1. SULPHUR RECOVERY UNIT (SRU) UNIT 22 28 April 2017
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2. TABLE OF CONTENT SECT. 1 - General Description
28 April 2017
TABLE OF CONTENT
SECT General Description
SECT Process Flow Description
SECT Main equipments 2
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3. 28 April 2017
SECTION 1
GENERAL DESCRIPTION 3
33/1 of Sec 1/1 of 20 3

4. General: For Bach Ho Crude operation only
28 April 2017
General:
For Bach Ho Crude operation only
To convert all sulphur compounds present in the acid gas feed from the ARU and SWS into liquid elemental sulphur
Process:
1/3 of H2S is burned and converted into SO2
2/3 of H2S then reacts with the SO2 formed to produce elemental liquid sulphur
Produced sulphur is then condensed and liquid sulphur cleared of H2S entrained
Treated gas is finally incinerated to convert the remaining pollutants into SO2
SRU located at the south west of the area 4, nest to the LCO HDT, ARU and SWS 4
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5. 28 April 2017 5
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6. Purpose & Duty of the Unit:
28 April 2017
Purpose & Duty of the Unit:
To convert all sulphur compounds in the following acid gases into elemental sulphur:
ARU off gas (from unit 20)
H2S rich SWS off gas (from unit 18)
To incinerate the following gases:
NH3 rich off gas from SWS (unit 18)
CNU off gas
Treated gas from the SRU
Design Capacity: 5 tons/day
Liquid Sulphur Recovery Efficiency: 95% min.
Turndown ratio: 50% 6
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7. Purpose & Duty of the Unit:
28 April 2017
Purpose & Duty of the Unit:
Purpose of each section
Section
Purpose
Sulphur Recovery (Claus) Section
Claus Process, to convert H2S into elemental liquid sulphur.
Section composed of a thermal stage (Thermal Reactor) followed by 3 catalytic steps:
Thermal reactor: burns approx. 1/3 of the H2S contained in the total acid gases feed with air to convert it into SO2.
Catalytic converters: to make the remaining 2/3 of the H2S react with the produced SO2 to give elemental sulphur
Condensation of the produced sulphur
Liquid Sulphur Storage and Degassing Section
Degassing Section To remove the dissolved H2S from the produced sulphur.
H2S content is decreased to less than 20 wt. ppm
Incinerator Section
To convert residual H2S contained in the treated gas leaving the Claus section and the degassing section into SO2.
To burn NH3 rich SWS off gas and CNU off gas.
Sulphur Apron
The sulphur apron is where is collected the solid sulphur from the degassing pit. 7
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8. 28 April 2017
AREA 3 - 3D Drawing
SRU 8
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9. Feed Characteristics: ARU off gas
FEED & CAPACITY FOR PRODUCTION OF DEGASSED LIQUID SULPHUR
Max. Distillate Case
Max. Gasoline Case
Composition
kg/hr
kg-mol/hr
Mol%
H2S
102.6
3.01
18.97
119.6
3.51
20.66
NH3
0.0
0.00
H2O
16.5
0.92
5.77
19.0
1.05
6.21
Cyanide
CO2
511.4
11.62
73.24
531.4
12.08
71.11 N2
1.0
0.04
0.23
0.21 CO
0.1
0.004
0.02 H2
0.3
0.15
0.94
0.87 C1
1.4
0.09
0.55
1.6
0.10
0.59 C2
1.1
0.22 C3
0.4
0.01
0.06
0.8
0.11
Total
634.8
15.87
100.00
674.9
16.98 9

10. Feed Characteristics: ARU off gas
FEED & CAPACITY FOR PRODUCTION OF 5 TONS / DAY OF SULPHUR
Max. Distillate Case
Max. Gasoline Case
Composition
kg/hr
kg-mol/hr
Mol%
H2S
129.6
3.802
18.97
164.2
4.818
20.66
NH3
0.0
0.00
H2O
20.8
1.157
5.77
26.1
1.448
6.21
Cyanide
CO2
645.9
14.676
73.24
729.6
16.578
71.11 N2
1.3
0,045
0.23
1.4
0.049
0.21 CO
0.1
0.005
0.02 H2
0.4
0.188
0.94
0.202
0.87 C1
1.8
0.110
0.55
2.2
0.137
0.59 C2
1.1
0.04
0.22 C3
0.046
1.5
0.050
Total
801
20.040
100.00
926.6
23.312 10

