takreer_rfcc 1st day calss

7/22/2019 Takreer_RFCC 1st Day Calss

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GS-Caltex RFCC Process

Overview

June, 2013


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Residue Fluidized Catalytic Cracking is a process used to convertresidues to gasolines and middle distillates

Atmospheric Residue (100%)

H2, C1 - C2 Gases

LPG

C5

Cracking Naphtha (LCN)

Light Cycle Oil (LCO)

RFCC Oil (RO)

CrackingCatalyst

Residue Fluidized Catalytic Cracking

Fluidizedmeans that cracking and coke burning reactions take placewith fluidized cracking catalyst


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Introduction to RFCC

History


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Project Proceedings

1992. 1 Kick-off Meeting with Stone & Webster

1994. 2 Pile Driving for Foundation

1994. 7 Erection of Main Fractionator

1994. 9 Erection of Reactor & Regenerators 1995. 8 CO Boiler Firing

1995. 9 Mechanical Completion

1995.12 Feed-in


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Project Outlines

Capacity : 70,000 B/D

Plot Area

On Site : 70,000 M2

Off Site : 240,000 M2

Investment Cost : US $ 530Million

Manpower : 1,110,000 Man-days


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RFCC Complex Capacities and Licenses

Unit Capacity Licensor Detail Eng Const.

RFCC 70,000 B/D S & W LGEN DIC

Slurry Filter 8,700 B/D PALL PALL DIC

Sulfur Bed 17,500 B/D ISG ISG DIC

LPG Sweetening 17,500 B/D Merichem DEC LGC

C5 Sweetening 8,500 B/D UOP DEC LGC

LCN Sweetening 19,500 B/D UOP DEC LGC

HCN Sweetening 12,000 B/D UOP DEC LGC

SRU 100 Ton/Day TPA DEC LGC

DeSOx 566,200 NM3/Hr Haldor Topsoe DEC DIC

MTBE 2,500 B/D CD Tech LGEN DIC

(TAME) (2,800 B/D) (CD Tech) (LGEN) Delayed


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Main Features of GS-Caltex RFCCU

One of the Largest RFCC Units in the World

Most Severe Design Feedstock (CCR: 5~ 7 wt%)

Two Stage Stacked Regenerators

Two Catalyst Coolers

LD2 Separator in Reactor (2009 RSS Separator)

Power Recovery Train

Two CO-Boilers

1st Application of Haldor Topsoe DeSOx Unit to RFCCU

Oxygen Enrichment

ZSM-5 Injection

APC/VPS Utilization


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RFCC Improvement

History


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Improved Items Since Start-up (1)

In 1996

Conversion Precursor Analysis of Feed Stock

Cat. Cooler Tube Leak Solve (Published on O&GJ)

Radio-tracer Study

Detected 80% Vapor Underflow at the Ramshorn Separator

TPA(Top Pump Around) Injection in Feed Nozzle


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In 1997

Slurry Filter Troubleshooting(Published in O&GJ)

Ramshorn Separator Modification

Yield Increase 3 Vol%(Dry Gas, Coke Make Decrease)

Modified Dust Removal System of 3rd Stage Separator

Improvement DeSOx Unit

Catalyst Screening System

SO2 Converter

Stack Plume

Mechanical(Fabric Bellows, Acid pump, etc)


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In 1998

Improved Fouling of MF Bottom System Through

HP Steam Generator(152E-201A/B/C/D) Tube Size up

Installed Additional Air Compressor

Integrated Amine System(DGA to DEA)

Catalyst Evaluation

DCR Set up & Test

High Conversion, Less Coke Make Catalyst Selection


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In 1999

Installed O2 Enrichment(100% O2 Injection) System

LPG Capacity Increase Through Common LPG Unit

Recovered Flaring LPG From Sulfur Bed

Modified ESP Ash Handling System

Operation optimization

Operation Guide Set-up Through Test Run

Dry Training For Emergency S/D Case

Troubleshooting History Keeping & Training

Knowledge Sharing Network Establish(Homepage)

