Sulphur - Magazine July-Aug - 2021 - Compressed

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Number 395 July | August 2021
SULPHUR
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Crude to chemicals
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Sulphur forming project listing
Claus ammonia destruction
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July | August 2021
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40 NOx reduction in acid plants

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■ Contents ISSUE 395 SULPHUR
JULY-AUGUST 2021
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----A---WORLD---LeADeR---
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-------in---suLphuR�
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----------pROcessing----------
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�AnD---hAnDLing-----
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End-to-end systems from receipt of molten sulphur to loading
31 of solid material – single source supply by IPCO.
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• Premium Rotoform pastillation.
33 • Duplex steel belts specifically alloyed to resist corrosion.
• High capacity drum granulation.
34 • Downstream storage – silo and open/closed stockpiles.
• Custom-built reclaimers for any location.
35 • Truck, rail and ship loading and bagging systems.
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• Large scale block pouring.
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ipco.com/sulphur
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IPCO_Sulphur_ad_210x297.indd 1 02/12/2020 16:10
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JULY-AUGUST 2021
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SULPHUR
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6 www.sulphurmagazine.com
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NUMBER 395 JULY | AUGUST 2021
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CONTENTS
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16 Crude to chemicals
11 With demand for conventional fuels projected to peak and fall over the next
12 Cover: peterschreiber.media/
decade, some refiners are looking to petrochemical production as a way of
iStockphoto.com diversifying their product slate.
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19 Sulphur forming project listing
14 Sulphur’s annual listing of new sulphur forming projects around the world.
20 Sulphuric acid alkylation
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The continuing spread of alkylation technology and the preference for the
16 sulphuric acid route are leading to increased demand for acid in refineries.
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22 Sulphuric acid project listing
Sulphur’s annual survey of recent and planned construction projects.
18 24 Reducing NOx emissions in metallurgical oleum tower production
19 A. Goudarzi of CECO Industrial Solutions discusses the science behind NOx
content and how it impacts sulphuric acid producers. In a recent project in
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Korea, TWIN-PAK candle filter technology was successfully used to reduce NOx
emissions in metallurgical oleum tower production, enabling the producer to
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operate the plant without penalties or shutdowns.
22 28 New showcase drum granulator commissioned
Acid alkylation
23 Sulphur processing and handling equipment manufacturer IPCO has completed the
Steady growth in refinery acid
demand. commissioning of a groundbreaking new drum granulator in Italy that will serve as
24 a global showcase for this patented system. C. Metheral of IPCO, describes the
innovative approach and key features of the SG20 sulphur granulation system.
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32 The three “Ts” reconsidered
26 Are the three “T”s (temperature, turbulence, time) of Claus unit ammonia
27 destruction still meaningful with improved understanding of the thermal reactor?
CFD models appear to be adequate at higher temperatures but not at lower
28 temperatures. A. Keller, on behalf of the Amine Best Practices Group, reviews
how meaningful the rules of thumb for Claus unit ammonia destruction really are.
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38 Upgrading for greater efficiency
30 P. Foith of CS Combustion Solutions reports on a Claus thermal stage retrofit and
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31 how the novel combination of a CS low pressure swirl burner, additional mixing using
a VectorWall™ and a new waste heat boiler design achieved the desired results.
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40 Temperature measurement in sulphur recovery
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Drum granulator Recently, market interest in unpurged thermocouples has increased with
Commercial installation for the introduction of new unpurged thermocouple designs utilising alternative
34 innovative forming system. thermowell materials such as monocrystalline sapphire. Daily Thermetrics and
35 Delta Controls report on their latest developments.
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REGULARS
Read this issue online at: 4 Editorial Back on the rollercoaster.
37 www.sulphurmagazine.com
6 Price Trends
38
8 Market Outlook
Published by:
39 9 Sulphur Industry News
40 11 Sulphuric Acid News
14 People/Calendar
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Editorial
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7 Back on the
rollercoaster
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C
ommodity markets are often volatile, and a plethora of technical issues. Now, though, there is
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sulphur and sulphuric acid can be more so something of a perfect storm created by Indonesia’s
13 than most, with much of their supply com- ban on nickel ore export, a shortage of nickel sul-
ing from involuntary production, and sulphur supply phide deposits encouraging a focus on oxide-based
14 in particular often dependent on the timing of large laterite ores, and a rapidly growing need for purer,
scale oil and gas projects. Even so, this year’s price Class 1 nickel that laterites can find hard to sup-
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rises, in some cases tripling in just over a year, have ply, which is driving a huge new concentration of
16 been especially eye-catching. Chinese-funded HPAL projects in Indonesia. Lygend
The continuing delay to Qatar’s Barzan LNG pro- is only the first, and acid demand for nickel produc-
17 ject and a slower than expected start-up for Kuwait’s tion could again rise by several million t/a over the
new refineries have helped keep supply tight at the next decade. Indeed, Indonesia’s nickel production,
18 same time that phosphate consumption seems to which has risen from 24,000 t/a to 636,000 t/a
“
be strong, and the threat of Chinese export restric- in just five years, turning it into the world’s second
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tions is keeping phosphate markets nervous. largest nickel producer (after China), is projected
20 Chinese sulphur imports have been higher than to become the world’s largest nickel producer this
expected, keeping an already tight market tighter year, and likely to become dominant in international
21 This year’s still. On the acid side, high sulphur prices discour- nickel markets. With smelter acid in fairly short
22 price rises… age sulphur burning acid production, and strikes supply, most of the acid requirement for Indonesia
and shutdowns in Chile and Canada have helped is likely to come from sulphur burning acid plants.
23
have been balance new Chinese smelter acid production. And This is all for the longer term, however. In the
especially eye- covid continues to impact upon demand for refined meantime, the global vaccination programme
24 fuels and hence refinery run rates, reducing sulphur offers the hope that fuels demand will continue
catching.” availability from that segment of the market. to recover, and with it sulphur supply. There are
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And then there is the start-up of the PT Hal- strong signs that this is already happening, and
26 mahera Persada Lygend high pressure acid leach it should eventually feed into sulphur availability
(HPAL) plant in Indonesia, which will add up to and hence prices – especially if one of the Middle
27 300,000 t/a of sulphur demand for nickel pro- East mega-projects also finally starts ramping up.
duction at capacity – whenever that is reached. For the time being we seem to be at the top of the
28
Although this is no bigger than some of the new rollercoaster, and as we all know, there’s only one
29 phosphate projects that are starting up, it is a sign way to go from there. n
of one of the major changes that may be happen-
30 ing in sulphur and sulphuric acid markets. It is only
the first of several new HPAL plants that are under
31 construction in Indonesia and Australia to feed new
nickel sulphate demand for battery production, pre-
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dominantly in China. The China nickel story used
33 to be based around stainless steel demand, and
that encouraged the first wave of HPAL plants in the
34 1990s and 2000s, part of a wave of acid leaching
that swept copper and uranium as well as nickel
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markets, and added 20 million t/a and more to
36 acid demand. However, on the nickel side they were
eventually undercut by nickel pig iron (NPI) produc-
37 tion using cheap Indonesian ore, as well as suffering Richard Hands, Editor
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42 4 www.sulphurmagazine.com Sulphur 395 | July - August 2021
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JULY-AUGUST 2021
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We are everything
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worley.com/comprimo worley.com/chemetics
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July August 2021.indd 1 3/3/2021 12:33:21 PM
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Price Trends
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as additional nickel HPAL projects come
6 MARKET INSIGHT
online at the Morowali Industrial Park on
7 Meena Chauhan, Head of Sulphur and Sulphuric Acid Research, the island of Sulawesi. This is being driven
Argus Media, assesses price trends and the market outlook for sulphur. by demand for battery metals for the elec-
8 tric vehicle (EV) sector.
Brazilian spot prices firmed through
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SULPHUR US import duties on OCP phosphate prod- June with the benchmark assessed at
10 ucts deterred any sales to the US since $225-235/t c.fr at the end of the month.
The upturn in demand for fuel oil and refined April, while alternative markets have been This rise came as freight rates from major
11 products through the second quarter has found with global fertilizer demand remain- f.o.b. markets firmed to all-time highs and
led to an increase in oil production, with this ing strong in recent months. offtakers looked to secure cargoes, placing
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trend expected to continue through the sec- In Russia, fertilizer-based sulphur con- upward pressure on prices. A period of sta-
13 ond half of the year. OPEC+ was planning to sumption will drive the region’s demand bility is expected in the short term, but the
continue to reintroduce 2.1 million bbl/d of growth in the forecast with expansions at bullish freight market remains a risk to this.
14 supply back into the market between May existing phosphoric acid lines ramping up. Sulphur consumption in the fertilizer sec-
and July. The impact of the vaccine rollout in Phosagro has completed construction at tor is expected to remain healthy through
15
some countries is evident with fuel demand its Volkhov expansion. An extra 395,000 the rest of the year although Yara’s Serra
16 rising as the weeks go on. Operating rates t/a of P2O5 capacity will be available by the do Salitre SSP facility is now expected to
at refineries in the US have continued to end of the year, increasing sulphur demand start up during the first quarter of 2022.
17 improve and through May and June Euro- by over 300,000 t/a. Phosagro has also Demand from the expansion project will add
pean refiners restarted idled capacity, also completed construction at its expansion at 300,000 t/a sulphur demand at capacity.
18 increasing throughput. But in sulphur terms, Balakovo, increasing sulphur consumption. In the US, on the lithium front, there are
we have yet to see a major easing in the Commissioning will commence in 2022. three main projects in development that
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tight supply situation. Availability in some The rise in domestic sulphur demand is could impact the medium to long term sul-
20 regions remains squeezed. The Middle East expected to put downward pressure on phur market balance significantly. Lithium
appears to be the first region to be filtering sulphur exports from the country. In other Americas’ Thacker Pass project sits as the
21 additional cargoes into the market, resulting demand news, Udokan Copper continues most advanced and is expected to start up
in softer prices through June and the view to progress with construction at its mine in from 2024. The project includes two sulphur
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that the sentiment that a price correction is the far east of Russia. Ore grinding facili- burners. Cypress Developments also plans
23 under way. ties are complete and work continues on a sulphur burner at its Clayton Valley project.
The main focus through July will be the concentrator and leaching site. Phase A feasibility study is planned to be started in
24 third quarter contract negotiations. In North 1 start-up is expected in the second half 2021 as well as a pilot plant. According to
Africa, Moroccan end user OCP was in dis- of 2022. The company is understood to be initial project plans, solid sulphur from west
25
cussions with major suppliers through June. considering options for the sulphuric acid coast refineries would be trucked to the site.
26 The curtailment of availability of supply from requirement. This may be met by captive Ioneer’s Rhyolite Ridge project also includes
Russian producer Gazprom is likely to limit acid capacity through a sulphur burner or plans for a sulphur burner.
27 the downside potential in pricing. While OCP procured directly on the merchant market. As Covid-19 restrictions continue to
reduced DAP production in the first quar- Over in Indonesia, Lygend’s Halmahera ease across the US, refinery run rates have
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ter of this year, sulphur demand remained nickel HPAL site has begun production of improved, data from the Energy Information
29 strong for phosphoric acid production. Con- nickel and cobalt. It is understood to be Administration show. In the second week of
sumption in Morocco is expected to remain receiving sulphur cargoes at Obi Island June, refinery utilisation reached 93%, up
30 healthy through the second half of the year, for use at the site’s two sulphur burners. from 91% the week prior and 74% this time
keeping import demand strong. Any shortfall Sulphur demand at capacity will be over last year. Sulphur demand is expected to
31 in supply from Russia is expected to be met 300,000 t/a. Sulphur demand in the coun- hold firm in the coming months from both
by cargoes from the Middle East region. The try is expected to rise further in the outlook the fertilizer and industrial sectors.
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33 Fig. 1: Global sulphuric acid demand changes, year on year Fig. 2: Copper vs acid prices, 2019-21
34 +42%
12 140
10 8
Net 120
35 8 LME Copper 7
Other
Sulphuric acid, $/t
100
million tonnes
6 6
36 SE and S Asia 5
Cu ’OOO $/t
4 80
Middle East 4
2 60 Sulphuric acid Chile c.fr
37 0 Eur, Rus, Ce Asia 3
Americas 40
-2 2
38 -4 Africa 20 1
-6 NE Asia 0 0
39 2019 2020 2021 Jan Jan Jan
2019 2020 2021
40 Source: Argus Source: Argus
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PRICE TRENDS
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SULPHURIC ACID cussions were still ongoing. For six-monthly pending its maintenance at AltoNorte until
6
contracts, increases were forecast to be October. It has been expected to be offline
7 Global sulphuric acid prices have contin- higher given the steep price rises since the in July for 30 days, taking a potential
ued to firm in recent months with signs of start of the year. 124,000 t off the market. Sulphur based
8 the price run slowing during June as buyer North African prices firmed by $135/t acid producer Noracid was heard suspend-
resistance has kept prices stable in some between the start of 2021 and 1 July to ing its August turnaround, but this was
9
regions. Strong support remains on the $180/t c.fr. This has been driven by strong unconfirmed by the company.
10 demand front from the processed phos- demand and a tight market balance. Acid Vale, a large nickel and sulphuric acid
phates sector and industrial and metals trade to Morocco has been strong with producer, halted operations in June at its
11 markets. Supply remains tight for smelter imports to the country totalling 717,000 t Sudbury, Canada operations after workers
acid and regional tightness in sulphur con- in the January-April 2021 period, up by 41% went on strike. Progress was not heard
12
tinues to put pressure on operating rates on the year. China has led trade to the made by 1 July with off-takers concerned
13 at sulphur burners. Sulphuric acid price country and this trend is expected to con- around supply sources. The North Ameri-
premiums continue to rise further, dis- tinue as smelter-based acid supply grows in can balance is set to remain tight in the
14 connecting from the sulphur benchmark the forecast. We currently expect Moroccan near term until the plant returns to produc-
as global supply remains stretched from acid imports to reach 1.9 million t in 2021 tion. Prices increased notionally in early
15
smelters and sulphur burners. but there is potential for levels to exceed July to $190-210/t c.fr in line with other
16 In NW Europe, average prices for exports 2.0 million tonnes. markets but while enquiries continued,
firmed by $106/t to $135/t f.o.b. between On the demand front robust copper trade remained muted.
17 January to July this year on the back of tight prices have been supporting short term Chinese smelter acid production is fore-
supply and healthy demand. The Western operations at mines as well as the poten- cast to rise by 5%, or 1.8 million tonnes,
18 European supply squeeze is expected to tial for new projects to start up. Latin Amer- in 2021 on a year earlier, but tightness in
persist into 2022, with the closure of the ican demand is forecast to remain firm the copper concentrate market remains
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Inovyn UK acid plant adding to the tighter across the metals sectors. Peru and other a risk. Environmental concerns are also
20 balance. Covid-19 remains a risk factor and countries in the region have struggled with adding uncertainty, with major smelt-
some turnarounds have been delayed from rising infection rates despite rolling out vac- ers pledging to reduce concentrate pur-
21 the 2021 schedule to the first half of 2022. cines. Brazil is driving demand from new chases by 8.8% this year. This is because
The UK acid import requirement is forecast projects, expanding its phosphoric acid of climate change mitigation strategies,
22
to remain firm with a strong demand out- output, which will largely be met by captive equivalent to 300,000 t of refined metal.
23 look from the water treatment sector, this sulphur-based acid supply from 2022. Smelters are the leading driver in the short
has repercussions for acid trade flows In Chile, third quarter contracts were term for capacity growth, with over 6 mill-
24 across and from Europe. reported concluded by buyers ranging ion t/a of new capacity expected to be
Contract negotiations for the third quar- $190-215/t c.fr but figures are expected added between 2021 and 2022. Prices
25
ter and the second half of 2021 continued to vary according to the size of the buyer. out of China have been firm and above
26 into the start of July in the region. Some BHP reports that negotiations with work- levels achieved out of Japan/South Korea
settlements were understood to have been ers regarding the planned August strike through the year so far. This was largely
27 reached. Smelter-based acid settlements at Escondidos are likely to continue into because higher liquidity for the spot mar-
increased by e15/t but some contract dis- the first week of August. Glencore is sus- ket from China to test pricing. n
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Price Indications
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33 Table 1: Recent sulphur prices, major markets

34 Cash equivalent January February March April May
Sulphur, bulk ($/t)
35
Adnoc monthly contract 112 163 189 157 154
36 China c.fr spot 141 175 223 230 246
Liquid sulphur ($/t)
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Tampa f.o.b. contract 96 96 96 192 192
38 NW Europe c.fr 139 160 190 228 228
Sulphuric acid ($/t)
39 US Gulf spot 83 100 135 160 160
40 Source: various
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Market Outlook
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6 Historical price trends $/tonne

7
300 300
8
Sulphur (Adnoc monthly f.o.b.)
$/tonne
9
Liquid sulphur (NW Europe)
Sulphuric acid (Ex-term Tampa)
10
11
12
200 200
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14
15
16
17 100 100
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19
20
21
22 0 0
2013 2014 2015 2016 2017 2018 2019 2020 2021
23
Source: BCInsight
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SULPHUR but firm freight rates and demand will con- l Japanese suppliers report limited
26 tinue to prop up delivered benchmarks. potential for spot cargo availability in
l Significant capacity additions in the Mid- The downside will be limited by poten- the short term because of lower sulphur
27 dle East are still awaited. The more posi- tial DAP price gains and demand, with content in copper concentrates and dis-
tive outlook for fuel demand is providing strong demand from downstream sectors ruptions to operations during the first
28
support to seeing these projects ramp keeping consumption of sulphur healthy. half of the year. Acid capacity in Japan
29 up in the coming months. New supply is Increased trade for nickel projects is is expected to remain stable at 8.6 mil-
expected from Saudi Arabia following the a market bull, following the restart of lion t/a in the outlook with production
30 commissioning of a gas project in 2020, Ambatovy in Madagascar and the start-up at around 6.0 million t in 2021. Exports
sulphur availability is likely to improve of metals projects in Indonesia, support- are forecast to be down to 2.9 million
31 from the country through the second half ing the view that the market will remain t this year, below 2020 levels because
of 2021 and into 2022 as a result. balanced in the short term. of turnarounds and reduced supply.
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l News is awaited on the potential for a l Outlook: Prices are not expected to
33 Chinese export tax with fears over poten- SULPHURIC ACID ease in the short term, despite appear-
tial measures providing a bullish senti- l The expected improvement in sulphur ing to have reached a ceiling. The tight
34 ment to the DAP market. supply in the second half of the year will supply situation is not expected to
l China’s January-May sulphur imports rose provide some relief to sulphur burner ease in the coming months, with turna-
35
by 10% from a year earlier to 3.61 million operators that have struggled with the rounds and industrial action impacting
36 t. The outlook for China imports for the tight market in recent months. But the availability. Strong demand from key
year and in the forecast will be a key factor tightness from the smelter sector is not industries as well as low inventories
37 in determining global trade patterns. Total expected to improve in the short term. at smelter acid suppliers is keeping
imports for this year are forecast at 9 mill- l Nickel producer Meta Nikel is under- the price outlook firm. Indications for
38
ion t and a similar level for 2022, but it is stood to be assessing whether to November spot cargoes are at higher
39 the lowest level of imports since 2008. embark on a sulphur burner project in prices to levels in early July – suggest-
l Outlook: The prospect of supply tightness Turkey to meet its demand for sulphuric ing there may be room for further price
40 easing out of the Middle East is expected acid. This is currently met by imports of increases before a peak is reached for
to provide some softening to export prices smelter acid, largely from Bulgaria. the year. n
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Sulphur Industry News
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6 UNITED ARAB EMIRATES

