MRPL-ONGC

WEL COME

Presentation on
SULPHUR
Block

SULPHUR RECOVERY
10 YEARS AGO SULPHUR WAS SELLING @$100+ PER TON.
PRESENTLY RATE <$40 PER TON
NO MORE COMMERCIALLY VIABLE - MONEY MAKING
PRODUCT

GOVT REGULATIONS

SRU REDUCES POLLUTION, NEED TO RECOVER SULPHUR

EMISSIONS , ODOUR, OPACITY, GROUND LEVEL
CONCENTRATION,
INCREASED SULPHUR PRODUCTION

MRPL-ONGC

Sulphur Block

This content the following units

1. 322 -Amine Regeneration Unit
2. 326 - Sour Water Stripper Unit
3. 614/714/814 -Sulfur Recovery Unit
With Sulfur Pelletizer Unit

MRPL-ONGC

MRPL-ONGC

Block Diagram Of Sulphur Block

Sour Water

SWS

Sour Gas

SRU

Stripped Water

Rich Amine

AR
U
Lean Amine

Acid Gas

Liquid Sulphur

Pelletizer

Sulphur in Pellet form

SOUR WATER STRIPPER UNIT-326

MRPL-ONGC

SOUR WATER STRIPPER UNIT

PURPOSE OF THE UNIT

MRPL-ONGC

REFINERY STRIPPER UNIT ( SWS-I ).

Hydro Treated Sour water STRIPPER UNIT(SWS-II).
BY STRIPPING OFF DISSOLVED H2S & AMMONIA FROM SOUR WATER.
STRIPPED WATER WILL BE SENT TO DESALTER IN CDU OR WWTP FOR
DISPOSAL.

DESIGN DATA
Design capacity
SWS-I : 218.4 MT/hr
SWS-II : 67.9 MT/hr
20% over design margin shall be kept in reboiler and pump around section of
SWS-I & II. For the rest of the unit, 15% over design margin shall be kept for
SWS-I and 10% over design margin shall be kept for SWS-II.
ON-STREAM FACTOR
The unit on-stream factor - 8000 hours per annum
PLANT TURNDOWN CAPABILITY
SWS unit-I - 30% of the design capacity.
SWS unit-II - 30% of the design capacity.

MRPL-ONGC

Characteristics of Sour Water Streams to Refinery SWS-I

H2S content of 500 ppmw max and 200 ppmw Hydrocarbon

in sour water feed to the unit.

MRPL-ONGC

Characteristics of Sour Water Streams to Hydroprocessing SWS-II

MRPL-ONGC

SWS Column
detail

MRPL-ONGC

Single stage Sour Water Stripper 326DA001

Type
:
Tower (28 Trays)
Fluid
:
Sour Water
OPERATING CONDITIONS:

Temperature
Pressure
Pressure Drop

Top
90 C
0.9 Kg/cm2g
0.2 Kg/cm2

Bottom
121 C
1.1 Kg/cm2g

AMINE REGENERATION UNIT1200

MRPL-ONGC

AMINE REGENERATION UNIT

Amine Regeneration Unit322

MRPL-ONGC

Purpose of the Unit

The Amine Wash and Regeneration Unit is designed to
process sour gas loaded stream of MDEA
( Absorber & Extractor), DHDS and send back to user
units after removing H2S, CO2 and hydrocarbons.

Amine Regeneration Unit-1200

MRPL-ONGC

The objective of the unit is to achieve the desired level of

H2S and CO2 content in the Lean Amine.
Capacity (Design):
The capacity of the unit is to treat 9491 T/D of Rich
Amine.

ARU Feed-Product Specifications

Feed-Product Specifications
Feed: Rich Amine

From
Quantity(T/D)
Composition(wt. %)
H2S
CO2
MDEA
H2O

SGU
137.78

DHDS
3378.53

UGS
2556.76

3.67
0.02
34.17
62.12

5.58
0.0
37.84
56.42

4.04
0.26
37.87
57.80

Products:
Lean Amine
MDEA : 40 %
H2S : 0.007 mole H2S/Mole MDEA (Max.)
CO2 : 0.003 mole CO2/mole MDEA (Max.)
H2O : Balance

MRPL-ONGC

ARU UNIT- 1200 Process flow diagram

MRPL-ONGC
Acid gas to flare
Acid gas to SRU

Rich Amine from

DHDS/FCC/CDU

Reflux drum
Regenerator

Feed
Drum

ARU
Regenerator
Reflux pump

Mech
Filter

Carbon
Filter

Reboiler

Lean Amine to
DHDS/FCC/CDU

Amine
Tank

ARU Process flow description

MRPL-ONGC

The unit consists of the following sections:

Rich amine flash section:
The rich amine solution having H2S, CO2, hydrocarbon and
water vapor etc. is flashed in rich amine flash drum to remove
only hydrocarbons (H2S flashing is not allowed). After
flashing, lighter hydrocarbons will go to H2S flare header
under pressure control and heavier ones are collected in the
flash vessel and can be pumped out of the unit. After this, rich
amine solution goes to amine regeneration section.

