Configurations and methods for acid gas and contaminant removal with near zero emission

• US 7,597,746 B2
• Filed: 02/12/2003
• Issued: 10/06/2009
• Est. Priority Date: 12/17/2002
• Status: Active Grant

• Current Assignee: Fluor Enterprises Incorporated (Fluor Corporation)
• Original Assignee: Fluor Technologies Corporation (Fluor Corporation)
• Inventors: Mak, John, Graham, Curt
• Primary Examiner(s): Smith; Duane
• Assistant Examiner(s): WU, IVES J
• Application Number:
  US10/532,262
• Publication Number:
  US 20060150812A1
• Time in Patent Office: 2,428 Days
• Field of Search: 951/99, 951/14, 951/36, 951/39, 95143-148, 95235-237, 951/81, 951/83, 951/59, 951/69, 952/28, 952/29, 961/21, 96131-132, 962/34, 962/43, 423228-229, 423/220
• US Class Current: 95/169
• CPC Class Codes: B01D 53/1406 Multiple stage absorption
• CPC Class Codes: B01D 53/1456 Removing acid components
• CPC Class Codes: B01D 53/1462 Removing mixtures of hydrogen sulfide and carbon dioxide
• CPC Class Codes: B01D 53/1487 Removing organic compounds
• CPC Class Codes: B01D 53/8612 Hydrogen sulfide
• CPC Class Codes: C01B 17/0404 by processes comprising a dry catalytic conversion of hydrogen sulfide-containing gases, e.g. the Claus process
• CPC Class Codes: C01B 17/0408 Pretreatment of the hydrogen sulfide containing gases
• CPC Class Codes: Y02C 20/40 of CO2
• CPC Class Codes: Y02P 20/151 Reduction of greenhouse gas [GHG] emissions, e.g. CO2

Abstract

A gas (1) comprising hydrogen sulfide, carbon dioxide, and hydrocarbon contaminants is treated in a plant (FIG. 2) in a configuration in which waste streams are recycled to extinction. In especially preferred aspects of contemplated methods and configurations, hydrogen sulfide and other sulfurous components are converted to a sulfur product (37), carbon dioxide (44A) is separated at a purity sufficient for enhanced oil recovery or sale, and hydrocarbon contaminants are purified to a marketable hydrocarbon product (49).

Claims

1. A gas treatment plant comprising:

a first absorber in which a lean solvent absorbs carbon dioxide, hydrogen sulfide, and a hydrocarbon;

a second absorber fluidly coupled to the first absorber in which at least part of the hydrogen sulfide is separated from the carbon dioxide;

a sulfur plant that receives the at least part of the hydrogen sulfide to produce a sulfur product and a tail gas, wherein at least part of the tail gas is hydrogenated and is recycled to the absorber; and

a regenerator that is fluidly coupled to the first and second absorber, wherein the regenerator produces an acid gas, and wherein at least part of the hydrocarbon is separated from the acid gas as a hydrocarbon liquid.

2. The gas treatment plant of claim 1 further comprising a third absorber that receives at least part of the hydrocarbon liquid and in which residual sulfurous compounds are at least partially removed from the hydrocarbon liquid.

3. The gas treatment plant of claim 2 wherein the residual sulfurous compounds are fed to a sulfur plant.

4. The gas treatment plant of claim 1 wherein the second absorber is operated at a lower pressure and at a higher temperature than the first absorber such that that the carbon dioxide desorbed from the solvent in the second absorber has a purity of at least 90 mol %.

5. The gas treatment plant of claim 4 wherein the carbon dioxide is used for enhanced oil recovery or used as commercial product.

6. A gas treatment plant comprising:

an absorber that is configured to receive (a) a feed gas comprising carbon dioxide and hydrogen sulfide, (b) a carbon dioxide saturated lean solvent, and (c) wherein the absorber is further configured to produce an overhead vapor comprising at least a portion of the carbon dioxide;

a conduit fluidly coupled to the absorber and configured to allow combination of a lean solvent with the overhead vapor to so allow formation of the carbon dioxide saturated lean solvent, and a cooler configured to allow cooling of the carbon dioxide saturated lean solvent to thereby allow for increased selective absorption of the hydrogen sulfide from the feed gas in the lean solvent.

7. The gas treatment plant of claim 6 wherein the absorber produces a bottom product that is reduced in pressure and heated to a temperature sufficient to desorb the carbon dioxide from the bottom product.

8. The gas treatment plant of claim 7 wherein at least a portion of the hydrogen sulfide in the desorbed carbon dioxide is absorbed in a second absorber using a portion of the carbon dioxide saturated lean solvent.

9. A gas treatment plant comprising:

a solvent regenerator that receives from a plurality of absorbers a solvent comprising an acid gas and a hydrocarbon, and that produces an overhead vapor;

a separator that receives the overhead vapor and separates the acid gas from the hydrocarbon to form a hydrocarbon liquid; and

a stripper that is fluidly coupled to the separator and fractionates the hydrocarbon liquid to produce a hydrogen sulfide depleted hydrocarbon product and a vapor comprising hydrogen sulfide that is fed to a sulfur plant.

10. The gas treatment plant of claim 9 wherein the acid gas is fed to an absorber in which a carbon dioxide depleted hydrogen sulfide rich solvent scrubs the acid gas.

11. The gas treatment plant of claim 10 wherein the scrubbed acid gas is fed to the sulfur plant.

12. The gas treatment plant of claim 11 wherein the sulfur plant produces a tail gas, and wherein at least part of the tail gas is hydrogenated and is recycled to at least one of the plurality of the absorbers.

13. A gas treatment plant comprising:

an absorber that receives from a solvent regenerator a vapor that comprises hydrogen sulfide and a hydrocarbon, and that further receives a carbon dioxide-depleted solvent comprising hydrogen sulfide; and

wherein the absorber produces a hydrocarbon-depleted overhead vapor comprising hydrogen sulfide that is fed to a sulfur plant, and a hydrocarbon-enriched bottom product that is recycled to the solvent regenerator.

14. The gas treatment plant of claim 13 wherein the carbon dioxide-depleted solvent is produced by another absorber that separates hydrogen sulfide from carbon dioxide using a carbon dioxide saturated lean solvent.

15. The gas treatment plant of claim 13 wherein a portion of the carbon dioxide-depleted solvent is fed to the solvent regenerator.

16. A method of treating a gas comprising:

optionally contacting a gas with a first portion of a lean solvent to absorb at least one of a heavy hydrocarbon and a heavy mercaptan from the gas into the first portion of the lean solvent;

cooling the gas and contacting the cooled gas in an absorber with a second portion of the lean solvent to absorb at least one of a light hydrocarbon, a light mercaptan, and H2S into the second portion of the lean solvent, wherein the second portion of the lean solvent is saturated with carbon dioxide;

contacting the gas exiting the absorber with a third portion of the lean solvent to saturate the third portion with carbon dioxide thereby forming a gas solvent mix; and

cooling and separating the gas solvent mix, thereby forming the second portion of the lean solvent that is saturated with carbon dioxide.

17. The method of claim 16 wherein the step of optionally contacting is performed before the gas enters the absorber, and wherein the contacted gas is cooled before the contacted gas enters the absorber.

18. The method of claim 16 wherein part of the second portion of the lean solvent that is saturated with carbon dioxide is employed in another absorber as an absorbing solvent that removes hydrogen sulfide from a vapor.

19. The method of claim 18 wherein the another absorber is operated under conditions to reject carbon dioxide from the part of the second portion of the lean solvent.