and little oxygen can penetrate the product.

We have developed an entire family of Rotoform systems, each designed forspecific applications or process requirements:• High capacity production• Corrosive products• Melts which feed in at high

temperature• Abrasive and sedimenting melts• Subcooling melts• Production of micropastilles

(down to 1 mm dia.)

The characteristics of the Rotoform process

The Rotoform unit forms the

heart of our pastillation process

The Sandvik Rotoform processcombines the Rotoformer dropdepositor with a steel belt coolerto create a pastillation system capable of delivering pastilles ofhighly uniform shape, stability andquality.The process itself is environmentally friendly and canbe adapted to meet low or high capacity requirements.

Sandvik flaking process

Product pump

Filter

Liquid sulphur

Air

exha

ust

Flakes

Crusher

Steel belt cooler

M M

Cooling water tank or pit

Cooling water

Cooling waterreturn

Surge tank

The flaking process is specially developedfor high capacity production of bulk material.

This proven solidification system consistsof an overflow weir feeder and a steelbelt cooler. The heated weir distributesthe product over the steel belt and formsa film that is taken up by the running steelbelt.

The liquid product solidifies to an evenlayer on the steel belt, which is cooled byspraying water from the underside.Retaining strips of Neoprene or rubberprevent the product from spilling overthe edges of the steel belt.

At the cooler end, a crusher breaks thesolid product layer into small irregular flakes. After leaving the crusher, the flakesare fed into a chute for further processing.

Sandvik flaking system

Overflow weir for

flaking system

Sulphur Pitch

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The Rotoform process for

Typical data for the Rotoform process

Product

Pastille shape hemispherical, uniform

Pastille size 2-4 mm

Bulk density >1,150 kg/m3 loose>1,320 kg/m3 packed

Dust (<0.3 mm) as produced <0.2%

Friability stress level II (acc. to SUDIC) <2%

Unit

Capacity max 6 t/h

Capacity range 70-100%

Belt area 7.5 m x 1.5 m

Floorspace requirement approx. 11.0 m x 2.0 m

Rotoform principleFree flowing dust-free sulphur pastilles

Formed sulphur• Free flowing pastilles of uniform size

and quality. Ideal for subsequenthandling, storage and transport.

• Premium spec. quality according toSUDIC (Sulphur DevelopmentInstitute of Canada) test.

Process• Indirect heat transfer – no contact

between product and cooling medium.• Controlled crystallisation – well

defined cooling time.• Environmentally friendly – emissions

within the limits of international laws;recycling of cooling water.

• Flexibility – rapid changeover to partialoperation without affecting quality.

• Quick start-up and shut-down of plant.

Equipment• Ability to increase capacity by grouping

several identical units.• Suitable for remote areas and harsh

weather conditions (hot or cold).• Continual process development and

improvement.• Customer support and back-up

through test and pilot plants.• Worldwide service network available

at short notice.

This unique combination of benefits hasresulted in more than 250Rotoformunits being built for the pastillation ofsulphur.

Free flowing pastilles of a uniform size and shape

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sulphur pastillation

Sulphur transport and storage

RF-Unit 3

Cooling water tank or pit

Cooling water

Cooling waterreturn

Filter

Liquid sulphur

Sulphur surge tank

Sulphur pump

M

M

M

PC

RF-Unit 1

RF-Unit 2

RF-Unit 4

Bucket elevator

Conveyor

Storage silo

Truckloading

Sandvik Rotoform system for sulphur pastillation

Feed end of Sandvik

Rotoform units

Recent years have seen us establish ourselves as a reliable partner to a growing number of internationally-renowned engineering companies thatserve the petrochemical industry, andSandvik sulphur pastillation units are nowoperational on all five continents.

Our activities range from cooperationduring FEED (front-end engineering design) to EPC (engineering procurement construction) contracts,and turnkey solutions include liquid sulphur supply, solidification and downstream handling of solid sulphur aswell as utility equipment and control systems.

