Sulfur recovery process

Claim 2

Process for the recovery of sulfur from a Claus plant effluent stream comprising: (a) introducing a Claus plant effluent stream containing hydrogen sulfide, and sulfur dioxide and water into an absorber zone comprising a zinc oxide sorbent, sufficient reducing equivalents being present in the thus introduced stream for converting substantially all sulfur compounds present to hydrogen sulfide; (b) reacting hydrogen sulfide and sulfur dioxide in the presence of said reducing equivalents and of the zinc oxide sorbent in the absorber zone at a temperature effective for removing hydrogen sulfide and sulfur dioxide from the Claus plant effluent stream and removing hydrogen sulfide and sulfur dioxide from the Claus plant effluent stream in the presence of the zinc oxide sorbent and producing a laden sorbent and an absorber zone effluent stream of reduced sulfur compound content; and (c) regenerating the laden sorbent by passing an oxygen containing gas in contact therewith and producing a regenerated sorbent and a regeneration effluent stream containing at least one of elemental sulfur and sulfur dioxide.

Claim 3

The Process of claim 1 further comprising: operating a Claus plant comprising a thermal reaction zone and at least one Claus catalytic reaction reaction zone and producing a Claus Plant effluent stream comprising water, hydrogen sulfide, sulfur dioxide, elemental sulfur, and sufficient reducing equivalents for hydrogenation of all sulfur compounds present in the Claus plant effluent stream to hydrogen sulfide.

Claim 4

The Process of claim 1 further comprising: enriching the gaseous effluent stream from the Claus plant with reducing equivalents sufficient for converting substantially all sulfur compounds therein to hydrogen sulfide.

Claim 5

The Process of claim 3 comprising: generating the reducing equivalents for conversion of substantially all sulfur compounds in the Claus plant effluent stream in a reducing gas generator zone and enriching the Claus plant effluent stream with the reducing equivalents.

Claim 6

The Process of claim 1 wherein the absorber zone comprises at least a first absorber zone and a second absorber zone, and comprising: (a) reacting hydrogen sulfide and sulfur dioxide in the presence of said reducing equivalents and the zinc oxide sorbent in the first absorber zone and removing hydrogen sulfide and sulfur dioxide and producing a laden sorber and an absorber effluent stream lean in hydrogen sulfide and sulfur dioxide; (b) continuing absorption in the first absorber zone for a period of time less than that required for hydrogen sulfide breakthrough; (c) thereafter reacting hydrogen sulfide and sulfur dioxide in the presence of said reducing equivalents and the zinc oxide sorbent in the second absorber zone and removing hydrogen sulfide and sulfur dioxide and producing a laden sorbent and an absorber effluent stream lean in hydrogen sulfide and sulfur dioxide; (d) simultaneously with step (c) regenerating the laden sorbent in the first absorber zone by introducing a regeneration stream comprising an oxygen-containing gas thereunto at a temperature effective to convert the laden sorbent to active sorbent and to produce the regeneration effluent stream comprising sulfur dioxide.

Claim 7

The process of claim 5 further comprising: diverting a portion of the absorber effluent stream as a part of the regeneration stream.

Claim 8

The process of claim 5 wherein: the regeneration stream comprises a dilute oxygen containing gas having less than about 10 mol % oxygen therein.

Claim 9

The process of claim 5 wherein: the regeneration stream comprises an oxygen-containing gas having in the range of from about 5 to about 10 mol % oxygen therein.

Claim 10

The process of claim 1 further comprising: returning the thus produced regeneration effluent stream as a feedstream comprising sulfur dioxide to a thermal reaction zone in a Claus plant.

Claim 11

The process of claim 1 further comprising: returning the thus produced regeneration effluent stream as a feedstream comprising sulfur dioxide to a thermal reaction zone in a Claus plant from which the Claus plant effluent stream is derived.

Claim 12

The process of claim 1 wherein: step (b) is carried out at a temperature above about 1000° F.

Claim 13

The process of claim 1 wherein: step (b) is carried out at a temperature in the range of about 1000° F. to about 1200° F.

Claim 14

The process of claim 1 wherein: step (c) is carried out at a temperature in the range of about 800° F. to about 1800° F.

