We have a long legacy of innovation inengineering within the sulphur industry.
Our expertise extends beyond thesolidification stage to encompass processsystems, degassing, block pouring and melting.
ipco.com---------world---leader---------in------sulphur
processing----and------------handling--------

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----- The Sulphur
company – a world
leader in sulphur
processing andhandling
IPCO is a world leader in sulphur solidification and handling plants
having delivered complete end-to-end systems from receipt of molten
sulphur to loading of solid material to hundreds of companies aroundthe globe since 1951.

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Bulk ship loading
directly froman IPCO sulphur
forming andstorage facility.

Today, the company manufactures equipment
for sulphur degassing, molten loading for truck
and rail, block pouring, remelting, a full range ofsulphur solidification technologies, downstream
storage and reclamation, as well as bulk loading
for truck, rail and ships.
Our Rotoform system, designed for small to
mid-size capacity requirements, is the world’s
most widely used process for the production ofpremium quality pastilles and offers unrivalled
product uniformity and environmentallyfriendly operation.

Where higher capacity is required, our sulphur
granulator drum system is a fully automated,once through, sulphur granulation process
based on rotating drum technology.
More than 700 Rotoform systems are
currently in use across the sulphur industry
and our expertise extends far beyond thesolidification stage, encompassing everythingfrom the receipt of molten sulphur from the
SRU to a complete range of downstream
handling operations.

Molten sulphur being fed onto the steel
belt to produce pastilles.

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Reap the benefits of single source supply
by working with ‘the sulphur company’
Choose to work with IPCO and you open thedoor to a wealth of expertise covering every
aspect of sulphur processing and handling.
We can design, integrate and commission
equipment for every stage of the process,from upstream preparation, degassing andfiltering of molten sulphur through a rangeof different solidification options, to downstream conveying, storage, reclamation andbagging or bulk loading.

This includes installations where considerations
such as the potential risk of earthquakes or­specific local weather conditions need to betaken into account.
And by assuming total responsibility fora ­project, we not only ensure full system­optimization but can also deliver cost savings
through significant project efficiencies.

Our experts can also help you maximize
productivity and achieve a faster ROI throughoperator training and planned maintenanceprograms.

Strength and stability of a global
engineering group
Choose IPCO and you benefit not only from ourtechnical expertise but also from the ­reassuranceof working with one of the world’s foremost
engineering groups.

Process system expertise
Our sulphur processing systems are employedaround the world – often in remote locations
or challenging conditions – and we support
them all through a global service network.
So wherever you’re based, you get the
support you need.

IPCO is a high-technology engineering businesswith advanced products and world-leading
positions within selected areas. We also
benefit from the strength and stability thatcomes with being an internationally active,
mid-size company owned by the Wallenberg
foundations.

Our engineering, consulting and project
management teams have the expertise toundertake end-to-end project managementfrom feasibility studies and front end
engineering design (FEED) through tocomplete engineering procurement construction(EPC) packages.

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Engineering & consulting services.
Block pouring.
Melting.
Liquid sulphur degassing.
Small/mid-size capacity solidification.
High capacity solidification.
Storage (silo or stock pile).
Reclaiming.
Bagging.
Truck/rail/ship loading.
Global service and spare part supply.

Ship loading with telescopic chute to reduce
dust creation.

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Developing the solutions to meeta global sulphur challenge
Premium quality forming
While elemental sulphur can be stored andtransported in its molten form, it is usually morepractical and economical to convert it into a solidstate, certainly – as is often the case – when it is
to be shipped from one continent to another.
It was in order to establish standards for formed
sulphur – and its suitability for transportation(i.e. export) – that, in the late 1970s, SUDIC(Sulphur Development Institute of Canada) set
about defining what has now become globally
recognised as a ‘premium’ quality product.

