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

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

Slide 5 of 12

Thermal

Stage
To Steam System HP Steam #1 Reheater #1 Converter

Catalytic Stages
HP Steam #2 Reheater #2 Converter To Condensate System To Condensate System Waste Steam Condenser To Steam 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)

To Steam System

To Steam System

SWS GAS K.O. Drum #1 Condenser #2 Condenser #3 Condenser #4 Condenser

SWS Acid Gas Feed

BFW Sulfur to Pit Combustion Air Blower

BFW Sulfur to Pit

BFW

Sulfur to Pit

BFW Sulfur to Pit

Acid Gas Preheater Acid Gas from ARU/SWS Mixer Combustion air from Blower Oxygen from Oxygen Supply System Burner Furnace WHB Catalytic Stages

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

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

Furnace Temperature ( C )

1500 1450 1400 1350 1300 1250 1200 1150 1100

Oxygen Concentration in Enriched Air(Molefr.)

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

Oxygen Concentration in Enriched Air(Molefr.)

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%

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)

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 Sulphur

Condenser-IV

Condenser-V

Incinerator Air , Fuel Gas

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