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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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Improved Items Since Start-up (2)
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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Improved Items Since Start-up (3)
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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Improved Items Since Start-up (4)
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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Improved Items Since Start-up (5)
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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Improved Items Since Start-up (6)
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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Improved Items Since Start-up (7)
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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Improved Items Since Start-up (8)
In 2009
Reactor RSS
Stripper Packing Install
Cyclone Replacement
DeSOx GGH Replace
DeC4 Auxilary Rebolier Install
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Improved Items Since Start-up (9)
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)