G80SO63XX11P3

AgipGas BV
WESTERN LIBYA GAS PROJECT
LIBYAN BRANCH
Snamprogetti Lummus Gas Ltd
AGBV Doc. No.
0177/NC/02
G-80-S-O-63XX 11
CTR Job No.
CTR Doc. No.
310300
5E-631-PA-E-86627
Plant
MELLITAH PLANT
Snamprogetti
ABB Lummus Malta
AGBV Job No.
Location
Sh. 1 of 13
GSPLAJ
Rev.
P1 P2 P3
PROCESS DUTY SPECIFICATION FOR

SULPHUR SOLIDIFIER UNIT, SOLID SULPHUR STORAGE,
CONVEYING AND METERING FACILITIES
P3
07/07/03 Approved for Design General Revision
A.Angelucci
G.M.Bosi
C.Stocco
P2
21/02/03 Approved for Design
A.Angelucci
G.M.Bosi
C.Stocco
P1
18/12/02 Issued for Approval
A.Angelucci
G.M.Bosi
C.Stocco
Prep.
Check.
Appr.
Rev.
Date
Description
PMS Rev.
AGBV Appr.
Form code: MDT.GG.QUA.0004 Sh. 01/Rev. 3.96

Data file:330287973.doc
This document is CONFIDENTIAL and the sole property of the AGIP GAS BV. It shall neither be shown to third parties nor used for other purposes than those for
which it has been issued/sent. Any unauthorized attempt to reproduce it, in any form, is strictly prohibited.
AgipGas BV
LIBYAN BRANCH
Plant
MELLITAH PLANT
Snamprogetti
ABB Lummus Malta
AGBV Job No.
AGBV Doc. No.
0177/NC/02
G-80-S-O-63XX 11
CTR Job No.
CTR Doc. No.
310300
5E-631-PA-E-86627
Location
GSPLAJ
Sh. 2 of 13
Rev.
P1 P2 P3
Index
SCOPE
GENERAL
2.1
Material
PROCESS REQUIREMENTS
EQUIPMENT REQUIREMENTS
SYSTEM DESCRIPTION
5.1
Cooling water system description
5.2
Exhaust air system description
5.3
Design Basis
INSTRUMENTATION
6.1
Solidifier Units
6.2
Belt Conveyor to Warehouse
6.3
Portal Reclaimer
6.4
Tripper
6.5
Truck loading station
6.6
Control Scheme Architecture
ELECTRICAL
GUARANTEE REQUIREMENTS
UTILITIES COMSUMPTIONS
10
REFERENCE DOCUMENTS
_______________________________
AgipGas BV
LIBYAN BRANCH
Plant
MELLITAH PLANT
Snamprogetti
ABB Lummus Malta
AGBV Job No.
AGBV Doc. No.
0177/NC/02
G-80-S-O-63XX 11
CTR Job No.
CTR Doc. No.
310300
5E-631-PA-E-86627
Location
GSPLAJ
Sh. 3 of 13
Rev.
P1 P2 P3
SCOPE
This specification outlines the process requirements for the design of one sulphur solidifier
system (based on solid sulphur pastilles process) and relevant solid sulphur storage and
metering facilities. The system will be installed at Mellitah Plant.
The solid sulphur transportation from the Metering System to the berth and the Ship Loading
system are outside this scope of work.
For scope of work Battery Limit refer to para 9.
GENERAL
For climate, ambient conditions and utilities characteristics refer to G-65-S-Z-0001 00 Design
Premises for Mellitah Plant.
2.1
Material
Materials shall be suitable for the fluid handled and shall be subject to the Owner approval.
The spray system will utilize as cooling medium water which has a chloride content of about
140 ppm as NaCl.
The material of the Belt Cooler shall be suitable for cooling water with the above mentioned
characteristics.
PROCESS REQUIREMENTS
The system is designed to receive molten sulphur, to solidify it in pastilles form, to store them
in warehouse stockpile and to handle the product in bulk for metering.
The design capacity of the solidification system is 530 t/day of solid sulphur 99.5 wt % purity.
The system will include 6 units of 6 t/hr (four units will be in operation, one in stand-by and the
other one in maintenance).
The duty cycle is 24 hr/day.
The Solid Sulphur Storage and Metering System is designed considering to export the product
with ship vessels of 15.000 tons (Cargo capacity).
The liquid sulphur is available from two storage tanks (outside of the scope of work).
Provisions to be also provided for future local truck loading facilities.
_______________________________
AgipGas BV
LIBYAN BRANCH
Plant
MELLITAH PLANT
Snamprogetti
ABB Lummus Malta
AGBV Job No.
AGBV Doc. No.
0177/NC/02
G-80-S-O-63XX 11
CTR Job No.
CTR Doc. No.
310300
5E-631-PA-E-86627
Location
GSPLAJ
Sh. 4 of 13
Rev.
P1 P2 P3
EQUIPMENT REQUIREMENTS
The system will consist of the following main equipment.
Solidification Part
5E-632-CK-001 A/B
5E-632-XX-003
5E-632-HA-001
5E-632-HA-002
5E-632-HA-003
5E-632-PA-002 A/B
5E-632-VB-001
5E-632-XX-001 A-F
5E-632-KE-001 A/B
5E-632-XX-002
5E-632-TA-001
5E-632-PA-003
Sulphur Filters
Sulphur Preconditioning System, consisting of:
Sulphur Cooling Heat Exchanger
Thermalfluid Cooling Heat Exchanger
Thermalfluid Heating Heat Exchanger
Thermalfluid Pumps
Thermalfluid Expansion Vessel
Sulphur Solidifier Units
Exhaust Air Fans
Release Agent System, consisting of:
Release Agent Tank, including Stirrer
Release Agent Pump
Handling Part
5E-632-YH-001
5E-632-YH-002
5E-632-YH-003
5E-632-YH-004
Feeding Belt Conveyor