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Saipem wins contract expand Shah sour gas plant
The Abu Dhabi National Oil Company (ADNOC) has awarded a 45% increase on the plant’s original capacity of 1.0 bcf/d when
$510 million engineering, procurement and construction (EPC) it came on-stream in 2015.
9
contract to Italy’s Saipem to expand production capacity at the “Shah’s expansion will optimise the plant as well as improve
10 Shah sour gas plant, as the UAE looks to increase its output of both capacity and higher-end product recoveries, further growing our
gas by 2030. The Optimum Shah Gas Expansion (OSGE) & Gas contribution as a safe and reliable supplier of gas to ADNOC and the
11 Gathering project has been awarded by ADNOC Sour Gas, a joint UAE,” said Tayba Al Hashemi, chief executive at ADNOC Sour Gas.
venture between ADNOC and US energy major Occidental. The The scope of the development work at the Shah gas plant
12
contract will increase gas processing capacity at the Shah plant includes engineering, procurement, construction, pre-commis-
13 by 13% per cent to 1.45 bcf/d from 1.28 bcf/d by 2023 and sup- sioning, commissioning, and start-up of facilities to increase
ports ADNOC’s objective of enabling gas self-sufficiency for the plant production capacity. Saipem will also extend the existing
14 UAE. The Shah gas plant currently meets 12% of the UAE’s total gas gathering network and new pad facilities, as well as all asso-
supply of natural gas, as well as producing 5% of the world’s ciated off-sites and utilities needed to integrate the new facilities
15
elemental sulphur. The expansion will cumulatively represent a with existing installations. n
16
17 Gulf chemical industry “requires self-sufficiency in chemicals which will reduce The totally-enclosed Siwertell unloader was
demand for imports from the GCC region. the only system that could meet the port’s
18 bold leadership” Dr. Abdulwahab Al-Sadoun, Secretary standard and offer safe, high-capacity
Securing a bright future for the GCC’s chemi- General of the GPCA, added, “Chemical through-ship performance.
19
cal industry will require bold leadership that industry leaders must leverage the lessons “Ashdod Port Company chose Siwertell
20 adapts to the new trends emerging in the learned from the COVID-19 pandemic and technology to secure its substantial and
post-pandemic reality, said speakers at the lead with a renewed sense of purpose to growing dry bulk cargo volumes for a num-
21 inaugural edition of the Gulf Petrochemicals create value for its shareholders, costum- ber of reasons,” explains Bertil Andersson,
& Chemicals Association (GPCA) Leaders ers, society and our planet. The next decade Siwertell Sales Manager. “Most significantly,
22
Forum. Delivering the inaugural address will require companies to embrace people our Siwertell unloaders are the only proven
23 at the forum, Yousef Al-Benyan, chairman centricity, innovate and adopt agile decision solution for safe, enclosed and continu-
of the GPCA and vice chairman and CEO making. To succeed, the industry would also ous sulphur unloading. They also meet the
24 of SABIC, said that industry leaders would need to drive customer collaboration and port’s strict environmental requirements,
need to change how they think about growth, formulate effective partnerships. It would handling materials without dust or spillage.
25
innovation and operating models. He high- need to develop products that meet the All these units are fitted with the Siwertell
26 lighted a major acceleration – during the future needs of our times and demonstrate Sulfur Safety System (4S), which detects
pandemic – of already established trends leadership in the digital transformation.” and extinguishes fires early, shutting down
27 such as digitalisation, a re-energised focus the system to stop their spread, and safely
on sustainability and innovation, the circular ISRAEL containing them before they can become
28
economy, the move towards decarbonisa- a full-blown blaze. To contain explosions,
tion and renewable energy, as well as the
Siwertell to deliver sulphur unloader steel casings are reinforced and explosion-
29
energy and materials transition among oth- for Ashdod venting valves are fitted along the conveyors
30 ers. The pandemic emphasised the power Bruks Siwertell has signed a contract with to relieve pressure.”
of collaboration, without which the world Ashdod Port Company Ltd for the delivery Ashdod’s bulk terminal operates 24
31 would not be anywhere near a global recov- of a Siwertell ST 490-M screw-type ship hours a day and the new ship unloader is
ery, he remarked. The industry’s challenge unloader destined to serve Ashdod, Israel’s destined to serve this facility. It will be built
32
now shifts to building a new ecosystem that largest seaport in terms of cargo volumes. and transported fully-assembled via heavy-
33 allows us to thrive in the long run, Al-Benyan The new Siwertell ship unloader has been lift vessel for installation at the port. Deliv-
added, expressing his confidence in the ordered as part of the port’s major expan- ery is scheduled for April 2021.
34 industry’s ability to emerge even stronger sion plans. It will be rail-mounted and used
35
from this period of change. to discharge sulphur and petcoke at continu- UNITED STATES
Buoyed by a gradual economic recov- ous rated capacities of 600 t/h and 500 t/h
ery within the region and its largest export respectively from vessels up to 60,000 dwt.
Controls Southeast Inc. and
36
market, China, the GCC chemical industry A fundamental requirement of the port Comprimo join forces on degassing
37 believes that it is well positioned for long- was environmental protection. Although a Comprimo, Worley’s Sulphur Technology
term growth. Real growth in the GCC region valuable and widely used commodity, it is business, has become an authorised
38
is expected to be at 2.5% between 2021- now environmentally unacceptable for sul- licensor for Controls Southeast Inc. (CSI),
39 2023, while China is targeting 6% growth in phur to be spilled during unloading. How- an AMETEK Company, for its patented sul-
2021. This may be a welcome development ever, its containment increases the build phur degassing technology ICOn. To date,
40 but comes with its own challenges, as the up of sulphur dust ‘hot spots’, creating there is one ICOn unit in operation and
Asian country accelerates its move towards the potential to explode and cause fires. two scheduled to start in 2021. By adding
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ICOn to its portfolio, Comprimo can now Preem’s endeavours to reduce Sweden’s
6 CHINA
offer the Shell degassing (shared license total carbon emissions by 20%, and follows
7 with Shell) or the ICOn technology via CSI. New refinery to begin test runs in Q3 a revamp in 2010 that upgraded the unit
ICOn degasses the liquid sulphur in to co-process 30% renewable feedstock,
8 a small vessel over a fixed bed catalyst China’s Shenghong Petrochemical plans to again using HydroFlex. The unit was one of
that promotes the release of the dissolved start test runs at its 320,000 bbl/d crude the first in the world capable of processing
9
H2S in the sulphur. It uses less plot space unit in August or September, according to renewable feedstock. Preem is aiming to
10 while allowing the choice of multiple design press reports. The new refinery, in the east- produce 5.0 million m3 of renewable fuels
configurations when considering the vari- ern port city of Lianyungang, will be the only by 2030, reducing carbon emissions by
11 ous inputs/outputs of sparging gases and greenfield oil refinery coming on stream in 12.5 million t/a, corresponding to 20% of
liquid sulphur. This flexibility in design China this year, with a capacity equal to Sweden’s total emissions.
12
makes it very suitable for revamp situa- nearly 3% of the country’s crude oil imports.
13 tions. While the Shell degassing is better Commercial operations at the plant are OMAN
suited for new build facilities, the selection likely to begin in 1Q 2022, upon comple-
14 preference might change depending on the tion of downstream facilities. The refiner is Yibal Khuff to come online in Q3
size and individual situation. reportedly in talks with suppliers to secure State-owned Petroleum Develxopment
15
“For years, our customers have relied about 15 million bbl of crude oil, focusing on Oman (PDO) says that it is preparing to
16 on CSI to help solve their toughest chall- low-sulphur, low-acid grades, to be used for start operations at Yibal Khuff in the third
enges. With our customers’ continued its trial runs through the end of 2021. quarter of this year, adding around 20,000
17 focus on sustainability and safety, there bbl/d to the country’s overall crude output.
was a need for a better way to reduce ARGENTINA PDO says that the project is currently 99.7%
18 emissions and make it safer to transport complete, and will raise crude production by
and handle sulphur. Licensing our ICOn sul-
Axens to supply hydrodesulphurisation around 21,900 bbl/d according to contrac-
19
phur degassing technology to Comprimo’s unit to Buenos Aires Refinery tor Petrofac, more than double the 10,000
20 Worley Sulphur Technology business pro- Shell licensee Raízen Argentina has selected bbl/d target that PDO set in 2015. It will
vides our customers with a best-in-class Axens for the supply of a Prime-G+ FCC also deliver 6.1 million m³/d (2.23 bcm/
21 solution that helps address these chal- gasoline hydrodesulphurisation unit for its year) of sour gas for local power generation
lenges,” said Thomas Willingham, division Buenos Aires refinery. Raízen is developing and Oman’s numerous enhanced oil recov-
22
vice president and CSI Business Leader. a modernisation and expansion program for ery (EOR) projects. The project start-up has
23 “At the end of the day, it’s about help- its existing 110,000 bbl/d refinery to meet slipped from its original target date of 2019,
ing our customers be good neighbours by more stringent motor fuels specifications in as Petrofac worked to overcome technical
24 contributing to a more sustainable world. Argentina by January 1st 2024. Part of this challenges arising from handling the field’s
Applying degassing technologies lowers program, downstream of the FCC unit, is an extremely high sulphur content.
25
emissions and helps ensure the sulphur integrated solution based on Prime-G+ tech-
26 handling and transportation are safer. We nology. The 10,200 bbl/d unit will be deliv- CANADA
are pleased that ICOn technology from ered in modular form to enable Raízen to
27 CSI, combined with our Shell degassing execute the project in a competitive sched- Sour gas plant receives permit approval
license, offers our customers options ule, typically saving up to six months while CSV Midstream Solutions says that it has
28
when it comes to degassing,” said Frank ensuring the performance of the unit. This is received Environmental Protection and
29 Scheel, senior vice president of Comprimo. achieved by a high degree of pre-fabrication Enhancement Act (EPEA) regulatory permit
and pre-commissioning. approval from the Alberta Energy Regulator
30 SWITZERLAND “We are confident that having Axens (AER) for its proposed Albright Sour Gas
delivering the modular hydrodesulfurisation processing facility near Grande Prairie,
31 Axens teams up with Sulzer on unit is the key to timely achieving our tar- Alberta. The main activity of the plant will
hydrodesulphurisation gets and succeeding in the modernisation be to separate and remove sour gas from
32
Axens, and Sulzer Chemtech have formed and growth of our Buenos Aires refinery,” crude sour gas for operators at Wembley,
33 an alliance to license a process for fluid said Julio Ramos, Product Quality Project in the Wapiti-Montney metropolitan area. It
catalytic cracking naphtha processing. Manager from Raízen Argentina. is designed to process 4.2 million m3/d of
34 The combined offering is based on Axens’ sour gas, generating 370 t/d of sulphur.
35
Prime-G+® hydrodesulphurisation technol- SWEDEN CSV says that it employed an early
ogy and Sulzer Chemtech’s GT-BTX PluS® community engagement philosophy prior
36 extraction technology. The combination Topsoe revamps hydrotreater to entering the formal regulatory approval
offers a unique solution to reduce octane Haldor Topsoe has completed a revamp of process for the development in order to
37 loss to a very low level for the gasoline Preem’s renewable hydrotreater unit at their better understand the impact upon local
pool. The technology is especially impor- refinery in Gothenburg, Sweden. The 6,600 communities of the planned project.
38
tant in countries that are upgrading fuel bbl/d hydrotreater is now able to co-process Daniel Clarke, CEO commented; “We are
39 specifications to meet environmental 85% renewable feedstock using Topsoe’s proud of the work our early engagement team
requirements, and it can be applied in HydroFlex™ technology. HydroFlex converts has done fostering strong relationships and
40 new, or retrofits of existing units in opera- a wide variety of renewable feedstocks into building upon the heritage and initiatives that
tion to maximise profit. transportation fuels. The revamp is part of currently exist within the community.” n
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DEMOCRATIC REPUBLIC OF CONGO tion of the Model 74 Contactor reactor, which

6
reduces the number of total reactors and plot
7
Production begins at Kamoa-Kakula space required, at an overall lower capital
cost for the alkylation unit. It has a volume of
8
9
copper mine 68.1 m3 (18,000 gallons), an increase from
the standard size Contactor (Model 63) of
43.5 m3 (11,500 gallons) per reactor.
10 “In the last few years, DuPont and
Sinopec have had the opportunity to start
11 ®
up several STRATCO alkylation units
together, providing DuPont with the oppor-
12
tunity to develop a strong relationship with
13 each refinery. The success in both start-
up and operation continues to meet and
14 exceed expectations, enabling the Sinopec
PHOTO: IVANHOE MINES
organization to make a vast amount of

15
high quality alkylate to improve the overall
16 quality of their gasoline pool. We are very
appreciative for the experience we’ve had
17 The Kakula Copper Mine in the Democratic Republic of Congo. with each of these refineries,” said Kevin
Bockwinkel, global business manager,
18 Production has begun at Ivanhoe Mines’ Kakula copper mine in the DRC. The company STRATCO Alkylation Technology.
says that total production for this year is expected to be 80-95,000 t/a of copper in
19
concentrate, with a phase two expansion to 400,000 t/a due to be completed by Q2 UNITED STATES
20 2022. Ivanhoe is working with China’s Zijin Mining on the development plan for phases
2 and 3 of the mine, as well as a feasibility study for the Kipushi zinc mine further to Rhyolite Ridge project wins key permit
21 the east. Both projects lie close to the DRC’s southern border, with Angola and Zambia ioneer Ltd says it has received a Class II
respectively. Phase 3 of Kamoa will lift capacity to an anticipated 600-800,000 t/a Air Quality Permit for its lithium-boron Rhyo-
22
of copper in concentrate, making it the second largest copper mine in the world after lite Ridge project in Nevada, a major pro-
23 Escondida in Chile. Canadian-based Ivanhoe expects to be digging 3.8 million t/a of ject milestone, following a detailed review
ore at Kakula with 6% copper content in Phase 1. of the project by the state of Nevada’s
24 The DRC has a long-standing ban on exports of copper concentrate, and so pro- Bureau of Air Pollution Control. The permit
cessing of the copper is planned to occur in-country. Around 40% of the copper concen- was a key requirement for construction to
25
trate from Phase 1 (up to 150,000 t/a of concentrate) will be processed into a 99% begin at the site.
26 copper blister at the nearby Lualaba Copper Smelter under a 10 year contract. Ivanhoe The project comprises a quarry, over-
recently announced that an offtake agreement for 100% of Phase 1 production has burden storage facility, an ore process-
27 been signed with the Citic Metals and Gold Mountains International Mining Company ing facility responsible for boric acid and
Ltd (a subsidiary of Zijin). Each of the companies will be receiving 50% of the Kamoa- lithium carbonate production, and a spent
28
Kakula Phase 1 production. ore storage facility, as well as the first sul-
29 Further down the line, there are plans for a new smelting complex beginning opera- phuric acid plant permitted in the state of
®
tion in 2026. Ivanhoe signed a power supply agreement with a hydro-electric plant in Nevada. The acid plant features MECS /
30 April this year for the projected Kamoa expansions. The smelter would produce around SNC Lavalin designed heat recovery tech-
300,000 t/a of blister copper, as well as an estimated 1,600 t/d of sulphuric acid nology, which means the plant will gener-
31 a by-product. Ivanhoe’s plan is that the sulphuric acid produced at Kamoa would be ate all of the electricity and heat required
sold to copper-oxide mining operations in the central African copper belt that currently for normal operations, according to ioneer.
32
purchase acid from Zambia or overseas. n This means the operation will be energy-
33 independent and using co-generated zero-
carbon power. The acid plant features
34 to process MTBE raffinate feedstock and state-of-the-art controls that limit emissions
CHINA produce 9,240 bbl/d (360,000 t/a) and to among the lowest in the world for this
35
Sinopec starts up two new 10,240 bbl/d (400,000 t/a) of alkylate, type of plant, the company claims.
respectively. The low-sulphur, high-octane, ioneer’s Managing Director, Bernard
36 alkylation units
low-Rvp alkylate with zero olefins will ena- Rowe, said: “The issuance of the Class II
37 DuPont Clean Technologies says that it ble Sinopec to meet the China VI low sul- Air Quality Permit represents a significant
has achieved a successful start-up of two phur fuel standard at these two refineries. milestone for the Rhyolite Ridge lithium-
38 ®
STRATCO sulphuric acid alkylation units The start-up brings the number of boron project and supports our detailed
39 at the Zhongke Refinery and Petrochemical STRATCO units in operation with Sinopec plans for a processing plant with low emis-
Company LTC refinery in Zhejiang, and the organization to six, with a seventh unit due sions and minimal hazardous air pollutants.
40 Sinopec Shanghai Company (SPC) refinery to come online this year. Sinopec Shanghai After regulatory review and public com-
in Jinshan, Shanghai. Both are designed refinery is the second commercial installa- ment period, we are pleased that Rhyolite
41

