SULPHUR RECOVERY UNIT

(SRU)
UNIT 22

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 TABLE OF CONTENT

SECT. 1 - General Description

SECT. 2 - Process Flow Description
SECT. 3 - Main equipments

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 SECTION 1

GENERAL DESCRIPTION

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General:

 For Bach Ho Crude operation only

 To convert all sulphur compounds present in the acid gas feed from the ARU and
SWS into liquid elemental sulphur

 Process:
 1/3 of H2S is burned and converted into SO2
 2/3 of H2S then reacts with the SO2 formed to produce elemental liquid sulphur
 Produced sulphur is then condensed and liquid sulphur cleared of H2S entrained
 Treated gas is finally incinerated to convert the remaining pollutants into SO2

 SRU located at the south west of the area 4, nest to the LCO HDT, ARU and SWS

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Purpose & Duty of the Unit:

 To convert all sulphur compounds in the following acid gases into elemental sulphur:
 ARU off gas (from unit 20)
 H2S rich SWS off gas (from unit 18)

 To incinerate the following gases:

 NH3 rich off gas from SWS (unit 18)
 CNU off gas
 Treated gas from the SRU

 Design Capacity: 5 tons/day

 Liquid Sulphur Recovery Efficiency: 95% min.

 Turndown ratio: 50%

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Purpose & Duty of the Unit:
 Purpose of each section

Section Purpose
Sulphur Recovery Claus Process, to convert H2S into elemental liquid sulphur.
(Claus) Section Section composed of a thermal stage (Thermal Reactor) followed by 3
catalytic steps:
Thermal reactor: burns approx. 1/3 of the H2S contained in the total acid
gases feed with air to convert it into SO2.
Catalytic converters: to make the remaining 2/3 of the H2S react with the
produced SO2 to give elemental sulphur
Condensation of the produced sulphur
Liquid Sulphur Storage Degassing Section To remove the dissolved H 2S from the produced
and Degassing Section sulphur.
H2S content is decreased to less than 20 wt. ppm
Incinerator Section To convert residual H2S contained in the treated gas leaving the Claus
section and the degassing section into SO2.
To burn NH3 rich SWS off gas and CNU off gas.
Sulphur Apron The sulphur apron is where is collected the solid sulphur from the
degassing pit.
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AREA 3 - 3D Drawing SRU

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Feed Characteristics: ARU off gas
 FEED & CAPACITY FOR PRODUCTION OF DEGASSED LIQUID SULPHUR

Max. Distillate Case Max. Gasoline Case

Composition kg/hr kg-mol/hr Mol% kg/hr kg-mol/hr Mol%
H2S 102.6 3.01 18.97 119.6 3.51 20.66
NH3 0.0 0.00 0.00 0.0 0.00 0.00
H2O 16.5 0.92 5.77 19.0 1.05 6.21
Cyanide 0.0 0.00 0.00 0.0 0.00 0.00
CO2 511.4 11.62 73.24 531.4 12.08 71.11
N2 1.0 0.04 0.23 1.0 0.04 0.21
CO 0.1 0.004 0.02 0.1 0.00 0.02
H2 0.3 0.15 0.94 0.3 0.15 0.87
C1 1.4 0.09 0.55 1.6 0.10 0.59
C2 1.1 0.04 0.23 1.1 0.04 0.22
C3 0.4 0.01 0.06 0.8 0.02 0.11
Total 634.8 15.87 100.00 674.9 16.98 100.00 9
Feed Characteristics: ARU off gas
 FEED & CAPACITY FOR PRODUCTION OF 5 TONS / DAY OF SULPHUR

Max. Distillate Case Max. Gasoline Case

Composition kg/hr kg-mol/hr Mol% kg/hr kg-mol/hr Mol%
H2S 129.6 3.802 18.97 164.2 4.818 20.66
NH3 0.0 0.00 0.00 0.0 0.00 0.00
H2O 20.8 1.157 5.77 26.1 1.448 6.21
Cyanide 0.0 0.00 0.00 0.0 0.00 0.00
CO2 645.9 14.676 73.24 729.6 16.578 71.11
N2 1.3 0,045 0.23 1.4 0.049 0.21
CO 0.1 0.005 0.02 0.1 0.005 0.02
H2 0.4 0.188 0.94 0.4 0.202 0.87
C1 1.8 0.110 0.55 2.2 0.137 0.59
C2 1.1 0.04 0.23 1.1 0.04 0.22
C3 1.4 0.046 0.23 1.5 0.050 0.22
Total 801 20.040 100.00 926.6 23.312 100.00 10
Feed Characteristics: H2S Rich SWS off gas
 FEED & CAPACITY FOR PRODUCTION OF DEGASSED LIQUID SULPHUR

