54046279 Presentation

MRPL-ONGC

1

Presentation onSULPHUR

Block

WEL COME

MRPL-ONGCSULPHUR RECOVERY

10 YEARS AGO SULPHUR WAS SELLING @$100+ PER TON.

PRESENTLY RATE <$40 PER TON NO MORE COMMERCIALLY VIABLE - MONEY MAKING

PRODUCT

GOVT REGULATIONS SRU REDUCES POLLUTION, NEED TO RECOVER

SULPHUR EMISSIONS , ODOUR, OPACITY, GROUND LEVEL CONCENTRATION,

INCREASED SULPHUR PRODUCTION

MRPL-ONGCSulphur Block

This content the following units

1. 322 -Amine Regeneration Unit2. 326 - Sour Water Stripper Unit3. 614/714/814 -Sulfur Recovery Unit With Sulfur Pelletizer Unit

MRPL-ONGCBlock Diagram Of Sulphur Block

SWS

ARU

SRU Pelletizer

Sulphur in Pellet form

Sour Water

Rich Amine

Lean Amine

Stripped WaterLiquid Sulphur

Sour Gas

Acid Gas

MRPL-ONGCSOUR WATER STRIPPER UNIT-326

SOUR WATER STRIPPER UNIT

MRPL-ONGCPURPOSE OF THE UNIT

REFINERY STRIPPER UNIT ( SWS-I ). Hydro Treated Sour water STRIPPER UNIT(SWS-II). BY STRIPPING OFF DISSOLVED H2S & AMMONIA FROM SOUR WATER. STRIPPED WATER WILL BE SENT TO DESALTER IN CDU OR WWTP FOR

DISPOSAL.

MRPL-ONGC

Design capacitySWS-I : 218.4 MT/hrSWS-II : 67.9 MT/hr20% over design margin shall be kept in reboiler and pump around section ofSWS-I & II. For the rest of the unit, 15% over design margin shall be kept

forSWS-I and 10% over design margin shall be kept for SWS-II.

ON-STREAM FACTOR The unit on-stream factor - 8000 hours per annum

PLANT TURNDOWN CAPABILITY SWS unit-I - 30% of the design capacity. SWS unit-II - 30% of the design capacity.

DESIGN DATA

MRPL-ONGC Characteristics of Sour Water Streams to Refinery SWS-I

H2S content of 500 ppmw max and 200 ppmw Hydrocarbonin sour water feed to the unit.

MRPL-ONGCCharacteristics of Sour Water Streams to Hydroprocessing SWS-II

MRPL-ONGCSWS Column detail

Single stage Sour Water Stripper 326DA001 Type : Tower (28 Trays) Fluid : Sour Water

OPERATING CONDITIONS:

Top Bottom Temperature 90 °C 121 °C Pressure 0.9 Kg/cm2g 1.1 Kg/cm2g Pressure Drop 0.2 Kg/cm2

MRPL-ONGCAMINE REGENERATION UNIT-1200

AMINE REGENERATION UNIT

MRPL-ONGCAmine Regeneration Unit-322

Purpose of the Unit

The Amine Wash and Regeneration Unit is designed to process sour gas loaded stream of MDEA

( Absorber & Extractor), DHDS and send back to user units after removing H2S, CO2 and hydrocarbons.

MRPL-ONGC

The objective of the unit is to achieve the desired level of H2S and CO2 content in the Lean Amine.

Capacity (Design):

The capacity of the unit is to treat 9491 T/D of Rich Amine.