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Ridge is the first project with sulphuric acid Metso Outotec’s pyro- and hydromet- and dialogue on this essential element
6
production to receive a Class II Air Quality allurgical technologies are capable of and its vital role in life on earth.
7 permit in Nevada.” the processing of secondary raw materi- “GPI looks forward to convening experts
The company expects to mine and pro- als, including valuable metals like copper with a variety of diverse backgrounds and
8 cess 63.8 million tonnes of ore over the and platinum. The Ausmelt™ and Kaldo™ views to develop a variety of different
26-year mine life at an average annual rate processes can be used for integrated pri- approaches to phosphorus use,” said El
9
of 2.5 million t/a. mary smelting and standalone smelting, Habti. “Sustainable and innovative use of
10 complemented with efficient gas cleaning phosphorus is essential to improve life on
WORLD systems. Further refining can be accom- earth in all its forms.”
11 plished with Metso Outotec’s state-of- The global institute has appointed Dr
Copper smelting activity rebounds the-art electrorefining and electrowinning Amit Roy as its first executive director to
12 from low point processing technologies. The DC furnace spearhead the operations (see People
13 Global copper smelting activity reached is based on proprietary technology featur- section). His initial focus will be creating
its highest point this year in May, with ing advanced environmental performance the Consortium for cutting-edge phos-
14 South America the top producing region, and efficient slag and alloy separation pro- phorus research projects, building global
according to Earth-i and Marex Spectron’s viding high metal recoveries. coalitions, and establishing research hubs
15
SAVANT platform. SAVANT’s global copper “We are excited about this order, as it will around the world.
16 smelting index averaged 49.4 for May, a strengthen our position in treatment of sec-
return to long-run average levels after a ondary raw materials. Our DC furnace tech- CANADA
17 record low point of 39.8 in March 2021. nology is well suited for secondary smelting
The platform, which monitors about 90% applications, including precious metal
Falco and Glencore agreement on
18 of smelting capacity, put the rise down to recycling. This delivery is well in line with copper-zinc project
copper’s price surge stimulating a sup- our strategy to grow in circular economy,” Falco Resources Ltd says it has concluded
19
ply response. Copper prices reached a explains Jyrki Makkonen, Vice President, an agreement in principle with Glencore
20 10-year high of over $10,000/tonne in Smelting business line at Metso Outotec. Canada Corporation establishing a frame-
May on the London Metal Exchange. work of terms and conditions pursuant to
21 Marex global head of analytics Dr Guy MOROCCO Falco’s Horne 5 gold-silver-copper-zinc
Wolf said the record low levels of smelter project in Quebec. The project covers the
22
activity in March had led to “an explosive
Morocco sets up Global Phosphorus former Horne and Quemont mines, for-
23 price rally” for refined copper. “The natu- Institute merly copper-zinc sulphide mines, which
ral supply response to that became evi- Morocco’s Mohammed VI Polytechnic will be de-watered and rehabilitated, as
24 dent in the data towards the end of April University and the Ibn Rochd Foundation well as the Horne 5 deposit, which lies at
has continued throughout May – hence for Science and Innovation (FIRSI) have a depth of 0.6-2.3 km. The new mine will
25
the consolidation in copper prices,” he announced the creation of the Global produce an anticipated average 15,500
26 said. “We are now entering a fascinat- Phosphorus Institute (GPI), an independ- t/d of ore over the mine’s 15 year life.
ing period, where seasonal declines in ent non-profit international institution. Ore will be processed by primary grinding
27 smelter activity in China and the rest According to a press release, the GPI in a single SAG mill and ball mill, followed
of Asia are to be expected, and other “aims to bring together scientists, policy by three flotation and thickening circuits
28
regions showing no signs of slowdown. makers and communicators, industry lead- dedicated to recovering copper, zinc and
29 Given the importance of Chinese demand, ers, educators and a variety of food secu- pyrite concentrates. The pyrite concen-
it remains to be seen if the external sup- rity stakeholders on a single platform.” It trate would then be leached along with
30 ply can satisfy China’s demand during also aims “to create and share innovative the pyrite flotation tailings in separate
this maintenance window.” solutions to balance the need and use of leaching circuits. Pumping out the old
31 phosphorus in the production of healthy mines is expected to take two years from
32
FINLAND food, animal feed and natural fibres as we the completion of de-watering infrastruc-
protect our environment for a prosperous ture in H2 2021/H1 2022. Access to
33
Metso Outotec wins order for and equitable society in the spirit of the the Quemont 2 shaft is contingent upon
precious metals recycling plant United Nation’s Agenda 2030 for Sustain- Falco’s agreement with Glencore, which
34 Metso Outotec says that it has received an able Development.” operates the Horne smelting facility only
order for the engineering and delivery of key Hicham El Habti, the president of 700m away.
35
equipment for the expansion of a precious Mohammed VI University and new presi-
36 metals recycling plant, although the cus- dent of the GPI said: “GPI will promote AUSTRALIA
tomer and the value of the contract were global, science-based, inclusive dialogue
37 not disclosed. Metso Outotec’s equipment and collaborations on subjects ranging
Patent application for new phosphate
delivery consists of a direct current (DC) fur- from industrial phosphorus use and recy- fertilizer blend
38
nace with feeding equipment and process cling to nutrient management and stew- Minbos has lodged an Australian provi-
39 control system. The order has been booked ardship. Morocco, as the custodian of the sional patent application for a new phos-
in Metals’ Q2/2021 order intake. Typi- planet’s largest known reserves of phosphate rock fertilizer blend. The provisional
40 cally, this type of an order is in the range of phate… has a unique duty to encourage patent claims to produce a 100% organic
e8-15 million. and support global research, innovation phosphate fertilizer using less reactive
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phosphate rocks than conventional production. The new patent by 2030 it is predicted that the global electric vehicle sales are
6
application has been filed to cover the new blend following analy- predicted to reach 31.1 million units, and the Indonesian gov-
7 sis of results comparing different product forms from Minbos’ Cab- ernment is targeting production of 600,000 four-wheeled electric
inda phosphate granules in field trials in Angola, and greenhouse vehicles and 2.45 million two-wheelers. “Indonesia has sufficient
8 trials at the International Fertilizer Development Centre (IFDC) in resources and reserves of nickel and cobalt, supported by other
the US. minerals such as copper, aluminium and tin which will become
9
The company says that its new phosphate rock fertilizer blend vital for the electric vehicle industry,” said Luhut in his official
10 promotes the early release of phosphate nutrients from phosphate statement.
rock, potentially eliminating monoammonium phosphate from the The HPAL plant will process lower grade nickel ore (limonite) to
11 proposed Cabinda Phosphate granule formulation. This results in produce Class 1 nickel mixed hydroxide precipitate (MHP) in the
a purely organic fertilizer blend. Minbos says its new blend will form of nickel sulphate and cobalt sulphate.
12
be trialled during the company’s 2021 and 2022 growing season
13 through soil incubation tests, growth chamber trials and green- INDIA
house trial. The company also says that the production of the new
14 phosphate rock fertilizer blend can potentially be applied to the
Chemetics wins new acid plant contract
company’s granulation plant and be including in the production Chemetics Inc. has been awarded a contract by Bodal Chemicals
15
profile from commissioning in 2022. Ltd for a new 1,050 t/d sulphuric acid plant using solid sulphur as
16 “This is a promising development for the company’s plans to feedstock. The plant will produce both 32-33% oleum and 98.5%
participate in the development of a regional agricultural power- Sulphuric acid for the production of dye intermediates. Because
17 house,” said Minbos CEO Lindsay Reed. “The new fertilizer blend Bodal Chemicals was seeking to conserve water use and maxim-
has the potential to deliver healthy, organic crop yields for Angola ise energy recovery, the new acid plant will be designed using an
18 and its farming communities for decades to come.” air-cooled cooling water system and an enhanced boiler feed water
®
preheating system with SARAMET acid coolers.
19
INDONESIA Vancouver-based Chemetics, part of the Worley Group, says
20 that this project award continues the company’s success in
Zhejiang Huayou HPAL project to come in under budget serving the Indian sulphuric acid market; in the last three years
21 Zhejiang Huayou Cobalt’s first nickel and cobalt project in Indone- Chemetics has signed contracts for three new sulphuric acid
sia will enter the commissioning stage at the end of this year, with plants and several sulphuric acid concentration plants in India.n
22
capital expenditure coming in below planned levels, according to
23 the company. The project, on Sulawesi, is one of several Indone-
sian nickel and cobalt plants using high-pressure acid leach (HPAL)
24 technology. The project is a joint venture between Huayou, stain-
less steel giant Tsingshan Holding Group and China Molybdenum
25
Co. It is designed to have annual capacity of 60,000 t/a of nickel
26
27
content and 7-8,000 t/a of cobalt content in their nickel-cobalt
mixed hydroxide product.
“We are confident to say to the market that the capex is lower
Pumps specialist
28
than the original design. The original design is around $1.2-1.3 bil- for the sulphur industry
lion,” said George Fang, Huayou’s executive vice chairman, speak-
29 ing at an online industry conference, though he did not provide Rheinhütte Pumpen supplies chemically
a revised figure for the plant’s cost. “We are in the final stage resistant centrifugal pumps to handle
30 of construction. We will finish all construction and start commis- molten sulphur and sulphuric acid.
Optimal customer and engineering solu-
sioning at the end of this year,” he said, noting it will take about
31 tions are provided in a large selection of
another 12 months for the plant to ramp up to full operation. “If more than 30 metal and plastic materials
there no was no Covid-19, we would have finished half a year combined with special shaft seals.
32
earlier.”
33 Huayou is also building another HPAL project in Indonesia,
which was announced in May, with annual capacity of 120,000
34 tonnes in nickel content, double the size of the Huayue plant, in
conjunction with battery producer EVE Energy. Fang said that that
35
project is at the start of engineering and construction, and would
36 source nickel from Indonesia’s Weda Bay region.
37 HPAL plant inaugurated

In late June Indonesia’s Minister for Maritime Affairs and Invest-
38
ment Luhut Binsar Pandjaitan inaugurated production operation
39 at the PT Halmahera Persada Legend high pressure acid leaching
(HPAL) facility on Obi Island, South Halmahera. The HPAL plant
40 has been built at an investment cost of over $1.0 billion and ITT RHEINHÜTTE Pumpen GmbH
Rheingaustraße 96-98 | D-65203 Wiesbaden | www.rheinhuette.de
will produce nickel for electric vehicles. Minister Luhut said that
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People
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The International Fertilizer Association (IFA) Phosphates Ltd and Mangalore Chemicals fications will make him succeed in building
6
says that Svein Tore Holsether has been and Fertilizers; and Mayo Schmidt, presi- out this Institute”
7 elected as its new chair of the Association. dent and CEO, Nutrien. IFA members also Amit Roy has been involved in phos-
IFA said in its press release that the selec- re-elected to the board of directors Raviv phorus research for more than four dec-
8 tion of Holsether, the president and CEO of Zoller, president and CEO, ICL Group. ades beginning with his graduate work for
Yara International, is a continuation of the Rami Hiulumäki has been appointed a doctoral degree. At the IFDC he devel-
9
industry’s commitment to sustainability. vice president and head of Metso Outo- oped new products and processes for con-
10 “I am honoured to be appointed Chair tec’s Group Tax function. Rami succeeds version of phosphate rock into fertilizers
of IFA because the fertilizer industry has a Jarno Siivola, who left Metso Outotec on along with other activities related to food
11 key role in finding sustainable solutions to June 1st to join a new employer. Rami Hiu- production and agricultural development.
some of the greatest challenges the world lumäki joins Metso Outotec from Nokia, As CEO of IFDC, he oversaw a number of
12
is facing. As an industry, we need to lead where he has headed the Group Tax func- major publications including Fertilizer Raw
13 the way to decarbonise food and build resil- tion since 2018. Prior to that, he worked in Material Resources of Africa, World Phos-
ient and fair food systems,” Holsether said. various tax roles in Nokia, Nokia Siemens phate Rock Reserves and Resources and
14 Dmitry Konyaev, CEO of Russia’s Ural- Networks and Deloitte. Rami will start at Sustainable Phosphorus Management, A
Chem, has become the new vice chair Metso Outotec during 3Q 2021. Global Transdisciplinary Roadmap. These
15
of the Association. Both Holsether and The newly launched Global Phosphorus publications helped raise global aware-
16 Konyaev serve on the executive board of Institute (GPI) has announced the appoint- ness about phosphorus and inspired
directors, which also welcomed two new ment of Dr Amit Roy as Executive Director similar initiatives around the globe. He
17 appointments: Jeanne Johns, managing to develop and lead the Institute. His initial also launched more than 20 international
director and CEO of Incitec Pivot Ltd, and focus will be creating a consortium for cut- IFDC branch offices to establish collabora-
18 Tony Will, president and CEO of CF Indus- ting-edge phosphorus research projects, tive global research programs and spear-
tries. Mostafa Terrab, group chairman and building global coalitions, and establishing headed the 2006 Africa Fertilizer Summit
19
CEO of OCP, Morocco, remains on the research hubs around the world. held in Abuja, Nigeria.
20 executive board of directors as Immediate “We are pleased that Amit joins GPI “I am honoued and excited to develop
Past Chair, along with Zhai Jidong, vice to direct this new global initiative,” said GPI into the global convener of all things
21 president international for Kingenta, and Hicham El Habti, president of Morocco’s phosphorus,” said Roy. “This platform will
Alzbeta Klein, director general of IFA. Mohammed VI Polytechnic University and be available to anyone from the local dairy
22
There are also five new Board Directors president of the GPI. “His vast experience farmer to the climate scientist to the chem-
23 elected by the membership: G. David Dela- combined with his enormous breadth of istry student to the food manufacturer
ney, CEO, Itafos; Ahmed El-Hoshy, Group knowledge, research work and experience interested industries because we must
24 CEO, OCI NV; Shakeel Ahmad Khan, CEO, in managing the International Fertilizer ensure that phosphorus, a non-substituta-
Petronas Chemicals Marketing; Suresh Development Center (IFDC) are valuable ble vital element, is responsibly managed
25
Krishnan, managing director, Paradeep assets to GPI. I am confident that his quali- and available for future generations.” n
26
27
Calendar 2021 ! The following events may be subject to postponement or cancellation due to the global
coronavirus pandemic. Please check the status of individual events with organisers.
28
SEPTEMBER Contact: Mike Anderson, Brimstone STS Seminar, NOORDWIJK, Netherlands
29 Phone: +1 909 597 3249 Contact: Paula Zaharko,
12-15
Email: mike.anderson@brimstone-sts.com Sulphur Experts
30 2021 Australasia Sulfuric Acid Workshop,
20-24 Tel: +1 281-336-0848 Ext 101
BRISBANE, Australia
31 Sulphur Recovery Seminar, Email: Paula.Zaharko@SulphurExperts.com
Contact: Kathy Hayward,
Sulfuric Acid Today KANANASKIS, Alberta, Canada 11-15
32
Email: kathy@h2so4today.com Contact: Paula Zaharko, Sulphur Experts Sulphur Recovery Seminar,
33 Tel: +1 281 336 0848 Ext 101 NOORDWIJK, Netherlands
Web: www.acidworkshop.com
Email: Paula.Zaharko@SulphurExperts.com Contact: Paula Zaharko,
34 13-17
28-30 POSTPONED TO MAY 2022 Sulphur Experts
Amine Treating and Sour Water
35 8th Sulphur and Sulphuric Acid Conference, Tel: +1 281-336-0848 Ext 101
Stripping Seminar,
CAPE TOWN, South Africa Email: Paula.Zaharko@SulphurExperts.com
KANANASKIS, Alberta, Canada
36 Contact: South African Institute of Mining
Contact: Paula Zaharko, NOVEMBER
and Metallurgy
37 Sulphur Experts 1-3
Tel: +27 (011) 834 1273
Tel: +1 281 336 0848 Ext 101 Sulphur & Sulphuric Acid Conf. 2021
38 Web: www.saimm.co.za
Email: Paula.Zaharko@SulphurExperts.com Contact: CRU Events
39 14-16 OCTOBER Tel: +44 (0) 20 7903 2444
‘Virtual Vail 2021’: Annual Sulphur 4-8 Fax: +44 (0) 20 7903 2172
40 Recovery Symposium – Virtual event Amine Treating and Sour Water Stripping Email: conferences@crugroup.com
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37th
4 Oil | Gas | Fertilizers | Metallurgy | Industrial
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Sulphur + Sulphuric Acid 2021
Virtual Conference & Exhibition
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1-4 November 2021

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STAY CONNECTED AND INFORMED -

