Sulfur Pastillator AS15000
The AS15000 turns molten sulphur into uniform solid pastilles on a moving steel belt, so the product leaves the plant as a free-flowing bagged or silo-stored solid instead of as a block or a dust-generating crushed grade. It is built from three main assemblies: a dropformer, a cooler and a control system. Liquid produc...
What This Machine Does
The AS15000 turns molten sulphur into uniform solid pastilles on a moving steel belt, so the product leaves the plant as a free-flowing bagged or silo-stored solid instead of as a block or a dust-generating crushed grade. It is built from three main assemblies: a dropformer, a cooler and a control system. Liquid product held in a vessel or agitator is pumped through a filter to the sharp nozzle granulator, which deposits it as regular droplets across the width of the steel belt inside the cooler. Cooling happens in stages, beginning with a pre-cooling stage that takes the material from high-temperature liquid down to its melting point, after which it solidifies and is cooled further before discharge. Solidified pastilles are lifted off the belt by a discharge knife and pass through chutes to bagging, or onto a conveyor to a silo for automatic weighing and packing. Because the droplet is formed and solidified rather than crushed, the plant generates far less dust, which is the main working-environment complaint in sulphur handling.
Why Buyers Choose This Machine
- Forms pastilles by controlled droplet deposition so the product is not crushed and does not generate dust
- Reduces dust and improves the operating environment around sulphur handling
- Staged cooling from high-temperature liquid through the melting point gives consistent solidification
- Discharge knife lifts the finished pastilles off the belt cleanly with no manual handling
- Product routes directly to bagging chutes or by conveyor to a silo for automatic weighing and packing
- Filter ahead of the granulator keeps nozzle blockage from interrupting the run
- Uniform pastille size makes the product free flowing in downstream handling and storage
Where Sulfur Pastillator AS15000 Earns Its Place
Problems It Solves
- Crushed or block sulphur generates dust that is a health and housekeeping problem across the whole plant
- Irregular lump product does not flow and bridges in silos hoppers and bagging equipment
- Manual breaking and handling of cast blocks is labour intensive and slow
- Unfiltered feed blocks the forming nozzles and interrupts a continuous run
- Uncontrolled cooling gives inconsistent solidification and pastilles that break down in transport
- Without a conveyor and silo route, bagging becomes a manual bottleneck at the end of the line
Who It Is For
- Sulphur recovery plants in refineries and gas processing facilities
- Chemical producers handling molten product that must be solidified for sale
- Fertiliser and agrochemical manufacturers packing sulphur products
- Engineering contractors specifying solidification and packing lines
- Plant operators replacing a dust-generating crushing route
Application Scenarios
- Solidifying molten sulphur from a refinery or gas processing sulphur recovery unit
- Producing bagged sulphur pastilles for agricultural and chemical distribution
- Feeding a silo and automatic weighing and packing line with a free-flowing solid product
- Replacing block casting or crushing with a direct-forming process to cut dust
- Forming other hydrophilic melt products that need condensation and solidification
Technical Detail
Technical Features
- Sharp nozzle granulation with dropformer assembly
- Steel belt cooler for staged solidification
- Dedicated control system for the forming and cooling process
- Feed pump and filter ahead of the granulator
- Pre-cooling stage taking liquid from high temperature down to melting point
- Discharge knife for removing solidified pastilles from the belt
- Chute route to bagging or conveyor route to silo
- Automatic weighing and packing integration on the silo route
Specifications
| Machine type | Steel belt sulphur melt pastillator (sharp nozzle granulation) |
|---|---|
| Models | AS15000 |
| Major components | Dropformer, cooler, control system |
| Feed route | Vessel or agitator, pump, filter, sharp nozzle granulator |
| Solidification | On steel belt inside the cooler, staged from pre-cooling through the melting point |
| Product discharge | Discharge knife to chutes for bagging or conveyor to silo |
| Downstream integration | Automatic weighing and packing from silo |
| Typical product | Sulphur pastilles |
| Steel belt width | Configured within the 1000 mm to 2100 mm range |
Figures above are taken from the product information we hold. Send us your application and we will confirm the exact specification for the model quoted.
How It Is Built and What Can Be Changed
Operations Performed
- Drop forming
- Pastillation
- Pre-cooling
- Solidification
- Discharge and conveying
Materials Handled
- Molten sulphur
- Steel belt
Quality Control
- Dropformer nozzle spacing and droplet formation checked across the belt width during commissioning
- Steel belt tracking and drive alignment verified before the line is released
- Cooling stage temperature profile checked from feed temperature through the melting point
- Control system interlocks and sequence tested through a full run
- Pastille size and solidification checked on product from the discharge knife during commissioning
Customisation Options
- Steel belt width selected within the 1000 mm to 2100 mm range for your required throughput
- Discharge routed to bagging chutes or to a silo conveyor depending on your packing arrangement
- Feed pump and filter specified for your product viscosity and feed temperature
- Control system configured to your plant control and instrumentation standard
- Supply voltage frequency and plant interface specified for your site
How It Compares With the Alternatives
| Block casting and crushing | Crushing produces fines and dust and an irregular product; drop forming produces a uniform pastille directly, which is the point of the dust reduction |
|---|---|
| XAIMC TDG series sulphur drum granulator | The drum granulator builds granules on a material curtain inside a rotating cylinder; the pastillator forms a droplet on a steel belt, which gives a more uniform pastille shape |
| Prilling towers | A prilling tower needs considerable height and an air handling system; the steel belt route is a floor-level installation |
| Manual bagging from stockpile | Direct conveying to a silo with automatic weighing and packing removes the manual handling step at the end of the line |
Running the Machine
Step 1
Bring the feed product to the required temperature in the vessel or agitator
Step 2
Start the feed pump and confirm the filter is clear before the product reaches the granulator
Step 3
Start the steel belt and cooling circuit and let the cooler reach its working temperature profile
Step 4
Start drop forming and check droplet size and spacing across the belt width
Step 5
Confirm pastilles are fully solidified before they reach the discharge knife
Step 6
Route the discharged product to bagging chutes or to the silo conveyor for weighing and packing
Step 7
Shut down by stopping the feed first and letting the belt clear before stopping the cooler
Other Machines in Chemical Machinery
Related Applications and Guides
Chemical and Sulphur Processing
Refineries and chemical plants that handle low melting point materials need them in a form that can be transported packaged and dosed. XAIMC supplies
Questions About Sulfur Pastillator AS15000
What throughput can the AS15000 achieve?
Throughput depends on the steel belt width and the product. Send us your required tonnes per hour, feed temperature and product and we will size the belt and quote the configuration.
What are the main components?
A dropformer, a cooler and a control system, plus the feed pump and filter ahead of the granulator.
Can it handle products other than sulphur?
The process suits melted materials that are hydrophilic and require condensation and solidification. Send us your product data including melting point and viscosity and we will confirm.
How is the finished product handled?
A discharge knife lifts the pastilles off the belt. From there they pass via chutes to bagging, or by conveyor to a silo for automatic weighing and packing.
How much does it reduce dust?
Dust reduction comes from forming the pastille directly rather than crushing solidified product. Tell us your current process and we will explain what changes on your site.
What do you need from us to quote?
Product, required throughput, feed temperature and viscosity, your packing arrangement, and your site supply voltage and frequency.
What are your trade and payment terms?
FOB CFR and CIF are available. Payment is 30 percent by T/T on order and 70 percent before shipment, or an irrevocable L/C at sight.
Request a Quote on the Sulfur Pastillator AS15000
Send us the work you need it to do, the voltage on your site and the port you ship to. We will come back with the model, the tooling and the lead time.