P E. Process Flow and Control Diagrams - Fischer-Tropsch Archive

° 

E. Process Flow and Control Diagrams (ZncludlngMaterlal 

Balance) 

Unit 32 are as follc~s: 

Process Flow and Control Diagrams for Gas Fractioaation 

Drawlu~,NOo Title 

D-32-MP-1NP 

~-32-MP-2NP 

D-32-MP-3NP 

D-32-MP-4NP 

D-32-MP-SNP 

PFCD Gas Fractiouat$on - Depentaulzatlon 

PFCD Gas Fractlouatlon - Depentanlzatlon 

PFCD Gas Fractionatlon - Gasollne Splitting 

PFCD Gas Practlonation - Depropanlzatlon 

Material Balance - Gas Fractlonatlon 

II-I .2 ° 13-12

A 

C 

D 

, I 2 I = I 4,+ 

ii iiiii m + 

3Z-01-2001 32-01-13~tl 32-01-1 I01 32-01-1301 32-01-130~ ~2-01-1303 

GAS FIf ACTIORATIOH AnsOABF.fl OEETImHIZER ABSORnER DEETHAH~ZEA AOSOflg~IAHr'Lt ",rl AOSORB~ 9EETHA--HrZER ABSCfl'~n~ZEA 

ItEFIIIG,~flATXOI4 IpACIfAIiE Slg( P,I[OOILEli ' -- A ~ " CHILLER R£OOtLER ~ 

3, I UUUTtJ/Im 5,S mOlWlll~ 3~a umTU/m 3. I UeO1U/HA O3,~'-~HII 

32-01-2001 

] 

--I P"A-32 

/ kMIIO~LVREFRIG£AkTIdH 

/ 3~A'32 

__JAMMOMLAIAEFR|OEItATIOM 

. ~ 4"~U;,-32 

SEPARATOR DRUM 

I n-31'llP..I I

'+ 

,~ ~ ~I ,, ~ ~ ~, ~,: ~.;~ ~1,~ ~.~ ~ ~'~'l, ,~. 

3Z-0t-I203 32-af-t204 

~z--~i ~ ~osoeeu O(~r~NZZEn =XTF~Onm 

IfAT[R D~IAil OItUHS ~ CORTACT DRUM ' " 

I 

0l'13Q~ DO HOT POCKET 

-oi-j_i 

ll( 2-_____.~2 

IOH~FF 

¢~ I~B "32 

32-01-1501 

]Z-Ol-15O2 

FIGURE 4-2 

I 

,,,(.,C.ga[ 

HJC. ,.H.F. 

I 

t 

I < 

SET S 

_:._~ I T4 PS|O 

32~f-f203 

FZGUilE 2-4 

-1-- 

KOTE 2 

NOTE~ 

I. Tile F~UIPkEHT SttOWN OH tHIS DRAW][HO IS FOR 

ONE 1RAIH. THE PLANT WILL CONTAIN OHLY 

• E NOTE 3 

OIR TKAIH, 

2, lOyAL LIGIIT IITgROCARBOI~ AVDL4G( MOLECUI,~R 

IIUOIIT • 44.0 

3, UEIllAKOL IS AOD~ AS REQUIRED TO %HHIOJT 

HYDRATE FORMATXON, METHAHOL 15 HOTFl~QUIREU 

FOR H~P, IkL 0P(flATIQR 

!"-AA-]Z ~,, ...... 

FUEL 6AS/HF.AO~A ~ 

4. THE nGUR~ ltUMQ(l~ REFER TO TIlE TYPYJ~L 

EQUIPU(NT COItFIGURAl%OH$ SHaH OH DRAWING 

O-OI~-~. 

L.P. FLARE ~ I[--1 

' HE 

- 1'-~'32 / ~ -- H.N.F. 

- -I F FROM DEPEHTANIZTz, R 

3Z'-O I- 1204 ~ ~ RETLUX DRUM 

It~,R.]2.! FIGURE 2-2 

150 PSIG 5TEAR ~ li~ 

¢ONDEI(SATE ~ WASTE WATER 

DEETIL~HIZI~R BOTTOMS/ DEPEHTANIZ[R 

LEAN OIL/ LEAR OIL P5~ 

(OLII~EHT ~ 0;4 IH~ 0~II%~ 

3~"01-1S01 

~-01-'~ 

32-01-1101 

]Z-Ol-12Ol 

32-01-1202 

32-01-1203 

3Z-01-1204 

]2 "Ol'l'qOI 

32.,,01*1]02 

9"01-1501 

)2-01-150Z 

32-01-Z801 

3n ,.r. - U,S. DEP~TI'ENT OF ENERGY 

~, COAL- TO- METHPNOL- TO" GASOLINE PLPJqT I~ 

~s ~]o~no~ - "at 3;= ~='="'~-32-MP- I NP 

D

'-XA-ll 

I 0,,:: "" t il' ), lull. GAS ItEADII 

, I, l I 3 I 

ll-01-1102 ~ 31-01-1]05 

,~[IITANIIEII pEPEIIllllllll I All I ClLEn O~lt 3l'01 ' '"~ 

l~ PSiO 

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39-01-110l 

..... . I'-'B-31 ~.IL F, I1,1 F, 

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32""01-1503 32"01-15~1 

,s2.01.150 l 

FICUII( 4-Z. FIGtII~ 4-Z 

32-01-150._....__~3 3201-1505 32-01-1507 .. 

32"0U-1504 31-01-150@ 32"0101501 ~.; 

,LEAN OIL PLIMP All) SPARE ,D~ENTAI~z~t OO'ITOM5 DEPEliTANIZI[R REFLUX, "'"" 

T5 H,P. PLO~ AllO 5PARE ptAil AlE) 5PAItE ;~,,," 

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31-01-1501 3Z-01=IS0~i 

]~-01-15011 3~.-01=15i0 

FIGUR~ 4-2 F[OI~E 4-2 

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32-01-1~5 ]Z-OI-ISOG 

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L D-"-Z-.MP-2 ~ O~HTANXZF~R BOTTOI~ 

DEPEHTANIZER EXCHANGER 

4P-AA-32-Z 

~9-6'~-MP-I UP ~ ARCCA,~TZC XYOROCARBONS/STGPJkG( ~..~. 

J ° 

I 

'q2-01-1307 32-01-1103 3Z-01-13011 3Z-01-1320 

SPL'IT]'I~ BOTTOi4S G~SOI.INE .SPLITIER 01SOLI~ sPLrri'£R GA~-------~'~-"IT~ 

-- AIR COOLER ' AIR G'IOL~ FEF-o/OVERH~eo 

10.5 1~61U/XR 62.2 li4JTU/XR 

S"AA-32-! 

'~2-Ot-I30T 

F~GURr 4- I 

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liOTE 4"-" '~ IG~ 

(HDTE 2) 

4"A~-32-Z 

SET • 

2O PSXG I~ r I0' 

32-01-1320A 

.. FIGURE 3-~ 

L ! 

"-~--~--1 I 

._ t_~_..~ 

FLC:I 

32-01-1103 

FZGURE I-I 

32-01-1513 32,'-01-151 '~ 

32-01-1514 32-'01-i516 

F'/GLI~[ 4-2 I~GURE 4-2 

.je 

24"-k~-32-I 

6"-'kk-32-X 

32"01-1308A 

Z 

? 

(m,, m~. ....... 

m 

..... 

IO'-AA-37 

32-01-1513 3~-01-1SI5 ._.. : 

3Z-01-1514 32--01-1516 

GASOLINE SPL2'rTER GA'~,ot.mr SPLX'TI"ER GASO~"-" .... : 

IO X.P. 200 H.P. !.,~ u P 

3 

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32"01-1206 

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32'01-1311 

"FZGURE 3-t 

32-01-130~Jk t 

32"01-13058 I 

W. 

SET • 

,~20 PSIG 

4"P G' I~ 

L.P. FLARF.~--- 

I . I r--R-32-I 

I I;00 PSIG STEAM" I r-I 

4'*1~-32-1 

® 

! -- 5 - ~ " 

11"'~-32 

fUEL 0,5 ,~ 

8"-AA-32-I 

LIGI~ GASOLINU STY[ 

P-Bk-3~-I 

#,ROiikTIO XYOROCAi~OILY STOAkGE 

4~DA'32-1 

AROMATIC X Y O ~ i~l' 

NOTEs1 

h THE [~J~'M(NT SHOIlM ON TILLS DRklINO 15 roA 

~I~ILRAIN, Ill PLANT Wg.L CONTAIN ONLY OH( 

7 

, ,.,,,, 

~, DLI~NG HOT LJ~T REGEIIERAYIOI~ A 14 DAY Pf..RIOR, 

u~.lJl[ PLIIEN BOTTOMS |5 SENT TO S'IORAG( 

ov ~Tcmw; com~ wv(5 A~o ,~c.vATIwo 

!~',~ ~mre .on~ me ,z to 

r ~.IIT[~ BOTTORS To 5TODAGE, A 

3, O~|WG NOT UNIT OPEI~TIOH, 'rill{ DASOLI.N( 

SPLITTER BOTTOMS 5TOAAG( PUWP IS OPEI~TEO 

OR A |ill DAY P(R[OO TO PROVIDE ."HE ADGEO 

EEO AEOU~9£O TO 'THE HGT UNIT TO ME(T 1HE 

XTO PLANT STREMI DAY FACTOR 0~" 9~, THE XOT 

IJHl'f MrdtAllOl~ 15 BASED OH A 5TREAM DAY 

FACION Of 8~¢. GASOLDiE SPLITTER BOTTOUS 

PUMP *1 IS ALSO OPF.~TEO OU~HO HGT UNIT 

OPEJUT[QN. 

4, VAPOR 3(¢ (MOt.() 

VAPOR WOL(~L~ IElb'Hl, 54.6 

5, THE FLOUR( IOJUB~S REFER TO THE TTPICAL 

EOUIPiI(IIT COIfI~T!ONS SHOWN ON DP,,klIN3 

0-01.'~-2, 

~NT SHORN 01 T~S D~YIHG~ 

3~-0 I-I I(~ 3Z-OI-ISI3 

32-01-120G 3Z-01-1514 

32,4}1-130T ~1-1SI5 

32-G1-1308 32-0l-t51S 

3Z-DI-1309 ~-4)I-ISIT 

3Z-01-1310 ~'01-1518 

3Z-01-1311 

)~J~. IE.A 3Z~1-1320 

U.S, DEPP.RTHENT OF ENERGY 

V.q.G~ & CO, 

Be,me B.P.B. ...... 

- TO - METHANOL " TO - GASOLINE PLANT II 

lm

A 

c 

' ~ I"AA-'~! 

[ ,-~z-~-z ,e)s'-~-3z IIEPEXTANIZF.A PROOUCT/ 

DEPEIITAHIZ~ REFLUX DI1UU 

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i AWINQ 

O,G¢.Zi lllJYsl 

DISCII IPTION 

1 I°1 

, 4U, 

32-01-1313 32"01"1311 32-01-1 IOI 

D_~HR(R ~,LKI'LAIIOH FEED _ ALKYLA'-"TIOH FEED . ~ DEPIIOPA~-'(R ~ ~ 32-01-1]14 

rf'~ / ~.1"~1~ B(CIIAHG[I1, ALl ctxx, r~ IkTEll COOLER ._R~EFLIJX CONOE~EII 

I;,O ili6TLVI~ 5,5 llglW~ hE 14JOTWIHI 

32-01-1312 

F[OURE 3-I 

k"T I 2~0 PSIO 

6"0 I0' LP FL4RJ~ -II-'-I 

3Z-I)l-I IOq .4 

ncunE I-..__....~ 

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I 

1 

8"'~-32 

"-~i ~ I ~-AA-32-! 

_ I 0"'~-32-| 

T 

I 

-[~ 

gE~'DllrrlOH 

3 

8'.-~-32-! 

12".-AA-32-! 

32"-01-1'~19 

32"01-1520 

FIGURE 4-2 

4"-'AA-32 

]2-01-1519 

32-01-15:'0 

DEPROPAH~ RDI.UXIPR~I~T 

PUI~' Xl~ SP~E 

SO X.P. 

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FIGURE 3-S 

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'IZ-Ol- IZI,_.___..~S T 

z-_._~q FIGURE 

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I 

F'-I 

I 

,I, 

I50 PSIG STEAM I I 

II~M~3Z I'"1 

FUEL OAS i{F.~ER : L I 

DBPROPANIZ~ O01X(~,/ HF ALi~LATIOH Uil~! "-~LHHIP'I 

COXOEN~'IrE I I 

4'--~-SZ .r-~--. ---- 

I, ~ JOUEIEIiT glOlll 01( THIS DP, Ar.,A{I IS FOR 

OK[ TRkII, THE PLANT ~t,t, CONTAIN O~LY ONE 

IP, XIH, 

L DURZHO IRT UNXT REG[HOU,11t~, k 14 DAY P~IOO, 

r~a,tHE ~M.IT~ ~OTTO~S IS 5E~ To STO~,A~ 

I~ 511TCHIIW I~TROt. VALVF~ AKO ACT~VATII40 

IXi GXSOLtI~ 5,f.I.tTTO~ IPOITOUS PUUP e~, TO 

FINP SPL~TI~ ~OT~OUS TO STOP-AG f 

3, DUe, laG ~ UMI' ~l:l~T10~, THI[ GA~t,Tl[ 

SPLITTI~ I~TTOUS S1~eA~£ PU~ IS OP[RATI~ 

FOIl k lilt bY PERI~O TO PAOV]O£ TH[ H)OEO 

FEED REQtJtR~ TO THE HOT UHtT I0 MEET THE 

IIT6 pLANT sTREAM DAY FAt;TOll OF tl~. THE HOT 

UNIT OPERATION tS 6A,~t.O OH A STRIr:AM OAY 

FAC;OR ~F 05%. GASOLTX£ 9PLtTTEfl 90TTOI~ 

PI~P 01 ~S XLSO ~P~U, TEO OUt~ flGT UHIT 

MBkTION. 

4, VAPOA ~4Z lllOLEI 

YAP~ HOL[CUL~R Ir~GflT., gq.6 

5. life Ft~JR( IItIMOEI~ R~FER TO IH£ ?YPTCAL 

[OUU~MEHT COHF]OUR~TIOH$ SHOtIN Off D~NG 

D.01-.Id~-2. 

@~[IT ~ OH ~ OlUr~, 

3Z-Ol-II(~ 

3Z-01-1201' 

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~-01-1~13 

112,-01-1314 

32-01-1115 

3Z-OI-131E 

,. ~-01-1311 

0~,,,,~.~ E,:°oI:IN 

U.S.DEP~THENT OF F.I~GY 

~ ~ V,R, 6RACE & CO, Ke~oc~ 

I - 50,0~8 B,P,D, 

l--~~._.___--i ;~" i;;;;N J"";,~,,,.-,~,¢,~,,,"~ E~'L.J ........ F ~,,, I_ 

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. . . . . . . . . . . . . . . . . . . . 441, 

,! ORAWIH(S 

CO~PONEBT 

M.N. 

DEEIHAHIZEg UEETHANIZER OEETHARTZER 

LIQUID VAPOR LEAN OIL 

FEED FEED CEED 

IIYUROGE8 2.016 6. t0 88.?t 

HETHAfl( 16.042 204.33 479.25 

,CAROOH.HOHOXID[ 2B.OIO 5.01 52,45 

CARBON DIOXIDE 44.010 190.00 174.33 

HIIROGEN 28.016 0.53 4.59 

ETHEHE i20.052 4.55 3,15 

ETHANE 3~068 57.07 20.70 

PROPENE 42.076 24.45 3.93 

PDOPANE 44.094 505,44 79.77 

lSO BUTANE 59.120 009.85 55.14 

I-8UTENE 55. 104 113.97 ! 5.82 

R-BUTANE 5~ 120 2T9. 51 12. 10 

ISO PEXTARE 72. 146 1,013.04 10.99 5.57 

I-PENTEN( 72,146 189.27 3.GO 1.12 

N-PEXTAXE T2.146 115.74 1.65 0.55 

CYCLO FEXTANE TO. 130 20.64 0.21 0:06 

2 METHYL PENTAHE 86.172 BET. iS! 5.79 155.79 

CI+HEAV]ER , 2? 995.47 5.54 554.69 

WATER 16.015 0.43 5.20 

"~OTAL - NO~HR (DRY1 7,543.71 996.84 7:1.79 

..... TOTAL - LU/HR 519,499.85: 27,980.55 76,100.75 

MOLECULAR WEIGHT 91.981 28.07 105,43 

OEI./$TflEAM DAY 81.236. _.'T----'--' 5,615, 

..... USC[D ~ 9. 076,62 

PRESSURE - P510 166.30 158.]0 120.30 

TENP - 0£ I0~ 100, 205. 

H - MBTU/N8 79.61~ 81 6,855.10 13,580.00 

DEPROPAHIZER 

FE(O 

@ 

OEPROPANIZER 

VAPOR 

OVZRH~D 

@ 

DEPROPAR[ZER 

BOTTOMS 

CO~POHEUT 

HYOflOGER 

H.W. 

2. OIG O. 000 

METHANE 10. 042 O. DO0 

CARUOH MOHOXIDE 28. 010 0.000 

~RBON DIOXIDE 44.010 0.02 0.034 0.02 

. Hih~OQl:d 20. 016 : O.O.O,O 

ETHEflE 20. 052 0..01 O, OI 4 0. OI 

ETHANE 30. OE8 5, I B 34. 334 5. 18 

PROPEHE 42.078 24.51 109.269 0.01 24.50 

PROPAHr 44. 094 I 560. OH 3978.127 

I. 92 . 5TU..IG 

lEO BUTANE 58.120 943.85 69.939 933.70 10. IS 

I'OUTEHE 58,104 119. 75 2.797 119.29 9.46 

H'BUTAflE 50,120 291.56 1.600 291.43 0.23 

. I-PEMEN£ 

H-PENTANE 

. CYCLQ PEHTAHE 

2 HEIHVL PENIAN( 

C *HEAVIER 

.... SEATER 

72.146 

72.146 

72. 146 

"tO. 13i~ 

86.172 

19,016 

1016. 51 

192.54 

107. 86 

I1.03 

59.99 

4.14 

9, DOll 

9,001 

IOIr-- 53 

192.54 

107. 88 

11.03 

5°,99 

4.14 

TOTAL - MOL/HR 

TOTAL - L~HR 

MOLECULA R WEIGHT 

B~I./$TRr..AH DAY 

u~C, FO 

205,240.46 

61.43 

24.014. 

44. 13 

mlli~Z3~13] mE]]~l~ 

55,.33 

44. 13 

20,332. 

PRESSUR~ - PSIG 207.30 205,30 210.90 200.30! 

TEl~- °F 160. 115.51 23?. 112, 

H - LtOTI!/HR I 37.080.90 39,891.35 4,480.751 

[ 

NO, ~--'iIQN NO. I DATE mY ~ SiC( MIGU ~,IILNT 

I 2 I 3 

I 

DEETllAHI2Efl DEETXXUI; 

VAPOR REFLU) 

OVERHEAD DRUH 

OVEEHO 

sa.2e~ .I 

731,164 cn~ 

39,474 31 

429.040 3(~ 

5,498 

5,093 

90.072 7| 

E, 419 

117,995 "~ : 

4,430 

O. iT5 

o. 13a __0.O31 

O. 812 

O. 13S 

0.059 

0.003 

7.027 

3.74 

h526.304 -- 1.34( J 

42o057. 34,77( 

27. 55 2~ 

13.901.0 12,258.94J . 

155,40 I$1 

65. 23 ~' J 

i 

- I 

9,471 

9,o21 

SOT.'JI I 

299Z.31 I 

s 

,, TO.O I 

256. ] 

r,254.Ol 

~l,h,-~l~: ~rL~... htv a .._ 

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F. Plo,t Plan/General Arransement Draw£n~e 

Plot Plan and General Arrangement Drawings for Gas 

Fractlonation Unit 32 are us follows: 

Drawing No. Title 

D-32-PD-INP Plot Plan - Unit 32 and Unit 38 Gas Fractionation 

and HGT 

D-32-PD-2NP Elevation - Unit 32 and Unit 38 Gas Fractiouation 

and HGT 

II-1.2.13-13 

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UNIT 3B iS PROPRIETARY. 

