Join us for an interactive Sulphur Troubleshooting Clinic featuring experienced plant operators, trusted consultants, and leading technology providers. This session will explore high-priority gas treating, sulphur recovery and sulphur handling topics tailored to the specific priorities and pressures facing the region’s sulphur industry. Each topic will kick off with a brief introduction, followed by open discussion between the expert panel and participants—offering a unique opportunity for collaborative troubleshooting, shared insights, and practical takeaways.

Theion Consulting Sàrl

Wylton (China) Chemical Co., Ltd

CRU Group

• U.S. Policy Landscape: Where do current tariffs, trade dynamics, and environmental regulations stand—and what do they mean for oil, gas, and sulphur supply chains?
• What Comes Next? Key risks and opportunities as policy continues to evolve
• Global Response: How governments and markets worldwide are reacting—both politically and economically

A strategic reassessment of the global oil and gas, and sulphur landscape is essential as the industries face mounting pressures from the energy transition, supply chain disruption, geopolitical instability, and shifting demand patterns. Central to this discussion is the critical role of oil and gas in supporting the industries’ value chain. This keynote will offer an in-depth exploration of how renewed strategic focus and alignment can strengthen supply chain optimization and drive stability and growth in an increasingly complex global environment.

• Powering the Energy Transition: Sulphur and sulphuric acid strategic role in advancing global energy solutions  
• Unlocking Critical Resources: Rare earths and battery metal recovery

As the global economy pivots toward sustainable technologies and cleaner energy solutions, sulphur and sulphuric acid are emerging as critical elements in this industrial transformation. The panel explores their evolving roles – from key inputs in traditional industries to enablers of next-generation energy storage and advanced resource recovery. Delegates will gain insights into market trends, technological breakthroughs, and strategic applications that position sulphur and sulphuric acid at the forefront of the new industrial era

Catalysts for Agricultural Innovation – Feeding the Future: The rising role of Sulphur and Sulphuric Acid in Next-Generation Fertilizers

This keynote address will explore the innovations transforming fertilizer production, distribution, and application, showcasing how sulphur and sulphuric acid are emerging as the cornerstone in creating a more productive, resilient, and sustainable agricultural future. As we strive to ensure food production and security for a thriving tomorrow, our goal is to drive the critical advancements needed for the future development of the fertilizer industry.

Guest Speaker

Pricing, Supply Shifts & Demand Hotspots Uncovered

• What is shaping sulphur pricing volatility?
• Where are the new demand centers emerging?
• How are global trade routes and supply chains adapting?
• What are the strategic implications for producers and buyers?

Step into this high impact briefing to decode the latest developments in the global sulphur market. Get ahead of the curve with expert insights into pricing trends, evolving supply dynamics, and the sectors and regions driving demand growth.

Economics, Sustainability & The Future of the Industry  

• Is Deglobalization the Key? Policy and regulatory landscape shaping regional independence
• Global Trade Challenges and Sanctions – Impact on fertilizer industry
• Risk identification and mitigation. Driving long term resilience and sustained operational performance
• Capital Strategies – Financing growth in uncertain markets
• Regional Market Snapshots – Strategic updates from key producing and consuming regions

This panel will explore the critical economic and sustainability trends shaping the future of the sulphur and sulphuric acid industries. With growing momentum toward deglobalization, policy and regulatory shifts are driving a renewed focus on regional self-reliance. At the same time, the green transition is accelerating efforts to decarbonize value chains and meet rising ESG expectations. Against a backdrop of market volatility, strategic capital deployment remains essential to enable resilient growth. Regional market snapshots will offer timely insights into how key producing and consuming regions are adapting to these converging pressures.

• Key pricing trends
• Trade flows and production capacity shifts
• Global trade changes – impact on acid trade flow, acid quality (electronic grade) and  ultra-pure grades
• Policy and environmental impacts
• Strategic outlook for producers, traders, and consumers

Gain critical insight into the shifting dynamics of the global sulphuric acid market. From regional supply-demand imbalances and feedstock volatility to downstream fertilizer trends and environmental pressures, this presentation delivers the data, forecasts, and strategic analysis you need to stay ahead in a complex, fast-evolving market.

