SUPERDEGAS- A PROCESS OF INTEGRATING SULFUR COLLECTION AND DEGASSING FOR ZERO EMISSION

Abstract

SuperDegas process refers to innovative process of the liquid sulfur collection and degassing which takes place in the underground container in a concrete pit or a carbon steel vessel located in the concrete pit. SuperDegas process consists of at least three compartments: (1) sulfur collection to agitate and create turbulent, higher velocity, and higher pressure in the liquid sulfur for more effective degassing by using vertical pumps; (2) consists of the proprietary air spargers and Morpholine catalyst for degassing. Morpholine catalyst degas the liquid sulfur 30 times faster than Quinoline or any other solvent with sparging air and within 1 hour residence time from 16-30 hours and to meet less than 10 ppmw of H2S in liquid sulfur. (3) The last compartment receives the degassed sulfur by overflow and transport through a pump or pumps to other facilities. An eductor will sweep vapor phase containing H2S, vaporized Morpholine with air where the pit vent can be sent to incineration or the reaction furnace. The tail gas stream from SRU can sweep the pit and the discharge shall be recycled to the tail gas unit, which ultimately zero emission can be achieved.

Claims

1. An integrated process for the liquid sulfur collection and degassing in the underground container, where the produced sulfur from any type of sulfur recovery processes including Claus; containing polysulfides and hydrogen sulfide is treated in the SuperDegas process comprising the following 7 steps: Astep 1) The process comprises an underground container as a concrete pit or a carbon steel vessel inside of the concrete pit of consisting at least three compartments; Bstep 2) The process comprises to collect the liquid sulfur into the first compartment containing at least one vertical pump inside the container to agitate, create turbulent by increasing velocity and higher pressure of the liquid sulfur; Cstep 3) The second compartment of SuperDegas process introduces the higher pressure streams of liquid sulfur containing polysulfides and hydrogen sulfide into the second compartment of the sulfur container; where it comprises the proprietary air spargers; and the Morpholine catalyst to promote faster degassing; Dstep 4) The third compartment of SuperDegas process comprises the degassed liquid sulfur that is stored and is transferred to other facilities by using at least one sulfur vertical pump inside the container; Estep 5) The SuperDegas process comprises an eductor to sweep the vapor phase of the sulfur container, containing H2S and vaporized Morpholine by using plant air or compressed air with at least 5 barg (70 psig) pressure; Fstep 6) The SuperDegas process comprises the container vent stream containing H2S flows to the incineration, or to recycle back to the reaction furnace of any Claus type in the SRU units; Gstep 7) The SuperDegas process comprises the tail gas stream from any type of Claus unit can be used to sweep the vapor phase of the sulfur container that contains H2S and recycles back to the tail gas treating unit.

2. The process of claim 1, wherein, the sulfur collection is integrated with a unique integrated system consists of the proprietary air spargers and the Morpholine catalyst to perform the sulfur degassing.

3. The process of claim 1, wherein, the operating pressure of the container is between 0-10 barg (150 psig).

4. The process of claim 1, wherein, the agitation of sulfur to create higher velocity and turbulent with higher pressure takes place in the collection compartment before the degassing compartment.

5. The process of claim 1, wherein, the proprietary air spargers can be applied independently and alone to create turbulent for an effective sulfur degassing process with or without using the Morpholine catalyst in the concrete pit.

6. The process of claim 1, wherein, an external sulfur cooler exchanger of any commercial type or internal cooling element coils is used to maintain the sulfur temperature of 130-145 C in the concrete sulfur pit.

7. The process of claim 1, wherein, if the external sulfur cooler is not used, the internal heating and internal cooling element coils is integrated to maintain the sulfur temperature of 130-145 C in the concrete sulfur pit.

8. The process of claim 1, wherein, the number of the proprietary air spargers is the function of the sulfur capacity where a uniform liquid distribution in the container as a pit or vessel is established.

9. The process of claim 1, wherein, the liquid degassed sulfur from the underground container as a concrete pit or underground carbon steel vessel contains less than 10 ppmw of H2S.

10. The process of claim 1, wherein, the required degassing residence time from 16-30 hours are reduced to within 1 hour by using the Morpholine catalyst in the underground sulfur pit or in the underground carbon steel vessel.

11. The process of claim 1, wherein, to sweep the vapor space in the container that is containing H2S and vaporized Morpholine an eductor or similar type like equipment known as blower or ejector can be used.

12. The process of claim 1, wherein, the sulfur container consists of at least one or more the degassing compartment.

13. The process of claim 1, wherein, the air will be bubbled into the liquid sulfur pipe from the bottom using the proprietary air spargers or air distributor inside of the sulfur container a concrete pit or the carbon steel vessel to achieve a good mixing and to separate the H2S from the liquid phase.

