about

On 20 th June

By P.Kannadoss

Naphtha PDS Reformer

DHDS BLOCK
DHDS SRU

Plant 76

Plant77(Diesel)

Naphtha PDSReformer

PLANT-76 Consists of two major sections 1)PDS 2)Reformer nit

PDS !"jecti#e$ %o pro& ce low s lph r (1'ppm) naphtha from fee& naphtha (1''' ppm ) Reformer !"jecti#e $ %o pro& ce h(&ro)en from sweet naphtha fee& Pro& ct p rit($ **+**, (#ol me) Capacit( $ 22-.'' Nm/0hr of h(&ro)en 1icensor $ Reformer 2 3%4 PS5 66 U!P

7hat is DHDS8 4t is acron(m of Diesel H(&ro De S lph risation 7h( DHDS is nee&e& in present scenario8 - 5im of the nit is to re& ce 9S: content from 1+;6 wt, to '+2. wt , in reactor64 an& .''ppm in reactor644+ - %o meet the en#ironmental control norms an& specifications+ - %o maintain en#ironment clean an& safe+ - Since &iesel is wi&el( se& f el in &e#elopin) co ntries

li<e 4n&ia- DHDS important+

nit is more

7hen the nit was commissione&8 Septem"er 1*** with Reactor64 2''2 Reactor 244 a&&e&+ 7ho are the licensors an& cons ltants8 1icensor 2 =0s 4>P 5?@NS>rance+ Project mana)ement cons ltant 2 =0s @41- New Delhi

H(&ro &es lph riAation $6 4t is a catal(tic process that remo#es s lph r from the h(&ro car"ons "( reactin)

with h(&ro)en at hi)h press re an& temperat re+

Feed stocks: Strai)ht r n )as oils HSD from Pt6 1- Pt61.- Pt6 2'1 1C! an& HC! from >CCU Bas oils from Cis"rea<er nit Product :1ow s lph r Diesel By product :7il& naphtha or S(nthetic naphtha

Feed +Hydro e! --" Lo# $S% d&ese' + !(p)t)( + *ecyc'e (s + Ac&d (s to S*+

Process Descr&pt&o!
Feed ,ro- O./S t(!k 016 F&'tered &! t)e PALL ,&'ter Hydro e! ,ro- *2C (!d D&ese' FroFeed pu-ps (re -&3ed &! spec&,&ed r(t&o .&3&! e!sures (de4u(te PP (t t)e &!'et o, t)e re(ctor .&3ed stre(- &s pre )e(ted #&t) t)e re(ctor e,,'ue!t

Pre )e(ted -&3ture &s )e(ted &! re(ctor )e(ter to re4u&red re(ctor &!'et te-p Fur!(ce out'et e!ter t)e ,&rst re(ctor F&rst re(ctor co!s&sts o, t)ree N&-o c(t('yst 5eds 63ot)er-&c o'e,&! s(tur(t&o! (!d )ydro de su'p)ur&s(t&o! re(ct&o! (re t(k&! p'(ce &! 7st re(ctor To co!tro' t)e te-per(ture r(&se (cross t)e 5eds 4ue!c)&! &s do!e 5y recyc'e (s 7st re(ctor O8L &s t)e seco!d re(ctor &!'et 9!d re(ctor )(s s&! 'e c(t('yt&c 5ed o, N&-o c(t('yst T)e re(ctor e,,'ue!t &s e3c)(! &! )e(t #&t) ,ur!(ce ,eed (!d str&pper ,eed:o!e p(rt; F&!(' coo'&! &s (c)&e<ed &! (&r coo'er (!d t)e! &! co!de!ser

T)e re(ctor e,,'ue!t co!t(&!s (--o!&us('ts To (<o&d (--o!&u- s('ts depos&t&o! &! t)e coo'ers (!d co!de!ser t)e #(s) #(ter &s &!=ected Coo'ed (!d co!de!sed e,,'ue!t &s co''ected &! co'd sep(r(tor T)ree p)(se (re sep(r(ted
&; L&4u&d )ydroc(r5o! :d&ese'; --" str&pper> &&; recyc'e (s --" (-&!e (5sor5er> &&&; #(ter #&t) (--o!&u- s('ts--" #(s) #(ter druTo S*+ : p(rt'y;

