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
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