Amine Regeneration Unit-1200

MRPL-ONGCARU Feed-Product Specifications

From SGU DHDS UGSQuantity(T/D) 137.78 3378.53 2556.76Composition(wt. %)H2S 3.67 5.58 4.04CO2 0.02 0.0 0.26MDEA 34.17 37.84 37.87H2O 62.12 56.42 57.80

Feed-Product SpecificationsFeed: Rich Amine

Products: Lean AmineMDEA : 40 %H2S : 0.007 mole H2S/Mole MDEA (Max.)CO2 : 0.003 mole CO2/mole MDEA (Max.)H2O : Balance

MRPL-ONGCARU UNIT- 1200 Process flow diagram

ARU Regenerator

Feed Drum

Rich Amine from DHDS/FCC/CDU

Reboiler

Regenerator

Reflux pump

Amine Tank

Reflux drum

Mech Filter

Carbon Filter

Lean Amine to

DHDS/FCC/CDU

Acid gas to flare

Acid gas to SRU

MRPL-ONGCARU Process flow description

The unit consists of the following sections:

Rich amine flash section:

The rich amine solution having H2S, CO2, hydrocarbon and water vapor etc. is flashed in rich amine flash drum to remove only hydrocarbons (H2S flashing is not allowed). After flashing, lighter hydrocarbons will go to H2S flare header under pressure control and heavier ones are collected in the flash vessel and can be pumped out of the unit. After this, rich amine solution goes to amine regeneration section.

MRPL-ONGC

Regeneration section:

The rich amine solution goes to amine regenerator which is equipped with LP steam reboilers at the bottom. In this regenerator, amine solution is heated indirectly as a result of which H2S, CO2 and other gases get separated and these gases from top goes to Sulfur Recovery Unit in order to recover elemental sulfur from H2S.

In case of shut down of Sulfur Recovery Unit, the gases goes to H2S flare. The bottom liquid of the regenerator which is called lean amine, after removal of above gases, is cooled in air-cooler before going to the storage tank.

ARU Process flow description

MRPL-ONGC

Lean amine storage and filtration section:

Regenerated amine solution (i.e. lean amine) after air cooling is received in amine storage tank which acts as a inventory vessel. From this tank, lean amine is sent to unit 1300, 3500, and 4000 after cooling to required temperature in water coolers. A part of lean amine solution is recycled back to the storage tank after filtration.

Amine unloading and drains collection section:

Amine solution (100% wt.) is unloaded from trucks into an underground vessel from where it is pumped to storage tank. This underground vessel is also used to collect amine solution from different low point drains in the unit during turnarounds as amine solution is not allowed to go to any other drain / system.


MRPL-ONGC

Even during upstream unit upsets and carryover of heavier hydrocarbons, all amine is drained to the vessel, oil removed / skimmed and fresh solution is sent back to storage tank. This vessel has got LP steam injection facility for dilution of freshly unloaded amine from the tank.


MRPL-ONGCSULPHUR RECOVERY UNIT-5000

SULPHUR RECOVERY UNIT

MRPL-ONGCWhy we need SRU

Tightening of emission standards by Govt./regulatory bodies.

Increasing demand for environment friendly fuels (low Sulphur).

Use of High Sulphur and heavier Crude oil.

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Objective:

* convert H2S to elemental sulphur

* Avoid pollution of the environment while recovering the

sulphur for other uses

Capacity of SRUDesign : 555 MT/D (Three train each of 185MT/D)

SULPHUR RECOVERY UNIT-624

MRPL-ONGC INTRODUCTION

What is Claus Reaction ?

When two moles of Hydrogen Sulphide (H2S) react with one mole of Sulphur Dioxide (SO2) to give Elemental Sulphur in presence of Catalyst, the reaction is called Claus Reaction” Carl Friedrich Claus is the London chemist.

2H2S + SO2 3/n Sn + 2H2O n = No. of atoms in Sulphur molecule

1/3rd of total H2S in feed gas is burned to SO2, this SO2 reacts with remaining H2S to give elemental Sulphur in Thermal Reactor H2S + 3/2O2 SO2 + H2O 2H2S + SO2 3/n Sn + 2H2OOverall Reaction 3H2S + 3/2 O2 3/nSn + 3H2O

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(1) Acid gas from Amine regeneration unit

(a) Feed Quantity = 623.5MT/SD

(b) Composition :


Components MT/SD MT/hr TOTAL

H2S 405.20 96.77CO2 6.00 1.43H2O 7.50 1.80TOTAL(MT/SD) 418.70 100.00

(c) Condition at Battery Limits: Pressure : 0.80 kg/cm2g Temperature: 40 oC

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Feed Specification(2) Acid Gas from Sour Water Stripper Unit

(a) Feed quantity = 9.72 MT/SD

(b) Composition :

.


