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The Hazira Onshore terminal begins where the South Bassein-Hazira
Pipeline ends and ends at the distribution outlet points for the gas and
condensate streams. The terminal has facilities for receiving the two-
phase flow, separating into condensate and gas streams, condensate
stabilization and distribution.
The two-phase flow is received in the slug catcher, where the gas and
condensate streams are separated. The gas is filtered, metered and sent
to the GSU plants for further processing.
The separated condensate from the slug catcher is metered and sent to
the CFU plants for further treatment. The gas is supplied in the existing
36´ pipeline and 42´ pipeline. The following main equipments are
provided at this terminal:
-Pig receiver
-Pressure reducing valves
-Slug catcher
-Filtering unit
-Metering unit
The pig-receiving trap makes it possible to recover the pig when
scraping the line and to remove any foreign matter and residual solids
entrained by the pig itself.
There are pressure controllers downstream of the pig receiving
stations. The sour gas (42´) pipeline has downstream pressure control
valve input depending on HBJ requirement.



Three slug catchers in 3 phases (I, II&III). It is designed to handle
associated gas coming from Bombay high field and from satellite fields
to knock out the condensate from the incoming gas. The condensate
free gas is either processed in gas processing plants or diverted to
consumers. Separate pressure regulating skids are provided on the
trunk BUT (Bombay High Uran trunk) to maintain GSU (Gas
Sweetening Unit) inlet pressure i.e. the skid downstream pressure.
Downstream of the control valves is the slug catcher, which has existing
48 fingers and new 6 fingers. During normal operation phase-I slug
catcher (24 fingers) separate condensate from 25MMSCMD sour gas
from 42´ line. Phase-II slug catcher (24 fingers) separate gas and
condensate from 36´ line, suitable inter-connections have been envigsed
in the existing line to hook up with the new line from offshore.
However, during pigging of the 42´ line, all the 48 fingers will be lined
up to receive the liquid hold up in the 23 km line. During this time the
3.6 lines shall be lined up to the 6 new fingers to separate gas and
condensate. Each finger is 498 mts long. Slug catcher consists of
condensate storage section, separating section, primary riser, and
secondary riser. Gas and condensate from pig receiver is fed to slug
catcher separation section where the gas is separated. The separated gas
goes to gas filtering unit through primary risers. Condensate, which is
removed from gas, is stored in slug catcher and for further separations
of the entrained gas. The separated gas from primary riser, secondary
riser and equalizing riser combines together and goes to filtering unit
through 26´-P-04-219-D174.Slug catcher-III has 6 fingers.



c
 c
The gas from the slug catcher is sent for filtration in which any
condensate entrained along with the gas is separated. Sour gas from Ph-
I slug catcher is sent for to existing filtration unit and sweet gas from
Ph-II / Ph-III slug catcher is sent to new filtration unit. For normal
operation, two filters will be operated to cover the 25MMSCMD of sour
gas and one is standby. New filtration unit has three filters. Each filter
can treat max.5800000SCMH sweet gas to remove 99% of 10ü solid
particles. For normal operation, two filters are operated to cover sour
gas. Sweet gas which is removed of solid particles goes to metering unit
and then goes to DPD unit.
Each filter is equipped with liquid automatic discharge, which is
controlled by the liquid level inside the filter itself. The condensates
from sweet and sour gas are metered separately.
Gas filter separate from condensate or particle with principle of
centrifuge.
Gas filter has 200-2´ dia cyclones. Feed is injected tangentially into the
upper part of the gas filter section and develop a strong swirling, motion
within the cyclone. Liquid containing the fine particles fraction is
discharged out through the under flow.
Gas filters equipped with differential pressure gauge to moniter the any
leakage. The liquid coming out of the filters will be sent to a single
collecting line, connected both with the line conveying the condensates
to the blow down and with the feeding line of the stabilization plant.
The condensates from sweet and sour gas are metered separately.
Provision is kept for mixing the sweet gas condensate in the sour
condensate, after which it goes to the sour condensate fractionation unit.

-To hold the slug fluid coming at uran at the time of pigging of the gas
pipe lines.
-To separate continuously coming condensate along with saturated gas.
-To partially stabilize the liquid condensate & inject into crude inlet to
CSU, in case of CFU-I/II are down or running at maximum capacity.
-To supply gas to GSU for sweetening.
-Condensate from the associated gas compressors also can be stored in
the slug catcher when CFU-I/II is not in operation.

















