Compact modular sulphur
recovery solutions
Benoît Mares and Christian Streicher Prosernat
P
rosernat has been awarded a contract for
the delivery of modular Sulphur Recovery
Units (SRUs) for an Early Production Facility
(EPF) project in Middle East. For this project
the SmartSulf™ technology licensed has been
selected among other options less favourable in
terms of capex and opex. The unit capacity is of
2 parallel trains of 100 TS/d each. The specific-
ity of the SmartSulf process technology which
allows to achieve high sulphur yields without
need for additional tail gas treatment, has been
considered as a definite advantage for the pro-
ject. The modular delivery by Prosernat allows
to keep with the tight overall project schedule.
The overall project is being developed on a BOT
(Build-Operate-Transfer) model and the capac-
ity of Prosernat to follow the BOT Contractor in
terms of contractual scheme was also a key deci-
sive factor.
 
A compact, low cost technology
Local environmental regulations required for
this kind of SRU an overall sulphur recovery of
at least 99.4 %. This level can be guaranteed with
the SmartSulf process without need for instal-
lation of any downstream Tail Gas treatment
Process. The concept of the SmartSulf process is
based on the use of a 2 catalytic stages Claus unit,
different from conventional Claus by the fact that
the catalytic reactors are operated under isother-
mal conditions and the second catalytic stage is
operated under subdewpoint conditions in order
to achieve much higher sulphur yields than in
a conventional Claus process. This concept is
described with Figure 1. The fundamental idea of
the SmartSulf process is removing the heat pro-
duced by the exothermic Claus reaction directly
in the catalyst bed rather than in a downstream
heat exchanger. This controls the temperature
throughout the catalyst bed within a narrow
range. The heat exchanger applied is a thermo-
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plate with large clearances. The space in between
the plates is filled with catalyst so that the cooling
heat exchanger is embedded in the catalyst.
The acid gas is fed in a thermal section, strictly
similar to what is found in conventional Claus
design. After sulphur condensation and reheat-
ing the tail gas from thermal stage is fed to the
first catalytic stage. Both catalytic reactors are
equipped with an internal heat exchanger in
order to control the temperature in the reactors.
The heat of the Claus catalytic reaction is being
removed by circulating water counter-currently
in the heat exchanger inside of the reactor. The
first catalytic reactor is being operated at tem-
peratures above sulphur subdewpoint. However
by controlling the temperature at the outlet of
the first reactor higher catalytic conversions are
already being achieved than in a conventional
first stage Claus reactor. After sulphur condensa-
tion the gas from the first reactor is then fed to
the second catalytic reactor. This reactor is being
operated at temperatures below sulphur subdew-
point, thus achieving much higher conversions.
Because the temperature is kept controlled until
the outlet of the reactor the conversions achieved
are in fact even higher than those obtained in
conventional subdewpoint tail gas treatment pro-
cesses. For a typical acid gas in a refinery over-
all sulphur recoveries are above 99.5 %. Tail gas
form the SmartSulf unit can therefore in most
cases be directly sent to the incinerator without
Figure 1 Schematic of the SmartSulf process
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 Figure 2 3D model of the 100 TS/d SmartSulf
the need for any downstream tail gas treatment
unit. This is being the case for the early produc-
tion facilities considered in Middle East.
Once the second catalytic reactor is loaded with
liquid sulphur, the couple of automatic 4 ways
valves are being rotated so that the first reactor
originally operated in “hot mode” becomes now
operated in subdewpoint mode. The second cat-
alytic reactor is now operated in “hot mode” and
therefore regenerated by vaporising all the accu-
mulated sulphur, which is then condensed in the
external sulphur condenser.
The SmartSulf process is a real breakthrough
in sulphur recovery technologies, allowing high
sulphur recoveries without need for tail gas treat-
ment unit. To summarise the key reasons for
selecting Prosernat and its SmartSulf process for
this EPF project have been:
• The capacity of the process to meet local envi-
ronmental regulations
• The compactness of the process with a mini-
mum amount of equipment items compared to
other technologies
• The low cost of this technology, compared to
alternative Claus + tail gas treatment options
• The capacity of Prosernat to supply the unit
2 October 2017
fully modularised within a tight timeframe
• The capacity of Prosernat to support its cus-
tomer for such BOT project through financing
and continuous operational support.
