Separation Technology for the Hydrocarbon Processing Industry

Sulzer Chemtech

Separation Technology for the Hydrocarbon Processing Industry

Technology Leadership

Sulzer Chemtech produces a wide array of tower internals. With this broad spectrum of custom- designed fractionation trays, random and structured packing we can meet any process requirement in any size tower throughout the chemical, refining, petrochemical, and gas processing industries. For over 50 years, Sulzer Chemtech has been serving these industries with our innovations, which set a new standard in many applications. Sulzer Chemtech Achievements:

1956 Nutter Float Valve trays in an olefin plant, among others for a 120” i.d. C2 Splitter 1964 BX gauze packing for Distillation of heat sensitive fragrances

Industrial Applications from A to Z

1975 BX plastic gauze packing for HCl Absorption towers

Ammonia and fertilizer production

11

1977 Nutter V-Grid trays for C3 Splitters

DMF / DMAc recovery

13

1985 Nutter Ring for Demethanizer

Ethylene

4/5

1985 Mellapak for Water Quench towers

Ethanolamine

6/7

1988 Design of Heat Pump systems

Ethylene glycol

6/7

1988 Mellapak for Ethylene Oxide towers

Ethylene oxide

6/7

1995 Mellagrid for Water Quench towers

Heat pump / heat integration

13

High pressure gas saturation

8/ 9

1997 Katapak for Reactive Distillation of Methylal 2000 MellapakPlus for various applications For classical column operations such as distillation, absorption, stripping and extract ion, and for alternatives such as crystallization, membrane permeation and reactive distillation, we are continuously developing new product ideas to meet the economical and technical objectives of our customers. For numerous applications Sulzer Chemtech provides superior plant performance, improved product quality, increased capacity, and reduced energy consumption.

Methanol Selective H2S absorption Synthesis gas applications

2

8-10 8/ 9

Tail gas treating

10

Treatment of corrosive products

14

Sulzer Chemtech offers the full range of column internals with trays, random and structured packings optimized through column simulation, process design, basic engineering and field services. Sulzer Chemtech is a worldwide leading supplier for separation technology; thanks to our customers and the confidence they instill into our products and capabilities. From the very first to the very last of our more than 30,000 columns in operation we have never stopped listening to our customers about t heir needs. At Sulzer Chemtech, we are eager to develop a successful appli cation for your needs.

12

Color index of the diagrams

•

Structured packing

•

Trays

•

Random packing

Application Know-How and Service are our Driving Force

Sulzer Chemtech has 50 years of accumulated application knowhow and experience in developing, designing, supplying and servicing mass transfer equipment in the Chemical, Petrochemical, Refining, Gas Processing and Speciality industries. Only the very best technical solutions can secure the competitive advantages which our customers need in today’s highly demanding conditions. Leadership in technology and application know-how is fundamental to our success.

0694 2507 

Replacement Service

Reliable and fast supply through a world-wide manufacturing network of: • any hardware • most valves • most tray decks • complete trays

Technical and Process Support

• Column simulations and design • Process simulations and plant optimization • Feasibility studies for capacity and/or purity improvements • CFD modelling • Pilot plant testing

Field Services

• Installation consulting, inspection or supervision • Full installation services • Trouble shooting assistance • Scanning • Start-up assistance

0601 2505-4

0695 2510-13

3

Ethylene Plants Whatever your plans are, we have the right solution for every service Water quench tower with Mellapak/Mellagrid Before revamp

Benefits:

After revamp

+70% higher capacity 37 oC 920 m3 /h 29 oC

Random packing p

≥

1230 m3 /h 57 o C

100 mbar Trays

230 t/h 99 oC

70

oC

35 oC T = 8 oC

1250 m3 /h 33 oC Mellapak 

T = 2 oC

1050 m3 /h, 59 oC

p = 10 mbar

Mellapak + Mellagrid

400 t/h 94 oC

80 oC

The revamp of the water quench tower trays and random packing to structured packing Mellapak ®  led to improvements in capacity and in efficiency. In addition, energy costs were reduced considerably due to the following reasons: • Less cooling energy requirements and no steam consumption for the reboiler of the C3 Split ter, due to better efficiency of structured packing. • Less energy requirements for the compression stage due to low pressure drop in the packed bed.