11. Feed Characteristics: H2S Rich SWS off gas
FEED & CAPACITY FOR PRODUCTION OF DEGASSED LIQUID SULPHUR
Max. Distillate Case
Max. Gasoline Case
Composition
kg/hr
kg-mol/hr
Mol%
H2S
82.0
2.41
88.94
50.3
1.48
88.09
NH3
0.0
0.00
H2O
4.8
0.27
9.96
3.1
0.17
10.12
Cyanide
0.7
0.03
1.10
1.79
CO2 N2 CO H2 C1 C2 C3
Total
87.5
2.71
100.00
54.1
1.68 11

12. Feed Characteristics: H2S Rich SWS off gas
FEED & CAPACITY FOR PRODUCTION OF 5 TONS / DAY OF SULPHUR
Max. Distillate Case
Max. Gasoline Case
Composition
kg/hr
kg-mol/hr
Mol%
H2S
103.6
3.039
88.94
69.0
2.026
88.09
NH3
0.0
0.00
H2O
6.1
0.340
9.96
4.2
0.235
10.21
Cyanide
1.0
0.038
1.10
1.1
0.039
1.70
CO2 N2 CO H2 C1 C2 C3
Total
110.7
3.416
100.00
74.3
2.300 12

13. Feed Characteristics: NH3 Rich SWS off gas
FEED COMPOSITION AND CAPACITY TO INCINERATOR
Max. Distillate Case
Max. Gasoline Case
Composition
kg/hr
kg-mol/hr
Mol%
H2S
14.7
0.43
3.24
8.9
0.26
2.76
NH3
157.6
9.27
69.75
112.3
6.61
70.25
H2O
64.7
3.59
27.01
45.7
2.54
26.99
Cyanide
0.0
0.00
CO2 N2 CO H2 C1 C2 C3
Total
237.0
13.29
100.00
166.9
9.41 13

14. Feed Characteristics: CNU off gas
FEED COMPOSITION AND CAPACITY TO INCINERATOR
Naphtenic / Sulfidic Sour (Mixed Crude)
Naphtenic / Sulfidic Sweet (Bach Ho Crude)
Phenolic Sour (Mixed Crude)
Phenolic Sweet (Bach Ho Crude)
Std Vol. Flowrate m3/hr
22.5
29.3
Min
H2O wt% 7
H2S wt% 53 28 -
RSH wt% 5
Fuel Gas wt% 40 60 93 14

15. Product Specifications: Degassed Liquid Sulphur
Component
Specification
Purity (as S) (wt %)
≥ 99.9 (dry basis)
Organics (wt %)
≤ 0.02 (dry basis)
Ashes (wt %)
≤ 0.04 (dry basis)
Water (wt %)
≤ 0.10
H2S content (wt.ppm)
≤ 10
Colour
Bright Yellow 15

16. Product Specifications: Emissions from Incinerator
Component
Limit
SO2 (mg/m3)
500 max (dry basis)
H2S (mg/m3)
2 max (dry basis)
NOX (mg/m3)
1000 max (dry basis)
CO (mg/m3)
Particulate in Smoke (mg/m3)
400 (dry basis)
Dust containing silica (mg/m3)
50 (dry basis)
Ammonia (mg/m3)
100 (dry basis) 16

17. Basis of Design: Chemicals Requirement
CLAUS Catalytic Reactors Catalyst
Alumina-Titanium for 1st reactor
Alumina only for the 2nd and 3rd reactors
Catalyst supported on a layer of active catalyst support
Catalyst
Item
Description
Volume to be loaded (m3)
A-2201-R-02
1st reactor
Alumina-based catalyst
0.94
Titanium oxide catalyst
A-2201-R-03
2nd reactor
1.32
A-2201-R-04
3rd reactor
1.88
Catalyst Bed Support
Item
Description
Volume to be loaded (m3)
A-2201-R-02
1st reactor
0.28
A-2201-R-03
2nd reactor
0.20
A-2201-R-04
3rd reactor 17

