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

AGENDA

INTRODUCTION

CRUDE OIL PRICE

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

BENCHMARK PLANT

HYPOTHETICAL SULPHUR PLANT Acid Gas Feed mol% kmol/hr H 2 S 60% 1,300 CO 2 30% 650 Hydrocarbon (as C 1 ) 1% 22 H 2 O 9% 195 Total 100% 2,166 Temperature, ° C 54 Pressure, barg 0.69

BENCHMARK PLANT CASE A SRU WHB Stack Gas BURNER RF 1 s t 2 n d 3 r d INCINERATOR REHEATER REHEATER REHEATER 1 s t Acid 2 n d WHB 3 r d Gas ACID GAS CONVERTER CONVERTER BURNER CONVERTER PREHEATER Fuel INCINERATOR 1 s t 2 n d 3 r d 4 t h CONDENSER CONDENSER CONDENSER CONDENSER COMBUSTION AIR PREHEATER STACK Sulphur Sulphur Sulphur Sulphur Air Air CLAUS AIR INCINERATOR BLOWER AIR BLOWER LEGEND ELECTRIC POWER FUEL CONSUMER HP STEAM PRODUCER CONSUMER HP STEAM CONSUMER LP STEAM PRODUCER LLP STEAM PRODUCER

BENCHMARK PLANT CASE B SRU WHB BURNER RF 1 s t 2 n d 3 r d REHEATER 1 s t REHEATER 2 n d REHEATER Acid 1 s t CBA 2 n d CBA CONVERTER Gas CONVERTER ACID GAS REACTOR REACTOR PREHEATER COMBUSTION 1 s t 2 n d 3 r d AIR PREHEATER CONDENSER CONDENSER CONDENSER Air Sulphur Sulphur Sulphur CLAUS AIR BLOWER Stack Gas INCINERATOR 4 t h WHB CONDENSER BURNER Fuel LEGEND Sulphur INCINERATOR ELECTRIC POWER FUEL CONSUMER HP STEAM PRODUCER CONSUMER Air HP STEAM CONSUMER LP STEAM PRODUCER LLP STEAM PRODUCER STACK INCINERATOR AIR BLOWER NOTE: Sub-dewpoint process is shown. Direct oxidation process would produce similar SRE.

BENCHMARK PLANT CASES C & D SRU WHB QUENCH BURNER RF COLUMN 1 s t 2 n d TGTU PREHEATER REHEATER 1 s t REHEATER 2 n d HYDROGENATION Acid Gas ACID GAS CONVERTER REACTOR QUENCH WATER CONVERTER PREHEATER AIR COOLER COMBUSTION 3 r d 1 s t 2 n d AIR PREHEATER CONDENSER CONDENSER CONDENSER TGTU WHE Quench Air Sulphur Water Sulphur Sulphur CLAUS AIR Purge QUENCH BLOWER PUMP LEAN AMINE AIR COOLER Stack Gas ABSORBER CONDENSER REFLUX DRUM INCINERATOR LEGEND WHB LEAN/RICH BURNER FUEL ELECTRIC POWER HP STEAM EXCHANGER REGENERATOR CONSUMER CONSUMER PRODUCER Fuel HP STEAM LP STEAM LLP STEAM INCINERATOR CONSUMER PRODUCER PRODUCER REBOILER LP STEAM Air CONSUMER STACK RICH AMINE LEAN AMINE INCINERATOR PUMP PUMP AIR BLOWER

BENCHMARK PLANT CASES E & F QUENCH WATER SRU WHB QUENCH BURNER RF TRIM COOLER COLUMN 1 s t TGTU 2 n d PREHEATER REHEATER REHEATER 1 s t 2 n d Acid HYDROGENATION Gas ACID GAS CONVERTER REACTOR QUENCH WATER CONVERTER PREHEATER AIR COOLER COMBUSTION 3 r d 1 s t 2 n d AIR PREHEATER CONDENSER CONDENSER CONDENSER TGTU WHE Quench Air Water Sulphur Sulphur Sulphur CLAUS AIR Purge QUENCH BLOWER PUMP LEAN AMINE LEAN AMINE AIR COOLER TRIM COOLER Stack Gas CONDENSER REFLUX DRUM INCINERATOR LEGEND WHB LEAN/RICH BURNER FUEL ELECTRIC POWER HP STEAM EXCHANGER REGENERATOR CONSUMER CONSUMER PRODUCER Fuel HP STEAM LP STEAM LLP STEAM INCINERATOR CONSUMER PRODUCER PRODUCER ABSORBER LP STEAM COOLING WATER REBOILER Air CONSUMER CONSUMER STACK RICH AMINE LEAN AMINE INCINERATOR PUMP PUMP AIR BLOWER

