section 22 - sulfur recovery

7/25/2019 Section 22 - Sulfur Recovery

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FIG. 22-1

Nomenclature

H = Acid Gas =

= equilibrium constant* Claus Process =

LT/D = Residence Time

P = =

=

* For the lo !ressure" #a!or !hase Claus reaction

KEY

= $%am!le calculation &rom the boo'= A!!lication or'sheet &or user to &ill out= (umbers that must be &illed in accordin) to the users data an= (umbers that must be &illed in accordin) to )ra!hs and chart

heat content orenthal!+" ,tu/lb or,tu/lb-mole

.p

lon) ton !er da+ A lon)ton is 0012 lb3

!artial !ressure"atmos!heres

Tail Gas Cleanu!4nit

total !ressure"atmos!heres

0H05 6 57

08 0H

07 6 9/% 5

%

.!= P

H0730P

5%39/%3 / P

H0530P

5703 3

Kp= ( [Mols H

2O]2[Mols S

x]3/x) / ( [Mols H

2S]2[Mol


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d s!eci&ic situation

&eed stream to sul&ur reco#er+ !lant consistin)o& H

05" C7

0" H

07" and usuall+ less than 0 mol

: h+drocarbons

a !rocess in hich ;/9 o& the H05 in the acid)as &eed is burned to 57

0hich is then

reacted ith the remainin) H05 to !roduce

sul&ur< This is also re&erred to as the modi&iedClaus !rocess

the !eriod o& time in hich a !rocess streamill be contained ithin a certain #olume or!iece o& equi!ment" seconds

a !rocess unit desi)ned to ta'e tail )as &rom aClaus sul&ur reco#er+ !lant and remo#eadditional sul&ur ith the )oal o& meetin)en#ironmental sul&ur emission standards

SO2] ) * ( / Total Mols )3/x 1


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Feed Gas Conditions ;;2 >F Dr+ ,ulb Te02


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! ;22 >F! ? >Fischar)e Tem! ;E2 >F

idit+ 2


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Feed Gas Conditions ;;2 >F Dr+ ,ulb Te02


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! ;22 >F! ? >Fischar)e Tem! ;E2 >F

idit+ 2


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d" !rocess" or ser#ice b+ trade-name" trademar'" and ser#ice mar' manu&acturer or otherise does not constit

ma)esF3 = -91";?2

Find o%+)en required

= ;1


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$quilibrium tem!erature can determined b+ readin) Fi)< 00-0? or can be a!!ro%imated b+ the &olloin

;92 ;


11/145

= 0;"B2?"22 ,tu/hr HC Combustion = ;"B09"192 ,tu/hr Claus Reaction = ;"9;1"23 ,tu/hr

09"20"1B0 ,tu/hr

,+ inter!olation" &lame tem!erature is a!!ro% 0;B>F

% = ;9 moles/hr Feed GasH Q ;;2

mol/hr ,tu/lb-mol ,tu/hr

0;


12/145

,+ inter!olation" &lame tem!erature is a!!ro% 0;B9>F

%= ;12 moles/hr Feed Gas

H Q ;;2mol/hr ,tu/lb-mol ,tu/hr

0;


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;92 ;EE2 0;B

;9 022 0;B9;12 092 0;B0

%" mol/hr $quil< and Flame Tem!erature >F3

nterce!t ;9F3

Flame Tem!erature>F3

12! 13" 132 13# 13$ 13! 1#"

"

%""

1"""

1%""

2"""

2%""

3"""

&(x) = - ".3%#!333'2x 2211.3''%"33'

&(x) = %1x - #$%

Calculation of Reaction Furnac

x, moles H2S reacting

Temperature, F


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nterce!t ;91


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From $q 00-0,tu

$q 00-,tu

From $q 00-B

,tu

Reaction Products mol/hr3

;1


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;290;;E01290;0B

00-0EF ,+ $quations !a)e 00-0E,tu/lb-mol ,tu/hr

B00


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= 0;"B2?"22 ,tu/hr = ;"B09"192 ,tu/hr = ;"9;1"23 ,tu/hr

