SULFUR PLANT DESIGN MANUAL TAB SUBJECT 4 B D E F 6 INDEX TABLE OR RIGURE NO, PAGES Table of Contents 1-5 Introduction General el Modifications to Manual RECEIVED Historical Background and Patents Design Parameters JUN 5 1972 Source of Feed Plant Size F Engrg. Standarés Feed Characteristics Desired Recovery utility Balance General Guideline for Selection of Plant Type Figure Bel Process Description 143 General Process Description Combustion Methods Figure ¢-1 Reheat Alternates Figure 0-2 Flow Diagrams 12 General Flot Configuration Suggested Hot Gas Bypass Layout Figure D-1 Process Flow Diagram ~ Hot Gas Bypaes Reheat Figure D-2 Process Flow Diagram - Fired Reheat Figure D3 Mechanical Flow Diagram - Hot Gas Bypass Reheat ‘Figure Dui Mechanical Flow Diagram - Fired Reheat Figure D-5 Utility Flow Diagram Figure D-6 Process Flow Diagran - Pandm Direct Oxidation Figure D-7 Equipment Qualified Vendors List Vessels ak General Sulfur Converters Discussion Sizing Criteria sulfur Product Coalescer Converter Catalyst Volume Figure G-1 Horizontal Sulfur Converter Figure G-2 Vertical Sulfur Converter Figure G-3 Horizontal Coalescer Figure Gh Vertical Coalescer Figure G5 Complex Horizontal Coalescer Figure 6 17A~289-472 -1.DEX RECEIVED TABLE OR 7A3 SUBJECT FIGURE NO, PAGES H Pumps and Compressors JAN JL 72 1-2 General 7 cee Engrg. Sander’ Air Blower Pumps Typical Air Blower Specification Figure H-1 Typical Sulfur Pump Specification Figure H-2 Typical Sour Water Pump Specification Figure H-3 I Furnaces and Heaters 6 General Sulfur Furnaces Reheaters Incinerators Typical Reactor Furnace Specification ‘Table I-1 ‘Typical Rrheater Specification Table 1-2 ‘Typical Incinerator Specification Table 1-3 ‘Typical Reactor Furnace Sketch Figure I-1agb ‘Typical Reheater Sketch Figure 1-2 ‘Typical Incinerator Sketch Figure 1-3 J Waste Heat Boilers 13 General Waste Heat Boilers Design Considerations ‘Typical WEB Process Specification Figure J-1 Typical WHB Narrative Specification Table J-2 Typical WHE Sketch Figure J-2 K Heat Exchangers (Economizers) 12 General Design Considerations Typical Economizer Specification (BFW Heater) Figure Kel Typical Sulfur Condenser Specification Figure K-2 Typical Gas-Gas Reheater Specification Figure K-3 Limits of "Fog" Formation Figure K-l L Miscellaneous Equipment 13 General Purchased Sulfur Plants Waste Gas Stacks Vendor Lists and Costs Table L-1 ‘Typical Gas Stack Specification Table L-2 17A-289-272INDEX AB M P Q s SUBJECT Piping codes specification Miscellaneous Comments Typical Piping Specifications ‘Typical Piping Details Instrumentation General Control Principles Sulfur Storage General Liquid Sulfur Storage ‘Sumps on Storage Tanks Solid Storage Solid Block Storage Std, Size Tank & Sump Costs & Steam Req'd Typical Single Sump Design Typical Duel Sump Design Utilities and Chemicals General Average Plant Operating Requirements Electrical Power Fuel Gas steam Chemicals & Catalyst Catalyst Properties Operating Date for Reactor using Cobalt-Moly Catalyst with Activated Bauxite Catalyst Sulfur Plant Economics summary of Fluor Plants (Modern) Summary of Fluor Plants (Olin-Mathieson) hoo a/c sulfur Plant - only Cost Curve Process Hand Calculations General Feed(2) Plant Configuration Air Requirements Combustion Converters Waste Heat Boiler Condensers Example 1 - Acid Gas >50% Nol % Alternate 14 - Straight Through w/Hot Vapor Bypass Reheat Alternate 1B - Straight Through w/Direct Fired Reheat TABLE OR FIGURE NO, PAGES 13 Table N-1. Figure M1 13 RECEIVED AUG 28 1972 1-6 ‘Standards Pigure 0-1 Pigure 0-2 Figure 0-3 1-3 Table Pl Table B2 Table P3 Table Q-1 Table Q-2 Figure Q-1 1-6 Figure S-1 1-65 1 7A~289-0872-1INDEX. TAB u AA BB TABLE OR SUBJECT FIGURE NO, Example 2 - Acid Gas 30-50 Mol % Figure T-1 Alternate 24 - Straight Through w/Feed and Air Preheat Alternate 2B - Acid Gas Bypass Example 3 - Acid Gas <15 Molf Figure U-1 Example 4 - Acid Gas Containing WH, Figure V-1 Example 5 - (Future) Operating Instructions RECEIVED General Equipment Preparation AUG 28 1972 startup of Cold Plant Startup of Hot Plant Engrg. Standards Plant Shutdown Special Procedures Operating Instructions for Cobalt-Moly Catalyst (c29-2-01 from CCI) Analytical Procedures Bauipment and Reagents Process Control Analysis Chromatograph Analysis Fraction of Sulfur as COS and CS, in Tail Gas Table Y-2 ‘Typical Chromatograph Tail Gas Afalysis Figure Y-1 Column Configuration and Analytical Sequence Figure Y-2 Relationship of "fail Gas Ratio" to "Drue Tail Gas Ratio" Figure ¥-3 Relationship of "True" Tail Gas Ratio to Sulfur Conversion Figure y-b Hazards Fires Health Hazards Air Pollution corrosion Data Psychronetric Chart Figure BB-1 Sulfur Vapor Pressure W BB2 Conversion Chart, I=5 "BBs ‘ » 1805 "Bel 7 fa 9] 1590) "BBS " ", I=100 BB-6 Observed AT in Catalyst Beds BB-7 Sulfur Dew Point BB-8 Composition of Sulfur Vapor "BBS Sulfur Temperature - Enthalpy " BB-1o Sulfur Liquid Enthalpy "BBL PAGES 1-10 “7 15 1-13 1-15 1-2 1 7A~289-0872-1INDEX ms ce DD EE TABLE OR SuBIECT FIGURE NO, PAGES Data (Cont'd) Enthalpy of Gases - Low Temperature Range Figure BB-12, 1-4 Enthalpy of Gases - Mid-Temperature Range BBe13, 1k Enthalpy of Gases - High Temperature Range “ppl, 1k Heat of Formation BB+16, 1-8 Specific Gravity of Liquid sulfur “ BB-17 Viscosity of Liquid Sulfur “p18 Viscosity of Sulfur Vapor " BBe19 Thermal Conductivity of Liquid sulfur BB-20 Thermal Conductivity of Sulfur vapor “ BB21 uarantees 1-2 General RECEIVED Typical Guarantee Performance Guarantee Performance Test AUG 28 872 Pollution Control Engrg. Standards 143 General Regulations Tail Gas Treating Waste Disposal Tail Gas Treating Processes Figure DD-1 Computer Program Introduction Basic Compound Data General, Initial Data Sheet Non-standard Compound Data sheet Material and Heat Balance Data Printout Sheet General Data Sheet Information Standard Output Format Data Input and Error Messages Accounting Summary Dump Alter Control Card Non-standard Specie Initial Data Sheet Acid Gas Stream Fuel Gas Stream Air Blower Furnace 1TA-289-0872-1‘INDEX TAB EE SUBJECT Computer Program (Cont'd) Waste Heat Boiler Acid Gas Reheat Fuel Gas Reheat Hot Gas Reheat Heat Exchanger Conbine Streams split streams converter stack Print out Bibliography ‘TABLE OR EIGURE NO. PAGES RECEIVED AUG 28 1972 Engrg. Standards ak 1TA~289-0872-1FLUOR CORPORATION Page 1 Enopyorton 178-290-272 GENERAL The Sulfur Plant Design Manual has been revised and updated to make it a useful tool for calculating the more exact product quantities and qualities required in modern, competitive design. This section is organized as follow: RECEIVED JAN 31 Modifications to the manual. Historical background and patents. Engrg. Standaras 3. Design paramete 4, Plant selection. ‘The block flow diagram, Figure B-1, “General Guidelines for Type of Plant Arrangement", at the end of this section, will assist the engineer in the selection of the correct flow pattern. However, this chart should not be used to override good engineering judgment in the design of a plant, It is intended to assist the engineer in formulating a basic process approach. Modifications to the Nenual (August 1971) The following changes have been made to the manual issued in 1963: "Tab B" - Introduction - Combines the "Scope" and "Special Considerations” eetioné in the previous issues of this manual. ‘The format has been changed and updated to reflect (1) the expiration of Fluor's license with Olin Mathieson and (2) clarification of the limitations in Pan American direct oxidation process. A new agreenent between Pan Anerican and Fluor was negotiated in 1965. The patents perteining to this agreement have been listed along with a brief description of each, "gab C" - Process Description - Rewritten to reflect modern design Philosophy including expanded and clarified methods for reheating converter feeds. "ab D" - Flow Diagrams - Process, Mechanical and Utility Flow Diagrams have been added illustrating the minimum equipment and instrumentation considered essential for plant operation, These diagrams represent a "poor boy" design and are intended to be used as the base case. The old Mathieson flow diagrams have been deleted. IKPage 2 FLUOR CORPORATION INTRODUCTION "tab F" - Qualified Vendors List - This section replaces the equipment Tist section. "nab G"_- Vessels - Revised to include alternate converter configurations, methods of selecting vertical versus horizontal converter vessels, criteria for sizing the Tail Gas Scrubber and the Sulfur Converter, etc. ‘Typical Vessel sketches and specification sheets are included. "gab H" - Pumps, Compressors, and Drivers - The discussion of air lower selection has been revised and a typical drawing added. “gab I" - Furnaces - Completely rewritten to include newly developed Gesign parameters. A typical process specification is included. The incinerator specification has been updated. “tab J" - Boilers - Mechanical design features are defined and a new Specification sheet and waste heat boiler sketch have been added. "tab K" - Heat Exchangers - Added a graph for predicting conditions Producing sulfur fog in exchange equipment. Edited and updated the sample specifications and typical equipment drawings. "ab M" = Piping - Format hes been changed and detailed piping specifi- Cations replaced by a one-page sunmary sheet, The narrative presentation has been expanded. “Tab Nl" - Instrumentation - Updated to reflect recent plant installations and operating experience. Bnphasis has been shifted to defining principles of sulfur plant control. "rab 0" - Storage - The drawings have been updated and the latest methods of sulfur storage have been included. "tab P" - utilities - Revised to reflect recent operating data. Recomended values for quickie estimates have been added. The list of catalyst vendors has been expanded to include catalysts with higher conversion. “tab Q" = Plant Costs - A cost/capacity curve for 400 A/C estimate Based on plants escalated to January 1971 is included. These charts represent one and two train designs utilizing two, three, or four conversion stages. Also included are 400 A/C estimates for a tail ges scrubbing facility. 17B-290-272RECEIVED FLUOR CORPORATION JAN BE 1972 Page 3 INTRODUCTION Engrg. Standards “gabe R" through "i" - Procese Calculations - Revised to include the few minimization of free energy method for predicting thermodynamic equilibria product distribution. Three typical problems and the recommended method for handling ammonia-rich feed streams are included. "ab X" = Operating Instructions - Revised to delete procedures relating Yo the Mathieson type plant. New instructions are included for modern plant designs. Mpab y" - Analytical Procedures - Added new section discussing application ‘Of gas chromotography for control. Mpab 2" = Hazards Added discussion of air pollution and Feduetion of sulfur dioxide emission. "ab AA" = Corrosion - Rewritten to reflect corrosion in modern plants. "tab BS" - Data - New thermodynamic properties have been added consistent With the restructured computer program. Physical properties data have been expanded and updated. "gab CC" - Guarantees - Updated to include guarantees based upon the Hew calculation methods and actual operating experience. “gab Dp" - Pollution Control - Replaces previous section called "Waste Disposal”. Has been revised to reflect present and pending legislation for pollution control. “gab BE" = Computer Program - Completely restructured to represent the initun free energy calculation approach and to define the new program which permits modular computerization of sulfur plant design similar to our GPS system. “Tab FF" - Bibliography - All new section which includes all references Gpplying to data and procedures in this manual. References to outdated and irrelevant articles have been excluded, Historical Background and Patents Sulfur recovery plant designs are based on the traditional Claus reaction in which 1,8 and SQ, are catalytically converted to elemental sulfur and steam at elevated temperatures, This is basic to all traditional sulfur plants with equipment arrangement and mechanical detail variations being utilized to develop optimum conditions for maximum sulfur recovery. More 1 7B-290-272Page 4 FLUOR CORPORATION INTRODUCTION recently, sulfur recovery systems such as the SNPA-Lurgi "Sulfreen Process" and the "IFP Process", etc., have been developed, which utilize technology somewhat different than the traditional systems to recovery sulfur from gas streams containing #,S, CO,, etc. Early Fluor plants (from about 1949 to 1959) offered the patented Olin- Mathieson process, which included @ regenerative reaction furnace design developed by Mathieson and stacked vertical catalytic converters. The major drawback of this process was the cost of the reaction furnace which made this type of plant non-competitive with later designs. Fluor's contract with Olin-Mathieson has since expired and this type of plant is uneconomical to offer. Fluor (1959 to 1960) redesigned the Mathieson-type plant in order to obtain a more competitive position. The furnace was replaced by an external combustion chanber directly on the waste heat boiler or as an alternate, direct firing into the lining tube of the waste heat boiler. The converters were changed from vertical to horizontal vessels, and in general, the equinment design criteria were tightened. Fluor obtained license from Pan American Petroleum Corporation in 1960 to offer sulfur plant designs based upon patents held by them. Pan American's patents involve conventional Claus type plants and a direct low temperature oxidation process. This direct oxidation process is different from any experience or process design held by Fluor prior to the licensing agreement. A compact package plant with patented mechanical features is also covered in the agreement. ‘This package unit, called the "Webb" package, is particularly attractive in capacities up to 50 L/D. The Fan American patents cover sulfur recovery processes as defined by the following: (1) UWS. letters Patent 2,726,641 - This patent covers the direct oxidation of HS to sulfur at 400 to 1000°F in the presence of a catalyst with the products inmediately injected into a liquid bath of molten sulfur or water held at a temperature of 230 to 320°F. (2) U.S. Letters Patent 2,742,347 - This patent covers sulfur recovery in the following manner: Not more than 75 volume percent of the oxygen is added to the acid gas. This mixture is reacted at a temperature between 600 and 750°F in a hollow reaction zone con- sisting of an interior of catalytic ferrous metal. The balance of the stoichiometric quantity of oxygen is added and the mixture passes through a catalyst bed that maintains the reaction temperature between 400 and 1200°P by using inert materials in decreasing concentration through the catalyst bed. 117B-290-272RECEIVED FLUOR CORPORATION Page 5 JAN SL INTRODUCTION G3) (4) >) (6) Engrg. Standards U.S. Letters Patent 2,758,913/Canadian Letters Patent 553,058 - This patent covers the direct oxidation process. Insufficient oxygen is added to the first converter feed with the balance of ‘the oxygen added ahead of the second catalyst bed. The reaction temperature is controlled by the use of decreasing inerts in the catalyst bed. The inlet of the bed contains 90 to 99% aluminun inerts and decreases to approximately zero at the outlet. The reaction temperature is maintained high enough to convert H,S to elemental sulfur, but not high enough to oxidize hydrocarbons. The temperature does not exceed 1200°F at any point through the bed. U.S. Letters Patent 2,689,207 - This patent covers the addition of hydrocarbons or hydrogen and carbon monoxide to an acid gas con- taining at least 15% H,S to control the reaction temperature. The hydrocarbons or hydrogen and carbon monoxide are added before oxidation in the ratio of not more than 1/3 of the 1,8 (molal vecis). U.S. Letters Patent 2,939.76: sh Letters Patent, French Letters Patent Spanish Letters Patent 297,970/west German Application Serial Tva/Iei - This patent covers the "webb" padkage plant. This plant is a compact sulfur recovery unit in which all lines are self-draining, thus eliminating steam jacketing. The “Webb” oiler combines the waste heat boiler and condensers into one piece of equipment. A combined separator and sulfur storage tank is also used. U.S. Letters Patent 3,057,698/Canadian Letters Patent 691,152 - This patent covers improvements to the “Webb” package unit. The combination separator and storage tank is eliminated and sulfur is separated in condenser outlet chambers. Sulfur seal legs are incorporated into the boiler to maintain liquid sulfur at the seals at all times. an Letters Patent 645 8: Bey Design Parameters Combustion of the acid gas feed with a controlled amount of air is the first step in a conventional sulfur plant design for which the following two design approaches are used depending upon the H,S concentration in the feed ges: (a) straight-through plant - all of the feed gas goes to combustion end (b) bypass plant - sufficient H,S is delivered to combustion to produce 2 minimum two to one HS:80, ratio in the converter feed. 17B-290-272Page 6 FLUOR CORPORATION INTRODUCTION A straight-through plant is normally used with feed gas HS concentrations above 50 mole percent. A minimum adiabatic flame temperature of 1680°F must be maintained to sustain combustion in a conventional (Scotch Marine) type furnace. This temperature can be reduced to 1300~1400°F when a separate refractory lined furnace is used because added residence time is available to develop the same equilibrium as in the conventional furnace. When feed gas and/or air preheat is employed, the straight-through design is applicable down to approximately 30 mole percent feed HS. Below 30%, the sulfur conversion drops off and other types of plant cénfiguration are recommended. A bypass type plant is generally used in the 15 to 50 mole percent range of HS feed concentration. In this type of plant, approximately 65-67% of thie acid gas bypasses the combustion step and is combined with the oxidized product from the waste heat boiler. The actual bypass quantity is set so that the ratio of H,S:80, in the sulfur converter feed is always slightly more than 2:1°to efisure a reducing atmosphere in the vessel. An oxidizing atmosphere at sulfur converter reaction temperature will corrode out the vessel in a few months, (2:1 maximizes conversion.) Detailed designs of sulfur plants are a function of one or more of the parameters listed below: a, Source of feed gas b. Plant size ce. Feed characteristics d. Desired recovery e. Utility balance a, Source of Feed Gas Feed gas streams to sulfur plants originate primarily from acid gas treating units such as Fluor Econamine, Amine treating, ete., and contain essentially H0, CO, and ,$ with small amounts of 00S, 6S, and light hydrocarbon8. | Acid gase8 rich in NH, from refinery Sour’ gas strippers are frequently fed to the sulfur’plant to be processed concurrently with acid gases from gas treating units. These ammonia rich gases mst be oxidized completely separate from the acid gas furnace before combining with the acid gas stream being fed to the sulfur converters, because ammonium sulfates may be formed in the furnace if the streams are combined before the amonia is completely oxidized. The sulfates will precipitate at the lower temperatures used for conversion and sulfur recovery and cause equipment fouling and subsequent plugging. ‘The important factor to remember is that the feed mixture to a suifur converter mst contain an 18:80, ratio of no less than 2. 1 7B-290-272FLUOR CORPORATION RECEIVED Be U TRIRODICTION JUN 5 1972 ng Plant Size rere. Standards Detailed designs are generally performed by Fluor for sulfur plant capacities above 50 long tons per day. Below 50 long tons per day, package unit designs are cbtained from outside vendors (such as the "Webb" type). ‘The maximum plant size in a single train unit is about 1500 long tons per day. However, for all plant capacities above 1000 long tons per day, an evaluation must be made to determine the economical plant configuration. Feed Characteristics A number of alternate methods which may be used for processing acid gas feeds containing 1,8 concentrations below 50 mole percent are listed below: ‘Types of Feed Process Arrangement 30-50 mol % HS Preheat the feed gas and/or the combustion air - this is economically attractive if an inexpensive heat source is available. 30-50 mol HS Add fuel gas to the feed acid gas ~ this can be used if fuel gas is cheap and does not result in the conbined gases containing more than 0.1 mol % of hydrocarbons boiling above propane. 5-25 mol % HS Pan Anerican's direct oxidation process - this can only be used for acid gas feeds containing no hydrocarbons boiling above propane. Maximum sulfur recovery is approxi- mately 80f with this process. See the technical file 3.455.3.10 in the Process Library for details. Also included in this file is a write-up defining the operation of the plant Fluor designed for Houe Oi) at the Carstairs - Cronfield Plant in Canada. 