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

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

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

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

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

Burner CatalyticStages

Acid Gas Preheater

Combustion air from Blower

Mixer Oxygen from Oxygen Supply System

Furnace WHBAcid Gas from

ARU/SWS

FIC

PROCESS GASFOR SULPHURRECOVERY

FIC

FIC

MIXER

RATIO CONTROLLER

  O2 ANALYZER

FVUV

AIR BLOWER

ACID GAS MB

O2- STORAGEVESSEL

MAINCOMBUSTION

CHAMBER

O2- VAPORIZER 

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

1100

1150

1200

1250

1300

1350

1400

1450

1500F

urn

ace

Tem

per

atu

re (

C )

Oxygen Concentration in Enriched Air(Molefr.)

0

50

100

150

200

250

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

0.00

5.00

10.00

15.00

20.00

25.00

30.00

35.00

Cap

acit

y e

nh

an

cem

en

t (%

)

Oxygen Concentration in Enriched Air(Molefr.)

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%

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)

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

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