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Sulfur Recovery and Gas Handling Operations & Troubleshooting

Introduction

Sulfur Recovery and Gas Handling Operations & Troubleshooting

Course Objectives

By the end of this course, participants will be able to:

• Understand the roles and responsibilities of all Emergency Responders
• Understand the fundamental chemistry and thermodynamics of the Claus process
• Apply process modifications and optimization techniques
• Analyze and troubleshoot operational problems
• Implement effective tail gas handling procedures
• Manage sulfur storage and handling operations
• Ensure compliance with environmental and safety regulations
• Perform process calculations and optimizations
• Apply best practices in mercury and toxic emissions control

Who Should Attend?

This course is designed for:

• Process engineers and operators
• Operations supervisors
• Technical support personnel
• Plant managers
• Maintenance engineers and technicians
• Environmental compliance officers
• HSE professionals
• Process control engineers
• Project engineers involved in sulfur recovery units

Course Outlines

Day 1: Fundamentals of Sulfur Recovery

• Introduction to Sulfur Recovery Processes
• “Claus” Sulfur Recovery Chemistry and Thermodynamics
  • Equilibrium principles
  • Reaction kinetics
  • Temperature effects
• Pressure considerations
• Process Flow Diagrams
• Basic Process Calculations
• Laboratory Analysis Techniques

Day 2: Advanced Claus Process and Modifications

• Claus Process Considerations and Modifications
  • Straight-through vs. Split-flow
  • Multi-stage operations
• The EUROCLAUS Concept
  • Process advantages
  • Implementation strategies
  • Performance optimization
• Process/Mechanical Considerations
  • Equipment design
  • Materials selection
• Thiopaq Process Overview
• Practical Calculations and Exercises

Day 3: Tail Gas Treatment and Environmental Control

• Tail Gas Handling Systems
• SCOT Tail Gas Treating
• Particulate Removal Systems
• Mercury/Toxics Emissions Control
• Incineration Systems
• Sulfur Product Specifications
• Storage and Handling Procedures
• Environmental Compliance Requirements

Day 4: Gas Handling Fundamentals and Operations

• Gas Processing Fundamentals
  • Types of process gases
  • Gas properties and behavior
  • Process flow diagrams
• Gas Handling Equipment
  • Compressors
  • Dehydration units
  • Heat exchangers
  • Separation equipment
• Process Control and Monitoring
  • Key parameters
  • Instrumentation
  • Control systems
• Operating Procedures
  • Normal operations
  • Start-up and shutdown
  • Emergency procedures

Day 5: Troubleshooting and Problem Solving

• Systematic Troubleshooting Approach
  • Problem identification
  • Root cause analysis
  • Solution implementation
• Common Operational Problems
  • Equipment issues
  • Process upsets
  • Control system problems
• Case Studies and Practical Examples
• Emergency Response and Safety
• Best Practices and Lessons Learned
• Final Assessment