5 Reasons Why Performance Evaluations are Essential for Your Processing Units
Annual health checks for Sulfur Recovery Units (SRU) and Amine Units have become an industry standard, ensuring operational performance and reliability form ongoing operations and before scheduled turnarounds.
1-Establishing Baseline Performance
Baseline performance data is crucial for assessing the current state of SRUs and Amine Units. This data acts as a reference point, allowing operators to detect deviations from normal operations. Without a baseline, identifying specific issues becomes challenging, leading to extended downtime and increased maintenance costs.
2-Early Detection of Issues
Regular health checks enable early identification of operational inefficiencies, potential corrosion, contamination, fouling, and other issues. Catching these problems early helps prevent them from escalating into costly shutdowns or safety incidents.
3-Optimization Opportunities
By regularly analyzing system performance, SRE’s health checks reveal optimization opportunities. This could involve setting new operating parameters, fine-tuning the amine circulation rates, or adjusting the temperatures within the SRU. These improvements can lead to better recovery rates, lower emissions, and reduced energy consumption.
4-Supporting Turnaround Planning
Comprehensive health checks provide valuable data for planning turnarounds. Knowing the condition of equipment and potential trouble areas allows for precise scheduling and resource allocation, minimizing downtime and optimizing repair efforts.
5-Ensuring Compliance and Safety
In industries dealing with hazardous materials like H2S, safety is paramount. SRE’s rigorous safety protocols, including the use of SCBAs and trained engineers for sample collection, ensure that all health checks comply with the highest safety standards, protecting personnel and the environment.
Sulfur Recovery Engineering (SRE) offers comprehensive health check services that go beyond routine maintenance, establishing baseline performance, pinpointing optimization opportunities, and identifying potential issues early to avoid costly unscheduled and emergency shutdowns.
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From Fuel to Fines: Key Operating Costs in Sulfur Recovery Units
Managing a Sulfur Recovery Unit (SRU) involves more than just initial setup costs; it encompasses a spectrum of ongoing expenses that can significantly impact operational efficiency and regulatory compliance. Let's delve into the breakdown of these costs based on a recent YouTube transcript, categorizing them into three main areas: operating costs, maintenance costs, and emergency costs.
1. Operating Costs
Operating costs are fundamental to day-to-day SRU functionality and include:
Fuel Gas: Used in incinerators, thermal oxidizers, and other processes to convert sulfur compounds into SO2. Costs can vary based on the type and availability of gas.
Hydrogen: Essential for hydrogenation reactors and other units. While using on-site hydrogen can save on procurement costs, it may contain contaminants that reduce catalyst lifespan.
CO2 Emissions: Many jurisdictions impose costs per ton of carbon emitted, impacting overall operational expenses.
2. Maintenance Costs
Maintenance ensures the longevity and efficiency of SRU components:
Catalysts: Crucial for sulfur conversion, with costs varying by type (e.g., Illumina, Titania) and lifespan (typically 4-6 years).
Condenser Tube Sheet Failures: Result from improper thermal management during startups and shutdowns, potentially costing upwards of five figures to repair.
Refractory Damage: Repair costs can escalate dramatically if damaged during a runaway fire.
Plugged Rundown Lines: Costs can arise from unplugging lines, especially if external assistance is required.
Performance Evaluations: Conducted periodically to optimize SRU operations, typically costing around $35,000 per evaluation for comprehensive assessments.
3. Emergency Costs
Emergencies can lead to severe financial repercussions and regulatory penalties:
Regulatory Fines: Non-compliance fines can be substantial, sometimes reaching millions, depending on the severity of emissions violations.
Production Losses: SRU downtime can incur significant daily losses, ranging from $100,000 to over $1 million, highlighting the criticality of swift troubleshooting and repair.
Consent Decrees: Regulatory mandates may require frequent performance evaluations, increasing operational costs.
The operation of SRUs involves meticulous cost management across various fronts. From daily operational expenditures to mitigating potential emergencies and regulatory fines, understanding and planning for these costs are critical for maintaining operational reliability and compliance. By proactively addressing these cost factors, refineries and gas plants can optimize their SRU operations and ensure sustainable performance in the face of regulatory scrutiny and operational challenges.
Understanding these nuances not only helps in budgeting effectively but also in strategizing long-term operational excellence and compliance within the dynamic landscape of sulfur recovery management.
