The SUPERCLAUS® process has been developed to recover elemental sulfur from H2S containing gases originating from gas treating plants such as alkanolamine units or physical solvent plants. SUPERCLAUS® plants are also able to process H2S/NH3 containing gases originating from Sour Water Strippers with the objective to yield up to 99.3% overall sulfur recovery without any further tail gas clean-up.
The SUPERCLAUS® process consists of a thermal stage followed by three or four catalytic reaction stages with sulfur removed between stages by condensers. The first two or three reactors are filled with standard Claus catalyst while the last reactor is filled with the selective oxidation catalyst. In the thermal stage, the acid gas is burned with a substoichiometric amount of controlled combustion air such that the tail gas leaving the last Claus reactor contains typically 0.8 to 1.0 vol.% of H2S. The catalyst in the SUPERCLAUS® reactor oxidizes the H2S to sulfur at an efficiency of more than 85%.
Two main principles are applied in operating the SUPERCLAUS® process:
- Operating the Claus plant with excess H2S to suppress the SO2 content in the Claus tail gas.
- Selective oxidation of the remaining H2S in the Claus tail gas by means of special catalyst which efficiently converts the remaining H2S in the presence of water vapor and excess oxygen to elemental sulfur only.
Other operating features that apply to Jacobs Comprimo's Claus process are applicable for the SUPERCLAUS® process as well. These include NH3 destruction up to 30 vol.%, the capability to process small amounts of heavy hydrocarbons and aromatics (BTX) up to 2 vol.%, turndown ratios of 100-15% and production of 99.9% pure bright yellow sulfur.
Application in both new and existing plants. The proprietary SUPERCLAUS® catalyst possesses some unique properties:
- Oxidation of H2S to sulfur is complete
- No sensitivity to water vapor
- Further oxidation of SO2 is negligible even in the presence of excess oxygen
- Components such as H2, CO and other combustibles are not affected
- The catalyst does not promote the Claus equilibrium reaction
- Long catalyst lifetime.
- Sulfur recovery up to 99.3%.
- Reduction of SO2 emissions by up to 90%.
- Simple continuous operation.
- Low additional investment costs.
- NH3 destruction.
- Capability to combust heavy hydrocarbon and aromatics.
- High turndown.
- High reliability - less than 1% unscheduled shutdown time.
Since the first commercial demonstration of the SUPERCLAUS® process in 1988, more than 190 plants with a capacity up to over 1200 t/d are in operation or under construction.
Jacobs Nederland B.V., Leiden, The Netherlands, and Jacobs Canada, Calgary together forming Jacobs Comprimo® Sulfur Solutions.