BENCHMARK PLANT ENERGY BALANCE BASIS

BENCHMARK PLANT ENERGY BALANCE (MW) CASE A B C D E F SRE 97% 99.0% 99.3% 99.9% 99.98% 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 +62.0 +60.6 +62.3 +61.3 +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. SO 2 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 7F-301 MAIN COMBUSTION CHAMBER 7E-0342 7E-307 7E-308 7E-0341 OXIDATION AIR 7E-309 7C-302 7C-303 NO. 1 7C-304 NO. 2 NO. 3 NO. 4 PREHEATER Acid NO. 1 NO. 2 REHEATER NO. 3 REHEATER Gas REHEATER REHEATER 7E-310 REACTOR REACTOR REACTOR ACID GAS 7E-301 Air PREHEATER WASTE HEAT BOILER 7C-0342 7E-301 7E-303 7E-304 7E-305 7E-311 NO. 1 NO. 2 SUPERCLAUS STEAM NO. 3 PROCESS CONDENSER CONDENSER REACTOR CONDENSER CONDENSER AIR PREHEATER 7E-0344 Air SUPERCLAUS Sulphur Sulphur 7K-301A/B STEAM CONDENSER Sulphur MAIN AIR BLOWER Sulphur 7E-304 Stack NO. 4 Gas CONDENSER Sulphur 7E-0343 NO. 5 CONDENSER LEGEND ELECTRIC POWER FUEL CONSUMER SH STEAM CONSUMER CONSUMER SA STEAM PRODUCER SL STEAM PRODUCER SL STEAM CONSUMER Air 7F-320 INCINERATOR

CASE STUDY BASIS

CASE STUDY PROCESS PARAMETERS DESIGN ACTUAL EXPECTED FULLY OPTIMIZED Acid Gas Feed (Nm 3 /h) 47,313 39,893 39,893 40,000 Acid Gas H 2 S 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 2 nd / 3 rd 15 / 14 15 / 38 15 / 15 15 /15 Reheaters ( o C) Stack Gas O 2 Content (%) 1.0 5.5 2.0 2.0

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

CASE STUDY OVERALL ENERGY KPIs SH/HP Steam SA/HP Steam SL Steam Fuel Gas Electric Power NET 2,000 1,600 1,434 (kWh per Metric Ton 'S' Produced) 1,200 800 Energy KPIs 439 357 400 0 -63 -400 -800 -1,200 Design Actual Expected Fully Optimized Plant

CASE STUDY SH/HP STEAM KPIs Design Actual Expected Fully Optimized Plant 0 -101 -101 -105 -118 (kWh per Metric Ton of 'S' Produced) -100 SH/HP Steam Energy Consumption -88 -87 -90 -99 -200 -125 -123 -140 -147 -300 -119 -117 -400 -156 NET = -432 -171 -48 NET = -484 -500 -42 NET = -525 NET = -535 SH Steam (60 barg) Consumption HP Steam (40 barg) Consumption -600 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

CASE STUDY SA/HP STEAM KPIs Design Actual Expected Fully Optimized Plant HP Steam (40 barg) 2,000 Production NET = 1,934 (kWh per Metric Ton of 'S' Produced) SA/HP Steam Energy Production 677 1,500 SA Steam (15 barg) Production 1,000 1,256 1,123 1,031 1,029 500 0 SRU WHB Incinerator WHB

CASE STUDY SL STEAM KPIs Design Actual Expected Fully Optimized Plant 800 700 NET = 704 NET = 690 NET = 683 SL Steam Energy Production / Consumption NET = 672 128 120 124 121 (kWh per Metric Ton of 'S' Produced) 600 500 400 300 578 572 561 553 200 100 0 -2 -2 -2 -2 -100 No. 1 & No. 2 Condensers No. 3 Condenser Oxidation Air Heater

CASE STUDY FUEL GAS KPIs Design Actual Expected Fully Optimized Plant 0 (kWh per Metric Ton of 'S' Produced) Fuel Gas Energy Consumption -200 -659 -706 -755 -400 -1,143 -600 -800 -1000 -1200 Incinerator

CASE STUDY ELECTRIC POWER KPIs Design Actual Expected Fully Optimized Plant 0 -20 Electric Power Thermal Energy Consumption -40 (kWh per Metric Ton of 'S' Produced) -60 -145 -152 -153 -80 -100 -120 -140 -3 -3 -3 -160 NET = -148 NET = -156 NET = -156 -180 Main Air Blower Steam Condensers

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?

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