4. 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
4
6. 6
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%
7. 7
Purpose & Duty of the Unit:
Purpose of each section
Section Purpose
Sulphur Recovery
(Claus) Section
Claus Process, to convert H2S into elemental liquid sulphur.
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
and Degassing Section
Degassing Section To remove the dissolved H2S from the produced
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.
16. 16
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)
17. Basis of Design: Chemicals Requirement
17
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)
A-2201-R-02 1st reactor
Alumina-based catalyst 0.94
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
22. 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
22
25. Main Equipment – Thermal Reactor
25
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:
Acid Gas Lance / Tip
Fuel Gas Lance / Tip
Burner Front Plate
Stainless Steel / AISI 310
Stainless Steel / AISI 310
Killed Carbon Steel
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
26. Main Equipment – Thermal Reactor
26
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.
27. 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
27
31. Main Equipment – A-2001-SG-01
31
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)
32. Main Equipment – A-2001-SG-01
32
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)
33. Main Equipment – A-2001-SG-01
33
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)
34. Main Equipment – A-2001-SG-01
34
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)
35. Main Equipment – A-2001-SG-01
35
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)
36. 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
36
40. 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
40
43. 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
45. Main Equipment – Blowers
45
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
46. Main Equipment – Blowers
46
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
(kg/cm2g)
0.11 0.11 0.11
Inlet Temperature (°C) 36 36 (MIN.:14) 36
47. Main Equipment – Blowers
47
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