A process for recovering sulfur from sulfur-containing gases.

0001In a number of processes, such as the refining of crude oil, the purification of natural gas and the production of synthesis gas from, for example, fossile fuels, sulfur containing gas, in particular H₂S containing gas, is released. On account of its high toxicity and its smell, the emission of H₂S is not permissible.

0002The best known and most suitable process for recovering sulfur from hydrogen sulfide is the so-called Claus process. In this process hydrogen sulfide is converted by oxidation to a considerable extent into elemental sulfur; the sulfur thus obtained is separated by condensation. The residual gas stream (the so-called Claus residual gas) still contains some H₂S and S0₂.

0003The method of recovering sulfur from sulfur containing gases by the so-called Claus process is based on the following reactions: <ul id="ul0001" list-style="none"><li>2H₂S + 30₂→2H₂O + 250₂ (1)</li><li>4H₂S + 2SO₂<img file="EP0242006A1_D0001.tif" /> 4H₂0 + 6/nS_n (2)</li><li>Reactions (1) and (2) result in the main reaction:</li><li>2H₂S + 0₂ →2H₂O + 2/nS_n (3)</li></ul>

0004A conventional Claus converter - suitable for processing gases having an H₂S content of between 50 and 100% - comprises a burner with a combustion chamber, the so-called thermal stage, followed by a plurality of reactors - generally two or three - filled with a catalyst. These last stages constitute the so-called catalytic stages.

0005In the combustion chamber, the incoming gas stream, which is rich in H₂S,is combusted with an amount of air at a temperature of ca. 1200°C. This stoichiometric amount of air is adjusted so that one third of the H₂S is fully combusted to form S0₂ in accordance with the following reaction <ul id="ul0002" list-style="none"><li>2H₂S + 30₂→2H₂O + 3SO₂ (1)</li></ul>

0006After this partial oxidation of H₂S the non- oxidized part of the H₂S (i.e. basically two-thirds of the amount offered) and the S0₂ formed react further as to a considerable portion, in accordance with the Claus reaction: <ul id="ul0003" list-style="none"><li>4H₂S + 2SO₂<img file="EP0242006A1_D0002.tif" /> 4H₂0 + 3S₂ (2)</li></ul>

0007Thus, in the thermal stage, approximately 60% of the H₂S is converted into elemental sulfur.

0008The gases coming from the combustion chamber are cooled to about 160°C in a sulfur condenser, in which the sulfur formed is condensed, which subsequently flows into a sulfur pit through a siphon.

0009The non-condensed gases, in which the molar ratio of H₂S:SO₂ is unchanged and so still 2:1,are subsequently heated to about 250°C, and passed through a first catalytic reactor in which the equilibrium <ul id="ul0004" list-style="none"><li>4H₂S + 2SO₂<img file="EP0242006A1_D0003.tif" /> 4H₂0 + 6/nS_n (2)</li></ul>is again established.

0010The gases coming from this catalytic reactor are subsequently cooled again in a sulfur condenser, in which the liquid sulfur formed is recovered and the remaining gases, after being re-heated,are passed to a second catalytic reactor.

0011When the gaseous feedstock contains H₂S concentrations of between about 15 and 50%, the above described 'straight-through' process is not used, but instead a variant thereof, the so-called 'split-flow' process. In the latter process one-third of the total amount of feedstock is passed to the thermal stage and combusted completely to S0₂ therein. Two-thirds of the feedstock is passed direct to the first catalytic reactor,by-passing the thermal stage. When the feedstock contains H₂S concentrations of between 0 and 15% the Claus process can no longer be used. The process then used is, for example, the so-called Recycle Selectox process, in which the feedstock is passed with an adjusted amount of air into an oxidation reactor, the so-called oxidation stage. The reactor contains a catalyst which promotes the oxidation of H₂S to S0₂, and the amount of oxidation air is adjusted so that an H₂S:SO₂ ratio of 2:1 is established, whereafter the Claus reaction proceeds. The gas from the oxidation reactor is cooled in a sulfur condenser, in which the sulfur formed is condensed and discharged.

0012To dissipate the reaction heat generated in the oxidation reactor, a portion of the gas stream coming from the sulfur condenser is re-supplied to the oxidation reactor.

0013It is clear that in the Recylce Selectox process, the oxidation stage,which is catalytic and does not lead to high temperatures, is equivalent to the thermal stage in the Claus process.

0014In the following, both stages are referred to as oxidation stages.

0015Depending on the number of catalytic stages, the sulfur recovery percentage in a conventional Claus converter is 92-97%.

