Sour Gas Flow Control for Pressure-Stable Sulfur Recovery
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current desulfurization processes for raw natural gas streams require significant contact time and reduced flow rates, leading to decreased production rates and increased re-pressurization costs, as they struggle to efficiently remove hydrogen sulfide without compromising gas stream pressure.
Innovation Solution
A dynamically adjustable flow rate control system that continuously measures sulfur concentration and calculates updated flow rates to optimize contact time with reagents and oxidizers, allowing for maximum gas flow while maintaining adequate desulfurization, using a system comprising a pressure vessel, flow control valve, sulfur concentration sensor, and PLC to adjust flow rates in real-time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flow rate is reduced to achieve adequate contact time for desulfurization, then sulfur removal efficiency is improved, but production rate decreases
Solution Approach 1:
The patent implements dynamic flow rate adjustment based on real-time sulfur concentration measurements. The system continuously monitors H2S levels and automatically adjusts the flow rate through a control valve, transitioning from static to dynamic operation. This allows the system to optimize contact time dynamically, maintaining high removal efficiency while maximizing production rate by only reducing flow when sulfur levels require it.
Solution Approach 2:
The system employs a closed-loop feedback mechanism where sulfur concentration is continuously measured and fed back to the control system. Based on this feedback, the PLC calculates appropriate flow rate adjustments and actuates the control valve accordingly. This feedback loop enables automatic optimization of the trade-off between contact time and production rate without manual intervention.
2Reliability
If flow rate is reduced to achieve adequate contact time, then desulfurization effectiveness is improved, but gas stream pressure decreases requiring re-pressurization
Solution Approach 1:
The system dynamically adjusts flow rate based on actual sulfur concentration rather than using a fixed conservative rate. This dynamic control prevents unnecessary pressure drops by maintaining higher flow rates when sulfur levels are low, thereby reducing or eliminating the need for re-pressurization while still achieving effective desulfurization when needed.
Solution Approach 2:
The control system automatically manages the trade-off between desulfurization effectiveness and pressure maintenance. By continuously monitoring sulfur levels and self-adjusting the flow rate, the system eliminates the need for external re-pressurization operations, as the dynamic control prevents pressure drops from occurring in the first place.
3Reliability
If static safety margins are used to ensure adequate contact time, then desulfurization reliability is improved, but production rate decreases
Solution Approach 1:
The system replaces static safety margins with real-time feedback control. Instead of operating at a consistently reduced flow rate to ensure adequate contact time, the system monitors sulfur concentration and only reduces flow when measurements indicate it is necessary. This feedback-driven approach eliminates the need for conservative static margins while maintaining desulfurization reliability.
Solution Approach 2:
The system changes the operating parameter (flow rate) dynamically based on measured sulfur concentration rather than maintaining a fixed conservative parameter setting. When sulfur levels are low, the flow rate increases to maximize production; when sulfur levels rise, the flow rate decreases to ensure adequate contact time. This parameter adaptation eliminates the need for static safety margins.
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 enhances desulfurization efficiency by dynamically responding to sulfur concentration fluctuations, reducing the need for static safety margins and minimizing re-pressurization costs, thereby improving production rates and maintaining high gas stream pressure.
Implementation Method 1
a sensor that measures sulfur concentration in the sour gas stream
Implementation Method 2
inputting reagent and oxidizer to the pressure vessel to convert hydrogen sulfide to elemental sulfur, sulfur species, or both
Implementation Method 3
oxidizer from the oxidizer tank... convert hydrogen sulfide to elemental sulfur
Implementation Method 4
a phase separator that separates sweet gas as a gaseous phase after the hydrogen sulfide is converted to elemental sulfur
Data Source
AI summary
A dynamically adjustable rate sulfur recovery process continuously calculates and adjusts sour gas stream operating pressure and/or flow rate to maximize sweet gas output, thereby improving efficiency. A corresponding desulfurization system may include a fixed-sized pressure vessel, a flow control valve that controls the rate of flow of a sour gas stream into the pressure vessel, a sensor that measures sulfur concentration in the sour gas stream, a reagent tank, an oxidizer tank, and a phase separator that separates sweet gas as a gaseous phase after hydrogen sulfide in the sour gas stream in the pressure vessel is converted to elemental sulfur, sulfur species, or both by contact with reagent from the reagent tank and oxidizer from the oxidizer tank. A PLC (programmable logic controller) continuously calculates updated flow rates based on sulfur concentration measurements from the sensor to achieve maximum sweet gas production.