The presentation will examine operational experience, showcasing plant data and results from several successful projects recently completed in the Middle East region. These projects have significantly contributed to the advancement of the BASF Gas Treating Technologies current and future developments. Presentation will include comprehensive plant data, highlighting key performance indicators and outcomes that demonstrate the efficacy and impact of the work.

BASF

The presentation provides technical decision makers with strategies on how to maximize the return on investment (ROI) of their sulphuric acid plant by utilizing Chemetics’ 60 years of experience and innovation in sulphuric acid plant design and equipment fabrication. Strategies include minimizing downtime time through reliable equipment designs, unlocking value by capitalizing on by-product availability, and considerations related to balancing CAPEX and operating expenditure (OPEX).

Optimized Gas Treating (OGT) introduces a groundbreaking, first-of-its-kind rate-based liquid extraction model, validated against real operating plant data. This innovation stems from years of customer feedback highlighting the absence of reliable models for meaningful simulation of LPG treaters and other extraction processes. Now available in ProTreat, OGT’s commercial process simulator, this advanced model empowers the industry with robust, highly accurate tools for the design, operation, and troubleshooting of liquid treaters—delivering significant benefits across the full lifecycle of extraction operations.

Optimized Gas Treating

Sulphur Plant: Technologies and Strategies for Effective H2S Removal

Q&A Session

The presentation highlights the operational performance of byproduct silica in a sulphur-burning sulphuric acid plant, demonstrating its effectiveness in real-world conditions. Performance is quantified through key metrics, including the replacement of approximately 2,000 kilograms per month of Decalite and consistent maintenance of sulphur ash content below the 50 ppm maximum limit. This work introduces a novel material—amorphous silica, a byproduct of the aluminium fluoride (AlF3) manufacturing process—for use in this application. Equally innovative is the circular economy pathway outlined for valorizing the silica, representing a fresh approach to resource efficiency and industrial sustainability.

MECS has decades of experience in designing safe & reliable sulphur trioxide (SO3) production units. In this session, MECS will share its vast operational experience so companies interested in producing e-grade sulphuric acid can develop a deeper technical understanding around the production of high purity sulphur trioxide (SO3).

The presentation showcases a significant advancement in tail gas treatment, replacing traditional reduction–absorption technology with direct thermal oxidation followed by membrane-assisted acid enrichment. This innovative approach enables compliance with stringent SOx emission targets while reducing both energy consumption and carbon footprint. Notably, the integration of reverse osmosis membranes for acid concentration marks a novel application in SRU tail gas treatment and aligns with circular water management principles.

Drawing on actual operating experience, this presentation will highlight both the benefits and the challenges of implementing catalytic incineration—a proven yet underutilized concept that deserves renewed attention in light of today’s urgent drive to reduce carbon footprints. While not introducing proprietary innovations, this technology-neutral paper is grounded in open-art technology, offering practical insights free from commercial bias. Common operational problems will be outlined alongside effective solutions, providing attendees with a balanced, experience-based perspective to guide informed decision-making.

The presentation tackles common operational challenges, including refractory damage from sulphur impingement and catastrophic corrosion caused by unburnt sulphur pooling—issues often worsened by suboptimal spray nozzle designs. It highlights how Lechler’s KSD nozzle delivers unique, targeted benefits to mitigate these risks through precise temperature control, consistent droplet sizing, and an anti-drip mechanism. These features collectively extend refractory life, improve operational efficiency, and address critical industry needs with an innovative, purpose-built design.

SepR8 represents a transformative shift in sour gas processing—one that combines high recovery of valuable hydrocarbons with ultra-low emissions. By unlocking economically stranded sour gas reserves, it enables low-carbon production of power, hydrogen, and ammonia. SepR8 has the potential to play a pivotal role in delivering cleaner, more cost-effective energy on a global scale.

8 Rivers Capital, LLC

This presentation shares real-world case studies of Wet gas Sulphuric Acid (WSA) units used as Sulphur Recovery Units in refineries, highlighting significant gains in energy efficiency. It includes fresh data from newly commissioned refineries worldwide, including sites in the Americas, and offers a balanced comparison with traditional Claus SRUs using both licensor data and operational plant results. Aimed at refineries facing pressure to boost energy efficiency and meet CO2 reduction targets, the presentation demonstrates how targeted SRU upgrades can help operators meet these challenges while enhancing overall plant performance.

