KHABAROVSK REFINERY HYDROPROCESSING PROJECT

PROCESS DESCRIPTION

APRIL 29th – MAY 3rd 2013, MADRID, SPAIN

TRAINING COURSE

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TRAINING COURSE

TO HIGHLIGHT THE MAIN PROCESS FEATURES,STARTING FROM THE BASIC KNOWLEDGE OF THE THEORY

BLOCK DIAGRAM OF SRU/TGTBLOCK DIAGRAM OF SRU/TGT

INTRODUCTION

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MAIN SECTIONS

CLAUS SECTION

To remove H2S and sulphur compounds from acid gas producing elemental sulphur

TGT SECTION

The tail gas is reduced so that all sulphur compounds and residual SO2 are converted to H2S

DEGASSING SECTION

To remove H2S and polysulphides (H2Sx) from the produced liquid sulphur

AMINE SECTION To regenerate the rich amine containing H2S and CO2 and recycle the acid gas to the Claus Section

PLANT SECTIONS:PLANT SECTIONS:

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MAIN SECTIONS

To remove H2S and NH3 from sour water streams and recycle the SWS Acid Gas to the Claus Section

AMINE REGENERATIONSECTION

To regenerate the rich amine containing H2S and CO2 and recycle the Amine Acid Gas to the Claus Section

PLANT SECTIONS:PLANT SECTIONS:

SOUR WATER STRIPPINGSECTION

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PURPOSE• To remove hydrogen sulphide and sulphur compounds

from acid gas, producing elemental sulphur.

• As a second effect, NH3 content of the SWS stream will be highly reduced in the Claus Thermal Reactor.

 

CATALYTIC STAGE

THERMAL STAGE

CLAUS SECTION

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PROCESS STREAMS

The process streams involved in the Claus Section are:

 FEEDS

- Amine Acid Gas;

- Sour Water Stripper Acid Gas;

- Amine Acid Gas Recycle from TGT Regenerator

 

PRODUCTS

- Tail Gas to TGT Section

- Liquid Sulphur to degassing/storage

CLAUS SECTION - Process Streams

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CLAUS SECTION - PROCESS FLOW DIAGRAM

K.O. Drum installed to prevent any liquid drop going to the burner.

Amine Acid Gas Scrubber has the purpose to remove the NH3 in the AAG.

AAG recycled from Regenerat. section is mixed with AAG coming from AAG header

Combustion Air is supplied by Blower.

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SWSAG and part of the AAG are mixed prior to enter in the Claus Burner.

Thermal Reactor, WHB:residence time, gas cooling and heat recovered.

Any sulphur condensed in the Thermal Reactor Waste Heat Boiler is drained to Sulphur Pit via dedicated hydraulic seals.

CLAUS SECTION - PROCESS FLOW DIAGRAM

COMB. AIR

AMINE AG

SWS AG

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THERMAL STAGE

The minimum requirements for the Thermal Reactor in case of treatment of feedstock which contains impurities are:

Installation of a well proven high intensity burner

Appropriate residence time in the Thermal Reactor

Adequate temperature in the Thermal Reactor

COMPLETE DESTRUCTION OF ALL IMPURITIES

The Thermal Reactor has been designed with double zones configuration to achieve

The concentration of H2S and the presence of impurities in the feedstock to Claus Unit play an important role for the selection of the more appropriate plant configuration

CLAUS THERMAL REACTOR : Main Equipment

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The produced Svap is condensed in each Sulphur Condenser and drained via hydraulic seals.

CATALYTIC STAGE

2 Claus Reactors, filled with alumina catalyst to complete the Claus reaction between H2S and SO2

The first reactor has been designed also for the use of titania catalyst (to promote Hydrolisis of COS, CS2).

Claus Heaters:Hot gas by-pass for the first

Claus Converter;Electrical Heater for the

second Claus Converter.

Steam side:1st, 2nd and 3rd Condensers operating P = 4.5 kg/cm2 g

Condensation and removal of sulphur, before the inlet to first and second catalytic stage, enables further conversion of sulphur in each catalytic reactor.

CLAUS SECTION - PROCESS FLOW DIAGRAM

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SULPHUR DEGASSING SECTION

PURPOSE

• To remove H2S and H2Sx from the liquid sulphur produced.