 
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c

Two gas sweetening trains of Ph-III A(37& 38) can handle a total of
12.6 MMSCMD of sour gas.The remaining trains of GSU can handle 28
MMSCMD with 5 trains operating and one standby. This makes the
total capacity 40.6 MMSCMD with one train of capacity 5.6
MMSCMD as standby.
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The following mixed gas composition has been considered for the
design of GSU and GDU.





 
c #

  !" 
  !"
† 0.21 0.19
† 6.00 6.50
#†
 0.137 0.137
 79.84 78.596
† 7.48 7.41
 4.14 4.54
´ 0.18 0.23
Ë 0.17 0.22
â 0.22 0.15
ù 0.05 0.11
 0.01 0.05
' 0.002 0.01
>  0.001 -
 The design composition of sour gas is as per the Material balance
given by SNEA after the test runs. Additionally the design shall be
check case composition containing 6.5% (mole) CO by adjusting
methane content.
Pressure at battery limits : 96-54 kg/cmƒabs
Temperature at battery limits : 20-33 ±C
Gas sweetening train will have a maximum operating pressure of 77
kg/cmƒa. A pressure control valve and heating device upstream of the
pressure valve will prevent hydrate formation. H S and CO content
will vary depending on conditions.

 

 

The product from each gas sweetening train will meet the following
specification.
Sweet and dry gas:
#
$ %&&'($)*

++,-'+ .%)/01)/23'ƒ,+
'&,-'+ %4±
Rich MDEA flash gas:
#
$ %&&'($)*

++,-'+ %)023'ƒ,+
'&,-'+ %500±
Acid gas:
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++,-'+ 1)/23'ƒ,+
'&,-'+ 04±



 


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In the sweetening process, gas is washed with aqueous solutions of MdeA.
The MDEA and TEG trains are connected with one another by a pipie rack
supplying products and required utilities.
GAS SWEETENING UNIT
The main purpose of this gas treatment step is to remove the H S from the
sour gas with a high severity, and at same time the CO co-absorption to
the minimum required and in any case, to not more than 32%.
MDEA PROCESS PRINCIPLES
The selective removal of HS is made by washing the sour gas with an
aqueous solution of Methyl-Di-Ethanol-Amine.
The process principles are similar to the well known SNPA-DEA
process.The only difference is the behavior of the ethanolamine used.
Methyl-Di-Ethanol-Amine(MDEA) is a tertiary amine, which does not
react easily with CO .The selectiveity is so promoted by using the
differences in reaction rates between both H S and CO and the tertiary
amine.
First the case of a primary or secondary amine whose reactions with the
acid components H S and CO are similar, is investigated.
HS reacts to give amine hydrosulfide:
H S + R NH ö HS$ , R NH R
CO can react directly with amine to form an amine carbonate:
CO + 2R NH ö R NCOO$ , R NH R
But CO can react with water or hydroxyl ions to form carbonic acid or
bicarbonate ions:
CO + H O ö H CO

CO + HO ö HCO
$
There are basically two units:
1) High pressure absorption.
2) Amine regeneration.
1"#&++,+$&$


- Sour gas liberated from CFU also joins this stream under flow control.
- This combined sour gas comes in counter current contact with lean
amine solution (MDEA:-Methyl Di Ethanol Amine) in absorption
column having 14 type trays.
- The sweet gas leaves from the top of the column with 4 PPM H2S
which is cooled and routed to GSU/LPG units through knock out
drum (KOD).
 - The rich amine from the column to medium pressure absorber/flash
drum. The flash gases go to fuel header and rich amine (containing
H2S) passes through the plate heat exchanger before it enters the
regeneration column having 21 trays for regeneration of amines.
- Regenerated lean amine from the bottom goes back to the MDEA tank
and is recycled in the process.
- Acid gas consists of 98% of carbon dioxide and 2% of hydrogen
sulphide.
- It is liberated from the top of the regenerator column for sulfur
recovery.
 
-Ê To reduce the hydrogen sulphide content of sour gas to 4PPM.
-Ê To limit the carbon dioxide co-operation to the minimum required no
more than 32%.

&($(6
-Ê Counter current absorption using aqueous solution of MDEA.
-Ê Regeneration of rich MDEA solution to lean MDEA solution in two
stages.
STAGE I:-
Flashing of intermediate pressure in MP flash drum to
regenerate fuel gas.
STAGE II:-
Reboiling of rich MDEA in regenerator to generation acid
gas to SRU.


#9
&-
The SRU is designed to treat 35,000 NM³/Hr of acid gas originating from
the gas sweetening unit. Each train is capable of treating up to 7000
NM³/Hr of acid gas with a hydrogen sulphide concentration ranging
between .3 and 5.2 mole percent i.e. 3000 to 52000 ppm of H S.The
sulphur production will range between 0.7 and 12.2 metric tons per day
per train .Under normal circumstances four trains will operate at full
capacity while two remains on standby/under maintenance.

