1.

Introduction

1

2.

Executive Summary

2

3.

Experimental

5

3.1

Task 1.  Develop a Bench-Scale, Prototype Process to Remove H₂S from Low-Quality Natural Gas

5

3.1.1

Overview of the Hybrid CrystaSulf Process

5

3.1.2

Chemistry of the Hybrid CrystaSulf Process

7

3.1.3

Requirements of Catalyst Used to Oxidize H₂S to SO₂

8

3.2

Task 2.  Develop a Detailed Plan for Lab Testing of the Task 1 Both Onshore and Offshore Applications Process for

9

3.3

Task 3.  Complete Lab Testing of Task 2 and Demonstrate Scale-Up Economic Advantages for Onshore and Offshore Applications

9

3.3.1

Catalyst Testing Equipment and General Methodology

9

3.3.2

Testing of TDA #3 Catalyst

12

3.3.3

Comparison of TDA Catalysts 1, 2, and 3

13

3.3.4

Oxidation of C₂+ Hydrocarbons

13

3.3.5

Effect of BTX Contamination on Catalyst Performance

16

3.3.6

Effect of Knockout Drum Condensate

19

3.3.7

Bench Unit Testing at the Pilot Plant Site

22

3.3.8

Economic Assessment of Scale-Up to Onshore and Offshore Locations

26

3.4

Task 4 – Develop a Test Plan For Pilot-Scale Demonstrations of the Hybrid Process; Conduct Modifications to Existing Pilot Plant

26

3.4.1

Design of Scaled –Up Catalytic Oxidation Reactor

27

3.4.2

Catalyst Pellet Production

28

3.4.3

Catalyst Durability Study

30

3.4.4

Selection of Catalyst

30

3.4.5

Investigation of Alternate Catalysts for CrystaSulf-DO

31

3.4.6

Modification of Existing Pilot Plant

34

3.5

Task 5 – Conduct and Document Pilot-Scale Demonstration of Hybrid Process; Develop Commercialization Plan

34

4.0

Results and Discussion

35

4.1

Testing of TDA #3 Catalyst

35

4.2

Comparison of TDA Catalysts 1, 2, and 3

39

4.3

Oxidation of C₂+ Hydrocarbons

42

4.4

Effects of BTX Contamination on Catalyst Performance

45

4.5

Knockout Condensate Test Results

49

4.5.1

Knockout Condensate Test #1

49

4.5.2

Knockout Condensate Test #2

53

4.5.3

Knockout Condensate Test #3

55

4.6

Results of Bench Unit Testing with Pilot Plant Gas

56

4.7

Economic Assessment of Scale-Up to Onshore and Offshore Locations

61

4.8

Pilot-Scale Demonstration and Development of Commercialization Plan for Hybrid Process (CrystaSulf-DO)

67

4.8.1

Selection of Direct Oxidation Hybrid Process Mode

67

4.8.2

Alternate Funding Sources for Direct Oxidation Testing

68

4.8.3

Investigation of Alternate Catalysts for Direct Oxidation CrystaSulf

68

4.8.4

Direct Oxidation Catalyst Testing

71

5.0

Conclusions

72

6.0

References

73