09"209"201 ,tu/hr

,+ inter!olation" &lame tem!erature is a!!ro% 0;0;>F

>F ,+ $quations !a)e 00-0E,tu/lb-mol ,tu/hr

B00


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,+ inter!olation" &lame tem!erature is a!!ro% 0;?9>F


B00


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ure that meet the thermod+namic equilibrium and heat balance

Note: Page 22-2% assumes tempe"atu"e o& 212expanation.

ure that meet the thermod+namic equilibrium and heat balance

1#2

e Temperature

+,il Tp i0a (+,il Tp)

Fla Tp i0a (Fla Tp)


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ublished in the $n)ineerin) Data ,oo' as !ublished b+ the Gas Processor 5u!!liers Associatios!readsheets based on the GP5A $n)ineerin) Data ,oo' sam!le calculations" the use o& such ic+ or reasonableness o& &actual or scienti&ic assum!tions" studies or conclusions" or merchantabithout limitation" those resultin) &rom lost !ro&its" lost data or business interru!tion3 arisin) &rased on rather broad assum!tions includin) but not limited toI tem!eratures" !ressures" com!o

Note: Page 22-2% assumes tempe"atu"e o& 212expanation.

1#2

e Temperature

+,ilii, Tpat, (F)

i0a (+,ilii, Tpat, (F))

Fla Tpat, (F)

i0a (Fla Tpat, (F))


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Step 1 Combustion/Reac

Find o%+)en required

Total

Assume %=mols o& H05 reactin)

% ;/0% % 9/1%

aterial ,alance Combustion/Reac

Assume JP throu)h the burner andThen P=

At equilibrium

Calculate air required to burn ;/9 o&

H05 6 ; 7

08 H

07 6 57

0

CH16 07

08 C7

06 0H

07

H05 8 57

0

;/93*9/03*moles H053

H+drocarbons as C;3

0 * moles C;3

0H05 6 57

08 0H

07 6 9/0 5

0

H05C7

0

H07

570

(0

70

50

5B

5E

H+drocarbons as C;3

.!= P

H0730P

5%39/%3 / P

H0530P

570


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$quilibrium tem!erature can determ

Determine &lame tem!erature b+ he%=

Assume a ran)e in order to inter!ol


00?2 ;"11"0 H05

0B90 1";EE"E1 C70

02E; "0"; H070?229 EB1"?B; 570

;B1E9 "B29"E (0

;E ;"E1E"1; 5009"EE"1;0

Heat in

Feed GasCombustion Air

$quilibrium Tem!erature >F3 = -B

o/!" #it!out an$

H05C7

0

H07

H+drocarbons as C;3

70

(0H

07


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H05 CombustionHC CombustionClaus Reaction

% =

H05

C70

H07

H+drocarbons as C;3

70

(0

H07


00?2 ;"912"E2 H05

0B90 1";EE"E1 C70

02E; B"290";22 H07

0?229 ??"01 570

;B1E9 "B29"E (0

;E ;";"E? 50

09"EE0"9B2

Heat in

Feed GasCombustion Air

H05 CombustionHC CombustionClaus Reaction

Note: Page 22-2( cacuates Caus Reaction#it! 135.16 moes/!" but s!o#s 135 moes/!"in t!e exampe.


