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PETROFED Work Shop on Energy Management & Efficiency Improvement in Oil & Gas Sector

Oxy Enrich Process for Capacity Enhancement of Claus Based Sulfur Recovery Unit

NOVEMBER 13, 2009


NEW DELHI

OxyEnrich Process
OxyEnrich Process uses oxygen enriched air for oxidation of H2S to elementary sulfur in sulfur recovery unit and increases the plant capacity. Process minimizes nitrogen content in combustion air and results reduction in process gas flow in down stream of reaction furnace . Process increases reaction furnace temperature, which depends on oxygen concentration in air .

Process gives better conversion of H2S in reaction furnace and marginally increases overall sulfur recovery of the unit

MAIN DRIVERS FOR OPTING SULFUR REVAMP IN CPCL


ADDITIONAL ACID GAS GENERATION OF ABOUT 16% DUE TO NEW PROCESS UNITS BEING INSTALLED UNDER THE EURO- IV PROJECT AVAILABILITY OF VERY MARGINAL CAPACITY IN THE EXISTING UNITS ABOUT 10% REQUIRED CAPACITY LEVELS OBSERVED TO BE (ABOUT 30 TPD) NOT COST EFFECTIVE COMPARATIVELY , IF NEW UNIT OPTION IS ADOPTED SCOUTED FOR VIABLE OPTIONS FOR MARGINAL AUGMENTATION REQUIREMENT OF QUICK AND LOWER COST OPTIONS IN HAND

DEMONSTRATION RUN OF OXYGEN ENRICHMENT IN SULFUR RECOVERY UNIT OF CPCL

SALIENT FEATURES:
Technology is First of its kind being implemented in Indian Refineries. Project jointly undertaken by CPCL & EIL (R&D). Technology will be jointly licensed by CPCL & EIL. Demonstration Run being done by CPCL from 11/5/2009 No Major hardware modifications in the existing unit. Capacity increase by 15% to 22% (From 90 TPD to 104 / 110 TPD of Sulphur in each Train) Oxygen content in Air Enriched from 19.6 to 28 vol% Low cost option for enhancing SRU capacity. Cost towards demonstration run is about Rs.2 Cr.
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MAJOR MILESTONES OF DEMONSTRATION RUN

SNO 1 2 3 4 5 6

ACTIVITY Signing of MoU with EIL Process Package Developed by EIL Detailed Engineering Activities carried out by EIL Installation of Piping & Control Valves Oxygen Mixing Drum installation Successful Commissioning of the System

DATE 25-09-07 25-10-08 25-10-08 30-04-09 07-05-09 11-05-09

Slide 5 of 12

Major Benefits of OxyeEnrich Process


Greater processing capacity of sulfur recovery unit

Stable flame in main burner even at lean acid gas processing

No major modification for 25% -30% capacity enhancement

Low capital cost for grass root sulfur units due to smaller equipment sizes

Processing low quality feed without problem

Less sulfur mist lead to better operation

Low backpressure ensures trouble free operation

Conventional Claus Process

Claus SRU Configuration


Thermal Stage
To Steam System HP Steam #1 Reheater #1 Converter To Condensate System

Catalytic Stages
HP Steam #2 Reheater #2 Converter To Condensate System HP Steam #3 Reheater #3 Converter

AAG K.O. Drum

Steam Drum BFW Thermal Reactor (Reaction Furnace) Burner To Condensate System

To TGTU

Amine Acid Gas Feed Rxn Cooler (WHB)

Waste Steam Condenser

To Steam System

To Steam System

To Steam System

SWS GAS K.O. Drum #1 Condenser #2 Condenser #3 Condenser #4 Condenser

SWS Acid Gas Feed

BFW Combustion Air Blower

Sulfur to Pit

BFW

Sulfur to Pit

BFW

Sulfur to Pit

BFW

Sulfur to Pit

O2 Enrichment : Direct O2 injection to Combustion Air


Acid Gas Preheater
Acid Gas from ARU/SWS Mixer Oxygen from Oxygen Supply System Burner Furnace WHB Catalytic Stages