Components MT/SD wt%

H2S 5.44 55.96

NH3 1.96 20.16H2O 2.32 23.88TOTAL(MT/SD) 9.72 100.00

(c) Conditions at Battery Limit : Pressure : 0.8 kg/cm2g Temperature : 90 oC

MRPL-ONGC PRODUCT SPECIFICATIONS

Product from SRU : Liquid Sulphur to Pastillation Unit

Colour : Bright Yellow (as Solid State) Purity : Min 99.7 wt% on dry basis H2S : < 10 ppmw Ash Content : Max 250 ppmw

Battery Limits Temperature : 150 0C Pressure : 5 Kg/cm2 g

Incinerator Stack Gases

SO2 - 180 ppm NOx - 100 ppm

MRPL-ONGC

GasSweetening

Claus SulfurRecovery

Claus off-gasTreating

Off-gasIncineration

SulfurDegasification

Product SulfurHandling

Sour WaterStripper

off-gas

Sulfur

H2S/CO2gas

To stack

Sour gas

Purified gas

Stripped water

Sour water

H2S/NH3 gas

Block Scheme Sulfur Removal

MRPL-ONGC

Modified Claus ProcessClaus Process

sulfurcondenser(130-150°C)

free flamereaction furnace

(1000-1400°C)

waste heatexchanger(130-170°C)

sulfurcondenser(130-150°C)

catalyticreactor

(200-300°C)

catalyticreactor

(200-300°C)

steam steam

steam

sulfur

sulfur

air airH2S gasH2S gas

stackstack

sulfur

Claus & Modified Claus Process

MRPL-ONGC

steamreheater

reactorincinerator

combustionchamber

waste heatboiler

feed gas

FrC

stack

steam

S S

condenser

air

S

H 2S 2

SO 2 1=

S

Claus Process

MRPL-ONGCActual Reactants and Products

free flamereactionfurnace

andw aste heatexchanger

H2 SHC's / COS/CS

2

H2 /HCN/NH

3

RSH/CO2 /H

2 O

O 2

N 2/C

O 2/H 2

O/Ar

steam

furthertreatment

BFW

H 2SSO 2H 2O

S2/S4/S6/S8COS/CS2

H 2/CO 2/CO/N 2

acid gas

air

MRPL-ONGCClaus Process for Sulfur Recovery

FREE FLAME REACTION &COMBUSTION CHAMBER

(930 - 1400°C)

WASTE HEAT BOILER AND/OR SULFUR CONDENSER

REHEATER(200-250°C)

CATALYTIC REACTOR(200-350°C)

SULFUR CONDENSER(130-200°C)

SUPERCLAUS® REHEATERAND REACTOR

(200 - 260°C)

SUPERCLAUS® SULFURCONDENSER(125 - 130°C)

INCINERATOR & VENT TOATMOSPHERE

OXYGEN SOURCE STREAM (AIR)STREAM CONTAINING H2S (ACID GAS)

THERMAL STAGE TYPICAL SULFURRECOVERY EFFICIENCY

60% AT THERMAL STAGE

90% AFTER 1ST REACTION STAGE95% AFTER 2ND REACTION STAGE97% AFTER 3RD REACTION STAGE

STEAM PRODUCTION

CATALYTIC STAGES

LIQUID SULFUR

STEAM PRODUCTION

LIQUID SULFUR

HEAT REJECTION

LIQUID SULFUR

SRE = 99.0 -99.4% AFTERSUPERCLAUS® STAGE

BYPASS

MRPL-ONGC

Fuel gas

ARU

SWS

Thermal ReactorWaste heat boiler

BFW

HP Steam

Combustion air

To 1st

condenser

To Sulfurcondenser

1300-1350ºc

Acid Gas

Acid Gas

KOD

KOD

KOD

Combustion Chamber

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SULPHUR RECOVERY PROCESS DESCRIPTION

The SUPERCLAUSTM-99 process, is based upon the partial combustion of H2S with a ratio controlled flow of air.