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%=

H05

C70

H07

H+drocarbons as C;3

70

(0

H07


00?2 ;"00?"191 H05

0B90 1";EE"E1 C70

02E; B";9"221 H07

0?229 ?0"?1E 570

;B1E9 "B29"E (0

;E ;"2"BE0 5009"E?"92E

Heat in

Feed Gas

Combustion AirH05 CombustionHC CombustionClaus Reaction


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nterce!t,+ $quations !a)e 00-0E

,ased on equations on Pa)e 00-0EF3 = -000"?22 ,tu

JK 90>F3 = -91";?2 ,tu

= ;1


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ined b+ readin) Fi)< 00-0? or can be a!!ro%imated b+ the &olloin)

;92 ;


29/145

= 0;"B2?"22 ,tu/hr = ;"B09"192 ,tu/hr = ;"9;1"23 ,tu/hr

09"20"1?0 ,tu/hr

,+ inter!olation" &lame tem!erature is a!!ro% 0;B>F

;9 moles/hr Feed GasH Q ;;2 >F ,+ $quations !a)

mol/hr ,tu/lb-mol ,tu/hr ,tu/lb-mol

0;


30/145

,+ inter!olation" &lame tem!erature is a!!ro% 0;B9>F

;12 moles/hr Feed Gas

H Q ;;2 >F ,+ $quations !a)mol/hr ,tu/lb-mol ,tu/hr ,tu/lb-mol

0;


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;92 ;EE2 0;B

;9 022 0;B9;12 092 0;B0


;9F3

Flame Tem!erature>F3

12! 13" 132 13# 13$ 13! 1#" 1#2

"

%""

1"""

1%""

2"""

2%""

3"""

&(x) = - ".3%#!3'!$1x 2211.#"%3'"#%#

&(x) = %1x - #$%

Calculation of Reaction Furnace Temp

i

Fl

i

x, moles H2S reacting


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;91


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From $q 00-0

$q 00-

From $q 00-B

ducts mol/hr3

- %

6 %

- ;/0%

6 9/1 %

6 ;/1 %

3O;/0


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00-0E,tu/hr

;E;";;1;2E"900

;"2;

9"2019;;";

00-0E,tu/hr

;BE"9E1

B22"901

0B"?E?"19

e 00-0E H Q 0022 >F ,+ $quations !a),tu/hr ,tu/lbmol ,tu/hr ,tu/lb-mol

;"9?1"B 00?02 ;"1"000 00?2

9"B?"?22 0B992 1";EE"EE 0B90

"B2?"911 02?2 "0B"2?0 02E;E02";92 0?222 EB1"B? 0?229

";0;";9B ;B1E2 "B2;"B?1 ;B1E9

;"?E";2? ;EB2 ;"E1E"B22 ;E00"B1"2?9 09"EE"09B

,+ $quations !a)e 00-0E= 9;;"; ,tu/hr = ?"19 ,tu/hr


35/145

= 0;"B2?"22 ,tu/hr = ;"B09"192 ,tu/hr = ;"9;1"23 ,tu/hr

09"209"201 ,tu/hr

,+ inter!olation" &lame tem!erature is a!!ro% 0;0;>F

e 00-0E,tu/hr

;E;";;1

;2E"900

;"2;

9"201

9;;";

e 00-0E,tu/hr

;BE"9E1

B22"901

0B"?E?"19


;"0B?"91 00?02 ;"91;"B00 00?2

9"B?"?22 0B992 1";EE"EE 0B90

"?21"BB0 02?2 B"20E"00 02E;

?B";2E 0?222 ??";? 0?229

";0;";9B ;B1E2 "B2;"B?1 ;B1E9

;"E0"?0? ;EB2 ;";"?22 ;E

00"B10"B?? 09"E?E"2EB

,+ $quations !a)e 00-0E= 9;;"; ,tu/hr = ?"19 ,tu/hr

= 0;"B2?"22 ,tu/hr = ;"B09"192 ,tu/hr = ;"9B"03 ,tu/hr

00"?0"11 ,tu/hr

Note: Page 22-2( cac#it! 135.16 moes/!" bt!e exampe.


