Transcript Claus Section - Itering Languages

KHABAROVSK REFINERY
HYDROPROCESSING PROJECT
BASIS OF DESIGN
TRAINING COURSE
APRIL 29th – MAY 3rd 2013, MADRID, SPAIN
INTRODUCTION
•
Tecnimont KT has prepared a training course for operators in order to
prepare the personnel of the Khabarovsk Refinery to the plant operation of
the new Sulphur Recovery Section (SRU) with Tail Gas Treating Section
(TGT), Amine Regeneration Section (ARU) and Sour Water Stripping Section
(SWS).
•
The new Sulphur Recovery Complex is composed of two parallel trains and
common facilities, as follows:
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Common facilities – Unit 230-30X
Train #1 – Unit 230-31X
Train #2 – Unit 230-32X
TGT (common to both Trains), Incinerator – Unit 230-33X
Amine Regeneration Section – Unit 230-10X
Sour Water Stripping Section – Unit 230-20X
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TRAINING COURSE CONTENT
•
1. Basis of Design (common)
•
2. Process Description (common)
•
3. Process Theory (common)
•
4. Main Equipment Description (SRU)
•
5. Control system and ESD (SRU)
•
6. Precommissioning, Commissioning and 1st Start-up (SRU)
•
7. Normal operation of Sulphur Recovery Unit
•
8. Normal operation of Tail Gas Treatment Unit (RAR)
1 day
1 day
1 day
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TRAINING COURSE CONTENT
• 9. Main Equipment Description (ARU/SWS)
• 10. Control system and ESD (ARU/SWS)
1 day
• 11. Precommissioning, Commissioning and Start-up (ARU/SWS)
• 12. Plant safety and maintenance concept (common)
• 13. Trouble shooting (common)
• 14. Test Run (common)
1 day
• 15. Open discussion (common)
• 16. Final assessment and Evaluation test (common)
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PLANT DESIGN
The Sulphur Recovery and Tail Gas Treatment design is finalised according to the
following configuration:

Claus Section (two parallel identical trains)

Degassing Section

Tail Gas Treatment / Amine Recovery (RAR Section)

Incineration Section
(common to both trains)
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PLANT CONFIGURATION: BLOCK DIAGRAM
AMINE
SECTION
AMINE ACID GAS RECYCLE
CLAUS
TRAIN 1
230-31X
FUEL GAS
LEAN
AMINE
REFINERY
ARU
AMINE ACID GAS
(AAG)
HYDROGEN
RICH
AMINE
LIQUID
SULPHUR
SULPHUR
DEGASSING
SECTION
TGT
SECTION
FLUE GAS
INCINERATOR
TO ATMOSPHERE
SWEEP AIR
LIQUID
SULPHUR
REFINERY
SWS
SOUR GAS
(SWG)
LIQUID SULPHUR
SULPHUR
SOLIDIFICATION
SOLID SULPHUR
CLAUS
TRAIN 2
230-32X
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PLANT DESIGN
The selected process configuration is carried out according to the followings:

Claus Section based on modified CLAUS process;

Liquid Sulphur Degassing Section for removing H2S by the produced
Undegassed sulphur;

Tail Gas Treatment Section for processing the Claus tail gas, based on
RAR (Reduction, Absorption, Recycle) process;

Amine Section with TGT Absorber, for removing H2S on tail gas, and
with Amine Regenerator, dedicated for TGT operation, based on the use
of MDEA (Methyl- diethanolamine) solution diluted at 50%wt.;
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PLANT DESIGN

Incineration Section for oxidation of tail gas coming from TGT Section
(or from the Claus Section in case of by-pass of TGT Section).

Amine Regeneration Section will process Rich Amine coming from
Hydrocracking Section (HCU) using DEA (Diethanolamine) solution
diluted at 25%wt.;

Sour Water Stripping Section will process the Sour Water coming from
Hydrotreating Section (DHT), Hydrocracking Section (HCU), TGT and
SRU Section;
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EQUIPMENT OVERVIEW
Valid for each of the TWO PARALLEL trains
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Claus Section is composed of:
Amine Acid Gas Scrubber with relevant pumping system
SWS Acid Gas Separator with relevant pumping system
C.A. Blowers
Thermal stage, including waste heat recovery system
2 Catalytic stages (preheating, reaction, condensation)
Hydraulic seals
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EQUIPMENT OVERVIEW
The Common parts are:

Degassing Section composed of:
Sulphur Pit, equipped with Degassing Column, Undegassed and Transfer
pumps
Sulphur Solidification Package
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

Incineration Section composed of:
Thermal Incinerator and Burner
Incinerator Stack
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
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EQUIPMENT OVERVIEW
The Common parts are:
TGT (Tail Gas Treatment) Section composed of:
 Tail Gas Heater (electrical)
 Hydrogenation Reactor
 Tail Gas / Gas Exchanger
 Quench Tower, equipped with pumping/filtering/cooling system
 Recycle Gas Blower and Preheater
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EQUIPMENT OVERVIEW
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Amine Section (of TGU) composed of:
Absorber
Rich Amine Pumps
Lean / Rich Amine Heat Exchanger
Lean Amine pumping/cooling/filtering system
Regenerator, equipped with Reboiler and overhead circuit
Amine Drains Drum
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EQUIPMENT OVERVIEW
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Amine Regeneration (ARU) Section is composed of:
Rich Amine Flash Drum with pumping system
Lean Amine pumping/cooling/filtering system
Lean / Rich Amine Heat Exchanger
Regenerator, equipped with Reboiler and overhead circuit
Amine Sump Drum
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EQUIPMENT OVERVIEW

