10 Supporting Processes

8/13/2019 10 Supporting Processes

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SupportingProcessesChapter13


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SupportingProcesses

Processes

Hydrogenproduction&purification

Gasprocessingunits

Sourwatermanagement

Acidgastreating

Sulfurrecovery&tailgastreating

Liquidsweetening

Watertreatment

Utilities

Steamandcondensate

Coolingwater

Fuelgas

Flaresystems

Instrumentair

Powergeneration

Fireprotection

Offsites

Tankfarm

Truckandrailloading

Chemicalstorage

Shopsandwarehouses

Powerdistribution

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SupportingProcesses

Processes


Gasprocessingunits

Sourwatermanagement

Acidgastreating


Liquidsweetening

Watertreatment

Utilities

Steamandcondensate

Coolingwater

Fuelgas

Flaresystems

Instrumentair

Powergeneration

Fireprotection

Offsites

Tankfarm

Truckandrailloading

Chemicalstorage

Shopsandwarehouses

Powerdistribution

3


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SourcesofHydrogeninaRefinery

Byproductfromotherprocesses

CatalyticReformer

Mostimportantsourceofhydrogenfortherefiner

Continuously

regenerated

reformer:

90

vol%

Semicontinuouslyregeneratedreformer:80vol%

FCCUOffgas

5vol%hydrogenwithmethane,ethane&propane

Severalrecoverymethods(canbecombined)

Cryogenic

Pressureswingadsorption(PSA)

Membraneseparation

Manufactured

SteamMethaneReforming(SMR)

Mostcommonmethodofmanufacturinghydrogen

90 95vol%typicalpurity

Gasification/PartialOxidation

Producesynthesisgas(syngas)

Hydrogenrecovery

Pressureswingadsorption(PSA)

Membraneseparation

Moreexpensivethansteamreformingbut

canuselowqualitybyproductstreams

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HydrogenManufacturing

SteamMethaneReforming(SMR)

CH4+

H2O

CO

+

3

H2

Highlyendothermic

PartialOxidation(POx)

2

CH4+

O22

CO

+

4

H2

Highlyexothermic

Autothermal Reforming

CombinesSMR&POx toachieveanenergyneutralprocess

Oftenusesoxygenratherthanair

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SMRBasicProcessDescription

Reforming. Endothermiccatalyticreactionat1400 1500F.

CH4+H2O CO+3H2

Shiftconversion. Exothermicfixedbedcatalyticreactionpossiblyintwosteps(650 700F&450F).

CO+H2O CO2+H2

UsuallyonlyHTSRifPSA/membraneforH2purification.

6

GasPurification. AbsorbCO2(amine)orseparateintopureH2stream(PSAormembrane).

Methanation. ConvertresidualCO&CO2backtomethane.Exothermicfixedbedcatalyticreactions

at700 800F.NotusedifPSA/membraneforH2purification.

CO+3H2 CH4+H2O

CO2+4H2 CH4+2H2O


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SMRAlternateDesigns

Traditionalwith2stagesshiftreactors 95%to98%purity

NewerdesignswithPSA(Pressure

Swing

Adsorption)

lower

capital

costs,lowerconversion,butvery

highpurity(99%+)

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ReformerFurnaceDesign

8

HydrogenProductionbySteamReforming

RayElshout,ChemicalEngineering,May2010


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AlternateHydrogenPurificationProcesses

Feedgasexperiencespressuredropacrosscontactingcolumn

CO2releasednearatmosphericpressure

Contaminantsadsorbed;releasedatnearatmosphericpressure

HighconcentrationH2productexperiencespressuredropacrossbedofadsorbentbeads

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ProcessConsiderations

Kaes [2000] Molburg & Doctor [2003] Nexant Report [2006] Other

Model as conversion reactor Model as equilibrium reactor.

Sulfur compounds converted to H2S &

adsorbed in ZnO bed.

Small temperature increase 500 - 800F depending on technology.

700F most typical.

Typically up to 725 psi (50 bar)

Reformer 1450 - 1650F exit 1500F 20 - 30 atm (295 - 440 psia)

Equilibirium Gibbs reactor with 20F

approach (for design).

