1. 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
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2. 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

3. 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

4. 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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5. MAJOR MILESTONES OF DEMONSTRATION RUN
SNO
ACTIVITY
DATE 1
Signing of MoU with EIL 2
Process Package Developed by EIL 3
Detailed Engineering Activities carried out by EIL 4
Installation of Piping & Control Valves 5
Oxygen Mixing Drum installation 6
Successful Commissioning of the System
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6. 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
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7. Conventional Claus Process

8. Claus SRU Configuration

9. 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

10. 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
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11. Case Study for OxyEnrich Process
Plant Capacity : 65 TPD
Typical Feed Composition

12. Result : Effect on Furnace Temperature

13. Result : Effect on Combustion Air Rate

14. Result : Capacity Enhancement

15. 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 : %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%

16. 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)

17. 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

18. 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

19. 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

20. Technology Demonstration : Salient features
No Major hardware modification
Capacity increased by 22%
Oxygen content in Air Enriched up to 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
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21. 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

22. THANK YOU
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