Case Study: Troubleshooting Decrease in Recovery Efficiency
Problem Identification
An existing client brought SRE in to troubleshoot an unexplained decrease in recovery efficiency within their Sulfur Recovery Unit (SRU). The plant had three SRU trains and had been experiencing high H2S levels in the product from the downstream degassing operation.
Steps Taken to Address the Problem
1-Initial Compositional Analysis:
SRE performed a compositional analysis of the process gas and found low conversion across Converter 2.
The SRU was generally well-operated, and no significant changes had occurred since the last test period.
2-Simulation and Catalyst Activity:
Simulations reconfirmed that the catalyst activity in the second converter bed was lower than expected.
Despite the catalyst being replaced only six months prior, the sudden reduction in efficiency was puzzling.
3-Inlet Temperature and Sample Testing:
Further analysis revealed that the converter inlet temperature was above the normal recommendation.
SRE installed a sample probe at the inlet, discovering a different gas composition than at the converter one outlet.
4-Identifying a Leak:
The analysis suggested a hole in the multipass condenser, allowing process gas from the first pass to contaminate the second pass.
This leakage explained the reduced conversion efficiency and increased inlet temperature at Converter 2.
5-Degassing Operation Review:
Before the client shut down to repair the condenser leak, SRE evaluated the degassing pits to understand why H2S levels were up to 200 ppm in the liquid sulfur.
Adjustments to the agitator and pump circulation rates were tested. It was found that the circulation rate was too low for adequate degassing.
One of the two sulfur pumps was found to be barely operational and required a complete overhaul.
6-Repair and Validation:
The condenser and pump repairs were scheduled during a planned shutdown.
SRE assisted with the shutdown and subsequent startup, performing tests to verify the effectiveness of the repairs.
Post-repair tests confirmed that recovery efficiency improved to above the license limit of 98%, and H2S levels in the liquid sulfur returned to specification.
Summary of Findings and Benefits
Operational Improvements: Quick identification and repair of the multipass condenser leak and the sulfur pump issues restored the plant's efficiency.
Financial Savings: Early detection and repair prevented further damage to the SRU and avoided substantial costs associated with contaminated product.
Product Quality: Restored liquid sulfur to meet H2S specifications, ensuring high-quality output.
This case study illustrates SRE's proficiency in diagnosing and resolving complex SRU issues efficiently. By identifying and repairing leaks and optimizing degassing operations, SRE restored the client's recovery efficiency and product quality. Other companies can benefit from SRE's thorough approach and expertise in maintaining and improving SRU operations, avoiding potential downtimes and financial losses.
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7 SRU Catalyst Killers: Identifying and Mitigating Contaminants in Sulfur Recovery Units
Catalysts are the heart of the sulfur recovery process, crucial for ensuring high efficiency and low emissions. However, various contaminants can deactive and damage these catalysts, leading to reduced performance and increased operational costs. This article explores the primary contaminants, their mechanisms, and methods for mitigation, alongside the financial impact of catalyst misuse.
Catalysts in sulfur recovery units (SRUs) facilitate the conversion of hydrogen sulfide (H2S) into elemental sulfur. Over time, contaminants can deactive these catalysts, impacting their effectiveness and lifespan. Identifying and understanding these contaminants is critical for maintaining optimal performance.
Major Contaminants and Their Impact
1- BTEX (Benzene, Toluene, Ethylbenzene, Xylene)
Mechanism: BTEX components are not fully destroyed in the reaction furnace (RF) and polymerize on the Claus catalyst.
Deactivation Type: Permanent.
Mitigation: Ensure complete destruction in the RF, maintain correct temperatures, and monitor BTEX levels in the feed.
2-Methanol
Mechanism: Methanol bypasses the RF via an acid gas bypass, leading to polymerization on the catalyst.
Deactivation Type: Permanent.
Mitigation: Properly control bypass systems and monitor methanol concentrations.
3-Soot and Liquid Sulfur Deposition
Mechanism: Incomplete combustion during startup or improper burner stoichiometry leads to soot formation, plugging converter beds.
Deactivation Type: Temporary.
Regeneration: Heat soak.
Mitigation: Optimize startup procedures and maintain burner efficiency.
4-Sulfation
Mechanism: Excessive free oxygen from the RF or reheaters causes sulfation of the catalyst.
Deactivation Type: Permanent.
Mitigation: Control oxygen levels and ensure proper operation of reheaters.
5- Steam (Hydrothermal Aging)
Mechanism: Long-term exposure to excessive water vapor leads to structural damage.
Deactivation Type: Permanent.
