Sulfur Recovery
Envitrack has extensive experience in supplying sulfur recovery catalysts (for Claus Process and Tail Gas Treatment) and offers reliable solutions for various industrial applications. In addition, we can also provide troubleshooting and consulting services to optimize system performance and improve recovery efficiency.
Claus Process with Direct Oxidation Reactor
The Claus Process is the leading gas desulfurization method, recovering elemental sulfur from acid gases, widely used in refineries and steel plants.
The addition of a direct oxidation reactor further enhances sulfur recovery, achieving yields above 99%. Envitrack has developed a next-generation direct oxidation catalyst, RCAT®-9007, offering an alternative to older types of catalysts used in the industry.
The Sulfur Recovery Unit (SRU) operates using a modified Claus Process, incorporating two or three Claus Reactors and one Direct Oxidation Reactor to maximize sulfur recovery. In the burner, H₂S is partially combusted at a high temperature, producing sulfur dioxide (SO₂). Within Claus Reactors, H₂S and SO₂ react over a Claus catalyst to form elemental sulfur (Sₓ). After each catalytic stage, liquid sulfur is collected in Claus Condensers, while unreacted gases advance to the next stage.
The Direct Oxidation Reactor further boosts sulfur recovery by selectively oxidizing residual H₂S into elemental sulfur, utilizing the advanced RCAT®-9007 catalyst for superior conversion and selectivity to sulfur.
Sulphur Recovery Catalysts
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Direct Oxidation Catalyst RCAT®-9007
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Alumina Based Catalyst RCAT®-9001
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TiO₂ Promoted catalyst RCAT®-9002
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TiO₂ based RCAT®-9003 for COS and CS₂ hydrolysis
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Fe-promoted catalyst RCAT®-9004
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Tail Gas Treatment
The tail gas treatment process is an essential step in improving sulfur recovery efficiency. It reduces sulfur vapor and SO₂ contained in the tail gas from the Claus process by converting it back to H₂S in a designated reactor using special cobalt-molybdenum (CoMo) based catalysts. This catalytic step ensures further improvement of the overall sulfur recovery in the SRU. First, tail gas goes through a reduction section, where sulfur compounds are converted to H₂S, followed by an absorption section, where the H₂S is absorbed into an amine solution. The captured H₂S is then returned to the Claus process for further conversion to sulfur.
This additional step, when combined with the Claus process, ensures minimal sulfur emissions and highly efficient sulfur recovery.
In typical oil refining plants and gas processing plants, Claus process followed by the tail gas treatment process can yield sulfur recovery rate of over 99.9%, depending on the composition of the feed gas.
Tail Gas Treatment
CoMo based Tail Gas Treatment catalysts:
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RCAT®-4210T
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RCAT®-4210S
Low-temperature Tail Gas Treatment catalysts:
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RCAT®-4211T
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RCAT®-4211S
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Inert Support Spheres
Inert materials are excellent at preventing catalyst poisoning, clogging of catalyst pores, and prolonging their operational lifetime. Sulfur Recovery Units catalysts are traditionally supported by high resistence ceramic balls of various sizes.
CBSM 19 (High Resistance Ceramic Balls) are made only with high-quality materials and precisely controlled processes.
The high-quality CBSM support media ensures optimal performance with your catalyst, eliminating common issues found with lower-quality alternatives. In many cases, it has been proven to extend catalyst life and prevent premature replacement. CBSM is ideal for applications such as sulfur recovery, alkylation, dehydrogenation, desulfurization, catalytic conversion, catalytic cracking, catalytic oxidation, catalytic reforming, hydrofining, isomerization, powerforming, and thermal cracking.
Envitrack supplies also high purity alumina balls ABSM suitable for high temperature processes.