PROCESS CONTROL DESCRIPTION

PRODUCTION OF HYDROGEN FROM FUEL OIL

COMBUSTION OF HEAVY FUEL
Combustion is a process where in chemical combination happen and resulting a release of
heat, which is oxygen, carbon and hydrogen. The fuel can be solid, liquid or gas. The release of
heat or energy from fuel comes from air. And its purpose is too safely and maintain efficiently
desired boiler output that do not need much attention from the operator. The basic principle
applied to combustion control is to meet the load of the boiler required, regulating quantities of
fuel and air needed to achieve optimum combustion and at the same time maintain safe
conditions of operators and the equipment, usually the unit in terms of Calories or BTUs (British
Thermal Units). The calorie is defined as the amount of the energy require to raise one degree of
water one degree Celsius. One of the major goal for the plant performance is to have or to reach
the optimum level of his program.
HEAVY STORAGE TANK
heavy storage are used to store heavy fuels, which temperature should be monitor or has a
control temperature in order to avoid combustion and pressure for the release or the withdrawal
of fuel, the tank must be resistant for corrosion against the effect of climate change in the
environment, such as wind, moisture, exposure to sunlight. The primary function of this tank is
to supply fuel that needed for the production of hydrogen fuel, level control transmitter has been
installed to check whether it is in high and low level to ensure its efficiency in production.
LIQUID OXYGEN TANK
This type of equipment must design depending on the quantity, used to store, storage tanks, and
storage volume may vary from a few gallons to thousands of gallons. Vaporization takes place
continuously this function to maintain cold temperature. The important thing to note that
dispense gaseous oxygen, the valves must equipped with standard Compressed Gas Association
or the CGA outlets. Equipment may attached but with the suitable regulating pressure. The
valves withdrawal provided for liquid products must also equipped with the following standard

of the CGA, connections for outlets differ to the used of gaseous withdrawal. This would prevent
the connections between the process using the liquid or the gaseous product.
HEAT EXCHANGER
The purpose of heat exchanger or designed is to transfer or exchange heat from one matter to the
efficiently. When fluid is used to transfer heat, the fluid could be in liquid form, such as oil,
water or it could be moving air. The basic components of heat exchanger can be view as tube
with one fluid running and another fluid are flowing on the outside tube. Heat exchanger are
classified typically according to the arrangement of flow and type of construction.
REFRACTORY LINE-FRAME-REACTION
This equipment must possess with quality resistance to heat, in this area the components mixed a
steam and oxygen, before it would mixed with reactant, oxygen preheated to 210 degrees, the
type of frame reactor should have the ability to resist in steam as it carry that passes through the
refractory lined flame reactor.
CARBON AND H2S REMOVAL STAGE
WASTE HEAT BOILER
Waste heat boilers can operate in a range of applications recovering heat which is produced as a
by-product of another process. These hot water and steam boilers are conventionally-fired
boilers based on a 3-pass design, with an additional separate integrated smoke tube pass for
waste heat utilization. The waste heat system uses hot flue gases from upstream combustion
processes to assist in the generation of thermal or process heat.
SCRUBBER
Scrubbers are commonly used in process-air applications to eliminate potentially harmful dust
and pollutants. A liquid, in general water added with active chemicals adapted to the process, is
sprayed in to the air flow. Aerosol and gaseous pollutants in the air stream are removed by either
absorption or chemical reactions with the water solution. Water with chemicals are sprayed with
high pressure through nozzles into the air flow. Water droplets are separated from the exhaust
and re-circulated back to the water reservoir. Evaporated water is replaced by fresh water and

chemicals. Dust and pollution products from the process are removed periodically through the
drain.
WATER HEATER
When heated water is needed, the gas fired burner is started which generates large volumes of
hot gases. These gases enter the lower heat transfer chamber and start moving upward through
the "packed mass" heat exchanger. At the same time cold fresh water starts flowing through the
distributor onto and downward through the torturous path of the packed mass heat exchanger.
The large surface area of the packing causes the water to spread out into a very thin film. The
hot gases traveling upward through the packing readily releases its heat to the water film, rapidly
rising its temperature. Just as quickly, the hot gases cool. Gas-fired heaters have a burner that's
fed gas through a control valve and a thermostat switch. Because fuel-fired heaters heat the tank,
which in turn heats the water, there will be more wear and tear.
DEMINERALIZED WATER STORAGE TANK
Carbon Dioxide Removal System for Demineralized Water Tanks prevents penetrating of carbon
dioxide (CO2) by removing it from supply air.