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FROM YOUR PLANT, OFFICE OR HOME
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CRU’s Sulphur + Sulphuric Acid will run as The dual-stream technical agenda, covering
15 a fully virtual event in 2021 – connecting you technical updates on the production and
16 with an even wider audience of sulphur and processing of sulphur and sulphuric acid,
acid industry professionals from around the will feature industry-leading presentations
17
globe. covering new innovations in process,
18 technology, materials and equipment
19 Drawing on the success of the 2020 virtual developments, as well as practical case
event you can expect expanded content studies highlighting operational experience
20
streams, enhanced networking opportunities and improvement.
21 and much more – all from the convenience of
22 your plant, office or home.
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SPONSORS:
600 + 250
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industry
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professionals operators
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31 40+ countries
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exhibitors represented
30 HOURS
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of presentations and OFFICIAL PUBLICATIONS:
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Q&A sessions -
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live and on-demand
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For more information or to book your place please visit:
42 www.sulphurconference.com
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CRUDE TO CHEMICALS
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Saudi Aramco’s Yanbu complex.
10
11
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PHOTO: GPCA
13
14
Crude to chemicals
15
16
17
18 With demand for conventional fuels projected to peak and fall over the next decade, some
19 refiners are looking to petrochemical production as a way of diversifying their product slate.
20
M
ost refineries are reliant on the and electric vehicles – many countries in integration. At the same time, increased out-
21 production of liquid fuels. On the developed world are planning to ban the put of natural gas liquids from US shale gas
average, around 55% of all refin- sale of fossil fuel driven vehicles from about production also encouraged ethane cracker
22
ery products are sold as gasoline, diesel 2030. Overall, the US Energy Information investments, with a lower ethylene produc-
23 and other middle distillates, kerosene etc, Administration predicts that US fuel con- tion cost than naphtha, especially given how
as well as bunker fuels, and refineries sumption for light-duty vehicles will decline low US natural gas prices have gone. But
24 depend upon the difference between the by 1% annually through 2050. At the same US tight oil production has also moved the
price of oil that they buy and the price of time, there are tightening regulations on sul- US close to self sufficiency in oil and led to
25
the fuels that they sell to make their mar- phur content of fuels and the carbon dioxide significant US oil exports for the first time
26 gin. Conversely, petrochemicals like olefins that they produce when burnt, which are in decades, bringing down the price of oil
such as ethylene and propylene, aromatics, placing increasing pressures on refineries globally and shutting out some medium and
27 glycols, and polymers represent currently to invest in expensive process equipment heavy grades as OPEC cuts production.
collectively only 5-20% of refinery output, items to remove more sulphur and produce IHS Markit suggests that the pull of
28
depending on the refinery’s configuration. less, e.g., high sulphur fuel oil as against changing demand means that oil refiners
29 Traditionally, the relationship the rela- more middle distillates. US fuel oil demand are seeing an opportunity to convert lower
tionship between refining and petrochemi- is predicted to fall by 25% this decade. value oil into higher value chemicals and
30 cals has been at one remove; refineries In contrast to fuels, petrochemical mar- therefore seeking to “push” barrels of oil
focused on fuels production, and sold the kets continue to be relatively buoyant. In (displaced and new) into chemical markets.
31 naphtha that they produced to operators of spite of a growing backlash against ‘single This is leading to increasing interest in crude
steam crackers, who would then turn it into use plastics’ in the developed world, global to chemicals technologies, which in effect
32
ethylene, propylene, and other basic chemi- demand for plastics products and synthetic merge a refinery and petrochemical plant
33 cal building blocks. However, changes in the fibres continues to grow, and with them into one; in theory returning higher margins
market for oil products, on both the supply demand for olefins such as polyester and to refiners relative to more traditional fuels
34 and demand sides, are now encouraging aromatics like paraxylene. Urbanisation and products. Figure 1 shows projections by
refinery operators to integrate petrochemi- rising wealth in the middle classes of devel- Wood Mackenzie that over the next 15 years
35
cal production into their product slate. oping nations are also driving above-GDP most new demand for oil-based products is
36 growth rates, and China’s consumer boom in going to come from the chemical sector.
Market changes particular has led to increasing demand for
37 packaging, consumer goods, and car parts. Three ‘generations’ of crude to
On the demand side, car sales have been One the supply side, the past decade
38
tapering off even in the developing world, has seen a surge in output from US tight
chemicals
39 and vehicles are becoming more fuel effi- oil production. This lighter crude slate has There are three ‘generations’ of crude to
cient, requiring less gasoline per unit. Also, meant higher light distillate yields for LPG, chemicals technology, but all have the
40 while currently still only a small sector of the naphtha and gasoline, resulting in higher common feature of increasing the refinery
market, there is the growing push for hybrid light products with potential for chemical yield of light olefins (ethylene or propylene)
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CRUDE TO CHEMICALS
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or aromatics such as benzene, toluene, duction. FCC units meanwhile break down tively hydrogenated. Heavy naphtha is dedi-
6
and xylene. In general, to maximise the VGO into gasoline. The process generates cated to the aromatics block, designed to
7 conversion of crude oil into petrochemi- propylene at around 5-20% of output, but synthesise benzene, toluene and xylene. It
cals, the refiner must utilise streams that refiners can run FCCs at higher severities also has a high severity FCC (HSFCC) pro-
8 would otherwise be used for the produc- (higher temperatures and longer residence cess using deep feed pretreatment and its
tion of fuels such as kerosene and diesel times) to increase propylene yield further. patented permutable reactor system (PRS)
9
to produce naphtha, as well as upgrading upstream of the HSFCC to maximise the
10 heavy bottom of the barrel products into Crude to chemicals options overall olefins yield.
steam cracker friendly feedstocks.
11 The first ‘generation’ depends upon A variety of ‘second generation’ options Benefits of integration
existing refinery units and can typically now exist for refinery crude to chemicals
12
produce chemical yields of 15-20%. The processing. One is the direct processing One of the benefits that can come from
13 second generation of technologies now of crude oil via steam cracking to produce integrating petrochemicals production with
being integrated into new and existing ethylene and a small quantity of propylene. refining is that it provides an opportunity
14 refineries can lift this to 40-50%. Future, The direct use of crude oil in steam crack- to integrate and optimise allocation of
‘third’ generation designs could potentially ing for the production of light olefins has resources and feedstocks, maximise the
15
convert up to 80% of a crude barrel into historically been hampered by coke forma- process streams that can be shared and
16 petrochemicals. tion and fouling of crackers, but ExxonMo- exchanged between the two halves of the
As far as existing technologies go, a typ- bil have a process using light crude which facility, and allow the sharing of utilities,
17 ical refinery begins with fractional distilla- has been in operation in their Singapore logistics and energy costs. It may also
tion, breaking down the crude feed into its refinery since 2014 (see below). allow a producer to switch product yields
18 constituent parts, ranging from light, short- Saudi Aramco has filed patents for the between refining and chemicals, depend-
carbon-chain molecules such as gasoline, integration of hydroprocessing/de-asphalting on where the greatest value lies at the
19
naphtha, and propane to heavy diesel and ing with steam cracking for olefin production. time. All of this can help to reduce cost
20 vacuum gas oil (VGO). VGO is usually then The hydro-processing/de-asphalting step and improve overall profitability. It can also
further processed in a downstream hydro- produces a highly paraffinic, de-asphalted decrease capital intensity through scale;
21 cracker or fluid catalytic cracker (FCC), and de-metalised stream, which can later be refinery scale petrochemicals production
depending on the desired product output. processed in the steam cracking unit. can be much larger than standalone pet-
22
Hydrocracking is targeted towards die- Middle distillates such as diesel and rochemical sites and offer corresponding
23 sel production and generates no olefins, residues from vacuum distillation can be efficiency gains.
since any double bonds are hydrogenated, hydrocracked to produce a naphtha range Aramco said that its thermal crude-
24 but naphtha from the hydrocracker can be stream, which then be processed to pro- to-chemicals technology (developed with
sent either to an ethylene steam cracker duce aromatic compounds. Axens and TechnipFMC) could cut capital
25
to produce olefins or to a reformer to be Axens offers its H-Oil process in associ- costs by 30% compared to conventional
26 refashioned into aromatics. To increase ation with naphtha fixed-bed hydrocrackers. refining by allowing several oil treatment
chemical output, hydrocracker operators Light naphtha is routed to a steam-cracker, steps to be combined into one operation –
27 can target naphtha rather than diesel pro- whose olefinic streams have to be selec- removing sulphur, cracking heavy fractions
etc into a suitable feedstock for steam
28
Fig. 1: Global crude oil demand growth cracking via several ‘layers’ of catalyst.
29
10 100% Asia
30
chemicals proportion
8 80% The majority of crude to chemicals plants
31 planned or operational have been in Asia
6 60% and the Middle East. One of the first mov-
32
million barrels per day
petrochemicals
ers was ExxonMobil, which opened an eth-

4 40% ylene cracker in Singapore in 2014 based
33
on crude feedstock rather than naphtha.
34 2 20%
ExxonMobil has its own proprietary tech-
nology which allows the processing of light
35 0 0%
crude directly by pre-heating of the crude
36 -2 -20% oil, partially vapourising the heated crude
in a flash tank and feeding the vapor from
37 five year periods, 2000-2035
-4 -40% the flash tank to the steam cracker to
00-05 05-10 10-15 15-20 20-25 25-30 30-35 produce ethylene, propylene, and related
38
transport petrochemicals resid/comm/agric electricity other products.
39 In India, Reliance has a crude oil to
chemicals project under development at
40 Source: Wood Mackenzie its Jamnagar refinery – the world’s largest
- which plans to more than double crude
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CRUDE TO CHEMICALS
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conversion to chemicals. The project will bbl/d of crude, again with paraxylene as 400,000 bbl/d refinery producing chemi-
6
convert the site’s entire FCC capacity to the main chemical output. The first crude cals at 45-50% of output will be gener-
7 Petro-FCC, and will add large naphtha cata- distillation unit at Zhejiang Phase 1 came ating 10 million t/a of petrochemicals,
lytic cracking, steam cracking, and aromat- onstream in November 2020, and the sec- compared to 2 million t/a for a typical
8 ics blocks to raise chemicals conversion to ond in March 2021. naphtha-based ethylene cracker. East
over 35% for the site. Asia in particular could face a problem
9
S-OIL at Ulsan in South Korea has Saudi Aramco with the combined paraxylene output of
10 recently built the world’s first commercial China’s new crude to chemicals plants
high severity FCC unit coupled with heavy oil One of the largest crude to chemicals and consequent oversupply in the Asia-
11 hydrodesulfurisation and associated units projects on the horizon was to have been Pacific aromatics market; China imports
to reduce high sulfur fuel oil production. at Yanbu in Saudi Arabia, where state oil 11 million t/a of paraxylene per year, and
12
The project has raised crude conversion to company Saudi Aramco and state petro- will temporarily more than achieve self suf-
13 chemicals from 8% to 13% for the refinery. chemical giant Sabic – itself now 70% ficiency (although demand is continuing to
owned by Aramco – were planning a $20 increase), displacing product from South
14
China billion petrochemical complex based on Korea, Taiwan and Japan.
processing 400,000 bbl/d of Arabian On the other hand, olefins markets
15
China’s huge demand for petrochemicals light crude into 9 million t/a of down- are likely to be less affected, as they are
16 and the fall in global oil prices around stream chemicals and base oils, with generally already quite large. Furthermore,
2014-15, along with the opening up of an on-stream target date of 2025. The while large crude to chemicals projects can
17 crude import licences to private compa- facility would sell 45-50% of its output cost billions of dollars, increased crude
nies, and the ban on Chinese refiners as chemicals, including olefins, aromat- to chemicals production might lead to a
18 from exporting fuels have all combined ics, glycols, and polymers. It was seen as rethink in the scale of a typical refinery.
to encourage Chinese refiners to cross an acknowledgement by the world’s larg- Refineries are often large because margins
19
into crude to chemicals production. The est oil producer that the future of oil was are slim, but the higher margins achievable
20 first was Hengli Petrochemical’s 400,000 in petrochemicals. Aramco had targeted from chemicals might mean smaller facili-
bbl/d refinery and paraxylene complex in $100 billion in chemical investments out ties were more profitable.
21 Dalian, which came on-stream in 2019. to 2035, to convert 3 million bbl/d of oil
22
The plant is capable of processing 20 – one third of its output – into chemicals. Changing the industry
million bbl/year of crude, using Axens The company has been developing its
23 technology, including H-Oil ebullated bed own patented crude to chemicals technol- Crude to chemicals offers the possibil-
hydroconversion technology for processing ogy in partnership with Chevron Lummus ity of radically reconfiguring the refining
24 vacuum residue, a Solvahl de-asphalting Global and McDermott. The company has industry, at least as far as some of the
unit for processing of unconverted residue, also signed an agreement with Axens and large scale operators are concerned. The
25
hydrocracking for processing atmospheric TechnipFMC to work on a high-severity FCC impact on the sulphur industry may not be
26 gas oil to produce the maximum yield of process for chemicals. a profound one – most sulphur is already
naphtha and hydrotreating for naphtha pro- However, in October 2020 came signs recovered from a barrel of oil. However,
27 cessing. Continuous catalytic regenerative that Aramco and Sabic were reassessing it has the potential to prevent any future
reforming maximises aromatics production this plan, with an announcement that they decline of the refining industry in the face
28
from naphtha, with paraxylene purification were instead considering integrating Ara- of falling fuel demand, as well as switch-
29 for full isomerization of other C8 aromat- mco’s existing refineries in Yanbu with a ing refining activity towards more advan-
ics into paraxylene. The plant overall yields mixed feed steam cracker and derivative taged feedstock locations as well as
30 around 40% chemicals production, mostly olefins units. The companies said in a joint places where petrochemical demand is
paraxylene for polyester fibre and polyethyl- statement that this would increase cost rising. Research and analysis company
31 ene terephthalate (PET) production. efficiency and competitiveness as well as FutureBridge suggests that the type and
A similar sized project is underway at creating value opportunities for petrochem- level of refinery and petrochemical inte-
32
Zhejiang Petrochemical, which is building a icals. The reassessment was prompted gration will primarily be driven by feed-
33 crude-to-chemicals complex in two phases in the covid-related collapse in global oil stock advantage, and hence will vary from
in China’s Zhejiang Province. Each phase demand and prices, and a need for Aramco region to region. In the US and the Middle
34 has a capacity of 400,000 bbl/d of crude to cut costs, particularly on the capex side. East, which are not dependent on crude
processing, with around 50% of this going to According to Sabic, however, the two oil imports where there is sufficient avail-
35
make chemicals. UOP is providing technolo- companies maintain that they are still com- ability of cheap natural gas liquids, direct
36 gies for the complex, including hydrocracking mitted to “advancing crude to chemicals production of crude oil to chemicals could
to break down vacuum gas oil into naphtha technologies through existing development become the prevailing option, whereas
37 and reforming and extraction to make aro- programs with the goal to increase cost for regions, such as Europe and Asia,
matics from the naphtha. At capacity, it will efficiency.” dependent on crude oil feedstock import
38
produce 8.8 million t/a of paraxylene, as and with limited availability of NGLs, the
39 well as 500,000 t/a of propylene using UOP A glut of chemicals? adoption of crude-to-chemicals technology
propane dehydrogenation technology. will be governed by the capital efficiency
40 Shenghong Petrochemical is another The scale of production from refinery of the project and demand for the petro-
large project, looking to process 300,000 crude to chemicals plans can be large. A chemicals output. n
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PROCESS PLANT SURVEY
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7
Sulphur forming project listing 2021
8 Sulphur’s annual listing of new or recently completed sulphur forming projects worldwide covers
9 both new sour gas and refinery sulphur forming projects as well as upgrades at existing units.
10
System manufacturer/ Operating Operating Units Product Scheduled New project/ Scheduled
11 supplier company site type throughput expansion completion
12
BAHRAIN
13 Enersul Bapco Sitra 3 granule 1,500 t/d new 2021
14 BELGIUM
IPCO Duval Antwerp n.a. pastille n.a. new 2020
15
CANADA
16 Matrix PDM Heartland Sulphur Scotford 1 prill 2,000 t/d new 2020
17 EGYPT
IPCO Midor El Amreya 3 pastille 230 t/d new 2021
18
INDIA
19 Enersul HPCL Vizag 2 granule 1,000 t/d new 2021
20 ITALY
IPCO Econova n.a. 3 pastille 580 t/d expansion 2020
21
IPCO Econova n.a. 1 granule 700 t/d new 2021
22 IRAQ
23 IPCO Missan Oil Co Halfaya n.a pastille 200 t/d new n.a.
KAZAKHSTAN
24
Enersul Caspian General Contr. n.a. 3 granule 1,500 t/d new 2020
25 KUWAIT
26 Enersul KNPC Mina al Amina 1 granule 1,200 t/d expansion 2020
Enersul KNPC New Refinery Project 4 granule 4,800 t/d new 2021
27
MALAYSIA
28 Enersul Petronas RAPID Pengerang, Johor 5 granule 2,000 t/d new 2021
29 OMAN
IPCO Duqm Refinery Duqm, Oman 3 granule 900 t/d new 2022
30
QATAR
31 Enersul Qatargas Ras Laffan 2 granule 2,400 t/d expansion 2021
32 RUSSIA
Enersul Syzran Refinery Samara 1 granule 350 t/d expansion 2021
33
SINGAPORE
34 Enersul SPCA Advance Pte. Ltd Singapore 4 granule 2,400 t/d new 2022
35 SPAIN
Enersul Petroleos del Norte Bilbao 1 granule 350 t/d expansion 2021
36
THAILAND
37 Enersul Thai Oil Sriracha 3 granule 1,500 t/d new 2022
38 UNITED ARAB EMIRATES

Enersul ADNOC Shah 2 granule 2,320 t/d new 2022
39
US VIRGIN ISLANDS
40 Matrix PDM Limetree Bay Refinery St Croix 1 prill 1,000 t/d new 2020
41

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ALKYLATION
3
6 A STRATCO alkylation unit at a refinery. Fig. 1: Global alkylation capacity by

region, million bbl/d
7
10
Sulphuric
11
12
13
14
15 acid North America Middle East

PHOTO: PHOENIX EQUIPMENT
Latin America
alkylation
China
16
Europe Other Asia
17 Total: 2.4 million bbl/d
18 Source: OPEC
19
20 The continuing spread of alkylation technology and the their installations. However, the number of
new HF installations has fallen dramatically
21 preference for the sulphuric acid route are leading to over the past 20 years, due to increasing
22
increased demand for acid in refineries. safety concerns, and only about one third
of US refineries now use HF. While both
23 sulphuric and hydrofluoric acids are highly
A
lkylation is a refinery process which Sulphur vs HF corrosive and can cause terrible burns on
24 converts light olefins into a high- skin contact, the danger with HF is that it
quality gasoline blendstock by react- Acid is used to catalyse the alkylation reac- is more volatile, and can form an expand-
25
ing them with isobutane. The most common tion, and the two main ones used are sul- ing toxic vapour cloud that travels along the
26 is C4 alkylate, made by alkylating butylene phuric and hydrofluoric (HF) acid. There are ground and which can affect a much wider
with isobutane. However, alkylate can also two main HF processes, licensed by UOP area, and which also has the potential for
27 be made from propylene and isobutane, and ConocoPhillips, while sulphuric acid explosion, whereas sulphuric acid merely
or pentene and isobutane. It is particularly licensors include DuPont (the major licen- pools as a liquid. With the acids being used
28
desirable because of its combination of prop- sor), ExxonMobil/Axens, CB&I (now Lum- in close proximity to hydrocarbons such
29 erties; zero sulphur content, no aromatic con- mus), and a Kellogg process which is no as LPG, there is a potential for explosions
tent, low vapour pressure and high octane longer offered commercially – KBR instead which can rupture acid tanks and release
30 number, and is used as a blendstock in the now has a solid acid alkylation technology large volumes of acid. A series of HF acci-
manufacture of cleaner burning, premium called K-SAAT, with installations in both dents and near misses at US refineries, and
31 quality gasoline. In the US, a creeping ban China and the US. Chevron and Honeywell culminating in an explosion and fire at the
on the use of MTBE – the major alternative have developed a non-acidic process using Philadelphia Energy Solutions (PES) refinery
32
octane improver – and the increasing use of an ionic liquid called ISOALKY, though there in Philadelphia in 2019, have led the US
33 ethanol as a gasoline component have also is so far only one commercial reference. Chemical Safety Board (CSB) to call upon
led to increased demand for alkylate as a The China University of Petroleum has also the Environmental Protection Agency (EPA)
34 balancing component. It is reckoned that in developed an ionic process which is mar- to review its regulation of HF in alkylation
California the proportion of alkylate used in keted by Wall as Ionikylation, and which has and other applications and look for substi-
35
gasoline rose from 17% (when MTBE was been used in several Chinese refineries. tutes. So far, however, an EPA response to
36 permitted) to 23% now that up to 10% etha- Installation and operating costs are the CSB request has not been forthcoming.
nol is blended. similar for sulphuric and hydrofluoric acid Meanwhile, the CSB’s final report on PES
37 Although alkylation has traditionally alkylation. Sulphuric acid is cheaper than is still pending approval. Operators argue
mainly been a North American phenom- HF but is more complex to regenerate and that the use of modifiers in HF can reduce
38
enon, its use is spreading worldwide – our has higher usage rates. In the early days of the formation of vapour clouds and water
39 news this issue notes that DuPont has the processes sulphuric acid was preferred, spray systems can be used to contain any
licensed its STRATCO alkylation process but during the 1980s and 90s, HF gained release. Nevertheless, there have been sev-
40 to two more Chinese refineries, making six predominance, and by the turn of the cen- eral conversions from HF to sulphuric acid or
plants in China now using that process. tury there was roughly a 50-50 split between other systems. DuPont markets its ConvEx
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ADV Siirtec_Sulphur 85x262 (layout 2)_Layout 1 26/02/19 10:01 Pagina 1
2 48
ALKYLATION
3
5
technology for converting HF alkylation plants to sulphuric acid which
6
can also be used to expand unit capacity at the same time.
7 In China, which has had a number of the alkylation installations
outside of the US, there are only two HF alkylation plants operat-
8 ing, and considerable scrutiny of the process by the Environmental
Protection Ministry.
9
Another factor favouring sulphur is that as refineries have been
10 pushed towards increased sulphur removal from crude feeds, so
the volumes of elemental sulphur available at refineries have
11 increased, making for a ready potential feedstock for on-site sul-
phuric acid production, and helping to control the cost and any
12
99.9+%
logistical difficulties of importing acid.
13
14
Spent acid regeneration
With the cost of merchant acid increasing, and costs of safe
15
disposal of spent acid likewise, the option to regenerate spent
16 acid is becoming an increasingly attractive one, with a number sulphur recovery efficiency
of companies now providing acid regeneration services, either on
17 a merchant basis or via a captive acid regeneration unit. Where
refiners have taken the option of on-site acid generation, it can be
we make it real
18 relatively straightforward to build acid regeneration capacity into with our sulphur technology
the existing sulphuric acid plant.
19
20 Capacity
21 Total US alkylate capacity is just over 1.3 million bbl/d, accord-
ing to the Energy Information Association, just over half of it in
22
the PADD 3 region (US Gulf Coast). This has been a slow, steady
23 rise from around 1.0 million bbl/d in 1990. Over the same period,
alkylation capacity outside the US has risen to around 1.1 million
24 bbl/d, according to OPEC figures (see Figure 1), with installations
at, e.g. Reliance’s refinery in Jamnagar where an 83,000 bbl/d unit
25
– one of the largest in the world – now operates. Chinese capacity
26 now represents about 100,000 bbl/d of this, with a number of
alkylation sections added to refineries over the past decade to
27 help meet China-VI (<10ppm sulphur content) gasoline standards. we can develop your project
28
Additional alkylation capacity out to 2025 is projected to add from its inception to early production
another 200,000 bbl/d of capacity, with OPEC projecting a further
29 600,000 bbl/d of capacity being added in the decade from 2025- • Claus unit and tail gas treatment (HCR)
2035, by which time global alkylation capacity will reach 3.2 mil-
• Oxygen enriched air Claus
30 lion bbl/d. This represents a modest but still noteworthy average
annual growth rate of about 1.8-2.0% over the period. • Advanced ammonia Claus
31 • Sulphur degassing
32 Sulphuric acid demand • Thermal and catalytic oxidisers
• Major Claus equipment
33 While HF functions almost as a ‘pure’ catalyst, for the sulphuric
(main burners, thermal reactors, WHB, condensers)
acid alkylation route there is a fractional conversion of acid, and
34 hence ‘consumption’ is relatively high; around 10-12 kg of acid
per barrel of alkylate produced at best, and potentially as high as
35
15-25 kg/bbl alkylate if the cracker is being run at high severity.
36 Not all of this is pure consumption; acid concentrations must be
kept high (>90%) in order to prevent acid ‘runaway’, where cata-
37 lytic activity rapidly declines and polymerisation is enhanced, and
so the acid must be continually topped up with fresh acid and
38
spent acid removed from the system. But this effective consump-
39 tion of acid means that the total market for sulphuric acid as an
alkylate catalyst is thus around 10 million metric tonnes per year;
www.siirtecnigi.com - marketing@siirtecnigi.com
40 only a small fraction of the global market for sulphuric acid (less
than 4%), but still an important end-use. n
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SULPHURIC ACID PLANTS
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7 Sulphuric acid projects 2021