Model as equilibrium reactor. 850-1000F (455-540C) inlet

1470-1615F (800-880C) outlet

650 - 700F entrance for HTS + LTS 660F entrance 940F (504C) inlet500 - 535F entrance when no LTS

Equilibirium Gibbs reactor Fixed 90% CO conversion

All components inert except CO, H2O,

CO2, & H2.

400 - 450F entrance 400F entrance

Equilibirium Gibbs reactor 480-525F (249-274C) outlet

All components inert except CO, H2O,

CO2, & H2.

Fixed 90% CO conversion

Methanation 500 - 550F entrance

Equilibirium Gibbs reactor

All components inert except CH4, CO,

H2O, CO2, & H2.Amine Purification Model as component splitter Model as component splitter MDEA circulation, duty, & work estimates

from GPSA Data Book

Treated gas 10 - 15F increase, 5 - 10

psi decrease, water saturated

Treated gas 100F & 230 psi (16 bar)

exit

Rejected CO2 atmospheric pressure &

water saturated

95% CO2 recovery

PSA Model as component splitter Model as component splitter

100F entrance 90% H2 recovered 75 - 85% recovery for "reasonable"

capital costs (higher requires more beds)

H2 puri ty as high as 99.999% H2 contains 0.001% product stream as

contaminant

200 - 400 psig feed pressure for refinery

applications4:1 minimum feed:purge gas ratio. Purge

gas typically 2 - 5 psig.

Desulfurization

Reactors

High TemperatureShift Reactor

Low Temperature

Shift Reactor

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IntegratedProcess

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SMRInstalledCost

Includes

Feedgasdesulfurization

Reformer,shiftconverter,methanator,

wasteheatboiler,MEAunit

H2deliverytobatterylimits@250psig&

100F

Initialcatalystcharge

Excludes

BFWtreating

Coolingwater

DehydrationofH2product

Powersupply

13

PetroleumRefiningTechnology&Economics,5th ed.Gary,Handwerk,&Kaiser

CRCPress,2007


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SupportingProcesses

Processes


Gasprocessingunits

Sourwatermanagement

Acidgastreating


Liquidsweetening

Watertreatment

Utilities

Steamandcondensate

Coolingwater

Fuelgas

Flaresystems

Instrumentair

Powergeneration

Fireprotection

Offsites

Tankfarm

Truckandrailloading

Chemicalstorage

Shopsandwarehouses

Powerdistribution

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GasProcessingUnits

Twoprimaryfunctions

RecoverC3+componentsfromthevariousgasstreams

Crudedistillation,cokers,FCCU,reformers,hydrocrackers,

Producelowsulfur,drygasforuseasfuelorhydrogenfeedstock

Primarilymethane&ethane

Leanoilabsorptionwithtreatingtoremoveacidgases

Deethanizerusesnaphtharangeabsorbingoil

Spongeoilin2nd absorber

Relativelynonvolatile,ofkerosene/dieselboilingpointrange

Sidecutfromcokerorcatcrackerfractionator

Richspongeoilsentbacktocolumnwherespongeoil

originates

OftentherearetwoGPUs thesecondisdedicatedtostreamscontainingolefins

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GasProcessingUnits

16

Petroleum Refining Technology & Economics 5th Ed.by James Gary, Glenn Handwerk, & Mark Kaiser, CRC Press, 2007


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GasPlantWithFCCFractionator

17

Primary

Absorber

SecondaryAbsorber

Fuel Gas

Stripper

Separator

Wash H2O

Gasoline

C3'S C4'S

Rich Sponge Oil

Rich Oil Recycle

LCO

SlurryRx

Effluent

Main

Fractionator

HCO Return

Stabilizer

(Debutanizer)

Steam

Lean Sponge Oil

C3/C4

Splitter

Wash H2O

High Pressure

HCO Draw

Stripper Overhead Recycle

GeraldKaes

SimulationOfPetroleumRefineryProcessesUsingCommercialSoftwareCoursenotes,2006


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SupportingProcesses

Processes


Gasprocessingunits

Sourwatermanagement

Acidgastreating


Liquidsweetening

Watertreatment

Utilities

Steamandcondensate

Coolingwater

Fuelgas

Flaresystems

Instrumentair

Powergeneration

Fireprotection

Offsites

Tankfarm

Truckandrailloading

Chemicalstorage

Shopsandwarehouses

Powerdistribution

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SourWaterManagement

SourwatercontainsH2S,NH3,andphenols mustbetreatedbeforedisposal

SourcesofSourWater:

