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    PROJECT

    REPORT

    June 2

    2014Design and simulation of CO2absorptionand stripping section for removal of co2.

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    ACKNOWLEDGEMENT

    All praises to Almighty ALLAH who gave us light in darkness and gave us

    understanding and ability to complete our report and all respects are for his

    Prophet MUHAMMAD (PBUH, on whom be ALLAH,S blessings and

    salutations)

    I would like to thank PROF. DR. MAHMOOD SALEEM for granting me the

    chance to pursue this Assignment in an environment that facilitated my

    learning.

    I take immense pleasure in thanking our worthy teacher for valuable help

    regarding this assignment.

    Abid Hussain Roll No. PG-M10-20

    ICET University of the Punjab

    new campus Lahore.

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    PLANT DESIGN ASSIGNMENT REPORTE ON

    DESIGNING OF SYNTHESIS GAS PURIFICATION (CO2removal) SECTIONUSING ACTIVATED-MDEA

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    PLANT DESIGN MID TERM ASSIGNMENT

    REPORTE ON

    DESIGNING OF SYNTHESIS GAS

    PURIFICATION (CO2 removal) SECTION USINGACTIVATED-MDEA

    BSc. Engineering (7thSemester)

    Submitted By: Abid Hussain

    Roll No. PG-M10-20

    Supervised by: Prof. Dr. Mahmood Saleem

    Institute of Chemical Engineering and Technology

    Faculty of Engineering & Technology

    University of the Punjab

    New Campus Lahore

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    ABSTRACT:

    Ammonia is an important and useful for the production of urea. Since then it has been widely

    used in the production of other chemicals, products and fertilizers specially. The synthesis

    gas stream leaving the low temperature shift converter contains approximately 18.4 mole%Carbon dioxide on a dry gas basis. It is essential to remove all CO2 from the synthesis gas

    before entering the ammonia synthesis loop. Here we will use activated MDAE as an

    absorbent for CO2 removal. Solution in our process.

    Hence in the first chapter of this report I have given the introduction and contextual of CO2

    gas. Removal process using aMDEA as solvent. The second chapter includes the detailed

    process description of purification section, equipment working , feed and product

    composition and conditions. The 3rd chapter contained detail material and energy balance

    calculation using chemcad for all the process equipment to design Syn. Gas purification

    section of ammonia plant.

    I had 6 week training at FAUJI FERTILIZER COMPANY ,SADIQ ABAD, RAHIM YAR

    KHAN . So the design data I used in my calculation is courtesy of FAUJI FERTILIZER

    COMPANY. I design the process in following steps.1st, draw its flow sheet , list down all

    required equipment and then I performed material and energy balance of the equipment and

    of the whole process using CHEMCAD.

    I hope that the reader will find the information contained to be useful.

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    ContentsChapter 1 ................................................................................................................................................. 9

    1.1 INTRODUCTION ................................................................................................................................. 9

    1.2Synthesis Gas purification process:-.................................................................................................. 9

    1.3Background of purification processes:- ............................................................................................. 9

    1.4 ......................................................................................................................................................... 10

    CHAPTER 2 ............................................................................................................................................ 11

    PROCESS DESCRIPTION ..................................................................................................................... 11

    2.1Absorption Column:- ................................................................................................................ 11

    2.2Absorbent Regeneration (CO2stripping Section:- ................................................................... 12

    2.2) Low pressure flashing column:- ............................................................................................. 12

    2.3) Stripper :- .............................................................................................................................. 13

    CHAPTER 3 ............................................................................................................................................ 14

    MATERIAL AND ENERGY BALANCE ................................................................................................... 14

    CHAPTER NO.4 ...................................................................................................................................... 17

    4.1 Absorber Design: ......................................................................................................................... 17

    Select between Plate & Packed column: ...................................................................................... 17

    Factors affecting the absorption Column : ................................................................................... 18

    Foaming ......................................................................................................................................... 18

    Entrainment .................................................................................................................................. 18

    Weeping/Dumping: ....................................................................................................................... 19

    Flooding ......................................................................................................................................... 19

    State of trays & Packing: ............................................................................................................... 19

    Column Diameter: ......................................................................................................................... 19

    Standard Design steps:.................................................................................................................. 19

    1.Calculation of theoretical number of stages:35

    .............................................................................. 21

    Calculation of Diameter of Column:37............................................................................................... 22

    Calculation of Pressure drop: ............................................................................................................ 25

    Down comer Design: ......................................................................................................................... 26

    Entrainment Calculation: .................................................................................................................. 27

    Calculation of Height of Column: ...................................................................................................... 28

    4.2 Stripper Design: ............................................................................................................................... 28

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    Stripper ............................................................................................................................................. 28

    Stripping Phenomenon: ................................................................................................................ 28

    Stripping Agents: ........................................................................................................................... 28

    Types of Stripper: .............................................................................................................................. 28

    .............................................................................................................Error! Bookmark not defined.

    Standard Design Steps: ................................................................................................................. 29

    Calculation of Weeping Point: ...................................................................................................... 32

    Calculation of Pressure drop: ........................................................................................................ 34

    Calculation of Height of Column: .................................................................................................. 36

    4.5 MDEA Surge Drum: ......................................................................................................................... 37

    Design Specifications .................................................................................................................... 37

    CHAPTER NO.5 ...................................................................................................................................... 38

    Dynamic Simmulations. .................................................................................................................... 38

    CHAPTER NO.6 ...................................................................................................................................... 39

    6.1 Plant Cost Estimation: ............................................................................................................... 39

    6.2 Capital Investment: ................................................................................................................... 40

    6.2.1 Direct costs: ................................................................................................................... 40

    6.2.2 Indirect costs: .................................................................................................................... 40

    6.3 Types of Cost Estimation: ...................................................................................................... 40

    6.4 Methods of Estimating Capital Investment: ......................................................................... 41

    6.5 Percentage of Delivered Equipment Cost: ................................................................................ 41

    Cost of Absorber: .......................................................................................................................... 41

    7.6 Direct Cost:50.................................................................................................................................. 44