The removal is achieved by means of direct contact with air

(Stripping Air from Combustion Air Blower) in a internal Degassing Column filled with catalyst.

PROCESS

STREAMS

The process streams involved in the Sulphur Degassing are:  FEEDS

- Undegassed Liquid Sulphur with H2S content about of 300ppm wt.- Stripping Air 

PRODUCTS

- Degassed Liquid Sulphur with H2S content less than 10ppm wt.- Sweep Air to Thermal Incinerator

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Air (hot) is fed from Combustion Air Blower through steam jacketed pipe.

SULPHUR DEGASSING – PROCESS FLOW DIAGRAM

Sulphur Pit is equipped with Undegassed Sulphur Section and Degassed Sulphur Storage Section.

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Sulphur Pit temperatureThe temperature inside the sulphur pit must be 135÷145 °C in order to control the viscosity of the liquid sulphur, which has to be easily pumped/ transferred (steam coils are provided).

Sweeping the sulphur pitIn order to ventilate the vapour space above the sulphur level - and thus maintaining the H2S concentration below the lower explosion limits – Steam Ejector is provided. The resulting Sweep Air is sent directly to the Incinerator.

SULPHUR DEGASSING – PROCESS FLOW DIAGRAM

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PURPOSE

To reduce all sulphur compounds contained in the tail gas from Claus Section into H2S, over a catalytic reactor.

After the reduction stage, there is the cooling stage, where the gas is cooled in the gas/gas heat exchanger and the water content is reduced by condensation.

Finally, the H2S contained in the quench tower outlet gas is absorbed along the TGT Absorber and recycled to the Claus Unit.

R.A.R. Technology (REDUCING, ABSORPTION, RECYCLE)The goal of the process is the reduction/hydrolysis into H2S of sulphur

compounds (SO2, Sx, COS, CS2) and the selective absorption of H2S with the amine solution.

The H2S released during the regeneration of the amine solution is recycled to Claus Unit.

TAIL GAS TREATMENT SECTION

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PROCESS STREAMS

The process streams involved in the TGT Section are : 

FEEDS

- Tail Gas from Claus Unit- Lean Amine (MDEA 50%wt.) from Amine Regenerator  

PRODUCTS

- Tail Gas to Thermal Incinerator- Rich amine (MDEA 50%wt.) to Amine Regenerator

TAIL GAS TREATMENT SECTION – Process Streams

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Hydrogenation Reactorfilled with special catalyst, capable to convert all sulphur compounds in the Claus tail gas to H2S, under slight H2 excess.

For turndown capacities, the Recycle Gas Blower is used to maintain in recirculation to ensure the min. flow of gas for the Hydr. Reactor and the TGT Absorber (also at start-up/SD).

TGT Heater is designed to heat the tail gas coming fromboth Claus trains and preheatedin the gas/gas exchanger.

Hydrogenation Reactor• Inlet/Outlet temperature =

280 °C/310 °C at SOR

TAIL GAS TREATMENT SECTION– PROCESS FLOW DIAGRAM

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Quench Tower• Gas from Quench Tower

temperature = 38 °C• H2 content @ Quench Tower

outlet = 3% vol.

The Quench circuit is completed by the Quench Water Cooler, by the Sour Water Filter, and by the draw-off line (excess of condensed water).

TAIL GAS TREATMENT SECTION– PROCESS FLOW DIAGRAM

TGT Absorber• MDEA solution = 50% wt. • Lean MDEA inlet temp. = 40°C• Tail Gas outlet temp. = 42°C

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PURPOSE

To regenerate the rich amine containing H2S and CO2 from TGT Absorber.

To recycle the acid gas back to the Claus.