Crudeunitoverhead

Hydrotreaters

CokerandFCC

GasPlants

Sour

water

production

can

be

managed

by

cascading

water

from

less

sour

sources(e.g.NaphthaHDS)tomoresoursources(e.g.Coker)

SourwateristreatedintheSourWaterStripper

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SourWaterStripper

Strippedwatermaybereusedintherefinery

RemovedH2SandNH3aresenttheSulfurRecoveryUnit

Oneproprietaryprocess ChevronsWWT willrecoverasaleableammoniaproduct

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SourWaterStripper

22

Sour Water

Stripper

Stripped Water

Cooler

Condenser

Reflux

Drum

Steam

Stripper Reboiler

Recovered Oil

Feed Pumps

Stripped Water

Pumps

Reflux PumpsFeed/Bottoms

ExchangerFeed Surge

Drum

Sour Water

from Refinery

Stripped Water

SWS Acid Gas to SRU


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ChevronWWT Process

23

CourtesyofChevron


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SupportingProcesses

Processes


Gasprocessingunits

Sourwatermanagement

Acidgastreating


Liquidsweetening

Watertreatment

Utilities

Steamandcondensate

Coolingwater

Fuelgas

Flaresystems

Instrumentair

Powergeneration

Fireprotection

Offsites

Tankfarm

Truckandrailloading

Chemicalstorage

Shopsandwarehouses

Powerdistribution

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AcidGas(H2SandCO2)Removal

Chemicalsolventprocesses

Aminesweetening(MEA,DEA,MDEA,DGA)

Hotpotassiumcarbonate

Physicalsolventprocesses

Selexol

Poly(EthyleneGlycol)DimethylEther

Rectisol

Methanol

Propylenecarbonate

Hybrid

Sulfinol

Sulfolane+amine

UCARSOL

Dryabsorbents

Molecularsieve

Activatedcharcoal

Ironsponge

ZincOxide

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AcidGasRemoval

Inarefinery,themostcommonsolventsareMDEA,DEAandMEA

Eachprocessunit(e.g.Hydrotreater,FCC,Coker,etc.)willhaveoneormoreamineabsorbers

Richamineisprocessedinaregeneratorcommontoallprocessunits.(However,largerrefineriesmayhaveseveraldifferentsystems,eachwithitsown

regenerator.)

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AmineChemistry

GasTreatingAminesare:

WeakLewisBases

H+ fromweakacidsreactwiththeelectronsonN:

ABCsubstituentsinfluence:

HowfastacidsreactwithN:

Temperaturebulgeinabsorber

Energyrequiredinregenerator

ChemicalStability

Unwantedreactions

27

AMINE

N

A

B

C

Primary amineA = CH2CH2OHB = HC = H

Secondary amineA = CH2CH2OHB = CH

2

CH2

OHC = H

Tertiary amineA = CH2CH2OHB = CH2CH2OHC = CH3

DowOil&Gas GasTreatingTechnologyPresentationtoURSWashingtonDivision,August2009

RichAckman [email protected]


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AmineChemistryReview

BothH2S&CO2areweakacidswhendissolvedinwater

H2S+H2O H3O+ +HS

CO2+H2O H3O+ +CO2OH

Reactionswithprimary&secondaryamines

R2NH+H2S R2NHH+ +HS

2

R2NH

+

CO2 R2NHH+

+

R2NHCO2

Reactionswithtertiaryamines

R3N+H2S R3NH+ +HS

R3N+CO2+H2O R3NH+ +CO2OH

28

Tertiary amine CO2

hydrolysis slowvs. other reaction


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AmineChemistryReview

OtherReactionstoConsider

H2SandIron(ironsulfide)

CO2andIron(ironcarbonates)

AmineCarbamatesandAmines(HEED,HEEUTHEED,diamines,etc.)