0016By known processes, the H₂S present in the residual gas from the Claus reaction is converted, by combustion or some other form of oxidation,into SO₂, whereafter this S0₂ is emitted to the atmosphere. This has been permissible for low concentrations or small amounts of emitted SO₂ for a long time. Although S0₂ is much less harmful and dangerous than H₂S,however, this substance is also so harmful that its emission is also limited by ever stricter environmental legislation.

0017As has been observed, in the Claus process as described above, in view of the equilibrium reaction which occurs, the H₂S:SO₂ ratio plays an important role. In order to obtain an optimum conversion to sulfur, this ratio should be 2:1. Generally speaking, this ratio is controlled by means of a so-called H₂S/SO₂ residual gas analyzer. This analyzer measures the H₂S and S0₂ concentrations in the residual gas. A controller then maintains the ratio of 2:1 constant on the basis of the equation <chemistry id="chem0001" num="0001"><img file="EP0242006A1_D0004.tif" /></chemistry>by varying the amount of combustion air, depending on the fluctuations in the gas composition and the resulting deviation in the above equation. Such a control of the process,however, is highly sensitive to these fluctuations.

0018Furthermore, the sulfur recovery efficiency (calculated on the amount of H₂S supplied) is no higher than 97%, and so the gas flowing from the last catalytic stage - the residual gas - still contains substantial amounts of H₂S and S0₂, determined by the Claus equilibrium, and this in a molar ratio of 2:1.

0019The amount of H₂S present in the residual gas can be separated by absorption in a liquid.

0020The presence of S0₂ in the residual gas, however, is a disturbing factor during the further processing thereof and must therefore be removed prior to such further processing. This removal and hence the after-treatment of the gas is complicated.

0021The great disadvantge of the presence of S0₂ is that this gas reacts with conventional liquid absorbents to form undesirable products. To prevent undesirable reactions of the S0₂, therefore, the SO₂ is catalyticallly reduced with hydrogen to form H₂S over an A1₂0₃ supported cobalt molybdenum catalyst in accordance with the so-called SCOT process. The total amount of H₂S is subsequently separated by liquid absorption in the usual manner.

0022In accordance with another method, for example, the BSR Selectox process, after reduction of the S0₂ in residual gas to H₂S and after condensation of the water vapour, the gas is passed into an oxidation reactor, as in the Recycle Selectox process. The oxidation air is adjusted so that an H₂S:S0₂ ratio of 2:1 is adjusted, whereafter the Claus reaction proceeds. Both in the SCOT process and in the BSR Selectox process, the removal of S0₂ from the residual gas is a relatively expensive operation.

0023The above-described after-treatment of the gases, carried out by means of a so-called Tail Gas Treater, which involves an investment of another 50-100% of the cost of the preceding Claus converter,can result in an increase of the sulfur recovery efficiency of up to 98-99.8%.

0024In NL-A-6901632, it is proposed that the ratio of hydrogen sulfide to sulfur dioxide in the above reaction (1) be adjusted to between 2.5:1 to 4.0:1.

0025In NL-A-7603622, it is proposed that the above reaction (1) be conducted with an insufficient amount of oxygen, that is to say, with a proportion of oxygen less than required to combust one third of the quantity of H₂S supplied to the burner. Thus, relative to H₂S, a substoichiometric amount of S0₂ is formed in reaction (1), so that ultimately, in view of the equilibrium reaction (2), the resulting ratio of H₂S:SO₂ becomes higher than 2:1.

0026There is no disclosure in that patent application as regards a ratio of H₂S:SO₂,nor is any suggestion given as to how such a ratio must be concretely realized.

0027Accordingly, the methods as described in the above patent applications have the advantage that the removal of H₂S from the residual gas is much easier when substantial amounts of S0₂ are contained therein. The methods also have substantial disadvantages, however, namely, that in the presence of sulfur vapour measuring low S0₂ concentrations in the residual gas is very difficult. Indeed, controlling the process on the basis of such measurements has turned out to be virtually unfeasible in practice.

0028According to the present invention, hydrogen sulfide present in the gaseous feedstock to a Claus converter is partially oxidized with oygen, whereafter the product gas from the oxidative stage is reacted further, by using at least two catalytic stages, in accordance with the equation: <chemistry id="chem0002" num="0002"><img file="EP0242006A1_D0005.tif" /></chemistry>with the H₂S concentration in the residual gas leaving the last catalytic stage being controlled to have a value of between 0.8 and 5% by volume by reducing the amount of combustion or oxidation air passed to the oxidation stage, and/or by causing a portion of the hydrogen sulfide containing feedstock to bypass the oxidation stage, and adding it to the gas flowing to a catalytic stage.

