Utility Considerations for Sulfur Recovery Units
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1 Utility Considerations for Sulfur Recovery Units By Elmo Nasato Nasato Consulting Ltd. Nasato Consulting Ltd MESPON 2015
2 Key Learning Point Emphasis on Process Side Design and Operation Neglect on Utility Side Design and Operation Consequence Reduced Reliability Nasato Consulting Ltd
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4 SRU Utilities Steam (imported and exported); Boiler Feed Water, Utility and Make-up Water; Fuel Gas and Natural Gas; Nitrogen; Instrument Air; Electricity. Nasato Consulting Ltd
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6 Steam - Imported Excessive Moisture heat loss/trap overload Corrosion due to non-condensibles Mechanical design Strength weld Seal weld Process Design Fouling factor Steam traps Insulation Purge design High temperature sulfur viscosity Nasato Consulting Ltd
7 Steam Trap Installation Detail Keep SRU Hot! Nasato Consulting Ltd
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9 Steam/Condensate Connections for Steam Jacket Nasato Consulting Ltd
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12 Sulfur Pump Supply Pressure Control
13 Pure Sulfur Viscosity Curve
14 Seal Weld Procedure
15 Strength Weld Procedure
16 550 psig Steam Reheater Failure
17 550 psig Steam Reheater Leak
18 Boiler Design Changes Higher Steam Side Operating Pressures Older Designs: Pressure Range: 150 to 250 psig (10 to 17 barg) Steam Temperature: 354 to 399 ⁰F (179 to 204 ⁰C) Modern Designs: Pressure Range: 450 to 600 psig (31 to 41 barg) Steam Temperature: 457 to 484 ⁰F (236 to 251 ⁰C) Carbon Steel Sulfidation Temperature: 650 ⁰F (343 ⁰C) Nasato Consulting Ltd Smaller Margin For Error
19 WHB Operating Regime Smaller Margin For Error Nasato Consulting Ltd
20 Typical Waste Heat Boiler Design
21 Typical Waste Heat Boiler Design Older Designs Common to have two or three intermittent blowdown connections. Common to include intermittent blowdown at both hot and cold end. Kettle Style: water sample from exchanger: representative Modern Designs Common to have only one intermttent blowdown. Typically located at cold end; WRONG END Thermosyphon: water sample from Steam Drum: risky More Prone to Failure Nasato Consulting Ltd
22 Recommended Boiler Water Limits Drum Pressure (psig) Range Total Dissolved Solids Boiler Water maximum (ppmw) Range Total Alkalinity Boiler Water (ppmw) Suspended Solids Boiler Water maximum (ppmw) Range Total Dissolved Solids Steam (ppm) Nasato Consulting Ltd
23 Boiler Blowdown Remove water containing suspended and dissolved solids; replaced with relatively pure feedwater. Scale forming salts concentrate and crystallize on the heating surfaces. Result can be tube failures, tube-to-tubesheet failures. Two principal types of blowdown: intermittent and continuous. Intermittent is done manually AND is necessary for operation of boiler regardless of whether or not continuous blowdown is employed. Continuous blowdown is a continuous and automatic removal of concentrated boiler water. Nasato Consulting Ltd
24 Boiler Blowdown Outside activity reduced; many factors. Intermittent blowdown not always a routine procedure. Nasato Consulting Ltd
25 Intermittent blowdown NOT a routine procedure. Located at WHB outlet. Failure of IBD line in winter operation.
26 Failure to recognize importance of BFW quality and blow down procedures. Result Two WHB failures in 10 months.
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29 WHB Tubesheet High Temperature Sulfide Attack Nasato Consulting Ltd
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31 Water in Sulfur Rundown
32 Critical Burner Nozzle Purges Flame scanners Sight glasses on the burner and reaction furnace Igniter port Reaction furnace temperature measurement Idle ports such as natural gas Nasato Consulting Ltd
33 Purge Rotameter Assembly
34 Nitrogen Purge Header Detail Each Purge MUST have its own rotameter Nasato Consulting Ltd
35 Partially Plugged Furnace Port
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37 Fuel Gas/Natural Gas There is a DIFFERENCE Composition Air required Contaminants Burner Design/Operation Flame moderation Options excess air, steam, nitrogen Effects on SRU Sulfur fires Soot Refractory Design Nasato Consulting Ltd
38 Natural Gas Firing Temperatures w/ Steam Moderation Nasato Consulting Ltd
39 Low Pressure Steam Requirement for Flame Moderation when Firing Natural Gas at 95% Stoichiometry Nasato Consulting Ltd
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47 THERMAL SHOCK DUE TO HIGH TEMPERATURE RESTART WHEN FURNACE WAS OFF LINE FOR SEVERAL HOURS
48 Liquid Storage
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50 SRU Utilities Key to successful SRU operation: Pay special attention to the design and operation of the utility components Nasato Consulting Ltd
51 Conclusions Operations: Training include Utilities Walk through the Metal Forest Design: Devil in the Details DO NOT IGNORE UTILITIES Nasato Consulting Ltd
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