APPLICATION NOTE

SULFUR RECOVERY AND TAIL GAS TREATING UNIT

Process Analyzer
Applications
The Claus sulfur recovery unit (SRU) IPS-4 UV/IR ANALYZER 930 H2S IN SULFUR PIT ANALYZER

and tail gas treating unit (TGTU)

require a suite of process gas
analyzers to operate safely, protect
the catalyst/amine at high efficiency
and meet environmental regulations
for sulfur dioxide (SO2) emissions. 888 PIT AND TAIL GAS ANALYZER 900 TAIL GAS ANALYZER

The development of sulfur recovery for oil refining, gas

processing and coke oven plants was largely driven by
environmental regulations in the early 1970s, resulting
in AMETEK's development of the SRU tail gas analyzer.
Optimization of the process and further enhancements
gave genesis to numerous other analyzer applications.
This application note covers the seven possible analyzer
931 TGTU ANALYZER 914 CEMS
tags that are addressed by AMETEK (see Figure 1,
simplified process flow diagram).
The hydrogen sulfide (H2S)/SO2 SRU tail gas (air demand)
analyzer (AT3) is the one constant – every SRU will and total HC, the feed gas analyzer can quantify the acid
employ this critical analytical measurement. If the SRU gas contaminants (BTX, methanol, CO2).
is followed by a TGTU, there is at least one, and possibly To identify a potentially explosive environment in the
two, additional analyzers located at sample point sulfur pit or tank, an analyzer (AT2) measuring H2S
locations AT4, AT5 and/or AT6. should be permanently installed.
The feed gas/acid gas analyzer (AT1) is becoming more Finally, the emissions analyzer (AT7), in its simplest
prevalent, as recent developments provide real-time form, reports the SO2 emission but can also be used as a
full composition analysis to mitigate hydrocarbon (HC) process optimization tool if the emission is expressed in
upsets. In addition to measuring H2S, ammonia (NH3) mass basis terms.

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 APPLICATION PROCESS
Reduction gas
Converters & condensers generator

Amine and SWS

acid gas
AT1 AT3

Reaction furnace & waste heat exchanger

AT2
Sulfur pit (tank)
Figure 1. Simplified process flow diagram showing eight process analyzer tags

AT1. ACID GAS ANALYZER (SRU Feed Forward Control) MEASURES: H2S + Total HC (NH3, CO2, BTX)

IPS-4 UV/IR H 2S THC SO 2

A full composition, real-time analyzer accounts for all O2 consuming 100.000 0.250 3,5

species in acid gas streams. Using a combined ultraviolet (UV) and 90.000

2,0
infrared (IR) “full spectrum” technique, total hydrocarbon (THC) is 80.000 0.200

Transient Hydrocarbon Upset:

measured in the IR as “methane equivalent” and H2S is measured in

CONCENTRATION %
70.000
12 fold increase in total HC, -2,4
6 minutes in duration causes an
the UV so the exact amount of air can be added (or subtracted) from 60.000 increase in H2S. 0.150

the reaction furnace for steady state control. 50.000 -1,9

40.000 0.100
Benefits of acid gas analyzer include: -1,4
30.000
• Where transient spikes of HC cause sudden increase in air
demand – resulting in an H2S spike at the tail gas – and when the 20.000 0.050 -0,9

event is over, SO2 breakthrough into the TGTU, (see Figure 2) 10.000
-0,4
• NH3 measurement for (refinery) sour water stripper (SWS) acid gas. 0.000 0.000

9:36 10:36 11:36 12:36 1:36 2:36 3:36

• Additional measurements for quantification of -0,1

benzene-toluene-xylene (BTX) and methanol (MeOH) TIME

29/04/

contamination in (natural gas processing) acid gas

• Material balance and mass emission calculations Figure 2. Field data/HC process upset
• Heated Acid Gas (HAG) probe offers a single connection for sample
extract and return to process. Always consider adding the HAG (Refer to application note F-0299 Feed Forward Analysis for Sulfur
probe and sample point at feed stage or SRU outage Recovery Units for additional details).
• Rated NEMA-4X (IP65) for outdoor installation; a cabinet or shelter
is not required

AT2. SULFUR PIT (TANK) ANALYZER (Lower Explosive Limit) MEASURES: H2S/SO2

888/930
H S Pit Gas 2 THC SO 2 H 2S
100.000 0.250
Liquid sulfur contains ~350 parts per million (ppm) of dissolved H2S 3,5 3,5

90.000
and spontaneous degassing results in accumulation in the head 2,0 2,0
80.000 0.200
space. If the sweep gas is Transient
interrupted, H2S can reach the lower
Hydrocarbon Upset: H2S values above the LEL:
CONCENTRATION %

70.000
explosive limit (LEL) (~3.25 %), (see Figure 3).
12 fold increase in total HC,
6 minutes in duration causes an
-2,4 Simultaneous SO2 values indicating
a smoldering (pyrophoric) fire.
-2,4
60.000 increase in H2S. 0.150

Benefits of the pit gas analyzer include:

50.000 -1,9 -1,9

40.000 0.100
• Computational fluid dynamics (CFD) modeling confirms -1,4 -1,4
30.000
localized H2S concentrations can be 16 times the mean value,
20.000 0.050
indicating values of ~2,000 ppm H2S which may constitute an -0,9 -0,9