0029The process according to the invention offers the advantage that no sensitive control of the process is required, because it is only the concentration of the H₂S in the residual gas and not the ratios of H₂S:S0₂ therein which play a role. Claus catalysts are sensitive to sulfation under the influence of traces of oxygen in the reaction gases. In the process according to the present invention, as the Claus reaction proceeds, an ever increasing excess of H₂S is formed in the reaction gases, in particular in the last Claus reactor. This excess of H₂S reduces any sulfate that has been formed, whereby the problem of sulfation of the catalysts is counteracted and a longer service life thereof is obtained.

0030In the process according to the present invention, the concentration of the hydrogen sulfide gas in the residual gas can be controlled in several ways. Thus, for example, the signal from an H₂S analyzer in the residual gas can be used to set or adjust the amount of combustion air or oxidation air supplied to the oxidation stage. The signal can also be used to pass, as a function thereof, a-variable - amount of H₂S direct to the first or second catalytic reactor or to both reactors.

0031Measurements conducted in a Claus plant comprising two catalytic stages and operated using the present invention, indicated that, to provide a proportion of 0.8-5% by volume of H₂S in the residual gas, an amount of air must be supplied that is equivalent to 86-98.5% of the stoichiometric quantity (i.e., relative to the amount of air required to combust one-third of the amount of H₂S supplied to the burner). It will be clear, where reference is made to a quantity of air, what is meant is the amount of gas containing the required amount of oxygen. When the amount of air passed to the Claus burner is not reduced but a portion of the gaseous feed-stock is caused to by-pass the oxidation stage, approximately 1.5-14% of the available quantity of H₂S containing gas must be by-passed which is dictated by the reactions which occur.

0032According to the invention it has further been found that a concentration of H₂S in the residual gas of about 1-3% by volume corresponds to an H_ZS/SO_Z ratio therein of about 15-800, while with increasing percentages by volume of H₂S in the residual gas - within the range defined according to the invention - this value rapidly becomes infinitely high, so that only immeasurably small quantities of S0₂ are present. This offers an additional advantage, because for the further processing of this gas the removal of S0₂ is unnecessary.

0033The process according to the invention can be suitably applied for the treatment of gases containing hydrogen sulfide, but also for gases containing both hydrogen sulfide and substantial quantities of ammonia (cf NL-C-176160), in the latter case, the temperature in the combustion chamber should be at least 1250^oC.

0034In the process according to the invention, the hydrogen sulfide gas remaining in the residual gas can be processed to form sulfur by a known per se method. Such methods are described in the literature. Preferably, however, the remaining gaseous hydrogen sulfide is oxidized with air in an oxidation stage to form sulfur in accordance with the following reaction:

0035<chemistry id="chem0003" num="0003"><img file="EP0242006A1_D0006.tif" /></chemistry>

0036Surprisingly it was found that, when the concentration of the hydrogen sulfide leaving the last catalytic stage is maintained at a value of between 0.8 and 5% by volume, not only is a sufficiently low S0₂ concentration obtained in the residual gas, but also, after this selective oxidation, an optimum sulfur recovery percentage of 98.0-99.8 can be obtained. This oxidation can in principle take place in two ways, namely, by dry-bed oxidation or by oxidation in a liquid, in which, in general, sulfur and water vapour have first been removed from the residual gas.

0037In the dry-bed oxidation, the H₂S concentration in the residual gas is preferably maintained between 0.8 and 3% by volume, because above 3% by volume of H₂S the total sulfur recovery percentage is decreased.

0038Commonly, when the H₂S concentration is higher than 2% by volume, the oxidation bed is cooled or the H₂S concentration is reduced by dilution of the gas with, for example, a recycling gas stream to prevent that as a result of an increase in temperature from the reaction heat generated, the sulfur formed is oxidized to form sulfur dioxide in the gaseous phase.

0039In the dry oxidation bed, the oxidation to sulfur can be effected by a known per se method using an oxidation catalyst. One example of an oxidation catalyst and the application thereof is described in US-A-4311683.

