BARAUNI EXPANSION PROJECT (BXP)

y y y y y

RFCCU CRU DHDT HGU SRU

RESIDUE FLUIDISED CATALYTIC CRACKING UNIT (RFCCU)

PROCESS DESCRIPTION The main product of cracking reaction in a fluid catalytic cracking (FCC) reactor are1. Absorber Gas 2. Liquified Petroleum Gas (LPG) 3. Heavy Naptha 4. Light cycle Oil (LCO) 5. Heavy cycle oil (HCO) 6. Slurry oil REACTION SYSTEM General The riser is designed to rapidly and infinitely mix the hot regenerated catalyst with liquid feed stocks.Fresh feed is pumped to the base of t he riser and divided into equal flows to each of four bed injectors. The feed which has been preheated is finally atomized and mixed with dispersion steam in the feed injector mixing chamber and injected into the riser. The small droplets of feed contact hot regenerated vaporized oil internally mixes with the catalyst particles and cracks into lighter more valuable products along with slurry oil, coke and gas located further up the riser.In addition to these oil injectors, injectors are provided to feed naptha at the riser bottom. Injectors are provided to recycle the filtrate from the slurry filter to the riser. Fresh feed preheat Fresh feed is pumped on flow control from the feed surge drum to the feed preheat exchangers to recover heat from the process . The feed is heated against HN lean oil, HCN, LCO, HCO recycle, slurry product and slurry pump around before being set to the riser feed nozzles. The feed pump is automatically controlled by partial bypassing the fresh feed side of the slurry pump around feed exchangers.

Feed Oil feed to the riser is preheated before entering the reaction system. Dispersion steam is supplied to each fresh feed injector to promote fresh feed atomization and vaporization, the total dispersion steam is flow controlled with flow to each feed injector balanced by hand controlled glove valves. Riser Reactor supplied by the hot regenerated catalyst riser outlet temp (ROT) is regulated controlling the regenerated catalyst admitted to the riser through the regenerated The sensible heat, heat of vaporization and heat of reaction by the oil feed catalyst side valve (RCSV). The reaction system design begins at the reactor or riser base. The bottom section may cause turbulence and uneven catalyst flow pattern. Therefore a high density zone is provided to absorb shocks and stabilize the catalyst flow during the transition to upward flow. Reactor pressure floats on the main fractionator s press and therefore is not directly controlled at the converter section. A press controller at the wet gas compressor knock out drum provides for steady operating press of the reaction system. The initial separator and reactor cyclone separates the product vapors from spent catalyst and return the catalyst to the stripper bed. The cyclone dip legs are equipped with surrounded trickle valve to prevent reverse flow of gas up the dip legs. Stripper

Catalyst exiting the inertial separator is pre -stripped with steam from steam rings just below the diplegs. This is an important feature for reducing coke yield. The catalyst is further stripped by steam from the main steam ring as the catalyst flows down the stripper.

A series of baffles enhance the contacting of steam and spent catalyst. The stripper bed is fluidized by the stripping steam which displaces the volatile hydrocarbon contained on and in the catalyst particles before they enter the first stage regenerator. Coke remaining on the catalyst is burned off in the regenerators. A fluffing steam ring is located in the bottom head of the stripper to ensure the catalyst is fluidized before entering the spent catalyst standpipe. The catalyst is aerated in the spent cat alyst standpipe to maintain proper density for stable head gain. The main steam ring, plus the fluffing ring and the pre stripping rings are designed to provide about 5 kg of steam per metric ton of catalyst. Normal rate for all three rings is 3 kg of stea m per metric ton of catalyst.
(1) Reaction System Spent Catalyst Transfer

The stripped spent catalyst flows down the spent catalyst standpipe and through the spent catalyst slide valve (SCSV). Aeration steam is added to the standpipe at several elevations to maintain proper density and fluid characteristics of the spent catalyst. The spent catalyst slide valve controls the strippers level by regulating the flow of spent catalyst from the stripper. Spent catalyst flows into the first-stage regenerator through a distributor, which drops catalyst onto the

regenerator catalyst bed. Stone & Websters spent catalyst distributor is a bathtub design with weirs for even catalyst flow. To maintain properly fluidized catalyst, fluidization air is introduced through sparger pipes located along the bathtub distributors bottom section. This special distributor ensures that the entering coke-laden catalyst is spread across the regenerator bed.
(2) Regeneration System General

The first stage regenerator burns 60 to 70 percent of the coke and the remainder is burned in the second stage regenerator. This two -stage approach to regeneration adds considerable flexibility to the process. Potential heat is rejected in the first stage regenerator from incomplete combustion of carbon to carbon monoxide. When processing heavy feeds and the need for heat rejection is high, the amount of coke burned in the first stage regenerator is increased, thereby lowering the final temperature of the regenerated catalyst. When running lighter feeds, the amount coke burned in the first stage regenerator is reduced, thus increasing the regenerated catalyst temperature. The amount of coke burned in the first stage can be varied by adjusting the air flow rate. This feature allows operating flexibility for processing different feedstocks. Regenerator temperature is not directly controlled. As the coke burn increases with higher combustion air rates, the regenerator temperature will rise. The heat of combustion released by the burning coke heats the catalyst and will later supply the heat required by the reactor. The heat balance of a two -stage regeneration unit is more flexible than a single stage regeneration system. Potential energy in the form of carbon monoxide from the first stage regenerator can be adjusted while complete regeneration of the catalyst is accomplished in the second stage.

Regeneration System Air Blower and Air Heaters

An axial air blower driven by a steam turbine supplies combustion air for the process. The steam supply to the turbines is throttled on cascade air flow trimcontrol/compressor speed and is exhausted through the turbine to a surface condenser system. Atmospheric air is introduced to the air blower through an intake filter and silencer. The blower air is distributed to a header system serving combustion air to first stage regenerator rings, second stage regenerator rings, lift air, withdrawal-well ring air, spent catalyst distributor sparger, and auxiliary air to the catalyst hopper area. A check valve in the blower discharge line prevents back-flow of catalyst upon blower shut-down. Blower surging is prevented by venting air using a sophisticated anti -surge controller. Combustion air to each regenerator is flow-controlled. Low air flow to either regenerator will trigger the emergency shutdown circuit during blower failure. Combustion air to the first stage regenerator is balanced between two air rings

with the flow to each ring adjusted by manual control of butterfly valves. The outer and inner air rings are designed to handle 72% and 28% of the combustion air to the first stage regenerator, respectively. Direct fired air heaters are located in the combustion air lines to the first stage regenerator outer combustion air ring and second stage regenerator combustion air ring. The air heaters are used only during start-up to heat the catalyst and FCC equipment. Instrumentation is provided to prevent equipment overheating during air heater operation and a flame -safety package is included to prevent unsafe conditions during burner operation. Due to low refinery fuel gas header pressure, fuel gas will be imported from the coker unit for use in the air heaters during the FCC start-up.

Regeneration System First Stage Regenerator Spent catalyst containing coke flows from the spent catalyst distributor and is sp

read across the bed in the first stage regenerator. Part of the coke is burned by c ombustion air from the air ring. This regenerator operates in a countercurrent (ai r enters at the bottom while spent catalyst enters at the top) mode which helps pr event catalyst overheating. The regeneration conditions are mild to limit hydrot hermal deactivation of the catalyst. By controlling the combustion air to the first stage regenerator, the temperature in the first stage is limited to approximately 705 deg.C. The partially regenerated catalyst flows down through the first stage regenerator bed to the entrance of the lift line. Aeration is supplied in this area to ensure smooth flow of catalyst to the lift line. A hollow-stemmed plug valve (PV) regulates the catalyst flow to the lift line. The plug valve controls the first stage regenerators bed level. Air injected through the hollow stem plug valve into the lift line is flow controlled to lift the catalyst in dilute phase to the second stage regenerator. Blower air to the lift line should be maintained above 6500 Nm3/hr. Minimum allowable catalyst/air mixture velocity is 4.5 m/s for smooth catalyst lift line operations. In the event that lift a ir is lost, catalyst will fill the lift line and air blower discharge pressure may not be sufficient to lift the dense catalyst. Five emergency blast steam taps are provided on the lift line to fluidized and reduce the catalyst head in the lift line. Four sets of two-stage cyclones separate entrained catalyst from the flue gas exiting the first stage regenerator. The flue gas passes through a slide valve and an orifice chamber where the pressure is reduced to approximately 0.09 kg/cm2G. Incineration of the CO in the flue gas is then accomplished at the CO incinerator. Pressure on the first stage regenerator is modulated by controlling the flue gas valve upstream of the orifice chamber. By controlling the flue gas valve, the differential pressure between the first stage and second stage regenerators is adjusted.