8 Sulphur’s annual
9 survey of recent and
10 planned construction
projects in the sulphuric
11
acid industry includes
12
several large-scale
13
acid plants both for
14 phosphate processing
PHOTO: PT HALMAHERA PERSADA LYGEND

15 and to capture sulphur
16 dioxide from smelters.
17
18
19
Right: The Obi Island HPAL plant
20 under construction.
21
Company Site Application Capacity Licensor Contractor Type of Start-up
22 project date
23
ALGERIA
24 Sonatrach Oud el Kebrit Sulphur burning 4,500 t/d n.a. n.a. New 2022
25 BRAZIL
26 Klabin Ortigueira WSA 150 t/d Haldor Topsoe Andritz New n.a.
27 CHILE
Codelco Chuquicamata Smelter off-gas 2 x 2,050 t/d DuPont MECS SNC Lavalin New 2020
28
Enap Refinerias SA Hualpen WSA 140 t/d Haldor Topsoe Tecnicas Reunidas New 2024
29
CHINA
30 Shandong Chambroad Shandong WSA 419 t/d Haldor Topsoe n.a. New 2020
31 Wanhua Chemical Yantai, Shandong Spent acid regen 630 t/d Chemetics n.a. New 2023
PetroChina Jihua Spent acid regen 450 t/d Chemetics n.a. New 2022
32
CNOOC Hainan Spent acid regen 460 t/d Chemetics n.a. New 2022
33
Shandong Yulong Yantai, Shandong Spent acid regen 95 t/d Chemetics n.a. New 2023
34
DEMOCRATIC REPUBLIC OF CONGO
35 Kamoto Copper Co Lualaba Sulphur burning 1,900 t/d DuPont MECS Desmet Ballestra New 2021
36 EGYPT
El Nasr Ain Sukhna Sulphur burning 2 x 1,900 t/d Outotec Intecsa New 2020
37
WAPHCO Abu Tartur Sulphur burning 5,000 t/d Outotec n.a. New 2024
38
Sprea Misr Ramadan City Sulphur burning 500 t/d Nuberg Nuberg New 2022
39
FINLAND
40 Boliden Harjavalta Smelter off-gas 2,000 t/d Outotec n.a. New 2020
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JULY-AUGUST 2021
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SULPHURIC ACID PLANTS
3
6 Company Site Application Capacity Licensor Contractor Type of Start-up

project date
7
8 INDIA
Bodal Chemicals Sakhya Sulphur burning 1,050 t/d Chemetics n.a. New 2022
9
Arti Chemicals Vapi Sulphur burning 570 t/d Chemetics n.a. New 2023
10 MBAPL Rajua Sulphur burning 300 t/d n.a. n.a. New 2022
Rama Phosphates Indore Sulphur burning 170 t/d n.a. n.a. New 2021
11
INDONESIA
12
PT Pertamina Balikpapan WSA 74 t/d Haldor Topsoe n.a. New 2020
13 PT Pertamina Cepu Jambaran-Tiung Biru Sulphur burning n.a. Chemetics n.a. New 2021
PT Halmahera Lygend Obi Island Sulphur burning 2,700 t/d n.a. n.a. New 2021
14
PT Smelting Gresik Smelter off-gas 1,330 t/d Chemetics n.a. New 2024
15 Eramet Weda Bay Sulphur burning 3,000 t/d DuPont MECS CC6 New 2025
16 LITHUANIA
17 Orlen Lietuva Mazeikiai Spent acid regen 75 t/d DuPont MECS n.a. New 2025
MOROCCO
18
OCP Jorf Lasfar Sulphur burning 2 x 5,000 t/d Chemetics Intecsa New 2022
19
PERU
20 Petroperu Talara WSA 560 t/d Haldor Topsoe Cobra New 2021
21 RUSSIA
PhosAgro Volkhov Sulphur burning 2,400 t/d n.a. n.a. New 2022
22
NorNickel Norilsk Smelter off-gas n.a. Outotec n.a. Revamp 2022
23
SAUDI ARABIA
24 Ma’aden Ras al Khair Sulphur burning 5,000 t/d n.a. n.a. New n.a.
25 SOUTH AFRICA
Anglo Platinum Polokwane WSA 148 t/d Haldor Topsoe Hatch New 2020
26
SWEDEN
27 Boliden Ronnskar Smelter off-gas n.a. Outotec n.a. Revamp 2020
28 UNITED STATES
29 ioneer Nevada Sulphur burning 3,500 t/d DuPont MECS SNC Lavalin New 2023
30
31
32
Watch free fertilizer
33
market presentations
E ARS
34
35
Argus deliver concise and insightful webinars analysing R E
F BIN
WE
36 the nitrogen, phosphate, potash, sulphur and sulphuric
acid markets. The webinars are offered on-demand
37
and live – and are completely free to watch.
38
39 Watch the free webinars here:

www.argusmedia.com/webinars
40
41

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JULY-AUGUST 2021
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NOX EMISSIONS REDUCTION
3
7 Reducing NOx emissions

in metallurgical oleum
8
10
11
12
13
tower production
14
A. Goudarzi of CECO Industrial Solutions discusses the science behind NOx content and how it
15 impacts sulphuric acid producers. In a recent project in Korea, TWIN-PAK® candle filter technology
16 was successfully used to reduce NOx emissions in metallurgical oleum tower production. After
17 installation of the candle filter mist eliminators the plant was compliant with environmental
18
regulations enabling the producer to operate the plant without penalties or shutdowns.
19
E
20 verchanging regulations and air Using CECO Filters TWIN-PAK® & Graded There are three common sources of
pollution control is a major global Bed™ technology the operator was able NOx formation:
21 concern, organisations are looking to further enhance performance to meet l above 815°C NOx formation starts
for smart solutions to reduce emissions regulations. to increase exponentially and reach
22
to meet stipulated limits by governing higher than 800 ppm at temperatures
23 bodies. Elevated temperatures required NOx content and how it impacts of 1,650°C;
for metallurgical roasters often create l unbalanced oxygen concentrations and
24 higher levels of nitrogen oxides (NOx)
sulphuric acid producers higher combustion residence times;
which require abatement or exceed emis- The reaction between nitrogen and oxygen l wet electrostatic precipitators (WESP) are
25
sion limits. As the gas flows through the results in nitric oxide (NO) and nitrogen commonly known to spark NOx formation.
26 operation from the roaster to the final dioxide (NO2) formation – otherwise known
stack output, mitigating NOx levels has as NOx or nitrogen oxides. With stricter controls on air pollution regu-
27 become a major global initiative which lations and implementation of NOx emis-
N2 + O2 2NO
has transgressed to the metallurgical sul- sion reductions to mitigate the impact on
28 2NO + O2 2NO2
phuric acid industry. CECO Filters in devel- our ecosystem, more producers are experi-
29 opment with a major Korean metallurgical encing stringent changes in environmental
producer “Company K”, utilised the last A common day problem for most metal- permitting and are required to take action
30 line of defence, candle filter mist elimina- lurgical sulphuric acid producers is high to comply with new local norms. These
tors, to remove NOx outputs to meet the levels of NOx formation and output at the changes have been geographically notice-
31 local requirements. stack. able throughout the last decade.
32
Fig. 1: Top compartment retrofit Table 1: Stream 1 – inlet parameters
33
Volumetric gas flow rate 100,000 Nm3/h
34
Temperature 70°C
35
SOURCE: CECO INDUSTRIAL SOLUTIONS
Gauge pressure 1800 mm H2O (g)

36
Mist loading 4,000 mg/Nm3
37
NOx content < 80 ppm
38
Allowable pressure drop < 130 mm H2O (g)
39
NOx requirement at stack < 60 ppm
40 Source: CECO Industrial Solutions
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JULY-AUGUST 2021
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3
5
NOx has an affiliation to sulphuric design solutions for greenfield projects to
6
acid and absorbs onto molecules to form
Fig. 2: TWIN-PAK® candle filter reduce capital expenditures without impact-
7 nitrosylsulphuric acid. This enables candle ing operation expenditures and maintaining
filters with highly dense fibres to create a an overall economical solution by optimising
8 liquid film layer of sulphuric acid to absorb the total cost of ownership for operators.
NOx contaminants in the gas streams In this project, the TWIN-PAK® filter
9
passing through the candle filter media arrangement offered greater reductions in
10 bed. pressure drop compared to conventional
filters, decreasing the pressure drop by
11 NO + NO2 + 2H2SO4 2NO∙HSO4 + H2O 50% (180 mm H2O (g) to 90 mm H2O (g)),
as well as creating more surface area to
12
N2O3 + 2H2SO4 2NO∙HSO4 + H2O enable better NOx absorption (Fig. 2).
13
Graded Bed™ candle filter media
14 An optimised solution to
technology
15
a common problem
Candle filter technology operates under
16 A Korean producer faced local laws swiftly wetted or partially flooded mechanisms
changing on NOx emissions from 120 to effectively remove sub-micron oleum
17 ppm to 60 ppm. They contacted CECO mist using closely packed fibrous media
Filters for mist eliminator solutions to in multiple density arrangements to enhance
18 help resolve the problem. CECO proposed performance. CECO’s Graded Bed ™
adding candle filter mist eliminators to technology was cleverly designed to bal-
19
the oleum tower. The current tower didn’t Source: CECO Industrial Solutions ance the level of flooding contained within
20 house any filters and required retrofit- the media and create a fine oleum film
ting the top compartment of the tower to layer for contact.
21 install filter units. TWIN-PAK® candle filters The affiliation of absorption between
The oleum production presented sulphuric acid or oleum and NOx gases is
22
pressure drop concerns and restrictions TWIN-PAK® was developed specifically to utilised to reduce NOx concentrations in
23 through the existing plant set-up and the address conventional candle filter restric- the gas stream to effective levels and in
customer was limited to solutions with tions through arrangement reconfiguration by compliance to local norms (Fig. 3).
24 a compact design to fit into the existing optimising performance through increased
25
constraints and increased throughput filtration area to give additional capacity Pilot testing and results
capacity while meeting the pressure drop flow, reduced pressure drop, better filtration
26 limitation for the existing blowers (Fig. 1 efficiency and output performance, ideal for During the validation and prior to testing
& Table 1). retrofitting solutions, as well as compact of media, CECO worked with the customer
27
Fig. 3: Graded Bed™ Candle Filter Media Technology Fig. 4: Pilot unit
28
29
stage 1
stage 2
stage 3
30
31
32
33
34 wet gas flow dry gas flow
35
36
37
38
39
40 Source: CECO Industrial Solutions
41

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JULY-AUGUST 2021
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3
6 Fig. 5: Installation photographs

7

10
11
12
13
14
15
16 Fig. 6: Results diagram to offer multiple design case studies

based on CECO’s graded bed filtration
17 arrangements. As the project evolved, it
became apparent that the client’s need
18 was primarily focused on available pres-
stream 3 sure drop and the constraints which they
19
faced for the retrofit solution. The client
20 opted for the lowest case pressure drop
design with a value of less than 100 mm
21 H2O.
CECO supported and provided pilot
22
testing filters to ensure that the filter was
23 IAT FAT able to achieve the reductions of NOx
and meet the pressure drop requirement.
“
24 This was done to validate the theoretical
stream 2
data and convert theory into empirical
25 stream 1 data using pilot testing and validation of
26 A smart solution that reduces performance. The results from the pilot
testing were positive and provided confir-
27 the total NOx output of the mation of the pressure drop at given flow
plant in accordance with rates and also, significantly reduced NOx
28
removal rate. CECO collected multiple
29
environmental regulations data points and developed further empiri-
cal knowledge of absorption rates of NOx
and enabling the producer
30 and sulphuric acid at multiple operating
to operate the plant without conditions (Figs. 4 & 5).
31 After installation and adding additional
oleum tower
penalties or shutdowns filtration area, the commissioning results
32
Source: CECO Industrial Solutions
from CECO Filter’s TWIN-PAK® technology
33 confirmed the units were able to remove
NOx levels more effectively to 32 ppm
34 Table 2: Stream 2: Oleum tower output or less from 80 ppm (at commissioning
stage), while reducing the pressure drop
35 Pressure drop < 90 mm H2O (g) from 130 mm H2O (conventional filters)
36 Outlet mist content < 20 mg/Nm3 to 90 mm H2O with TWIN-PAK® filters. The
oleum output levels were also enhanced by
37 higher efficiency performance, ultimately,
providing a smart solution that reduces
38
Table 3: Stream 3: Stack output the total NOx output of the plant in accord-
39 ance with environmental regulations and
NOx content < 32 ppm enabling the producer to operate the plant
40 without penalties or shutdowns (Fig. 6 &
Tables 2 & 3). n
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JULY-AUGUST 2021
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13
LEWIS
14
15 ®
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With over 127 years experience, Lewis® pumps and valves are engineered with genuine
35 Lewmet® alloys, meaning they provide better corrosive resistance than anyone else.
Our team is focused on one thing, and one thing only, creating the most durable products
36 in the world. It’s no surprise we’re market leaders, there’s just nothing as strong as Lewis®
pumps and valves.
37
38
Learn more at onlylewis.weir LEWIS®
39
Minerals
40 Copyright© 2018, 2020, Weir Slurry Group, Inc. All rights reserved. The trademarks mentioned in this document are trademarks and/or www.minerals.weir
registered trademarks in the name of The Weir Group PLC and/or its subsidiaries.
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JULY-AUGUST 2021
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SULPHUR FORMING
3
10
11
12
13
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15
16
17
18
19
20
21
22
PHOTO: IPCO
23
24
25
New showcase T
26 he IPCO SG20 is a fully automated
sulphur granulation system based
27 on rotating drum technology. Its
high productivity ‘once through’ operation
drum granulator
28
delivers a solidification capacity of up to
29 800 t/d. The unit has been delivered to
a long-standing customer in Italy, a com-
30 pany operating multiple sulphur solidifica-
commissioned
tion lines, and an agreement is in place
31 that will enable prospective customers to
visit the site and assess the system in
32
operation.
33 The SG20, a scaled-down version of
the company’s 2,000 t/d SG30 model, is
34 Sulphur processing and handling equipment manufacturer designed for medium-range capacities. The
35
IPCO has completed the commissioning of a groundbreaking newest model is notable for its remarkably
quiet operation, well below standard noise
new drum granulator in Italy that will serve as a global limits, and for easy access to all compo-
36
showcase for this patented system. C. Metheral of IPCO, nents for monitoring and maintenance.
37 The system delivers a high quality prod-
describes the innovative approach and key features of the
uct satisfying the shape criteria and Stress
38
SG20 sulphur granulation system. Level I and II friability parameters of the
39 SUDIC product specification. This ensures
efficient, clean and environmentally safe
40 storage and handling during transporta-
Above: IPCO SG20 drum granulator in Italy. tion. The SUDIC specification also limits
41
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JULY-AUGUST 2021
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SULPHUR FORMING
3
5
moisture content; excess moisture not
6 Fig. 1: Basic process flow diagram
only adds weight, leading to unnecessary
7 transportation and melting costs, but also
results in increased acidity, risking corro- solid sulphur granules
8 sion in storage, handling and transporta- air
sulphur dust exhaust air
tion equipment. water
9 granulation
The same operating principles apply drum
wet scrubber
liquid sulphur
10 to both models. This is a single-pass
process, which eliminates any need for
solid sulphur seeds water sulphur dust
11 screens or recycle conveyors to send sul-
phur back through the drum. The sulphur liquid sulphur
12 seed generation system
seed or nuclei particles are created out- Source: IPCO
13 side the drum by freezing sprays of liquid

sulphur in a water bath. Generating the
14 particles externally simplifies the process
and allows wider flexibility with the incom-
15
ing liquid sulphur temperature. It also
16 provides an innovative way to recycle the
sulphur waste stream from the wet scrub-
17 bing system, which is explained later.
Fig. 1 shows a basic process flow dia-
18 gram of the drum granulation process.
PHOTOS: IPCO
19
Innovative approach to drum
20
granulation Fig. 2: Major build-up (left) vs. minor build-up (right) inside ducting.
21 The IPCO patented SG system has
been designed to resolve the drawbacks
22
often associated with traditional drum
23 granulation technology, in particular clean-
ing, maintenance and process control.
24 IPCO’s experience in the supply of sul-
phur solidification and handling equipment
25
extends all the way back to 1951 and this
gives the company an unparalleled insight
PHOTOS: IPCO
26
into the problems encountered by operators
27 and maintenance personnel. The design of
the SG series involved identifying the root
28
cause of each issue, and then working out Fig. 3: Unheated nozzles (left) can be prone to plugging; heated nozzles (right) stay clear.
29 how it could be eliminated or, at the very
least, its effects minimised. but the result is a dramatic reduction in freeze in the tip, blocking flow at the next
30 cleaning requirements: the SG20 can run start-up. Even if the nozzle is clear, sul-
31
Substantial reduction in sulphur continuously for a full week before requir- phur vapour from inside the header can
ing a shutdown. Even then, the cleaning condense and freeze in the tips if the sys-
build-up requirement is minimal compared with tra- tem is shut down for an extended period.
32
Older drum technologies have always ditional drum granulation systems. In either case, rectifying the problem will
33 required regular shutdowns to clean out require an operator to manually clean out
34
the build-up of sulphur within the system. Heated sulphur nozzles the nozzle or replace it before starting up
This could be as frequent as every 12-24 the system. A single frozen or plugged
hours, with an obvious and significant Liquid sulphur has to be maintained at a nozzle can make the difference between
35
impact on overall system productivity. And specific temperature range (around 120 to premium granules and off-spec product.
36 even when systems could be run for longer 160°C), so any cold spot in a processing IPCO has overcome this issue by incor-
than this, the cleanout process would be system has the potential to cause prob- porating the industry’s first heated sulphur
37 much more challenging, leading to longer lems. In the case of traditional drum gran- spray nozzle. Again, the technical specifica-
shutdown periods. ulators, the problem area in this respect tions are protected by IPCO, but the out-
38
Having identified the points within the has often been the sulphur spray nozzles, come is that the nozzles in the SG series
39 system where sulphur build-ups occur due to the fact that they extend outside the will not freeze up, and the time-consuming
(Fig. 2), and studying each one, IPCO has steam-jacketing (Fig. 3). task of sending an operator into the drum
40 designed the system to minimise this If liquid sulphur remains in the nozzle to resolve the problem has been com-
issue. The specifics remain confidential when the system is shut down it will pletely eliminated.
41