Mitigation: Minimize steam introduction and prevent boiler leaks.
6-Thermal Aging
Mechanism: High temperatures during sulfur fires cause catalyst sintering.
Deactivation Type: Permanent.
Mitigation: Avoid thermal excursions and maintain safe operational temperatures.
7-Heavy Hydrocarbons
Mechanism: Heavy hydrocarbons crack and form coke, blocking catalyst pores.
Deactivation Type: Permanent.
Mitigation: Optimize feedstock composition and prevent heavy hydrocarbon carryover
Avoiding Contamination
Preventing catalyst contamination involves maintaining strict operational controls and regular monitoring:
Ensure proper destruction of contaminants in the RF.
Control bypass systems to prevent methanol and heavy hydrocarbons from entering the catalyst beds.
Optimize startup and shutdown procedures to minimize soot formation.
Maintain proper temperatures to avoid sulfur condensation.
Regularly inspect and repair boiler systems to prevent hydrothermal aging.
Avoid thermal excursions by controlling process temperatures and preventing sulfur fires.
Financial Impact of Catalyst Misuse
Catalyst deactivation leads to significant financial burdens due to reduced efficiency, increased maintenance costs, and potential unscheduled shutdowns. Misuse can result in:
Increased operational costs due to frequent catalyst replacements.
Higher energy consumption and lower process efficiency.
Downtime for maintenance and catalyst regeneration or replacement.
How We Can Help: Performance Testing and Optimization
Sulfur Recovery Engineering (SRE) offers comprehensive performance testing and optimization services. Our experts can:
Conduct thorough assessments to identify contamination sources.
Provide tailored solutions to prevent and mitigate catalyst deactivation.
Offer regular monitoring and maintenance programs to ensure long-term efficiency and reliability.
Protect your catalysts and ensure optimal performance of your sulfur recovery units. Contact SRE today to schedule a consultation and learn how we can help you maintain peak efficiency and minimize operational costs.
Overcoming Heat Stable Salts: Enhance Your Amine Treating Process
Introduction
In the operation of amine units, the degradation of the solvent is a common issue caused by contaminants such as oxygen, sulfur dioxide, acids, or acid precursors present in the feed gas. One of the most significant problems arising from this degradation is the formation of Heat Stable Salts (HSS). Understanding the formation, impact, and remediation of HSS is crucial for maintaining the efficiency and longevity of amine treating systems.
Formation of Heat Stable Salts
Heat Stable Salts are formed when acid anions like formate, acetate, thiosulfate, thiocyanate, and chloride react with amine molecules. These salts are termed "heat stable" because they cannot be regenerated by heating. Various sources contribute to HSS formation:
In refineries, gases from the Fluid Catalytic Cracking Unit (FCCU) can contain formic and acetic acids.
Oxygen in refinery gas streams or air leaks in gas gathering systems can lead to the formation of carboxylic acids.
HCN in the feed gas can react with sulfur in the amine solution to form thiocyanate.
Impact of Heat Stable Salts on Amine Systems
The presence of HSS in amine systems leads to several operational issues:
Reduced Acid Gas Carrying Capacity: HSS bind with amine molecules, decreasing the amount of amine available for acid gas absorption.
Corrosion: High concentrations of HSS can be corrosive, facilitating corrosion reactions and dissolving protective films on metal surfaces.
Foaming: Changes in the surface-active properties and increased viscosity of the solution can lead to foaming, which disrupts operations.
Erosion: The precipitation of salts or corrosion end products can accelerate the erosion of metal components.
Addressing the Problem
Reducing or removing HSS from the amine solution is essential for maintaining system efficiency. The following strategies can be employed:
Monitoring and Prediction: Regular solvent analyses to determine the HSS profile and predict when remedial action is necessary.
Control Strategies: Adjusting operational configurations to reduce the formation of contaminants or improve the removal of contaminants upstream.
Neutralization Technology: Using neutralizers to convert HSS into less corrosive forms, thereby extending the solvent's life.
Solvent Purification: Employing methods such as electrodialysis, ion exchange, or vacuum distillation to remove HSS.
Our experts can help you find the root cause of the problem and provide tailored solutions to maintain your system's efficiency and reliability.
Advantages of Managing Heat Stable Salts
Effective management of HSS offers several benefits:
Reduced Corrosion and Equipment Replacement Costs: Minimizing the corrosive impact of HSS extends the life of equipment.
Optimized System Capacity: Ensuring maximum acid gas removal efficiency prevents unit shutdowns and maintains operational targets.
