4_Bapiraju_CPCL

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PETROFED Work Shop on

Energy Management & Efficiency Improvement

inOil & Gas Sector

Oxy Enrich Process for Capacity

Enhancement of Claus Based

Sulfur Recovery Unit

NOVEMBER 13, 2009

NEW DELHI


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OxyEnrich Process uses oxygen enriched air foroxidation of H2S to elementary sulfur in sulfur

recovery unit and increases the plant capacity.

Process minimizes nitrogen content in combustion airand results reduction in process gas flow in downstream of reaction furnace .

Process increases reaction furnace temperature, whichdepends on oxygen concentration in air .

Process gives better conversion of H2S in reactionfurnace and marginally increases overall sulfurrecovery of the unit

OxyEnrich Process


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MAIN DRIVERS FOR OPTING SULFUR REVAMP IN CPCL

ADDITIONAL ACID GAS GENERATION OF ABOUT 16%

DUE TO NEW PROCESS UNITS BEING INSTALLED UNDERTHE EURO- IV PROJECT

AVAILABILITY OF VERY MARGINAL CAPACITY IN THE

EXISTING UNITS ABOUT 10%

REQUIRED CAPACITY LEVELS OBSERVED TO BE (ABOUT

30 TPD) NOT COST EFFECTIVE COMPARATIVELY , IF NEW

UNIT OPTION IS ADOPTED

SCOUTED FOR VIABLE OPTIONS FOR MARGINALAUGMENTATION

REQUIREMENT OF QUICK AND LOWER COST OPTIONS IN

HAND


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Slide 4 of 8

SALIENTFEATURES: Technology is First of its kind being implemented in Indian

Refineries.

Project jointly undertaken by CPCL & EIL (R&D).

Technology will be jointly licensed by CPCL & EIL. Demonstration Run being done by CPCL from 11/5/2009

No Major hardware modifications in the existing unit.

Capacity increase by 15% to 22%

(From 90 TPD to 104 / 110 TPD of Sulphur in each Train) Oxygen content in Air Enriched from 19.6 to 28 vol%

Low cost option for enhancing SRU capacity.

Cost towards demonstration run is about Rs.2 Cr.

DEMONSTRATION RUN OF OXYGEN ENRICHMENT IN

SULFUR RECOVERY UNIT OF CPCL


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Greater processingcapacity of sulfur

recovery unit

No majormodification for 25%

-30% capacityenhancement

Processing lowquality feed

without problem

Lowbackpressure

ensures troublefree operation

Less sulfur mistlead to better

operation

Low capital cost forgrass root sulfur

units due to smallerequipment sizes

Stable flame inmain burner

even at lean acidgas processing

Major Benefits of OxyeEnrich Process


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Conventional Claus Process


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SWS Acid

Gas Feed

Amine Acid

Gas Feed

SWS GASK.O. Drum

AAG K.O.

Drum

Thermal Reactor

(Reaction

Furnace)

Burner

Combustion

Air Blower

Rxn Cooler

(WHB)