The #400 Sulfuric Acid Plant in Pocatello houses what is believed to be the oldest still-operating stainless-steel “blooper” converter in service—now an impressive 40 years old. During the facility’s 2025 turnaround, an ambitious series of projects were undertaken to extend its operational life. These included replacing the internal superheater, installing three new catalyst beds, fully renewing the converter insulation, conducting a comprehensive structural inspection, and carrying out extensive repairs based on inspection findings. This effort reflects both the engineering challenges and the resourcefulness required to keep a legacy asset performing reliably in today’s demanding industrial environment.

This presentation draws on operational experience from a full-scale sulfuric acid plant installation, where performance was tracked over several months under real process conditions. It introduces an innovative strategy to protect corrosion-prone zones in gas coolers using modular, corrosion-resistant components and targeted design modifications informed by computational modelling. Both the successes and challenges—such as unexpected pressure drops and mechanical failures—are openly examined, providing valuable lessons for future improvements. Addressing the persistent issue of localized corrosion in transient temperature zones, the work outlines practical redesigns that enhance durability, reduce downtime, and better align with plant maintenance schedules.

Novel Applications and Breakthrough Solutions in Sulphur Industry

Q&A Session

Whether building a new plant or replacing a tower in an existing facility, careful consideration is critical before awarding a replacement tower project. Key decisions include whether to choose a brick-lined tower, known for robustness when expertly installed, or a high-silica alloy tower, which offers corrosion resistance, long life, and reduced dependence on skilled labour while maintaining capacity and pressure drop. Additional factors such as distributor type, pour points, packing design, and mist eliminator efficiency must also be evaluated. Finally, installation logistics—from greenfield projects to complex field assembly and downtime-minimizing strategies for replacements—play a crucial role in ensuring a successful outcome.

Ergon Armour Cast Serv.

WSI

This presentation explores creative, practical solutions that have enabled refineries to avoid unplanned outages or extend Sulphur Recovery Unit (SRU) operations until a planned turnaround. It will detail how each measure was implemented, how it mitigated or managed specific issues, the limitations of operating in “abnormal mode,” and the additional actions needed to ensure success. While not every solution is universally applicable, understanding what is possible—and how to assess and implement these strategies—can help operators minimize losses and prevent costly, unplanned shutdowns.

SGS Sulphur Experts Inc.

This presentation draws on real-world operational experience from a successfully operated Tail Gas Treating Unit (TGTU) to share best practices and lessons learned in hydrogenation catalyst lifecycle management. It addresses key challenges, including activating catalyst active sites, safely passivating spent catalysts, and managing pyrophoric materials, offering proven, practical solutions to each. By combining technical insight with field-proven strategies, the discussion aims to help operators optimize catalyst performance, improve safety, and extend unit reliability.

ARAMCO  

A US refinery operating on bio feedstocks for several years considered expanding to maximize Sustainable Aviation Fuel (SAF) production, which would raise sulphur output by approximately 900 lbs/day. Existing solid scavenger beds were unlikely to handle this increase, prompting Comprimo to evaluate technologies to boost sulphur processing capacity. The study assessed restarting the facility’s small, decommissioned amine and sulphur recovery units to meet future capacity needs and resolve issues with the current scavenger beds. This option was compared with alternative technologies, and the study’s key findings and recommendations will be shared in this presentation.

The sulfuric acid plant at Ilo’s copper smelter, which captures and treats sulphurous gases from melting and conversion furnaces, has achieved over 40 months of continuous operation and is on track to reach four years—a record since start-up. Central to this success is the performance of the reactor’s first bed, maintained through effective gas cleaning, impurity control, and a detailed analysis of the variables influencing conversion reactions. Using computational fluid dynamics, fluid-dynamic and thermal profiles were modelled and validated with operational data, guiding targeted initiatives that enhanced reactor efficiency and extended run length.