5-15 mol % 1,8 Oxidized elemental sulfur to obtain SO,- @ portion of the sulfur produced is bufned in a special furnace and then combined with the feed gas, 5-15 mol % 1s ‘Two-stage (or more) with one-third feed - ‘two-third bypass plant with both air and feed gas preheated. TB-290-472-1.Page 8 FLUOR CORPORATION INTRODUCTION a ‘Types of Feed Process Arrangement Wis Rich Oxidize thie stream completely in a separate combustion zone and then combine with the combustion effluent from the other acid gas combustion. The important criteria is to produce a combined effluent feed to the sulfur converter containing no less than a two-to-one ratio of H,S:S0,. Feed concentrations of hydrocarbons should be limited to 1.0-1.5 mol Cy, less than 0.5 mol $ Cy, and less than 0.1 mol 4 Gy+. ‘This will ensure good catalyst life and "bright" sulfur production. At times, gases from other sources are also used to feed the sulfur plant. Hydrocarbons in the feed should be minimized in order to (1) maintain reasonable combustion temperatures, (2) minimize plant costs, (3) preclude depositing carbon on catalyst, and (4) prevent production of "off spec" product. Although methane and ethane in the feed are not deleterious to either the product specification nor the catalyst life, they co-influence plant costs and combustion temperatures. Feed gases containing as mich as 30 mol 4 C,~Cy have been successfully processed. Excess propane plus hydrocarbon con- centrations up to 3 mol % of the acid gas feed have been successfully processed without substantially reducing catalyst life. However, as a practical limit, the total quantity of these components should be Limited to less than 1.0 to 1.5 mol %, with the butane no more than 0.5 mol %. Unsaturates, aromatics and C,+ hydrocarbons must be kept to less than 0,1 mol % at all times. Desired Recovery The recovery required for a modern sulfur plant will be generally set by air pollution control regulations as defined by customer specifications given to Fluor. In general, recovery will vary between 93 to 98-1/2f. As a rough rule-of-thumb, a two-stage unit will recovery 93 to 95% of the sulfur in the feed, a three-stage unit about 97% maximum and a four-stage unit about 98.54. Present (1971) sulfur plant technology does not economically permit the high recoveries of sulfur required to meet the air pollution regulations proposed in pending Federal legislation. Therefore, tail gas scrubbing units will becone mandatory on sulfur plants whenever air pollution regulations specify maximum $0, stack emissions of no more than 2,000 ppm, An economic evaluation will be required to determine the optimum between number of stages of recovery in the sulfur plant and size of the tail gas scrubbing unit. 17B-290-272FLUOR CORPORATION Page 9 RECEIVED INTRODUCTION . JAN Sb 1872 e. Utility Balance Engrg. Standarés The utility-steam balance in a sulfur plant affects the heat recovery schemes and as a result, the various’ exchangers (economizers) in the plant. Tne "Webb" package plant design (for 50 long tons per day and less) favors low pressure steam generation because the waste heat boiler functions as a sulfur condenser. This lovers the temperature of the outlet gas which results in a lower pressure steam being generated, usually in the 35-50 peig range. High pressure steam (200-400 psig) can be produced in plants having separate waste heat boilers and sulfur Condensers. The condensers can also be designed to produce low pressure steam and/or preheat boiler feed water. Any and/or all Of these variables may be present in any given sulfur plant. Therefore, an economic evaluation is usually needed to determine ‘the proper plant configuration and equipment selection unless a specific customer recommendation has been made. 17B-290-272formes 295 Ze 12 NrFLUOR CORPORATION Page 1 -FROOESS DESCRIPITON RECEIVED 170-291-272 . JAN SL 1972 GENERAL Engrg. Standards sulfur plant feed gases normally consist of a mixtiire of HS, C0, COS, 150, 03, and hydrocarbons originating in gas treating and/or sour water stripping operations. PROCESS DESCRIPTION ‘Acid gas feed to the sulfur plant is first sent to a knockout drum to remove entrained liquids and then burned. The hot flue gases are cooled by generating stean in a waste heat boiler and flow to one or more conversion stages for the production, condensation, and recovery of elemental sulfur. Cooled gases fron the final conversion stage are first disentrained and, in most modern units, are then processed in a tail gas treating unit to achieve high sulfur recoveries required to meet air pollution regulations, Vent gases from this operation are then incinerated to completely oxidize all components and vented to the atmosphere through a stack, Pollution standards may necessitate tail gas scrubbing. ‘The major reactions in a sulfur plant are: Combustion #5. + 3/2 Og—w-S0, + 1,0 Conversion 2,5 + 30, —-=3S + 2H,0 overall HS +1/20—e8 + 10 Additional sulfur product is formed from other sulfur bearing compounds in the feed, such as mercaptans and sulfides. Taree methods which are now used for sulfur plant combustion are listed below and schematically charted on Figure C-1 at the end of this section: Waste heat doller with attached conbustion chamber - consider for plants smaller than 100 L/D. ‘A separate combustion furnace and waste heat boiler - preferred for larger sized units. Produces high overall sulfur conversion. Waste heat boiler with direct firing into the Lining tube - most economical arrangement up to 75 LI/D, but results in lower sulfur conversion.Page 2 FLUOR CORPORATION PROCHSS DESCRIPTION Hot gases from the combustion step are normally used to generate steam in the waste heat boiler. Sulfur produced during combustion may be condensed by generating low pressure steam in a condenser upstream of the first converter. This is particularly advantageous if low level steam can be utilized elsewhere in the complex. 'S and 80, from the combustion step are reacted to produce sulfur over a bed of granulaf catalyst in each converter stage. ‘The gases to each converter stage may be reheated to maintain the optimum converter inlet temperature. The four methods most frequently used for reheating are listed below and the first three are shown schematically on Figure C-2 at the end of this section: 1. Injection of hot vapor from either the combustion step or some point in the waste heat boiler into converter feed gas. 2, Direct fired reheat burner using fuel gas or a small quantity of acid gas feed. 3. Gas-to-gas heat exchange of the converter feed and effluent gases to utilize the exothermic heat of reaction from the converter to reheat converter feed. Indirect reheat using fuel gas or steam. Method (1) results in the lowest overall sulfur recovery because some of the reactants bypass the converter stages. In addition, the piping and valving required is expensive and complicated and may result in maintenance problems. Method (2) uses a direct fired reheater in which the hot flue gases formed by burning either fuel gas or a slip stream of feed gas are combined with the main stream of feed gas to develop the conversion temperatures required. Flow ratio controllers are required on each bumer to maintain correct acid gas-to- air ratios, which results in additional instrumentation and piping and usually inereaces the cost over Method (1). Method (3) should be considered when high sulfur recovery guarantees (over 968) are required and a high capacity tum- down is not anticipated, Tt also has the highest installed cost because large exchangers are required for the poor heat transfer coefficients associated with gas-to-gas exchangers, the interstage sulfur condensers mist be designed for higher outlet temperatures which increases the feed to each converter stage, and the exchanger imposes an additional 0.5 psi pressure drop in the equipment train. Method (3) also has limited operating flexibility because the heat of reaction is vary sensitive to varying feed compostions and total feed rates. It may be impossible to maintain the converter temperature at reduced HS concentrations or lower feed rates without auxiliary heating. Three of four'catalytic stages are involved and employing the effluent from the first bed to heat the feed to the last bed will usually achieve the required recovery. Method (4) gives very high sulfur recoveries and a high capacity turndown ratio. However, the initial cost is usually higher than the other schemes when the additional equipment for firing fuel gas is included. The use of high pressure steam adversly effects the utility balance ina sulfur plant and mist be considered in the overall economics when evaluating a scheme, 170-291-272FLUOR CORPORATION Page 3 PROCESS DESCRIPTION Another seldom used reheat method involves using an external source of heat, This alternate may be economically attractive if an inexpensive source of heat is available elsewhere in the complex. Sulfur is recovered between each converter stage by cooling the product gases, usually by preheating boiler feed water and for generating low pressure steam. The condensed sulfur from each stage drains to the sulfur sump. ‘he final step in ell "traditional" sulfur plants has been the disposal of tail gas by passing the effluent gases from the last sulfur condenser through 2 coalescer to remove all entrained sulfur, incinerating with fuel gas to ensure complete oxidation, and then venting the gas to the atmosphere through a stack. In some areas this may still be allowed. However, pending governmental legislation all over the world will make additional tail gas treating mandatory to meet the proposed maximum allowable emission standards. In these units, the effluent from the last sulfur condenser passes through a coalescer and is then processed in a "tail gas treating unit" for removal of sufficient sulfur to meet the regulations, Hffluent gases from this unit are then incinerated and vented to the atmosphere through a stack. An economic evaluation should be made to determine the optiman use of converter stages and tail gas treating capacity. The Liquid sulfur is pumped from the sump into tank cars, to liquid storage, or to a solid storage facilit: RECEIVED JAK Engrg. Standards ae 170-291-272FiouRe C1 COMBUSTION METHODS on RECEIVED FEB 11 1972 fo ms acne i Engrg. Standards = cn elas SEPARATE REACTOR FURUACE (agove 18 11/0) 7” rom 20.70 sumuce Dict FRI beac wane aeFlouRe €-2 SULFUR PLANT DESIGN MANUAL REHEAT ALTERNATES encase fowcere} omar esa omc f or var srPass ReNEaT RECEIVED FER? Engrg. Stendards q DIRECT FRED RENEAT 5 EAT OF REACTION ROvEATFLUOR CORPORATION RECEIVED Page 1 FLOW DIAGRAMS JAN 31 1972 GRNERAL, Engrg. Standards The flow diagrams and sketches included in this section are as follows: Figure D-l Recommended Hot Gas Bypass Layout Figure D2 Process Flow Diagram - Hot Gas Bypass Reheat (+ MH, Rich Feed) Figure D-3 Process Flow Diagram - Acid Gas Fired Reheat Figure D-h Mechanical Flow Diagran - Hot Gas Eypass’ Reheat, Figure D-5 Mechanical Flow Diagran ~ Acid Gas Fired Reheat Figure D-6 Utility Flow Diagram - Hot Gas Bypass Reheat ‘These flow diagrams illustrate the following two widely used flow patterns which typify the many design variations which may be included in the design of "Claus" type sulfur plants: (1) To stages of conversion with hot gas bypass type of reheat, Mobil Oil, Contract 4350, is an example of this type of plant; and (2) Four stages of conversion with reheating by acid gas fired reheaters and indirect reheating prior to the last conversion stage. Shell Canada, Ltd., Proposal 6350-15, illustrates this. Schematic flow diagrams for typical tail gas treating processes are illustrated in Section DD, "Pollution Control". Any or all of the alternate heating, reheating and bypass configurations shown on these flow diagrams could be incorporated in any new plant design depending upon feed characteristics, product requirements and pollution regulations. ‘The flow sheets included in this section represent sulfur plant designs having the bare minimum equipment, instrumentation and piping for a plant to operate satisfactorily, and illustrate what is known as a "poor boy" or minimum cost plant. Additional equipment for a particular design is at the discretion of the designer, However, customer specifications may dictate the plant requirements. Plot Configuration A layout sketch is also included in this section as a general guide. This layout is based on the following requirements: (a) ‘The waste heat boiler economizers, tail gas scrubbers and boots on the converter outlet ducts should be as close to the sump as the foundation requirements permit because drain lines are subject to plugging.Page 2 FLUOR CORPORATION FLOW DIAGRAMS (b) the economizers and converters must be accessible for repair and main- tenance purposes. Cleaning of condenser or economizer tubes is generally not required. (e) Large ducting should be routed as directly as possible, expansion stress permitting. the air blower, incinerator, stack and tail gas clean-up system are not shown, ‘Alternate layouts have been considered; such as, placing the econonizers, doots in ducting, and the tail ges scrubber directly over the sump with the drain lines as vertical pieces of pipe less subject to plugging. However, the alternate layouts are estimated to be more expensive. It is normally better to use a "package" plant approach for small units (50 L/D and less) particularly for bypass type plants when required Liquid sulfur storage is low. In these units, the economizers and WHB are mounted above a horizontal vessel designed for low pressure. Sulfur fron all condensers drain into seal legs in the sump inside the vessel. The last economizer discharges both gas and sulfur liquid into this drum, A vertical sump pump is used for pumping out sulfur and a pump well is provided. Drain lines from the boots on converter discharge ducts are not provided. u7p-292-272FIGURE 0-1 SUGGESTED LAYOUT FOR HOT GAS BYPASS TYPE SULFUR PLANTS JAN 31 1972 RECEIVED Engrg. Standares CONVERTERS TAIL GAS SCRUBBER o TAL Gas FIRST ECONOMIZER SULFUR SUMP ACID GAS. FEEDaZz ebeg ones 280) we To Ne azaTo34| o6ed eaz ebed ea naw ara sna ‘ins tte, wai pt aay oznroay —- ] = SE 7 = waa 7z e6eg vaie---1 _ Page 2 DS¢ abe say eBed sazes-s0cta-act "vsn NI GaANtud a NVI HNaINS NOWVOIXO L9auIG WY NVA “INI ‘SHOLINALSNOD weudeig Moly seoo%g GNY SUB3NISNa soma La £0 ently — 234 tu) 08S pees our or eawstusee SNOBUYOOHGAH ON !310N suamore wiv wwais: aondbua wnains [recy :D RECEIVE Engrg, Standards Es S88 7a LI ugaaouos sg aivi “TURIN? watuganoo nnuguvais “WWANSISvik NOLWaINg {Saw segaruvon conronstion naa QUALIFIED VENDORS LIST RECEIVED Vege AUG 28 1972 Engrg. Standards Reactor Furnace John Zink Company J.T. Thorpe, Inc. Bcono-Therm Corporation Foster-Wheeler Corporation Waste Heat Boilers Victoria Machinery Dept Company (vancouver, B.C.) Toronto Iron Works Tower Iron Works (Seekonk, Mass.) Erie City Iron Works Union Iron Works Refractory-Castable Insulation A. P. Green J.T. Thorpe, ine. Pumps Lawrence Pump Company Chas. P. Lewis Company Dean Hill Company Goulds Pump Company Compressors Centrifugal Elliott Hoffman Allis-Chalmers Delaval Rotary Ingersoll-Rand Roots Connerville Package Units Ford, Bacon & Davis ‘Trentham Corporation Pona Engineers Pritchard, Eco, Inc. HOK Docinerators J. 7, Thorpe, Ine. Corina Incinerator Burners Vorth American Manufacturing Peabody Engr. Company John Zink Company sulfur Condensers (Beonomizers) wD Toronto Iron Works Tower. Iron Works (Seekonk, Mass.) Foster-iheeler Struthers-Wells Any reputable shell & tube manufacture Bypass Valve on Reactor Furnace J.T. Thorpe, Inc. Pumps Taber Pump Company Allis-Chalmers Pacific Pump Co. catalyst Porocell Corporation Reynolds Metal Company Stauffer Chemical Company Mill White Company Pechiney-Saint Gobain (France) Catalysts and Chemicals, Inc. (CCT) Liquid Sulfur Burners Todd Monsanto Chemico Chemipulp Process, Inc. Sirod Realty Corporation Joun Zink Company Celeco (Tumba, Sweden)FLUOR CORPORATION Page 1 VESSELS 176-295-272 bent AUG 28 1972 ‘Engrg. Standards GENERAL This section defines suggested procedures for the design of the sulfur converter, tail gas coalescer and feed gas knockout drum. Typical vessel sketches are included at the end of this section. SULFUR CONVERTERS (See Figures G-z & G-3) Discussion ‘The selection of converter configuration must always be economically justified, especially when the catalyst volume exceeds 3000 cu ft and/or more than two-stage design is contenpleted. Horizontal and vertical designs have both been successfully employed. Horizontal vessels appear more economical in two-stage units and vertical vessels may be more advantageous in multi-stage, large sized plants. Rail, barge and/or other shipping limitations strongly influence the maximum economical size of horizontal shop fabricated vessels and the choice of equipment. In some cases, two parallel shop fabricated vessels may be more economical than one large field fabrication. Vertical converters conserve plot area, but require large diameters and extensive internal and external support members. These requirements result in costs typically associated with field fabrication. Horizontal converter sizing procedures are described below under "Sizing Criteria". The first-stage converter is always lined with either castable refractory or fire- brick across the bottom and up the sides, to the top of the catalyst bed when catalyst regeneration is required. The top section above the catalyst bed need not be lined. All other converters are left unlined. Vertical converters consist of multiple beds stacked in a single unit separated by a “vapor tight” partition plate. The primary catalyst bed is placed at the bottom of the converter and lined with firebrick or haydite castable mix. Lining of the remaining beds is not mandatory. Inlet gas enters at the top of each bed and flows down through the bed to prevent fluffing of the catalyst and cut down losses. The design pressure of converters should be specified as low as permissible, con- comitant with its operating pressure (normally 0 to 7 psig), to minimize cost and avoid the need for code stamping. For instance, a design pressure below 14.9 psig avoids the need for code stamping in Canada. HKPage 2 FLUOR CORPORATION Cover all structural internals with refractory to protect against excessive short term heat caused by local internal fires during upset conditions and/or decarboni- zation of the catalyst. Sizing Criteria Sizing of converters is based on the criteria listed below: 1. The total catalyst volume (activated bauxite plus cobalt-moly) is calculated from the space velocity obtained on Figure G-l. The space velocity is defined fas the volune of total feed entering the reactor at reactor inlet conditions yer unit time divided by the volume of catalyst. The figure is based ona 36" bed depth of total catalyst. In the first converter only, 12" of C29-2-01 cobalt-moly catalyst which is supplied by Catalysts and Chemicals, Inc. (CCI) is loaded imnediately below 24" of activated bauxite catalyst when CS, and/or COS are expected in the converter effluent stream and sulfur recoveries of better than 93 percent are required. The length-to-dianeter ratio of horizontal vessels will vary between 4:1 and 6:1. Provide sufficient space above and below the catalyst bed to ensure uniform flow of gas through the bed, In many cases, multiple nozzles or deflection plates may be advisable, Allow 2-1/2 ft. to 3 ft. free board space for leveling the catalyst bed, and for the possible future addition of a 6" catalyst overlay. 3. Flace a minimum three foot square deflector plate 8 to 10 inches below the inlet nozzle drilled with two inch holes on one foot centers. 4, Locate the inlet and outlet nozzles so that the path length followed by all material is approximately the same; .e., inlet and outlet are at opposite ends, or center inlet with dual outlets on opposite end. 5. The pressure drop across an unfouled catalyst bed containing only conventional alumina or bauxite catalyst should be approximately 1.3 inches of water, not including entrance and exit losses. Preliminary pressure drop and other cperating data for a converter in which the C29-2-01 catalyst is used in conjunction with activated bauxite catalyst is listed in Table P-3 of Section P. Final design data must be obtained from the catalyst vendors (CCI, etc.). Every converter chamber should have at least one manway above the catalyst bed and one under the bed to provide access for inspection, When catalyst regeneration is not planned an additional catalyst manhole dump may be installed at the catalyst bed support level. 7. Catalyst is loaded from the top manway and is supported on a carbon steel grating. Those listed below have been used on previous Fluor jobs. These configurations may be equally acceptable. 17G-295-0872-1FLUOR CORPORATION Page 3 a, 3/8" x 2" carbon steel bearing bars on 1-3/k" centers - covered with @ stainless screen. b. 5/16" x 2-1/2" carbon steel bearing bars on 1-3/8" centers without a sereen, but covered with graded firebrick balls. c. 3/16" x 2" carbon steel bearing bars on 1-3/4" centers - with a 3/16" stainless steel screen. 4. Sulfuric acid converters use a mechanite grating with quartz. 