    7.7 In-Direct cost: .................................................................................................................................. 44

    OPERATIONAL PROBLEMS. ................................................................................................................... 45

    7.1 Problems occurring during operation: .................................................................................. 457.2 Foaming:................................................................................................................................ 45

    Causes of Foaming: ....................................................................................................................... 45

    Prevention of Foaming: ................................................................................................................. 46

    7.3 Corrosion: .................................................................................................................................. 46

    Mechanism of Corrosion: .............................................................................................................. 47

    Metods of Minimizing Corrosive Attacks: ..................................................................................... 47

    7.4 Chemical Losses54.................................................................................................................. 47

    7.5 Losses due to Volatility: ........................................................................................................ 48

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    7.6 Entrainment: ......................................................................................................................... 48

    References: ........................................................................................................................................... 48

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    Chapter 1

    1.1 INTRODUCTION

    Absorption of CO2 from process gas because carbon dioxide gas present in

    synthesis gas is poison for ammonia synthesis catalyst. In this section synthesis gas is

    proceed to remove CO2 and CO, producing a high purity H2and N2. Bulk removal of carbon

    dioxide is talented by the use of an improved benefield low heat process which uses the four

    stage flash of the semi lean solution. to minimize external heat requirements. Final removal

    of remaining CO2 and CO. is accomplished by catalytically converting the CO2 to methane

    and water in the mathenator using hydrogen. The MDAE low heat process circulates an

    aqueous sol. containing a nominal 37% MDAE and 3 % piprazine . This solution chemicallycombines with CO 2 on the process gas but not significantly with the other voters. Additives

    are injected into the solvent to enhance the CO2absorption rate, inhibit corrosion and to

    control foaming.

    1.2Synthesis Gas purification process:-There is long history of different processes used for gas cleansing, here is given their

    name just , while MDAE method will be discussed in detail.

    1)

    MEA (mono ethanol amine ) process2) Benfield process (also called Hot process)

    3)

    Activated MDEA process

    1.3Background of purification processes:-

    In the early days of ammonia manufacture, monoethanolamine (MEA) was frequently used

    for CO2 removal from the synthesis gas. Somewhat later, hot potassium carbonate (the

    Benfield, or Hot Pot process) was used, often in a split flow configuration described as a twostage Benfield Low Heat process for energy conservation. In the last 20 years, a verysubstantial fraction of these plants have been retrofitted using BASFs a-MDEA process.

    Activated MDEA as solvent:-

    NMethyldiethanolamine (MDEA) is a tertiary amine whose amino group is incapable ofreacting with CO2. However, it is alkaline and so is an excellent sink for protons produce by

    CO2hydrolysis. Because it is nonreactive, aqueous MDEA by itself absorbs CO2 far tooslowly to be an effective solvent for giving ammonia synthesis gas. But when spiked with a

    relatively small attentiveness of piperazine, a diamine that reacts extraordinarily fast with

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    CO2, the resulting blend is an excellent solvent for treating syngas and removing CO2 in the

    production of LNG.

    In this paper, we first present the results of a measurable study of the piperazine promotion of

    MDEA, specificsly the effects of piperazine to MDEA ratio, total amine strength, and the

    treating temperature on presentation of a typical ammonia syngas CO2 removal system. In a

    recent patent, Waner et al. (2009) proposed using the alkali metal salts of a number of tertiary

    amino acids, appropriately promoted with reactive amines such as MEA. Some of the

    potentially more intereting results of our study include the utility of operating at higher

    temperatures with lower rather than higher total amine concentrations, and the existence of

    operating boundaries that can lead to unstable operation when approached too closely.

    Following a discussion of amino acids and their mode of operation, we critically analyze the

    possibility of using the potasium salt of the tertiary aminoacid dimethylglycine, promotedwith piperazine as a syngas treating solvent. The results show that it is possible to treat

    syngas quite effectively using such a solvent but with much lower concentration of the

    piperazine promoter. Furtermore, results suggest that the crossexchanger commonly used asa heat integration tool in treating plants can be completely eliminated.

    1.4

    aMDEA Composition:-

    MDEA=37%

    Piprazine=3%

    and remaining is water

    Advantages of using a-MDEA:-

    There are many advantages of using -MDEA solution some of which most important are

    More CO2absorption.

    No time for regeneration.

    Low energy requirement for regeneration.

    In CO2removal section Amerel is used as antifoaming agent for a-MDEA solution.

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    CHAPTER 2

    PROCESS DESCRIPTION

    After the synthsis gas has been prepared it is purified off carbon dioxide and carbonmonoxide to yield a high purity nitrogen hydrogen synthesis gas. The CO2 removal system

    consists of an Absober and a CO2 Stripper with the carbonate solution circulating in a closed

    loop between the two.

    2.1Absorption Column:-

    Process gas leaving the top of CO2 Absorber Feed Gas Separator is now called as raw

    synthesis gas which enters the CO2 absorber at the bottom. The internal packing at the

    bottom part, BED3 and BED2 , is replaced from IMTP#50 to structured packing.The lean -

    MDEA solution at 500C from the lean rich exchanger and lean cooler enters the absorber

    from the middle inlet.

    While the two stream flow conter-current through the absorber, the lean solution gradually

    absorbs the CO2 present in the feed gas ,and leaves the absorber bottom as rich solution

    stream at 480C to LP flash column.The treated gas at 500C exits the absorber from the top

    through CO2absorber top knokout drum. Mist carry-over to the downstream equipment is

    minimized by packing in the previous lean absorption section, which is now performing as

    demister.

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    Process Flow Sheet:-

    E-3

    E-9

    E-11E-12E-13E-14E-10

    E-15

    E-17

    E-18

    Sour gas

    Rich MDAE

    P-4

    Regenerated MDAE

    P-6

    P-7

    P-8

    P-9

    E-19

    P-10

    P-12

    Pure syn. gass

    E-20P-14

    P-15

    Absorption column

    Flashing column

    stripper

    reboiler

    heater

    Plate and frame heat

    exchangerRich solution pump

    FIG: 2.1 Purification section flowsheet.

