What Has Your Sulphur Plant Done For You Lately? GPA-GCC 25 th - - PowerPoint PPT Presentation

What Has Your Sulphur Plant Done For You Lately?

GPA-GCC 25th Annual Technical Conference Onur Halil Kirpici ADGAS Angie Slavens UniverSUL Consulting

AGENDA

INTRODUCTION

CRUDE OIL PRICE

PERSPECTIVES

Innovation is born out of adversity

Producers who stay focused on efficient, cost effective operations during challenging times will evolve and become stronger Sulphur recovery is a cost of production Sulphur plant is a net energy exporter

BENCHMARK PLANT

HYPOTHETICAL SULPHUR PLANT

Acid Gas Feed mol% kmol/hr H2S 60% 1,300 CO2 30% 650 Hydrocarbon (as C1) 1% 22 H2O 9% 195 Total 100% 2,166 Temperature, °C 54 Pressure, barg 0.69

BENCHMARK PLANT CASE A

BURNER RF SRU WHB Acid Gas CLAUS AIR BLOWER Air 1 s t CONDENSER Sulphur 1 s t REHEATER 1 s t CONVERTER 2 n d CONDENSER Sulphur 2 n d REHEATER 2 n d CONVERTER 3 r d CONDENSER Sulphur 3 r d REHEATER 3 r d CONVERTER 4 t h CONDENSER Sulphur BURNER INCINERATOR INCINERATOR WHB INCINERATOR AIR BLOWER Air Fuel Stack Gas STACK

LEGEND

ELECTRIC POWER CONSUMER HP STEAM PRODUCER HP STEAM CONSUMER LP STEAM PRODUCER LLP STEAM PRODUCER FUEL CONSUMER

ACID GAS PREHEATER COMBUSTION AIR PREHEATER

BENCHMARK PLANT CASE B

NOTE: Sub-dewpoint process is shown. Direct oxidation process would produce similar SRE.

BURNER RF SRU WHB Acid Gas CLAUS AIR BLOWER Air 1 s t CONDENSER Sulphur 1 s t REHEATER 1 s t CONVERTER 2 n d CONDENSER Sulphur 2 n d REHEATER 2 n d CONVERTER 3 r d CONDENSER Sulphur 3 r d REHEATER 1 s t CBA REACTOR 4 t h CONDENSER Sulphur BURNER INCINERATOR INCINERATOR WHB INCINERATOR AIR BLOWER Air Fuel Stack Gas STACK 2 n d CBA REACTOR

LEGEND

ELECTRIC POWER CONSUMER HP STEAM PRODUCER HP STEAM CONSUMER LP STEAM PRODUCER LLP STEAM PRODUCER FUEL CONSUMER

ACID GAS PREHEATER COMBUSTION AIR PREHEATER

BENCHMARK PLANT CASES C & D

BURNER RF SRU WHB Acid Gas CLAUS AIR BLOWER Air 1 s t CONDENSER Sulphur 1 s t REHEATER 1 s t CONVERTER 2 n d CONDENSER Sulphur 2 n d REHEATER 2 n d CONVERTER 3 r d CONDENSER Sulphur TGTU PREHEATER HYDROGENATION REACTOR BURNER INCINERATOR INCINERATOR WHB INCINERATOR AIR BLOWER Air Fuel Stack Gas STACK TGTU WHE QUENCH COLUMN QUENCH PUMP Quench Water Purge ABSORBER REGENERATOR RICH AMINE PUMP LEAN/RICH EXCHANGER LEAN AMINE PUMP REBOILER REFLUX DRUM

FUEL CONSUMER LP STEAM CONSUMER

LEGEND

ELECTRIC POWER CONSUMER HP STEAM PRODUCER HP STEAM CONSUMER LP STEAM PRODUCER LLP STEAM PRODUCER

ACID GAS PREHEATER COMBUSTION AIR PREHEATER QUENCH WATER AIR COOLER LEAN AMINE AIR COOLER CONDENSER

BENCHMARK PLANT CASES E & F

BURNER RF SRU WHB Acid Gas CLAUS AIR BLOWER Air 1 s t CONDENSER Sulphur 1 s t REHEATER 1 s t CONVERTER 2 n d CONDENSER Sulphur 2 n d REHEATER 2 n d CONVERTER 3 r d CONDENSER Sulphur TGTU PREHEATER HYDROGENATION REACTOR BURNER INCINERATOR INCINERATOR WHB INCINERATOR AIR BLOWER Air Fuel Stack Gas STACK TGTU WHE QUENCH COLUMN QUENCH PUMP Quench Water Purge ABSORBER REGENERATOR RICH AMINE PUMP LEAN/RICH EXCHANGER LEAN AMINE PUMP REBOILER REFLUX DRUM