I _ 7 

AOS~OER DE(IHANII01 

DI~ERTANIZ(fl 

O~OLIH[ SPLITIER 

DEbOrAH IZER 

WATKR I~tAV DRUm I 

WATER 5RAW DNR413 

AOSOHBE~ O((TIIARI2ER REFLUX DRUM 

rATER K.~ ORUM 

D[PERTANIZER REFLUX DRUM 

OA~OLII~ SPLITTER REFLUX DRUM 

PEPROPANIZ£R H(FLU~ DRUM 

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46e-~lOER D[(THANIZ(A CHILLER 

Nt~'~OR8ER O((nUU41ZER HEROILEk 

O(PERTANIZLR AIR COOLER 

D[P(NTAMllEROYHO, CONG~ISER 

D(PERTAHIZ£R REROILER 

SPLITTER OOTTOI~ AIR COOLER 

GASOLINE SPLITTZR AIR COOLER 

GASOLINE SPLITTER REOOILE~ 

LIGlff O~OLINEPROCOCT AIR COOLER 

tIGHT GASOLINE PRCOUCT COOLER 

DEPROPANI|(R FEED/'OQTTOM~ EXCHANGER 

ALKYLATION FErn AIR COOLER 

DEPR~PAMIZERR(FLL~COHDEI~$£H 

D[PROPAHIZ(R RrnOILER 

PROP~E PRODUCT COOLER 

ALKYLATIOI FErn lATER COOLER 

OEPENTAHIZER FEED/BOTTOU~ (XI~ANGER 

GASOLIHC SPLITTER FC[DIOVHD.E'~CHANGER 

ABSORBER 0EETHANIZ~ SlOE R[ROILER 

COLO LEM~OIL Pt,,MP ~0 SPARE 

LEAH OIL ~ ~ SPAR( 

D£P(NTARIZER 80TTOI~ PUMP M(D SP~E 

DEP(KIANIZ(R REFLUX PtJl~ A.'~D SPAR~ 

DEP(HTNIiZER OVHO.PLZ4= A~ SPARE 

GASOLINE SPLITTER BOTT~PUMP NO, 2 At, O SPARE 

GASOLINE 5~LITTER OOTTOM~PUMP riO. I k~SPAR£ 

CASOLI~( e..Pt,.:TTER PROOUC|/flEFLUX PUMP Atl0 SPAR( 

DEPROPAEIZERREFLUXPUMPAHD SPARE 

GAS rRACTIONA, TION REFRIG(RATION PACEACE 

~*, 18 ~ M &O • IO 

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V.R. GRACE & CO. 

50.069 B.P.O. 

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COAL,,- TO - HETHP, NOL - TO - GASOLINE PLANT 

PLOT PLAN 

~NIT 32 AND UNIT 38 tl 

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G. Single-Line Diagram 

II I I i .... III| 

See Volume l~, 1.2.12(G) for the Single-Liue Diagram for Gas 

II-1,2.13-14

a , 

C 1.2.14 IIF ALKYI~TION - UNIT 33 

/ 

\ 

A. Basis of Design 

A hydrofluoric acid (HF) alkylatlonunlt has been selected 

for the conversion of a mixture of butylenes, amylenes, and isobu~ne to 

produce alkylate as a blending component of finished gasollne. The IIF 

Alkylatlon Unit is a conventlonal-type facility v~thout octane upgrading. The 

HF Alkyla~Ion Unit selected Is based on a proprietary alkylatlon process 

llcenaed by Phillips Petroleum Company. 

The feed stream is derived from the conversion of methanol 

to gasoline in a Mobil ~ffG unit ~-~th subsequent fractionation to separate the 

butylene and amylene components in depentanizer and depropanizer to~ers. The 

feed Is depentanized to keep the C6+ fraction at a low level so that the 

hexane fraction is less than 0,2Z by volume of alkylatlon feed, This is 

necessary to reduce tar and decrease ac!~ consumption during the alkylat£on 

process. The feed is also depropanlzed to keep total propanes at a low level 

for alkylatlon and to reduce aeSd losses that occur when propane is vented. 

The feed contains a h~h-~mylene content~th about 60~ dry 

volume amylenes to the total olefins present in the feed. Phillips has 

exper±ence processing feeds with a hlgh-amylene content, up to about 31Z by 

vol,~e amylenes to the total oleflns present in the feed. 

The HF Alkylation unit product streams consist of alkylate 

as a gasoline-blending component, n-butane to adjust Easoline vapor pressure, 

and £eobutane to adjust gasoline vapor pressure ~r£th the excess to sales. The 

synthetic al~ylate product is about 7.5% by volume of the total ~asoline 

pool, with CS+ naphtha about 88Z by volume and the remainder butanes. Since 

n-butane ls in short supply and there is excess ieobutane in the feed, some 

isobutane Is added to gasoline when needed for vapor pressure adjustment of 

finished gasollne. 

II-I. 2.14-1

Provision for an n-butane side-cut from the deisobutauizer 

~s included in the HF Alkylation unit deeisn. The alkylate product should be 

£1exible in n-butane content to allow for a Reid vapor pressure (RVP) of 

total alkylate of about 5 to 6 psi for storage. When blending alkylate with 

naphtha for storage, a higher RVP is allowed; for instance, about 8 to 9 psl. 

Since the feed contains excess isobutane, the overhead 

product from the deisobutanizer is expozted for sales. The isobutane product 

is a high-purity stream with less than 0.SZ by volu~e n-butane content. 

Alkylat£on unit feed and product stream compositions are presented in the 

following tables, 

Propene 

Propane 

Component 

Isobutane 

l-Butene 

n-Butane 

Isopentane 

1-Pentene 

n-..Pentane 

Cyclopentane 

2-Hethylpentane 

C6+ Heavier 

Total, lb mol/hr 

Total, !b/hr 

Pressure, psia 

Temperature, °F 

lIFAlk~lnt~on Unlt Feedstock 

i 

|m mn • 

II-1,2.14-2 

lb mol/hr molZ 

0.01 

1.92 0.07 

933.70 34.11 

119.29 4.36 

291.43 10.64 

1,016.53 37.14 

192.54 7.03 

107,88 3.94 

11.03 0.40 

59.99 2. I9 

4.54 o.,4 

2,738.45 100.00 

178,900 

45 

100 

, II

C 

C 

Product Streams 

m 

Ieobutane Product 

Component (lb mol/hr) (molZ) (lb mol/hr) (molZ) 

. • .,L ,, , . . . . . . . . , • 

Propene . . . . 

Propane 1.92 0.35 - - 

Isobutane 552.13 99.22 12.20 4.42 

l-Butene . . . . 

n-BuCane 2.41 .43 244.24 88.47 

Isopentane - - 19.56 7 • I I 

l-Pentene . . . . 

n-Pent:ane . . . . 

Cyclopentane . . . . 

2-F~e thylpent ane . . . . 

C6+ Heavier . . . . 

AIL71ate . . . . 

~ L Z i ~ i 

Total, lb mol/hr 556.46 100.00 276.00 100.00 

Total, l"j/hr 32,315 16,310 

Pressure, [~,s ta 85 60 

Temperature, °F 110 110 

, .m i . i i , i i | . , 

IT-I • 2 • 14-3 

l ,, , • , , ,, i i 

n-Butane Product Alkylate rroduet 

(Ibmol/hr) (molZ) 

i 

ii i 

N m 

44.87 2.80 

1,067.42 56.55 

m m 

107.95 6.73 

11.03 0.69 

59.97 3.74 

0.54 0.04 

312.00 19.45 

1,603.78 100.00 

130,196 

5-6 

110 

N

B. Process Selection RatLonale 

, . , , 

~he Phillips EF Alkylation Process is a commercially proven 

technology. Phillips has about 80 plants operatlnS successfully throughout 

the world. Its capital and eperatlnE costs are lower than for the other 

processes examined. Phillips experience with hlgh-amylene feeds fits well 

with the present design, which contains about 60Z by vol,~e mnylenes to total 

oleflns in the feed. The process provides rellabilltywith a good turndown 

ratio. 

I. Operability. The HF Alkylatlon Unit can be operated at 

about 50~ of design capacity, It can be brought to full-load operation within 

a few hours. 

2. Reliabillty. The plant is designed with all pumps 

spared and with block valves and bypass valves installed around control and 

relief valves. The design will permit maintenance on such items without 

shutting do~n, 

3. 0nstream Tlme. The operating factor for HF alkylatlon 

will be better than that of a fluid catalytic crackSng unit and is estimated 

at about 95Z stream factor. 

4. ~alntenance Costs. The maintenance cost estimate for 

| u 

the HF Alkylatlon unit Is 3o5Z of unit capital cost. 

5. EquLpment Lead Time, With the exception of the HF 

regenerator, the Phillips alkylation plant is designed entirely ~f carbon 

steel, The acid regenerator can be of either Monel-clad or solLd Monel 

construction. Monel construction is a major factor in determining the 

equipment lead time, 

6. Comm.erclal. Exper.i..ence. Table TI-1.2.14-1 summarizes 

plants using Phillips HF Alkylation Process in operation and under 

co~tractiou, 

II-1 • 2. I-',-4

q 

i m i~4"W~ZllJ~J~8~ANi 

Table IZ-1.2.14-1 - Racen£ Phillips HF AlkylaCion L~eensees 

Company 

Gulf 0il Corporation 

Harathon 011 Company 

Getty Oil Company 

Texas City Refining 

Ltndsey Oil L~mt*.ed 

BP Trading Limited 

BP ~ading L~nited 

Marathon Oil Company 

Texaco-Gul£ 

Amoco-Murphy LtmiP-ed 

Mobil Oil Corporation 

Mobil Oil Corporation 

Gulf Oil Corporation 

BP Trading Limited 

CFR 

Mobil Oil Corporatiou 

Petrobras 

Trintoc 

~PC 

Albatross Oil Processing 

Saber Refining 

Tenneco 0tl 

, . , | 1 1 . 

Startup Design Capacity 

Refinery Location Year (bpsd) (mtpd) 

Philadelphia, PA 

Texas City, TX 

81 Dorado, KS 

Texas City, TX 

Killingholme, England 

Rotterdam, Holland 

Grangemouth, UK 

Garyville, L% 

Pembroke, Wales 

Milford Haven, Wales 

Croydon, England 

Durban, South Africa 

Clnclnnaci, OH 

Kwlnana, Australia 

LaMede, France 

Saudi Arabia 

Cubatao, Brazil 

Point Fortin, Trinidad 

garri, Nigeria 

Antwerp, Belgium 

Corpus Christi, TX 

Chalmette, IA 

II-1.2.14-5 

1973 15,000 1,667 

1974 11,000 1,222 

1976 10,000 1,111 

1979 6,000 667 

1981 4,200 457 

1982 5,000 556 

1981 4,200 467 

1980 21,000 2,333 

1982 18,000 2,067 

1981 3,000 333 

1982 14,500 1,611 

1981 2,500 278 

1Q~O 2,000 222 

1981 3,000 333 

1981 3,000 333 

1984 14,500 1,611 

1984 3,000 333 

1984 5,500 611 

1983 3,000 333 

1984 4,800 538 

1983 7,700 859 

1984 16,000 1,778 

.ll

C. Process Descript~on 

Refer to Process Flow and Control Diagrams D-33-HP-INP, 

-2NP, -3NP~ and -~NP for eq~;.:~e~t arrangement and material balance. 

Depropanlzed hydrocarbon liquid from the Gas Yractionatlon 

Section flows to Feed Surge Tank 33-01-120S~ which has an 8-hr holdup to 

ensure continuous hydrocarbon £1ow to the HF Alkylatlon Unit. The hydrocarbon 

£eed eomposltlon is shown £n the above table aea mlxture cons£stlng o£ 

butylene and amylene olefIns. 

The total hydrocarbon oleflnlc feed, along with recycle 

isobutane, is charged to the reac=or sectlon of the HF Alkylatlon unit. The 

combined feed is dlsperaed th;ough ~pray nozzles and mlxed wltb hydrofluoric 

acld before entering the reactor riser. The reactor operates by dlf£erentlal 

gravlty ~Iow and has no novlng parts such as Impellers or mixers; also, acid 

circulation pumps are not required. Total conversion o£ reactants to 

hlgh-quallty alkylate occuro almost instantly. 

From the reaction zone, the hydrocarbon components and acid 

catalyst flow upward to the settling zone. Here, acid catalyst breaks out as 

a bottom phase and flows by gravity on a return cycle through the shell side 

of parallel Acid Coolers 33-01-1301 and -1302 to the reaction zone, where the 

reaction cycle is repeated. Heat of reaction is removed by heat exchange with 

a large volume o£ coolant £1ow£9~ through the tubes. Cooling water used is 

available for further cooling elsewhere In the unite The hydrocarbon phase 

£rom ~he settling zone, containing minute quautities o£ propane, recycle 

isobutane, normal butane, pentanes, cyclopeut~ne, and alkylate, is charged to 

Maln FracClonaCor 33-01-1101 £or recovery o£ oroduct streams. 

The main fractlonator overhead is charged to ~F-leobutaue 

Stripper 33-01-1103 for H~ acid removal overhea~. The bottoms isobutane 

p~oduct is catalytically defluorluat:~d, K0H treated, and yielded as isobutane 

product. Recycle Isobutane, essentlal for £avorable control of reaction 

mechanisms, Is produced as a vapor overhead stream from she main £ractlonator 

II-I. 2.14-6

and also from the HF lsobutane stripper bottoms, The condensed and cooled 

recycle £sobutaue is returned to the reaction zone. 

The alkylate bottom product from the maln fractlonator 

containing about 2Z n-butane is acceptable for motor fuel blending. An 

n-butane product of about 85~ purlty and sultable for motor fuel blending Is 

taken as a vapor slde-draw near the bottom of the main Eractlona~oro This 

sldestream Is condensed and sent to storage for vapor pressure blendimg In 

gasoline. 

A small slipstream of acid Is wlthdrawn from Acld Settler 

33-01-1202 and fed to Acld Rerun Tower 33-01-1102 te remove dlssolved water 

and polymerlzed hydrocarbons. ~_ overhead product from the rerun column is 

clean hydrofluoric acid, which is condensed and returned to the system. The 

bottom product from the rerun tower Is a mixture of acld-soluble o11s and an 

HF water azeotrope. This stream is sent to Main Fractlonator Heater 

33-01-1401 to be dlsposed of by burning. 

Auxiliary systems included w£thtn the battery limits include 

(1) Acid Relief Neutralizer 33-01-1201 to remove HF from relief gas leaving 

the battery limits, (2) Recycle Acid Rerun Tower 33-01-1102 to remove 

acid-soluble o11s that occur in the reactor acid, (3) Acid Storage Tank 

33-01-1203 for anhydrous HF acld dur£ng periods when the unit is shut down 

for turnaround, (4) HF Acld Neutralizer 33-01-4102 for surface dralnage and 

sewer drainage in the acid area, and (5) a change room and storage room for 

cleaning and storlng necessary protectlve clothJ.ng requlred on occaslon by 

operatlng and maintenance personnel. 

Process hydrocarbon vapors from the relief gas header 

containing HF acid are contacted in Acid Relief Neutralizer 33-01-1201 with 

dilute aqueous sodium hydroxide prior to entering the flare system. Calcium 

chloride is used to precipitate calcium fluoride from spent caustic in 

Calcium Fluoride Precipitator 33-01-4101. Insoluble calcium fluoride settles 

out to form an inert sludge, which has been successfully used as a sanitary 

landfill ~r£thout known environmental problems. 

Y.I-I • 2.14-7

i ~ i m ~Itleo~,,~ tl~ tlWr e41~ ¸~ ~ , 4~ ~t~ ~ ~ e1,et~e~*l~fr~q 4 ~ le ~ ~le~ l l i ~ I 

Fro~ produc~ screams that require KOH treaters~ the spent 

KOH is processed through a spent caustic neutralizer using Na2CO 3. 

Drainage from the spent caustic neutralizer flows to the plan~ was~e~mter 

treament system, 

Product streams such as L~G, are defluorlnated over an 

activated alum2na bed. After the bed is "spent," it is considered ~nert and 

can be disposed of ~n a sanStary ~and£111. 

D. Risk Assessmen~ 

The hydrofluoric acid (HP) alkylat~on unit designed by 

Phillips Petroleum Company converts a m~xture of butylenes, smylenes, and 

isobutane to produce alkylate as a blending component of f~n~shed gasoline. 

The Phillips HF Alkyiation Process is a ccunnercially proven 

technology. Phillips has abou~ 80 plants operatiug throughout the world. 

Phillips experience wi~h high-amylene feeds t~cs wel~ wi~h the present 

des~su, which contains about 60Z by volume amylenes co ~o~al ole£ins in the 

feed. The process provides reli~bil£ty with a high-onstream factor. The plant 

is designed with all pumps spared and with block valves and bypass valves 

installed around control and relief valves. The design permits maintenance on 

such items without shutting down. Corrosion and equipment ~ouliug are not 

expected to be problems. The technical risk is considered ~ntmal. 

ZI-I • 2.14-8

L" ~" 

E. 

are as follows: 

Drawing No. 

D-33-MP-INP 

D-33-MP-2NP 

D-33-MP-3NP 

D-33-MP-4NP 

IO I~lt~lh m~Qrtl~ pN ~ Nml 

Pro,tess Flow and ,Control Dia~ra~_s (Including ~aterlal 

Balance) 

Process Flow aud Control Diagrams for HF KLkylation Unit 33 

Title 

PFCD HFAlkylatlon - Acid System 

PFCD HF Alkylation - Fractlonation 

Material Balance -~IF Alkylatlon 

PFCD ~Y Alkylatlon - Waste Disposal 

I'r-I. 2.16-9 

i ! 

E*m

,,,, , ; . ,, • , m .~,,~ ,, • •, , i~ , ,,,i , 

,,~t.~o~ 33-o1-I3o~ ~ 33-o1-,2o3 3,|.0~.t3o] 33..o1-13o5 

ACID COOt, EA ACln COOLEII ISO~UTAH[ IT[CYCLE ACID SETTLER ACID STORAGI[ ACID VAPO4~IZER ACV,~'S~[RTJF-'[~I"~f- £1! 

' ~ " " IUOCO0(,I~ 

ALK~LATE FEEl)/ 

FEEO SL~G[ TARK 

COOt.ING WATER SUPPI.YICUOLIIIG TOW~ 

'1 "-~:" ("'J ' 1 I 

33-01-1202 

l- 

RF..A( TO~ RF.ACTO~ CWR ~'~ 

OI~ICNIPI"ION 

I.~ RECYCLE ISOOUTANE ~ 0 6 

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SETTLER EFFLUUIT tic 

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.~01 130-~ 

33-01-150G 

~3-oH5o! 

33-01-IS~"5 

3'~-01-15o.i 

A rm RERUli 

m 

33-.01-1~06 

3,]-.01-1509 

i "~'o RELIEF HEADER 

14'-A-33 

H1TRO~ER ~ 

3]-01-1102 

--el 

33-01-1508 

33-01-1509 

~DI FRACTIONAT~ FEED .,. 

PLI~ AHO SPARE 

iI c Is~v.I I linAwl r~ I I F~ an i.~: 

il n Ist~ni I leAwl r~l I F.gO_U~L~ 

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1, 'fXE £00L1110 IfilEIt FACILCT~ FOR 1X£ H,F. 

ALKYL~T|OR UHIT 11; A Sf~,[~11[O S¥STEId, 

33-01-1]0a 

"R-]3-I 

2. "~X£ |SOOUTANE FLOg( LIH[ T~S|NTO TIIEISO- 

OtlTAV£ STIAtAC[ FACIL~Y AT "qlE PUll ~ °]SCitAItG£ 

L1HE. (XOItMALL¥ NO FUR DURtKO UHiT OPB- 

' LSOOUTAH[ FLUSWSTOSAGE ~0-$7-ilP-4 liP U kT|0e). 

tHOE 2) 

ALKYLATE/llA~ FRACT|OHAT~ ~ 0-33,-MP'2 liP, J 

Hrll~,l rP.xcTloax~oa o~cm~o ~,cuuut.xT'nn, ~ o.-~].-i,-~ m, I 

|S06UTANE STI~PP[R 

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RECYCLE 

¢ ~,~li~iu¢/ 

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RECYCLE ]SO~UTANE COilOEKSE~ 

CoADrNSATL 

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33-01-1307 

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I$ORUTANE 

33-01-1308 

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33-'01-130~A 

33-01._._- r~ ,m 

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EFFUENT Hr./ 

WklN FILICTIOXATOR 

"el 

ACID IAI~ItI~US/$TORAG[} 

,,-----4 0-33-L~-2 NP~ 

AC~O SO~L( czts, 

CA. S. O. )lmlN I~CT]OXATOR 

AI.KT~TU ~ D-$3-tlP-2 ~P I 

FRACT1ORATOR 

i~A-33 

ALKILAT( COOL~ 

D335Pl KID. 0~, 

I 

EOUIPI~NT S.~Ot3 OH TXIS DRAWING 

33-01-II0Z 33"01-1307 

33-'01-1202 33-01-130B 

33-01-1203 33-01-130~ 

3]'01-1301 :33"01-130~ 

• 13-01-130Z 33"-01 - ISOG 

33-01-1303 33-01-150'/ 

33"01-1304 33-01-1508 

33-4]1-1305 33-01-150~ 

33-01-130(~ 

I U.S, DEPI~RTHENT OF ENERGY 

e~sKETT V.R, GAACE & CO. 