L&4u&d )ydroc(r5o! ,ro- co'd sep(r(tor &s pre )e(ted ( (&!st str&pper e,,'ue!t (!d re(ctor e,,'ue!t He(ted e,,'ue!t &s ,ed to str&pper to produce d&ese' #&t) correct ,'(s) po&!t (!d H9S co!te!t

Str&pp&! -ed&u- &s super )e(ted .P ste(-

Str&pper
Str&pper 5ottoStr&pper 5otto- e3c)(! e )e(t #&t) ,eed Se!t to co('escer to sep(r(te e!tr(&!ed -o&sture co!te!t ,ro- str&pper 5otto?(ter #)&c) &s co''ected &! co('escer &s routed to #(s) #(ter druA,ter re-o<&! #(ter drop'ets t)e e,,'ue!t &s dr&ed &! <(cuu- dryer

T)e product &s coo'ed (!d se!t to stor( e

Str&pper o<er )e(d

L& )t e!ds (!d H9S t(ke! ,ro- O@HD Str&pper O@HD &s coo'ed (!d co!de!sed T)ree p)(ses (re sep(r(ted ,roco!de!sed O@HD
Hydro c(r5o! '&4u&d ,or *e,'u3 (!d st(5&'&Aed !(p)t)( ?(ter --" to #(s) #(ter dru2(s --" tre(ted #&t) 'e(! D6A to re-o<e H9S H9S ,ree (s &s '&!ed up to F2 )e(der

H9S r&c) (s &s se!t to S*+ T)e (s ,ro- t)e co'd sep(r(tor &s se!t to HP (-&!e (5sor5er T)e (s &s tre(ted #&t) Le(! D6A :90 #tB D6A; to re-o<e H9S H9S ,ree (s &e> recyc'e (s :1C0- 7#tB o,
H9S;

&s se!t to t)e *2C

H9S r&c) (s &s se!t to S*+ ('o! #&t) H9S r&c) (s ,ro- LP (-&!e (5sor5er .(ke up (s ,ro- upstre(- )ydro e! u!&t &s co-pressed (!d -&3ed #&t) recyc'e (s

*e(ct&o!s
Desirable reactions Desulphurisation (Elimination of sulphur)
Mercaptans R SH + H2 R H + H2 S Sulphides R S R + 2H2 2 R H + H2S

Denitirification

(Elimination of nitrogen)
Catalyst R-CH2CH2CH3 + NH3 Paraffin Ammonia

(Ni3S2) R-CH2CH2CH2NH2 + H2 ---------- Amine

Hydrogenation of oxygenated compounds

atalyst (!i"S2) R H2 H# H2 + H2 %lefin $$$ R H2 H2 H" &araffin

Demetalisation Hydrogenation of olefins and diolefins

Undesirable reactions Hydro crac'ing (reduces product yield and consumes more Hydrogen) o'ing (co'e deposit is the main cause of catalyst acti(ity reduction)

C(t('yst Det(&'s
)*o types of !imo type catalyst are used in reactor + HR ,-. for hydrogenation of unsaturates HR$"-/ for the hydrodesulfuri0ation1 dearomati0ation and hydrodenitrification of hydrocar2on %ne type of !imo type catalyst is used in reactor ++ HR$--/ for (ery high denitrification and aromatichydrogenation acti(ities and desulfurisation acti(ity e3ual to oMo catalysts4

!y t"o catalyst in one reactor#

)o achie(e a high desulphurisation acti(ity and deep desulphurisation

C!oice of catalyst
%lefins

hydrogenation1 denitrification and desulphurisation rates 5romatics hydrogenation ycle length

Rec(cle Bas Compressor

)ur2ine

dri(en compressor of "6/- 78 and 999.2R&M rated Multi stage centrifugal compressor System consists of lu2e oil1 dry gas seal1 condensate reco(ery1 (acuum e:ector

=a<e Up Bas Compressor

reciprocating compressors1electric motor dri(en +t is hori0ontal non $lu2ricated cylinder type1 single compression stage and dou2le thro*
)*o

>ee& >ilter
)his

unit is a duplex design filter )o remo(e suspended solid particles in the feed a2o(e 2. microns4 !um2er of filter elements ; ./" per filter (essel

> rnace
)he 66<9 heater is of con(entional forced draft cylindrical type4 )he heater consists of three sections; 9) <ire2ox or radiant section 2) on(ection i)&rocess section ii) Steam super heating section4 iii) 5ir preheater section ") Stac'4

B(s&c steps ,or t)e DHDS u!&t St(rtup

5ir is purged from the H4& and =& Systems *ith inert gas =ea' chec'ing of H& and =& systems *ith !21 H& system purging *ith H2 H2 gas circulation is started Heater is fired up Ra* HSD% circulation is started through =& side feed cut into reactor &ressure and flo*s are 2rought to normal operating (alues as the heater is 2rought up to normal temperature

B(s&c steps ,or t)e DHDS u!&t S)utdo#!