Organicacids&Amine(HeatStableAmineSalts)

Oxygen&Amine(DEA,Bicine,Acetates,glycolates)

OtherSpecies

Mercaptans(RSH)areweakacids

H2Sisstrongerandwilldisplacethemercaptan

COS

NormalmechanismishydrolysistoH2S&CO2

CS2

Physicalabsorption

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GasTreatingAmines

GenericAmines

MEA(monoethanolamine)

15 18%wt.(5 6.1%mol)

DEA(diethanolamine)

25 30%wt.(5.4 6.8%mol)

DIPA(diisopropanolamine)

30% 50%wt.(5.5 11.9%mol)

MDEA(methyldiethanolamine)

35% 50%wt.(7.5 13.1%mol)

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DowUCARSOLHybridSolvents

HighSelectivity PreferentiallyAbsorbsH2Svs.CO2 UCARSOLHS115,HS101,HS102,HS103,HS104,HS104B

HighCapacity H2SRemovalWithTotalCO2Removal

UCARSOL

CR

402 ControlledCO2Removal&LowEnergyRequirements

UCARSOLAP802,AP804,AP806

CryogenicCO2Specifications(Ammonia&Hydrogen)

UCARSOLAP810,AP814,NH605,NH608

HybridSolventsforCOS&MercaptanRemoval

UCARSOLLE701,LE702

HighCapacitySolventsforRefineryUse NoSlip;LowSolubilityinCrackedLPGService

UCARSOL LE713,LE714,LE777,LE801

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AmineSolventCapacity&Performance

AdvantagesofUCARSOLSolvents

Higherholdingcapacityvs.mostcompetitiveproducts

ControlledCO2slip

DonotremoveextraCO2anddilutesulfurplantfeed

MorecapacityinsolventforH2S

Usuallylessenergyconsumption

AccuratemodelingtoassessperformanceInitialdesignand

Initialdesignandserviceinexistingplants

Howhighcanasolventbeloaded

Flashing/hydraulicissues

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AmineSolventCapacityComparison

33

Wt% Mol%Load

Range

Relative

Capacity

MEA 18% 6.1% 0.35 1DGA 50% 14.6% 0.45 3.09

DEA 28% 6.3% 0.48 1.41

MDEA 50% 13.1% 0.49 3.02

CompSol 20 50% 10.4% 0.485 2.37

CR 402 50% 14.7% 0.49 3.38

AP 814 50% 13.9% 0.485 3.16




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TypicalAmineTreatingPlant

Typicalplantconfiguration

Broad

range

of

treating

applications Lowtointermediatespecifications

Selectivetreating,lowH2S

Lowinstalledcost

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AlternateAminePlantConfigurations

35

AbsorberwithIntercooler

Intercoolerincreasestherichloading/solventutility

Musthavestainlesssteelforreliability

Higherinstalledcostthantypicalplant


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36

FlashRegenerationPlant

Highpartialpressurespecification(CO2

>16psi)

Usuallylowerenergycost

Highcirculationrates

Needhighpartialpressureacidgasinfeedforeconomics


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37

Lean/SemiLeanwithRegeneratorSideDraw

Lower

reboiler

energy

than

typical

plant Lowercirculationratevs.flashregeneration

Lowertreatedgasacidgasspecvs.flashregen

Higherinstalledcost


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Lean/SemiLeanwithAssistedFlash

Lowestregenerationenergyconfiguration

Highcirculationrate

Lowtreatedgasspecification

Highestinstalledcost

Mostcomplextooperate

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AmineTowerParameters

TowerDesignConsiderations

GasComposition

Trays

SystemFactorBubbleArea

o MEA/DEA 0.75abs(0.85reg)

o MDEA&FormulatedSolvents 0.70abs(0.85reg)

SystemFactorDowncomer

o MEA/DEA 0.73abs(0.85reg)

o MDEA&FormulatedSolvents 0.70abs(0.85reg)

o Standard

Cross

Flow

vs.

High

Capacity CalmingSection,MDTrays

Packings

RandomPacking

o Capacityvs.efficiency,GPDCoverlay

Structured

Packing

39




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Absorberdesignconsiderations

Pinchpointslimit

Topoftowerleanpinch

Temperaturebulgemaximum

Bottomoftowerrichpinch

ConfidencelevelinVLE

Temperatureprofileindicator

40

AbsorberTemperature Profiles

Liquid Phase

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

80 100 120 140 160 180 200

Temperature [F]

Stage

C-1 Conservative

C-2 Controlled Efficient

C-3 Intercooler


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RegeneratorEnergyRequirement

StrippingRatio(molewater/molAG)