 

 
The acid gas composition will vary with the variation in sour gas
throughout, arrival pressure and temperature at hazira.
The acid gas has the following properties:


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Sulphur produced by the SRU is a consequence of meeting an
environmentally acceptable gaseous effluent.
The sulphur is expected to have the following characteristics:-

&&- //)/!
$+ 0.1%
+ Less than 400 ppm
+ Less than 500 ppm
+?
? Commercial Nil
 250 ppm max.
$' Solid, in flakes form

2 25-30 kg bags



 
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The locant unit will reduce the H S by 99.9% from 5.2% to 10 ppmv.The
locant unit works by contacting the H S with a liquid phase catalytic
reagent, which absorbs the H S and converts it to elemental sulphur and
H O.Details of thetheory and operation of the locant unit designed for this
application are contained in the following sections.
#
 
The locant process brings about the following reactions to produce solid
elemental sulphur from hydrogen sulphide gas.
,+$&$
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 A6"@#† A6"C))) 1"
+$8$
#†
 A6"B#M@#
DCCCCC))CCCCCC))) :"

$6$8$
#
DB#M@
DCCCCCCCC))CCCCCCC))) E"
*6$,-'$+ MM"

DD@:MMMB
= +$6"@:MMCCC))CCCCC) %"
($
 #†
 +"@:MMMB:#M@
=@:MMCC)))CCCC) 0"
The metal ions must then be deoxidized in the regeneration part of the
process using oxygen from either ambient air (anaerobic process) or the
process gas itself (aerobic process).
,+$&$
† +"@:#†B† A6"@:#†CCC)))CC))) ;"
$$F'$+
G A6"@#†@:MMB: #"D@:MMMCCC) ."
($
G +"@#†@:MMB: #"D@:MMCCC)))C 5"
$7?66A$+ 0"6 5"$(+
#†
 +"@G† +"@#†B
= +$6"@:#† A6"
In this overall reaction, the metal serves to transport electrons from
the absorber side of the reaction to the regeneration side, and it is
necessary to supply at least two metal ions per atom of sulphur made. In
this sense, the metal ions are a reagent. However, they are not used up
in the overall reaction and serve as a catalyst for the reaction of catalyst
for the reaction of H S and O .Because of this dual function, the metal
ion concentrate, ARI-310 solution is described as a catalyst reagent.
The auto circulation LO-CAT unit addressed in this manner utilizes the
differential density between two aerated liquid phases at different
aeration rates to circulate ARI-310 solution from the oxidizer section to
the absorber section of the vessel. The solution absorbs HS and small
amounts of CO and is returned to the oxidizer. Air is introduced in the
oxidizer section of the vessel, whose oxygen is absorbed into the
solution.This absorbed oxygen regenerates the catalyst. Equation (9)
indicates that there is no net production of H ions of OH ions and the
pH of the solution is not changed by the basic reaction. However,
several competing side reactions do go on to a limited extent, and
require the addition of KOH. Or other alkaline material to maintain the
pH of the solution high enough to give good HS absorption. The side
reactions are less clearly defined from a chemical standpoint, but may
be represented by the following generalized reaction:
:#
@:†B
†@#†
When this is combined with the ionization reactions, it is apparent that
there is a net production of HM ions whenever S O
is produced. This
would lead to a decrease in the pH of he solution, and to prevent this, it
is necessary to add an alkaline reagent such as KOH either continuously
or intermittently to control the pH of the solution. Usually pH values in
the mildly alkaline range between 7.5 and 8.5 are satisfactory for most
applications. The exact pH required will vary with the type of absorber
and absorber efficiency required. Operation at an excessively high pH
will encourage the formation of thiosulphate ions even though a larger
fraction of the dissolved H S will be in the form of s ions at high pH
values. Operation at abnormally low pH of the solution. To prevent this
form happening, it is necessary to further buffer the solution with an
alkaline reagent such as KOH.As a general rule, a concentration of
10wt% KOH is required in the circulating solution for a gas steam
containing solution for a gas stream containing 1 atmos partial pressure
of CO .This will give a solution pH of between 7.5 and 8.5.Batch or
continuous make up will be required to overcome the withdrawal losses
from the system. It is apparent that the formation of sulphate and
thiosulphate and addition of alkaline reagents to control the pH will lead
to increasing concentrations of dissolved salts in the ARI-310 solution
with time.