DDDDecrease

feed throughput to >?@ Shut off the diesel feed to unit DD7eep recycle gas rate at minimum DDStop the *ash *ater in:ection ut off stripping steam

Drain the hydrocar2ons from separator to slop Stop amine feed to H& amine a2sor2er Depressurise the H& system ut off the stripper feed and isolate coalescer Depressurise the stripper and reflux drum and purge *ith nitrogen

@mer)enc( Proce& re
+nitial steps to protect the atalyst and e3uipment from damage during almost any upset4 Reduce heat input to the reactors to 'eep reactor temperatures under ontrol Maintain recycle gas flo* through the e3uipment =imit hydrogen a(aila2ility to minimi0e heat release

@mer)encies
DA5S =E57 %R <+RE +! )HE B!+) DRE C =E A5S %M&RESS%R <5+=BRE DM57E$B& A5S <5+=BRE D<EED <5+=BRE )here are t*o types of feed loss;

=oss of fresh feed to the feed surge drum

$ =oss of feed pump D=%SS %< 85SH 85)ER D=%SS %< 5M+!E )% SCS)EM D<BR!5 E %+= RB&)BRE %R )BDE =E57 DHE5EC H2S =E57 DHE5EC S%BR 85)ER =E57 D&REHE5) EF H5!AER )BDE =E57 D)EM&ER5RBE EF BRS+%! +! )HE DRE5 )%R DED DB)+=+)+ES <5+=BRE

Oper(t&! Co!d&t&o!s
<eed surge drumD &ressure ('gGcm2g) 94. E%R

Reaction section DDDS%R &ressure ('gGcm2g)

DDDReactor inlet; DDDReactor outlet ; )emperature ( ) H DDDDReactor inlet; DDDDReactor outlet ; H& separator D&ressure ('gGcm2g D)emperature ( )

DDD-/4" -"4"

-/4" -"4"

"22 ".?

"." "/?

">4, .?

StripperGsta2ili0erGcoalescer section &ressure profiles ('gGcm2g) .4? DD Reflux drum >4? DD Stripper Dottom >4" DD Sta2iliser )op DDDD>4? DD Sta2iliser Dottom >4" DD

oalescer )emperature profile (I ) D Reflux drum -? Stripper )op Stripper <eed Stripper Dottom Sta2iliser )op Sta2iliser <eed Sta2iliser Dottom oalescer

DDDD-4? S%R 9./ 2.? 2-> 9/" 9-9 2"9 ,6 E%R 9., 2.? 2-> 969 9". 2"" ,>

Control Philosoph( !f %he Process

D<eed <lo* rate DReaction section &ressure control $controlled 2y the pressure at the cold DDDD separator DReactor 2eds temp control $inlet temp of the reactor 2eds controlled 2y 3uench in:ection D%perating parameters Reactor *eight a(erage 2ed tempD(85D)) $ temp increase fa(ors all the hydrogenation reaction

)he hydrogen && at the outlet of the reactor $ +t is function of purge1Dthe recycle gas flo*1Dtemp at reactor %G= the composition of the effluent and the reactor %G= pressure $ && H2 outlet of the reactor must 2e a2o(e "? 'gGcm2 $ && H2 enhances reaction1 reduces co'e formation Space (elocity $ +ncreased space (elocity results in lo*er reaction rate

Process descri$tion
<EED SE )+%! )he feed to the DHDS Bnit is a 2lend of straight run and crac'ed gas oils4 )he DHDS unit recei(es feed from three different sources 94 Straight run gas oil from %MJS tan' .?> 24 = % and H % from < "4 B unit rac'ed gas oil from Eis 2rea'er unit of refinery +++

)an' .?> of %MJS recei(es feed from 94 High sulfur diesel from plant 9 24 High sulfur diesel from plant 9. "4 High sulfur diesel from plant 2?9 of refinery +++ rac'ed gas oil from < B and EDB unit is directly 2rought to the DHDS unit4 8hereas straight run gas oil is fed to the unit from storage under feed surge drum 66 ?9 le(el control =+ 99?94 BE99?9 is the shut off (al(e *hich shuts *hen BE99?2 in < shuts off EDB feed *hen ?9 le(el goes high4 ?9 le(el goes to high high4 B line shuts off the feed for the similar causes4 )hen BE ./?9

