Acid gas processing

These systems can generally remove H2S to only several hundred ppmv or reduce sulfur only 80-95% depending on the feed coal sulfur. The most commonly used acid gas processes for these conditions are potassium carbonate ("hot pot") processes, which several companies offer. 

The Claus process converts the H2S to sulfur by controlled combustion of the acid gas and Claus reaction on a catalyst. 

The reaction of adipic acid with ammonia in either Hquid or vapor phase produces adipamide as an intermediate which is subsequentiy dehydrated to adiponitrile. The most widely used catalysts are based on phosphoms-containing compounds, but boron compounds and siHca gel also have been patented for this use (52—56). Vapor-phase processes involve the use of fixed catalyst beds whereas, in Hquid—gas processes, the catalyst is added to the feed. The reaction temperature of the Hquid-phase processes is ca 300°C and most vapor-phase processes mn at 350—400°C. Both operate at atmospheric pressure. Yields of adipic acid to adiponitrile are as high as 95% (57). 

The Eastman Chemicals from Coal faciUty is a series of nine complex interrelated plants. These plants include air separation, slurry preparation, gasification, acid gas removal, sulfur recovery, CO /H2 separation, methanol, methyl acetate, and acetic anhydride. A block flow diagram of the process is shown in Eigure 3. The faciUty covers an area of 2.2 x 10 (55 acres) at Eastman s main plant site in Kingsport, Teimessee. The air separation plant is... 

The process options reflect the broad range of compositions and gas volumes that must be processed. Both batch processes and continuous processes are used. Batch processes are used when the daily production of sulfur is small and of the order of 10 kg. When the daily sulfur production is higher, of the order of 45 kg, continuous processes are usually more economical. Using batch processes, regeneration of the absorbant or adsorbant is carried out in the primary reactor. Using continuous processes, absorption of the acid gases occurs in one vessel and acid gas recovery and solvent regeneration occur in a separate reactor. 

Sulfur Compounds. Various gas streams are treated by molecular sieves to remove sulfur contaminants. In the desulfurization of wellhead natural gas, the unit is designed to remove sulfur compounds selectively, but not carbon dioxide, which would occur in Hquid scmbbing processes. Molecular sieve treatment offers advantages over Hquid scmbbing processes in reduced equipment size because the acid gas load is smaller in production economics because there is no gas shrinkage (leaving CO2 in the residue gas) and in the fact that the gas is also fliUy dehydrated, alleviating the need for downstream dehydration. 

Gas purification processes fall into three categories the removal of gaseous impurities, the removal of particulate impurities, and ultrafine cleaning. The extra expense of the last process is only justified by the nature of the subsequent operations or the need to produce a pure gas stream. Because there are many variables in gas treating, several factors must be considered (/) the types and concentrations of contaminants in the gas (2) the degree of contaminant removal desired (J) the selectivity of acid gas removal required (4) the temperature, pressure, volume, and composition of the gas to be processed (5) the carbon dioxide-to-hydrogen sulfide ratio in the gas and (6) the desirabiUty of sulfur recovery on account of process economics or environmental issues. 

Process selectivity indicates the preference with which the process removes one acid gas component relative to or in preference to another. For example, some processes remove both hydrogen sulfide and carbon dioxide, whereas other processes are designed to remove hydrogen sulfide only. Thus it is important to consider the process selectivity for hydrogen sulfide removal compared to carbon dioxide removal, ie, the carbon dioxide-to-hydrogen sulfide ratio in the natural gas, in order to ensure minimal concentrations of these components in the product. 

One of the principal aspects of refinery gas cleanup is the removal of acid gas constituents, ie, carbon dioxide, CO2, and hydrogen sulfide, H2S. Treatment of natural gas to remove the acid gas constituents is most often accompHshed by contacting the natural gas with an alkaline solution. The most commonly used treating solutions are aqueous solutions of the ethanolamines or alkah carbonates. There are several hydrogen sulfide removal processes (29), most of which are followed by a Claus plant that produces elemental sulfur from the hydrogen sulfide. 