Recorded Max Feed of 83,700 BPSD in Dec 12, 1999


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In 2000

Expander Service

Cat. Cooler Steam Let-down System Service

Held 3rd RFCC Peer Review

Injected ZSM-5

R2 Partial Burning Mode Operation

Recorded Max Feed of 84,500 BPSD on March 30, 2000 Recorded Conversion Max (77.5%)


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In 2001

Expander Modification 2 Stage to Single

Modified Air Blower Filter to Dual Bag Filter System

Increased O2 Injection Capacity by 12,000 Nm3/Hr Installed 4th Cyclone at Downstream of 3rd Stage Separator

Installed LPG Vaporizer for RFCC

Replaced Stripper Reboiler and Modified Column Internal Modified DeC3 Column Internal


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In 2005

Modified Feed Nozzle to Micro-Jet Type (ABB-Lummus)

Introduced Selective Hydrogenation Unit (SHU)

Replaced Main-Fractionator Tray

Replaced Stripper Tray

Replaced Column Trays (DeC5, DeC4, DeC3, Splitter)

Replaced Primary & Secondary Absorber Trays

Improved Cooling, Pumping & Hydraulic Systems of the

Downstream Units


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In 2009

Reactor RSS

Stripper Packing Install

Cyclone Replacement

DeSOx GGH Replace

DeC4 Auxilary Rebolier Install


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In 2012

RSS Improvement

ESP Modification

WSA Condenser Glass Tube Modification

SO2 Converter Burner Replace


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RFCC Catalyst Employment

YearCatalystBrand

Catalyst FeatureDaily

Usage,

ton

Feed Rate,BD

Price,USD/MT

1995

1996

GraceDavisonOrion I

Start Up CatalystRecommended by Licensor (SWEC)

26 64,000 1,900

1996

1997

GraceDavisonOrion II

Optimize Catalyst Activity 28 67,000 1,900

1997

2000

BASFUltrium I

Improve Catalyst Activity(Less Bottom)

21 72,000 1,800

2000

2003

BASFUltrium II

Improve Bottom Cracking & ActivityRetention (Less Bottom)

25 78,000 1,800

2003

2008

BASFUltrium III

Improve Coke Selectivity & MetalTolerance (Higher Feed & Less CatAddition)

27 90,000 1,900

2008 Now

JGC C&CCVZ I

Improve Metal Tolerance(Less Cat Addition)

20 92,000 2,700


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RFCC Operation &

Monitoring


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Key Parameters

Feed

Quality

Operation

Variables

Catalyst

Properties

Converter

(Rx-Regen)

Catalytic

Cracking

R/C

(80,000 B/D)

Dry Gas (27,000 Nm3/Hr)

C3 (11%)

C4 (16%)C5 (15%)

LCN (30%)

HCN (7%)

LCO (15%)

RO (9%)

Coke (8~9 wt%)


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Feed Properties

Physical Property

API Gravity : 19~22 (API = 141.5/Sp.Gr. - 131.5 ) Distillation Temp 50% : 480~520 C

Aniline Point : 90~100 C

Viscosity : 150~200 cSt @ 50C

MCR(Micro Carbon Residue) : 4.5~6 wt%

Sulfur : 1.6 ~ 2.1 wt%

Nitrogen : 1300~1600 ppm

Metal (Ni:5~12 ppm/V: 5~20/Fe: 2~4), Na (


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Catalyst Properties

Silica(SiO2), Alumina(Al2O3) based Zeolite Catalyst

Component : Zeolite, Matrix, Binder, Filler Physical Property

APS(Average Particle Size) : 80 um

ABD(Apparent Bulk Density) : 0.8~0.9 g/cc

PV(Pore Volume) : 0.3 cc/g

MAT(Micro Activity Test) : 68~70 wt%

Surface Area : 140 m2/g,

Chemical Property

Nickel(3500 ppm), Vanadium(5000 ppm), Fe(5500 ppm)