' 5O, i~O B, PJ). 

bd~]~ e COAL - TO - METI-I~OL - TO "~oN[ - GASOLINE PLANT "G'~'~ .... 

1~ ~e~.,~z~,.N" I~nsnm cow~ | Acre ,STSTeU "~-33-MP- i' NP 

I o I 

7

,IP, 

c 

D 

I = I a I 4~ =" 

~ 33-Ol-131t 33-01-1313 33-01-II03 33-{ 

MAtH F~CYIOHATOfl 

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MAtH FRACTIOtlATOI! 

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~ 0 1 1 

MAt 

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MAtH F~ACYIOMATIO(I RECYCLE ISOOtlTAHE |SOB TA~'~ 5"1RZPP~ |,~09,iJTAHE STRIPPER 

Oi/EIIIIEAD ACCUM~LATOI1 CONDFJSER FEED OOTTOI~ EXCHANGER " ' 

' 

ISOOO"~j ',, 

X'-'----~ 

-- . 

'(O-3]-if-I flPj ALKYLATE/AC]O VAPmTZER 

(D-33-HP-I HP I RECYCt.E L~O~UTAX.~ 

150OUTANE RECYCLE SI;~LER 

~~--"]'BECYCLC Z:~QQUTAN,T." 

]SO~UTAIE R[CYCLECONDEHSF.,.R 

I D'33-i~-I NP~) "SETTLER EFR.UEHT HC/MA|X FRACY. 

FEEO °OTTOI~a EXC1L~G[R 

33-01=1401 3]=O1=I 101 33-01-!310 33-DI-12._._..._~ 

MAt# FRACTIONATm MAI H F~CT,~OHATOfl, H'BUTAHE BUTANE KO~I 

33-01-I101 

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r-24"A-33 

33-01-1311A J T 

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33--01-1510 

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I 0-3]-I~-I HP~ 6"-A-33 

ALI~TLATE/AC[O VAJ'~i~I~, MAIlt FRkCT|OILAI'O~ 

FEED BOTTOMS EXCHANGER 

DRAWINa tt(O, !Ji 

33-01-1510 ]]-DI-I~;! 

33-01°ISII 33-DI-1513 

MAIN FRACTZCKATC~ M~IX FRACT]ONATOR 

REOOXLE~PUUP k SPANE REFLUX PUI~ k SPARE 

iltlllll'li 

1 I = I 3 

33-GI-1313 

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33"°~'I'°----~31 

33-01=13ZD 

ISORUTANE 

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' +33-01-1320 3},'01-131? J3-01-I206 3Z~01-1207 

t~'~'-~'tPPER. ALK'~LAIE~ ,~,, ISOOUTAH£ IS08UTAHE 

-- ~80.__~ pEFLU0flIHAI~ DEFLUOIIIHAI~ 

3-Ol-IIOl ~c 

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33-01-1315 

33"01-1206 

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MOTOR FtJ~l. 

HORUAI, ~JlAH,T,/5TORL.GE 

~| \-/ i.~nUl~flU-I 

- Sl&~6E 

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"PHILLIPS PETROLEUM COMPANY 

• _ lWm.esv~ o v I 

FOR CliENT APpp,~tA~. 

I,,e, ,,,,+ i I 

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LAlrlON UNIT IS A SEGREOATED SY~EM, 

SEE DWJ~tIXI4O HI'MP-15 14P 

~UIPWF.,HT SH011H nH TI~S DRAW'~6 

~LI-0l-I t01 33-01-1315 

33-01-1103 33-01-1316 

~,~-01-1204 33-01-1311 

't:~Ol-120G 3"t-D I - I :"llO 

33-01-12OT 

33-01-1208 

33-01-120~ 33-D1-131~ 

33-01-13i0 33-01-|320 

3~-01-1311A 33-'01-1401 

33-01-1:3119 3'~-DI-15t0 

33-01-15ll 

33-01-I512 

33-01-1513 

ocA U.S. DEPARTMENT OF ENERGY 

I eAs~rr 

-i 

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V,R, IgL4t:E & CO, ' 

5o.e~n e.P.O, 

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42. 08 O. o1 

'i~ROPANE 44.09 I. 92 

iSnOUT~L 5e. 12 933.70 

I-.BUTEHE 56. IO 119.29 

N'-BUTAHE 58.12 

[SOPEHTAHE 72.15 I~01E.53 

I-PERTEHE TO. 13 192. 54 

N-PEtl:rAHE 72. 15 107. 88 

C~CLOPENTANE TO. 13 11.03 

2"IJETHI'LPENTANE O6. IT 59.g9 

,,C G 4- HEAVIER 4.14 

ALXYLATE 110.00 

! l~ I o,~ ~ PllCu CLIrNT 11 

ILYDROCARDOI4 |SOgUTANE H-BUTAHE ALKYLATE ASO 

FEED PROOUCT PROOUCT PROOUC? 

1.92 

552. 13 12.20 

291.43 ?..41 244.24 '44.87 

19.55 1,067.42 

101'.95 

11.03 

59, 97 

312.00 

'.TOTAL L6 MO:./HR 2. 738. 45 556.461 276.00 I~ E03.*/8 

TO|AL LES/'I,~ 178, 898. G 3.315`0 i 16.,309.6 130.19G.O ?6.6 

BPSO 20,332 3,915.0 1,909 13.B40 -- 

LBS/Bbl 

211.26 198. 10 205.05 225,8 

IN 

65.3 58. I 59. I 81.2 -- 

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PHILLIPS PETROLEUM COMPANY 

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THE I~UIH N. PIm~O/S CO4Pmty 

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NOTEw 

I, THE ~ WA~F~/L~Y f~ ~Fo ALKY- 

~H U~ ~A SEOn~1~ SYST r~ 

2, TIl~ ]~UTAfl[FLUSII L~ r ~S INTO ZS~ 

BIJTAN[ SIOI~4OEFA(~IJ[T¥ OH P~ DISCHARGE 

~,~ , (N~LLY #0 FLOW DURING U~T ~- 

]OH). 

US. DEPARTMENT OF ENERGY 

W.R.GRAOE & CO. xem.c~ 

5B,BBca B.P.D. 

CON. - TO - METHANOL - TO - GASOLINE PLANT 

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33"01-1518 

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33-01-1515 

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33"01-1201 

33"01-1514 

33"01-15i5 

33-01-4101 

33-01-4102 

US. OEPARTHENT OF ENERGY 

BAS~TT V.R.GRACE & CO, 

5~.gBB B.P.O. 

COAL - TO - HETHANOL - TO - GASOLINE PLANT = 

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.menZSeO~L | D-33-MP-4 HP I'c-.~ 

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Unit 33 are a~ follows: 

F. Plot Plan/General Arrangement Drawings 

Plot Plan and Ceneral Arrangement Drawings for HF Alkylation 

Drawlng No. Title 

D-33-PD-1NP 

D-33-PD-2NP 

Plot Plan - Unit 33 ~A1kylatlon 

E1evatlon - Unit 33~ Alkylatlon 

II-1.2.14-10 

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~1 "~'1 ,,,J ,,,J , ,,,c ~ . . . . ~ LIWITS 

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MATCH LINE III C/L ROAD £.6830'-0' 

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33-01-1101 MAIN FRACTIOHATOR COLLIli 

33-01-1102 ACID IERUN COLU#I 

33"01"110~ I,~)DUTAHE STRIPPER COLU~ 

wsms 

:3-01-1201 ACID RELIEF HEUTRALIZER 

33-01-1Z02 ACID SETTLER 

33"01-IZ03 ACID S'IORAGE 

3,1-01-1204 MAIN FRACTIOFIATOR OVERHEAD ACCLIM. 

33-D1-1206 ISOSUTAHE DFJ:LUORIMATO~ 

~3-Ol-120T ISO~UT/~I[ DEFLUORIHATOR 

33-DI-1208 ISOOUT~E KOIt TREATER 

33-Ol-IZOl DUTAHE XOfl TREkTER 

HEAT EkCHANGI~RS,AH'p COII~)I~I$[RS 

33-01-1301 ACIO COOLER 

33"01"1:302 ACID COOLER 

33-01-1303 ACIP VAPORIZER 

33-01-1304 StRIPPiNg ISO~UTAHE HEALER 

33"01-1305 ACID SUPERHEATER 

:3]-01-1:304; I$OeUTANE RECYCLE SUGCOOLER 

33-01-1~07 ISOBUT/~IE RECYCLE COt~EH$[R 

33-01-1308 MAIN FRACT, I~. RECYCLE EXCHAHG[R 

3].Ol-I]Oq.l~O MAIN FRACT FD. BI"MS. EXCHANGER 

]]-Ol-I]lO N-RUI'AHE CO~ERSER 

33-D1-1311~,8 MAIN FRACY. OVERHEAD COHD. 

33-01-1~12 RECYCLE iSOOUT~E COND. 

33-01-1313 ISODUTANE STRIP. FD. OTMS, EXCH. 

3]-01-1314 DEFLUORIMATOR.FD. BIM~. EXCI¢ 

33-01-1115 

:)3-Ol-131G 

DEFLUORIf;ATOR FD. It~TER 

OEFLUmlHATOA I5OBUTAHE CLR. 

33-01-t317 

33-0t-I]18 

ALKTLAT[ COOLER 

MAIN FRACT. SIDE ArnOILER 

33-OI.ISI~J MAIN IPRAC]. SlOE REBOILER 

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]]-~1-1401 MAIH FRACL REaOIIER HEALER 

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33-01-1506 ACID 12[RLI+I PLIP 

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31-DI-1508 MAIN FRACL FEEO PUMP 

33-D1-1505 ~JklR IPRACT, FErn pLIUPISPAREJ 

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33-O1-1511 MAIN FR~CT. RE~OILER PUUP(SPIR() 

33-D1-1512 MAIN ERACT. REFLUX PUMP 

33-01-1513 ICqH FRACT. REFLUX PUMPI ~ARE) 

33-01-1514 CAUSTIC CIRC. PLMP 

33-01-1515 CAUSTIC CIRC. PUUPI SPARE) 

31.01.41¢1 CALCIIM FLUORIDE PRECIPITkTOI~ 

3)-01-4102 RP ACID NEUTRALIZER 

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m rr VJR.GPJCE & CO. 

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Ci G. Si~gle-Line Diagrnm 

f .... 

Alkylation Unit 33. 

See Volume II, 1.2.12(G) for the S£ngle-Line Diagram for HF 

II-1.2.14-11 

._

1.2.15 ACID GAS REMOVAL - DNIT 34 

A selective Rectlsol process has been selected to remove sulfur 

compounds (H2S/COS) and carbon dloxlde (CO 2) from a coal derived eynChesls 

gas. The process uses methanol for physical absorption of the acid gases. The 

licensor of the proprietary process selected for this project is the Lotepro 

Corporation. The shifted and unshlfted feed gas streams are washed 

separately. In tbe regeneration of the methanol, sulfur-bearlng gases are 

isolated and transferred to the sulfur recovery unit for the production of 

elemental sulfur. 

The Acid Gas Removal unit product stream consists of purified 

synthesis gas that is compressed and used for methanol synthesis, 

A. ~asls of Design 

In the selection of an acid gas removal process, the 

following design parameters had to be fulfilled for a candidate process to be 

considered: 

(1) A treated product gas purity of less than 0.1 ppmv 

total sulfur and 3 to 6 volume percent CO 2 achieved by 

absorption of CO 2, H2S, and COS from the feed gas. 

(2) The CO 2 tall gas stream must contain less than I0 ppmv 

of total sulfur so that it can be vented to the 

atmosphere without thermal incineration. 

(3) An H2S-rlch acid gas stream containing a mlnlmum of 25Z 

H2S and suitable for a Clans unit feed must be produced, 

(4) The technology must be commercially proven. 

The followlng feed and product stream data summar~,zz the 

normal operating conditions for th~ four-module Acid Gas Remov~l unit. 

TI-I.2.15-I

Component 

H2 

CO 

Ar 

CH4 

CO 2 

H2S 

COS 

02 

Total Dry', lb mol/hr 

Feed SCreams 

Shi£ted Feedgas Uushifted Feedgas Str~ppir~ Gas 

(lb mol/hr) (Ib mol/hr) (lbmol/hr) 

73,546.7 23,511,6 - 

513.8 309.2 8,655.6 

12,820.3 28,463.3 - 

172.4 103.8 - 

214.4 129.0 - 

53,771.4 11,567.3 - 

1,~6.8 827.0 - 

12~! 51.0 - 

i w 

142~497.9 64,962.2 8,655.6 

H20 171.4 75.3 

Total WeC, lb mol/hr 142,669.3 65,037.5 

Total, lb/hr 2,951,690 1,401,320 242,500 

Pressure, psla 790 790 33 

T,~uper:~cure, °F 100 100 68 

~[T--1.2.15--2 

I I I I ' It

( ~,. 

Component 

H2 

N2 

CO 

Ar 

CH4 

C02 

H2 S 

cos 

O2 

Total Dry, lb mol/hr 

H20 

Total Uet, lb ~ol/1~ 

To~al, lb/P~ 

Pressuce, pB~a 

T~mperatuze, oF 

Feed Strea~s (Contd) 

Air to 

Torvex 

(lb ~ol/hr) 

3,077.9 

39,5 

m 

828.7 

3,946.1 

4~.4 

3,995.5 

87,810 

II-1.2.15-3 

63 

82 

~ash Uater 

to TatZ Gas 

~ash Column 

(lb mol/hr) 

30,595.0 

30,595.0 

551,200 

16 

100 

m 

m

,,' 

P 

Component 

H2 

"2 

CO 

Ar 

CR4 

CO2 

~2S 

COS 

O2 

Total Dry, lb mol/h¢ 

H20 

CH30H 

Total Wet, lb mol/h¢ 

Total, lb/;~¢ 

Pressuce, psia 


Shifted 

Syngas 

(lb mol/hr) 

i i lira 

73,392.8 

508.2 

12,819.8 

166.4 

196.6 

733.3 

Trace 

Trace 

87,817ol 


m 

4.3 

87,821.4 

563,490 

760 

82 

Unohifted 

Syngas 

(lb mol/hr) 

i i 

23,359.5 

304.8 

27,880.3 

m 

101.2 

122.7 

3,4~0.2 

Trace 

55,248.7 

3.0 

55,251.7 

995,830 

IZ-1.2.15-4 

766 

82 

i ii i i i 

ii i , i 

Total 

5yuaas 

(lb mol/hr) 

96,752.3 

813.0 

40,700.1 

267.6 

319.2 

4,213~4 

Trace 

Trace 

143,065.6 

m 

7,3 

143,072.9 

1,559,320 

760 

S2 

Acid Gas 

to Claus 

(ib mol/hr) 

0.6 

119.7 

0.3 

Trace 

Trace 

3,331.7 

2,273.7 

62.8 

5,788.8 

m 

6.0 

5,794.8 

231,450 

25 

92 

m 

! 

m

, .,. , ~.,,, ,...,,,,,.,,..,,..,..,,.,,, ,. 

product Strqamo (Contd) 

J, i .i .,= ii . . • • . . = 

Total Waste- Water from 

Tail Gas water Wash Column 

Component (lb mol/hr) (lb mol/hr) (lb mol/hr) 

H 2 5.0 - - 

N 2 11.624.0 - - 

co 35.5 - - 

Ar ~.7.7 - - 

C~4 5.6 - - 

C0 2 58,354.2 - 19.9 

H2S O. 1 - - 

COS 0.3 - - 

02 ..... 360.2 - - 

T~tal Dry, lb mol/hr 70,432~6 - 19,9 

H20 

CH30H 

Total Wet, lb mol/hr 

Total, lb/hr 

3,511.4 327.7 27,480.9 

1~6 0.2 14.0 

73,945.6 327.9 27,514.8 

2,971,680 5,910 496,420 

Pressure, psia 16 46 17 

Temperature, °F 145 279 65 

II-1.2.15-5

C,,. 

f 

,, 

" 

B. Prouess Selection Rationa!e 

The selective Rectisol process as offered by Lotepro 

Corporatlon is a commercially proven technology. Its capital and operating 

costs are lower than costs for other processes examined, For th~ Gasoline 

Plant, the proces~ has been configured into four identical trains. The 

water/methanol separation is configured into two t~.ains. This arrangement 

provides flexibility and a high turndown ratio. The licensor guarantees the 

process performance and utility consumptions. 

1. Pressure. The higher partial pressure of CO 2 and 

H2S in th~ feed gas results in increased absorption races and solvent 

temperature rises i~ the absorption columns, reducing the solubility of acld 

gas components in the solvent and requiring a higher solvent circulation. A 

cold solvent presaturated wlth C0 2 minimizes the solvent circulation rate, 

There are a number of Eectlsol plants that operate at higher pressures than 

this plant will require. No problems are antlclpated related to system 

pre s sure • 

2. Gas Impurltles. Impurities enter the gas purification 

,~t in the feed gas stream and are produced in the unit by side reactions 

with ciz~ulating solvent. 

A sldestream of spent methanol ~s continuously distilled 

in a methanol ~ractlouat,~r thst will remove all dirts and dissolved 

i~purities via a bottom waste stream. 

3. ,Malntenence and Operation Characteristics. In the 

Rectieol process, hydraulic turbines are not required to recover energy; it 

makes use of fewer rotary machines and vessels compared to competitive 

processes. Therefore, its maintenance cost will be lower than the maintenance 

cost required for other processes. Also, the Rectisol process should be 

somewhat easier to start up, operate, and shut down. 

II-1.2.1.5-6 

I p

4. Variations in H2S Concentration. The sulfur content 

of the coal may vary from 2.3 to 5.1 weight percent. The concentration o£ 

sulfur compounds (H2S ÷ COS) present in the feed to the gas purification 

system may vary from 1.3 to 3.3 volume percent. In order to avoid large 

variations in B2S concentration of the ~eed going to sulfur recovery unit 

(~'htch may vary from 25 to 40 volume percent if not controlled), the gas 

purification system must be flexible enough to separate the correct amount of 

CO 2 and produce a constant composition £eed for the sulfur recovery unit. 

The Rectisol process achieves this objective by 

adjusting the amount of CO 2 in the vertt stream In a stripper/reabsorber 

column as discussed In the Rectlsol process descrlption. 

5. Equipment Availability. Equipment availabillty Is 

defined as the ratio of days each piece of equipment Is available to operate, 

whether operating or not, to days in a f£xed period of tlme (usually the 

period between two planned major overhauls). 

The Rectisol acid gas removal process uses conventional 

equipment, simple In design. The availability of equipment in the systems is 

better than 97%. 

6. Proven Technology. At least nine plants employing the 

Rectlsol process have been successfully constructed and are being operated in 

the United States. Table II-1o2.15-1 shows the list of the plants, plant 

capacities, and other process variables. Many other plants that utilize the 

Recttsol process are operated outside the Ur~ted States. 

C. Process Description 

Refer to Process Flow and Control Diagrams D-34-MP-1NP, 

-2NP, -3NP, -4~P, -Sh~, and -61~P for the acid gas removal material balance. 

The equipment arrsng ,~ent ie shown on Drawings D-34-PD-1NP and -2NP. 

II-1.2.15-7 

I

\ 

Customer 

Texaco I~C. a 

Wilmlngron, California 

Texaco Inc. 

Montebello, California 

Table XI-1.2.15-I - List of Rectisol Units 

~ustalled in the United States 

Feed Gas 

Order (14HSCFD) 

1965 

1966 

Borden Chemical Co. 1966 

Geismar, Louisiana 

Roan& Haas Co. 1966 

Philadelphia, Pennsylvania 

Brooklyn Union Gas Co. 1968 

Brooklyn, New York 

Long Island Lighting Co. a 1969 

Holbrook, New York 

American Air Liquids 1969 

for Monsanto 

Texas City, Texas 

Celanese Chemical Corp. 

Clear Lake, Texas 

Syngas (Dupont U. S • X. ) 

Deer Park, Texas 

aTurnkey ProJ eet 

i .i i • | • i 

1975 

1976 

80.0 

(H 2 rich gas 

from P.O.) 