10.000
imminent hazard -0,4 -0,4
0.000 0.000
• SO2 is monitored
9:36 to alarm11:36
10:36 for a smoldering
12:36 pyrophoric
1:36 2:36 sulfur
3:36 fire -0,1 -0,1

• The pit gas analyzer can also be used for mass balance purposes 29/04/2014 16:12:11.289 90,00 days 28/07/2014 16:12:11.289
TIME
as a sulfur pit vent routed to the incinerator accounts for
approximately one-third of the emissions
Figure 3. Sulfur pit high H2S and SO2 values (just prior to an incident)

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2
 AT7
AT5 AT6
Cobalt-molybdenum
Reduction reactor AT7
Thermal oxidizer
AT5 AT6
uction gas Cobalt-molybdenum
erator Reduction reactor Thermal oxidizer

AT4 H2S recycle to Claus inlet

Quench
AT4 column Absorber & stripper columns H2S recycle to Claus inlet
Quench column Absorber & stripper columns
lfur pit (tank) CLAUS SULFUR RECOVERY UNIT TAIL GAS TREATING UNIT

AT3. TAIL GAS ANALYZER MEASURES: H2S/SO2 (COS, CS2)

888/900 Tail Gas

Measurement of H2S/SO2 in SRU tail gas for feedback (trim)
control of the process air. Reliability has evolved to the point
where the analyzer anticipates and reacts to adverse process
conditions. With an installed operating base in excess of
2,000 units, AMETEK offers two types of tail gas analyzers,
the Model 888 and Model 900.
Benefits of the 888 Tail Gas:
• Close-coupled (no sample line), mounts directly on the pipe
• Does not require climate-controlled shelter, rated for 60°C (140°F)
without external cooling, and automatic flow control
Benefits of the 900 Tail Gas:
• Extractive (sample line) – for installation in an analyzer house in
extreme climates, or if the sample point location is compromised
due to piping design, or for measurement ofcarbonyl sulfide and
carbon disulfide (COS and CS2)
• Sample handling is close-coupled but external to the process,
at a safe and accessible distance
• Optional double-block isolation from the process

AT4/AT5/AT6. TAIL GAS TREATING UNIT (TGTU) ANALYZER MEASURES: H2/H2S (SO2, COS, CS2)

931/932 TGTU
The TGTU increases sulfur recovery efficiency up to 99.99% is a measure of the amine absorber efficiency and the primary
(<100ppm SO2 emissions) by combining a reduction stage and contribution to SO2 emissions. COS can be measured at the absorber
amine treating to recycle H2S back to the SRU. outlet. COS is typically <5ppm but process upsets in the reduction
reactor can result in hundreds of ppm, (see Figure 4). A valuable
The primary purpose of measuring excess hydrogen (H2), (0 to 5%) is
tool to isolate process problems and quantify the contributions to
to ensure full conversion of all sulfur compounds to H2S.
emissions. CS2 can also be measured at this sample point
The secondary function is the measurement of the residual sulfur
compounds. The sample point can be in one of three locations. As (Refer to application note F-0229 Reduction/Amine Tail Gas Treaters
H2 does not essentially change after the reduction reactor, the utility with Model 931/932 Analyzers).
SO 2 of the sulfur gas measurement varies according to designHneeds
2S
3,5
and sample point location. 931 and 932 analyzers, both use UV 3,5

spectroscopy to measure single, and multiple species, respectively.

2,0 2,0

H2S values above the LEL: COS ~400 ppm COS + 100 ppm H2S
resulting in ~350 ppm SO2
-2,4
Benefits of the TGTU analyzer include: Simultaneous SO2 values indicating
a smoldering (pyrophoric) fire.
-2,4
emission exceedance.

-1,9
AT4 – Absorber -1,9
H 2S
Measurement of SO2 breakthrough from the reduction reactor to the
-1,4
quench column. SO2 values in excess of 5ppm can deactivate the amine
-1,4

-0,9
AT5 – Quench Outlet -0,9

Measurement of H2S (0 to 5%) to quantify the load to the amine

-0,4
treater and provide a material balance on the SRU -0,4

-0,1 AT6 – Absorber Outlet -0,1

The most common sample point for H2S (0 to 250 ppm), which
29/04/2014 16:12:11.289 90,00 days 28/07/2014 16:12:11.289

Figure 4. COS upset data from TGTU absorber

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3
AT7. CONTINUOUS EMISSIONS MONITORING (CEM) SYSTEM

MEASURES: SO2/O2 (NOx, TRS, Mass Emission, Dual Range)

909/910/919/920/914 CEM
SO2 emission, measurement base, and parameters vary according to:

• If SO2 is reported on a mass basis, requires a stack gas flow rate and “hot-wet” analysis of SO2
• If the SRU is followed by a TGTU, the measurement base is typically “dry” basis
• If the TGTU can be bypassed, the SO2 analyzer can be dual-ranged (0 to 500 ppm/0 to 1% SO2)
• The 914 is a built-to-order CEM that includes all the components needed for a compliance monitoring and reporting project, using a dry
extractive sampling technique
• The 909 and 910 analyzers incorporate gas flow rates. The 919 and 920 do not

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can also attend your site to cover planned maintenance schedules and repair emergency breakdowns.

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© 2020, by AMETEK, Inc. All rights reserved. Printed in the U.S.A. A-0478 Rev 3 (0720)
One of a family of innovative process analyzer solutions from AMETEK Process Instruments.
Specifications subject to change without notice.

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