0040The method described therein is the Selectox process (R.H. Hass, M.N. Ingalis, T.A. Trinker, B.G. Goar, R.SS. Purgason, 'Process meets sulfur recovery needs', Hydrocarbon Processing, May 1981, pag.104-107). In this process, H₂S is oxidized to S and S0₂ using a special catalyst. Approximately 80% of the H₂S supplied is oxidized to elemental sulfur, if water vapour is removed to a substantial extent. Another application of a dry-bed process which is not sensitive to water vapour in the process gas is the absorption of H₂S in an absorption mass as described, for example, in European patent application 71983.

0041In accordance with a particular embodiment of the process according to the present invention, the oxidation is carried out in a dry bed, using a catalyst comprising a carrierof which under the reaction conditions applied the surface exposed to the gaseous phase does not exhibit alkaline properties with a catalytically active material applied thereto or formed thereon, the specific area of the catalyst being less than 20m²/g catalyst, and less than 10% of the total pore volume having a pore radius of between 5 and 500 A. The catalyst generally contains at least 0.1% by weight, calculated on the total mass of the catalyst, of a material that is catalytically active for the selective oxidation of H₂S to elemental sulfur. A preferred catalytically active material is a metal oxide, a mixed oxide of a plurality of metals, or a mixture of metal oxides. Such a catalyst is described in the patent application filed concurrently herewith. Neither the catalyst per se nor its preparation are claimed in the present application.

0042The specific area of the catalyst used in accordance with the above particular embodiment of the process according to the invention is preferably no larger than 10m²/g catalyst. The substantial absence of micropores, too, is of importance for the results to be obtained by this catalyst: preferably, no more than 2% of the total pore volume will be in the form of pores having a radius of between 5 and 500 A.

0043A particularly suitable carrier is alpha-alumina, but silica whose specific area satisfies the above requirements, such as hydrothermally sintered silica, can be suitably applied. It is also possible to use non-ceramic materials as carrier material, such as metal mesh, metal mouldings, or packing bodies.

0044As stated above, the catalytically active material used is preferably a metal oxide, a mixed oxide of a plurality of metals or a mixture of metal oxides. Preferably, however, the catalytically active material used is iron oxide or a mixed oxide of iron and chromium (with a molar ratio of Cr:Fe that is lower than 0.5 and preferably between 0.02 and 0.15).

0045The active component is preferably present on the carrier in a proportion of more than 1% by weight calculated on the total weight of the catalyst. Best results are obtained with catalysts in which this percentage by weight is between 3 and 10, calculated as the weight of the metal oxide or mixed oxide of two or more metals, and calculated on the total weight of the catalyst.

0046In this connection it should be emphasized that this concerns the active material present on the carrier. In fact, by sintering or a different method of preparation, a portion of the active material, in particular the metal oxide, may be encapsulated within the carrier, for example, by the sintering of narrow pores. The difference between this encapsulated or embedded metal oxide and the metal oxide present on the carrier, however, can be readily determined by the socalled temperature-programmed reduction (TPR). Details of this measuring technique are described in N.W. Hurst, S.J. Gentry, A. Jones and B.D.McNicol Catal.Rev.Sci.Eng 24(2), 233-309 (1982). The amount of metal oxide present on the carrier and accessible to gases can thus be determined. As described in detail in our patent application filed concurrently herewith, corresponding to Netherlands patent applicaiton 8600959, of April 16, 1986, the catalysts preferably used in the particular embodiment of the process according to the present invention can in principle be prepared using known methods of preparing supported catalysts. With regard to such preparation, however, in view of the unusually small specific area and low microporosity of the catalysts, specific measures should be taken, to ensure, in particular, that the porosity is not increased during preparation.

0047Particular care is required in homogeneously applying the catalytically active material to the carrier material, while in addition it should be ensured that this homogeneity is maintained during and after the drying procedure.

0048In order to satisfy these requirements, in the preparation of the catalyst, the carrier material with a small specific area is impregnated under dry conditions with a complex solution. This method is known by the name of incipient wetness method. The complex solution comprises the cations of the active materials complexed in the solution with an organic molecule. Also added to the solution is a quantity of a viscosity increasing compound, such as hydroxyethyl cellulose. By impregnating the carrier material with this complex solution by means of the incipient wetness method, a low-area catalyst is obtained, to which the active material is applied highly homogeneously, and whose microporosity has not increased as compared with the starting carrier material.

0049During the drying procedure, the temperature must be increased very slowly to maintain homogeneity. Finally a sintering treatment is carried out with the catalyst, whereby micropores are sealed. Electron micrographs, porosimetric measurements, B.E.T. measurements and reactor experiments show whether the catalysts satisfy the requirements.

