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SULPHUR RECOVERY UNIT

(SRU)
UNIT 22

TABLE OF CONTENT
SECT. 1 - General Description
SECT. 2 - Process Flow Description
SECT. 3 - Main equipments

SECTION 1
GENERAL DESCRIPTION

General:
For Bach Ho Crude operation only
To convert all sulphur compounds present in the acid gas feed from the ARU and
SWS into liquid elemental sulphur
Process:
1/3 of H2S is burned and converted into SO2
2/3 of H2S then reacts with the SO2 formed to produce elemental liquid sulphur
Produced sulphur is then condensed and liquid sulphur cleared of H2S entrained
Treated gas is finally incinerated to convert the remaining pollutants into SO2
SRU located at the south west of the area 4, nest to the LCO HDT, ARU and SWS

Purpose & Duty of the Unit:


To convert all sulphur compounds in the following acid gases into elemental sulphur:
ARU off gas (from unit 20)
H2S rich SWS off gas (from unit 18)
To incinerate the following gases:
NH3 rich off gas from SWS (unit 18)
CNU off gas
Treated gas from the SRU
Design Capacity: 5 tons/day
Liquid Sulphur Recovery Efficiency: 95% min.
Turndown ratio: 50%

Purpose & Duty of the Unit:


Purpose of each section
Section

Purpose

Sulphur Recovery
(Claus) Section

Claus Process, to convert H2S into elemental liquid sulphur.


Section composed of a thermal stage (Thermal Reactor) followed by 3
catalytic steps:
Thermal reactor: burns approx. 1/3 of the H2S contained in the total acid
gases feed with air to convert it into SO2.
Catalytic converters: to make the remaining 2/3 of the H2S react with the
produced SO2 to give elemental sulphur
Condensation of the produced sulphur

Liquid Sulphur Storage Degassing Section To remove the dissolved H2S from the produced
and Degassing Section sulphur.
H2S content is decreased to less than 20 wt. ppm
Incinerator Section

To convert residual H2S contained in the treated gas leaving the Claus
section and the degassing section into SO2.
To burn NH3 rich SWS off gas and CNU off gas.

Sulphur Apron

The sulphur apron is where is collected the solid sulphur from the
degassing pit.
7

