Sulfur Plant Services

Many existing sulfur units were constructed in the 1970s and 1980s. Through careful operations, maintenance, and a little TLC, these units still have some productive life left. Once you get past the mechanical integrity challenges of operating vintage units, process control and safety systems come into focus. PTI's portfolio includes multiple unit revamps, safety upgrades, burner management, and process control system upgrades with modern instruments and automation platforms. Our business units combine Sulfur Process Engineering with System Integration and Control expertise under one roof to execute your automation upgrade.

On its best day, a 3-Bed Modified-Claus Unit has a practicable recovery of about 97.5%. In the real world, hydrocarbons, soot, catalyst poisons, pluggage, fouled boilers and condensers can choke your throughput and adversely impact your recovery efficiency. Debottlenecking begins upstream of the SRU and doesn't end until the stack. Our engineers have the experience and insight to identify and help implement the easy fixes to improve your unit operations or to properly apply advanced process simulations and design to squeeze every last drop of sulfur from your facility.

The devil is in the details - not just anyone can properly design an amine or sulfur unit. Each unit in a processing plant has unique design considerations, and the Sulfur Block is no exception. Does the designer you're considering know how velocity in rich amine piping affects corrosion or why sulfur rundown lines need piping crosses and rod-out valves at each turn? PTI engineers and designers have decades of successful experience in Sulfur Block process simulation, equipment design, piping design, and control configuration.

Oxygen Enrichment and Oxygen Injection has long been used to displace nitrogen in combustion air and increase unit capacity. Replacing nitrogen in combustion air gas can result in throughput increases of 25% to 100%. The challenge is safely handling the oxygen stream, controlling the oxygen and air mixture or injection, and designing equipment to safely handle higher temperatures. Our team has the experience to provide the complete design solution for using oxygen to increase the capacity of your unit including metallurgy selection, oxygen safety and control equipment, and thermal and catalytic equipment design modifications.

Not every challenge in your Sulfur Block needs to be solved with a formal Consulting Study or Capital Project. Our team believes in helping customers by developing long-term relationships. Our engineers are available to provide ad-hoc and ongoing technical support for your operations. From short field-trips to put an "extra set of eyes" on a unique problem or challenge, providing performance feedback for your current feed composition and rates, or participating in PHAs and HAZOPs as a Subject Matter Expert (SME) to augment your team. PTI is here to help.

Staff turnover, retirement, and new hires impact the "Tribal Knowledge" of your Sulfur Block operations. Sulfur may not be the most glamorous unit in your plant, but it comes with unique challenges that, if neglected, can make it the most visible. Our engineers have experience with varied Sulfur Block configurations and have developed training programs to provide your team with everything from a general refresher with insights on industry Best Practices to detailed Sulfur Unit training for operators and engineers new to the Sulfur Block.

The availability of low-sulfur feedstocks have created a relatively new challenge for many producers. Sustained reliable operation at reduced sulfur rates can be as challenging as debottlenecking. Our portfolio includes a significant number SRUs built to accommodate broad operating ranges. Achieving 10:1 turndown or sustained operation well below "Nameplate" capacity requires more than just re-ranging your instruments and changing the trim in your control valves. Design strategies for sulfur condensers, disengaging plenums, temperature management, and catalyst bed performance are just a few of the unique turndown challenges PTI has solved.

The Sulfur Block may not contain the money-making units in most facilities, but it is vital to meeting environmental emission standards and permit requirements. Changing feedstocks and product splits can throw your operations a curve ball. Debottlenecking, reliability, and capacity improvements are a challenge, but an increasing number of producers are dealing with the challenges of reduced sulfur in their feed. SRU turn-down and reduced throughput without compromising reliability and recovery efficiency can be equally challenging. PTI's engineers are experienced in helping operators on both ends of the spectrum.