De-Butanizer Revamp at PreemRaff, Lysekil,...
Transcript of De-Butanizer Revamp at PreemRaff, Lysekil,...
1De-C4 Revamp / Gas Plant FCC / PreemRaff / AIChE April 2007
Sulzer Chemtech
De-Butanizer Revamp at PreemRaff, Lysekil, Sweden
Norman Burcher, Erika Wikstrom, PreemRaff
Giuseppe Mosca*, Andrew Hausman, Sulzer Chemtech
Peter Wilkinson, Shell Global Solutions
Presented at the AIChE Spring National Meeting, 23 April 2007, Houston, TX
* Speaker
2De-C4 Revamp / Gas Plant FCC / PreemRaff / AIChE April 2007
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Outlook
1) Background
2) Scope of the Revamping
3) Tower modifications
4) Test run data
5) Analysis of the plant data
6) Conclusions
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Background, page 1 of 2
1) A new Hydrocracker plant went on stream beginning 2006 at PreemRaff for hydro-treating the Vacuum Gasoil.
2) The feed quality to the FCC improved significantly.
3) The conversion of the FCC plant was increased towards the production of Gasoline and LPG by higher dosage of ZSM-5 catalyst, as well as improved feed-stock.
4) The feed rate to the De-Butanizer increased, as well as its LPG content.
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Fluid Catalytic Cracking Reactor, Main Fractionator, Absorbers & Stripper
Feed
HCN
LCO
Slurry
To De-C4
Stripper
To Amine
Absorber
MF
Reactor
Sponge
AbsorberPrimary
Absorber
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LCN
De-C4
T-1506
Stripper T-1504
Rich LCO
Lean LCO
MF OVHD
Sponge Abs.
T-1505Primary Abs. T-1503
C3 / C4
T-1512
D1507
De-C2 T-1513
Rich Amine
To Caustic
Abs. T-1802
Spent Caustic
Lean Amine
T1507T1508 T1804
F1801
Fuel Gas
To C3 Splitter T-1514
T1801
D1510
To EA1521
D1517
E1508
EA1528
E1530 E1509
E1522 E1523
E1521A E1521B
EA1502
P1544
P1545
E1524
P1543P1517
D1536D1537
D1806D1519
D1508EA1526
EA1501
EA1503
P1516
P1521
EA1525
P1542
By pass
EA1530
FCC Gas Plant
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Background, page 2 of 2
5) The De-Butanizer was originally equipped with 30 Conventional 2 pass trays, and put on stream in 1985.
6) Ten years later, it was retrofitted with 30 High Performance Chordal Downcomer trays to boost the capacity by 15 %.
7) The column achieved the target of the first revamping, and was running at its maximum useful capacity, in particular the Stripping section was not able to produce more than 80 m3/h of Stabilized Naphtha with 75 m3/h of LPG from the Rectifying section.
8) The tray efficiency at the maximum achievable throughput was not more than 65%
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Scope of the Revamp
1) Increase the capacity by approx 15 % over the maximum achievable throughput after the first revamp:
case 1: feed 175 m3/h; LPG 79.3 m3/h; LCN 95.7 m3/h case 2: feed 175 m3/h; LPG 90.3 m3/h; LCN 84.7 m3/h
2) Operating range: 1 to 2.5, to comply with the two different cases: Normal and Rich LPG.
3) Maximize the Mass Transfer Efficiency.
4) C5s content on the top Stream less than 0.6 % Vol.
5) RVP of the bottom LCN <=85 KPa
6) Minimize the investment cost
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Scope of the Supply
Based on a process study developed by an Engineering company and cross-checked by the Refinery, the following goods were supplied:
1) 15 HiFi PlusTM trays in the rectifying section, designed by Sulzer and cross-checked by Shell Global Solutions.
2) 15 ConSep™ Trays in the Stripping sections designed by Shell Global Solutions.
3) Top reflux distributor designed by Sulzer.
4) Mixed Phase feed inlet distributor designed by Sulzer.
5) Expansion Rings and other tower internal supports designed by Sulzer.