AREA 3 - 3D Drawing

SRU

Feed Characteristics: ARU off gas


FEED & CAPACITY FOR PRODUCTION OF DEGASSED LIQUID SULPHUR
Max. Distillate Case

Max. Gasoline Case

Composition

kg/hr

kg-mol/hr

Mol%

kg/hr

kg-mol/hr

Mol%

H2S

102.6

3.01

18.97

119.6

3.51

20.66

NH3

0.0

0.00

0.00

0.0

0.00

0.00

H2O

16.5

0.92

5.77

19.0

1.05

6.21

Cyanide

0.0

0.00

0.00

0.0

0.00

0.00

CO2

511.4

11.62

73.24

531.4

12.08

71.11

N2

1.0

0.04

0.23

1.0

0.04

0.21

CO

0.1

0.004

0.02

0.1

0.00

0.02

H2

0.3

0.15

0.94

0.3

0.15

0.87

C1

1.4

0.09

0.55

1.6

0.10

0.59

C2

1.1

0.04

0.23

1.1

0.04

0.22

C3

0.4

0.01

0.06

0.8

0.02

0.11

Total

634.8

15.87

100.00

674.9

16.98

100.00

Feed Characteristics: ARU off gas


FEED & CAPACITY FOR PRODUCTION OF 5 TONS / DAY OF SULPHUR
Max. Distillate Case

Max. Gasoline Case

Composition

kg/hr

kg-mol/hr

Mol%

kg/hr

kg-mol/hr

Mol%

H2S

129.6

3.802

18.97

164.2

4.818

20.66

NH3

0.0

0.00

0.00

0.0

0.00

0.00

H2O

20.8

1.157

5.77

26.1

1.448

6.21

Cyanide

0.0

0.00

0.00

0.0

0.00

0.00

CO2

645.9

14.676

73.24

729.6

16.578

71.11

N2

1.3

0,045

0.23

1.4

0.049

0.21

CO

0.1

0.005

0.02

0.1

0.005

0.02

H2

0.4

0.188

0.94

0.4

0.202

0.87

C1

1.8

0.110

0.55

2.2

0.137

0.59

C2

1.1

0.04

0.23

1.1

0.04

0.22

C3

1.4

0.046

0.23

1.5

0.050

0.22

Total

801

20.040

100.00

926.6

23.312

100.00

10

Feed Characteristics: H2S Rich SWS off gas


FEED & CAPACITY FOR PRODUCTION OF DEGASSED LIQUID SULPHUR
Max. Distillate Case

Max. Gasoline Case

Composition kg/hr

kg-mol/hr

Mol%

kg/hr

kg-mol/hr

Mol%

H2S

82.0

2.41

88.94

50.3

1.48

88.09

NH3

0.0

0.00

0.00

0.0

0.00

0.00

H2O

4.8

0.27

9.96

3.1

0.17

10.12

Cyanide

0.7

0.03

1.10

0.7

0.03

1.79

CO2

0.0

0.00

0.00

0.0

0.00

0.00

N2

0.0

0.00

0.00

0.0

0.00

0.00

CO

0.0

0.00

0.00

0.0

0.00

0.00

H2

0.0

0.00

0.00

0.0

0.00

0.00

C1

0.0

0.00

0.00

0.0

0.00

0.00

C2

0.0

0.00

0.00

0.0

0.00

0.00

C3

0.0

0.00

0.00

0.0

0.00

0.00

Total

87.5

2.71

100.00

54.1

1.68

100.00

11

Feed Characteristics: H2S Rich SWS off gas


FEED & CAPACITY FOR PRODUCTION OF 5 TONS / DAY OF SULPHUR
Max. Distillate Case

Max. Gasoline Case

Composition

kg/hr

kg-mol/hr

Mol%

kg/hr

kg-mol/hr

Mol%

H2S

103.6

3.039

88.94

69.0

2.026

88.09

NH3

0.0

0.00

0.00

0.0

0.00

0.00

H2O

6.1

0.340

9.96

4.2

0.235

10.21

Cyanide

1.0

0.038

1.10

1.1

0.039

1.70

CO2

0.0

0.00

0.00

0.0

0.00

0.00

N2

0.0

0.00

0.00

0.0

0.00

0.00

CO

0.0

0.00

0.00

0.0

0.00

0.00

H2

0.0

0.00

0.00

0.0

0.00

0.00

C1

0.0

0.00

0.00

0.0

0.00

0.00

C2

0.0

0.00

0.00

0.0

0.00

0.00

C3

0.0

0.00

0.00

0.0

0.00

0.00

Total

110.7

3.416

100.00

74.3

2.300

100.00

12

Feed Characteristics: NH3 Rich SWS off gas


FEED COMPOSITION AND CAPACITY TO INCINERATOR
Max. Distillate Case

Max. Gasoline Case

Composition

kg/hr

kg-mol/hr

Mol%

kg/hr

kg-mol/hr

Mol%

H2S

14.7

0.43

3.24

8.9

0.26

2.76

NH3

157.6

9.27

69.75

112.3

6.61

70.25

H2O

64.7

3.59

27.01

45.7

2.54

26.99

Cyanide

0.0

0.00

0.00

0.0

0.00

0.00

CO2

0.0

0.00

0.00

0.0

0.00

0.00

N2

0.0

0.00

0.00

0.0

0.00

0.00

CO

0.0

0.00

0.00

0.0

0.00

0.00

H2

0.0

0.00

0.00

0.0

0.00

0.00

C1

0.0

0.00

0.00

0.0

0.00

0.00

C2

0.0

0.00

0.00

0.0

0.00

0.00

C3

0.0

0.00

0.00

0.0

0.00

0.00

Total

237.0

13.29

100.00

166.9

9.41

100.00

13

Feed Characteristics: CNU off gas


FEED COMPOSITION AND CAPACITY TO INCINERATOR

Naphtenic /
Sulfidic Sour
(Mixed Crude)

Naphtenic /
Sulfidic Sweet
(Bach Ho Crude)

Phenolic Sour
(Mixed Crude)

Phenolic Sweet
(Bach Ho Crude)

Std Vol. Flowrate m3/hr

22.5

29.3

Min

Min

H2O wt%

H2S wt%

53

28

RSH wt%

Fuel Gas wt%

40

60

93

93

14

Product Specifications: Degassed Liquid Sulphur

Component

Specification

Purity (as S) (wt %)

99.9 (dry basis)

Organics (wt %)

0.02 (dry basis)

Ashes (wt %)

0.04 (dry basis)

Water (wt %)

0.10

H2S content (wt.ppm)

10

Colour

Bright Yellow

15

Product Specifications: Emissions from Incinerator

Component

Limit

SO2 (mg/m3)