    2.2Absorbent Regeneration (CO2stripping Section:-

    Stripping of CO2from a-MDEA solution, to regenerate solvent for recycling is carried out in

    this section.

    Regeneration takes place in following two steps.

    Flashing in Low pressure flashing column and

    Stripping in (Stripper)

    2.2) Low pressure flashing column:-

    The rich soltion at 850C is flushed in the newly installed LP-Flash column at 0.9kg/cm

    2.Liquid from

    LP flash column is pumped through to lean-rich exchanger where it is heated before going to the

    stripper. In stipper after separation of CO2from the -MDEA solution, CO2product vapor is recycled

    to the bottom part of LP flash column. CO2product vapor from LP flash and CO2vapors from stripper

    is cooled to 380Cby direct contact cooling with quench or reflux water in a packed bed above the

    striping secton of the LP flash column, quench water is circulated by the flash column Quinch Pump

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    to the LP flash quench cooler . In this exchanger the quench water is heat is rejected to the cooling

    water, water condnsed from the CO2 product vapour during cooling is removed from the cooling

    circuit to fulfil the water make up requirements. After being cooled the 99% CO2 product passes

    through the demister pad, exists the column and is exported for use in urea plant.

    The main advantages of using LP Flash column are:

    Chemically unbound CO2molecules removal.

    No heat requirement like stripper.

    2.3) Stripper:-In LP flash column only chemical unbound molecules of CO2are removed, chemically bound

    molecules are removed by using CO2stripper.

    The a-MDEA solution containing chemically bound CO2 molecules exiting from bottom of

    LP flash column is sent to middle section of stripper being pumped by rich solution

    pump.Steam for the purpose of striping is produced in steam generator and provision is made

    to control steam supply from SH and SL heaters

    Regenerated solution leaves and goes to Solution tank by gravity flow is used as

    holding tank to provide residence time . The lean solution at 1190C from 117-F is then cooled

    down sequentially in lean-rich exchanger and lean cooler to 50% with concentration, prior to

    recycle into the absorber. Acid off gas and 114-C leaves striper from the top at 104 0C is

    directed to the bottom part of LP flash column.

    CO2 gas separated from striper at 50C is pass through heat exchanger and cooled to 38C to

    remove any entained water. Hence we obtained 99% CO2 which is transported to urea

    section.

    While absorber overhead gas, purified Syn. Gas , containing approx. 1000ppm of CO2 is

    disengaged of any entrained liquid and preheated to about 316C , in methanator effluent

    exchanger and finally sent to Methanator for further purification.

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    CHAPTER 3

    MATERIAL AND ENERGY BALANCE

    FlowDiagram.

    CO2

    aMDEA

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    aMDEA at inlet of absorber Sour gas inlet

    Sweet gas outlet: stripper inlet

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    CO2 outlet from stripper: Regenerated aMDEA

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    CHAPTER NO.4

    4.1 Absorber Design:Absorber

    The removal of one or more seleced components from a mixture of gases by absorption into

    a appropriate solvent.

    Select between Plate & Packed column:

    Vapor liquid mass transfer operation may be carried either in plate or packed column. These

    two kinds of operation are quitelly different. The relative advantages of plate over packed

    column are as follows:

    1. Plate column are designed to deal wide range of liquid flow rates without flooding.

    2. If a system contains solid contents; it will be handled in plate column, because solid will

    accumulate in the voids, coating the packing materials and making it ineffective.

    3. Dispersion difficulties are handld in plate column when flow rate of liquid are low as

    compared to gases.

    4. For large column heights, weight of the packed column is more than plate column.

    5. If periodic cleaning is needed, man holes will be provided for cleaning. In packed

    columns packing must be removed prier cleaning.

    6. For non-foaming processes the plate column is preffered.

    7. Design information for the plate column is more readily available and more reliable than

    that for packed column.

    8. Inter stage cooling can be provided to remove heat of reaction or solution in plate

    column.

    9. When temperature change is involved, packing may be damaged.

    Choice of Plate Type:

    There are three main types of plate, sieve plate, bubble cap and value plate. We have

    selected sieve plate because:

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    1. They are lighter in weiht and less expensive. It is easier and cheaper to install.

    2. Pressure drop is low as compared to valve and bubble cap plates.

    3. Peak efficiency is generaliy high.

    4. Maintenance cost is redced due to the ease of cleaning.

    5. In case of capacity ratng, sieve plate has high rank as compared to valve and bubble

    plates.

    Sieve plate:

    Sieve plate is simplest type of cross-flow plate. Vapour passes up through perforations in

    the plate; and the liquid is retained on the plate by vapour flow. The perforations are usually

    small holes, but larger holes and slots are used. The arrangement, number and size of the

    holes are design parameters.

    Because of their efficincy, wide operating range, ease of maintenance and cost factors, sieve

    and valve trays have replaced the once highly thought of bubble cap trays in manyapplications.

    Factors affecting the absorption Column :

    Vapor Flow Conditions:

    1. Foaming

    2. Entrainment

    3. Weeping/dumping

    4. Flooding

    Foaming:

    Foaming refers to the expansion of liquid due to passage of vapor or gas. Although it

    provides high interfacial liquid-vapor contact, extreame foaming often leads to liquid

    buildup on trays. In some cases, foming may be so bad that the foam mixes with liquid on

    the tray above.

    Whether foaming will occur depends primarily on physical properties of the liquid mixtures,

    but is occasionally due to tray desins and condition. Whatever the cause, separation

    efficiency is always reduced.

    Entrainment:

    Entrainment refers to the liquid carried by vapour up to the tray above and is again caused

    by high vapor flow rates. It is negative because tray efficiency is reduced: lower volatile

    material is carried to a plate holdng liquid of higher volatility. It could also contaminate high

    purity distillate. Excessive entrainent can lead flooding.

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    Weeping/Dumping:

    This phenomenon is caused by low vapor flow. The pressure exerted by the vapor is

    insufficient to hold up the liquid on the tray. Therefore, liquid starts to leak through

    perforations. Excessive weeping will lead to dumping. That is the liquid on all trays will crash

    (dump) through to the base of the column (via a domino effect) and the column will have tobe re-started. Weeping is indicated by a sharp pressure drop in the column and reduced

    separation efficiency.