Tripper Car
Portal/Scraper Reclaimer
Reclaimer Product Conveyor
Metering Stations
5E-632-JM-001
5E-632-JM-002
Feeding Metering Station

Reclaiming Metering Station
Buildings
5E-632-ZP-001
5E-632-ZP-002
Shelter for Solidification Unit

Warehouse
_______________________________
AgipGas BV
LIBYAN BRANCH
Plant
MELLITAH PLANT
Snamprogetti
ABB Lummus Malta
AGBV Job No.
AGBV Doc. No.
0177/NC/02
G-80-S-O-63XX 11
CTR Job No.
CTR Doc. No.
310300
5E-631-PA-E-86627
Location
GSPLAJ
Sh. 5 of 13
Rev.
P1 P2 P3
SYSTEM DESCRIPTION
Sulphur pastilles will be obtained feeding liquid sulphur to a solidification system, where six
Solidifier Units are provided (four operating, one standby and one in maintenance) each one
with a design capacity of 6 t/hr. The liquid sulphur is stored at about 135 C in the tanks 5E631-TA-001 and 5E-631-TA-002 and it is transferred to the Sulphur Pit 5E-632-TH-001 by
means of two centrifugal horizontal pumps 5E-632-PA-001 A/B (one spare). The sulphur is
maintained in the pit at about 135 C using low pressure steam as heating medium. From the
Pit the liquid sulphur is fed continuously to the solidification units by means of two vertical type
Liquid Sulphur Pumps 5E-632-PH-001 A/B (one in operation and one standby), one additional
pump 5E-632-PH-001 C will be provided as capital spare and it will be stored in the spare
parts warehouse building. Liquid sulphur transfer pumps, sulphur pit and sulphur pumps are
outside scope of work.
Liquid sulphur preconditioning unit, including sulphur filters, is provided to keep under control
liquid sulphur temperature at the inlet of solidifier unit.
In the Solidifier Units the sulphur is produced in the form of pastilles and cooled down by
means of cooling water. Uniformly sized drops of sulphur product are continuously deposited
onto a stainless steel Cooling Conveyor Belt. The uniform drops, once in contact with the belt,
form into 3 to 6 mm diameter pastilles.
The pastilles are indirectly cooled as they travel the length of the belt by sprying cooling water
underneath.
Once the pastilles have traveled the length of the conveyor, they are in solid form at about 70
C. A release agent (Diasil SRA, Tegopren 5863 or equivalent) is applied, before the sulphur
product is deposited on the belt to ensure trouble free product discharge.
The solidified pastilles are sent to the warehouse, by means of the one Belt Conveyors 5E632-YH-001 and the Tripper Car 5E-632-YH-002. A continuous belt weigher 5E-632-JM-001
fitted into the belt conveyor 5E-632-YH-001 will record rate of feed and total capacity of
material delivered to the store. Because of its particle size in the range of few millimeters the
sulphur pastilles have good flow behaviour, as long as they are not stored for a longer period
at compressive stress. However, storage periods of some days up to few weeks in the
warehouse cannot be avoided, as the warehouse serves for the storage of sulphur until a
sufficient quantity is available for ship loading. This led to the formation of columns of caked