500 max (dry basis)

H2S (mg/m3)

2 max (dry basis)

NOX (mg/m3)

1000 max (dry basis)

CO (mg/m3)

500 max (dry basis)

Particulate in Smoke (mg/m3)

400 (dry basis)

Dust containing silica (mg/m3)

50 (dry basis)

Ammonia (mg/m3)

100 (dry basis)

16

Basis of Design: Chemicals Requirement


CLAUS Catalytic Reactors Catalyst
Alumina-Titanium for 1st reactor
Alumina only for the 2nd and 3rd reactors
Catalyst supported on a layer of active catalyst support
Catalyst
Item

Description

Catalyst

Volume to be loaded (m3)

A-2201-R-02

1st reactor

Alumina-based catalyst

0.94

Titanium oxide catalyst

0.94

A-2201-R-03

2nd reactor

Alumina-based catalyst

1.32

A-2201-R-04

3rd reactor

Alumina-based catalyst

1.88

Catalyst Bed Support


Item

Description

Volume to be loaded (m3)

A-2201-R-02

1st reactor

0.28

A-2201-R-03

2nd reactor

0.20

A-2201-R-04

3rd reactor

0.28

17

SECTION 2
PROCESS FLOW DESCRIPTION

18

SECTION 3
MAIN EQUIPMENTS

21

Main Equipment Thermal Reactor


To completely oxidize HC and all impurities (such as HCN) and to burn 1/3 of the
total H2S to SO2
2 zone reaction furnace:
1st zone: all combustion air, all H2S rich SWS off gas and 50% of ARU off gas
are burnt (1240C)
2nd zone: Hot flue gas from the 1st zone and 50% of the ARU are mixed (900C)
Thermal reactor burner: combined type with 2 lances:
1 for fuel gas combustion during plant start-up and for turndown case
1 for acid gas combustion during normal operation
2 flame scanner and 1 ignitor
Quench line to moderate the flame temperature during fuel gas run
Reaction chamber is internally refractory lined and equipped with 1 optical
pyrometer and specials thermocouples to detect continuously the temperature in
both reaction zones
22

Main Equipment Thermal Reactor

23

Main Equipment Thermal Reactor

24

Main Equipment Thermal Reactor


Thermal Reactor A-2201-R-01 Burner
Nozzle Data for Burner
Design Pressure (kg/cm2g)

5.2

Operating Pressure (kg/cm2g)

0.49

Design temperature (C)

343

Operating temperature (C)

250

Material:
Acid Gas Lance / Tip
Fuel Gas Lance / Tip
Burner Front Plate

Stainless Steel / AISI 310


Stainless Steel / AISI 310
Killed Carbon Steel

Burner Construction
Installation

Horizontal, flanged to the thermal reactor

Gas Tight Construction

Yes

Fuel Gas connection

Flexible pipe to allow gun withdrawal during


acid gas operation

Flame control

2 flame detectors, each complete with


amplifier

Max noise level

85 dB at 1 m distance

25

Main Equipment Thermal Reactor


Thermal Reactor A-2201-R-01
Length (TL to TL) (mm)

2700

Internal Diameter (mm)

1290

Position

Horizontal

Design Temperature (Fuel Gas Firing only) (C)

1450

MIN/MAX Operating temperature (C)

Zone I: 1250/900

Zone II: 1250/850

Refractory
Bricks Group

Grade 28

Classification Temperature

1540C

Thermal Conductivity at 600C

0.34W/mC

CaO content

1% typ.

Fe2O3 content

1.5% max.

Alkalies content

2% max.

26

Main Equipment A-2001-SG-01


5 passes boiler producing saturated low pressure steam at 4.1 kg/cm2G in the shell
side by condensing sulphur in the tube side:
pass I = 1st pass of WHB
pass II = 2nd pass of WHB
pass III = 1st sulphur condenser
pass IV = 2nd sulphur condenser
pass V = 3rd sulphur condenser
The 5 passes are all oriented horizontally
The tubes of each pass are plain tubes, made of killed carbon steel
A-2201-SG-01 is provided with 2 mist eliminators at Pass III and IV outlets

27

Main Equipment A-2001-SG-01

28

Main Equipment A-2001-SG-01

29

Main Equipment A-2001-SG-01

30

Main Equipment A-2001-SG-01


PASS I
Surface (m2)
Service

7.5
Shell Side

Tube Side

BFW / LP steam

Process Gas

Inlet

Outlet

Vapour (kg/hr)
Steam (kg/hr)

