SULFEROX®

Converting hydrogen sulphide to elemental sulphur

Shell Global Solutions

ABOUT THE TECHNOLOGY

There are numerous methods for reducing hydrogen
sulphide in process streams and each has a specific
application range (Figure 1). Extensive pilot plant testing
and commercial operations show that the SulFerox
process is very well suited for handling gas streams that
yield between 0.1 and 20 t/d of sulphur.

PROCESS DESCRIPTION
SulFerox is a redox-based process that converts the
hydrogen sulphide in sour gas to elemental sulphur
through reaction with aqueous ferric iron. The process
forms solid sulphur particles that are easily filtered out.

There are three steps in the process: absorption,

AT A GLANCE regeneration and sulphur recovery. During absorption,

Customer driver: The need for an effective treatment of
gases containing any level of sulphur
Solution: SulFerox process for the treatment of natural
gas, refinery gas, syngas and other gas streams
Value delivered: Cost advantages in treating gases
containing a wide range hydrogen sulphide levels
Proof point: More than 30 plants worldwide operating
the SulFerox process
Acid-gas treating has traditionally required an amine plant to
remove hydrogen sulphide and a Claus unit to convert the
concentrated hydrogen sulphide stream to sulphur. The SulFerox
Hydrogen sulphide concentration (ppmv)
the sour gas stream comes into contact with a liquid
containing soluble iron (III), and hydrogen sulphide is
selectively oxidised to form elemental sulphur.
Regeneration involves re-oxidation of the iron (II) to
maintain a supply of active iron (III). To maximise sulphur
recovery, the elemental sulphur formed in the first
reaction is concentrated in a surge tank and then filtered
out. The filtrate is returned to the process for maximum
ferric iron solution recovery.
In most cases, filtration and melting produce yellow
sulphur of a quality comparable to that of conventional
Claus unit sulphur.
1,000,000

50
t/d
process is an alternative to these steps and consequently offers 100,000
20
t/d
sulp
hur
sul
phu
substantial savings in capital and operating costs by removing r
Amine/Sulfinol + Claus
(+SCOT™)
hydrogen sulphide directly from gas streams and converting it 10,000

to elemental sulphur. THIOPAQ O&G

50
1,000 kg/
ds
The SulFerox process was first applied in 1990, and has since ulp
hur
SulFerox

been used worldwide for applications including: 100

Non-regenerable Amine/Sulfinol +
n refinery hydrotreater off-gas; solids and liquids SulFerox/
THIOPAQ O&G
10
n amine off-gas; 0.01 0.1 1 10
Gas flow (106 Nm3/d)
n refinery process streams;
n coke oven gas; Figure 1: Hydrogen sulphide processing selection chart.

n primary natural gas treating; and

n associated gas (onshore and offshore).
 pRoof poINTs
To date, more than 30 plants worldwide have applied
the SulFerox process to produce sulphur at outputs
ranging from 0.1 to 20 t/d.
OIL AND GAS, OFFSHORE USA
The SulFerox process is very well suited for gas
processing on an offshore platform where the key
requirements for process installations are a small
TREATED footprint and low weight. The first offshore SulFerox
GAS
SPENT AIR
plant was installed and started up on a platform off
Sulphur-free
the coast of California. The operator uses the
REGENERATOR

fuel gas
SURGE TANK SulFerox process to treat natural gas that is fed into
SPARGE TOWER

the unit at 150 psig and has a hydrogen sulphide

DEGASSER content of 1.2vol%. The plant produces about 3 t/d
VESSEL
SOUR
GAS
of sulphur.
Filter
SILICON CARBIDE MANUFACTURING, USA
SFX SLURRY A North American silicon carbide manufacturer uses
FILTRATE
TANK

AIR BLOWER PUMPS

SULPHUR CAKE
the SulFerox process to remove hydrogen sulphide
from by-product waste gas and convert it to elemental
SFX SOLUTION
EXCHANGERS
SFX CIRCULATION
SFX FILTRATION sulphur. The resultant sulphur-free gas is suitable for
PUMPS
HEATING/COOLING PUMPS
use as a fuel source. The process equipment comprises
Figure 2: Typical SulFerox process flow system. a particulate cleaning station, desulphurisation units, a
compression unit, a dehydration unit and a gas
pipeline to the power plant.
BUSINESS VALUE
The Shell Global Solutions SulFerox process offers a flexible
solution for sour-gas treatment. Operating in the 0.1–20-t/d
AMINE AND GAS PROCESSING
sulphur range, the SulFerox process requires less process
TREATED GAS
equipment and energy to operate than the amine–Claus
alternative (Figure 2). FEED
GAS Amine STACK GAS
SRU TGTU Incinerator
unit
Removing contaminants from sour streams helps to support
efficient operations and maximise the value of the product SULFEROX PROCESS
slate. SulFerox is a flexible system that offers several TREATED GAS

advantages over conventional systems:

n reduced capital expenditure and lower operating costs; FEED GAS SULFEROX VENT GAS

n 
flexibility to cope with changes in gas volume and hydrogen
sulphide content; SULPHUR
n 
effective treatment of gases with very low hydrogen sulphide
Figure 3: A SulFerox unit can replace a complete amine and acid gas
concentrations; processing train.
n non-toxic elemental sulphur product; and
n suitability for low- and high-pressure (<450-psig) applications.
SulFerox is a Shell trademark.

For further information, please visit our website at www.shell.com/globalsolutions

Shell Global Solutions is a network of independent technology companies in the Shell Group. In this
HAVE YOU CONSIDERED HOW YOU CAN material, the expressions “the Shell Group”, “Shell” and “Shell Global Solutions” are sometimes used
for convenience where reference is made to these companies in general or where no useful purpose is
n effectively remove hydrogen sulphide? served by identifying a particular company.

n 
handle low-, moderate- and high-pressure (<450-psig) The information contained in this material is intended to be general in nature and must not be relied on
as specific advice in connection with any decisions you may make. Shell Global Solutions is not liable
applications? for any action you may take as a result of you relying on such material or for any loss or damage
suffered by you as a result of you taking this action. Furthermore, these materials do not in any way
n 
cope with variations in gas volumes and hydrogen constitute an offer to provide specific services. Some services may not be available in certain countries

sulphide content? or political subdivisions thereof.

Copyright © 2011 Shell Global Solutions International BV. All rights reserved. No part of this
n 
reduce the capital expenditure and operating costs for publication may be reproduced or transmitted in any form or by any means, electronic or mechanical
including by photocopy, recording or information storage and retrieval system, without permission in
sour‑gas processing? writing from Shell Global Solutions International BV.
GS33760911 Am(A)