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JULY-AUGUST 2021
XX
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SULPHUR FORMING
3
6 Redesigning the drum to minimise is evaporated into the air as the sulphur Injecting the sulphur dust captured
cools, and the air is then discharged to the by wet scrubbing back into the process,
7
roller wear atmosphere. However, as the exhaust air it is consumed as seed in the drum (Fig.
The drum granulation process is based on contains sulphur dust, it has to be treated 1). This is a simple and energy efficient
8 the use of a rotating drum to form curtains in order to prevent atmospheric pollution. solution, one that requires no extra work
of falling granules. As the nuclei particles Managing this has traditionally meant in terms of operating and maintaining the
9
travel along the drum, they are progres- choosing between two options, the steam- sulphur melting/filtering equipment.
10 sively enlarged to the required size by jacketed cyclone and the wet scrubber with
11
means of sulphur sprayed from a bank of dust collection system, and there are draw- Managing H2S emissions
nozzles running the length of the drum. backs to both.
In older systems, the drum would be The steam-jacketed cyclone melts the As is the case with all sulphur produced
12
positioned at an angle so that gravity would sulphur dust that has been captured to cre- as part of the oil refining process, the sul-
13 advance the granules towards the outlet ate sulphur vapour. The result is high levels phur processed at this facility in Italy con-
end of the system. However, granulation of dust emissions, a major problem for sys- tains levels of hydrogen sulphide (H2S).
14 drums are large and heavy pieces of equip- tems operating in environmentally sensitive The drum granulation process involves
ment and the need to rotate on an angle areas. The process also requires high vol- spraying liquid sulphur through nozzles,
15
inevitably creates high levels of stress on umes of steam in order to heat up the air which releases a portion of this H2S into
16 the rollers that support the drums, result- stream while melting the sulphur dust. the air stream.
ing in alignment issues requiring ongoing The second technology, the wet scrub- Levels of H2S vary depending on the
17 maintenance. ber with dust collection system, captures liquid sulphur supply and acceptable
IPCO’s SG series granulators (Fig. 4) the fine sulphur particles with water to stack emission levels will differ around
18 take a different approach. Instead of turn- form a sludge, which in turn needs pro- the world too. European regulations place
ing on an angle, they operate on a com- cessing. The usual approach is to melt strict limits on H2S so measur es have to
19
pletely level base, using angled internal and filter the waste, then feed it back into be taken to prevent it from entering the
20 flights to advance the product instead of the liquid sulphur supply system. Although atmosphere.
gravity. This means no unnecessary wear a more complicated process than the The solution here is the addition of an
21 and tear on the rollers, and no mainte- steam-jacketed cyclone, it results in lower H2S scrubbing system, an option that can
nance to keep the unit aligned. dust emissions. be incorporated to ensure compliance with
22
IPCO has taken a new approach. As a the most stringent of emission require-
23 Dust emissions and scrubber waste wet scrubbing system has the lowest sul- ments, anywhere in the world (Fig. 6).
phur dust emissions (and therefore low-
24 Drum granulators work by removing heat est impact on the environment), this was Consistent operation
from the product to convert it from a liquid chosen as the basis of the solution. How-
25
state into a more easily handleable solid. ever, instead of requiring a second stage While technology is key to successful sul-
26 In the case of sulphur solidification, this of processing, the waste stream is recycled phur forming, there are many other factors
heat exchange is carried out using air and directly into the external seed generation at play, all of which can impact on the qual-
27 water: air is pulled into the drum, water system (Fig. 5). ity of the end product.
28
29
30
31
32
33
34
35
36
37
38
PHOTOS: IPCO
39
40
Above: Fig. 4: SG20 drum (left). Fig. 5: Scrubber waste discharge to seed generation system (centre). Fig. 6: Exhaust stack (right).
41
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JULY-AUGUST 2021
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SULPHUR FORMING
3
5
Throughput rates, liquid sulphur feed and building a process simulation that can
6
temperature, geographic region, ambient be applied to any operating conditions.
7 temperature, humidity levels, seasonal
8
conditions, the weather; all need to be Summary
taken into account as part of the solidifi-
cation process and this can place a high In designing the SG series, IPCO has taken
9
degree of responsibility on the operator. all the inherent advantages of drum granu-
10 It is possible to set up a drum granulator lation – highest capacity, highest quality
to operate to fixed parameters but this is end product – and enhanced the technol-
11 likely to result in sub-optimal performance ogy in ways that overcome the challenges
if and when conditions change. previously associated with this approach
12
The ability to adjust operating parame- to sulphur forming (Table 1).
13 ters relies on the operator having sufficient Cleaning and maintenance require-
experience to understand how the system ments have been significantly reduced,
14 will react under varying conditions. Get it resulting in increased equipment availabil-
right and the result will be consistently ity. Emissions of both sulphur dust and
15
high-quality sulphur granules; get it wrong H2S are well within the limits of prevailing
16 and product quality will suffer, water will be environmental legislation. Noise levels are
wasted, and build-ups will occur, resulting far below standard limits. A new approach
PHOTO: IPCO
17 in shutdowns. to drum design minimises stress of rollers
While operator training and follow-up to increase equipment life, and, perhaps
18 support visits can help build the neces- most important of all, operation has been
sary skills over a period of time, there is simplified: the unit can be stopped and Sulphur production by SG20 being stockpiled.
19
a risk of a system operating at less than started at the touch of a button, and a
20 100 percent efficiency – and producing game-changing operator guidance system premium quality pastilles of uniform shape
less than premium quality product – until means that a high-quality product can be and size. More than 700 Rotoform pastil-
21 the required level of in-house expertise has produced at all times, regardless of opera- lation systems have been installed for sul-
been developed. tor experience. phur processing to date.
22
IPCO has overcome this by developing a IPCO is a world leader in sulphur pro- Together, the drum and pastillation
23 process simulation solution that takes all cessing and handling, having delivered options make up IPCO’s premium forming
guesswork out of realising the full potential complete end-to-end systems to hundreds product range, giving customers access to
24 of its patented drum granulation system. of companies around the globe since all technology options under a single brand.
The SG series operator guidance sys- 1951. In addition to granulation drums, The IPCO SG20 drum granulation sys-
25
tem – an industry-first in the field of sulphur IPCO’s well-known Rotoform system meets tem installed in Italy is available for cus-
26 drum granulation – was developed by ana- small to medium capacity requirements for tomer visits on request. Interested parties
lysing a wealth of operating data collected sulphur, offering excellent product uniform- are invited to contact their local IPCO office
27 from both the SG20 and SG30 systems, ity, environmentally friendly operation and to organise a visit. n
28
Table 1: Advantages and benefits of the SG system
29
Feature Advantage Benefit
30 Minimised build-up Reduced housekeeping l Increased equipment availability
l Less labour
31
Heated sulphur nozzles No frozen nozzle tips l Increased equipment availability
32 l Less labour
Completely level drum Minimal shearing forces on rollers l Increased equipment life
33
l Less maintenance (no alignment)
34 Combustion of wet scrubbing with Lowest sulphur dust emissions l Easier environmental permitting
external seed generation Recycled scrubber waste l Eliminates scrubber waste stream
35
l Lower steam consumption
36 H2S scrubbing solution for drum granulator Reduced H2S emissions l Easier environmental permitting
37 Operator guidance system Precise control in all scenarios l Reduced training and experience
requirements
38 l Efficient use of utilities
Simple operation of equipment l Easy to maintain product quality and
39
efficient use of utilities
40 Source: IPCO
41

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JULY-AUGUST 2021
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2 48
CLAUS UNIT AMMONIA DESTRUCTION
3
7 The three “Ts”

reconsidered
8
10
11
Are the three “T”s (temperature, turbulence, time) of Claus unit ammonia destruction still
12
meaningful with improved understanding of the thermal reactor? CFD models appear to be
13
adequate at higher temperatures, e.g. 1,200°C, but not at lower temperatures, e.g. 800°C and
14
1,000°C. A. Keller, on behalf of the Amine Best Practices Group, reviews how meaningful the
15 rules of thumb for Claus unit ammonia destruction really are.
16
17
T
18 here is a near ad-nauseum collec- how the ammonia destruction takes place. the 1990s, computing speed increased
tion of technical papers concerning Concerning temperature, most opera- exponentially. Chemical engineers now
19
the destruction of ammonia in Claus tions departments rely on pyrometers had the computing power to make com-
20 thermal reactors (as reaction furnaces are peering into or embedded thermocouples putational fluid dynamic (CFD) modelling
now being called). There have been argu- indirectly reporting a value purporting to practical.
21 ments for the use of “oxidising” conditions be the temperature in the thermal reactor. Models have moved from around 30 thou-
in “front zones” of the thermal reactors We shall also see this number may not be sand cells for a Claus burner/thermal reac-
22
while others have maintained that oxi- meaningful in terms of how the ammonia tor to over 30 million cells. With the details
23 dising zones encourage the formation of destruction takes place. that these models can develop, is it worth
sulphur trioxide causing plugging in down- Concerning turbulence, it is presumed asking if the gospel notions of the three “Ts”
24 stream equipment. Papers abound advo- that better mixing bringing oxidiser and fuel are still worthy of their gospel quality?
cating split furnace zones or “good mixing” together improves ammonia destruction. It
25
burners. Ultimately, nearly all of these is up to each Claus burner/thermal reac- Temperature and composition
papers get to the same rules of thumb for tor technology provider to convince each
26
adequate ammonia destruction in a Claus potential client that their burner/thermal
effects on ammonia destruction
27 burner/thermal reactor: reactor design is best suited to this task. The landmark study by Alberta Sulphur
l Time: 0.8-2 seconds of thermal reactor We shall also see where some technology Research Limited (ASRL) on the chemical
28
residence time is needed; offerings have been criticised, but fortui- conversion of ammonia in Claus thermal
l Temperature: 1,200-1,250°C (2,192- tous design circumstances allowed these reactors in the late 1990s1 corrected many
29
2,282°F) is the minimum temperature technologies to perform adequately. of the known rules of thumb of that day
30 requirement; Most of the shaky assumption blame concerning ammonia destruction. What is
l Turbulence: Mixing in the burner and can be placed squarely on the industry’s being discussed in this work is not meant
31 furnace need to adequately combine lack of digital computing power prior to the to change or alter any of the conclusions
the air and acid gas being burned. 1990s. With the advancement of solid- made in their analysis, but to put their
32
state electronics through the 1980s into results into the perspective of burner/
33 Known as the three “Ts” for good ammo-
nia destruction, they have been considered Fig. 1: Reactor apparatus in tube furnace
34 close to gospel for the practitioners of Claus
sulphur recovery, but they unfortunately rest
35 NH3 feed inlet
on some fairly shaky assumptions.
36 Concerning residence time, most chem-
ical engineers would compute this simply reactor exit annulus reactor tubes reactor feed annulus
37 as the volume of the thermal reactor space
divided by the volumetric rate of the gases
38
through the reactor as if this were merely reactor
exit
39 a turbulent flow in a pipe exercise. As we sample tube SO2/Ar feed tube extension SO2/Ar feed inlet
shall see later on, this is not meaningful
40 for the bulk flow of gas in the burner/ther-
mal reactor, nor is it meaningful in terms of
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6 Fig. 2: Comparison of ASRL experimental yields and CFD predicted yields for various reactor conditions
7
reactor temperature: 800°C reactor temperature: 1,000°C
8 gas residence time: 0.421 sec gas residence time: 0.177 sec
moles/100 moles reactant

4.5 4.5
4.0 4.0
9 3.5 3.5
product yield,
product yield,
3.0 3.0
10 2.5 2.5
2.0 2.0
1.5 1.5
11 1.0 1.0
0.5 0.5
0.0 0.0
12 H2 N2 H2S SO2 H2O S2 NH3 H2 N2 H2S SO2 H2 O S2 NH3
gas species gas species
13
ASRL test 4, RT=0.421 CFD, RT=0.641 ASRL test 3, RT=0.177 CFD, RT=0.345
14
15
reactor temperature: 1,200°C reactor temperature: 1,200°C
16 gas residence time: 0.153 sec gas residence time: 0.472 sec

4.5 4.5
4.0 4.0
17 3.5 3.5
product yield,
product yield,
3.0 3.0
2.5 2.5
18 2.0 2.0
1.5 1.5
19 1.0 1.0
0.5 0.5
0.0 0.0
20 H2 N2 H2S SO2 H2O S2 NH3 H2 N2 H2S SO2 H2O S2 NH3
gas species gas species
21
ASRL test 2a, RT=0.153 CFD, RT=0.145 ASRL test 2b, RT=0.153 CFD, RT=0.472
22
23
24 thermal reactor performance and to recon- and all reactions having achieved chemical space closest to the heating source on the
sider the three “Ts” rules of thumb. equilibrium inside of any of the differential outside of the reactor tube wall, is heated
25
Some important conclusions from the cells being computed. more rapidly than the Ar-SO2 mixture enter-
26 ASRL work that are useful for understand- Let’s examine some of the modelling ing in the middle tube.
ing CFD models of different burner/thermal results testing both sets of assumptions. In Fig. 4, the scale on the side shows
27 reactor systems can be summarised as: Fig. 2 is a comparison of yields of vari- the ammonia concentration in the inlet
Reduction of SO2 by ammonia to form ous species measured in the lab versus and the change in concentration as the
28
nitrogen, water, H2S, or elemental sulphur is those predicted by the CFD model. The ammonia is first heated then reacted.
29 kinetically favoured over thermal decomposi- cases were run to try to match the resi- The rapid heating of the ammonia without
tion of ammonia to nitrogen and hydrogen or dence times computed from the laboratory water being present leads to some thermal
30 direct oxidation of ammonia by oxygen. work showing a small discrepancy. At the decomposition as the ASRL study showed
Above 1,200°C, the kinetics of SO2 lower temperature, the CFD assumption of in a separate experiment. Reaction of the
31 reduction by ammonia results in nearly achieving equilibrium is invalid according remaining ammonia with SO2 is fairly rapid
complete ammonia destruction in much to the measured results. At the higher tem- when the two streams are combined and
32
less than one second residence time. perature, the CFD assumption of reaching reach 1,286K (1,013°C or 1,855°F) to
33 Fig. 1 is a schematic, provided by ASRL equilibrium is fairly consistent with meas- 1,348K (1,075°C or 1,967°F).
to a member company, of the tubular reac- ured results. In Fig. 5 the scale depicts the mole
34 tor placed in a temperature-controlled In Figs 3, 4 and 5, we see three data fraction of SO2 in the Ar-SO2 mix dissi-
furnace to perform this study. The geome- extractions from the model depicting the pating as it contacts the ammonia in the
35
try of this reactor was used by the member reactor temperature profile, ammonia con- reaction zone. The Ar-SO2 mix is being
36 company to construct a CFD model of the centration profile, and SO2 concentration heated more slowly than the ammonia,
reactor to validate the turbulent, plug-flow profile for Test 2a. but the heating does nothing to the
37 assumption used to determine experimen- In Fig. 3, temperature is shown in kelvin stable SO2 molecule. At the point of mix-
tal residence time used to correlate con- (K). 418K is 144°C or 293°F, depicted by ing with the hot ammonia, SO2 is rapidly
38
version. the blue colour at the bottom of the scale. consumed.
39 The experiment was conducted with 1,472K (1,119°C or 2,190°F) as depicted Unlike the confirmation of the chemical
some fixed assumptions, plug flow and iso- by the reddish orange colour near the top reaction results obtained in the laboratory,
40 thermal conditions. The CFD modelling fixed of the scale is the furnace and outer tube the CFD modelling dispels some of the
assumptions were the mixing parameter temperature. Ammonia, entering the annular three “Ts” assumptions. We certainly don’t
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5
have plug flow. Not everything is perfectly
6 Fig. 3: CFD generated temperature profile for Test 2a (reactor entrance)
mixed and at a constant temperature, and
7 1,534 near complete destruction is taking place
1,472 below 1,200°C. Most importantly, ammo-
8 1,410
nia appears to react quickly near the mix
1,348
point and does not require the entire resi-
9 1,28
1,224 dence time of the tube.
10 1,162
11
1,100
1,038
CFD application in commercial units
976 We can apply these small-scale lessons
12 914
learned to commercial-sized burner/ther-
852
13 mal reactor systems. The emphasis in
790
728 doing this must be kept on the notion of
14 666 the three “Ts” and their application to the
604 burner/thermal reactor design.
15 542 We will examine two well-known tech-
480 nology offerings. The first is a low mixing
16 418
intensity burner with a two-zone thermal
17 reactor using amine acid gas split between
the two zones (see Fig. 6). The second will
18 Fig. 4: CFD generated ammonia concentration profile for Test 2a (reactor entrance) be the single-zone thermal reactor using a
high mixing intensity burner (see Fig. 7).
19 1.0000 For each offering, there are six images
0.9500
20 0.9000 extracted from the CFD models done.
0.8500 These are wall temperature, gas tempera-
21 0.8000 ture, oxygen mole fraction, SO2 mole frac-
0.7500 NH3 reaction predicted in the reactor feed annulus tion, ammonia ppmv, and velocity.
22 0.7000
0.6500
23 0.6600
0.6000
Low intensity mixing burners
24 0.5500
0.5000 In Fig. 6b we see that the first zone, which
0.4500 is supposed to be hotter than the second
25 0.4000 zone is much cooler, on average. What is
0.3500 most important to note is that ammonia
26 0.3000
0.2500 contained in the acid gas is being heated
27 0.2000 up by hot gas recirculating in a narrow
0.1500 annular space prior to contact with the SO2
28 0.1000
generated by the combustion.
29 In Fig. 6f, note that the scale was to pri-
marily show low values for completeness
30 Fig. 5: CFD generated SO2 concentration profile for Test 2a (reactor entrance) of destruction purposes. Regions in red
represent higher concentrations.
31 0.0347 Burning with excess air would give a
0.0330 hotter flame as more H2S is converted
32 0.0312
to SO2 and water in a highly exothermic
0.0295
33 0.0278 reaction. However, the profiles show that
0.0260 if a box were drawn around the first zone
34 0.0243 (assuming perfect mixing), technically it
0.0225 would be an oxidising environment. How-
35 0.0208
ever, we see that oxygen leaves the first
0.0191
36 0.0173 zone only because it remains unmixed.
0.0156 Next, we notice that SO2 is plentiful
37 0.0139 where the acid gas and air are mixing and
0.0121 burning, but not so plentiful in the recircula-
38 0.0104
0.0087
tion zone of first thermal reactor zone. SO2
39 0.0069 made in the initial flame is rapidly consumed
0.0052 to make sulphur and water by reacting with
40 0.0035 H2S. It also appears from the ammonia con-
centration profile that SO2 is also aiding in
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3
6 Figs 6(a)-(f): Low intensity mixing burners Fig. 7(a)-(d): High intensity mixing burners
7
Approximate thermocouple locations
8
9
temperature, °F
10 2,600
2,200
11 1,800
1,400
Temperature, °F
12 1,000
80 704 1,328 1,952 2,576 3,200
13
14 Fig. 7(a): Temperature profile (acid gas enveloping air)
15
Fig. 6(a) Two-zone thermal reactor inner wall temperature profile
16
approximate
Approximate pyrometer
pyrometer locations
locations temperature, °F
17
3,000
2,800
18 2,600
2,400
2,200
19 2,000
1,800
20 Fig. 6(b) Two-zone thermal reactor gas temperature profile (plan view) Mole fraction of O2
0.000 0.041 0.082 0.122 0.163 0.204
21
O2 mole fraction
0.250
22
0.1875
0.125 Fig. 7(b): Single zone thermal reactor oxygen mole fraction profile
23 0.0625
0
24
Fig. 6(c) Two-zone thermal reactor oxygen mole fraction profile
25
26 SO2 mole fraction

