Fives Pillard combustion solutions for Sulfur Recovery Units · Fives Pillard 4 CLAUS burners Main...
Transcript of Fives Pillard combustion solutions for Sulfur Recovery Units · Fives Pillard 4 CLAUS burners Main...
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Tail gas incinerator
Fuel gas
Air
Air
Boiler
H2S ����S2 # 65% H2S ����S2 : # 97.5 %
Main burner
Auxiliary burner
Incinerator burner
Furnace
Sulfur condensors
Typical flow sheet of Sulphur Recovery Unit
The Fives Pillard expertise
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CLAUS burners
Main burner is the HEART of the Claus process:• Generates SO2 required for the Claus reaction• Accounts for ~60% to 65% of H2S conversion into S2
General rules of design• Intense & compact flame to maximize residence time (S2 formation)• Flame stability• Shall allow sufficient turn-down ratio• Allow efficient co-firing with natural gas (no soot formation)• Sturdy and proven design• Safe start-up and reliable flame detection
Claus burner design is the primary method to achieve good mixing of oxidant and feeds!
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Fives Pillard burners for CLAUS reaction furnace
Fives Pillard burners for Acid Gas produce high intensity compact flames with:
• High Sulphur quality • Reduced pollutants levels (BTX)• Increased S2 conversion level• Reduced soot formation with Co-firing
• Rich up to very lean acid gas• Co-firing application (proprietary Staged Co-Firing technique)
Fives Pillard burners for Acid Gas deliver excellent performance with:
• Excellent mixing• High flame stability• High turn-down ratio • Adjustable flame to accommodate changing acid gas composition
Leading to improved plant operation reliability:
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Fives Pillard burners for CLAUS reaction furnace
Tangential mounting type
Tangential Fives Pillard Burner
Claus reactionfurnace
Axial mounting type
Axial Fives Pillard Burner
Claus reaction furnace
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Fives Pillard burners for CLAUS reaction furnace
Axial mounting type Tangential mounting type
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Simulated Sulphur (S2) profile (% mass): axial versus tangential firing
Simulated efficiency : around 60%
Axial mounting type
Fives Pillard burners for CLAUS reaction furnace
Simulated efficiency : around 64%
Tangential mounting type
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Claus burner (axial mounting type) with adjustment system
Acid gasCombustionair inlet
Adjustment system
Steam
Fuel gas piping
• measures the temperature variation between two points in a flame
Flame Scanner for Acid Gas flames
Main advantages:
• Detection free from any fixed hot point (wall, bricks, etc…)
• High reliability
• "All in One" concept: detector and amplifier integrated in the head
• Flame level indicator available at detector head and control room
South Pars 2, 3 ,4, 5, 9 and 10 are operating successfully
The Fives Pillard DARKSCAN :
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Flame ignition / start-up
� Packlight Ignitor Ø 48
• Electric - Gas 20kW to150kW• All-In-One design • Includes flame detection & display • Suitable for continuous operation (pilot)
� Powerpack Ignitor Ø 25
• Electric 9Joules/spark• Automated retraction design• Not suitable for continuous operation (pilot)
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Why using Co-Firing technique?
� For lean acid gas applications
� For "sensitivity" cases
• Temporary lower H2S content in acid gas or reduced acid gas flow
� Alternative to larger investment cost
• Aromatic upstream or downstream treatment for BTX
• Acid gas enrichment in lean acid gas application
Alternative to higher operating cost
• Oxygen enrichment to increase flame temperature
• Higher amine treatment operating cost (higher flow treated)
� Easy to implement on existing SRU
� Reduces BTX > 95% (favorable for catalyst lifetime)
� Reduces benzene emissions at stack
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Co-Firing with a conventional burner
The activation energies• H2S + 3/2 O2 � H2O + SO2 Ea = 62 kJ / mol
• CH4 + 2O2 � CO2 + 2H2O Ea = 250 kJ / mol
H2S burns first all the available oxygen
fuel gas combustion is carried out under sub-stoichiometric conditions causing :
• Unburnt HC ,
• Soot emissions
• COS/CS2 increase
The burner makes a single and compact flame
The additional fuel gas supplied in burner center with acid gas
Conventional burner