ARU Process flow description

MRPL-ONGC

Regeneration section:
The rich amine solution goes to amine regenerator which is equipped
with LP steam reboilers at the bottom. In this regenerator, amine
solution is heated indirectly as a result of which H2S, CO2 and other gases
get separated and these gases from top goes to Sulfur Recovery Unit in
order to recover elemental sulfur from H2S.
In case of shut down of Sulfur Recovery Unit, the gases goes to H2S flare.
The bottom liquid of the regenerator which is called lean amine, after
removal of above gases, is cooled in air-cooler before going to the storage
tank.

ARU Process flow description

MRPL-ONGC

Lean amine storage and filtration section:

Regenerated amine solution (i.e. lean amine) after air cooling is received in
amine storage tank which acts as a inventory vessel. From this tank, lean
amine is sent to unit 1300, 3500, and 4000 after cooling to required
temperature in water coolers. A part of lean amine solution is recycled
back to the storage tank after filtration.
Amine unloading and drains collection section:
Amine solution (100% wt.) is unloaded from trucks into an underground
vessel from where it is pumped to storage tank. This underground vessel is
also used to collect amine solution from different low point drains in the
unit during turnarounds as amine solution is not allowed to go to any
other drain / system.

ARU Process flow description

MRPL-ONGC

Even during upstream unit upsets and carryover of heavier

hydrocarbons, all amine is drained to the vessel, oil removed /
skimmed and fresh solution is sent back to storage tank. This
vessel has got LP steam injection facility for dilution of freshly
unloaded amine from the tank.

SULPHUR RECOVERY UNIT5000

MRPL-ONGC

SULPHUR RECOVERY UNIT

Why we need
SRU

MRPL-ONGC

Tightening of emission standards by

Govt./regulatory bodies.
Increasing demand for environment
friendly fuels (low Sulphur).
Use of High Sulphur and heavier Crude
oil.

SULPHUR RECOVERY UNIT-624

MRPL-ONGC

Objective:
* convert H2S to elemental sulphur
* Avoid pollution of the environment while recovering the
sulphur for other uses

Capacity of SRU
Design : 555 MT/D (Three train each of 185MT/D)

22

INTRODUCTIO
N What is Claus Reaction ?

MRPL-ONGC

When two moles of Hydrogen Sulphide (H2S) react with one mole of
Sulphur Dioxide (SO2) to give Elemental Sulphur in presence of
Catalyst, the reaction is called Claus Reaction Carl Friedrich Claus is
the London chemist .
2H2S + SO2 3/n Sn + 2H2O
n = No. of atoms in Sulphur molecule
1/3rd of total H2S in feed gas is burned to SO2, this SO2 reacts with
remaining H2S to give elemental Sulphur in Thermal Reactor
H2S + 3/2O2 SO2 + H2O
2H2S + SO2 3/n Sn + 2H2O
Overall Reaction
3H2S + 3/2 O2 3/nSn + 3H2O

SULPHUR RECOVERY UNIT

MRPL-ONGC

(1) Acid gas from Amine regeneration unit

(a) Feed Quantity

= 623.5MT/SD

(b) Composition :
Components

MT/SD

H2S
CO2
H2O
TOTAL(MT/SD)

405.20
6.00
7.50
418.70

MT/hr

TOTAL
96.77
1.43
1.80
100.00

(c) Condition at Battery Limits:

Pressure
: 0.80 kg/cm2g
Temperature: 40 oC

24

SULPHUR RECOVERY UNIT

MRPL-ONGC

Feed Specification
(2) Acid Gas from Sour Water Stripper Unit
(a) Feed quantity

= 9.72 MT/SD

(b) Composition :
Components

H2S
NH3
H2O
TOTAL(MT/SD)

MT/SD
5.44
1.96
2.32
9.72

wt%
55.96
20.16
23.88
100.00

(c) Conditions at Battery Limit :

Pressure
: 0.8 kg/cm2g
Temperature : 90 oC
.

