NEW SULFUR MELTING TECHNOLOGYMark Gilbreath - USA

COMPANIES• Devco

- Sulfur Forming Units- EPC Contracts and PM- Modular construction methods and experience

• River Consulting- Engineers for Material Handling, Balance of Plant , Marine, Electrical &

Controls• CTI

- Decades of Sulfur Technology and Operations- Former Freeport Sulfur staff experts- Proven Melter Technology

Established 1979 Offices: Tulsa, OK; Al-Khobar, KSA; Doha,

Qatar; Beijing, China Owned and operated California Sulphur

Company, Bay Sulfur Company & Devco Australia

Process Engineering, Project Engineering, Project Management, Project Controls, Procurement & Facilities Integration of Natural Gas & Refining Processes

Projects Range from Equipment sale to Turn-Key installation

SOUTH YOLOTAN TURKMENISTANPETROCHINA SULPHUR FORMING

Established 1981 Offices - Columbus, OH; New Orleans,

LA; Pittsburgh, PA; Tulsa, OK 230 + Designers, Engineers & Project

Managers Industries Served – Natural Gas,

Refining, Power, Food, Materials Handling, Marine

Project Management Project Controls Multidiscipline Engineering Design- civil, structural, mechanical,

instrumentation, electrical Control System Integration Procurement Estimating Construction Management

HI – CAP SULFUR MELTER SYSTEM

1950

Pit Melters Agitated Tank Melters

1964 1993

Agitated Tank Melters

Internal Coils External Heat Exchangers

Continuous Removal of Non-Meltables

Easy Clean Out Pump Tank

External Heat Exchangers

Freeport Sulphur Company

Freeport Research & Engineering CTI

1998

Submerged Combustion

Melting

SULFUR MELTING EXPERIENCE TIMELINE

CTI Melter, 1,000T/d

CENTRAL ASIA

MODULARIZATION – SULFUR MELTER PLANT• External Heat Exchangers – NO COILS IN

MELTER VESSEL• Thermal efficient – small melter vessel• Solids clean out during operation• HEX maintenance during operation

HI – CAP MELTER FEATURES –

• Designed for 155 stph dry basis, Higher moisture, Moderate acidity• No steam coils in melter vessel• Based on proven concepts• External Heat Exchanges (HEX) give high heat transfer coefficients• Installed spare Heat Exchanger and Sulfur HEX Pump• Melter tank elevated with concave bottom allows for continuous removal of

melter non-meltables to the pump tank• Pump tank designed for quick non-meltables removal while hot• Above allows longer periods between major turnarounds resulting in higher

availability• Simple controls – flow rate of solid sulfur feed

KEY FEATURES CTI SULFUR MELTER

• Tank, baffles and agitator all designed to create strong vortex

• Liquid height to diameter ratio sized for effective agitation

• Solid sulphur and high temperature liquid sulphur inlet feeds both directed & mix in vortex

• Vortex causes immediate immersion of sulphur solids in liquid sulphur, expeditiously wetting all surfaces, melting the solids

• Raised tank with conical bottom and sump to collect larger non-meltable solids.

• Continuous underflow constantly removes non-meltables creating a “Self-Cleaning” melter.

MELTER TANK DESIGN FEATURES

• High volume sulphur melting units with capacities up to 4,000 tons per day.

• External heat exchanger (HEX) gives high heat transfer coefficient, allowing high melting rates

• High circulation rate through HEX for efficient heating and melting

• All vessels and equipment are above ground.

• Vertical “in-tank” pumps.

• All molten sulphur is contained during unplanned shutdown.

• Customizable to meet specific customer requirements.

KEY MELTER SYSTEM COMPONENTS

CTI SULFUR MELTER DESIGN GA

AIR

FLOW PATTERNS - CTI SULFUR MELTER

Flow pattern of molten sulfur.

Vortex formed with hot area in vortex, along bottom and side walls.