0.130
27 0.0975
0.065
28 0.0325 Mole fraction of SO2
0
0.000 0.022 0.044 0.066 0.088 0.110
29
Fig. 6(d): Two-zone thermal reactor SO2 mole fraction profile
30
31 recirculation zone velocity, ft/s Fig. 7(c): Single-zone thermal reactor SO2 mole fraction profile
40
32 20
0
-20
33 -40
34
Fig. 6(e): Two-zone thermal reactor velocity profile
35
NH3, ppmv
36
2 Mole fraction of NH3
1.5
37 1 0.000 0.015 0.031 0.046 0.062 0.077
0.5
38 0
39 Fig. 6(f) Two-zone thermal reactor ammonia ppmv profile Fig. 7(d): Single-zone ammonia mole fraction profile
40 Source: Xxxxxx
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3
5
ammonia destruction close to where the again see two types, air enveloping acid see with the CFD modelling that the real
6
incoming acid gases and air collide. gases and acid gases enveloping air. question we should have asked is: Were
7 Without the benefit of CFD modelling, The design in Fig. 7a is a one zone fur- our assumptions leading to the three “Ts”
a prescient conclusion/recommendation nace with choke ring. Acid gas enveloping valid?
8 from the ASRL work clarifies this: air produces the central cone-shaped com- Laboratory work and actual plant opera-
This study has, however, shown that bustion zone seen in the first low intensity tions, confirmed by CFD modelling, say the
9
SO2 reacts quite readily with ammonia burner model. A series of model profiles assumptions were incorrect. Both labora-
10 forming N2, water or H2, and sulphur similar to that analysis follow. tory and plant CFD models appear to dem-
or H2S, displaying reaction rates which Again, profiles for oxygen, SO2, and onstrate the following:
11 exceed those of either dissociation or oxi- ammonia mole fraction are used to illus- Ammonia destruction has two compo-
dation. Also, it was shown that the ammo- trate the impact of the burner-thermal reac- nents. The first is preheat of the ammonia
12
nia/SO2 reaction is able to proceed in the tor design on ammonia destruction taking containing gas by the hot gases recirculat-
13 presence of water. These observations into consideration adherence to three “Ts” ing in the thermal reactor. All the models
and others described in the main text sug- thinking. Figs 7b-d are for the acid gas show the hottest place in the thermal reac-
14 gest the following protocol for ammonia enveloping air case. tor is at the combustion boundary. Both
destruction in the Claus furnace. The range of the scale didn’t allow allow the ammonia containing gases to
15
l Utilise a burner/furnace configuration intermediate concentration to show up as quickly reach the desired temperature “T”.
16 which allows the SWSG to impinge on a before. The second part is SO2 reaction with
hot SO2-rich flame. Essentially the model shows the ammo- ammonia. The CFD models confirm H2S is
17 l This could be accomplished by feeding nia cannot stand up to the high tempera- the fastest consumer of oxygen. Once oxy-
all the oxygen required for ammonia ture and high SO2 content in the narrow gen is consumed by the H2S in the flame,
18 and H2S conversion with the AG through combustion zone denoted by the rapid only SO2 remains to attack the ammonia.
a main burner with the SWSG impinging consumption of oxygen. The time element In the end, several different styles
19
on the flame. of the three “Ts” does not seem to play of burner-thermal reactor arrangements
20 a significant role in ammonia destruction. accomplish similar levels of performance
What we have here is a “which comes This burner/thermal reactor perfor- because they foster the conditions of pre-
21 first, the chicken or the egg?” scenario. mance is more of a function of the other heat and SO2 formation in the combustion
The burner/thermal reactor that was mod- two elements, temperature and turbu- zone setting up ideal conditions for ammo-
22
elled was vintage 1980, the ASRL work lence. However, three “Ts” thinking, nia destruction.
23 was done in 1998, and the CFD modelling whether using temperature measured by If ammonia is not being destroyed, there
was done in 2007. The burner/thermal thermocouple or pyrometer or adiabatic could be many things going on. CFD model-
24 reactor was destroying ammonia effec- flame temperature as a guideline for oper- ling can identify what is expected. It is difficult
tively for almost two decades prior to the ations, appears to be unimportant. The to model the myriad of plugging, destroyed
25
ASRL work, yet it implemented the ideas important temperature is in the combus- burner parts, or other impediments to ammo-
26 developed from the study. CFD model- tion zone where the ammonia destruction nia destruction that may occur.
ling showed the burner/thermal reactor action is. This temperature, as the CFD As with many rules of thumb, the three
27 designed using the three “Ts” philosophy models show, can be several hundred “Ts” are an expression of experience
did not work exactly according to the three degrees higher than measured or com- driven common sense. Sometimes there
28
“Ts” rules, especially time and turbulence, puted temperatures. is a tendency to make common sense
29 but it still did the job. This leaves us with only one of the scientifically absolute. The three “Ts” are
Let’s look at the last suggested proto- three “Ts”-turbulence in this case. meaningful, but as the ASRL laboratory
30 col from the ASRL work now. There is a great failing with the CFD work and the CFD models show, they are
l Employ furnace temperatures exceed- models though. Measured ammonia never not scientifically absolute. n
31 ing 1,250°C and furnace residence agrees with the equilibrium assumptions
32
times of >1.5 sec. made for computing reaction chemistry. Acknowledgement
This is likely a failure of the assumptions
33 Without the benefit of CFD done on the used to build the mixing part of the model. This article is an abridged form of the paper
laboratory reactor (late 2012), this conclu- Fault for not achieving sufficient “How Meaningful Are Rules of Thumb for
34 sion was likely the result of making the destruction is typically attributed to not Claus Ammonia Destruction?”, presented
assumptions of plug flow/perfect mixing having all three “Ts” in place. Without by Al Keller, on behalf of the Amine Best
35
and somewhat genuflecting to the three CFD modelling, decisions that may cause Practices Group at Brimstone “Virtual” Vail
36 “Ts”. severe performance related problems or Symposium September 15-17, 2020.
damage to the burner-thermal reactor may
37
High intensity mixing burners be enacted.
38
Now let’s turn our attention to high inten- Concluding remarks Reference
39 sity mixing burners with thermal reactors.
High intensity is defined by incorporating We now come back to the original ques- 1. Mechanisms of Ammonia Destruction in the
40 swirl vanes internal to the air and acid gas tion, “How meaningful are rules of thumb Claus Front End Furnace, ASRL QB 104, Vol
streams prior to the burner tip. We will for claus unit ammonia destruction?”. We 34, No. 4, pp 1-50
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POWERING
A COMPLETE
19
20
21
OFFER
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Building on its latest acquisitions, Axens Group offers a broader
41
range of solutions that enhances the profitability and environmental
42 performance of its clients. www.axens.net
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SRU THERMAL STAGE RETROFIT
3
7 Upgrading for
greater efficiency
8
10
11
New state-of-the-art equipment has been installed in the thermal stage of one of Europe’s largest
12
Claus SRU units. Substoichiometric firing and a furnace designed with CFD calculations and a
13
modern compact boiler system design based on detailed heat engineering and FEM calculations
14
were key to the success of the retrofit. P. Foith of CS Combustion Solutions reports on the retrofit
15 and how the novel combination of a CS low pressure swirl burner, additional mixing using a
16 VectorWall™ and a new waste heat boiler design achieved the desired results.
17
18
A
successful retrofit was recently
19 Fig. 1: CS low pressure swirl burner
completed at a 700 t/d Claus plant
20 in Germany, overcoming the prob-
lems of poorly operating existing equip- secondary air primary air
l Pressure drop air side
21 ment in the existing thermals stage of the max. 44 m bar(g)
SRU unit. The original burner, reactor and l Pressure drop Claus gas side
22 max. 36 m bar(g)
waste heat boiler all had issues.
The original burner at the site was a l Required guarantee less than
23 50 m bar(g) pressure drop
multi flame burner with low pressure drop l No condensing of the Claus gas
24 on the Claus gas side. Due to construction (steam traced heated shell)
issues the burner had undefined mixing l Stable operation in all load cases
25 (CFD studies)
between the air and Claus gas, the flame
stability during start-up and lower load l Stable and reliable start-up
26
cases was poor and there was corrosion
27 due to gas condensation. In the original
Claus gas secondary stage Claus gas first stage
design there was a ceramic block for each
28
individual flame (48 flames) with undefined Source: CS Combustion
29 mixing of oxidation air and Claus gas. The

ceramic blocks was not centrical, hence
30 the Claus gas was not evenly distributed. which arose due to thermal stress caused iciently high turbulence and mixing of air
Even though the original reactor was by an inhomogeneous temperature profile. and Claus gas, despite the low-pressure
31 equipped with a checkerwall in the first The main challenges of the retrofit were: availability. In addition, the aim was to
third of the chamber it had inhomogene- l process parameters upstream and down- get as close as possible to the theoretical
32
ous temperature distribution, hot spots stream should not be affected (remain maximum achievable H2S to S conversion
33 damaging the refractory and problems with the same); of 70% at these process parameters of
long burner flames as the checkerwall was l only low pressure is available on the 1,338K to meet the guaranteed conversion
34 positioned too close to the burner. Claus gas side (high turbulence is dif- rate of 65%, as well as increasing the maxi-
Besides temperature distribution, the ficult with low pressure availability); mum sulphur capacity to 120%.
35
other main purpose of the checkerwall l low pressure availability on the air side;
36 was to improve the H2S to S conversion, l high H2S to sulphur conversion rate; The following steps were taken to meet
which was also not being met. The check- l overall size and dimensions should these requirements:
37 erwall was therefore very inefficient. remain the same (reactor and waste l CS low pressure swirl burner: To mini-
The original waste heat boiler (WHB) heat boiler). mise the pressure drop over the burner
38
was a smoke tube boiler with an internal and ensure proper mixture of Claus gas
39 by-pass with a capacity of 75 tonnes per The target was for a maximum pressure with oxidation air, the original burner
hour @ 36 bar(g) and 250°C. The steam drop of 100 mbar(g) through the complete was replaced with a low pressure dou-
40 drum was installed directly on the boiler. unit (burner, reactor and waste heat boiler). ble staged swirl burner, based on exist-
The biggest issue was welding cracking, Of utmost importance was to generate suff- ing and proven CS burners (Fig. 1).
41
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SRU THERMAL STAGE RETROFIT
3
6 Fig. 2: VectorWall™ (left) and close-up of vector tiles (right)

7
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13
14
IMAGES: CS COMBUSTION
15
16
17
18
l Additional mixing section by using a
19 Fig. 3: CFD analysis VectorWall™: The swirl and turbulence
20 was further increased by utilising a
VectorWall™ with low pressure drop
21 (Fig. 2). The new reactor has the same
dimensions as the original one but is
22
equipped with a VectorWall™ instead
23 Temperature, K of a checkerwall. The VectorWall™
1,790 generates separate mixing zones for
24 1,716
even distribution over the entire cross
1,642
1,568 section.
25 1,494
1,420 l New waste heat boiler and CFD
1,346
26 1,272 analysis: A new waste heat boiler was
1,198
1,124 specially designed by a partner to keep
27 1,051
977 the pressure drop as low as possible.
903 Like the original waste heat boiler,
28 829
755 it was a smoke tube type boiler with
681
29 607 the steam drum installed on top. The
533
459 design of the heat exchangers, bypass
311
30 and internal piping focused on keeping
the pressure drop as low as possible,
31 while ensuring the necessary steam
capacity. Multiple CFD analyses were
32 Mole fraction, S2 done to verify the design and to ensure
33 0.062 that the guaranteed H2S to S conver-
0.059
0.056 sion rate of 65% or above, as well as
34 0.053
0.046 an increase of the maximum sulphur
0.043
0.040 capacity to 120% were met.
35 0.037
0.034
36 0.031
0.028
0.025
Results
0.022
37 0.019 The result of the retrofit was a complete
0.015
0.012 new thermal process stage for a Claus
38 0.009
0.003 plant with a sulphur output of 700t/d. The
39
0.000 state-of-the-art design is low maintenance,
has a low pressure drop throughout the
40 Source: CS Combustion overall unit and achieves a sulphur conver-
sion of ≥65%. n
41

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CLAUS THERMAL REACTOR
3
7 Temperature
measurement in
8
10
11
12
13
sulphur recovery
14
Temperature monitoring and measurement of the Claus thermal reactor in sulphur recovery units
15 is one of the most challenging applications in the oil and gas industry. Recently, market interest
16 in unpurged thermocouples has increased with the introduction of new unpurged thermocouple
17 designs utilising alternative thermowell materials such as monocrystalline sapphire.
18
DELTA CONTROLS CORPORATION
19
20 Purged vs unpurged thermocouples in Claus thermal reactors

