Overview
In August 2024, Detas Elektronik & Energi A/S chose to work with ETC to supply our 6300 burner control systems for a major sulphur recovery project.
Sulphur recovery processes are critical in industries such as refining and gas treatment, where stringent safety and environmental standards must be met due to the hazardous nature of the materials involved. To meet the strict standards, Detas Elektronik & Energi A/S needed a solution that met these requirements from a partner they could trust. Having used ETC’s products for many years, Carsten Dahl, Director of the company was confident in our well-established safety credentials and approached us to work with them on this project.
The project
As mentioned, the project had to meet strict safety and environmental standards due to the hazardous nature of the materials involved.
Essentially, processes that precede sulphur recovery are what generate the primary ingredient for the final product, producing H₂S gas as a by-product or “off-gas.”
Detas’s client required control systems for two burners that were integral to the sulphur recovery process. The two-furnace application is designed to recover sulphur from the off-gas, making it available for reuse as sulphur itself rather than as a marketable product.
Given the safety-critical environment, the client’s primary concern was ensuring that any equipment installed on-site would not only meet but exceed, international safety standards. Detas recommended our 6300 burner control systems.
The solution
Why ETC’s 6300 system?
Our 6300 burner control system is renowned for its compliance with industry-leading safety approvals, making it an ideal choice for applications where safety cannot be compromised.
For this project, the safety features of the 6300 system, including fail-safes, interlocks and comprehensive diagnostic capabilities, provided the client with the assurance that their operations would be safeguarded against potential risks, particularly in such a volatile environment.
6300 features
The 6300 is aimed at providing integrated control for smaller scale installations of processes within an industrial chain. It is designed as a low cost, single fuel fully integrated burner control with integration of:
- Flame and air pressure monitoring
- Leak detection
- Valve proving
- PID modulation
- Air Fuel Ratio Control
All in a single unit designed to simplify wiring and interconnections and improve reliability.
Reliable, continuous operation
One of the big appeals of the 6300 is the system’s robustness in managing and monitoring burner performance and small footprint. Another crucial factor for using the 6300 for this project was its ability to deliver reliable and continuous operation because the sulphur recovery process requires consistent performance without the risk of unexpected shutdowns.
The installation process
As with many industrial installations, the project was not without its challenges.
One of the primary technical issues encountered involved the screening of cables. Cable screening is vital in complex industrial environments to protect signals from electromagnetic interference (EMI), which can disrupt communication between control systems and connected equipment.
In this particular installation, the complexity of the site and the need to integrate the system with existing infrastructure, and to use existing cabling on site made the proper screening of cables a significant issue to address.
Solving installation challenges
Carsten worked closely with the installation team to ensure that all cables were correctly shielded, following best practices for EMI prevention. This attention to detail was crucial for ensuring that the system would perform optimally in an environment subject to potential electrical interference.
Firmware customisation for continuous operation
Another unique aspect of this installation was the need for a firmware modification to accommodate the specific flame scanner chosen by Carsten and the client.
The flame scanner is an essential component of the burner control system, responsible for detecting and monitoring the flame’s presence. For continuous operation in the sulphur recovery process, the non ETC flame scanner needed to work seamlessly with the 6300 system to ensure the burners remained operational without interruptions.
Tailored solutions
The standard firmware in the 6300 system required adaptation to align with the characteristics of the chosen flame scanner. To address this, our engineering team implemented a bespoke firmware change to enable continuous operation.
Our ability to customise allowed the system to maintain the high level of operational reliability required for the client’s sulphur recovery process, preventing any potential delays or downtime.
The successful completion of the firmware adaptation demonstrated our technical flexibility and willingness to meet specific customer needs. At ETC, our responsiveness to technical challenges reinforces why we have a reputation for providing high-quality and adaptable burner control systems that are capable of meeting the diverse requirements of different industries.
The result
By working with ETC and using our 6300 burner control system in this sulphur recovery application, Detas was able to deliver both safety and performance in a demanding industrial environment.
Despite some installation challenges such as cable screening and the need for firmware modifications, we successfully provided a solution that ensured the client’s burners could operate safely and continuously.
By combining Detas’s and our expertise with the reliability of the 6300 system, the client was able to meet their operational targets without compromising on safety. This project underscores our commitment to working closely with clients, adapting to their specific needs, and providing reliable solutions in complex industrial processes.
Working with ETC
Carsten Dahl, Director of Detas Elektronik & Energi A/S , commented:
“This was a safety-critical project, so having a partner we could trust was essential. We’ve worked with ETC for years so knew we could rely on them to deliver what our client required.
The 6300 system achieved exactly what we needed it to, and ETC were, as always, great to work with throughout the project. From supporting the installation to adapting the firmware for a specific setup, the collaboration made a real difference and helped us deliver a successful outcome for the client.”
For further information on our 6300 burner control system, or to explore our other products and how ETC can provide bespoke solutions, get in touch.