Claus Catalysts and Tail Gas Treatment Solutions for Sulfur Recovery 02 Claus Catalysts and Tail Gas Treatment Solutions Overview Overview Claus Catalysts and Tail Gas Treatment Solutions 03
BASF Sulfur Recovery Introduction Sulfur Recovery Unit (SRU) Tail Gas Treatment Units (TGTUs) Sulfur recovery is an important process Typically, acid gases, removed from A TGTU further reduces the sulfur Overview for natural gas processing plants and natural gas, and refinery sour gases are content in the Claus tail gas to meet refineries. The raw feed streams often sent to a Claus SRU. In the Claus Unit, more stringent requirements on sulfur
contain gases, such as H2S and CO2. sulfur is recovered via thermal and emissions. Of the multiple TGTU types
H2S is a highly toxic gas and contributes catalytic stages (Figure 2). The reaction and their various configurations, two
to SO2 emissions. To comply with envi- furnace converts 60-70% of H2S to types are shown in Figure 1. Through ronmental regulations, the sulfur species elemental sulfur in the thermal stage. different processes, these TGTUs BASF Claus Catalysts and Tail Gas Our dedication to the sulfur recovery process results are converted to elemental sulfur and Multiple catalytic converters with Claus convert residual sulfur species in the tail in high-quality products, proven technologies, and water via sulfur recovery technologies Catalysts increase sulfur recovery gas to elemental sulfur and remove it to Treatment Solutions combine the strength reliable services that meet and exceed our customer’s (Figure 1). beyond 95% in the catalytic stages. achieve a higher rate of sulfur recovery. of BASF, the global leader in catalysis, with expectations and requirements. If you are looking the experience and expertise of our for a manufacturer who knows how to make the right reaction happen, trust BASF Claus Catalysts and Tail chemists and engineers. Gas Treatment Solutions. Figure 1. Block flow diagram for sulfur recovery consisting of a SRU and TGTUs.
Sulfur Recovery Unit (SRU) Tail Gas Treatment Units (TGTUs)
TGTU Recycle
Claus Tail Gas Hydrogenation Amine Tail Gas Claus SRU Reactor Treating Unit Acid Gas Feed/ Off-gas to Refinery Sour Incinerator Gases
Sulfur Sub-dew Point Reactors Over 40 years of experience Comprehensive product line Global customer service and Off-gas to technical support Incinerator
Sulfur
Figure 2. Schematic of a modified Claus SRU based on the straight-through configuration.
Catalytic Stage Thermal Stage Reheater Reheater Reheater
Air Amine Catalytic Catalytic Catalytic Acid Gas Converter Converter Converter SWS Gas
TGTU Recycle Reaction Waste Furnace Heat Boiler Liquid Liquid Liquid Tail Gas Steam Sulfur Sulfur Sulfur Liquid Sulfur
Sulfur Sulfur Sulfur Sulfur Condenser Condenser Condenser Condenser 04 Claus Catalysts and Tail Gas Treatment Solutions Portfolio Portfolio Claus Catalysts and Tail Gas Treatment Solutions 05
BASF Claus Catalysts BASF Tail Gas Treatment Solutions Portfolio Portfolio
BASF has the most extensive line of Claus Catalysts in BASF offers Tail Gas Treatment Solutions to increase the industry from one provider. In addition to sulfur recovery from Claus tail gas. The solutions non-promoted and promoted activated alumina include catalysts and technologies that are proven for catalysts, we offer titania catalyst and active and inert sulfur recovery to achieve the desired performance and bed supports. BASF Claus Catalysts provide the quality Catalyst production Comprehensive Superior catalysts to meet environmental requirements. Capable of achieving Cost-effective tech- Versatile technology needed for maximizing the performance of the SRU. since 1983 product line meet your requirements over 99.9% recovery nology to meet new for various of sulfur regulations configurations
Applications and Benefits Applications and Benefits Inlet
Support Hydrogenation of any remaining sulfur species to H2S with Maximum H2S, CS2, COS, and SO2 conversion in the catalytic a CoMo type catalyst ® converters of the Claus process under various conditions Claus Catalysts Selective removal of H2S using OASE yellow, Optimal catalyst for every condition and stream ExxonMobil FLEXSORB™, and OASE® sulfexx™ Support Low abrasion and high strength to minimize dust and fines technologies
Uniform size and shape for lower pressure drops Outlet Cost-effective solutions to meet CAPEX/OPEX requirements
Hydrogenation Reactor
Product Overview CoMo Catalyst
