1. HYDROPROCESSING PROJECT PROCESS DESCRIPTION
KHABAROVSK REFINERY
HYDROPROCESSING PROJECT
PROCESS DESCRIPTION
TRAINING COURSE
APRIL 29th – MAY 3rd 2013, MADRID, SPAIN

2. BLOCK DIAGRAM OF SRU/TGT
INTRODUCTION
TRAINING COURSE
TO HIGHLIGHT THE MAIN PROCESS FEATURES,
STARTING FROM THE BASIC KNOWLEDGE OF THE THEORY
BLOCK DIAGRAM OF SRU/TGT

3. MAIN SECTIONS PLANT SECTIONS:
To remove H2S and sulphur compounds from acid gas producing elemental sulphur
CLAUS SECTION
DEGASSING SECTION
To remove H2S and polysulphides (H2Sx) from the produced liquid sulphur
The tail gas is reduced so that all sulphur compounds and residual SO2 are converted to H2S
TGT SECTION
AMINE SECTION
To regenerate the rich amine containing H2S and CO2 and recycle the acid gas to the Claus Section

4. MAIN SECTIONS
PLANT SECTIONS:
AMINE REGENERATION
SECTION
To regenerate the rich amine containing H2S and CO2 and recycle the Amine Acid Gas to the Claus Section
SOUR WATER STRIPPING
SECTION
To remove H2S and NH3 from sour water streams and recycle the SWS Acid Gas to the Claus Section

5. CLAUS SECTION PURPOSE CATALYTIC STAGE
To remove hydrogen sulphide and sulphur compounds from acid gas, producing elemental sulphur.
As a second effect, NH3 content of the SWS stream will be highly reduced in the Claus Thermal Reactor.
PURPOSE
THERMAL STAGE
CATALYTIC STAGE

6. CLAUS SECTION - Process Streams
The process streams involved in the Claus Section are:
FEEDS
Amine Acid Gas;
Sour Water Stripper Acid Gas;
Amine Acid Gas Recycle from TGT Regenerator
PRODUCTS
Tail Gas to TGT Section
Liquid Sulphur to degassing/storage
PROCESS STREAMS

7. CLAUS SECTION - PROCESS FLOW DIAGRAM
Amine Acid Gas Scrubber has the purpose to remove the NH3 in the AAG.
AAG recycled
from Regenerat.
section is
mixed with
AAG coming
from AAG header
K.O. Drum installed to prevent any
liquid drop going to the burner.
Combustion Air
is supplied by
Blower.

8. CLAUS SECTION - PROCESS FLOW DIAGRAM
SWSAG and part of the
AAG are mixed prior
to enter in the Claus
Burner.
AMINE AG
SWS AG
Thermal Reactor, WHB:
residence time, gas
cooling and heat
recovered.
COMB. AIR
Any sulphur condensed in the Thermal Reactor Waste Heat Boiler is drained to Sulphur Pit via dedicated hydraulic seals.

9. CLAUS THERMAL REACTOR : Main Equipment
The concentration of H2S and the presence of impurities in the feedstock to Claus Unit play an important role for the selection of the more appropriate plant configuration
THERMAL STAGE
The minimum requirements for the Thermal Reactor in case of treatment of feedstock which contains impurities are:
Installation of a well proven high intensity burner
Appropriate residence time in the Thermal Reactor
Adequate temperature in the Thermal Reactor
The Thermal Reactor has been designed with double zones configuration to achieve
COMPLETE DESTRUCTION OF ALL IMPURITIES

10. CLAUS SECTION - PROCESS FLOW DIAGRAM
CATALYTIC STAGE
2 Claus Reactors, filled with
alumina catalyst to complete
the Claus reaction between
H2S and SO2
The first reactor has been
designed also for the use of
titania catalyst (to promote
Hydrolisis of COS, CS2).
Claus Heaters:
Hot gas by-pass for the first Claus Converter;
Electrical Heater for the second Claus Converter.
Steam side:
1st, 2nd and 3rd Condensers
operating P = 4.5 kg/cm2 g
The produced Svap is condensed in each Sulphur Condenser and drained via hydraulic seals.
Condensation and removal of sulphur, before the inlet to first and second catalytic stage,
enables further conversion of sulphur in each catalytic reactor.

