In addition to conducting performance tests to optimize the sulphur recovery process, Sulphur Experts also conducts detailed capacity and de-bottlenecking studies for all types of sulphur plants and their tail gas units.

An on-site test will yield all of the process specific data required to determine the current condition of the sulphur plant. From there, full heat and material balances are completed, and this data in conjunction with the plant's mechanical drawings are then used to evaluate each major operating component in the facility. Finally, a comparison between the test results and the original design data is made. From this it is possible to identify the maximum feed gas flow rate which can be successfully processed, and identify those units which limit the operation for any given feed gas flow rate.

Generally, a capacity and de-bottlenecking study provides the following information:

• Feed Gas Flow Rates     (more ...)
  • A comparison of maximum tested flow rate, the design flow rate, and the maximum potential flow rates based on the individual unit limitations (described below)
• Combustion Air Blower      (more ...)
  • Comparison of measured and design air capacity (flow and discharge pressure).
• Plant Pressure Drop     (more ...)
  • Measured plant pressure drop for the tested plant feed gas rate
  • Maximum plant operating pressure based on the sulphur dip legs
  • Maximum plant operating pressure based on the combustion air blower capability.
• Reaction Furnace     (more ...)
  • Furnace residence time and comparison with good engineering design
  • Furnace flame temperature.
• Reheaters     (more ...)
  • Heat duty
• Catalytic Converters     (more ...)
  • Residence time or space velocity and comparison with good engineering design.
• Condensers     (more ...)
  • Heat Duty
  • Process gas mass velocity for entrainment evaluation.
• Incinerator / Stack     (more ...)
  • Process gas flow rate and stack gas velocity
  • Incinerator heat duty
  • Fuel gas and combustion air demand
  • Incinerator residence time.
     

Conceptual Engineering Studies

A wide variety of detailed Engineering studies can be performed for most aspects of the sulphur plant, including critiquing and reviewing conceptual designs, and generating design data and information based on current or future plant operations. Examples of some conceptual Engineering projects include:

• Determining the current SRU recovery efficiency (based on recent plant test data)
• Establish the reaction furnace performance for the expected acid gas composition (COS and CS₂ formation rates)
• Completing a range of Sulsim® cases to determine the effect of catalyst activity on overall recovery performance. The cases will reflect the expected performance with new catalyst (“start of run”) and deactivated catalyst (typical for “end of run”) conditions. The effects on the Claus reaction and the COS and CS₂ hydrolysis rates will be evaluated.
• Establish the operating conditions required for optimum recovery efficiency (converter and condenser temperatures, etc.)
• Identify and determine the effect of various plant problems on recovery efficiency capability (air flow control, leaking switching valves, poor bed regeneration etc.)
• Evaluate the impact of other possible plant emission sources (pit vent, H₂S in incinerator fuel gas etc.)