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,+ inter!olation" &lame tem!erature is a!!ro% 0;?9>F

e 00-0E,tu/hr

;E;";;1

;2E"900

;"2;

9"2019;;";

e 00-0E

,tu/hr ;BE"9E1

B22"901

0B"?E?"19


;";B2"291 00?02 ;"00E"200 00?2

9"B?"?22 0B992 1";EE"EE 0B90

"E2;"E2 02?2 B";9;"??0 02E;

B0"2E 0?222 ?0"B? 0?229

";0;";9B ;B1E2 "B2;"B?1 ;B1E9

;"E9"91B ;EB2 ;"2"E22 ;E00"B9B"0E0 09"E?2"9B

,+ $quations !a)e 00-0E= 9;;"; ,tu/hr

= ?"19 ,tu/hr = 0;"B2?"22 ,tu/hr = ;"B09"19; ,tu/hr = ;"1;B";223 ,tu/hr

00"0;"E? ,tu/hr

,+ inter!olation" &lame tem!erature is a!!ro% 0;??>F


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d+namic equilibrium and heat balance

d+namic equilibrium and heat balance

rature

+,ilii, Tpat, (F)

0a (+,ilii, Tpat, (F))

a Tpat, (F)

0a (Fla Tpat, (F))


38/145

calculation method" !rocess" or ser#ice b+ trade-name" trademar'" and ser#ice mar' manu&actur

sibilit+ o& such dama)es< &olin) and actual control set-!oint dead-band limitationsF

2


46/145

n no e#ent ill the GPA or GP5A and their members bThese calculation s!readsheets are !ro#ided to !ro#ide


47/145

Fi)< 00-0;

Cooled Reaction ProductsH Q?22

,tu/lb-mol ,tu/hr

??1 99?"?0

BEBE ;"20"BB

BE ;"BB;"1B2?92 0;9"??;

1?02 0"?1"1

2? ?0

;;2 00"1?

0?22 109"EB"?90"0;

Fi)< 00-0

atmF

Fi)< 00-0;

Cooled Reaction ProductsH Q ?22


E


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ormation in thes Publication" hether based on arrant+" contract" tort or an+ other le)al theor+ alace detailed and accurate Desi)n $n)ineerin) ta'in) into account actual !rocess conditions" &lui


53/145

sociation GPA3F,tu/hr

;0"2?

1E"010

??E"B2?

"BE

;"0B"919

;"0?

;2"9?E0"E02"12

ublished in the $n)ineerin) Data ,oo' as !ublished b+ the Gas Processor 5u!!liers Association as a ss!readsheets based on the GP5A $n)ineerin) Data ,oo' sam!le calculations" the use o& such in&ormatc+ or reasonableness o& &actual or scienti&ic assum!tions" studies or conclusions" or merchantabilit+" &itithout limitation" those resultin) &rom lost !ro&its" lost data or business interru!tion3 arisin) &rom theased on rather broad assum!tions includin) but not limited toI tem!eratures" !ressures" com!ositions"


75/145

Step 1st Re!eate"7ne o& the !rinci!al !ur!oses o& reheatin) is to maintain the !rocess )as abo#e the

Assume 02

B


76/145

sul&ur de!oint throu)hout the catal+st bedF hi)herF

Fi)< 00-0;

H Q 92 >F,tu/hr

;0"2?

1E"010

??E"B2?

"BE

;"0B"919

;"0?

;2"1;00"E02"1E9

dited in coo!eration ith Gas Processors Association GPA3F

Fi)< 00-0;

>F


85/145

E; E9

Fi)< 00-0;

>F

Con#erter 7utlet

Tem!erature >F3 Fi)F3calculated

3! 3' #" #1

perature

r


86/145

,T4/hr,T4/hr,T4/hr

;


87/145

5te! ;st Catal+tic Con#erter

+ ;/0+ + 9/;B+JH 90>F3 = -1992 ,tu

Feed Gas Q 1?>F 7utlet Conditionsmol/hr mol/hr

E


88/145

;


89/145

999


90/145


02


91/145

+N 3O-/E

EE9B??

r heat balanceF

equilibrium in#ol#in) &ormation o& 50" 5

B" and 5

E

5Eis consideredF3

calculated


92/145

Fi)< 00-0;

