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Sulzer Chemtech
Process Technology and Equipmentfor Oil Refineries and Crude Oil Production
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Sulzer Chemtech is the process engi-neering division of the internationalSulzer Corporation with headquar-ters in Winterthur, Switzerland. Acti-vities include equipment and (appli-cation) know-how in separation andmixing technology. Products includestructured packing and trays forseparation columns, fractional crys-tallisation systems, equipment formixing and reaction processes andcatalyst supports.
Excellence in Refining Technology
Leading in research anddevelopment
With proven design procedures andinnovative engineering solutions,Sulzer Chemtech can meet the re-finery’s objectives. Sulzer Chemtechhas the personnel, experience andengineering capability to model andanalyse mass and heat transferproblems in distillation, absorption,extraction, mixing and reaction andfractional crystallisation. Apart frompilot tests, computational fluid dy-namics (CFD) for optimising and finetuning of the geometry are used forthe development of new products.
Pilot plant
Customer-specific applications canbe tested in our pilot plant. Resultingdata can be used for a reliable de-sign of the production plant.To achieve the design criteria for distillation applications on movingbarges and platforms, pilot testswith a swinging laboratory columnwere done to simulate offshore con-ditions.
Components, engineering andsystems
For more than 30 years SulzerChemtech has provided innovativemass transfer technology to the oil,gas and petrochemical industry. Awide variety of separation and mix-ing methods and process equipmentallows us to design optimal systems.
Crude oil distillationFCC vacuum towers and gas plantsLube oil distillationLiquid-liquid extractionCoking and visbreaking1-Butene separation plantsFractional crystallisationetc.
Process simulationFeasibility studiesBasic designDetailed engineering HardwareInstallationCommissioningStart up assistance
for
Numeric simulation of the cross-sectionalconcentration distribution in the SMImixer.
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Sulzer Chemtech has experience indesigning column internals for mov-ing platforms. The design is basedupon the successful combinationof laboratory tests with a movingcolumn and industrial applications.
Industrial applications includes:
• Separators (oil, gas, water)
• Gas drying
• Gas sweetening
• Multi cyclone separators
• Crude oil stabiliser
• Sea water deaeration
Sulzer Chemtech can provide following services:
• Feasibility studies
• Process design and basicengineering packages
• Hardware supply, i.e. Mellapakand internals
Crude Oil Production
Sulzer Chemtech stabiliser system basic process steps.
Special liquid distributor for moving columns
Moving pilot column
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Stabilised Condensate
Feed L/VSeparation
WaterRemoval
PartialEvaporation
Distillation
Lights + LPGSea orCooling Water
Tempered Wateror Hot Oil
Produced Water
Spindle oil
SAE 10
SAE 30
Aromatic Extraction
Raffinate
Solvent +aromatics
Distillates
Solvent
Gas oil
Lube Tower
Tankfarm
Desalter
Salt water
Atmospheric tower
Vacuum tower
LPG
Steam
Preflash Tower
Kersosene
Lightgas oil
Heavygas oil
Long residue
LVGO
HVGO
Slop wax
Airblow
Naphta
Sweet gas
H2S
Off gas
Reformate
Amine Contactor
Stripper
Gasoline Stabiliser
Separater
GasolineReformer
Desul-phuriser
Short residue
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Atmospheric Tower
Pollution RegulationsBetter fractionation between LGOand HGO will increase the LGO (citydiesel) yield and improve the quality.
Increased HGO yieldBetter fractionation and less entrain-ment, with Mellapak in the washsection, will increase the HGO yield.This will also relieve the vacuumtower.
Increased CapacityDebottlenecking a pump aroundsection often results in 20% or morecapacity. Structured packing nor-mally does not require more spaceto achieve the required heat transfer.
ExampleA revamped wash section with aninvestment of about US$ 0.5 Mio.for hardware and installation workwill result in a pay back time of ap-prox. 4 months.
Static Mixer
TankfarmCrude sampling homogeniserCrude blender
DesalterProduce the water dispersion forcrude desalting. • No moving parts.• Danger of leakage and mainte-
nance are eliminated.
Overhead LinesRemove salts from gases in over-head lines.• Preventing salt deposits in piping,
cooler or column top section.