FUEL CONSUMER LP STEAM CONSUMER

LEGEND

ELECTRIC POWER CONSUMER HP STEAM PRODUCER HP STEAM CONSUMER LP STEAM PRODUCER LLP STEAM PRODUCER

ACID GAS PREHEATER COMBUSTION AIR PREHEATER QUENCH WATER AIR COOLER LEAN AMINE AIR COOLER CONDENSER QUENCH WATER TRIM COOLER

COOLING WATER CONSUMER

LEAN AMINE TRIM COOLER

BENCHMARK PLANT ENERGY BALANCE BASIS

BENCHMARK PLANT ENERGY BALANCE (MW)

CASE SRE A 97% B 99.0% C 99.3% D 99.9% E 99.98% F 99.98% UTILITY HP Steam +77.4 +78.8 +66.8 +67.0 +67.0 +67.0 LP/LLP Steam +27.2 +27.9 +16.9 +10.6

• 57.4
• 14.0

Fuel Gas

• 43.8
• 47.1
• 38.3
• 39.4
• 39.6
• 39.6

Electric Power

• 4.1
• 4.1
• 6.1
• 6.5
• 9.9
• 7.6

Cooling Water

• 27.3
• 13.6

UNIT SRU +60.6 +62.3 +61.3 +62.0 +62.0 +62.0 TGTU

• 14.0
• 20.7
• 119.6
• 60.3

INCINERATOR

• 4.0
• 7.1
• 8.3
• 9.5
• 9.6
• 9.6

NET EXPORT/IMPORT +56.6 +55.4 +39.3 +31.8

• 67.1
• 7.9

COMPARISON TO CASE A

• 2%
• 31%
• 44%
• 219%
• 114%

ENERGY BALANCE vs. SO2 EMISSIONS

ENERGY BALANCE, BY UTILITY

BENCHMARK PLANT ENERGY KPIs

Every ton of ‘S’ produced in Claus SRU generates ~1,400 kWh of thermal energy, but amine-based TGTU erodes this

REAL WORLD PLANT CASE STUDY

CASE STUDY

CASE STUDY PFD

SH STEAM CONSUMER SA STEAM PRODUCER SL STEAM CONSUMER SL STEAM PRODUCER ELECTRIC POWER CONSUMER FUEL CONSUMER

7F-301 MAIN COMBUSTION CHAMBER 7E-301 WASTE HEAT BOILER Air 7E-301

• NO. 1

CONDENSER Sulphur 7E-307

• NO. 1

REHEATER 7C-302

• NO. 1

REACTOR 7E-303

• NO. 2

CONDENSER Sulphur 7E-308

• NO. 2

REHEATER 7C-303

• NO. 2

REACTOR

LEGEND

7E-311 PROCESS AIR PREHEATER 7E-310 ACID GAS PREHEATER Acid Gas 7K-301A/B MAIN AIR BLOWER 7E-304

• NO. 3

CONDENSER Sulphur 7E-309

• NO. 3

REHEATER 7C-304

• NO. 3

REACTOR 7E-304

• NO. 4

CONDENSER Sulphur 7E-305 STEAM CONDENSER 7E-0341

• NO. 4

REHEATER 7C-0342 SUPERCLAUS REACTOR 7E-0342 OXIDATION AIR PREHEATER Air 7E-0343

• NO. 5

CONDENSER Sulphur 7E-0344 SUPERCLAUS STEAM CONDENSER Stack Gas 7F-320 INCINERATOR Air

