A Case Study on throughput improvement in a Steel Melting Shop
PETROFED Work Shop on Energy Management & Efficiency Improvement in Oil & Gas Sector
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Transcript of PETROFED Work Shop on Energy Management & Efficiency Improvement in Oil & Gas Sector
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PETROFED Work Shop on Energy Management & Efficiency Improvement
in Oil & Gas Sector
Oxy Enrich Process for Capacity Enhancement of Claus Based
Sulfur Recovery Unit
NOVEMBER 13, 2009NEW DELHI
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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 UNDER THE 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 MARGINAL AUGMENTATION
REQUIREMENT OF QUICK AND LOWER COST OPTIONS IN HAND
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Slide 4 of 8
SALIENT FEATURES:
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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MAJOR MILESTONES OF DEMONSTRATION RUN
Slide 5 of 12
SNO ACTIVITY DATE
1 Signing of MoU with EIL 25-09-07
2 Process Package Developed by EIL 25-10-08
3 Detailed Engineering Activities carried out by EIL 25-10-08
4 Installation of Piping & Control Valves 30-04-09
5 Oxygen Mixing Drum installation 07-05-09
6 Successful Commissioning of the System 11-05-09
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SWS AcidGas Feed
Amine AcidGas Feed
SWS GASK.O. Drum
AAG K.O.Drum
Thermal Reactor(ReactionFurnace)
Burner
CombustionAir Blower
Rxn Cooler(WHB)
To SteamSystem
BFW
HPSteam
ToCondensate
System
#2Reheater
BFW
To SteamSystem
Sulfur toPit
#2Condenser
BFW
To SteamSystem
Sulfur toPit
#1Condenser
#4Condenser
Waste SteamCondenser
To TGTU
HPSteam
ToCondensateSystem
#1Reheater
HPSteam
ToCondensateSystem
#3Reheater
BFW
To SteamSystem
Sulfur toPit
#3Condenser
BFWSulfur to
Pit
#1Converter
#2Converter
#3ConverterSteam
Drum
Thermal StageCatalyticStages
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Burner CatalyticStages
Acid Gas Preheater
Combustion air from Blower
Mixer Oxygen from Oxygen Supply System
Furnace WHBAcid Gas from
ARU/SWS
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FIC
PROCESS GASFOR SULPHURRECOVERY
FIC
FIC
MIXER
RATIO CONTROLLER
O2 ANALYZER
FVUV
AIR BLOWER
ACID GAS MB
O2- STORAGEVESSEL
MAINCOMBUSTION
CHAMBER
O2- VAPORIZER
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Plant Capacity Plant Capacity : 65 TPD : 65 TPD
Typical Feed Composition Typical Feed Composition
Acid Gas H2S rich SWS NH3 rich SWSH2S %V 93.40 66.53 2.69H2O %V 4.43 33.37 42.00H2 %V 0.07 0.00 0.00
CH4 %V 0.06 0.00 0.00C2H6 %V 2.04 0.00 0.00NH3 %V 0.00 0.11 55.30
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1100
1150
1200
1250
1300
1350
1400
1450
1500F
urn
ace
Tem
per
atu
re (
C )
Oxygen Concentration in Enriched Air(Molefr.)
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0
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Air
Flo
w r
ate
Km
ole
/hr
Oxygen Concentration in Enriched Air (Molefr.)
Combustion Air Flow Rate Oxygen injected in Air
Total Combustion Air to MCC
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0.00
5.00
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25.00
30.00
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Cap
acit
y e
nh
an
cem
en
t (%
)
Oxygen Concentration in Enriched Air(Molefr.)
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Feeds Acid Gas Acid Gas
Source Source : Amine Regenerator O/H: Amine Regenerator O/H H2S concentration H2S concentration : 74-90%v: 74-90%v
Vaporised Oxygen Vaporised Oxygen Source Source : Liquid Oxygen Storage Vessel : Liquid Oxygen Storage Vessel
Combustion AirCombustion Air O2 concentration O2 concentration : 19.6-28%v: 19.6-28%v
Controlling Parameters Temperature of Reaction Furnace Effluent Temperature of Reaction Furnace Effluent
Maximum allowable temperature Maximum allowable temperature : 1500: 1500ooCC Backpressure of the unitBackpressure of the unit
Maximum allowable pressureMaximum allowable pressure : 0.74 Kg/cm2: 0.74 Kg/cm2 Sulfur recovery of the unitSulfur recovery of the unit
Minimum sulfur recovery Minimum sulfur recovery : 99% : 99%
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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)
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Condenser-II
RFLine Burner
Incinerator
Condenser-III
Reheater
WHB Claus Reactor-I
Condenser-I
MCRC-IIIMCRC-II
Condenser-IV Condenser-V
MCRC-IS
T
A
C
K
Acid
Gas
Air
Fuel Gas
Sulphur
LP Steam
Air , Fuel Gas
LP
LP Steam
Claus Bypass
Acid Gas, Air , Fuel Gas
OxygenLiquid Oxygen Vaporization Unit
Air Blower
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OPERATING PARAMETERS BEFORE (Oxygen
Enrichment )
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
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