(3) Regeneration System Second Stage Regenerator

The partially regenerated catalyst flows up the lift line and enters the second stage regenerator below the air ring. A distributor on the end of the lift line provides efficient distribution of catalyst and air from the lift line. Catalyst is then completely regenerated to less than 0.05% carbon at more severe conditions than in the first stage. Very little carbon monoxide is produced in

the second stage and excess oxygen is controlled by flow control of the second stage regenerator combustion air for efficient and complete combustion. Because most of the hydrogen-in-coke was removed in the first stage, very little water vapor is produced in the second stage. This low water vapor minimizes hydrothermal deactivation of the catalyst as higher regeneration temperatures are experienced. Three two-stage external refractory-lined cyclones are used on the second stage flue gas to remove entrained catalyst . This design expands the operating envelope for regenerator temperatures, which tend to be higher for resid -type feeds. The first stage cyclone diplegs are external to the regenerator. Catalyst recovered in the cyclone is returned to the regenerator be d below the normal operating level by way of the dip legs. Aeration is supplied to the diplegs to provide for smooth fluidized catalyst flow and is necessary to prevent catalyst from backing up into the cyclones.
(4) Regeneration System - Regenerated Catalyst Transfer

The hot regenerated catalyst flows from the second stage regenerator through a lateral to the withdrawal well (WDW). In the withdrawal well, a quiescent bed is established at proper standpipe density (545 kg/m3) by controlling the fluidizing air rate to the WDW ring. Injecting aeration air at several elevations on the regenerated catalyst standpipe provides a smooth stable flow of catalyst down the standpipe. As the head pressure increases down the standpipe and the catalyst mass is compressed, these aeration points are used to replace the "lost" volume, thereby ensuring proper catalyst flow properties. Each aeration tap has adjustable flow rates to maintain desirable standpipe density as catalyst circulation rates and/or catalyst type s vary. At the bottom of the regenerated catalyst standpipe the RCSV controls the flow of hot catalyst. The reactor -riser outlet temperature sets the position of the RCSV, which regulates the catalyst flow. Catalyst continues moving down the 45 slanted wye section to the riser base where the catalyst beings the upward flow toward the fresh feed injectors. Fluidization gas used in the wye section ensures stable catalyst flow in the 45-degree lateral transfer. Prior to the fresh feed injectors, a high-density zone must be provided to absorb shocks and stabilize the catalyst flow. The stabilization steam promotes smooth and homogeneous catalyst flow as the catalyst moves upward toward the fresh feed injectors. The stabilization steam ring is located at t he base of the wye.

CATALYTIC REFORMING UNIT (CRU)

CATALYTIC CRACKING UNIT (CRU)

1.0 1.1 PROCESS DESCRIPTION Introduction

To get motor spirit of low lead and high octane number, the Catalytic Reformer Unit is setup at Barauni Refinery in 1990. The plant is having following facilities:

1. 2. 3. 4. 5. 6. 7. 8.

Naphtha Splitter Unit Naphtha Hydro Treater Unit Catalytic Reformer Unit Feed and Hydro-Treated Naphtha Storage Facility Circulating Water Facility. Compressed Air & PSA system Hydrogen Storage & Un-loading Facility. Flare System

The purpose of Reformer is to enhance the octane number by changing the hydrocarbon structure in the presence of catalyst and hydrogen. It is not advantageous to operate reformer with lighter hydrocarbons. So splitter was required to get suitable catalyst, but impurities / water act as catalyst poison, so we need hydro-Treater to remove impurities and water.
1.2 General Process Description

Catalytic Reforming Unit (CRU) improves the quality of MS (Petrol) by increasing it octane number or antiknock property. The raw material / feed is (Gasoline) received from AVUs column to Tank in CRU. From tanks through pump it is fed to Naphtha splitter column.In column it is splited into two parts. Top portion i.e. light naphtha in routed to HGU as feed of the Unit and O M & S after caustic wash in AVU I & II through pump. The bottom product i.e. heavy Naphtha is sent to Hydro Theater Unit (HTU) where its organic impurities like Sulphur, N2, O2 are removed and stripped off from top of stripper column. The bottom product of stripper column i.e. DSN (De sulphurised Naphtha) is feed to CRU. In CRU, this DSN is aromatized / dehydrogenated by catalyst in reactors along with hydrogen. This hydrogen is recycled with compressor. The excess hydrogen produced is compressed by hydrogen Rich gas compressor.
The hydrocarbon from Reactor goes to L.P. separator.The bottom of the separator is naphtha and it is pumped to H.P. separator through pump and the top of the L.P. Separator goes to compressor. The Bottom of the H.P. Separator is sent to LPG separator. After removing or separating the LPG, the Naphtha is pumped to stabilizer column for residual LPG removal. The LPG from top of the

column are removed and the bottom stabilized product is called reformate and sent to O.M & S as M.S. constituent. 1.3 PROCESS & PLANT DESCRIPTION Naphtha Splitter Unit (NSU):

IBP-140 0C cut naphtha from storage (TK 250, 251, 252) is fed to splitter column 01-CC-001 under flow control by off site pump 41-PA-1A/B at tray No. 14. The feed is heated up to 95 0C in splitter feed/bottom exchanger 01-EE-001 A/B against splitter bottom stream before it enters the column. The overhead vapors are totally condensed in air condensers 01-EA-001. The liquid collected is pumped by splitter reflux pump 01 -PA-001 A/B and one part sent as top reflux back to the column under flow control 02-FC-1102 to maintain the top temperature. The balance, which constitutes the IBP-70 0C cut naphtha is sent to HGU as their feed (bypassing 01EE002) and rest light naphtha is sent to storage under reflux drum level control 01-LC-1101 after cooling in a water cooler 01-EE-002. Reflux drum boot water is drained in OWS manually. The pressure of splitter is controlled at reflux drum by passing a part of hot column overhead vapors around the condenser or releasing the reflux vapors to flare through a split range controller.The splitter bottom product which constitutes 70-140 0C cut naphtha is pumped to splitter feed/bottom exchanger 01-EE-001 A/B by hydro Treater feed pumps 01-PA-003 A/B. The bottom product after exchanging heat with feed is split into two streams. One is fed to the hydro Treater unit at a temp. of 65 0C and the other is sent to storage under column level control 01-LC-1102 after being cooled in splitter bottom column 01-EE-003. The heat necessary for splitter reboiling is supplied by splitter reboiler furnace 01-FF-001 and desired temperature maintained by controlling the fuel firing. Splitter reboiler pumps 01-PA-002 A/B. provide the circulation through reboiler 01-FF-001 is double pass vertical cylindrical furnace having four burners fired from the bottom. It has soot-blowing facility for convection section.

Hydrotreater Unit (HTU): A) Reaction and Separation Section:

The naphtha from NSU is fed to HTU by a pump 01-PA-003 A/B. The feed flow is controlled by flow control valve 02-FC-1101. The feed then mixed with Rich Hydrogen Gas from HP separator of reformer. 02-FC-1202 controls the Rich Hydrogen gas flow. Both the liquid naphtha and rich hydrogen gas are preheated in a series of exchangers 02-EE-001 A/B/C/D/E/F, which are feed/reactor effluent heat exchangers. Then mixture is heated up to reaction temperature in a furnace 02-FF-001 and fed to the reactor 02-RB-001. The furnace 02-FF-001 is four pass having three burners fired from bottom. The furnace is having facility of soot blowing. The reactor inlet temperature is maintained by 02-TC-1101 cascaded with either fuel oil or fuel gas PC's. The furnace is provided with all safety shut down inter locks. It has also provision of decoking.The desulphurisation and hydro treating reaction takes place in 02 RB-001 at almost constant temperature since heat of reaction is quite negligible. The reactor is provided with facility o f steam and air for regeneration of catalyst. The catalyst for reactor is HR-306. The reactor effluent after having heat exchanged in 02 -EE-001 series with feed goes to air cooler 02-EA-001. The air cooler fans pitch is variable i.e. cooling load can be adjusted as per situation requirement. After air cooler the effluent is cooled in a trim cooler 02-EE-002. The product is collected in a separator vessel 02-VV-001. Sour water is drained from the separator drum boot manually. The separator drum pressure is maintained by routing the gas to HGU compressor K-05 fully through 2-PC-1201B and any excess gas can be routed to FG system through 02PC1201. In event of emergency the separator excess pressure can be released to flare through an on-off c/v HV-1201. B) STRIPPER SECTION:

The separator liquid is pumped by 02-PA-001A/B under flow control 02-FC1201 cascaded with 02-LC-1201 to stripper feed/bottom exchanger .The stripper column consists of 28 Nos. of valve trays one to eight number of trays are single pass and the rest double pass. Feed coming from 02-EE-003 A/B/C enters at 9th tray from two sides. The overhead vapors are cooled down in 02-EA-002-air

condenser and collected in 02-VV-002-stripper reflux drum. The fan load can be adjusted. The condensed hydrocarbon s are returned to column top by pump 02-PA-002A/B under flow control 02-FC-1301 cascaded with 02-LC-1302 as reflux to maintain the top temp. The water accumulated in the boot is sent for disposal as sour water. 02-PC-1301 releasing excess gas in the FG sys tem maintains the reflux drum pressure. The facility is there to inject corrosion inhibitor by pump 02-PA-005A.Stripper bottom product exchanged heat with stripper feed in 02-EE-003A/B/C and then sent to reformer as hot feed. The excess or required hydro-treated naphtha is sent to storage after being cooled in 02-EE-004 A/B under level control 02-LC-1301.
1.3.3 CATALYTIC REFORMER U NIT (CRU): Hydro treated naphtha from hydro Treater unit is pumped to required pressure by 03-PA-001 A/B under flow control 03-FC-1101 A/B and mixed with recycle gas from the recycle gas compressor (03-KA-001). The mixed feed is pre heated in the feed -effluent exchanger 03-EE001 followed by feed/effluent exchanger 03-EE-002. Then the mixture is brought up to the reaction temperature (480 0 C) by heating in the pre-heater 03-FF-001 and then fed to 1st reactor 03-RB-001. As the reaction is endothermic, the temperature drops, so the first reactor effluent is heated in the first inter heater 03-FF-002 prior to be sent to the second reactor 03-RB-002.In the same way 03-RB-002 effluents are heated in the second inter heater 03-FF-003 prior to be fed to the third reactor 03-RB-003. The effluent from the last reactor 03-RB-003 is split into two streams and send for heat recovery parallely to feed/effluent exchanger (03EE-002) and stabilizer reboiler (03-EE-003). The outlet from the two exchangers is combined by a these way valve 03 -TIC-1101 and then cooled down successively in the Zeemann Secathen exchanger (03-EE001), reformer effluent cooler 03-EA-001 and effluent trim cooler 03EE-004. The cooled reactor effluent is flashed in the reformer separator 03-VV-001. Vapor and liquid phase are separated in separator 03-VV-001. Part of the gas phase constitutes the hydrogen recycle gas to the reactor circulated by recycle gas compressor 03 -KA-001. The hydrogen rich gas compressor 03-KA-002 A/B compresses remaining amount, corresponding to the amount of gas produced. The pressure control in