25

PRODUCT
SPECIFICATIONS

MRPL-ONGC

Product from SRU : Liquid Sulphur to Pastillation Unit

Colour
Purity
H2S
Ash Content

: Bright Yellow (as Solid State)

: Min 99.7 wt% on dry basis
: < 10 ppmw
: Max 250 ppmw

Battery Limits
Temperature : 150 0C
Incinerator Stack Gases
SO2 - 180 ppm
NOx - 100 ppm

Pressure

: 5 Kg/cm2 g

Block Scheme Sulfur Removal

MRPL-ONGC

Claus & Modified Claus Process

MRPL-ONGC

MRPL-ONGC

Claus Process
reactor

reheater

incinerator

steam

stack

waste heat
boiler
steam

H 2S 2

combustion
chamber

SO
condenser

FrC

feed gas

air

=
1

MRPL-ONGC

Actual Reactants and Products

s te a m

fr e e fla m e
r e a c tio n
fu rn a c e
and
w a s te h e a t
exchanger

BFW

H 2S
SO 2
H 2O
S 2/S 4/S 6/S 8
C O S /C S 2
H 2 /C O 2 /C O /N

fu rth e r
tre a tm e n t

Claus Process for Sulfur Recovery

MRPL-ONGC

MRPL-ONGC

Combustion Chamber

ARU
Acid Gas

HP Steam

K
O
D

1300-1350c

To 1st
condenser

K
O
Acid Gas D
SWS

Thermal Reactor

Fuel gas

K
O
D

Waste heat boiler To Sulfur

condenser

Combustion air
BFW

SULPHUR RECOVERY UNIT

MRPL-ONGC

SULPHUR RECOVERY PROCESS

DESCRIPTION

The SUPERCLAUSTM-99 process, is based upon the partial

combustion of H2S with a ratio controlled flow of air.
Correct quantity of air for complete oxidation of all
hydrocarbons and NH3 present in the acid gas feed.
H2S percentage of 0.5-0.7 vol% at the inlet of the selective
oxidation reactor (SUPERCLAUS Reactor) is to be
maintained.
The SUPERCLAUSTM-99 process operates according to the
new process where the air to acid gas ratio is adjusted to
achieve an H2S/SO2 ratio of greater than 2/1 in the burner
effluent.
.
33

SULPHUR RECOVERY UNIT

MRPL-ONGC

A special process gas analyzer is provided on the effluent gas

stream from sulphur condenser no.3 to measure the H 2S
concentration and to control the trim air to the burner to
achieve the desired H2S concentration of 0.5 to 0.7 vol % H2S.
To obtain a concentration of H2S in the process gas entering the
Superclaus stage in the range of 0.5-0.7 vol%, the concentration
of H2S in the process gas entering the third Claus stage should
be in the range of 0.8-1.0 vol%.
If the H2S concentration of gas entering the SUPERCLAUS TM
stage is too high, more air is added to the main burner to
produce more SO2, or If the H2S concentration entering the
SUPERCLAUS TM stage is too low, less air is added to the main
burner.
.

34

CHEMICAL
REACTIONS
COMBUSTION CHAMBER
H2S + 3/2 02 -------------->H2O + SO2
2H2S + SO2
--------------> 3S + 2H2O
=============================
3 H2S + 3/2 O2 -------------->3S + 3H2O
CLAUS REACTOR
2 H2S + SO2 --------------> 3/n Sn + 2 H2O
SUPERCLAUS REACTOR
H2S + 0.5 O2 --------------> S + H2O

MRPL-ONGC

REDUCTION
REACTIONS
CO + H2O --------------> H2 + CO2
SO2+ 3H2 --------------> H2S+ 2H2O
SX + XH2 --------------> XH2S
COS + H2O ------------> H2S + CO2
CS2+2H2O -------------> 2H2S + CO2

MRPL-ONGC

Hydrogen Sulphide

MRPL-ONGC

Hydrogen Sulphide properties:

Properties

Description

Physical state

Normally encountered as a gas

Color
Odor

MRPL-ONGC

Colorless

No visible sign of H2S to warn you of its presence.

Smells like rotten eggs

Impairs your sense of smell at low concentrations.
Do not rely on your sense of smell to detect H2S.

Vapor density

Heavier than air

It may flow or settle in low lying areas like pits, trenches and natural
depressions.

Flammable
Flammability

Solubility

Burns with a blue flame and gives off sulfur dioxide gas, SO2.
SO2 is hazardous and irritates the eyes and the respiratory system.
Explosive when mixed with air.

Dissolves in water, oil, sludge, emulsions, well fluids and molten

sulfur
H2S is released when liquids are agitated, depressurized or heated.

MRPL-ONGC

H2S exposure limits:

Occupational
Exposure Limit

8 hour OEL

15 minute OEL

Ceiling OEL

Concentration

OEL Description

10 ppm

A time-weighted average (TWA) maximum

exposure for an eight hour work day.

15 ppm

A TWA exposure limit of up to 15 minutes with

a 60 minute separation between each
exposure.

20 ppm

No one should be exposed to greater than 20

ppm of H2S at any time without adequate
respiratory protection.

