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, 2009
NEW DELHI
OxyEnrich Process
OxyEnrich Process uses oxygen enriched air for oxidation of H2S to elementary sulfur in sulfur recovery unit and increases the plant capacity. Process minimizes nitrogen content in combustion air and results reduction in process gas flow in down stream of reaction furnace . Process increases reaction furnace temperature, which depends on oxygen concentration in air .
Process gives better conversion of H2S in reaction furnace and marginally increases overall sulfur recovery of the unit
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
DEMONSTRATION RUN OF OXYGEN ENRICHMENT IN SULFUR RECOVERY UNIT OF CPCL
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.
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MAJOR MILESTONES OF DEMONSTRATION RUN
SNO 1 2 3 4 5 6
ACTIVITY Signing of MoU with EIL Process Package Developed by EIL Detailed Engineering Activities carried out by EIL Installation of Piping & Control Valves Oxygen Mixing Drum installation Successful Commissioning of the System
DATE 25-09-07 25-10-08 25-10-08 30-04-09 07-05-09 11-05-09
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Major Benefits of OxyeEnrich Process
Greater processing capacity of sulfur recovery unit
Stable flame in main burner even at lean acid gas processing
No major modification for 25% -30% capacity enhancement
Low capital cost for grass root sulfur units due to smaller equipment sizes
Processing low quality feed without problem
Less sulfur mist lead to better operation
Low backpressure ensures trouble free operation
Conventional Claus Process
Claus SRU Configuration
Thermal Stage
To Steam System HP Steam #1 Reheater #1 Converter To Condensate System
Catalytic Stages
HP Steam #2 Reheater #2 Converter To Condensate System HP Steam #3 Reheater #3 Converter
AAG K.O. Drum
Steam Drum BFW Thermal Reactor (Reaction Furnace) Burner To Condensate System
To TGTU
Amine Acid Gas Feed Rxn Cooler (WHB)
Waste Steam Condenser
To Steam System
To Steam System
To Steam System
SWS GAS K.O. Drum #1 Condenser #2 Condenser #3 Condenser #4 Condenser
SWS Acid Gas Feed
BFW Combustion Air Blower
Sulfur to Pit
BFW
Sulfur to Pit
BFW
Sulfur to Pit
BFW
Sulfur to Pit
O2 Enrichment : Direct O2 injection to Combustion Air
Acid Gas Preheater
Acid Gas from ARU/SWS Mixer Oxygen from Oxygen Supply System Burner Furnace WHB Catalytic Stages
Combustion air from Blower
RATIO CONTROLLER O2STORAGE VESSEL
O2VAPORIZER O2 ANALYZER
FIC
FIC
FV
UV
AIR BLOWER
MIXER PROCESS GAS FOR SULPHUR RECOVERY
FIC
ACID GAS
MB
MAIN COMBUSTION
CHAMBER
Case Study for OxyEnrich Process
Plant Capacity Typical Feed Composition
: 65 TPD
H2S H2O H2 CH4 C2H6 NH3
%V %V %V %V %V %V
Acid Gas H2S rich SWS NH3 rich SWS 93.40 66.53 2.69 4.43 33.37 42.00 0.07 0.00 0.00 0.06 0.00 0.00 2.04 0.00 0.00 0.00 0.11 55.30
Result : Effect on Furnace Temperature
Furnace Temperature ( C )
1500 1450 1400 1350 1300 1250 1200 1150 1100
Oxygen Concentration in Enriched Air(Molefr.)
Result : Effect on Combustion Air Rate
Air Flow rate Kmole/hr
250
200 150 100 50
0
Oxygen Concentration in Enriched Air (Molefr.)
Combustion Air Flow Rate Total Combustion Air to MCC Oxygen injected in Air
Result : Capacity Enhancement
Oxygen Concentration in Enriched Air(Molefr.)
Technology Demonstration : Feed / Controlling Parameters
Feeds
Acid Gas Source H2S concentration Vaporised Oxygen Source Combustion Air O2 concentration
: Amine Regenerator O/H : 74-90%v : Liquid Oxygen Storage Vessel : 19.6-28%v
Controlling Parameters
Temperature of Reaction Furnace Effluent Maximum allowable temperature : 1500oC Backpressure of the unit Maximum allowable pressure : 0.74 Kg/cm2 Sulfur recovery of the unit Minimum sulfur recovery : 99%
Technology Demonstration : Capacity Enhancement of CPCL-SRU
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
Design Capacity
: MCRC
: 90 TPD Sulfur
Design Sulfur Recovery : 99.0% ( min)
Technology Demonstration : Plant Configuration After Revamp
Air Blower
Oxygen
Liquid Oxygen Vaporization Unit
LP Steam Acid Gas, Air , Fuel Gas Line Burner Claus Reactor-I LP Reheater S
Air Acid Gas RF WHB
Condenser-I
Claus Bypass
Fuel Gas MCRC-I MCRC-II MCRC-III
Condenser-II
LP Steam
T A C K
Condenser-III
Condenser-IV
Condenser-V
Sulphur
Air , Fuel Gas
Incinerator
Technology Demonstration : Steps in Project Execution Adequacy check of equipments/instruments through test run and in-house simulator Preparation of Process Package for oxygen enrichment facility Procurement of Equipments like Control valves, Oxygen
Analyzer, Oxygen Supply and storage system etc.
Installation and Erection of oxygen mixing device and oxygen supply system
Commissioning of Oxygen enrichment system and test run
Technology Demonstration : Key Operating Data
OPERATING PARAMETERS
BEFORE (Oxygen Enrichment ) 2115 3900 19.6 1160 0.71 NA Above 99 4.20
AFTER (Oxygen Enrichment) 2600 3100 26.8 1340 0.71 22 Above 99 5.60
Feed Gas Flow ( Acid Gas), Nm3/Hr Enriched Air Flow, Nm3/Hr Oxygen Content in Enriched Air, vol % MCC Temperature, C Unit Back Pressure, kg/Cm2 % Increase in Unit Throughput Sulphur Recovery, % Steam Production, MT/Hr
Technology Demonstration : Salient features
No Major hardware modification Low cost option for enhancing SRU capacity Capacity increased by 22%
Improvement in MCC Temp and stable flame even at Lean acid gas
Oxygen content in Air Enriched up to 26.8 vol%
Low backpressure in the unit
Quality of Sulphur continued to be good
EIL-CPCL Deliverables for Implementation of OxyEnrich Process
Supervision of test run for performance evaluation of running SRU Adequacy check of Existing Equipments & Instruments Preparation of Process Package for oxygen enrichment facility Detail Engineering of new oxygen enrichment facility Commissioning