Together, these factors determine not only thequality of the formed sulphur but also the easewith which it can be handled and the potential
impact on the environment during storage andtransportation (formed sulphur can be handled
as many as 15 times between solidificationand subsequent reprocessing).
We have therefore focused the design anddevelopment of all IPCO sulphur forming
products – as well as our complete array ofdownstream handling equipment – on ensuringthat SUDIC premium quality sulphur reaches theend user.

In determining this quality, SUDIC looked at
friability and fines content, both critical toefficient, clean and environmentally safe
production and handling. The other major
factor was moisture content; excess moisture
not only adds weight, leading to unnecessarytransportation and melting costs, but also
results in increased acidity, causing corrosion inconveyors, silos, trucks, rails cars and ship holds.
A ‘wetter’ product is also more susceptible
to freezing into lumps during cold weather,a significant factor in colder climates.

The perforated feed device on
IPCO’s Rotoform system helps ensurepremium quality sulphur solidification

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Circular stockpile – 30 000 tons.

Specifications
According to the SUDIC definition, premium quality sulphur will meet thefollowing specifications 21 days after forming:

Mean size

between 2 and 5 mm

Size distribution

less than 5% bigger than 4.75 mm
minimum 75% between 4.4 and 2.4 mm
less than 2% smaller than 1.18 mm
less than 0.1% smaller than 0.3 mm

Moistureless than 0.5% by weight

Friability

less than 1% fines (< 0.3 mm) under stress level I

Bulk density

1 040 kg/m3 loose, 1 200 kg/m3 agitatedAngle of repose

not less than 25°

Compaction

below 0.2% fines by weight (< 0.3 mm) under static load

less than 2% fines (< 0.3 mm) under stress level II

below 0.5% fines by weight (< 0.3 mm) under dynamic load

IPCO forming equipment meets or exceeds these specifications.

7Low cost, high capacity sulphur degassing,block pouring and melting
Liquid sulphur degassing
IPCO sulphur degassers provide an economicalmeans of reducing poisonous hydrogen sulfide
in liquid sulphur.
Its high degassing capability – H2S is reduced toless than 10 ppm – minimizes the potential fordownstream regulatory safety violations andits robust design and ease of operation ensures
low operating and maintenance costs.
Self contained, compact and portable, this skid
mounted unit is supplied with all necessary wiringand pipework and is extremely easy to use:
• Maximum degassing capability to below
10 ppm H2S.
• Superior environmental performance.
• Continuous operation under negative
pressure in a fully contained system.
• Limited manual labor or exposure to ­potential hazards.
• Low operating and maintenance cost.
• Efficient use of energy.

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Reliable and efficient reduction ofhydrogen sulfide
Molten sulphur is pumped through thedegassing reactor where billions of tiny air
bubbles transfer the H2S gas from themolten liquid to the headspace of thesealed reactor tank.
A carefully defined volume of catalyst is thenintroduced, quickly reducing the hydrogen
polysulfide molecules to gaseous H2S, resulting
in the degassing of both H2S and H2SX within
the molten sulphur.
H2S rich airflow exits the degassing reactor
and is transferred via ducting to an
appropriate effluent treatment system,
while the degassed molten sulphur istransferred to downstream systems.

A practical and economical solution to
the storage of large volumes of sulphur
Block pouring and melting
Fluctuations in global sulphur output andprojections of future supply outstripping
demand mean that sulphur producers face anincreasing challenge of medium to long term
storage of large volumes of sulphur.
In-depth expertise in large scale blockpouring solutions
Block pouring offers a practical andeconomically viable solution to this, andour sulphur forming experts have extensive
experience in the design of such systems.
As well as supplying all necessary equipment –pouring towers, forms etc. – we can also provide
a full consultancy service covering every aspectof the block pouring site, from safety andenvironmental compliance to pouring
techniques and future melting considerations.

High performance, low maintenancesulphur remelters
IPCO sulphur melters are compact, skidmounted units, offering predictable, highcapacity throughput. Unlike conventionalsulphur melters, IPCO melting technologies
allow the effluent to be captured for treatment
before anything is released to the environment.