11. SULPHUR DEGASSING SECTION
To remove H2S and H2Sx from the liquid sulphur produced.
The removal is achieved by means of direct contact with air (Stripping Air from Combustion Air Blower) in a internal Degassing Column filled with catalyst.
PURPOSE
The process streams involved in the Sulphur Degassing are:
FEEDS
Undegassed Liquid Sulphur with H2S content about of 300ppm wt.
Stripping Air
PRODUCTS
Degassed Liquid Sulphur with H2S content less than 10ppm wt.
Sweep Air to Thermal Incinerator
PROCESS STREAMS

12. SULPHUR DEGASSING – PROCESS FLOW DIAGRAM
Sulphur Pit is equipped with Undegassed Sulphur Section and Degassed Sulphur Storage Section.
Air (hot) is fed from
Combustion Air
Blower
through steam
jacketed pipe.

13. SULPHUR DEGASSING – PROCESS FLOW DIAGRAM
Sulphur Pit temperature
The temperature inside the sulphur pit must be 135÷145 °C in order to control the viscosity of the liquid sulphur, which has to be easily pumped/ transferred (steam coils are provided).
Sweeping the sulphur pit
In order to ventilate the vapour space above the sulphur level - and thus maintaining the H2S concentration below the lower explosion limits – Steam Ejector is provided.
The resulting Sweep Air is sent directly to the Incinerator.

14. TAIL GAS TREATMENT SECTION
R.A.R. Technology (REDUCING, ABSORPTION, RECYCLE)
The goal of the process is the reduction/hydrolysis into H2S of sulphur compounds (SO2, Sx, COS, CS2) and the selective absorption of H2S with the amine solution.
The H2S released during the regeneration of the amine solution is recycled to Claus Unit.
To reduce all sulphur compounds contained in the tail gas from Claus Section into H2S, over a catalytic reactor.
After the reduction stage, there is the cooling stage, where the gas is cooled in the gas/gas heat exchanger and the water content is reduced by condensation.
Finally, the H2S contained in the quench tower outlet gas is absorbed along the TGT Absorber and recycled to the Claus Unit.
PURPOSE

15. TAIL GAS TREATMENT SECTION – Process Streams
The process streams involved in the TGT Section are :
FEEDS
Tail Gas from Claus Unit
Lean Amine (MDEA 50%wt.) from Amine Regenerator
PRODUCTS
Tail Gas to Thermal Incinerator
Rich amine (MDEA 50%wt.) to Amine Regenerator
PROCESS STREAMS

16. TAIL GAS TREATMENT SECTION– PROCESS FLOW DIAGRAM
TGT Heater is designed to
heat the tail gas coming from
both Claus trains and preheated
in the gas/gas exchanger.
Hydrogenation Reactor
filled with special catalyst,
capable to convert all sulphur
compounds in the Claus tail gas
to H2S, under slight H2 excess.
Hydrogenation Reactor
Inlet/Outlet temperature = 280 °C/310 °C at SOR
For turndown capacities, the Recycle Gas Blower is used to maintain in recirculation to ensure the min. flow of gas for the Hydr. Reactor and the TGT Absorber (also at start-up/SD).

17. TAIL GAS TREATMENT SECTION– PROCESS FLOW DIAGRAM
Quench Tower
Gas from Quench Tower temperature = 38 °C
H2 Quench Tower outlet = 3% vol.
TGT Absorber
MDEA solution = 50% wt.
Lean MDEA inlet temp. = 40°C
Tail Gas outlet temp. = 42°C
The Quench circuit is completed by the Quench Water Cooler, by the Sour Water Filter, and by the draw-off line (excess of condensed water).