Hydrogenation of sulfur species CS2, COS, SO2 and Sx in Catalyst Type Product Name Characteristics feed to reactor Different shapes and sizes for a low pressure drop DD-431 High surface area with tailored pore size distribution for enhanced Claus activity Activated Alumina 3/16” (4.8 mm) Excellent Claus catalyst for common SRUs and sub-dew point reactors Long and stable performance Low temperature operation DD-831 Improved resistance to deactivation 3/16” (4.8 mm) High COS hydrolysis for a longer time period than pure alumina catalysts Promoted Alumina S-100 SR High surface area to scavenge free oxygen and prevent sulfation 3/16” (4.8 mm) Extreme advantage for Claus plants using direct reheat Amine Tail Gas Treating Unit Ti-1100e High titanium dioxide content for conversion reactions 1/8” (3.2 mm) Improved conversion of COS and CS at lower operating temperatures which reduces OASE® yellow Technology FLEXSORB™ Technology OASE® sulfexx™ Technology Titania 2 the load on the TGTU Selective removal of H2S Highly selective removal of H2S Ultra-selective removal of H2S as low Resistant to deactivation Easy to swap from MDEA based Very high CO2 rejection as 10 ppmv Active Bed Support Extremely effective in preventing catalyst deactivation and catalyst bed plugging solvent in TGTUs Lower recirculation rates and lower Eliminate the need for chiller unit (ABS) Additional catalytic activity for Claus reactions compared to an inert bed support Lower solvent circulation rates for energy consumption Energy savings of 15% versus Bed Supports lower energy consumption Lower corrosion FLEXSORB™ Technology Ceramic Bed High resistance to mechanical and thermal shock Support (C-167) Chemically inert, robust bed support Increased acid gas capacity Uses conventional equipment and No equipment changes Noncorrosive and nontoxic solvents simple to operate Low carbon footprint *Most catalysts and bed supports are available in other sizes. Suitable for high ambient temperatures Lower the SRU CAPEX/OPEX
OASE® is a registered trademark of BASF. FLEXSORB™ is a trademark of ExxonMobil. Sulfexx™ is a trademark of BASF. 06 Claus Catalysts and Tail Gas Treatment Solutions Services Case Studies Claus Catalysts and TailRubrik Gas Treatment BASF StyroStar Solutions® 07
BASF Technical Support BASF Technical Support Service Case Studies
BASF’s state-of-the-art Claus Catalysts and Tail Our promise: With worldwide experience Case Study 1: Case Study 2: Gas Treatment Solutions are backed up by the best technical support in the industry. BASF understands and expertise, BASF’s technical support Optimizing Catalyst Configuration Optimizing Amine Tailgas Treating that technical support and service are paramount for team delivers high-quality, reliable support Situation: In a gas plant, the gas contained high COS/CS Situation: In a Tailgas Unit, the high H S slip of the amine achieving customer success. We are dedicated to 2 2 to help our customers optimize performance concentrations that resulted in a low sulfur recovery of absorber of > 100 vppm lead to high SO2 emissions at the offering solutions that work together with our out 99.29%. refinery’s stack. standing customer service and technical support. and maximize profitability. Solution: BASF technical experts analyzed the operation and Solution: BASF’s OASE Gas Treatment team came up with provided an optimized design with the first converter partially solution to swap the existing MDEA solvent to OASE® yellow loaded with Ti1100e for a sulfur recovery of 99.61%. while the unit was in operation. A subsequent adjustment of the plant parameters in close cooperation with the refinery’s
Impact: The optimized design: operations has lead to substantial drop of the H2S concentra-
Some of the most common services we provide include: Reduced emissions by 40% tion (< 50 vppm) and the SO2 emissions, energy savings and Required no capital investment lower amine make up. Increased unit lifetime Impact: The optimized design:
Reduced SO2 emissions by over 30% +0.3% = 6MT less SO2 Cooling water and steam savings by over 15% General guidelines for catalyst Computer simulation of new and loading and unloading and startup Increase in S recovery emissions per day existing Claus reactors and shutdown
Recommendations of product and Technical seminars on catalyst operational parameters to optimize usage and optimization plant performance and save costs
Plant troubleshooting via phone, Sample analysis of catalyst email, or plant visit, if necessary Americas Europe, Middle East, Africa BASF Corporation BASF De Meern BV Catalysts 25 Middlesex/Essex Turnpike The Netherlands Iselin, New Jersey, 08830, USA Tel: +31-30-666 9444 Tel: +1-732-205-5000 Email: [email protected] Fax: +1-732-205-7725 Email: [email protected]
Asia Pacific Middle East & Egypt BASF (China) Company Limited BASF FZE 300 Jiang Xin Sha Road JAFZA One, Floor 15, Tower B Pudong, Shanghai 200137 Sheikh Zayed Road P.R. China Dubai, United Arab Emirates Tel: +86-21-2039 2549 Tel: +971 4 807 2222 Fax: +86-21-2039 4800-2549 Fax: +971 4 8072 2150 Email: [email protected] Email: [email protected]
About Us
BASF’s Catalysts division is the world’s leading supplier of environmental and process catalysts. The group offers exceptional expertise in the development of technologies that protect the air we breathe, produce the fuels that power our world and ensure efficient production of a wide variety of chemicals, plastics and other products, including advanced battery materials. By leveraging our industry-leading R&D platforms, passion for innovation and deep knowledge of precious and base metals, BASF’s Catalysts division develops unique, proprietary solutions that drive customer success. BASF – We create chemistry
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