Increased capacity sulfur recovery plant and process for recovering elemental sulfur
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
C01B-017/04
C01B-017/00
B01J-012/00
B01J-012/02
B01J-019/00
출원번호
US-0467453
(2006-08-25)
등록번호
US-7501111
(2009-03-10)
발명자
/ 주소
Keller,Alfred E.
Ramani,Sriram
Allison,Joe D.
Lusk,Steven E.
Hatcher,Nathan A.
Swinney,Larry D.
Shaver,Rebecca S.
출원인 / 주소
Conoco Phillips Company
인용정보
피인용 횟수 :
8인용 특허 :
82
초록▼
Claus sulfur recovery plants that include one or more single-stage or multi-stage compact tubular Claus catalytic reactor-heat exchanger units are disclosed. In some instances, these new or improved Claus plants additionally include one or more compact heat exchanger containing cooling tubes that ar
Claus sulfur recovery plants that include one or more single-stage or multi-stage compact tubular Claus catalytic reactor-heat exchanger units are disclosed. In some instances, these new or improved Claus plants additionally include one or more compact heat exchanger containing cooling tubes that are filled with a heat transfer enhancement medium. The new compact tubular Claus catalytic reactor-heat exchanger units and HTEM-containing heat exchangers are also disclosed. A process for recovering sulfur from a hydrogen sulfide-containing gas stream, employing the new tubular Claus catalytic reactor-heat exchanger unit, and in some instances a HTEM-containing heat exchanger, are also disclosed.
대표청구항▼
What is claimed is: 1. A tubular Claus catalytic reaction unit for converting SO2 and H2S to elemental sulfur and water, said reaction unit comprising: a sulfur separator comprising a reactant gas channel and a process gas channel, said sulfur separator having a liquid sulfur outlet and at least on
What is claimed is: 1. A tubular Claus catalytic reaction unit for converting SO2 and H2S to elemental sulfur and water, said reaction unit comprising: a sulfur separator comprising a reactant gas channel and a process gas channel, said sulfur separator having a liquid sulfur outlet and at least one liquid sulfur inlet, said process gas channel having a process gas outlet; at least one concentric tubular reactor assembly disposed between said reactant gas channel and said process gas channel, wherein the concentric tubular assembly comprises: an annular Claus catalytic reaction zone in fluid communication with said reactant gas channel, an annular sulfur condensation zone adjacent to and in fluid communication with said catalytic reaction zone, for receiving reacted gases from said reaction zone and for condensing and collecting sulfur, said condensation zone comprising a process gas outlet in fluid communication with said process gas channel and said sulfur separator; and a temperature control zone in thermal communication with said condensation zone. 2. The Claus catalytic reaction unit of claim 1 wherein each said concentric tubular reactor assembly comprises: first and second ends; a group of concentric tubes extending between said first and second ends, and comprising: a perforated inner tube having an interior gas channel, a perforated middle tube, and a non-perforated outer tube, wherein said annular catalytic reaction zone is disposed between said inner and middle tubes; and wherein said annular sulfur condensation zone is disposed between said middle and outer tubes, said condensation zone having at least one liquid sulfur outlet and a process gas outlet; wherein said reactant gas channel adjoins said first end, is in fluid communication with said interior channel, and wherein said process gas channel adjoins said second end, is in fluid communication with said sulfur condensation zone, and comprises at least one process gas outlet, and wherein said temperature control zone comprises: a first end adjacent to said reactant gas channel, a second end adjacent to said process gas channel, a shell comprising an interior fluid space surrounding at least a portion of each said outer tube, a heat transfer fluid inlet, and a heat transfer fluid outlet. 3. The unit of claim 2 configured in a vertical orientation with respect to the axis of the concentric tubes. 4. The unit of claim 2 configured in a horizontal orientation with respect to the axis of the concentric tubes. 5. The unit of claim 2 wherein each said reactor assembly comprises a removable closure attached to the inner and middle tubes at each said reactor assembly's second end. 6. The unit of claim 1 comprising a plurality of said concentric tubular reactor assemblies, wherein said reactant gas channel comprises a first reactant gas channel, said process gas channel comprises a third process gas channel having a process gas outlet, and said unit comprises at least a first pair of said concentric tube assemblies configured for receiving reactant gas from said first reactant gas channel and emitting process gas into a first process gas channel that is adjacent to said third process gas channel. 