sulphur pastilles.
Solid Sulphur is reclaimed from the store by a portal reclaimer 5E-632-YH-003 at capacity of
430 tons/h onto a belt conveyor 5E-632-YH-004 running the full length of the store at ground
level. This conveyor has a capacity of 430 tons/h and is equipped with a moveable/emergency
hopper for emergency by-pass feed in the event of portal scraper stoppage; the backup hoppers
will be loaded by front loaders in case of break-down of the portal scraper. In addition,
provisions for future local truck loading shall be provided.
A continuous belt weigher 5E-632-JM-002 fitted into the belt conveyor 5E-632-YH-004 will
record rate of feed and total capacity of material delivered to the Pipe Conveyor (about 2.3 km
long, not included in the scope of work of Contractor) and routed to the Jetty for ship loading.
The design capacity of the shiploading system is 430 ton/hr of solid sulphur and it allows to
load a ship vessel of 15.000 tons (Cargo Capacity) in about 2 days.
_______________________________
AgipGas BV
LIBYAN BRANCH
Plant
MELLITAH PLANT
Snamprogetti
ABB Lummus Malta
5.1
AGBV Job No.
AGBV Doc. No.
0177/NC/02
G-80-S-O-63XX 11
CTR Job No.
CTR Doc. No.
310300
5E-631-PA-E-86627
Location
GSPLAJ
Sh. 6 of 13
Rev.
P1 P2 P3
Cooling water system description

The cooling medium foreseen for sulphur soldifier is open loop type. In fact the water sprayed
is collected underneath the cooling belt conveyors in the collecting hoppers under the solidifier
units and sent to the Cooling Water Return Pit 5E-632-TH-002. Two pumps (5E-632-PH-002
A/B) are provided to transfer the cooling water from the Pit to the cooling water return system.
Manufacturer shall prevent any cooling water contamination. Both cooling water pit and
cooling water pumps are outside Manufacturer scope of work.
5.2
Exhaust air system description

Exhaust air, including H2S and sulphur fumes from liquid sulphur during solidification is sucked
by the exhaust fan 5E-632-KE-001 A/B (one in operation and one spare) and is led to the
atmosphere outside the shelter. Manufacturer will consider provisions to control the air
discharge to the atmosphere in order to avoid environmental impact and pollution. Due to
presence of the sulphur fumes, corrosion resistant exhaust fans shall be provided.
_______________________________
AgipGas BV
LIBYAN BRANCH
Plant
MELLITAH PLANT
Snamprogetti
ABB Lummus Malta
5.3
AGBV Job No.
AGBV Doc. No.
0177/NC/02
G-80-S-O-63XX 11
CTR Job No.
CTR Doc. No.
310300
5E-631-PA-E-86627
Location
GSPLAJ
Sh. 7 of 13
Rev.
P1 P2 P3
Design Basis
5.3.1
Liquid Sulphur conditions at B.L.
Temperature
Pressure
Purity
Ash Content
Hydrocarbons
Acidity
H2S
5.3.2
Cooling Water Supply conditions at B.L.
Temperature
Pressure
5.3.3
: 32 C
: 5 barg
Cooling Water Return conditions at B.L.
Temperature
Pressure
5.3.4
: 135 C min
: 3 barg
: > 99.5 %
: < 500 ppmw
: < 500 ppmw
: < 300 ppmw
: < 10 ppm
: 44 C, maximum return temperature from individual user.