18. PROCESS FLOW DESCRIPTION
28 April 2017
SECTION 2
PROCESS FLOW DESCRIPTION 18
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21. SECTION 3 MAIN EQUIPMENTS
28 April 2017
SECTION 3
MAIN EQUIPMENTS 21
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22. Main Equipment – Thermal Reactor
To completely oxidize HC and all impurities (such as HCN) and to burn 1/3 of the total H2S to SO2
2 zone reaction furnace:
1st zone: all combustion air, all H2S rich SWS off gas and 50% of ARU off gas are burnt (1240°C)
2nd zone: Hot flue gas from the 1st zone and 50% of the ARU are mixed (900°C)
Thermal reactor burner: combined type with 2 lances:
1 for fuel gas combustion during plant start-up and for turndown case
1 for acid gas combustion during normal operation
2 flame scanner and 1 ignitor
Quench line to moderate the flame temperature during fuel gas run
Reaction chamber is internally refractory lined and equipped with 1 optical pyrometer and specials thermocouples to detect continuously the temperature in both reaction zones 22

23. Main Equipment – Thermal Reactor23

24. Main Equipment – Thermal Reactor24

25. Thermal Reactor A-2201-R-01 Burner
Main Equipment – Thermal Reactor
Thermal Reactor A-2201-R-01 Burner
Nozzle Data for Burner
Design Pressure (kg/cm2g)
5.2
Operating Pressure (kg/cm2g)
0.49
Design temperature (°C)
343
Operating temperature (°C)
250
Material:
Acid Gas Lance / Tip
Fuel Gas Lance / Tip
Burner Front Plate
Stainless Steel / AISI 310
Killed Carbon Steel
Burner Construction
Installation
Horizontal, flanged to the thermal reactor
Gas Tight Construction
Yes
Fuel Gas connection
Flexible pipe to allow gun withdrawal during acid gas operation
Flame control
2 flame detectors, each complete with amplifier
Max noise level
85 dB at 1 m distance 25

26. Main Equipment – Thermal Reactor
Thermal Reactor A-2201-R-01
Length (TL to TL) (mm)
2700
Internal Diameter (mm)
1290
Position
Horizontal
Design Temperature (Fuel Gas Firing only) (°C)
1450
MIN/MAX Operating temperature (°C)
Zone I: 1250/900 Zone II: 1250/850
Refractory
Bricks Group
Grade 28
Classification Temperature
1540°C
Thermal Conductivity at 600°C
0.34W/m°C
CaO content
1% typ.
Fe2O3 content
1.5% max.
Alkalies content
2% max. 26

27. Main Equipment – A-2001-SG-01
5 passes boiler producing saturated low pressure steam at 4.1 kg/cm2G in the shell side by condensing sulphur in the tube side:
pass I = 1st pass of WHB
pass II = 2nd pass of WHB
pass III = 1st sulphur condenser
pass IV = 2nd sulphur condenser
pass V = 3rd sulphur condenser
The 5 passes are all oriented horizontally
The tubes of each pass are plain tubes, made of killed carbon steel
A-2201-SG-01 is provided with 2 mist eliminators at Pass III and IV outlets 27

28. Main Equipment – A-2001-SG-0128

29. Main Equipment – A-2001-SG-0129

30. Main Equipment – A-2001-SG-0130

31. Main Equipment – A-2001-SG-01
PASS I
Surface (m2)
7.5
Shell Side
Tube Side
Service
BFW / LP steam
Process Gas
Inlet
Outlet
Vapour (kg/hr)
1533.8
Steam (kg/hr)
790.5
Water (kg/hr)
814.6
24.1
Temp.(°C)
112
152
897
455
Press. (kg/cm2g)
4.1
0.44
Duty (kW)
245
Service heat transfer coefficient (W/m2 °C):
66.1 Clean: 68.1
No. of tubes: 6
Tubes Diameter (mm)
7.62
Length (mm)
4500
Pitch
125 (SQUARE) 31