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Rotoform plant for sulphur bentonite

M

Granules silo

Storage

Baggingweighing

Release agent applicator

Water collecting tank

Liquid sulphur

Bentonite

Release agent

Cooling water

Cooling waterreturn

Product pump Filter Rotoformer Steel belt cooler

Exh

aust

air

M

Surge vesselFilter

MM

Product pumpSulphur bentonitepreparation pit

Sulphur bentonite

The mixture of sulphur and bentonite (a special form of clay) makes sulphur suitable for use as a low cost and efficientfertilizer. We have developed a processfor mixing these two products and forming the resulting sulphur bentoniteinto free flowing pastilles.

The heart of this system is the RotoformAS, specifically developed to enable thepastillation of mixtures of melts and abrasive materials.

The end product has a very low dustcontent and this, together with other keyproperties, ensures that Rotoform-produced sulphur bentonite complieswith the highest environmental standards.

Our expertise in this process enables usto provide complete installations,covering everything from the receipt ofbase materials right through to weighingand bagging of the final product. Dust free and free flowing pastilles

of sulphur bentonite

Rotoform – unit for sulphur bentonite

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Wax pastillation process

Paraffin wax is a common by-productwhen oil is refined into lubrication oiland, like other refinery by-products, isusually converted into a solid form foreasier handling, transport and storage.

In the past, the traditional method of solidification was to form this wax into2.5 or 5 kg slabs. However, the development of an efficient pastillationprocess delivered such a range of benefits that many slab production plants have now been replaced by Rotoform pastillation systems.

The advantages provided by the Rotoform pastillation process include:

• Free flowing pastilles for better handling, storage and metering whenblended with other products.

• Low energy costs due to the large heat exchange surface of the steel belt(liquid to solid in less than a minute).

• Rapid rate of cooling enables ‘modified’waxes (i.e. suspensions or mixtures ofwaxes of different gravities or viscosities) to be solidified without firstneeding to be separated.

• High degree of automation means thata plant of five Rotoform units producing 10 t/h, complete with downstream bagging equipment, canbe managed by a single operator.

Rotoform – feeding side

Rotoform discharge

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Pastillation of pitch and hard bitumen

The high feeding temperatures of pitchand hard bitumen – as high as 320ºC –has until recently prevented the economically viable pastillation of theseproducts.

However, with the development of a purpose-designed system, the RotoformHT (High Temperature), both pitch andhard bitumen can now be solidified in anefficient and cost effective manner.Pastillation is performed on a continuously running steel belt and delivers consistently sized, hemisphericalpastilles without any deformations, failsor strings.

Our expertise goes far beyond the Rotoform pastillator and steel belt coolerthat are at the heart of this process; wecan engineer, supply, erect and commission the entire system, startingfrom receipt of the liquid materialthrough to weighing and loading – ontotruck, rail or ship – of the bagged or bulkproduct.

Uniform, hemispherical, dust-free pastilles of pitch

Discharge of pitch pastilles

Rotoform system for production of pitch pastilles

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Different products from A-Z

AdditivesAlkane sulphonateAluminium sulphateAmmonium nitrateAntioxidantsAntiozonantsAnthraceneAsphalt

Benzoic acidBisphenol ABis-hydroxyethyl-terephthalate (BHET)Bitumen

Calcium chlorideCalcium nitrateCalcium stearateCaprolactamCarbazolCatalysts Cleaning agentCobalt naphtenateCobalt stearateCrotonic acid

DetergentsDiaminodiphenylmethane(DMA)

Emulsifier

Fat chemicals- Fatty acid- Fatty alcohol- Fatty amide- Fatty ester- Fatty stearateFood products- Cacao mass- Cheese- Chocolate- Edible fats- Gelatine- Gum base- Sauces

- Soup concentratesFungicides

HerbicidesHot melt adhesives - Based on ethylene vinylacetate,polyurethane, polyamide,polyester

- Reactive hot melt

Insecticides

Lactam 12

Magnesium chlorideMagnesium nitrateMaleic anhydrideMaster batchMonochloracetic acid

