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SULPHUR RECOVERY
WHY ?
1) Corrosion
RSR + 2H2
(Sulphide)
atmosphere)
ACID RAIN
Parameter Sulphur ppm max. Benzene Vol % max. Aromatics Vol % max. Olefins Vol % max. RON
BS-2000
1000/500
BS-II 500 3
BS-III 150 1 42
BS-IV 50 1 35 21 91/95
3/5 88/93
21
88/93 91/95
SRU BLOCK
A typical Sulpher Recovery Unit complex consists of process units like:
Amine regeneration Unit Sour Water Stripping Unit Sulpher Recovery Unit Tail Gas Treating Unit
Incineration
Rich Amine Sour Gas Sour Water Sour water stripping(SWS) Sweet Water Sulphur Storage
104 OC RICH SOLVENT FLASH DRUM 40 OC CW 59 OC LEAN SOLVENT TRIM COOLER 50 OC AMINE REGENERATOR COLUMN
59
OC
AMINE FILTER
127 OC
126 OC
104 OC RICH SOLVENT FLASH DRUM 40 OC CW 59 OC LEAN SOLVENT TRIM COOLER 50 OC AMINE REGENERATOR COLUMN
59
OC
AMINE FILTER
127 OC
126 OC
104 OC RICH SOLVENT FLASH DRUM 40 OC CW 59 OC LEAN SOLVENT TRIM COOLER 50 OC AMINE REGENERATOR COLUMN
59
OC
AMINE FILTER
127 OC
126 OC
104 OC RICH SOLVENT FLASH DRUM 40 OC CW 59 OC LEAN SOLVENT TRIM COOLER 50 OC AMINE REGENERATOR COLUMN
59
OC
AMINE FILTER
127 OC
126 OC
104 OC RICH SOLVENT FLASH DRUM 40 OC CW 59 OC LEAN SOLVENT TRIM COOLER 50 OC AMINE REGENERATOR COLUMN
59
OC
AMINE FILTER
127 OC
126 OC
90 OC SOUR GAS
TO FLARE
TO SRU
92.4 OC
LP CONDENSATE LP CONDENSATE
90 OC SOUR GAS
TO FLARE
TO SRU
92.4 OC
LP CONDENSATE LP CONDENSATE
90 OC SOUR GAS
TO FLARE
TO SRU
92.4 OC
LP CONDENSATE LP CONDENSATE
Hydrogen
Water Hydrogen Sulphide
0.04-.06
7.5- 8.5 86-92
Hydrocarbons
0.01- .03
Water
Hydrogen Sulphide Ammonia
40-43
15-17 38-42
Hydrocarbons
1-2
Modified-Claus Process
Acid Gas Sour Gas Free flame reactor HP steam O2
925-12500C (1700-23000F)
Wasteheat exchanger
Catalytic converter
170-3500C (340-6600F)
LP steam
Sulphur condenser
130-2000C (270-3900F)
Reaction furnace
Function
Burn 1/3 of the H2S H2S + 3/2 O2 SO2 + H2O + Heat Produce sulphur directly 2H2S + SO2 2H2S + 3/n Sn +Heat Destroy feed contaminants 2NH3 +3/2O2 3H2O +N2
Zone 1
Zone 2
Air
H2S + 3/2 O2 2H2S + SO2 2NH3 +3/2O2 SO2 + H2O + Heat 2H2S + 3/n Sn +Heat 3H2O +N2
Catalytic Reactions
2H2S + SO2
COS + H2O CS2 + 2H2O
3/x Sx + 2H2O
H2S + CO2 2 H2S + CO2
Sulphur Condenser
Operating Limits:
above sulphur melting / freezing point
1190C (2460F)
SuperClaus Section
The remaining gases are then passed through three stage of in-line-reheaters, catalytic converters, and condensers with each stage recovering 61%, 22% and 9% of the total sulphur respectively.
RHTR1 RHTR 2 RHTR 3 TAIL GAS ANALYZER
P HX-1 HX-2 HX-3
CV 1
T-1
CV 2
T-2
CV 3
T-3
HX-4 HX-5
HX-6
CNDS 2
CNDS 3 SULPHUR
CNDS 4 SULPHUR
SULPHUR
Acid Gas
Sour Gas
BFW
BFW
232 OC
IST CONVERTER
AIR BLOWER
HP STEAM
2ND REHEATER LP STEAM 173 OC
2ND CONDENSER
BFW
FINAL CONDENSER
BFW
SULPHUR YARD
Tail Gas Treating Unit essential to minimize sulphur emissions Sulphur Recovery of 99.9 %.
This unit consists of 3 sections Hydrogenation Section Amine absorption and regeneration Section
T-3
TAIL GAS
H2 TO INCINERATION
Co - Mo Hydrogenation Reactor
T-1
Incinerator Section
TO REACTION FURNACE
T-2
The tail gas from the Claus units is heated by superheated HP steam and mixed with hydrogen.
Then passed over a catalyst bed in order to convert any SO2 present in the tail gas back to H2S.
This gas is then cooled and passed through an Amine absorber, where H2S is absorbed in MDEA. The rich MDEA thus formed is regenerated in the amine regeneration system inbuilt within the TGTU and returned to the absorber.
The acid gas released is sent back to SRU for Sulphur Recovery.
The Tail gas then goes to the Incinerator, where it is burnt off and the flue gas goes to the stack. The main reaction in the hydrogenation reaction is
SO2 + 3H2
H2S + 2H2O
Thank You