separator is achieved by a kick back gas flow from HP Absorber (03VV-003) to separator. Should the gas be produced in excess to 03-KA002 A/B capacity, degassing in split range to fuel gas is performed, through 03-PC-1401 A and 03-PC-1402. The separator liquid is sent by reformer separator bottom pumps (03PA-002 A/B) under level control 03-LC-1401 for recontacting with the gas compressed by -+03-KA-002 A/B.The hot flue gases from all the three reformer furnaces are combined and sent to stream generation system for waste hea t recovery to produce MP steam.Provision is there to dry the recycle gas into a dryer (03-RB-004). The dryer a later be regenerated. The unit has also been provided with facilities for continuous chloriding, water injection, DMDS/CCL4 injection and caustic soda circulation.The separator (03VV-001) vapor after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 A/B) and recontacted with separator liquid. The recontacted vapor and liquid is cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003). The aim of this device is to allow for high recovery of the C5 contained in the gas phase of separator and improves the quality (H2 concentration) of the produced gas.A part of hydrogen rich vapor goes to HTU as a make up hydrogen through 02FC1202 and balance goes to the suction KO drum of HGU compressor K-05 that is run to provide H2 to DHDT after purification in a PSA unit through 3PC1601B.03PC1601 remains inline with fuel gas system at a slight higher set point than 3PC1601B.So that any excess gas can be routed to FG system through 03PC1601. The liquid from the 03-VV-003 is drawn off under level control 03 -LC-1601 and mixed with stabilizer vapor distillate. The combined stream is cooled in LPG absorber feed cooler 03-EE-006 and flashed in LPG absorber. Off-gas is sent under pressure control to fuel gas system. Stabilizer feed pumps 03-PA-003 A/B pumps the liquid from 03-VV-004. After pre heating in stabilizer feed/bottom exchanger 03-EE-007 the mixture is fed to the stabilizer 03-CC001 at tray No. 13.Stabilizer over head vapors is partially condensed in stabilizer condenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005. The vapor phase is sent to LPG absorber for C3 and C4 recovery. A part of condensed liquid is pumped as reflux to the column by stabilizer reflux pump 03-PA-004 A/B under the flow control and the balance is sent to LPG Recovery Unit under level control of reflux drum.

DIESEL HYDRO TREATMENT UNIT (DHDT)

DIESEL HYDROTREATMENT UNIT (DHDT)

1.1

INTRODUCTION

Petroleum fraction contains various amount of naturally occurring contaminants including organic sulfur, nitrogen, and metals compounds. These contaminants may contribute to increase levels of air pollution, equipment corrosion, and cause difficulties in t he further processing the material. The Unionfining process is a proprietary fixed-bed, catalytic process developed by UOP for hydro treating a wide range of feedstocks. The process uses a catalytic hydrogenation method to upgrade the quality of petroleum distillate fractions by decomposing the contaminant with negligible effect on the boiling range of the feed. Unionfining is designed primarily to remove sulfur and nitrogen. In addition, the process does an excellent job of saturating olefinic and aromatic compounds while reducing Conradson carbon and removing other contaminants such as oxygenates and organometallic compounds. The desired degree of hydro treating is obtained by processing the feedstock over a fixed bed of catalyst in the presence of large amounts of hydrogen at temperatures and pressures dependent on the nature of the feed and the amount of contaminant removal r equired. The hydrotreater unit is designed to improve the Diesel cetane number to 48.5(min) while meeting the diesel stability specification of 1.6 mg/100ml(max) and reducing sulfur content to 0.2wt%. Future provisions are considered in this unit to produce HSD of cetane no.51 and further reduction of sulfur content to 0.05wt%. The two features of Hydro treating Process and refining reactions. Unionfining units are designed for dependable, stable operation. UOP's selective, high-activity catalysts operate for long periods of time between regenerations. Specific process objectives determine which UOP catalyst is best suited for a particular installation. The activity and selectivity of the catalyst is influenced only to a slight extent by the type of feed processed. The same catalyst in varying quantities can be used to hydrotreat straight run naphtha, vacuum gas oil, and catalytically and thermally cracked distillates. The widespread use of catalytic reforming units has made available large quantities of excess hydrogen, making it feasible to hydrotreat many, or all, of the distillate produced by the refinery.

This Operation Manual has been prepared to aid the personnel responsible for the operation of the Diesel Hydro treating (DHDT) unit for the Barauni Refinery Expansion Project of the Indian Oil Corporation Limited (IOCL), India. The supervisory operating guidelines were prepared by UOP, and the operation manual prepared by IOCL covers detailed operation procedure based on the supervisory operating guidelines.

1.2

General Process Description

The function of DHDTU is to improve the Diesel quality by removing the impurities like Sulphur, suspended particles and by the increasing the cetane number of Diesel. Increased cetane number help to improve the ignition property of fuel. The Diesel is fed to the unit through pump, removes water particles suspended particles by feed coalscer and feed filter the pump send the feed to reactors from surge drum through feed Exchanger and heater.In reactor the product react with H2 in presence of catalyst and inc rease the cetane number of Diesel. The products then enter to high -pressure receiver after releasing temperature through exchangers.The H2 from HGU through Compressors 702-K-02 A/B enters to the receiver.The liquid product from bottoms enters to stripper column C3 via low-pressure flash drum and Exchanger train.The gaseous product (H2) from enters to suction of Recycle gas Compressor & enters to Reactors after gaining temperature from Exchanger Train.The gaseous product from top of low-pressure flash drum is taken to Amine absorber where H2S is absorbed in Amine.
1.3 PROCESS & PLANT DESCRIPTION

The exact arrangement of lines, vessels, etc. may vary from unit to unit, but basically all units will consist of a reaction section and a fractionation section. These two sections are described below in general terms.
1.3.1 REACTION SECTION 1.3.1.1 Fresh Feed System The feed to the unit can be either cold (40deg C) or hot (100deg C). Feed obtained from offsite storage tanks at 40deg C is pumped into a Feed coalescer (702-V-01) for the removal of potential free water. The feed is further heated to

100deg c in a preheater exchanger (702 -E-01). Hot feed is sent from offsite and pumped by Hot feed pumps (702 -P-08A/B). The combined feed is sent through a Feed Filter (702-G-01) for removal of suspended solids to the feed surge drum (702-V-02), which is blanked with nitrogen to prevent gum formation resulting in possible equipment fouling. The feed pumps (702-P02A/B) take suction from the feed surge drum (702-V02) and pump the raw oil to reactor loops and the feed is preheated via process exchangers (702-E-06 and 702-E-03) with reactor effluent. The feed pumps are high head machines capable of pumping large volumes of oil at pressures of over 120 kg/cm2. The manufacturers instructions must be consulted before operating the charge pumps since special care must be taken to avoid damage due to low flow, high temperatures, vibration, etc. Proper lubrication and cooling must be assured at all times both for the pump and its driver if serious damage is to be avoided. This type of pump should never be operated against a blocked discharge, nor at flow rates below the minimum recommended by the manufacturer. A spillback to the surge drum may be added to maintain minimum flow at reduce throughput.
1.3.1.2 Feed Heat Exchange

In a more commonly used heat recovery s cheme, the reactor charge is preheated by the reactor effluent in a series of feed -effluent exchangers before entering the reactor charge heater This attempts to recover as much heat as possible from the heat of reaction. Liquid feed is preheated separatel y with reactor-effluent exchanges (702-E-06 and 702-E03) before combining with the recycle gas, which is also preheated, with reactor-effluent exchanges (702-E-07, 702-E-05 and 702-E-02). The combined feed stream enters a mixed phase heater to reach the desired reactor inlet temperature (340-370 ). A fresh feed bypass around one or more exchangers is used to provide better control of the charge heater outlet temperature. Austenitic stainless steel materials are normally used in the hottest heat exchangers. The austenitic stainless steel in DHDT are 1) E08 A/B 2) E07 3) E06 A1/B 2 4) E05 5) E04 A/B 6) E03 A1/2/3 & B1/2/3 7) E02 8) F01

These materials provide the best resistance to the corrosive atmosphere and severe operating conditions. However, they are subject to stress corros ion when exposed to air and moisture. This type of corrosion can be avoided by neutralizing the sulfide scale on the tube walls and by avoiding the condensation of moisture in the tubes. Protection of austenitic steel equipment is described in detail in the Special Procedures section.
1.3.1.3 Makeup Hydrogen System Make-up H2 is obtained from Hydrogen unit at a pressure of 19.5kg/cm2g. Since the reactor section pressure is 90-95 kg/cm2g, the make-up gas must be compressed before it can join the system. The compression system consists of two identical makeup compressors (702-K-02A/B). Reciprocating compressors are used to raise the pressure of the gas, with two stages of compression varying in accordance with the difference between the supply and reaction section pressures. From the discharge of the last stage of compression, the makeup gas joins the recycle gas just before Effluent condenser (702-AC-01). The point of entry into the reactor circuit depends on whether or not a stage of compression can be saved by entering the circuit at a lower pressure location.