Carbon : 0.04~0.06 wt%


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Operation Variables

C/O Ratio : 6.0~7.0

ROT : 520 ~ 530 C

R2 Temperature : 720 ~ 730C

PHT : 180 ~ 200C

TPA : 0 ~ 5,000 B/D

Cat. Make-up Rate : 20 ~ 30 Ton/Day

Air Flow Rate : 320 ~380 KNM3/Hr

Oxygen Flow : 0~12,000 Nm3/hr

ZSM-5 Injection : 0.5 ~ 0.8 Ton/Day

MF Top Temperature : 125~130C


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Yield Pattern and Conversion

Feed : 92,000 BPSD (ATB)

Yield (vol% FF)

LPG : 26.8

C5 ~ HCN : 53.3

LCO : 16.4

DO : 8.3

Total : 104.8 Conversion : 75.3 vol%

Coke Yield : 8.1 wt%

By-product

Fuel Gas : 29,700 NM3/Hr Molten Sulfur : 126 Ton/Day

H2SO4 : 80 Ton/Day


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Profit Maximization

Profit Feed Cost : $ 38.6/Bbl

Product Cost : $ 59.4/Bbl Gross Margin : $ 20.8/Bbl

Opex. Cost : $ 1.1/Bbl

Net Margin : $ 19.7/Bbl

What gives more Profit? Source of Crude Mix

Exchange Rate

Seasonal Price Change of Product

Optimal Operation

Maximum APC Target Value Setting

i


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Converter Section


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Main Fractionator Section

Daily MB For Main Fractionator & Downstream, made by S. J. Jung, TST 331 Rev 7

332 0.0 Start Time: 2003-6-12 00:00:00 End Time: 2003-6-12 08:00 Feed TK332 2003-6-12 00:00:00 Daily Average

Operation Data: +- 1% Change Comp to previous day, Lims Data: +/- 5% Change comp to 2 month avg No.2 KD HDS H2 28.4 Feed TK333

Conv: 75.4 %: Vol% of Fresh Feed (Apparent) 4,010 Nm3/hr C1 33.5 H2 19.2 0.6(H2/C1 Ratio)

Liq.Rec: 105.9 M/F O/H Dist. C3+ 3.9 C1 33.0

Feed Quality 263 kl/hr 28,614 Nm3/hr 24,610 21,308 Nm3/h C3+ 4 .05 Note:

MCR 5.22 1st Spill Back 119 39,679 b/d 319 SCF/BBL

Visco 114.3 WGC Nm3/hr Nm3/FF EfficiAni 92.0 1st In: 65483 121 90% C3Mix 11.4% 517 Nm3/hr

API 20.4 2nd In: 62324 115 79% 35.6 #REF! 61.7 kl/hr 55 Propylene

S 1.2 45,405 Nm3/hr 32,315 Nm3/hr DP 9,317 b/d 22.9 43.2 kl/hr

Ni 5.6 0.00 ton/hr kk C3= 100.1

V 12.0 42(T) C3=% 10.5 540.9 T/D

N2 1215 40(T) 76.8

50% 485 128 0.2(C4tot) 12.0 41

Air 343 2.01 70 kl/hr 52 118(rlxF) kl/hr Propane

O2 9226 19.9 58.0 kl/hr 36 14.8 kl/hr

R1 T 682 113 kl/hr C4+ 0.6

R2 T 723 27,838 Nm3/hr 17,098 b/d

CO/CO2 0.50 51 Nm3/kl feed 3187(Stm) Cogen C4 Raff inate

Ex O2 0.1 110 886(TPA) 8.2kl 63.5 kl/hr

Cat'C 130 55 30 kl/hr 1.7(C3tot) 18.0 kl/hr 9,586 B/DHSS 300 16.6 C4 mix 1,3BD 180

