A reliable sulphur recovery unit depends on more than one well-made vessel. The burner, reaction furnace, waste heat boiler, condensers and reactors must work as one process train. Ruichang designs and manufactures this equipment around the real feed gas, operating range and project conditions.
You can source a single replacement item, a coordinated equipment package, or a modular sulphur recovery unit from Ruichang. The supply boundary is set for each project. It may cover process engineering, key equipment, piping, instruments, electrical work, insulation and module assembly.
Our work covers new plants, capacity expansion and revamp projects. Early review of the acid gas and site data helps us select a practical process route and define the right equipment interfaces.
30+ years
SRU combustion experience
200+
Equipment applications
150,000 t/a
Largest stated SRU experience
Up to 99.9%
With SCOT tail gas treatment
90%-95%
Workshop installation
Complete Equipment Scope
Ruichang supplies the main equipment used from acid gas combustion to final tail gas handling. The scope can start with one burner or vessel. It can also cover a complete set in which duties, pressure drop, nozzle orientation and control interfaces are checked together.
This flexible supply model is useful for both new projects and existing units. A plant may need to replace an ageing waste heat boiler, add a tail gas system, or increase capacity without changing every item. We review the existing process before fixing the new supply boundary.
For an integrated package, Ruichang can coordinate process data, combustion design, mechanical design, module layout and factory testing. The final scope is stated in the project proposal, so the client knows which interfaces are included and which remain with other parties.
Replacement equipment needs extra care at the connection points. Existing nozzle positions, foundation loads, piping movement, instrument signals and maintenance space all affect the new design. Clear site measurements and drawings reduce the risk of changes during installation.
Key SRU Equipment
Each item has a clear duty, but its design basis comes from the whole unit. The table below gives a practical view of the main equipment and the information that affects selection.
| Equipment | Main duty | Project basis |
| Acid gas burner | Mixes acid gas, fuel gas and combustion air for a stable thermal reaction | Feed composition, turndown, air ratio, flame shape and furnace geometry |
| Thermal reactor | Provides the high-temperature reaction zone for the Claus thermal stage. | Gas flow, reaction temperature, residence time, refractory and nozzle layout. |
| Waste heat boiler | Cools hot process gas and recovers useful heat as steam | Inlet temperature, steam conditions, fouling risk and allowable pressure drop. |
| Sulphur condenser | Cools process gas and condenses elemental sulphur after reaction stages. | Gas duty, steam level, sulphur drainage, corrosion allowance and clean-out access. |
| In-line heater | Raises process gas temperature before catalytic conversion or tail gas treatment. | Required outlet temperature, fuel, control range and pressure loss. |
| Catalytic reactor | Holds the catalyst used for Claus conversion and related process steps. | Catalyst type, gas composition, space velocity, temperature and bed pressure drop. |
| Hydrogenation reactor | Converts remaining sulphur compounds during SCOT-type tail gas treatment. | Tail gas composition, hydrogen supply, catalyst duty and operating temperature. |
| Tail gas incinerator | Oxidises combustible sulphur compounds before the treated gas is discharged. | Tail gas flow, emission target, fuel demand and heat recovery requirement. |
| Auxiliary systems | Support operation, control, safety, heat recovery and module integration. | Piping, instruments, electrical work, insulation, skids and battery limits. |
Why Matched Equipment Matters
The thermal section sets the conditions for the rest of the unit. The acid gas burner must keep a stable flame across the agreed operating range. The reaction furnace must provide enough space and residence time for the required reactions. At the same time, the waste heat boiler must recover heat without creating an unnecessary pressure loss.
Downstream equipment has the same close relationship. Gas temperature must be suitable for sulphur condensation and then raised again before the catalytic stage. Condenser duty, reheater duty, catalyst selection and reactor pressure drop therefore need a common design basis.
When equipment comes from several suppliers, small differences in duty or interface data can cause site changes and commissioning delays. A matched Ruichang package gives the project team one coordinated set of equipment data. It also makes technical review and change control easier.
The review should cover more than the normal design point. Start-up, low load, maximum flow and changes in acid gas composition can place different demands on the burner and downstream equipment. Checking these cases early helps define a workable control range for the complete train.
Claus and Tail Gas Treatment Options
The Claus process is the usual starting point for converting hydrogen sulphide into elemental sulphur. Acid gas is burned in the thermal stage. The hot gas then passes through heat recovery, sulphur condensation, reheating and catalytic conversion stages.
The required recovery level and emission limit decide what comes after the Claus section. Ruichang materials describe a selective oxidation process with a sulphur recovery rate of about 99.5%. This route may suit projects that need a compact process with a defined feed basis.
