Claus Tail Gas Treating Units: Switching to Low Temperature Tail Gas Operation

Eric Roisin

Agenda

Tail Gas Treatment by Hydrogenation Industrial Operation Feedback - BP

Germany
Catalyst Drop-in in Existing unit New Unit

Conclusion
2

Three Drivers for Maximum Sulfur Recovery

Feed the right amount of air Load the most appropriate Claus catalysts Implement a Tail Gas Treatment solution

> 99.8%

Hydrogenation Based TGTU

air 270-300C to incinerator Recycle to Claus furnace

fuel gas
TG 103/133 Quench column

Claus Tail Gas steam

water

Reactor Section

to SWS

Amine Section
4

Regenerator

Absorber

LT Catalyst Porfolio

Market leading catalysts

TG 107 High density High activity

TG 136

Low density Low pressure drop

A Revolution for Existing / New Units

air 210-240C to incinerator Recycle to Claus furnace

fuel gas
TG 107/136 Quench column

Claus Tail Gas steam

water

Reactor Section

to SWS

Amine Section
6

Regenerator

Absorber

Steam reheater
air 210-240C

A Revolution for Existing / New Units

Operation at low temperature 40 % savings on energy Lower CO2 emissions Higher Temp. safety margin From direct to indirect reheater Less risk of misoperations (soot or excess air) Longer catalyst lifetime Equipment downsized 10% Capex reduction 10-15% OpEx reduction 20%
Ref.: Marco van Son, Sept. 15th 2005 Brimstone, Vail (CO)

fuel gas
TG 107/136

Claus Tail Gas steam

water

Reactor Section

Agenda

Tail Gas Treatment by Hydrogenation Industrial Operation Feedback - BP

Germany
Catalyst Drop-in in Existing unit New Unit

Conclusion
8

Industrial Operation Feedback

Catalyst Drop-in at BP Germany

Operating history from BP Gelsenkirchen
Study undertaken by Jacobs-Comprimo to revamp SRU & TGTU in 2003 New SRU/TGTU train required Pilot studies demonstrated high performances of TG 107 BP decided to install a load of TG 107 in train # 4 TGTU Start up June 2004

Existing refinery unit with a direct fired reheater

10

SRU 4 TGTU Performances with Previous Catalyst

11

SRU 4 - Reactor Temperature Profile with Previous Catalyst

Temp. bottom

Temp. in

12

SRU 4 - Reactor Temperature Profile with TG 107

-60C
Temp. bottom

Temp. in

13

SRU 4 TGTU performances with TG 107

14

Outcomes of the First Trial

One year of testing, various temperature, conditions, H2S/SO2 ratios, burning stoichiometry...

240C kept as maximum temperature, allowing the construction of a unit equipped with steam reheater
Catalyst load still in operation after 9 years
15

New Unit in BP Germany

2006-2007 Erection of SRU 5 plant New unit with indirect 40 barg steam reheater

16

SRU 5 - Reactor Temperature Profile with TG 107

Temp. bottom

Temp. in

17

SRU 5 TGTU Performances with TG 107

18

New Unit in BP Germany

SRU 5 unit is still delivering Inlet temperature still @220C today TG 107 benefits confirmed by 6 years of operation
More than 20 years of operating experience with low temperature catalysts M. Schmidt, Sulphur, Berlin, 28-31/10/2012 130,000 GJ saved on fuel gas 1,000 tpy CO2 reduction

TG 107s performances are widely recognized

19

TG 107 &TG 136 Always Benefit (1/2)

For existing units: Operating cost savings Lower CO2 emissions Case study for a 320 t/day plant in Canada (2009)
Fuel gas savings: 440 ton/year CO2 emission reduction: 1210 ton/year Cost savings (excluding CO2 credits):

410 000 $ per year

Improved operation reliability
20

TG 107 &TG 136 Always Benefit (2/2)

Additional benefit for new units: Simplified design 10-15% savings on installation cost Minimized risk of misoperation
Axens catalyst development allowed this revolution in the design of Claus TGTUs

21

Switching to LT Operation with Axens

Proven Performances at 210-240C TG 107:
9 years of continuous operation for the first reference

TG 136:
Industrial feedback from Imperial Sarnia published in LRGCC 2012

New LT design widely accepted by every TGTU stakeholder

22

Driving Sulfur Recovery Towards Excellence

Axens pioneered every catalyst evolution
Alumina: CR-3S TiO2: CRS 31 and now CRS 31 TL BTX management: CSM 31 LT hydrogenation: TG 107 and TG 136

Sulfur recovery catalyst world leader

23

Claus Tail Gas Treating Units Switching to Low Temperature Tail Gas Operation
Eric Roisin