You are on page 1of 26

GAS ARABIA SUMMIT, 5th annual meeting

Sour Gas Meeting


Liquid Sulphur H andling Facilities and Long D istance Pipelines

Rolf Szczepanek, 31/01/2010

Liquid Sulphur Handling Facilities and Long Distance Pipelines


Table of Contents
Physical Properties
Heating
Station

Systems
facilities

Pumps
Loading / Unloading Facilities
Tanks
Solidification units
Silo
Pipelines
Main

Project Risks

N:\GB-S\sp-proj\+Prsentation GB-S\Schwefelpraesentation

page 2

Liquid Sulphur Handling Facilities and Long Distance Pipelines


Physical Properties of -Sulphur
9

1800

1790

6
5

1780

density / kg/m

viscosity / mm/s

viscosity
density

4
3
120

130

140

150

1770
160

temperature / C

narrow operating range (125C to 150C) special demands


on redundancy, heating and insulation
N:\GB-S\sp-proj\+Prsentation GB-S\Schwefelpraesentation

page 3

Liquid Sulphur Handling Facilities and Long Distance Pipelines


Heating Systems
Station

piping, valves
and pumps
Jacketing or tracing

Pipelines

Electrical

Steam

Conventional Heating Cables

Hot Water

Skin Effect Heating System

Thermal Oil

Hot water

Electrical heating cables

N:\GB-S\sp-proj\+Prsentation GB-S\Schwefelpraesentation

page 4

Liquid Sulphur Handling Facilities and Long Distance Pipelines


Heating Systems, boiler unit

TO-Heaters
Brake
2 x 700 kW

N:\GB-S\sp-proj\+Prsentation GB-S\Schwefelpraesentation

page 5

Liquid Sulphur Handling Facilities and Long Distance Pipelines


Heating Systems, Pipes
Pipe in Pipe System for
heating by Thermo-Oil,
Hot Water, Steam

Fixed
support
of
jacketed
pipe

N:\GB-S\sp-proj\+Prsentation GB-S\Schwefelpraesentation

page 6

Liquid Sulphur Handling Facilities and Long Distance Pipelines


Heating Systems, jacketed Pumps and Valves

N:\GB-S\sp-proj\+Prsentation GB-S\Schwefelpraesentation

page 7

Liquid Sulphur Handling Facilities and Long Distance Pipelines


Station facilities, Pumps
Centrifugal Pumps

conventional coupled

magnetically coupled
Screw Pumps

N:\GB-S\sp-proj\+Prsentation GB-S\Schwefelpraesentation

page 8

Liquid Sulphur Handling Facilities and Long Distance Pipelines


Station facilities, Loading / Unloading Facilities

Railway Unloading
Station, Brake
5 x 60 m / h
Screw pumps

N:\GB-S\sp-proj\+Prsentation GB-S\Schwefelpraesentation

page 9

Liquid Sulphur Handling Facilities and Long Distance Pipelines


Station facilities, Loading / Unloading Facilities

NPSHA = 1.6 m
Screw pumps

N:\GB-S\sp-proj\+Prsentation GB-S\Schwefelpraesentation

page 10

Liquid Sulphur Handling Facilities and Long Distance Pipelines


Station facilities, Tanks

10,000 to, Sulphur Plant Brake / Germany


N:\GB-S\sp-proj\+Prsentation GB-S\Schwefelpraesentation

page 11

Liquid Sulphur Handling Facilities and Long Distance Pipelines


Station Facilities, Tanks
Insulation

N:\GB-S\sp-proj\+Prsentation GB-S\Schwefelpraesentation

page 12

Liquid Sulphur Handling Facilities and Long Distance Pipelines


Station Facilities, Tanks

Heating coils on bottom


N:\GB-S\sp-proj\+Prsentation GB-S\Schwefelpraesentation

Roof heating
system

page 13

Liquid Sulphur Handling Facilities and Long Distance Pipelines


Station Facilities, Solidification

Granulation

N:\GB-S\sp-proj\+Prsentation GB-S\Schwefelpraesentation

page 14

Liquid Sulphur Handling Facilities and Long Distance Pipelines


Station Facilities, Solidification
Pastilation

Flaking

N:\GB-S\sp-proj\+Prsentation GB-S\Schwefelpraesentation

page 15

Liquid Sulphur Handling Facilities and Long Distance Pipelines


Station facilities, Silo
10,000 to, Sulphur Plant
Brake / Germany
spiral slide
conveyor

emptying tube

discharge opening
air in-/outlet

emptying tube
discharge opening
swelling (Beton)

gangway

ridged roof, 35 (concrete)