On multi-stage compressors the gas from the first stage must be cooled to about 45deg C before it can enter the second stage. The spillback gases, used to control the interstage suction from and make up suction drum pressures also need to be cooled in First stage discharge cooler (702-AC-03) and First stage discharge trim cooler (702-E-10) before being returned to the first suction drum (702-V-07). Reciprocating compressors are driven by electric motors. The manufacturers instructions for the startup, shutdown and care of these units must be studied and well understood. In general, close attention must be paid to the compression ratio across each cylinder as well as the suction and discharge temperatures. Excessive compression ratios must be avoided since they will lead to high cylinder discharge temperatures, rapid wear, low compressor efficiency, and a possible overloading of the drive. The cylinder discharge temperatures give a very good indication of the performance of the machine and should be recorded on a regular basis. Higher than normal temperatures show that cylinder or interstage cooling may be inadequate, or that the compressor valves are faulty. In such cases, quick remedial action must be taken in order to avoid overheating and damaging the cylinders. It must be remembered that higher than design compression ratio and high molecular weight gases (as indicated by a reduction in H2 purity) will increase the load on the driver..

The flow of makeup gas through the compressor and into the unit is controlled by a complex system of pressure controllers on the high pressure separator and the first stage suction drum. The basic philosophy of the control scheme is to control the flow of gas as the demand for hydrogen dictates (as determined by the pressure in the high pressure separator). As hydrogen is consumed in the reactors, the pressure in the high pressure separator will start to decrease. This will in turn call for more makeup gas by closing the control valve in the spillback line from the final stage discharge to suction. This will cause the suction pressure of the final stage to decrease, which then closes the spillback around the second stage of compression. This works in the same way back through each stage, with the net result that less gas is spilled back through each stage and more gas flows forward into the Process. In the event that the unit is calling for more makeup gas than is available (hydrogen consumption is too high), the pressure control system essentially works in reverse. The first stage suction drum pressure will start falling because there is not sufficient gas available from the hydrogen plant to replace what is being pumped out of the suction drum. When this happens, the pressure controller on the first stage suction drum senses the decrease in pressure and, in order to protect the first stage of the compressor from excessive compression ratio, overrides the second stage suction drum pressure controller and forces the first stage spillback valve to open. This spills back more gas back to the first stage suction drum to build the pressure back up. When this happens, the second stage suction drum pressure starts falling and its pressure controller opens the second stage spillback. The same thing happens to all stages of compression and the final result is that the high-pressure separator pressure will start decreasing. At this point the operator will recognize that hydrogen consump tion is exceeding supply and must be reduced either by decreasing reactor temperatures or feed rate or both. Alternatively, the hydrogen supply may be increased. It is very important for operating personnel to become familiar with the mode of control used so that pressure beyond the capability of the equipment may be avoided. The maximum allowable compressor temperatures and compression ratios should be obtained from the manufacturer and posted in the control room or near the compressors.
1.3.1.4 Recycle Hydrogen System

After separation of the gas and liquid phases in the high pressure separator (702-V-04), the gas leaves from the top of the high pressure separator and flows to the suction of the recycle gas compressor via Recycle gas K.O drum (702 -C01). The recycle gas will be sent to an amine scrubber to remove H2S in the future.

Non-condensable gases are removed from the condensate receiver by means of steam jet ejectors. The condensate is removed from the receiver and pumped to the refinery condensate header or H2 Plant in OSBL. Note that condensate should never be allowed to enter the turbine since it would seriously damage the rotor and other internals. Whenever the compressor is out of service the turbine casing drains should be kept open and sufficient steam flow should be maintained to keep the turbine warm. Lube oil circulation should also be maintained when the compressor is down, and only shut off when required for maintenance. After the recycle compressor discharge, some recycle gas will be split off the main stream for use as quench gas between catalyst beds in the reactor. Separate quench gas streams are used to reduce reactor interbed temperatures before each catalyst bed. Quench flow is regulated by a flow controller cascaded from a temperature controller at the top of the catalyst bed below the quench zone.
1.3.1.5 Recycle Gas Scrubbing (Future Provision)

The recycle gas stream contain H2S. The H2S reduces the hydrogen partial pressure and suppresses catalyst activity. This effect is more pronounced with high sulfur containing feed streams. For these cases, a recycle gas amine scrubber may be specified. Recycle gas scrubbing is very unit specific, but would typically only be specified when the recycle gas would contain > 3 vol% H2S. Depending upon the exact design, the separator gas may be cooled with either lean amine or cooling water before entering a knock out drum. Recycle gas scrubber (702 -C-02) and Recycle gas cooler (702 -E-15) will be installed for 0.05 wt% sulfur Case 2 feed stock in the future to meet .the requirement of low sulfur of 0.05 wt% diesel. The gas from the KO drum (702-C-01) enters the bottom of the scrubber and is contacted counter-current with amine. The tower is divided by a liquid tight accumulator tray into a lower amine scrubbing section followed by a water wash section. Lean amine is pumped to the tower by booster pumps and enters at the top of the scrubbing section. The amine temperature is usually maintained ~10 above the gas temperature to minimize foa ming. The amine and the gas flowing up the tower come into contact over the trays where intimate mixing between the two is achieved and H2S is absorbed by the amine. The "rich" amine falls to the bottom of the scrubber from where it is sent on level contro l to the amine regeneration section. Entrained amine is removed from the gas by contacting it with water that is pumped to the top of the tower. The water collects in the accumulator tray at the bottom of the water wash section and is pumped via the water circulation pumps

back to the top of the scrubber. When the amine content of the circulating water stream exceeds 5 wt%, it may be removed by routing it to the rich amine stream. Makeup water can then be added batchwise to replenish the level on the accumulator tray. The H2S free gas goes into the recycle gas compressor to be recycled to the reactor.
1.3.1.6 Reactor

Once the feed and recycle gas have been heated to the desired temperature, the reactants enter the top of the reactor. As the reactan ts flow downward through the catalyst bed, various exothermic chemical reactions occur and the temperature increases. Each bed will contain a 3 element radial thermocouple assembly at the top and at periodic levels down through the bed dependent upon bed length. Multiple catalyst beds are provided depending upon the heat of reaction and unit capacity. Reactor skin thermocouples will be provided at the bottom of each bed and on the bottom reactor head, for monitoring the reactor wall temperature. Specific reactor designs will depend upon several variables. Reactor diameter is typically set by the cross-sectional liquid flux. As the unit capacity increases, the reactor diameter increases to the point where two parallel trains would be considered. Reactor height is a function of the amount of catalyst and number of beds required. Other local factors may also influence the reactor design including seismic activity and weight limitations. Crane, bridges and road capacities are also factors. The reactors are typically divided into individual catalyst beds supported on a beam and grid support system. The support system is separated from the next bed of catalyst by a quench gas distributor, reactant mixing internals and a vapor/liquid re-distributor tray. The reasons for separating a reactor into separate beds are the following: a. If the gas and liquid flows become poorly distributed part way through the reactor, the catalyst will not be effectively utilized, By separating a reactor into multiple beds with redistribution trays in between, the reactants existing one bed are redistributed evenly across the cross sectional area of the next catalyst bed. In this way, should there be a problem with distribution in a bed, the catalyst in the lower beds will still be effectively utilized. b. If the radial temperature profile becomes skewed part way through a reactor, the reaction rates will be different in different parts of the

catalyst bed. This overworks the part of the catalyst that is hotter and under-utilizes the part of the catalyst bed that is cooler. It is also potentially hazardous if the hotter portion becomes significantly higher than the bulk temperature and forms a hot spot, especially if the hot spot is next to the reactor wall. Mixing of the reactants reestablishes thermal equilibrium and thus, after every quench zone, assures that all the catalyst is efficiently utilized. c. In certain situations the heat of reaction will be large enough that the temperature increase across a reactor will be greater th an the design. If this were allowed to happen, a reaction could become unstable and result in a temperature runaway. Therefore, cold recycle gas about 170 -150deg C (40-65deg C) is brought into the reactor at the interbed quench points in order to cool the reactants and thus control the reaction rate. Good distribution of reactants at the reactor inlet and at the top of each subsequent catalyst bed is essential for optimum catalyst performance. UOP's proprietary reactor internals are used to accomplish thi s distribution.
1.3.1.7 Reactor Effluent Cooling Due to the exothermic nature of the reactions taking place in the reactor, the temperature of the material leaving will be greater than the reactor inlet temperature. The heat of reaction as well as a lar ge portion of the heat contained in the reactor feed are recovered in a series of heat exchangers. The reactor effluent is used to preheat not only the liquid feed but also recycle gas and stripper feed. 1.3.1.8 Reactor Effluent Water Wash Final cooling of the reactor effluent is obtained in air fin cooler (Effluent Condenser, 702-AC-01). Water is injected into the stream before it enters Effluent condenser in order to prevent the deposition of salts that can corrode and foul the cooler. The sulfur and ni trogen contained in the feed are converted to hydrogen sulfide (H2S) and ammonia (NH3) in the reactor. These two reaction products combine to form ammonium salts, which can solidify and precipitate as the reactor effluent is cooled. Likewise, ammonium chlo ride may be formed if there is any chloride in the system. The purpose of the water is to dissolve these salts before they precipitate. Water is normally injected in a vertical run of pipe through an injection quill that facilitates mixing of the water with the reactor effluent.

