Operating a Superclaus® Unit

October 2014

Presented to: MESPON 2014, Abu Dhabi

P.O. Box 141 2300 AC LEIDEN THE NETHERLANDS Tel (+31 71) 582 7111 Fax (+31 71) 582 7050

Introduction to Jacobs

Who We Are

• Committed to BeyondZero® safety

• Relationship based company

• Global resource base of 70.000 employees in 25+ countries on 5 continents

• Publicly traded on NYSE

• Net earnings FY13 (12 months ended) $423.1 million

• Revenues FY13 (12 months ended) $11.8 billion

• Backlog FY13 of $17.2 billion

• In business since 1947

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Professional & Technical Services in 12 Markets

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Comprimo® Sulfur Solutions

• A Dutch company Comprimo® in business since 1924

• Leading Licensor in the gas Treating and Sulfur Technology

Own patents (SUPERCLAUS®, EUROCLAUS®, Scrubbers and NH3 Destruction)

Licensor for Shell Technologies incl. LT-SCOT, Degassing and Amine Treating processes

Expertise Amine Treaters and SWS

• Jacobs purchased Comprimo® (1999)

• Jacobs purchased Delta Hudson (2000)

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Our Processes

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Capability of Jacobs Comprimo® Sulfur Solutions

Technology Delivery Gas Treating & Sulfur Technology • Basic Engineering Packages • FEED Packages • EPCm • Consulting Services

Technology selection Capacity increase Recovery improvements

• Startups and Training • Research & Development

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Operating a Superclaus® Unit

SUPERCLAUS® Process

• Recovery of 99.0% or higher • 2 or 3 stage Claus plus SUPERCLAUS® Stage

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Chemistry SUPERCLAUS® Process

H2S + 0.5 O2 S + H2O

• No equilibrium reaction

• No reverse Claus reaction

• Direct oxidation of H2S to Sulfur

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SUPERCLAUS® Operation (1)

• Difference with Claus process:

- Operate off Claus ratio

(H2S set point)

- Requires oxygen

SeOxidat

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• Operation of the SUPERCLAUS® reactor: - Optimum temperature of the bed (below 280°C outlet)

- Inlet around 210°C

- Oxygen in outlet < 0.5 vol.% (0.2)

SUPERCLAUS® Operation (2) Se

Oxidat

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SUPERCLAUS® Operation (3) Se

Oxidat

• Points of consideration: - Too high outlet temperature promotes SO2 formation - Too much oxygen promotes SO2

formation

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SUPERCLAUS® Catalyst Development Su

lfur Y

ield

0

0.2

0.4

0.6

0.8

1

180 200 220 240 260 280 300 320

Temperature (°C)

1st

3rd

2nd

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Operating Window SUPERCLAUS® Reactor (1/2)

• T-in 190 – 220°C (typically 210°C)

• T-bed bottom > 240 and < 260°C

• H2S-in 0.5 – 0.9 vol.%

• O2-out 0.2 – 1.0 vol.% (typically 0.5 vol.%)

• H2S slippage 2% of inlet H2S

• Top 50% of bed makes 75-90% of total delta-T

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SUPERCLAUS® Operational Items

• Catalyst life > 5-8 years Some units > 12 years

• Risks - Temperature run-away T < 350°C (max 500°C) - Oxygen shortage catalyst deactivation Partly recovered at correct conditions - H2SO3 formation at startup condenser at <4 barg

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Selox Air Control

• Tail gas analyzer for O2 not very reliable (maintenance issues) • Therefore a mass balance formula is preferred

• SCA =

• Jacobs support for Calculated control to replace analyzer

airout2air2

tail2out2 MWxOO

SH6.0O03.1xPCxTGF

−−

−−

−

+

SC-reactorRH

QA100%

1.03 TGF + Øv selox

103%

Øv selox air, kmol/h (SCA)

Øv-tail (TGF) kmol/hH2S-tail vol.%Plant capacity (PC)

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Inline Burners/Steam Reheaters

Inline burner • Substoichiometric combustion 90-95%, prevent formation of

SO2 / SO3 / soot

• Selox air injected into static mixer just upstream of reactor, gives lowest SO2 formation

• SUPERCLAUS® on bypass: inline burner also shutdown: M.O.V. in startup selox line

• Use of stable natural gas p, T, MW corrected flows

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Inline Burners / Steam Reheaters

Steam reheaters • Investment cost steam reheater versus inline burner • More pressure drop (0.03 – 0.04 bar) compared to inline

burner (< 0.01 bar) • Outlet temperature restricted • Sulfur fire in 3rd steam reheater is usually a combination of

O2 / temperature / liquid S

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Special Design Requirements/Developments

• Bypass line tie-in at: Inlet final condenser

Downstream coalescer (when NH3 in feed gas)

• Use of a static mixer (selox air)

• Leaking bypass valve: Strahman valve in bypass line for H2S detection

• Sulfur sight glass in sulfur rundown line

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Operation issues: Prevent Sulfur Fires

• Specially during bypass, start-up and shut-down

• High O2-content (>10 vol.% air)

• High T > 230°C (446°F)

• Liquid S present

• At final condenser inlet channel

• At steam reheater

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Additional slides – 10 Commandments for troublefree SRU operation

Commandment 1 – Apply a high intensity main burner

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Commandment 2 – Do not damage your main burner

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Commandment 3 – Prevent excess air with fuel gas combustion

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Commandment 4 – Keep your Main Combustion Chamber (MCC) hot

• Maintain sufficient wall temperature to avoid corrosion due to acid condensation: Apply correct refractory lining types and thickness Apply weathershield Do not use insulation

• Prevent fast heating / cooling of refractory lining to prevent damage (always)

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Commandment 5 – Sulfur condensers should be short

• Waste Heat Boiler outlet temperature is 300 – 330°C (≤ 340°C)

• First sulfur condenser outlet temperature is typically 190°C For bulk sulfur removal (90% efficiency)

• Second sulfur condenser outlet temperture is typically 175-180°C For bulk sulfur removal (85-90 % efficiency)

• Third sulfur condenser outlet temperature is typically 160-165°C For bulk sulfur removal (80% efficiency)

• Apply sulfur dewpoint margin of 10°C for reactor inlet and outlet

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Commandment 6 – Catalytic reactors should be as cold as possible

50

55

60

65

70

75

80

85

90

95

100

0 200 400 600 800 1000 1200

Temperature, °C

Con

vers

ion

% to

sul

fur

sulfur dewpoint

catalytic region

flame region

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Commandment 7 – Plant Control: Use Burner Control to maximize sulfur recovery

90

91

92

93

94

95

96

97

98

99

100

-8 -6 -4 -2 0 2 4 6 8

Excess air, %

Con

vers

ion

Effic

ienc

y, %

stoichiometric limit

stoi

chio

met

ric lim

it

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Advance Burner Control

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Plant Control ABC+

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Commandment 8 – Maintain your tail gas analyzer

• Maintenance is required : 2 hours a week

• Advised tail gas analyzers: Ametek Model 900 Ametek NSL 880 Brimstone 942

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Commandment 9 – Operate your final condenser and coalescer close to the sulfur melting temperature

• Maximize sulfur recovery by minimizing operating temperature • Avoid plugging • No Excess oxygen

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Commandment 10 – give a little love and attention

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