OUTLINE OF SULFUR RECOVERY PROCESSES
BSDT Seminars
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I. Overview of
Sulfur Recovery
A.
Processing H2S
B.
Typical
processing
elements
1.
Scrubbing and
concentration
processes
2. H2S
conversion
processes
3. Final
H2S
removal
processes
4.
Typical sulfur
recovery system
block flow
diagram
C. Safety
considerations
II. Sour water
treating
A. Basic
sour water
chemistry
1. Pure
sour water
chemistry
2. Real
sour water
chemistry
B. Feed
stream
preparation
1.
Degassing
2.
Storage
C. Sour water
treating
equipment
1. Sour
water stripper
2.
Overhead system
D.
Process variable
monitoring and
control
1.
Process
temperatures
2.
Pressure
3. pH
4.
Monitoring the
E.
Alternative
processes
1. Sour
water oxidizers
2.
Recovering
ammonia
F. Test
questions
A.
Purpose
B.
Process
principles
1. Basic
chemistry
2.
Vapor-Liquid
equilibrium
reactions
3.
Absorber heat
balance
4.
Regenerator heat
balance
5.
Commercial
amines and their
properties
C. Amine
unit process
flow
D. Amine unit
equipment &
operation
D.1. Gas and LPG
treating
equipment and
operation
1. Feed
preparation
2.
Absorber O/H KO
drum
3. Gas
absorber
4. LPG
contactor
5.
LPG-amine
coalescer
D.2.
Amine
regeneration
equipment and
operation
6. Flash drum
7. Rich
amine pump
8.
Lean/rich
exchanger
9.
Regenerator
10.
Reboiler
11.
Regenerator
overhead
condenser
12.
Reflux drum
13.
Reflux pump
14. Lean
amine coolers
15. Amine
filter
16. Amine
carbon bed
filter
17.
Carbon treater
after filter
18. Amine
surge tank
19. Lean
amine pump
20.
Reclaimers
21. DGA
reclaimers
22. NH3
scrubber
23. Sumps
24.
Safety relief
systems
E. Amine unit
monitoring
1.
Monitoring amine
quality
2. Heat
stable salts
3.
Recaliming
4. Makeup
water
5.
Analytical
considerations
6. Unit
performance
F.
Conversion to
“super” amines
G. Materials and
corrosion
H. Amine unit
economics
1.
Benefits
2. Costs
3.
Tradeoffs
4.
Project
justification
I. Test
questions
A. Basic
Claus unit
chemistry
1. Acid
gas streams
2.
Converting H2S
to sulfur
3.
Equilibrium and
process
variables
4. Sulfur
product
properties
5. Contaminants
6. Ammonia
destruction
B.
Modified Claus
unit process
flow
C. Claus
unit equipment &
operation
C.1. Front end
equipment
1. KO
drums
2. Air
blower
C.2.
Thermal section
3. Thermal
reactor
3.1.
Burner
3.2.
Thermal reactor
mechanical
considerations
3.3. Air
control – feed
forward/feedback
controls
3.4.
Process
considerations
for ammonia
destruction
4. Waste heat
boiler
C.3.
Catalytic
section
5. Reheaters
6.
Catalytic
reactors
(converters)
7. Sulfur
condensers
8. Sulfur
Seals
C.4. Back
end equipment
9. Sulfur
pit
10.
Sulfur degassing
11.
Sulfur storage
tank
12.
Sulfur shipping
and forming
13.
Thermal oxidizer
D.
Monitoring
performance
1.
Catalyst
2. Claus
unit pressure
3. Sulfur
production
4. Claus
unit performance
E.
Startup/Shutdown
issues
1.
Startup
2.
Shutdown
F.
Emergency
shutdown system
1.
Emergency trips
2. ESD
actions
3.
Handling
emergency
shutdown
G.
Process
enhancements
1. Oxygen
enrichment
2. Advanced
controls
H. Test
questions
V. Tail gas
treating units
A.
Purpose
B.
Process options
C. Amine
based unit
equipment &
operation
1. Tail
Gas Conditioning
2.
Hydrogenation/hydrolysis
reactor
3.
Reaction
Products Cooler
4. Quench
column
5.
Absorber
6.
Regenerator
D. Other
commercial
processes
1.
Reduction-oxidation
chemical
processes
2.
Extended Claus
Reaction
3. Direct
Oxidation
4.
Oxidation to SO2
E. Test
questions
VI.
Troubleshooting
the sulfur
recovery system
A.
Approach to
troubleshooting
B.
C.
Amine unit
D.
Claus unit
E.
VII.
Sulfur recovery
system sample
calculations
A.
Miscellaneous
notes
B.
Amine system
mass balance
calculations
C.
Claus unit
production and
air rate
calculations
D.
Tail gas
treating unit
mass balance
calculations
E.
O/H temp set
point
calculation for
regenerator
steam control
F.
Regenerator heat
balance
calculations
G.
Bulk amine
loading estimate
H.
Sour water
stripper mass
balance
calculations
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