548 kl/hr Slop C3 O/H DP 64.4 kl/hr Feed 15.3%

ROT Wash F 82,819 b/d 3.5 S.B. 2.01 9,729 b/d 82.4 kl/hr MTBE

8.7% 526 310 122(outT) Meri. 2.87 12,447 b/d 16.3 kl/hr

241 (LCO) 596(LCO) Abs. n.a. iC4= 16.6 2,460 B/D

TPA 345 (HCO) 122 LPG: 143 kl/hr 1,3 B/D 2,316 4(MeOH) Purity 99.0

4.2 kl/hr 357 (Desup) 26.5% Olefin 57.0 40.1'C(FeedT) 1ryCon 93. 9

700 b/d 222(F) C2 61 200(rlxF) C5 17.2%

LCO 16.5% 1,024 11.00 32(rlxT) 127 28(rlxF) 83 70(rlxF) 93 kl/hr

194(PHT) 195(F) 89 kl/hr 31 kl/hr 0.92 66(rlxT) 2.34 42(rlxT) 14,062 b/d

fc034 344 13,500 b/d 235 kl/hr Sour H2S 20.1 Ol efin

532.80 540 kl/hr 90% D 359 35,548 b/d Sweet St 60.0 50.4

80453 81,600 b/d API 14.4 453 kl/hr 180(outT) 286 kl/hr 19(Stm) C5 84.0 Lab C4

Visco 3.1 68,404 b/d 49(Stm) 43,189 b/d 122(HPA) C6+ 8.9 7.1Slop 2.0 179 162(inT) 221 Gap: 24'C (HCN5%-LCN95%) 147 LCN 27.5%

MF Btm S.F. 1.9(DP) (Design:16'C) 148.8 kl/hr

API 1.1 8.1% HCN 9.9% 22,465 b/d

Visco 4717.4 43 kl/hr API 0.2 AnalC4 0.91 Nap Spl Feed-O/H 54 kl/hr Sulf 70.0

Al 280.3 6,531 b/d Visco 590 51 kl/hr 8,097 b/d 8.8 kl/hr 129kl/hkl/hr Ol efin 22.3

Sb 5.8 Sulfur 4.4 End P 228 140.0 k l/hr 8.6k l/h 19,398 b/d Doc' Sweet

FP 58 21,140 b/d IBP 73.0

Action : Description By Whom Due Done 122 kl/hr End P 171

1. No.2 K/D HDS Feed Inlet WABT HCN R/D

2. 8 kl/hr 0 kl/hr 133 275 283.9

3. 0 kl/hr LSR S In 637 RON in 90.5

4. 0 b/d -18564 #REF! S Out 98 RONOut 87.8

5. Remv 85% Loss 2.7

RFCC Oil

LAB Result

RFCC Oil R/D

DeC4 Feed Spl Feed

Abs Off Gas

Strp Feed

DeC5 Feed

DeC3 Feed

Sulfur, wppm

2001-06-26

Feed Tank:

Feed

Off Gas

Dry Gas

Coke Yield

Sup Lean

Strp O/H

MainFractionator

Reactor

WGC

HP Sep

Pri-

Abs

Sec-

Abs

Stripper

DeC4

Naphtha

Splitter

DeC5

DeC3

(31,051Nm3/hr), (89)

[ , Nm3/hr]

DeC2

PP

Splitter

C

ommonLPG

MTBE

(19,942B/D)

(16,021B/D)

(8,678B/D)

[9,483B/D]

(84,288B/D)

[82,945B/D]

(11,280B/D)

[13,635B/D]

(19,383B/D)

[26,220B/D]

(D:37,603B/D)

(M:47,302B/D)

(27,733B/D)

(38,671B/D)

(10,280B/D)

[12,200B/D]

(10,280B/D)

[11,670B/D]

(B1 Design)

[Max Capacity till now]

(50,989)

[50,989]

(28,540)

[36,965]

(25,631)

[33,700]

Amine

Abs

( 8,350B/D)

[14,376B/D]

(69,180B/D)

[70,849B/D]

(16,968B/D)

[18,180B/D]

(6,692B/D)

[10,161B/D]

(23.5 ton)

[27.0 ton]

1st 2nd

(63,329) (58,161)

[74,762] [68,009]

LCN

Sweet'

Sweet'

