Why Sulfur Plants Plug
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- Опубликовано: 26 сен 2024
- Dealing with plugging in your sulphur plant? Learn how to avoid plugging, how to reverse it (if possible), and how not to make the same mistakes in the future.
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That was just awesome. Great work by Sulphur experts.
Thank you, Shabraz!
Thank you Gerald Bhome for the nice presentation on Sulfur Line plugging mechanism, Very informative and useful for the troubleshooting of our SRU.
Great thanks 😊 maybe steam tracing system design and proper operation is also a good subject
Excellent initiative, a window to explore all those daily common situations and the possible solutions. Thanks and keep it up, it's very helpful.
So informative! Query: Gas injector wells near choke valve always see sulfur deposition downstream of choke valves. Gas has acid gases such as H2S, CO2 etc. Similar deposition also seen with Dry Gas Seal for gas compression system as well. Any way we can prevent it? Thanks.
Why does the steam jet ejector from run down vessel choke
Hello! Most choking / plugging of these steam ejectors is due to sulphur freezing somewhere in the ejector line. The rundown vessel gases contain sulphur vapour (in addition to H2S, SO2, and some other sulphur species) which will freeze if any part of the ejector line drops below 119°C / 246°F. All ejector lines are steam jacketed (or equivalently heated), however there are often small areas where the jacketing isn’t installed (i.e. flanges) or is not working. It is essential that the entire line from the rundown vessel to the end destination be fully heated, and that the jacketing be checked regularly to ensure it is working.
How can you operate the plant with less than 50 percent capacity with low H2S concentrations for an optimum control of combustion air in order to maintain the air to acid gas ratio to burn exactly one third of H2S
Great question! As per the previous question/answer, operation at low capacity can be improved by co-firing with natural gas. Operation at low H2S concentration (regardless of capacity) can be a problem because the flame temperature may not be hot enough to destroy contaminants or to sustain the flame. There are five options to improve the flame temperature in this case: 1) co-fire with natural gas (which also boosts the plant throughput); 2) replace some of the combustion air with pure oxygen; 3) preheat the furnace air and / or acid gas; 4) increase the H2S concentration by changing or optimizing the amine used in the plant; 5) use an acid gas bypass design. The best choice for an individual plant depends on a number of site specific items, and a detailed study should be done to determine the best option for a specific plant.
What is the corrosion mechanism in sulfur recovery plants? Is carbon steel material corrosion resistant in normal operating conditions? Is there any way to stop corrosion? Thanks in advance and great video
Hello and thank you for your question! There are two primary corrosion mechanisms. The first is contact corrosion between frozen sulphur, liquid water, and the steel vessel/pipe. Obviously, this can only occur if the vessel/pipe wall is below the freezing point of sulphur (119°C / 246°F) and does not occur above these temperatures. The second is sulphidation of the steel by H2S at temperatures above around 300°C / 575°F. For these reasons cold parts of the plant are kept externally heated / insulated in order to keep the vessel and pipe walls above the sulphur freezing point, while hot parts of the plant are internally refractory lined in order to keep the vessel and pipe walls below 300°C / 575°F. Within these temperature limits, there is essentially no corrosion of carbon steel, which is why carbon steel is used for almost all of the sulphur plant construction.
How do you deal with flame instability at low loads, is fuel gas cofiring rate need to be increased
All reaction furnace burners have a lower operating limit, below which the flame may become unstable or may move into the burner tip itself (damaging the burner). This lower limit should be provided by the burner manufacturer. You are correct that, if you are below this lower limit, then the easiest way to get back above the limit is to co-fire with natural gas.
Thank you! What is the purpose of the piston style valve?
The purpose and advantage of the piston type valve is that it is "self cleaning". When the valve is closed and the piston is inserted through the valve bore and into the process pipe, this drills / cleans out the sample path. This also guarantees that the sample path is open and clear when the valve is opened. For a sulphur plant, where sulphur freezes and plugs the sample point at 119C/246F, this type of self-cleaning valve is a big advantage.
Please let us know if you have further questions.
@@sulphurexpertsinc7755 Is it designed to sample the degassed sulfur for the H2S content?
@@_chess_master Piston valves can be used to collect samples of degassed sulphur for H2S content analysis. We find, however, that they don’t work very well on pressurized liquid sulphur lines - the liquid sulphur tends to “spray” out of the nozzle instead of pour out for easy collection. Our preference for liquid sulphur sampling is actually to lower a can / pail / thermos on a chain into the degassed sulphur vessel - it seems to be much easier and safer than collecting the sample from any type of valve on a pressurized line.
Is bypassing of acid gas though bypass line to rxn furnace recommended for low throughput
Bypassing of acid gas is one of five options for increasing the reaction furnace temperature in case the acid gas quality does not allow for sufficient temperature. It is NOT a solution for low throughputs.
@@sulphurexpertsinc7755 in case of split reaction furnace, should we continue to bypass acid gas even during low throughput, what if the temperature is still low in the front end of the furnace
What is the solution for COS ingress to Absorber
We are not sure if you are referring to the amine absorber upstream of the sulphur plant, or to the amine absorber in the tail gas unit downstream of the sulphur plant? Upstream of the sulphur plant there are additives that can be added to the amine (like Sulfolane) that can pickup COS and mercaptans, although they will also increase hydrocarbon pickup. Downstream of the sulphur plant, the tail gas unit reactor should reduce the COS to a few ppm before the gas goes to the absorber; if this is not occurring then the reactor catalyst needs to be optimized or changed.
what is the procedure to prevent sulfur dust/particals coming from hydrogenation reactor towards quenching column? Due to which quench column plugged very badly....
As long as the hydrogenation catalyst is a) active, b) at the right temperature, and c) has sufficient hydrogen, it will easily convert 100% of elemental sulphur to H2S and there will be no elemental sulphur going to the quench column. Hydrogenation of elemental sulphur is one of the fastest reactions in the reactor, so even if there is some deactivation or even if the temperature is imperfect, there should still be no elemental sulphur to the quench column. Therefore the most critical thing to prevent elemental sulphur from leaving the reactor and going to the Quench tower is to ensure sufficient hydrogen supply. A properly designed tail gas unit will have a Hydrogen analyzer downstream of the Quench tower, and the operators will know if they are running out of hydrogen. If the excess hydrogen drops towards zero, then additional hydrogen can be added to the reactor (if the plant has this ability) or the demand for hydrogen can be decreased by quickly lowering the SO2 entering the reactor (by removing air from the reaction furnace and lowering the SO2 in the Claus plant tail gas.
What is the procedure to dechoking the condenser or separater when Sulpher is plugging?
Rodding
Why does the condenser choke when you shut down the plant
A proper shutdown should begin with process steps that remove all sulphur from the plant, which is often called a “sweep” or a “strip”. If this is done properly, then there will be no remaining sulphur in the plant that can freeze when the completely shut down. If the sweep is not done properly, then any remaining sulphur will freeze when the plant is cooled. The criteria for a proper sweep depends on a number of items; you can contact us by e-mail if you want to discuss further at TheExperts@SulphurExperts.com
@@sulphurexpertsinc7755 what if it is not a planned shut down, if the plant suddenly trips due to many reasons
Great video!