Southern Peru

Declining ore grades and variable feed blends to smelter and roaster operations are driving greater fluctuations in impurity loads throughout the downstream gas cleaning and acid production chain. At the same time, tightening environmental regulations are placing increased demands on plant operations to manage emissions in all forms and prepare for all potential contingencies. This presentation will showcase a range of process solutions from Metso designed to sustain high productivity and availability while keeping both capital and operating costs under control.

Sulphur Plant: Reliability-Centered Operations and Maintenance

Q&A Session

This presentation draws on real-world case studies from global sulphuric acid plants, sharing hands-on experience in maintenance and protection strategies such as tank relining, system upgrades, and predictive inspections. What sets it apart is the strategic integration of advanced inspection technologies, modern lining systems, and reliability engineering principles to enhance turnaround planning and reduce long-term OPEX. Vendor-neutral and solution-focused, the session addresses high-impact operational challenges—including corrosion, unplanned shutdowns, safety risks, and inefficient reline cycles—offering practical, field-tested approaches to mitigate these issues and optimize asset performance.

REMA TIP TOP

This presentation examines operational and safety considerations for Sulphur Recovery Unit (SRU) shutdowns triggered by tail gas thermal oxidizer trips, based on a case study from Motiva’s Port Arthur, TX refinery. It outlines the site’s current trip philosophy, quantifies the operational downtime associated with thermal oxidizer-related SRU shutdowns, and highlights the benefits of optimized restart procedures that remain fully aligned with safety standards. The session concludes with a review of LFL compliance and explores the feasibility of alternative restart strategies to enhance operational resilience and minimize production losses at the Port Arthur facility.

This presentation explores the performance of Claus process catalytic reactors through advanced 3D transient simulations of industrial-scale units, focusing on gas flow distribution, temperature variations, and heat losses under normal, turn-down, and co-firing conditions. Significant temperature fluctuations in the catalyst bed were identified, particularly during turn-down and co-firing, which can reduce efficiency, increase reheater duty, and pose reliability risks. The work demonstrates how simulation predictions can inform machine learning models to map limited thermocouple data to full 3D temperature profiles in real time. Findings highlight that optimizing inlet flow distribution and other design features can enhance reactor performance, reliability, and operational efficiency, while reducing costs and mitigating risks of premature SRU shutdowns.

Continuum Engineering Inc.

This presentation shares hands-on insights from the 2025 Turnaround of SRU Train-1 at HPCL Mumbai Refinery, highlighting practical strategies in planning, execution, and commissioning of a complex refinery shutdown. Innovative approaches included three-day air blowing of process lines to prevent plugging, RLNG-based reactor heating for soot-free ignition, dual-train sulphur pit operation, and logic upgrades for critical shutdown functions. Data-driven improvements, such as control valve overhauls, transmitter upgrades, and enhanced redundancy, improved reliability and operational efficiency. The presentation also addresses challenges like equipment access delays, pit shutdown disruptions, and safety gaps, demonstrating replicable solutions that advance turnaround planning, safety, and SRU performance for the global refining community.

Hindustan Petroleum Corporation Ltd

This presentation highlights NORAM’s work on upgrading a 50-year-old sulphur burning, double contact, double absorption sulphuric acid plant to increase production by approximately 40%, amid the challenges of the COVID-19 pandemic. Key milestones include a high-level debottlenecking study, basic engineering, and execution of turnarounds in 2023 and 2025, featuring major equipment upgrades such as a new NORAM Split Flow™ gas-to-gas heat exchanger, replacement of two catalytic converters, economizers, superheaters, acid tower internals, and extensive ducting. The project’s complexity was amplified by the complete field erection of a 13-meter diameter, 25-meter tall four-bed stainless steel converter, along with intricate logistics involving fabrication and transportation of components over thousands of kilometers. The session will focus on the strategies employed to manage these challenges and ensure seamless project execution.

NORAM Engineering and Constructors Ltd.