Guidelines for the protection of the reactor effluent air fin condenser may be found in the Process equipment section. The following guidelines should be followed to determine wash rate and quality:

a) Sufficient water should be injected to ensure at least 20% of the water remains liquid after injection. This is to avoid flashing all the water and creating an acidic environment when the first drop of water begins to condense or a localized high concentration of salts. b) Sufficient water should be injected to maintain the concentration of ammonium bisulfide in the sour water below 8-wt%. This will minimize the potential corrosivity of the sour water in the reactor effluent condenser tubes and outlet piping. c) The minimum wash water injection rate is 5 vol%( 15-18 m3/hr) of the fresh feed. d) Wash water should be clean condensate. Condensate from battery limit is used as wash water. e) The reactor effluent condenser piping should be balanced to ensure even water and effluent distribution in each bank. The velocity through the tubes should be 3 ~ 6m/sec.
1.3.1.9 Vapor / Liquid Separation

This unit has the HP separator (702-V-04) and the Flash drum (702-V-05). The HP separator operates at 84kg/cm2g and 54deg c where three phases are separated. The hyrdrocarbon liquid phase from HP separator is routed under level control to the Flash drum through Power recovery turbine (702 -PRT-02) to recover the energy. The sour water containing salts is also routed to the bottom of the flash drum. The gases are further compressed in recycle comp ressor (702K-01) and recycled. The Flash drum operates at 17.6kgcm2g and 54deg C where three phases are again separated. The sour water is removed under level control and sent to sour water stripping unit at battery limit. This water contains a large concentration of highly toxic H2S and NH3, and should not be drained to the sewer for any length of time. The hydrocarbon liquid phase is routed stripper heat exchanger train (702-E-08A/B and 702-E-04A/B) where it is heated by exchangers with reactor effluent to the required stripper inlet temperature of 260 .
1.3.2 FRACTIONATION SECTION The function of the fractionation section is to separate sour gas and naphtha from the diesel product. This can be accomplished with a column fractionation

scheme. The hydrocarbon liquid collected in the Flash drum (702 -V-05) is sent to a stripper column on level control. The feed is preheated by reactor effluent. Stripping steam (MP steam) is used under flow control to reboil the stripper. Steam added to the bottom of the tower helps strip light ends from the bottoms. Light ends and H2S gather at the top of the stripper and are partially condensed in Stripper overhead condenser (702 -AC-04) and Stripper overhead trim cooler. Corrosion inhibitor is injected into the stripper overhead line ahead of the overhead condenser. Three phases are separated in the stripper overhead drum (702-V-08). Sour water is combined with the sour water from the Flash drum and sent to waste water-stripping unit at battery limit. The liquid hydrocarbon are pumped through the stripper reflux pumps (702 -P07A/B) and spilt into three streams. First one is reflux which is returned to top of the stripper under level control and second is other reflux routed to the 7 th tray of the stripper under the flow control after being heated by the diesel product hot naphtha recycle exchanger (702 -E-12). And third stream is liquid distillate (unstabilized naphtha), which is routed to FCC unit at battery limit. Vapor stream is sent to the absorber knockout drum (702-V-09). This stream is mixed with gas from the Flash drum before it enters Absorber knockout drum. The gas from absorber knockout drum is routed to the bottom of the LP absorber (702-C-04). Lean amine is fed directly from battery limit into the absorber under flow control. After washing the H2S in the hydrocarbon gas the amine gets collected in the bottom of the absorber. Rich amine is sent under level control to the amine treating unit at battery limit. The overhead gases from the absorber are routed to the Stripper gas amine knockout drum (702 -V-10) to remove the traces of amine in the carryover. The sweet ga s is routed to fuel gas header under the pressure control of the stripper receiver (702 -V-08). The stripper bottom product exchanges against the returned naphtha reflux to 7 th tray of the stripper and undergoes further cooling in the feed preheat exchanger (702-E-01), the diesel product cooler (702-AC-05) and the diesel product trim exchanger (702-E-14). Water is removed from the diesel product in the diesel product coalescer (702-V-11) and the diesel product is sent under flow control to the storage tank at battery limit.
1.3.3 Utility Facility 1.3.3.1 Flare System

The flare system consists of a flare knock out drum and flare header flare of 36. Relieved gas from safety valves comes to the flare knock out drum( 702-V-16) and liquid is separated from gas if any. Operator sends liquid to closed blow down system manually. When liquid level reaches at low, LV -6201 is closed automatically by interlock logic in order to prevent gas from going to closed

blow down system. Gas from flare knock drum goes to refinery flare header stack at battery limit. Ultrasonic type flow meter on 36 flare header line is installed to monitor gas flow rate to refinery flare system. After being expanded to 42, flare header ties -in to 42 refinery flare header.
1.3.3.2 Amine Sump Rich amine drained from process equipment is collected in Amine Sump(702 -V17) through underground pipe by gravity. Amine Sump is operated at the pressure of 0.6 kg/cm2g by PCV-6301 with nitrogen purge. Purged gas is sent to relief header. Level of Amine Sump is controlled by starting the pump on high liquid level and stopping the pump on liquid level automatically. Rich amine from Amine Sump through 3 line, LP Amine Absorber through 6 line and Stripper Gas Amine Knock out Drum through 1 line are combined and sent to Rich Amine Flash Drum at Amine Treating unit after 6 line is expanded to 8. 1.3.3.3 Closed Blow Down Hydrocarbon drained from process is collected in Closed Blow Down Drum (70-V-15) through 8 under ground blow down header by gravity. The operating pressure of 0.6 kg/cm2g is controlled with PCV-6101 by nitrogen purge. Gas is purged to relief header if any. Cooling water coil is installed in Closed Blow Down Drum in order to cool hydrocarbon liquid. Level of Closed Blow Down Drum is controlled by starting the pump on high liquid level and stopping the pump on liquid level automatically. Hydrocarbon liquid is cooled to 40C after passing through CBD Cooler (702-E-21) and then is sent to off-spec slop tank at OSBL. 1.3.3.4 Oily Water System (OWS) The Oily Waste Sewer (OWS) collects oily waste from pump drains, equipment drains and line drains. The system consists of underground carbon steel pipes of class A3A of Piping Material Specification, RCC Manholes, CS Funnels, Vent Pipes, flame arresters, CI manhole covers & frames, MS rungs, Cleanouts etc. as required. 1.3.4 Contaminated Rain Water Sewer (CRWS) System The contaminated rainwater sewer system collects contaminated rain water, floor wash and process drains from equipments discharging to CRWS. The system consists of underground carbon steel pipes of class A3A of Piping Material Specification, RCC Manholes, CS Funnels, Vent Pipes, flame arresters, CI manhole covers & frames, MS steel Gratings, MS rungs, Cleanouts, rectangular drains covered with MS grating to collect the rain water from uncontaminated areas.

HYDROGEN GENERATION UNIT (HGU)

HYDROGEN GENERATION UNIT (HGU)

Introduction A Hydrogen Unit with a nominal capacity of 34,000 metric tones per annum of hydrogen is included in the processing scheme of Barauni Refinery. The primary objective of the Hydrogen Unit is to produce hydrogen of 99.9 -vol % purity to meet the hydrogen requirement of the Hydro treating Unit. The process licensor : LSTK Contractor : Haldor Topsoe A/S, Denmark. L&T Chiyoda : EIL

Process Consultant

General Process Description MAIN SECTIONS OF HGU ARE: -

   

HDS SECTION REFORMER MT SHIFT SECTION PSA SECTION

Naphtha feed from surge drum V-04 is pumped to E-01 A/B feed vaporizer. FCC off gas is compressed & mixed to naphtha feed at its pump discharge. Recycle hydrogen is mixed to combined feed stream before the vaporizer. Naphtha, FCC off gas and Hydrogen mix a fter vaporization of naphtha feed in E-01, is superheated to 266 0C in E-02 with superheated HP steam. Then it is sent to R-01 for hydrogenation of organic S and Cl compounds to H 2S and HCl respectively. HCl is absorbed in R-02 and H2S is absorbed in R-03A/B. Desulphurized feed and unutilized H2 comes out of R-03 at around 385 0C. The de-sulphurised feed is mixed with the HP steam and heated to 490 0C in E-11. This stream goes to pre- reformer R-04, where controlled reforming reactions change the feed to methane.

In reformer, the reforming reaction takes place and the feed and steam is converted to CO, CO2, H2. The steam reformed gas outlet from reformer contains CO, O2, H2, unconverted CH4 & unutilized steam. The process gas at outlet of reformer is at around 930 0C, which is cooled to 200 0C in WHB and BFW preheaters and passed through MT shift converter R -05 & LT shift converter R-06. In shift converters, the carbon monoxide on reaction with steam gets converted to H2 and CO2. The unutilized steam is condensed in step cooling, down stream of R-06 and then the reformed gas is sent to PSA-1 to remove the CH4, CO, CO2 and production of 99.9% pure hydrogen. Desulphurisation Section

General Information
Straight Run Naphtha alone or mixed with FCCU-off-gasses is used as feed to the desulphurisation section. In the desulphurization section the sulphur and chlorine compounds are hydrogenated to form H 2S and HCl in the hydrogenator, 703-R-01, and are removed in the absorbers, 703-R-02 (HCl) and 703-R-03 A/B (H2S). Furthermore, the olefins present in the FCCU off-gas are saturated with hydrogen in the hydrogenate.

Feed
The hydrogen generation unit can be fed either by naphtha alone or naphtha mixed with FCCU off-gas. The pressure in the desulphurization section controls the feed flows. 703-PIC-1308 situated downstream 703-R-03 A/B, gives a set point to the naphtha feed flow controller, 703 -FIC-1102. Naphtha The liquid naphtha feedstock is supplied at low pressure, about 4 kg/cm2g, to the naphtha surge drum, 703-V-04. From the naphtha surge drum the naphtha is pumped by the naphtha feed pumps, 703-P-01 A/B to the desulphurization section, the second acting as spare. The pump discharge pressure is about 36 kg/cm2 g.