>F

Fi)< 00-0;

>F


93/145

E; E9

Fi)< 00-0;

>F

Con#erter 7utlet

Tem!erature >F3 Fi)F3calculated

3! 3' #" #1

emperature

pis)

les/hr


94/145

,T4/hr,T4/hr,T4/hr

;:

and edited in coo!eration ith Gas Processors Association GPA3< imeliness o& such in&ormation< Re&erence herein to an+ s!eci&ic commercial !roduct" calculation method" !rocess"

arrant+" contract" tort or an+ other le)al theor+ and hether or not ad#ised o& the !ossibilit+ o& such dama)es< a'in) into account actual !rocess conditions" &luid !ro!erties" equi!ment condition or &olin) and actual control s


95/145


96/145


97/145


98/145

or ser#ice b+ trade-name" trademar'" and ser#ice mar' manu&acturer or otherise does not constitute

t-!oint dead-band limitations


99/145


100/145


101/145


102/145

r im!l+ endorsement" recommendation or &a#orin) b+ the GPA and/or G


103/145

ncine"ato"

Con#ersion $&&icienc+ E:

?:

Tail )as com!ositionH Q922


9F3 = -;"2B9"B22


104/145

9F3 = -91";22

FuelH Q ;22


;2 B?


105/145


92 10


106/145

EB1"2?B ,tu/hr

5 From 5te! ;3 11E"21E ,tu/hr

"99E"020 ,tu/hr

5te! 0< Calculate net heat release &or &uel at 2


107/145

Heat Balance

Heat Out ;;"E2";02 ,tu/hr

Heat In

Feed 0"09"B2 ,tu/hr Air ;B"9 ,tu/hr

Fuel ;9"029 ,tu/hr EB1"2?B ,tu/hr

;;"012 ,tu/hr

;B";?0 ,tu/hr

099"0 ,tu/hr

E"20B"2?E ,tu/hr;;"E91"E2 ,tu/hr

Desired accurac+ &or con#er)ence Mheat in !lus heats o& reaction - heat outN/heat in3

The heat in !lus heat o& reactions equals the heat out ithin ;:" #alidatin) the con#er)enceF,tu/hr

E"1E

129";

??"09

"0??

;"2;"929

;2

0"0??";2 From !a)e 00-0E

0"09"B2

em! ;222 >F

From $q 00-0-000"?22 ,tu

$q 00-;2-;9B"B22 ,tu

Pa)e 00-9;-E2E"B22 ,tu

Pa)e 00-9;-;"2B9"B22 ,tu

AirH Q ;22 >F

,tu/lb-mol ,tu/hr

?


119/145

10F

,tu/hr

;"B"1;9

0"2"1B

";E

1"91"?1

99"BEE";9E"091

,tu/hr

,tu/hr,tu/hr

,tu/hr

,tu/hr,tu/hr,tu/hr

cess air" base rate ;2 mol/hr

!a)e 00-9;-91";22 ,tu

;22 >F,tu/hr

"B??

"B??

;22 >F


120/145

,tu/hr

;1"?E1

9"1E9

0"9B9?2"B92

s;222 >F

,tu/hr

;21"922

?1"212

?E0"222

020"222;";B0"912

,tu/hr,tu/hr

,tu/hr,tu/hr,tu/hr

,tu/hr

Fuel basis


121/145

mols/hr methane as &uelF390 ?22 A -01; -0 -0B1 -09990 ?22 , ?


140/145

-09E -002 -900 -01 -2 -;09B -;?


141/145

the )as !rocessin) industr+< All in&ormation and calculation &ormulae has been com!iled and editedluntar+ and the GPA and GP5A do not )uarantee the accurac+" com!leteness" e&&icac+ or timeliness oa !articular !ur!ose or non-in&rin)ement o& intellectual !ro!ert+

section 22 - sulfur recovery

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