    Flooding:

    Flooding is brought about by excessive vapour flow, causing liquid to be entrained in the

    vapor up the column. The increased pressure from excessive vapor also backs up the liquid

    in the down comer, causing an increase in liquid holdup on the plate above. Depending on

    the degree of flooding, the extreme capacity of the column may be severely reduced.

    Flooding is detecting by sharp increases in column differential pressure and significant

    decrease in separation efficiency.

    State of trays & Packing:

    Remember that the actual number of trays required for a particular separation duty is

    determined by the efficiency of the plate. Thus, any factors that cause a decrease in tray

    efficiency will also change the perfomance of the column. Tray efficiencies are effected by

    fouling, wear and tear and corrosion and the rates at which these occur depends upon the

    properties of the liquids being proessed. Thus appropriate materials should be specified for

    tray construction.

    Column Diameter:

    Vapor flow velocity is dependent on column diameter. Weeping determines the minimum

    vapor flow required while flooding determines the maximum vapor flow allowed, hence

    column capacity. Thus, if the column diameter is not sized properly, the column will not

    perform well

    Standard Design steps:

    1) Calculation of theoretical number of stages.

    2)

    Calculation of actual number of stages.3) Calculation of diameter of column.

    4) Calculation of weeping point.

    5) Calculation of pressure drop.

    6) Downcomer design.

    7) Entrainment calculations.

    8) Calculation of height of column.

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    ABSORBER DESIGN

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    1.Calculation of theoretical number of stages:35

    The main componnt which we want to be absorbed in MDEA is H2S.so, we take it as a

    reference.

    H2S:

    In = 3.73

    Out = .0109

    Moles of H2S absorbed = 3.719

    Eai=

    = 0.997 or 99.7%

    Minimum for H2S.( )min = KiEaiL=

    lean oil entring absorber.Vn+1=

    rich gas entering absorber.

    Value of K depends on T & P.

    So, average tower conditions for ki:

    T = 110 F

    P = = 433psia.

    36Ki= 1.6

    So, ( )min= 1.6 x 0.997= 1.5952.

    Operating ( ) = 1.25 (1.5952)= 1.994.

    Operating absorption factor

    Aio= ( ).

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    =

    = 1.246.

    Theoretical stages at operating conditions.

    Eai= AioN+1

    Aio / AioN+1

    1

    0.997 = (1.246)N+11.246 / (1.246)N+11

    (N+1) log 1.246 = log ( )

    (N+ 1)(0.0995) = 1.919

    N = 19.09.

    It means 19 theoretical trays are needed.

    1. Calculation of Actual Number of stages:

    We take 70% efficiency.

    So,

    Actual number of stages == 27 stages.

    Calculation of Diameter of Column:37Flooding velocity is given by

    Uf= K1 Where,

    Uf= Flooding vapor velocity in m/s , base on net column cross-sectional area.

    K1= Constant obtained from figure 11.27 vol.6 Coulson & Richardson .

    FLV= Where,

    Lw=Liquid mass Flow rate ,

    Vw= Vapour mass Flow rate ,

    In this Case,

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    Lw= 148.045

    Vw= 17.18

    Pv= 21.47 [ ]PL= 1001.48

    FLV=

    = 1.26

    We use Plate Spacng 700mm.

    38K1= .034

    Then, UF= 0.034 = 0.23

    We take actual velocity as 85% of flooding velocity

    So, v= 0.85 x 0.23

    = 0.20 Maxium volumetric vapor flow rate =

    =0 .80

    Net area required = An=

    = 4 m

    2

    We take dwncomer area as 12% of total area

    Column cross sectional area = Ac=

    = 4.55 m2

    Down comr area = Ad= 4.55 -4 = .55m2

    Active area , bubbling area = Aa= Ac2 Ad

    = 4.552(0.55)

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    = 3.45 m2

    Total hole aea as 10% of active area , so

    Hole area = AH= 0.10 x 3.45 = 0.345 m2

    Column diameter = Dc= = = 2.40 m.

    2. Calculation of Weeping Point:

    For the calcuation of weeping point, hole diameter must be selected so that at lowest

    operation rate, the vapor flow velocity is still above weeping point.

    Maximum liquid flowrate = 148.045

    Minimum liquid rate , at 70% turn down = 0.70 x 148.045

    = 103.631

    x 100 = x 100 = 12%39

    = 0.77

    lw= 0.77 x 2.40 = 1.85m

    we know

    how= 750 * +2/3Lw= weir length, m

    how = height over weir , mm liquid

    Lw= liquid flow rate

    Minimum how= 750 [] 2/3

    = 109mm.

    We take , hw= 50mm

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    hw+ how = 109 + 50 = 159mm.

    40K2= 31.2

    Uh(min) = [

    ]

    Uh = minimum vapor velocity through holes, m/s

    Dh= hole diameter, mm

    Uh= ]

    Uh= 0.77m/s

    Actual mimum vapor velocity =

    =

    = 1.62 m/s.

    So, minium operating rate will be well above weeping point.

    Calculation of Pressure drop:

    = 9.81 x 10-3ht PL= total pressure drop , Pa(N/m2)ht= total pressure drop , mm liquid

    Total presure drop is giver by

    ht= hd+ (hw+ how) + hr

    ht= total plate presure drop

    hd= dry plate pressure drop

    hr= resdual head

    hw= height of weir

    how= weir crest, mm liquid

    hd= 51 [

    ]2

    Co= Ofice coefficient

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    Uh= Vapor velocity through holes , m/s

    Uh= = 2.32 m/s.