Inlet

Outlet

1533.8

1533.8

455

790.5

Water (kg/hr)

814.6

24.1

Temp.(C)

112

152

897

4.1

0.44

Press. (kg/cm2g)
Duty (kW)

245

Service heat transfer coefficient (W/m2 C):

66.1

No. of tubes:

Tubes Diameter (mm)

7.62

Length (mm)

4500

Pitch

125 (SQUARE)

Clean: 68.1

31

Main Equipment A-2001-SG-01


PASS II
Surface/unit (m2)
Service

11.9
Shell Side

Tube Side

BFW / LP steam

Process Gas

Inlet

Outlet

Vapour (kg/hr)
Steam (kg/hr)

Inlet

Outlet

1533.8

1533.8

240

790.5

Water (kg/hr)

814.6

24.1

Temp.(C)

112

152

455

4.1

0.420

Press. (kg/cm2g)
Duty (kW)

107

Service heat transfer coefficient (W/m2 C):

51.6

No. of tubes:

14

Tubes Diameter (mm)

5.54

Length (mm)

4500

Pitch

85 mm (TRIANGULAR)

Clean: 53.0

32

Main Equipment A-2001-SG-01


PASS III
Surface/unit (m2)
Service

15.7
Shell Side

Tube Side

BFW / LP steam

Process Gas

Inlet

Outlet

Vapour (kg/hr)

Inlet

Outlet

1533.8

1504.4

Liquid (kg/hr)

29.4

Steam (kg/hr)

790.5

Water (kg/hr)

814.6

24.1

Temp.(C)

112

152

240

4.1

0.40

Press. (kg/cm2g)

162

Duty (kW)

37

Service heat transfer coefficient (W/m2 C):

65.7

No. of tubes:

35

Tubes Diameter (mm)

2.77

Length (mm)

4500

Pitch

46 mm (TRIANGULAR)

Clean: 67.9

33

Main Equipment A-2001-SG-01


PASS IV
Surface/unit (m2)
Service

16.2
Shell Side

Tube Side

BFW / LP steam

Process Gas

Inlet

Outlet

Vapour (kg/hr)

Inlet

Outlet

1504.4

1356.6

Liquid (kg/hr)

147.8

Steam (kg/hr)

790.5

Water (kg/hr)

814.6

24.1

Temp.(C)

112

152

321

4.1

0.28

Press. (kg/cm2g)

171

Duty (kW)

84

Service heat transfer coefficient (W/m2 C):

75.8

No. of tubes:

36

Tubes Diameter (mm)

2.77

Length (mm)

4500

Pitch

46 mm (TRIANGULAR)

Clean: 78.9

34

Main Equipment A-2001-SG-01


PASS V
Surface/unit (m2)
Service

14.4
Shell Side

Tube Side

BFW / LP steam

Process Gas

Inlet

Outlet

Vapour (kg/hr)

Inlet

Outlet

1356.6

1329.5

Liquid (kg/hr)

27.1

Steam (kg/hr)

790.5

Water (kg/hr)

814.6

24.1

Temp.(C)

112

152

223

4.1

0.173

Press. (kg/cm2g)

162

Duty (kW)

28

Service heat transfer coefficient (W/m2 C):

62.7

No. of tubes:

32

Tubes Diameter (mm)

2.77

Length (mm)

4500

Pitch

46 mm (TRIANGULAR)

Clean: 64.8

35

Main Equipment Catalytic Reactors


Purpose: To convert H2S into gaseous elemental sulphur by reaction between H2S
and the SO2 formed in the thermal reactor, on catalyst beds
Reaction between H2S and SO2 produces elemental sulphur in each reactor for as
long as the equilibrium is not reached for the pressure and temperature conditions
within each reactor
R-02, 03 and 04 are physically located in a unique vessel divided into 3 compartments
The reactors vessel is equipped with an external MP steam coil operating at 250C
and 14.1 kg/cm2g

36

Main Equipment Catalytic Reactors


A-2201-R-02

A-2201-R-03

A-2201-R-04

Service

1st catalytic reactor

2nd catalytic reactor

3rd catalytic reactors

Catalyst Volume (m3)

Alumina-based: 0.94
Titanium oxide: 0.94

Alumina-based: 1.32

Alumina-based: 1.88

I.D. (mm)

1900

1900

1900

Length (mm)

