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Fives Pillard combustion solutions for Sulfur Recovery Units

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Tail gas incinerator

Fuel gas

Air

Air

Boiler

H2S ����S2 # 65% H2S ����S2 : # 97.5 %

Main burner

Auxiliary burner

Incinerator burner

Furnace

Sulfur condensors

Typical flow sheet of Sulphur Recovery Unit

The Fives Pillard expertise

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The Claus burner

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CLAUS burners

Main burner is the HEART of the Claus process:• Generates SO2 required for the Claus reaction• Accounts for ~60% to 65% of H2S conversion into S2

General rules of design• Intense & compact flame to maximize residence time (S2 formation)• Flame stability• Shall allow sufficient turn-down ratio• Allow efficient co-firing with natural gas (no soot formation)• Sturdy and proven design• Safe start-up and reliable flame detection

Claus burner design is the primary method to achieve good mixing of oxidant and feeds!

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Fives Pillard burners for CLAUS reaction furnace

Fives Pillard burners for Acid Gas produce high intensity compact flames with:

• High Sulphur quality • Reduced pollutants levels (BTX)• Increased S2 conversion level• Reduced soot formation with Co-firing

• Rich up to very lean acid gas• Co-firing application (proprietary Staged Co-Firing technique)

Fives Pillard burners for Acid Gas deliver excellent performance with:

• Excellent mixing• High flame stability• High turn-down ratio • Adjustable flame to accommodate changing acid gas composition

Leading to improved plant operation reliability:

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Fives Pillard burners for CLAUS reaction furnace

Tangential mounting type

Tangential Fives Pillard Burner

Claus reactionfurnace

Axial mounting type

Axial Fives Pillard Burner

Claus reaction furnace

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Fives Pillard burners for CLAUS reaction furnace

Axial mounting type Tangential mounting type

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Simulated Sulphur (S2) profile (% mass): axial versus tangential firing

Simulated efficiency : around 60%

Axial mounting type

Fives Pillard burners for CLAUS reaction furnace

Simulated efficiency : around 64%

Tangential mounting type

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Claus burner (axial mounting type) with adjustment system

Acid gasCombustionair inlet

Adjustment system

Steam

Fuel gas piping

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Flame detection & flame start-up

• measures the temperature variation between two points in a flame

Flame Scanner for Acid Gas flames

Main advantages:

• Detection free from any fixed hot point (wall, bricks, etc…)

• High reliability

• "All in One" concept: detector and amplifier integrated in the head

• Flame level indicator available at detector head and control room

South Pars 2, 3 ,4, 5, 9 and 10 are operating successfully

The Fives Pillard DARKSCAN :

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Flame ignition / start-up

� Packlight Ignitor Ø 48

• Electric - Gas 20kW to150kW• All-In-One design • Includes flame detection & display • Suitable for continuous operation (pilot)

� Powerpack Ignitor Ø 25

• Electric 9Joules/spark• Automated retraction design• Not suitable for continuous operation (pilot)

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Fives Pillard Staged Co-Firing technology

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Why using Co-Firing technique?

� For lean acid gas applications

� For "sensitivity" cases

• Temporary lower H2S content in acid gas or reduced acid gas flow

� Alternative to larger investment cost

• Aromatic upstream or downstream treatment for BTX

• Acid gas enrichment in lean acid gas application

Alternative to higher operating cost

• Oxygen enrichment to increase flame temperature

• Higher amine treatment operating cost (higher flow treated)

� Easy to implement on existing SRU

� Reduces BTX > 95% (favorable for catalyst lifetime)

� Reduces benzene emissions at stack

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Co-Firing with a conventional burner

The activation energies• H2S + 3/2 O2 � H2O + SO2 Ea = 62 kJ / mol

• CH4 + 2O2 � CO2 + 2H2O Ea = 250 kJ / mol

H2S burns first all the available oxygen

fuel gas combustion is carried out under sub-stoichiometric conditions causing :

• Unburnt HC ,

• Soot emissions

• COS/CS2 increase

The burner makes a single and compact flame

The additional fuel gas supplied in burner center with acid gas

Conventional burner

Confirmed at South Pars (Iran) – Phase 1 Hamworthy : resulting in poor sulphur quality

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Fives Pillard Staged Co-Firing technique

O2

O2

nat. gas

nat. gas

acid gas

First stage: natural gas combustion in over-stoechiometry

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Fives Pillard Staged Co-Firing technique

O2

O2

H2S

Second stage : H2S Combustion

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Third stage : Claus reaction (H2S + SO2)