Claim 15

The process of claim 1 wherein: step (c) is carried out at a temperature in the range of about 1100° to about 1500° F.

Claim 16

Process for the recovery of sulfur to a final emissions level of less than 250 parts per million total residual level of hydrogen sulfide and sulfur dioxide, the process comprising: (a) introducing an acid gas stream comprising hydrogen sulfide into a Claus sulfur recovery plant comprising a Claus thermal reaction zone and at least one Claus catalytic reaction zone, recovering sulfur in the Claus sulfur recovery plant and producing a gaseous effluent stream comprising water, hydrogen sulfide, and sulfur dioxide; (b) providing in the gaseous effluent stream reducing equivalents sufficient to reduce substantially all sulfur compounds therein to hydrogen sulfide; (c) hydrogenating substantially all sulfur compounds in the gaseous effluent stream to hydrogen sulfide; (d) contacting the resulting hydrogen sulfide in an absorber zone with an effective zinc oxide sorbent for absorbing hydrogen sulfide and producing a laden sorbent and an absorber effluent stream lean in hydrogen sulfide, the absorber zone comprising at least a first absorber zone and a second absorber zone and the process comprising the steps of: (1) contacting the hydrogen sulfide containing stream with an effective zinc oxide sorbent in the first absorber zone and absorbing hydrogen sulfide and producing a laden sorbent and an absorber effluent stream lean in hydrogen sulfide; (2) continuing sorption in the first absorber zone for a period of time less than that required for hydrogen sulfide breakthrough; (3) thereafter contacting the hydrogen sulfide containing stream with an effective zinc oxide sorbent in the second absorber zone and absorbing hydrogen sulfide and producing a laden sorbent and an absorber effluent stream lean in hydrogen sulfide; (4) producing a regeneration stream comprising dilute oxygen-containing gas by blending a portion of the absorber effluent stream lean in hydrogen sulfide from an absorber on absorption with an oxygen-containing gas and simultaneously with Step (3) regenerating the laden sorbent in the first absorber zone by introducing the regeneration stream comprising dilute oxygen-containing gas thereinto and converting laden sorbent to active sorbent and producing a regeneration effluent stream comprising sulfur dioxide; (5) discharging a remaining portion of the absorber effluent stream from the absorber on absorption; and (e) returning the thus produced regeneration effluent stream comprising sulfur dioxide to the Claus thermal reaction zone of the Claus sulfur recovery plant from which the gaseous effluent stream is derived.

Claim 17

Process for the recovery of sulfur to a final emissions level of less than 250 parts per million total residual level of hydrogen sulfide and sulfur dioxide, the process comprising: (a) introducing an acid gas stream comprising hydrogen sulfide into a Claus sulfur recovery plant comprising a Claus thermal reaction zone and at least one Claus catalytic reaction zone, recovering sulfur in the Claus sulfur recovery plant and producing a gaseous effluent stream comprising water, hydrogen sulfide, and sulfur dioxide; (b) providing in the gaseous effluent stream reducing equivalents sufficient to reduce substantially all sulfur compounds therein to hydrogen sulfide; (c) hydrogenating substantially all sulfur compounds in the gaseous effluent stream to hydrogen sulfide; (d) contacting the resulting hydrogen sulfide in an absorber zone with an effective zinc oxide sorbent for absorbing hydrogen sulfide and producing a laden sorbent and an absorber effluent stream lean in hydrogen sulfide, the absorber zone comprising at least a first absorber zone and a second absorber zone and the process comprising the steps of: (1) contacting the hydrogen sulfide containing stream with an effective zinc oxide sorbent in the first absorber zone and absorbing hydrogen sulfide and producing a laden sorbent and an absorber effluent stream lean in hydrogen sulfide; (2) continuing sorption in the first absorber zone for a period of time less than that required for hydrogen sulfide breakthrough; (3) thereafter contacting the hydrogen sulfide containing stream with an effective zinc oxide sorbent in the second absorber zone and absorbing hydrogen sulfide and producing a laden sorbent and an absorber effluent stream lean in hydrogen sulfide; (4) producing a regeneration stream comprising dilute oxygen-containing gas by blending a portion of the absorber effluent stream lean in hydrogen sulfide from an absorber on absorption with an oxygen-containing gas and simultaneously with Step (3) regenerating the laden sorbent in the first absorber zone by introducing the regeneration stream comprising dilute oxygen-containing gas thereinto and converting laden sorbent to active sorbent and producing a regeneration effluent stream comprising sulfur dioxide; (5) discharging a remaining portion of the absorber effluent stream from the absorber on absorption; and (e) returning the thus produced regeneration effluent stream comprising sulfur dioxide to the Claus thermal reaction zone of the Claus sulfur recovery plant from which the gaseous effluent stream is derived.