There is no carbon dioxide present in

demineralized water because carbon dioxide is removed by the anion unit. The pH of
demineralized water is 10 because the demineralized effluent is in the form of sodium hydroxide.
QUENCHING TOWER
In pollution scrubbers, sometimes hot exhaust gas is quenched, or cooled by water sprays, before
entering the scrubber proper. Hot gases (those above ambient temperature) are often cooled to
near the saturation level. If not cooled, the hot gas stream can evaporate a large portion of the
scrubbing liquor, adversely affecting collection efficiency and damaging scrubber internal parts.
If the gases entering the scrubber are too hot, some liquid droplets may evaporate before they
have a chance to contact pollutants in the exhaust stream, and others may evaporate after contact,
causing captured particles to become entrained. In some cases, quenching can actually save
money. Cooling the gases reduces the temperature and, therefore, the volume of gases,
permitting the use of less expensive construction materials and a smaller scrubber vessel and fan.
Once the dust has been removed in the hot gas cleaning process, the gas is adiabatically cooled

down to the saturation temperature in a quench stage. The gas outlet temperature depends on the
water content of the gas at the inlet as well as on the acid concentration in the quench liquid.
CARBON MONOXIDE CONVERSION
SATURATOR
The carbon monoxide conversion occurs in two stages of catalytic conversion and working with
a hot water circuit combined with a saturator and desaturator. The incoming gas is contacted in
hot water pumped from the base of the desaturator in the saturator and the pressure transmitter is
used for additional reset and calibration options. A relief valve is used to control or limit the
pressure shown by the pressure indicator and controller. The pressure is relieved by allowing the
pressurized fluid to flow from an auxiliary passage out of the system.
CATALYTIC CONVERSION PREHEATER
It passes to two in series heat exchangers. The first unconverted gas is heated against the
converted gas from the second stage of catalytic conversion. The two preheater is alarmed if the
temperature drops low by a temperature alarm low connected to a temperature transmitter.
CATALYTIC CONVERSION
The catalytic converter is then used to oxidize the hydrocarbons and carbon monoxide to form
carbon dioxide and water. After the second preheater, the gas would pass through a check valve
to allow it to flow in one direction and closes the other direction automatically to prevent flow in
the opposite direction as indicated by a flow transmitter. A gate valve is used to drain the fluid. A
control valve is always present to regulate the flow or pressure of the fluid in the equipment.
DESATURATOR
A cooling fluid is used in the second catalytic converter and is connected to a control valve and
relief valve as it enters the desaturator. Desaturator is used as a conversion of a saturated
compound into an unsaturated compound by a removal of two hydrogen molecules and the
creation of a double bond.
CONDENSER

As the level transmitter keeps the hot water in level as it proceeds to the condenser where the
cooling fluid is flowing by the controlled valve. It also needs regulation in the temperature using
temperature transmitter and a temperature alarm high.
FINAL H2S ELIMINATION PROCESS DESCRIPTION
TRAY TOWER SEPARATOR 1, 2, 3, 4
Hydrogen Sulfide (H2S) often is a colorless gas with a rotten egg odor, which is commonly
referred to as sewer gases. Hydrogen Sulfide is highly poisonous and highly corrosive in
wastewater applications. Corrosion of metal and concrete is a major issue associated with the
generation and oxidation of hydrogen sulfide. And to meet process requirements the final H 2S
removal takes place in four vertical vessels each approximately 60 feet (18.3 m) in height and 8
feet (2.4 m) in diameter and equipped with five trays of iron-oxide absorbent, which is a water
treatment process that is used to remove arsenic from water. Arsenic is a common natural
contaminant of well water and is highly carcinogenic. Each vessel is provided with a locking lid
of the autoclave type. The total pressure drop across these vessels is 5 psi (35 kN/m2). Gas
leaving this section of the plant contains less than 1 ppm of H 2S and passes to the CO 2 removal
stage at a temperature of 35C. The oil/gas separators are normally designed in stages, in which
the first stage separator is used for preliminary phase separation, while the second, third and
fourth stage separator are applied for further treatment of each individual phase.
POTASSIUM CARBONATE WASH
CO2 removal is accomplished employing high pressure potassium carbonate wash with
solution regeneration. This is done with the split-stream process of the potassium carbonate
solution through the gas absorber controlling the level and pressure. A portion of the lean
solution from the regenerator is cooled with temperature controller and fed into the top of the
absorber, while the major portion is added hot at a point some distance below the top. The main
solution-stream is withdrawn from the stripping column at a point above the reboiler so that only
a portion of the solution passes down through the bottom of the stripping column to the reboiler.
Since this portion of the solution is regenerated by the total steam supply to the stripping column,
it is thoroughly regenerated and is capable of reducing the CO 2 content of the gas to a low value.
The main solution-stream is fed into the midpoint of the absorber, while the more completely

regenerated portion is fed at the top. The acid gas is then ejected from the regenerator and the
high purity gas is collected from the stripping column measured by the quality sensor.