Fives Pillard Staged Co-Firing technique

H2S

SO2

SO2

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Fives Pillard Staged Co-Firing technique

S2 formation start

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Fives Pillard Staged Co-Firing on TOTAL Lacq - US 11

Acid gas

11 H 101

Reaction

Furnace

Main

Burner

Waste boiler

+

Condensor

Auxiliary

Furnace

Catalyst

(2 stages)

SULFREEN

Air

11

F 101

Tail gasfrom US8

incinerator

Fuel gas

• Acid Gas flow 33 000 kg/h

• H2S 60 %

• Combustion air temperature 230 °c

• Acid gas temperatrue 210 °c

• Natural gas flow 200 kg/h

• Additional air 3 800 kg/h

• Additional mass flow + 6%

Initial value of BTX (Benzene, Toluene, Xylene ) : 500 to 1500 ppm

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BTX reduction vs Temperature

0

20

40

60

80

100

800 900 1000 1100 1200 1300

Reaction Furnace Temperature

% B

TX

red

uctio

nBTX reduction measured at TOTAL Lacq Plant

Co-firing+ 150°C

Preheating air and acid gas

+ 100°C

Total : + 250°C

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425 439

4313

0

100

200

300

400

500

Without Cofiring With Cofiring

BT

X

(ppm

v)

95,2 95,2

0

20

40

60

80

100

Without Cofiring With Cofiring

SU

11

EF

FIC

IEN

CY

(%

)

TOTAL Lacq plant – Site results(average value records based on 2 x one month periods)

90% 97%

97% BTX reduction usingCo-firing technique

Sulphur recovery efficiencyremains unchanged

BTX measured Sulphur recovery efficiency measured at US11 outlet

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Conclusions about Co-Firing technique

� Requires a good burner to maintain Claus unit efficiency & sulphur quality avoiding soot formation.

� Allow to process efficiently very lean acid gas with conventional Claus unit and associated Tail Gas Treatment.

� Allow for efficient destruction of BTX and improves catalyst lifetime

� Allow for an increase in flame temperature enabling potential NH3 destruction

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In-Line / Re-Heating and Reducing Gas Generators burners

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In-Line / Re-Heating burners

In Claus process catalytic converters are used after the Claus furnace to achieve the required sulphur conversion efficiency

Direct-fire burners (or heat exchangers) are used to reheat the process stream before entering the catalytic stage

Direct-fire In-Line burners must:

• Ensure compact flame to fit small & short combustion chamber size

• Fire either natural gas without soot formation and/or acid gas

• Provide sufficient turn-down

• Ensure flame stability

• Avoid oxygen carry-over (oxygen break-through) to the catalytic section

• Allow temperature uniformity of the hot gases

• Be of Safe & Reliable design

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Reducing Gas Generators (RGG) burners

Applied in several processes upstream TGT units to increase recovery efficiency >99% (amine based process such as SCOT or BSR):

• To reheat process stream from 130°C to 280°C and to produce H2 & CO for the downstream TGT reaction

• Operate on fuel gas only, around 80% of stoichiometry • Atomizing steam is added (ratio approx. 2:1) to reduce soot formation• Similar design as In-Line / Re-Heating burner

RGG burners must:• Ensure compact flame to fit small & short combustion chamber size• Fire fuel gas without soot formation• Minimize oxygen carry-over (oxygen break-through)• Provide sufficient turn-down• Ensure flame stability• Allow temperature uniformity of the hot gases• Be of Safe & Reliable design

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In-Line / Re-Heating / RGG burner

Combustion air

Fuel gas

Steam

Ignitor

Flame scanners (UV)

Sight port

Air Swirler

Gas Lances

SteamLance

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In-Line / Re-Heating / RGG burner

Connection for flame scanners

Fuel gas

Steam

Connection for flame ignitor

Sight port

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In-Line / Re-Heating / Reducing Gas Generator burners

The advantages of Fives Pillard In-Line / Re-Heating / Reducing Gas Generators burners:

• Provide high intensity compact flames to fit narrow & shorter length combustion chambers with high thermal load

• Can operate in sub-stochiometric condition with stable flame

• Burn fuel gas at low combustion air ratio without soot formation

• Ensure reliable flame detection

• Ensure automated and safe start-up

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Thermal incinerator burners

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Thermal incinerator

Purpose is to thermally oxidize the residual polutants contained in the Tail Gas

Thermal incinerator requires:

• Sufficient temperature

• Residual Oxygen

• Residence time

• Efficient mixing

Thermal incinerator burners must:• Have a properly sized flame to fit combustion chamber• Ensure sufficient swirl to promote quick mixing of the hot gases with tail gas• Provide sufficient turn-down• Ensure flame stability• Allow temperature uniformity of the hot gases• Be of Safe & Reliable design

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Tail Gas Incinerator & associated burner

Tail Gas Incinerator (South Pars) Tail Gas Incinerator burner (South Pars)

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Incinerator burner ("Front Tail Gas supply")

Incineration air

Combustion air

Tail Gas

Fuel gas

Ignitor

Flame scanner(UV)

Tail Gas exit

Gas Lances

Air Swirler

Air lances

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Incinerator burner ("Side Tail Gas Supply")

Combustion airIncineration air

Tail Gas

Fuel gas

Ignitor

Flame scanner

(UV)

Combustion air

Tail Gas

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Incinerator burners

The advantages of Fives Pillard Incinerator burners:

• Provide high intensity compact flames to fit narrow & shorter length combustion chambers with high thermal load

• Can operate in sub-stochiometric condition with stable flame

• Burn fuel gas at low combustion air ratio without soot formation

• Ensure reliable flame detection

• Ensure automated and safe start-up

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A few references

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� Scope of Work: • 4 Reaction Furnace burners (tangential type)• 4 In-Line / Re-heating burners• 2 Tail Gas Incinerator burners• Tail Gas Incinerator engineering

Licensor : TOTAL

South Pars 2 & 3 project NIOC / TOTAL (2000)

� Operating conditions of the CLAUS reaction furnace

• Acid gas 14 000 kg/h 217 °C• Natural gas (co-firing) 112 kg/h 20 °C turn-down ratio 1 to 8• Combustion air 9 140 kg/h 223 °C• Furnace 950 °C 205 mbar• Acid gas composition : 24 %H2S mini measured 20.5%

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� Reaction furnace burner operating conditions

• Acid gas 23 180 kg/h 220 °C• Natural gas (co-firing) 240 kg/h 20 °C turn-down ratio 1 to 8 • Combustion air 18 920 kg/h 223 °C• Furnace 950 °C• Acid gas composition : 36 %H2S

� Scope of Work :• 4 Reaction Furnace burners (tangential type)• 2 Tail Gas Incinerator burners• Tail Gas Incinerator engineering

South Pars 4 & 5 project NIOC / TOTAL (2002)

Licensor : TOTAL

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� Reaction furnace burner operating conditions

• Acid gas 23 400 kg/h 220 °C• Natural gas (co-firing) 240 kg/h 20 °C turn down ratio 1 to 12 !!• Combustion air 18 645 kg/h 220 °C• Furnace 950 °C• Acid gas composition : 36 %H2S (mini measured 20.5%)

� Scope of Work : • 4 Reaction furnace burners (tangential type) • Tail gas incinerator burner

South Pars 9 & 10 NIOC (2005)

Licensor : TOTAL

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• Acid gas 56 200 kg/h 250 °C • Natural gas (*) 1 200 kg/h 20 °C start-up & stand-by operation only• Combustion air 44 600 kg/h 270 °C• Furnace 950 °C• Acid gas composition : 26 %H2S note: 50% acid gas by-pass

� Scope of Work• Replacement of Reaction Furnace burner (tangential type)

ADGAS Das Island (2008)

Licensor : WORLEY PARSONS

� Reaction furnace burner operating conditions

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� NIOC South Pars 15 & 16 (2011)

• 4 Reaction Furnace burners (Axial type)64.5% H2S acid gas, without Co-Firing

• 4 Inline / reheating burners

Latest references

Licensor : LURGI

� NIOC South Pars 12 (2011)

• 4 Reaction Furnace burners (Axial type) 46.25% H2S acid gas, without Co-Firing

Licensor : WORLEY PARSONS

� NIOC South Pars 17 & 18 (2011)

• 4 Reaction Furnace burners (Axial type) 55.3% H2S acid gas, without Co-Firing

• 2 Inline / reheating burners

Licensor : LURGI

� NIOC South Pars 22, 23 & 24 (2011)

• 4 Reaction Furnace burners (Axial type) 64.5% H2S, without Co-Firing

• 2 Inline / reheating burners

Licensor : LURGI

Fives Pillard Customers focus

EPC : Technip / Worley Parsons / Fluor / GS Eng / L URGI / Iranians…

Direct Clients: Welcron Kangwon / Prosernat / Bremb ana..

Prospects (potential) : Hanyang / LGI / FBM Hudson…

Conclusion:

Closed market with good margins, few opportunities to enter, few advantages to put on the table compared with market leaders.

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Thank you