sulphur recovery unit
TRANSCRIPT
SULPHUR RECOVERY UNIT
WHY DO WE REQUIRE SULPHUR RECOVERY UNIT ? ?
SULPHUR RECOVERYWHY ?1) Corrosion
2) Causes Pollution to Atmosphere HYDRODESULFURISATIONRSH + H2(Mercaptan)
RH + H2S 2RH + H2S
RSR + 2H2(Sulphide)
RSSR + 3H2 H2Scombustion
2RH + 2H2S CO2 + SO2(in
(sulfur compounds in finished products)
atmosphere)
ACID RAIN
3) Statutory requirement of the governmentBHARAT STAGE NORMS : FUEL SPECIFICATION
Parameter Sulphur ppm max. Benzene Vol % max. Aromatics Vol % max. Olefins Vol % max. RON
BS-20001000/500
BS-II 500 3
BS-III 150 1 42
BS-IV 50 1 35 21 91/95
3/5 88/93
-
21
88/93 91/95
SRU BLOCKA typical Sulpher Recovery Unit complex consists of process units like:
Amine regeneration Unit Sour Water Stripping Unit Sulpher Recovery Unit Tail Gas Treating Unit
(ARU) (SWS) (SRU) (TGTU)
Sulphur recovery schematicLean Amine Acid GasAmine Regeneration Unit(ARU)
Stack Gas SO2Modified (SRU) Claus plantTail gas (TGU) clean-up
Incineration
Rich Amine Sour Gas Sour Water Sour water stripping(SWS) Sweet Water Sulphur Storage
AMINE REGENERATION UNIT Simple to understand and operate. Difficult to operate well. Easiest to mess up. The principal aim of operating an Amine Unit well is to keep the circulating amine clean. Easier said than done.
Diagram of Amine Regeneration Unit1.05 KG/CM2 RICH AMINE FROM UNITS 92 OC REGENERATOR AIR CONDENSER ACID GAS 0.95 KG/CM2 CW TO FLARE TO SRU 55 OC REGENERATOR REFLUX DRUM LP STEAM REGENERATOR REBOILERS LEAN SOLVENT TO UNITS
104 OC RICH SOLVENT FLASH DRUM 40 OC CW 59 OC LEAN SOLVENT TRIM COOLER 50 OC AMINE REGENERATOR COLUMN
59
OC
RICH/LEAN SOLVENT EXCH 72 OC
REGENERATOR TRIM CONDENSER
LEAN SOLVENT AIR COOLER
REGENERATOR REFLUX PUMP 127 OC
RICH AMINE PUMP
AMINE FILTER
AMINE CIRCULATION TANK (785 M3)
REGENERATOR BOTTOMS PUMP
127 OC
126 OC
LP CONDENSATE 8.0 KG/CM2 40 OC
LEAN SOLVENT PUMP
Diagram of Amine Regeneration Unit1.05 KG/CM2 RICH AMINE FROM UNITS 92 OC REGENERATOR AIR CONDENSER ACID GAS 0.95 KG/CM2 CW TO FLARE TO SRU 55 OC REGENERATOR REFLUX DRUM LP STEAM REGENERATOR REBOILERS LEAN SOLVENT TO UNITS
104 OC RICH SOLVENT FLASH DRUM 40 OC CW 59 OC LEAN SOLVENT TRIM COOLER 50 OC AMINE REGENERATOR COLUMN
59
OC
RICH/LEAN SOLVENT EXCH 72 OC
REGENERATOR TRIM CONDENSER
LEAN SOLVENT AIR COOLER
REGENERATOR REFLUX PUMP 127 OC
RICH AMINE PUMP
AMINE FILTER
AMINE CIRCULATION TANK (785 M3)
REGENERATOR BOTTOMS PUMP
127 OC
126 OC
LP CONDENSATE 8.0 KG/CM2 40 OC
LEAN SOLVENT PUMP
Diagram of Amine Regeneration Unit1.05 KG/CM2 RICH AMINE FROM UNITS 92 OC REGENERATOR AIR CONDENSER ACID GAS 0.95 KG/CM2 CW TO FLARE TO SRU 55 OC REGENERATOR REFLUX DRUM LP STEAM REGENERATOR REBOILERS LEAN SOLVENT TO UNITS
104 OC RICH SOLVENT FLASH DRUM 40 OC CW 59 OC LEAN SOLVENT TRIM COOLER 50 OC AMINE REGENERATOR COLUMN
59
OC
RICH/LEAN SOLVENT EXCH 72 OC
REGENERATOR TRIM CONDENSER
LEAN SOLVENT AIR COOLER
REGENERATOR REFLUX PUMP 127 OC
RICH AMINE PUMP
AMINE FILTER
AMINE CIRCULATION TANK (785 M3)