32. Main Equipment – A-2001-SG-01
PASS II
Surface/unit (m2)
11.9
Shell Side
Tube Side
Service
BFW / LP steam
Process Gas
Inlet
Outlet
Vapour (kg/hr)
1533.8
Steam (kg/hr)
790.5
Water (kg/hr)
814.6
24.1
Temp.(°C)
112
152
455
240
Press. (kg/cm2g)
4.1
0.420
Duty (kW)
107
Service heat transfer coefficient (W/m2 °C):
51.6 Clean: 53.0
No. of tubes: 14
Tubes Diameter (mm)
5.54
Length (mm)
4500
Pitch
85 mm (TRIANGULAR) 32

33. Main Equipment – A-2001-SG-01
PASS III
Surface/unit (m2)
15.7
Shell Side
Tube Side
Service
BFW / LP steam
Process Gas
Inlet
Outlet
Vapour (kg/hr)
1533.8
1504.4
Liquid (kg/hr)
29.4
Steam (kg/hr)
790.5
Water (kg/hr)
814.6
24.1
Temp.(°C)
112
152
240
162
Press. (kg/cm2g)
4.1
0.40
Duty (kW) 37
Service heat transfer coefficient (W/m2 °C):
65.7 Clean: 67.9
No. of tubes: 35
Tubes Diameter (mm)
2.77
Length (mm)
4500
Pitch
46 mm (TRIANGULAR) 33

34. Main Equipment – A-2001-SG-01
PASS IV
Surface/unit (m2)
16.2
Shell Side
Tube Side
Service
BFW / LP steam
Process Gas
Inlet
Outlet
Vapour (kg/hr)
1504.4
1356.6
Liquid (kg/hr)
147.8
Steam (kg/hr)
790.5
Water (kg/hr)
814.6
24.1
Temp.(°C)
112
152
321
171
Press. (kg/cm2g)
4.1
0.28
Duty (kW) 84
Service heat transfer coefficient (W/m2 °C):
75.8 Clean: 78.9
No. of tubes: 36
Tubes Diameter (mm)
2.77
Length (mm)
4500
Pitch
46 mm (TRIANGULAR) 34

35. Main Equipment – A-2001-SG-01
PASS V
Surface/unit (m2)
14.4
Shell Side
Tube Side
Service
BFW / LP steam
Process Gas
Inlet
Outlet
Vapour (kg/hr)
1356.6
1329.5
Liquid (kg/hr)
27.1
Steam (kg/hr)
790.5
Water (kg/hr)
814.6
24.1
Temp.(°C)
112
152
223
162
Press. (kg/cm2g)
4.1
0.173
Duty (kW) 28
Service heat transfer coefficient (W/m2 °C):
62.7 Clean: 64.8
No. of tubes: 32
Tubes Diameter (mm)
2.77
Length (mm)
4500
Pitch
46 mm (TRIANGULAR) 35

36. Main Equipment – Catalytic Reactors
Purpose: To convert H2S into gaseous elemental sulphur by reaction between H2S and the SO2 formed in the thermal reactor, on catalyst beds
Reaction between H2S and SO2 produces elemental sulphur in each reactor for as long as the equilibrium is not reached for the pressure and temperature conditions within each reactor
R-02, 03 and 04 are physically located in a unique vessel divided into 3 compartments
The reactors vessel is equipped with an external MP steam coil operating at 250°C and 14.1 kg/cm2g 36

37. Design Case Operating Conditions (Max. Gasoline)
Main Equipment – Catalytic Reactors
A-2201-R-02
A-2201-R-03
A-2201-R-04
Service
1st catalytic reactor
2nd catalytic reactor
3rd catalytic reactors
Catalyst Volume (m3)
Alumina-based: 0.94
Titanium oxide: 0.94
Alumina-based: 1.32
Alumina-based: 1.88
I.D. (mm)
1900
Length (mm)
1375
1300
Material:
Shell
Heads
Flanges
Coils
Beam
Killed Carbon Steel
Design Case Operating Conditions (Max. Gasoline)
Liquid Flow (kg/hr)
Vapour Flow (kg/hr)
1504.4
1356.6
1321.5
IN Press. (kg/cm2g)
0.33
0.21
0.09
OUT Press. (kg/cm2g)
0.40
0.28
0.173
IN Temp. (°C)
240
205
190
OUT Temp. (°C)
321
223
193 37