Confirmed at South Pars (Iran) – Phase 1 Hamworthy : resulting in poor sulphur quality
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Fives Pillard Staged Co-Firing technique
O2
O2
nat. gas
nat. gas
acid gas
First stage: natural gas combustion in over-stoechiometry
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Third stage : Claus reaction (H2S + SO2)
Fives Pillard Staged Co-Firing technique
H2S
SO2
SO2
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Fives Pillard Staged Co-Firing on TOTAL Lacq - US 11
Acid gas
11 H 101
Reaction
Furnace
Main
Burner
Waste boiler
+
Condensor
Auxiliary
Furnace
Catalyst
(2 stages)
SULFREEN
Air
11
F 101
Tail gasfrom US8
incinerator
Fuel gas
• Acid Gas flow 33 000 kg/h
• H2S 60 %
• Combustion air temperature 230 °c
• Acid gas temperatrue 210 °c
• Natural gas flow 200 kg/h
• Additional air 3 800 kg/h
• Additional mass flow + 6%
Initial value of BTX (Benzene, Toluene, Xylene ) : 500 to 1500 ppm
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BTX reduction vs Temperature
0
20
40
60
80
100
800 900 1000 1100 1200 1300
Reaction Furnace Temperature
% B
TX
red
uctio
nBTX reduction measured at TOTAL Lacq Plant
Co-firing+ 150°C
Preheating air and acid gas
+ 100°C
Total : + 250°C
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425 439
4313
0
100
200
300
400
500
Without Cofiring With Cofiring
BT
X
(ppm
v)
95,2 95,2
0
20
40
60
80
100
Without Cofiring With Cofiring
SU
11
EF
FIC
IEN
CY
(%
)
TOTAL Lacq plant – Site results(average value records based on 2 x one month periods)
90% 97%
97% BTX reduction usingCo-firing technique
Sulphur recovery efficiencyremains unchanged
BTX measured Sulphur recovery efficiency measured at US11 outlet
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Conclusions about Co-Firing technique
� Requires a good burner to maintain Claus unit efficiency & sulphur quality avoiding soot formation.
� Allow to process efficiently very lean acid gas with conventional Claus unit and associated Tail Gas Treatment.
� Allow for efficient destruction of BTX and improves catalyst lifetime
� Allow for an increase in flame temperature enabling potential NH3 destruction
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In-Line / Re-Heating burners
In Claus process catalytic converters are used after the Claus furnace to achieve the required sulphur conversion efficiency
Direct-fire burners (or heat exchangers) are used to reheat the process stream before entering the catalytic stage
Direct-fire In-Line burners must:
• Ensure compact flame to fit small & short combustion chamber size
• Fire either natural gas without soot formation and/or acid gas
• Provide sufficient turn-down
• Ensure flame stability
• Avoid oxygen carry-over (oxygen break-through) to the catalytic section
• Allow temperature uniformity of the hot gases
• Be of Safe & Reliable design
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Reducing Gas Generators (RGG) burners
Applied in several processes upstream TGT units to increase recovery efficiency >99% (amine based process such as SCOT or BSR):
• To reheat process stream from 130°C to 280°C and to produce H2 & CO for the downstream TGT reaction
• Operate on fuel gas only, around 80% of stoichiometry • Atomizing steam is added (ratio approx. 2:1) to reduce soot formation• Similar design as In-Line / Re-Heating burner
RGG burners must:• Ensure compact flame to fit small & short combustion chamber size• Fire fuel gas without soot formation• Minimize oxygen carry-over (oxygen break-through)• Provide sufficient turn-down• Ensure flame stability• Allow temperature uniformity of the hot gases• Be of Safe & Reliable design
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In-Line / Re-Heating / RGG burner
Combustion air
Fuel gas
Steam
Ignitor
Flame scanners (UV)
Sight port
Air Swirler
Gas Lances
SteamLance
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In-Line / Re-Heating / RGG burner
Connection for flame scanners
Fuel gas
Steam
Connection for flame ignitor
Sight port
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In-Line / Re-Heating / Reducing Gas Generator burners
The advantages of Fives Pillard In-Line / Re-Heating / Reducing Gas Generators burners:
• Provide high intensity compact flames to fit narrow & shorter length combustion chambers with high thermal load
• Can operate in sub-stochiometric condition with stable flame
• Burn fuel gas at low combustion air ratio without soot formation
• Ensure reliable flame detection
• Ensure automated and safe start-up