REGENERATOR BOTTOMS PUMP
127 OC
126 OC
LP CONDENSATE 8.0 KG/CM2 40 OC
LEAN SOLVENT PUMP
Diagram of Amine Regeneration Unit1.05 KG/CM2 RICH AMINE FROM UNITS 92 OC REGENERATOR AIR CONDENSER ACID GAS 0.95 KG/CM2 CW TO FLARE TO SRU 55 OC REGENERATOR REFLUX DRUM LP STEAM REGENERATOR REBOILERS LEAN SOLVENT TO UNITS
104 OC RICH SOLVENT FLASH DRUM 40 OC CW 59 OC LEAN SOLVENT TRIM COOLER 50 OC AMINE REGENERATOR COLUMN
59
OC
RICH/LEAN SOLVENT EXCH 72 OC
REGENERATOR TRIM CONDENSER
LEAN SOLVENT AIR COOLER
REGENERATOR REFLUX PUMP 127 OC
RICH AMINE PUMP
AMINE FILTER
AMINE CIRCULATION TANK (785 M3)
REGENERATOR BOTTOMS PUMP
127 OC
126 OC
LP CONDENSATE 8.0 KG/CM2 40 OC
LEAN SOLVENT PUMP
Diagram of Amine Regeneration Unit1.05 KG/CM2 RICH AMINE FROM UNITS 92 OC REGENERATOR AIR CONDENSER ACID GAS 0.95 KG/CM2 CW TO FLARE TO SRU 55 OC REGENERATOR REFLUX DRUM LP STEAM REGENERATOR REBOILERS LEAN SOLVENT TO UNITS
104 OC RICH SOLVENT FLASH DRUM 40 OC CW 59 OC LEAN SOLVENT TRIM COOLER 50 OC AMINE REGENERATOR COLUMN
59
OC
RICH/LEAN SOLVENT EXCH 72 OC
REGENERATOR TRIM CONDENSER
LEAN SOLVENT AIR COOLER
REGENERATOR REFLUX PUMP 127 OC
RICH AMINE PUMP
AMINE FILTER
AMINE CIRCULATION TANK (785 M3)
REGENERATOR BOTTOMS PUMP
127 OC
126 OC
LP CONDENSATE 8.0 KG/CM2 40 OC
LEAN SOLVENT PUMP
SOUR WATER STRIPPER UNIT STRIPS OUT H2S AND NH3 FROM SOUR WATER GENERATED IN PROCESS UNITS(HCU and DHDT). SIMPLE UNITS TO UNDERSTAND AND OPERATE. USUALLY OPERATE WELL. NH3 + H2S NH4+ + HS-
Diagram of Refinery Sour Water Stripper Unit0.9 SOUR WATER FROM UNITS REFINERY SOUR WATER STRIPPER COLUMN KG/CM2
90 OC SOUR GAS
TO FLARE
65 OC REFINERY STRIPPER CR AIR COOLER
TO SRU
SOUR WATER SURGE DRUM FEED/BOTTOMS EXCHANGER 71.6OC
92.4 OC
90 OC REFINERY STRIPPER CR PUMP 123.6 OC 123.8 OC LP STEAMREFINERY STRIPPER REBOILER
40 OC SWS FEED PUMPS STRIPPED WATER TO ETP 40 OC
STRIPPED WATER AIR COOLER 123.8 OC REFINERY STRIPPER BOTTOM PUMP
STRIPPED WATER TRIM COOLER STRIPPED WATER TO CDU/DCU
LP CONDENSATE LP CONDENSATE
Diagram of Refinery Sour Water Stripper Unit0.9 SOUR WATER FROM UNITS REFINERY SOUR WATER STRIPPER COLUMN KG/CM2
90 OC SOUR GAS
TO FLARE
65 OC REFINERY STRIPPER CR AIR COOLER
TO SRU
SOUR WATER SURGE DRUM FEED/BOTTOMS EXCHANGER 71.6OC
92.4 OC
90 OC REFINERY STRIPPER CR PUMP 123.6 OC 123.8 OC LP STEAMREFINERY STRIPPER REBOILER
40 OC SWS FEED PUMPS STRIPPED WATER TO ETP 40 OC
STRIPPED WATER AIR COOLER 123.8 OC REFINERY STRIPPER BOTTOM PUMP
STRIPPED WATER TRIM COOLER STRIPPED WATER TO CDU/DCU
LP CONDENSATE LP CONDENSATE
Diagram of Refinery Sour Water Stripper Unit0.9 SOUR WATER FROM UNITS REFINERY SOUR WATER STRIPPER COLUMN KG/CM2
90 OC SOUR GAS
TO FLARE
65 OC REFINERY STRIPPER CR AIR COOLER
TO SRU
SOUR WATER SURGE DRUM FEED/BOTTOMS EXCHANGER 71.6OC
92.4 OC
90 OC REFINERY STRIPPER CR PUMP 123.6 OC 123.8 OC LP STEAMREFINERY STRIPPER REBOILER
40 OC SWS FEED PUMPS STRIPPED WATER TO ETP 40 OC
STRIPPED WATER AIR COOLER 123.8 OC REFINERY STRIPPER BOTTOM PUMP
STRIPPED WATER TRIM COOLER STRIPPED WATER TO CDU/DCU