Max. Distillate Case Max. Gasoline Case

Composition kg/hr kg-mol/hr Mol% kg/hr kg-mol/hr Mol%
H2S 82.0 2.41 88.94 50.3 1.48 88.09
NH3 0.0 0.00 0.00 0.0 0.00 0.00
H2O 4.8 0.27 9.96 3.1 0.17 10.12
Cyanide 0.7 0.03 1.10 0.7 0.03 1.79
CO2 0.0 0.00 0.00 0.0 0.00 0.00
N2 0.0 0.00 0.00 0.0 0.00 0.00
CO 0.0 0.00 0.00 0.0 0.00 0.00
H2 0.0 0.00 0.00 0.0 0.00 0.00
C1 0.0 0.00 0.00 0.0 0.00 0.00
C2 0.0 0.00 0.00 0.0 0.00 0.00
C3 0.0 0.00 0.00 0.0 0.00 0.00
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Total 87.5 2.71 100.00 54.1 1.68 100.00
Feed Characteristics: H2S Rich SWS off gas
 FEED & CAPACITY FOR PRODUCTION OF 5 TONS / DAY OF SULPHUR

Max. Distillate Case Max. Gasoline Case

Composition kg/hr kg-mol/hr Mol% kg/hr kg-mol/hr Mol%
H2S 103.6 3.039 88.94 69.0 2.026 88.09
NH3 0.0 0.00 0.00 0.0 0.00 0.00
H2O 6.1 0.340 9.96 4.2 0.235 10.21
Cyanide 1.0 0.038 1.10 1.1 0.039 1.70
CO2 0.0 0.00 0.00 0.0 0.00 0.00
N2 0.0 0.00 0.00 0.0 0.00 0.00
CO 0.0 0.00 0.00 0.0 0.00 0.00
H2 0.0 0.00 0.00 0.0 0.00 0.00
C1 0.0 0.00 0.00 0.0 0.00 0.00
C2 0.0 0.00 0.00 0.0 0.00 0.00
C3 0.0 0.00 0.00 0.0 0.00 0.00
Total 110.7 3.416 100.00 74.3 2.300 100.00 12
Feed Characteristics: NH3 Rich SWS off gas
 FEED COMPOSITION AND CAPACITY TO INCINERATOR

Max. Distillate Case Max. Gasoline Case

Composition kg/hr kg-mol/hr Mol% kg/hr kg-mol/hr Mol%
H2S 14.7 0.43 3.24 8.9 0.26 2.76
NH3 157.6 9.27 69.75 112.3 6.61 70.25
H2O 64.7 3.59 27.01 45.7 2.54 26.99
Cyanide 0.0 0.00 0.00 0.0 0.00 0.00
CO2 0.0 0.00 0.00 0.0 0.00 0.00
N2 0.0 0.00 0.00 0.0 0.00 0.00
CO 0.0 0.00 0.00 0.0 0.00 0.00
H2 0.0 0.00 0.00 0.0 0.00 0.00
C1 0.0 0.00 0.00 0.0 0.00 0.00
C2 0.0 0.00 0.00 0.0 0.00 0.00
C3 0.0 0.00 0.00 0.0 0.00 0.00
Total 237.0 13.29 100.00 166.9 9.41 100.00 13
Feed Characteristics: CNU off gas
 FEED COMPOSITION AND CAPACITY TO INCINERATOR

Naphtenic / Naphtenic /
Phenolic Sour Phenolic Sweet
Sulfidic Sour Sulfidic Sweet
(Mixed Crude) (Bach Ho Crude)
(Mixed Crude) (Bach Ho Crude)
Std Vol. Flowrate m3/hr 22.5 29.3 Min Min
H2O wt% 7 7 7 7
H2S wt% 53 28 - -
RSH wt% - 5 - -
Fuel Gas wt% 40 60 93 93

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Product Specifications: Degassed Liquid Sulphur

Component Specification
Purity (as S) (wt %) ≥ 99.9 (dry basis)
Organics (wt %) ≤ 0.02 (dry basis)
Ashes (wt %) ≤ 0.04 (dry basis)
Water (wt %) ≤ 0.10
H2S content (wt.ppm) ≤ 10
Colour Bright Yellow