7. The unit of claim 6 wherein said unit further comprises at least a second pair of concentric tube assemblies configured for receiving process gas from said first process gas channel and for emitting process gas into a second process gas channel that is adjacent to said first reactant gas channel and comprises a liquid sulfur outlet. 8. The unit of claim 7 wherein said unit further comprises at least a third pair of concentric tube assemblies configured for receiving process gas from said second process gas channel and for emitting process gas into said third process gas channel. 9. A Claus sulfur recovery plant comprising: a thermal zone for producing a gaseous effluent comprising elemental sulfur, SO2 and unreacted H2S; at least one heat exchanger; and at least one tubular Claus catalytic reaction unit in accordance with claim 1, for receiving said gaseous effluent and converting SO2 and unreacted H2S to elemental sulfur and water, wherein a first said heat exchanger is disposed between said thermal zone and one said tubular Claus catalytic reaction unit, for partially cooling said gaseous effluent from said thermal zone. 10. The Claus sulfur recovery plant of claim 9 wherein said at least one heat exchanger includes a first heat exchanger comprising: a plurality of tubes, wherein each said tube contains a heat transfer enhancement medium, a liquid sulfur outlet, and a process gas outlet in fluid communication with said tubular Claus catalytic reaction unit. 11. The sulfur recovery plant of claim 10 wherein said heat exchanger containing said heat transfer enhancement medium has a heat transfer coefficient at least 2.5 fold greater than the heat transfer coefficient of an identical heat exchanger without said heat transfer enhancement medium. 12. The sulfur recovery plant of claim 9 wherein at least one said heat exchanger comprises a second heat exchanger consisting of a sulfur condenser which includes a liquid sulfur outlet and a plurality of tubes containing heat transfer enhancement medium. 13. In a Claus sulfur recovery plant comprising a thermal zone followed by a waste heat exchanger containing a plurality of cooling tubes, and at least one Claus catalytic reaction unit in series flow arrangement with said waste heat exchanger, each said Claus catalytic reaction unit comprising a heater, Claus catalytic reactor and sulfur condenser, the improvement comprising: (a) insertion of the tubular Claus catalytic reaction unit as defined in claim 1 in parallel flow arrangement with said at least one Claus catalytic reaction unit; and/or (b) replacement of at least one Claus catalytic reaction unit with at least one tubular Claus catalytic reaction unit according to claim 1. 14. A process for producing elemental sulfur from a feed gas stream containing hydrogen sulfide and sulfur dioxide, said process comprising: (a) introducing a feed gas stream comprising hydrogen sulfide and sulfur dioxide into the Claus catalytic reaction unit according to claim 2; (b) circulating a heat transfer fluid in said temperature control zone to maintain the temperature of the heat transfer fluid in the range of about 125�� C. to about 157�� C.; (c) contacting the feed gas stream with said Claus catalyst in said catalytic reaction zone, causing the hydrogen sulfide and sulfur dioxide to react, forming a process gas stream comprising elemental sulfur and water; and (d) cooling said process gas stream to cause the condensation of at least a portion of the elemental sulfur in said process gas stream, whereby, aided by the force of gravity, liquid sulfur collects in said sulfur condensation zone and seep into said reactant gas channel by way of said plurality of liquid sulfur outlets. 15. The process of claim 14 wherein, in step (b), circulating said heat transfer fluid in said temperature control zone comprises maintaining the temperature of said process gas stream from step (c) in the range of about 125�� C. to about 157�� C. 16. The process of claim 14, wherein said Claus catalytic reaction unit is a multi-stage Claus catalytic reaction unit wherein said reactant gas channel comprises a first reactant gas channel, said process gas channel comprises a third process gas channel having a process gas outlet, and said unit comprises: at least a first group of said concentric tubular reactor assemblies configured for receiving reactant gas from said first reactant gas channel and emitting process gas into a first process gas channel that is adjacent to said third process gas channel, at least a second group of concentric tubular reactor assemblies configured for receiving process gas from said first process gas channel and for emitting process gas into a second process gas channel that is adjacent to said first reactant gas channel and comprises a liquid sulfur outlet, and at least a third group of concentric tubular reactor assemblies configured for receiving process gas from said second process gas channel