8. Bauxite catalyst is placed on top of a layer of 3/" and 1-1/2" screened fire- brick particles nominally 6" in depth. In the first converter only, load the (29-2-01 catalyst below the bauxite catalyst and above the firebrick particles. ‘The average density of bauxite catelyst is 54 lbs/ft®, ‘The average density of C29-2-01 catalyst is 35 lbs/fts. 9. Insulate externally to maintain a metal wall temperature above 250°F to prevent formation of sulfurous acid which will severely corrode the metal wall. SULFUR PRODUCT COALESCER (See Figure Gl, G-5 & G6) Horizontal and vertical vessels have both been used as sulfur plant coalescers. Most large capacity plants have employed horizontal vessels with a single inlet nozzle and dual outlets. Vertical vessels have been used almost exclusively in ‘tthe Los Angeles office up to 150-200 long tons per day of sulfur production. An economic optimum between vertical and horizontal vessels must be developed for each design. A complex, horizontal separator (sized using C=200 in the forma shown below) should be utilized when no tail gas fecilities are contemplated, maximum sulfur recovery is mandatory and cost is a secondary consideration. ‘The typical design paraneters and vessel configuration shown on Figure G-6 would provide e maximum sulfur entrainment loss of about 1.5% for a plant designed to process low (5-108) HS feed gas. ‘Me use of tail gas treating units in modern plant designs may mitigate the need for having a separate coalescer drum, because entrained elemental sulfur will be recovered together with whatever sulfur is formed in the treating unit. Alternately, a disentrainment chamber may be included in the outlet channel of the last sulfur condenser to minimize sulfur losses and reduce cost. If a decision is made to use a coalescer drum, the following design criteria are recommended, RECEIVED AUG 28 1972 Engrg. Standards IK 176-295-0872-1Page 4 FLUOR CORPORATION ae Use the Brown-Souders correlation listed below to calculate the diameter of tae vessel. Gac pi(a-p,) Where G = Vapor Velocity, 1b/nr/ft® Vapor Density, 1b/tt p, = Liquid Density, lb/ft? © = 200 to 900 Phe selection of the "C" value in the above formula is somewhat empirical and is a function of the concentration of both the acid gas in the plant feed and the desired percent recovery of sulfur. Sulfur entrainment loss can amount to as much as 2% of the produced sulfur. Therefore, with high recoveries of sulfur end/or lover concentrations of acid gas in the plant feed, a "lower" "c" value should be used. Conversely, at low recoveries and/or high acid gas concentration in the feed, a "higher" value may be acceptable. The final design of the coalescer is dependent on whether a tail gas clean-up unit is ineluded in the plant design, and requires an economical evaluation to optimize ‘the incremental costs between the tail gas unit and coalescer. install e 6" demister pad to remove finely entrained elemental sulfur. In some of our units a 1-1/2" steam coil has been positioned close to or in the mesh element in order to melt solidified sulfur during upset conditions. This modification is not considered mandatory. Install a heating medium, such as steam coils, electric tape, etc., in or ground the bottom of the vessel to keep the sulfur from solidifying and plugging the drain. If a steam coil is used, it must be of all-welded construction to prevent steam leaks. Make sure that the top head of the top section of the vessel is properly jmsulated to prevent condeneation of sulfurous acid which would produce excessive corrosion. 17G-295-0872-1YFLUOR RECIVED FIGURE G1 CONVERTER CATALYST VOLUME JUN 5. 1972 Engrg. Standards SPACE VELOCITY = ACTUAL FT.3 FEED/HOUR/FT.? CATALYST SSS = _ : js = 5 a a MOLE % HzS IN TOTAL PLANT FEED PRINTED IN USA. v7e-c1206.572-1PROCESS DESIGN DATA VESSELS Co0e STAM _ NONE BS ‘OTHER SPECS: 23 DESIGN coNDITIONS? WIA va ge HAYDITE AGGREGATE rressune Wo sig 8 Ee 3 LINING, . WALUMINA CEMENT IN A 4:1 TRMERATURE 775 °F 815 MAKING LIQUID LEVEL Ga ink RATIO OR EQUAL. (OPERATING CONDITIONS. V-1A UL aaisaaeta PRESSURE 4 PSIG 4 (wd) TEMPERATURE 660 °F 8s TNORWAL LIQUID LEVEL Fr. GRADED BALLS on | CORROSION ALLOWANCES 1/4 ‘CRUSHED MATERIAL FIREBRICK| “ SHELL ‘CARBON STEEL ® INTERNALS CARBON STEEL (4) ‘TRAYS, . caps S Lining AS NOTED PACKING - TYPE OF TRAY ) TYPE OF PACKING. - 7 8 Nozze sorenute 3 i ms | wm sie ats i tte ‘sl as cor pea @ SPECIFIC GRAVITY OF LIGUIO STRESS RELIEVE NO NOTES & REF. OwGS CAI frarnala 10 be removeble thre 17" 1.0. menhele, (2) Steom jackered noxsles 0:1 & D2 Wreducing CATALYST Sagauyst Aang & 2 nie at geanne (2) Conm In VIA be Hh W/L. fling. COVERED W/ss ‘WIRE MESH! (All fatornola except groting to be lined = 2" Hoydite ‘Agatogare plus Alumina Cament ino 41 ratio erogal. FiouRe G-2 V-1A & 1B HORIZONTAL SULFUR CONVERTER (TYPICAL OF TWO) :CATALYST "CRUSHED FIRE BRICK GRATING Engrg, Stanaercs © YU o ® PARTITION PLATE PROCESS DESIGN DATA VESSELS (cove STAMP omer sPecs. DESIG’ CONDI TIONS PRESSURE 10 Tewerarune 650 °F © 750°F SwxiMem LiQuiD LEVEL Fr. ‘OPERATING CONDITIONS: | PRESSURE 0-5 psig i TEWERATURE 460-600 °F *NORAL LIQUID LeveL rr | comsosion ALLownces Yes ed TATERIAL SHELL canon sree INTERUALS CARBON STEEL (2) revs : cars : mins ® pxcxins : TYPE OF TRAY o | TYPE OF PACKING = FIREPROOF ING no. INSULATICN YES (Win. Shell tomp = 2500F) NOZZLE SCHEDULE size ere [7m size aT. 4 Tose To) PY st orate xa |) i Vener ier Veper Outer ‘/Mlngs Merwe 7 2 /Dewn . FIGURE G-3 V-1A,B,C,D VERTICAL SULFUR CONVERTER (TYPICAL OF FOUR REACTORS) SPECIFIC GRAVITY OF LiguID STRESS RELIEVE NO NOTES 8 REF. ONGS | (1) All Conn. to be flush w/.D. of lining. (2) Section Enclosing Bad No.1 tebe lined w/2 Hoydive aggrogete mixed 4:1 w/Alumine coment el. (2) All iotaroate except grating to be Hined w/2"* Hoydive oppregete mixed 4il w/alumina coment or eavel (2) Flush w/tining on bottom Nozael w/red flange & 2 =X" CONTRACT No.\ PROCESS DESIGN DATA RECEWEO \ HORIZONTAL VESSEL oat Engrg. Stanoarés oman CALC. USING FORMULA IN @ = @ @ TANGENT LINE TANGENT LINE TYPE 304 6" 55 esi VLE O@ Koro. 6 o 3 i i i i i i i i 2 i i i PRINTED IN U.S.A, te tf uy [oot star WOME omen Srecs 8 Sz DESIGN CONDITIONS: | PRESSURE 0 Psic | *AXIMUM LIQUID LEVEL FT, 7 TEMPERATURE 20 °F # = FewenaTone eg a2 CORROSION MLOWNGS 8 ash < TH Timine io gE wavertacs:|sHeu, CARBON STEEL 238 NOZZLE SCHEDULE fe = : as m [* [eal™ [oalaal | | a #&= ~, # Bee 288 RIG. 2 2 ge aN SPECIFIC GRAVITY OF LIQUID aes | FicuRe 6-4 ete ell eereereremerense HORIZONTAL PRODUCT COALESCER (1) Dy & Dz ore Steom Jacketted Nozzles w/2-M" nipples for steom (TYPICAL) eal eaatas (2) n/m TonTRACT WO- FLUOR CORPORATION. Fonu Eon Rev. 10-67RECEIVED le PROCESS DESIGN DATA VERTICAL VESSEL. 31 O77 ' valu S172 Tora ¥ Engrg. Standards OTHER SPECS: SES ETO 2 ressue asa1o PSIG ML GS toeenmune #80 °F Sewxibear LiQuiD LeveL Fre (OPERATING CONDITIONS pressure? psig reweeraTune 280 op NORMAL LIQUID LEVEL Fr. Catuctate FROM ["compasion ALLOWANCES 1/8" FORMULA - IN SECTION & MATERIALS: SHELL CARBON STEEL INTERNALS CARBON STEEL ces. 2 i Lining. - 6° YORKMESH OR PACKING - EQUAL TYPE 30185 x i i i i i i TYPE OF TRAY TYPE OF PACKING i ri | FHREPROOFING NONE: h INSULATION YES (in, Shall omps 25067) 8 MORILE SOUEDULE of _« size RTS. ca SIZE RTS fe alee : [ae : ie g ce a 3] ' ry Te" 7 steaun 7 SPECIFIC GRAVITY OF LIQUID STRESS RELIEVE NOTES & REF. DNGS. (1) »/tnvarnal steam ceil tight o (2) All latarnats 0 be romeval ew 17" 1.0. Manor, FIGURE G-5 VERTICAL PRODUCT COALESCER (TYPICAL) — RAT NO rocciaoware THE FLUOR CORPORATION Uo. Fonn Bose Rey 10a7PRINTED IN U.S.A, PROCESS DESIGN DATA RECeIVzD HORIZONTAL VESSEL JUN 5 1972 usa Engrg. Standards i i 3 : 5 i 5 2 5 : 3 z 3 cnsoe 8 : ¥ ba cove stave OTWER SPECS: 1 rs ie DES10¥ conoI TIONS: [PRESSURE 516 | Tuaxiwum Liquio LeveL rr. —— TEMPERA TURE oF ee Fer EnaTORE 7 23g ast CORROSION ALLOWANCES re eareni ats: [sues eee es Eee Tine PROOFING “Lissucation 3E nore SonFOUE 385 me | a | 8 | ors | sise . a wm |e rt me aed SPECIFIC GRAVITY oF Li@uID ty STRESS RELIEVE Figure 6-6 FAIS vores 0 er, oes, COMPLEX HORIZONTAL (1) Dy, Dz & Dg are steam jacketed nozzles with two %"* PRODUCT COALESCER tipple fortum in and come ot. crvrcat) (2) Staats mut be ght apie bottom sal CONTARET WO. 7 ewer FLUOR CORPORATION Fon Ban Rev. 1087FLUOR CORPORATION Page 1 PUMPS, COMPRESSORS AND DRIVERS 2 are RECEIveD Jaw G GENERAL Engrg. Stancerc: Manufacturer's standard equipment shall be provided suitable for outdoor service and in accordance with the manufacturer's recommendations for the particular service. nypical specifications for the air blower, sulfur pum and sour water pump are included at the end of this section. ‘The air blower is usually driven by a back pressure steam turbine operating at 200-300 psig inlet and 35-60 psig exhaust. This is particularly true in self- contained plants. ‘The air blower may be driven by an electric motor if the sulfur unit is integrated with other units and economics so dictate. Motor drivers are almost always used for pump drivers. Motors shall be non~ overloading at any point on the pump curve, in addition to conforming to other customer pump specifications. Types of motors will generally conform to one of the following electrical classifications. Class I, Division 2, Group D - Explosive vapors or gas of the gasoline ‘type with a lover hazard potential. Class II, Division 1 or 2, Group G - Dust hazard from non-conducting dust (normally used in a solid sulfur storage area). AIR BLOWER The design head of the air blower is determined by the pressure drop through ‘the sulfur plant from the incinerator inlet back to the furnace. The design volune is determined by the feed gas quantity and composition and the selected process configuration. The plant pressure drop is always defined by plant layout, which is generally unavailable until long after the job schedule requires a specification for the air blover. Therefore, the values listed below have been developed from operating data to estimate the pressure drop in the system starting fram zero psig at the inlet to the incinerator. Add a1 to 1.5 psi "safety factor” to the calculated value to establish the blower rating.Page 2 FLUOR CORPORATION Across inlet filter 0.1 psi Across the air register of the burners 0.5 psi Across each converter bed 0,05 psi* Lines between equipment 0.05 psi Across each tube pass of WHB and tube side of each condenser 0.25 to 0.4 psi Shell side of gas-to-gas exchanger 0.5 to 0.75 psi Direct fired reheaters 0.2 psi Tail gas scrubber 0.05 psi Air control valve 0,5 to 0.7 psi Safety Factor 1 to 1.5 psi Add entrance and exit losses to this value Air blowers requiring internal lubrication (e.g., sliding vane rotary blowers) are unsuitable because the oil will carbonize and foul the catalyst and/or discolor the product sulfur. Lobe type blowers (e.g., Roots Connersville) have been found to cause excessive vibration unless provisions are made to overcome this problen (e.g., pulsation bottles and adequate duct length, etc.) PUMPS Single-stege centrifugal pumps with mechanical seals are preferred in sulfur plant service. These pumps require steam jacketing using 35-75 psig steam to keep temperatures between 270°F and 290°F. Pump parts of cast iron and steel are satisfactory for normal liguid sulfur ‘temperature ranges (below 300°F). Avoid pump parts made of copper alloys. Pure nolten sulfur is not erosive or corrosive and is the preferred lubricant for both horizontal and vertical sulfur pumps. Carbon bearings are used in some types of sulfur pumps, but are not recommended. Sulfur pumps should be piped and mounted over the sulfur sump to provide easy removal and installation. After the unit is in operation, welding and lining repaizs cannot be done over the sump because of fire hazard. LTH-296-272FIWURE Hol ‘re FLUOR CORPORATION, LTD. SPECIFICATION SHEET CENTRIFUGAL COMPRESSOR sheer Mo, ___nEV. ATE, eee) RECEIVED ote: VENDOR MUST ENTER ALL MISSING PERTINENT OATA AND RETURN MITH PROPOSAL. JAN 34 1972 For Typical Specafivatios NANUFACTURER Engrg. Standotcs pestination Sulfur Plant Manual TYPE AND SIZE UNIT. Sulfur SERIAL NO, ITEM wo. No. REQUIRED Quote No. parE service __Air Blower (2) PURCHASER ORDER NO. DATE PROCESS REQUIREMENTS Oth GAS HANDLED BAROMETER, STD CU ET_PER MIN (14.7 paio ~ Soe Ory) ™ WEIGHT FLOW, Ib per hour INLET. CONDITIONS Pressure, pelo Temperature, d - (a) Relotive Humidity, percent & oy Molecular Weight (M) B65 Cp/Cy (Ki) a 1 Compressibitiny (21) Le La Inlet Volume, ev ft per min DISCHARGE CONDITIONS Pressure, pale bef 20.7 Temperature, Cp/Cy (Ka) La ae Compronsiility (Za) Le 1.0 HORSEPOWER REQUIRED BY DRIVER SPEED, rpm ESTIMATED SURGE, ICFM (At Speed Above) ADIABATIC HEAD (Hg) PERFORMANCE CURVE NO. CORROSIVENESS AND REMARKS REGARDING GAS (2) Normal /Min. (2) Use steam turbine wriver eh as Ug imELGURE 1-2 RECe. 0 SPECIFICATION sHEET JAK © L CENTRIFUGAL PUMP SHEET Wo. Engrg, Stancat@e "© ron Typical Specification rew wo. _P=10L ini Sulfur Plant Manual P.o.no service Sulfur Loading woTon onive_X__Tuneine onive Pum uPR ze a twee _ Vertical wo.neqo, 1 ‘OPERATING CONDITIONS, EACH PUMP PERFORMANCE, Tere Ligutd Sulfur U.8.ep0 af PT, FOR. Tare BOD] peorosat cami . DIsen PRESS. pete 5 osu neg’ (uaTER), fe cf BB = Bs ne. psn “09 ar ean —— ~_ woe pre ure Passs.. es er. oe ve ress, or wero, te wax oo RATED vis seer, sey 8 Nesu AVAIL. FE MAX MEAD RATED IMP, £ comny170$, cmuned Tye 2028 | urn corr ere OF oD "AND_MATERIALS ROTATION FACING COUPLING EXD ‘Taincawutne CENTERLINE) (FOOT) sneger—) CvertTea 2] WATER COOLING ur (AMI. > exon X > sean Te (sioLevauure -X ) (oouRE VOLUTE =) COIFFUSER str. por Tape orenines (ENT) CORA.) (GAGECOINS Peoesta. rozz.ss ze | asa arinG | PACING rosrti0N eae neo t t comes BrScHAnGe al OTA, WATER REG. eo Tarde or ATED 5 or Fre_aclased | ruusrano en" § BEARING 10. RADTA. leeve ‘rust — tony SEAL FLUSIING PLAN. COUPLING an OUARD: HR omiveR WLP oy ‘AUX PIPING BY MFR. Cacaive: we mete YOS ize __no. oF eins |Camewrer CO nme Corre ean seas WR ws W908 Hone ari ass aoe SEAL FLUSH rane rive FOR VERTIC PP S: SHAFT TRUST WP) (DORM) 1» Tests as _ Tae FERS Reoureea | vines WATERIAL CODE=EXTERNAL CASING DRO Por | TEAST WON |TTBRNALS coe z SH | cott-taxcamous | steeve cwacxen) [om mROSTATIC ard stor snare (sea) € WAX.ALOW, CASE p-WARDENED eas Pants t | areeox. wercis: pu mase MOTOR DRIVER BY TURBINE DRIVER BY WER FINAL DATA (AS BUILT) re TEFC eu | et stea.psig eer | Pin stepwise, xe yaw nist ©, enwust, oF RED, oe — | seu. sex. one wo. a veursmusereveres 40/3/60 | sremreare, FL _ vee | PUP SORA 6. tesenes Ball ume suarnos ume we cea, o2m : ~ sazz.es| S122 | soa eaTinG AGI [postion | (MECH EAL) (ACKTHG) SALPPED - y — Oi mstauieo (boxe seraeareny [exuust st cketed_colum & disc! — Pump Length to PageWecasiacnr¥e iaeetentner@acnehFIGURE SPECIFICATION SHEET RECE ES JAN EL 2 sions ev. CENTRIFUGAL PUMP — Pete SHERISN care ron_Typical Specification rreuno,___P=102 tee Sufi Flant Manual panto service Sour Water Transfer aoe sare rans ome Powe re waee PE ears OPERATING CONDITIONS, EACH FUME PERFORNANCE Sree SS ater Dee ett ok | PE SE bisen ress. ute 105 veavene cauttn, prp GO Burr PRESS. psig MAX 5 RATED____| NO.OF STAGES PH eae burr mest pot 20D caer ~~ varie teenie, LO peetevanpien (oars cred BOBS IHG wre | et cones peer ar CONSTRUCTION AND MATERIALS ‘Tasine-wountinG (CoNTERL Ne ) GURAGLET > (WarTeaL | waTaR cooLaNe eur uA > wai, sean We (SINREVOLUTE —) (OOUMLE VOLUTE—)- (DIFFUSER STUFF. box TWoPED OPENINGS (VENT) (DRAIN) (CATE.COMMS =) PepestaL _ __moezes [asa eariyc | _pactas posttioN cus ~~ surnon t T a ‘coouee —_ BIscMaGE TOTAL WATER RED. ape CO Pace: WR na TPE Chweor seis wk ae woOe FOR VERTICAL PUMPS: SHAFT THRUST (UP) (DOM) #91 Lass. coe ‘AUX PI ay roped ete eure) [ir a et ie = wears Pe = Oe = iNAL_DATA, “ACTUAL TWPELL OF — (As BUILT) seers puareaut H0/ 3/60 — | rower roe wai sears Bal] wee ____| neaernas, | we CLEARANCE, OFA (80H SEAL) (PACKING) SHIPPED Co iwstausen Deore serararenyFLUOR CORPORATION Page 1 FURNACES: HEATERS EURNACES AND EATERS RECEIVED 2rn-297-272 Jah 62197 General Engrg. Stondsee: Tis section discusses the combustion equipment used in a sulfur plant which includes the sulfur furnace(s), the reheat furnace(s) and the incinerator. Included et the end of this section are typical process ‘specifications for these equipment. ‘The Olin Matheson furnace used in the past is considered uneconomical and has been deleted from the manual. Sulfur Furnace The sulfur furnace burns acid gas streams with a controlled amount of air. Present day sulfur plantsuse either a "Scotch Marine” direct fired design or an external combustion chamber (sometimes called a reactor furnace). The direct fired configuration provides for combination of the acid gas feed inside the Waste Heat Boiler and is limited to firing quantities of relatively high HS concentration acid gases which will conform to economically sized boilers. These furnaces are discussed in detail in section J, "Waste Heat Boilers". The "reactor" type furnace consists of a refractory lined cylindrical shell containing one or more burners. This design provides for completing the oxidation process before routing the products of combustion to the Waste Heat Boiler. The minimum theoretical flame temperature for combustion of pure HS is approximately 1680°F. ‘This temperature will vary depending on the quantity of other combustibles end inerts in the feed gas. ‘he air required for the burner is established by the type of sulfur plant (i.e., straight through or bypass) and the calculated flame temperature. Combustion temperatures in the 2000-2200°F range are common. When Ni rich gases, such as Sour Water Stripper overhead, are processed in a sulfur plant, excess air is required to ensure complete combustion. Because the quantity of HS normally associated with NH, is not enough to satisfy the 2/1 ratio of H,8/S0, of the commingled feed to the converter, supplemental HS must be provided (usually from the primary Hj8 rich feed strean). In addition, a separate burner or preferably a separate conbus- tion chamber is considered the most desirable design for obtaining overall sulfur plant recoveries above 964. When recoveries below 96% are con- templated, a single combustion chamber is satisfactory (i.e., the Mobil- Joliet design). The most economical arrangement for this system is as follows: HKPage 2 FLUOR CORPORATION FURNACES AND HEATERS ‘The shell of the furnace must be internally lined and externally insulated to maintain a shell temperature above the water dew point of the flue gases and prevent the formation of highly corrosive sulfurous acids. Furnace heat release varies linearly between 30,000 and 12,000 Btu/tr/ft? for iig8 contents of 25 to 100 Mol.f respectively in a straight through plant design. The heat release will be approximately 20% higher for the bypass type plant. ‘The turndown ratio should normally be limited to 4/1, 2 standard in burners. The addition of specially designed burners as added burners allow 5/1 and 6/1 tarndown ratios but at increased cost. The furnace shell operating temperature must be maintained above 300-350°F to remain above the water dew point and avoid formation of highly corrosive condensed sulfurous acid. The effect of turndowns must be considered when setting the design surface temperature. One unique design method usea for controlling shell surface temperatures in areas having wide range ambient air conditions consistedof installing a 1/8" insulation enclosed in a Weatherproof aluminum shroud, equipped with a chimney vent and adjustable dampers ‘The furnace lining consists of high temperature, pall resistant refractory plus a layer of insulation. The most widely used method consists of firebrick refractory backed by either castable insulation or insulating block. For preparation of the furnace specifications specify the combustion air and acid gas pressure at the burner as 0.5 psi above the desired furnace outlet pressure. Reheaters Reheaters are used (instead of hot vapor bypass) for heating sulfur con- verter feed streams to maintain reaction temperatures. Design of these heaters conforms to generally accepted heater design practice and includes the same design limitations described in the "Sulfur Furnace" section. 171-297-272FLUOR CORPORATION Page 3 RECciVeD FURNACES AND HEATERS Incinerators ancinerecers Engrg. Standards ‘The incinerator is designed to burn either the sulfur coalescer vapor or tail gas scrubber tover vapor before these gases are vented to the atmos phere through the stack. Package unit designs usually are purchased for this service. Often it is convenient to also burn waste streans from other sources in the incinerator (such as inlet separator Liquids, hydrocarbons, liquids from regeneration of adsorbers, etc.). These streams must be listed as separate feed streams when preparing a process specification. ‘A vertical incinerator at the base of a stack is not recommended unless the unit is small, the contract competitive and the client requests or sanctions this type of service, These units have frequently failed. For checking vendor quotations use the following General Design criteria. 1. 40,000-50,000 Btu/hr/ft® for firebox volume. 2. Allow 5% for internals. 3. Use 100 ft/sec maximum muzzle velocity for sizing stack if included in the quote. 