Module No. 12 : Gas processing Unit No.

5 - Sulphur recovery unit

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 UNITS IN THIS COURSE

UNIT 1 GAS COMPRESSION SYSTEMS

UNIT 2 AMINE GAS SWEETENING UNIT

UNIT 3 NATURAL GAS LIQUIDS (NGL) RECOVERY UNIT

UNIT 4 GAS FRACTIONATION PLANT

UNIT 5 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 Page

5.0 COURSE OBJECTIVE 3

5.1 INTRODUCTION 4

5.2 FUNCTIONS OF THE SULPHUR RECOVERY UNIT EQUIPMENT 5

5.3 BASIC FUNCTIONS OF THE SULPHUR PLANT 7

5.3.1 Basic Description of the Reaction that Produces Sulphur 8

5.4 DESCRIPTION OF THE FLOW OF GAS THROUGH THE SULPHUR UNIT 9

5.4.1 Acid Gas Feed System 9

5.4.2 Reaction Furnace and Waste Heat Boiler 10

5.4.3 No 1 Condenser 11

5.4.4 No 1 Reheater and No 1 Converter 12

5.4.5 No 2 Condenser 12

5.4.6 No 2 Reheater and No 2 Converter 12

5.4.7 No 3 Condenser 12

5.4.8 No 3 Reheater and No 3 Converter 13

5.4.9 No 4 Condenser 13

5.4.10 Incinerator 13

5.4.11 Sulphur

Storage Pit 13

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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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 Module No. 12 : Gas processing 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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 Module No. 12 : Gas processing 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 re

exothermic.

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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Unit No. 5 - Sulphur recovery unit
Module No. 12 : Gas processing

5.4 DESCRIPTION OF THE FLOW OF GAS THROUGH THE SULPHUR UNIT

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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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 Module No. 12 : Gas processing 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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