Often the revamping of existing sulfur recovery systems requires replacing some of the equipment. At the same time, economic considerations can dictate re-using as much of the existing system as is possible and practical. This paper examines the process used to connect a new thermal reactor to an existing waste heat exchanger. Included are some of the design considerations necessary to ensure a safe and reliable final arrangement. The complexity of the configuration — including the stresses developed in the existing equipment and the interconnection — required the use of Finite Element (FE) to assess the final design.

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