Construction of the SmartSulf unit
Each of both 100 TS/d train of the SmartSulf will
be delivered modularised in the following form
(see also Figure 2 3D model of the SRU):
• 1 module for feed gas pre-treatment (knock-out
drum + air pre-heater)
• 3 modules for the whole catalytic section
(including sulphur condenser and 4-ways valves)
• 1 package for the thermal section with reaction
furnace, burner and waste heat boilers with base
plates and access platform supplied loose for site
installation
• 1 incinerator conditioning skid (for tail gas and
combustion air)
• 1 loose incinerator and burner
Specific equipments
The SmartSulf reactors for the project are 3.6 m
diameter. Those reactors are proprietary items
based on specific manufacturing knowledges
especially for the assembly of internals (header,
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plates), mechanical design and testing of the
reactors, welding procedures, thermal stress con-
siderations, non destructive tests…
Another specific item for the SmartSulf appli-
cation is the 4-ways valves. The process is cyclic
and designed so that after 24h, the two reactors
switches. The second Reactor that contains the
catalyst loaded with sulphur has to be regener-
ated. For that purpose, switching 4-way valves
are actuated and modify the process gas circula-
tion through the unit. The former second reactor
becomes the first one and vice-versa. The switch-
ing procedure is completely automatic and takes
only a few seconds.
The two 4-ways valves for the JPF case are 16
inches and are especially designed for sulphur
environment applications. Full availability of the
valves is achieved through tailor made design
such as full steam jacket of the valve (body and
disc), free draining body with no possible sul-
phur accumulation, sealing system to ensure
Class IV tightness… Those valves are delivered by
Prosernat as proprietary items.
As mentioned earlier the sequence is com-
pletely automatic. Prosernat develops the com-
plete functional analysis and also the logic
diagrams as required by the Client. For the pro-
ject, the logic was implemented by the Client
directly in its control system. The advantage is
that the sequence is programmed using the same
hardware and software as the ones used for the
overall plant control and monitoring. It simplifies
a lot in terms of maintenance.
Plot area
The plot area required for the SmartSulf unit is
similar to the plot area required for the installa-
tion of a standard Claus unit with two catalytic
stages. The two 100 TS/d trains of SmartSulf are
easily installed in a 50 m x 70 m foot print. In
fact an existing Claus unit can be retrofitted into
a SmartSulf unit and has been already been done
in past projects.
Modularisation strategy and schedule
The modularisation strategy for this project was
selected due to the location of the site and fast
track project schedule.
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In a modular approach, the units are manufac-
tured and tested in a workshop and then shipped
to the customer. Manufacturing in a workshop
compresses the construction schedule because
the manpower, materials, equipments and
technical resources are immediately available.
Finally, construction in a workshop helps keep
the costs down and increases safety.
The customer is in charge of the civil engineer-
ing which can be done in parallel with the mod-
ule construction at the workshop. Thanks to the
modular approach the units can typically be com-
pleted in one-third to one half of similar stick-
built units.
Conclusion
By combining the expertise of its own technol-
ogies and its experience in modular systems,
Prosernat has already demonstrated many times
that it can offer a compact solution for fast track
projects. Indeed, the SmartSulf offers a solution
with a minimum number of equipments while
meeting the environmental specifications without
the use of an additional Tail gas treatment Unit.
Modularisation is an answer to many specific
challenges faced by the oil and gas industry, such
as harsh site conditions, size limitations at site
or for transport as well as tight project schedule.
Prosernat experience with above 400 modular
units installed worldwide, is being successfully
applied for sulphur recovery.
The EPF project is an example of such vari-
ous project challenges, in the case of Sulphur
Recovery Units and of how those challenges can
be met by Prosernat by combining its unique
technology portfolio, huge experience of modu-
larisation and flexibility in meeting customer’s
needs.
LINKS
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October 2017 3