For a higher recovery target, Ruichang also offers a SCOT process. It uses hydrogenation and an amine-based tail gas treatment step, and the stated recovery rate is above 99.9%. The final guarantee must use the agreed feed composition, operating range, utilities and test method.
Tail gas incineration can be added after treatment. Depending on the emission plan, the incinerator package may include a dedicated burner, heat recovery, air preheating, DeNOx equipment or downstream scrubbing.
No single route is right for every plant. A high H2S feed, a lean feed with hydrocarbons, or an ammonia-bearing stream may need a different thermal design. Utility cost, plot space, operating skill and local emission rules also influence the final choice.
Modular Sulphur Recovery Units
A modular supply plan moves a large part of site work into the workshop. For a suitable project, about 90% to 95% of installation work can be completed before shipment. Equipment, steelwork and piping can be assembled under controlled conditions, with inspection and testing carried out before the modules leave the shop.
This approach can shorten the site schedule and reduce the number of workers needed at site. It also limits the effect of bad weather, remote location and restricted construction space. The real benefit depends on module size, transport route, lifting plan and local site conditions.
Road-Transportable Modular Case
One Ruichang reference combines a 7,000 t/a sulphur recovery unit with a 35 t/h solvent regeneration unit. The inland project was divided into six small modules that could be moved by road. Large columns were transported separately.
Marine-Transport Integral Module
For a coastal project, the Claus section of a 130,000 t/a unit was designed as one integral module. The stated module weight was about 2,000 tonnes. Marine transport allowed the client to move the large assembled section by ship.
Engineering and Manufacturing
SRU equipment brings together process, combustion, mechanical, piping, structural, instrument and electrical work. Ruichang can support process simulation, burner design and equipment engineering as part of the agreed project scope.
CFD can be used to review flow, temperature and gas distribution in the burner and reaction chamber. FEM supports module structure, lifting and transport checks. These tools help the engineers find weak points before fabrication begins.
Manufacturing work may include plate cutting, rolling, welding, machining and burner fabrication. Quality activities are set by the approved inspection plan and may include material checks, NDT, hydrotest, shop assembly and factory acceptance testing.
For modular work, equipment installation, piping, cable trays, wiring, painting and insulation can be completed in the workshop where practical. The transportation and lifting study is developed with the module layout, not added after fabrication.
Project documentation is prepared around the agreed inspection and review points. Typical records may include material certificates, welding and NDT reports, pressure test records, equipment drawings and packing lists. The required document set should be agreed before manufacturing starts.
Why Choose Ruichang for SRU Equipment
An SRU project needs more than separate items of equipment. Ruichang combines combustion, heat recovery, process equipment and modular engineering in one coordinated supply scope. This helps EPC contractors review the main equipment and its interfaces with one technical team.
- More than 30 years of experience in combustion and heat-transfer equipment.
- More than 200 sulphur recovery equipment applications.
- Project experience with SRU capacities up to 150,000 t/a.
- Coordinated supply of burners, thermal reactors, waste heat boilers, sulphur condensers and downstream equipment.
- Claus, selective oxidation and SCOT-type options for different recovery targets.
- Modular delivery with 90%-95% workshop installation when the project size, site and transport route allow.
FAQ
Ruichang designs equipment for the project duty rather than selecting one fixed catalogue model. Current stated experience includes more than 200 applications and SRU projects up to 150,000 t/a. The practical capacity for a new inquiry depends on feed composition, process route and site conditions.
Yes. Ruichang can supply individual burners, reactors, waste heat boilers, sulphur condensers, heaters and incinerators. Existing equipment data and interface drawings are needed for a replacement or revamp item.
The available Ruichang scope includes Claus sulphur recovery, selective oxidation and SCOT-type tail gas treatment. Process selection starts with the acid gas, required recovery, emission limit and available utilities.
Yes, when the site and transport route allow it. Equipment, piping, steelwork, instruments, electrical work and insulation can be assembled in the workshop. The module split is agreed after transport and lifting limits are reviewed.
The guarantee is written for the selected process and the agreed design cases. It must state feed composition, flow range, utilities, operating conditions and the performance test method. A general process figure is not a guarantee for every feed gas.
Yes. A revamp may replace one item, add tail gas treatment, raise capacity or reduce site work through preassembled sections. The review needs the existing process data, plot, tie-ins, foundations, utilities and shutdown window.
Discuss Your SRU Equipment Requirement
Email sales@burnertec.com to discuss an individual item, a matched equipment package or a modular sulphur recovery unit.