Correct quantity of air for complete oxidation of all hydrocarbons and NH3 present in the acid gas feed.

H2S percentage of 0.5-0.7 vol% at the inlet of the

selective oxidation reactor (SUPERCLAUS Reactor) is to be maintained.

The SUPERCLAUSTM-99 process operates according to the new process where the ‘air to acid gas’ ratio is adjusted to achieve an H2S/SO2 ratio of greater than

2/1 in the burner effluent..


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A special process gas analyzer is provided on the effluent gas stream from sulphur condenser no.3 to measure the

H2S concentration and to control the trim air to the

burner to achieve the desired H2S concentration of 0.5 to

0.7 vol % H2S.

To obtain a concentration of H2S in the process gas

entering the Superclaus stage in the range of 0.5-0.7 vol

%, the concentration of H2S in the process gas entering

the third Claus stage should be in the range of 0.8-1.0 vol%.

If the H2S concentration of gas entering the SUPERCLAUS TM stage is too high, more air is added to the main

burner to produce more SO2, or If the H2S concentration

entering the SUPERCLAUS TM stage is too low, less air is added to the main burner.

.


MRPL-ONGCCHEMICAL REACTIONS COMBUSTION CHAMBER H2S + 3/2 02 -------------->H2O + SO2

2H2S + SO2 --------------> 3S + 2H2O ============================= 3 H2S + 3/2 O2 -------------->3S + 3H2O CLAUS REACTOR

2 H2S + SO2 --------------> 3/n Sn + 2 H2O

SUPERCLAUS REACTOR

H2S + 0.5 O2 --------------> S + H2O

MRPL-ONGCREDUCTION REACTIONS

CO + H2O --------------> H2 + CO2

SO2+ 3H2 --------------> H2S+ 2H2O

SX + XH2 --------------> XH2S

COS + H2O ------------> H2S + CO2

CS2+2H2O -------------> 2H2S + CO2

MRPL-ONGCHydrogen Sulphide

MRPL-ONGCHydrogen Sulphide properties:

Properties DescriptionPhysical state Normally encountered as a gas

Color Colorless No visible sign of H2S to warn you of its presence.

OdorSmells like ”rotten eggs” Impairs your sense of smell at low concentrations. Do not rely on your sense of smell to detect H2S.

Vapor densityHeavier than air It may flow or settle in low lying areas like pits, trenches and natural depressions.

Flammability

Flammable Burns with a blue flame and gives off sulfur dioxide gas, SO2. SO2 is hazardous and irritates the eyes and the respiratory system. Explosive when mixed with air.

SolubilityDissolves in water, oil, sludge, emulsions, well fluids and molten sulfur H2S is released when liquids are agitated, depressurized or heated.

MRPL-ONGCH2S exposure limits:

Occupational Exposure Limit

Concentration OEL Description

8 hour OEL 10 ppmA time-weighted average (TWA) maximum exposure for an eight hour work day.

15 minute OEL 15 ppmA TWA exposure limit of up to 15 minutes with a 60 minute separation between each exposure.

Ceiling OEL 20 ppm

No one should be exposed to greater than 20 ppm of H2S at any

time without adequate respiratory protection.

MRPL-ONGCSO2 Properties:

Properties DescriptionPhysical state Normally encountered as a gas.

Color Colorless.

Odor Biting smell, irritates nose and mouth.

Vapor density

Heavier than air It may flow or settle in low lying areas like pits, trenches and natural depressions.

Flammability Not flammable.

Solubility Forms an acid with water, dissolves in many organic solvents.