CASE STUDY BASIS

CASE STUDY PROCESS PARAMETERS

DESIGN ACTUAL EXPECTED FULLY OPTIMIZED Acid Gas Feed (Nm3/h) 47,313 39,893 39,893 40,000 Acid Gas H2S Content (mol%) 31.3 34.3 34.3 35.0 Sulphur Production (MTPD) 504 466 466 477 Acid Gas Bypass (%) 50 53 53 50 Approach to Dewpoint in 2nd/ 3rd Reheaters (oC) 15 / 14 15 / 38 15 / 15 15 /15 Stack Gas O2 Content (%) 1.0 5.5 2.0 2.0

CASE STUDY FULLY OPTIMIZED PLANT

EXISTING PLANT FULLY OPTIMIZED PLANT

Main Air Blower Electric motor drive Steam turbine drive; uses superheated 40 barg (HP) steam SRU WHB Produces 15 barg (SA) steam Produces 40 barg (HP) steam Preheaters & Reheaters Use superheated 60 barg (SH) steam, imported from OSBL Use 40 barg (HP) steam, generated in SRU Sulphur Condensers 4.7 barg (SL) steam produced in No. 1, 2 and 3 Condensers; closed loop steam production / condensation in No. 4 and 5 Condensers 4.7 barg (SL) steam produced in No. 1, 2 and 3 Condensers; BFW preheating in No. 4 and 5 Condensers Incinerator Air Blower N/A (natural draft) Steam turbine drive; uses superheated 40 barg (HP) steam Incinerator WHB No Yes; produces 40 barg (HP) steam

CASE STUDY OVERALL ENERGY KPIs

357

• 63

439 1,434

• 1,200
• 800
• 400

400 800 1,200 1,600 2,000

SH/HP Steam SA/HP Steam SL Steam Fuel Gas Electric Power NET Energy KPIs (kWh per Metric Ton 'S' Produced)

Design Actual Expected Fully Optimized Plant

CASE STUDY SH/HP STEAM KPIs

• 118
• 101
• 101
• 105
• 99
• 88
• 87
• 90
• 147
• 140
• 125
• 123
• 171
• 156
• 119
• 117
• 48
• 42
• 600
• 500
• 400
• 300
• 200
• 100

Design Actual Expected Fully Optimized Plant SH/HP Steam Energy Consumption (kWh per Metric Ton of 'S' Produced)

Acid Gas Preheater Process Air Preheater

• No. 1 & No. 2 Reheaters
• No. 3 & No. 4 Reheaters

Main Air Blower Steam Turbine Incinerator Air Blower Steam Turbine NET = -535 NET = -484 NET = -432 NET = -525 SH Steam (60 barg) Consumption HP Steam (40 barg) Consumption

CASE STUDY SA/HP STEAM KPIs

1,123 1,031 1,029 1,256 677 500 1,000 1,500 2,000

Design Actual Expected Fully Optimized Plant SA/HP Steam Energy Production (kWh per Metric Ton of 'S' Produced)

SRU WHB Incinerator WHB NET = 1,934

SA Steam (15 barg) Production

HP Steam (40 barg) Production

CASE STUDY SL STEAM KPIs

553 572 578 561 121 120 128 124

• 2
• 2
• 2
• 2
• 100

100 200 300 400 500 600 700 800

Design Actual Expected Fully Optimized Plant

SL Steam Energy Production / Consumption (kWh per Metric Ton of 'S' Produced)

• No. 1 & No. 2 Condensers
• No. 3 Condenser

Oxidation Air Heater NET = 672 NET = 690 NET = 704 NET = 683

CASE STUDY FUEL GAS KPIs

• 755
• 1,143
• 706
• 659
• 1200
• 1000
• 800
• 600
• 400
• 200

Design Actual Expected Fully Optimized Plant Fuel Gas Energy Consumption (kWh per Metric Ton of 'S' Produced)

Incinerator

CASE STUDY ELECTRIC POWER KPIs

• 145
• 153
• 152
• 3
• 3
• 3
• 180
• 160
• 140
• 120
• 100
• 80
• 60
• 40
• 20

Design Actual Expected Fully Optimized Plant Electric Power Thermal Energy Consumption (kWh per Metric Ton of 'S' Produced)

Main Air Blower Steam Condensers NET = -148 NET = -156 NET = -156

CASE STUDY SUMMARY

SUMMARY & CONCLUSIONS

SUMMARY & CONCLUSIONS

Some operators already see and exploit the benefits of their sulphur recovery facilities….will you do the same?

THANK YOU FOR LISTENING. ANY QUESTIONS?