N:\GB-S\sp-proj\+Prsentation GB-S\Schwefelpraesentation

bottom plate (concrete)


supporting wall (concrete)

page 16

Liquid Sulphur Handling Facilities and Long Distance Pipelines


Pipelines
Special

Design Criteria

Decision on heating system; Electrical (conventional / skin effect) or hot water


Sectioning: optimization of length and voltage
Redundancy: two independent circuits
Pre-tensioning and/or expansion elbows
Special design of insulation, and supports
SCADA
temperature and viscosity profile
set point for temperature controllers
calculation of survival time
monitor insulation quality
Displacement system
N:\GB-S\sp-proj\+Prsentation GB-S\Schwefelpraesentation

page 17

Liquid Sulphur Handling Facilities and Long Distance Pipelines


Pipelines

solid density ~2000 kg/m3


re-melting is critical due to ~10 % volume increase

N:\GB-S\sp-proj\+Prsentation GB-S\Schwefelpraesentation

page 18

Liquid Sulphur Handling Facilities and Long Distance Pipelines


Pipelines, Heating Systems

Electrical/C onventional, 3 Line, 4.5 km


N:\GB-S\sp-proj\+Prsentation GB-S\Schwefelpraesentation

page 19

Liquid Sulphur Handling Facilities and Long Distance Pipelines


Pipelines, Heating Systems

N:\GB-S\sp-proj\+Prsentation GB-S\Schwefelpraesentation

Electrical/Skin Effect

page 20

Liquid Sulphur Handling Facilities and Long Distance Pipelines


Pipelines, Heating Systems
Heat loss: ~ 90 W/m (8/12-Pipeline, 6-return line)
Max. distance of Heater stations, existing: appr. 40 km
(Shells Caroline-Shantz pipeline, 41 km, worlds longest sulphur
pipeline)
Disadvantages:
Hot Water return line (6)
increased heating requirements
Deaeration
No redundant heating circuit

Advantages:
Increased heat capacity
more time in case of failure
Remelting from the end
reduced risk of bursting
Long heating sections

Hot Water Heating System


N:\GB-S\sp-proj\+Prsentation GB-S\Schwefelpraesentation

page 21

Liquid Sulphur Handling Facilities and Long Distance Pipelines


Pipelines, Supports

4 Line, Underground, Pipe in Pipe System Voigtei Barenburg, 7


km

N:\GB-S\sp-proj\+Prsentation GB-S\Schwefelpraesentation

page 22

Liquid Sulphur Handling Facilities and Long Distance Pipelines


Pipelines, Supports and Expansion Elbows

3 Sulphur Pipeline, Buschhaus Alversdorf, 4.5 km


N:\GB-S\sp-proj\+Prsentation GB-S\Schwefelpraesentation

page 23

Liquid Sulphur Handling Facilities and Long Distance Pipelines


Pipelines, supports

sliding support
N:\GB-S\sp-proj\+Prsentation GB-S\Schwefelpraesentation

ILF design

fixed-point support
page 24

Liquid Sulphur Handling Facilities and Long Distance Pipelines


Main Project Risks

Insulation No cold bridges


Efficient heating system sufficient, but not too much
Selection of Pumps very critical
Possibility of Pipeline Draining or Displacement No stop of
flow
Redundancy (flow, displacement system, energy)

N:\GB-S\sp-proj\+Prsentation GB-S\Schwefelpraesentation

page 25

Liquid Sulphur H andling Facilities and Long D istance Pipelines

Thank you for your attention!