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Product Specifications: Emissions from Incinerator

Component Limit
SO2 (mg/m3) 500 max (dry basis)
H2S (mg/m3) 2 max (dry basis)
NOX (mg/m3) 1000 max (dry basis)
CO (mg/m3) 500 max (dry basis)
Particulate in Smoke (mg/m3) 400 (dry basis)
Dust containing silica (mg/m3) 50 (dry basis)
Ammonia (mg/m3) 100 (dry basis)

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Basis of Design: Chemicals Requirement
CLAUS Catalytic Reactors Catalyst

 Alumina-Titanium for 1st reactor

 Alumina only for the 2nd and 3rd reactors
 Catalyst supported on a layer of active catalyst support

Catalyst
Item Description Catalyst Volume to be loaded (m3)
Alumina-based catalyst 0.94
A-2201-R-02 1st reactor
Titanium oxide catalyst 0.94
A-2201-R-03 2nd reactor Alumina-based catalyst 1.32
A-2201-R-04 3rd reactor Alumina-based catalyst 1.88

Catalyst Bed Support

Item Description Volume to be loaded (m3)
A-2201-R-02 1st reactor 0.28
A-2201-R-03 2nd reactor 0.20
A-2201-R-04 3rd reactor 0.28 17
 SECTION 2

PROCESS FLOW DESCRIPTION

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 SECTION 3

MAIN EQUIPMENTS

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Main Equipment – Thermal Reactor
 To completely oxidize HC and all impurities (such as HCN) and to burn 1/3 of the
total H2S to SO2

 2 zone reaction furnace:

 1st zone: all combustion air, all H2S rich SWS off gas and 50% of ARU off gas
are burnt (1240°C)
 2nd zone: Hot flue gas from the 1st zone and 50% of the ARU are mixed (900°C)

 Thermal reactor burner: combined type with 2 lances:

 1 for fuel gas combustion during plant start-up and for turndown case
 1 for acid gas combustion during normal operation

 2 flame scanner and 1 ignitor

 Quench line to moderate the flame temperature during fuel gas run

 Reaction chamber is internally refractory lined and equipped with 1 optical

pyrometer and specials thermocouples to detect continuously the temperature in
both reaction zones
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Main Equipment – Thermal Reactor

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Main Equipment – Thermal Reactor

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Main Equipment – Thermal Reactor
Thermal Reactor A-2201-R-01 Burner
Nozzle Data for Burner
Design Pressure (kg/cm2g) 5.2
Operating Pressure (kg/cm2g) 0.49
Design temperature (°C) 343
Operating temperature (°C) 250
Material: Stainless Steel / AISI 310
Acid Gas Lance / Tip Stainless Steel / AISI 310
Fuel Gas Lance / Tip Killed Carbon Steel
Burner Front Plate
Burner Construction
Installation Horizontal, flanged to the thermal reactor
Gas Tight Construction Yes
Fuel Gas connection Flexible pipe to allow gun withdrawal during
acid gas operation
Flame control 2 flame detectors, each complete with
amplifier
Max noise level 85 dB at 1 m distance 25
Main Equipment – Thermal Reactor

Thermal Reactor A-2201-R-01

Length (TL to TL) (mm) 2700
Internal Diameter (mm) 1290
Position Horizontal
Design Temperature (Fuel Gas Firing only) (°C) 1450
MIN/MAX Operating temperature (°C) Zone I: 1250/900 Zone II: 1250/850
Refractory
Bricks Group Grade 28
Classification Temperature 1540°C
Thermal Conductivity at 600°C 0.34W/m°C
CaO content 1% typ.
Fe2O3 content 1.5% max.
Alkalies content 2% max.

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Main Equipment – A-2001-SG-01
 5 passes boiler producing saturated low pressure steam at 4.1 kg/cm2G in the shell
side by condensing sulphur in the tube side:
 pass I = 1st pass of WHB
 pass II = 2nd pass of WHB
 pass III = 1st sulphur condenser
 pass IV = 2nd sulphur condenser
 pass V = 3rd sulphur condenser

 The 5 passes are all oriented horizontally

 The tubes of each pass are plain tubes, made of killed carbon steel

 A-2201-SG-01 is provided with 2 mist eliminators at Pass III and IV outlets

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Main Equipment – A-2001-SG-01

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Main Equipment – A-2001-SG-01

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Main Equipment – A-2001-SG-01