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Modifications in the Rectifying Section
Feed
Ch
ord
al D
C H
PT
HiF
i P
lus
TM
Tra
ys
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Top Reflux
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Feed
Ch
ord
al D
C H
PT
Co
nS
ep
™T
rays
Modifications in the Stripping Section
PreemRaff
To Reboiler
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HiFi Plus™ trays in the Rectifying Section
HiFi™ downcomer
MVG valve
Self-Balancing Multi-pass Trays
Pass 1 Pass 2 Pass 3
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HiFi Plus™ trays in the Rectifying Section
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13De-C4 Revamp / Gas Plant FCC / PreemRaff / AIChE April 2007
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ConSep™ Trays in the stripping section
HiFi™ downcomer
Swirl Tube
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ConSep™ Trays in the stripping section
HiFi™ downcomer
Swirl Tube
Secondary downcomer
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ConSepTM : The Ultra System Limit Mass Transfer Component tested at FRI
Liquid flow Vapor flow
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Combination
Large Bubbling Area and Liquid
Handling Capacity of HiFiTM Tray
Liquid De-Entrainment
Device of Swirl Tube TrayV
L
Clear Vapor
Liquid
entrainment
Liquid
Liquid
Liquid
Clear Vapor
Liquid
entrainment
Liquid
Liquid
Liquid
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Efficiency Comparison with high capacity trays at FRI
(iC4/nC4 at 11.4 bar)
0
20
40
60
80
100
120
140
0.00 0.02 0.04 0.06 0.08 0.10 0.12 0.14
Column load factor (m/s)
Tra
y e
ffic
ien
cy (
%)
Shell ConSepTM tray
Sulzer VGPlusTM tray
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Swirl Tubes underneath the active area
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Top Reflux Distributor
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Mixed Phase Feed Inlet Distributor
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Test Run 16-19 January 2007
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Test #1: 16Jan, 0 am 11 pm, 24 hours
82
83
84
85
86
87
88
89
90
1 2 3 4 5 6 7 8 9 10 1112 1314 15 1617 18 19 20 21 2223 24
Time (Hours)
Flo
w R
ate
(m
3/h
)
Top Reflux
250
300
350
400
1 2 3 4 5 6 7 8 9 1011 1213 141516 171819 202122 2324
Time (Hours)
Pre
ssu
re D
rop
(m
Bar)
Tower Pressure Drop
6.5
6.6
6.7
6.8
1 2 3 4 5 6 7 8 9 10 11 12 1314 1516 1718 1920 2122 2324
Time (Hours)
Reb
oil
er
Du
ty (
MM
Kcal/
h)
Reboiler Duty
0.3
0.5
0.7
0.9
1.1
1.3
1.5
1 2 3 4 5 6 7 8 9 10 11 12 1314 1516 1718 1920 2122 2324
Time (Hours)
C5s c
on
ten
t (%
Vo
l.)
C5s Bottom T1512
Maximum acceptable
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Sulzer ChemtechPreemRaff
Test #1: 16Jan, 0 am 11 pm, 24 hours
8090
100110120130140150160170180190
1 2 3 4 5 6 7 8 9 1011 1213 141516 171819 202122 2324
Time (hours)
Flo
w R
ate
(m
3/h
)
Bottom Top Feed
40
45
50
55
60
1 2 3 4 5 6 7 8 9 10 1112 1314 15 1617 18 19 20 21 2223 24
Time (Hours)
Perc
en
t (%
)
Top Receiver Level Btm Tower Level
57
58
59
60
1 2 3 4 5 6 7 8 9 10 1112 1314 15 1617 18 19 20 21 2223 24
Time (Hours)
Tem
pera
ture
(°C
)
Top Pilot Tray #5
120
121
122
123
1 2 3 4 5 6 7 8 9 1011 1213 141516 171819 202122 2324
Time (Hours)
Tem
pera
ture
(°C
)
Bottom Pilot Tray #29
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EA1528
E1530 E1523
E1521AB
EA1502
P1543P1517
D1536
D1508
EA1526
EA1501
P1542TC302
E1508
TI-19
TI131
FC-04TI348
TI350
TI362PI348
TI364FC181TI513
TC512
FC23
TI-25
TC354
FC182
TI13
FC-81 FC205
HCO HCN
To Amine Absorber
PI302
PI162
PI161
PI47
TI400FC-05
TC303
TI63
PI337
TI353
PI336
FC175
PI396
FC152
FC174
86
220
6.48
139.5 8
C5 %M 0.3
RVP KPa 77
C4s %V. 3.9
C5s %M 0.700.52
180.9
100.4 50.6
34.9
121.4
358
5.33
TI363
121.1
94.3
117
85.7
212
240
58.4
48.6
42.4
31.8
134.9100.9
39.5 111
67
66.4
28.6
28
17.2
7.716.8
16.1
9.5
7.2
18
Test #1: 16Jan, 0 am 11 pm, 24 hours
TC352
TC-349
PreemRaff
P (Barg)xx
xx T (°C)
xx F (m3/h)
T-1506 T-1512
25De-C4 Revamp / Gas Plant FCC / PreemRaff / AIChE April 2007
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Test #1: 16Jan, 0 am 11 pm: measured plant data
Material Balance: Out - In 185.9 - 180.9
185.9=
Out= 2.69 %
Top Reflux: 86 m3/h
Reboiler Duty: 6.64 MMKcal/h
Simulation results of Test #1, Feed = 185.9 m3/h
Top Reflux (m3/h): 86.1
7.01
Tray Efficiency (%): 93.3
Reboiler Duty (MMKcal/h):
85.3
6.96
100
86
7.00
93.9
Feed
180.9
C4s+LCN
50.6 100.4m3/h
C3s-
34.9
Reb. Duty deviation: Sim. - Plant 7.00 – 6.64
7.00=
Sim.= 5.14 %
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26De-C4 Revamp / Gas Plant FCC / PreemRaff / AIChE April 2007
Sulzer ChemtechPreemRaff
Test #2: 17Jan, 2-9 pm, Maximum Useful Capacity at 7.15 pm
0.3
0.5
0.7
0.9
1.1
1.3
1.5
14 15 16 17 18 19 20 21 22 23
Time (Hours)
C5s c
on
ten
t (%
Vo
l.)