MRPL-ONGC

Occupational Exposure

LimitConcentrati

on OEL Description

8 hour OEL 5 ppmA time-weighted average (TWA) maximum exposure for an eight hour work day.

SO2 exposure limits:

MRPL-ONGCMAC Value

The maximum allowable concentration of gas, vapor,

mist or dust, is the concentration in the air on the

workplace which, as far as the present knowledge

reaches, by repeated exposition (even during a longer

period or a complete working life) does generally not

harm the health of the employees and/or their offspring

in any way.

MRPL-ONGC

Poisoning by

Inhalation

Mouth

Skin

MRPL-ONGCH2S Poisoning

Poisoning by inhalation

H2S dissolves in blood

Affects breathing by stopping respiratory control center

in the brain

Respiration stops

Oxygen in blood is quickly used up, heart stops

H2S is slowly oxidized to non-toxic sulfur components

MRPL-ONGCH2S Toxicity Levels (1/2)

LOW

0-10 ppmIrritation of the eyes, nose and throat.

MOD

10 – 50 ppm

Headache.Dizziness.Nausea and vomiting.Coughing and breathing difficulty.

HIGH

50 – 300 ppm

Severe respiratory tract irritation.Eye irritation/acute conjunctivitis.Shock.Convulsions.Coma.Death in severe cases.

MRPL-ONGCH2S Toxicity Levels (2/2)

H2S exposure Possible Health Effects

Less than 1 ppm You can smell it.

10 ppm (8 hour OEL) No known adverse health effects.

10 – 200 ppmEye and respiratory tract irritation and loss of smell. Will also cause headache and nausea.

200 – 300 ppm Immediately Dangerous to Life and Health (IDLH).

500 – 700 ppm

Affects the central nervous system. After a couple of minutes, it causes loss of reasoning, loss of balance, unconsciousness and breathing to stop.

700 – 1000 ppmImmediate loss of consciousness. Permanent brain damage and death will occur if you are not rescued immediately.

MRPL-ONGCSO2 Toxicity Levels

SO2 exposure Possible Health Effects

Less than 3-5 ppm You can smell it.

5 ppm (8 hour OEL) No known adverse health effects.

20 ppm Eye and respiratory tract irritation.

50 – 100 ppm Max. allowable concentration for 30-60 minutes.

> 400 ppm Danger for health, even with short exposure.

MRPL-ONGCH2S Detection Equipment

MRPL-ONGCHow to React ?

Protect yourself (first!) Evacuate yourself from the area (wind direction!!)

Alarm the control room Operators have to evacuate the area Well protected operators search for victims

MRPL-ONGCHow NOT to React ?

Do not try to find reason for H2S release

Do not (try to) rescue colleagues Do not panic Do not run fast

MRPL-ONGCSulphur palletizer unit-6200

SULPHUR PELLETIZER UNIT

MRPL-ONGCSulphur pelletizer unit-6200

Purpose: To convert liquid sulphur into solid pellets form

Technology Supplier: Sandvik Asia

Capacity of the unit:

5 MT/Hr per stream (Total 4 streams)


Liquid Sulphur Characteristics

Sulphur content: not less than 99,8 % H2S content: less than 10 ppm Temperature: max. 150°C Pressure: max. 4,5 kg/m²g Viscosity: < 100 mPa·s

MRPL-ONGCSulphur palletizer unit-6200Solid Sulphur Characteristics

Shape: pestilles Mean size: between 2 and 4 mm Size distribution: less than 5 % bigger than 4,75 mm

minimum 75 % between 4,4 and 2,4 mm less than 2 % smaller than 1,19 mm

less than 0,1 % smaller than 0,3 mm Moisture : less than 0,5 % by weight Bulk density: 1040 kg/m³ loose, 1200 kg/m³ agitated Angle of repose: not less than 25°

MRPL-ONGC

Rotoformor

Sulphur pelletizer unit

MRPL-ONGCSulphur palletizer unit

Steel belt cooler

MRPL-ONGC

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THANK YOU

54046279 Presentation

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