SRU Presentation for new

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

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) 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.

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AREA 3 - 3D Drawing SRU

Feed Characteristics: ARU off gas

FEED & CAPACITY FOR PRODUCTION OF DEGASSED LIQUID SULPHUR

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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

Feed Characteristics: ARU off gas

FEED & CAPACITY FOR PRODUCTION OF 5 TONS / DAY OF SULPHUR

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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

Feed Characteristics: H2S Rich SWS off gas

FEED & CAPACITY FOR PRODUCTION OF DEGASSED LIQUID SULPHUR

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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

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

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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

Feed Characteristics: NH3 Rich SWS off gas

FEED COMPOSITION AND CAPACITY TO INCINERATOR

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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

Feed Characteristics: CNU off gas

FEED COMPOSITION AND CAPACITY TO INCINERATOR

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Naphtenic / Sulfidic Sour (Mixed Crude)

Naphtenic / Sulfidic Sweet

(Bach Ho Crude)

Phenolic Sour (Mixed Crude)

Phenolic Sweet (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)

Basis of Design: Chemicals Requirement

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CLAUS Catalytic Reactors Catalyst

Alumina-Titanium for 1st reactorAlumina only for the 2nd and 3rd reactorsCatalyst supported on a layer of active catalyst support

Catalyst

Item Description Catalyst Volume to be loaded (m3)

A-2201-R-02 1st reactorAlumina-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

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SECTION 2

PROCESS FLOW DESCRIPTION

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SECTION 3

MAIN EQUIPMENTS

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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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 / TipFuel Gas Lance / TipBurner Front Plate

Stainless Steel / AISI 310Stainless Steel / AISI 310Killed 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


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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.

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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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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PASS II

Surface/unit (m2) 11.9




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


No. of tubes: 14


Length (mm) 4500

Pitch 85 mm (TRIANGULAR)


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PASS III





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


Duty (kW) 37


No. of tubes: 35


Length (mm) 4500



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PASS IV





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


Duty (kW) 84


No. of tubes: 36


Length (mm) 4500



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PASS V





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


No. of tubes: 32


Length (mm) 4500


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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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: 0.94Titanium oxide: 0.94

Alumina-based: 1.32 Alumina-based: 1.88

I.D. (mm) 1900 1900 1900

Length (mm) 1375 1300 1375

Material:ShellHeadsFlangesCoilsBeam

Killed Carbon SteelKilled Carbon SteelKilled Carbon SteelKilled Carbon SteelKilled 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

OUT Temp. (°C) 321 223 193


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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

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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 filterInlet, Discharge & Blow-off SilencersPSVDischarge 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


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Incinerator Air Blowers A-2201-B-02 A/B


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 filterSilencerBlowoff silencerOutlet 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


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Dilution Air Blowers A-2203 A/B


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

SRU Presentation for new

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