Strongfunctionofrichfeedtemp

Strongfunctionofrichloading

TowerTraffic(lbssteam/gallean)

Masstransferdriven,leanendpinch

UnitEnergy

Btu/lb.molacidgas

Functionofrichloadingandplantconfiguration

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AmineApproximateGuidelines

MEA DEA DGA

Acid gas pickup scf/gal @ 100F 3.1 - 4.3 6.7 - 7.5 4.7 - 7.3

Acid gas pickup mol/mol amine 0.33 - 0.40 0.20 - 0.80 0.25 - 0.38

Lean solution residual acid gas mol/mol amine 0.12 0.01 0.06

Solution concentration wt% 15 - 25 30 - 40 50 - 60

Reboiler duty BTU/gal lean solution 1,000 - 2,000 840 - 1,000 1,100 - 1,300

Steam heated reboiler tube bundle flux Btu/hr-ft 9,000 - 10,000 6,300 - 7,400 9,000 - 10,000

Direct fired reboiler tube bundle flux Btu/hr-ft 8,000 - 10,000 6,300 - 7,400 8,000 - 10,000

Reclaimer steam bundle or fire tube flux Btu/hr-ft 6 - 9 N/A 6 - 8

Reboiler temperature F 225 - 260 230 - 260 250 - 270

Heat of reaction Btu/lb H2S 610 720 674

Btu/lb CO2 660 945 850

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SimplifiedDesignCalculations

GPM

QyC

x

43

Estimateaminecirculationrate

C = 41 if MEA

45 ifDEA

32 ifDEA(highloading)

55.8 ifDGA

Q = Sourgastobeprocessed[MMscfd]

y = Acidgasconcentrationininletgas[mol%]

x = Amineconcentrationinliquidsolution[wt%]

UseonlyifcombinedH2S+CO2ingasbelow5mol%

Amineconcentrationlimitedto30wt%


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PhysicalSolvents Selexol

Characteristics

Poly(EthyleneGlycol)DimethylEther

CH3 O (CH2 CH2 O)n CH3 wherenisfrom3to10

Clearfluidthatlooksliketintedwater

Capabilities

H2Sselectiveornonselectiveremoval verylowspec. 4ppm

CO2selectiveornonselectiveremoval 2%to0.1%

Waterdewpointcontrol

Hydrocarbondewpointcontrol

Seerelativesolubilities;moreefficienttoremovehydrocarbonvs.refrigeration

Organic

sulfur

removal

mercaptans,

disulfides,

COS

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SelexolProcesses

Physicalsolventsfavorhighpressure&highpartialpressure

Configurations

H2S&organicsulfurremoval

Steamstrippingforregeneration

CO2removal

Flashregeneration

ChillerforlowCO2

Specialapplications

Siloxanesareremovedfromlandfillgas

Metalcarbonylareremovedfromgasifiergas

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SelexolProcess

46

http://www.uop.com/objects/97%20Selexol.pdf


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SupportingProcesses

Processes


Gasprocessingunits

Sour

water

management

Acidgastreating


Liquidsweetening

Water

treatment

Utilities

Steamandcondensate

Coolingwater

Fuel

gas

Flaresystems

Instrumentair

Powergeneration

Fire

protection

Offsites

Tankfarm

Truckandrailloading

Chemicalstorage

Shopsandwarehouses

Powerdistribution

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SulfurPrices

48

SpecialReport:Moreproductsulfurreductiononhorizon

Oil&GasJournal,Oct.12,2009


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SulfurRecovery

MosttypicallyamodifiedClausprocess

H2Srichstreamburnedwith1/3stoichiometric air. Hotgasesarethenpassedover

aluminacatalysttoproducefreesulfur

Combustion: H2S+1.5O

2H

2O+SO

2

ClausReaction: 2H2S+SO2 2H2O+3S

Sulfurformationreactionmildlyexothermic

Sulfurconversionreactorskeptabove400F(sulfurdewpoint)

TheClausreactionisreversible therefore,100%conversioncanneverbeachieved

Practically,Clausunitsarelimitedtoabout96%recovery

Tailgasunitsareusedtoprovideimprovedconversion

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ModifiedClausProcess

50

PetroleumRefiningTechnology&Economics 5th Ed.byJamesGary,GlennHandwerk,&MarkKaiser,CRCPress,2007