Hot section Cracker/  Furnace

Oil quench/Primary fractionator

Water quench

Feedstock (e.g. Naphtha, Gas oil, Ethane)

3- stage gas compression

Caustic wash tower

4th-stage gas compression

Olefins

Steam

Water Dehydration unit • Activated alumina • Molsieves • TEG system

Fuel oil

Aromatics Refrigeration unit

Caustic wash tower with Nutter rings or Mellapak  Benefits of structured packing:

• Smaller column diameter, due to higher capacity

Water Random packing

Water

Mellapak 

NaOH NaOH

9m

• Reduced packing height, due to higher separation efficiency • Lower pressure drop • Reduced foaming tendency, due to less turbulences

7.5 m

• Less entrainment 9m ID 5500

4

• Higher fouling resistance

7.5 m ID 4900

C2 splitter and/or C3 splitter with Shell HiFi trays Objectives: +20 % feed rate, same product specification I ni ti al d es ig n

1s t O pt io n: 1 f or 1 r et ray

24.4 Gcal/hr

4.6 Gcal/hr

25.3 Gcal/hr 169 trays 307 mm spacing

130 trays

C3 feed +20 %

C3 feed

• For higher capacity: Replacement of existing trays enables handling of increased column loads at higher exchanger duties. • For higher capacit y and / or higher efficiency: Replacement of existing trays by a higher number of new high capacity trays enables a reduction in reflux and load requirements, but puts more emphasis on tray capacity and efficiency at low tray spacing. • For new columns: Technology can be used to minimize dimensions of new columns, such as the diameter and height.

2 nd O pt io n: 4 f or 3 r et ray

28.2 Gcal/hr I.D. 4000 130 trays 430 mm spacing

Benefits:

C3 feed +20 %

I.D. 4000 4.6 117 trays Gcal/hr 457 mm spacing

117 trays

20.9 Gcal/hr Propane

4.6 Gcal/hr

150 trays 350 mm spacing

24.2 Gcal/hr

21.4 Gcal/hr

Cold section De-methanizer

De-ethanizer

C2 splitter

De-propanizer

C3 splitter

De-butanizer

C2H2 Acetylene

Acetylene recovery

C2H4 Ethylene

C3 H 6 Propylene

to EO-plant

CH4,H 2 C2 Hx

C3 Hx

C2 H 6 Ethane recycle C2+

C 3H 8 Propane

C3+

New C3 splitter with conventional trays

C4+

Reuse of existing C3 splitter with MVGT trays

C5+

High performance MVGT trays allow the reuse of the existing tower without replacing it by a new one. The advantages of MVGT: • Higher capacity at same efficiency

ID 3600 mm

ID 3200 mm

• Tray spacing can be kept

120 trays 450 mm spacing

120 trays 400 mm spacing

• No welding to column shell, as existing attachments can be reused

Feed

• Minimized plant shut down time

Feed 61 trays 450 mm spacing

61 trays 450 mm spacing

• Lower revamp costs

5

Ethylene Oxide and Derivates

67% Ethylene Glycols

7% Ethanolamines

-

Antifreeze agent PET production Polyester production Heat transfer liquid Plastizicer / softener Solvent

-

Textile finishing Cosmetics / Soaps Detergents Gas purification

EO

-

5% Glycol Ethers

Brake fluid Solvent for paint Detergents Gas purification

Revamp of a CO2 absorption column from high capacity trays to Mellapak 

Bevore revamp Gas quantity (t/h)

110

CO2 at entry (vol. %)

4.7

CO2 at exit (vol. %)

1.4

CO2 absorption (t/ h)

7.1

EO production

- Detergents - Surfactants - Emulsifiers

21% other Ethoxylates

Wash colunm

Know-how

• Distillation of Ethylene Oxide (EO) • Technologies and key components for: - Ethylene Glycols - Ethanolamines - Glycol Ethers - Alkylethanolamines

CO 2 absorption / 

For various reaction technologies cooperating with experienced partners Reactor

Ethylene

Upgrade with Mellapak and MellapakPlus Gasload EO production EO in outlet gas Pressure drop

