Closing the Loop on Feed-Forward Analyzer Air Control Technology
PITTSBURGH, USA (May, 2025) – A newly formed partnership between AMETEK Process Instruments and Worley Comprimo, part of Worley’s Technology Solutions, provides Sulfur Recovery Unit (SRU) stakeholders with critical analytical measurements combined with advanced burner control technology to deliver enhanced automated air control management.
The implementation of the 2ACT™ Solution ensures plant operators gain a fully automated system that minimizes SRU upsets, enhances reliability, and delivers strong returns on investment. At the heart of this partnership, the innovative 2ACT™ Solution offers an all-in-one approach to advanced air control—significantly boosting SRU performance and efficiency while reducing operational costs. The 2ACT Solution uses AMETEK’s IPS-4 ultra-violet and infrared analyser to measure H2S, CO2, NH3, H2O and total hydrocarbons (THCs) by continuously sampling the acid gas upstream of the SRU. The change in air demand requirement is then calculated, with main and trim air adjustments implemented automatically by the feed forward control scheme designed by Worley Comprimo.
In SRUs, tail gas/air demand analyzers provide accurate concentration analysis of sulfur compounds, providing important insight into sulfur recovery efficiency and a means of feed-back adjustments of the trim levels of air or oxygen at the thermal reactor. Plant engineers have been investigating ‘feed-forward’ analysis, which is the addition of H2S, CO2, NH3, H2O and THC measurements of the acid gas feed to the SRU, to further optimize efficiency, reduce downtime and comply with emissions regulations. This feed-forward analysis combined with advanced burner control technology enables the reduction in reaction time to changes in feedstocks that may cause SRU plant upsets or an unwanted increase in emissions.
Benefits of the 2ACT Solution include maintaining an optimal H2S to SO2 ratio at the outlet of the Claus Plant to maximize recovery efficiency, mitigating damage to Tail Gas Treatment Unit (TGTU) components, lowering SO2 emissions and carbon footprint with improved uptime and plant throughput.
Mike Hevey, Division Vice President and Global Business Manager at AMETEK said, “While we have the measurement device and experience, it was important to work with a leading partner to provide a completely automated solution for plant operators. Worley Comprimo covers all aspects of the sulfur value chain, making them the ideal fit, enabling our two companies to deliver this solution that ultimately reduces downtime, costs and emissions”.
Frank Scheel, Senior Vice President at Worley Comprimo said, “combining the right analyser with the smart designed feed forward control provides our joined customers with a valuable tool to operate their Sulphur plant and control their emissions accurately”.
“The 2ACT Solution, developed by industry-leading experts, provides SRU stakeholders with the critical measurements and air control system design, to finally close the loop on feed-forward enabled, advanced burner controls.”
For more information about this partnership and the resulting complete automated solution in SRU air control, go to: go.ametekpi.com/2ACTSolution
About AMETEK Process Instruments
AMETEK Process Instruments is a leading provider of process gas analyzers used worldwide by markets ranging from oil, gas, and power to pharmaceutical and semiconductor chip manufacturing.
AMETEK Process Instruments is a business unit of AMETEK, Inc., a leading global provider of industrial technology solutions serving a diverse set of attractive niche markets with annual sales of approximately $7.0 billion.
About Worley Comprimo
Worley Comprimo is a global provider of gas treating and sulfur recovery technology focused on reducing emissions, increasing site reliability and improving plant economics. For over 60 years, our technology has been at the forefront of sulfur recovery, featuring in more than 1,200 sulfur recovery units worldwide.