SULPHUR : PRESENT AND FUTURE

USES OF SULPHUR IN INDIA

1. 65 % fertilizer sector

2. 15 % for manufacturing H2S04

3. 10 % textile sector

4. 10 % other use

Import Data of Countries : 2012

China US

Brazil India60 %

20 %

15%

5%

0

0.5

1

1.5

2

2.5

2010 2011 2012 2013

PRODUCTION OF SULPHUR IN INDIA IN RECENT YEARS

MILLION TONS

FUTURE PREDICTIONS OF IMPORT ININDIA

0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

2012 2013 2014 2015 2016

MILLIO

N TO

NS

Production of sulphur in INDIA from different refineries

2 IOCL Guwahati 600

3 IOCL Barauni 12000

4 IOCL Koyali 18000

5 IOCL Haldia 24000

6 IOCL Mathura 48 000

7 IOCL Digboi -

8 IOCL Panipat 144000

9 IOCL Bongaigaon 3650

10 BPCL Mumbai 87600

11 BPCL Kochi 47450

12 CPCL Manali 22000

13 CPCL Nagapattinam 21000

14 Numaligarh Refinery Ltd Numaligarh 4000

15 Manglore Refinery &

Petrochemicals Ltd

Manglore 202575

16 ONGC Tatipaka, AP -

17 Bharat Oman Refineries Ltd (JV ) Bina 131400

18 HPCL Mittal Energy Ltd Bathinda 40000

19 Essar Oil Ltd Vadinar 246375

20 HPCL Mumbai 47450

21 HPCL Visakapattanam 60350

TOTAL 2638700 MT/ANNUM ( PRODUCTION )till

2014

Cost of imported sulphur of India in recent years

YEAR QUANTITY (million tonne ) COST in Rupees ( crore )

2008 0.8 300

2009 1 340

2010 1.2 370

2011 1.4 390

2012 1.75 450

2013 2 500

DIFFERENT TECHNIQUE USED TO OBTAIN SULPHUR

1.From H2S ( Claus Process )

2.Earth surface

3. Frasch process

PRESENT TECHNOLOGY AND DETAILS

1. Claus Process : MCRC 99 % recovery

2. Section :Thermal section and Catalytic section

3. Raw Materials : a. H2S , b. O2

REACTION :

1] H2S + 3/2 O2 SO2 + H2O

2] 2H2S + SO2 nSx + 2H2O

Different technologies used by oil refineries for recovery of sulphur

Technologies H2S %required

Recovery Advantages Disadvantages Bed Type

Straight type 80 -90 % 99% High recovery more bed required

3

Split type 15 -50 % 93 % Burner on continuously

Less recovery 2

Oxygenenrichment

80 -90 % 98-99% Less S02emission

Pure O2 required 2-3

Acid gas enrichment

70- 85 % 95-96 % 1. Solvent increases recovery

2. Less

2. Undesirable reactions

2

CO

C-2

C-3

LEGENDS : 1. F : Furnace2. WHB : Waste heat boiler 3. LB : Line burner 4. C -1 : Condenser no 15. CO : Converter6. C- 2 : Condenser no 27. C- 3 : Condenser no 3 Present Recovery : 85 %

Capital cost of plant based on capacities

Capacity ( Mt/ day) Cost in Rs ( Crore )

40 300

70 600

100 800

140 1000

Operating cost of plant

Type Plant capacity

70 mt/day

Utilities 5 Cr/year

Catalysts and chemicals 2 Lakh/year

Operations and maintenance

2 Cr/year

Total 7.2 Cr/ year

Prototype : Design of Sulphur Condenser

• Design of sulphur condenser :

Design parameters :

1.Process gas : H2S , S8 , S4 GAS ( SHELL SIDE )

2.Tube Side : Boiler feed water

3.U :55 W/m2 K

4.LMTD :63.84 C

5.Load [Q]: 97399.27 W

6.Heat transfer area : 5.423 m2

7.Temperature [Inlet] : 260 C

8. Working Temperature[Outlet] : 160 C

9.Design Temperature [Inlet] :315 C

10.Design Temperature[Outlet] :190 C

Target areas •

The different parameter were studied and following points were put forward to increase efficiency , reduce the manufacturing and operating cost of condenser :

2. Applying an converter inside tube side of sulphur condenser.

3.Converting S4, S6 sulphur molecules to S8 (desired product) which will decrease the operating cost of condenser .

4.Using alternative options for material of Construction ( MOC ) which will increase overall heat transfer coefficient (U) and will lead to increase in production of sulphur .

5.Reducing the residence time of recovering sulphur by changing the temperature and pressure parameters of tube side and shell side .

6.Reducing the size of condenser by maintaining the efficiency.

7.Decreasing the viscosity of sulphur below 0.9 poise which willlead to higher heat transfer in tube side . .

To achieve the goal of increasing the efficiency we need to work in following areas :

1. Process knowledge .

2. Existing process evaluation.

3. Process modification leading to a suitable process in order to meet the new emission requirements.

4. Decrease capital and operating costs.

Any Question

Thank you !