HONEYWELL UOP SULFUR RECOVERY Reducing Emissions with High Reliability MEET ENVIRONMENTAL REGULATIONS WITH EASE From a global leader in refining and gas processing technology, UOP’s sulfur recovery systems meet the industry’s most stringent environmental regulations with high reliability and operational flexibility, leading to increased profitability.
Sulfur is removed as a contaminant RELIABLE RECOVERY STAY ON-STREAM from crude oil and sour gas streams to SOLUTIONS Conventional sulfur recovery units reduce harmful emissions and protect With half a century of Ortloff™ sulfur are often plagued with reliability and downstream equipment. It can also be recovery engineering, design and startup operability issues that cause costly recovered as a marketable by product. experience and more than 100 installations unplanned shutdowns. Based on As sulfur dioxide emissions regulations worldwide, UOP has developed a continued innovation and hands-on become more stringent globally, refiners comprehensive portfolio of sulfur recovery owner/operator experience, UOP has and gas processors need proven sulfur units (SRUs) with high recovery efficiencies developed unique sulfur recovery unit recovery solutions to reliably comply and excellent on-stream times. UOP designs that are more robust, easier with the strictest requirements. technology stems from the professional to operate and less prone to corrosion adaptation of the best industry processes and failure. This results in service combined with proprietary technology and lives of more than 30 years and KEY ADVANTAGES expertise. UOP experts work with refiners significantly minimizes both planned and gas processors to select the most and unplanned shutdowns. • Excellent plant reliability with cost-effective sulfur recovery solution to on-stream times of 99-plus percent reliably meet their processing goals. • Cost-effective, streamlined modular solutions available COMMON SRU UOP SRU DESIGN BENEFIT PROBLEM SOLUTION • 30-plus year service lives for Allows for startup without warming robust waste heat boiler designs Catalyst deactivation and Cold catalyst bed catalyst reactor beds, reducing refractory damage during startup capability the risk of fire or sooting, extend- • Minimal operator and maintenance startup design ing catalyst life and preventing attention required refractory failures Eliminates the most frequent • Longer time between turnarounds Lost revenue from boiler Robust waste heat cause of extended SRU shutdowns with fewer catalyst change-outs failures boiler design and sulfur shedding with industry- leading performance Dependable valve designs Unreliable switching Superior sulfur eliminate solids formation, valve valves vapor valve design sticking and leakage which can cause high emissions Avoids extended shutdowns from Tailgas Cleanup Unit Improved TGCU water accumulation in the blower (TGCU) startup blower blower location casing and reduces emissions failure during startup and shutdown Generates saturated or superheated Wasting the heat value Tailgas Thermal high pressure steam with less of the fuel gas consumed Oxidizer (TTO) waste fuel gas consumption than an in incineration heat recovery auxiliary boiler Saving between $2 million to $20 million per turnaround for a 400 kbpd refinery UOP SRU SOLUTIONS tailgas cleanup processes to achieve UOP Selectox™ Processes recovery efficiencies up to 99.95 UOP Ortloff Modified Claus Process The Selectox and Recycle Selectox™ percent. UOP combines proprietary plant The Modified Claus Process is the Processes recover sulfur from dilute acid design knowledge and equipment with workhorse for sulfur recovery and is used gas streams by using a specialty catalyst licensed industry processes for improved worldwide in more sulfur plants than any and process flow scheme. operational efficiencies and fewer other process. The Modified Claus Process maintenance problems. These cost-effective technologies can can achieve up to 97 percent sulfur recover sulfur from gas streams ranging These processes include: recovery efficiency and produces very from 0.5 to 45 percent hydrogen sulfide. high-quality sulfur, free of contaminants. • BP Amoco’s Cold Bed Adsorption (CBA) By following the Selectox process with In the typical Modified Claus Process, Process which modifies the standard Callidus Tailgas Scrubbing plants can the acid gas feed is partially oxidized to catalytic Claus reaction by operating achieve very low SO2 emissions. generate sulfur dioxide, which then reacts below the sulfur dew point temperature Modular Solutions with the remaining hydrogen sulfide over for 99-plus percent sulfur recovery UOP’s modular sulfur recovery solutions a catalyst to produce sulfur. Most Claus • Shell Claus Off-gas Treating (SCOT), the are based on a streamlined design and sulfur plants contain two or three catalytic most widely recognized amine-based fabrication process. With extensive stages and can be followed by a tailgas tailgas cleanup process cleanup process and/or a UOP Callidus® TTO. modular equipment experience, UOP • UOP Callidus Tailgas Scrubbing which solutions offer proven high reliability, UOP Ortloff Tailgas Cleanup Processes all but eliminates SOx emissions with a lower costs and faster delivery. The For higher sulfur recovery efficiencies, cost-effective, highly reliable system pre-engineered, factory-built approach UOP Ortloff sulfur recovery processes allows for predictable expenses and can be combined with a wide range of schedules, so refiners and gas processors can stay on budget and on schedule.
EXAMPLE UOP SRU PORTFOLIO PERFORMANCE
TECHNOLOGY RECOVERY LEVEL SOX EMISSIONS RELATIVE CAPEX 3-Stage Claus + TTO 95-97% 4,000 – 10,000+ ppmv 1.0 2+2-Stage Claus/CBA + TTO 98-99.3% 500 – 1,500 ppmv 1.2 – 1.4 3-Stage Claus + TGCU + TTO 99-99.95% 50 – 500 ppmv 1.8 – 2.0 2+2-Stage Claus/CBA + TTO + TSU 99.9+% 25 – 500 ppmv 1.4 – 1.6 ONE-STOP SHOP DEDICATED AFTERMARKET CONNECTED PLANT As a leading process licensor, UOP offers SUPPORT Honeywell UOP’s connected solutions a full scope of integrated solutions for the From start to finish, Honeywell UOP global and services ensure that refining and gas refining and gas processing industry. With sales, engineering, service and support processing plants run at the peak of their UOP as a single-source provider, operators staff is there to understand customer goals capability. The Honeywell Connected can benefit from: and ensure needs are met with proven Plant is a suite of applications that delivers products and technology. Honeywell UOP’s higher levels of safety, reliability, efficiency • Improved process unit integration and dedicated customer support organization and profitability. These proven industry an optimized flow scheme addresses aftermarket needs, including solutions are based on Honeywell’s • Efficient project execution and reduced revamps, debottlenecking and capacity decades of domain knowledge and schedule risk increases, process performance controls experience. A connected plant • Guaranteed performance improvement, hardware upgrades, turns data into actionable insight to operations training and field support optimize operations, predict plant failures • Simpler negotiations supervision. Extensive service offerings, and eliminate unplanned downtime. coupled with unmatched technical knowledge and experience, can help refiners and gas processors focus on profitability.
MORE THAN 100 YEARS OF GLOBAL EXPERIENCE, AND COUNTING UOP provides process technology, materials, and equipment for the gas processing, refining and petrochemical industries. With 19 engineering and R&D centers and 14 manufacturing facilities in 19 countries, UOP is close to its customers wherever they are. Since 1914, UOP has developed more than 70 licensed processes and 5,000 active patents and applications for the industries served.
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The information in this Honeywell Company document should UOP LLC, A Honeywell Company not be construed as a representation for which UOP assumes 25 East Algonquin Road legal responsibility, or an authorization or recommendation to practice a patented invention without a license. Des Plaines, IL 60017-5017, U.S.A. Tel: +1-847-391-2000 UOP8442 | 10/19 Printed in U.S.A. www.uop.com © 2019 UOP LLC. A Honeywell Company All rights reserved.