Summary
Maintaining the correct temperature throughout the sulfur recovery process is essential for efficient catalyst performance and stable operation. Temperature measurements at condenser, reheater and reactor provide the process insight required to optimize sulfur recovery and detect deviations before they impact plant performance.
The benefits: Reliable reheater control for efficient sulfur recovery
24/7
monitoring
of reheater performance and reactor inlet conditions
2–5 %
potential reduction in steam energy consumption
through optimized temperature control
0%
risk of sulfur condensation
under normal operating conditions
The challenge: Maintaining optimal reactor inlet conditions
In Claus sulfur recovery units (SRU), process gas must be reheated before entering each catalytic reactor stage. Maintaining the correct temperature is essential for efficient sulfur recovery and stable plant operation.
If the gas temperature falls below the sulfur dew point, sulfur can condense in piping and on catalyst surfaces, resulting in fouling, catalyst deactivation and increased pressure drop. Excessively high temperatures can negatively affect reaction equilibrium, reduce sulfur yield and accelerate catalyst degradation.
Operators therefore need reliable temperature data to maintain process stability, maximize recovery efficiency and protect critical assets throughout the reheating process.
Our solution: Temperature measurement as the key control variable
Temperature measurement in sulfur recovery units is not only a monitoring parameter. It is a primary control variable (PV) for effective and efficient reheater operation. Accurate measurements throughout the process provide the information required to maintain optimal reactor inlet conditions, verify heat transfer performance and identify process deviations before they impact sulfur recovery efficiency. Real-time temperature monitoring also helps detect abnormal conditions such as sulfur deposition, heat exchanger inefficiencies and catalyst deactivation at an early stage.
Critical measurement points extend beyond the reheater itself and provide valuable process insight across the entire sulfur recovery unit:
- Condenser temperature measurement helps calculate heat recovery, monitor sulfur recovery and prevent unwanted sulfur dual phases or solid suspended particles.
- Reheater temperature measurement helps determine the thermal energy transferred to the process gas and the gas conditions entering the catalytic reactor.
- Reactor temperature measurement and profiling provide visibility into catalyst performance, thermal behavior and remaining catalyst life.
To ensure reliable operation, temperature measurement solutions must combine high accuracy, fast response times and robust process sealing. Precise inlet-to-outlet temperature measurement helps prevent sulfur deposition, supports energy recovery calculations and enables rapid response to changing process conditions while maintaining safe and efficient operation.
Temperature measurement solutions throughout the reheater for sulfur recovery units
Endress+Hauser offers a comprehensive portfolio of invasive and non-invasive temperature measurement solutions for sulfur recovery applications. Depending on the measurement task, solutions range from modular thermometers and surface temperature sensors to engineered thermowells designed for demanding process conditions.
Accurate temperature measurement at key locations throughout the reheater helps operators maintain reliable temperature control, improve process stability and support efficient sulfur recovery throughout the Claus process.
Reheater inlet pipeline and nozzle
- Monitor upstream condenser performance, establish temperature profiles along the inlet pipeline and detect potential sulfur condensation risks at the inlet nozzle.
- iTHERM SurfaceLine TM611 enables accurate non-invasive temperature monitoring along the pipeline without process intrusion, helping to assess heat dissipation and condensation risk.
- At the inlet nozzle, iTHERM ModuLine TM151/TM152 provide reliable invasive temperature measurement with corrosion-resistant thermowells for precise process gas monitoring and asset integrity support.
Reheater outlet nozzle and HP pipelines (CCP)
- Verify reactor inlet conditions, monitor the quality of the gaseous stream and evaluate the heat transferred by the high-pressure steam system.
- iTHERM ModuLine TM151/TM152 deliver accurate invasive temperature measurement at the outlet nozzle, helping to confirm stable process conditions before the catalyst stage.
- On the HP steam pipelines, iTHERM SurfaceLine TM611 supports non-invasive temperature monitoring for heat balance calculations and efficiency assessments of the reheater.
Reheater shell side and tube side (CCP)
- Track temperature gradients during start-up and operation, identify tube-side cold spots and support continuous equipment integrity monitoring.
- iTHERM ModuLine TM151/TM152 enables reliable shell-side temperature measurement with robust sensor technology for demanding process conditions.
- iTHERM SurfaceLine TM691 provides accurate tube skin temperature monitoring in narrow spaces, helping to detect local heat transfer inefficiencies. Together, both solutions provide valuable insights into thermal stresses, differential expansion risks and overall reheater performance.