Naphthalene Neopentylglycol (NPG)Nickel catalyst

ParadichlorbenzolPesticidesPhoto gelatinePhthalic acidPitchPolyethylene glycolPolyethyleneterephthalate(PET)Polystyrene PolyvinylacetatePotassium hydroxidePotassium nitratePotassium polyphosphatePowder paintsPVC additivePVC stabilizers

Resins- Acrylic- Colophonium- Epoxy

- Hydrocarbon- Phenolic- Polyamide- Polyester- Silicon- Tall oilRubber chemicals

Sodium acetateSodium hydroxideSodium nitrateSodium sulphide SorbitolStabilizers Stearic acid Subcooling meltsSulphurSulphur + BentoniteSurfactantsSynthetic soap

Tar pitchTensidesToluene-diisocyanate (TDI)Triazole (BTA,TTA)Trimellitic anhydride (TMA)Triphenyl phosphate (TPP)

UreaUV-stabilizers

Waxes- Paraffin- AKD- Microcrystalline- PE-wax- PP-wax- Bee-wax- Filled wax- Flavoured wax- Wax colours - Montan wax - Coating wax

Zinc nitrateZinc stearate

Products most commonly handled using our process systems

Our extensive experience in the designof melt granulation systems – from flaking, stripforming and cutting to advanced pastillation lines – means weare able to offer proven solutions for awide range of chemicals, plastics andintermediates.

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The Sandvik bitumen asphalt packagingsystem is a self-contained system thatautomatically produces regularly sizedpacks with little operator attention.

Hot fluid asphalt is fed onto the Sandviksteel belt cooler. Chilled water is sprayed on the underside of the belt,and air is blown from above. Thesmooth, durable surface of the Sandviksteel belt provides an ideal surface forthe temperatures and loadings involved.At the end of the belt the solidified asphalt bands are cut into consistently sized slabs which are stacked to formblocks.These in turn are automaticallyshrink-wrapped in polyethylene foil, andtransferred to pallets. The whole processtakes just over 15 minutes, and the packed end product is easily handled, andcan be thrown straight into melting vessels on site. Standard pack sizes are 710 x 345 x 100 mm, weighing 25 kg, butthis can be adapted to individual needs.

Two steel belt coolers for rapid

cooling of the bitumen

Cutting and stacking of slabs

Sandvik bitumen asphalt processing: high speed production of easy-to-handle

packs

Conveying of bitumen stacks

The Sandvik packaging system From liquid to ready-to-load in a little over fifteen minutes

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The Sandvik bitumen-asphalt packagingline provides rapid, environmentallyfriendly production, plus a number of other important user benefits.

• Continuous automatic operationmeans low labour costs. A plantproducing 10,000 tonnes per year canbe operated by 2 workers.

• High output of the system, thanks tototal time from liquid asphalt topalletized packages of little over 15 minutes.

• Low costs also result from thepolyethylene packaging – far cheaperthan alternative materials.

• Easy handling is assured by theflexibility to produce packs to specific,consistent sizes. Complete packs canbe thrown into melting vessels, withoutthe need to remove the packaging material.

• Regular pack configuration means easyloading and unloading, with packsdesigned to match standard palletsizes, and optimum use of storagespace.

A wrapped pallet with blocks ready for shippingWrapping and shrinking

Liquid bitumen is fed on to the Sandvik steel belt cooler

Feeding

Cooling

Cutting

Stacking

Transfer

Wrappingand shrinkingPalletizing

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for bitumen

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The Sandvik package of supply and services

Feasibility studies

Engineering and project management

Based on our experience and steady development we can offeryou the latest technology and service for your investment,starting from feasibility studies,test- and pilot production,engineering,manufacturing andsupply,erection, commissioningand start-up until handover of acomplete plant ready for full production.

Manufacturing and supply

for the oil and gas industry

Research and development

Erection, commissioning and start-up After sales service

Test and pilot production

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Sandvik – your partner for the petrochemical industry

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www.smt.sandvik.com/sps

Sandvik Process Systems is approved to DIN EN ISO 9001:2000– the international recognition ofhighest quality standards andpractices.