• Predictable, maximum throughput rates.
• Efficient use of energy.
• Reduced sulphur concentration inrecovered contaminants.
• Low operating cost; low maintenance.
• Environmentally friendly.

Solid sulphur is melted in a settling tank whileheated liquid sulphur is recirculated through thetank, aiding in the melting process. The heavier
contaminants settle out of the molten sulphur
and are continuously removed via a sludge
extraction conveyor:

9Premium Rotoform solidification for small
to medium capacity requirements
Our flagship Rotoform system – the only
indirect solidification process on the market –offers unrivalled product uniformity,
direct-from-the-melt pastillation andenvironmentally friendly operation. These,
and a whole range of other qualities, havecombined to make the IPCO Rotoform theworld’s favorite premium solidification process:more than 700 Rotoform units have been
supplied for sulphur forming operations.

The belt is cooled by water sprayed on theunderside and the resulting heat transfer resultsin rapid solidification of the product.

Throughout the years capacity demands haveincreased and we have responded by adding
new designs and models to the Rotoform family
to meet a full range of throughput requirements.

Pastilles to sudic premium product specification
The efficiency of this single step, liquid-to-solid
process results in a product quality classified
as ‘premium’ as defined by the Sulphur
Development Institute of Canada (sudic)
specifications (see page 7).

From melt to solid in a single step
The Rotoform consists of a heated, cylindricalstator and a perforated rotating shell that turns
concentrically around the stator, depositing
sulphur drops across the whole operating widthof a continuously running steel belt. The
circumferential speed of the Rotoform is
synchronised with the speed of the belt,
ensuring that drops are deposited accurately,
consistently and without deformation.

The sulphur droplets are then discharged assolid, hemispherical pastilles at the end of thecooling system. To eliminate the possibility ofdamage to the pastilles during discharge, a thinfilm of silicon-based release agent is sprayedonto the steel belt.

The uniform shape and size of Rotoform
pastilles make them free-flowing for easy
handling, while a predictable high bulk
density is a major advantage in terms of storage
and transportation.

Unrivalled product uniformity, direct-from-the-melt
pastillation and environmentally friendly operation
have made the IPCO Rotoform the world’s favourite
premium solidification process.

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Discharge ofsulphur pastilles fromsteel belt cooler.

Basic principle of Rotoform
Rotating shell

Heating channel
Heating channel

Pastilles
Steel belt

Benefits include:• Low friability, which minimizes productdegradation and dust.
• High angle of repose, good flow characteristics.
• High purity and consistent quality.
• Low residual h2s (< 10 ppm).
• Low moisture content (the IPCO Rotoform
process does not increase the moisture
content).
• Unrivalled uniformity.
The Rotoform process also offers a number ofenvironmental advantages:• As the cooling water never comes into directcontact with the sulphur, there is no risk ofcross contamination.
• Solidification takes less than 10 seconds so
there is little time for h2s to escape, resulting
in very low emission values.
• Low levels of sulphur dust levels mean noneed for exhaust air treatment.

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rotating drum technology for low cost,high capacity solidification
IPCO sulphur granulators are fully automatedprocesses based on rotating drum technology.
Our system is the highest capacity sulphur
granulation unit on the market, and produces
formed sulphur to SUDIC specifications(see page 7).
Seed or nuclei particles of solid sulphur are
generated externally by freezing sprays of liquidsulphur in a water bath at controlled pressures
to form the desired size range. These particles
are then augured into a slowly rotating drumwith appropriately placed flights attached to

its inner surface. The flights create curtainsof particles inside the drum as well as gently
moving them towards the discharge end.
As the nuclei particles travel along the drum,
they are progressively enlarged to the required
size by means of sulphur sprayed from a bankof nozzles running the length of the drum.
The temperature in the drum is moderated by
the evaporation of water from spray nozzles
located inside the drum.

A fully automated sulphur granulation process withthe highest capacity granulation unit available.