38. Main Equipment – Catalytic Reactors38

39. Main Equipment – Catalytic Reactors39

40. Main Equipment – Liquid Sulphur Storage & Degassing Pits
Purpose: to collect liquid elemental sulphur at the outlet of the 1st, 2nd, 3rd and final sulphur condensers via steam jacketed sulphur legs
Each sulphur leg is provided with dedicated perforated plate filter
Seal legs sized to avoid blow up of process gas in all operating conditions
Each leg can be isolated for maintenance
Sulphur pit divided in 2 sections:
Non degassed sulphur pit and degassed sulphur storage pit each sized for one day of production and equipped with 2 jacketed transfer pumps
Purpose of the sulphur degassing tank: to reduce H2S entrained with the sulphur to a safe level 40

41. Main Equipment – Liquid Sulphur Storage Pit41

42. Main Equipment – Liquid Sulphur Degassing Tank42

43. Main Equipment – Incinerator
Purpose: To oxidize all sulphur bearing compounds in waste gases (tail gas from SRU and vent air from sulphur degassing pit) to sulphur dioxide prior to release to atmosphere
Normal operating temperature: 750°C
 Condition obtained by burning NH3 rich SWS off gas and CNU off gas
Burner equipped with dedicated lances for:
Fuel Gas
CNU off gas
NH3 rich off gas
ARU off gas + H2S rich off gas (bypass gas)
Claus Section Tail Gas and the Vent Gas from Degassing Section are injected just downstream of the flame via dedicated nozzles
Cylindrical & Horizontally installed
Incinerator chamber I.D. = 1450 mm
Forced draft type burner.
Air box incorporated in the burner 43

44. Main Equipment – Incinerator44

45. Combustion Air Blowers A-2201-B-01 A/B
Main Equipment – Blowers
Combustion Air Blowers A-2201-B-01 A/B
Number Required
2 (1 operating + 1 standby)
Manufacturer & Model
Robuschi & ES65/2P RVP 80 ATEX3
Blower Type
Rotary Compressor
Driver Type & Manufacturer
Electric Motor & ABB
Driver Rated Power (kW) 22
Driver Speed (RPM)
2930
Drive System
Direct Coupled
Accessories:
Inlet air filter
Inlet, Discharge & Blow-off Silencers
PSV
Discharge Blow-off valve
Operating Conditions
MIN.
MAX.
RATED
Delivered Flow (Nm3/h) 79
549
604
Inlet Pressure (kg/cm2g)
ATM
Outlet Pressure (kg/cm2g)
0.6
Inlet Temperature (°C) 36
Outlet Temperature
115 45

46. Incinerator Air Blowers A-2201-B-02 A/B
Main Equipment – Blowers
Incinerator Air Blowers A-2201-B-02 A/B
Number Required
2 (1 operating + 1 standby)
Manufacturer & Model
Not available
Blower Type
Centrifugal Fan
Driver Type & Manufacturer
Electric Motor, fixed speed
Driver Rated Power (kW)
Driver Speed (RPM)
Drive System
Direct Coupled
Accessories:
Inlet air filter
Silencer
Blowoff silencer
Outlet expansion joint
Operating Conditions
NORMAL
MAX.
RATED
Delivered Flow (Nm3/h)
2429
6077
6332
Inlet Pressure (kg/cm2g)
ATM
Outlet Pressure (kg/cm2g)
0.11
Inlet Temperature (°C) 36
36 (MIN.:14) 46

47. Dilution Air Blowers A-2203 A/B
Main Equipment – Blowers
Dilution Air Blowers A-2203 A/B
Number Required
2 (1 operating + 1 standby)
Manufacturer & Model
Not Available
Blower Type
Centrifugal Fan
Driver Type
Electric Motor
Operating Conditions
DESIGN
NORMAL
Total Dry Flow (kg/h)
176000
160000
Inlet Pressure (mmH2O)
ATM
Outlet Pressure (mmH2O)
300
250
Inlet Temperature (°C) 36 47