4, Use separate specifications for incinerators and stacks for sulfur plants larger than 100 Li/day. Normally, @ natural (induced) draft incinerator followed by a vent stack is the most economical design. A snaller incinerator and stack is possible with a forced draft design. However, the increased operating and invest- nent cost of the blower because of the increased capacity and added pressure Grop of 0.1 to 0.25 usually overcomes the advantage of the smaller inciner- ator and stack. An economic analysis is required to determine the best design. Provide a pilot light and ignition for the incinerator. At times, a torch may serve as the ignition. In addition, a flame failure alarm or breeching temperature alarm should be specified. WK 171-297-272Page 4 FLUOR CORPORATION TABLE TYPICAL SPECIFICATION FOR REACTOR FURNACE EM H-1 SCORE ‘This specification covers the design, materials, fabrication and installa- tion of refractories for a Reactor Furnace for installation in the Province of Alberta, This Furnace will provide flue gas for a Waste Heat Boiler by the combustion of an acid gas stream containing H,S. Auxiliary fuel gas will be used during startup. The firing end, complete with burner, will be enclosed in a building. PROCESS SPECIFICATION Acid Gas Component to Burner ‘Air to Burner Furnace Outlet No 0.0 6466.39 6466.39 #0 97.0 192.0 2785.73 co, 785.06 0.0 785.06 cos 0.0 0.0 22.32 4,8 3368.21 0.0 613.05 803 0.0 0.0 306.52 02 0.0 1718.92 8.37 bas 0.0 0.0 323.51 G 2.he 0.0 0.0 c 0.95 0.0 010 cs 175 0.0 010 ney 2.87 0.0 010 acy 0.25 0.0 0 Mols/Hr 4258.50, 8377.31, 11310.94 Ibs/Hr 151,421 239,604 385,828 ww 35.97 28.85 34.11 Pressure, psig 5.25 4.75 3.65 ‘Temperature, °F 80 120 aio Heat Release = 280 MM Btu/Hr Design Conditions Shell Design Pressure 14.9 psig Code None Max. Acid Gas Rate 4600 Mo1/ue Max. Combustion Air Rate 9000 Mol /Hr Max. Heat Release 310 MMBtu/ Hr Max. Operating Outlet 2800°F Overall Pressure Drop 3" W.C, (Acid Gas Side) Turndown 6:1 Atmospheric Pressure 12.2 psia 171-297-272FLUOR CORPORATION TYPICAL SPECIFICATION FOR ACID GAS REHEATERS SCOPE TABLE 1-2 ‘ITEM H-2 RECEIVED 23 872 Engrg. Standards This specification covers the design, materials and fabrication of three acid gas reheat burners. set forth on separate pages. PROCESS SPECIFICATION Gas Stream Acid Combustion Component, ‘to Heater Gas Air TN 6466.39 503.15 Hg0 2875.73 - co 785.06 = cos 22.32 -- 1S 613.05 262.08 50, 306.52 - o% 8.37 133.75 Sas 1.02 = oy - 0.19 es 0.07 & = oak ny - 0.22 ns = 0.02 10988 45 323.80 636.90 bs / tr 308,286 11,646 18,376 ww 28.06 35.97 28.85 ‘Temperature, °F 280 80 120 Pressure, psig 2.55 3.50 3.50 Heat Release WK 21.946 MyBtu/Hr Normal 25.000 MMBtu/Hr Design The process requirements for each reheater are Hot Gas Stream From Heater 6969.54 3029.81 846.15 2h.19 664.56 332.28 9.07 26.20 11981.80 338,308 28.2 483 2.45 171-297-272Page 6 FLUOR CORPORATION TABLE I~: ‘SPECIFICATION FOR INCINERATORS ‘ITEM H-3 SCOPE ‘this specification covers the design, materials, fabrication and installe~ tion of refractories of horizontal ineinerator(s) to burn the residual HS ant elenental sulfur in the tail gas froma sulfur plant. ‘he flue gas from ineinerator(s) shail contain all available sulfur in the form of sulfur dioxide which shall be dispersed into the atmosphere via a foot Stack, The stack shall be provided by others. The process requirenents for each incinerator are set forth on separate pages. PROCESS SPECIFICATION Component Tail Gas Fuel Gas Combustion Air Stack Gas Ne 7428.87 5.04 4158.18 1592.09 #0 3879.99 = 710.27 cy 926.13 1337.57 cos 6.48 - S 45.81 80 22.91 0% - s a5 o e 356.28 ce - 20.84 C3 —=_ —= 12311.30 38h.50 5263.49 2794.78 Lbs/Hir 322,284 6587 151,852 480,723, MW 26.18 17.13 26.85 26.79 Temperature, °F 100 6 1200 Pressure, psig ‘Atmos. 20 Mins. Atmos. Heat Release = MwBtu/ Hr Excess Air $ Turndown Ratio ‘Atmospheric Pressure = 12.2 psia Ambient Air “O° to 90°F 171-297-272ae) go & SAWN aavuL NazHD aye = GG SQ 2 = 2 n0zzm, WY 3 yorue aula (saat ONY, G392¥E GNVH sv9 a1ov auvanoaas wouvansn aunoisva, [oe] #31108 13H r aLSYM OL a aqanozowaaHt waNNvas So! fs sie a a230Nt Py (alaig Fyfor—[!9°W WO) BOWNUNA YOLVIY WIIdAL et-1 aunotd BuaH SaHDYLLY ananassy yaNuneFLUOR CORPORATION FIGURE bb TYPICAL REACTOR FURNACE RECEIVED JAN 32 1972 Engrg. Standards : COEN BURNER MODEL DAZAS COMB. PEEPHOLE ‘& TORCH DOOR PILOT ACID GAS NATURAL GAS INLETS INLET EXPANSION ROLLERS END VIEW A+A AS PURCHASED ‘x AIR INLET ‘Te CONN. cio” GAS INLET, NATURAL GASES INLET MATCH WHE THROAT DIA. A EXPANSION al ROLLERS ELEVATIONviz 7300" waNune Jang na NyDIuaHY HLUON Engrg. Standares 13tuno svo 1aAa8 _/ LaTNI svD. vaaae ‘aasvHound s¥ YALVEHAY WIIdAL zt aunoia nolayuos4oo wosFLUOR CORPORATION FIGURE 1-3 RECEIVED TYPICAL WASTE GAS INCINERATOR & BREECHING waste cas fT INLET oucT SECTION A- A WASTE Gas. DUCT INLET bu AS PURCHASED AIR INLETS: YAN G1 1972 Engrg. Standares SECTION B-B ae (CUSTOMER To SPECIFY EXACT LENGTH) v4424M1 svo-Wwian 01 SaNo4ssuAOD #4 4. ‘Banavaaamas s¥9 ‘Ag GBLNGSzEaN BHNLXIN YOUYA 40 NOLLIGNOD ANY Hod Os01 “AON 86EE 94 LL “ON EY "TOA AULSINAHD ONIWZBNIONS ¥ TWIMUSNON! \ZDNaNaAaE SdoavA unaThs NOLLYWUOd 904 40 SLIM 535¥9 UBM SH7/A0aVA ansans #7FLUOR CORPORATION Page 1 MISCELLANEOUS EQUIPMENT 271-300-272 RECEIVED YAN 32 1972 General. Engrg. Standards ‘This section defines the scope of purchased sulfur plants which consist of skid mounted or package units and the design of the waste gas stacks. Purchased Sulfur Plants ‘A "package" plant refers to closely integrated units purchased from vendors which include the equipment required to recover sulfur from acid gas streams and store the product. These units normally do not include the feed knockout drum, product coalescer, incinerator or vent stack and can be enveloped in an area 25" x 50’ for capacities up to 50 Li/D. Skid mounted units refer to supplying sulfur plant equipment on one or more skids which simplifies field erection. Ford, Bacon & Davis supplies these units for plant capacities up to 150 L1/D of sulfur. They recoumend that the plant be completely preassembled, disassembled, and re-erected fat the plant site for all units above 20 IT/D capacity. the companies listed on Table I-2 provide sulfur plant packages. However, only Ford, Bacon & Davis will guarentee recovery in the 964 range. They use the Pan Anerican Petroleum Corporation process followed by a licensed tail gas scrubbing process. Waste Gas stacks Waste gas stacks are provided to vent effluent gas from a sulfur plant to the atmosphere. Stack configuration is determined by the quantity and temperature of the gases leaving the incinerator in the sulfur plant and also by the local air pollution codes as discussed in Section DD, Pollution Control. A typical stack specification is included in this section. A common stack is generally used when two or more incinerators are required in a sulfur plant with individual breeching for each incinerator. A sample connection must always be installed about 100! above grade to measure the sulfur loss. Be sure that access to this connection is providePage 2 FLUOR CORPORATION TABLE L-1 Plant Capacity Guarantee Company Location Lm/D Recovery Cost Date ‘Trentham Corporation Houston, 270 max. Cost in ‘Texas 80-90% with function of HBS < 20h 0.6-0.7 power of capacity. (1) ‘Ford, Bacon & Davis Garland, 3-150 om On application ‘Texes 99% with for specific tail gas Proposal. scrubbing Howe-Baker Mngr., Inc. Tyler, - - (2) Texas Pritchard, Heo, Inc. Kansas City, -- Missouri Pona Engineers Houston, -- Texas (1) uoted by Trentham Corporation, January 1971: Elemental Sulfur Plant Skid Mounted, Two Stage Sulfur Plant (not including incinerator and stack) 5 LyD $ 70,000 15 L/D 160,000 50 L/D $275,000 75 un/D 100 La/D (2) Howe-Baker indicate they no longer bid competitive applications but reserve their interest to plants offering unique processing problems (high ammonia feeds, ete.) where their custom design capabilities are fully utilized. Pan American Petroleun Corporation licensor. 171-300-272FLUOR CORPORATION Page 3 TABLE 1-2 TYPICAL WASTE GAS STACK SPECIFICATION Scope Thie specification covers the design, materials, fabrication and installation of a stack for the dispersal of flue gas from two sulfur recovery plant incinerators. Process Requirenents RECEIVED NORMAL FLOWS Ji Mols/Hr gre. Standars Incinerator Incinerator Comp FoA-505 F-A-506 Total a 11592.09 16591.26 28183.35 10 470.27 6498.99 11209..26 co 1337.57 1897.37 3234.94 sq 83.79 231.53, 315.32 & 221.06 34.76 565.82 17944.78 25563.91 43508.69 Ibs/iir 480,723 690,976 1,271,699 Co 26.79 27.03 26.93 Temp., °F 1200°F 1200°F 1200°F OPERATING CONDITIONS Required Draft at Base Minimum Temperature at Base Excess Air Atmospheric Pressure Ambient Air Mechanical Design Stack height shell be (1) feet. 2" Water Minimum 1000°F 25% 12.2 psia -4O°F to 90' Stack diameter shall be (1) feet I.D. of the liner at the top. (1) Based on local ground level emission standards for air pollution. HK 171-300-272viuon coronation RECEIVED rage 1 PIPING JAN UL 1972 301-272 Engrg. Standarcs codes ‘All piping shall be in accordance with applicable portions of the latest revisions of the ASA Code Pressure Piping and ASA B-31.1 except as modified. Specification Sulfur plant piping is normally carbon steel throughout. Table M-1 & Figure M-1 represent typical piping requirements and the major "special" considerations in sulfur plant piping. Detailed specifications may be obtained by referring to any of the Fluor designed sulfur plant projects listed in Section Q. Miscellaneous Comments a. Sample Connections Sample points should be placed on the top or sides of the ducts above the center line and be conveniently accessible to facilitate sampling. Such positioning will reduce the problem of sample valve plugging. b. Insulation Selection of insulation should be made on economic heat conservation principles. This should provide a more conservative insulation specifi- cation than would other process considerations such as minimum wall temperature, moisture dew point, ete. c. Jane Sizing Piping should be sized for optimum design based on economic evaluation. However, 100 ft/sec will prove to be the optimum velocity for most plants.’ This should correspond to 0.05 to 0.15 psi/100 ft of duct. Ducting from converters to the exchanger downstream should be designed for thermal stresses at no less than 800°F to allow for conditions present when regenerating the catalyst. Sulfur Lines Sulfur drains to the rundown sump may be required from: Economizers or gas exchangers Converters Tail gas scrubber Waste heat boiler Low point in process line Collector rings HKPage 2 FLUOR CORPORATION PIPING ‘Te actual number of drain points will depend on the process design, equimment arrangement and type of equipment, and extraordinary conditions, such as startup. : Nozzles mist always be stean jacketed with steam connections being provided. Sulfur lines to the rundown sump should be steam jacketed (or traced) to prevent plugging of the line, Some sulfur plant designers insist that all sulfur lines including sulfur transfer lines must be steam jacketed. on a well-designed steam jacketed sulfur line, crosses at elbows are not really necessary if the steam heating system is reliable. A minimum of one trap every 20 feet is considered essential in this service to avoid cold spots in jackets partially flooded with condensate. In addition, limit the length of spools to 20 feet for ease of rodding out sulfur plugs. Steam jacketing is recomended instead of steam tracing with heat transfer cenent. However, the economics of its use must either be justified, or the customer must request its use, Poor workmanship in tracing installations has been one of the principal causes of dissatisfaction with heat transfer cement tracing in previous jobs, Traced transfer lines may be applicable where the ambient temperature seldom gets below O°F and when installed with a metal channel cover strapped to the pipe to provide physical protection for the tracing and to ensure the cavity is filled with transfer cement (Mobil used this tracing systen for a half mile sulfur transfer line at their Joliet refinery). In low temperature zones (below O°F) steam jacketing of the pipe is recommended. Extruded aluminum pipe, sold under the trade name "Unitrace" or "Duotrace", and providing aluminum channel for steam heating as an integral part of the pipe, has not gained acceptance for piping inside a sulfur plant. Its low initiel material costs are offset by problems and expense in its installation. However, it may be applicable for a long (mile or more), single sulfur line with lateral branches. Vents over the sulfur sump and sulfur tanks should be at least 6" diameter and steam traced to avoid plugging with sulfur vapors. Sulfur drain lines usually terminate at the sump inside seal legs. However, some plant layouts may be more economical with local steam jacketed seal legs which overflow to a common sump. See these seal legs in a sketch of sulfur plant piping details in this section, 17M-301-272PLUOR CORPORATION Page 3 RECEIVED PIPING JAN S Engrg. Standards e. Bypass Valves ‘The hot gas bypass line is normally refractory lined carbon steel. However, Mobil (Contract 4350) is using Type 309 stainless steel with two 600 psig steam tracers for the hot gas bypass line. The engineer should evaluate the performance of this service. Refractory lined valves may be purchased but most designs favor the use of Type 309 stainless steel valves. Automatic control of these valves is not necessary as they require a minimum of attention once the sulfur plant is on stream. f. Acid Gas Feed Line and Knockout Drum ‘The acid gas feed line must not be pocketed. The knockout drum should de installed as close to the burner as possible and the downstream acid gas line steam traced to preclude condensation. The entire acid gas line from reflux accumulator to burner inlet should be steam traced if there is possibility of freezing! ‘The knockout drum should be provided with a high-level alarm. The high level switch may also be used to activate a level control dump valve, if one is provided. A safety shutdown system activated by the high level switch has been used in the past, but is not recommended. Bypass to Flare ‘A quick opening pressure-controlled bypass valve to flere should be installed on the acid gas feed line, set to open before either the treating plant or sulfur plant is shut down. This bypass aids in startups and shutdowns. A butterfly block valve on the acid gas should be installed just upstream of the sulfur plant furnace. Both valves should be easily accessible and operable from the ground. HOK ‘1LTM-301-272sAroqovsstyes Area qnq eaysuedxe st BntdeBpay weyx03s (1) *Teuueys Tugs yoays Ta9}s uogTwS UFTA pazoajoId quOMID ToZSULIy WOU URTA BuTqNy Teaqs UOquWo oq TreYs FuTowsy umayg (9) *saprs aqysoddo 0} spurt puw saBuNTJ pue sTerazET Jo spua Suyyoouuos uo saBuets uath sessoro adtd yBnosyy sutea 04 peqoauuos aq TTEYS STeIAWET TTY puE saBuUTJ ynoywarq Jo Toqumu quapotssns w uTEquOD TTwYs adzd Jo sunz TrV (<) uOTFETNSUF Jepun Buzqng Jo eyzBuey Butuzof soz suotun go sovtd uF s#urga7s Surqnz prem qeyaos een ‘sqayowl uy sBuyuado pasnun Intg “BuTany Toaqs uogrvs Jo susoM Aq epeu aq TrYs Sdaaodume yexoer (4) *sasodand Butueeto Jog SoBUBTI PUTTA UITH PETTeISUT ‘aTqTssod azeyM ‘sassoro yqTM apew aq ATQuseJoad TTeYsS UOTIDeITP UT seBuBYD {8 ‘paqetnsuy pus payayouf weoys oq TTeUS SeuTT TTY (2) *sfotTe aaddoo x0 zaddoo oN (1) a g a 3 oa (9) (s) (4) 7 #28 (Gs) @ (n) (2) G) (n) (2) (1) tuo sta0ag Teroeas ae (g)s¥9au9 Burag G*Gy0E s0tazg safuetg pectsreag WITH ssaTuress 60€ do uta, Teng UT eqveg pagTttays ATE aqn]-uoN qoxoeP z= AyZaaqING paBuvTs — TSUOH BATRA TTET HROTTEWS BZ S4VOS PagTTTEAS ,.2/T-TF :BuTATeA, promaang @ paBuwry 0811 9 ,2/T-2 pTangang pasuetZ PIA8M JaxOG faeTTeMS Fz tuoTyonazsuoD aQt/E ZT? uS2T°O — 0OT'OuG/T UeT> —,050°0 n00T"O Fe0uBKOTTY UOTSoALOD f,0SE 4,0SL udtoaig — yBhoaua aeangowsnuey/m yoouD = d,02- 4,02 4,06 065 4,002 u8n0zyy d,02- I4yUyT aanqecedway, (920 pesteu)ysy 40ST (208g pastex) vey #0St isuTqey *g'9 peurt Azoqoeasau eegg uoarep He p09 in ROR Wh hi ToT GME GED ivaaES SaNTT IVSHTE unos SVD TIvL unzins WvaLs ‘wngIns CINSIT WOMWVOTAIOSAS ONTdTa NVI WEIS TVOIEAL TR 1M-301-272lrg. in Vault |FLWOR CORPORATION 7 re TYPICAL SULFUR PLANT PIPING DETAILS FEB Zs tH sun 1 | press ne | [sem secre sea. ug ns Listen Stitt tou STE. Sto Sa suc row ane we SEAL LES FOR SULFUR ORAIN LINES. saIncess REFRACTORY LINED { Fenvonarto secrion 10 rae w-te Fae wt REHEAT GAS MIXING TEE REWEAT MIXING TEE (PREFERRED METHOD) (ALTERNATE METHOD)FLUOR CORPORATION Page 1 INSTRUMENTATION RECEIVED 302-272 gag 1 972 General Engrg, Standards This section contains a discussion of general instrumentation philosophy for sulfur plant design. Review the mechanical flow diagrams under tab D, "Plow Diagrams", for a more detailed outline of instrumentation. Primary control of the sulfur plant is the metering of the total acid gas stream (or totalizing flows when there are more than oné stream), and the proportioning air flow based on an assumed normal composition for the sulfur-bearing streams. Plants can be operated with no more additional controls than furnace shutdown instrumentation, temperature control on the incinerator, plus temperature indication for manual adjustment of other plant variables, The tail gas sample analyses can indicate appropriate adjustment to air flow ratio. Use of continuous analyzers on the tail gas stream has posed problems, the largest of which is plugs in the sampling system. Tracing the sample line and minimizing the distance to the analyzer are keys to a successful working system. Fluor has applied chromatographs in this service in two recent jobs, and vendors have also reported successful applications. DuPont Instruments report in the Oil & Gas Journal, August 10, 1970, Page 155, the successful application of the DuPont 400 Photometric malyzers to sulfur plant tail gas i,S/SO, ratio measurement. This instrument system had been used to replace a chromatograph installation that had sampling system problems and is reported to have increased sulfur yield 0.5-1 by closed loop reset of the air rate. Moreover, outage time of only 1% was claimed during eight months of operation. Sampling in the incinerstor pose no problems so long as they are withdrawn well up the stack where the reactions are complete. Infra red analyzers supply @ continuous monitor of Sd, emissions. Sample ports on the stack at right angles to each other to run pilot tube traverses and take samples are recommended and in sme areas are mandatory. Instrument specifications follow normal chemical plant practice, except for the temperature indicator at the outlet of the reactor furnace where the materials used include a ceramic well, metal-ceramic tube with a platinun-platinum-rhodium thermocouple, or a well made of Haynes Stellite. Bare copper tubing must be avoided in instrument lines and mercury cannot be used in the instruments. Polyethylene is preferred for the control tube.Page 2 FLUOR CORPORATION INSTRUMENTATION Control Principles Controls for automatically diverting acid gas flow from the sulfur plant ‘are almost mandatory. Acid gases are toxic and must be vented safely before release to the atmosphere. Safety devices monitor’acid gas feed to the sulfur furnace which would vent acid gas flow during an emergency shutdown. ‘These vent gases must be routed to the incinerator or flare! me total gas flow rate is the primary process variable, and the air flow ropartioned Go that measurement, The chenistry of the entire process depeie on adding Sir to burn all the hydrocarbon to 1,0 and CO,, and exactly 1/3 of the total HS fed to the system to SO, and H,0. Deviation in the stoichionetric quantity of air added will reduce sulfur recovery. Metering the inflow of HS is subject to error rising from variations in Stream composition plus inherent errors in flow measurenent. The measure- nent of flow can be improved by including a compensation for pressure and tenperature variations. Direct coupensation for shifts in composition of ‘the acid gas stream(s) has not been attempted to date. In split-flow plants, 2 maximum of 2/3 of the acid gas approximately is diverted around the furnace to keep the flame temperature at 2 sufficiently high level. ‘The total acid gas/air ratio control concept remains the same. Gauge performance for correctly proportioning ¥a/0, to the sulfur plant by measuring the TigS/St ratio in the plant tail gas, The most important control objective is to achieve a 2/1 mol ratio of H,S to S0,, which reflects a perfect proportioning of air and acid gas needed to achieve a maximum conversion to sulfur. Use of the tail gas H,8/S0, ratio to reset ‘the air flow rate is, therefore, an indirect way to compensate for variations in acid gas stream composition. Note that the penalties for operating with a given excess of air are not as severe as would be the corresponding air deficiency, When guaranteed recoveries of 96% or higher are sequired, three or four catalytic stages my be required. Under these conditions, the presence of COS end CS, will have @ significant bearing on recovery, and the correct tail gas ratio is: ¥)8 + 00S + 2052 _ 5 9 a = 2.0, The quantitative loss of sulfur from a plant can be monitored by stream analyzers on the tail gas or stack ges streams. Achieving the optimm Sddition rates of ingredient does not ensure the maximum recovery of sulfur. Converter inefficiency and vapor pressure and entrainment loss of sulfur Will still produce sulfur losses to the atmosphere. Air pollution regulations might require a monitor on the actual sulfur vent losses. “pvaluation of Sulfur Plant Efficiency" is a pertinent article in Decenber 1, 1970, O11 and Gas Journal. 