    We tak carbon steel plate, so

    plate thickness = 5mm

    hole diameter = 5mm

    so,

    41Co= 0.84

    hd= 51 []2 [ ]

    = 8.34 mm

    hr=

    = 12.8mm

    ht= 12.48 + 8.34 + 50 + 109

    = 179m liquid

    = 9.81 x 10-3x 179 x 1001.48= 1757 Pa

    = 0.26 Psia (per plate)Down comer Design:

    The downomer area and the plate spacing must be such that the level of the liquid and frothin the downomer is well below the top of outlet weir on the plate above. If the liquid rises

    above the outlet weir the column will flood.

    hb= (hw+ how) + ht+ hdc

    Where,

    hb= downcomer bckup, measured from plate surface, mm

    hdc= head loss in doncomer, mm

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    hdc= 166 []

    where,

    hdc= head loss in downomer, mm

    Lwd = liquid flowrate in dwncomer, kg/s

    Am = Either downcomer area or clearance area under the downcomer Aopwhich is smaller.

    Aop = hop Lw

    Where, hop = height of botom edge of apron above plate

    Lw= length of weir

    hop = hw10

    = 5010 = 40mm

    So, Aop= 0.040 x 1.85m

    = 0.074m

    hdc= 166 []2

    = 6.62mm

    So, backup in downcomer = hb= (50 +109) +6.62 + 179

    = 34..62mm = 0.33462m

    Then , backup in downcoer < (plate spacing + weir height)

    0.33462

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    == 86%

    We already know FLV

    FLV= 1.26

    42It is well below 0.1, so there is no chance of entrinment and process is satisfactory.

    Calculation of Height of Column:

    No. of plates = 27

    Tray spacing = 0.70m

    Tray thickness = 0.005m

    Total thickness of trays = 0.135m

    Top clearance = 1m

    Bottom clearance = 1m

    Total height = 20m

    4.2 Stripper Design:Stripper:

    It is a counter current multi-stage separation column, with liquid feed at top and vapor

    feed at the bottom stage.

    Stripping Phenomenon:

    Strippng is a mass transfer operation that involves the transfer of a solute (as H2S & CO2in

    our case) from the liquid phase to the gas phase.

    Stripping Agents: Air

    Stream

    Inert gas

    Hydocarbon gases

    Reboled vapors (as in our case)

    Types of Stripper:

    i. Refluxed Stripper:

    It is emloyed if simple stripping is not sufficient to achieve the desired separation andcontacting trays are needed above the feed tray.

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    ii. Reboiled Stripper:

    If the botom product from a stripper is thermally stable, it may be Reboiled at the bottom of

    the column.

    iii. Open steam/Air stripper:

    Direct stearm may also be used. Sometimes air or inert gases may also be used

    (Combination of above can be made based on systems requirement)

    Principle of separation: difference in volatilities

    Created or added phase: vapor

    Separating agent: stripping vapor

    Standard Design Steps:

    Calculation of

    1) Theortical number of stages.

    2) Actual number of stages.

    3) Diamter of column.

    4) Weeping point.

    5) Pressure drop.

    6) Downomer design.

    7)

    Entrainment calculations.

    8) Height of column

    1. Calculation of theoretical number of stages:43

    The main component which we want to be stripped from MDEA is H2S. So, we take it as a

    refence.

    Let us supose that 100% of H2S is not stripped and very minute quantities remains in the

    lean MDEA coming back from Stripper.

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    Fraction of H2S stripped = Esi= 0.998

    Minimum V/L for H2S = ()min=

    Value of K depends on T & P.

    So, average tower conditions for value of ki:

    T = 230 F

    P = 26psia.

    36Ki = 35

    So,

    (

    )min=

    =

    = 0.0285

    Operating ( ) = 1.25 (0.0285)= 0.0356.

    Operating striping factor

    Si=

    (

    ). Ki= 0.0356 x 35

    = 1.246.

    Theoretical stags at operating conditions.

    ESi= SiN+1

    Si / SiN+1

    1

    0.998 = (1.246)N+11.246 / (1.246)N+11

    (N+1) log 1.246 = log ( )

    (N+ 1)(0.0955) = 2.0969

    N = 20.78

    It means 21 theoretcal trays are needed.

    2. Calculation of Actual Number of stages:

    We take 70% efficiency.

    So,

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    Actual number of stages =

    = 30 stages.

    3. Calculation of diameter of column:37

    Flooding velocity is given by

    Uf= K1 Where,

    Uf= Floodig vapor velocity in m/s , base on net column cross-sectional area.

    K1= Constant obtaind from figure 11.27 vol.6 Coulson & Richardson .

    FLV= Whre,

    Lw=Liquid mass Flow rate ,

    Vw= Vapur mass Flow rate ,

    In this case

    In this Case,

    Lw= 315

    Vw= 20.38

    Pv= 1.96 [

    ]

    PL= 935.24 FLV=

    = 0.71

    We use Pate Spacing 800mm.

    38K1= .05

    Then, UF= .054

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    = 1.8

    We take actul velocity as 85% of flooding velocity

    So, Uv= 0.85 x 1.18

    = 1.00

    Maximum volmetric vapor flow rate =

    =10.4

    Net area required = An=

    = 0.4 m2

    We take downcomer areaas 12% of total area

    Column cross sectional are = Ac=

    = 11.82 m2

    Down comer area = Ad= 11.210.4 = 1.42m2

    Active area , bubbling area = Aa= Ac2 Ad

    = 11.822(1.42)

    = 8.98 m2

    Total hole area as 10% of activ area , so

    Hole area = AH= 0.10 x 8.98 = 0.898 m2

    Column diameter = Dc=

    = = 3.88 m.

    Calculation of Weeping Point:

    For the calculation of weepig point, hole diameter must be selected so that at lowest

    operation rate, the vapor flow velcity is still above weeping point.

    Maximum liquid flowrate = 315

    Minimum liquid rate , at 70% turn down = 0.70 x 315

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    = 220.5

    x 100 = x 100 = 12%39

    = 0.77lw= 0.77 x 3.88 = 2.99m

    we know

    how= 750 * +2/3Lw= weir length, m

    how = height over weir , mm liquid

    Lw= liquid flow rate

    Minimum how= 750 [] 2/3

    = 138mm.

    We take , hw= 50mm

    hw+ how = 138 + 50 = 188mm.