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VariationsoftheClausProcess

SinglezoneortwozoneReactionFurnace

Singlezonemostcommon

Twozoneusuallyprovidedtoprocessammonia

Numberofcatalyticstages

2stageand3stageunitsarecommon

Converterreheatmethod

IndirectheatingbyHPsteam(mostcommon)

Hotgasbypass(shownonthepreviousslide)

Directheatingbyinlineburnerfiringfuelgasoracidgas

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ClausTailGasTreating

Themostcommonprocessconsistsof:

Hydrogenation toconvertoxidizedsulfurspeciestoH2S

Quench toremoveandrecoverprocessheatandtoremovewater

AmineTreating toremoveH2SandrecycleittotheSRU TheSCOT processisoneexample

Othertailgastreatingprocesses: CBA (ColdBedAdsorption) Stretford

SuperClaus

Selectox

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TailGasHydrogenation&Quench

QUENCH

COLUMN

QUENCH WATER

PUMPS

PARTICULATE

FILTER

QUENCH WATER

COOLER

TRIM

COOLER

SOUR QUENCH

WATER

SOUR GAS TO

TGU ABSORBER

WASTE HEAT

EXCHANGER

LPSTEAM

BLOWDOWN BFW

HYDROGENATIONREACTOR

RECYCLE

BLOWER

K.O. DRUMINLINE HEATER

RECYCLE

BLOWER

(OPTIONAL)

FUEL GAS

TEMPERING

STEAM

COMBUSTION

AIR

REDUCING

HYDROGEN

CLAUSTAIL GAS

56


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TailGasAmineTreating

57


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SupportingProcesses

Processes


Gasprocessingunits

Sour

water

management Acidgastreating


Liquidsweetening

Water

treatment

Utilities

Steamandcondensate

Coolingwater

Fuel

gas Flaresystems

Instrumentair

Powergeneration

Fire

protection

Offsites

Tankfarm

Truckandrailloading

Chemical

storage

Shopsandwarehouses

Powerdistribution

59

Li id S i


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LiquidSweetening

Conversionofsulfurbearingmercaptans todisulfides

Cheaperthandirecthydroprocessing

UOPsMerox processisverycommon

Catalyticoxidationprocess.Carriedoutinanalkalineenvironmentwithaqueous

solutionofNaOH (strongbase)orNH3(weakbase).

Reactions(usingNaOH)

Extraction: 4RSH+4NaOH 4NaSR+4H2O

Regeneration: 4NaSR+O2+2H2O 2RSSR+4NaOH

Overall: 4RSH+O2 2RSSR+2H2O

Cancontroltolessthan10ppmw mercaptanlevel

60

M li d t LPG (N OH t l t)


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Merox appliedtoLPG(NaOH catalyst)

61

http://www.uop.com/uopmeroxgastreatingflowscheme/

M li d t k ( lid t l t & NH )


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Merox appliedtokerosene(solidcatalyst&NH3)

62

http://www.uop.com/uopkerojetfuelsweeteningprocess/

Supporting Processes


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SupportingProcesses

Processes


Gasprocessingunits

Sour

water

management Acidgastreating


Liquidsweetening

Water

treatment

Utilities

Steamandcondensate

Coolingwater

Fuel

gas Flaresystems

Instrumentair

Powergeneration

Fire

protection

Offsites

Tankfarm

Truckandrailloading

Chemical

storage

Shopsandwarehouses

Powerdistribution

63

Waste Water Treatment


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WasteWaterTreatment

Potentialsourcesofwastewater

Surfacerunoff

Leaks,opendrains,spills,rain

Crude&productstoragetankwaterdrains

Desalterwater

Waterdrainsfromatmosphericstillrefluxdrums

Waterdrainsfrombarometricsumpsoraccumulatorsonvacuumtowerejectors

Waterfromhydraulicdecokingofcokedrums

Condensedsteamformcokedrumpurgingoperations

Product fractionatorrefluxdrumsoncatcrackers,hydrotreaters,alkylationunits,lightends