Crude Distillation Unit
LGO
HGO
Crude
Steam
Long residue
Gas
Naphtha
Kerosene
Diesel
Gas oil
Fuel oil
VisbreakerFractionator
Cokedrum
er
Wash water
Fractionatorbottoms
Heavy cycle oil
Light cycle oil
Rich oil
Lightnaphtha
Heavynaphtha
NaphthaSplitter
DebutaniserLean oil
Stripper
PrimaryAbsorber
SecondaryAbsorber
Propane
Propylene
C3-Splitter
Fuel gas
Deethaniser
Deprop-aniser
C4
Acid gasremoval
Mainfractionator
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Vacuum Tower for CrackerFeed Preparation
Additional Diesel Side CutAn additional fractionation sectionbetween LVGO and HVGO will re-cover diesel from the LVGO.
Wash SectionIn deepcut operation flash zone tem-peratures greater than 400° C arerequired. The preferred solution forthis mode operation is a combinedbed with Mellapak in the upper andMellagrid in the lower part.This together with the Sulzerpatented VEP gravity distributor hasbeen used in more than 30 washsections.
Flash ZoneA special vane feed inlet deviceimproves the phase separation ofthe liquid from the gas. This meansless entrainment into the washsection.
Vane feed inlet device
Crude Distillation Unit
Diesel
LVGO
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Today the lube oil market is chal-lenged by new product require-ments. The refinery must cope withthe new situation. This has a directinfluence on the lube oil tower andthe aromatic extraction of lube cuts.Sulzer Chemtech has a large experi-ence with more than 50 referencecolumns world-wide.
Aromatic Extraction
Sulzer Chemtech can offer a reliabletechnology for the extraction of aro-matics from lube oils.
We have experience with Furfurol,Phenol and NMP as solvents.
Extraction columns equipped with the Sulzer extraction packing SMVPoffers:
• Increased capacity for debottlenecking of existingcolumns.
• Moderate contacting of the phases for reduced entrainment.
• High flexibility.
• No moving parts and thereforelow maintenance costs.
Lube Oil Plant
Lube Oil Tower
Advantages of Mellapak Benefits for the customer
• Low pressure drop • Increased capacity
• Good separation efficiency • High distillate yields
• High flexibility • Improved distillate quality
• Selected packing types • Additional new lube cuts
• Compact internals
Aromatic extraction
Lubetower
SolventSpindle oil
SAE 10
SAE 30
Solvent +aromatics
Raffinate
Gas oil
Distillates
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The “bottom of the barrel” has become more important to refineriesbecause heavier crudes are beingprocessed and the market forvacuum residues is decreasing.
Sulzer Chemtech can offer solutionsthat increase plant capacity, reducethe risk of fouling and extend therun time.
Our products are successfullyinstalled in:
• Delayed Coker Fractionators
• Flexicoker Fractionators
• Visbreaker Fractionators
• Vapour quench cooler with static mixers
Comparison of tray and Mellapak column for H2S removal (to scale).
Coking and Thermal Cracking Processes
Mellagrid
Sulzer Mellagrid was specificallydeveloped to combine the efficiencyof Mellapak with the mechanicalresistance of grid. Advantages are:
• Not sensitive to coking or foulingdue to its geometrical structureand smooth surface.
• Much better demisting and sepa-ration efficiency than traditionalgrid.
• The structure and element heightallow for easy cleaning. It can beremoved, unscrewed and cleanedwith water jet.
• Mechanically robust structure.
Special Liquid Distributor
Plugging resistant and with a highturn down ratio.
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um tower
LVGO
HVGO
Slop wax
Airblower
Wash water
Fractionatorbottoms
Heavy cycle oil
Light cycle oil
Rich oil
DLean oil
Stripper
PrimaryAbsorber
SecondaryAbsorber
Dean
Acid gasremoval
H2S
Off gas
Reformate
Amine Contactor
Stripper
Gasoline Stabiliser
Mainfractionator
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FCC Main Fractionator
The advantages using structuredpacking in the FCC Main Fractiona-tor are:
• Reduced pressure drop (typicallyfrom approx. 350 mbar to about60 mbar).
• Increased capacity.
• Improved separation betweenside products.
Slurry Section
The use of Sulzer Mellagrid togetherwith a slurry distributor increases column throughput and heat transferperformance while reducing risk offouling.
Due to the geometrical structure ofMellagrid entrainment of catalystparticles is reduced.
Installation of structured packing.
