Western Research

!impartial technical support to every major

oil and gas company in the world !do not sell equipment or license technology !wide exposure to different technologies and

operating procedures

Improved Performance

Key elements

● process evaluation ● process modification ● process monitoring ● process knowledge

Process Evaluation

● data gathering − on-site review of operating data

● stream sampling − using proprietary techniques

● stream analysis − using proprietary techniques

● simulation − using in-house engineering software

● engineering review − operational changes − design changes

Amine (AGE/TGTU) - Case Study ● combined AGE/TGTU absorber ● 40% MDEA strength

Parameter Oct 16 Oct 17 Optimized

H2S in Absorber Outlet(ppm wet) 356 202 126

Emission Reduction (%) 39.4 62.0

Amine (AGE/TGTU) Case Study Results

On-Site ● Sulphur / Amine Experts analysed all gas streams ● recommendation to reduce lean loading from 0.006

to 0.003 mol/mol ● overnight optimisation was conducted and: H2S in the tail gas reduced from 356 to 202 ppm (wet) - a 40% reduction Off-Site Detailed Evaluation ● further optimisation of lean loading, amine strength

(50%), circulation & temperatures ● optimised operating conditions will result in: H2S 126 ppm (wet) in the tail gas - a 62% reduction

Superclaus® - Case Study ● conventional modified-Claus, two catalytic

reactors ● followed by Superclaus® stage ● one year in operation

Test No. Unit Superclaus Outlet Recovery %

Stack Recovery %

1 400 98.24 No sample

2 400 98.14 No Sample

23 400 98.58 98.46

24 400 98.56 98.51

Superclaus® - Case Study

● tuning of bed temperature and oxygen concentration

● relatively low recovery efficiency due to high CS2 in tail gas

Result: ● recovery increased from 98.20 to 98.55 ● 20% reduction in emissions

Superclaus® Catalyst Management ● catalyst ages over time, performance can be

managed by increasing the temperature

Table 4.2-3 - Train 3 Superclaus® Performance Summary Test 2 Test 8 2006 Reactor Temperature Inlet°C Maximum (°C)

215 235

200 220

193 220

Reactor Performance Activity 1 (%) Selectivity 2 (%) Yield 3 (%)

99.5 85 85

55 100 55

97.1 89.8 87.2

Temperature and O2 Control

Incinerator Case Study

As Found 900°C (1650°F) - 8% O2

Step 1 790°C (1455°F) - 7% O2

Step 2 650°C (1200°F) - 6% O2

No Plume!

Incinerator Optimization - Case Study

● tuning of temperature and oxygen concentration

● SO2 mass emission unchanged

Result: ● elimination of visible plume

Important consideration: ● ground level SO2 concentrations !!! ● requires detailed dispersion modelling

Process Modification

● short term process changes − immediate on-site operational changes to improve

performance ● operation recommendations

− detailed process and equipment evaluation − recommendations to improve performance − prioritized recommendations by most effective and least

capital ● process design evaluation

− equipment modifications to improve performance − equipment changes to increase performance − equipment debottlenecking

Sulphur Reliability - Case Studies ● refractory and waste heat boiler failures ● lethal incidents and major downtime

Loss of reaction furnace refractory

Sulphur Reliability - Case Study 1 Results

● root cause analysis, need to look at −original equipment −maintenance and repair procedure −operating history, control scheme and manual

Overheated refractory - loss of containment

Root cause: incorrect control scheme

Sulphur Reliability - Case Study 2 ●H2S attack on tubesheet

Reliability - Case Study Results

● tube leak resulted in loss of containment − outlet chamber flange leak due to acid attack

● root cause: poor repair procedure

Filtration - Case Study ● 40% MDEA system ● one absorber, one regenerator ● not able to increase throughput due to foaming ●H2S specification in treated gas not met ● fuel gas sent to flare

before after

Case Study Results

● Filtration Experts performed on-site evaluation and performance testing of inlet separation

● root cause of the problem was deficient system design and poor separation efficiency

● new inlet separator design and installation As a result: ● foaming stopped

− capacity increase to near design limit − savings: USD 5.3 million/year in gas/liquids alone − H2S specification in the treated gas met, resulting in

USD 150 000/day being processed and not going to flare

Process Monitoring

● regular plant performance testing − allows for benchmarking performance

● maintenance prioritization − determine need for amine or catalyst

replacement ● process trending

− determine catalyst performance ● efficiency and optimization monitor

− meet regulatory permit requirements

Incinerator Emission - Case Study ● new 400 ppmv CO emission limit ● current incinerators were not in compliance

Incinerator Emission - Case Study

● concluded that existing incinerators are capable of meeting 400 ppmv CO − requires an increase in temperature − tuning of oxygen concentration

Result: ● eliminated capital cost project and

significant down-time

Incinerator Emission - Case Study Down-side: ● increase in fuel gas increases operating cost

(+25%) ● upstream CO conversion investigated

− requires plot space and investment − significant reduction in fuel gas consumption (>50%)

Important consideration: ● ground level SO2 concentrations !!! ● requires detailed dispersion modelling

Process Knowledge

● education −engineer and operator training

● experience −ensure operator ownership

● thermodynamics − know the chemistry

● kinetics − know the process limitations

Process Knowledge - Case Study ● Sulphur Experts on site for training ● sooting from main burner Result: ● high pressure drop across the first reactor Training and support provided the comfort to: ● implement a sulphur wash ● restore unit capacity without down-time

Normalised Pressure Drop Example

Technical Service Program Key elements ● emergency priority assistance (hot-line) ● data review and trending ● set up a monitoring program with key performance

indicators ● conduct a full visual inspection of all SRU equipment

(during a turnaround) ● regular on-site meetings to discuss unit performance

and operation ● periodic on-site performance testing and optimization

(annually) ● in-house training