This presentation draws on over a decade of operational experience at Petrokimia Gresik’s DCDA sulphuric acid plant, highlighting challenges such as jug damper degradation, catalyst overheating, and economizer failures. Solutions include a re-engineered jug damper for enhanced durability, non-destructive dry ice blasting for superheater cleaning, and a redesigned stainless steel economizer with a modified BFW flow direction to reduce acid condensation. Data-driven results demonstrate significant improvements, raising production from 77% to 2,000 MTPD of acid and 100 TPH of steam, while mitigating reliance on external steam. This case study illustrates how targeted engineering interventions, grounded in field experience, can substantially enhance plant reliability, efficiency, and operational performance.

PT Petrokimia Gresik

Sulphur Plant: Reliability-Centered Operations and Maintenance

Q&A Session

This presentation addresses the challenge of modifying an existing sulphuric acid regeneration plant to increase production while improving economic and environmental performance. Messer’s newly patented SAR+ solution achieves this by injecting oxygen directly into the furnace, partially displacing combustion air. The abstract shares over three years of operational and emissions data from a spent acid regeneration unit where this approach was implemented, demonstrating increased acid feed rates and higher sulphuric acid production, alongside a reduced carbon footprint and lower NOx and SO2 emissions. Additional long-term operational and emissions benefits, beyond the original project objectives, are also highlighted, underscoring the reliability and effectiveness of the SAR+ solution.

Messer

The ENAP Bío Bío refinery in Hualpén, Chile, experienced several high SO2 emission events from its sulphur recovery units in 2022. Following a recent DCS and SIS system transition, ENAP collaborated with Worley Comprimo to evaluate whether control and logic changes contributed to these events. Simultaneously, a comprehensive review of SRU design and operations was conducted to identify solutions for emission prevention and optimization. The study also assessed downstream technologies capable of mitigating high emission events from SRU operational issues. This presentation will highlight the evaluated technologies and demonstrate how they can deliver both immediate and long-term emissions reductions for the refinery.

Worley Comprimo

This presentation focuses on catalysts in the sulphur and acid industry, highlighting the unique challenges of catalyst screening in South Africa, Zambia, and the Democratic Republic of Congo. It examines how regional socioeconomic and environmental factors, including carbon reduction policies in South Africa, influence pollution control and operational practices. Key topics include technological and design challenges of screening equipment, improvements in logistics and energy infrastructure, and advancements in catalyst formulations driven by stricter SO2 emission regulations. The presentation also explores innovations such as platinum-based catalysts and extended converter run times, offering insights into the future of catalyst screening from both operational and service perspectives.

RADS ENGINEERS & PROJECTS

This panel expands the conversation beyond traditional H2S and SO2 control to include carbon monoxide (CO), nitrogen oxides (NOx), and carbon dioxide (CO2). As global environmental expectations evolve, operators face increasing pressure to manage a broader spectrum of emissions. The panel will explore the environmental and operational significance of each pollutant, review regulatory trends across key regions, and share best practices and technologies for achieving compliance. Panelists will include a diverse mix of operators, consultants, technology licensors, and academic experts—offering a well-rounded discussion that combines real-world challenges with emerging solutions. Originally assembled and presented in 2020, this panel returns with fresh insights and updated content to reflect the changing emissions landscape. With 2025 bringing new regulatory developments and performance expectations, the session will feature new contributors and updated case studies highlighting the latest technologies, innovations, and best practices for comprehensive emissions control in sulphur recovery operations.

Panel Discussion

This presentation highlights P&P’s development of Platinum Promoted Honeycomb Catalysts as a novel approach to SO2 oxidation in sulphuric acid production, with 33 installations worldwide since 2010. Key advantages include lower ignition temperatures, higher activity, and reduced pressure drop, offering an effective alternative to vanadium oxide systems. Case studies illustrate emission reductions and OPEX savings in mid-sized and 1000 MTPD DCDA plants, as well as improvements from 3+1 to 3+2 plant configurations. The catalyst enables substantial platinum recovery—up to 75%—providing significant economic benefits over conventional catalysts. Additional applications in total oxidation of CO, NH3, and H2S are discussed, along with reversible arsenic poisoning and thermal regeneration strategies. Finally, retrofit opportunities for increasing acid production in existing plants demonstrate the technology’s operational and economic value, particularly in the context of stricter emission regulations and global decarbonization pressures.

