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New catalysts target key industry challenges

Summary

Selecting the right catalysts for the SO2 converter in a sulphuric acid plant has always been about balancing expenses, gains, and compliance. With increasing demands for sustainability and in challenging economic times, operators need to adjust their plants to get even more from less. This has led to market demand for new catalytic solutions that offer better productivity and a lower climate footprint, all at the lowest cost possible. Catalyst design and formulations continue to evolve with Haldor Topsoe, DuPont Clean Technologies and BASF all adding new types of sulphuric acid catalysts to their portfolios.

Abstract

haldor topsoe Tipping the scales with VK38+ catalyst M. Granroth VK38+ is a new potassium-promoted catalyst that is part of a range of proven, top-performing sulphuric acid catalysts from Topsoe. This catalyst stems from more than eight decades of catalyst innovation and is a move forward from existing solutions. Keywords: sulphuric acid catalyst, SO2 converter, potassium promoted catalyst VK38+, catalyst activity, catalysts strength, pressure drop, Daisy shape catalyst, caesium catalyst, SO2 emissions, environmental footprint, catalyst formulation, catalyst shape, SuperGEAR catalyst, XLP-310, XLP-110, PeGASyS, extruded catalyst, Quattro catalyst, star ring, 04-110, 04-111, Haldor Topsoe, MECS, DuPont Clean Technologies, BASF

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SRU troubleshooting tools

Summary

Process and simulation models can be valuable tools when troubleshooting to solve operational issues in sulphur recovery units. Two examples are provided. In the first case study it is shown how a tuned model was useful in troubleshooting an SRU that was experiencing lower than expected recovery efficiency and apparent channelling in the first catalytic converter. In the second case study an SRU simulation tool is used to investigate sulphidic corrosion in a waste heat boiler.

Abstract

Sulfur Recovery Engineering (SRE) The merits of tuned simulations I. S. Mohammed At one time, unit engineers were allowed to spend their time identifying problems, spending large amounts of time creating simulations, gathering data, conducting analysis of that data, calculating different variables, and then verifying their hypotheses, all to improve the operation of their units. Keywords: Simulation, modelling, troubleshooting, operational issues, sulphur recovery unit, tuned simulation, predictive, catalyst bed channelling, low recovery efficiency, gas samples, sulphidic corrosion, waste heat boiler, thermal cycling, Couper-Gorman curves, oxygen enrichment, corrosion rate, Sulfur Recovery Engineering, Optimized Gas Treating.

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Fire prevention and suppression for molten sulphur tanks and pits

Summary

Fires are known to occur in sulphur storage pits and tanks somewhat frequently due to the presence of both flammable material and air, so methods for preventing and extinguishing these fires are critical. D. J. Sachde, K. E. McIntush, C. M. Beitler, and D. L. Mamrosh of Trimeric Corporation review fire suppression methods used in the industry including snuffing/sealing steam, rapid sealing, water mist, and inert gas blanketing. Protective tank design features to reduce the likelihood of a sulphur fire are also reviewed. Benefits and limitations, design considerations, and recommended guidance for suppression and preventative measures are discussed.

Abstract

Hydrogen sulphide (H2S) is a byproduct of processing natural gas and refining crude oils, which generally must be removed and controlled. A modified Claus sulphur recovery unit (Claus SRU) is a method for converting the removed H2S to molten elemental sulphur. The molten sulphur from a Claus SRU is stored and handled in several steps, as depicted in Fig. 1. Keywords: sulphur safety, fire suppression, fire prevention, molten sulphur tanks, sulphur pits, snuffing steam, sealing steam, inert gas blanketing, tank design, sulphur fire, fire detection, suppression industry standards and guidance, water mist, mechanical sealing, pyrophoric iron sulphide, flammable components, sulphur storage, ignition sources, sweep gas, sulphur plugging, Trimeric Corporation

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Hidden opportunity: the water side of sulphur recovery units

Summary

Failure investigations, equipment design and process upgrade projects for SRUs often overlook the impact of water quality. In this article E. Nasato of Nasato Consulting and L. Huchler of MarTech Systems explore impacts of higher heat transfer rates, control of boiler and condenser water chemistry, conventional equipment design/configurations and monitoring program designs. SRU operators can improve the effectiveness of their failure investigations by implementing a broader, more holistic approach that assesses equipment design, process conditions, operating protocols and water quality issues.

Abstract

During the last several decades, most of the focus to improve the efficiency and capacity of sulphur recovery units (SRUs) has been on the process side: raising the operating pressure to generate higher-value, higher-temperature steam and increasing the process-side temperatures to increase throughput. Keywords: utilities, sulphur recovery unit, SRU, failure investigations, equipment design, process upgrade, water quality, heat transfer rates, boiler, condenser, water chemistry, monitoring, waste heat boiler, WHB, WHB tubesheet, kettle, thermosiphon, sulphidation, mechanical design, oxygen enrichment, control issues, continuous blowdown, intermittent blowdown, blowdown valve sizing, high purity make-up, level control, shutdown, commissioning, short turnarounds, long service runs, water treatment, Nasato Consulting, MarTech Systems

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Is sulphur the missing ingredient?

Summary

Ron Olson of The Sulphur Institute considers sulphur's important role in plant health.

Abstract

Sulphur is demanding more attention these days because the amount provided free of charge, via acid rain and other sources, is becoming less. There have been large changes in the global and regional sulphur dioxide (SO2) emissions over the last few decades. At the same time, increasing yield trends have increased sulphur removal by the crop. Keywords: CORN, SOYBEAN, SULPHATE, SULFATE, POTASSIUM, CROP, YIELD, ACRE, HECTARE, SMART, DEFICIENT, DEFICIENCY, GROW

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Canadian sulphur

Summary

After many years of slow decline, Canadian sulphur exports have begun to rise slightly, but dwindling US markets are seeing a move towards more sulphur forming to expand export opportunities.

Abstract

Canada continues to be one of the world’s largest exporters of elemental sulphur and a major player in the sulphur arena. Although the history of the past two decades has been one of slow decline from the dominant market position it once enjoyed, rising oil sands upgrading and a stabilisation of output from sour gas plants are leading to higher sulphur production once more. Keywords: SANDS, BITUMEN, SOUR, SYNCRUDE, DILBIT, EXPORT, REFINERY, REFINING, UPGRADE, UPGRADER, MOLTEN, MARKET, PRILL, PRILLED

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China's phosphate industry

Summary

Continuing rationalisation in China's phosphate industry has been reducing demand for sulphur and sulphuric acid at the same time that the country is producing more of both.

Abstract

China’s phosphate industry has come to be one of the defining features of the global sulphur industry. The rapid expansion in Chinese phosphate capacity in the period 2000-2015, especially of mono- and di-ammonium phosphate capacity (MAP/DAP) initially began as in import replacement policy, but capacity building continued long after self-sufficiency was reached, and turned China from a net importer into a net exporter of phosphates, with India an increasingly important customer. Keywords: PHOSPHORIC, ROAST, PYRITE, MINE, MINING, AMMONIUM, DAP, MAP, COVID, GYPSUM, PHOSPHOGYPSYM, NUTRIENT, CONSUMPTION

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