18. AMINE REGENERATION SECTION
To regenerate the rich amine containing H2S and CO2 from TGT Absorber.
To recycle the acid gas back to the Claus.
PURPOSE
The process streams involved in the Amine Regeneration Section are:
FEEDS
Rich Amine (MDEA) from TGT Absorber
PRODUCTS
Lean Amine (MDEA) to TGT Absorber
Acid Gas Recycled to Claus
PROCESS STREAMS

19. AMINE REGENERATION SECTION– PROCESS FLOW DIAGRAM
Rich Amine to Regen. = 100 °C
Recycle Gas temperature = 50°C
Regenerator Reflux Drum pressure = 0.9 kg/cm2 g
AMINE ABSORPTION
Lean Amine to TGT Absorber temperature = 40 °C
Lean Amine to filtration system about 50% of total amine flow
Amine type: MDEA

20. AMINE REGENERATION SECTION– PROCESS FLOW DIAGRAM
AMINE FACILITES
Steam Condensate make up is fed to Reflux Drum to maintain 50%wt.
Amine Drain Drum is provided to collect amine drains and is equipped with Amine Drain Pump. Blanketing medium to protect amine from degradation.
Amine Filters are designed to remove particles (mechanical filters) and to absorb entrained impurities (active carbon filter).

21. INCINERATOR SECTION PURPOSE PROCESS STREAMS
To perform the incineration (=oxidation at high temperature) of residual H2S and all sulphur compounds to SO2, in presence of excess air.
To discharge the flue gas to the atmosphere via a stack in safe conditions (dispersing the resulting product at altitude).
PURPOSE
The process streams, involved in the Thermal Incinerator, are the followings:
FEEDS
- Tail Gas from TGT Absorber
Sweep Air from Sulphur Pit
Thermal Incinerator is sized to accomplish the combustion of tail gas coming directly from Claus train, in the event of TGT section shutdown (TGT by-pass).
PRODUCTS
Flue Gas from Stack
PROCESS STREAMS

22. INCINERATOR SECTION– PROCESS FLOW DIAGRAM
Oper. temp.= 650°C
Natural draught type
Flue Gas O2 content = 2% vol. minimum on wet basis
O2 analyzer at the Stack
Due to low heating value of tail gas, it is necessary to sustain the combustion using the fuel gas. The fuel gas flow to the burner is adjusted by temperature control in the thermal incinerator.

23. AMINE REGENERATION SECTION (ARU) – Process Streams
To regenerate the rich amine containing H2S from Hydrocracking Section (HCU).
To produce Amine Acid Gas that shall be treated in the Claus Trains.
PURPOSE
The process streams involved in the ARU Section are:
FEED
- Rich Amine (DEA 25%wt.) from HCU
PRODUCTS
- Amine Acid Gas to Claus Trains
- Lean Amine (DEA 25%wt.) to HCU
PROCESS STREAMS

24. ARU SECTION – PROCESS FLOW DIAGRAM
AMINE REGENERATION
Rich Amine to Regen. = 93 °C
Acid Gas temperature = 55°C
Regenerator Reflux Drum pressure = 0.9 kg/cm2 g
Lean Amine to HCU temperature = 55 °C
Lean Amine to filtration system = 15% of total amine flow
Amine type: DEA

25. ARU SECTION – PROCESS FLOW DIAGRAM
AMINE FACILITES
Demi-water make up is fed to Regenerator Reflux Drum to maintain 25%wt.
Rich Amine Flash Drum is provided to collect rich amine from HCU Section and is equipped with Rich Amine Pump and Slop Oil Pump.
Amine Filters are designed to remove particles (mechanical filters) and to absorb entrained impurities (active carbon filter).
Amine Sump Drum is provided to collect amine drains from HCU Section and is equipped with Amine Sump Pump. Blanketing medium to protect amine from degradation.

26. SOUR WATER STRIPPING SECTION – Process Streams
To remove Hydrogen Sulphide and Ammonia from Sour Water Streams.
To produce Sour Water Stripper Acid Gas that shall be treated in the Claus Trains.
PURPOSE
The process streams involved in the ARU Section are:
FEED
- Sour Water from SRU
- Sour Water from TGT
- Sour Water from HCU
- Sour Water from DHT
PRODUCTS
- Sour Water Stripper Acid Gas to Claus Trains
- Stripped Water to HCU/DHT
PROCESS STREAMS

27. SWS SECTION– PROCESS FLOW DIAGRAM
Sour Water Stripping
Sour Water to Stripper = 84 °C
SWS Acid Gas temperature = 85°C
Stripper pressure = 0.9 kg/cm2g
Stripped water to HCU/DHT temperature = 90°C
SWS FACILITES
Sour Water Feed Surge Drum is provided to collect sour water streams and is equipped with Stripper Feed Pump and Slop Oil Pump.
Sour Water Stripper is also equipped with pumping/pumparound cooling system

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