PROCESS

STREAMS

The process streams involved in the Amine Regeneration Section are: FEEDS

- Rich Amine (MDEA) from TGT Absorber 

PRODUCTS

- Lean Amine (MDEA) to TGT Absorber- Acid Gas Recycled to Claus

AMINE REGENERATION SECTION

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AMINE REGENERATIONRich Amine to Regen. = 100 °C

Recycle Gas temperature = 50°C

Regenerator Reflux Drum pressure = 0.9 kg/cm2 g

AMINE ABSORPTIONLean Amine to TGT Absorber temperature = 40 °C

Lean Amine to filtration system about 50% of total amine flow

Amine type: MDEA

AMINE REGENERATION SECTION– PROCESS FLOW DIAGRAM

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AMINE REGENERATION SECTION– PROCESS FLOW DIAGRAM

AMINE FACILITESSteam Condensate make up is fed to Reflux Drum to maintain 50%wt.Amine Drain Drum is provided to collect amine drains and is equipped with Amine Drain Pump. Blanketing medium to protect amine from degradation.Amine Filters are designed to remove particles (mechanical filters) and to absorb entrained impurities (active carbon filter).

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PURPOSE

To perform the incineration (=oxidation at high temperature) of residual H2S and all sulphur compounds to SO2, in presence of excess air.

To discharge the flue gas to the atmosphere via a stack in safe conditions (dispersing the resulting product at altitude).

PROCESS STREAMS

The process streams, involved in the Thermal Incinerator, are the followings: FEEDS- Tail Gas from TGT Absorber- Sweep Air from Sulphur Pit

Thermal Incinerator is sized to accomplish the combustion of tail gas coming directly from Claus train, in the event of TGT section shutdown (TGT by-pass).

PRODUCTS Flue Gas from Stack

INCINERATOR SECTION

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Due to low heating value of tail gas, it is necessary to sustain the combustion using the fuel gas. The fuel gas flow to the burner is adjusted by temperature control in the thermal incinerator.

INCINERATOR SECTION– PROCESS FLOW DIAGRAM

Incinerator• Oper. temp.=

650°C

• Natural draught type

• Flue Gas O2 content = 2% vol. minimum on wet basis

• O2 analyzer at the Stack

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PROCESS STREAMS

The process streams involved in the ARU Section are: 

FEED - Rich Amine (DEA 25%wt.) from HCU 

PRODUCTS - Amine Acid Gas to Claus Trains - Lean Amine (DEA 25%wt.) to HCU

AMINE REGENERATION SECTION (ARU) – Process Streams

To regenerate the rich amine containing H2S from Hydrocracking Section (HCU).

To produce Amine Acid Gas that shall be treated in the Claus Trains.

PURPOSE

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AMINE REGENERATIONRich Amine to Regen. = 93 °C

Acid Gas temperature = 55°C

Regenerator Reflux Drum pressure = 0.9 kg/cm2 g

Lean Amine to HCU temperature = 55 °C

Lean Amine to filtration system = 15% of total amine flow

Amine type: DEA

ARU SECTION – PROCESS FLOW DIAGRAM

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ARU SECTION – PROCESS FLOW DIAGRAM

AMINE FACILITESDemi-water make up is fed to Regenerator Reflux Drum to maintain 25%wt.Rich Amine Flash Drum is provided to collect rich amine from HCU Section and is equipped with Rich Amine Pump and Slop Oil Pump. Amine Filters are designed to remove particles (mechanical filters) and to absorb entrained impurities (active carbon filter).Amine Sump Drum is provided to collect amine drains from HCU Section and is equipped with Amine Sump Pump. Blanketing medium to protect amine from degradation.

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PROCESS STREAMS

The process streams involved in the ARU Section are: FEED - Sour Water from SRU - Sour Water from TGT - Sour Water from HCU - Sour Water from DHT

PRODUCTS - Sour Water Stripper Acid Gas to Claus Trains - Stripped Water to HCU/DHT

SOUR WATER STRIPPING SECTION – Process Streams

To remove Hydrogen Sulphide and Ammonia from Sour Water Streams.

To produce Sour Water Stripper Acid Gas that shall be treated in the Claus Trains.

PURPOSE

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Sour Water StrippingSour Water to Stripper = 84 °C

SWS Acid Gas temperature = 85°C

Stripper pressure = 0.9 kg/cm2g

Stripped water to HCU/DHT temperature = 90°C

SWS SECTION– PROCESS FLOW DIAGRAM

SWS FACILITESSour Water Feed Surge Drum is provided to collect sour water streams and is equipped with Stripper Feed Pump and Slop Oil Pump. Sour Water Stripper is also equipped with pumping/pumparound cooling system

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