Water condenser/separator systems for Claus processes

Claim 2

A process for recovering solid sulfur and water of reaction from a Claus process gas at pressures at or below approximately 30 psia wherein the solidified sulfur does not adhere to process equipment surfaces, comprising the steps of: (a) introducing the Claus process gas, containing at least water, sulfur, hydrogen sulfide and sulfur dioxide, into a gas-liquid contactor having an inlet gas-liquid contact zone wherein the surface is wetted by a falling water film and a gas-liquid disengaging zone; (b) cooling the Claus reaction effluent below the freezing point of sulfur of approximately 248° F. and below the water condensing temperature by introducing cooling water into the said inlet zone such that a spray of water directly contacts the Claus gas and said water forms a falling water film on all interior surfaces of said inlet gas-liquid contact zone to preclude adherence of solid sulfur to such surfaces; (c) separating thus formed aqueous solid sulfur suspension from the dehydrated, sulfur-free Claus effluent in the bottom of said contactor in said gas-liquid disengaging zone; (d) removing the said Claus process gas from said gas-liquid contactor; and (e) removing the said aqueous sulfur suspension from said gas-liquid contactor.

Claim 3

A process for recovering solid sulfur and water of reaction, separately respectively, from a Claus process gas at pressures at or below approximately 30 psia wherein the solidified sulfur does not adhere to process equipment surfaces, comprising the steps of: (a) introducing the Claus process gas, containing at least water, sulfur, hydrogen sulfide and sulfur dioxide, into a gas-liquid contactor having an inlet gas-liquid contact zone wherein the surface is wetted by a falling water film and a gas-liquid disengaging zone; (b) cooling the Claus reaction effluent below the freezing point of sulfur of approximately 248° F. and below the water condensing temperature by introducing cooling water into the said inlet zone such that a spray of water directly contacts the Claus gas and said water forms a falling water film on all interior surfaces of said inlet gas-liquid contact zone to preclude adherence of solid sulfur to such surfaces; (c) separating thus formed aqueous solid sulfur suspension from the dehydrated, sulfur-free Claus effluent in the bottom of said contactor in said gas-liquid disengaging zone; (d) removing the said Claus process gas from said gas-liquid contactor; (e) removing the said aqueous sulfur suspension from said gas-liquid contactor; (f) sparging the said aqueous sulfur suspension with a stream of hydrogen sulfide-containing gas substantially free of SO 2 and O 2 in an inlet zone of a separator; (g) settling solid sulfur from water in a calming zone of said separator to separate the solid sulfur from the water; (h) removing solid sulfur from said separator; and (i) removing net water from the said separator and cooling the remaining water and returning the said cooled water to the inlet gas-liquid contact zone of the said gas-liquid contactor.

Claim 4

A process for recovering solid sulfur and water of reaction, separately respectively, from a Claus process gas at pressures at or below approximately 30 psia wherein the solidified sulfur does not adhere to process equipment surfaces, comprising the steps of: (a) introducing the Claus process gas, containing at least water, sulfur, hydrogen sulfide and sulfur dioxide, into a gas-liquid contactor having an inlet gas-liquid contact zone wherein the surface is wetted by a falling water film and a gas-liquid disengaging zone; (b) cooling the Claus reaction effluent below the freezing point of sulfur of approximately 248° F. and below the water condensing temperature by introducing cooling water into the said inlet zone such that a spray of water directly contacts the Claus gas and said water forms a falling water film on all interior surfaces of said inlet gas-liquid contact zone to preclude adherence of solid sulfur to such surfaces; (c) separating thus formed aqueous solid sulfur suspension from the dehydrated, sulfur-free Claus effluent in the bottom of said contactor in said gas-liquid disengaging zone; (d) removing the said Claus process gas from said gas-liquid contactor; (e) removing the said aqueous sulfur suspension from said gas-liquid contactor; (f) sparging the said aqueous sulfur suspension with a stream of hydrogen sulfide-containing gas substantially free of SO 2 and O 2 in an inlet zone of a separator; (g) settling solid sulfur from water in a calming zone of said separator to separate the solid sulfur from the water; (h) removing solid sulfur from said separator; and (i) removing net water from the said separator and cooling the remaining water and returning the said cooled water to the inlet gas-liquid contact zone of the said gas-liquid contactor.

Claim 5

The process of claim 2 wherein the Claus process gas enters the said gas-liquid contactor in the range of 248° F. to 450° F.

Claim 6

The process of claim 2 wherein the Claus process gas is cooled to a temperature in the range of 90° F. to 170° F.

Claim 7

The process of claim 2 wherein the Claus process gas is introduced into the contactor concurrently downward with the water spray.

Claim 8

The process of claim 2 wherein the Claus process gas is introduced and contacted countercurrently upward with the water spray in said inlet gas-liquid contact zone of said contactor.

Claim 9

The process of claim 2 wherein gas-liquid of the inlet gas-liquid contact zone discharges at a submerged point in the gas-liquid disengaging zone.

Claim 10

The process of claim 2 wherein additional cooling of step (b) is provided by external cooling source.

Claim 11

The process of claim 2 wherein the aqueous sulfur suspension temperature in the separator is maintained at a temperature of 120°-250° F.

Claim 12

The process of claim 9 wherein said aqueous sulfur suspension temperature is maintained by an external heating source.

Claim 13

The process of claim 2 wherein the H 2 S sparging gas introduced in the inlet zone of the said separator is derived from a portion of an acid gas feed to a Claus process.

Claim 14

The process of claim 2 wherein the net water removed from the separator is filtered to remove solids.

Claim 15

The process of claim 2 wherein the remaining water removed from the separator is filtered to remove solids.

Claim 16

The process of claim 2 wherein the H 2 S sparged inlet zone is physically separated from the calming zone.