: ATM
Product Characteristics (Pastilles)
Solid Sulphur Temperature

Solid Sulphur purity
Shape, Size and Size Distribution
diameter.
Compaction
Bulk Density
Moisture content
Angle of repose
Dust (as produced)
Friability
: 70 C
: 99.5 %
: Generically semispherical, between 1 mm and 6 mm in
Less than 5% is retained on a 6.3 mm screen.
A minimum of 75% of materials is retained a N 31/2 U.S.
Screen (5.6 mm).
A minimum of 75% of materials is retained a N 7 U.S.Screen
(2.8 mm).
Less than of 2% of materials is retained a N16 U.S. Screen
(1.00 mm).
Less than of 0.5% of materials is retained a N 50 U.S.
Screen (300 microns).
: Fines generated after direct shear test under static loading
of 165 KPa (approximate 15 m stockpile) not to exceed 0.2%
fines by weight.
Fines generated after direct shear test under dynamic loading
at 165 KPa, not to exceed 0.5% by weight.
: 1100 kg/m3
: < 0.5% wt
: > 25
: < 0.5%
: < 2% (stress level II after 1 day)
_______________________________
AgipGas BV
LIBYAN BRANCH
Plant
MELLITAH PLANT
Snamprogetti
ABB Lummus Malta
5.3.5
AGBV Job No.
AGBV Doc. No.
0177/NC/02
G-80-S-O-63XX 11
CTR Job No.
CTR Doc. No.
310300
5E-631-PA-E-86627
Location
Sh. 8 of 13
GSPLAJ
Rev.
P1 P2 P3
Capacity of the system
Solidification units capacity (six units in total)

Working hours
Warehouse Stockpile net capacity
Reclaimer design capacity
Conveyor from warehouse to pipe conveyor
Conveyor from Solidification units to warehouse
Feeding Metering Station
Reclaiming Metering Station
: 6 t/hr each
: 24 hr/day
: 1 x 25000 tons
: 430 t/hr
: 430 t/hr
: 28 t/hr
: 28 t/hr
: 430 t/hr
_______________________________
AgipGas BV
LIBYAN BRANCH
Plant
MELLITAH PLANT
Snamprogetti
ABB Lummus Malta
6
6.1
AGBV Job No.
AGBV Doc. No.
0177/NC/02
G-80-S-O-63XX 11
CTR Job No.
CTR Doc. No.
310300
5E-631-PA-E-86627
Location
GSPLAJ
Sh. 9 of 13
Rev.
P1 P2 P3
INSTRUMENTATION
Solidifier Units
The control of molten sulphur flow shall be precisely monitored and automatically controlled by
means of a vortex flow meter associated with variable frequency pump drivers and by a
pressure control on the liquid sulphur return line.
A series of thermocouples shall be provided to monitor the process temperatures the necessity
of any adjustment or an upset condition by using preconditioning unit.
Temperature, pressure, flow and levels parameters throughout the system are monitored along
with other information.
Each Solidification Units will have a Local Operator Panel for local maintenance operations of
the unit(s).
6.2
Belt Conveyor to Warehouse

