Movable Sulfur Condenser Resolves Thermal Stress in Claus Units
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Solution Overview
Problem
The existing sulfur recovery units (SRUs) face instability due to non-uniform thermal expansion and contraction, leading to excessive thermal stresses and increased costs due to the need for large expansion loops and complex pipe layouts, especially in larger plants processing high volumes of hydrogen sulfide gas.
Innovation Solution
The SRU design includes fixing key components like the reaction furnace and condensers to the ground while allowing adjacent devices to move relative to them, reducing the number of expansion loops and pipe length, and using a U-shaped pipe configuration to minimize thermal stress, thereby reducing the overall layout size and material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If expansion loops are installed to absorb thermal expansion, then thermal stresses are reduced, but the layout size and device complexity increase
Solution Approach 1:
The patent makes the sulfur condenser movable relative to the reaction furnace by installing it on a movable support structure with sliding plates instead of fixing it to the ground. This dynamic configuration allows the condenser to move with thermal expansion of the pipe, eliminating the need for expansion loops and reducing layout size while maintaining low thermal stress
Solution Approach 2:
The patent changes the support condition of the sulfur condenser from fixed to movable, enabling it to accommodate thermal expansion through movement rather than requiring rigid expansion loops. This parameter change in the support system resolves the contradiction between stress reduction and layout compactness
2Ease of manufacture
If the sulfur condenser is fixed to the ground, then installation is simple, but thermal stresses increase due to restrained thermal expansion
Solution Approach 1:
The sulfur condenser is installed on a movable support structure with sliding plates that allow horizontal movement, transforming the static fixed support into a dynamic movable support. This enables the condenser to accommodate thermal expansion naturally, reducing thermal stress while maintaining installation simplicity through the straightforward sliding plate mechanism
3Stress or pressure
If expansion loops are used to accommodate thermal expansion, then thermal stress is reduced, but the number of devices and pipe length increase
Solution Approach 1:
The patent extracts and removes the expansion loop component entirely from the system. Instead of adding expansion loops to accommodate thermal expansion, the invention makes the sulfur condenser itself movable, thereby eliminating the need for expansion loops and reducing device complexity while still achieving thermal stress reduction
4Stress or pressure
If pipe structures with expansion loops are installed, then thermal expansion is absorbed, but material usage and cost increase
Solution Approach 1:
The patent removes the expansion loop structures from the system by making the sulfur condenser movable. This extraction of the expansion loop component eliminates the additional pipe materials and structural materials that would be required for expansion loops, thereby reducing material usage and cost while still accommodating thermal expansion
Solution Approach 2:
The patent changes the support configuration from fixed to movable, allowing the sulfur condenser to naturally accommodate thermal expansion through movement. This parameter change eliminates the need for additional expansion loop materials, reducing overall material usage while maintaining thermal stress management
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces thermal stresses, decreases the size and cost of the SRU layout, and lowers pressure losses, allowing for a more efficient and compact sulfur recovery process with reduced power requirements for oxygen feeding.
Implementation Method 1
Since the reaction gas has a high temperature as discussed above, the pipes and devices constituting the SRU expand due to heat as the temperature rises
Implementation Method 2
the pipes and devices constituting the SRU expand due to heat as the temperature rises
Implementation Method 3
hydrogen sulfide is reacted with oxygen in air at high temperatures to obtain elemental sulfur (S2) and water (H2O) from hydrogen sulfide (H2S)
Implementation Method 4
hydrogen sulfide is reacted with oxygen in air at high temperatures to obtain elemental sulfur (S2) and water (H2O) from hydrogen sulfide (H2S)
Implementation Method 5
a first sulfur condenser configured to cool reaction gas discharged from the reaction furnace and condense sulfur contained in the reaction gas
Implementation Method 6
a first sulfur condenser configured to cool reaction gas discharged from the reaction furnace and condense sulfur contained in the reaction gas
Implementation Method 7
a reheater configured to re-heat condensed gas discharged from the first sulfur condenser
Implementation Method 8
a catalytic Claus reactor configured to conduct a catalytic Claus reaction of reaction gas discharged from the reheater
Data Source
AI summary
A sulfur recovery unit comprising: a reaction furnace configured to carry out a high-temperature Claus reaction between hydrogen-sulfide-containing gas and oxygen-containing gas introduced to the reaction furnace; a sulfur condenser configured to cool reaction gas discharged from the reaction furnace and condense sulfur contained in the reaction gas; and a pipe that connects the reaction furnace to the sulfur condenser, wherein the reaction furnace is fixed to the ground; and the sulfur condenser and the pipe are arranged so as to be able to move relative to the reaction furnace.