C5s Bottom T1512
MUC
Maximum acceptable
350
400
450
500
14 15 16 17 18 19 20 21 22 23
Time (Hours)
Pre
ssu
re D
rop
(m
Bar)
Tower Pressure Drop
MUC
99
100
101
102
103
104
105
106
14 15 16 17 18 19 20 21 22 23
Time (Hours)
Flo
w R
ate
(m
3/h
)
Top Reflux
7.3
7.4
7.5
7.6
14 15 16 17 18 19 20 21 22 23
Time (Hours)
Reb
oil
er
Du
ty (
MM
Kcal/
h)
Reboiler Duty
27De-C4 Revamp / Gas Plant FCC / PreemRaff / AIChE April 2007
Sulzer ChemtechPreemRaff
Test #2: 17Jan, 2-9 pm, Maximum Useful Capacity at 7.15 pm
58
59
60
61
14 15 16 17 18 19 20 21 22 23
Time (Hours)
Tem
pera
ture
(°C
)
Top Pilot Tray #5
MUC
126
127
128
129
14 15 16 17 18 19 20 21 22 23
Time (Hours)
Tem
pera
ture
(°C
)
Bottom Pilot Tray #29
8090
100110120130140150160170180190
14 15 16 17 18 19 20 21 22 23
Time (hours)
Flo
w R
ate
(m
3/h
)
Bottom Top Feed
40
45
50
55
60
14 15 16 17 18 19 20 21 22 23
Time (Hours)
Perc
en
t (%
)
Top Receiver Level Btm Tower Level
28De-C4 Revamp / Gas Plant FCC / PreemRaff / AIChE April 2007
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EA1528
E1530 E1523
E1521AB
EA1502
P1543P1517
D1536
D1508
EA1526
EA1501
P1542TC302
E1508
TI-19
TI131
FC-04TI348
TI350
TI362PI348
TI364
TC-349
FC181TI513
TC512
FC23
TI-25
TC354
FC182
TI13
FC-81 FC205
HCO HCN
To Amine Absorber
PI302
PI162
PI161
PI47
TI400FC-05
TC303
TI63
PI337
TI353
PI336
TC352
FC175
PI396
FC152
FC174
105.2
220.4
8.29
144.1 7.98
C5 %M NA
RVP KPa NA
C4s %V. NA
C5s %M NA1.47
180.7
95.4 56.8
34.7
109.8
358
5.02
TI363
Test #2: 2-9 pm, 17Jan; Maximum Useful Capacity at 7.15 pm
128.1
94.1
119.4
85.6
212
240
59.9
48.8
42.3
30.3
134.1101.4
41
66.8
67.9
28.7
28.5
17.1
7.52
16.8
16
NA
6.95
NA
111.4
T-1506 T-1512P (Barg)xx
xx T (°C)
xx F (m3/h)
29De-C4 Revamp / Gas Plant FCC / PreemRaff / AIChE April 2007
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Test #2: 17Jan, 2-9 pm, MUC at 7.15 pm: measured plant data
Simulation results of Test #2, Feed = 186.9 m3/h
Material Balance: Out - In 186.9 - 180.7
186.9=
Out= 3.32 %
Top Reflux: 105.2 m3/h
Reboiler Duty: 7.52 MMKcal/h
Feed
180.7
C4s+LCN
56.8 95.4m3/h
C3s-
34.7
Top Reflux (m3/h): 108.2
8.35
Tray Efficiency (%): 66.7
Reboiler Duty (MMKcal/h):
101.3
8.02
73
105.2
8.21
69.4
Reb. Duty deviation: Sim. - Plant 8.21 – 7.52
8.21=
Sim.= 8.40 %
30De-C4 Revamp / Gas Plant FCC / PreemRaff / AIChE April 2007
Sulzer ChemtechPreemRaff
Test #3: 10 pm 17Jan / 09 am 18Jan, 12 hours
99
100
101
102
103
104
105
106
1 2 3 4 5 6 7 8 9 10 11 12
Time (Hours)
Flo
w R
ate
(m
3/h
)
Top Reflux
350
400
450
500
1 2 3 4 5 6 7 8 9 10 11 12
Time (Hours)
Pre
ssu
re D
rop
(m
Bar)
Tower Pressure Drop
7.3
7.4
7.5
7.6
1 2 3 4 5 6 7 8 9 10 11 12
Time (Hours)
Reb
oil
er
Du
ty (
MM
Kcal/
h)
Reboiler Duty
0.3
0.5
0.7
0.9
1.1
1.3
1.5
1 2 3 4 5 6 7 8 9 10 11 12
Time (Hours)
C5s c
on
ten
t (%
Vo
l.)