    40K2= 31.2

    Uh(min) = [ ]

    Uh = minimum vapor velocity through holes, m/s

    Dh= hole diameter, mm

    Uh=

    ]

    Uh= 6.17m/s

    Actual minimum vapor velocity =

    =

    = 8.11 m/s.

    So, minimum operating rate will be well above weeping point.

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    Calculation of Pressure drop:= 9.81 x 10-3ht PL= total pressure drop , Pa(N/m2)ht= total pressure drop , mm liquid

    Total pressure drop is giver by

    ht= hd+ (hw+ how) + hr

    ht= total plate pressure drop

    hd= dry plate pressure drop

    hr= residual head

    hw= height of weir

    how= weir crest, mm liquid

    hd= 51 []2

    Co= Orifice coefficient

    Uh= Vapor velocity through holes , m/s

    Uh= = 11.6 m/s. We take carbon steel plate, so

    plate thickness = 5mm

    hole diameter = 5mm

    so, 41

    Co= 0.84

    hd= 51 []2 [ ]

    = 20 mm

    hr=

    = 13mm

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    ht= 188 + 13 + 20

    = 221mm liquid

    = 9.81 x 10-3x 221 x 935.24

    = 2027.6 Pa

    = 0.29 Psia (per plate)4. Downcomer Design:

    The downcomer area and the plate spacing must be such that the level of the liquid and

    froth in the downcomer is well below the top of outlet weir on the plate above. If the liquid

    rises above the outlet weir the column will flood.

    hb= (hw+ how) + ht+ hdc

    Where,

    hb= downcomer backup, measured from plate surface, mm

    hdc= head loss in downcomer, mm

    hdc= 166 []2

    where,

    hdc= head loss in downcomer, mm

    Lwd = liquid flowrate in downcomer, kg/s

    Am = Either downcomer area or clearance area under the downcomer Aopwhich is smaller.

    Aop = hop Lw

    Where, hop = height of bottom edge of apron above plate

    Lw= length of weir

    hop = hw10

    = 5010 = 40mm

    So, Aop= 0.040 x 2.99m

    = 0.120m

    hdc= 166 [ ]2

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    = 13.07mm

    So, backup in downcomer = hb= (50 +138) +13.07 + 221

    = 422.07mm = 0.422m

    Then , backup in downcomer < (plate spacing + weir height)

    0.422

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    4.5 MDEA Surge Drum:

    Flow rate of MDEA = 2349334.04 Ib/hr

    Density of MDEA at 160oF = 64.6 Ib/ft

    3

    Basis 24 hoursVol. of MDEA for 24 hr = 2349334.04 x 24/64.6 = 872817.6 ft3

    Total vol. of vessel = vol. of MDEA + 10% allowance

    = 872817.6 x 1.10 = 960099.36 ft3

    Let us suppose that 0.3% of MDEA solution is slipped in the surge tank

    =960099.36 *0.03=2858.29 ft3=81m3

    V = d2h/4

    Let, h/d = 3 or h = 3d[1]

    V = 3 d3/4

    From here, d = 3.25m so, h=9.75 m

    Design Specifications

    Time of operation = 24hr

    Dia. Of vessel = 3.25m

    Height of Vessel = 9.75m

    Recommended material of instruction is carbon steel.

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    CHAPTER NO.5

    Dynamic Simmulations.

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    CHAPTER NO.6

    6.1 Plant Cost Estimation:

    As the process design is completed it becomes possible to make accurate cost estimation

    because detailed specification can thus be obtained from various manufactures. However

    no design project should proceed to the final stages before costs are considers and the cost

    estimation should be made throughout all the early stages of the design when completespecifications are not available. Evaluation of costs in the preliminary design is said pre

    design cost estimation. Such estimation should be capable of providing a basis for company

    management to decide whether or not further capital should be invested in the project.

    An evaluation of costs in the preliminary design phase is sometimes called as guess

    estimation and often rule of thumb are used. A plant design obviously must present a

    process that is capable of operating under conditions which will yield a profit.

    A capital investment is required to any industrial process, and determination of necessary

    investment is an important part of plant design project. The total investment for any

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    process consists of physical equipment and facilitates in the plant plus the working capital

    for money which must be available to pay salaries. Keep raw materials and products on

    hand and handle other special items requiring a direct cash layout.

    6.2 Capital Investment:

    Before industrial plant can be put into operation, large amount of money must be supplied

    to purchase and install the necessary machinery and equipment, land services facilitates

    must be obtained and plant must be erected, complete with all pipe control services. In

    addition it is necessary to have money available for payment of expenses involved in plant

    operation.

    The capital needed to supply the necessary manufacturing and plant facilities is called fixed

    capital. Fixed cost capital investment while necessary for the operation of the plant termed

    as Working Capital. The sum of fixed capital investment and the working capital is known as

    total capital investment.

    Fixed capital investment classified into two subdivisions: namely

    Direct costs

    Indirect costs

    6.2.1 Direct costs:

    The direct cost items are incurred in the construction of planet in addition to the cost of

    equipment:

    Purchase equipment

    Purchase equipment installation

    Instrumentation

    Piping

    Electrical Equipment and materials

    Building (including services)

    Service facilities

    Taxes

    6.2.2 Indirect costs:

    These include:

    Design and engineering

    Contractors expanses

    Contractors fee

    Contingency

    6.3 Types of Cost Estimation:

    Various methods are employed for estimating capital investment are as follows:

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    Preliminary estimate

    Definitive estimate

    Detailed estimate

    In choosing the method for cost estimation following factors are considered:

    Amount of detailed information available

    Accuracy desired

    Time spent on estimation

    6.4 Methods of Estimating Capital Investment:

    Seven methods of estimating capital investment are outlined below:

    Detailed item estimate

    It cost estimate

    Percentage of delivered equipment cost

    Lang factor for approximation of capital investment

    Power factor applied to plant capacity ratio

    Investment cost per capacity

    Turnover ratio

    6.5 Percentage of Delivered Equipment Cost:

    This method for estimating the fixed or total capital investment requires determination of

    the delivered equipment cost. The other items included in the total direct plan cost are then

    estimated as Percentage of Delivered Equipment Cost.