To Steam

System

BFW

HP

Steam

To

Condensate

System

#2

Reheater

BFW

To Steam

System

Sulfur to

Pit

#2

Condenser

BFW

To Steam

System

Sulfur to

Pit

#1

Condenser#4

Condenser

Waste Steam

Condenser

To TGTU

HP

Steam

To

Condensate

System

#1

Reheater

HP

Steam

To

Condensate

System

#3

Reheater

BFW

To Steam

System

Sulfur to

Pit

#3

Condenser

BFWSulfur to

Pit

#1

Converter

#2

Converter

#3

ConverterSteam

Drum

Thermal StageCatalytic

Stages

Claus SRU Configuration


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Burner CatalyticStages

Acid Gas Preheater

Combustion air from Blower

Mixer Oxygen from Oxygen

Supply System

Furnace WHB

O2 Enrichment : Direct O2 injection to Combustion Air

Acid Gas from

ARU/SWS


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FIC

PROCESS

GAS

FOR

SULPHUR

RECOVERY

FIC

FIC

MIXER

RATIO CONTROLLER

O2 ANALYZER

FV

UV

AIR BLOWER

ACID GAS MB

O2-

STORAGE

VESSEL

MAIN

COMBUSTIONCHAMBER

O2-

VAPORIZER


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Plant Capacity : 65 TPD

Typical Feed Composition

Acid Gas H2S rich SWS NH3 rich SWS

H2S %V 93.40 66.53 2.69

H2O %V 4.43 33.37 42.00

H2 %V 0.07 0.00 0.00

CH4 %V 0.06 0.00 0.00

C2H6 %V 2.04 0.00 0.00

NH3 %V 0.00 0.11 55.30

Case Study for OxyEnrich Process


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1100

1150

1200

1250

1300

1350

1400

1450

1500

FurnaceTemperature(C)

Oxygen Concentration in Enriched Air(Molefr.)

Result : Effect on Furnace Temperature


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0

50

100

150

200

250

AirFlowrateKmole/hr

Oxygen Concentration in Enriched Air (Molefr.)

Combustion Air Flow Rate Oxygen injected in Air

Total Combustion Air to MCC

Result : Effect on Combustion Air Rate


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Oxygen Concentration in Enriched Air(Molefr.)

Result : Capacity Enhancement


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Feeds Acid Gas

Source : Amine Regenerator O/H H2S concentration : 74-90%v

Vaporised Oxygen

Source : Liquid Oxygen Storage Vessel

Combustion Air

O2 concentration : 19.6-28%v

Controlling Parameters Temperature of Reaction Furnace Effluent

Maximum allowable temperature : 1500oC

Backpressure of the unit

Maximum allowable pressure : 0.74 Kg/cm2

Sulfur recovery of the unit

Minimum sulfur recovery : 99%

Technology Demonstration : Feed / Controlling Parameters


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Objectives :

Demonstration of OxyEnrich Process in a commercial plant

Commercial use of OxyEnrich Process for processing additional

acid gas to be generated in Euro IV Project

Existing SRU

Process : MCRC

Design Capacity : 90 TPD Sulfur

Design Sulfur Recovery : 99.0% ( min)

Technology Demonstration : Capacity Enhancement of CPCL-SRU


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Condenser-II

RFLine Burner

Incinerator

Condenser-III

Reheater

WHB Claus

Reactor-ICondenser-I

MCRC-IIIMCRC-II

Condenser-IV Condenser-V

MCRC-I

S

T

A

C

K

Acid

Gas

Air

uel Gas

Sulphur

LP Steam

Air , Fuel Gas

LP

LP Steam

Claus Bypass

Acid Gas, Air , Fuel Gas

OxygenLiquid Oxygen Vaporization Unit

Air Blower

Technology Demonstration : Plant Configuration After Revamp


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OPERATING PARAMETERS

BEFORE

(OxygenEnrichment )

AFTER(Oxygen

Enrichment)

Feed Gas Flow ( Acid Gas), Nm3/Hr 2115 2600

Enriched Air Flow, Nm3/Hr 3900 3100

Oxygen Content in Enriched Air, vol % 19.6 26.8

MCC Temperature, C 1160 1340

Unit Back Pressure, kg/Cm2 0.71 0.71

% Increase in Unit Throughput NA 22

Sulphur Recovery, % Above 99 Above 99

Steam Production, MT/Hr 4.20 5.60

Technology Demonstration : Key Operating Data


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No Majorhardware

modification

Capacityincreased by

22%

Oxygen contentin Air Enrichedup to 26.8 vol%

Quality ofSulphur

continued to begood

Lowbackpressure in

the unit

Improvement inMCC Temp and

stable flame even atLean acid gas

Low cost optionfor enhancingSRU capacity

Technology Demonstration : Salient features


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Supervision of test run for performance evaluation of running SRU

Adequacy check of Existing Equipments & Instruments

Preparation of Process Package for oxygen enrichment facility

Detail Engineering of new oxygen enrichment facility

Commissioning

EIL-CPCL Deliverables for Implementation of OxyEnrich Process


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