Module No.

12 : Gas processing

Unit No. 5 - Sulphur recovery unit

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UNITS IN THIS COURSE

UNIT 1 UNIT 2 UNIT 3 UNIT 4 UNIT 5

GAS COMPRESSION SYSTEMS AMINE GAS SWEETENING UNIT NATURAL GAS LIQUIDS (NGL) RECOVERY UNIT GAS FRACTIONATION PLANT SULPHUR RECOVERY UNIT

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Module No. 12 : Gas processing

Unit No. 5 - Sulphur recovery unit

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TABLE OF CONTENTS
Para 5.0 5.1 5.2 5.3 COURSE OBJECTIVE INTRODUCTION FUNCTIONS OF THE SULPHUR RECOVERY UNIT EQUIPMENT BASIC FUNCTIONS OF THE SULPHUR PLANT 5.3.1 5.4 Basic Description of the Reaction that Produces Sulphur Page 3 4 5 7 8 9 9 10 11 12 12 12 12 13 13 13 Sulphur 13

DESCRIPTION OF THE FLOW OF GAS THROUGH THE SULPHUR UNIT 5.4.1 5.4.2 5.4.3 5.4.4 5.4.5 5.4.6 5.4.7 5.4.8 5.4.9 5.4.10 5.4.11 Storage Pit Acid Gas Feed System Reaction Furnace and Waste Heat Boiler No 1 Condenser No 1 Reheater and No 1 Converter No 2 Condenser No 2 Reheater and No 2 Converter No 3 Condenser No 3 Reheater and No 3 Converter No 4 Condenser Incinerator

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Module No. 12 : Gas processing

Unit No. 5 - Sulphur recovery unit

5.0

OBJECTIVE

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On completion of this unit the trainee will be able to: Describe and identify the most important pieces of equipment used in a sulphur recovery unit. Describe the functions of each piece of equipment used in the sulphur recovery process.

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Module No. 12 : Gas processing

Unit No. 5 - Sulphur recovery unit

5.1

INTRODUCTION

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The process used in the sulphur recovery unit is called the "Claus" process. In this process both catalytic and non-catalytic methods are used to combine hydrogen sulphide (H2S) with sulphur dioxide to produce sulphur. Depending on the percentage of H2S in the feed gas, a portion of the feed is burned in the reaction furnace with a carefully controlled .amount of air. The rest of the feed flows directly to the first catalytic converter. This type of split flow makes the conversion to sulphur more efficient, (up to 98%). The high and stable temperatures produced by the acid gas burner ensure maximum conversion takes place in the thermal section. Chemically, when H2S is burned with air it oxidises into sulphur dioxide. If the burning is done using a controlled amount of air, only a portion of H 2S is oxidised producing chemical sulphur, H2S and SO2. With the help of a catalyst it is possible to combine the H 2S and SO2. to produce sulphur and water. In this process H2S is burned under controlled conditions. These conditions produce just the right amount of sulphur dioxide required to catalytically combine with the unburnt H2S Approximately 33 % of the H2S in the feed oxidises to S02. This gives a ratio of H2S to SO2 throughout the plant of 2:1. This is the ideal ratio for producing sulphur. The catalytic conversion is done in three converters. Unconverted H 2S and SO2 from the reaction furnace is reheated, mixed with hot H 2S from the bypass line and fed to No 1 converter.

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Module No. 12 : Gas processing

Unit No. 5 - Sulphur recovery unit

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5.2

FUNCTIONS OF THE SULPHUR RECOVERY UNIT EQUIPMENT

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Figure 5-1 Gas Flow through Sulphur Recovery Unit Acid Gas Knockout Drum The acid gas knockout drum is used to separate the liquids (sour. water) from the acid gases. The sour water is pumped to the sour water unit.

Preheater High pressure steam is used in the preheater to increase the temperature of the acid gases. Increasing the temperature of the acid gases will give good combustion in the reaction furnace.

Reaction Furnace In the reaction furnace 2/3 rds (66 %) of the acid gas stream is combined with a controlled amount of air. This is to ensure combustion of 1/3rd of the hydrogen sulphide (H2S) to sulphur dioxide (SO2). Some of the hydrogen sulphide (H 2S) and sulphur dioxide SO 2 are also combined to produce sulphur vapours and water.

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Module No. 12 : Gas processing

Unit No. 5 - Sulphur recovery unit

Waste Heat Boiler

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The waste heat boiler removes the heat energy that is produced by the combustion of H2S Boiler feed water is used in the waste heat boiler for cooling the hot gases. The waste heat boiler uses this heat energy from the combustion of H2S to convert the boiler feed water to high pressure steam for use in the plant.

No 1 Condenser Boiler feed water is used in the condenser to condense (turn to liquid) all of the sulphur vapours. The condenser uses the heat energy from the gases to convert the boiler feed water to low pressure steam.