0.90 

(a 2 rich gas 

from P.O.) 

17.0 

13.0 

12.0 

53.0 

(H 2 rich gas 

from steam 

reformer) 

(H 2 rich gas 

from P.O.) 

(H 2 rich gas 

from P.O.) 

11-1.2.15-8 

PreaBure 

(psig) 

460 

1,100-2,500 

300 

340 

340 

600 

340 

425 

840 

ni~f! ...... --rll 

Components 

Removed (vol Z) 

i i i i i • 

CO 2, H2S 

C02, H2 S 

C02 

C02 

CO2 

C02 , H2S 

C02, 

10.2%--20 ppmv 

C02, H2S 

CO2, tt2S 

(2 stages) 

. 

i

_ . . . . . . . . . . . . . . _ . . . _ . 

1. H_2S/CO 2 Removal. The shifted and unshifted feed 

gases that are supplied to the Acid Gas Removal unit in separate streams are 

injected with methanol tc prevent the formation of ice and hydrates as the 

gas is cooled down in Heat Exchangers 34-01-1301 and 34-01-1308 against 

purified product gas and cold tall gas. After s~paratlon of the condensed 

methanol-water mixture ~n Knockout Drums 34-01-1201 and 3/t-01-1205, the 

shifted gas enters Shifted Gas Methanol Wash Column 34-01-1101. The unshlfted 

feed gas enters Unshlfted Gas Methanol Wash Column 34-01-1104. Both streams 

wlll be washed with methanol, 

In the upper part of Shifted Gas Methanol Wash Column 

34-01-1101, C02 is removed to the required level with cold lean methanol 

from the warm regeneration section. In the bottom section of Column 

34-01-1101, H2S + COS is absorbed down to O.1 ppm. In order to minimize the 

temperature rise in the lower section caused Ly the heat of solution, a 

spllt-sUream of CO2-1oaded methanol from the CO 2 wash section of the 

absorber is used for sulfur removal. The heat of solution for the 

CO 2 absorption is removed by temperature rise of the downstream flowing 

methanol and by cooling the methanol In Exchanger 34-01-1302 against 

vaporizing refrigerant. 

As the solubility of CO 2 in methanol is less than the 

solubility of H2S , the methanol flow of the CO 2 removal section o£ Wash 

Column 34-01-1101 must be greater than to th~ H2S removal section. The 

methanol surplus from the CO 2 removal section of the tower is taken from 

the middle of the column. 

The uushtfted feed gas in Unshifted Gas Methanol Wash 

Column 34-01-1104 is washed with cold lean methanol. The purified gas leaving 

the top of the column is warmed in Unshifted Feed Gas Cooler 34-01-1308 and 

then combined with the purified shifted gas. The heat of solution is removed 

by warming the solvent and vaporizing external refrigerant in Methanol 

Chiller 34-01-1309. 

1I-1.2.15-9

.::.', : ,,, '..',, ;,', I lJl ...[ 

The H2S-loaded methanol from the mhe H2S-loaded methanol from the m 

34-01-1101 is routed to Recycle Gas Flash D~m 34-01-1203~ Recycle Gas Flash Drum 34-01-1203, 

at an intermediate pressure to recover dlssolved 1{2 anressure to recover dissolved 1{2 an 

from ~rum 34-01-1203 Is recycled by Recycle Gas Compressor s recycled by Recycle Gas Compressor 

feed gas. 

The same procedure is used £or the he ~ame procedure is used £or the 

from Column 34-01-1101~ which is expanded Into Drum 3~1, which is expanded Into Drum 3t 

£1aehed gases recompreseed by Compressor 34-01-1801. seed by Compressor 34-01-1801. 

The H2S-loaded methanol from thehe H2S-loaded methanol from the 

34-01-1104 Is flashed in Recycle Gas Flash Drum 34-oed ~.n Recycle Gas Flash Drum 34-C 

dlssolved I{ 2 and CO to be recycled vla Compressor 34-0P be recycled via Compressor 34-01 

from Drum ~4-01-1206 is flashed in the sump of CO StrlppinlS flashed In the sump of CO Strlppln 

to remove the bulk of dissolved CO. dissolved CO. 

2. CO-Rich Tail Gas. To limit the CO ~-Rich Tail Gas. To limit the CO ¢ 

gas, a CO-rich gas is generated by expanding separately t~enerated by expandlng separately tk 

from Flash Drums 34-01-1202, 34-01-1203, and 34-0~-01-1202, 34-01-1203, and 34-01 

34-01-1106. The C0-rich tall gas leaves the top o£ CO Lch tall gas leaves the top o£ CO 

34-01-1106. After warming in Exchanger 34-01-1301, it Isrmlng in Exchanger 34-01-1301, It is 

catalytic Incineration before venting to the atmosphere, before venting to the atmosphere. 

3. H2S ' Enrichment. The methanol from tzS Enrichment. The methanol from t 

34-01-1106 vtll be fed into HRS Concentration Colum~d into H2S Concentration Colum: 

increase the B2S concentration :l.n the tall gas feed to~entratlon in the tall gas feed to 

removal process, CO 2 is stripped from the vent ~tream in 3 stripped from the vent ~tream in 

of the column, and H2S Is rewashed In the upper ~ H2S is rewashed In the upper 

sulfur-free methanol from Drum 34-01-1202 not used for re~om Drum 34-01-1202 not used for re 

36-01-1106. 

The tail gas from Column 34-01-1102~e tail gas from Column 34-01-1102 

sulfur-free, The gas is warmed in Exchanger 34-01-1301, an1 warmed in Exchanger 34-01-1301, an 

the methanol content ls reduced in Water Wash Column 34=01-) reduced in Water Wash Column 34-0!-: 

• ~ | rl ,,i 

II-1,2.15-10 II-1.2.15-I0

t 

i 

I 

tl 

At an intermediate tray of Column 34-01-1102, cold 

methanol is withdrawn and used as refrlgerant in Exchanger 34-01-1307, To 

provide the necessary head, Pumps 34-01-1503 and -1504 are used, 

4. Warm Regeneration. The methanol from the sump of 

Column 34-O1-1102, now enriched in H2S , is pumped by Cold Stripper Bottoms 

Pump 34-01-1507 through Heat Exchangers 34-01-1310 and 34-01-1311 to Methanol 

Regenerator Column 34-01-1103. The complete desorption of H2S and CO 2 

from the loaded methanol will take place here by means of methanol vapors, 

generated In Regenerator Reboiler 34-01-1313o 

The vapors from the top of Column 34-01-II03 will be 

cooled in Water Cooler 34-01-1312 and then in Exchangers 34-O1-1314 and 

34-01-1315 against the cold H2S fraction and refrigerant, The condensate is 

separated in Separator 34-01-1208 and routed back via Cold Stripper Bottoms 

~:'~ 34-01-1507 to the regeneration column, The E2S fraction leaving Drum 

34-01-1208 will be warmed in Exchanger 34-01-1314 and will leave the tmlt as 

feedstock for a Claus sulfur recovery plant. 

The regenerated methanol leaving the sump of Column 

34-01-1103 is cooled In Regenerator Bottoms Exchanger 34-01-1311 to ambient 

temp. :ature and buffered in Methanol Collection Vessel 34-01-1207 before 

being pumped to the methanol wash columns for shifted and unshlfted gas. Zts 

temperature is lowered in Exchangers 34-O1-1310 and 34-01-1307 against cold 

loaded methanol. A small portion of the resenerated methanol is injected into 

the two feed gas streams, 

5, Methanol-Water Se~aratlon. The condensate from Drums 

34-01-1201 and 34-01-1205 that contains a mixture of methanol and water is 

heated in Reflux Cooler 34-01-1317 and fed to Methanol Fractlonator 

34-01-1105, where methanol and water are separated by distillation. The 

column is heated by means of medium-pressure steam in Methanol FracCionator 

Reboiler 34-01-1316. The methanol vapor from the top of Column 34-01-1105 

ll-l,,2,15-11 

m

I i I I I I III'I~mUEmlEMI~ 

/ 

will be routed to the hot regeneration, while the water is withdrawn as 

waste. The reflux supplied to Coluem 34-01-1105 is regenerated methanol from 

Column 34-01-1103, pumped by Pump 34-01-1509 and cooled in Exchanger 

34-01-1317. 

6, General. In order to reduce the methanol losses, a 

methanol slop system is provided. Zt consists of a buried main methanol 

header wlth branch connections to all pieces of equipment where leakages of 

methanol can occur. 

The methanol header wlll collect such leakages Into 

Methanol Slop Drum 34-01-1210, also buried. Vertical Pump 34-01-1511 Is 

installed in order to recycle the solvent to the regeneration section of the 

unit. 

Storage Tank 34-01-1211 is used to store methanol° A 

fllllnE pump Is provided. The tank is used to collect methanol streams during 

plant shutd.wns. In such eases, when the methanol is not pure, It is made up 

through the regeneratlou section. 

D. Risk Assessment 

J 

Shifted and unshifted raw feed gases are treated in the 

Rectlsol unit for the removal of C02, H2S , COS, higher hydrocarbons, gum 

formers, and other impurities that are produced in the coal gasifler. 

Crude gas, saturated wlth water vapor, will he indirectly 

cooled by cold purified gas and external refrigeration. Icing will be 

prevented by the injection of methanol. The gas then enters the first 

absorber, where sulfur compounds and CO 2 will be removed to the required 

le~rel by washing the raw feed gas with cold methanol, The overhead from the 

absorber column is routed to the methanol synthesis unit, and the rich 

methanol from the absorber bottoms, after flushing and heating, is 

regenerated completely in the H2S regenerator. 

II-1.2.15-12 

P

m II 1 I[[ , ~ . . . . I II ~ 

Although methanol is classified as toxic and flammable, 

these potential hazards are controlled to acceptable levels of safety by 

application of standard method~ for pl~nt design a~d operational handling. 

This plant wil! be the largest installation of its kind in the world. Thus, 

it is important to examine some of its ~tak factors and evaluate the process 

reliability. 

I. Capacity. The large capacity of the plant will not 

cause any processing problem. In order to avoid mechanical and installation 

problems, the system is designed in four parallel trains, 

2. Integration With Other..,Processin~ Units. The Rectisol 

process has not been ol~..rated in conJuction with the Texaco Coal Gasification 

Process. However, it has been used in conjunction with a different coal 

gasification process producing gas of similar composition in a plant in South 

Africa. The operation of the African installation has been satisfactory, and 

there is no reason to believe that the performance would be different in the 

W.R. Grace & Co. project. 

3. Equipment. The Rectisol process uses equipment of 

simple and conventional design. In certain parts of this system, spiral wound 

exchangers are used. Lotepro Corporation has used spiral wound exchangers of 

comparable size and duties in its other installations without mechanical or 

operational difficulties. 

4. Pressure. There are several Rectlsol acid gas removal 

Installations that operate at higher pressures than the 790-psla pressure 

required for this project. Pertinent information accumulated from the 

experience with hlgh-pressure Ina~a!latlons Is incorporated into the final 

design of this project. 

The risk of designing a Rectisol acid gas removal 

process~lth a feed rate ~f 2 billion scfd at 790 psia has been reduced to a 

low level by attention to the detailed engineering design and accumulated 

know-how from other installations. The llcens~r guarantees a plant 

availability of better than 97X for the Reotisol section of the project. 

IX-1.2.15-13 

,, ,,t ,

t, 

~4 B. ,Process 

Balance) 

Unit 34 are as follows: 

Flow and Control Dia~ram. (Including Hatorial 

Proco88 Flow and Control Diagrams for Acid Coo Removal 

Drawin~ No. Title 

m 

D-34-NP-INP 

D-34-HP-2NP 

D-34-MP-3NP 

D-34-HP-~NP 

D-34-1fl ~'-SNP 

D-34-MP-61~P 

PFCD Acid Gas Removal - Methanol Wash 

PFCD Acid Gas Removal - Gas Separation 

PFCD Acid Gas Removal - Hethano. 1, Cooling 

PFCD Acid Gas Removal - Methanol Wash 

PFCD Methanol Storage - Methanol Storage 

Material Balance - Acid Ca8 Re.oval 

II-1.2 • 15-1~ 

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34-01-1107 

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~OLr'~UEHTSHOrd~THISDR&IlleC: 

34-01-1105 

34"01-131& 

34-O1-1401 

D3414~lIP. I)GA 

I " LLS, I)F..P/~TMENT QF ENERGY 

~s~rr WJRr, ORACE & CO, 

B.P.D. P ANT 

co,w.- TO- - TO- OnSOU L 

I; 

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STREAM RAMS SH[FT(D 

FEEOGAS 

¢OI~POHEH7 ~L. WT. LO-WOL/HR MOL 

Hz 2.016 i8~587.0 51.61 

Hz 29.016 • 126. 5 0.3G 

CO 28.010 3205.1 9.00 

Ar 39.948 43. 1 0.12 

CH I 16.042 53.6 0.15 

CO l 44.010 13~443.! 3T. 23 

HiS 34.08Z 351.7 1.02 

COS 60.076 3°0 0. OI 

0~ 32.000 

SUBTOTAL 35~E25.1 IOO.OO 

H~O 

m~e, 

18,016 

~2.o4 

,,. 53.2 

TOTAL 39,678.3 

Pr PS[A ?90.0 

T t °F ' I00 

STREAU HUMBER 

STRBd4 RAME ACID GAS 

TO CLAUS 

COLmO;4ERT MOL. NT. LB,.MOL/HR MOL 

He 2.016 0.2 O.OI 

flz 28.015 29. 9 2. 07 

CO 28. 010 O, I O. Ot 

Xr 3~'. 949 TRkCE O. 9 PPMV 

CH" I 16. 042 TRACE I. 3 PPit,/ 

¢0| 44. 010 832. 9 57. 5'~ 

HzS 34. 062 560. 4 39. 28 

COS 60.076 15.7 1.08 

p.oe 92. ooo 

SUBTOTAL 1,44T.2 IOO. 00 

HzO 18.016 

CHsOH 32. 04 I. 5 

tOTAL I. 448.7 

.P+, PS~ 24. T 

T. °F 92 

r + tlii 

I 

]~1 _1 i I 

.__i+l.. i 

$11[PTEO UHSHtFI EO UNSH]FTrn 

SYNGAS FEEDGAS SYH-GAS 

LO-~L/HR MOL ~ LEO-MOL/ER MOL 7. LB-MOL/HR MOL 2 LB- 

18, 348.2 83.57 5p818,0 36,15 S, 835. 4 42.28 2~ 

127. I 0.58 77.3 0.46 77,5 0.55 

3205.0 14.60 T~ 116.0 43;61 li, 970. I 50,46 I( 

41.6 0. 19 2G.0 O. IG 25.3 q~. 19 

49,2 O. 22 32.3 0,20 30.7 0.22 

I 

185.3 0.64 2.891.5 17.61 070.1 8,30 

TRACE (0. I PPI, IV 20G. 8 1.27 

TRACE 12. 8 O. 08 TRACE 

21,554,4 I OO,_~ 16,241.1 

24. 3 

I00. O0 13,813.1 100.00 3. c 

I.I 0.8 

.21,595.S 16,265. 4 131813.g )4 

7(0. O 790. 0 765. 8 

82 |00 82 

WASTC WATER AIR TO TORVEX WATER TO TAP_ 

GAS WASH COLUMN 

LB-MOI./HR I I,(OL ~. LB-MOt/HR I MOL 7. LB'-MOL/HR MOL Y. 

TE9. 5 78.00 

9.+ Coo 

207. 2 21.00 

986.6 ! IOPL O0 

15. 9 99. 97 12. 4 7649. 9 I OO. O0 

i ' 

L~ 

.W.,,m,-- 

"[.55 

~.4~ 

~.i5 

~22 

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r 

TOTAL 

SYN-OA~ 

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t4.!e8. I 

203. 3 

lOb!T5.0 

EG. 9 

79. O 

[Tr, xc~ 

TRACE 

hB 

35,010.3 

1'50. 0 

62 

LOAOED WATER 

~A FRO~ WASIf ~LUI~I 

z LS..~O.,,~ 

*T.S~ 

0,57 2~ 153.8 

28. 45 

0.,i9 

0.,22 

2.94 

too ool ~o :s3oe 

SIRIPPZNO 

GAS 

2, 163, B 

23. 9 

62 

u~.z 

TOTAL TAIL GAS 

100,00 

I00. O0 

~ LE-~IOL/;4R HOL ~ LB-HOI../I',R HOL Z 

62 0.01 

2. 506.0 16.45 

.... 8,9 0.05 

1 65 0.01' 

I,t 0,01 

S.O 14.$88.5 82.86 

F. Plot Plan/General Arransement DrawlnEs 

Removal Unit 34 are as follows: 

Plot Plan and General Arrangement Drawings for Acid Gas 

Dra~rlng No. Title 

D-34-PD-INP 

D-34-PD-2NP 

Plot Plan - Unit 34 Acid Gas Removal 

Elevatlon - Unit 34 Acid Gas Removal 

II-1.2.1.5-15 

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F I U.S. DEPARTMENT OF ENERGY KENTUCKY 

I--BASKETT W.R. GRACE & CO. 

50.000 B.RD. 

t COAI~- TO - METHANOL, ,,TO - GASOLINE PLANT 

" pLo~ ~N ~1" ~;-I~,8;" I'\~I • 

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follows: 

O. si.gle-Line Diagram 

The Single-Line Diagram for Acid Gas Removal Unit 3~ is as 


D-51-EE-7NP One-Line Diagram- Unite 34 and 39 

II-1.2.15-16 

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I U.S. DEPARTMENT oF ENERGY 

BASKETT W,R. GRACE & CO. KENTUCKY 

~, 50.000 B.RD. 

COAL "TO - METHANOL- TO - GASOLINE PLANT 

ACtD GAS REMOVAL U-34 ~ ''" 

leRocm~ ~ATER r~n~. u-~9| D-5 I-EE- 7NP I/-e:~ 

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1.2.16 SULFUR RECOVERY (CLAUS) - UNIT 36 

The Sulfur Recovery Unit (SRU) is designed to convert the sulfur 

compounds in the acid gas £rom the Acid Gas Removal (Reetisol) Unit to 

elemental sul£ur, which will be recovered as a salable product. The tail gas 

from the SRU is £urther treated for the removal o£ the remaining sulgur 

compounds iu the Sul£ur Removal Unit be£ore being vented to the atmosphere. 

Two parallel, 50% SPJ3 trains are provided. 

A. Basis ,of Design 

The quantity of acid gas from the Acid Gas Removal - Unit 34 

requires that two parallel 50% SRU trains be installed. This arrangement 

requires less field £abrieation and provides greater operational flexibility. 

The £ollowing Reed and product stream data summarize the normal operating 

condition information £or the two 50% plants. 

Feed Streams 

Total Acid Gas 

Component (lb mol/hr) (mol%) 

H2 0.59 0.01 

CH 4 - _ 

CO 0.34 60 ppmv 

C02 3,331.73 57.55 

N2 119.67 2.07 

A - - 

H2 S 2,273.71 39.28 

COS 62.80 1.08 

Total Dry, lb mol/hr 5,788.84 100.00 

Total, lb/hr 234,490 

Pressure, psia 25 

Temperature, °F 92 

II-I. 2.16-1

C Product Streams 

Component 

Tail Gas (end of run) 

(Ib mol/hr) (mo1%) 

H 2 67.14 0.88 

C~ 4 - _ 

CO 130.90 1.71 

CO 2 3,199.96 41.75 

N 2 4,142.12 54.05 

0 2 - . 

H2S 79, 32 I. 03 

COS 2.28 0.03 

SO 2 39.74 O. 52 

$6 O. 34 440 ppm 

$8 2.10 0.03 

m 

Total Dry 7,663.90 100.00 

H20 2,514.08 

Total Wet 10,177.98 

Total lb/hr 311,960 

Pressure, psia 18 

Temperature, °F 280 

|,, 

II-l. 2.16-2 

Sulfur Product (end of run) 

(lb mol/hr) ~molZ) 

m 

i 

m 

m 

m 

70,430 

274.54 

274.54 

1 

274.54 

65 

290 

I00.00 

I00. O0

B, Process Seleetlon Ratlonale 

The Claus sulfur recovery process is universally used 

throughout the world for bulk recovery of sulfur from acld gases containing 

hydrogen sulfide (H2S) . 