and for emitting process gas into said third process gas channel; and step (a) comprises: (a1) passing said feed gas stream into said at least a first group of concentric tubular reactor assemblies, whereby a first reacted gas mixture comprising elemental sulfur, unreacted H2S and unreacted SO2 is formed and a first quantity of elemental sulfur is condensed, and the resulting first stage process gas is emitted into said first process gas channel; (a2) passing said first process gas into said at least a second group of concentric tubular reactor assemblies, whereby a second reacted gas mixture comprising elemental sulfur, unreacted H2S and unreacted SO2 is formed and a second quantity of elemental sulfur is condensed, and the resulting second stage process gas is emitted into said second process gas channel; (a3) passing said second process gas into said at least a third group of concentric tubular reactor assemblies, whereby a third reacted gas mixture comprising elemental sulfur, unreacted H2S and unreacted SO2 is formed and a third quantity of elemental sulfur is condensed, and the resulting third stage process gas is emitted into said third process gas channel; and (a4) collecting said condensed sulfur. 17. The process of claim 16, wherein, in step (b), circulating said heat transfer fluid in said temperature control zone comprises contacting each said non-perforated outer tube of each said reactor assembly in said multi-stage Claus catalytic reaction unit with said heat transfer fluid. 18. The process of claim 16, wherein step (d) comprises cooling said first, second and third process gas streams from steps (a1-a-3) in the respective sulfur condensation zones, causing liquid sulfur to collect in said respective sulfur condensation zones. 19. The process of claim 18, wherein said heat transfer fluid inlet is disposed nearer to the last group of concentric tubular reactor assemblies than to the earlier groups of reactor assemblies, said interior fluid space comprises a baffle disposed between said last group of reactor assemblies and said earlier groups of reactor assemblies, and said heat transfer fluid comprises water, and step (d) further comprises introducing pressurized water into said fluid inlet, wherein said pressurized water is at a temperature in the range of about 100�� C. to about 125�� C., to cool the process gas and condensed sulfur from the last group of reactor assemblies to a lower temperature than that of the process gas and condensed sulfur from the earlier reactor assemblies, whereby the overall sulfur recovery of the process is enhanced. 20. A process for recovering elemental sulfur from a gas stream containing hydrogen sulfide, the method comprising: a thermal stage comprising passing a feed gas stream comprising hydrogen sulfide and an O2-containing gas through a Claus burner/furnace, or passing said feed gas stream through a catalytic partial oxidation reactor, to yield a process gas stream comprising elemental sulfur, water, SO2, and unreacted H2S, if any; partially cooling said process gas stream; introducing at least a first portion of said partially cooled oxidized gas stream into a tubular Claus catalytic reaction unit according to claim 2, circulating said heat transfer fluid in said temperature control zone at a temperature or temperature range that maintains the temperature of the gases at about the dew point of sulfur, whereby liquid sulfur forms in each said sulfur condensation zone and a second process gas stream is produced. 21. The process of claim 20 further comprising: introducing a second portion of said partially cooled process gas stream into a first sulfur condenser, whereby additional liquid sulfur is formed and a third process gas stream is produced; subjecting said third process gas stream sequentially to at least one other Claus catalytic reaction unit, different than said Claus catalytic reaction unit of claim 2, wherein each said other Claus catalytic reaction unit comprising a heater, Claus catalytic reactor, and sulfur condenser, thereby forming additional liquid sulfur and producing a fourth process gas stream; recovering said liquid sulfur; combining said second and fourth process gas streams; and subjecting said combined process gas stream to a tail gas treatment to remove residual sulfur-containing compounds, to produce an exhaust gas. 22. The process of claim 21 wherein at least one said sulfur condenser comprises a plurality of cooling tubes containing a heat transfer enhancement medium. 23. The process of claim 20 wherein said thermal stage comprises passing said feed gas stream through a short contact time catalytic partial oxidation reactor at a gas hourly space velocity of at least 20,000 h-1, wherein said short contact time reactor comprises a mixing zone, a reaction zone, and a cooling zone.
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이 특허에 인용된 특허 (82)
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