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Main Equipment – A-2001-SG-01
PASS I
Surface (m2) 7.5
Shell Side Tube Side
Service BFW / LP steam Process Gas
Inlet Outlet Inlet Outlet
Vapour (kg/hr) 1533.8 1533.8
Steam (kg/hr) 790.5
Water (kg/hr) 814.6 24.1
Temp.(°C) 112 152 897 455
Press. (kg/cm2g) 4.1 0.44
Duty (kW) 245
Service heat transfer coefficient (W/m2 °C): 66.1 Clean: 68.1
No. of tubes: 6
Tubes Diameter (mm) 7.62
Length (mm) 4500
Pitch 125 (SQUARE)

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Main Equipment – A-2001-SG-01

PASS II
Surface/unit (m2) 11.9
Shell Side Tube Side
Service BFW / LP steam Process Gas
Inlet Outlet Inlet Outlet
Vapour (kg/hr) 1533.8 1533.8
Steam (kg/hr) 790.5
Water (kg/hr) 814.6 24.1
Temp.(°C) 112 152 455 240
Press. (kg/cm2g) 4.1 0.420
Duty (kW) 107
Service heat transfer coefficient (W/m2 °C): 51.6 Clean: 53.0
No. of tubes: 14
Tubes Diameter (mm) 5.54
Length (mm) 4500
Pitch 85 mm (TRIANGULAR)
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Main Equipment – A-2001-SG-01
PASS III
Surface/unit (m2) 15.7
Shell Side Tube Side
Service BFW / LP steam Process Gas
Inlet Outlet Inlet Outlet
Vapour (kg/hr) 1533.8 1504.4
Liquid (kg/hr) 29.4
Steam (kg/hr) 790.5
Water (kg/hr) 814.6 24.1
Temp.(°C) 112 152 240 162
Press. (kg/cm2g) 4.1 0.40
Duty (kW) 37
Service heat transfer coefficient (W/m2 °C): 65.7 Clean: 67.9
No. of tubes: 35
Tubes Diameter (mm) 2.77
Length (mm) 4500
Pitch 46 mm (TRIANGULAR) 33
Main Equipment – A-2001-SG-01
PASS IV
Surface/unit (m2) 16.2
Shell Side Tube Side
Service BFW / LP steam Process Gas
Inlet Outlet Inlet Outlet
Vapour (kg/hr) 1504.4 1356.6
Liquid (kg/hr) 147.8
Steam (kg/hr) 790.5
Water (kg/hr) 814.6 24.1
Temp.(°C) 112 152 321 171
Press. (kg/cm2g) 4.1 0.28
Duty (kW) 84
Service heat transfer coefficient (W/m2 °C): 75.8 Clean: 78.9
No. of tubes: 36
Tubes Diameter (mm) 2.77
Length (mm) 4500
Pitch 46 mm (TRIANGULAR) 34
Main Equipment – A-2001-SG-01
PASS V
Surface/unit (m2) 14.4
Shell Side Tube Side
Service BFW / LP steam Process Gas
Inlet Outlet Inlet Outlet
Vapour (kg/hr) 1356.6 1329.5
Liquid (kg/hr) 27.1
Steam (kg/hr) 790.5
Water (kg/hr) 814.6 24.1
Temp.(°C) 112 152 223 162
Press. (kg/cm2g) 4.1 0.173
Duty (kW) 28
Service heat transfer coefficient (W/m2 °C): 62.7 Clean: 64.8
No. of tubes: 32
Tubes Diameter (mm) 2.77
Length (mm) 4500
Pitch 46 mm (TRIANGULAR) 35
Main Equipment – Catalytic Reactors
 Purpose: To convert H2S into gaseous elemental sulphur by reaction between H2S
and the SO2 formed in the thermal reactor, on catalyst beds

 Reaction between H2S and SO2 produces elemental sulphur in each reactor for as
long as the equilibrium is not reached for the pressure and temperature conditions
within each reactor

 R-02, 03 and 04 are physically located in a unique vessel divided into 3 compartments

 The reactors vessel is equipped with an external MP steam coil operating at 250°C
and 14.1 kg/cm2g

