CO2 REMOVAL

Description of the Units

P & I Dwg No. 60-GD-3C-6431-33 (P-7 to P9). Process gas (16-60-PG-2012-33D-I) enters the MDEA reboiler E-4215 after passing through Low Pressure Steam Boiler E4214.. The inlet temperature to E-4215 is controlled by controlling the steam pressure in E-4214 Via PIC-42021. The heat input to the regenerator C-4301 is controlled by TlC-43058 through TV-43058 while regulating stripper1p temperature. The process gas is introduced into E-4216 A/B, where it is further cooled by exchanging heat with demin-water, passing through its shell side. Gas inlet temperature is monitored on TI-43003, while demin water outlet is monitored on TI-43010. Condensate from the process gas is separated in K.O drum V-4304 before the gas finally enters the CO2 absorber C-4302. Process gas temperature and pressure inlet to absorber C-4302 are monitored on TI-43001 and Fr-43001 respectively. A 2-60PG3001-33C, off take for recycle gas has been taken, before gas enters the absorber for providing H2 rich gas to reformer. In the absorber C-4302, CO2 is absorbed from the process gas by countercurrent absorption in two stages. Gas leaving from the top contains only 500 ppm of CO2 on dry basis. Rich solution from bottom of CO2 absorber, C-4302,passes through a shut-down valve, UV-43003 provided for quick shut-off in case of low level in the absorber. This is to avoid risk of gas break through to down stream equipment, which are designed for low pressure. UV- 43003 closes immediately on actuation of 1-5 security. Absorber C-4302, level is controlled by LRC43019,associated with low level alarm. This controller is regulating three control valves, HV-43001 and LV-43019 A/B. HV-43001 is a 16 control valve installed on exhaust line of DHTP-4301 working in split range i.e between 4-12 mA signal from the controller LRC-43619. SimilarlyLV-43019 A/B are 10 two independent control valves which receives 12 to 20 mA signal from the controller LRC-43019. This signal after passing through an E/P LY-43019 is boosted to 3toI psi signal. This 3 to 15 psi signal is splinted into 3-9 psi signal which operates LV-43019 A and 9-15_psi signal regulating LV-43019 B. Absorber C-4302, is provided with three low level switch, namely LSXL-43020 A, LSXL-43020 B and LSXL- 43020 C. LSXL-43020 A/B are installed on common tappings, while LSXL-43O2OChas independent tappings. Low level security LAXL43020 will actuate if any of the two above switches activate i.e on 2 out of 3 logic, as a consequence 1-5 will be activated thereby cutting of f process gas to CO2 absorber and also Stopping MDEA Solution flow from absorber i.e closing UV-43003.

The pressure in HP flash drum, V-4302 is controlled at 5.5 kg/cm2 by PIC-43008, equipped with two control valves PV- 43008 A/B working in split range. PV-43008 A is installed at discharge of recycle gas compressor K-4301, through it gas is recycled back to suction of the compressor. PV-43008A operates between 4-l2mA signal, and is also provided with a by pass valve. In case of tripping of K-4301, HP flash drum 1-4302 pressure is controlled by PV-43008 B (vent valve) operating between 122OmA controller signal. For further protection of the vessel PSV-43006 A/B/C/D/E have been provided, having set pressure at 12 k/cro2. The flashed rich solution leaves V-4302 through LV-43015 A and B, two independent control valves, controlling the level in V-4302. An independent high level alarm LAH-43013 and low level alarms LAL-43015 A/B associated with respective LIC s are also provided. In addition an independent low level security LAXL-43014 will actuate 1-38 as a consequence SOV s, on LIC43015 A/B will de-energies, and valves will close. The temperature of solution leaving HP flash is monitored Von TI-43046. In normal operation MDEA solution after passing through LIC-43015 A or B rises upwards to the overlying LP flash vessel V4301, where operating pressure is 0.3 kg/cm2, main part of flashing-off. CO2 is performed here, due to pressure reduction. The flashing is further enhanced by the introduction of steam/CO2 mixture from the stripper C-4301. Level in V-4301 is not controlled in any way as the vessel serves as an accumulator for the whole system, LR- 43012 indicates the level and is associated with high and low level alarms. An independent very low level security LAXLL-43O11. has been provided for safety of MDEA pumps. P-4301 A/B and 2-4302 A/B through 1-4 A. From V-4301 semi lean solution is split into two streams 12-60-MD-3002-11G goes to suction of P-4302 A/B where as 24-60MD-3000-11G goes to main stream pumps P-43O1 A/B. The temperature0fsolution leaving V-4301 is monitored an TI- 43045.