FCCU Off-Gas The FCCU off-gas is supplied at low pressure, about 12.5 kg/cm2g, and is compressed in the feed compressor, 703-K-03 A/B, and mixed with the feed naphtha from 703-P-01 A/B. If the suction pressure to 703-K-03 A/B becomes low, first a low passive alarm 703-PAL-1006) is given, and if the pressure continues to decrease an active interlock, I-112, will ramp down the FCCU off-gas flow on flow controller, 703-FIC-1103. When the pressure goes back to normal, the operator must manually reset I-112 and take FCCU off-gas back in operation. (Note 1)

Feed Control
Flow controllers, 703-FIC-1103 for the FCCU off-gas and 703-FIC-1102 for the naphtha, control the feed flows.

Figure 1: Feed

703-FIC-1102 acts in cascade with a pressure controller, 703-PIC-1308, keeping a constant pressure in the desulphurization section. FIC -1103 is controlled indirectly by FIC-1102 (flow of naphtha) and HIC-1102, which sets the ratio between FCCU off-gas and naphtha. This control system will ensure that all FCCU off-gas is used as feed up to a maximum of 30% by weight of the total feed. The cascade regulation principle as illustrated in Figure 1 is to ensure fast and stable regulation. (Note 2) In case of too high pressure in the desulphurization section , the pressure controller,703-PIC-1306 (located downstream of the desulphurization section), will activate the switch, USY-1306, to open the isolation valve, 703-PV-1306 B, and it will adjust the pressure by releasing gas to the air cooler, 703-AC-01, through the control valve, 703-PV-1303 A. Feed Vaporization and Preheating The pressurised feed is mixed with recycle hydrogen from the Recycle G as Compressor, 703-K-04 A/B. The flow of hydrogen is controlled by 703-FIC-1201. The liquid naphtha is vaporized in one of the feed vaporizers, 703 -E-01 A/B. It is fore-seen that the vaporizer in service may have to be cleaned on a regular basis. The vaporizer taken out of service shall then be cleaned and prepared for being put into service when needed. Controlling the pressure of the condensing steam on the tube side (by means of 703-PIC-1201) can control the temperature of the feed leaving the vaporizer in service. The temperature of the vaporized naphtha feed is a means of fine tuning the hydrogenator inlet temperature as described in section 2.5. The vaporized feed is heated further up with superheated steam in the feed preheater, 703-E-02. Depending on the mixture between naphtha and FCCU off-gas, the outlet temperature will vary between 266 and 380C. It is further described in the following section. The temperature is controlled by 703-TIC-1202, which controls the feed bypass over 703-E-02. 703-TIC-1202 is controlled in cascade by 703-TIC-1301, which controls the outlet temperature of the hydrogenator, 703 -R-01. 703-HIC-1201 acting on the bypass over 703-E-02 can be adjusted to obtain a proper operating range of 703-TV-1202. The steam leaving 703-E-02 is routed to the process feed mixing point.

The low alarm on 703-TIC-1202 is to warn the operator against the resulting reduced efficiency of the desulphurization section and the high alarm is to warn the operator against the temperature of the desulphurization section exceeding the design temperature. (Note 3) During start-up the feed preparation/desulphurization section is heated first in N2 recycle and later with hydrocarbon feed vented through 703 -AC-01 to 703-V-08 by use of 703-PIC-1306. During such operation the superheated steam used in 703-E-02 cannot be routed to the process and is therefore vented by use of 703-PIC-1203 at the outlet of 703-E-02. While recycling feed naphtha in the HDS section, DMDS can be added continuously in order to keep the hydrogenator 703-R-01 sulphided. The minimum sulphur content in the feed is 2 ppm, wt. The catalyst must be sulphided in order to maintain the activity and to avoid any potential methanation reaction.

Ejector, 703-J-01 When the feed only consists of naphtha and hydrogen, the ejector is not required and can therefore be bypassed and the recycle line should be blocked to prevent a possible bypass over the hydrogenator. Normal inlet temperature is 380C.
FCCU off-gas contains olefins, which evolves a large temperature increase in the hydrogenator due to saturation with hydrogen. To keep this temperature increase below 100C, an ejector is installed. The ejector makes it possible to lower the outlet temperature from 703-E-02, and then achieve the remaining heating from the hot recycled feed. The lowest normal inlet temperature with FCCU off -gas is 300C. With a maximum temperature increase of 100C, the normal outlet temperature will be around 400C. In order to make the best control of the temperatures in the hydrogenator, it is important to move the outlet temperature control from the top to the bottom as the reaction hotspot moves with the catalyst ageing. However, the temperature control should not be fixed at the bottom (or the outlet) as a temperature runaway must be caught as early (as close to the hotspot) as possible. See Figure 2 below.

Figure 2: Ejector

Desulphurization
During normal operation sampling takes place downstream of the hydrogenator as well as between the absorbers. When sulphur breakthrough occurs, 703-R-03 A is isolated, and only 703-R-03 B is kept in operation. After purging and cooling the spent catalyst in 703-R-03 A is replaced. After heating in N2 circulation the absorber can be put back into operation. Since the two absorbers furthermore have two catalyst beds each, the possibility exists that samples for analysis can be taken between the beds. The pressure in the desulphurization section is controlled by 703 -PIC-1308 and 703-PIC-1306. As already explained 703 -PIC-1308 acts in cascade with 703-FIC-1102 (and indirectly 703-FIC-1103) on the feed flow in order to balance the capacity of the HDS section with the reformer section during normal operation. During start-up the desulphurized naphtha is not routed to the reformer but condensed in 703 -AC-01 and collected in 703 -V-08, from where it is returned to the naphtha surge drum, 703-V-04. During this operation 703-PIC-1306 controls the pressure in the HDS section.

Mixing of Process Feed and Process Steam The desulphurized process feed is mixed with process steam before the final preheating in 703-E-12 in the waste heat section of the tubular reformer. See Figure 3 below.

Figure 3: Steam/Carbon control During normal operation 703-FIC-1502 controls process feed flow. During startup and operation at low capacity, feed flow is controlled by 703 -FIC-1506. The flow switch 703-FSAL-1501, which activates the tubular reformer trip IS-1 must then be bypassed. During normal operation 703-FIC-1503 controls the main process steam flow. The flow switch 703-FSAL-1505 activates the tubular reformer trip IS-1. During start-up and shut-down the steam flow is controlled by 703 -FIC-1507. The steam/carbon ratio of the feed to the reformer section is constantly monitored by 703-FFI-1504, while indication of 703-FFI-1510 is the ratio of process steam to cold hydrocarbon. The two steam/carbon ratios are based on

carbon numbers entered into the computer by the operator through 703-HIC-1501 (for 703-FFI-1504) and 703-HIC-1503/1504 (for 703-FFI-1510; one HIC for naphtha and one HIC for FCCU off -gas). The values are determined by analysis of the naphtha and FCCU off -gas. 703-FFSAL-1509 constantly monitors the steam/carbon ratio based on a carbon number corresponding to the input of 703 -HSY-1506. 703-FFSAL-1509 activates the tubular reformer trip IS-1. In case of a tubular reformer trip, IS-1, the following activities related to the mixing of process feed and steam will occur: The automatic shut-down valves upstream of the reformer preheat coil will double block and bleed the process feed. Set point of 703-FIC-1502 and 703-FIC-1506 will be set to zero. Main process steam valves 703-FV-1503 will be shut off. Set point of 703-FIC-1502 will be set to zero.

The set point of 703-FIC-1507, process steam bypass, is set at 10,800 kg/h and is gradually decreased to zero in the course of 10-20 minutes. The emergency hydrogen line (FIC-1508) is opened at a set point of 1,250 Nm3/h and also ramped down over a period of 30 minutes. The flow of hydrogen will keep the re forming catalysts in the reduced state during a tubular reformer trip, while the flow of steam protects the hot part of the reformer from overheating. Reforming Section

Prereformer, 703-R-04 All higher hydrocarbons in the feedstock are converted with steam into a mixture of methane, hydrogen, carbon dioxide, and carbon monoxide in prereformer 703-R-04. During normal operation the inlet temperature to the prereformer should be kept close to 490rC. A higher temperature may result in carbon formation and a lower temperature reduces the activity and may lead to incomplete conversion of higher hydrocarbons, which may result in carbon on the tubular reformer catalyst. At temperatures below 430rC polymerisation reactions may take place resulting in gum formation on the prereformer catalyst. At very low temperatures (< 350-400rC), hydration of the prereformer

catalyst may take place (see hydration curves enclosed in the appendices of Chapter II). The inlet temperature to 703-R-04 is adjusted by desuperheating the process steam with process condensate (or during start-up boiler feed water) using 703-TV-1207 A/B before the combined stream of feed and steam is superheated in 703-E-12. The quenching and the inlet temperature to the prereformer is controlled by 703-TIC-1513 giving setpoint to 703-TIC-1207 both having alarms for high and low temperatures. (Note 5) The allowable temperature range inlet the prereformer is 470 -510rC. Alarms are provided at the lower and upper operating limits. It is therefore very important that the inlet temperature is monitored closely. (Note 6) Initially, a temperature drop from 490rC to 470rC can be observed at around 0.5 metre down the bed, followed by a temperature rise to approximately 503rC at around 1 metre down the bed. As the catalyst ages, this profile will move downwards. The location of the temperature drop varies with the feed. The above is for the normal operation at 30% FCCU and 70% SRN. The movement of the temperature profile in 703-R-04 should be closely followed (703-TI-1515 to 1528), since it gives an indication of the remaining life of the prereformer catalyst. If the rate of profile movement down through the catalyst bed accelerates, this is a sign of poisoning (most likely by sulphur). By analysing the movement of the temperature profile, the remaining time before breakthrough of higher hydrocarbons can be estimated. The mixture of gas and steam (the process gas) is heated to approximately 490rC in 703-E-12, the prereformer feed preheat coil in the waste heat section of the tubular reformer 703-F-01. 703-TIC-1513 indicates the inlet temperature to 703-R-04. One or more of the following actions can adjust the prereformer inlet temperature: Quenching of process steam by use of 703-TIC-1207. Quenching is the fastest acting adjustment of the prereformer inlet temperature. Adjustment of firing pattern in the tubular reformer. Adjustment of the heat input to the feed vaporizers, 703-E-01 A/B, by adjustment of the pressure of the condensing steam on the tube side by use of 703-PIC-1201.