Claim 18

The process of claim 15 wherein: the regeneration stream comprises less than about 10% oxygen.

Claim 19

The process of claim 15 wherein: the regeneration stream comprises in the range of about 5 to about 10% oxygen.

Claim 20

The process of claim 15 wherein: step (c) occurs in the presence of an effective hydrogenation catalyst comprising at least one metal selected from the group consisting of Groups VB, VIII, and the Rare Earth Series of the Periodic Table of the Elements.

Claim 21

The process of claim 15 wherein: step (c) occurs in the presence of an effective cobalt-molybdenum hydrogenation catalyst.

Claim 22

The process of claim 15 wherein: step (c) occurs in the presence of an effective zinc oxide sorbent having about 90 weight percent zinc oxide.

Claim 23

The process of claim 15 wherein: step (c) occurs in the presence of an effective zinc oxide sorbent having about 90±5 weight percent zinc oxide, about 3 to 7 weight percent alumina, and about 0.5 to 3 weight percent calcium oxide.

Claim 24

The process of claim 15 comprising: operating the Claus plant comprising the thermal reaction zone and the at least one Claus catalytic reaction zone to produce a gaseous effluent stream comprising water, hydrogen sulfide, sulfur dioxide, elemental sulfur, and sufficient reducing equivalents for hydrogenation of all sulfur compounds present in the gaseous effluent stream to hydrogen sulfide.

Claim 25

The process of claim 15 further comprising: enriching the gaseous effluent stream from the Claus plant with reducing equivalents sufficient for converting substantially all sulfur compounds therein to hydrogen sulfide.

Claim 26

The process of claim 23 further comprising: hydrogenating sulfur compounds in the gaseous effluent stream in the presence of an effective catalyst based on zinc oxide at an effective temperature and absorbing the resulting hydrogen sulfide on the zinc oxide.

Claim 27

The process of claim 23 comprising: generating the reducing equivalents for conversion of substantially all sulfur compounds in the gaseous effluent stream from the Claus plant in a reducing gas generator zone and enriching the gaseous effluent stream from the Claus plant with the reducing equivalents.

Claim 28

The process of claim 15 comprising: contacting the hydrogen sulfide containing stream produced in Step (c) of claim 15 with the zinc oxide sorbent in the absorber zone at a temperature in the range of above 600° F.

Claim 29

The process of claim 15 wherein: the hydrogen sulfide containing stream produced in Step (c) of claim 15 is contacted with the zinc oxide sorbent at a temperature in the range of about 600° F. to about 1200° F.

Claim 30

The process of claim 15 wherein: the hydrogen sulfide containing stream produced in Step (c) of claim 15 is contacted with the zinc oxide sorbent at a temperature in the range of about 600° F. to about 1000° F.

Claim 31

The process of claim 15 wherein: the hydrogen sulfide containing stream produced in Step (c) of claim 15 is contacted with the zinc oxide sorbent at a temperature in the range of about 1000° F. to about 1200° F.

Claim 32

The process of claim 15 comprising: introducing the regeneration stream comprising the dilute oxygen-containing gas into the first absorber zone at a temperature in the range of about 800° F. to about 1800° F.

Claim 33

The process of claim 30 wherein: the temperature is in the range of about 1100° F. to about 1500° F.

Claim 34

The process of claim 15 further comprising: removing water from the hydrogen sulfide containing stream prior to contacting same with zinc oxide sorbent in the absorber zone.