1TN-302-272RECEIVED JAN 3.4 1872 Ts Engrg. Standards FLUOR CORPORATION INSTRUMENTATION Pressure drop of all streams must be minimized. The major acid stream usually is not throttled, but floats on the back pressure through the sulfur plant. Low pressure drop flow meters and control valves are mandatory throughout. A complete temperature profile of the plant is inexpensive and useful in trouble-shooting operating problems. Proper interpretation of shifts in plant temperatures can indicate the deactivation of catalyst beds (usually caused by fouling), the entrainment of sulfur, or other probable causes for a decline in yields. Control the air compressor in a manner that will minimize power consumption. Venting of air on the compressor discharge side as a means of control serves only as a protection against surge. Throttling of air flow on the compressor suction or variable speed control of turbine drives are pre- ferred control methods. HK LIN-302-272FLUOR CORPORATION Page 1 UTILITIES AND CHEMICALS 17 E-30K-0872-1 General Utility and chemical requirements are listed in Table P1 for use in "quickie" type estimates for sulfur plants (not including tail gas treating) having feed zoncentrations of from 30 to 90 mole per cent HS and NH, concentrations of from 0 to 30 mole per cent of the total HS in the total'plant feed. The values in Table P-1 are not to be used in final design calculations. Tail gas treating technology is developing rapidly. Fluor's latest in house process design parameters should be checked for the treatment methods to be used and for the utility data available. Teble F Average Plant Operating Requirements Per L1/pey of Sulfur Plant Production Fuel Gas 0.15 M4 Bou/hr (LEV) Power (2) 0.05% KW Boiler Feedvater Consumed, 20°F 330 1b/ne RECEIVED Total steam Generated, 250 psig (saturated) 300 1b/ne steam to Drive Air Blower, 250 psig to 50 psig 100 lb/hr AUG 28 1972 250 psig Steam (sat.), Net Production 200 lb/hr fngrg. Stondards Chemical and Catalyst 0. tons (2) Correction is required to these values for water and steam conditions other than those shown. (2) Add 150 watts for lighting and instruments for all size plants. Electrical Power Bleetric power consumption in a sulfur plant is normally small because the air slower is usually driven by a stean turbine operating at 250 psig steam pressure and exhausting to 50 psig. Motor drivers are normally used for all pump drivers, and the air blower may occasionally be motor driven, When the air blower is steam driven, the consumption for other services is normally intermittent (i.e., operates for about four hours each day). IKPage 2 FLUOR CORPORATION UTILITIES AND CHEMICALS Fuel Gas Fuel gas is used in the incinerator to completely oxidize all components in the tail gas, and also during startup to bring the feed to combustion temperature. Fuel gas may also be used to fire any feed and reheat heaters. Fuel gas is occasionslly mixed with the feed gas to ensure combustion temperatures in the furnace, Startup usually requires 2 to 5 Mt Btu/LT sulfur. Steam Stean generation is normally greater than steam consumption, ‘The generated stean is usually used to drive the air blower and for plant heat. When there is need for 45 to 55 peig steam on plot or in adjacent unite, the sulfur plant is designed to generate steam at a pressure (over 150 psig) which will operate a steam turbine on the sulfur plant air blower and exhaust at ebout 50 to 55 psig. ‘This exhaust steam can then be used for sulfur plant sump heating, steam tracing, etc., with any excess exported to other units, When the adjacent units do not require low pressure steam, the sulfur plant is designed to generate only enough steam for the air blower and on plot heating. The sulfur condensers are used to preheat boiler feedwater and/or to generate additional low pressure steam when required, An extemal source of stean must be available to operate the air blower and/or sump heating coils ané for stean tracing during startup and down time. Boiler feedwater consumption includes 10% lowdown. 1s & Cetalysts Chemical consumption in a sulfur plant is primarily the catalyst used in the converzers. Normal life for the conventional activated alumina or bauxite catalyst is two to five years. Since the C29-2-01 cobalt-moly catalyst has been used in conjunction with bauxite catalyst in sulfur plant converters only since early January, 1971, a one year catalyst life is the best that can be estimated at this time (July, 1972). Properties for sulfur plant catalysts are listed in Table 2. chemi ‘Two tyes of conventional conversion catalysts are available; low silica grade activated bauxite and activated alumina. Activated bauxite is the economic choice when moderate conversion efficiencies of 90 to 95% using two stages are required. However, the more expensive activated alumina may be economical whenever high efficiency and sulfur recovery is required in a two-stage unit and/or where ‘the plant size is very large. 17P-30h~0872-1FLUOR CORPORATION Page 3 URILIDTES AND CHEMICALS Catalysts and Chemicals, Inc. (CCT) has developed operating data on use of a 12 inch layer of C29-2-01 cobalt-moly catalyst immediately below the conventional bauxite catalyst in the first converter. Use of the cobalt- moly catalyst has consistently achieved 70 to 85% conversion of COS and CS,. This percent conversion is significantly greater than the percent conversion that can be achieved with only conventional bauxite catalyst in the first converter. The CCI data is listed in Table 3. ‘The number of conversion stages, type of catalyst, type of tail gas process must all be evaluated for optimum design. RECEIVED AUG 28 1972 Engrg. Standards HUK 17 P-304-0872-1Aus 28 1972 engrg. Standards RECEIVED 60 oes eee eet 30 arent me ATR 50-0871FLUOR CORPORATION Page SULFUR PLANT DESIGN MANUAL TABLE P-3 OPERATING DATA FOR REACTOR USING COBALT-MOLY CATALYST WITH ACTIVATED BAUXTTE CATALYST Cobatt-Moly catalyst c29-2-01 Size of Cobalt-Moly Catalyst 1/8" extrusions Bed Depth, inches * w Inlet Temperature, °F 650-750 Estimated OP, inches of #0 9 Expected Conversion cos, % Initial 5 RECEIVED 6 months 90 AUG 28 1972 1 year 85 cs,, % Intttar 90 Celta) 6 months B 1 year 70 Expected Cycle 6 months to 1 year Load 12" of C29-2-01 below 24" of activated bauxite catalyst all in the first reactor, Note: The above data obtained from CCI is based on actual operating information from existing plants. 17P-304-0872-1FLUOR CORPORATION RECEIVED Page 1 SULFUR PLANT ECONOMICS == JAly Ji |: 17Q-305-272 Engrg. Standares The cost data evaluated in this section are confidential and for use in Fluor optimization studies. These costs may not be presented to outside sources without the approval of the Manager of Process Engineering. Table Gl and Q@-2 represent a summary of all sulfur plants designed by Fluor in Ios Angeles and Houston since 1956. ‘he sulfur plant 400 A/C equimment costs shown on Figure Q-1 are based on U.S. Gulf Coast costs for January 1971. These costs have been developed from Fluor plants erected since 1962 and corroborated with data available for sulfur plants erected by competitors during the same period. Cost data prior to 1962 are considered obsolete because they are predicated on designs not considered applicable to modern optimized high recovery sulfur plants. The incinerator and stack are 20 to 35% of the total equipment cost in a conventional sulfur plant. These stacks are designed to meet specific ground level 80, concentrations. The installation of tail gas treating units in modern sulfur plant designs may result in lower stacks because 60 to 85% of the equivalent S0, previously vented through the stack will be removed. Therefore, stack and incinerator costs in modern plants should be a much smaller percentage of the total plant cost. The Cost Engineering Department must be consulted when developing a "selling price”. Current sulfur prices and shipping costs can be obtained from Sulphur, a quarterly magazine published by The British Sulphur Corporation, Ltd., London.Page 2 FLUOR CORPORATION SULFUR PLANT COSTS Current (March 1971) delivered sulfur prices per long ton ar’ U.S. Gulf Coast $23-25, U.S. Atlantic Seaboard $27-31 Northwest Europe $22-26 Nediterranean $26-32 Indian Ocean Area $28-32 Far Bast and Pacific $25-30 Latin America $25-29 current (arch 1971) sulfur prices FOB at the plant are as low as $8 at per long ton at Canadian prices. 17@-305-272SULFUR PLANTS TABLE Q-1 (Recent Sulfur Plant Designs by Fluor) Name & Location Carstairs Operators’ Committee Carstairs, Alberta, Canada ‘Transcontinental Gas Company Tilden, Texas Caltex O11 Company Capetown, South Africa Canadian Superior Oil, Ltd. Didsbury, Alberta, Canada Kuwait National Petroleum Company Shuaibe, Kuwait Creole Fetroleun Corporation Amuay, Venezuela Shell Oi1 Company of Canada Waterton, Alberta, Canada Mobil il Corporation Joliet, Illinois Wintershall, A.G. Contract No. eer. 6266 1023 6347 850k 8764 8268 4350 Year 1961 1961 1964 1965 1966 1968 1969 1970 Page 3 RECeiv2D JAN SL 1972 Engrg, Standares Capacity. Long Tons, 4a B 958 570 315 12ko 250 179-305-272Page RECEIVED SULFUR PLANTS JAN 3 TABLE Q-2 Engrg. Standards (sulfur Plant Designs by Fluor under Olin-Mathieson Patents) Capacity Name & Location Contract No. Year Long Tons/Day American O11 Company 5159 1956 50 Yorktown, Virginia Caribbean Refining Company 615k 1955 20 Bayamon, Puerto Rico Great Northern O11 Company 5607 1954 6 Pine Bend, Minnesota Gulf 011 Corporation 5190-80 1951 23 Crane County, Texas Gulf Oi1 Corporation 5550-23 1954 150 Philadelphia, Pennsylvania Humble Oil & Refining Company 5510-62 1953 25 Jourdanton, Texas Nevis Operators’ Comittee 6234 1959 104 Nevis, Alberta, Canada Pontiac Eastern Refining Corporation 6146 1955 20 Hattiesburg, Mississippi Potash Company of America 5075~7h 1950 30 Silvertip Field, Wyoming Shamrock Oi1 & Gas Company pike 1952 31 Shearin, Texas Shell Chemical Corporation 5190-58 1951. 56 Deer Park, Texas Shell 011 Company 5540-6 1954 ho Jumping Found, Canada Sinclair Refining Company 5190-84 1951 20 Marcus Hook, Pennsylvania Stanolind O11 & Gas Company 5292-9 1952 20 North Cowden Field, Texas Stanolind Gil & Gas Company 5298 1952 55 Slaughter Field, Texas Union O41 Company S466 1953 60 Qleum, California 179-305-272ueseizeet (sisv9 Ata) a334 MI StH NolLDvas aTOH=s2H an 4) | ste *)( ava (+1) (roe (—__#ve_) a 60) \anains iondoas s¥oL 9n03) {9 sart-f9 a i 1 aset=% st saya z (seve A¥a) aNniuan sv == TON TWLOL“aNMHLaN ANaTYAINER “Wa == ) J=aurovav> ans wainoa SINVTd ngs AOI 51509 LNaNgINO YOrYHGENERAL FLUOR CORPORATION Page 1 SULFUR PLANT CALCULATIONS RECEIVE CALCULATION PROCEDURE 27R-306-272 JAN St Engrg. Standsré> 2 This section describes the various parameters involved in each step of a sulfur plant "hand" calculation. Examples of detailed calculation pro- cedures for various plant configurations are included in Sections $, T, U, V, and W. EED(s) ‘The feed characteristics required to perform a sulfur plant calculation includes the following: (a) Complete component breakdown particularly for all sulfur bearing compounds. (>) Inlet temperature and pressure. (e) Expected fluctuations in feed conditions. A sulfur plant feed(s) is(are) assumed to be saturated with water at the operating temperature unless specifically called out as water free. Saturation water is calculated if not given in the original feed specifi- cation. ‘The enthalpy of each feed stream is calculated using Figures BB-12-1 to BB-15-h. PLANT CONFIGURATION Selection of plant configuration depende upon the concentration of H,S in the acid gas feed. The following tabulation describes the suggested plant configuration for ranges of HS in the feed gas: (2) Mol 4 HS 2 506, ary basis. All of the acid gas feed is sent to the combustion step. (2) Mol # HS < 50h, 2 306, dry basis. Two alternate schemes are possible and each should be carried far enough so an economic selection can be made. (a) (b) Feed and air preheated to a high enough temperature so that ‘the combustion temperature is above 1660°F, Two-thirds of the acid gas feed bypasses the combustion step. 1 All of the required air and one-third of the feed are sent | to the combustion step. |FLUON ConPORATION Ree Page 2 SULFUR PLANT CALCULATIONS aw 51 197 (3) Mol $ 8 < 30f, 2 15, dry basis. Ener, Stsnaares All of the air required and one-third of the acid gas feed are sent to the combustion step. Two-thirds of the acid gas feed ‘bypasses the combustion step. (4) Nol § HS < 154, ary basis. ‘The S0, required for reaction with HS in the feed is generated by oxidizing elemental sulfur. None of the acid.gas feed goes to the combustion step. ATR REQUIREMENTS The principe reactions in Claus type Sulfur Plants are: 28 + 30) —» 280, + 2H,0 (thermal) 2H,S + SO, —r 38 + 2H,0 (thermal and catalytic) The overall reaction for one mol of HaS ist ey Oe seh 10 The type and distribution of hydrocarbons and mercaptans in a suifur plant feed gas will depend on the source of gas. The hydrocarbons will normally be C5 Co; Cy and C, with C, the major component and will react with oxygen during complete combustion as shown below. Mercaptan sulfur will also be completely burned as indicated, Cn Cote + 302 —> 200, + 31,0 CS + 2+ CO, + 24,0 + S CoHeS + Z0,—r 200, + 3H,0 + 8 Bach mol of hydrocarbon or mercaptan fed to the combustion step with n atoms of carbon requires (3n + 1)/2 mols of oxygen for combustion. Oxygen must also be provided for other compounds in the furnace feed such as THs, COS, CS;, Hz, etc. MH + 90,—> be, + #10 cos + bo, —+ Go, + 8 8 + Op —F 00 + 28 fp + bo —> 10 1 7R-306-272FLUOR CORPORATION Page 3 qhe total oxygen required for combustion is supplied from anbient air. (21% 02, 79% Nz + 120.) Design conditions for ambient air are usually the design air specified in the Basic Jobsite Date Questionnaire. Figure BB-1 is used together with these air data to develop the total H,0 concentration in the air. ‘The temperature of the mixture entering the combustion zone is calculated ‘by heat belance using Figures BB-12-1 to BB-15-h. cous TON The combustion step is calculated using the computerized minimization of free energy technique available on the computer which calculates the complete combustion effluent product distribution and adiabatic flame temperature. The combustion temperature must be above 1660°F for the Hes to oxidize to SQ, in a standard design furnace or above 1300°F in a special design furnace. Computer liaison must be consulted before filling out the input sheets. During combustion, many side reactions occur. These include: Fast, Cl, + WS SoCs. + Aas 7 oat RECEIVED C0. + HeS$—7C0s + #20 Siew JAR 3 £1972 COa + HeS ee CO + HO + S Engrg. Standares CO + HO EH + Ce ‘The COS concentration in the combustion effluent gas is usually close to thermo chemical equilibrium while the CS, concentration is more than 100 times higher than the equilibrium value. In sulfur plant feed gases con- taining only C, end Cz hydrocarbons, negligible quantities of CS, are produced by the reaction shown above and are therefore unimportant to overall sulfur recovery. However, heavier hydrocarbons in the feed gas drastically increase the CS, production. Both COS and CS, form repidly at furnace flame temperature and decompose slowly as temperature is reduced. ‘These relationships must be carefully evaluated when setting guarantees for overall sulfur recovery. ‘The combustion effluent usually contains He, 00, and SO which will react fas they pass through the waste heat boiler. To simplify the hand calcu- lation procedure, we assume that these components react before entering the boiler and calculate an "equivalent" waste heat boiler feed by converting these compounds as follows: (1) HpS formation from lig and $0, H + 80, —>+H,S + 0, (2) C0, formation from CO and Op co + Bp —+ C0, ‘LTR-306-272FLUOR CORPORATION RECEIVED Page (3) 80, formation from SO and O, JAN 31 1972 80 + }0, —> 80, Engrg. Standares ‘An oxygen balance is then calculated. If excess 0p is formed in (1), (2) and (3), it is reacted with elemental sulfur in the WHB effluent according to Equation (i). If a deficiency of 0, exists, it is generated by assuming the reaction of H,O and SQ) in the WHB effluent according to Equation (5). (4) 8) + 20, —> 280 (5) HO + 80,—> HS + 80. WASTE HEAT BOILER (WHB) ‘The outlet temperature from the waste heat boiler depends upon the sulfur plant configuration, the steam pressure generated in the WHB, and the desired overall sulfur recovery. In general, higher WHB outlet temperatures (say 450 to 500°F or more) produce minimum sulfur condensation in the WEB and lower overall plant recoveries. Lower temperatures (say 350 to 450°F) give more WB sulfur condensation and higher sulfur recoveries. ‘The following temperatures are recommended based on Fluor experience: (1) straight through design -- Set the WHB minimum outlet temperature at the sulfur dew point determined from Figure BB-8 plus 20°F. The actual temperature will depend upon steam pressure and sulfur recovery. (2) Acid gas feed bypass -- Set the WHB outlet temperature high enough to maintain the selected inlet temperature to the first converter when the WHB effluent is mixed with the acid gas feed bypass. (3) Hot vapor bypass -- Same as (1) above. Hot vapor bypass reheat is usually obtained from the furnace effluent line ahead of the waste heat boiler at about 1000 to 1300°F or from one of the return channels in the waste heat boiler at about 700 to 1000°F. The smaller the hot vapor bypass quantities the higher the sulfur recovery, particularly if the reheat stream bypasses a conversion stage. Therefore, higher reheat temperatures are usually preferred because hot vapor gas flows are reduced. Plant sporating i 2 en condense in the WHB even though no condensation can be calculated based on the “observed” outlet temperature. This is caused by the condensation of sulfur vapor on the walls of tubes in the WHB which are cold enough to produce a sweating effect similar to hot, moist air on a cold surface. For sizing all equipment downstream of the WHB, assume that 20% of the elemental sulfur present in the waste heat boiler effluent will condense at tempers- tures above 400°F. Do not change the WHB specification to show this Coniensetion above UOOE+ Below TOOT, aszuse that condensation follows appreciable mount of snl fir me; 17R-306-272FLUOR CORPORATION Page 5 the dew point correlation shown on Figure BB-8. The heat of condensation is hegligible compared to the sensible heat of cooling the bulk stream and may de neglected when calculating the waste heat boiler duty. . RECEIVED: Tae heat balance around the boiler will include: Jan 31 972 (1) Heats of reaction for the Hig, $0, and CO reacting. (2 Heats of transition between the different sulfur species. Engrg, Standart (3) Sensible heat in cooling the vapors. Heats of reaction and transition are calculated using Figures BB-16-1 to 9. Sensible heat data are obtained from Figures BB-12-1 through BB-14-. CONVERTERS ‘The converter inlet temperature is set to ensure equilibrium conditions at the converter outlet. The minimum inlet temperature should be 400°F, Note that for converters the inlet temperature and dew point may coincide. The heat of reaction quickly raises the temperature above the sulfur dew point. Condensation has not been a problem in operating plants. Sulfur conversion is favored by lower temperatures (1s00 to 425°F) wnile the COS reaction is favored by higher temperatures (600°F). ‘The COS formed in the furnace is partially decomposed to HpS in each conver sion step by the following reaction: CoS + HO —+ HS + CO, However, this reaction is slow and therefore the COS fed to a converter is assumed to decompose as follows: ist Converter - 1/2 of the total 2nd Converter - 1/3 of the renainder 3rd Converter - 1/l of the remainder th Converter = 1/5 of the renainder AlL elemental sulfur and SO in the converter feed must be converted to equivalent HS and SQ, using the reaction equations shown below in order to use the conversion equilibrium curves, Figures BB-3 to BB-6: 38, + 44,0 —> 4HS + 280, Se + HzO —> HS + 250, 3S + 160 —> 16%,8 + 850, 380, + HS —> 480, + 1,0 Estimate the outlet temperature from the converter using Figure BB-7 and Figures BB-3 to BB-6 to obtain the sulfur conversion at this estimated tem- perature which is calculated using the following parameters: Actual iS conversion = total 16 converted ~ 1S from sulfur reconversion 450, —> 9a + Ho Sulfur produced = H,S ‘17R-306-272FLUOR CORPORATION Page 6 ‘The sulfur composition is obtained from Figure BB-9. With the COS reacted as before, the sulfur produced is calculated from the conversion, and all of the 0, reacted as shown below: cos + HO —>+ HS + CO ene) bi JAN G1 1972 Engrg. Standards 250, + WHS —> 38, + MHZ0 850, + 16H,S—> 3S. + 16,0 380, + HS —> 480, + 10 The heat of reaction is calculated using Figures BB-16-1 to BB-16-9 and added to the inlet enthalpy of the converter feed to obtain the calculated outlet enthalpy. An assumed enthalpy is calculated at the outlet using the assumed outlet temperature. The assumed and calculated outlet enthalpies are compared. A new temperature is assumed and the converter calculation repeated until the two values agree within 1 to 3f. CONDENSERS Elemental sulfur product is formed ty cooling the converter effluent streans in sulfur condensers usually by exchange against boiler feed water to either preheat the boiler feed water or generate low pressure steam. Condensing temperatures are maintained as low as possible. Select an outlet temperature for all but the last condenser between 300 to 400°F depending upon the economic optimum between reheat costs and sulfur recovery costs (i.e., a lower temperature results in increased sulfur recovery but increased reheat requirements and higher condenser costs, etc.). Set the outlet temperature for the last condenser between 250 to 25°F but never below 260°F because sulfur solidifies at 2b3°F and plugging may occur at lover temperatures. ‘The quantity of condensed sulfur is calculated using Figure BB-8. The condenser duty is calculated using Pigures 89-10, BB-l1, and BB-12-1 to BB-12-h, 2TR-306-272FLUOR CORPORATION Page 1 SULFUR PLANT CALCULATIONS RECenveD 178-307-2 cra 7197 eels FEB 7 1972 Engrg. Standsr 5 EXAMPLE 1 Normal Acid Gas - Straight-Tarough The calculations in this example are predicated on the following desiga paraneters: 1. Feed HgS concentration above 50 mol % (dry basis). This allows a combustion temperature above 1650°F without bypassing feed gas around ‘the combustion step. 2, Carbon disulfide (CS) and mercaptans (RSH) are included to illustrate how they are handled. 