SULPHUR RECOVERY UNIT (SRU)

-

SULPHUR RECOVERY UNIT (SRU)

1.1

Introduction

Amine regeneration unit The purpose of this unit is to receive rich amine (containing a high amount of dissolved H2S) from DHDT and FCCU, remove the h2s from it and return the lean amine (containing very low H2S) back to DHDT and FCCU for further absorption. The H2S thus released is sent to sulphur recovery unit. Sour water stripper unit The purpose of this unit is to receive sour water (containing a high amount of dissolved H2S) from DHDT, FCCU, AVUs and remove the H2S from it and return the stripped water back to the units. The H2S thus released is sent to sulphur recovery unit. Sulphur recovery unit The purpose of this unit is to receive H2S from ARU and SWS and convert it to elemental Sulphur using clause reaction, followed by super clause reaction. This liquid Sulphur is converted to solid form in the Sulphur yard.

The Sulphur Recovery Unit (Unit 706) in Barauni Refinery consists of two trains 706-1 (Train 1) & 706-2 (Train 2) of 40 MT/day capacities each with 10 % design margin. The guaranteed turndown for SRU is 30 % (or 13.3 MT/day) based on the design base case feed gas rate (110 %) and12 composition as given below.The feed gas to SRU is a mixture of the Acid Gas ex ARU and the Sour Gas ex SWSU . Each train in designed for 2738 kg/hr of feed.
PRODUCT YIELD AND SPECIFICATION State: liquid sulphur Colour : bright yellow (in solid state) Purity : min 99.9% wt, on dry basis H2S content : 10 ppm wt max

General Process Description

Amine Regeneration Unit:

Rich Amine i.e. more H2S in Amine received from DHDT/RFCCU are taken in Flesh Drum (704-V-01) & it pumps through 704-P-01A/B to column 704-C-01 via exchangers 704-E-01 to gain heat in Rich Amine to remove H2S from Rich Amine. H2S is extracted from top of the column and sent to SRU/ Sour flare and Lean Amine is collected at bottom and sent to DHDT / RFCCU to adsorb H2S in the Process to become Rich Amine.
Sour Water Stripping Unit: H2S dissolved in water is known as sour water. Sour Water received from DHDT / RFCCU received in 705-V-01 goes to column 705-C-01 through pump 705-P-01A/B via exchanger 705-E-01A/B/C to gain Heat in Sour Water. Column tops contains H2S gas and sent to SRU/ Sour flare. And bottom product of column is stripped water sent to RFCCU/ ETP. Sulphur Recovery unit: Product from ARU/SWSU is taken in Main Combustion Chamber (MCC- 706-F101) to burn H2S in controlled extent. Here sulphur vapour form at high temperature (1200C) and the process gas sent through waste heat boiler (706-E-101) to reduce heat and then process gas goes to Sulphur condenser (706-E-102) to form gaseous Sulphur to liquid Sulphur. This liquid Sulphur goes to Sulphur pit via Sulphur lock. Sulphur is pumped to yard through Sulphur pit pump (706-P-101/102). The Sulphur lock arrests the process gas which contains a good amount of H2S. This process gas is sent to reactor 706-R-101 to convert H2S to Sulphur vapour and then Sulphur vapour sent to condenser 706-E-103 for condensing Sulphur for Sulphur pit and yard. Process gas from top of 706-E-103 goes to reactor to continue the process up to 706-R-103. After 706-R-103 the process /tail gas with minimum (1%) qty of H2S is burnt in incinerator (706-E-102) at a Temp 726-785C.

General Information SRU (Sulphur Recovery Unit)

The sulphur recovery process applied in the design, which is known as the Super Claus process, is based on the partial combustion of hydrogen sulphide (H2S) with a ratio controlled flow of air, which is maintained automatically in a correct quantity to accomplish the complete oxi dation of all hydrocarbons and ammonia present in the acid gas feed and to obtain an H2S percentage of 0.5 0.7 vol % at the inlet of the Superclaus Reactor. In the conventional Claus process, the Air to Acid Gas Ratio is maintained to produce an H2S/SO2 ratio of exactly 2:1 in the burner effluent gases. This is known to be the optimum ratio of H2S/SO2 for the Claus reaction. The Superclaus process operates according to a different philosophy. In this process, the air to acid gas ratio is adjusted to achieve an H2S/SO2 ratio of greater than 2:1 in the burner effluent. The combustion air is controlled in such a manner that the concentration of H2S in the process gas entering the Superclaus stage is in the range of 0.5 0.7 vol % H2S.

(I) Claus Section

The main reaction in the main burner is : H2S + 3/2 O2 SO2 + H2O + heat

The major part of the residual H2S combines with the SO2 to form sulphur, according to the equilibrium reaction 2 H2S + SO2 3/2 S2 + 2 H2O heat By this reaction, known as the Claus reaction, sulphur is formed in vapour phase in the main burner and combustion chamber. The primary function of the waste heat boiler is to remove the major portion of the heat generated in the main burner and utilize it to produce HP Stea m. The process gas from the waste heat boiler is passed into the 1st Sulphur condenser, where the formed sulphur is removed from the gas. The process gas leaving the sulphur condenser still contains a considerable concentration of H2S and SO2, therefore the essential function of the following equipment is to convert these components to sulphur.In the 1st, 2nd and 3rd reactor stages, the H2S and SO2 react again to form sulphur, but at a lower temperature and in presence of a catalyst.

In the Superclaus stage, the remaining H2S is selectively oxidized to sulphur. For this reason it is essential that the combustion in the main burner is such that at the downstream of the 3rd Reactor stage the amount of H2S is in the range of 0.5 0.7 vol % and the SO2 concentration is as low as possible. Before entering the 1st Reactor, the process gas flow is heated by indirect steam reheat to obtain the optimum temperature for a high conversion of H2S and SO2 to elemental sulphur and simultaneously a high conversion of COS and CS2 to H2S and CO2.

In the 1st Reactor, the H2S and SO2 react again until equilibrium is reached 2 H2S + SO2 3/8 S8 + 2 H2O + heat The effluent gas from the 1st Reactor passes to the 2nd Sulphur Condenser. The Process gas flow is routed to the 2nd Steam Reheater, then passed to the 2nd Reactor, where equilibrium is established. The Sulphur is condensed in the 3rd Sulphur Condenser. The Process gas from the 3rd Sulphur Condenser is routed to the 3rd Steam Reheater, then passed to the 3rd Reactor, where equilibrium is established. The Sulphur is condensed in the 4th Sulphur Condenser.
SUPERCLAUS SECTION The process gas from the 4th Sulphur Condenser is routed to the 4th Steam Reheater, then passed to the Superclaus Reactor. Before it enters the reactor, a controlled amount of air is added. Proper mixing is obtained in a Static mixer. In the Reactor, the H2S reacts with oxygen to form Sulphur according to the reaction 2 H2S + O2 2/8 S8 + 2 H2O + Heat

The sulphur is condensed in the 5th Sulphur Condenser. A Sulphur Coalescer is installed downstream of the last Sulphur Condenser to separate entrained Sulphur mist.
The Sulphur condensed and separated in the condensers and Coalescer is drained via the Sulphur Locks and the Sulphur cooler into the Sulphur Pit. The tail gas leaving the Coalescer still contains an amount of H2S, which is dangerous if released directly to the atmosphere. Therefore the gas is thermally

incinerated, converting residual hydrogen sulphide and sulphur vapour to sulphur dioxide in presence of oxygen. Afterward the gas is cooled in the Incinerator Waste Heat Boiler and steam superheaters and routed to the stack. In the Incinerator Waste Heat Boiler, HP Steam is produced and in the superheaters LP and HP Steam from the train are superheated before export to the refinery steam header.
SULPHUR DEGASSING SECTION The produced liquid Sulphur contains H2S, partly dissolved and partly present in the form of polysulphides(H2SX). Without treatment of the Sulphur, the H2S will be slowly released during storage and transport and might create an explosive mixture due to exceeding the lower explosive limit of H2S in air, which may vary from 3.7 vol % H2S at 130 oC to 4.3 vol % H2S at ambient conditions. The Shell Sulphur Degassing process has been developed to degasify liquid Sulphur to 10 ppmwt H2S/H2SX, which is the safe level to avoid exceeding the lower explosive limit. The function of this process is to enhance the decomposition of polysulphides and to strip the H2S from the Sulphur. Simultaneously, the greater part of the H2S is oxidized to Sulphur. This is done by bubbling air through the Sulphur. The air decreases the partial pressure of the H2S, and causes agitation and circulation of the Sulphur. In this way the H2S content is reduced from approx 350 to less than 10 ppmwt. The released H2S together with the air is routed to the Thermal Incinerator, in which it is oxidized to SO2. The degassed sulphur in intermittently pumped to the liquid Sulphur tanks or Sulphur Yard. From the liquid sulphur tanks, liquid sulphur is pumped into the truck via the Sulphur loading pumps and sulphur loading arms. DETAILED PLANT DESCRIPTION Feed Knock out Drums The Amine acid gas feed from the Amine Regeneration Unit (Unit 704) is introduced via the Amine acid gas K.O.Drum (706 -V-001). The SWS gas feed from the Sour Water Stripper Unit (Unit 705) is introduced via the SWS gas K.O.Drum 706-V-002. Sour water separated in the knock out drum is is