0050The use of the catalyst described above for the oxidation in a dry bed of the hydrogen sulfide containing residual gases obtained using the process according to the present invention has the important, in particular economic advantage that such a catalyst is practically insensitive to the presence of water vapour in the residual gas, so that the removal of sulfur and water vapour from this residual gas is unnecessary.

0051It has been found that - with a view to a maximum sulfur recovery percentage - the choice of the optimum volume percent of H₂S in the residual gas is dependent on the extent of the efficiency of the last oxidation from H₂S to sulfur in the dry oxidation bed. When the efficiency to sulfur of the catalyst used therein is 80-85%, preferably a volume percentage of H₂S in the residual gas of 0.8-1.7 is selected. When the efficiency is 85-90%, preferably a percentage of 1.0-2 is selected, and when the efficiency is 90-95%, the volume percentage of H₂S in the residual gas is preferably adjusted between 1.4 and 2.4.

0052The liquid oxidation, too,can take place using a known process. Examples of known processes are the Stretford process (the Chemical Engineer, February 1984, pages 84 ff), the Lo-Cat process of Air Resources Inc. or the Takahax process. Preferably, for the liquid oxidation an H₂S concentration is selected which is not too close to the lower limit of 1-4% by volume, because at a low H₂S concentration the activity of the liquid decreases relatively rapidly by undesired side reactions of residual quantities of 50₂.

0053The control of the oxidation air to the selective oxidation is not critical and hence simple.

0054The process according to the invention can be carried out in an existing Claus plant and requires only relatively simple modifications of the existing control of the gas streams. In case a 2-stage Claus plant is used, a selective oxidation reactor will have to be provided in the specific embodiment of the present invention, which in relation to the cost involved in other residual gas processing plants is inexpensive. Thus the application of the process according to the present invention leads to considerable economic advantages.

0055In case a 3-stage Claus plant is used only the third catalytic reactor needs to be arranged as a selective oxidation reactor. In this case, too therefore, a considerable economic benefit is obtained.

0056The process according to the present invention will now be described in more detail with reference to the accompanying Figs. 1,2 and 3.

0057As shown in Fig.1, the feedstock gas (= Claus gas) is supplied through line 1 to the Claus burner with combustion chamber 2. The amount of combustion air, controlled by the quantity-proportion regulator 3 and H₂S analyzer 23, is supplied to Claus burner 2 through line 4. The heat generated during the combustion (1200⁰C) of the Claus gas is dissipated in a boiler heated by spent gases, producing steam that is discharged through line 6.

0058The Claus reaction takes place in the burner and the combustion chamber. The sulfur formed is condensed in boiler 5 (150°C) and discharged through line 7. The gas is passed through line 8 to a heater 9 where it is heated to the desired reaction temperature of 250°C before being supplied through line 10 to the first Claus reactor 11. In reactor 11 the Claus reaction takes place again, whereby sulfur is formed. The gas is discharged through line 12 to the sulfur condensor 13. The condensed sulfur (150°C) is discharged through line 14. Thereafter the gas is passed through line 15 to the next reactor stage, which again includes a heater 16, a reactor 17 and a sulfur condenser 18. In this reactor the Claus reaction takes place again. The condensed sulfur (150⁰C) is discharged through line 19. The steam generated in the sulfur condensers is discharged through lines 20 and 21.

0059The H₂S concentration in the residual-gas line 22 is controlled by an H₂S analyzer 23 to a range of from 0.8 to 5% by volume. The H₂S analyzer controls a control valve in combustion air line 24 or a control valve in the H₂S line 25. Through 25 a portion of the H₂S can be passed direct to the first catalytic stage 11, by-passing the thermal stage.

0060The residual gas is passed through line 22 to the sulfur removing stage 26. This sulfur removing stage may be a known sulfur removing process, such as, for example, a dry-bed oxidation stage, an absorption stage or a liquid-oxidation stage. The air required for the oxidation is supplied through line 27. The sulfur formed is discharged through line 28.

0061The gas is then passed through line 29 to an after-burner 30 before being discharged through chimney 31.

0062As shown in Fig.2, a lean Claus feedstock gas is supplied through line 1 to an oxidation reactor 2. An amount of oxidation air controlled by the quantity-ratio regulator 3 and H₂S analyzer 19 is passed to the oxidation reactor through line 4. In the oxidation reactor a portion of the H₂S is oxidized over a special catalyst to form S0₂ whereafter the Claus reaction takes place.