The solution from P-4302 A/B discharge enters, solution heat exchanger E-43O1 via LV-43003, Solution temperature at outlet E4301 is monitored an TI-43006 as it enters at the top of stripper through 8-60-MD-3005-31C. In the stripper C-4301, most of the remaining CO2content in the semi lean solution is stripped off by means of heat input to the reboiler E-4215. A 1O-60-MD-3006-11G of MDEA solution is drawn from stripper and enters the reboiler E-4215 on its shell side. The steam produced due to transfer of heat from the process gas, passing through the tube side of E-4215,js fed to the stripper as stripping steam via 20- 60-MD-2000-11G. The level in C-4301 is controlled on the upstream side by LIC-43003. controlling an 6-LV-43003 installed at discharge of P-4302 A/B and upstream of E-4301. The control signal to LV-43003 is Calculated .in an adder card - LY--43003 by the value. c the flow signal coming from FT-43002 i.e the lean solution flow to the lean absorber of C-4302. The advantage of having this control philosphy is to have a fast responding feed forward control in order to re-establish the level in stripper C- 4301, in case there is change of flow to the lean absorber, (See. attach sketch). In addition to LIC-43003, associated with low level alarm, the stripper has been provided with three local level glasses, an independent high level alarm and a low level shut-down LAXL-43005 for safety of pump P4303 A/B through 1-4 B Lean solution from bottom of C-4301 passes through exchanger E-4301 via 1260-MD-3014-11G, its temperature can be monitored by TI-43007 at the inlet and TI-43008 at the outlet, It is further cooled in E4306 by means of demin water and finally in E-4303 by means of cooling water. The solution temperature outlet E-43Q3 is controlled by TIC- 43019 manipulating TV43019, installed on by pass line of E-4303 10-60-MD-30039-11G Ultimately the lean solution at approximately 50C is transferred to the lean absorber (upper part of the C-4302) by means of the lean solution pump P- 4303 A/B. The flow is regulated through a 6 control valve FV-43002 being controlled by FRC-43002. Two independent transmitters have been provided for monitoring flow through 8-60-MD-3037-13B. FT-43002A passes signal to FRC-43002 and LY-43003 while FT-43002 B signal goes to low flow alarm and shutdown switch FSXL-43002, actuating trip of methanator 1-6. As mentioned earlier, MDEA solution leaving the LP flash vessel, V-4301 is divided into two stream of 24 and 12. The main stream 24-60-MD-3000-11G carrying. bulk of solution goes to the suction of flashed solution main pump P-4301 A/B from where it is transferred to semi lean absorber C-4302, the flow is regulated via 14 control valve FV-43003, controlled by FRC-43003. As in case of lean solution, two independent transmitters have been provided for monitoring flow of semi lean solution through 2060-MD-43001-13B. FT-43003 A passes signal to FRC-43003 for regulating flow while FT-43003 B signal goes to low flow alarm and shutdown switch FSXL-43003 actuating trip of methanator 1-6. The driver for P-4301 A is the reverse pump DHTP.4301 in combination with an electric motor. MP-4301 A can also serve as the sole driver. Motor driver MP-4301. B is provided as stand-by. A 3 side stream is drawn from the semi lean solution pump discharge P-4301 A/B for filtration in the filter S- 4301. The driving force for liquid flow through the fitter is the pressure drop across the flow control valve FV-43003. Flow through the filter is monitored by local FI-43006 and pressure drop through PDI-43019. A 2 demin water line is also provided for back washing of filter elements. Multi element cartridge filters with folded cloth are employed that can filter out 3-10 pm size particles. A separate filter of the same type, S-4302 is installed for filtering out make-up solution before feeding into the system. The steam/CO2 mixture leaving from the top of regenerator C-4301 is utilized as stripping steam in LP flash vessel V-4301, so as to enhance C0 removal. The temperature of this stream is monitored on TIC-43058 also controlling heat, input to the reboiler E4215. Stripper C- 4301 has been protected from over-pressurization by PSV- 43003 and from negative pressure by PSV-43020. Pressure drop can be monitored on PDR-43003. Finally CO2/steam mixture evolving from V-4301, its temperature being monitored an fI-43012 is cooled in LP flash Gas Cooler E-4304, having C.W flow n its tube side. Water condensed is separated. in the CO2 separator V-4303. The temperature and pressure of product C0 going to urea plant via 30-60-DC-3003-31c are monitored on TI-43011 and PRC-43004. For venting of C02, two control valves PV-43004 A/B of 8 and 16 respectively, working in split range through the control signal from PRC 43004 have been provided. The condensate separated in V-4303 is returned to semi lean solution stream by means of the overhead condensate pump, P4306 A/B. The level in V-4303 is controlled by LIC-43007, regulating LV-43007 installed at the discharge line of P-4306 A/B. Part of condensate stream is introduced into the flashing vessels V-4301 and V-4302 in order to avoid loss of chemicals by entrainment. Since the water balance of the system is positive excess water can be transferred to the process condensate stripper via hand operated globe valve installed on 2-60-PC.-3008-311A, its flow can be monitored locally on FI-43502. Provision of draining into the sewer has also been provided.