WEIXIAN sulphonation/sulfonation plants represent the highest level in the industry. So far, we can provide from a one-tube pilot plant to 10t/h mass production plant. Among 200+ projects we have done, the majority of them were turnkey basis, including but not limited to:    · LABSA (sulfonic acid) production line · SLES production line · SLS production line · AOS production line · HABSA production line · MES production line · SLS/AOS/sulfonic acid sodium salt drying units · Other anionic surfactant production lines   By adopting state-of-the-art designs and processes, all the performance aspects including plant reliability, finished product qualities, and unit raw material/power consumption are superior to that of competitive plants.

WEIXIAN sulfonator adopts multi-tube falling film reactor. Capacity range is from 1-tube to 240-tube (10t/h). Since 1995, WEIXIAN has supplied hundreds of sulfonators, including 20+ with the capacity over 5t/h. WEIXIAN has successfully applied two world largest 7.5t/h sulfonators in by 2023.   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   Regarding the reaction tubes, high precision cold rolling and annealing are applied, and processed under a 1040℃ 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 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 each holes by inspection mandrel 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 (15℃), 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%

Unlike the former rotating type with an agitator, ours is a static type, which is featured in more homogeneous aging effect with no back-mixing. By adopting a special inner structure, each material molecular in the static aging vessel will have equal residence time (staying time). On the contrary, the residence time of each molecular in a rotating aging vessel is uneven, which shows a normal distribution. Our aging time is adjustable from 0-60 minutes by controlling the liquid level in the vessel. Normally, the aging time is set to be 30 minutes; when a higher active matter percentage is required, for example, 97.5% - 98% LABSA, the aging time can be set to 45 - 60 minutes. Besides the performance, power consumption and maintenance requirements are reduced due to the nature of static equipment.

Stripping tower 79T1 is static equipment, without motor or rotating parts. Compared to outdated technology, our stripping tower doesn’t need maintenance. WEIXIAN designs the stripping tower based on the characteristic of sulfonated/sulphonated products. In the stripping tower, degassing, water removal, dioxane stripping, and cooling can be achieved in the same equipment, which can save power consumption, and ensure stable running and product quality.

The high-shear neutralization reactor is composed of multiple high-speed dispersing shearing discs, and the mechanical seals and bearings are all customized for high-speed mixing/shearing purpose. Stable operation at 960 rpm.   The neutralization reactor has the advantages of efficient and uniform mixing, flexible operation, stable system pressure, and low failure rate.

It adopts the cathode plate hollow-out design to avoid “black acid” accumulation. Cathode SS wires are replaced by SS tubes, in order to eliminate the risk of breaking.   The working voltage is 40,000 V, featured in excellent SO3 and organic acid mists removal performance.

The conversion tower adopts vertical SS304 stainless steel packed structure with a temperature resistance of 700°C.   It is featured in stable conversion rate, flexible operation and temperature control, and maintenance-free. Four-layer packed tower, each layer is filled with V₂O₅ catalyst, which is a combination of low-temperature and medium-temperature catalysts, which can not only maintain the advantage of low light-off temperature but also ensure a conversion rate greater than 98%. This feature greatly improves the start-up preheating efficiency and shortens the preheating time.   There are corresponding thermometer interfaces on the top and bottom of each bed to precisely control the temperature and ensure the conversion efficiency. Each bed has a manhole for on-site catalyst loading.

The heat-pipe exchanger has high heat transmission efficiency. The equipment also has a compact structure, and small thermal side flow resistance. Its structure is safe, reliable, and better than the heat exchanger of other structures, and the damage of a single (or few) heat pipe will neither affect the overall performance of the equipment nor affect the plant production. The waterway is outside the flue, so it requires no shut down for replacement and overhaul. Design life is 10 years plus. This equipment is used in combination with the start-up pre-heater, which produces steam before cold start-up, external steam supply is no needed.   The recovery rate is 100kg sulfur burning generates 250kg steam. The first/second stage recovery of exhaust gas generates steam, and the third stage recovery produces hot water with efficiency of 36.5%, 44.2% and 67.3% respectively.

Our Control System adopts Siemens, ABB, Supcon, Hollysys, Honeywell or equivalent brands. We adopt on-site instruments from international brands, such as massflow meter from Emerson; dewing point meter from Michelle; pH meter from Mettler Toledo; transimitter from YOKOGAWA etc.,Major electrical components are all internationally famous brands such as SIEMENS, SCHNEIDER, or ABB.   The whole plant will be fully automatically controlled at a high level. We have in-house engineers for the programming and configuration. Remote operation parameter adjusting can be realized, if get the permission from the owner.