recovery,

Coolingtower&boilerwaterblowdown

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WasteWaterTreatment

Water

accidentally

contaminated

byoil

Oilfreewater

Waterexpected

tobe

contaminated

byoil

Sewage

Processunits

Ballastwater

Sourwater

stripper

Gravityoil

separator

Gravityoil

separator

Homogenization

tank

Biotreatment

Aerationbasin

Holdingbasin

Bufferbasin

Processareas

Gravityoil

separator

Receivingtanks

Intermittent

Oiltrap Communitors

Drainage

ContinuousContinuous

exutilityplant

Flocculation

flotationunit

Metering/samplepoint

Dischargeof

treatedeffluent

tomarineoutfall

65

Source:http://www.nzic.org.nz/ChemProcesses/energy/7A.pdf



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WasteWaterTreatment

OilcontaminatedwaterskimmedinAPIseparators

Largeconcretesumps

Skimmedoilpumpedtosloptanks&reprocessed

Somewaterusedindesalters. Balancefurtherpurified

Flotationtanks

Mixtureferrichydroxide&aluminumhydroxideaddedtocauseimpuritiestocoagulate

Frothfurtherthickened&sludgeincinerated

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WasteWaterTreatment

Digestiontanks

WaterfromFlotationTanksoxygenatedunderpressure

Maybemixedwithsanitarysewage

Controlled

amount

of

bacteria

consumes

remaining

oil

or

phenolics

Bacteriacontinuouslyremoved&incinerated

Finalpolishinginsandfilters

Reusedinrefinery

Furtheroxidized&discharged

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WasteWaterTreatment

Oilfreewaterhassimplerprocessing

Fromcoolingtowerorboilerblowdown

Highsolidscontent

Neutralized

Variousoptions

Evaporatedinsolarponds

Injectedintodisposalwells

Furtheroxidized&mixedwithotherwater&discharged

Acidsludges&sourwater

Acidsludgemustbeneutralized

Acidgasesstrippedfromsourwater

SenttoAPIseparators

68

Supporting Processes


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SupportingProcesses

Processes


Gasprocessingunits

Sourwatermanagement

Acidgastreating


Liquidsweetening

Water

treatment

Utilities

Steamandcondensate

Coolingwater

Fuelgas

Flaresystems

Instrumentair

Powergeneration

Fire

protectionOffsites

Tankfarm

Truckandrailloading

Chemical

storage Shopsandwarehouses

Powerdistribution

69

Steam Boiler


66/84

SteamBoiler

70

http://www.spiraxsarco.com/resources/steamengineeringtutorials/theboilerhouse/shellboilers.asp

SteamBoilerwithSuperheater


67/84

p

71

http://www.spiraxsarco.com/resources/steamengineeringtutorials/theboilerhouse/miscellaneousboilertypeseconomisersandsuperheaters.asp

Burner


68/84

72

gas

Air

Air

oil


69/84

SteamGeneration CombustionAirPreheat


70/84

74

SteamGeneration CombustionAirPreheat


71/84

75

SteamBoiler BoilerFeedwaterPreheat


72/84

76

http://www.spiraxsarco.com/resources/steamengineeringtutorials/theboilerhouse/miscellaneousboilertypeseconomisersandsuperheaters.asp

NOx ReductioninFlueGas


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RefineriesandPetrochemicalUnits:

SignificantNOxReduction previousregulatoryrequirements

NOxproducedwhencombustingin:

Processfiredheaters

Utilityboilers

FluidCatCrackingUnit(FCCU) regenerators

NOxReduction:

Burnerreplacement

LowNOx

UltralowNOxburners

Fluegas

SelectiveCatalyticReduction(SCR)

SelectiveNonCatalyticReduction(SNCR)

FCCUFlueGasScrubberSystems(i.e.BelcoLoTOx,etc.)

77

NOx UltraLowNOx Burner


74/84

78

NOxSCR


75/84

Steam

Soot Blower

To Stack

From Furnace

Ammonia

Compressed Air

Ductwork

CatalystBed

79

NOxReduction


76/84

Appliestocombustionsources

Firedheaters

Boilers

FCCU

regenerator

flue

gas

NOxreductionsubstantiallyreducesCO2(e)

OnetonofN2Oisequivalentto310tonsofCO2

Muchreductionhasalreadybeenimplemented

80

SuperheatedSteam


77/84

Advantages

Nowaterdropletsinturbines

Lowererosionoftheturbineblades

Lowerfriction

Higherpipelinevelocities(upto100m/s)