3. Four converter stages. 4, Side-by-side tabulation showing the differences between two alternate methods of reheating converter feed. A. Alternate 1A. Hot vapor bypass reheat. B. Alternate 1B. Direct fired reheat. 5. Heat of reaction across a conversion stage to reheat converter feed for the fourth conversion stage. 6. Combustion air at 75°F, 90h saturated. FEED Compound Lb Mols/ir Mol Fraction Coy 84.0 0.210 #8 300.0 0.750 csp 2.4 01006 cs 8.0 01020 ce Wo 01010 cysH 0.8 CoSH 018 ‘TOTAL 400.0 Temperature = 120°F Pressure = 4.5 psig Atmospheric Pressure = 14.7 psig DHJFLUOR CORPORATION FEED, WET BASIS Page 2 ‘FEED, WET BASIS Water vapor pressure at 120°F = 1.7 psia Mol fraction Hg0 = qos 089) RECciv—) = ep OO = asst ae Engrg 357 Compound «Lb Mols/Hir —Btu/Eb Mol © M_Btu/Hr He0 39.1 346 13.5 CO, Bh.0 391 3z.8 Hes 300.0 a 105.3 CS2 eeu 54g 1.3 GQ 8.0 35 3.0 Ce 4.0 560 2.2 csi 0.8 527 ok casi 0.8. 766 0.6 ‘TOTAL G1 159.1 ELANT CONFIGURATION Mol % Hes > 5 (ary basis). must select the t A straight-through design is used in which all of the acid gas feed is sent to the combustion step. ‘The designer now e of reheat. The two alternates shown on Figure S~11 have been chosen from the many different combinations of reheat which are available. These two are not necessa ly representative or preferred, but are only included to illustrate the calculation aprroach. Varied methods should be tried and the optimum case develored. Alternate 1A Hot vapor bypass reheat for first three conversion stages, heat of reaction reheat for fourth conver- sion stage. Alternate 1B Direct fired reheat for first three conversion stages, heat of reaction reheat for fourth conversion stage. 178-307-272papas 1, ze Te NWP o2arso34 s:9uL ExeFLUOR CORPORATION Page 4 ATR REQUIRED Oxygen Required For HaS, 30/2 = 150.0 1b mol/br vor, (SGN) = 16.0 ab nol /ur RECEIVED ror cz, (2) = 4.0 ab mol /ar FEB 7 1972 vor csi, 8-202) = 1.6 ap mol/ar Engrg Stntir’s ror csi, (322) = 2.8 ab mol/nr For CS, (2.4)(1) = _2.4 1b mol/nr otal 0p 186.8 1b mol/ar rota air = 2868. 889.5 1b mol/nr Total Ne = 702.7 We nol/ar Hg0 = 0.027 1b mols/Ib mol dry air = (.027)(689.5) = 24.0. Ab mols/ar ‘Temperature = 75°F Conpound Lb Mols/iir Btu/Lb Mol M Beu/iir Og 186.8 Mol M Btu/ir 2 186.8 162 30.3, Ne 702.7 160 ane. H20 63.1 185 11.7 COg 84.0 207 174 ‘HS 300.0 187 56.1 CSe 2.4 293 0.7 G 8.0 19 ce ho 296 case 0.8 279 cS 0.8 405 ‘TOTAL 1352.6 A plot of temperature vs. enthalpy gives 92°F at 146.3 M Btu/Hr. DHS 178-307-272FLUOR CORPORATION Page 6 COMBUSTION STEP ‘The feed has the same combustion temperature when oxidizing in the combustion furnace as in the direct fired reheaters. computer Input Symbol Bb Mola stir ge 186.8 Ne 702.7 RECKIVED Hep 63.2 Fea 78 pe 8h.0 . Hes 300.0 ‘Engrg. ‘Stender “+ cs2 2.4 cH 8.0 c2H6 Lo cHuS 8 c2HS 8 sl 0001 se 0002 sé +0001 sg2 -0001, S93 0001 cps 0001 ne 0001 op 0001 Np 0001 pe 4.0001 Np3 +0001 c 0002 sp 0002 os 0002 Temperature = 92°F Pressure = 18.7 psia 178-307-272FLUOR CORPORATION Page 7 COMBUSTION EFFLUENT (from computer output) al HaS Op S02 80, DES Compound Lb Mols/ir Ne 102.7 1,0 311.9 RECENd20 Coa 79.0 Fea 7 HS 45.2 a 102.5 Engrg, Stnter’s 803 53-9 cos 1.0 Ha 36.1 co 24.8 80 2 TOTAL 1360.3 of the He, CO and SO will react to form HigS, COz and SOp» formation from Hy and S0j Hp + S0p—)HeS + 0, 36-1 38.2 38.2382 Ib mols/br formation from CO and 03 co + 1/2 0g ——¥C0, 2b.8 ask 24.8 Yb mols/hr formation from SO and 03 $0 + 1/2 0; —> S02 12 0.6 1.2 I nols/br formation from the balance of the oxygen Oxvgen remaining = 38.1 - 12.4 - 0.6 25.1 1b mols/br SB, + 20,—> 28% eG co es 178-307-272Equivalent combustion effluent 1b mols/hr. FLUOR CORPORATION Page 8 Combustion 1,8 0 30a Equivalent Compound Effluent Formation © Formation © Formation —_Effluent. Os 438.1 -12.4 0.6 -25.1 Ne 702.7 702.7 20 3.9 31.9 0 79.0 424.8 103.8 Hes 45.2 +36.2 83.3 Sa 102.5, 12.6 89.9 S03 53.9 -38.1 41.2 425.2 42.2 cos 1.0 1.0 Ha 38.1 -38.1 co 24.8 24.8 so ‘TOTAL 1360.3 -12.4 1334.7 Temperature = 2212°F Pressure = 18.7 psia ‘The amount of gas required for reheat is unknown, and normally numerous trials would be required to determine the bypass quantity. number of trials can be reduced by: However, the (1) Assuming 1000 1b mols/hr from the equivalent combustion effluent. (2) (3) Add reheat streams as required. Finish calculations by prorating the actual equivalent combustion outlet by 1000 1b mols/hr + reheat, 178-307-272WASTE HEAT BOILER INLET FLUOR CORPORATION Page 9 Compouna Actual Db Mols/Hr 1000 Lb Mols/Hr Basis Ne 102.7 926.5 #20 31L.g 233.7 C0 103.8 118 Has 83.3 62.4 Se 89.9 67.4 80 hea cos, 1.0 ‘TOTAL 1334.7 Temperature = 2212°F Pressure = ‘18.7 psia Check dew point of waste heat boiler effluent. DH Total sulfur = (6l4.1 1bs/1b mol)(67.4 1b mols/nr) = 4320 Ibs/nr Total sulfur free gas = 932.6 1b mols/nr Lbs sulfur = B32 Lage TOOO mols sulfur free gas o32.0 Pressure = 18.2 psia (allowing 0.5 psi for waste heat boiler) Dew Point = 507° S Set waste heat boiler outlet temperature at dew point temperature plus 20°F 507 + 20 = S527°F, use 530°F Assume 20% of the sulfur condenses = 0.2(4320) = 864 1ds/hr Sulfur remaining in vapor = 4320 - 664 = 3456 Ibs/ar 178-307-272FLUOR CORPORATION Page 10 comENSER Inlet At 530°F, Sp = 0,000 mol fraction Se = 0133h ol fraction Se = 0.666 mol fraction Let: x = Ib mols/hr of Sg y= Yb aole/ar of Se aay 7 OB aay + 066 x = 0,502y 192.4x + 256.5y = 3456 . 3456, s y+ sapeayetpsaey © 88 2 solar x = 4g 1b mols/hr conpouna 1000 Ub Mols/itr Basis Ne 526.5 Hg0 233.7 Oa 18 HS. 62.4 Se : Se Ag Se 9.8 S02 31.5 cos 0.7 TOTAL 947.3 Assume the outlet is cooled to 350°F TO00 Ib mols sulfur free gas ur 178-307-272FLUOK CORPORATION Total sulfur = 3456 lbs/nr Total sulfur free gas = 932.6 1b mols/nr RECevED Fep 7 1972 Page 11 Engrg, Standar! Sulfur remaining in vapor = (167)(0.9326) = 174 1bs/nr Sulfur condensed = 3456 - 17h = 3282 1bs/nr At 350°F, Sp = 0,00 mol fraction Se = 0:21 mol fraction Se = 0.79 mol fraction Let: x = Ib mols/nr of Se y = 1b mols/nr of Se sip + oa St - on ary, x = 0.266 ag2.ix + 256.5y = 17% : ats ; ¥ = TSE NY(0. 266) + 256.5 Ce eae x = 0.2 Ib mols/nr outlet Compound 1000 Lb Mols/iir Basis a 7 H20 C03 Hes Sa Se Se 809 cos TOTAL Temperature = 350°F Pressure = 17.7 peia DHS 178-307-272FLUOR CORPORATION CONVERTER Alternate 1A Assume a converter inlet temperature of 400°F is desired, and the hot vapor bypass is available at 1000°F. Condenser effluent vapor at 400°F Se = 0.00 mol fraction Ss = 0.25 mol fraction Se = 0.75 mol fraction Total sulfur = 174 Ibs/nr Let: x = Ib mols/hr of Se y = 1b mols/hr of Sp x = 0.2 rus] 2 a xy x = 0.333y 192.4x + 256.5y = 174 = 174 ¥ = “Tez Y(0.333) + 250.5 = 0.6 lb mols/ar 0.2 1b mols/ar Heat required by condenser outlet vapor going from 350°F to 400°F RECciv2) Page 12 Fea 78 Engrg. Start Alternate 1B Assume a converter inlet temperature of 400°F is desired. The effluent from the direct fired reheaters is 22l2°F. Condenser effluent vapor at 400°F 0.00 mol fraction 0.25 mol fraction 0,75 mol fraction otal sulfur = 174 Ibs/ar let: x y Lb mols/ar of Se lb mols/nr of Se +h = = 0.25 a a x+y 0.75 0.333y 1g2.hx + 256.5y = 17h _ 27h ¥ > “TIGEH)(0.333) + 258.5 = 0.6 4b mols/hr x= 0.2 Ib mols/ar Heat required by condenser outlet vapor going from 350°F to 00°F 178-307-272RECiveD FLUOR CORPORATION Frag 7 1979 Page 13 Engrg, Stondor 3 At 350°F At 350°F Compa Lb Mols/Hr Btu/Lb Mol M Btu/Hx| Compd Lb Mols/Hr Btu/Lb Mol M Btu/Hr Na 526.5 1,920 1 Me 526.5 1,920 1010.9 #0 233.7 2,240 H,0 233.7 2,240 $23.5 COs 171.8 2,690 0 7.8 2,690 209.3 HAS 62.4 2,290 48 62.4 2,290 142.9 Sa e . ee . : - Se 0.2 10,700 21 | Se 0.2 10,700 Et Se 0.6 10,700 6.4 Se 0.6 10,700 6.4 5803 31.5 3,060 96.4 | 80. 31.5 3,060 6.4 cas 0.7 2,940 2.1 | cos OT 2,940 2.1 933.4 1993.6 933.4 1993.6 At WOOF ‘At 4O0°F Compa Lb Mols/Hr Btu/lb Mol M Btu/Hx] Compd Lb Mols/Hr Btu/Lb Mol M Btu/Hr Na 526.5 2,290 1205.7 Ne 526.5 2,290 1205.7 He0 233.7 2,650 619.3 | He0 233.7 2,650 619.3 0 17.8 3,220 250.5 | CO 718 3,220 250.5 Has 62.4 2,730 170.4 HS 62.4 2,730 170.4 Sa - . - | 8 5 - 7 Se 0. 12,800 2.6 | S6 0.2 12,800 2.6 Se 0.6 12,800 7-7 Se 0.6 12,800 77 80. 31.5 3,640 1ib.7 | sop 31.5 3,640 114.7 cos O.7 3,520 cos 0.7 3,520 2. ‘TOTAL 933.4 2373.4 | TOTAL 933-4 2373.4 OQ = 2373.4 - 1993.6 S86 = 2373.4 ~ 1993.6 = 379.8 M Btu/ir = 379.8 M Btu/ar pus 278-307-272FLUOR CORPORATION Heat released by hot vapor bypass cooling fram 1000 to 400°F Hot vapor bypass at 1000°F 0.10 mol fraction 0.59 mol fraction 0.31 mol fraction 1 Yb mol/br of hot vapor bypass with ell sulfur shown as Sz Compound Lb Mols/Htr Np 0.5265 #0 0.2337 CO. 0.0778 #8 0.0624 Sa 0.067% 50, 0.0315 cos 1007 TOTAL 1.0000 Total sulfur = 4,32 lbs/hr Let: Ib mols/hr of Sp Ib mols/nr of Sp Lb mols/hr of Se pcg y oo rr Sayre 7 OR y= 5.9% 2 = 31x Page 14 Heat released by reheater effluent vapor cooling from 2212°F to 400°F Rebeater effluent vapor at 2212°F 1 1b mol/hr of reheater effluent vapor with all sulfur shown as Sz Compound Lb Mols/iir Ne 0.5265, #0 0.2337 . a o.o77a RECEIVED HS o.c6ek peg 7 1972 So 0.0674 nary, stan S02 0.0315 cos 0.0007 TOTAL 1.0000 Reheater effluent vapor at 400°F Se mol fraction Se mol fraction Se mol fraction Total sulfur = 4,32 1bs/br x = 0,333 4.32 y T9E-VY(O.333) + 256.5 = 0,0135 1b mols/hr x = 0,00k5 1b mols/hr 178-307-272FLUOR CORPORATION Page 15 Gh.ix + 19@by + 256.52 = 4.32 compound Lb Mols/Hr Ne 0.5265 4.32 . + qomueneheescar H.0 0.2337 COp 0.0778 = 0.0022 1b mols/br HS 0.0624 RECEIVED y = 0.0128 1b mols/hr 8s : Se o.oous = FEB 7 ‘W372 z = 0,0067 1b mols/hr Se 0.0135 Engrg. Stender.’s S02 0.0315 cos _0.0007_ TOTAL 0.9506, Heat released cooling fron 2212°F to 400°F Btu/Lb Btu/Lb Lb Nols Mol at Mol at Compa per Hr 2212°F oO? _Btu/iir Ne 0.5265 + 16,200 2290 7,323.6 0 0.2337 20,200 2650 4202.4 CO, 0.0778 25,600 3220 1,741.2 pS 0,062 22,000 2730 1,202.4 Sp 0.0674 18,400 2610 1,064.2 $0, 0.0315 26,900 3640 132.7 cos 0.0007 27,500 3520 16.8 TOTAL 1.0000 16,182.3 Heats of transition 38, —9 Se ani0° 51.5 28.9 M Btu/Mol 0.0135 0.0045 Lb Mols/iir hoo Ally” = -0,5652 M Btu/Hr DEJ 178-307-272FLUOR CORPORATION At 1000°F Compound Lb Nols/iir N 0.5265 #20 0.2337 CO, 0.0778 HS 0.0624 S Se 803 cos ‘TOTAL Hot vapor bypass at 00°F Sz = 0,00 mol fraction 8, = 0.25 mol fraction Se = 0.75 mol fraction Total sulfur = 4.32 lbs/hr 0.333y ree 192! 33) + 250.5 0,0135 1b mols/hr 0,0045 1b mols/br RECEVZD FER 7 1972 Engrg. Standar:s Sg —» Se 51.5 28.9 0.054 0.0135 M Btu/Mol Lb Mols/Hr wh? = ~2,3909 M Btu/ar vw. bh = 16,182.3 + 565.2 + 2390.9 = 19,136.4 Btu/He Total reheat required with all sulfur shown as Sp = 379,800 © 19,138.0 Reheater effluent, 1b mols/hr 19.8 1b mols/ar Compound 2212°F 4ooer Ne 1o.k 10.4 H,0 46 4.6 COp 1.6 1.6 HS ais) 1.3 Sa 13 - Ss - on Se - 0.3 S02 0.6 0.6 cos e a TOTAL 19.8 18.9 178-307-272FLUOR CORPORATION 2 Page 17 ngre, sand"? At HOO°F converter inlet, 1b mols/ar Condenser condenser Compound Lb Mols/Hir Compa _Qutlet_ Reheat __Inlet Ne 0.5265 Ne 526.5 10.4 536.9 HO 0.2337 HO 233.7 4.6 238.3 COg 0.0778 C02 17.8 1.6 79.4 #8 0.0624 HS 62.4 13 63.7 Se - Se - - - Se 0.0045 Se 0.2 0.2 0.3 Se 0.0135 Se 0.6 0.3 0.9 80 0.0325 S03 31.5 0.6 32.1 cos cos O.7 ‘TOTAL 0.9506 TOTAL «933.4 18.9 952.3 Temperature = 400°F Pressure = 17.7 psia The calculation procedure is identical with Example 1A from this point. The methods used in completing a material balance for this type of plant configuration are detailed in example Alternate 1A. lternate 14 Btu/Lb Mol —_Btu/Lb Mol Compound Lb Mols/Hr at 1000°F at WOO°r = Btu/Hr Ne 0.5265 6,670 24290 2312.3 4,0 0.2337 7,960 2,650 120.9 C0 0.0778 10,100 3,220 535-3 HS 0.062 8,360 2,730 351.3 Se 0.0022 7,720 2,610 a2 Se 0.0128 38,000 12,800 322.6 Se 0.0067 38,000 12,800 168.8 S03 0.0335 10,800 3,640 225.5 cos: 0.0007, 10,900 3,520 5.2 TOTAL 1.0000 5172.1 DHS 178-307-272FLUOR CORPORATION Page 18 Heats of transition isp —— Se 51.5 28.9 M Btu/Lb Mol 0.0022 0.0006 Lb Mols/iir anO? = 0.0960 M Btu/Hir sh = 5172.1 + 96.0 = 5268.1 Btu/Hr ngra, Sander” w Total reheat required with all sulfur shown as Sy = 72.1 1b mols/br Hot vapor bypass, 1b mols/br Gompouna all. Sas Sp Na 38.0 a0 16.8 16.8 16.8 Op 5.6 5.6 5.6 1,8 4S 45 4S Se 4B 0.2 - Se - 0.9 0.3 Se - 0.5 1.0 S80, 2.3 2.3 cos on a ‘TOTAL 2.2 68.9 68.6 178-307a272Converter inlet, 1b mols/ar FLUOR CORPORATION Page 19 Compound Condenser outlet Reheat Converter Inlet Ne 526.5 38.0 564.5, H20 233.7 16.8 250.5, Og 77.8 5.6 83.4 HS 62.4 45 66.9 Ss - - - Se 0.2 0.3 0.5 Se 0.6 1.0 1.6 S803 31.5, 2.3 33.8 cos 0.7 ‘TOTAL 933.4 68.6 1002.0 Temperature = 400°F Pressure = = 17.7 psia cos recovery RECEIVED COS + HzO —> HeS + COs oe Ob Osh Oh Ob Fea 7 72 Sulfur reconversion Engrg. Standarcs Sg + 4Hig0 —> UiigS + 2503 0.5 2.0 2.0 1.0 38— + 16H20 —> 16H,S + 8S0, 1.6 8.5 8.5 43 DHT 178-307-272FLUOR CORPORATION Page 20 Lb Mols/#r Compound Inlet OS Recover, SReconversion Equivalent Feed a 564.5 561.5 0 250.5 -0.4 -2.0 -8.5 239.6 COp 83.4 40.4 83.8 HS 66.9 40.4 42.0 +8.5 17.8 Se - - Se 0.5 -0.5 Se 1.6 -1.6 802 33.8 42.0 44.3 39.2 cos 0.8 044 ok TOTAL 1002.0 3.2 1005.2 outlet temperature = 560°F Ro = H,S/SQ, 77.8/39-1 = 1.990 EIVED Wo = H,0/S0, = 239.6/39.1 = 6.128 RECEIVE 7 7 + FER 7 972 1 = Ynerts/30g = 4 83.8 Ob. 16,59 cz Engrg. Standards I= 5, C= 0.849 I= 2, 822 I = 16.6, C= 0.833 Total Hys —> S = (0.833)(77.8) H,S from sulfur reconversion = Actual conversion 64.8 1b mols/ar 64.8 - 10.5 54.3 Ib mols/hr 2.0 + 8.5 = 10.5 1b mols/ar 178-307-272FLUON CORPORATION Page 21 HpS + 1/280, —» 1.581 + Hel 54.3 27.2 83.5 pire RECEIVE! At 560°F EIVED S_ = 0.00 mol fraction a AER Se - 0.36 mol fraction FEB ¥ B72 Sp = 0.64 mol fraction Engrg. Standerds a 1 mols gota sulfur = (32.1 22 )(61.5 2B) = 2616 bs/ar Let: x = lb mols/hr of Sp y = I nols/nr of Sy 2 = 0.36 7 ¥ ; 192.4x + 256.5y = 2616 2616 Y= “THSSE)(0.5085) + 256.5 = 7.2 1b mols/hr x 4,0 Lb mols/hr Check heat balance 378-307-272FLUOR CORPORATION Page 22 Reactions COS + Hg0 —> HgS + CO Ob 0.4 04 0. mols /br 09° 62.1 205.2 12.6 -169.4 M Btu/ib mol eee = -5.9 M Btu/br Engrg. Standa:°s 280, + MigS —> Sg + tig0 8.0 16.0 4.0 16,0 1b mols/hr a6 330.8 12.6 425.3 -105.2 M Btu/Ib nol 60 = -334.0 M Btu/hr 850, + 16,5 —» 35, + 16440 19.2 38.4 Te a8 SL —C w96° = 862.3 M Btu/ar totar 196° = 5.9 - 334.0 - 862.3 1202.2 M Btu/hr Heat into converter Compound Lb Mols/Hr Btu/Lb Mol M Btu/Hr Np 564.5 2,290 1292.7 Hg0 250.5 2,650 663.8 03 83.4 3,220 268.5 HS 6.9 2,730 182.6 Sa 7 . . Se 12,800 6.4 Se 12,800 20.5 80, 3,640 123.0 cos 3,520 2.8 ‘TOTAL 2560.3 178-307-272FLUOR CORPORATION Page 23 Expected heat out of converter = 2560.3 + 1202.2 = 3762.5 M Btu/hr RECEIVED FER. 1972 ‘Actual heat out of converter Engrg. Standards Compound Lb Mols/Hr Btu/Lb Mol M Btu/Er Ne 564.5 3,430 1936.2 20 304.5, 4,020 qeah.a C0, 83.8 4,960 415.6 8 12.9 4,260 53.7 Se 7 . . Se 4S 19,400 87.3 Se 8.8 19,400 170.7 802 6.6 5,500 36.3 cos o 5,400 2.2 ‘TOTAL 986.0 3926.2 4 error 3926.1 ~ 3762.5 ooo 3926.1 koe Hot close enough. Assume 550°F at converter outlet and recalculate heat balance. I= 5, ¢ = 0,860 I= 25, C = 0.833 I = 16.6,¢ = 0,84 Total HS —> S (0.844)(77.8) 65.7 1b mols/nr Hg8 from sulfur reconversion = 10.5 1b mols/hr 65.7 - 10,5 55.2 1b mols/hr Day 178-307-272 ‘Actual conversionFLUOR CORPORATION Page 2 HigS + 1/280, = 1.58, + H,0 2 27.6 82.8 2 ” 7 » RECEIVED At 50°F Sp = 0,00 mol fraction Se = 0.355 mol fraction Se = 0.645 mol fraction Total sulfur = 2658 Ibs/hr x = 0,550hy : 2658 Y= TISETY(0.5508) + 256.5 7.3 Wo mols/hr 4.0 1b mols/br Check heat balance Reactions COS + Hg0 —> HS + Coz Ob 0.4 0.4 0.4 Lb mols/hr aH2°° 62,2 105.1 12.5 169.4 Btu/1b mol 550 ang 5.9 M Btu/ne 2802 + Migs —3 Sp + digo 8.0 16.0 4.0 16.0 1b mols/ar ax7° 230.8 12.5 © +25.5 105.1 Btu/ib mol ang? = ~333.2 M Btu/hr 178-307-272FLUOR CORPORATION Page 25 850, + 16HS —> 35, + 16H,0 19.5 38.9 7.3 38.9 Ib mols/nr RECEIVED fe FA 3 197 aa 130.8 -12.5 425.5 -105.1 Btu/lb mol FER oy i972 550 Engrg. Standarcs AH = 865.4 M Btu/br Total aw = 1204.5 M Btu/nr Expected heat out of converter = 255l,7 + 120h.5 = 3759.2 M Btu/hr Actual heat out of converter Compound Lb Mols/Hr Btu/Lb Mol M Btu/ir Ne 564.5 3,360 1896.7 HO 305.0 35930 1198.7 C02 83.8 4,850 406. HgS le.k 4,070 50.5 Be 4s 18,900 85.2 Se 8.9 18,900 168.2 803 6.3 . 5,390 34.0 cos ob 5,280 2 ‘TOTAL 985.8 3641.7 — 3OuL.7 = 3762.5 3 error = ESE x 200 = 2.36 Close enough Dus 278-307-272FLUOR CORPORATION Page 26 REHEATER + CONDENSER Inlet Compound Lb Mols/Hr Ne 564.5 #0 308.5 C0 83.8 RECEIvED #8 a2. 8 = Se 4S Se 8.9 803 6.3 cos ou TOTAL 985.8 Assume outlet is cooled to 350°F op: Converter = 0.05 psi Reheater 0.2) psi Condenser = 0.25 psi = 17.2 psia lbs sulfur OOO Tb mols sulfur free gas ~ 1% Total sulfur = 3149 1bs/ar Total sulfur-free gas - 972.4 1b mols/hr Sulfur remaining in vapor = 190(0.972K) = 185 1bs/br Sulfur condensed = 3149 - 185 2964 lbs/br 0,266y (see page 12) E 185 Y= “TseRY(O.226) + 256.5 x = 0.6 1b mols/nr 0.2 1b mols 178-307-272FLUOR CORPORATION Page 27 Condenser Outlet Vapor Compound Lb Mols/Hr Ne 564.5 H20 304.5 COg 83.8 HS 12.9 RECEIVED Sp e Se 0.2 Se 0.6 S02 6.6 cos o.b ‘TOTAL 973.5 Temperature = 350°F Pressure = 17.2 psia CONVERTER Assume @ converter inlet temperature of 4OO°F is desired and the hot vapor bypass is available at 1000°F. Condenser effluent vapor at 400°F x = 0,333y (see page 12) . 285 ¥ = U9 Y(0.355) + 256.5 = 0.6 1b mols/br x = 0.2 1b mols/br DH 178-307-272FLUOR CORPORATION Page 28 Ab 350°F Compound Lb Mols/itr Btu/Lb Mol M Btu/He Ne 564.5 1,920 1083.8 #0 30h.5 2,240 682.2 C0, 83.8 2,690 225.4 RECieD HS 12.9 2,290 29.5 fa : ‘ : £B 14 M02 Se 0.2 10,700 2 Engrg, Sonosre Se 0.6 10,700 6.4 802 6.6 3,060 20.2 cos nk 2,940 1.2 TOTAL 913-5 2050.7 At MOOR Compouna Lb Mols/ir Btu/Lb Mol M Btu/Hr Ne 564.5 2,290 1292.7 #0 30h.5 2,650 606.9 03 63.8 3,220 269.8 HS 12.9 2,730 35.2 82 - : . Se 0.2 12,800 2.6 Se 0.6 12,800 LT 802 6.6 3,640 24.0 cos ond 3,520 1b TOTAL 913.5 240.3 ag = 2hk0.3 - 2050.7 = 369.6 M Btu/Hr Total reheat required with all sulfur shown as Sp 389,600 oT SoG = (73-9 Lb Nols/ie 178-307-272FLUOR CORPORATION Hot vapor bypass, 1b mols/hr Page 29 Compound ALLS as Sy 1000°F Ne 38.9 38.9 20 17.3 17.3 Oa 5.7 DT #8 4.6 4.6 82 5.0 0.2 . ved Se - 0.9 0.3 92 Se - 0.5 2.0 803 2.3 2.3 2.3 bong, standards cos 0.2 On Hone TOTAL 73.9 70.5 10.2 Converter inlet, 1b mols/hr Compound Condenser Outlet Reheat Converter Inlet Na 564.5 38.9 603.4 #0 304.5 17.3 321.8 003 83.8 5.7 89.5 HS 12.9 4.6 17.5 Se S 5 . Se 0.2 0.3 0.5 Se 0.6 1.0 1.6 802 2.3 8.9 cos On 0.5 TOTAL 70.2 1043.7 Temperature = 4OO*F Pressure = ‘17.2 psia COs recovery COS + Hy —9 Has + COp or) oe Olas oa 178-307-272 DHJFLUOR CORPORATION Sulfur reconversion Se + MgO —> bes + 2509 0.5 2.0 2.0 1.0 38— + 16H,0 —> lé6HaS + 6850, Page 30 RECEIVED FEB 11 1972 Engrg. Standar?s ‘Tguivalent Feed 16 85 85 3 Lb Mols/Hr Compouna Iplet_ COS Recovery _S Reconversion No 603.4 7 10 321.8 -0.2 -2.0 -8.5 CO, 89.5 40.2 HS a5 40.2 42.0 48.5 Sa : Se 0.5 Se 1.6 S02 8.9 41.0 cos 0.5 TOTAL 1043.7 3.2 Outlet temperature = 450°F Ro = HgS/SOs = 28.2/14.2 = 1.986 Wo= Ho0/S0. = 31L2/14.2 = 22.91 I= Inerts/50g - —B-4+89-7+03 _ 19.93 = 25,C = 0.835 = 50,¢ = 0.822 oe eee Total HS —) Ss (0.822) (28.2) 23.2 1b mols/hr 603.4 31.2 89.7, 28.2 14.2 0.3 1046.9 HaS from sulfur reconversion = 2.0 + 8.5 = 10.5 1b mols/br Actual conversion = 23.2 - 10.5 = 12.7 1b mols/hr HaS + 1/2802 1.58; + H20 12.7 6.4 l9a 12.7 178-307-272FLUOR CORPORATION Page 32 At 450°P Total sulfur = (32.1 1bs/mol)(19. 1b nols/hr) = 613 Ibs/ar let: x = 1b mols/br of Sg RECEIVED y = YW mols/hr of Se FEB — 77 (0:28 Engrg. stevdards oy = 0.72 x = 0.38897 613, Yo “CSET. 3BB9) + 256-5 1.9 1b mols/nr * 0.7 Ib mols/ar Check heat balance Reactions cos + H20—> Has + Coz 0.2 0.2 0.2 0.2 1b mols/ar aif5° 61.6 20.9 -12.8 269.4 M Btu/1b mols at - 2.94 Btu/ir DE 178-307-272FLUOR CORPORATION Page 32 280, + Wigs —> Sg + Iiigo Lb 2.8 ©.7 2.8 Wh mols/ar ani? 130.3 -12.8 428.2 104.9 M Btu/Ib mol a5? . 