FCC Unit
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Lightnaphtha
Heavynaphtha
NaphthaSplitter
DebutaniserPropane
Propylene
C3-Splitter
Fuel gas
Deethaniser
eprop-iser
C4
s
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Complete Systems
Propylene Plant
Sulzer Chemtech can offer theprocess and basic engineering,tower internals, reboilers and theturbocompressor for a grass rootpropylene plant with vapour recom-pression.
Example
• Production of 125,000 tons peryear polymer grade propylene.
• Use Sulzer Chemtech vapour recompression technology.
• Use high efficiency structuredpacking Mellapak to reduce towerdimensions and compressor power.
1-Butene Technology
Sulzer Chemtech is able to supply a process for the separation of 1-butene. A number of variations arepossible depending on the customerrequirements. Years of experienceand continuous development haveresulted in the capability of supply-ing tailor made designs, assuring themost economic 1-butene produc-tion. Sulzer Chemtech’s structuredpacking, heat coupling or heat pump systems have been proved in com-mercial service.
FCC Unit
Fractionation Trays
Over the last 40 years the productknowledge has developed to a leadingmass transfer technology with a wideapplication area.The High Performance Trays arebased on the unique V-Grid tech-nology and innovative downcomerdesign.
Example• Deethanisers• Depropanisers• C2- and C3-Splitters• Debutanisers• Deisobutanisers• Dehexanisers• Xylene Splitters
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LPG Sweetening with Amines
Sulzer Chemtech has experiencewith amine sweetening in bothliquid-liquid and gas-liquid systems.
Liquid-liquid Extraction
Extraction packing SMVP in aminetreating of LPG offers:
• Capacity increase of existing columns.
• High flexibility.• Low amine entrainment.• Low maintenance costs.• Small investment for the revamp
of existing columns.
Amine Contactors
Sulzer Chemtech has extensiveexperience with the absorption ofH2S and CO2 with various amines.More than 100 columns are inoperation world-wide.
Furthermore selective absorptioncan be used in sour gas systemscontaminated with CO2.
The advantages using Sulzer Chem-tech column internals are:
• High selectivity through short residence time.
• Small solvent quantities.• Low regeneration costs.• Low pressure drop.• Low investment costs.
Off (Tail) Gas Treating
The use of Mellapak in the Quenchand H2S absortion column results ina small pressure drop and thereforein important energy saving.
Desulphurization
Hydrodesulphurization
Static mixers from Sulzer Chemtechare used to remove salts from thereactor effluent and fractionatorover-head to avoid fouling of thecoolers. Reactor effluent scrubberalso clean the recycled hydrogen.
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SweetLPG
Amine
SulzerSMVPExtractionPacking
LPG + H2S
H2S-rich Amine
H2
Feed
Reactor
H2O
Sulfur recovery
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Acid Wash Mixer
Removes the alkyl-sulphates fromthe effluent stream for returningthem to the reactor.
Caustic Wash Mixer
Removes the acid traces from thereactor effluents to protect theseparation columns and other downstream equipment from corrosion.
Alkylation
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ReactorFlashdrum
Acid Spent Causticacid
Spentcaustic
Deisobutaniser
Caustic
Spent caustic
Depropaniser
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Only advanced process solutionstogether with high quality com-ponents can secure the competitiveadvantage of refineries in today’s highly competitive environment.
Innovative Components
Mellapak Columns with structured packing Mellapak,pioneered by Sulzer, have following advantages:
• High performance
• High capacity
• Low pressure drop
• High flexibility
MellapakPlus The invention of Sulzer gauze packing resulted ina decisive breakthrough in mass transfer equip-ment. A further milestone was the development ofthe Sulzer Mellapak. Mellapak opened up newand unforeseen perspectives in all areas ofthermal mass transfer.The new MellapakPlus is the latest developmentand offers the lowest pressure drop of all struc-tured packings available on the market.
Mellagrid Mellagrid can be used in every area, where themechanical strength of Mellapak could causesome concern or where plugging or coking are likely to occur.
Column internals The great success of our products has only beenpossible in conjunction with the continuingdevelopment of distributors and other internals.
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Innovative Components
Fractionation Trays A full range of fractionation trays especially suited for refinery applica-tions.
Optimised for fast installation andeasy maintenance.
Static mixers Advanced static mixing and reactiontechnology is suitable to many refin-ing process units.
• Blending liquids or gases.