All instrumentation and control system required for safe and efficient operation of the unit shall
be provided by the Manufacturer.
The instrumentation shall include at least the following:
Limit switches to indicate any belt failure and to stop the flow of liquid sulphur to the
solidifiers.
A zero speed switch or other suitable device shall be designed for sequential control and to
sense belt breakage, belt slippage or belt stoppage of the feed conveyors to the
Warehouse
A safety system (consisting of an emergency shut-down push button installed on local
panel) shall be provided to stop the operation of solidifier and the feed conveyor to
Warehouse.
6.3
Portal Reclaimer
The operation and control of the portal scraper reclaimer can be effected in three different
modes as follows:
Non-interlocked Manual Mode: this mode is used during maintenance, trouble-shooting and
repair to control each individual drive at their respective location without any inter-locking
effect from the PLC controls.
Interlocked Manual Mode: this mode of operation has all inter-locking functions in active
mode, mainly for the safe operation of the equipment by the local operator.
_______________________________
AgipGas BV
LIBYAN BRANCH
Plant
MELLITAH PLANT
Snamprogetti
ABB Lummus Malta
AGBV Job No.
AGBV Doc. No.
0177/NC/02
G-80-S-O-63XX 11
CTR Job No.
CTR Doc. No.
310300
5E-631-PA-E-86627
Location
GSPLAJ
Sh. 10 of 13 Rev.
P1 P2 P3
Automatic Mode: the scraper reclaimer is electrically interlocked with the discharging
conveyor; the scraper reclaimer operates automatically until the stockpiled material is
completely reclaimed or a command to stop reclaiming is received from the remote
control in DCS Control Room. However, the operator can also stop the reclaimer locally
by the key-switch control on the operators panel.
6.4
Tripper
Travelling tripper is motorized type travelling on rails including drive unit complete with selfbreaking gear reducer, hanging flat cable for power supply and control to tripper.
The operation and control of the tripper can be effected in two different modes as follows:
Manual Mode: tripper is operated from local panel through pushbutton by putting
Remote/Local switch in local mode
Automatic Mode: before putting tripper in operation, working zone for tripper is selected and
tripper is positioned at beginning of working zone from DCS Control Room; tripper
discharges material at a particular position till stockpile level reaches high, then tripper
moved to a predetermined distance until the stockpile is full in the working zone.
6.5
Truck loading station

No controls shall be provided for future local truck loading.
6.6
Control Scheme Architecture

Controls will be divided in two sections:
a) One PLC for Solidification Units and Warehouse loading.
b) One PLC on Reclaimer for Warehouse Product Transfer to Pipe Conveyor.
The PLC for Solidification Units and Tripper Car will be located at the Electrical Substation
S/S-6 as remote I/O; controls shall be designed to provide fully automated operation and
complete status monitoring of the Solidification Units and Warehouse Loading from DCS
Operator.
The DCS Operator will be responsible:
1) to transfer the Liquid Sulphur from the Storage Tank 5E-631-TA-001/002 the Liquid
Sulphur Pit 5E-631-TH-001.
2) to transfer the Liquid Sulphur from the Liquid Sulphur Pit 5E-631-TH-001 to the
Solidification Units.
3) cooling water system.
4) to load product into warehouse.
_______________________________
AgipGas BV
LIBYAN BRANCH
Plant
MELLITAH PLANT
Snamprogetti
ABB Lummus Malta
AGBV Job No.
AGBV Doc. No.
0177/NC/02
G-80-S-O-63XX 11
CTR Job No.
CTR Doc. No.
310300
5E-631-PA-E-86627
Location
GSPLAJ
Sh. 11 of 13 Rev.
P1 P2 P3
The PLC of reclaimer will be located inside Reclaimer operating cabin; controls shall be
designed to provide fully automated operation of warehouse unloading from Shiploader
Operator.
The Shiploader Operator will be responsible to perform a limited number of operations as
follows:
1) to reclaim the solidified sulphur pastilles from the Warehouse.
2) to load the ship vessels by means the pipe Conveyor and Shiploader.
Shiploader, Pipe Conveyor, Transfer Belt Conveyor and Reclaimer will automatically initiate a
controlled auto-sequence start-up and/or auto-sequence shutdown.
Shiploader Operator will have the overall control of the product Transfer Belt Conveyor,
Reclaimer and Shiploading System.
_______________________________
AgipGas BV
LIBYAN BRANCH
Plant
MELLITAH PLANT
Snamprogetti
ABB Lummus Malta
AGBV Job No.
AGBV Doc. No.
0177/NC/02
G-80-S-O-63XX 11
CTR Job No.
CTR Doc. No.
310300
5E-631-PA-E-86627
Location
GSPLAJ
Sh. 12 of 13 Rev.
P1 P2 P3
ELECTRICAL
The electrical equipment of Solidification Units and Metering System shall be selected
according to the Hazardous Area Classification. As a minimum, all electrical equipment shall
be suitable for installation in Zone 22 areas as per IEC 61241-3.
GUARANTEE REQUIREMENTS
Manufacturer shall guarantee the satisfactory operation of the system, the performance of
each equipment of the entire system. In addition, Manufacturer shall guarantee the product
quality according to the requirements of this specification with the system operated at the
design capacity.
The following figures will be guaranteed:
Pastilles dimensions
Solidification unit capacity
Pastilles temperature outlet
Solid Sulphur reclaiming rate
Conveyors capacity
H2S emission limit
Dust emission limit
SO2 emission limit
Water
Friability
: As per Industry Adopted Modified Sudic