An alternative method of recovering sulfur from such gases 

is to manufacture sulfuric acid. However, handling, storing, and shlppiug the 

quantities of sulfuric acid generated by this plant would be much more 

difficult than marketing the smaller quantity of sulfur, 

Hydrogen sulfide could be converted directly in a Stretford 

unit but with considerably higher Investment and operating cost. The largest 

Stretfcrd unit in the United States has a design capacity of 52 ltpd compared 

with up to 1,200 ltpd in the acld gas from the Acid Gas Removal Unit, 

C. Process Descriptio~ 

The purpose of the sulfur recovery unit is to convert the 

bulk. of the sulfur compounds In the aeld gas from the Acid Gas Eemoval Unit 

to elemental sulfur. This conversiou is accomplished by oxidizing ~uurnlug) 

one-thlrd of the H2S In the acid gas to SO 2 with alr, The SO 2 will then 

combine with the remaining two-thlrds of the H2S to form elemental sulfur 

and water vapor in accordance with the following reactions: 

H2S + 3/2 02 

2H2S + SO 2 

H2S + 1/2 02 

so2 + s2o 

3S + 2H20 

S + H20 (Overall reaction) 

These reactions create temperatures high enough to sustain 

the reaction thermally, and they will continue to equilibrium. The thermal 

reactions are followed by three catalytic reaction stages to complete the 

reaction to practical limits. 

II-l.2.16-3

( 

%. 

The acid gas enters the plant through Acid Gas Knockout Drum 

36-01-1201 to trap entraP.ned llquld. The feed stream is metered after passlng 

through the knockout d1:um. Airflow from Combustion Air Blower 36-01-1801 is 

controlled to malnta.ln a 2:1 H2S to SO 2 ratio in Reaction Furnace 

36-01-1401. The scld gas feed to the reaction furnace is preheated with 

600-pale steam and is burned with the combustion air. 

The hot gases from the reaction furnace are cooled first by 

generating 250-pslg steam in Reaction Cooler 36-01-1301 and then further 

cooled by generating 50-pslg steam in No. 1Sttlfur Condenser 36-01-1302. Most 

of the sulfur formed in the reaction furnace is condensed in the No. I 

condenser from which it flows through a sulfur seal into a sulfur pit. The 

cooled gases pass through a wire mesh coalescer for removal of entrained 

sulfur and flow to No. 1Reheater 36-01-1307. In the reheater, the process 

gas is heated to reaction temperature with 600-pale steam. The process gas 

then enters the first converter, where the reaction to form sulfur from H2S 

and SO 2 will continue. The reaction is exothermlc and heat Is generated in 

proportion to the amount of sulfur produced. The hot process gas Is cooled in 

the No. 2 condenser by generating 50-pale steam. The condensed sulfur passes 

through a sulfur seal and into the sulfur pit. The cooled process gas passes 

through a coalescer for the removal of entrained sulfur. 

The second and third stages are slmJ.lar to the flrst stage 

(each comprising a reheater, converter, and condenser/coalescer). The final 

condenser produces 15-pslg steam to cool the process gas as low as is 

practical. The other condensers produce 50-pslg steam. 

The tall gas from the flnal condenser is sent to Sulfur 

Removal Unit 37 to remove the remalnlng sulfur components. The sulfur 

recovered is collected in a rundown pit. From there it is pumped periodically 

to sulfur ~torage tanks. The sulfur in the sulfur pit contains H2S and 

polysulfldes so the pit vapor space must be swept wlth a." to prevent the 

evolved H2S from buildln E up to a potentially explosive concentration. 

II-1.2.16-4

The sulfur pit vent gas then is treated in the Sulfur 

Removal Unit for removal of the H2S. 

I. Flexibility and Turndown. Turndown of each plant to 

one-third of design capacity is possible with standard instrumentation. 

Features provided to give turndown flexibility are: 

measurable extent° 

(a) Metering and control valve rangeabillty; dual 

transmitters or other facilities are provided for 

turndown to 20% of design capacity. 

(b) The air blower is vented to the atmosphere to 

prevent surging. Automatic antlsurge control is 

provided. 

Turndown normally will not affect sulfur recovery to any 

2. Startu~. The SRU is started up by burning fuel gas 

with excess air on a cold startup with either fresh catalyst or catalyst that 

has previously been stripped of sulfur. This procedure allows the plant and 

catalyst beds to dry out and attain normal operating temperatures before 

introduction of acid gas feed to avoid corrosive conditions. ~en an acid gas 

flame is establlshed~ the fuel gas is shut off° 

S~artup on a warm plant or catalyst that has not been 

stripped of sulfur 18 accomplished by burning fuel gas substolchlometrlcally 

as described under "Shutdown." 

3. Shutdown. Fuel gas will be burned substoichio- 

metrically with steam to strip sulfur from the sulfur-laden catalyst beds and 

to sweep out acid gas reaction products. 

II-1.2.16-5

- ~ - , ~ . , - , ~ , . , ~ ,,,, ,,., °= ,,.,..,,,I..,,,,..,,_, ..... 

Ii 

t ~ 

D. 1~/sk AsSessment 

~ ~ 4 e*4~glU pJOIg ~ ~tQt rf~ f~n~ ~ ~*q~ ~ ~ i ~ ~t ~ ~ ,~6.4~ ~ ,~, i et ~f ~I ~4 * Jgp~i~ O m~w,i ,~ je ° . . . . 

Unscheduled emergency shutdown of the sulfur recovery unit 

can occur because of loss of the air blower, loss of flame in the reaction 

furnace, loss of boiler feedwater, or high-liquid level in the acid gas 

knockout drum. Unscheduled shutdown also can occur because of excessive 

condenser or converter fouling or e blocked sulfur drain line that builds up 

pressure drop over a period of time. 

In ~his design, two nominal trains are provided as well as 

spare air blowers. Each train handles 73% of the gas flow for the normal 

operating condition case. High-liquid level in the knockout drum can be 

prevented by proper operation of upstream areas. Many of these Claus units 

have been operated successfully for years without unscheduled shutdown. 

The modified Claus process is proven technology, with 

hundreds of units £n commercial operation. This process meets the Best 

Available Control Technology (BACT) Standards. The prime criterion for 

selecting a sulfur recovery system £s to meet the environmental restriction 

imposed by BACT. W.tth the BSRP ~ulfur removal unit, it also meets the Lowest 

Achievable Emission Rate (LAER) Standards necessary for nonattaimnent areas. 

The construction material is primarily carbon steel. From 

many years of engineering, procurement, and construction of these units, 

select vendors and fabricators are to be used that have proved their 

equipment for reliability~rlth a minimum of maintenance. The availability of 

equipment for this unit requires a nL~u~numo£ lead time. 

Sulfur recovery units are considered highly reliable 

operating units with a minimum of maintenance required. 

II-1.2.16-6

E° ,process Flow and Control Diagrams (Including Material 

Balance) 

(Claus) Unit 36 are as follows: 

Process Flow and Control Diagrams for Sulfur Recovery 


D-36-MP-1NP 

D-36-HP-2NP 

D-36-MP-3NP 

PFCD Sulfur Recovery (Claus) - Reactor 

PFCD Sulfur Recovery (Claus) - Recovery 

PFCD Sulfur Recovery (Claus) - Recovery 

II-1,2.16-7

A 

4 

C 

• . 24"AA-3G 

[ "~l ~'- Z'-kt-3G 

wsx[ ~TEn 

ACre OA5 FErn II40RmL) 

lEACH 1RA~H) 

COGENT MOL, WT, LB-UOL,'H+ 

H| 2,016 0.3 

n| 2I.OIG ' 59. P$ 

CO 28,010 O. ,S 

C0/t , ,lq.0io t~SS, C'; 

HIS '34.082 1135.65 

COS 60. O'lG 3 I. 40 

TOTAL 

e, ~. 

ZO~, 40 

24.+ 

T+ "F ~2 

I ~ I ~ I 

START-STOP 

CONTROL 

SET • 

15 PSIO I 

3G-0H20I 3G-OI-13GG 

ACZO GAS K.O, OIIUR ACtD~A~IT..R R~CTIOM FURKAC[ 

(I I) 

]6-OI-IS01 

3K'Ol'lSOZ 

FXGURE 4-Z 

24"-AA-36 

J 3G-01-120._.,.__II 

~ 1. 24"-A-3G-| 

36-01-1801 

36-01-1802 

3~-0t-150.__.__/ ~-01-1|01 

36-01-1502 

COMBUSTION AiR 

A~ ~a~_ BLBIER A~) SPARE 

__ NOTE 2 24'~U..3G.] 

I- 6oo eszo $T(X. -: I-"I 

24~.AA-35-I 

36-01-1401 

-t! 

g 

PU£L GAS 

2"S-36-][ 

wl 

A" 

i ¢OMPOHleNT MOL. liT. LIS-.laOt../Kfl 

HI 2.01G 71.31 

CH, 1(,.012 IS.SO 

N z 28.016 13.45 

1:01 44.010 "9. ,¢1 

CO 21.010 q.?T 

AR 3~. $45 4. 23 

CH1011 32-04 0.4'1 

ET ILII~ 30. O? I. 53 

ETHYLENE 2|.0S O* 13 

PROPt'LIENIr 42.01 0.23 

I:'I~MI[ 44. 011 5. 4 I 

|SO'3UT&ME 58. I Z O. IT 

H-BUTA~( $8.12 O.O'J 

N-'BUT£~E 54.09 0.~ 

[SOP(ITAN( 72.15 "I 

N-P;NTAN I:" 72, IS .,~O*OT 

I'-PENTE](E 5O. 12 

0.12 

0.03 

TOTAL 

e. ps,,A 

'129.15 

m 

T, °F 90 

++ : , __+_LL_L~ ! 

I 

,.+x-.+ ~ . ~ ' . 

.

,,,, ,. +,' ,,,.., , ;. ',' +. +,, .'., ' , , ,+ , , 

~,-01-1301 

35-01-I ~02 

' ~ 

R~I, CTI011~F R , 

SET e 

. ZB5 PSIG 

~..:~ I m' ~ ,r" I 

/ 

l 

3G-01-1202 

i " ~ ip ~ . ~ :3"..S=31;-! 

+IT ' 

~F'-DI-I~i)I 

e:t_ ~ 

? 

E] 

ll.31 

13.q5 

.. 9.61 

: s..__.~2. 

" 4.23i 

0.13 

O, IT 

; o,_,...~oe 

.°. 

O. I~ 

5 , I + O 

3G'-'JUL-~I-! 

5ULRJB/ kO, i CON~f.~g ..... 

4a"S'3G'I 

BF'IK/ UNIT StJOHEADER 

3~'S'36"I 

GOO PSI ICOla)ENSATFJ OONOENSE~S 

~+', 

I 

I, IgE I'QUIPgENT SN0WN ON THIS ORAW'IMG ARE 

FOIl OHE OF 1"10 1RAIIt.", 

|, ~[11[ FOLLOWIN0 [OU]PMENT ARE NOT SlIOtlN WITH 

FURIIACB 

-.-p- ,o, ,tmn.mv .u~. ,o.', 

~1 - I- 403 AUX~[ALfly BURNER No.3 

]4~ -1404 AUX'[LIJ~Iy OURN~R NO,3 

3, IX[ IPIOURE I(t,fgOERS REFER TO TYPtCAL 

(I}UIPMEHI'$ COHFXGUHATIOflS SllOiH (~Z4 

ORA~NG D"OI-MP-2 liP, 

[OUST SHOIII ~ TH',S D~IIIHGs 

3G*Ol-t201 

~5-01-1202 

3G-01-1301 

3G-OI-130G 

~$-01-1401 

~11-01-1501 

~G--OI-15OZ 

3&-'01-1801 

31-01-1803: 

' ~-- O3~MPUfP, CGA 

-- U.S, DEP~eIRTI'4EHT OF ENERGY 

- ~ ~ ~ ~ ~ . ~ I i | net l,,. CmL - +o- ram,No, - T,o.- oAs~mE ~ANT_ ,~ 

,:::++: +++-: r +°+++++ +--izi 

, ~ n ,^~.~. m,,~..,. I ,m.msEcm, | O-~G-M~-I .r 

'+ I + - . ' I 

A

A 

4 

C 

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I D-36"~-I I~' 3G'-AA-3G-! 

" SLILFUIPREAOTZOH FUP, KAC( 

_4~ 

h ~ 

:..-.... 

q 

-P--~-' 

., ,,~,.,..,.~ ,,','~:~' ,'.~!B'~ ~, ~,'~,~.'~,~.r ,"~'~*.~ ~*.,,'~).' I.% .;~.*,~i '".''~'~"" '::~ ' ~i~,":(';"~,l~'.~"~!:'.',; ~, '~,, 

3G-OI-130B 

3"-U-3G-] 

I0"-R-36-'I 

3G'-'AA-36-% 

G'-S'ZG-! 

3'-AJ-36-T 

I"-R-36-% 

3'-'.___.S-3S-Z 

( ) 

I -~ I 7 

600 PSIG S1T.AII 

3G",-AA-3G-! 

SULFUR OA~ NO, 3 COHDENSER I u"~t'r'= ~' 

SULFUR/ ~iULFUR p I T ~ 

BLOIO01~ H ~ O E R ~ 

600 P~G COHDEA~.dt, TE/REH~'I"r..ll D.-3,S-.1~3 NP 

O)61P21(P. OGA 

IIOTE~ 

I, THE (QUIPiI(ttT $HOIM OH THIS DIU, IIIHO Aflr 

FOR ONE OF 1110 TRAINS. 

~, |lie F|GUnE RIAtSI~S REFER TO TYPICAL 

~!J~l~ ¢ONFZGURAT%0/i$ SIIOW~t OH 

Dl~lll[i~e D-OI-MP-Z I~, 

w.~.~ ~ co. 

EQU~N(NT SHOYH ON TH]$ ORAWIHGz 

36-01-1203 

3li-01-1204 

3G-01-1302 

3G-Ol-1303 

~G-OI-130T 

3S-Ol-13011 

...... ~ C(3~1... - TO - HETHANOL - TO- GASOL]NE PLANT 

~,~.,~,~o~. l ~,,®~:i-,-,2 

#. PNISGNS 

I I, 

IcE~nJcKY 

D 

# 

~ , ~i~_

~" A 

¢ 

D 

' 

I I , 

+ I m I a I 

- 600 i"510 ST[AM 

~D'3£'IIP-2 NP n 3"U'3G-| 

n 600 PSI0 5"T[AM 

[~., . . . . .~m.-n-+6-t 

IO'.-R-3G-I 

v n ~o~ms~ 

LD'36-MP-2 lip ~. 36"~A-36-I 

--'SUL?*IJH qAS~ ¢OIIVERTE~ 

~.~0-36-UP-2 HI+ ~6"S-36-! 

' B.F.~./ sr~u Imuu 

..... ~ SULFUR 

L~.-,:, ~' 2 " ~ I~R'3G'! 

m,., OLO~a 

i I ~ -L~s "IPtlON 

~£-(I- I'q04 l[ 

"60Q PSIG L"OI4DEHSATEf 5"TEAu DROU 

D"iL_ I D~"'~ " | L "^'o"c'~ 

~:l llznei 1 I 

set • 

50 PSiG 

+ 

Z6-01-1304 36-01-1369 38-01-1205 

Xo, 3 COHOEH~[R ..Ho, 3 REHEATER. Ho,~l~n 

q 

,P 

A 

2 

DATZl BY 

36"-AA-36-I ~ ~ 

-D--~-- 

i n 

36-01-1309 

36"-~-36-I 

36"01-1205 

( 

"q6-OI- 1305 

! 

,+, 

i 

I" 

!, 

" ,T" 

~L cj~L,~,q ~.'1,~ ~1 ~ _..- 

I 44' 

,.o

~ ; m , 1 d, 

+,,~r+ . +,,,,,+.,+,~ .'I,,++,, '+,',+ • ~'+, .,++t ;+',+' L"+.!,,++ P',I ','), i . , '*+ '. M.+, ,,.* ~+, 'o'. , , ',' ~ ........ ' ""* ..... I , ,,+,':, " ;" '* + 

_ IL , ....... I 

3G-O1-4101 

:::'~ 36"'01"1305 SULFUR PIT" 

-- MO. 4 P.,OHOElt~f~ • 

.. I ~ 

I 

® 

10'-R"~"I 

15 I'SIO ST£AI, I IR.JWE~ --- [] 

A:II. GAS~ RI:nUC1NG GAS G~IM 

! B,F.~ ItF.J~B --- 

311-.01-111ttl 

31"01-1 I10'1 

ir+ - 

t 

I I 

I I 36"O1o4101 

~---,-,+_j 

~o-01-1803 ~'OI-t503 

l',-llo3r~l ~ i1--1 

BLOIgOIM HEADER - 

2"-AA-36-! 

4*,.-AJ-3G-I I P..~T-IP-IP IP) 

I SULFI~ ....... 

I..~_ "F i ~++ I 

Lk~. +m~ ~ ~t I 

0 I 7 

HOTESl 

li. THE F|CUJlP ~U~,~I~R s ItEFLPR TO lttPlCkL 

(QUIPMEflT L+uI(F~UR4TIO/4S SH01111 BI DRAIIIMO 

O'OI-MP-I' IP. 

[OUtPIi~T SHOIIH ON TIOS ImX~H~ 

36"01-1205 3G-01-1504 

36-O1-1304 )~'-01-lO03 

3G-01-1305 36'.'01-1804 

34;',-01-130g ]0-01-4101 

31;-'01-1S0) 

~.01~ AI~ SPARE+ 

l)31;~m', I~ 

I U3. ~PARTHENT OF ENERGY 

E 

~ 

• 

~ 

- 

" 

• .Pm~-. REsmnt -~"'--- 

~"'1:~.~.. I 

~ 

I~'~J '+' 

mm~'tt V.II.ORACE & CO. mm¢~ 

5e.g~ B.P.i). 

I COAL- TO- HETI-I.,~NOL - ~O- GA.S~D~IE F)I-I~IT .... 

I roll PJ t~ts'T ,my i,v~ 

I FOR CLIENT ~ ~-vz w +u.~o~oi t.u I'~P-,~ I l 

4~ ~. I I I~ ++,'.~,,~'~...cm, lm~Im m.m,u, +~+,,.- / ~., - . . . . . . I 

I s e I 

---'--'--" I 

A 

"2 

D

f .,, 

\. 

F. .Plot PlanlGeneral ~rrangement Drawings 

Plot Plan and General Arrangement Drawings for Sulfur 

Recovery (Claus) Unit 36 are as follows: 

Draw£n~ No. Title 

D-36-PD-INP 

D-36-PD-2NP 

Plot Plan - Unit 36 and Unit 37 SRU and BSRP 

Elevation - Unit 36 and Unit 37 SRU and BSRP 

TI--1,2.16--8 

~;,~ ~: ~:~ .

I 

,I .~ ....... ,' , ' "' ' ~.' ,;" ' %" ,,":1': ....... 

I 1 ' I .................... 2 ' .......................... "i '~ *''*~''''' .............. 3 I 

--I ' 4~ 

A 

ii. 

, 

j!- 

L 

~j 

I 

|~, 

iJ 

I F - - - - - - - - 

--I 

@ 

N 

I 

I 

I 

I I 

_ i 

I I I 

.:-..~- "~ . . . . . . . . . . . . • .... "'1" - "'"-, "1"" 

. . 

• -'=1- 

. 

. . 

. 

. . . 

- ....... 

. . . ... 

"'T" 

_~ 

"'--.-." 

. . . . 

"'f" i 

L~IIT PiP[WAY 

I I l I I 

I ! l I I t I 

I 

w 

I 

J_~ 1_ 

l...l.l Ij..l I I l I, l

" "' I ' 

mm~P 

I 

I I 

I 

Jl I 

I I I -~3 

C/L ROAD if AREA LlUlT H. I0, 305'-0' 

-'EE~ 

--EE~ 

I 

T 

d~ 

t I 

+ 

! 

5 

L 

+ 

I 

I I 

I I 

I I 

I I 

.................... ...~.0 ,~ o,___,~_~ --~ ....... .......................................................... 

. . . . . . . J k _ _ _ k - ~ l ~ ~ I _ _ ~ . . . . . . - . . . . . . I p - - I 

I 

I 

I , 

~ ° ~ ° ~ 

) I I . . . . . . . . . . . J - ~ IlL, _ _ -- , l . . . . . . . . l -- I 

n, 

~ k p ~ O V k L | m~ a,c~T ~ N~l 

rl~R el iElc]r _~t~ ~F~fI~lV |a~vnl~euuo~J ~j 

" ~lt~m'lr ION | ~a.,.w e ¢~.zmmr J 

! 