    The percentage used in making an estimation of this type should be determined on the basis

    of type of process involved, design complexity required, material of construction, location of

    the plant, past experiences, and other items depend on the particular unit under

    consideration.

    Purchased equipment cost for common plant equipment = Ce = E

    Ce= a + b (S)n

    Where a & b are cost constants

    S = size parameter

    n = exponent for that type of equipment

    Cost of Absorber:

    We know that

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    C= a+b(S)n

    Diameter of Absorber = 2.4 m

    sizing factor (S) = 2.4

    a = 110, b = 380, n= 1.846

    so,

    C = 110+380(2.4)

    = $1947 ( Cost/Tray)

    Total cost of one absorber = 1947 x 27

    = $52569

    As we have used two absorber, so

    Cost of both Absorbers = $52569 x 2

    = $105138

    This cost is for year 2007, so by applying inflation rate of 3.3% per year, we can find cost in

    2013.

    C = 105138(1.033)6= $127750.21

    1. Cost of Exchanger:

    We know

    C= a+b(S)n

    Sizing parameter of exchanger (S) = 584 m2

    a = 1350, b = 180, n = 0.9547

    so,

    C = 1350+180(584)0.95

    = $73313

    This cost is for year 2007, so by applying inflation rate of 3.3% per year, we can find cost in2013.

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    C = 73313(1.033)6= $89080.

    2. Cost of Inlet Gas Separator:

    Diameter = D = 2.06 m

    Length = L = 6.34 m

    From Graph48

    C = 22000

    Pressure Factor = 1.4 (at 30 psia)

    So,

    C = 22000 x 1.4 = $30800

    This cost is for year 2004, so by applying inflation rate of 3.3% per year, we can find cost in

    2013.

    C = 30800(1.033)9= $41253.

    3. Cost of Lean Solvent pump:

    Capacity of Pump = 3919 GPM

    From Graph

    C = $25000

    This cost is for year 1988, so by applying inflation rate of 3.3% per year, we can find cost in

    2013.

    C = 25000(1.033) = $49436.

    4. Cost of MDEA Surge Tank:

    Capacity of tank = 81 m3

    We know that

    C = C= a+b(S)n

    a = 5000, b = 1400, n = 0.7 (cone roof)49

    so, C = 5000+1400(81)0.7

    = $35343

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    This cost is for year 2004, so by applying inflation rate of 3.3% per year, we can find cost in

    2013.

    C = 35343(1.033)9= $47337.

    E = $354856

    7.6 Direct Cost:

    Component % of E Cost ($)

    Purchased Equipment Installation 0.25E 88714

    Instrumentation installation 0.07E 24840

    Piping 0.08E 28388

    Electrical 0.05E 17723

    Building 0.05E 17723Yard improvement 0.02E 7097

    Service facilities 0.15E 53228

    Land 0.01E 3549

    Total direct cost = D = 241262

    7.7 In-Direct cost:

    Engineering & Supervision = 0.33E = $117102 (1)

    Construction Expenses = 0.41E = $145490 (2)

    Total in-direct Cost = $262592

    Total Cost = direct Cost + indirect cost

    = $503855

    Contactors Fee = X = 0.05 (D+I) = $12063

    Contingency = Y = 0.10 (D+I) = $24126

    Fixed Capital Investment = (D+I+X+Y) = $540043

    Working Capital Investment = 0.15(D+I+X+Y) = $81006

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    OPERATIONAL PROBLEMS.

    7.1 Problems occurring during operation:One of the reasons that alkanolamine processes have become the predominant choice for

    both refinery gas giving and natural gas purification is their comparative freedom from

    operating difficulties. However, several factors can result in undue expense and cause

    difficulties in the operation of alkanolamine units. Chief among these, from an economic

    standpoint are corrosion and amine loss. Other operating problems, which occasionally limit

    the capacity of plant for gas purification, include foaming and plugging of equipment. In

    many cases, operation can be significantly improved by daily monitoring of key plant

    operating variables and by proper control and design of treating plant.

    7.2 Foaming:

    Foaming of alkanolamine solution is perhaps the most common operating problem in amine

    treating units. It is most frequently encountered in contractor, but may also occur in the

    stripping column.

    Causes of Foaming:

    Specific cause of foaming includes the following:

    Water soluble surfactants in the feed gas (e.g. well treating mixes, pipeline corrosion

    inhibitors) which lowers the amine metaphors surface tension. Excessive antifoam can

    also cause foaming.

    Liquid hydrocarbons e.g. entrained compressor lubricating oils in the feed gas or

    hydrocarbons condensation within the amine absorber.

    Particulate contaminants (e.g. mill scale, FeS correction products, rust contained in the

    feed gas or produced within amine treating units. Solids such as FeS do not cause

    foaming but concentrate at liquid/gas interface and stabilize the foam by increasing the

    surface viscosity retarding film drainage.

    Oxygen adulteration of feed gas or amine unit (usually at the amine sump or amine

    storage tank) and reation of amine heat stable salts. Dissolved iron can catalyze thereaction of amine with oxygen to foam carboxylic acid.

    Feed gas adulteraction such as carboylic acid, which react with amine to form heat

    stable salts.

    Contamination of amine unit with gases and oils during a turnaround.

    Amines filter elements that have been washed with surfactants or contaminated with

    oils during manufactue.

    Contaminants in the amine plant makeup water such as boiler feed water treating

    chemicals and corrosion inhibitors.

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    Prevention of Foaming:

    Foaming can be reduced or controlled by proper care of the amine solution. The

    following techniqes reduce the amine solution contamination and minimize foaming:

    A properly desined feed gas inlet separator and filter should be provided. A feed gas

    coalscer should be considered for feed gas stream contaminated with compressor

    lubricating oils and other finally dispersed aerosols. A properly size slug catcher should

    be provided if slgs can accumulate in the feed gas line.

    A feed gas water wash should be considered when the feed gas streams is severely

    contaminated wth carboxylic acid or water soluble, surface active pollutes. A feed gas

    water wash can also remove aerols and ultra fine chemicals.