: 6 t/hr each
: 70 C
: 430 t/h
: according to the para 5.3.5 of this spec.
: Refer to Health, Safety,
Enviromental Project Plan
: Refer to Health, Safety,
Enviromental Project Plan
: Refer to Health, Safety, Enviromental Project Plan
: no contamination
: < 2% (stress level II after 1 day)
UTILITIES COMSUMPTIONS
Expected consumption, based on four units in operations, of the following utilities has been
calculate during bidding phase:
Heating medium LP steam, 4,0 bar g, 152C
Consumption:
for operation:
for start-up:
100 kg/h
300 kg/h
Cooling water max. 32C, 3 bar

Consumption:
approx. 100 m/h (for 4 units)
Make-up water for release agent:
12 l/h (3 l/h per unit)
CL- content of water:
max. 140 ppm
_______________________________
AgipGas BV
LIBYAN BRANCH
Plant
MELLITAH PLANT
Snamprogetti
AGBV Job No.
AGBV Doc. No.
0177/NC/02
G-80-S-O-63XX 11
CTR Job No.
CTR Doc. No.
310300
5E-631-PA-E-86627
Location
ABB Lummus Malta
GSPLAJ
Sh. 13 of 13 Rev.
P1 P2 P3
Electric energy
Capacity installed:
Solidification units
Handling conveyors
Reclaimer
40 kW (without spare units)

40 kW
less than 150 kW
Instrument air (de-oiled and dry) Pressure 7 bar

Consumption:
approx. 0,5 Nm/h
Release agent Water/Tegopren, mixture 97 % water, 3 % Tegopren

Consumption:
0,015 kg Tegopren per ton of sulphur
Final consumptions list shall be defined during detail engineering and will be in the range of
+
/- 10% accurancy of the above expected consumptions.
10 REFERENCE DOCUMENTS
Heat Material Balance N:
Process Flow Diagram N:
G-80-Y-O-0002 00
G-80-D-O-1163 02
_______________________________

G80SO63XX11P3

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AgipGas BV

WESTERN LIBYA GAS PROJECT

AGBV Doc. No.

CTR Job No.

CTR Doc. No.

AGBV Job No.

PROCESS DUTY SPECIFICATION FOR

07/07/03 Approved for Design General Revision

21/02/03 Approved for Design

18/12/02 Issued for Approval

Form code: MDT.GG.QUA.0004 Sh. 01/Rev. 3.96

WESTERN LIBYA GAS PROJECT

AGBV Job No.

AGBV Doc. No.

CTR Job No.

CTR Doc. No.

Cooling water system description

Exhaust air system description

Belt Conveyor to Warehouse

Truck loading station

Control Scheme Architecture

WESTERN LIBYA GAS PROJECT

AGBV Job No.

AGBV Doc. No.

CTR Job No.

CTR Doc. No.

WESTERN LIBYA GAS PROJECT

AGBV Job No.

AGBV Doc. No.

CTR Job No.

CTR Doc. No.

Feeding Belt Conveyor

Feeding Metering Station

Shelter for Solidification Unit

WESTERN LIBYA GAS PROJECT

AGBV Job No.

AGBV Doc. No.

CTR Job No.

CTR Doc. No.

WESTERN LIBYA GAS PROJECT

AGBV Job No.

AGBV Doc. No.

CTR Job No.

CTR Doc. No.

Cooling water system description

Exhaust air system description

WESTERN LIBYA GAS PROJECT

AGBV Job No.

AGBV Doc. No.

CTR Job No.

CTR Doc. No.

Liquid Sulphur conditions at B.L.

Cooling Water Supply conditions at B.L.

Cooling Water Return conditions at B.L.

: 44 C, maximum return temperature from individual user.

Product Characteristics (Pastilles)

Solid Sulphur Temperature

WESTERN LIBYA GAS PROJECT

AGBV Job No.

AGBV Doc. No.

CTR Job No.

CTR Doc. No.

Capacity of the system

Solidification units capacity (six units in total)