Catacarb Section

Presented By:

Muddassar Sultan

National University of Sciences & Technology

Catacarb Section
It consists of following main equipments: High Temperature Shift Converter Low Temperature Shift Converter Desuperheater Absorber Stripper Rich Solution Flasher Drum Knock Out Drums

Following main operations are carried out: Conversion of CO to CO2. Removal of CO2 from Synthesis Gas.

High Temperature Shift Converter

Reaction: CO + H2O(s) Conditions:
o o o o Inlet Temperature: 675oF - 700oF Outlet Temperature: 750oF Catalyst: Iron Pressure Drop: 5psi

H2 + CO2

Composition:
Composition H2 CO CO2 Inlet % 56.25 12.38 7.96 Outlet % 60.25 2.18 16.24

Heat Exchangers
To LTS
BFW (Tube Side)

1112-C

Methanator Feed (Shell Side)

104-C

BFW (Tube Side)

103-C

From HTS

Bypass

Low Temperature Shift Converter

Reaction:

CO + H2O(s)
Conditions:
o o o o Inlet Temperature: 410 F Outlet Temperature: 435 F Catalyst: Copper Pressure Drop: 5psi

H2 + CO2

(Continued)

Composition:
Composition H2 CO CO2 Inlet % 60.25 2.18 16.24 Outlet % 61.2 0.21 17.5

Operating Parameters
Temperature in HTS should not exceed 950oF:
Catalyst Inactive Vessel Damage

Catalyst deformation is detected via pressure drop

Process Flow Diagram

PDIa-17 From Reformer PB

400o F
1112-C

700o

104-D HTS

108-D LTS

530o F 104-C

630o F
HCV

103-C
Control Valve

To Desuperheater

760o F
TRCE

HTA

Desuperheater
LTS effluent at 440oF is quenched to 350oF using process condensate

440oF

To Absorber

Desuperheater
102-F

350oF
Raw Gas Separator vessel

1105 CA & CB

260oF

Absorber:
AR

Syn Gas CO2 free

Lean Solution 16% CO2 Semi Lean 35%CO2 Rich Solution 75%CO2

Lean Solution

Low Temperature & High pressure

Polypropylene Flexi rings & Stainless Steel rings packing
Semi-Lean

Catacarb Solution is used to absorb CO2:

K2CO3 + CO2 +H2O

HLA

2KHCO3

Other components of Catacarb solution are:

- K2CO3 (35%) - Glycol (Defoamer) 101-E - Corrosion inhibitor - Diethanol Amine & Tertiary Ethanol Amine (enhance absorption capacity)

LLA
LICe

Raw Syn Gas

Rich Solution

Stripper:
Rich Solution

CO2 to Urea

High temperature & Low Pressure Polypropylene Flexi rings & Stainless Steel rings packing CO2 is stripped off the rich solution: 2KHCO3 K2CO3 + CO2 +H2O
Three Exchangers are provided at the bottom to provide heat

Air injection to regenerate reduced V2O5 Glycol addition for avoiding foaming
Semi-Lean

HLA

LLA 1105C A&B

LRe

1111C

Lean Solution

HPDA
Gases

PDIe

Absorber
1103-E

Semi Lean Solution

Rich Solution Flasher

Stripper

107-JT
Rich Solution

Knock Out Drum Working

CO2 Recovery
CO2 may be recovered by the flue gases out of the primary reformer..?

CH4 + O2
SO2 NO2 CO CO2

CO + CO2 + H20

Main Constituents of flue gases:

Thank You For Your Attention..!

Questions.?