    Onsite of offsie amine solution recovering to remove heat stable salts and amine

    degradation poducts. No more than 10% of the amine should be tied up as stable salts.

    Caustic additin to neutralize heat stable salts to mitigate corrosion and thereby reduce

    iron sulfite formation.

    A properly sized rich amine flash drum remove entrained and dissolved hydrocarbons.

    Liquid skimming facilitate in the absorber sump, the rich amine flash drum, the

    regenerator sump and the amine regenerator overhead accumulator.

    New plants and old plants that have undergone a major turnaround or often

    contaminated with oils, greases welding fluxes and corrosion inhibitors. A hot caustic

    wash (2-5 wt% caustic soda) followed by a hot condensate wash can remove these

    impurities and help to prevent foaming.

    Addition of antifoam is carried out.

    7.3 Corrosion:

    By far the most serious operating problem encountred with amine gas purification

    process is corrosion as would be expected this problem has been given widest attention.

    Generally, it occurs in regenerator heat exchanger and pumps. The extent and type of

    corrosion has been observed to depend upon such factors as the amine used, the

    presence of impurities in the solution leading with acid gas, the temperature and

    pressure, predominant in various part of the plant, the velocity with which the solution

    flows and others. However, it appears that the principal corroding agents are the add

    gases. The rate of corrosion growths with increase acid gas concentration n solution.

    Corrosion due to hydrogen sulfide and carbon dioxide is frequently observed a filter

    shell and the hot end heat exchanger tubes. To minimize corrosion by hydrogen sulfide

    and carbon dioxide, the acid gases must be shell in a relatively corrosive form until

    regeneration of amine solution is stripping still

    Overloading the amine solution will increasethe casual for corrosion due to pressure

    discount or high temperature in the heat exchanger. This danger can be remedied

    bymaintaining adequate pressure on the amine solution and by operating the unit at as

    low and acid gas alkanolamine ratio as possible. This ration should not exceed 0.05

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    moles of acid gas per mole of alkanolamne and should be event less of condition

    licences

    Mechanism of Corrosion:

    It is known that free or aggressive carbon dioxide causes severe corrosion particularly at

    elevated temperature and in the presence of water

    It is believed that the metallic iron with carbondi acid which results in the formation of

    stable iron bicarbonate. Further heating of solution any cause the release of carbon dioxide

    and the precipitate of the iron as the relatively insolule carbonate.

    Hydrogen sulfide attacks steel as an acid with the subsequent formation of insoluble ferrous

    sulfite. This compound forms a coating on the metal surface which does not adhere tightly

    and therefore affords little protection from further corrosion. There is no satisfactory

    correlation available for carbon dioxid hydrogen sulfide mixture, which relates the corrosive

    attacks to be probable with any givenratio of hydrogen sulfide to sulfur dioxide.

    However, certain generalized obseration has been made. It appears that in plant handling

    predominantly carbon dioxide, ver small extent of hydrogen sulfide may actually reduce

    corrosion. On the other hand, eac of the acid gases growths the corrosive attacks of the

    other

    Methods of Minimizing Corrosive Attacks:

    Corosion can be reduced by various methods, including certain protection in the operation

    ad process design of purification plants. Use of more expensive corrosion resistant materialnd continues or periodic removal of corrosion promoting agent from the solution.

    Acombination of several of these measures usually leads to most satisfactory and

    e\conomical to reduce corrosion attacks;

    The temperature of the solution in the reboiler and the temperature of the steam

    usedin the reboiler should be kept as low as proble.

    Use of high temperature heat carrying media, uch as oil, should be avoided to maintain

    the lowest possible skin temperature of metal

    Pressure regenerator with its supplemenry high temperatures results in severe corrosion

    of reboiler tubes; it is, therefore, good ractice to maintain the lowest possible pressure

    on the stripping column and reboiler

    To prevent oxygen from entering te system, it is prudent to maintain a blanket of inlet

    gas over all serving of the solutin, which could be exposed to atmosphere and to ensure

    the pressure the suction side ofall pumps.

    Continuous removal of suspeded solids (by nitration) and the decomposition product (by

    distillation of a side stream) enerally helps to reduce corrosion.

    7.4 Chemical Losses

    The loss of a solvent can bea serious operating difficulty in alkanolamine gas purificationplants. Corrosion can be icurred by entrainment of the solution in the gas stream

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    vaporization or chemical dgradation of the amine. Loss of the solvent by entrainment or

    vaporization is undesirable \not only because of the cost of chemicals but also because of

    the contamination of the ipelines by liquid deposited on the walls. In addition when

    alkanolamine solution are ued to purify the gas to be used in catalytic process, entrainment

    by vaporization of solvet esult in a serious poisoning of the catalyst.

    7.5 Losses due to Volatility:Glycol volatility losses are usually significant in ethylene glycol, di-ethylene glycol but very

    less in tri-ethylne and higher glycols, which have very high boiling points. Hence usually a

    very small amunt of glycol is lost by evaporation into gas stream in absorbers and also in

    regeneators.

    Prevention from Volatility Losses:

    Volatility losses can be prevented by following methods:

    A cold water flux is convyed at the top plate of regenerating column.

    Normally absorbers are operted at lower temperatures (80-1100F recommended) to

    avoid losses.

    7.6 Entrainment:

    In many cases most of the glycol loss occurs as carry over of solution with the product gas.

    Entrainment losses are fashined either by inefficient mist withdrawal or by foaming and

    subsequent carry over solution. Entrainment losses from glycol absorber vary significantly

    contingent on the mechanical design of both the upper solution of absorber and mist

    elimiation devices.

    Prevention from Entrainment Losses:

    Entrainment can be mi diminishd by the following techniques:

    Using efficient mist eliminaton equipment.

    Application of the foam inhibitor.

    References:

    1. ARTHUR KOHL AND RICHARD NELSON, Gas Purification, Edition 5th.

    2. Basic Principles and Calculations in Chemical Engineering.7th Edition.

    3. Coulson & Richardson's Chemical Engineering - Volume 6.

    4. GAS PROCESSORS SUPPLIERS ASSCIATION, Engineering Data Book

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