Oxy Enrich Process for Capacity Enhancement of Claus Based 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 bbbb 1

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. Slide 4 of 8 4

MAJOR MILESTONES OF DEMONSTRATION RUN SNO ACTIVITY DATE 1 Signing of MoU with EIL 25-09-07 2 Process Package Developed by EIL 25-10-08 3 Detailed Engineering Activities carried out by EIL 4 Installation of Piping & Control Valves 30-04-09 5 Oxygen Mixing Drum installation 07-05-09 6 Successful Commissioning of the System 11-05-09 Slide 5 of 12

Major Benefits of OxyeEnrich Process Greater processing capacity of sulfur recovery unit No major modification for 25% -30% capacity enhancement Processing low quality feed without problem Low backpressure ensures trouble free operation Less sulfur mist– lead to better operation Low capital cost for grass root sulfur units due to smaller equipment sizes Stable flame in main burner even at lean acid gas processing bbbb 6

Conventional Claus Process

Claus SRU Configuration

O2 Enrichment : Direct O2 injection to Combustion Air Acid Gas Preheater Acid Gas from ARU/SWS Catalytic Stages Burner Furnace WHB Oxygen from Oxygen Supply System Mixer Combustion air from Blower

RATIO CONTROLLER O2- STORAGE VESSEL AIR BLOWER MIXER PROCESS GAS FIC UV FV O2- VAPORIZER O2 ANALYZER FIC AIR BLOWER MIXER PROCESS GAS FOR SULPHUR RECOVERY FIC MAIN COMBUSTION CHAMBER ACID GAS MB bbbb 10

Case Study for OxyEnrich Process Plant Capacity : 65 TPD Typical Feed Composition

Result : Effect on Furnace Temperature

Result : Effect on Combustion Air Rate

Result : Capacity Enhancement

Technology Demonstration : Feed / Controlling Parameters Feeds Acid Gas Source : Amine Regenerator O/H H2S concentration : 74-90%v Vaporised Oxygen Source : Liquid Oxygen Storage Vessel Combustion Air O2 concentration : 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 : MCRC Design Capacity : 90 TPD Sulfur Design Sulfur Recovery : 99.0% ( min)

Technology Demonstration : Plant Configuration After Revamp Oxygen Air Blower Liquid Oxygen Vaporization Unit Air LP Steam Acid Gas, Air , Fuel Gas Acid Gas RF Claus Reactor-I WHB Condenser-I Line Burner Claus Bypass LP Reheater Fuel Gas S T A C K MCRC-I MCRC-II MCRC-III Condenser-II LP Steam Condenser-III Condenser-IV Condenser-V Sulphur Incinerator Air , Fuel Gas

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 ) AFTER (Oxygen Enrichment) Feed Gas Flow ( Acid Gas), Nm3/Hr 2115 2600 Enriched Air Flow, Nm3/Hr 3900 3100 Oxygen Content in Enriched Air, vol % 19.6 26.8 MCC Temperature, °C 1160 1340 Unit Back Pressure, kg/Cm2 0.71 % Increase in Unit Throughput NA 22 Sulphur Recovery, % Above 99 Steam Production, MT/Hr 4.20 5.60

Technology Demonstration : Salient features No Major hardware modification Capacity increased by 22% Oxygen content in Air Enriched up to 26.8 vol% Quality of Sulphur continued to be good Low backpressure in the unit Improvement in MCC Temp and stable flame even at Lean acid gas Low cost option for enhancing SRU capacity bbbb 20

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

THANK YOU bbbb 22