0063To prevent an unduly high temperature from arising within the oxidation reactor, as a result of the reaction heat, a quantity of gas is recycled by means of blower 6 through lines 5 and 7. The gas from reactor 2 is passed through line 8 to sulfur condensor 9, where the sulfur formed during the reaction is condensed at 150°C and discharged through line 10. The heat generated during the reaction is dissipated in sulfur condenser 9 with generation of steam, which is discharged through line 11. The gas is passed through line 12 to a heater 13, where it is heated, for example, to 220°C before being supplied to the Claus reactor 14. In reactor 14, the Claus reaction takes place again, whereby sulfur is formed. In condenser 15, the sulfur is condensed at 150⁰C and discharged through line 16, and steam generated is discharged through line 17. The H₂S concentration in the residual gas line 18 is controlled by an H₂S analyzer 19 to a range of from 0.8 to 5% by volume. The H₂S analyzer controls a control valve in the combustion-air line 20, or a control valve in H₂S line 21.

0064Through line 21, a portion of the H₂S can bypass the oxidation stage and pass direct to the catalytic stage 14.

0065The residual gas is passed through line 18 to the sulfur removing stage 22. The air required for the oxidation is supplied through line 23. The sulfur formed is discharged through line 24. The gas is then passed through line 25 to an after-burner 26 before being discharged through chimney 27.

0066Fig.3 shows in greater detail the oxidation or absorption in a dry bed and the oxidation in a liquid as indicated more generally in 26 of Fig.1 or 22 of Fig.2. In Figs. 1 and 2 the residual gas is supplied through lines 22 and 18, respectively, in Fig.3, the residual gas is supplied through line 1.

0067In Fig.3a, after the removal of the sulfur from the residual gas in separator 2, which is discharged through line 3, and the condensation of the water in 4, which is discharged through line 5, the gas is supplied through a heater 6 to a selective oxidation reactor 7. The removal of sulfur and water in 2 and 4 respectively, can take place using a known method, for example, as disclosed in US patent 4526590. In the selective oxidation reactor 7, a catalyst may be provided, for example, as described in the French patent publications 8009126, 8105029 or 8301426. The required oxidation air is supplied through line 8.

0068From the reactor, the gas flows to a sulfur condensor 9. The sulfur condensed is discharged through line 10, and the steam generated through line 11. The gas next flows through line 12 to the after-burner as designated by 30 in Fig.1 and 26 in Fig.2.

0069As shown in Fig. 3b, the residual gas is supplied through line 1 and heater 2 direct to the selective-oxidation stage, that is to say, without a preceding sulfur and water removing stage. This embodiment can be used when a catalyst is present in the oxidation reactor 4, as described above, consisting of a non-alkaline ceramic carrier to which at least 0.1% by weight of a catalytically active material, in particular a metal oxide, has been applied, so that the specific area of the catalyst is less than 20 m²/g, while less than 10% of the total pore volume has a pore radius of between 5 and 500 X. The oxidation air required is supplied through line 3. The sulfur condensed in sulfur condenser 5 is discharged through line 6 and the steam generated through line 7. The gas next flows through line 8 to the after-burner designated by 30 in Fig.1 and by 26 in Fig.2.

0070As shown in Fig.3c the residual gas is passed through line 1 to a reactor 2 filled with an absorption mass, for example, as described in European patent application 71983. In reactor 2, the hydrogen sulfide is removed from the residual gas by absorption. The gas next flows through line 3 to the after-burner, designated by 30 in Fig. 1 and by 26 in Fig. 2. When the bed is saturated, it is regenerated. Reactor 4 is connected in parallel to reactor 2 and is regenerated. By means of a circulation blower 5, a quantity of gas is circulated. This gas is heated in heater 6. The air required for the oxidation is supplied through line 7. The gas flows from reactor 4 to sulfur condenser 8. The sulfur condensed is discharged through line 9 and the steam generated through line 10. To keep the system at the required pressure, a small gas stream is discharged through line 11 and recycled to the feedstock for the Claus plant (line 1 in Fig.1 and Fig.2).

0071As shown in Fig.3d, sulfur is removed in separator 2, which is discharged through line 3. Subsequently, in condenser 4, water is condensed which is removed through line 5. The gas is passed to the liquid-oxidation stage 6. The oxidation stage may contain, for example a basic solution of sodium carbonate, ADA (anthraquinone disulphonic acid) and sodium metavanadate, as used in the well-known Stretford process.

0072H₂S is absorbed in the liquid and subsequently oxidized with air. The oxidation air is supplied through line 7 and the sulfur formed is discharged through line 8. The gas next flows through line 9 to the after-burner (30 in Fig.1 and 26 in Fig.2).