Smallerdistributionpipelines

Nocondensationinpipework steamtrappingonlyduringstartup

Disadvantages heattransfermedium

Inaccuratesizing&difficultcontrolofheattransferequipment

Superheatedsteamheattransfercoefficientssmall,variable,&difficulttoquantifyaccurately

Condensingsteammuchhigherheattransfercoefficients&thesteamtemperatureisconstant

o Accuratesizing

o Bettercontrolofequipment.

o Smallerequipment

Saturatedsteamleadstosmaller&cheaperheatexchangers

Someprocesseslessefficientusingsuperheatedsteam

Highertemperaturesmaymeanthathigherrated&moreexpensiveequipment

Highertemperaturesmaydamagesensitiveequipment

81

http://www.spiraxsarco.com/resources/steamengineeringtutorials/desuperheating/basicdesuperheatingtheory.asp

SteamDesuperheating


78/84

Superheatedsteamrestoredtoitssaturatedstate

DirectContact

Superheatedsteamdirectlymixedwithcoolingmedium

Usuallysamefluidasthevaporbutintheliquidstate

Coolingwater

Steamcondensate

82

WaterBathTypeDesuperheater


79/84

Advantages

Simple

Steamproducedatsaturation

temperature

Turndownonlylimitedbythecontrols

Disadvantages

Bulky

Notpracticalforhightemperatures

Applications

Widevariationsinflowrate

Noresidualsuperheatcanbetolerated

83

SinglePointRadialInjectionSpray


80/84

Advantages:

Simpleinoperation

Costeffective

Minimumsteampressuredrop

Disadvantages:

Lowturndownratio(~3:1max)onbothsteam&coolingwaterflow

Desuperheatedsteamtemperaturecanonlybereducedto10Cabovesaturationtemperature

Longerabsorptionlengththanthesteamatomisingtype

Pronetoerosiondamage

Overcomebyuseofathermalsleeve

Limitedpipesizes

Applications:

Constantsteamload

Constantsteamtemperature

Constantcoolanttemperature

84

AxialInjectionSpray


81/84

Advantages:

Simpleinoperation

Nomovingparts

Costeffectiveacrossrangeofsizes

Minimalsteampressuredrop

Disadvantages:

Lowturndownratio(~3:1max)onbothsteam&coolingwaterflow

Desuperheatedsteamtemperaturecanonlybereducedto10Cabovesaturationtemperature

Longer

absorption

length

than

the

steam

atomisingtype,butlessthantheradialtypedesuperheaters

Pronetoerosiondamage overcomebyuseofathermalsleeve

Applications:

Constantsteamload



85

MultipleNozzleAxialInjection Advantages:


82/84

Advantages:

8:1to12:1turndownratios

Absorptionlengthlessthansinglenozzledevices

Betterdispersionofwaterdroplets

Minimalsteampressuredrop

Disadvantages: Temperatureonlyreducedto8Cabove

saturationtemperature

Longerabsorptionlengththanthesteamatomisingtype

Pronetocauseerosiondamage

Thermal

sleeve

used Notsuitableforsmallpipesizes

Requireshighpressurecoolingwater

Canbeexpensive

Applications:

Highturndownratiorequired

Constantsteamload



86

FixedArea

VariableArea

VenturiType


83/84

Advantages

5:1steamturndownratio&over20:1coolingwaterturndownratio

Simpleoperatingprinciple

Nomovingparts

Accurate

control

within

3

C

of

saturation

temperature

Suitableforsteadyorvariablesteamconditions

Reducedwearindownstreampipework

coolingwateremergesasamist

Disadvantages Pressuredrop

Generallysmall&acceptable

Absorptionlengthislongerthansteamatomisingtype

Minimumcoolingwaterflowrequired

Applications Mostgeneralplantapplications

87

SupportingProcesses


84/84

Processes


Gasprocessingunits

Sourwatermanagement

Acidgastreating


Liquidsweetening

Watertreatment

Utilities

Steamandcondensate

Coolingwater

Fuelgas

Flaresystems

Instrumentair

Powergeneration

Fireprotection

Offsites

Tankfarm

Truckandrailloading

Chemicalstorage

Shopsandwarehouses

Powerdistribution

88

Documents

10 Supporting Processes