No 1 Reheater High pressure steam is used in the heat exchanger to increase the temperature of the unconverted acid gases. This ensures a good chemical conversion in the converter.

No 1 Converter The converter is filled with an activated alumina type catalyst. The catalyst increases the speed of the reaction between the hydrogen sulphide (H 2S) and sulphur dioxide (SO2). This chemical reaction produces sulphur vapour and water vapour. This chemical reaction is called an exothermic reaction because it produces heat energy.

No 2 Condenser Boiler feed water is used in the condenser to condense (turn to liquid) all of the sulphur vapours. The condenser uses the heat energy from the gases to convert the boiler feed water to low pressure steam.

No 2 and No 3 Reheater High pressure steam is used in the heat exchanger to increase the temperature of the unconverted gases. This ensures a maximum conversion in the downstream converters.

No 2 and No 3 Converters The converters are filled with an activated alumina type catalyst. The catalyst increases the speed of the reaction between the hydrogen sulphide (H 2S) and sulphur dioxide (SO2). This chemical reaction produces sulphur vapour and water vapour. It is an exothermic reaction.

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Unit No. 5 - Sulphur recovery unit

No 3 Condenser

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Boiler feed water is used in the condenser to condense all the sulphur vapours produced in No 2 converter to liquid sulphur. The condenser uses the heat energy from the gases to convert the boiler feed water to low pressure steam.

No 4 Condenser Boiler feed water is used in the condenser to condense the final sulphur vapours produced in No 3 converter to liquid sulphur. The condenser uses the heat energy from the gases to increase the temperature of the boiler feed water before it flows to the waste heat boiler.

Incinerator Any unconverted gas from No 4 converter flows to the incinerator. The incinerator burns all the waste gases at 600'C and changes them to inert products. They are oxidised to SO 2 before they are discharged to the atmosphere via the incinerator stack.

5.3

BASIC FUNCTIONS OF THE SULPHUR PLANT To take the H2S and convert (change) it to sulphur for sales. To burn all other waste gases to reduce pollution and to protect the environment.

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Unit No. 5 - Sulphur recovery unit

HOW HYDROGEN SULPHIDE (H2S) IS CONVERTED TO SULPHUR

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The hydrogen sulphide (H2S) is combined with sulphur dioxide (SO 2) to produce sulphur and water in a catalytic reaction. The sulphur which is produced is then condensed and removed in liquid form. 5.3.1 Basic Description of the Reaction that Produces Sulphur 2/3 rds (66 %) of the hydrogen sulphide (H2S) is combined with a controlled amount of air and burned in a reaction furnace. 50 % of the hydrogen sulphide (H2S) gas in the furnace oxidises and becomes sulphur dioxide (SO2). The remaining hydrogen sulphide (H2S) is combined with the sulphur dioxide (SO2) with the help of a catalyst to produce sulphur and water.

The chemical reactions which happen are: The H2S gas burns to produce SO 2 If the H2S and SO2 are in a ratio of 2:1, they will combine to produce sulphur.

THE SULPHUR PRODUCING REACTION HAPPENS IN TWO WAYS Automatically (non-catalytic) Due to the high temperature in the reaction furnace some H 2S + SO2 react to form sulphur + water. Catalytically (with the help of a catalyst) In the converter beds the activated alumina catalyst causes the reaction -to take place at a lower temperature. THE SULPHUR PLANT PRODUCES ONE MAIN BY-PRODUCT A large amount of heat energy. This is because the chemical processes a exothermic. re

This heat energy is used to produce steam at different pressures for use throughout the plant site. Some examples are: To preheat boiler feed water To preheat the acid gases To drive steam turbines.

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Module No. 12 : Gas processing

5.4

Unit No. 5 - Sulphur recovery unit

DESCRIPTION OF THE FLOW OF GAS THROUGH THE SULPHUR UNIT Page 19/13

5.4.1

Acid Gas Feed System

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Figure 5-2 Acid Gas Knockout Drum The acid gas flows from the gas sweetening unit to the acid gas knockout drum. In the knockout drum any liquids that are in the gas are removed. Most of these liquids are sour water. The sour water pumped to the sour water unit. Is pumped to the sour water unit. The gas leaves the top of the knockout drum and flows to the preheater. The gas is heated in the pre-heater by high pressure steam. The flow of gas is then split. Two thirds of the gas (66%) flows to the reaction furnace and the rest of the gas flows to the first converter.