C5s Bottom T1512
Maximum acceptable
31De-C4 Revamp / Gas Plant FCC / PreemRaff / AIChE April 2007
Sulzer ChemtechPreemRaff
Test #3: 10 pm 17Jan / 09 am 18Jan, 12 hours
8090
100110120130140150160170180190
1 2 3 4 5 6 7 8 9 10 11 12
Time (hours)
Flo
w R
ate
(m
3/h
)
Bottom Top Feed
40
45
50
55
60
1 2 3 4 5 6 7 8 9 10 11 12
Time (Hours)
Perc
en
t (%
)
Top Receiver Level Btm Tower Level
58
59
60
61
1 2 3 4 5 6 7 8 9 10 11 12
Time (Hours)
Tem
pera
ture
(°C
)
Top Pilot Tray #5
126
127
128
129
1 2 3 4 5 6 7 8 9 10 11 12
Time (Hours)
Tem
pera
ture
(°C
)
Bottom Pilot Tray #29
32De-C4 Revamp / Gas Plant FCC / PreemRaff / AIChE April 2007
Sulzer Chemtech
T-1506 T-1512
EA1528
E1530 E1523
E1521AB
EA1502
P1543P1517
D1536
D1508
EA1526
EA1501
P1542TC302
E1508
TI-19
TI131
FC-04TI348
TI350
TI362PI348
TI364
TC-349
FC181TI513
TC512
FC23
TI-25
TC354
FC182
TI13
FC-81 FC205
HCO HCN
To Amine Absorber
PI302
PI162
PI161
PI47
TI400FC-05
TC303
TI63
PI337
TI353
PI336
TC352
FC175
PI396
FC152
FC174
100
220
8.05
144.4 8
C5 %M 0.1
RVP KPa 66
C4s %V. 0.7
C5s %M 0.40.41
176.2
95.4 52.2
33.8
108.6
358
4.92
TI363
128
94.2
120.1
85.9
212
239.4
59.4
49.2
42.3
30
133.5101.1
40 111.4
66.1
66.9
28.8
27.9
17.1
7.6
16.7
16
9.2
7.1
18
Test #3: 10 pm 17Jan / 09 am 18Jan, 12 hours
PreemRaff
P (Barg)xx
xx T (°C)
xx F (m3/h)
33De-C4 Revamp / Gas Plant FCC / PreemRaff / AIChE April 2007
Sulzer Chemtech
Test #3: 10 pm 17Jan / 09 am 18Jan: measured plant data
Simulation results of Test #3, Feed = 181.4 m3/h
Material Balance: Out - In 181.4 - 176.2
181.4=
Out= 2.87 %
Top Reflux: 100 m3/h
Reboiler Duty: 7.38 MMKcal/h
Feed
176.2
C4s+LCN
52.2 95.4m3/h
C3s-
33.8
Top Reflux (m3/h): 105.5
8.09
Tray Efficiency (%): 80
Reboiler Duty (MMKcal/h):
100
7.82
86.7
Reb. Duty deviation: Sim. - Plant 7.82 – 7.38
7.82=
Sim.= 5.96 %
PreemRaff
34De-C4 Revamp / Gas Plant FCC / PreemRaff / AIChE April 2007
Sulzer Chemtech
Conclusions
1) The Unit was re-started 8 months ago.
2) The Column has a proven capacity higher than revamp design for the normal case: 185 VS 175 m3/h, with lower C5s content in the top and lower RVP in the LCN as well.
3) The overall tray efficiency (HiFi PlusTM & ConSepTM ) has exceeded any optimistic expectation: > 86%.
4) The column can operate steadily even at an average tray pressure drop of 14 mBar.
5) The Maximum Useful Capacity has been detected at an average tray pressure drop of 15.6 mBar, at which the trays can still provide an efficiency of 69%.
PreemRaff