0073The invention is illustrated in and by the following examples.

Example 1

0074Lsing the apparatus as described with reference to Figs.l and 3a, the Claus reaction is performed in a Claus plant having two catalytic stages. Supplied to the thermal stage are a Claus gas, containing 90% by volume of H₂S, corresponding to 90 kmoles/h, 5% vol.CO₂ and 5% vol.H₂0 and 43.53 kmoles/h 0₂ (a 'deficit' of 3.3%) as air oxygen. The H₂S volume percentage in the residual gas after the second catalytic stage is 1.2, and the S0₂ content therein 0.06%. After the removal of sulfur and water and using a dry-bed process for the oxidation of H₂S with an oxidation efficiency of 80%, a total sulfur recovery percentage of 98.8 is obtained.

Example II

0075Using the apparatus as described with reference to Fig. 1 and 3b, the Claus reaction is performed in a Claus plant having two catalytic stages. Supplied to the thermal stage are a Claus gas containing 90% by volume of H₂S corresponding to kmoles/h, 5% by volume of C0₂ and 5% by volume of H₂0, and 42.30 kmoles/h of 0₂ (a 'deficit' of 6.0%) as air oxygen. The H₂S volume percentage in the residual gas after the second catalytic stage is 2.03, the S0₂ content therein is immeasurably small, and its water content is 35.8% by volume.

0076The dry-bed oxidation is carried out using a water-insensitive oxidation catalyst, as defined hereinbefore, comprising an alpha-alumina carrier (Fluka, specific area 6.5 m²/g) to which 4.5% by weight of Fe₂0₃ and 0.5% by weight of Cr₂0₃ have been applied as catalytically active material, which, after pelletization and calcination has a BET area of 6.94m²/g, with less than 1% of the total pore volume being constituted by pores having a radius less than 500 A. Using this catalyst with an oxidation efficiency of 90%, a total sulfur recovery percentage of 99.2 is obtained.

Example III

0077In this example, the process as described with reference to Figs. 2 and 3c is carried out in a trial plant.

0078A lean Claus feedstock gas with a composition of 10% by volume of H₂S, 85% by volume of C0₂ and 5% by volume of water is passed to oxidation reactor 2 in Fig.4 at a rate of 10 moles/h. A quantity of air of 1.56 moles/h, controlled by the quantity ratio regulator 3 and H₂S analyzer 19 is also passed to the oxidation reactor. In addition, a quantity of gas of 2 moles/h containing 0.104 mole/h S0₂ is recycled to the oxidation reactor from reactor 4 in Fig.3c.

0079In the oxidation reactor a portion of the H2S is oxidized to SO_2x by the air oxygen, whereafter the Claus reaction takes place.

0080Via blower 6 in Fig.2 and lines 5 and 7, a quantity of 13 moles/h of gas is recycled. The gas coming from reactor 2 is passed through line 8 to sulfur condenser 9 and subsequently supplied through line 12 and a heater 13, in which it is heated to 220⁹C, to Claus reactor 14. In this reactor the Claus reaction takes place again, and the sulfur formed is condensed at 150⁰C and discharged through line 16. The H₂S concentration in the residual gas line 18 is controlled by an H₂S analyzer 19 to be 1.3% by volume. Through this line 18, the residual gas is passed to reactor 2 (Fig.3c), which is filled with an absorption mass. In order to keep the system at the desired pressure during the regeneration of the absorption mass, when the absorbed H₂S is oxidized to sulfur, a minor gas stream of 2 moles/h is bled off and recycled to the oxidation reactor.

0081In total, a sulfur recovery percentage of 99.8 is obtained.

Example IV

0082Using the apparatus as described with reference to Figs. 1 and 3d, the Claus reaction is carried out in a Claus plant having two catalytic stages. Supplied to the thermal stage are a Claus gas containing 90% by volume of H₂S, corresponding to 81.9 kmoles/h, 5% by volume of C0₂ and 5% by volume of H₂0, and 40.95 kmoles/h 0₂ (i.e., not a 'deficit'). In this case, however, through line 25, 8.1 kmoles/h H₂S (9.0% of the feedstock gas) is supplied to the first catalytic stage. The H₂S volume percentage in the residual gas after the second catalytic stage is 3.13; the S0₂ content thereof is immeasurably small.

0083After the removal of sulfur and water, and using a liquid-oxidation process for the absorption and oxidation of H₂S, with an absorption/oxidation efficiency of 95%, a total sulfur recovery percentage of 99.5 is obtained.