Combustion air from Blower

RATIO CONTROLLER O2STORAGE VESSEL


O2VAPORIZER O2 ANALYZER
FIC

FIC
FV

UV

AIR BLOWER

MIXER PROCESS GAS FOR SULPHUR RECOVERY

FIC

ACID GAS

MB

MAIN COMBUSTION
CHAMBER

Case Study for OxyEnrich Process

Plant Capacity Typical Feed Composition

: 65 TPD

H2S H2O H2 CH4 C2H6 NH3

%V %V %V %V %V %V

Acid Gas H2S rich SWS NH3 rich SWS 93.40 66.53 2.69 4.43 33.37 42.00 0.07 0.00 0.00 0.06 0.00 0.00 2.04 0.00 0.00 0.00 0.11 55.30

Result : Effect on Furnace Temperature


Furnace Temperature ( C )

1500 1450 1400 1350 1300 1250 1200 1150 1100

Oxygen Concentration in Enriched Air(Molefr.)

Result : Effect on Combustion Air Rate


Air Flow rate Kmole/hr

250

200 150 100 50


0

Oxygen Concentration in Enriched Air (Molefr.)


Combustion Air Flow Rate Total Combustion Air to MCC Oxygen injected in Air

Result : Capacity Enhancement

Oxygen Concentration in Enriched Air(Molefr.)

Technology Demonstration : Feed / Controlling Parameters

Feeds

Acid Gas Source H2S concentration Vaporised Oxygen Source Combustion Air O2 concentration

: Amine Regenerator O/H : 74-90%v : Liquid Oxygen Storage Vessel : 19.6-28%v

Controlling Parameters

Temperature of Reaction Furnace Effluent Maximum allowable temperature : 1500oC Backpressure of the unit Maximum allowable pressure : 0.74 Kg/cm2 Sulfur recovery of the unit Minimum sulfur recovery : 99%

Technology Demonstration : Capacity Enhancement of CPCL-SRU

Objectives : Demonstration of OxyEnrich Process in a commercial plant Commercial use of OxyEnrich Process for processing additional acid gas to be generated in Euro IV Project Existing SRU

Process
Design Capacity

: MCRC
: 90 TPD Sulfur

Design Sulfur Recovery : 99.0% ( min)

Technology Demonstration : Plant Configuration After Revamp


Air Blower

Oxygen

Liquid Oxygen Vaporization Unit


LP Steam Acid Gas, Air , Fuel Gas Line Burner Claus Reactor-I LP Reheater S

Air Acid Gas RF WHB

Condenser-I

Claus Bypass

Fuel Gas MCRC-I MCRC-II MCRC-III

Condenser-II
LP Steam

T A C K

Condenser-III

Condenser-IV

Condenser-V

Sulphur
Air , Fuel Gas

Incinerator

Technology Demonstration : Steps in Project Execution Adequacy check of equipments/instruments through test run and in-house simulator Preparation of Process Package for oxygen enrichment facility Procurement of Equipments like Control valves, Oxygen
Analyzer, Oxygen Supply and storage system etc.

Installation and Erection of oxygen mixing device and oxygen supply system
Commissioning of Oxygen enrichment system and test run

Technology Demonstration : Key Operating Data

OPERATING PARAMETERS

BEFORE (Oxygen Enrichment ) 2115 3900 19.6 1160 0.71 NA Above 99 4.20

AFTER (Oxygen Enrichment) 2600 3100 26.8 1340 0.71 22 Above 99 5.60

Feed Gas Flow ( Acid Gas), Nm3/Hr Enriched Air Flow, Nm3/Hr Oxygen Content in Enriched Air, vol % MCC Temperature, C Unit Back Pressure, kg/Cm2 % Increase in Unit Throughput Sulphur Recovery, % Steam Production, MT/Hr

Technology Demonstration : Salient features


No Major hardware modification Low cost option for enhancing SRU capacity Capacity increased by 22%

Improvement in MCC Temp and stable flame even at Lean acid gas

Oxygen content in Air Enriched up to 26.8 vol%

Low backpressure in the unit

Quality of Sulphur continued to be good

EIL-CPCL Deliverables for Implementation of OxyEnrich Process

Supervision of test run for performance evaluation of running SRU Adequacy check of Existing Equipments & Instruments Preparation of Process Package for oxygen enrichment facility Detail Engineering of new oxygen enrichment facility Commissioning

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