100 % 100 % 250 ppm 170 mbar

100 % 100 % 22 ppm 52 mbar

35 MD trays

2.0 vol % EO

6

2.0 vol % EO

137 % 185 % 100 ppm 73 mbar

2x7m Mellapak M 250.Y

2.7 vol % EO

2x7m MellapakPlus M 252.Y

Oxygen

EO absorption / 

Process Features

After revamp 168

•

Continuous process

•

Low by-product formation

•

Flexible product ratio

•

High yields on raw materials

•

High recovery rates

•

Low energy consumption

•

5.1 0.3 14.0

Extremely low pressure drops in the distillation section

•

High product purity

•

Joint developments

Ethanolamine production Ammonia H2 O

MEA

DEA

TEA

Reactor tripping

Water separation

EO distillation

Ethanolamine separation

Glycol production H2 O

MEG

DEG

TEG

stripping

Reactor

W at er s ep ar at io n

G lyc ol s ep ar at io n

7

Synthesis Gas Application

COS - Conversion unit 30 oC

1 to H 2S removal unit

28 o C

≤

Heater 72 oC

Reactor COS converter H2S Hydrolysis

15 wt ppm COS

COS + H 2O = > H 2S + CO2

Water 87 oC

Saturator

Cooler

2 ppmv H2S 24

147 oC

oC

32 bara

≈1400

wt ppm COS

H2 S ≈

90% CO2 - Slippage 200 ppmv H 2S

Selective H 2S Absorber No 1

Selective H 2S Absorber No 2

Synthesis gas

1

23 oC 5 mol % CO2 9600 ppmv H2S 32.5 bara

Compact Column Size

Sulzer packings permit high gas and liquid throughputs resulting in small column diameters (important factor for pressurized columns or when upgrading existing columns). High separation efficiency also allows the use of short-height columns. New columns incorporating these features result in large savings, both in weight, volume and in investment costs. The increased selectivity leads to a higher CO2 -slippage in the treated gas and to a lower CO2 content in the acid gas which leads to a higher capacity of the existing Claus plant or to lower CAPEX in case of a new plant. 8

30 oC 4.5 mol % CO 2 600 ppmv H 2S rich amine

Selective absorption of H2 S with MDEA

60 % CO2 slippage 2 Vol ppm H 2S

Mellapak 

90 % CO2 slippage 2 Vol ppm H 2S

Lean MDEA

Lean MDEA

Diameter 700 mm Height ca 11 m L/G ca 0.15

Tray column

Diameter 1100 mm Height ca 15 m

Pressure: 56 bar Gas temperature: 30-35 oC

L/G ca 0.15

Natural gas with H 2S + CO2 ca 1 Vol % Rich MDEA

Natural gas with H2S + CO2 ca 1 Vol %

Rich MDEA

CO - Conversion unit

Benefits for Conversion Units

• Reduced steam requirements, less energy consumption • Lower OPEX • Pay back time approx. 1 year • Less fouling problems

≥

188 oC Steam

200 oC

Saturator No 1

from H2S removal p = 29.9 bara 82% wt CO

Saturator No 2

28 oC CO + H 2O = > CO 2+ H 2

≤

70 oC

Converted gas to CO2 amine unit: ≤ 6 %wt CO ≥ 82 % wt CO 2

Removal unit Acid gas to Claus plant (see also tail gas treating on next page)

65 oC

Reactor CO converter

110 oC Cooler

212 oC

Regenerator

≈

390 oC

Reboiler lean amine Solvent heat exchanger

Saturator No. 2 Diameter: 2.94 m

181 oC ∆T ≥

188 oC 22 o C

∆T ≤

200 o C

203 oC

Pall ring 3" ∆T ≥

12 oC

Mellapak 

40 mbar

∆T ≤

140 oC

10 mbar

134 oC

152 oC

146 oC

9

Tail Gas Treating

Combustion

Acid gas 42 o C

H2 S

Clausplant

SO 2

H2S Hydrogenation

Quench column

Sulfur

200 oC Selective H 2S absorption

Regenerator

p = 1 bar

Sourwater stripper

Low Pressure drop with Mellapak 

High Selectivity

The higher selectivity of structured packing over other components results in the following advantages: • Reduction of CO2 concentration in acid gas which leads to • Reduction of pressure drop of the Claus plant which leads to • Increase of capacity of the Claus plant

means smaller blowers or compressors power compared with trays and random packing, as well as advantages for the upstream Claus process stages.

Quench for tail gas treating unit

Column diameter Pressure Gas flow rate

6.1 m Atmospheric 260,000 kg/h Trays

Random packing

Mellapak

Pressure drop (mbar)

70

25

9

Energy savings (milions kWh/year)

-

2.8

3.9

Cost reduction (US$/year)

-

180,000

260,000

10

Applications in Ammonia and Fertilizer Production

Condensate stripper Exhaust gas

p = 2.5 bara 110 o C

128 oC Feed 81 oC NH 3 Methanol

1000 ppm 1400 ppm

Type of packing Flow (t/h) NH3 outlet (ppm) Methanol outlet (ppm) Reuse of condensate

Steam

Pure condensate NH 3 < 1 ppm Methanol < 5 ppm

Original column Pall ring 2" 65 - 75 10 - 30 50 - 100 no

Revamp Mellapak 65 - 75