15

0 1 2 3 4 5 6 7 80

20

40

60

80

100

120

SULFUR HEAT TRANSFER COEFFICIENTS

LINEAR VELOCITY (ft/sec)

HEA

T TR

AN

SFER

CO

EFFI

CIEN

T (B

TU/H

R FT

2 °F

)

HEAT EXCHANGERS

STEAM COILS

HEAT EXCHANGERS VS STEAM COILS FOR MELTING SULFUR

• Bucket elevators and screw conveyors – stainless steel

• Concrete in silos - epoxy lined acid resistance concrete

• Silo cones - Stainless Steel lined Carbon Steel structure

• Melter vessel is carbon steel – ceramic brick in splash zone (top)

• Sulfur pump tank - carbon steel

• Heat exchangers -carbon steel

• Piping, valves, sulfur filters in contact with molten sulfur – carbon steel

MELTER DESIGN – MATERIALS OF CONSTRUCTION

MODULARIZATION – SULFUR MELTER PLANT

Advantages:

• Greater estimate accuracy • Controlled fabrication environment• Consistent workforce

- Drives quality- Controls schedule attainment

• Labor cost exposure reduced vs. field construction

• Simpler foundation design• Superior material control• Schedule risk reduced• Relocation of Equipment would be

cost effective

Candidates for modularization

Melter – partial modularization – partial field erected

Sulfur Filters

Piperacks, Utilities

Motor control rooms/ control room

MODULARIZATION

Misraq Filtration Unit

FILTER UNIT – MODULAR DESIGN

• Silo on left – Filter modules on right

MODEL VIEW OF MELTER PLANT

SUPPLEMENT INFORMATION ON FOLLOWING PAGES:

Mark Gilbreathmgilbreath@devcousa.com770.377.7348

6846 S. Canton Suite 400Tulsa, OK 74126USAwww.houstoninterests.com

SUPPLEMENTAL INFORMATIONMark Gilbreath - USA

MODEL MELTER PROJECT OVERVIEW

• Truck unloading on right – Silo in Center – Lime silo and melter left.

MODEL VIEW OF MATERIAL HANDLING

• Truck unloading on right – Filter modules on leftMODEL VIEW OF MELTER FACILITY

• Piperack Foundations

SITE PROGRESS PHOTOS

• Site View – May 2015

SITE PROGRESS PHOTOS

• Pipe Rack Foundations

SITE PROGRESS PHOTOS

• Silo Roof Preparation –

SITE PROGRESS PHOTOS

• Truck Unloading Deck Steel

SITE PROGRESS PHOTOS

SITE PROGRESS PHOTOS

SITE PROGRESS PHOTOS

• Bucket Elevator Base

SITE PROGRESS PHOTOS

• Sulfur Tank Modules in Fabrication

SITE PROGRESS PHOTOS

• HEX Modules• Scheduled ready to ship – 4.5.2015 - 5.5.2015

SITE PROGRESS PHOTOS

• Sulfur Filter Modules in Fabrication

SOUTH YOLOTAN TURKMENISTANPETROCHINA SULPHUR FORMING

2x 2,000 mtpd Devco II Sulphur Forming Units

2x 2,000 mtpd Silo Feed Conveyors

Structural, Instrumental & Electrical Design, Conveyor Design / Supply

Process / Project Engineering, Project Management and Procurement

Joint projects across multiple offices from employees in Tulsa, Columbus & Pittsburgh.

Piping Design

SOUTH YOLOTANPETROCHINA/TURKMENGAS

Civil, Structural, Instrumental & Electrical Design

Project Engineering, Project Management and Procurement

Joint projects across multiple offices from employees in Tulsa, Columbus,

New Orleans & Pittsburgh.

500,000 TPY Sulphur Purification Facility

TIC: $78.5 MM

Start date – December 13, 2012On-line (Projected) – Jan 2015

Fabrication

Plant Layout & Piping Design

Project Oversight, Process / Project Engineering

MISHRAQ STATE SULPHUR COMPANYMOSUL, IRAQ

Equipment with long deliveries • Pressure Leaf Sulphur Filters: 30-46 weeks• Sulphur Pumps: 36 weeks• Heat Exchangers: 30 weeks• Scrubber

– Scrubber proprietary equipment: 36 weeks– Scrubber ID fan: 36 weeks

MELTER FILTER PLANT -LONG LEAD EQUIPMENT

Sulfur Storage

• The sulfur storage system consists of two 60 ft. diameter concrete silos with elevated 50 degree cones and a screw feeder reclaim system.