Stricter SO2 legislation and evolving market demands continue to challenge sulphuric acid producers to increase throughput without exceeding emission limits. Traditional upgrades often reach their limits due to blower constraints and catalyst capacity, leaving few options for further production gains. This presentation highlights Topsoe’s VK38+ catalyst, a highly potassium-promoted solution introduced in 2020, which has delivered superior performance in over a dozen global installations. A real-world case study from a Middle Eastern fertilizer plant demonstrates how VK38+ enabled a significant production increase without equipment modifications or revamps, maintaining full compliance with emissions standards and achieving payback within a single campaign.

Topsoe A/S

This presentation shares extensive operational experience from SRU 704 at HPCL Mumbai Refinery, highlighting real-world challenges such as sulphur pit pump failures, seal degradation, condenser fouling, and high backpressure. It showcases innovative solutions, including specialized coatings to extend seal life, metallurgical upgrades for pump internals, advanced contra-tracing for improved heat management, and custom process control modifications to mitigate backpressure. A case study of a sulphur pit fire demonstrates objective evaluation of design and safety gaps, emphasizing evidence-based problem solving. The session highlights practical interventions that significantly enhanced reliability, safety, and efficiency in a standard Claus-SCOT configuration.

Hindustan Petroleum Corporation Ltd

This presentation highlights the deployment of an AI-Troubleshooting Agent at a leading sulphuric acid facility, demonstrating its integration into real-world workflows such as shift handovers, morning meetings, and event response. The AI enables real-time, multivariate anomaly detection and causal analysis, offering a novel approach beyond traditional alarm-based monitoring. Early observational results emphasize practical use, limitations, and lessons learned, showing how the tool helps identify hidden process deviations, reduce surprise downtime, accelerate root cause analysis, and improve cross-team coordination in mature chemical operations.

This presentation explores strategies for the commercial utilization of high-ash, low-sulphur Indian coal through gasification—a challenge historically marked by mixed results and uncertainty. Leveraging recent advancements in technology and catalysts, we provide an objective assessment of available technical options, carefully weighing their merits and limitations. The recommendations balance innovation with respect for proprietary technology and financial prudence, encouraging a fresh perspective on unlocking the potential of this unconventional coal resource.

Reducing the Environmental Footprint of Sulphur Recovery: Energy and Emissions Considerations

Q&A Session

This presentation explores the direct, in-situ measurement of sulphuric acid dewpoint within process gas streams, typically at the secondary economizer outlet, though also applicable to primary economizers and waste heat boiler outlets. Real-time knowledge of the acid dewpoint provides a reliable metric for controlling economizer outlet gas temperature, enabling improved plant profitability while minimizing downstream corrosion risk—demonstrating a practical approach to optimizing both performance and asset integrity.

This presentation shares operational insights from the deployment of inline measurement technologies in sulphuric acid and oleum production, highlighting real-world performance in critical process stages such as absorption, dilution, and oleum conversion. It introduces novel hybrid sensors that integrate sound velocity, density, and Coriolis principles to overcome traditional measurement challenges—particularly in the sulphuric acid/oleum transition zone. By addressing common issues like slow lab analysis, sensor drift, and accuracy at reversal points, the session demonstrates practical solutions for optimizing plant operations. Comparative performance data and practical integration considerations ensure a balanced, objective discussion relevant to engineers and plant operators seeking reliable, continuous process monitoring.

Sulphurnet

PegasusTSI, Inc.

This presentation explores best practices for molten sulphur storage and handling, focusing on safety, operational efficiency, and risk mitigation. Key topics include the use of scrubbers, such as caustic scrubbers, to control H2S and particulate emissions from molten sulphur tanks, and strategies for maintaining tank headspace within safe flammability limits. Instrumentation for monitoring conditions in tank headspaces and other molten sulphur-handling equipment is reviewed, alongside proven practices for extinguishing molten sulphur fires. The presentation also examines the impact of degassing molten sulphur on these safety and operational practices and highlights lessons learned from recent publicly reported fires and explosions in molten sulphur systems.