14. The process of claim 1, wherein, the container of the concrete sulfur pit consists of the internal heating coils in all compartments.

15. The process of claim 1, wherein, when the liquid sulfur is flushed with air, it is essential not to exceed; since the H2S lower the ignition temperature and the air flow should be calculated to maintain a safe operation.

16. The process of claim 1, wherein, the Morpholine catalyst is evaporated in the degassing compartment and it swept by air, nitrogen, or the tail gas stream and flows to the eductor, blower or similar equipment and do not have any impact on the degassed sulfur quality.

17. The process of claim 1, wherein, the liquid sulfur degassing can take place in a carbon steel vessel container located in the underground concrete pit consists of the same compartments arrangement for SuperDegas process with the exception as claimed.

18. The process of claim 17, wherein, the carbon steel vessel consists of external heating elements around the vessel.

19. The process of claim 17, wherein, wherein, if an external sulfur cooler exchanger is not used then the integrated design of the external heating and internal cooling elements is designed to maintain the sulfur temperature of 130-145 C inside of the carbon steel vessel.

20. The process of claim 17, wherein, the proprietary air spargers can be applied independently and alone to create turbulent for an effective sulfur degassing process with or without using the Morpholine catalyst in the carbon steel vessel as long as it is doable to have large carbon steel vessel for long residence time.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0055] While the inventions disclosed herein are susceptible to various modifications and alternative forms, only a few specific embodiments have been shown by way of example in the drawings and are described in detail below. The figures and detailed descriptions of these specific embodiments are not intended to limit the breadth or the scope of the inventive concepts or the appended claims in any manner. Rather, the figures and detailed written descriptions are provided to illustrate the inventive concepts to a person of ordinary skill in the art and enable such person to make and use the inventive concepts.

[0056] The following figures form part of the present specification and are included to further demonstrate certain aspects of the present invention. The invention may be better understood by reference to one or more of these figures in combination with the detailed description of specific embodiments presented herein.

[0057] FIG. 1 illustrates a sulfur collection and degassing process of SuperDegas in a concrete under-ground pit and in accordance with an embodiment of the present disclosure where the pit vent flows to the incineration or thermal oxidizer system.

[0058] FIG. 2 illustrates a sulfur collection and degassing process of SuperDegas in a concrete under-ground pit and in accordance with an embodiment of the present disclosure where the pit vent recycles back to the reaction furnace or the tail gas unit in the sulfur recovery unit to achieve zero emission.

[0059] FIG. 3 illustrates a sulfur collection and degassing process of SuperDegas in a carbon steel vessel inside of the concrete under-ground pit and in accordance with an embodiment of the present disclosure where the pit vent flows to the incineration or thermal oxidizer system.

[0060] FIG. 4 illustrates a sulfur collection and degassing process of SuperDegas in a carbon steel vessel inside of the concrete under-ground pit and in accordance with an embodiment of the present disclosure where the pit vent recycles back to the reaction furnace or the tail gas unit in the sulfur recovery unit to achieve zero emission.

[0061] An eductor is used to sweep the vapor containing H2S by using air or using portion or full stream of the tail gas feed stream from the sulfur recovery unit.

DETAILED DESCRIPTION OF THE INVENTION

[0062] One or more illustrative embodiments incorporating the invention disclosed herein are presented below. Not all features of an actual implementation are described or shown in this application for the sake of clarity. It is understood that in the development of an actual embodiment incorporating the present invention, numerous implementation-specific decisions must be made to achieve the developer's goals, such as compliance with system-related, business-related, government related and other constraints, which vary by implementation and from time to time. While a developer's efforts might be complex and time-consuming, such efforts would be, nevertheless, a routine undertaking for those of ordinary skill the art having benefit of this disclosure.

[0063] In general terms, Applicant has created new processes SUERDEGAS for the liquid sulfur degassing inside of the collection pit with significant reduced residence time compare to the commercial processes and with significant reduced H2S in the degassed liquid sulfur compare to the commercial processes have difficulty to meet 10 ppmw of H2S in the liquid sulfur while using much higher residence time and more capital cost investment. SuperDegas process uses proprietary air sparger plus Morpholine catalyst with less residence time and by recycling the vent gas to the reaction furnace to achieve zero emission with lower capital cost investment for new facilities and also for the revamp of the existing facilities.

[0064] The present invention relates to processes for recovering sulfur for onshore and offshore applications; refineries, gas plants, IGCC, gasification, coke oven gas, mining and minerals sour gas field developments and flue gas desulfurization onshore and offshore wherein sulfur recovery unit is required for new units or revamps.

[0065] In accordance with aspects of the present invention, it is an object of the present disclosure to provide a process for the liquid sulfur degassing economically acceptable for, present day industrial operations and higher safety standard.