21 T. Keys, M. McCallister, and M. Coady
T
22
emperature measurement in the capabilities of the refractory, it is and will suitable for sulphur recovery are designed
23 main reactor of the sulphur recov- be increasingly important to have accurate utilising special materials and protection
ery unit (SRU) is not only a primary and reliable temperature indication. mechanisms to provide accuracy and relia-
24 process variable, but also critical for the bility at the extreme process temperatures.
25
overall safety and reliability of the reactor. SRU temperature measurement These thermocouples utilise a series of alu-
Recently, many legacy reactors with limited mina ceramic thermowells and noble metal
to no temperature instrumentation may be
technologies type thermocouple elements. Thermocou-
26
required to handle more throughput than There are currently two technologies suit- ples in sulphur recovery utilise purged or
27 originally designed. In addition, many reac- able for reliable temperature monitoring in unpurged technology with purged designs
tors are adding supplemental oxygen result- the main reactor: infrared pyrometers and offering the highest reliability track record.
28
ing in increased operating temperatures. thermocouples. It is recommended to use Recent research and development efforts
29 With higher reactor operating tempera- both technologies for maximised reliability. by Delta Controls Corporation have resulted
tures, the importance of temperature moni- Pyrometers designed for sulphur recov- in a highly reliable unpurged alternative.
30 toring is greatly increased. As standard ery are specifically engineered for the opti-
process temperatures rise through the use cal characteristics of the reactor and high SRU thermocouple challenges
31 of oxygen enrichment and reach maximum temperature environment. Thermocouples Thermocouples, both purged and unpurged,
are presented with numerous individual chal-
32
Table 1: Chart of thermocouple temperature ranges lenges in the sulphur recovery environment,
33 and when presented together compound
Type Composition Temperature Range to create significant reliability challenges.
34 Proven thermocouple designs utilise a
B Pt-30% Rh versus Pt-6% Rh 0°C to +1,820°C
series of alumina ceramic thermowells and
35 E Ni-Cr alloy versus a Cu-Ni alloy -270°C to +1,000°C noble metal thermocouple elements.
36 J Fe versus a Cu-Ni alloy -210°C to +1,200°C The high temperatures permit only a
K Ni-Cr alloy versus Ni-Al alloy -270°C to +1,372°C few thermocouple types to fall in the reada-
37 ble range (see Table. 1). Also many metals
N Ni-Cr-Si alloy versus Ni-Si-Mg alloy -270°C to +1,300°C
commonly used on thermocouple sheaths,
38 R Pt-13% Rh versus Pt -50°C to +176°C
or thermowells, are not suitable due to
S Pt-10% Rh versus Pt -50°C to +1,768°C melting temperatures below +3,000°F
39
T Cu versus a Cu-Ni alloy -270°C to +400°C (+1,649°C). In addition to high tempera-
40 tures, the process is highly corrosive with
Source: NIST
process gases hydrogen sulphide, sulphur
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6
dioxide, and other sulphur species pre- Disadvantages of purged recrystallised like alumina resulting in a
sent. Noble metal thermocouple types molecular monocrystalline crystal lattice
7 such as B, R, and S may be subjected to a
thermocouple technology structure that is uniform throughout the
multitude of detrimental effects, including Purged thermocouple designs, when prop- thermowell. Traditional high purity alumina
8 hydrogen embrittlement, platinum oxide erly installed and maintained, are the ceramic has a higher molecular porosity
sublimation (see Fig. 1), and other degra- proven solution for reliable temperature that can allow process gases to diffuse
9
dation reactions. These reactions lead to indication from turnaround to turnaround. through the ceramic at the high operating
10 signal degradation or, ultimately, failure. However, purged thermocouples are not temperatures in the main reactor. Sapphire
An alumina thermowell does not pro- without compromise. Installing and main- is compositionally identical to high purity
11 vide complete protection from the process taining the purge system will require addi- alumina as both are composed of alumin-
gases. The porosity of the aluminium oxide tional costs and complexity that may be ium oxide, Al2O3. However, the monocrys-
12
at operating temperatures allows small considered a disadvantage. The purge gas talline structure of sapphire is not porous
13 amounts of process gases to diffuse through system also introduces additional poten- at high temperature and therefore the dif-
the thermowell, particularly at operating tial failure modes for the thermocouple as fusion of process gases through its crys-
14 temperatures. If these gases are allowed to the purge gas must remain free of contami- talline matrix is much slower than through
accumulate inside the thermowell, they will nants such as moisture or hydrocarbons alumina ceramic. While monocrystalline
15
corrode, contaminate, or otherwise degrade that may damage the thermocouple ele- structures are absent of grain boundaries,
16 the thermocouple within a few weeks. ments. The system requires periodic main- it is unlikely that process gas diffusion is
tenance to verify correct pressure and flow completely prevented.
17 Purged thermocouple technology settings as well as functionality. The utilisation of a sapphire thermow-
ell in an unpurged thermocouple design
18 The proven method of protecting thermo- Unpurged thermocouple technology exclusively is not sufficient for long term
couple elements is to purge the thermow- reliability of the instrument. The seals
19
ell with an inert gas, usually nitrogen, in Plants may attempt to reduce operational that surround the thermowell are critical
20 order to sweep away any process gases and capital expenditure costs by installing to the prevention of process gas diffusion
that diffuse through the primary thermow- unpurged thermocouples that are unsuit- into the assembly. Even the most effec-
21 ell (see Fig. 2). The gas is piped to the able for the challenges of the reactor envi- tive seals will not have a zero leakage
upper chamber of the thermocouple where ronment. Most of these attempts result rate. While contaminants may be impeded
22
it then travels down the holes of the ele- in a failed thermocouple after a relatively by the sapphire thermowell, the seals
23 ment support where the thermocouple short time resulting in the main reactor surrounding the thermowell are subject
wires are positioned. The gas envelops the losing critical temperature indication and to trace amounts of leakage. The trace
24 sensing junction at the end of the support. introducing associated safety concerns. contaminants can accumulate inside the
Any diffused process gas is mixed with the Recently, market interest in unpurged thermocouple assembly eventually caus-
25
nitrogen, then directed to the outlet. Due thermocouples has increased with the ing degradation of the thermocouple ele-
26 to the slow rate of process gas diffusion introduction of additional unpurged ther- ments.
through the thermowell, a purge flow of mocouple designs utilising alternative The Delta Controls Model HTV ther-
27 approximately 11 L/h is sufficient to pro- thermowell materials such as monocrys- mocouple (Fig. 3) reliably addresses the
vide protection without significantly cooling talline sapphire. Sapphire is grown from seal leakage problem by implementing
28
the thermocouple. a single crystal, rather than slip cast or a newly developed, patent-pending seal
29
Fig. 1: Effects of platinum oxide sublimation. The thermocouple element thins to a needle point and platinum deposits up the
30
ceramic element support as crystals. A) Mass loss thinning as a result of platinum oxidation. The bottom wire has full
31 cross section remaining. B) Platinum crystals deposited on a ceramic element support.
32
A B
33
34
35
36
37
38
39
40
Source: Delta Controls
41

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3
6 Fig. 2: Operation of a purged thermocouple Fig. 3: Unpurged thermocouple

7
10
11
12
13
14
15
16
17
18
Source: Delta Controls
19
20
mechanism designated as QSeal™. The technology, it is unproven in terms of reliabil-
21 design utilises a series of protection mech- ity and longevity in sulphur recovery service.
anisms to prevent process gas diffusion, The absence of grain boundaries in
22
gas accumulation, and seal leakage from monocrystalline sapphire can slow the
23 compromising the temperature indication. diffusion of process gases through the Source: Delta Controls
The issues are first addressed with careful thermowell, but it is unknown whether the
24 selection of advanced seal materials that diffusion rate is sufficiently minimised to
minimise diffusion through the seal struc- prevent thermocouple deterioration for the the associated application challenges in
25
ture. Secondly, a high compression wedge targeted five to seven years between turna- sulphur recovery service require more than
26 seal design mechanically reduces con- rounds. Another potential concern is the changing the thermowell material. Careful
taminant bypass around the seal. Finally, effect of the atmosphere contained within attention must be paid to the seal materials,
27 and most importantly, the seal system the thermocouple assembly will have on seal design, and overall architecture of the
design prevents any contaminants that the longevity of the device. A number of thermocouple assembly to assure safety,
28
bypass the primary seals from accumulat- deleterious reactions are known to occur longevity, and reliability.
29 ing within the thermocouple assembly to with platinum at high temperatures. These Unpurged sapphire thermocouples have
concentrations higher than the ambient reactions are not a problem in a purged only been used in SRUs for a relatively
30 atmosphere. Secondary seals, which are thermocouple, where the purge gas is con- short time. It will be 5 to 10 years before
exposed to a nearly ambient atmosphere, stantly replacing the atmosphere within the enough field data has been collected to
31 isolate the open end of the sapphire ther- thermocouple assembly with inert nitrogen. evaluate whether unpurged sapphire ther-
mowell; therefore, contaminant leakage How problematic contained atmosphere is mocouples are as reliable as purged ther-
32
through secondary seals is negligible. Mul- remains to be seen. mocouples in SRUs.
33 tiple redundant seals, in addition to the pri- Trials are underway, but an insufficient The Claus thermal reactor is a challeng-
mary and secondary seals, ensure process number of sapphire protected thermocou- ing environment for the long term reliability
34 containment is maintained in the event of ples have been installed long enough to of all temperature indicating devices. It is
thermowell breakage. clearly demonstrate turnaround to turna- imperative that an accurate temperature
35
round reliability. Until the technology has measurement be continuously reliable for
36 Disadvantages of unpurged matured and demonstrated reliability, it efficient and safe operation. Low reliability
is recommended that sapphire protected thermocouple design consequences include
37 thermocouple technology thermocouples only be installed in addition not only financial costs, but also potential
While thermocouples utilising a sapphire to other proven temperature measurement loss of safety critical SIS indication while in
38
thermowell have been in high temperature technologies such as purged thermocou- operation and increased down time of the
39 applications for many years, the designs ples or pyrometers. SRU. As proven in hundreds of worldwide
have only recently been evaluated for In conclusion, unpurged sapphire thermo- installations for nearly 50 years, a properly
40 use in sulphur recovery thermal reactors. couples show promise as an alternative to designed and installed purged thermocouple
Due to the recent implementation of this purged thermocouples; however, overcoming reliably serves this purpose. n
41
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3
6 DAILY THERMETRICS
7
8
A complete temperature measurement system
D. Keles
R
9
emoval of sulphur from natural elevated temperatures, which increases general, pyrometers are practical, however
10 gas or crude oil is one of the most the criticality of temperature measurement one should be careful with the readings as
critical operations within a plant. for the maximized lifetime of the refractory it could potentially be showing tempera-
11 Traditionally, this occurs within a thermal and therefore the reaction furnace. If not tures with a high error (up to 20%) due to
reactor that is a part of the sulphur recov- properly monitored, refractory lining could sulphur build up or potential drift.
12
ery unit. The reaction occurring is called as potentially melt which was the case in mod- The current high temperature assem-
13 Claus reaction, which removes the sulphur ern history catastrophes. The normal limit blies available in the market, or in other
from process stream occurs at elevated for refractory lining is 1,650°C, however words the ceramic thermowells, are widely
14 temperatures and is exothermal, therefore some refractories are rated much high tem- susceptible to hydrogen sulphide migra-
excess heat is created throughout the pro- peratures of up to 1,800°C. Monitoring the tion which corrupts the noble metal ther-
15
cess run. refractory temperature is critical to prevent mocouples within. The main reason for this
16 Even though there are several reactors the vessel shell from overheating and con- is the porous outer ceramic material that
involved within the Claus process, one of tainment of toxic gas. is utilised, which allows toxic gas to pass
17 the most important is the thermal reactor through and potentially reach the noble
18
(also called the Claus reaction furnace Temperature measurement thermocouple wires.
or main combustion chamber) since the To prevent this from happening, a nitro-
operating temperatures could be as high
challenges gen purge system is added to remove
19
as 1,500-1,600°C (2,700-2,800°F). In this Traditionally, the monitoring of this crucial this highly toxic gas, but this introduces
20 reactor, thermal energy is utilised to react temperature in the furnace is done either a temperature difference, generates high
hydrogen sulphide with oxygen to yield ele- with infrared pyrometers or special high operational costs and an extremely hazard-
21 mental Sulphur as well as water. temperature thermowells using a noble ous working condition due to the constant
Since the reaction within the thermal temperature sensor. High temperature monitoring and control required to operate
22
reactor is most efficient at higher tempera- thermowells are usually seen as unreliable the unit safely.
23 tures, temperature measurement control of as most of the technologies available in Moreover, the outer ceramic that is uti-
this reactor is extremely critical to ensure the industry were not successful in finding lised is not well suited for the Claus ther-
24 safe operation, considering the highly toxic answers to common problems within the mal reactor, which is prone to failure in the
gas that is contained. An important point to Claus thermal reactor. For this reason, unlikely event of refractory shift or thermal
25
consider here is the condition of refractory most operators prefer using pyrometers, shocks, not to mention the complex instal-
26 walls which could degrade over time at the despite their high maintenance costs. In lation procedures that consume valuable
time during turnarounds, as well as difficul-
27 Fig. 1: Representation of Claus furnace lining with the temperature ties if the thermowell nozzle has a smaller
instrumentation nozzle flange or is located on the horizontal axis.
28
29
Source: Daily Thermetrics Proven temperature measurement
technology
30
In the light of these drawbacks, the Daily
31 Thermetrics team has worked tirelessly to
come up with the latest iteration of their
32
design which provides high reliability and
33 is easy to operate, providing operators with
peace of mind (Fig. 1).
34 The new design with its optimised sen-
sor provides protection from the damag-
35
ing effect of toxic gas without the added
36 complication and costly requirement for
nitrogen purging. The design is therefore
37 maintenance-free.
While designing the assembly, the first
38
area to look at was the outer protection
39 tube, which is designed to be from sintered
silicon carbide supported by a high tem-
40 perature metal support tube to ensure the
highest resistance to thermal shock and
41

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JULY-AUGUST 2021
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3
5
shifting refractory. This outer protection heat boilers, incinerators and many more The main advantage is the easy attach-
6
tube already has an excellent track record for more than 40 years. ment of the assembly as it does not
7 within high temperature applications. It is However, in the last couple of years, require any welding and its position can be
resistant to 1,950°C and proven to provide working intimately with process licen- adjusted as desired.
8 the ideal solution due to its excellent ther- sors, engineering contactors and end cli- Overall, the Daily ImpermaWell™ is an
mal conductivity. ents, Daily Thermetrics has developed a innovative solution utilising proven tech-
9
Another area to consider was whether complete temperature measurement sys- nologies and with references in a variety
10 nitrogen purging is necessary, since there tem for the Claus thermal reactor, which of applications. Combining top shelf mate-
was the belief in the industry that purg- includes the patented Mag VSS™ magnetic rials and expertise from various applica-
11 ing is a must or the thermocouple wires skin sensor that is attached on the thermal tions, Daily ImpermaWell™ has already
could not survive in the toxic gas environ- reactor surface via the magnetic pull force been proven in commercial applications
12
ment. However, taking a deeper look at with the Daily ImpermaWell™ (Fig. 3). and obtained approvals by clients. This
13 the options available, it was obvious that This skin sensor assembly has 150 maintenance-free design reduces the total
an impermeable layer which would seal pounds of pull force (68 kg) and is rated cost of ownership, provided that no purg-
14 around the noble thermocouple wires up to 540°C surface temperature. It is a ing equipment is needed, and increases
could eliminate this need. general recommendation to install two of plant safe operation as process sealing
15
After a careful search, a monocrystal- these skin sensors at every metre on the is at the process connection and no toxic
16 line sapphire tube was selected to provide reaction furnace length for the monitor- process gas is allowed to enter secondary
the optimum solution which again is proven ing of refractory shift or falling that could equipment. Ultimately, it provides reliabil-
17 in extreme temperature applications. Due potentially happen during the operation. ity and peace of mind. n
to its homogenous structure,
18 in contrast to porous structure of Fig. 2: Daily ImpermaWell™ as an integrated design with measurement hot zone
19
ceramic protection tubes, its completely below the variable process connection flange and process sealing zone
impermeable to any toxic gas penetra- above the flange
20 tion, therefore eliminating the need for the
costly and high maintenance item of purg-
21 ing equipment.
The assembly offers a process rated
22
containment system to ensure full plant
23 safety at all times. The design itself has
primary, secondary and tertiary process
24 sealing that are rated greater than 1.5
times the pressure rating of the process Source: Daily Thermetrics
25
connection. This triple seal system is
26 tailored to mitigate any risk factors:
l first seal fitting for outer protection tube Fig. 3: Comprehensive coverage of the Claus furnace with total temperature
™ ™
27 for stability throughout operation; measurement utilising Daily ImpermaWell and Mag VSS
l second seal fitting for the sapphire tube
28
to ensure process containment in case
29 of potential failure;
l third seal fitting for the thermocouple;
30 l fourth seal fitting for the individual
noble thermocouple wires.
31
The assembly itself is an integrated
32
well which requires no specialty tools or
33 instructions for installation and could be
described as a plug and play system. An
34 additional advantage of this assembly is
the flexibility for all existing nozzles due
35
to variable flange sizing down to 2 inches
36 (5 cm) as well as an optional leak detec-
tion thermocouple that could be added
37 within the containment chamber for the
unlikely events (Fig. 2).
38
Daily Thermetrics has been provid-
39 ing high temperature assemblies for the
some of the most arduous applications
40 within the energy industry such as Claus Source: Daily Thermetrics
furnaces, partial oxidation reactors, waste
41
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JULY-AUGUST 2021
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3 Desmet Ballestra offers design and supply

4
of plants and relevant field services for the
production of sulphuric acid, oleum, SO2
5
7 and SO3.
8
• Permanent licensee of DuPont MECS® for major sulphuric acid/oleum units
9
• Proprietary technologies and know-how for small sulphuric acid/oleum
10
and SO2/SO3 units
11
• Updated DuPont MECS® HRSTM system for enhanced heat recovery
12
• Tail gas cleaning systems and emissions control
13
• Wide range of production capacities and customized solutions
14
according to specific customers’ requirements
15
• Spare parts and technical assistance support worldwide
16
17
18
Over 25 units have been
19
successfully delivered
20 and installed worldwide.
21
22
23
24
25
26
27
28
29
30
31
32
33
34
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37
38
39
40
41
Desmet Ballestra S.p.A. – Via Piero Portaluppi 17 – Milan – Italy – mail@ballestra.com
www.desmetballestra.com
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1 47

40 NOx reduction in acid plants

42 4 www.sulphurmagazine.com Sulphur 395 | July - August 2021

sulphur and much

42 6 www.sulphurmagazine.com Sulphur 395 | July - August 2021

33 Table 1: Recent sulphur prices, major markets

42 Sulphur 395 | July - August 2021 www.sulphurmagazine.com 7

6 Historical price trends $/tonne

42 8 www.sulphurmagazine.com Sulphur 395 | July - August 2021

6 UNITED ARAB EMIRATES

42 Sulphur 395 | July-August 2021 www.sulphurmagazine.com 9

42 11 www.sulphurmagazine.com Sulphur 395 | July-August 2021

DEMOCRATIC REPUBLIC OF CONGO tion of the Model 74 Contactor reactor, which

organization to make a vast amount of

42 Sulphur 395 | July - August 2021 www.sulphurmagazine.com 11

42 11 www.sulphurmagazine.com Sulphur 395 | July - August 2021

37 HPAL plant inaugurated

42 Sulphur 395 | July - August 2021 www.sulphurmagazine.com 13

42 11 www.sulphurmagazine.com Sulphur 395 | July - August 2021

1-4 November 2021

STAY CONNECTED AND INFORMED -

42 11 www.sulphurmagazine.com Sulphur 395 | July - August 2021

ers was ExxonMobil, which opened an eth-

42 Sulphur 395 | July - August 2021 www.sulphurmagazine.com 11

42 11 www.sulphurmagazine.com Sulphur 395 | July - August 2021

38 UNITED ARAB EMIRATES

42 Sulphur 395 | July - August 2021 www.sulphurmagazine.com 19

6 A STRATCO alkylation unit at a refinery. Fig. 1: Global alkylation capacity by

15 acid North America Middle East

42 22 www.sulphurmagazine.com Sulphur 395 | July - August 2021

42 Sulphur 395 | July - August 2021 www.sulphurmagazine.com 22

7 Sulphuric acid projects 2021

PHOTO: PT HALMAHERA PERSADA LYGEND

42 22 www.sulphurmagazine.com Sulphur 395 | July - August 2021

6 Company Site Application Capacity Licensor Contractor Type of Start-up

39 Watch the free webinars here:

42 Sulphur 395 | July - August 2021 www.sulphurmagazine.com 23

7 Reducing NOx emissions

Gauge pressure 1800 mm H2O (g)

42 22 www.sulphurmagazine.com Sulphur 395 | July - August 2021

34 wet gas flow dry gas flow

40 Source: CECO Industrial Solutions

42 Sulphur 395 | July - August 2021 www.sulphurmagazine.com 25

6 Fig. 5: Installation photographs

SOURCE: CECO INDUSTRIAL SOLUTIONS

16 Fig. 6: Results diagram to offer multiple design case studies

42 22 www.sulphurmagazine.com Sulphur 395 | July - August 2021

42 22 www.sulphurmagazine.com Sulphur 395 | July - August 2021

13 side the drum by freezing sprays of liquid

42 Sulphur 395 | July - August 2021 www.sulphurmagazine.com 29

42 33 www.sulphurmagazine.com Sulphur 395 | July - August 2021

42 Sulphur 395 | July - August 2021 www.sulphurmagazine.com 33

7 The three “Ts”

42 33 www.sulphurmagazine.com Sulphur 395 | July - August 2021

moles/100 moles reactant

moles/100 moles reactant

42 Sulphur 395 | July - August 2021 www.sulphurmagazine.com 33

42 33 www.sulphurmagazine.com Sulphur 395 | July - August 2021

14 Fig. 7(a): Temperature profile (acid gas enveloping air)