Example V

0084Using the apparatus as described with reference to Figs. 1 and 3c, the Claus reaction is carried out in a Claus plant having two catalytic stages. To the thermal stage, a Claus gas containing 90% by volume of H₂S, corresponding to 90 kmoles/h H₂S, 5% by volume of C0₂ and 5% by volume of H₂0, and 43.14 kmoles/h H0₂ (a deficit of 3%) as air oxygen are supplied.

0085In addition, a quantity of gas of 10 kmoles/h, containing 0.44 kmole/h S0₂ is recycled from reactor 4 (Fig.3C). The H₂S concentration in the residual gas line 22 is controlled by an H₂S analyzer to be 1.2% by volume, which corresponds to 3.26 kmoles/h. The residual gas is oxidized further, using the catalyst as described in Example II. The H₂0 content is 35.9% by volume, corresponding to 97 kmoles/h.

0086Supplied to the selective oxidation stage is 1.96 kmoles/h 0₂ as air oxygen, which comes down to an 0₂:H₂S ratio of 0.6, an oxygen excess of 20%. The gas to the selective oxidation reactor is heated to 180^oC. The H₂S in the selective oxidation reactor is fully converted with the bed temperature being 250^oC. The oxidation efficiency to elemental sulfur is 90%, the balance is converted to S0₂. After the condensation of the sulfur, the gas is mixed with a reducing H₂/CO gas, heated to 280⁰C and then supplied to a hydrogenation reactor (not shown). All S0₂ in the gas and the remaining sulfur components are converted to H₂S.

0087Through line 1 (Fig.3C), the gas is passed to reactor 2 which is filled with an absorption mass. The H₂S is absorbed in the absorption mass and thus removed from the gas. The gas flows from reactor 2 through line 3 and an after-burner to the chimney.

0088In order to keep the system at the desired pressure during the regeneration of the absorption mass, when the absorbed H₂S is oxidized to sulfur, a minor gas stream of 10 kmoles/h is bled off and recycled to the Claus plant.

0089In total, a sulfur recovery percentage of 99.9 is obtained.

Example VI

0090Using the plant as described with reference to Fig.l and 3b, the Claus reaction is carried out in a Claus plant having two catalytic stages.

0091A Claus gas containing 90% by volume of H₂S, corresponding to 90 kmoles/h, 5% by volume of C0₂ and 5% by volume of H₂0 and 43.53 kmoles/h 0₂ (a 'deficit' of 3.3%) as air oxygen are supplied to the thermal stage.

0092The H₂S volume percentage in the residual gas after the second catalytic stage is 1.22, which corresponds to 3.29 kmoles/h, and the S0₂ content therein is 0.06. Using the catalyst described in Example II, the H₂S in the gas is selectively oxidized to sulfur in the presence of a considerable concentration of water vapour. The H₂0 content is 35.9% by volume, which corresponds to 97 kmoles/h. 1.97 kmoles/h H0₂, as air oxygen, is supplied to the selective oxidation stage, which comes down to an 0₂:H₂S ratio of 0.6, an oxygen excess of 20%.

0093The gas to the selective oxidation reactor is heated to 180^oC. In the selective oxidation reactor, the H₂S is fully converted, with the bed temperature being 250^oC. The oxidation efficiency to elemental sulfur is 90%, the balance is converted to SO₂. After the condensation of the sulfur formed, the gas is mixed with a reducing H₂/CO gas, heated to 280°C, and then supplied to a hydrogenation reactor in which all of the S0₂ in the gas and the remaining sulfur components are converted to H₂S.

0094Subsequently the gas is re-supplied to a selective oxidaticn stage in which H₂S is oxidized to sulfur, using the catalyst (as used in Example II). The H₂S percentage by volume in this gas is 0.23, which corresponds to 0.64 kmoles/h. The H₂0 content therein is 36.2% by volume, which corresponds to 100 kmoles/h.

0095To the second selective oxidation stage, 0.51 kmoles/h 0₂ is supplied, as air oxygen, which comes down to an O₂:H₂S ratio of 0.8, an oxygen excess of 60%. The gas to the second selective oxidation reactor is cooled to 215⁰C. The H₂S in the second selective oxidation reactor is again completely converted, with the bed temperature being 230°C. The oxidation efficiency of H₂S to elemental sulfur in the second stage is 90%, the balance is converted to S0₂.

0096Thus, in the overall system, a total sulfur recovery percentage of 99.8 is obtained. The spent gas is passed through an after-burrer to the chimney.