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Sour Water Stripping (SWS) Section is composed of:
Sour Water Feed Surge Drum with pumping system
Stripper Feed / Bottom Exchanger
Sour Water Stripper, equipped with Reboiler
pumparound circuit
and
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FEEDSTOCKS to Sulphur Recovery and Tail Gas Treatment
The Sulphur Recovery Unit shall treat the following main streams:
• Amine Acid Gas, coming from Amine Recovery Section (ARU)
• SWS Gas, coming from Sour Water Stripping Section (SWS)
Moreover, other feeds sources are listed:
• Hydrogen make-up, is injected in the TGT section;
• Recycled acid gas, produced in the Amine Regenerator, is sent back to Claus
and joined with amine acid gas stream;
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FEEDSTOCKS to Sulphur Recovery and Tail Gas Treatment
Claus Section
There are two common acid gas headers (SWS AG header and AAG header),
which feed Claus trains.
Each SRU train shall be also able to operate with amine acid gas from
amine unit only (without gas from sour water stripper).
On the other hand, gas from sour water stripper can be routed to
SRU train, only when SRU train is operating with amine acid gas.
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FEEDSTOCKS to Sulphur Recovery and Tail Gas Treatment
Incinerator Section
Normally, the Incinerator section shall be able to process:
- Claus tail gas
- Sweep Air from Sulphur Pit
TGT by-pass operation:
the Incinerator section shall be also able to operate with TGT section
by-passed (direct oxidation of Claus tail gas).
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FEEDSTOCKS to Amine Recovery and SWS Sections
The Amine Regeneration Section (ARU) shall treat the rich amine streams
generated in Summer Diesel EOR operation case in the Hydrocracking Section
(HCU).
The Sour Water Stripping Section (SWS) shall treat the sour water streams
generated in SRU and TGT Sections, in the HCU Section and in the
Hydrotrating Section (DHT).
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PRODUCTS & EFFLUENTS - overall
The products/effluents of Sulphur Recovery and Tail Gas Treatment Units are:
•
Degassed Liquid Sulphur from Sulphur Degassing and Storage Drum
•
Sour Water from Amine Acid Gas Scrubber (continuous flow), by means of
pump
•
Sour Condensate from Sour Water
(discontinuous flow), by means of pump
•
MDEA condensate from Amine Acid Gas Separator (discontinuous flow), by
means of pump inside MDEA Drain Drum
•
Sour Water from Quench Tower (continuous flow)
•
Flue Gas from Stack of Thermal Incinerator to atmosphere
Stripper
Acid
Gas
Separator
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FEEDSTOCKS & PRODUCTS – overall balance
Amine
Acid Gas
SWS Acid
Gas
Flue
Sulphur
Recovery
&
Acid Gas
Recycle
Gas
Liquid
sulphur
Tail Gas
Treatment
Process
Hydrogen
make-up
Waters
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PRODUCTS & EFFLUENTS - overall
The products/effluents
Sections are:
of
Amine
Recovery
and
Sour
Water
Stripping
•
Amine Acid Gas containing H2S a high concentration (91.37% mol) that
will be treated in the SRU for final conversion to sulphur.
•
Lean amine solution (DEA) to HCU Section.
•
Sour Water Stripped Acid Gas Separator containing H2S (36.38% mol) that
will be treated in the SRU for final conversion to sulphur.
•
Stripped Water used as wash water in the Hydrocracking / Hydrotrating
Sections.
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CAPACITY - overall
The overall capacity of SRU/TGT Unit corresponds in terms of Sulphur Production:
• 40 t/d of liquid sulphur production by both trains at design condition (20 t/d for each
train) and SRU/TGT catalysts at start of run conditions (Design Case - SOR)
• 12 t/d of liquid sulphur production by both trains at turndown operation (6 t/d for each
train) and SRU/TGT catalysts at start of run conditions (Turndown Case)
SULPHUR CAPACITY (t/d)
FOR EACH TRAIN
OPERATING
SCENARIO
Design
Turndown
Trains #1 & #2
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SULPHUR RECOVERY EFFICIENCY – Claus section
•
The Sulphur Recovery Efficiency (SRE) for Claus section is defined as follows:
SREClaus
S IN  SOUT

100
S IN
where:
• SIN = total sulphur contained in feedstock to Claus section;
• SOUT = total sulphur contained in tail gas from Claus to TGT section.
•
Generally, the SRE% efficiency in the Claus section is limited up to about 95.2%, while
the TGT section allows the OSRE% to reach the expected value of 99.8% (at SOR).
•
The figure of 95.2% (as SRE% efficiency) is referred to the catalysts at start of condition
(SOR phase) in the Claus Section.
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OVERALL SULPHUR RECOVERY EFFICIENCY – each train
• Sulphur Recovery Efficiency = 99.8% at Start of Run Condition (with TGT on
stream, expected value at SOR)
• When the TGT section is normally operating with Claus tail gas, Overall
Sulphur Recovery Efficiency is verified by the measure of the total sulphur
contained in tail gas from Absorber.
• Overall SRE (%) for the whole Sulphur Recovery SRU+TGT is defined as
follows:
OSRE 
S IN  SOUT
100
S IN
where:
• SIN = total sulphur contained in feedstock to SRU+TGT
• SOUT = total sulphur contained in tail gas from Absorber.
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Rome
Viale Castello della Magliana 75
00148 - Italy
Ph. +39 06 602161
Fax +39 06 65793002
[email protected] – www.tecnimontkt.it
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THANK YOU FOR THE ATTENTION