12Low capex and opex for high capacity
sulphur forming
IPCO sulphur granulators are supplied
prefabricated for fast delivery and rapid
installation, and their simple design, lowmaintenance requirements and continuous
operation combine to deliver exceptional ROI:
• Highest capacity granulation unit available
in the industry.
• Uniform end product – external seed
generation enables controlled variation ofsize distribution during operation.
• Small footprint.
• Minimal rotating equipment.
• Fast delivery, quick installation, low
shipping costs.
• No sulphur ‘pre-conditioning’ required.
• Continuous operation – no need for routine
shut down.

• No solid waste streams or liquid effluents.
• Low maintenance – horizontal 0° drum
reduces stress.
Premium granular product to SudIc specification
The spherical product meets the shape criteria
and Stress Level I and II friability parameters of
the SUDIC premium product specification.
The completely spherical shape – along with therepeated spraying and cooling of thin layers ofmolten sulphur on the surface of the granules as
they pass through the granulator –accommodates the natural shrinkage of the
product as it completes the transition from melt
to solid, without weakening the product.

Basic principle of drum granulation

Rotating drum
Sulphur nuclei particles
Flights
Sulphur spray

Cooling spray
Sulphur granules

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Reliable and safe downstream
sulphur handling systems
From our small/mid-size capacity Rotoform
pastillation system to the high capacity IPCO
drum granulator, we have the systems to meet
any sulphur granulation requirement, enabling
the production of premium quality productsuitable for subsequent handling. But refineries
need more than this: once the sulphur has been
formed, it has to be conveyed, stored and thenbagged or bulk loaded.
And just as our name has become pre-eminent
in solidification, we are also able to provide
complete bulk material handling systems.
Our capabilities encompass everything fromthe supply of transfer conveyors and bucket
elevators to bulk storage and loading systems.
Sulphur handling also requires the use of
appropriate materials: if it comes into contact
with water it will create sulphuric acid, leading
to serious corrosion of conveyors, buildings,
trucks, trains and ship holds. Our facility designand consultancy services will ensure that this risk
is mitigated and your investment is protected.
We also ensure maximum productivity throughproven equipment and process design,delivering handling systems with operationalreliability in excess of 8 000 hours/year.
Safety & dust generation
One of the most important challenges whenhandling sulphur in a solid form is managing
the risk of dust explosion. Solidification to sudic
premium standard is an essential part of this as
low friability means a significantly lower risk ofdust generation, but equally important is theneed for safety management to be designed
into every stage of downstream handling.

Conveyor belts are protected against thebuild-up of static electricity and dust
suppressants are applied at final transfer
points. Bucket elevators are enclosed in dusttight casings and provided with upward-facing
explosion vents. The buckets themselves will
be antistatic with rubber-coated steel
carrying wires.
In terms of storage, closed silos or hoppers aresupplied with roof venting and equipped withbursting discs. When sulphur pastilles arestacked and reclaimed indoors, metal supports
in the building will be grounded and goodnatural or mechanical ventilation provided.
The same need for safety applies to loading
processes, so the risk of dust formation isminimized at truck, rail and ship-loading
facilities through the use of telescopic chuteswith level sensors.
Complete, integrated engineering solutions
Ever increasing levels of production mean thatrefineries will not only have to process moresulphur but also find safe and efficient ways ofstoring, handling and loading the solidified
material. Our experience across both areasmeans we are in a unique position to be able
to design, construct, install and commission
complete, integrated engineering solutions.

Our capabilities encompass everything fromthe supply of transfer conveyors and bucket
elevators to bulk storage and loading systems.

