de-butanizer revamp at preemraff, lysekil, sweden - … · de-butanizer revamp at preemraff,...

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


Sulzer Chemtech

Outlook

1) Background

2) Scope of the Revamping

3) Tower modifications

4) Test run data

5) Analysis of the plant data

6) Conclusions

PreemRaff


Sulzer Chemtech

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.

PreemRaff


Sulzer ChemtechPreemRaff

Fluid Catalytic Cracking Reactor, Main Fractionator, Absorbers & Stripper

Feed

HCN

LCO

Slurry

To De-C4

Stripper

To Amine

Absorber

MF

Reactor

Sponge

AbsorberPrimary

Absorber



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


Sulzer Chemtech

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%

PreemRaff


Sulzer Chemtech

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

PreemRaff


Sulzer Chemtech

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.

PreemRaff


Sulzer Chemtech

Modifications in the Rectifying Section

Feed

Ch

ord

al D

C H

PT

HiF

i P

lus

TM

Tra

ys

PreemRaff

Top Reflux


Sulzer Chemtech

Feed

Ch

ord

al D

C H

PT

Co

nS

ep

™T

rays

Modifications in the Stripping Section

PreemRaff

To Reboiler



HiFi Plus™ trays in the Rectifying Section

HiFi™ downcomer

MVG valve

Self-Balancing Multi-pass Trays

Pass 1 Pass 2 Pass 3


Sulzer Chemtech

HiFi Plus™ trays in the Rectifying Section

PreemRaff



ConSep™ Trays in the stripping section

HiFi™ downcomer

Swirl Tube



ConSep™ Trays in the stripping section

HiFi™ downcomer

Swirl Tube

Secondary downcomer


Sulzer Chemtech

ConSepTM : The Ultra System Limit Mass Transfer Component tested at FRI

Liquid flow Vapor flow

PreemRaff


Sulzer Chemtech

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

PreemRaff


Sulzer Chemtech

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

PreemRaff


Sulzer Chemtech

Swirl Tubes underneath the active area

PreemRaff



Top Reflux Distributor



Mixed Phase Feed Inlet Distributor


Sulzer Chemtech

Test Run 16-19 January 2007

PreemRaff



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




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


Sulzer Chemtech

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


TC352

TC-349

PreemRaff

P (Barg)xx

xx T (°C)

xx F (m3/h)

T-1506 T-1512


Sulzer Chemtech

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 %

PreemRaff



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



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

)


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 (%

)




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)



Test #2: 17Jan, 2-9 pm, MUC at 7.15 pm: measured plant data



186.9=

Out= 3.32 %

Top Reflux: 105.2 m3/h


Feed

180.7

C4s+LCN

56.8 95.4m3/h

C3s-

34.7


8.35

Tray Efficiency (%): 66.7


101.3

8.02

73

105.2

8.21

69.4


8.21=

Sim.= 8.40 %



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




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 (%

)


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

)



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


PreemRaff

P (Barg)xx

xx T (°C)

xx F (m3/h)


Sulzer Chemtech

Test #3: 10 pm 17Jan / 09 am 18Jan: measured plant data



181.4=

Out= 2.87 %

Top Reflux: 100 m3/h


Feed

176.2

C4s+LCN

52.2 95.4m3/h

C3s-

33.8


8.09

Tray Efficiency (%): 80


100

7.82

86.7


7.82=

Sim.= 5.96 %

PreemRaff


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



Thank You

De-C4 in the FCC Gas Plant PreemRaff, Lysekil, Sweden

de-butanizer revamp at preemraff, lysekil, sweden - … · de-butanizer revamp at preemraff,...

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