WCN

Pre

WCN

Rx

(17,200B/D)

[21,039B/D]

(70,000B/D)[83,740B/D]

HCN

Reactor

O/H Rec

DeSOx


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RFCC Process

Converter

P Bl k Di f RFCC C l


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Process Block Diagram of RFCC Complex

Flue Gas to

Stack

DeSOx

ESP

CO Boiler

PRT

ReactorR-1 / R-2Regenerator

Air Blower

RFCC

Sour

Water

Feed Tank

Stripper and Gas

Concentration

Acid Gas

Treater

Sour Water

Stripper

Sulfur

Recovery

DeC4

DeC5

C5 Extractor

LPG

Sweetening

Sulfur

Bed

Propylene

Splitter

C3H6

MTBE

UnitC4 Raffinate

MeOH

LCN

HCN

LCO

RFCC Oil

H2SO4

Fuel Gas

Molten Sulfur

P.P Plant

Propane

Butane/Cogen

Gasoline

DSL/KD HDS

4.0 % S B-C

LCN/

HCN

Splitter

WCN

HDS HCN

Sweetening

LCN Sweetening

DeC3

Main

Fraction

ator

MTBE

C5

Blending

C3H8

C S i C fi i


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Converter Section Configuration

Power Recovery TrainCatalystCooler

R1

Air

R2

Reactor

Feed

Steam

CO Boiler

3rd Stage Separator

RCSV

SCSV

Regenerator

Steam

HCO

Steam

Slurry

Steam

P R T i


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Power Recovery Train

Vendor : Dresser Rand CONMEC

Capacity

Expander : 206 KNM3/Hr

Air Blower : 328 KNM3/Hr

Steam Turbine : 93 Ton/Hr

Motor/Generator : 13 MW

Expander Operability

Power Recovery : 17 MW

Profit : $ 6.7 Million / Yr ( 8 Billion/Yr)* Base : 57.24 Won/KW, 1,200 Won/$, 97% Operability

C t l t C l


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Catalyst Cooler

Improves unit

flexibility to processheavier feeds

Simple, low costdesign

Mechanicallyreliable

Turndown flexibility0~100%

Individual tube

failure will not shutdown the unit

2ND STAGEREGENERATOR

16EA

LIFT AIR

PC

045

C125A

STEAM DRUM

HP STEAM

HEADER

HP BFW

CONTINUO

BLOW DOWN

M

GT101A,GM101B

FC

008

LC

018

TC

026

FC

008

FULIDIZATIONAIR

FAL

PI

PI

RO

PS

FALL

093AFI

LC

015

FC

031

FC

001

02FI

01LI

16EA

RO

OWS

PRT C fi ti


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PRT Configuration

Motor/Generator

3 Phases, 4 Poles+13MW

Generating

Air 850# SteamR1/R2

Energy Saving($ 6.7 Million/Yr)

Expander

2 Stages+17MW

Air

Blower12 Stages

-22MW

CO Boiler

Steam

Turbine+18MW

CO Boiler


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CO Boiler

Vendor : Mitsubishi Heavy Industry

Capacity : 168 Ton/Hr2 Sets

Fuel

Main : CO Gas in RFCC Flue Gas

Supplementary : Fuel Gas, Fuel Oil

4 Corner Firing System

CO Boiler Configuration


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CO Boiler Configuration

WaterDrum

FDF(Air)

Fuel Oil

Fuel Gas

R1 Gas

R2 Gas

Vent &Tail Gas

HSS(850#)

Flue Gas

Blow Down

HS(850#)

BFW

DSH SteamDrum

Economizer


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RFCC Process

Main Fractionator

Main Fractonator


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Main-Fractonator

RO

LCO

Wet Gas Compressor


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Wet Gas Compressor

Operation Condition

Flow Rate, Kg/Hr : 62,500 ~ 114,000

Inlet Condition Pressure, KG : 0.7 ~ 1.0

Temperature, oC : 38 ~ 40

Outlet Condition

Pressure, KG : 19 Temperature, oC : 96 ~ 114

Power, KW : 5,200 ~ 6,630

Efficiency, % : 78.8 ~ 85.0

Steam Consumption : 70 Ton/Hr Governing / Trip Speed : 5,180 ~ 6,790 / 7,470 rpm

Slurry Filter


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Slurry Filter

Vendor : Pall

Capacity

8,700 B/D (Slurry Oil)