Lower Maintenance Costs: Reducing the frequency of system cleanings and filter replacements lowers maintenance expenses.
Environmental and Economic Benefits: Avoiding solvent disposal reduces environmental impact and costs associated with solvent replacement.
Conclusion
Managing Heat Stable Salts in amine treating systems is crucial for maintaining system performance and longevity. Regular monitoring, effective neutralization, and advanced purification methods can significantly reduce the negative impacts of HSS. At SRE, we offer comprehensive amine analysis services to identify the exact salts present and determine the root cause of HSS formation. Our detailed analysis capabilities ensure precise solutions to optimize your amine system's performance.
We can help
If you're facing issues with Heat Stable Salts in your amine treating system, contact SRE for a complete amine analysis. Our experts can help you find the root cause of the problem and provide tailored solutions to maintain your system's efficiency and reliability.
Mastering Amine unit Issues 8 Scenarios Where SRE Can Assist
Amine plants play a crucial role in gas sweetening, but they can face numerous operational challenges. Sulfur Recovery Engineering (SRE) offers specialized services to troubleshoot and resolve these issues, ensuring optimal performance and reliability. Here’s a brief description of each problem and how SRE addresses it:
1-Foaming
Problem: Heavy hydrocarbons and contaminants in the inlet feed cause foaming in absorbers, leading to reduced efficiency and potential operational disruptions.
Solution: SRE utilizes advanced Gas Chromatography (GC) technology for rapid identification of contaminants, along with onsite foam testing and evaluation of anti-foam agents to mitigate foaming issues effectively.
2-Corrosion
Problem: Corrosive environments within the amine plant can degrade equipment integrity, leading to increased maintenance costs and safety risks.
Solution: SRE quickly identifies corrosion potential areas through simulation, reviews and refines monitoring programs, and helps minimize corrosion through an online operations and maintenance (O&M) monitoring program.
3-Off-Spec Gas / LPG
Problem: Off-spec gas or LPG indicates deviations from desired product specifications, impacting product quality and compliance.
Solution: SRE conducts rapid onsite testing to diagnose issues, identifies trace sulfur components, and achieves 99% closure of the sulfur balance, ensuring compliance with product specifications.
4-Fouling
Problem: Fouling in amine plants results from contaminants and particulates accumulating in key components, reducing operational efficiency.
Solution: SRE reviews and optimizes filtration programs to prevent fouling, ensuring smooth operation and minimizing maintenance downtime.
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5-Sulfur Plant Feed Quality
Problem: Inaccurate sulfur component levels and impurities in the regenerator overhead impact the efficiency of sulfur recovery processes.
Solution: SRE performs onsite analytical testing to accurately measure sulfur components, identifies mercaptans breakdown, speciates BTEX compounds, and quantifies hydrogen cyanide (HCN) concentrations. We quickly optimize the acid gas circuit to improve overall efficiency and reduce corrosive issues.
6-Hydrocarbon Entrainment
Problem: Ineffective separation equipment allows hydrocarbons to enter the process stream, reducing the purity and efficiency of amine treatment.
Solution: SRE reviews and enhances the performance of inlet separation equipment, quantifying hydrocarbon levels in the process stream to mitigate entrainment issues.
7-Inefficient Energy Usage / High Carbon Intensity
Problem: Excessive energy consumption and high carbon intensity increase operational costs and environmental impact.
Solution: SRE optimizes energy usage through circulation rate adjustments and reboiler duty fine-tuning, recommends alternative amines with lower energy requirements, and assists in transitioning from steam to electric drives for enhanced efficiency.
8-Root Cause Analysis of Common Alarms
Problem: Common alarms such as pressure differentials, analyzer errors, and pH fluctuations indicate underlying operational issues affecting plant reliability.
Solution: SRE conducts detailed root cause analysis on absorber pressure differential (delta P), H2S and total sulfur analyzer errors, fuel gas H2S analyzer errors, sulfur plant tail gas analyzer (ADA) erratic behavior, quench pH, quench cooler fouling, and hydrogen analyzer plugging. Our expert analysis identifies operational inefficiencies and implements targeted solutions to improve overall plant reliability and safety.
SRE’s specialized expertise and innovative solutions address the complex challenges faced by amine plants, ensuring efficient operation, regulatory compliance, and enhanced performance. By partnering with SRE, clients benefit from reduced downtime, lower operational costs, and optimized plant reliability in their gas sweetening operations.