• Each of the two silos will be designed to store 6,000 tons of sulfur at 65 pcf. The final silo design including hopper slope and height is based on material testing.– Silos equipped with elevated cones (50 degree slope) for gravity feed to the reclaim

system.– The hopper are mild steel construction with a S.S. liner.– The hoppers have vibrators around the perimeter to assist with material flow.– A Screw feeder is used to feed to the melter feed conveyors at a variable rate up to

200 tph @ 65 PCF. – Openings are placed in the bottom of the silo for ventilation and access.

DRY SULFUR STORAGE - SILO

Melter Feed System

• The melter feed system consists of two 24” BW conveyors rated at 200 tph at 65 pcf to feed the melter. Only one conveyor is needed to feed the melter at a time assuring sulfur feed to the melter while allowing for maintenance on the conveyors.

• The lime storage system consists of a 12 ft. diameter welded steel silo with a target box and bin vent filter to receive hydrated lime by self- unloading trucks. The lime silo will be located in a tower over the melter feed conveyors and gravity feed the melter feed conveyors.

• Conveyors:– Two (2) 24” BW feed conveyors is located in an open common gallery to the melter.

• Lime Storage Silo:– Lime silo is 12’ diameter equipped with a bin vent filter and piping for receiving lime

from self-unloading pneumatic trucks.

DRY BULK STORAGE AND HANDLING

Sulfur filtering is a fairly simple process:

• After melting and neutralizing, dirty sulfur is collected in the filter feed tank, located next to the sulfur melter.

• The filter feed pumps draw sulfur from the tank and provide sufficient pressure to send sulfur through the filters and into the clean sulfur collection tank.

• The actual filtration is done by filter aid, which is deposited on the screens during the pre-coating process, prior to filtering.- The filter screens provide structure to hold a thin layer of filter aid in place.- As the dirty sulfur passes through the filter aid, the fine solid contaminants are too

large to pass through

• After passing through the filters, the filtrate sulfur (clean sulfur) is collected and pumped to offsite liquid sulfur storage

SULFUR FILTRATION PROCESS

MISHRAQ MODULES DURING ASSEMBLY

MISHRAQ

MODULE ASSEMBLY

& TRANSPORTATION

MODULE INSTALLATION

200 MMSCFD Gas Processing Plant

Start Date – June 1, 2012On-line – June 2013

ENERGY TRANSFER PARTNERS GODLEY FACILITY

Civil, Structural, Piping, Instrumentation & Electrical DesignMan Hours: 23,442

Process / Project Engineering & ProcurementMan Hours: 1,542

Fabrication and Construction

Joint projects across multiple offices from employees in Tulsa, Columbus & Pittsburgh.

200 MMSCFD Gas Processing Plant

TIC $250 MM

ENERGY TRANSFER PARTNERS GODLEY FACILITY

200 MMSCFD Natural Gas Processing Plant

Start date – October 8, 2012 On-line – August 2013

ENERGY TRANSFER PARTNERS RED BLUFF FACILITY

Civil, Structural, Mechanical & Electrical DesignMan Hours: 25,613

Process / Project Engineering & ProcurementMan Hours: 3,765

Plant Layout & Piping DesignMan Hours: 13,313

Joint projects across multiple offices from employees in Tulsa, Columbus & Pittsburgh.

200 MMSCFD Natural Gas Processing PlantTIC: $350 MM

Fabrication & Construction

ENERGY TRANSFER PARTNERS RED BLUFF FACILITY

Energy Transfer / Regency Red Bluff - Texas

SUPPLEMENT INFORMATION ON FOLLOWING PAGES:

Mark Gilbreathmgilbreath@devcousa.com770.377.7348

6846 S. Canton Suite 400Tulsa, OK 74126USAwww.houstoninterests.com