[0066] Another object is to provide such a process which can tolerate variances in operating conditions within a given range without major equipment adaptations. A further object is to provide a process which can be utilized in co-acting phases to provide, at acceptable economics, the capacity required in present-day industrial operations, easy to operate and more reliable and robust operation.

[0067] In the discussion of the Figures, the same or similar numbers will be used throughout to refer to the same or similar components. Not all valves and the like necessary for the performance of the process have been shown in the interest of conciseness. Additionally, it will be recognized that alternative methods of temperature control, heating and cooling of the process streams are known to those of skill in the art, and may be employed in the processes of the present invention, without deviating from the disclosed inventions.

[0068] As indicated above, in typical operations involving sulfur recovery, the liquid sulfur from the sulfur condensers are normally collected through the sulfur seal to the underground sulfur pit. Then the sulfur is degassed inside of the pit to remove the H2S and then is transferred to the storage tank for sulfur forming/solidification or is sold in the liquid form. Applicants have created processes for collecting liquid sulfur and sulfur degassing the sulfur, wherein the processes disclosed herein have numbers of advantages over previously known and/or practiced degassing technologies associated with sulfur recovery technologies.

[0069] All the heat exchangers defined in this process can be of any type of commercial exchangers such as but not limited to shell and tube, plate and frame, air cooler, water cooler, boiler type, heating and cooling coils or any suitable exchangers.

[0070] The pumps and eductors defined in this process can be any type of commercial pumps suitable for sulfur handling inside of the pit or vessel and eductors can be any type of commercial eductors, ejectors, and blowers.

[0071] Turning to FIG. 1 of the SUPDEDEGAS process; the liquid sulfur stream from one or more sulfur condensers, which may come from a variety of sources such as from a Claus process or the like are collected in stream (1) through the sulfur seal or similar to the underground the first compartment of the sulfur pit. If external cooling is applied to maintain the sulfur temperature then the cooled sulfur (10) outlet stream (2) flows to the first compartment of the sulfur pit (15). As mentioned above, the sulfur cooler can be internal cooling systems like cooling coils suitable for this application.

[0072] As shown in the FIG. 1, the sulfur pit (15) is equipped with the heating coils at the bottom (45) to keep the liquid sulfur at the reasonable temperature suitable for degassing and to prevent solidification by using low pressure steam.

[0073] The first compartment of the sulfur pit (15) is equipped with at least one vertical pump (25) inside of the pit to agitate the liquid sulfur and also to increase the pressure which also creates velocity and turbulent of the liquid sulfur and promotes the separation of dissolved H2S from the liquid phase to the vapor phase and finally provides an additional storage during short maintenance of other compartment which none of the commercial degassing processes provides such flexibility.

[0074] The liquid sulfur stream (3) from the first compartment through the pump (25) flows to the second compartment where the degassing of the liquid sulfur takes place. This section consists of the air spargers (30) and the Morpholine catalyst injection stream (6) to promote fast degassing within 1 hour. The air stream (4, 5) to the sparger is supplied from the air compressor or the plant air if available at the minimum pressure of 5 barg through air drum (20). Number of spargers depends on the sulfur capacity that required degassing.

[0075] In SuperDegas process Morpholine catalyst degas the liquid sulfur 30 times faster than Quinoline or any other solvent with sparging air and 1 hour residence time from 16-30 hours and to meet less than 10 ppmw of H2S in liquid sulfur.

[0076] The pit vent eductor (40) collects the released H2S stream (10) using sweep air and by using medium pressure steam as the motive fluid. The eductor discharge stream (7) flows to the incineration system to convert all of the H2S to SO2 prior to releasing to the stack.

[0077] In addition, since Morpholine is evaporated by the sweep air to the eductor.

[0078] The degassed sulfur overflows from the second compartment overflows to the third compartment as the storage where liquid sulfur is pumped via at least one vertical sulfur transfer pump (35) to other facilities as stream (8).

[0079] In accordance with aspects of the present disclosure, certain benefits may be associated with the several processes described and illustrated in the figures where some combinations may be used.

[0080] Other and further embodiments utilizing one or more aspects of the inventions described above can be devised without departing from the spirit of Applicant's invention. For example, the process may include multiple stages, or may include loops within the process stages described. Further, the various methods and embodiments of the sulfur degassing processes disclosed herein can be included in combination with each other to produce variations of the disclosed methods and embodiments. Discussion of singular elements can include plural elements and vice-versa.

[0081] The order of steps can occur in a variety of sequences unless otherwise specifically limited. The various steps described herein can be combined with other steps, interlineated with the stated steps, and/or split into multiple steps. Similarly, elements have been described functionally and can be embodied as separate components or can be combined into components having multiple functions.