C/L ROAD & AREA LIMIT N, 99?5'-0" 

I 

_J 

.i,l.,,~ - THE ~ H, PP,/ZSQ~ CCL~/~t' J ..... UNITsRu3GPLOT PLANANDAND BsRpUNIT 37 ~---'=;:'zo' Z "m D :36 1~43--" -PD . - I NP' '-~le2" r,. 

pP.S/~F-HA* CAL1FORN I A 

s I 

0 I0 20 40 GO 80 

ZCkLEJ I ° • ZO'.O" 

I U.S. 0EPARTMENT OF ENERGY 

BASKETT ~l~.J~ GRACE & C~ =ENTLk."ICY 

59,BOB B.P.O. 

COAL - TO - HETH~OL - TO - GASOLINE PLANT 

e I 7 

A 

u 

D 

E 

m 

~,~!.!,.~;~:~;!i!i'~ 

:~:!~~i ~I~: G.! 

i: ~ ~.~'~

A 

D 

, ~.~`~.~"~*vv~"v~w~i:r~rn~.~:~.~?~i~.~:~:~.:~:~ ~ .. ,~.~ ,., ,.~. , ,,,-'.L, -.,,,,.,,' .... ,z.~,, ",,,,',. ,~,~'.'-:.-~,~,~f','~',,..,...'~., I":"' ,' ,r'," ", ,.' .,., ',,~.I~: ~'"t,," " ,, 

E 

, ........ - I ~' I ~ I ,4~,

13 

%, , , 

§ 

n , I 7 

, m m m 

' im '~ 

'lP" .IJFlr 

t U.S. DEPARTMENT OF ENERGY 

W~SK~r W.R. GRACE & CO. KENTUCKY 

'~1".: t-,- I I ~rp, coAL- TO- M~.ANOL- TO :pASOL,NE P~.T 

J I 

/,~ ~.,,~r ~ ,~,~ I--'----I i THE RALPH M. PAK|ONS COMPAIIY UNiT .I;~ ~ uNtf 57 p*.,~.~-,,..-- 

;J ~,n,o. sRu ~,'~ ~sP.P / D-36-1:O-?.He 

l~a =LNm.V I ~m~'.(.~ ],t-,to r,..~ I PASAOI[NA. C, kLIFORNIA 

m • 

I 

A 

D 

JZ/.

0 

is as £ollo~s: 

G. .Single-Line Diagram 

The Single-Line Diagram for Sulfur Recovery (Cleug) Unit 36 

Drawin~ No, T~tle 

D-51-EE-8NP One-Line Diagram - Unite 36 ~d 37 

I1-1.2.16-9

A 

C 

D 

~T 

i. 

1 

I.,j 

I 2 I 3 

BU~ 37"OIOIR 4160V 

JP'OPqS02 

6000/~500 ~VA 

J4.4 BV- • 

4.16 KV ¢ 

Z.,SX 

34,5XV 3#.~V 

~S 51-OlOar ~$ s~-ozoar 

I I 

J6"OI'4$OZ ~ J6"Ot-4[OJ 

t~O0,'2000 KW *~= v., v~ t500/2000 XV4 

z.e~ U, / 

" , ~ ~ G . ~s~--.-~ , Z-eX 

[..*WL.G.O. : _":~.~,,n~ | INOl,:,*,z B',' : ~c ,RoJ CUtNT 

I 2 I 

2 

,~ILFUR~ReMOy~, 

BU5~ 36-0201R 

3 

iioo, 

1"01"4~01 

'3 

~l-O~OBr 

~ J#,q RP" 

4.16 /t~' 

Z,,IX 

~. ~.. 

vl~t m 

,xr It.-.'. k~l:~' 1 ....... 

i "'P

4' s I e " "" : 

( IPOI'4IOI 

I 

.pIx 

• _ B~ 37"020lR 4160V _ . 

~ ~ j 

• ~ ja 

~oo 

I. I~OVtO r. ,~t. KWH. #ErtRS aT a?.t. 

I.OC4rlOt~$ #41I&ED • 

F U.S. DEPARTMENT OF ENERGY 

KENTUCKY 

I ~ ~ ~BASK~ W.R. GRACE & GO. - 

I ~ - ' - ' ~ ' - ~ ~ ~ 50.000 B.RD. 

I ~,,r,, ..... --- -," COAL.TO-METHANOL'TO'GASOLINE PLANT 

.... ;. / 

° ......... ~ ......... ,.~.ALP.. , o , .... ! O~ ~l~ O AC~ r ;;o~&J ~6oo [~ a21 

~ . ,rvr .... HP,,It,,~,,,, .... life RALPH M. PARI;0~S COMPANy I ;UU~JR RECOVERY UNIT U-3G p,,r., . . . . r. ,.,,,r~ I,/~ 

• °~-,i~,,. -~.. ...... ,,.,o~.,,c,~,o~., " IREK7-~suU~mOvAL PL~U-~7 / U-~l-,','-ol'~r I ~ 

t 

A 

m m

, ~J g~elnl~01Nq g JPe~t ql~Wqml e~ ~P W I ~ 4, I ~ ~n~ p ~ ; ~lJ~ 

1.2.17 SULFUR REMOVAL (BSRP) - UNIT 37 

. . . . D qmt,,Nll PW ~'l ~r '~l tn n.4 ~t i , 4~ le g Bt~ ~, Dq t tt Mg,e , ,r q~ ~, e ~ w p w iIjl ~ t jp~ ~f ll,l 

The Beavon Sulfur Removal Process (BSRP) has been selected to 

remove sulfur compounds (H2S P S02, COS, CS2, an~ sulfur) from the tail 

gas o~ the Claus sulfur recovery plant - Unit 36. The Bcavon Sulfur Eemoval 

Process is a proprietary process licensed by The Ralph H. Parsons Company and 

the Union 011 Company of California. 

The size of the two Claus sulfur recovery units requires that 

two pars/lsl trains of BSRP be provided. The major gas stream to be treated 

is the Cail gas stream from each Claus sulfur recovery unit, but a smaller 

stream of sweep gas from each sulfur storage pit also is treated. 

The treated gas is discharged to the atmosphere from the top of 

the absorber. The gas will contain less than 10 ppmv o£ H2S and less than 

100 ppmv of total sulfur compounds measured as SO 2 o 

A. Basis of Design 

The large amount of tail gas from each Claus unit requires a 

separate hydrogenation train for each stream. With this arrangement, the 

operator has the advantage of being able to tell from the H2S and ~2 

enalyzers in the tail gas unit how each Claus unit is operating and maintain 

better control of the operation. Two trains allow the desuperheater/contact 

condenser and the absorber column diameter to be within Parsons previous 

experience. Two trains of Stretford regeneration provide turndown flexibility 

with considerable power savings under turndown conditions. 

The total design capacity of both tail gas trains is 

71.81 Itpd of sulfur from 135 million scfd of tall gas. The hydrogenation and 

gas sc~ubblu E sections operate at less than 3 psl 8 pressure. 

II-1.2.17-I

The materlals of construction are carbon steel and 

sulfur-reslstant concrete, with stainless steel beln E used in areas of high 

turbulent Stretford solution flow and elevated temperature sulfur melting, 

expertise o 

The size of the equipment is within the range of Parsons 

Some undesirable side reactions take place Ln the Stretford 

solution. These reactions result in the formation of sodium thiosulfate 

(Na2S203) and sodium sulfate (Na2SO4) instead of sulfur. These 

salts ere quite soluble and can be allowed to build up to about 25Z total 

dissolved salts. If allowed to build up beyond that, co L'rosLon rates 

increase, regeneration rates decrease, and crystallization of 

Na2SO4"IOH20 (Clauber's salt) may occur in colder sections of the 

unit. The formation of these salts requires that the sodium associated with 

them be replaced. This Is done by the contlnuouu addlt~on of a small stream 

of caustlc. 

The decanter overhead stream contains a small amount of 

solution to remove salts from the system as fast as they are belng formed. 

The 2~7 anthraqulnone dlsulfonlc acid (ADA) and vanadium lost in dlscardlng 

this stream must be replaced perLodlcslly to maintain the recommended 

concentrations in the solution, i'h.~s is done by dissolving the powdered 

cbemlcals in Strctford solutlon in a~ agitated chemical mlx sump ~ud pumping 

the solution to the balance basin. 

II-I o2.17-2

( 

< 

q 001m0gWt ~e t * I~I ~mm O Nin nP H ~ IP 4 *f rl II 

Component 

R2 

Cll 4 

CO 

C02 

N2 

02 

ll2S 

COS 

SO2 

S6 

S8 

Total dry, ib mol/hr 

H2o 

Total wet, Ib mol/hr 

Total, Ib/ht" 

Pressure, psta 


Feed Stream 

Tall Gas From Claus 

(lb mol/hr) (molZ) 

67.14 0.88 

130.90 1.71 

3,199.96 41.75 

4,1~2.12 54.05 

79 • 32 I • 03 

2.28 0.03 

39.74 0.52 

O. 34 440 ppmv 

2.10 0.03 

7,663.90 100. O0 

2,514.08 

I0,177.98 

311,960 

18 

280 

"rZ-1.2.17-3 

J 

Sweep Gas From Claus 

Sul£ur Storage Pit 

(Ib mol/hr) (tool%) 

i 

194.30 78.79 

51.66 20.95 

0.64 0.26 

m 

m 

246 • 60 100 • O0 

7.62 

254.22 

7,250 

16 

280 

m

Componen~ 

H2 

CO 

CO 2 

O2 

B2 S 

COS 

Total dry, lb mol/hr 

H20 

Total wet, lb ~ol/hr 

Total, lb/hr 

Pressure psta 


Component 

Sulfur (S I) 

Total dry 

B20 

Total ~et 

Total, lb/hr 

Pressure, psla 


Treated Streams 

,if i 

Treated Gas to Atmosphere 

(lb mol/hr) (moil) 

103,04 1 • 16 

8.60 0.10 

3,506.06 39.47 

5,212.10 .58.68 

51.66 0.58 

0.09 10 ppmv 

0.42 50 p~mv 

8,881.97 100.00 

1,010.74 

9,892.71 

320,660 

15 

117 

I I I 

¢ 

Holten Sulfur Product 

(lb mot/hr) (molZ) 

.... 139,80 

139.80 

139.80 

4,480 

18 

280 

"rI-I. 2 • 17-4 

100.00 

100.00

.° 

C 

Component 

, ~ g ~ * ~ Q t ~ O I'*tq'~m~p~g~t4'~,,#l'#~/e~q A ~ t ~ a ~ N l ~ t , ~ ~ f ~ , , ~ l ~ , ~ o t ....... 

Solution Purge Stream 

(Ib/day) (~¢g) 

ADA 24 0.034 

(2,7 anthraquinone 

disul£onic acid) 

Vanadium 48 0°067 

NaHC03 292 0,407 

Na2S04 1,128 1.570 

Na2S203 2,510 3.497 

water 67,770 94.425 

Total 71,772 100.00 

B. Process Selection Rationale 

The Beavon Sulfur Removal Process was developed in 1970 and 

1971 by The Ralph M. Parsons Company with the cooperation of the Union O£1 

Company of California. The first commercial units were started up!n 1973. 

Since that tint, more than 50 units have been built or are being built. Most 

o£ the operating units achieve an onstream factor of over 95Z and at least 

one was onetream continuously for more than 2 years between rurnarounds. The 

units have met and exceeded environmental requirements virtually all the time 

even duringupsets of upstream units. At the present time, it is considered 

not only Best Available Control Technology (BACT) but also Lowest Achievable 

Emission Rate (LAER). ~ is ef£ective £or both stronE and weak actd gas. 

The BSRP is capable of handling 2-1/2 times the normal 

operating condition rate of H2S for short periods (2 co 3 hours) if the 

composition of the solution is matntatned~rlthin recommended ranges. 

11-1.2.17-5 

! I I i I

I 

Turndown is usually limited by metering and control valve 

rangeabillty on the air and gas to the tail gas heater (reducing gas 

generator). This is about 20X of design. Since there are two trains, the 

overall turndown is about 10Z. The use of two trains is advantageous in 

reducing power requirements on turndown to loss than S0Z to 60Z. Having one 

hydrogenation section for each Claus unit allows operators to monitor the 

operation of each unit through the H2S and H 2 analysis of the reduced gas 

of the appropriate BSRP and thereby obtain much smoother and efficient 

operation of the Claus unit. Each tail gas unit is started up and shut down 

~n co~Junutlon with the sulfur recovery unit preceding it. Essentially no 

sulfur compounds will be released to the atmosphere at any time, 

plant downtime will be rare. 

is required. 

All pumps and blowers are spared and maintenance requiring 

No unusual lead time for equipment or material procu.cement 


Eefer to Process Flow and Control Diagrar, s D-3?-MP-INP, 

-2NP, -3NP, and -4NP for material balance. 

The Beavon Sulfur Removal Process consists of two basic 

sections. The first section catalytically converts essentially all of the 

sulfur compounds in the Claus unit tail gas to hydrogen sulfide. This is 

called the hydrogenation section. This is followed by the Stretford section 

where the H2S is absorbed in an alkaline solution and converted to 

elemental sulf~ir particles. 

I. Hydrogenation Section. The sulfur recovery unit tall 

gas is heated to reaction temperature by mlxlng it in Reducing Gas Generator 

37-01-1401 with the products of combustion of fuel gas (normally natural gas) 

11-1.2.17-6

.C 

!!r i 

and air. The fuel gas is proportioned to the air rate so that combustion 

takes place with only 80Z to 90Z of the air necessary for complete 

combustion. Th~ air rate ~s controlled by the temperature ¢,f the mixed gas 

going to the reactor. Steam is added to the flame t~ promote clean burning 

and to prevent carbon formation. The steam flew i8 proportioned to the fuel 

gas flow. Some hydrogen and carbon monoxtde a~e formed to supplement that 

already in the tail gas. This provides an excess of reducing gas to ensure 

conversion of the sulfur compounds in the tail gas to hydrogen sulfide over 

the cobalt molybdate hydrogenation catalyst. 

Mater vapor normally present hydrolyzes COS, CS2, and 

CO to H2S and hydrogen in Reactor 37-01-1201 according to the following 

reactlonsz 

COS + H2O- " H2S + C02 (I) 

CS 2 + 2H20. L 2H2S + CO 2 (2) 

CO + H20 " H2 + C02 (3) 

according to the following reactions: 

Hydrogen will react with SO 2 and sulfur to form H2S 

S02 + 3H2 " H2S + 2H20 (4) 

S + H2 ~ H2S (5) 

All of the above reactions are exothermic, causing a 

temperature r~se through the catalyst bed. 

The gas from Reactor 37-01-1201 is cooled by exchange 

with boiling water in a water tube boiler, Re,etor Effluent Cooler 

37-01-1301. Steam is generated at 50 psig and the gas cooled from 725°F to 

about 330°F. The gas enters Contact Condenser/Desuperheater 37-01-!101, which 

is separated into two sections; the bottom section is called a desuperheater 

section. The gas is contacted with an alkal£ne solution descending through 

II-1.2.17-7

disc and donut baffle trays. The alkaline solution absorbs any SO 2 that may 

be $n the gas caused by upsets In the Claus unlt operation. The aenslble heat 

in the gas evaporates water from the alkaline solution end cools it 

adiabatically to its dew point of about 170°F. The alkaline solution Is 

circulated over the baffle trays by centrifugal pumps 37-01-1S01 and -1502. 

The pH of the solution is measured continuously and an alarm warns of a low 

pR. If the solution pH falls below 5 because of 50 2 in the tall gas, the 

deauperheater circulating solution and the condensate in the contact 

condenser section become very corrosive and can damage the equipment In a 

short time. The llquld level in the desuperheater is maincalned by the 

automatlc =ddltlon o£ condensate from the upper section of the column, the 

contact condenser section. Caustic is added whenever the pH gets low. 

Tb~. contact condenser section Is separated from the 

desuperheater section of the column by a chimney tray. Two bubble cap trays 

In the deauperheater section prevent entrainment of alkali from the 

desuperheater. The bubble cap trays receive the condensate makeup that 

~m!ntains the desuperheater level. 

Most of the water ~n the gas Is condensed in the contact 

condenser section by dlrecc contact with cooled condensate in a bed of 2-inch 

stainless steel pall rings. The condensate is cooled by circulating it 

through Solution Heater 37-01-1302 against a stream of Stratford solution and 

then through Contact Condenser Cooler 37-01-1303 against cooling water. The 

gas is cooled to 9S°F. The condensed water is routed to battery limits. It 

~r~ll contain some absorbed H2S. 

2. Stretford Sectton. The Stretford process is based on 

the ability of vanadium when in the five-velent state to react with H2S 

that has been absorbed in an ~lkaline solution, forming elemental sulfur. In 

this reaction, the vanadium is reduced to the four-valent state. Ox~dation of 

the Stratford solution with air returns the vanadium Co the five-relent 

state. Vanadium co=pounds ate Incapable of reactlngdlrectly~rlth the oxygen 

IT-1.2.17-8

I I 

~ r ~ p ~ l N e t , 0 I~ 

in the air. For this reason, ADA is used as an oxygen carrier to transfer 

oxygen ~rom. tha air to the tetravalent vanadium° 

The cooled reduced tail gas from Contact Condenser 

37-01-1101 contacts with Stretford solution in a venturi scrubber that 

discharge0 into Absorber Evaporator 37-01-1102. There are three 36-inch 

v,enturi scrubbers in parallel discharging into one absorber for each train. 

Each venturi has a 20-foot-long by 36-inch-diameter tail pipe; 4,434 gpm of 

Stretford solution is c~rculated Co each venturi for contact with one-third 

o£ the gas. The liquid and gas separate in the bottom of the absorber. The 

gas is further contacted with 3,326 gpm of lean Stratford solution in two 

packed beds of 3-inch stainless steel pall rings in the absorber. The gas, 

which contains less than 10 ppmv of H2S and less than 100 ppmv of total 

sulfur (mainly COS) measured as S02, is discharged from the top of the 

absorber to the atmosphere. 

The upper bed of pall rings in the absorber is used as 

an evaporative section to evaporate water from the Stretford solution to 

maintain the system water balance. The Stratford solution going to the cop 

bed is heated by exchange with the circulating condensate of Contact 

Condenser Desuperheater 37-01-1101 as mentioned previously or in 

steam-Jacketed sections of the eirc,,lating piping. Thts hotter solution heats 

the gas and saturates it with water° The water made in the reaction and used 

to replace the solution from the centrifuge cake is removed in this manner. 

The reduced Stratford solution flows from the absorber 

by ~av£ty to Reaction Basin 37-01-4101, which ensures enough time for the 

elemental sulfur to form as particulates; from there, it passes through a 

series of three oxidlzer basins. In the oxidizer basins, air from Oxidizer 

Air Blowers 37-01-1802/1803 is sparged through a proprietary turboaerator, 

which disperses fine air bubbles throughout each basin. The reox£dised 

solution flows to a pump basin called Balance Basin 37-01-4105, from where it 

is pumped to Venturi Scrubbers 37-01-2201 and Absorber 37-01-1102. The air in 

the oxidfzers not only reoxidizes the solution but also causes the sulfur 

II-1.2.17-9

"" } 

, ' I .~..,.~, o.,~,,,.,,o,,, I I.-J----t-..l__l..~_~_i ..... I ~ f ~ l ~ , u'-~' 

, i I ~ ,fl, tl , ~ rg i 0 J t ~ r . . . . t P t i q i ~ i 

particles Co float Co the surface. From Chert, they are aklm~ed Co a slurry 

basln as a 5Z Co 15Z by weight sulfur slurry, 

The sulfur slurry is concentrated to a 50% to 50% sulfur 

cake in a solid bowl scroll discharge let Centrifuge 37-01-2202. This cake is 

repulped with process water co about 25~ sulfur slurry in Agitated Repulp 

Tank 37-01-1901, The diluted slurry is centrifuged to a 50Z to 60Z sulfur 

cake, vhlch again is repulped in a 2nd Repulp Tank 37~01-1902, This tlme the 

water is a cooled stream from the Decanter Overhead Tank 37-01-1903. The 

resultant slurry (about 4OX sulfur) is pumped into Sulfur Melter/Decanter 

37-01-1304 equipped ~rlth a U-tube steam exchanger bundle. The vessel operates 

under about 55-pale pressure and is heated by 50-pslg steam. The slurry Is 

heated to above the melting point of sulfur and the molten sulfur and water 

separate. The sulfur is drawn off the bottom undez interface level control to 

Storage baeln 37-01-4108; from there, It is sent periodically to loading or 

is mixed ~£th sulfur from Claus Unit 35. The water phase is mixed with a 

cooled stzea~ of decanter overhead water Co prevent flashing and is routed 

through a backpressure control valve that will maintain the system pressure 

to a surge tank. Decanter Overhead Pump 37-01-1513 circulates the decanter 

overheads through DecanUer Overhead Cooler 37-01-1306 for cooling against 

coollng water and then to the second repulp tank to quench the decanter 

overhead stream or to the puree stream discharge. 