1375

1300

1375

Material:
Shell
Heads
Flanges
Coils
Beam

Killed Carbon Steel


Killed Carbon Steel
Killed Carbon Steel
Killed Carbon Steel
Killed Carbon Steel
Design Case Operating Conditions (Max. Gasoline)

Liquid Flow (kg/hr)

Vapour Flow (kg/hr)

1504.4

1356.6

1321.5

IN Press. (kg/cm2g)

0.33

0.21

0.09

OUT Press. (kg/cm2g)

0.40

0.28

0.173

IN Temp. (C)

240

205

190

OUT Temp. (C)

321

223

193

37

Main Equipment Catalytic Reactors

38

Main Equipment Catalytic Reactors

39

Main Equipment Liquid Sulphur Storage & Degassing Pits


Purpose: to collect liquid elemental sulphur at the outlet of the 1st, 2nd, 3rd and final
sulphur condensers via steam jacketed sulphur legs
Each sulphur leg is provided with dedicated perforated plate filter
Seal legs sized to avoid blow up of process gas in all operating conditions
Each leg can be isolated for maintenance
Sulphur pit divided in 2 sections:
Non degassed sulphur pit and degassed sulphur storage pit each sized for one
day of production and equipped with 2 jacketed transfer pumps
Purpose of the sulphur degassing tank: to reduce H2S entrained with the sulphur to a
safe level

40

Main Equipment Liquid Sulphur Storage Pit

41

Main Equipment Liquid Sulphur Degassing Tank

42

Main Equipment Incinerator


Purpose: To oxidize all sulphur bearing compounds in waste gases (tail gas from SRU
and vent air from sulphur degassing pit) to sulphur dioxide prior to release to
atmosphere
Normal operating temperature: 750C
Condition obtained by burning NH3 rich SWS off gas and CNU off gas
Burner equipped with dedicated lances for:
Fuel Gas
CNU off gas
NH3 rich off gas
ARU off gas + H2S rich off gas (bypass gas)
Claus Section Tail Gas and the Vent Gas from Degassing Section are injected just
downstream of the flame via dedicated nozzles
Cylindrical & Horizontally installed
Incinerator chamber I.D. = 1450 mm
Forced draft type burner.
Air box incorporated in the burner

43

Main Equipment Incinerator

44

Main Equipment Blowers


Combustion Air Blowers A-2201-B-01 A/B
Number Required

2 (1 operating + 1 standby)

Manufacturer & Model

Robuschi & ES65/2P RVP 80 ATEX3

Blower Type

Rotary Compressor

Driver Type & Manufacturer

Electric Motor & ABB

Driver Rated Power (kW)

22

Driver Speed (RPM)

2930

Drive System

Direct Coupled

Accessories:

Inlet air filter


Inlet, Discharge & Blow-off Silencers
PSV
Discharge Blow-off valve

Operating Conditions

MIN.

MAX.

RATED

Delivered Flow (Nm3/h)

79

549

604

Inlet Pressure (kg/cm2g)

ATM

ATM

ATM

Outlet Pressure (kg/cm2g)

0.6

0.6

0.6

Inlet Temperature (C)

36

36

36

Outlet Temperature

115

115

115

45

Main Equipment Blowers


Incinerator Air Blowers A-2201-B-02 A/B
Number Required

2 (1 operating + 1 standby)

Manufacturer & Model

Not available

Blower Type

Centrifugal Fan

Driver Type & Manufacturer

Electric Motor, fixed speed

Driver Rated Power (kW)

Not available

Driver Speed (RPM)

Not available

Drive System

Direct Coupled

Accessories:

Inlet air filter


Silencer
Blowoff silencer
Outlet expansion joint

Operating Conditions

NORMAL

MAX.

RATED

Delivered Flow (Nm3/h)

2429

6077

6332

Inlet Pressure (kg/cm2g)

ATM

ATM

ATM

Pressure 0.11

0.11

0.11

36 (MIN.:14)

36

Outlet
(kg/cm2g)

Inlet Temperature (C)

36

46

Main Equipment Blowers


Dilution Air Blowers A-2203 A/B
Number Required

2 (1 operating + 1 standby)

Manufacturer & Model

Not Available

Blower Type

Centrifugal Fan

Driver Type

Electric Motor

Operating Conditions

DESIGN

NORMAL

Total Dry Flow (kg/h)

176000

160000

Inlet Pressure (mmH2O)

ATM

ATM

Outlet Pressure (mmH2O)

300

250

Inlet Temperature (C)

36

36

47

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