Work continues on improving the efficiency of this process, such as for freeing the alkan olamine from heat-stable salts that can form (125). Formulations have been developed which inhibit degradation of mono- and diethanolamine in processing (126). Models (127), computer programs (128), and kinetics and enthalpies (129—136) have been developed to help determine equiUbria of the acid gas—alkanolamine—water system. Additional references relate to the use of tertiary alkan olamines, such as triethanolamine, for gas conditioning (137—139). 

Thus operating cells need aluminum fluoride [7784-18-17, AIF., rather than cryoHte. Much aluminum fluoride is produced in a fluidized bed by the reaction of hydrofluoric acid gas and activated alumina made by partially calcining the alumina hydrate from the Bayer process... 

Process Solvent Solution circulation Acid gas content in treated gas, ppm ... 

A.lkanolamine Process. Carbon dioxide is an acidic gas that reacts reversibly with aqueous alkaline solution to form a carbonate adduct. This adduct decomposes upon the addition of low level heat faciUtating CO2 removal. An aqueous solution of 15—20 wt % monoethanolamine (MEA) was the standard method for removing CO2 in early ammonia plants. 

The Rectisol process is more readily appHcable for acid gas removal from synthesis gas made by partial oxidation of heavy feedstocks. The solvents used in Purisol, Fluor Solvent, and Selexol processes have low vapor pressures and hence solution losses are minimal. Absorption systems are generally corrosion-free. 

Physica.1 Absorption. Whereas chemical absorption rehes on solvent reactions to hold acid gas components in solution, physical absorption exploits gas—hquid solubiUties. The amount of absorption for these solvents is direcdy proportional to the partial pressure of the acid gas components. Thus these processes are most appHcable in situations involving high pressure feed streams containing significant concentrations of acid gas components. To favor absorption, lower temperatures are often employed. Some processes require refrigeration. 

The solvent can be tailored to provide selective acid gas removal based on the Hquid—gas solubiHties. For example, the Selexol process, Hcensed by Union Carbide Corporation, uses the dimethyl ether of polyethylene glycol (DMPEG) to provide high hydrogen sulfide selectivity. The solubiHty of hydrogen sulfide in DMPEG is 8—10 times that of carbon dioxide. 

Cold methanol has proven to be an effective solvent for acid gas removal. Cold methanol is nonselective in terms of hydrogen sulfide and carbon dioxide. The carbon dioxide is released from solution easily by reduction in pressure. Steam heating is required to release the hydrogen sulfide. A cold methanol process is Hcensed by Lurgi as Rectisol and by the Institute Francaise du Petrole (IFP) as IFPEXOL. 

A derivative of the Claus process is the Recycle Selectox process, developed by Parsons and Unocal and Hcensed through UOP. Once-Thm Selectox is suitable for very lean acid gas streams (1—5 mol % hydrogen sulfide), which cannot be effectively processed in a Claus unit. As shown in Figure 9, the process is similar to a standard Claus plant, except that the thermal combustor and waste heat boiler have been replaced with a catalytic reactor. The Selectox catalyst promotes the selective oxidation of hydrogen sulfide to sulfur dioxide, ie, hydrocarbons in the feed are not oxidized. These plants typically employ two Claus catalytic stages downstream of the Selectox reactor, to achieve an overall sulfur recovery of 90—95%. 

The ore is ordinarily ground to pass through a ca 1.2-mm (14-mesh) screen, mixed with 8—10 wt % NaCl and other reactants that may be needed, and roasted under oxidising conditions in a multiple-hearth furnace or rotary kiln at 800—850°C for 1—2 h. Temperature control is critical because conversion of vanadium to vanadates slows markedly at ca 800°C, and the formation of Hquid phases at ca 850°C interferes with access of air to the mineral particles. During roasting, a reaction of sodium chloride with hydrous siUcates, which often are present in the ore feed, yields HCl gas. This is scmbbed from the roaster off-gas and neutralized for pollution control, or used in acid-leaching processes at the mill site. 

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