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From stacking and reclaiming
to bagging and loading
With handling equipment encompassing
everything from conveyor components torectangular /circular stackers and reclaimers, anda comprehensive range of bagging and loading
solutions, we can deliver downstream solid
sulphur handling plants for any requirement.
Covered / open stockpiles
Our custom-built stacking and reclaiming
systems can be used to deliver stockpile
solutions for any capacity or location. These canbe circular or rectangular, indoor or outdoor,
and the high angle of repose of sulphur pastilles(typically 28°) allows the development of highcapacity stockpile solutions.
The use of luffable stacker booms keeps theboom tip as close to the stockpile as possible,
minimising the drop height to reduce the riskof damaging the formed sulphur:• Open or closed storage.
• Portal and semi-portal reclaimers.
• Simple hoppers and belt feeders,front end loaders.

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Open silos
We can also design, manufacture and installstorage silos with top loading / bottom
reclamation equipment:• Closed silos for small to medium
capacity storage.
• Large capacity, concrete storage silos.
• Gentle handling of formed sulphur.
• Designed to highest safety standards.
Conveying
We can provide a full range of conveying andelevator solutions to suit all requirements andenvironments. We can also design systems
with the minimum number of transfer points forclean and efficient operation:• Wide belts to enable reduced velocity.
• Static-conductive conveyor belting.
• Dust-tight conveyor design with transfer skirts
and enclosed transfer points.

With a range of handling equipment andcomprehensive bagging and loading solutions,
we deliver downstream solid sulphur handlingplant for any requirement.

ChutesAll loading systems are equipped with chutes
designed to deposit materials with the minimum
amount of dust generation:• Cascade chutes slow down material drop tominimize dust.
• Level sensors reduce drop distance.
• Dust skirts beneath chutes contain any
remaining dust.
Truck loading
Our bulk materials handling team can design,
manufacture and install truck-loading equipment
to meet any requirement:• Telescopic loaders with level sensors
to reduce drop distance.
• Continuous truck loading.
• Single or multiple loading bays.

Ship loading
We offer four types of systems for ship-loading:stationary, linear travelling, radial quadrant andmobile units.
• Telescopic loaders with level sensors.
• Telescoping, luffing, slewing and shuttling.
• Remote control units.
Bagging
We can supply complete bagging systems
suitable for 50 kg bags or big bags
(500 / 1 000 kg):
• Pre-weighers.
• Open mouth bagging, automatic closing.
• Metal detection.

Rail loading
Rail loading systems can be designed to meet
any requirement with solutions for continuous or
stationary loading:• Telescopic loaders with level sensors.
• Loading up to four rail cars at once.
• Continuous loading via pivotal arm.

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Global after-sales support toprotect your investment
As a company operating in every corner of theworld, from the frozen Canadian north to thedeserts of the Gulf states, from the tropical heatof South America and the Indian subcontinent
to the remotest regions of Asia, we are able toprovide customer support on a global basis.
We have invested heavily in an infrastructurethat enables us to deliver service when andwhere it’s needed, through local technicians
backed up by a dedicated engineering team.
We can also provide in-depth skills training foryour in-house teams, ensuring optimum systemproductivity, a high quality end product andmaximum return on investment.
And a network of regional offices andproduction centers means that IPCO
expertise, advice and spare parts are nevermore than a phone call away.
We can work with your people to support
planned maintenance programmes that will
minimize the risk of costly downtime. We canwork with them to develop and implement bestpractices that ensure maximum plant efficiency
and full compliance with all relevant health& safety and environmental requirements.

In short we will provide a complete packageof support services to ensure that your IPCO
systems achieve maximum productivity at
all times.
When you choose IPCO as your supplier, you’re
not only investing in precision engineered,sulphur processing and handling solutions.
You’re also entering into what we hope will
become a long-term partnership! One that
we will support through many decades’
experience in meeting the needs of theworld’s oil and gas refineries:• Global capability.
• Trained, equipped and qualified engineers.
• Full system optimisation.
• Fast, cost effective commissioning.
• Transfer of know-how to in-house personnel.
• Tested under production conditions.
• Full technical service.
• Life-cycle concepts including maintenancecontracts or even planned operations.

As a company operating in every cornerof the world, we are able to provide
customer support on a truly global basis.

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