D. P~skAssessment 

At recommended concentrations of chenicals, the Stretford 

solutlon used to absorb H2S from the tall gas is capable of absorbing up to 

two-and-a-half times the design rate of H2S for 2 to 3 hours vlehout 

releaslngdangerous concentrations to the atmosphere. Here than 30 Beavon 

Sulfur Removal Units are la operatlou removing sulfur from the tall gas of 

Claus units to below I00 ppmo 

Loss of combustion air to the reducing gas generator does 

not require an immediate shutdown of the unit. The residual heat in the 

II-1.2,17-10 

V

( 

~Q 

C_ 

o I s 

refractory au.d catalyst bed allows several hours for reltghting the unit. 

Oxidizer air failure does uot require an immediate shutdown o£ the unit. The 

lares inventory o£ solution allows 1 to 2 hours to correct the problem. Both 

the c~buation and oxidizer air blowers for each train are spared by a common 

spare blower. 

Loss of circulation in the desuperheater does not require an 

i~nediate shutdown. Some units oporate continuously without a desuperheater. 

Loss of circulation in the contact condenser circuit does not require an 

immediate shutdown. The lack of heat ~cmoval will gradually heat up the 

Stretford solutiou, but this can be tolerated for several hours while the 

problem is helu E corrected. The desuperhQater pump and the contact condenser 

pump for each train are spared by a counnon circulating pump. 

A large sulfur slurry basin is provided for each train so 

that any problems with the slurry handling, concentration, and melting 

equipment can be corrected without a shutdown of the tail gas unit. All 

slurry pumps are 100Z spared. 

Loss of Stretford solution to the venturis and absorber for 

each train requires an immediate shutdown of both the Claus sulfur removal 

unit and the tail gas unit. There are two circulating pumps and a 50~ spare 

for each train. There is one BSRP train for each Claus sulfur recovery train; 

each is designed to remove 36 ltpd of sulfur from the tail gas of that train. 

IT-1.2.17-11

E, Process F10w and Control Diagrams 

(Including Material Balance) 

Process Flow and Control Diagrems for Sulfur Removal (BSRP) 

Unit 37 are as follows: 

Drawiug N¢o 

D-37-MP-11~P 

D-37'-~-2NP 

D-37-MP-31~P 

D-37-MP--41~P 

Title 

PFCD Sulfur Removal (BSRP) - Reactor 

PFCD Sulfur R~moval (BSRP) - Recovery 

PFCD Sulfur Removal (BSRP) - Regeneration 

PFCD Sulfur Removal (BSRP) - Common Equipment 

II-1.2.17-12

A 

C 

D 

FUEL GAS 

COtFOHENT, UOL. ~. LO-UOL/~R 

H~ 2. 016 206.37 

CH t 16,042, 47.76 

R| 2e.ole 30~R9 

CO I 44,010 ~'1. 81 

,CO 20.010 i li.¥o 

AR 31oe49 IZ,~ 

CH~OH 3Z. 04 I. 3S 

D'II* KI: 30?OT 4,41 

ETHYLENE 20,05 ....... O,,,3 T 

PROptLEHE 42.00 0,6? 

PROPANE 44,09 IS, 66 

,,ISOOUT~HE S8,1Z 0,49.....~ 

~nUrA~( 5a.12 O, ZG 

,-.UT~[ S4,0~ " 9'~JL._ 

L~...~ENTAHE 72:15 } 

.-re,TR,[ ~z,~s o.~9 

Z'PEHTEHE Go, m2 

CG 0.34 

5"? O..On 

?O~AL 37..3~eo 

P, PSfA SO 

T. ~F 9D 

] 4"-R-37-Z 

L.P. STEAM 

{" 0-36-J~-3 N,a~ 3G'-AA-37-] 

TAIl. GA~CLAUS I 

iJ 

I ONAWINQ NO. 

37-01-1801. 

COMPOHEItT I W TAT[. UAS " 

. I~. LE/It B 

S0e I 69,0| ..... 

Re I 28.01 2. Q'I I, 05... 

Se 1192,. 31 - "- 

- 1396.5 ':" ":' ': 

~o. , ~.o n.sg§;sp_ 

HI I 2.011 33~5~ r 

CLI I 28.0 59, q5 

COS I 60. 0 . . . . 

~. ~',i.~; - 

~O'raL WET I s, OO~ ~ 

I~f i 30. G? , ~,.~ 

,,, ~CFlf ,. -~,,i. 

P'~($5. PE.]A I 

ACFS I . 

37-01-1601 

co~eusrxo______~N 

AIR BLOWER 

~ m 

D[$CRIPTION DRAWING 

1 

3 

37-01-1401 

~EOUCXHG GAS 

GEHERAT.._...~ 

4'-A-3T-Z 

4"..R-3?-x , 

I a I 

~__ , v ,,,,,,.,,, 

s'~.o~.~o, ~'t.o~-~oz :rt-oz.z~oz :','~-oH0oz 

$1'Ek, DIIUM REACTOR REACTOR EFFI.UEHT ER/ 

COOL_._.£,'( 

29, OT I&fJTLVIm 

6ESUPERIIEA~ 

[ 

IL 

37-01-1401 

E 

] 

40'-kk-37-! 

o ! 

3T-Or-1301 

I I-120_.._.____~1 

3T-.O 

]G'-AA-3?-] 

31-01-1501 

3T"Ol-*1502 

DE~JPERHEAI'ER 

PUUP Ik SPARE 

5PARE L~ CO.ON 

lITtH CONTACT 

CO~)ENSER PU~ 

37-ol-tlo_....._._._..ji 

[ .-.~lm 

411, 

q,i ~* 

,JI vt 

(..,,,:,; 

___eL__ 

37-o___,..aso__!t 

37-01-1S0.....~Z 

FIGURE 4-2 

.... d';" 

---I " 

! 

37-01-1503 

i 3 I 4'w' 

F t' - 

t ._,n 

ilz4"lir~.-,-

I 

4~ ,, 

37-01-1302 

COtATACT ¢ONOEIISER 

"---~.~OIF.R - 

50. I'~-~-T'~HR 9,13 IA~TLVHR 

f 

I ['-~-] .Is 

I--I 14"W"31 14 14"¥'37 ~ 

L._j ~-- c.w. s, ~ c , ' C,W.R, ~ L..-I 

m I O",.AA-37 ~ J 

--{Z]- ..... --i 

r.__cLE_; ' 

~-- CAUSTIC ¢ if'-1 

-'q"0!-1503 

3T-01-1303 

5 

37 OI 1302 

31-01-130? 

,S~0~ 

"-----'~ SOUR COHOENSAT£ 

HEATER 

~. ~ ~"-~T~v,e 

t _ 0 

~IVOXIOiZEII DI.OVF.RS 

24".-AA-3T 

Ri[CIRCULATIOH GAS/AII~RnER 

8'-AA-3f 

50LUTIOi~D~,LANC[ ~,5~1 

30'-AA-37 _ 

OVERHEAD GAS/AB$ORUER 

8',-AJ-3T.! 

S~,UO~ABSO~SB 

EFFLUEHTIA~ 

;:: ~::~I ~.".~.~.EL ! L" ....... i .,o i ....... i 

~ R ~ w r w I ~ ~ ~,~ ~ ~ u_ 0o,~.,,, ,,,.,,,.... 

. ~ ~ ~ ~ ~z~ ~., ~snNs com~ 

IZT~I~. DGA 

1 7 

H01£,~ 

l, THE ~(HT SllO1iH 014 THIS OlIAHHG ARir 

FOR ~ OF TWO I~1K~ 

1. THI: F"IOUIIE 14UIZBEfl~ REFER TO tYPICAL (OIP- 

ItEaT ~NF)GU~TIO~ 5HOIH OH OflA~HO 

O'OI'LIP-I liP. 

_u 

rOU%PIIENT SHOWN OFI IHIS OU~liOl 

3T-Ol-I lot 31-OI-;30T 

3POI-120I ]7-01-140: 

37-0t-1202 37-01-1501 

37-01-1301 37-01-1502 

37-01-1302 37-01-1503 

37-01-1303 

LLS, OEPARTHENT OF ENERGY 

Kla~IRKY 

V.R. GP, a~,CE & 

fi6.888 B.P.D. 

TO - GASOLINE PLANT 

"" 5182 

PROCESS FLOW AND COHI'ROL DtAGIUII 

s~.F~ e~VAL zss~)-u,rr 3x ] D-3T-MP- I HP 

"fAIL GAS REAC10R 

(,, 

t,- 

m

A 

4, 

C 

,i 

1 I 2, I 3 I 

] |4'-AA-3T 

t 30*-AI-3T 

' . . . . . , ,,~ '? ,,', i,,,, .,p ', i ,,++i~, ,+'+,, /,, ,+ 

, ,o,,:,,~;'".'~'i,'~.;, '++,.+, ~'I'$ ~" ~,,;',,' " , . ,,,',, ~ ',, ,, ,', 

, 6 ! ' I 

,111 i i iJ i 

IT.OO-410+l ' ~ ,, ~ ll-Ol-41011 

, AoOxrim l.JtciXm~, i~L~c~ I~l!!t luu+m--l~kT'mst- "- 

I i~llf-ll )lO ,, i 

' ~ - - , , , i - - 

. .,.. 

P 

C 

D 

E~'~ PROCESS IIkTER 

[ o-:n-ur,-2 H~ 4",,AA-ZT 

SLURRY/SLUflRY OASZH 

,°,, 

+,,I' 

31,-01-1304 

"--prcANIB 

~'..'+ III OT~IIR 

o 

I 112"-AHJ-37-1 

PO~ 

I 

t ,,,,.,, o 

DECANTF.R OVERHBD/STQeA~ 

OYERllEAD/STORXGE 

[ L.,ol~oHru? J D[CANTER UI~EAFLOI| 

,, "" I LeSJ I~ 

SULFUR I ~3~I I 

• TOTAL I }-]51 I 

• SP. G~ I I "8 I 

L~F.MP. "P I 280 I 

LP~.S. esmt P~ I 

I'AJ-37-I I 

UNDERFLGWCI.AUS SIJLFLJR p~T 

3"kJ-37-I 

sut.eun/s~o~A~[ e~sm 

3"-A J-3?-I 

UN~ERFLO~b"TORAGE BASIl4 [ D-37~4 I~P> 

137~3NP.O~ 

I 

liOTEst 

t. T~ [(2LI],oWENI ' ~Ollt OK TlgS DP, 

FOR (~[ OF TWO TRAINS. 

(OUIpUF.~T R.IOWM OH THIS 9RAW]NG~ 

31-01-1304 37-01-1902 

31-01-1509 ~T-01-2202 

37-01-1S10 37-01-2203 

3T-01-1511 37-01-2407 

37"0J*1512 37-01-2408 

37-01-1901 

US. DEP~'RTHENT OF ENERGY 

AWING ARE 

T--"------------ ~ kr, R.GRACE ~ CO. m, nuc~ 

[--'-"--'-------'---- ~ 5e,ggB B.P.O. 

~mcN REe~T COAL " TO - METHANOL - TO - GASOLINE PLANT ..... i 

~ [ 

• 

4~ 

E W 

D[SCR,mO. 

'*'vo'mJN"l 

,u.v. e~.,, I 

FJC ]t~31~ 

5 

~I~gLPHN.~r,j,..~Y 

r'Jr'-"-;-,; 

P~el~EN~( CP, LTIFOR~I~ l 

pROCESSFLOI,NDcOHTROLDZAGKtu 

SULFUR R[~OVAL IBSRP)-UNIT 3T 

$OI.UTION kU,~,~TIO" | 

"HOWE 

w-,-. 

"~-37-MP-3 NP 

g, 

/

C. 

A 

4 

c 

L 1 

D-3T-1~-3 

'~' " ~" :" " ::":' "": ' ' ',~ ~i ', ..... ". ........ ,.,,: ,~,,.,,,,,~,,,,.~, 

' , I , I :' I - 

~5.~..up,. 5 ~, I I/~,-ak-]? 

SOLUTIOX PUP, G£ STREAM/ 

WASTE IIATEI~ (NOTE 3) 

~-L~ STR/PPEO COI~[IISATE 

CAUSTIC 

~['~ 50 PSIG ST[AM 

3T*01-4107 

3"1-01-4107 3T'01-1904 3T"01~t108 

C,F.UU~ m~[-UP .ST~[TFOeO SOLUIIO, .~L~[ 

[]ASIN gTOflAGE TANK ~ -- 

37-01-15i___.~5 3T-01-2409 

~ - ~ II'..AA-3T 

37-.08-1Sl8 

3t.-01-,51~ 

3T"01-1518 9-Ol-lgO! 

FIGI.~IE 5-1 

31'-01-1515 

~I(I[-UP SUI~ PUIO 

-Z40___...~! 37-,OI 

CHUIICAL ~AIC£-~ 

3T-O1-1SI8 

STK[TF~ ,~.U~ 

3?-O1-151t 

]T-01-1SI'I' 

C~MON TO BOTH TRAINS BAS]N AGITATOR S~P, AGE PL~ - ~111-1c11~ TI?ANSF'I~ 

TO ~ T~TNS euil~ k ~E 

37-01-4108 

I 2 I s I ": 

il 

R ,*, 

~: :: 

~ ._____.__...i_~

T 

Sl 

rl 

i 

:~T-OI-13~ 

-- COOLER 

TA,_._~ 4. 51 llial"--'-'~l~ 

3T"Ol -I~03 

¢"-k1~-3?-! 

SI..____.~3 

]T-OI -I 

3T-Ol-I I.__,.__~4 S 

F"IGORE 4-Z 

37"01-1513 

3T-01-1514 

OcC/,~O.O 

PL~ ~ & 5PA~E 

4"-A.~-31 

4"-11-37 

C.W.S. ~" 

4"~-3 t r-"i 

r..v.R. 

UI~'I" 3'/ 

o]'p4,4~Po ~x 

HOTEL 

I, THr ~UZPI~NT SXOWH OH THIS DP~II~.~ IS 

COt[oH TO O01H TRXI,'L 

Z, TX~ F]~'UR[ HLIIIOI~RS RUF..A TO TIPICAL 

~A c°"P~r 

o,, 

L~x,~ 

uovwTii~z~'i' x te/oA~r I 

I o.o34 z4 I 

so.. I o.~z' ,e I 

l~,SOo 

I"Q|slo~ 

~"~ 

"z'°~l I'"°1 ',"I 

zSm. tl i ),WI I Z Slo I 

,,.o, I ,,.4,~ ,T.,,O I 

[TOTAL i ~.00 TlfTt2 | 

'~I-.OI-J SOG 31'-01-I~3 

~iT','OI=l 5l] li1"01 - 1904 

3T,,'OI -I $14 31"01-Z40~ 

31-01"151'; ]?'01-4i0; 

3?-01ol51G 31-01-41G$ 

31-01-1511 

3]-01-15111 

U,S. OEP~THEXT OF EHEF-~Y 

~m~'~ W.I:I.I~tE & CO. ~ . 

~ / 5o.~ e.P.O, i 

| COAl. - TO - HETI'IAXOL - TO - GRSOL&IE PLANT ~ i 

4@ --- I I II ~-~, ~,~-" s~.r~ ~ __37 I~P 4 NP 

i s i o I i 

A 

4 

D

P 

\4 

F. Plot Plan/Ceneral At~ra~Bement Drav/nHa 

0. 

See Volume IZ, 1.2.16(F) for Plot Plan and General 

Arrangement l~av/nga for Sulfur Removal (BSRP) Unit 37. 

I1-1.2 o 17-13 

I

O. Sinslev-Line DiaKrsm 

Sulfur ~emoval (B~P) Unit 37. 

See 'Volume II, 1.2.16(C) for ths S£ngle-Line DiaSrsm for 

II-1.2.17-1&

. 

,m3t'L 

1.2.18 lmavY OASOLI,Z~,,,,,, ,ZIZ,ZIZ,ZIZ,ZIZ,Z~T'XNa ,-, uz,rX,T 38 

The gasoline produced in the methanol conversion reaction 

contains durene, a gasoline-range compound w£th n 175"F freeze point. Durene 

(1, 2, 4, 5 tetramethylheuzen~) is reduced in a Heavy Gasoline Treating unit 

to meet finished gasoline quality requirements. CaBes produced during heavy 

gasoline treating are stripped out of the gasoline stream and Bent to the 

fuel gas system. The treated gasoline product is sent to product blending. 

Treated heavy Eaooline is blended with light gasoline from the Gas 

Fractionation unit to produce a finished gasoline ~rlth about 2 wtX durene. 

A. Basts, of Design 

The HGT unit feed from the Cos FracttonationUnitw£11 be a 

heavy gasoline fraction containing durene (1, 2, 4, 5 tetremethylbenzene), 

which is reduced to a finished gasoline containing about 2wtZ durene. The 

feed and product stream compositions are indicated ~n the followt~ tables. 

Component 

Feed Streams 

HGT Makeup 

Feed Hydrogen 

(lbmol/hr) (lb mol/hr) 

Hydrogen - 316.32 

C 6 + Heavier 545.80 - 

Total Dry, lb mol/hr 545.80 316.32 

H20 - _ 

Total Wet, lh mol/ht 545.80 316.32 

Total, lb/l¢ 72,610.00 640.00 

Pressure, pets 590.0 650.0 

Temperature, °F 322 U0 

:I1:-1o 2.18-1

Fuel Gas 

Component 

C 5 + Heavier 

Total Dry, lb mol/hr 

H20 

Total Wet, lb mol/hr 

Total, lb/hr 

Pressure, psla 



, |, , , 

Heavy Fuel 

Gasoline Gas 

(lb mol/hr) (lb mol/hr) 

, , u ,.,., 

- 81.84 

589.97 

B. Process SelectionRatlonale 

iHi i 

589.97 81.84 

589.97 81.84 

71,110.00 2,140.00 

145 115 

I00 110 

The process selection of the Heavy Gasoline Treating (HGT) 

unit was made by Mobil Research and Development Corporation for the purpose 

of reducing durene to meet finished gasoline quality requirements. This unit 

is an integral part of MRDC's MTG process package° 

C. Process De.seription 

The arrangement of equipment and material balance for thls 

unit a~e presented on Process Flow and Coutrol Diagrams D-38-MP-INP and -2NP. 

1. Normal Operation. The HGT unit is similar to the mild 

catalytic hydro~reattug processes ased in petroleum refineries. The heavy 

gasoline feed from the Gas Fractionation unit is combined with a 

hydrogen-rich recycle stream, preheated iu the reactor effluent/feed 

exchanger, and enters the reactor. The reactor effluent stream is cooled with 

process streams and air before enteriug the separator. The treated heavy 

gasoline stream from the separator Is stabilized in the product stripper and 

~I-1.2.18-2

t F ~ ~ ~ t I I g ~ T ~ v ~ i tlt;~iir~rFreltl!1~:l 1111 1 ~ t J ~ r J ~ f i ¸ i i 

/ 

( 

pumped to storage. The bydcogcn rich vapor stream from the separator is 

recycled by the recycle compressor with a small purge flowing to the fuel gas 

system, 

2. .Catalyst Regeneration. Coke accumulates gradually on 

the catalyst durlngoperatlon, causing catalyst deactivation. The HGT unit 

must shut down for catalyst regeneration. Catalyst activity is restored by 

removing the coke. Regeneration consists of burning off the coke mtth a 

controlled oxygen burn. After catalyst regeneration is completed, the HGT 

unit iB returned to normal operation. 

described below: 

3. Catalyst. The catalyst required for the HGT unit is 

Type: Hobll 

Size: Inch 3/32 

Volume: ft 3 3,377 

Loading Density: No./ft 3 42 

4. Envtr.gnmental Data. When the HGT catalyst is 

regenerated, the regeneration gases are scrubbed by a tecirculattng caustic 

solution to remove any sulfur dioxide. There are no noxious emissions, but 

there is a small discharge of liquid effluent after scrubbing. No emissions 

other than minor process losses at pump valves and flanges occur durlng 

normal operation. 