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Main Equipment – Catalytic Reactors
A-2201-R-02 A-2201-R-03 A-2201-R-04
Service 1st catalytic reactor 2nd catalytic reactor 3rd catalytic reactors
Catalyst Volume (m3) Alumina-based: 0.94 Alumina-based: 1.32 Alumina-based: 1.88
Titanium oxide: 0.94
I.D. (mm) 1900 1900 1900
Length (mm) 1375 1300 1375
Material:
Shell Killed Carbon Steel
Heads Killed Carbon Steel
Flanges Killed Carbon Steel
Coils Killed Carbon Steel
Beam Killed Carbon Steel
Design Case Operating Conditions (Max. Gasoline)
Liquid Flow (kg/hr) 0 0 0
Vapour Flow (kg/hr) 1504.4 1356.6 1321.5
IN Press. (kg/cm2g) 0.33 0.21 0.09
OUT Press. (kg/cm2g) 0.40 0.28 0.173
IN Temp. (°C) 240 205 190
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OUT Temp. (°C) 321 223 193
Main Equipment – Catalytic Reactors

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Main Equipment – Catalytic Reactors

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Main Equipment – Liquid Sulphur Storage & Degassing Pits
 Purpose: to collect liquid elemental sulphur at the outlet of the 1st, 2nd, 3rd and final
sulphur condensers via steam jacketed sulphur legs

 Each sulphur leg is provided with dedicated perforated plate filter

 Seal legs sized to avoid blow up of process gas in all operating conditions

 Each leg can be isolated for maintenance

 Sulphur pit divided in 2 sections:

 Non degassed sulphur pit and degassed sulphur storage pit each sized for one
day of production and equipped with 2 jacketed transfer pumps

 Purpose of the sulphur degassing tank: to reduce H2S entrained with the sulphur to a
safe level

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Main Equipment – Liquid Sulphur Storage Pit

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Main Equipment – Liquid Sulphur Degassing Tank

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Main Equipment – Incinerator
 Purpose: To oxidize all sulphur bearing compounds in waste gases (tail gas from SRU
and vent air from sulphur degassing pit) to sulphur dioxide prior to release to
atmosphere

 Normal operating temperature: 750°C

 Condition obtained by burning NH3 rich SWS off gas and CNU off gas

 Burner equipped with dedicated lances for:

 Fuel Gas
 CNU off gas
 NH3 rich off gas
 ARU off gas + H2S rich off gas (bypass gas)

 Claus Section Tail Gas and the Vent Gas from Degassing Section are injected just
downstream of the flame via dedicated nozzles

 Cylindrical & Horizontally installed

 Incinerator chamber I.D. = 1450 mm

 Forced draft type burner.

 Air box incorporated in the burner 43
Main Equipment – Incinerator

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Main Equipment – Blowers
Combustion Air Blowers A-2201-B-01 A/B
Number Required 2 (1 operating + 1 standby)
Manufacturer & Model Robuschi & ES65/2P RVP 80 ATEX3
Blower Type Rotary Compressor
Driver Type & Manufacturer Electric Motor & ABB
Driver Rated Power (kW) 22
Driver Speed (RPM) 2930
Drive System Direct Coupled
Accessories: Inlet air filter
Inlet, Discharge & Blow-off Silencers
PSV
Discharge Blow-off valve
Operating Conditions MIN. MAX. RATED
Delivered Flow (Nm3/h) 79 549 604
Inlet Pressure (kg/cm2g) ATM ATM ATM
Outlet Pressure (kg/cm2g) 0.6 0.6 0.6
Inlet Temperature (°C) 36 36 36
Outlet Temperature 115 115 115 45
Main Equipment – Blowers
Incinerator Air Blowers A-2201-B-02 A/B
Number Required 2 (1 operating + 1 standby)
Manufacturer & Model Not available
Blower Type Centrifugal Fan
Driver Type & Manufacturer Electric Motor, fixed speed
Driver Rated Power (kW) Not available
Driver Speed (RPM) Not available
Drive System Direct Coupled
Accessories: Inlet air filter
Silencer
Blowoff silencer
Outlet expansion joint
Operating Conditions NORMAL MAX. RATED
Delivered Flow (Nm3/h) 2429 6077 6332
Inlet Pressure (kg/cm2g) ATM ATM ATM
Outlet Pressure 0.11 0.11 0.11
(kg/cm2g)
Inlet Temperature (°C) 36 36 (MIN.:14) 36 46
Main Equipment – Blowers

Dilution Air Blowers A-2203 A/B

Number Required 2 (1 operating + 1 standby)
Manufacturer & Model Not Available
Blower Type Centrifugal Fan
Driver Type Electric Motor
Operating Conditions DESIGN NORMAL
Total Dry Flow (kg/h) 176000 160000
Inlet Pressure (mmH2O) ATM ATM
Outlet Pressure (mmH2O) 300 250
Inlet Temperature (°C) 36 36

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