58.5 m Btu/nr 850, + 1685 —>3S_ + 16430 5.1 10.1 1.9 10.1 1b mols/hr wit? 30,3 11.8 428.2 -104.9 M Btu/Ib mol wt9° 200.2 w Btu/nr totar aul? = 2.9 - 58.5 - 222.2 = -283.6 M Btu/hr Heat into converter Compound Lb Mols/Hr Btu/Lb Mol M Btu/iir Ne 603.4 2,290 1361.8 #0 321.8 2,650 852.8 C0 89.5 3,220 288.2 HeS 17.5 2,730 47.8 Se - - - Se 0.5 12,800 6.4 Se 1.6 12,800 20.5 SOg 8.9 3,640 32.4 cos 0.5 3,520 1.8 TOTAL 1043.7 2631.7 Expected heat out of converter = 2631.7 + 283.6 2915.3 M Btu/Hr 278-307-272FLUOR CORPORATION Page 33 Actual heat out of converter Compound Lb Mols/Hr Btu/Lb Mol M Btu/Hr Te 603.4 2,640 1593.0 20 334.5 3,080 1030.3 0g 89.7 3,750 336.4 HaS 4.8 3,170 15.2 8, . . - Se Le 14,800 17.8 Se 35 14,800, BB me 3 S80. 2.4 4,220 20.1 cos 0.3 4,100 1.2 ‘TOTAL 1039.3, 3055.8 error = Sere x 100 = 4G Not close enough. Assume 430°F at converter outlet and recalculate heat balance. I= 25,C = 0,86 T= 50,C = 0,848 I = §B.8,c = 0.849 Total HS —> S = (0.649)(28.2) = 23.9 1b mols/br HaS from sulfur reconversion = 10.5 1b mole/hr Actual conversion = 23.9 -10.5 = 13.4 1b mols/ir HyS + 1/280, —> 1.55; + Hg0 13.4 6.7 20.1 13.4 DHS 178-307-272FLUOR CORPORATION Page 3 At 30°F 0.00 mol fraction 0.272 mol fraction 0.728 mol fraction ‘Total sulfur 645 1be/hr x = 0.37367 y TE. y = 2,0 1b mols/hr x = 0.7 lb mols/br Check heat balance Reactions COS + Hy0 —» HeS + CO, 0.2 0.2 0.2 0.2 Ib mols/hr wit3 61.5 108.9 -12.7 -269.4 M Btu/Ib mod 430 OH, -2.9 M Btu/br 280, + bigs —P Se + htigo Lh 2.8 0.7 2,8 1 mole/hr aii3° 1302-1167. 28.9 104.9 M Btu/Ib nol ait3° = 58.5 M Btu/ar 830, + 16H,5 —> 359 + 161,0 5.3 10.7 2.0 10.7 1b mols/br aif3° 30,2 -21.7 +28.9 -104.9 M Btu/2b mol a3? = -249.4 M Btu/br Total aXi3° = -2.9 - 98.5 - 2h9.4 = -310.8 M Btu/or 178-307-272LUOR CORPORATION Expected heat out of converter = 2631.7 + 310.8 = 2942.5 M Btu/br Actual heat out of converter Compound ‘L Mols/Hr Btu/ib Mol M Btu/Hr Na 603.4 2,490 1502.5 #0 335-1 2,910 975-2 Ca 89.7 3,540 317.5 HS we 2,990 12.6 8, . . - Se Le 14,000 16.8 Se 3.6 14,000 50.4 802 2.2 3,990 8.8 cos 0.3 3,870 L TOTAL 1039.7 2884.9 Gerror = Ae x 100 = 2.0% Close enough DH Page 35 Engig. Stondares 178-307-272FLUOR CORPORATION Page 36 CONDENSER Inlet Sompound 1b Mols/ir Ne 603.4 H,0 335.2 oe 89.7 HS ha bd - ED ne as 121972 Se 3.6 . 803 2.2 Engrg. Standards cos, 0.3 ee 1039.7 Assume outlet is cooled to 350°F aP: Converter = 0.1 psi Condenser = 0.3 psi “P= 16.8 psi dbs sulfur OOO Ib mols sulfur-free gas ~ 2% Total sulfur = 1154 lbs/hr Total sulfur-free gas = 1034.9 1b mols/br Sulfur remaining in vapor = (198)(1.0349) = 205 1bs/ar 1154 - 205 949 Ibs/hr Sulfur condensed x = 0,266y (see page 11 ) 205 TSEC TBS * (OT 1b mols/br 0.2 1b mols/br 178-307-272FLUOR CORPORATION Page 37 Condenser outlet vapor Lb Mols/tr MN 603.4 4H,0 335.2 CO, 89.7 8 he Sa - RECEIVED Se 0.2 Se 0.7 $02 2.2 cos 0.3 ORAL 1035.8 Temperature = 350°F Pressure = 16.8 psia CONVERTER Assume a converter inlet temperature of 400*F is desired and the hot vapor bypass is available at 1000"; Condenser effluent vapor at 400°F x = 0.333y (see page 12 ) y= Tg 0.6 ib mols/br * 0.2 Ib mols/nr DE 278-307-272FLUOR CORPORATION Page 38 At 350°F Compound «Lb Mols/Hr = Btu/Ib Mol © M ‘Btu/iie Np 603.4 1,920 1158.5 HzO 335.1 2,240 750.6 COg 89.7 2,690 241.3, RECEIVED Has ke 2,290 9.6 _ Sp : : - Fep 14 8/2 Se 0.2 10,700 2.1 Engrg. Standar?s Se 0.7 10,700 7.5 S02 a 3,060 6.7 cos 0.3 2.940 0.9 ‘TOTAL 1035.8 2177.2 At hoo°r Compound “Tb Mols/iir = Btu/Lb Mol © M_Btu/Hir Ne 603.4 2,290 1381.8 Hg0 335.1 €,650 888.0 COg 89.7 Sect 288.8 HigS we iL Se - - . Se 0.2 1z,800 2.6 Se 0.6 12,800 TT SO, 2.2 3,640, 8.0 cos 3 4,520 1 TOTAL 1035.7 2589.5 oq = 2589.5 - 2177.2 = 412.3 M Btu/Ar Total reheat required with all sulfur shown as Sp 412,300 > st = 78.2 ib nols/nr 278-307-272FLUOR CORPORATION Page 39 Hot vapor bypass, 1b mols/br Compound All S as Sy 1000°F 40°F Ne ana jaa daa #0 18.3 18.3 18.3 RECEIVED COy 6.2 6.2 62 FEB 14 972 Hes 4g 4g hs Se 5.3 0.2 - Engrg. Standards Se - 1.0). Ok Se - 0.5 qa $03 2h au cos aod TOTAL 78.2 14.6 TH All of the hot vapor reheat streams are known at this point. The actual flow through the plant can now be calculated by prorating the equivalent combustion effluent by 1000 1b mols/hr + reheat. Equivalent combustion effluent = 1000 1b mols/br Ist reheat 72.1 1b mols/hr 2nd reheat 73.9 1b mols/nr 3rd reheat 78.2 Ib nols/nr TOTAL 1204.2 Tb mols/hr COMBUSTION EFFLUENT Compound Actual Lb Mols/Hr Equivalent Lb Mols/tir Ny 702.7 702.7 #40 31.9 31.9 Go, 79.0 103.8 HS 45.2 83.3 82 102.5 89.9 Se . 2 Se . - 80. 53.9 hae cos, 1.0 1.0 Ha 38.1 : co 24.8 . so = 1334.7 pag 178-307-272WASTE HEAT BOTLER Compound, Ny 1,0 Coy ‘TOTAL Temperature Pressure Taiet 702.7 311.9 19.0 45.2 102.5 53.9 1.0 38.1 24.8 1.2 1360.3 pale 18.7 FLUOR CORPORATION ‘Lb Mols/Hr Hot Vapor Bypass 128.7 57.2 19.0 15.2 0.6 3.2 LS 7.6 0.3 233.2 1000 18.4 Outlet 574.0 254.8 84.8 68.0 29.3 5.3 10.7 3hoth 0.8 1062.1 530 18.2 Page 40 RECEWe9 FER 21272 Engrg. 3: 178-307-272FLUOR CORPORATION Page 1 Duty Inlet vapor at 2212°F_ RECEiVeD Compound Lb Mols/ir Btu/Lb Mol M Btu/Hir Ne 102.7 16,200 11,383.7 Erg. Stone H20 31.9 20.200 6,300.4 ated COs 79.0 25,600 2,022.4 HS 45.2 22,000 99h. 8, - - - Sa 102.5 28,400 1,886.0 Se - - - Se - - - S03 53.9 26,900 2,149.9 cos 1.0 27,500 27.5 Hy 36.1 15,500 590.6 co 24.8 16,300 4ok.2 so 2 17,500 21.0 ‘TOTAL 1360.3 25 ,080.1 Neglect heat of condensation Sulfur condensed = 942 Ibs/hr Dig 178-307-272FLUOR CORPORATION Page lz RECEIVED 1972 fe ie) 1 Heat released cooling to 1000°F ° ngrg. Standards Inlet vapor at 1000°F nae. St Compound Lb Mols/Hr Btu/Lb Mol M Btu/iir ‘Compound Na 702.7 6,670 4,687.0 H0 311.9 7,960 2,482.7 CO. 19.0 20,100 197.9 HS 45.2 8,360 317.9 8) - - - 8. 102.5 7,720 79.3 Se : : - Se - - - SO. 53.9 10,800 582.1 cos 1.0 10,900 10.9 He 38.1 6,460 26.2. co 24.8 6,730 166.9 so 7,310 8.8 ‘TOTAL 1360.3 10,151.6 Heats of transition 382 > Se 8 9 a.6 w stu/2e aot 51.0 17.0 1 mols/br 19200 2917.2 M Btu/hr bsg —> Se 4472000 “171.6 M Btu/1d mol 'f 36.0 9,0 Ib mols/br 210,000 a5. Beu/ae 278-307-272FLUOR CORPORATION Page 43 Heats of reaction (see page 7 ) He + 80,9 HS + 02 RECEIVED wo 155.8 38.5 0M Btu/Ib mol FEB 2 38.1 38.1 38.1 38,2 1b mols * Engrg. Standards ang. 4N69.1 M Btu/hr CO + 1/20, —> CO, 13 8.0 0 169.7 M Btu/1b mol 24.8 12.4 24.8 1b mols/br aor? = -3018.2 M Btu/ar SO + 1/20, —} 80, 130° 26,9 0 -155.8 M Btu/Ib mol 1.2 0.6 2.2 2b mols/ur 0H = -15l.7 M Btu/ar S, + 250, —9 280, a? 0 ° -155.8 M Btu/lb mol 12.6 25.1 25.1 1b mols/ar augs00° = -3910.6 M Btu/ar Day 178-307-272FLUOR CORPORATION Page Ul ‘Total heat released in cooling combustion effluent to 1000°F RECEIVED 25,080.1 - 10,151.6-+ 2917.2 + 1554. 469.1 + 3018.2 + 154.7 + 3910.6 FES 2,014.5 M Btu/br Engrg. Standards Lb Mols/Hir Compound Total Reheat Balance Ne 702.7 128.7 574.0 Ha 311.9 57.2 254.7 CO, 103.8 19.0 84.8 HS 83.3 15.2 68.1 8) - - - Sp 2.9 0.6 2.3 Se 17.0 3.1 13.9 Se 9.0 1s 15 803 wea 7.6 Bhs cos 1.0 0.3 TOTAL 1273.7 233.2 1040.5 Heat released cooling balance of waste heat boiler effluent from 1000 to 530°F Btu/Db Mol —-Btu/Lb Mol Compound “Lb Mols/Hr at, 1000°F at 530°F M Btu/Hr Ne 574.0 6,670 3,210 1,986.0 H20 254.7 7,960 3,760 1,069.7 0, 84.8 10,100 4,630 463.9 HS 68.2 8,360 3,890 304. 8) . E : . Sa 23 7,720 3,700 Se 13.9 38,000 18,100 Se 15 38,000 18,100 80 3h 10,800 5,150 cos 20,900 5,050 ‘TOTAL 178-307-272FLUOR CORPORATION Heats of Transition bsp) Sy 2H? 50.1 24.6 M Btu/Ib mol 2.3 0.6 2b mole/br 93° 2 -200.5.M Btu/hr Total heat released = 4li58.2 + 100.5 = 4598.7 M Btu/hr Duty = 22,014.5 + 4558.7 = 26,573.2 M Btu/hr Use 26.8 Mt Btu/hr (neglecting 9h2 1bs/hr of sulfur condensed) CONDENSER #1 Lb Mols/Hr Compound Inlet Outlet Na 574.0 574.0 #0 254.8 254.8 05 84.8 84.8 HS 68.0 66.0 5) . us: Se - = Se 0.2 Se 0.7 80 Bh cos. 0.8 ‘TOTAL 1129.2 ‘Temperature 350 Pressure 7.7 DHS Page 45 Engig. St 278-307-272FLUOR CORPORATION Page 46 Heat of condensation @ = (3579 1bs/hr)(297-90) Btu/1b RECciveD = 0.7kL MM Btu/Hr 7 FEB i+ Vapor cooling Engrg, Stand Btu/Lb Mol Btu/Lb Mol Compound Lb Mols/tir at _530°F at 350°F M Btu/Hr Na 574.0 3,210 1,920 7H0.5 H,0 254.8 3,760 2,20 387.3 C0, 84.8 4,630 2,690 264.5 Has 68.0 3,890 24290 108.8 3) _ . ei - Se : ’ 7 7 Se 0.2 18,100 20,700 1s Se 0.7 18,100 10,700 5.2 50 34.4 54150 3,060 19 cos 0.8 54050 2,940 LT ‘TOTAL 1017.7 1461 Duty = 0,7ll + 1.4814 2.2224 MM Btu/br Use 2.2 MM Btu/hr 178-307-272FLOR CORPORATION Page 47 CONVERTER #1 Db Mols/ir Compound Condenser Effluent Reheat inlet Outlet ™ 574.0 WS 615.5, 615.5 HO 254.8 18.3 273.1 332.0 COs 4.8 6.2 90.9 gael HS 68.0 Ag 12.9 13.5 8; . E . - So - 0.2 - - Se 0.2 1.0 0.5 49 Se 0.7 0.5 LT oT 809 he 25 36.9 6.9 cos 0.8 oun 0.9 nb TOTAL 1017.7 Bl 1092.4 1074.3 ‘Temperature 350 1000 400 559, Pressure 17.7. 18.2 ITT 17.65 REHEATER + CONDENSER #2 os qo oe RECEIVED Na 615.5 615.5 Hg0 332.0 332.0 CO, ged ou.d HS 13.5 14.0 8, - 100.7 Sa . - Se 4.9 0.2 Se oT 0.7 803 6.9 1.2 cos 0.4 o.k TOTAL 1074.3 1262.1 Temperature 550 350 Pressure 17.65 17.2 Dag 278-307-272FLUOR CORPORATION Page 48 Heat of condensation Q = (3232 Ibs/br)(300-90) Btu/1b = 0.679 Ma Btu/br Vapor Cooling Btu/Lb Mol Btu/Lb Mol Compound Db Mols/ar at 550°F at_350°F 4 Btu/Be Ma 615.5 3,360 1,920 886.3 Hg0 332.0 3,930 2,240 561.1 COp ok 4,850 2,690 197.4 Hes 24.0 4,070 2,290 2h.9 8, = a . . Se S a . - Se 0.2 18,900 10,700 1.6 Se 0.7 18,900 20,700 5.7 503 Te 54390 3,060 16.8 cas 4 5,280 2,940 0.9 TOTAL 1061.4 1694.7 Duty = 0.679 + 1.6947 = 2.3737 MM Btu/br Use 2.4 MM Btu/hr 178-307-272FLUOR CORPORATION: Page 49 CONVERTER Lb Mols, Compound Reheat Inlet Outlet Np 615.5 42.4 657.9 657.9 #40 332.0 18.9 350.9 365.3 C0 oy 6.2 97.6 97.8 HS 1.0 5.0 19.0 4.6 sy - - - - 8, - ove - . Se 0.2 1.0 0.5 1.3 Se 0.7 0.5 LT 3.9 803 1.2 2.5 9.7 2.4 cos out 0. 0.5 0.3 TOTAL 1061.4 76.8 = 1137.8 1133.5 Temperature 350 1000 400 430 Pressure 17.2 18.2 17.2 172 CONDENSER #3 Lb Mols/iir Compound inet Quélet Ne 657.9 657.9 : #0 365.3 365.3 CO 97.8 7.8 18 4.6 46 sy - 32.2 Se . - Se 13 0.2 Se 39 0.8 80 2h 2.4 cos 0.3 ‘TOTAL 1233.5 61.5 Temperature 430 350 Pressure Wa 16.8 Dus 278-307-272PLUOR CORPORATION Heat of condensation (2035 1bs/br) (284-90) Btu/ 1b = 0,201 MM Btu/br ae Vapor Cooling Compound Na #0 ‘TOTAL Duty Lb Mols/iir $57.9 365.3 97.8 46 0.2 0.8 au 0.3 il29.3 0.201 + 0.7119 0.9129 MM Btu/hr Use 0.91 MM Btu/hr Btu/Lb Mol at 430°F 2,490 2,910 3,540 2,990 14,000 14,000 3,990 3,870 Page 50 RECeis 2D FEES Ene Btu/Lb Mol at 350°F, M Btu/Er 1,920 375.0 2,240 2.8 2,690 83.1 2,290 ae 10,700 0.7 10,700 2.6 3,060 2.2 2,90 0.3 m21.9 178-307-272FLUOR CORPORATION Page 51 CONVERTER #3 ‘Lb Mols/Hr Compound © Condenser Effluent | Reheat Inlet X 657.9 4.8 702.7 H,0 365.3 20.0 385.3 Op 91.8 6.7 104.5 HS 4.6 53 9.9 8, . . - Sa . - Se 0.2 0.6 Se 0.8 1.8 SO, 2.4 5.0 cos 0.3 ou ‘TOTAL 1129.3 1210.2 Tenperature 350 1000 oo Pressure 16.8 18.2 16.8 cos recovery COS + Hy0 —>HgS + COg O1 On 1 0.2 Sulfur reconversion Se + 4ig0 —? bigs + 250, 06° 2h 2.4 12 3S, + 16H,0—> 16H,8 + 850, 18 9.6 96 4.8 DHS 178-307-272Page 52 Lb Mols/Hr Compound © Inlet GS Recovery § Reconversion Equivalent Feed Na 02.7 102.7 #0 385.3 “0.2 -2.4 9.6 313.2 Cp 10k. 40.2 104.6 HS 9.9 40.1 42.4 49.6 22.0 8) S - Se _ - Se 0.6 -0.6 Se 1.8 “1.8 809 5.0 41.2 44.8 11.0 cos ou -0.1 0.3 ‘TOTAL 1210.2 3.6 1213.8 Assume 415°F out of converter RECei R = H8/S02 = 22/1l = 2.0 FEB Wo = Hj0/S0, = 373.2/1. = 33.93 Engrg, Stand T= Inerts/so, = —O2T+IMN6 103 p3.42 I= 50,¢ = 0.815 I 100, ¢ 0.809 I= 73.4, c = 0.812 Total Hs —? s = (0.€12)(22) 17.9 1b mols/hr HyS from sulfur reconversion = 2.4 + 9.6 = 12,0 1b mols/nr Actual conversion = 17.9 - 12.0 5.9 Yb nols/nr HgS + 1/280 —> 1.58, + Had 5-9 3.0 89 5.9 178-307-272FLUOR CORPORATION Page 53 At Mi5tF 0.000 mol fraction 0.272 mol fraction 0.726 mol fraction (32.1 1bs/1b mol)(5.9 1b mols/br) = 189 Ibs/br 0.3736y 18: (ise BY SE) + 256. 0.6 1b mols/br x « « x = 0,2 1b mole/ar Check heat balance Reactions COS + HyO —> HS + CO, O21 0.2 0.20.21 mols/nr af ery 10.8 -11.6 169.4 Btu/b mol a. 2.5m Beware 280, + WHgS —> Sg + 4H,0 ob 0.8 0.2 0.8 1b mole/ar a5 430.2 -22.6 429.4 -104.8 M Btu/1b mod antl5 = -16.6 M Btu/nr 850, + 16iigS —4 35 + 61,0 1.6 3.2 0.6 3.2 1b mols/hr ui -130.1-11.6 429.4 104.8 M Btu/1b mol wt 7a, M Btu/nr toter a5 - 1.5 - 16.6 - Tak = -90.5 M Btu/br DHS 178-307-272FLUOR CORPORATION Page 54 Heat into converter Compound Lb Mols/Hr Btu/Lb Mol M Btu/Hr Np 102.7 2,290 1609.2 #0 385.3 2,650 1021.0 C0 104.5 3,220 336.5 RECeiveD Has 9.9 2,730 27.0 beg y Sy . . - Sy S : = Engrg. Stordarcs Se 0.6 12,800 TT Se 1.8 12,800 23.0 803 5.0 3,640 18.2 cos Ob 3,520 el TOTAL qel0.2 3044.0 3044.0 + 90.5 3134.5 M Btu/br Expected heat out of converter Actual heat out of converter Compound Lb Mols/iir Btu/Lb Mol M Btu/Hr Na, 702.7 2,390 1679.5, 20 389.2 2,760 1082.0 C0 104.6 3,360 353.5 HS 6.0 2,860 172 Sy - - - Se . . - Se 0.8 33,400 10.7 Se 2.4 13,400 32.2 805 3.0 3,810 cos 0.3 3,690 TOTAL 1209.0 3187.6 error = —U8U:S- 345 x 100 = 1% Close enough 178-307-272FLUOR CORPORATION Page 55 CONDENSER #4 Inlet Compound ‘Lb Mols/Hr Np 102.7 . RECEIVE! Ay at ECEIVED COp 104.6 FEB 14 1972 HS ce Engrg. Standards 8, . 82 . Se 0.8 Se 2. 802 3.0 cos 0.3 ‘TOTAL 1209.0 Temperature = 415°F Pressure = 16.7 Assume outlet is cooled to 350°F OP = 0.25 psi “P= 16,5 psia Ibs Sulfur [OOO mols/sulfur-free gas = 206 Total sulfur = 770 1bs/hr Total sulfur-free gas = 1205.8 1b mole/nr Sulfur remaining in vapor = (206)(1.2058) = 248 Ibs/hr Sulfur condensed = 770 - 248 = 522 1be/nr x = 0.2667 (see page 22) 2 YS UEEENO RETEST * 0-8 2 noke/ae x = 0.2 mols/br Heat of Condensation @ = 522 Ibs/nr (282 - 90) Btu/1b = 0.100 MM Btu/hr 178-307-272FLUOR CORPORATION Page 56 Vapor cooling Bey/lb Mol -Btu/tb ot Compound Ib Mole/Hr =a M5*F at 350°F. M Btu/ir Na 702.7 2,390 1.920 330.3 0 389.2 2,760 2,240 210.2 COy 104.6 3,380 2,690 72.2 #8 6.0 2,860 2,290 3.4 8 - - e eS Se . . e . Se 0.2 13,400 10,700 0.5 Se 0.8 13,400 10,700 2.2 80. 3.0 3,810 3,060 2.3 cos 0.3 3,690 2,940 0.2 TOTAL 1206.8 621.3 Duty = 0,100 + 0.6213 ee RECEIVED Use 0.72 MM Btu/hr FEB 17 REHEATER Engrg. Standarcs Converter feed must be reheated to 400'F Duty Btu/Lb Nol —-Btu/Lb Mol Compound Lb Mols/Hr Mk at_350°F M Btu/Hr Ne 702.7 2,290 1,920 260.0 Ha0 389.2 2,650 2,240 159.6 C0, 104.6 3,220 2,690 55.4 HS 6.0 2,730 2,290 2.6 5 . . . . 8 e e S - Bg 0.2 12,800 10,700 Ou Se 0.8 12,800 10,700 1.7 809 3.0 3,640 3,060 LT cos 0.3 3,520 2,940 0.2 TOTAL 1206.8 481.6 Reheater duty = 0.4616 ¥4 Btu/ir Use 0.48 MM Btu/lir 178-307-272FLUOR CORPORATION Page 57 CONDENSER $2 outlet of converter #1 is cooled from 550 to T in the reheater. try: T = 500°F Pressure = 16.25 psia Sulfur dew point total sulfur = 3149 1bs/br total sulfur-free gas = 972. 1b mols/hr Ibs. sulfur US “TOOT aels/or sulrur-free gas" ~O.g7ay * 3238 dew point = 41°F RECziv At 500°P Sp = 0,000 mol fraction 7 Ss = 0.322 mol fraction bgt 8 = 0.678 mol fraction Engrg. Standards x = O.47h9y o 31 ¥ = HRERNEAMBY FET * 9-2 mola/e x = 4,3 1b mols/br outlet vapor Compound Lb Mols/itr Btu/Lb Mol M Btu/ir Ms 615.5 3,000 1846.5 Hg 332.0 3,500 1162.0 Op Lek 4,300 393.0 48 13.5 3,620 48.9 Sy - - - 8. - - - Se Ag 16,900 82.8 Se 9.7 16,900 163.9 80, 6.9 4,800 33.2, cos ont 4,690 1.9 TOTAL 2074.3 3732.2 DET 178-307-272FLUOR CORPORATION Page 58 Duty = 4.1863 - 3.7322 = .lph2 Mu Btu/Hr Try T = 495°F outlet vapor Compound Lb Mols/Hr »«Btu/Ib Mol = Btu/Hr ™ 615.5 2,960 1821.9 #0 332.0 3,460 2148.7 C0, gu. 4,240 387.5 FEB 17 i HS 33.5 3,570 48.2 8 - - . Engrg. Standa Se - - - Se 4g 16,700 81.8 Se 9.7 16,700 162.0 80 6.9 4,740 32.7 cos 0.4 4,630 1.9 TOTAL 107.3 3684.7 Duty = 4.1863 - 3.6847 0.5016 MM Btu/br From a plot of Tvs. duty, T = 97°F CONDENSER #2 Inlet T = A97°P Duty = 2.374 - 0.482 1,892 MM Btu/ar Use 1.9 MM Btu/nr 178-307-272FLUOR CORPORATION CONVERTER #4 Compouna Inlet Ib Mols/Hr Ms 102.7 1,0 389.2 CO, 104.6 HS 6.0 3 - 5 - Se 0.2 Se 0.8 80, 3.0 cos 0.3, TOTAL 1206.8 Temperature = 10°F Pressure 16.25 psia COS recovery COS + HZO—> HS + CO, O.2 © OL Ol 02 Sulfur reconversion Sg + MgO —> Migs + 280, 0.2 0.8 0.8 OW 38, + 1610 —> 1615 + 850, 0.8 43 43 2.1 DHT Page 59 RECcrv FEB 17 Engrg, Standarés 178-307-272FLUOR CORPORATION Page 60 Bb Mols itr Compouna Inlet COS Recovery 8 Reconversion Squivalent Feed Np 102.7 702.7 #0 389.2 0.2 -0.8 -4.3 384.0 ©, 104.6 40.1 104.7 HS 6.0 40.2 40.8 44.3 1.2 4 - - 5, . - Se 0.2 -0.2 Se 0.8 -0.8 80, 3.0 40.4 42,2 5.5 cos 0.3 -0.1 0.2 TOTAL 1206.8 1s 1208.3 Assume 405°F out of converter R = HyS/SQ, = (12.2/5.5 = 2.04 Wo= H,0/S0, = 384.0/5.5 = 69.82 RECEivzD I = Inerts/so, = —0-T+104.7+ 0.2, 20 +02 - 146,84 FEB I oho oO Engrg. = 100,¢ 0.675, = 147, 0.652 Total HS -S_—-= -(0.652)(22.2) = 7.3 1b mols/ar H,S from sulfur reconversion = 0.8 + 4.3 5.1 Ib mols/hr ‘Actual conversion = 7.3 - 5.1 = 2.2 1b mols/hr HS + 1/280, 1.58, + H,0 2.2 lal 33 2.2 178-307-272FLUOR CORPORATION Page 61 At M05°F Sq = 0.00 mol fraction S_ = 0.25 mol fraction Se = 0.75 mol fraction Total sulfur = (32.1 1bs/Ib mol)(3.3 1b mols/ar) 106 1bs/hr x = 0.333y (see page 12) ye 106 = 0.3 1b mole/tr Engrg, Stanse-'s T92.H)(0.333) + 256.5 x = 0,1 1b mols/br Check heat balance Reactions cos + HjO —> HS + CO, Ol 9 OL 0.2 0.1 Ub mols/hr wit? 61.4 204.8 21.5 -269.4 M Btu/b mod a 2.5 M Btu/nr 280g + Wigs —? Sp + Hlg0 0.2 o.4 0.2 0.4 1b mols/br wit 230.0 -21.5 +29.7 204.6 M Btu/b nol os aif? = -8.9 M Btu/br 850, + bigs —> 3— + 16H20 0.8 1.6 0.3 1.3 1b mols/hr a5 430.0 11.5 1297 -204,8 Dtu/b aol ait = 36.4 m Btu/hr qotar HOF 2.5 - 8.4 - 36.4 = 86.3 M Btu/hr DHS 278-307-272FLUOR CORPORATION Page 62 Heat into converter Compound Lb Mola/Hr Btu/Lb Mol M Btu/Hr ed 102.7 2,290 1609.1 0 389.2 2,650 2032.8 C0, 104.6 3,220 336.8 a Co 2,730 26.4 81 = - c RECEW=O a 7 , > FEB IT BT ne 0.2 12,800 2.6 Se 0.8 12,800 aaa Engrg. Standar?s $0, 3.0 a an oe 0.3 3,520 TOTAL 1206.8 3018.5 Expected heat out of converter = 3018.5 + 46.3 3064.8 M Btu/br Actual heat out of converter Compound Lb Mols/ir Btu/Lb Mol M Btu/Hr Na 702.7 2,310 1623.2 40 39L.2 2,700 1056.0 COs 204.7 3,270 3h. 18 4a 2,770 uk s1 . e e Ss - e e Se oO. 13,000 13 Se 0.5 33,000 S0q 2.0 35700 cos: 0.2 35580 TOTAL 1205.4 3048.9 error = 646-308-9100 = 0.5% Close enough 178-307-272FLUOR CORPORATION Page 63 CONDENSER #5 Inlet Compound Lb Mols/Hr Na 702.7 40 391.2 co, 104.7 18 ha RECEIVED 81 : FEB 17 1972 Sp 5 | a fngte. 3 Se 0.5 805 2.0 cos 0.2 ‘TOTAL 1205.4 Temperature ‘405°F Pressure = 16.2 psia Assume outlet is cooled to 285°F oP = 0.3 psi = 15.9 psia lbs sulfur = 3% [000 mols sulfur-free gas) ~ Total sulfur = 147 lbs/ar Total sulfur-free gas = 1204.8 1b mols/br Sulfur remaining in vapor = (36)(1.2048) = 43 1bs/br Sulfur condensed = v7 - 43 = 104 1bs/br DHT 178-307-272FLUOR CORPORATION Page 64 At 265°P Sp 0.000 mol fraction Se = 0.163 mol fraction Se = 0.837 mol fraction x = O.19hTy RECEIVED \ Y= “TRETYOCTMTY + a56.5 * 0-1 I mole/br FEB 17 1972 0.03 1b mols/br * Engrg. Stan Heat of condensation ob 1bs/ar (280 - 74) Bbu/Ib 0.021 MM Btu/hr © Vapor Cooling Btu/Lb Mol —-_-Btu/Lb Mol Compound Lb Mols/Hr at, 05°F at 265°F M Btu/Hr XN, 702.7 2,320 1460 597-3 20 391.1 2,700 1690 395.0 CO 104.7 3,270 2010 131.9 HS aa 2,770 1730 4A 81 . . : . Se - - - - Se 0.03 13,000 8090 0.2 Se 0.15 13,000 8090 0.7 $03 2.0 3,700 2320 2.8 cos, 2 3,580 2210 0.3 TOTAL 1204.98 1132.4 Duty = 0,021 + 1.1324 = 1.1534 MM Btu/br Use 1.2 1M Btu/br 178-307-272FLUOR CORPORATION Page 65 SULFUR RECOVERY Da Waste heat boiler ge Lbs/ar Condenser #1 3579 lbs/br Condenser #2 3232 1bs/br Condenser #3 1035 1bs/br Condenser #4 522 lbs/br RECEIVED Condenser #5 204 Ybs/nr TOTAL sulfur recovered 91h 1ba/br FEB 17 1972 Engrg, Standards Sulfur remaining in vapor = 2h7 1bs/br Recovery = atte x 100 = 97.le 178-307-272FLUOR CORPORATION Page 1 SULFUR PLANT CALCULATIONS —_ RECEIVED FEB 7 1972 EXAMPLE 2 Engrg. Standsr?s Lean Acid Gas - Straight-Through __ And Acid Gas Bypass ‘The calculations in this example are predicated on the following design paranters: 1. Feed HS concentration between 30 and 50 mol % (dry basis). Side by side tabulation showing the differences between two alternate methods of processing this type of feed. A, Alternate 2A. Straight-through. Air and acid gas feed preheated enough to give a combustion temperature above 1680°F. This allows processing in a straight-through system and is calculated Like Example 1. B, Alternate 2B. Acid gas bypass. ‘wo-thirds of the acid gas feed bypasses the combustion step. Methyl mercaptan is included to illustrate the inert character of compounds bypassing the combustion step. Four conversion stages. Hot vapor bypass for converter feed reheat in first three conversion stages of Alternate 2A. 6. Heat of reaction across a conversion stage to reheat converter feed for fourth conversion stage in Alternate 2A and for all four conversion stages in Alternate 2B. 7. Combustion air at 75°F, 90% saturated. FEED Component CO, HS Gy SH ‘Total DHSFLUOR CORPORATION Page 2 ‘Temperature = 120°F Pressure = 4.5 psig RECEIVED Atmospheric Pressure = 14.7 psia rep 7? FEED, WET BASIS ogre. onde"? Water vapor pressure at 120°F = 1.7 psia Mol fraction Hj0 = 1.7/(14.7 +4.5) = 0.089 ¥0 « {D8a5 - 750 = 73.3 Ub Mols/ir Component Ib Mols/Hr Btu/Tb Mol #0 3.3 346 CO, 435.0 392 #8 300.0 352 eg 15 375 SH 527 823.3 PLANT CONFIGURATION Mol iS < 50%, > 306 (ary basis). Iwo processing schemes are possible fand each'will be calculated. ‘The type of converter feed reheat for each alternate should be decided at this point and a different alternate for each scheme will be calculated as shown in Figure -2. Tt mst be stressed ‘hat other combinations of reheat are possible and are explained in the process description. The engineer mist exercise good judgment in selecting the particular reheat schene for a given feed. Alternate 24 Alternate 2B A straight through design with all | Acid gas bypass design with 2/3 of of the acid gas sent to the combus- | the acid gas feed bypassing the tion step. Acid gas feed and air combustion step. Heat of reaction will be preheated enough so that reheat for all conversion stages. the combustion temperature is above 60°F, Hot vapor bypass reheat for the first three conversion stages, heat of reaction reheat for forth conversion stage. 