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Thermal incinerator
Purpose is to thermally oxidize the residual polutants contained in the Tail Gas
Thermal incinerator requires:
• Sufficient temperature
• Residual Oxygen
• Residence time
• Efficient mixing
Thermal incinerator burners must:• Have a properly sized flame to fit combustion chamber• Ensure sufficient swirl to promote quick mixing of the hot gases with tail gas• Provide sufficient turn-down• Ensure flame stability• Allow temperature uniformity of the hot gases• Be of Safe & Reliable design
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Tail Gas Incinerator & associated burner
Tail Gas Incinerator (South Pars) Tail Gas Incinerator burner (South Pars)
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Incinerator burner ("Front Tail Gas supply")
Incineration air
Combustion air
Tail Gas
Fuel gas
Ignitor
Flame scanner(UV)
Tail Gas exit
Gas Lances
Air Swirler
Air lances
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Incinerator burner ("Side Tail Gas Supply")
Combustion airIncineration air
Tail Gas
Fuel gas
Ignitor
Flame scanner
(UV)
Combustion air
Tail Gas
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Incinerator burners
The advantages of Fives Pillard Incinerator burners:
• Provide high intensity compact flames to fit narrow & shorter length combustion chambers with high thermal load
• Can operate in sub-stochiometric condition with stable flame
• Burn fuel gas at low combustion air ratio without soot formation
• Ensure reliable flame detection
• Ensure automated and safe start-up
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� Scope of Work: • 4 Reaction Furnace burners (tangential type)• 4 In-Line / Re-heating burners• 2 Tail Gas Incinerator burners• Tail Gas Incinerator engineering
Licensor : TOTAL
South Pars 2 & 3 project NIOC / TOTAL (2000)
� Operating conditions of the CLAUS reaction furnace
• Acid gas 14 000 kg/h 217 °C• Natural gas (co-firing) 112 kg/h 20 °C turn-down ratio 1 to 8• Combustion air 9 140 kg/h 223 °C• Furnace 950 °C 205 mbar• Acid gas composition : 24 %H2S mini measured 20.5%
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� Reaction furnace burner operating conditions
• Acid gas 23 180 kg/h 220 °C• Natural gas (co-firing) 240 kg/h 20 °C turn-down ratio 1 to 8 • Combustion air 18 920 kg/h 223 °C• Furnace 950 °C• Acid gas composition : 36 %H2S
� Scope of Work :• 4 Reaction Furnace burners (tangential type)• 2 Tail Gas Incinerator burners• Tail Gas Incinerator engineering
South Pars 4 & 5 project NIOC / TOTAL (2002)
Licensor : TOTAL
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� Reaction furnace burner operating conditions
• Acid gas 23 400 kg/h 220 °C• Natural gas (co-firing) 240 kg/h 20 °C turn down ratio 1 to 12 !!• Combustion air 18 645 kg/h 220 °C• Furnace 950 °C• Acid gas composition : 36 %H2S (mini measured 20.5%)
� Scope of Work : • 4 Reaction furnace burners (tangential type) • Tail gas incinerator burner
South Pars 9 & 10 NIOC (2005)
Licensor : TOTAL
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• Acid gas 56 200 kg/h 250 °C • Natural gas (*) 1 200 kg/h 20 °C start-up & stand-by operation only• Combustion air 44 600 kg/h 270 °C• Furnace 950 °C• Acid gas composition : 26 %H2S note: 50% acid gas by-pass
� Scope of Work• Replacement of Reaction Furnace burner (tangential type)
ADGAS Das Island (2008)
Licensor : WORLEY PARSONS
� Reaction furnace burner operating conditions
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� NIOC South Pars 15 & 16 (2011)
• 4 Reaction Furnace burners (Axial type)64.5% H2S acid gas, without Co-Firing
• 4 Inline / reheating burners
Latest references
Licensor : LURGI
� NIOC South Pars 12 (2011)
• 4 Reaction Furnace burners (Axial type) 46.25% H2S acid gas, without Co-Firing
Licensor : WORLEY PARSONS
� NIOC South Pars 17 & 18 (2011)
• 4 Reaction Furnace burners (Axial type) 55.3% H2S acid gas, without Co-Firing
• 2 Inline / reheating burners
Licensor : LURGI
� NIOC South Pars 22, 23 & 24 (2011)
• 4 Reaction Furnace burners (Axial type) 64.5% H2S, without Co-Firing
• 2 Inline / reheating burners
Licensor : LURGI
Fives Pillard Customers focus
EPC : Technip / Worley Parsons / Fluor / GS Eng / L URGI / Iranians…
Direct Clients: Welcron Kangwon / Prosernat / Bremb ana..
Prospects (potential) : Hanyang / LGI / FBM Hudson…
Conclusion:
Closed market with good margins, few opportunities to enter, few advantages to put on the table compared with market leaders.
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