D. .Risk, Ass,essment 

The HCT unit contains conventional petroleum-type equipment 

that has a high reliability from the standpoint of onstresm time. The HCT 

unit is typical of petroleum hydrotteating units in opecation today, The 

plant is designed with all pumps spared and with block valves and bypass 

valves installed around ~ontrol and relief valves. The design permits 

maLntenance on such itemu without shutdown. The operational aspect of the 

unit is similar to petT:oleu~ refSnLng facilities in present-day operation. 

II-1.2.18-3

Corrosion should not be n problem end equipmeDt fouling is not expected to 

occur. The technical risk is considered minimal, 

II-I • 2.18-4

. 

E. Process Flo~ and Control Diagrams 

(Including Mater~al Balance) 

Treating Unit 38 are as follows: 

Drawing No. 

D-38-I~-1 l~ 

D-38-MP-21~ 

Process Flow and Control Diagrams for Heavy Casoltne 

PFCD Heavy Gasoline Treat£ng 

T£tle 

Material Balance - Heavy Gasoline Treating 

II-1.2.18-S

A 

C 

E NTTROGIN IIC 

t" D'~'I "up-~' ~';~,w~o ~.,t,T 

~_4'.-B-38-I 

38-01-1401 

I ,,, ~, I ~ I 'V 

~'**A-3S 

2"-'A-31 

[-7:-- 15o PSZG 51'~g 

l~i:" SO Pb'lO S rEAg 

HC 

[3uC, ~ 

I¢¢ 

38"OI-2501 

38"01-1302A 

E OtIICRIPT~ 

r*..~ -. - ,| | iZ~rlll ~ ~ .Io. J OATI[ 

1 i --" 

IL 

38-01-1801 

_ 2"-B-38-Z 

XI 2"-B .38-X 

30"OI-IBOIT 

311"01-11~02T 

RI~rCLE 

Z 

E'-B-38 

NC 

WASTE WMEH 

i~B-3g-] 

G"B-)O-I 

~-ot-r~OtA 

IZ ~C ~ ~G~ 1 PREHEAT,.,r~ 

4'-8-38 

('-8--38 

8.'6-38-1 

( 

3;,'~:-i201 

I No l~Tt I .v (o*~s~:t,1~Ic,.~T{ , . 

m

P 

...., 

4f " I " 

II I i I II 

311.~,.130]A 36,-01-1~1 311-01-1|0~' 31,-01- rqO'+A 3B-01-1~03 " ~1-1306 

"m'm.,+m vm' ~ntPPm +,~-o,-~om .e.,em ~...PPm 

~+~+,~mmmm ,,,~m, tJu,+'--'-~m - - 

-] , 

,+,-,.__, L~oL_.. 

~e 

IASTE nTER 

-'-~-: ~-n'~ n~ ~.,~,,. 

..o 

2"A-31 

FLU£ ~P0L~xxanI~T;0N I o-sz-we-+ k~ 

Pt~E GAS ~ FUEL GAS ,'-I 

~1 ._..-o,.,., ( ) 

35-01-1301A ~ I 

"15~1-1~01D 38"01-; 

-~, ----, 30-131-1504 

3H1-1202 

~ II'-d~'31"~..01.1306 P-R-3B-I 

C~IOEN~kTE- I~ 

3l-'.'l-1103A IP-I-~0 _ r'-I 

4"-'A-3T-I 

35.-oI-I~Oe~ .L _ + 

30-01-1501 3111-~1 -1503 

3.11-01 -I 5~?. 38-'01-15~4 

I rm el~ ~AL i ~''" I I | 

PUUP STR]~ R£FI.UX 

me 

IBII ~ ~ 061elK, emt ~.~l'le'.)tl~ 

mmm~ mimml 

_-,t -- 

4 4~ ..+mu, mm. " n ...- I i IIn ,, r.'~o c~mmtA, 

Y-U-3~-I I~ 

530 l~O ~TE~ ~ 

4'-'A-~ 

,r:,~w ~so+,.te~.zs+ce.J~ I a-~'r,.~ ,e~ 

~U~M~T ~ ON THIS DRA~tNGa 

36-O1-1~1 3D-OI-I~ 

30-O1-120~ 3i-O1-13OT 

~O-Ol-I~O} ~O-Ol-130OA 

30-O1-1204 3i-01-13008 

38'-01-1301A 31"01-1401 

38"01-13018 :IIPO~-ISOI 

3~-01-130~ 31-01-150~ 

3P01-130"~ ~'01-1503 

38-01-130~ 3+*01-1504 

~6"01-130~ ~I-01-1~01T 

3~--01-1304 3|+-01-I~02T 

3S-OI-1305A =ll,-Ol-2S*~ I 

31-01-130~ 

LLS. DEP/~THENT OF ENERGY 

WJt.GRADE & CO, mnuc~ 

B.PJ1. 

CON. - TO - KETHN4(fl. - TO - C,~SOLINE PL.~TT 

~ ~ ~.mm D-3B2MP- I NP 

• I 

+: 

D

A 

. . . . ,, 

,,,,, , 

ORAWiNG NO, 

III 

1 

! DRAW|I(~ 

II 

.......... , ............... ,,.,,,,,~,,,,;.~ r;.~:, ,,','~'"''/:~,~"~!':~'::';"q.'.:~','~;"~,'~'!~'~".: ~:~;~'~;[~"~;!~?~`~/'~:~;~;~*~"~;~(t~ .... 

I :, I =, I 

~E~ w e ION 

i . 

~0. DATE 

STREA u 

ItGT 

F(EO 

MAK(-UP OFF PURGE PR00 

Hz GAS GAS 

13PS0 

5. i;os 

r~:cFo 2. sos 4so zss 

~/x~ 12.11;io 

6,~o z, olo ,]o i 

! APZ OR SG • EO°F 

o. 19 

Jill 

131.o4 

2.02 40.72 4. 12 I 

GPii 

189 

CFll 

35 

COIJPOXENT lUl 

HYDHnCEH 

2;02 o.o 

II~l.II qlkl [l~;l; 

ETHANE 

38.o7 i, 0,0 m,x,i ,i~i III ~.~, 

44. I0 0.0 

150BUTANE 5B. 12 O. 0 ' 

O.O 9.54 0.22 

H-BUTANE 5B. 12 0.0 

0.0 5. I I O. I0 

LSOPEHTANE 72. 15 0.0 

O. O 2. 54 O. OT 

H-PENTENE 12. 15 0.0 

O.O (1. iT 0,01 

2-METHYLPEHTANE e6, IS 0,0 

O. O O. 09 O. 0 I 

CE~HEAV] ER 545. BO 

O. O O. 03 (1. O I 

TOTAL ilPH 54% 60 .... 316. 31 49.131 ~Z. 47 

I .. ,, iLD;J,.rlA,~[i~:.wL!r'.~¥.~.~jFOROE~"I~ 

i C u=w P, Xl FJC FOR CL'.L~ 

6 S/ll/~ FEEt RA1 FJC ! FOR LTerl 

~, A S,,~', F,, RA~ F.JC [ FOR CL'oi~. 

8Y 3*IKD K¢ PRC~J **LIEN ncc'rmUPT ~N I NO. ,DATE IlY C)~D PIIOJ ¢;LI[NI 

~ '

, ,~~,~.~.e~'~ ~. ~~~'~'~'~.~..'~~',,,~.T~.~-~,~~.~:'r~.:~,~:'~, , ~ ~ ; 

~i'i' ''~ ° I ° I ' 

m 

PROOUP.T REGEHERATtVE 

RECYCLE 

GAS 

m 

5tel5 

.~ 22, 49 I 

" '11', I tO 12, 640 

O, D4 

120, 53 29. 55 

173 

1.264 

o. 0 

O. 36 

6. 03 

'" " 6.03 

6. 64 

15. 46 

I;,7l 

7.95 

Sq3. 70 

569, 9T 2, 465, 0 

"'.. :"~.:.: --_POHT 

.... PROVAL 

~.~_~, :- ~PpnOVA[, 

"...',°.- 5(~ RO/]~ 

O£SCRIPTION 

,Ok ...... 

J 

ll~ll ~ ~I OeNllel~'W C~'pa'ntla 

~4zsmm ooq~ 

::~':::'~.- ..... ,, ~.,~"~a.~'~., ~" 

S 

)39M?2HP, DGr, 

..... r 

U,S, DEPARTHENT OF ENERGY 

W.R. GRACE & CO. Kemuc~ 

58.888 B.P,I:)o 

COAL - TO - HETFIANOL " TO " GASOLINE PLANT 

It 

UNIT ~8 ~..~ ,.,,,,.~ ;r IZ 

~w c~sou,( Tn~n,; D-38-PP-2 NP 

A 

D 

N 

m~ 

J

q, ,/ 

F, Plot Plan/Cenerel Arrang.mnent Drawings 

See Volume II, 1.2.13(F) £or Plot Plan and General 

Arrangement Drawings £or Heavy Gasol£ne Treating Un:Lt 38. 

IZ-1,2,18-6 

m 

i

P 

C 

G. S~ngle-Llne Dia[~zam 

See Volume IX, 1.2.12(G) 

Heavy Gasoline Treating Unit 38, 

ZI-h2.18-7 

for the Single-Line Diagram for

1.2.19 PROCESS WATER TREATMENT - UNIT 39 

A. ,Basis of Desi~n 

The feed to the MTG plant contains water, and additional 

stolchlometrlc volumes of water are produced during the conversion of 

methanol to gasollne. In the eonverslon reaction, about 0.6 pound of water is 

produced per pound of methanol in the feed. The process ~ater is separated 

from the hydrocarbon products and obtained as liquid at about 178 pslg and 

100"F. Consideration has been given to recycling this water to other plants 

~n the overall Gasollne Plant to reduce the need for makeup water and 

wastewater treatment° The MTG water, at a pH of 3.5 to ~.0, contains traces 

of methanol, organic acids, hydrocarbons, and related oxygenates. The 

oxygenates are removed by an activated sludge trestlng unit, 

Since thls water treatment process is well suited to 

handllng sanitary wastes, the wastewater generated from domestic use of 

potable water and process area surface runoff pretreated by the oily water 

treatment system ere sent to the Mobil water treatment system. 

B, Process Selection Ratlonale 

i 

The process selection of aerobic biotreatment of the MTG 

process water available through Mobil Research and Development Corporation 

was made by Parsons. This process has shown that the contaminants are 

biodegradable by conventional treatment using a tricklin E filter and an 

activated sludge basin. Results have demonstrated that the Chemical Oxygen 

Demand (.COD) and Biochemical Oxygen Demand (BOD) are reduced to acceptable 

enviror~eutal limits. However, in the overall wastewater all effluent from 

this system is recycled. 


The wastewater stream from the MTG plant results from the 

water present in the methanol feed as well as water formed in converting 

lI-1.2.19-1 

~

P 

[ ,,, ,,, i , ,, 

methanol to gasollne. The water produced In the conversion reaction is about 

0,6 pound per pound of methanol in feed, 

The wastewater contains minor quantities of dissolved 

organic chemical contaminants totaling less than 0.2Z by weight. These 

contemlnante are primarily oxygenated organic compounds, such as organic 

acids, alcohols, and ketoneg, in addition to the methanol resulting from 

breakthrough Just prior to conversion catalyst regeneration. These are 

essentially removed ~n a wastewater treating facility. 

Pllot plant studies on the aerobic blotreatment of )fig 

process wastewater have shown that the contaminants are blodegradable by 

conventional treatment using a trickling fllter and an activated sludge 

basin. Results have demonstrated that COD and BOD are reduced to acceptable 

environmental limits. 

T~eatment steps for /fig wastewater involve routing the 

wastewater stream to a degasser where the pressure Is lowered to atmospheric. 

The gases are routed to a flare system. The wastewater then is sent to a 

neutralization tank where pH is adjusted with sodium hydroxide solutlon. 

Nutrients for biological growth (ammonia and phosphoric acid) are added after 

the neutralization basin, Following neutralization, the wastewater is pumped 

to a trickling filter. The trlckllng filter effluent flows to an activated 

sludge extended aeration unit. 

The waste activated sludge from the treatment process Is 

conventional aerobic blologleal sludge, which Is dewatered In the inert 

solids treatment system and then stored in the nonhazardous landflll. The 

organic content is hlgh since there is little or no inert materlal in the raw 

HTG process water. 

In addition to the process water discussed above, there are 

25 gpm of spent caustic containing 6I of sodium sulftte and sodium 

bicarbonate developed during HCT section catalyst regeneration, 25 gpm of 

domestic sanitary wastewater, and 740 gpm of pretreaCed surface water runoff 

termed olly water. 

II-1.2.19-2

In the Integrated complex producing gasoline £rom 

coal-derlved synthesis gas, about 40 volume percent of the blotreated water 

£rom the Process Water Treatment Unlt is seat to a deaerator to remove gases 

and then to the goal£1catlan unit as makeup water. The remainder o£ the water 

treated In thie system is routed to clean process water makeup. 

D. ,Risk Aa, sess=ent 

The Process Uater Treatment unit contains conve~tional 

biotreatment-type equipment that is in general use throughout the petroleum 

and -~emical Industrles. The technical risk Xs minimal. 

II-1.2.19-3 

Bin..-___

C 

/' 

". . ... ~ ,'. 

E. Process Flow and Control Di,aBrame (Including Nateria~ 

Balance) 

Treatment Unit 39 are as £ollows: 

Process Flow and Control Diagrams for Process Water 


D-39-MP-II~P PFCD Process Water Treating 

D-39-NP-21~P Material Balance - Process Water Treating 

II-1.2.19-4 

E

P .... 

A 

C 

D 

II 'INII I II 

~AWI#G NO 

' I 

1 , ,I ,,, I .... = ..... I 

31-01-1|09 39-01-1207 ~ 391-01-1206 39,.01-~401 39-01-120! 3~01-4101 

P~OCE$S WATER 

FLASH DRUM 

CAI~"IIO FEED 

'lANK 

PIIO~PII0~|C ACID 

FEEO TAHK 

_ ~ O N 

TANK 

.HE~ATION 

TANK MLXE~ 

NH] FEE'-"------~ 

~ 

TRICKLING FILTER 

PIT 

~1 : TO FLARE 

FROCES.~; lATER/ 

I~G U~T 

J E'O-CE-2 -" :~1"35 

, "ra SXRZ~A,~ IAS'~E 

.,=.. B~-1-3g 

LD-S3-CE-2 .r.~ PROCESS AREA DRAINAGE/ ~ I 

OILY WM[R TR,EAT~NT 

SYSTEM 

~ 39"01-120T 

~'D'ST-Id~-I NP) 6'-AA-39 

NNI,"S|~UkGE 

39-oz-zszz 39-0,-13|4 

c ~ e o P e ~ m 

]9-Ot-151_..__..~33 

[D-5'I-ilP-E lip ~ I'IIOSPI~OP, IC 

ACIIZ/SI"ORACE L ~ ---~ 

1 l! 

3~J-.O1-1514 

I 39-01-1205 

39-01-2401 

39-01-120E ATZURAL 

" ~ , 14~W-39 

39-01-1209 59"-01-1515 

39'-01-1515 39-'01-1S03 39-01-1305 

3901-1506 

XeZ~Ee A F ~ 

F E:O pUm~ AND ,,FEED PUMP AND 

SPARE $PJiRE 

3~01-1503 

~19,.01-1504 

' , ~ .~ ...... ~, ~.,1 

M-01-4101 

39-01-4106 

SLUDGE PIT' 

39-O1-1505 

]9-01-13u_.__.~ss 

39-01-4 t0.__.._~ZZ 

R,.W.',t~ 

39"01-1509 

33"01-1510 

3~l-DI-4106 

39-01-1509 39-0i-!511 39-01- 150"/ 

]9-ol-islo ~ox-,s,.._._._~2 3~-o,-iso, 

.SLUDGE RECYCLE SCUM bUMP ,CI.AP, ZFIED WA~'ER 

,,P~lP AND SPARe PUEP MiD SPA'RE .OZSCIU~RGE PLII~ 

AND SPARE 

, J I 

..... -------.-.J'~~FJCJ I F0R CL~(

ii ii jjlU I 

'i ~ 39,,.01-4103 39'-01-4101 3~'01-1604 

A ~ H ~ TRICKLING FILTER 

L___ 

3g,',411- IllO4 

"~-01-4193 

39o91-~40~A 

3"J-ot-=4m+ 

:q9-,ol-2,qo2( 

SL~0G'E/R£CYCLE 

39-01-1511 

39-'0i-1512 

--,I>

p .,., 

4 

C 

I'+1 + I 

I I ~AwiNa ~ I 

• ' i~"~Lll |fill 

.... 1 .I 2 I + I 4+ 

OI~RIPTIOK 

1 

IlL I 

,,,,, 

i 

OESCII lli'T I~ li,+,, 

COMPOHEHT 

PROCES~ 

WATER 

lATE IGPM) IISO 

60D !MO/L~ IS

, , ,, ,, 

EXCE~ 

SLUOG; 

~S 

I00 

is 

t l,~,°. ' |,,~D' 

I Fee ellr~ AmmvJt I I i 

v q 

txcrxsr~ ~OVAL I I I 

o==~m. I I pe,~a, r~l~l ~ 

44~ I = I 

I 

b38Mw~. O~ 

MATB~. BAI.A.~E ~IOIIN L~ FOE I~I~L 

I 

OEPARTt,~:NT OF ~.RGY 

U,,li.6mCE & CO. 

5t~,J~8 B.P.0. 

COAL - TO - Iv~TI~,NOL - TO - GASOLIHE PLANT 

FOe U~ 3S /~-39-MP-2 

6 I I 

A

P ....... , .,,,,,., ,, 

F, Plot Plan/Ceneral Arrangement Drawin~ 

The Plot PI~ and General ArrenEemeut DrawinE for Process 

Water Treatment Unit 39 is as follow~c 

Dra~n~, No. Title 

D-39-PD-INP Plot Plan - Unit 39 Process Water Treatmeut 

II-l.2o 19-5

m 

A 

C 

N 

Q 

l I ,,,,,,,,.a,,o. 

~IO-Gi-~i Iii/7111 

I 

m 

i 

la,,l 

ILl 

Z 

-r" 

I--" 

1 

s 

. . . . , ................ ., ~;r'~"~ ~, ,' . . . . . ,, , ,'. ' ' ~ ~'~. , ', '~' ,~,.~W ~ . ~ . • 

I , . I ,.:~ I ,. 

PIT 

r"L' I 

1, 

' I 

I ~ RECYCLE $1J~4P 

SCUM SUUP I 

D ES~q IPT~DN 

I 

I 

L 

],[._L I I I I I 'l'!' ' 

It It I f, t 

MATCHLINE & C/L ROAD N 9630'-0' 

BA'rTESy L D411"5 

+ + 

~ERAT IO,q 

BASIN 

[... .] 

I~ATT~rR~ LlUlTS 

%% ~" 

,,.," P¢8 "'-. 

1~o' ~1 ~,~1 

v 

MATCHL I NE "_ 

I,~- ~ ,'~[~-:--:.~- 

I~I~RI I~ll FJC Ir~ -]r~Y 

I~1~,~1 j,~l~'~ I I'~O.- 

I-I ~3.,.I-.I ~el /~;.Er, _.jl~--_ 

NO* DATI~ 8Y SI[C ~ ¢Ll[[q*Lr I - - ~. 

II I',,, I ~1 I,,

-0' 

. I I i ,,n .......... 

-'.::~ & ~L ROAD N 9310'-0' 

,~" pl." B "~o 

I.~. ~ 3g-OI-4GOI ~,~ [ 

FLASH~RUM 

NEU;RALI ZATIOX 

TANK 

I~1 I~1 

FEED T~ 

FEIm TANK 

-E3.E~)- 

FEED TAN~ 

\ / 

I 

m ~ 

m 

/ 

r,,,,, 

iaJ 

l i 

0 I0 ~ ~ $0 Io 

I 

[ 

I--~TT 

~S' OEP~RTMENT OF E~i~(;'f 

W.R. I~qCE & (:0. ~.mucxv 

COAL - TO - METH~DL - ~,.- G~SOLZNE PL~T 

r" PLO, PLAN I ,'.ao'-m ~, I ,,az I . 

UN,T 39 Z=~ 

P~CE!.:; '.qATER TRE./,TMENT I D-39-PD- I NP ....... ,: 

teD, . . .:, 

m 

D

m 

. m 

/ 

¢ 

G, Single'-Line Dtagrnm 

Bee Volume lI, 1.2.15(G) for the SingZe-Line Diagram for 

Process W~ter Treat~nent Unit 59. 

I 

II-l. 2.19-6

P E. Process Flow and Control Diagrams - Fischer-Tropsch Archive

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