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Risk assessment of Sulphur recovery (SRU) in the Oil and Gas Industry
Abstract
This paper discusses the sources of risks involved in the process of sulphur recovery such as leakage of
hydrogen sulphide from the equipment required for the processes. It also talks about the risks
assessment involved, and the environmental and adverse human health effects.
In the Oil and Gas Industry, there is a sulphur content level in fuelwhich is considered as a dangerous
pollutant and refineries need to upgrade their processes to meet the statutory standards so that
emission of it could be reduced. The Claus process is majorly used to convert the produced hydrogen
sulphide to elemental sulphur.
This paper would also entail the advantages and applications of Sulphur Recovery Unit in the Oil and
Gas Industry as well as therisk characterization and risk management involved in the processes.
Introduction
Sulphur recovery refers to the process of converting hydrogen sulphide (H2S) to elemental sulphur.
Hydrogen sulphide occurs naturally as an impurity in natural gas. Gases which contain sulphur
elements are referred to as sour gas. It is also a by-product of refinery processes such as gas
treatment units for crude oil containing sulphur. It is important to remove sulphur bearing
compounds from the gas to reduce corrosion in pipelines and to preserve public safety. Several
guidelines have been set by government bodies around the world for the maximum sulphur level
allowed in diesel, fuel, kerosene and other crude oil products.
The Claus process is the most common method used for sulphur recovery. 90 to 95 percent of
recovered sulphur is produced by the Claus process. Sulphur recovery unit (SRU) is sometimes
referred to as the Claus process. The Claus process is a two-step chemical reaction as shown in the
equation below.
2 H2S +3 O2 → 2 SO2 + 2 H2O 4 H2S +2 SO2 → 3 S2 + 4 H2O
A portion of the total H2S is burned in the reaction furnace to form SO2. The rest of the H2S then
reacts with the formed SO2 at a 2:1 ratio to form elemental sulphur. The Claus process involves a
three steps; thermal, catalytic and thermal reactions.
Hazard Identification and properties of contaminant
Hydrogen sulfide (H2S) is a clear, colorless, extremely toxic gas that has a rotten egg smell at low
concentrations that also cause irritation of eyes. The human nose can detect H2S at concentrations
below 100 parts per billion.
Hydrogen sulfide has a Chemical Abstracts Service (CAS) Number of 7783-06-4. It has a boiling point is
-60.2oC and a density (liquid) of 0.995 g/ cm3.
Sulphur gas has a boiling point of 445oC and a melting point of 120oC (amorphous). It has a density of
2.1 g/cm3 and is not soluble in water. It has an auto-ignition temperature of 232oC.
Find CAS Number or sulphur
Statutory standards of sulphur content level
The typical sulphur content level usually ranges between 5 ppm to 15 ppm in the Union Gas system,
including the 4.9 mg/m3 of sulphur in the odorant (mercaptan) added to gas for safety reasons. By
2007 in Canada, the new regulations for ultra-low sulphur diesel was set a maximum limit of 15 ppm
of sulphur in on-road diesel fuels [10]. A recent review of the sulphur content carried out by the US
EPA came out with the following limits; Distillate fuel oil (15 ppm (0.0015%) by weight), Residual
oil/residual oil-biodiesel blend (3000 ppm; (0.3%) by weight), Aviation fuel (3000 ppm; (0.3%) by
weight), Kerosene (15 ppm; (0.0015%) by weight) [11]. These new limits are to be in effect from July
1, 2018.
Advantages of Sulphur recovery unit.
Recovery of Sulphur from Hydrogen sulphide (H2S) reduces the amount of sulfur oxide (SO2) that can
be emitted when end users burn the refined petroleum products that contain the compound. This
helps reduce the chances of acid rain as Sulphur oxide is a precursor to acid rain. (2)
Sulphur recovery units are inherently low energy consumers and can be a net producer of medium
pressure steam which can be used in other parts of the plant. (2)
The elemental Sulphur produced from a traditional Sulphur recovery unit can be used for commercial
and industrial applications and is used in rubber products, detergents, paints, pharmaceuticals,
fertilizers, tyres etc. (2)
OSHA maximum
peak 50 ppm for 10 minutes - -
Immediately dangerous
NIOSH IDLH to life at 100 ppm - -
LC50 (ppm) - 713 ppm for 1 hr 673 ppm for 1 hr
LCLo(ppm) 800 for 5 minutes - -
NOAEL 13.9 mg/m3 (10 ppm)
LOAEL 41.7 mg/m3 (30 ppm) - -
Conclusion
References
1. Agency for Toxic Substances and Disease Registry (ATSDR). Medical Management Guidelines for
Hydrogen Sulfide, (2014). Toxic Substances Portal - Hydrogen Sulfide.
2. Ernst, N., (2014, April 9). Benefits of Sulphur Recovery. Chem Info. Retrieved from
https://www.chem.info/article/2014/04/qa-benefits-sulfur-recovery
3. Hydrogen sulphide; 7783-06-4 (2003). Integrated Risk Information System (IRIS). U.S. Environmental
Protection Agency.
4. Hydrogen sulphide, (1994). National Institute for Occupational Safety and Health (NIOSH). Centers for
disease control and prevention.
5. Mahmud Mohammadi and MaryaZadeh (2016). Assessing environmental risks using Equipment
Failure Mode and Effect Analysis (EFMEA) and modelling emissions using AERMOD in sulphur
recovery unit (SRU). International Journal of Advanced Biotechnology and Research (IJBR), 7(2), 1278-
1285.
6. Bohme Gerald and Sames John (1999). The Seven Deadly Sins of Sulphur Recovery. Sulphur Experts
Inc.
7. Ticheler-Tienstra, E.et. al., (2014). Risks of accumulated sulphur in sulphur recovery units. Jacobs
Nederland B.V.
8. Al-Sarawy, A. A, Raslan W. E. and Tawfeek M. A., (2016). Environmental Impact Assessment for Sulfur
Recovery Unit in Natural Gas Liquids Plant. International Journal of Scientific & Engineering Research
(IJSER), 7(1), 2229-5518
9. Alaei, R. et al., (2014). Safety assessment approach of hazard and operability (HAZOP) for sulfur
recovery unit Claus reaction furnace package; blower; heat exchanger equipment in South Pars gas
processing plant. Journal of Natural Gas Science and Engineering, 20(2014), 271-284.
10. Environment Canada, (2001). Reducing the level of sulphur in Canadian on-road diesel fuel. A
Discussion Paper on Designing Canadian Regulations to Align with the New U.S. Standard.
11. Connecticut Department of Energy and Environmental Protection, (2014). Fuel Sulphur Content
Limitations for Stationary Sources. New RCSA Section 22a-174-19b.