[0082] The inventions have been described in the context of preferred and other embodiments and not every embodiment of the invention has been described. Obvious modifications and alterations to the described embodiments are available to those of ordinary skill in the art. The disclosed and undisclosed embodiments are not intended to limit or restrict the scope or applicability of the invention conceived of by the Applicants, but rather, in conformity with the patent laws, Applicants intend to fully protect all such modifications and improvements that come within the scope or range of equivalent of the claims.

[0083] In accordance to the SuperDegas innovation, the operating pressure of the container is between 0-10 barg (150 psig).

[0084] In accordance to the SuperDegas innovation, the agitation of sulfur is to create higher velocity and turbulent with higher pressure takes place in the collection compartment before the degassing compartment.

[0085] In accordance to the SuperDegas innovation, the proprietary air spargers can be applied independently and alone to create turbulent for an effective sulfur degassing process with or without using the Morpholine catalyst in the concrete pit or carbon steel vessel.

[0086] In accordance to the SuperDegas innovation, an external sulfur cooler exchanger of any commercial type or internal cooling element coils is used to maintain the sulfur temperature of 130-145 C in the concrete sulfur pit.

[0087] In accordance to the SuperDegas innovation, if the external sulfur cooler is not used, the internal heating and internal cooling element coils is integrated to maintain the sulfur temperature of 130-145 C in the concrete sulfur pit.

[0088] In accordance to the SuperDegas innovation, the number of the proprietary air spargers is the function of the sulfur capacity where a uniform liquid distribution in the container as a pit or vessel is established.

[0089] In accordance to the SuperDegas innovation, the sulfur container consists of at least one or more the degassing compartment.

[0090] In accordance to the SuperDegas innovation, the air will be bubbled into the liquid sulfur pipe from the bottom using the proprietary air spargers or air distributor inside of the sulfur container a concrete pit or the carbon steel vessel to achieve a good mixing and to separate the H2S from the liquid phase.

[0091] In accordance to the SuperDegas innovation, the container of the concrete sulfur pit consists of the internal heating coils in all compartments made out of stainless steel or suitable material.

[0092] In accordance to the SuperDegas innovation, the Morpholine catalyst is evaporated in the degassing compartment and it swept by air, nitrogen, or the tail gas stream and flows to the eductor, blower or similar equipment and do not have any impact on the degassed sulfur quality.

[0093] Turning to the FIG. 2; the description concept of the SuperDegas innovation is the same as FIG. 1 except the pit vent flows to the reaction furnace in the sulfur recovery unit or to the tail gas treating unit to achieve zero emission.

[0094] With continued reference to FIG. 2, in accordance with the present disclosure, the liquid sulfur may be degassed using the SRU-tail gas stream. If the SRU tail gas stream is used to sweep the liquid sulfur, the temperature is preferably less than about 145 C. (about 293 F.) and the eductor recycles back to the tail gas unit.

[0095] Turning to FIG. 3; the description concept of the SuperDegas innovation is the same as FIG. 1 except a carbon steel vessel is located in the concrete pit where all the actions takes place in the carbon steel vessel instead of the concrete pit unless it is stated separately.

[0096] In accordance to SuperDegas innovation, the carbon steel vessel consists of external heating elements around the vessel.

[0097] In accordance to SuperDegas innovation, if an external sulfur cooler exchanger is not used then the integrated design of the external heating and internal cooling elements is designed to maintain the sulfur temperature of 130-145 C inside of the carbon steel vessel.

[0098] In accordance to SuperDegas innovation, the concrete pit that is holding the carbon steel vessel is equipped for winterization and necessary equipment for a safe operation.

[0099] Turning to FIG. 4; the description concept of the SuperDegas innovation is the same as FIG. 2 except a carbon steel vessel is located in the concrete pit where all the actions takes place in the carbon steel vessel instead of the concrete pit except stated separately.

[0100] All of the compositions, methods, processes and/or apparatus disclosed and claimed herein can be made and executed without undue experimentation in light of the present disclosure. While the compositions and methods of this invention have been described in terms of preferred embodiments, it will be apparent to those of skill in the art that variations may be applied to the compositions, methods, processes and/or apparatus and in the steps or sequence of steps of the methods described herein without departing from the concept and scope of the invention. Additionally, it will be apparent that certain agents which are both chemically and functionally related may be substituted for the agents described herein while the same or similar results would be achieved. All such similar substitutes or modifications apparent to those skilled in the art are deemed to be within the scope and concept of the invention. The disclosed and undisclosed embodiments are not intended to limit or restrict the scope or applicability of the invention conceived of by the Applicant, but rather, in conformity with the patent laws, Applicants intends to protect all such modifications and improvements to the full extent that such falls within the scope or range of equivalents.