Trimeric Corporation

This presentation showcases the comprehensive optimization of Wylton’s CHP75B catalyst, a key component in the contact process for sulphuric acid production. In response to increasingly stringent environmental and operational demands, the catalyst was engineered to deliver higher conversion rates, lower SO2 emissions, reduced pressure drop, and extended service life—all without compromising physical stability. Innovations include the addition of auxiliary dispersants to enhance active component distribution, specialized binders to increase strength, and process equipment upgrades to improve product quality. Characterization and pore structure analysis confirmed a 9.8% performance boost at 460 °C and a 29% increase in mechanical strength, with pore size and bulk density remaining stable—delivering measurable efficiency and sustainability gains for modern acid plants.

Wylton

This presentation will share operational insights from HPCL Mumbai Refinery’s Diesel Hydrotreater Sulphur Recovery Unit, where a persistent high differential pressure across the first pass of the process gas condenser—accounting for 70% of total backpressure—led to instability and reduced efficiency. A detailed root cause analysis traced the issue to LP steam leakage from the Zone-2 acid gas line jacketing, causing refractory failure, condensate fouling, and restricted flow. The session will highlight how targeted actions—steam isolation, condenser cleaning, and refractory repairs—restored stable operations, and will emphasize the critical role of early ΔP monitoring, inter-system integrity assessments, and condition-based maintenance in ensuring long-term reliability of Modified Claus process units.

This presentation examines the complex challenge of cleaning gas streams from molten sulphur operations—sources such as melters, pits, storage tanks, and loading stations—where hot gases laden with H2S, SO2, molten sulphur, and fine particulates must meet increasingly stringent emission limits, often below 5 ppm for acid gases and 20 mg/DNm³ for solids. Traditional systems require multiple vessels to quench, scrub, and filter these contaminants, each with operational risks like line plugging from sticky or condensed sulphur. Elessent’s DynaWave® Scrubbing System offers a proven, single-vessel alternative capable of simultaneously quenching high-temperature gases, removing acid gases through caustic scrubbing and oxidation, and capturing solid particulates. With over a decade of operational success, this technology simplifies plant design, reduces maintenance complexity, and ensures compliance in one integrated step.

This presentation will showcase how BASF, building on over a century of sulphuric acid and catalyst expertise, is redefining catalyst performance to meet the industry’s dual challenge of efficiency and ever-stricter emission limits. Leveraging advanced digital tools such as CFD simulations, BASF developed the Quattro catalyst family—engineered for superior surface area, mechanical stability, and versatile performance across processes. Taking innovation further, BASF’s groundbreaking X3D™ Technology introduces a radical new geometry that delivers a 50% increase in surface area and up to 75% lower pressure drop compared to conventional catalysts, setting a new benchmark in sulphuric acid production. With sulphuric acid catalysts as the launchpad, this disruptive shaping concept opens new possibilities for catalytic applications across the chemical industry.

BASF

In an era of rising energy costs and increasing pressure to reduce carbon footprints, the recovery of energy from unconventional process streams in sulphuric acid plants has never been more critical. Traditional hot acid heat recovery technologies, while effective, have often been hindered by high capital costs and safety concerns—limiting their widespread adoption. Today, advancements in design and engineering have effectively addressed these safety challenges, enabling energy recovery to be achieved not only through proven conventional systems but also through more economical, lower-cost solutions. These innovations open new opportunities for producers to enhance efficiency, improve sustainability, and strengthen their competitive advantage.

Clark Solutions

Sulphur Product Handling: Safe and Reliable Operations from SRU to Final Destination

Q&A Session

Drawing on over 70 years of sulphur processing expertise, CP Pumps Inc. presents proven solutions for safe, efficient molten sulphur handling through its MKP and MKTP sealless magnetic drive pumps. Field-tested in sulphur recovery and sulphuric acid plants, these pumps address critical challenges such as temperature control to prevent solidification, leak elimination to reduce hazardous deposits, and enhanced uptime through durable, specialized bearings. Featuring CP’s patented reverse drive principle, fully jacketed heating for uniform temperature distribution, and integrated thermocouples for real-time condition monitoring, they deliver both operational reliability and environmental safety. Case studies demonstrate how these innovations have optimized plant performance, showcasing a step change in pump technology for the industry

CP Pumps