intermittently collected in sour water drain vessel (706 -V-004) and routed back to ARU or SWSU by nitrogen propulsion. The Amine acid gas is heated to at least 92 oC in the LP Steam jacketed line in order to prevent deposition of Ammonium salts and/or condensation of water vapour when it is mixed with SWSU gas. A mixing temperature of at least 71 oC is essential. The mixed gas is further heated to 200 oC in the acid gas preheater 706-E-108/208. Combustion Air Blowers The air to main burner 706-F-101/201 is supplied by main air blower 706-K001/002/003, which also supplies air to Superclaus reactor and to the Sulphur Pit for sulphur degassing. The air is preheated to 200 oC in the air preheater 706-E-109/209. Main Burner and Combustion Chamber The air to the main burner is exactly sufficient to accomplish the complete oxidation of all hydrocarbons and ammonia present in the feed gas and to burn as much H2S as required to obtain 0.5 0.7 vol % H2S at the outlet of the 3rd reactor. Waste Heat Boiler To remove the heat generated in the main burner, the gas passes through the tube bundle of the Waste Heat Boiler (706 -E-101/201). The gas is cooled, thereby generating HP Steam of pressure 40 Kg/cm2g. Boiler feed water is introduced in the shell side of the boiler on level control. The steam generated is sent to the HP Superheater and finally exported. The process gas is then introduced into the 1st Sulphur Condenser (706 -E102/706-E-202), in which it is cooled. The sulphur vapour is co ndensed and the liquid sulphur is separated from the gas. The liquid sulphur is drained into the Sulphur pit by gravity via the 1st Sulphur lock (706 -V-101/201). Claus Stages

Upstream of the 1st Claus Reactor (706-R-101/201), the process gas from the waste heat boiler is heated by the 1st Steam Reheater (706 -E-110/210) to obtain the optimum temperature of 240 oC for the Catalytic Conversion . The HP Steam flow to the steam reheater is adjusted by the reactor inlet temperature controller. The H2S and SO2 react over the CR-3S and CRS-31 catalyst beds until equilibrium is reached. Moreover, the temperature is favourably high to obtain a good COS and CO2 conversion. The effluent gas from the 1st Reactor passes to the 2nd Sulphur Condenser (706-E-103/706-E203) where the sulphur vapour present is condensed and drained to the Sulphur Pit via the 2nd sulphur Lock (706-V-102/202). The outlet channels of the condensers are provided with demisters to recover sulphur entrained as mist with the process gas. The process gas passes to the 2nd Steam reheater (706-E-111/211) where it is heated to around 208 oC by HP Steam. This heated gas enters the 2nd Claus reactor (706-R-102/202) and again reaction takes place between H2S and SO2 in presence of catalyst. The effluent gas goes to the 3rd Sulphur Condenser (706-E-104/706-E-204) where again sulphur vapour is condensed into liquid sulphur and drained off to the sulphur pit via the 3rd Sulphur lock (706-V103/203). The 2nd Claus Reactor (706-R-102/202) contains CR-3S catalyst. The inlet temperature of the 2nd Reactor is controlled by the reactor inlet temperature controller. At low plant low throughput, this temperature has to be increased to 225 230 oC to ensure better sulphur recovery. The process gas then passes to the 3rd Steam reheater 706-E-112/212 and then to the 3rd Reactor (706-R-103/203). The Sulphur is condensed in the 4th sulphur condenser 706-E-105/706-E-205). This reactor is also equipped with CR-3S catalyst. The inlet temperature of this reactor is maintained at 193 oC and is maintained by the reactor inlet temperature controller. At low plant throughput, this inlet temperature has to be increased to 200 215 oC. The liquid sulphur is drained to the Sulphur pit via the 4th sulphur lock (706 -V-104/204).

The heat liberated in the sulphur condensers is utilized to produce LP steam at a pressure of around 3.5 Kg/cm2g. This steam is sent to the LP steam superheater and finally exported. Superclaus Stage In order to obtain a high sulphur recovery, the process gas is p assed to the 4th and last catalytic stage, known as the Superclaus stage. The process gas is heated in the 4th Steam reheater (706-E-113/213) after which preheated air is introduced into the process gas. Proper mixing is then achieved in the static mixer (706-M-101/201) after which the process gas enters the Superclaus reactor (706-R-104/204), Here the H2S is selectively oxidized to elemental Sulphur in the presence of the Superclaus catalyst. The air has to be supplied in excess in order to maintain oxidizing conditions in the reactor and to prevent sulphiding of the catalyst. The inlet temperature of the Superclaus reactor is maintained at 210 oC at design throughput and slightly lower (200 oC) at decreased plant load. Oxygen analyzer AT-1101 has been installed at the downstream of the Superclaus stage to monitor the oxygen content at the outlet of reactor . The oxidation air to super claus is controlled by tail gas analyzer output keeping the analyzer in H2S control mode.The output of the analyzer is multi plied by the relative load of the unit and the resulting signal is the set point for the flow controller in the oxidation air supply line.(Details is described in superclaus control description). The gas then passes to the 5th Sulphur Condenser (706-E-106/706-E-206). The liquid sulphur is drained into the Sulphur pit via the 5th Sulphur lock (706 -V105/205). In order to condense as much sulphur vapour as possible, this Sulphur condenser operates at a low temperature. This low temperature is obtained by generating steam at a lower pressure (1.2 Kg/cm2g) than in the preceding condensers. The steam is condensed in the steam condenser 706-AC-101/201 after which the condensate is drained back into the shell side of the condenser.Downstream of the Superclaus stage, the process gas passes through the sulphur coalescer (706-V-108/208), which is provided with a

demister. In this coalescer, the last traces of liquid sulphur are separated from the gas and sent to the sulphur pit via the 6th Sulphur lock 706 -V-106/206. In case of malfunctioning, the Superclaus reactor can be bypassed without taking the Claus stages out of operation. In this case the process gas is routed directly to the Thermal Incinerator. Thermal Incinerator In the Thermal Incinerator (706-F-104/204), the combustible components in the tail gas from the Sulphur Coalescer (706-V-108/208) and vent gas from the sulphur pit are thermally oxidized at a temperature of 765 oC with an excess of air. The off gas from the Merichem unit is also sent to the Incinerator. The gas to be incinerated is heated to the required temperature by mixing it in the thermal incinerator with hot flue gases in the Incinerator burner (706-F103/203). These hot flue gases are generated by burning fuel gas. The combustion air is supplied by the Incinerator Air Blower (706 -K-004/005/006). The Incinerator burner is a low NOX burner in which a shortage of oxygen exists in the flame zone to obtain a low NOX production. This is achieved by staged combustion. Primary air is supplied at 80 % Stoichiometry to the burner chamber. The remainder of the combustion air (staged air) is supplied after the burner throat. The staged air quantity ensures a 10 % excess air on the total combustion air to obtain complete combustion of the fuel gas. Both the primary air and the staged air flows are in ratio control with the fuel gas rate. In case Superclaus tail gas is being oxidized the required amount of secondary air is less than the amount required in case Claus tail gas is being oxidized. To ensure an excess of air oxygen analyzer AT-1501 is located in the flue gas flow to stack (706-M-002) adjusting the secondary air supply. At very low throughput or hot stand by mode, additional cooling is required by supplying more secondary air. Then the temperature controller on the Incinerator also adjusts in split range the fuel gas flow controller and the secondary air flow controller. To remove the heat generated in the thermal Incinerator, the flue gas passes through the tube bundle in the Waste Heat Boiler (706-E-114/214). The gas is

cooled to 505 oC thereby generating HP Steam. The flue gas is further cooled to 326 oC by passing through the shell sides of LP Superheater (706 -E-115/215) and then the HP Superheater (706-E-116/216). Finally the flue gas is routed to the stack. There is provision for introducing quench air in the flue gas line in case it s temperature becomes too high. The superheated LP and HP steam are routed through LP desuperheater (706M-104/204) and HP desuperheater (706-M-105/205) respectively before export to the refinery header. Sulphur Degassing System The sulphur from the sulphur lock is too hot for degassing. In order to limit the sulphur temperature in the pit to 160 oC, the liquid sulphur is first cooled in the sulphur cooler 706-E-107/207. Provision has been kept to connect LP steam in E107/E-207 during supercluas bypass. In the pit are located two bubble columns (706-M-103/203 and 706-M-104/204). A bubble column is a box open at the top and bottom. Each bubble column is divided into two sections by a separation baffle to prevent channeling of undegassed sulphur. Degassed sulphur flows through a rectangular hole in the separation baffles. The stripping air to the spargers is supplied by the main air blower. The air flow is manually controlled. In the bubble columns the liquid sulphur is vigorously agitated by bubbling of air through liquid sulphur, thereby accelerating the decomposition of polysulphides (H2SX) into H2S and S, stripping the H2S from the sulphur and oxidizing the H2S partly to Sulphur.in this way the H2S content in Sulphur is reduced to less than 10 ppmwt. The released H2S, together with the air is drawn by steam ejector 706-J-101/102/706-J-201/202 to the Thermal Incinerator. The vent gas outlet is provided with a demister for removing eventually entraines sulphur. During startup, both the steam ejectors operate in parallel as extra sweep air is required. Steam coils made of Stainless steel are provided in the Sulphur pit for compensation of heat losses and to keep the sulphur in molten condition. The level of liquid sulphur is kept constant by a separation wall in the pit over which the degassed sulphur flows into the storage section of the pit .