LP CONDENSATE LP CONDENSATE
Typical Acid Gas Composition ARUComponent Mole %
HydrogenWater Hydrogen Sulphide
0.04-.067.5- 8.5 86-92
Hydrocarbons
0.01- .03
Typical Sour Gas Composition SWSComponent Mole %
WaterHydrogen Sulphide Ammonia
40-4315-17 38-42
Hydrocarbons
1-2
SULPHUR RECOVERY UNIT USING MODIFIED CLAUS PROCESS
Modified-Claus ProcessAcid Gas Sour Gas Free flame reactor HP steam O2925-12500C (1700-23000F)
Wasteheat exchangerCatalytic converter170-3500C (340-6600F)
LP steam
Sulphur condenser
S liquid Further treatment
130-2000C (270-3900F)
Reaction furnaceFunction Burn 1/3 of the H2S H2S + 3/2 O2 SO2 + H2O + Heat Produce sulphur directly 2H2S + SO2 2H2S + 3/n Sn +Heat Destroy feed contaminants 2NH3 +3/2O2 3H2O +N2
TWO ZONE REACTION FURNANCE2/3rd Acid gas
1/3rd Acid GasSour Gas
Zone 1
Zone 2
AirH2S + 3/2 O2 2H2S + SO2 2NH3 +3/2O2 SO2 + H2O + Heat 2H2S + 3/n Sn +Heat 3H2O +N2
Zone 1 : Combustion chamber Zone 2 : Reaction Chamber
Catalytic Reactions2H2S + SO2COS + H2O CS2 + 2H2O
3/x Sx + 2H2OH2S + CO2 2 H2S + CO2
Catalytic Converter Activated Alumina Catalyst
Sulphur CondenserOperating Limits: above sulphur melting / freezing point 1190C (2460F)
below inlet sulphur dewpoint depends on sulphur vapour content
SuperClaus Section The remaining gases are then passed through three stage of in-line-reheaters, catalytic converters, and condensers with each stage recovering 61%, 22% and 9% of the total sulphur respectively.RHTR1 RHTR 2 RHTR 3 TAIL GAS ANALYZERP HX-1 HX-2 HX-3
CV 1T-1
CV 2T-2
CV 3T-3
HX-4 HX-5
HX-6
CNDS 2
CNDS 3 SULPHUR
CNDS 4 SULPHUR
SULPHUR
Acid Gas
Diagram of Sulphur Recovery UnitHP STEAM (42 Kg/cm2) 1400 OC LP STEAM WASTE HEAT BOILER 322 OC 180 OC REACTION FURNACE
Sour Gas
BFW
IST CONDENSER 208 OC
BFW
232 OC
IST CONVERTER
2ND CONVERTER TAIL GAS TO TGTU 132 OC
AIR BLOWER
HP STEAM IST REHEATER 287 OC
HP STEAM2ND REHEATER LP STEAM 173 OC
HEATED BFW 233 OC
2ND CONDENSER
BFW
FINAL CONDENSER
BFW
SULPHUR YARD
SULPHUR STORAGE YARD
Tail Gas Treating Unit essential to minimize sulphur emissions Sulphur Recovery of 99.9 %.This unit consists of 3 sections Hydrogenation Section Amine absorption and regeneration SectionT-3
TAIL GAS
H2 TO INCINERATION
Co - Mo Hydrogenation Reactor
T-1
Incinerator Section
TO REACTION FURNACE
T-2
AMINE ABSORPTION REGENERATION
The tail gas from the Claus units is heated by superheated HP steam and mixed with hydrogen.
Then passed over a catalyst bed in order to convert any SO2 present in the tail gas back to H2S.This gas is then cooled and passed through an Amine absorber, where H2S is absorbed in MDEA. The rich MDEA thus formed is regenerated in the amine regeneration system inbuilt within the TGTU and returned to the absorber.
The acid gas released is sent back to SRU for Sulphur Recovery.The Tail gas then goes to the Incinerator, where it is burnt off and the flue gas goes to the stack. The main reaction in the hydrogenation reaction is
SO2 + 3H2
H2S + 2H2O
Thank You