SO2 Properties:
Properties

Description

Physical state

Normally encountered as a gas.

Color

Colorless.

Odor

Biting smell, irritates nose and mouth.

Vapor density

MRPL-ONGC

Heavier than air

It may flow or settle in low lying areas like pits, trenches and natural
depressions.

Flammability

Not flammable.

Solubility

Forms an acid with water, dissolves in many organic solvents.

MRPL-ONGC

SO2 exposure limits:

Occupational
Exposure
Limit

8 hour OEL

Concentration OEL Description

5 ppm

A time-weighted average (TWA) maximum

exposure for an eight hour work day.

MAC Value

MRPL-ONGC

The maximum allowable concentration of gas, vapor,

mist or dust, is the concentration in the air on the
workplace which, as far as the present knowledge
reaches, by repeated exposition (even during a longer
period or a complete working life) does generally not
harm the health of the employees and/or their offspring
in any way.

MRPL-ONGC

Poisoning by

Inhalation
Mouth
Skin

H2S Poisoning

MRPL-ONGC

Poisoning by inhalation

H2S dissolves in blood

Respiration stops

Oxygen in blood is quickly used up, heart stops

H2S is slowly oxidized to non-toxic sulfur components

Affects breathing by stopping respiratory control center

in the brain

H 2S Toxicity Levels (1/2 )

L
O
W

0-10 ppm

M
O
D

10 50 ppm

H
I
G
H

50 300 ppm

MRPL-ONGC

Irritation of the eyes, nose and throat.

Headache.
Dizziness.
Nausea and vomiting.
Coughing and breathing difficulty.
Severe respiratory tract irritation.
Eye irritation/acute conjunctivitis.
Shock.
Convulsions.
Coma.
Death in severe cases.

H 2S Toxicity Levels (2/2 )

MRPL-ONGC

H2S exposure

Possible Health Effects

Less than 1 ppm

You can smell it.

10 ppm (8 hour OEL)

No known adverse health effects.

10 200 ppm

Eye and respiratory tract irritation and loss of smell.

Will also cause headache and nausea.

200 300 ppm

Immediately Dangerous to Life and Health (IDLH).

500 700 ppm

Affects the central nervous system. After a couple of

minutes, it causes loss of reasoning, loss of balance,
unconsciousness and breathing to stop.

700 1000 ppm

Immediate loss of consciousness. Permanent brain

damage and death will occur if you are not rescued
immediately.

SO 2 Toxicity Levels

MRPL-ONGC

SO2 exposure

Possible Health Effects

Less than 3-5 ppm

You can smell it.

5 ppm (8 hour OEL)

No known adverse health effects.

20 ppm

Eye and respiratory tract irritation.

50 100 ppm

Max. allowable concentration for 30-60 minutes.

> 400 ppm

Danger for health, even with short exposure.

H 2S Detection Equipment

MRPL-ONGC

How to React ?

MRPL-ONGC

Protect yourself (first!)

Evacuate yourself from the area (wind direction!!)
Alarm the control room
Operators have to evacuate the area
Well protected operators search for victims

How NOT to React ?

Do not try to find reason for H2S release
Do not (try to) rescue colleagues
Do not panic
Do not run fast

MRPL-ONGC

Sulphur palletizer unit-6200

MRPL-ONGC

SULPHUR PELLETIZER UNIT

Sulphur pelletizer unit6200

Purpose:
To convert liquid sulphur into solid pellets form

Technology Supplier:
Sandvik Asia

Capacity of the unit:

5 MT/Hr per stream (Total 4 streams)

MRPL-ONGC

Sulphur palletizer unit-6200

Liquid Sulphur Characteristics

Sulphur content:
H2S content:
Temperature:
Pressure:
Viscosity:

not less than 99,8 %

less than 10 ppm
max. 150C
max. 4,5 kg/mg
< 100 mPas

MRPL-ONGC

Sulphur palletizer unit-6200

Solid Sulphur Characteristics
Shape:
pestilles
Mean size:
between 2 and 4 mm
Size distribution: less than 5 % bigger than 4,75 mm
minimum 75 % between 4,4 and 2,4 mm
less than 2 % smaller than 1,19 mm
less than 0,1 % smaller than 0,3 mm
Moisture :
less than 0,5 % by weight
Bulk density: 1040 kg/m loose, 1200 kg/m agitated
Angle of repose:
not less than 25

MRPL-ONGC

Sulphur palletizer unit-6200

MRPL-ONGC

Sulphur pelletizer
unit
Rotoformor

MRPL-ONGC

Sulphur palletizer unit

Steel belt cooler

MRPL-ONGC

MRPL-ONGC

THANK YOU

60