Catalyst Loading

Inlet : 5,000 wppm

Outlet : less than 50 wppm

Slurry Filter Configuration


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Slurry Filter Configuration

HCO

Receiver Vessel

Slurry Filter

Slurry Oil Out

Vent

N2

Slurry Oil In

Reactor

Sulfur Bed


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Sulfur Bed

Vendor : ISG

Capacity

17,500 B/D LPG

Impurity

Inlet Outlet

H2S, wppm less than 1 0.1RSH, wppm 15 1

RSSR, wppm 10 1

COS, wppm 15 0.1

Water, wppm 1085 1

Sulfur Bed Configuration


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Sulfur Bed Configuration

CoalescerGuardBed317

SulfurBed

318A

SulfurBed318

B,C,D,E

LPG fromLPG Merichem

LPG toDepropanizer

Hot InPush Gas Cold Out Flare F/G

Hot OutCold In

1. Absorbing

2. Pressurizing

3. Gravity Drain

4. Push Drain

6. Deprussurizing

5. Absorbing

7. Cold Purging

8. Heating

9. Soaking

10. Cooling

11. Pressurizing

12. Gravity Filling

13. Push Filling

14. Stand By

Absorber Phase

Amine Treating Unit Configuration


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Amine Treating Unit Configuration

Regenerator

FlashDrum

Sour LPG

LPGAmineAbsorber

Sweet LPG

2ndAbsorber OffGas

Sweet GasLean Amine

MechanicalFilter

Reclaimer

AmineSolutionTank

AmineAbsorber

Rich Amine

50# Steam

250# Steam

Sour Water Stripping Unit


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Sour Water Stripping Unit

Sour WaterFeed

Sour WaterSurge D/M

Feed Pump

Sour

WaterStripper

NH3/Acid Gas(to SRU)

StripperReboiler

50# Steam

CondensateDesalter

Sulfur Recovery Unit


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Sulfur Recovery Unit

Final

Sulfur

CondenserNH3Acid Gas

AcidGas

Waste Heat

Boiler

Reaction

Furnace

#150 Steam

BFW

SulfurCondenser

BFW Seal Leg

Claus Reactor

#50 Steam

CO Boiler

BFW

Seal Leg

Unloading

Sulfur Pit

Air

Air Blower

Sulfur Distribution


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Sulfur Distribution

Feed Sulfur : 6,680 Kg/Hr

Main Fractionator Sulfur Distribution

Off-gas : 3,050 Kg/Hr (45 %)

LCO : 1,450 Kg/Hr (22 %)

Coke : 970 Kg/Hr (15 %)

Slurry : 760 Kg/Hr (11 %)

HCN : 170 Kg/Hr ( 3 %)

LCN : 150 Kg/Hr ( 2 %)

LPG : 120 Kg/Hr ( 2 %)

C5 : 10 Kg/Hr ( - %)

Total 6,680 Kg/Hr ( 100%)

Sweetening Unit Summary


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Sweetening Unit Summary

LPG C5 LCN HCN

Flow Rate, BPD 17,200 8,400 19,400 9,700

Inlet Impurity, ppm

H2S 3 Nil Nil Nil

RSH-S 1,850 316 700 600

Total Sulfur 1,853 340 1,600 3,100

Outlet Condition

Total Sulfur, ppm 25 50 960 3,100

Cu-Strip 1A 1A 1A 1A

Doctor - Sweet Sweet Sweet

Troubleshooting : Caustic Degradation by Amine Carry-Over

Key Operation Parameter : COACH (Catalyst, Oxygen, Alkalinity, Contact, Heat)

takreer_rfcc 1st day calss

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