• Dispersing liquids or contacting gases to equilibrium conditions.
• Washing or scrubbing hydrocar-bons.
• Vaporise liquids or condense gases.
Shell Mass Transfer The complete Shell Mass TransferTechnology Technology Package, previously
used only by Shell companies, isnow available from Sulzer Chemtechunder the terms of the alliance be-tween Shell Global Solutions BV andSulzer Chemtech Ltd.The technology covers high perfor-mance trays, associated internalsand phase separation equipment.The technology has been the Shellstandard for years and it is backedby an abundance of operational anddesign experience. Sulzer Chemtechnow offers these dependable highperformance trays and separators totheir customers.
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Industrial Applications from A to Z
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Mixers, Packings, Process design,Trays and Installation Service formany applications.
Alkylation – static mixer for product neutralisationAmine ContactorAromatic extraction from LubeOilAtmospheric Crude Oil Tower – more than 80 columnsworld-wide with Mellapak
Benzene TowerBitumen tower1-Butene –Distillation and heat pump technology
Coker FractionatorCrude sampling mixerC3-SplitterC4-SplitterC5-Splitter
DebutaniserDeethaniserDehexaniserDemethaniserDepropaniser
Deepcut Vacuum Tower –Mellagrid, Mellapak and VEPdistributorDesalting Water-oil Mixer
Ethylene Water Quench
FCC Main Fractionator – Mellagrid in slurry section
Gasoline blending mixer
H2S extraction from LPG
Kerosene Stripper
LNG-StabiliserLube Oil Tower – Low pressure drop, high separa-tion efficiency with Mellapak
Naphtha Splitter
Off-gas treatingOlefin separation
Para Xylene –Heat pump crystallisationPreflash TowerPrimary Absorber
Quench Tower
Reformer Feed Gas Mixer
Secondary AbsorberSolvent StripperSour Water StripperStabiliser
Toluene Tower
Vacuum Tower for Cracker Feed – over 150 columns with Mellapak world-wideVisbreaker Fractionator –Application for Mellagrid and Mellapak
Xylene Splitter
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Services to Customers
Worldwide Sales and Manufacturing
Sulzer Chemtech has together withthe Sulzer Corporation world-widepresence with offices in most coun-tries.Furthermore Sulzer Chemtech hasits own production facilities inSwitzerland, the USA, India, China,Singapore and Mexico.
Field Service
Sulzer Chemtech has the projectmanagement and technical skills toassure successful installations for newcolumns and revamps in refineries,gas processing and petrochemicalplants.Abilities range from site supervisionto complete installation.
Emergency Services
In the event of a break down or otherplant upsets, Sulzer Chemtech cansupply packing, column internalsand trays at short notice.
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Distributed by:
HeadquartersSulzer Chemtech LtdP.O. Box 65CH-8404 Winterthur, SwitzerlandPhone +41 52 262 50 28Fax +41 52 262 01 [email protected]
North and South AmericaSulzer Chemtech USA, Inc.8505 E. North Belt DriveUSA-Humble, TX 77396, USA Phone +1 281 441 5800Fax +1 281 291 0207
Asia, PacificSulzer Chemtech Pte. Ltd.10 Benoi SectorSingapore 629845Phone +65 6515 5500Fax +65 6862 7563
Sulzer Chemtech Ltd, a member of the Sulzer Corporation, with head-quarters in Winterthur, Switzerland, is active in the field of process en-gineering and employs some 2500 persons worldwide.Sulzer Chemtech is represented in all important industrial countriesand sets standards in the field of mass transfer and static mixing withits advanced and economical solutions.
The activity program comprises:
• Process components such as fractionation trays, structured and random packings, liquid and gas distributors, gas-liquid separators,and internals for separation columns
• Engineering services for separation and reaction technology such asconceptual process design, feasibilities studies, plant optimizations including process validation in the test center
• Recovery of virtually any solvents used by the pharmaceutical andchemical industry, or difficult separations requiring the combination of special techniques, such as thin film/short-path evaporation, distillation under high vacuum, liquid-liquid extraction, membrane technology or crystallization
• Complete separation process plants, in particular modular plants(skids)
• Tower field services performing tray and packing installation, towerand column maintenance, vessel welding, and plant turnaround projects
• Mixing and reaction technology with static mixers
• Cartridge-based metering, mixing and dispensing systems, and disposable mixers for reactive multi-component material