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Module No. 12 : Gas processing

Unit No. 5 - Sulphur recovery unit

5.4.2

Reaction Furnace and Waste Heat Boiler

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Figure 5-3 Reaction Furnace / Waste Heat Boiler Approximately 66 % of the acid gas feed to the sulphur unit flows to the reaction furnace (depending on the acid gas strength). A carefully measured amount of air flows to the reaction furnace. The amount of air depends on the flow of feed to the unit and on the % of H2S that is in the feed. The amount of air flow is controlled automatically so that it burns approx. 1/3 of the H 2S. The normal operating temperature of the reaction furnace is approximately 1200 C. The heat in the reaction furnace is used to make high pressure (HP) saturated steam in the waste heat boiler. The HP steam is made from the boiler feed water that is fed to the waste heat boiler. The steam is separated in the steam drum. The steam leaves the top of the steam drum and flows to the HP saturated steam main.

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Module No. 12 : Gas processing

Unit No. 5 - Sulphur recovery unit

5.4.3

No 1 Condenser

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Exhaust gases from the waste heat boiler flow to the first condenser (No 1 condenser). In the first condenser the exhaust gases from the waste heat boiler are used to make low pressure steam (LP). The LP steam is made from the boiler feed water that is fed to the condenser. This process reduces the temperature of the exhaust gases. (See figure 5-1). Any sulphur gases will be condensed to liquid sulphur. The liquid sulphur flows to a "sulphur seal" which allows liquid sulphur to drain away. However, the "sulphur seal" maintains a gas seal on the liquid in the sulphur seal pot. This seal prevents H 2S being released to the atmosphere. (See Figure 5-4).

Figure 5-4 Liquid Sulphur Seal Pot

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Unit No. 5 - Sulphur recovery unit

5.4.4

No 1 Reheater and No 1 Converter

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See Figure 5-1. The unconverted H2S and SO 2, along with CO 2 and other gases, leave No. 1 condenser and flow to the No. 1 reheater. Here, the temperature of the gases is increased. After this they combine with the other 33 % of hot gases that by-passed the reaction furnace. (This flow doesn't go through the reaction furnace because if all the gas went through the reaction furnace it would lower the temperature of the reaction furnace). The combined gases flow to No 1 converter and down onto a catalyst bed. The catalyst, (activated alumina type), increases the speed of the reaction between the H2S and SO2. This reaction converts the gases into sulphur gas. This reaction is exothermic. Therefore the gases which leave the converter are hotter than the gases which go in to the converter. (See figure 5-1). 5.4.5 No 2 Condenser Hot gases from No 1 converter flow to No 2 condenser. The heat from these gases is used to make the boiler feed water that flows to the condenser into LP steam. As the hot gases cool they condense to liquid sulphur. This liquid sulphur flows through a liquid sulphur seal pot which is the same as the one at No 1 condenser (see figure 3-4). The combined liquid sulphur flows from condensers 1 & 2 go to the liquid sulphur storage pit. 5.4.6 No 2 Reheater and No 2 Converter The cooled gases from No 2 condenser flow to No 2 reheater. Here, they are reheated by high pressure steam before they flow to No 2 converter. The reaction in No 2 converter is the same as in No 1 converter. Once again H 2S and SO2 combine to make sulphur. This reaction is exothermic so the temperature of the gases is increased again. (See figure 5-1). 5.4.7 No 3 Condenser No 3 condenser is the same as No 2 condenser. Hot gases from No 2 converter flow to No 3 condenser. Boiler feed water also flows into this condenser. The heat from the gases is used to change the boiler feed water into LP steam. This cools the hot gases and they condense to liquid sulphur. This liquid sulphur flows through a liquid sulphur seal pot which is the same as the one at No 1 and No 2 condensers. The liquid sulphur flows to the liquid sulphur storage pit.

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Module No. 12 : Gas processing

Unit No. 5 - Sulphur recovery unit

5.4.8

No 3 Reheater and No 3 Converter

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The cooled gases from No 3 condenser are heated by HP steam in No 3 reheater. No 3 converter is the same as No 1 and No 2 converters and the same reaction takes place. 5.4.9 No 4 Condenser The hot gases from No 3 converter flow to No 4 condenser. The gases are cooled by boiler feed water. The hot gases condense to liquid sulphur. The liquid sulphur combines with the liquid sulphur from No 3 condenser and flows to the liquid sulphur storage pit. It is important to keep the gases leaving No.4 condenser hot enough to prevent H20 vapour from condensing to water. If water comes into contact with sulphur it will form sulphuric acid which will corrode ducting in the incinerator. 5.4.10 Incinerator Any unconverted gas from No 4 condenser flows to the incinerator. In the incinerator any H2S. organic sulphur or sulphur vapour are oxidised to SO 2. The oxidised vapours are then discharged to the atmosphere through the incinerator stack. 5.4.11 Sulphur Storage Pit The liquid storage pit is designed to store at least one day's sulphur production. The contents of the pit are transferred to the liquid sulphur storage tanks as required. In the base of the pit there are heating coils which are heated by LP steam. The heat from the coils keeps the stored sulphur in a liquid state.

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