172-308-2729H EteFLUOR CORPORATION Page 4 ATR REQUIRED Oxygen Required REC > Alternate 2A Alternate 2p FEB 7 132 For HS, 300/2 = 150.0 For H,S, 300/2 - 150.0 Engrg, Stand: "5 vor ¢,, 7.5 2G) « 15.0 vor ¢,, 43 AMA) - 5.0 vor si, 7.5 (2Q2) - 15.0 For 8H, 43 AO}!4) « 5.0 Total 0, = 180.0 tb Nols/iir Total 0 = 160.0 tb Mols/Hr. total air = 280 ~ 857.1 wm wols/te total air = 282 - 761.9 wh Mols/ir Total Ny = 677.1 Tb Mols/tir Total tly = 601.9 Ib Mols/Hr Hg0 = 0.027 tb Mols/Ib Mol ary air | 1,0 = 0.027 Lh wols/Lb Mol ary air (027) (677.1) 18.3 Lb Mols/Hr (027) (601.9) 16.3 Db Mols/tir Temperature = 75°F Temperature = 75°F Th Mols/_Btu/M Btu/ Tb Mols/ Btu/—M Btu/ Comp. Hr Ib Mol Hr Comp. __Hr ib Wol Hr 0, 180.0 Ih -2.5 2 160.0 =u % 677-1 “9.5 % 601.9 -1h #0 18.3 16 -0.3 0 16.3 -16 Total 875.4 -12.3 Total 778.2 Enthalpy of total mixture Enthalpy of total mixture = 307.6 - 12.3 = 307.6/3 - 10.9 = 295.3 M Btu/ir = 91.6 M Btu/ir Try 90°F as temperature of mixture. Try 90°F as temperature of mixture. Lb Mols/ Btuf-—M Btu/ Tb Mols/ Btu/-_—M Btu/ Comp. __Hr Tb Mol __Hr Comp. Er Ib Mol __Hr Op 180.0 Ee 16.4 oO, 160.0 gu 1.6 % OTT. 9n 61.6 X 601.9 91 54.8 10 91:6 204 9.5 RO 40.7 104 ule CO, 435.0 u6 50.5 CO, 145.0 16 1618 5 300.0 106 31.8 HS 100.0 106 10.6 q 1.5 12 0.8 CQ 2.5 lz 0.3 csi 25 157 1.2 sh 2.5 157 ok Total 1698.7 11.8 Total 1052.6 101.7 177-308-272FLUOR CORPORATION Page 5 Alternate 2A Try 100°F as temperature of mixture. Mols/ Btu M Btu/ Alternate 2B ‘Try 100°F as temperature of mixture. Tb Mols/ —_Btu/_M Btu/ Comp. ir vol __ He Comp. Hr Ib Mol _Br a 160.0 162 29.2 Om 160.0 162 25.9 % 677-1 160 108.3 Ne 601.9 160 96.3 #0 91.6 185 16.9 | Ho 40.7 185 15 C0, 435.0 207 90.0 | co 15.0 207 30.0 HeS 300.0 187 56 | ms 100.0 187 38.7 gq 15 199 1.5 q 2.5 199 5 GSH T5279 2.1 | qsu 2:5 279 7 Total 1698.7 304.1 1052.6 179.6 ‘A plot of temperature vs. enthalpy gives 99°F at 295.3 M Btu/Hr. COMBUSTION STEP Alternate 2A ALL of the feed is sent to the furnace. Computer Input Symbol Ib Mols/Hr fe 180.0 m 677-1 wep 91.6 ope 435. 1s 300.0 cHy 7.5 cHs 75 si 0001 82 Soo01 38 Sooo1 spe Toor 593 -0001 cps Sooo1 we Zooor op Sooor Sooor Me “Soot mp3 0001 c So001 ose T0001 cs -0001 sp 10001 DH A plot of temperature vs. enthalpy gives 89°F at 91.6 M Btu/Hr. RECEIv=2. FEB 7 1372 Engrg. Stands Alternate 2B one-third of the feed is sent to the furnace while 2/3 bypasses the furnace. Computer Input Symbol Lh Mols/tie fe 160.0 he 601.9 Hep 40.7 ope 145.0 Hes 100.0 cH 2.5 cHis 2.5 si 20001 82 0001 88 0001 spe [0001 S93 20001 ops £0001 He {0001 op :0001 wp 20001 nga 0001 13 ‘0001 c 0001 cs2 0001 cs 20001 5p ‘ooo1 17T-308-272FLUOR CORPORATION Page 6 Alternate 2A ‘Temperature = 300°F Pressure = 18.2 psia COMBUSTION EFFLUENT Alternate 2A Compound Ub Mols/Hir % 677.1 #0 34619 Cy iazta 18 51-7 83 94.8 80, 56.2 cos 3.8 Hy 17.0 co 3hL 80 0.3 Total 1700.0 ALL of the Hp, CO, and SO will react to form HS, COz, and 50_- WS formation from lip and SO Hy +80, —> HS + Op wow woo 0, formation from CO and Op co +30, —» C0, Bhd lt. Bh. $0, formation from $0 and 0, 80 + 30, — 50, 32 3 Net oxygen required ATA + 2-17 = 0.3 bh Mols/ie 0, formation from HzO and SO, HzO + 80, —» gS + $0 22 23 Alternate 2B Temperature = 69°F Pressure = 18.7 psia RECEIVED: FEB 7 1972 Alternate 2B Engrg. Stenoar’s Compound Lb Mols/Hr Na 601.9 20 149.5 C0 16. S03 102.3 He 1.2 a 3.6 so 0.2 Total 1005.1 All of the H,, CO, and SO will react to form HS, C0,, and S03. HS formation from H, and SQ3 Hy +80, —> HS + 03 12 12 1.2 1.2 60 formation from CO and 0, CO + BO —» CO, oe a $0, formation from $0 and 0, 80 +40, — 80, 22 2 Net oxygen required 1.8 + .2- 1.2 = 0.8 Bb Mols/ir 0, formation from H,0 and $0, H,0 + $0, —» HS + $0, oo fo) Pe 277-308-272RECEIVED Page 7 FEB 7 1972 FLUOR CORPORATION Alternate 2A Engrg. Standards Equivalent combustion effluent 1b mols/hr Combustion HS co, S80, Equivelent Compound Effluent ‘Formation Formation Formation _Effluent Ne 617.1 677.1 #0 346.9 -0.2 346.7 05 Mae +34. 46.2 HS 57.7 417.0 + 2 mh. Se 4.8 4.8 S803 56.2 17.0 - .2 +3 39.3 cos 3.8 3.8 He 17.0 217.0 co ahaa <3. so 0.3 - Total 1700.0 “17.2 1682.8 Temperature = 1805°F Pressure = 18.2 psia The calculation procedure is identical with Example 1A from this point. Alternate 2B Equivalent combustion effluent 1b mols/nr Combustion #8 0, 80, Equivalent Compound _Bffluent _Formation Formation Formation _Effluent, Ne 601.9 601.9 #20 149.5 -5 149.0 2 16.4 43.6 150.0 eS 2+ 5 Lt 802 102.3 oL.2 + 5 +2 100.8 Re 1.2 -1.2 co 3.6 -3.6 so 0.2 “2 Total 1005.1 “1.7 1003.4 ‘Temperature = 2652°F Pressure = ‘18.7 psia Dis 177-308-272FLUOR CORPORATION Page 8 WASTE HEAT BOILER INLET Alternate 2B RECEIVED Compound Ib Mols/Hr te a.8 FEB 7 1972 ‘0 1g. co, 150.0 Engrg, Standards 8 LT S02 100.8 Total, 1003.4 Assume a converter inlet temperature of 00°F is desired. Calculate the outlet temperature of the waste heat boiler. let: T = outlet temperature of waste heat boiler ‘Avheat balance around this point gives: 1003.4(nT = n#00) = 548.9(n#00 - p20) Enthalpy of bypass Btu/Ib Mol -Btu/Ib Mol Compound Ib Mols/ir at MOU'F_ at 1Z0"F ‘gO 48.9 2650 3h6 CO 29010 3220 301 eS 200.0 2730 351 q 5.0 3150 375 si iso 517 Total 5h8.9 Enthalpy of saste heat boiler outlet at 4OO°F Compound Mol Fraction Btu/Lb Mol Np +5999 2290 #30 =1hB5 2650 CO +195 3220 eS 0017, 2730 80. 004 36h0 Total 1.0000 277-308-272FLUOR CORPORATION Page 9 Alternate 2B RECEIVED nt oe ose (nO _ 120) + 1400 FER 7 1972 . Lute 400, 2628.8 Engrg. Standards 4056.3 Btu/Lb Mol Try SHO, 560, and 580°F as outlet temperatures from waste heat boiler. Bbu/Db Mol Btu/Lb Mol Btu/Ib Mol Compound at SkO°F at 560°? at 58C°F Np 3290 3430 3570 #0 3850 ozo ittg0 CO, Litho 4960 5190 1S 3980 460 i3h0 80, 5270 5500 5740 Enthalpy of waste heat boiler outlet Btu/Ib Mol -Btu/Lb Mol Btu/Tb Mol. Compound Mol Fraction at 540°F at 560°F at 560°F le 5999 1973-7 2057.7 auun.6 20 +1485 571.7 597.0 622.2 C0 11495 708.6 Ths 715.9 eS +0017 6.8 TL Th 803 21004 29.1 552.2 576.3 ‘Total 1.0000 3782.9 3955.5 4123.4 A plot of Tvs. enthalpy gives 572°F at 4056 Btu/Ib Mol Converter inlet Ib Mols/lir. Compound WB Outlet Bypass Inlet Ny 601.9 601.9 HO 149.0 48.9 197.9 CO 350.0 290.0 4hio.0 HeS : 200.0 201.7 80 100.8 Gy si Total 1003.4 548.9 1552.3 DH 177-308-272FLUOR CORPORATION Page 10 Alternate 2B ‘Temperature 400°F Pressure = 16.2 psia ‘The calculation procedure is similar to Example 1A from this point. The only difference is that external reheat is used to reheat converter feeds. RECEIVED FER 7 1972 Engrg. Standards 172-308-272FLUOR CORPORATION Page 1 SULFUR PLANT CALCULATIONS 27u-309-272 RECEIVED FER 7 WI Engrg, Standot=s ‘EXAMPLE 3 Dilute Acid Gas - Sulfur Recycle The calculations in this example are predicated on the following design parameters: 1. Feed tigS concentration below 15 mol % (dry basis). Elenental sulfur Will have to be burned to provide the required 50,. ‘Two converter stages. FEED Compound Lb Mols/Hr Nol Fraction C0, 2640.0 0.880 #8 300.0 Q 60.0 Total 3000.0 Temperature = 120°) Pressure = 4.5 psig Atmospheric Pressure = 14.7 psia FEED, WET BASIS Water vapor pressure @ 120°F vot fection O = qetey + 0.089 1.7 psia Hao = ~22Ge5 - 3000 = 293.1 Lb Mols/He Sompound Do Mole /ie Beu/Lb Mol M Btu/tir #0 293.1 346 101.4 0g 260.0 392 1032.2 1S 352 105.3 q 375 22:5 DESFLUOR CORPORATION Page 2 PLANT CONFIGURATION Mol HS < 15f (ary basis). A sulfur recycle design is used in which 80, is obtained from oxidizing product sulfur. BLOCK FLW DIAGRAM RECEIVZ9 eroume ve FER 7? Engrg, Sten 3 Conve TONAL rou SULFUR AND ATR REGUIRED A minimum of excess air should be used in the SO, generator. Each applica- tion will have to be discussed with the $0, generator vendor to establish the minimum excess air requirement. A previous Fluor design used 7-1/26 excess air. ‘The main reaction is: S + O% ——> 80, ‘The SO, generator effluent is cooled before mixing with the acid gas feed to prevent the excess air from oxidizing hydrocarbons. All of the excess air is used to convert HS to SO, across the first converter by the following reaction: HS + $0, ——> 80, + The stoichionetric relationship between H,S and $0, must be maintained at H)S/S0, = 2 after all oxygen has been consumed. let: x = Ib mols/hr § burned y = Ib mols/hr HS converted to $0, 3 + 0 ——> 8 HS + $0, —> 8 + 1,0 y ay y y 1TU-309-272FLUOR CORPORATION Page 3 Using 7-1/2% excess air, 07s = dy QQ) After all oxygen is consuned, HS = 300- SQ, s x+y 300-¥ . oy ee (2) Simultaneous solution of equations (1) and (2) gives x = 139.5 lb mols/nr y = 7.0 1b mols/nr Total 0, required = (1.075)(139.5) 150.0 1b mols/nr Total air = 22° = 714.3 1b mols/nr Hy = T1k.3 = 190 = 564.3 1b mols/ar H,0 = 0,027 1b mols/Ib mol dry air (0.027)(714.3) = 19.3 lb mols/hr Temperature = 75°F Compound Ib Mols/tir Btu/Lb Mol uM Btu/ He , 150.0 ab -2.1 Re 564.3 -1h #0 19.3 -16 ‘Total, 733.6 10.3 The liquid sulfur should enter the SO, generator between 270 and 290°F. Assume 290°F. qo 5 2b mols ibs oe 8S = (139-5 =) (32.1 4a) 4U78 Lbs/nr Heat required to vaporize sulfur (4478 lbs/hr)(266 - 72) Btu/1b = 868.7 M Btu/hr 9° = 1180 Btu/Ib moi DES 270-309-272FLUOR CORPORATION Page 4 (2280) (239.5 7000 ~~ 968.7 = -70k.1 M Btu/ir Enthalpy of inlet sulfur Enthalpy of total mixture # -70h.1 - 10.3 = -T1b. M Beu/ te Engrg. Stanaoe:s The present (March 1971) minimization of free energy program is for vapors only, An equivalent feed temperature must be calculated at the enthalpy resulting from the heat of vaporization being used to cool the feed to keep the heat balance consistent. Try -40°F Compound Ib Nols/Hr Btu/Tb Mol M Beu/ He Oe 150.0 -800 120.0 Ne 564.3 -815 -159.9 Heo 19.3 -935 -18.0 Sy 339.5 072 3.7 Tovar 673.2 ~091.6 Try -50°F Compound Btu/Lb Mol ~368 -884 1020 - 728 A plot of temperature vs. enthalpy gives -lli*PF at -714.4 M Btu/ar. COMBUSTION STEP Computer Input symbol ge re rp sl s2 $8 see ‘Hes #2 No peFLU OR CORPORATION Symbol Lb Mols/Hr pat 0003 $03 .0001 sp +0001 H £0001 Y 20001 ° 20001 Np3 0001 Temperature = -bl°F Pressure 16.2 psia COMBUSTION EFFLUENT Compound Lb Mols/Hr Ne 564.3 0 19.3 S80 a8. 803 Total 723.2 ‘Temperature = 4701°F Pressure 18.2 psia Page 5 RECEIVED Feg 7 872 Enea standar?3 ALL of the compounds in the combustion effluent are stable and will not ‘The combustion effluent will be cooled to a temperature such that when mixed with the acid gas feed, the desired converter inlet temperature is obtained. react when cooled in the waste Assume the first converter inlet temperature is 400°F. A heat balance at the point of heat boiler. mixing gives: 723.1 (aT - 1400) = 3293.1 (nHO0 - n120) Compound Lb Mols/ir Btu/Eb Mol i 293.1 2650 ob, 2640.0 3220 HS 300.0 2730 q 60.0 3150 Total 3293.2 3293.1 (nO - 120) Dis 10,285.5 - 1262.4 902.1 M Btu/ar M_Btu/He 716.7 8,500.8 819.0 289.0 10,285.5 170-309-272FLUOR CORPORATION Combustion effluent at koo°r. Compound Lb Mols/tir Btu/Lb Mol te 56h.3 2290 H20 pe Fe! 2650 Sop 11835 3640 505 22.0 ile Total 723.1 723.1 (hT = n#00) = goak.1 M Btu/Hr WASTE HEAT BOTLER OUTLET 723.1 nT = 9024.1 + 1877 = 10,901.1 M Btu/Hr ‘Try 1780, 1790, 1800°F Bou/Lb Mol Btu/Lb Mol. Compound at 1760°F, at 1790°F Re 12,700 12,800 20 15,600 15,700 So 20,900 21,100 803 40,500 40,800 M Btu/Hr. —-M Btu/Hr. Compound Ib Mols/lir gt 17B0°F at 1 790°F Ne 564.3 7,166.6 7,223.0 10 19.3 301 303.0 SO. 118.5 2,76 4500.4 505 21.0 850) 856.8 Total 723.1 10,794.9 10,883.2 A plot of Tvs, enthalpy gives 1798°F at 10,901 M Btu/iir. WASTE HEAT BOILER Inlet at 4701°F Compound Lb Mols/Hr Btu/ Ib Nol Ne 564.3 37,800 #0 19.3, 51,200 80, 118.5 61,200 803 2. 97,200 Total 723.1 Daty = 32,612. - 10,901.1 LLM Btu/Hr Use 20.7 MM Btu/tir Page RECaIVED. FEB 7 Engrg. Stansst an Btu/Lb Mol at 1600°r 12,800 15,800 21,200 42}200 M Btu/Hr. at 1800°R 7,223.0 304.9 2,512.2 865.2 10,905.3 M Btu/ir 21,330.5 988.2 7,252.2 20h. 31,612.21 17U-309-272FLUON CORPORATION CONVERTER INLET Compound Ne 120 CO. HS SO, 803, Q ‘Temperature = 00°F Pressure = 17.7 psia Page RECcIvED FEB 7 1972 Engrg. Stand ‘The calculation procedure is similar to example Alternate 1A from this point, The methods used in completing 4 material balance for this type of plant configuration are detailed in example Alternate 1A. DHS 17U-309-272JOR CORPOKATION SULFUR PLANE CALCULATIONS 27v-320-272 EXAMPLE 4 Feed Containing Ammonia Page 1 RECEIVE) Feg 7 1372 Engrg. Stands" "s This example illustrates the basic difference when a feed containing ammonia mist be processe? in conjunction with another acid gas feed. FEEDS Feed 1 Feed 2 Compound Lb _Mols/Hr Mol Fract: Lb/Mols/Hr Mol Fraction Wig - = 8.6 0.460 60, 20.8 0.065 - = HS 290.0 0,925 10.0 0.540 o 3.2 0.010 - i Total 313.5 1.000 18.6 1.000 Temperature 120°F 110°F Pressure 4.5 psig 4.5 psig Atmospheric Pressure = 14.7 psia ‘FEEDS, WET BASIS FEED 1 Water vapor pressure at 120°F = 1.7 psia LT Mel fraction #0 = apts * 0-089 HO = + FEED 2 Water vapor pressure at 10°F = B35. 313.5 = 30.6 Lb Mol/#r 1.3 Mol fraction HO = aE pI5 = 0-068 Das Te Oe 18-6 18.6 = 1.4 Db Mols/HrRECcIvEO Fivor conroration FER 7 1372 Page 2 Engr, Sanders FEED 1 Compoun Ly Mols/ite Btu/Eb Nol M Btu/ir Hig0 30.6 Rig 7 cm 20.4 #8 q Total FEED 2 Compound Be Mote/ie Btu/ Db Wo M Beu/te #0 1k 265 iy 8:6 283 co, E - eS 10.0 269 27 q 7 . = Total 20.6 5.5 PLANT CONFIGUKATTON Bach feed is oxidized in separate burners, The normal acid gas feed is handled in the conventional manner and depending upon the HS concentration, is processed accordingly. The ammonia fecd is quantity of air such that all oxidizable compone #28 are completely oxidized. The HjS is oxidized to $0,. The balance of the air is added to the other feed keeping tthe overall oxygen require- ment for HpS is 1/2 mol/mol iS in loth feeds burner are mixed and the rest of tue processing i mann e that both burners may 52 in the sam is the most economical arran; Ege ye 27V-310-272FLUOR CORPORATION AIR RECUIRED FEED 2 Oxygen required For Nig, 8.6(3/4) = 6.5 For HS, 10(3/2) = 15 Total 02 21.5 FEED 1 oxygen required Total HyS requirement Supplied by FEED 2 Net supplied by FEED 1 ror ¢,, 3.12214) Total Feed 1 Total O = 141.2 Db Mols/tir Total air Le = 612.4 th Mols/Hr Total Ne = 531.2 Lb Mols/itr ¥g0 = 0.027 Wb Nols/Ib Mol dry air =(0.027)(672.4) = 18.2 Lb Mols/Hr Page 3 RECEIVED feos Lb Mols/Hr engre, Sere WH ~ 150.0 15.0 135.0 Lb Mols/Hr = 6.2 = 141.2 Lb Mols/tir Feed 2 Total @ = 21.5 Lb Mols/Hr nota ate = 25 102.4 Lb Mols/Hr Total N= 80.9 Lb Mols/itr H20 = 0.027 Lb Mols/Ib Mol dry air = (0.027)(102.4) = 2.8 Lb Mols/Hr Temperature = 75°F Temperature = 75°F Ib Mols/ _Btuf—M Btu/ Lb Mols/ _Btu/ —M Btu/ Comp. He Ib Mol _ir Comp. Ib Mol __He o bi.2 1h -2.0 Os ab M 531.2 su Tol Xe a4 #20 -16 #20 -16 Total 690.6 9.7 Total At this point all feeds can be combii temperature for input to the computes 221.6 216.0 Enthalpy of total mixture ned for calculating the total mix r program. + 5.5 = 9.7 = Lil M Btu/Hr 17V-310-272FLUOR CORPORATION Page 4 ‘Try 90°F as temperature of mixture. Compound Db Mols/iir Btu/Lb Mol M Btu/He etv2d O 162.7 92 au.g RECE! 612.1 gl 55.7 qe Ho 53.0 104 pipe Os ee Wig 8.6 ua 1.0 oa CO, 20.4 16 2.4 Emerg: 53° #5 300.0 108 2.8 G Bal 2 3 Total 1159.9 ‘Try 100°F as temperature of mixture. Compound Ib Mols/Hir Btu/D> Mol M Btu/ir Os 162.7 162 26.4 % e121 160 7.9 HaO 53.0 185 9.8 My 8.6 196 ult C03 20.4 207 ule eS 300.0 187 56.1 on 3.1 199 0.6 Total 1159.8 196.7 A plot of temperature vs. enthalpy gives 91°F at 116.0 M Btu/Hr. ALL of this fezd will be sent to the furnace. Computer Input Symbo1 pe te 129 NB ope Bs cul 3 82 88 spe 5p3 ps Fe DHS LIV-310-272FLUOR CORPORATION Page 5 Symbol Ib Nols/Hr op 0001 Np {0001 wpe 0001 Np3 20001 c 20001 cs2 20001 cs 0001 sp 0001 Temperature = 91°F Pressure = 16.7 psia COMBUSTION EFFLUENT Compound Ib Wols/Hr X 616.4 #0 282.8 CO. 15.7 Fes aie Se 104.0 50, 4.7 cos 0.2 ie wa co 7.6 so oe . Total 1165.5 Temperature = 22h1°F Pressure = 18.7 peia ‘The calculation procedure is similar with Example 1A from this point. TV-310-272FLUOR CORPORATION Page 1 OPERATING INSTRUCTIONS RECEIVED Tpege878 JAK SL 2 Genera Engg. Standards ‘This section contains suggested methods for startup, normal operation and shutdown, and includes special procedures for boiling out the waste heat boiler and regenerating the catalyst. ‘These instructions should be considered as a guide only, and are not intended to include all required preparatory details and operations. ‘he major considerations involved in the startup and shutdown of sulfur plants are: prevention of damage to refractory, prevention of sulfur fires and explosions, prevention of solidification of sulfur in the equipment, prevention of catalyst fouling and avoiding corrosion, and to carry out these phases of operation without harm to personnel. All refrectories contain moisture, some in the form of water crystalliza~ tion. Both on the initial and subsequent startups when the plant has been down for some time, moisture must be removed slowly to avoid refractory damage. Prescribed rates of refractory heat-up and cool-down for various phases of operation is offered by the equipment manufacturer to minimize damage. It is desirable to purge with an inert gas when placing a plant in operation to remove possible explosive gases before fuel or acid gas is admitted to ‘the unit. After initial operation, a sulfur plant will contain sulfur in some locations which will ignite at temperatures as low as 300°F if oxygen is present. If a sulfur fire starts and excess air is not quickly removed, permanent damage to the plant equipment due to overheating could result. Therefore, excess air should never be blown through a hot plant for more then a very brief period. The quantity of sulfur retained in the plant can be reduced during normal shutdowns by purging with a hot SO, rich gas stream. By oxidizing all the acid gas to S0,, sulfur production stops, and molten sulfur drains off or is slowly vaporized and passes out of the system with the tail gases. It is necessary to preheat all equipment well above the solidification temperature of sulfur to avoid system plugs. It is preferred to preheat by firing the auxiliary plant fuel, using precautions detailed in the next paragraph. Preheating by firing acid gas can be considered once the plant reaches a minimum temperature. Care must be exercised to avoid producing sulfur that could solidify in cold parts of the plant, and to prevent moisture from condensing and forming corrosive acids. WKPage 2 FLUOR CORPORATION OPERATING INSTRUCTIONS Catalyst activity is impaired by carbon deposition rising from the incom- Plete combustion of hydrocarbons or by fouling with condensing sulfur. Catalyst performance can be protected with proper attention to operating conditions. Sulfur fouling is remedied by promoting revaporization. Carbon deposition, however, requires the interruption of sulfur production, and regeneration of catalyst through a controlled burning with excess air, or perhaps even replacement of the catalyst. When firing hydrocarbon fuel, it is important that air does not fall below about 110-120 of the Stoichionetric requirement, if carbon formation is to be avoided. Equipment Preparation It is important to check out all sub systems and controle when commission- ing @ plant to demonstrate that they will perform prior to the initial plant startup. It is especially desirable to minimize problems in starting up a sulfur plant for the first time, because once the system is contamin- ated with sulfur, correction of system defects becomes more difficult. Manufacturers supply detailed activation procedures, and they should ve followed ani take precedent over specific instructions included in this section. The following activation procedures should serve only as @ checklist in preparation of detailed operating instructions for a specific plant. 1. Charge the Converter catalyst and level the beds. 2, Activate the Air Blower. Blow through the unit to remove dust from the catalyst bed; pressurize the system with eir and check for leaks. 3. Establish that the utility systems serving the plant are activated and there is a reliable supply of steam, power, hydrocarbon fuel, and instrument air. Ultimately, a continuous and stabilized acia gas stream mist be available prior to startup. 4, Dry out entire train of equipment (3 to 4 days’ operation) 5. Fill the sulfur seal legs with flaked sulfur and melt it with jacket steam. Seal legs should now be open to the rundown sump. 6. Comission the Incinerator. The incinerator generally takes longer to ary out than other equipment and should be started up first. However, on large plants the reactor furnace controls, since it mst be heated to more than 2000°F and has more courses of brick. Keep moisture out of train as much as possible at all times. Light the pilot burner and, using the main fuel gas burners, ary out the refractory by heating at a controlled rate. Thorpe specified the following procedure for a tail gas incinerator! 17K-312-272