)he feed is com2ined and the 2lend is filtered through feed filter pac'age 66)9 and sent to feed surge drum4 )he detail a2out the feed filter is descri2ed in special e3uipments chapter1 )he pressure of the surge drum 94. 'gGcm2g is maintained 2y fuel gas 2lan'eting using a split range pressure controller &+ 99?94 8hen the pressure drops the fuel gas is 2rought in and (enting through flare controls the excess pressure4 <eed surge drum gi(es a surge time of 2? minutes and pro(ides !&SH facility and spill 2ac' to 66A?95GD feed pump <EED &BM&S Reactor <eed &ump 66A$?95GD is a high$pressure multistage centrifugal pump dri(en 2y the H) motor4 )he pump 2oosts the diesel feed from 24? 7gGcm2 to >> 7gGcm21 to ena2le the oil feed to flo* through the high$pressure reaction section4 )otal oil feed rate to the reactor is set 2y a flo* controller <+ $$92?94 )o maintain minimum flo* of the pump1 the flo* from discharge is

sent 2ac' to the feed surge drum 66 $?9 2y automatic (al(e (C5R85C) and ensures minimum flo* through the pump at all times1 thus pre(enting mechanical damage4 <eed flo* controller <+ $92?9 is pro(ided *ith lo* flo* alarm4 BE92?2 shut off (al(e closes *hen feed pump trips to pre(ent pump damage from the re(erse flo* 2y high pressure recycle gas4 &olymeri0ation inhi2itor (antifouling agent) is in:ected in the fresh feed at feed pump suction4 <EED &REHE5) 5!D <BR!5 E )he li3uid feed is then mixed *ith the recycle gas and the com2ined mixture is fed into the preheat exchanger train4 )he mixing of recycle hydrogen *ith feed ensures an ade3uate hydrogen partial pressure at the inlet of the reactor4 )he mixed stream is heated in first feedGeffluent exchanger 66E9 5GDG GDGEG< then in second feedGeffluent exchanger 66E25GD and finally in the reactor heater 66<?9 to the re3uired reactor inlet temperature4 )he reactor inlet temperature is controlled 2y )+ 9.?9 *hich in turn controlling the fuel oilGfuel gas pressure to the heater 2urners (&+ 9-?"G&+ 9-?9)4 RE5 )%R SCS)EM 66<$?9 %G= oil$gas mixture enters first reactor 66 ?2 then to second reactor ?"4 +n the reactors the exothermic olefin saturation and Hydrodesulphurisation reactions ta'ing place in presence of catalyst1 result in a slight heat release that increases the temperature of the reactants4 )his increased temperature further increases the rate of reaction4 )his heat release therefore results in temperature rise across each 2ed4 +n order to control this temperature rise and1 li'e*ise1 the rate of reaction1 a series of reactor temperature controllers is pro(ided to control the temperature profile through the reactors; <irst <irst Rx 4 2nd 2ed +G= $ )+ $$9.9. Rx4 "rd 2ed +G= $ )+ $$9.2$ )+ $$9."-

Second Rx4 +G=

)emperature control is accomplished 2y manipulating the flo* of KcoldL 3uench gas that is introduced 2et*een the catalyst 2eds in each reactor4 )he temperature %G= at each 2ed %G= should 2e maintained same1 *hich may (ary

slightly depending upon the reaction rate in each 2ed4 )he 2ed %G= is 3uenched using cold 3uench gas +n order to measure the temperatures in the reactorsM thermocouples are placed in the catalyst 2eds4 92 thermocouples in the first 2ed of the first reactor1 nine in second and third 2ed of first reactor and fifteen in second reactors4 +n addition to pro(iding temperature control1 the temperatures measured at the top and 2ottom of each 2ed in each reactor can 2e used to monitor reaction progress and to indicate the location and extent of possi2le channeling of reactants4 )emperatures measured at different heights 2ut at the same circumferential position (i4e41 temperature difference across a 2ed) indicate the extent of reaction in the 2ed4 )emperatures measured at the same height 2ut at different circumferential positions in the 2ed can indicate the location and extent of possi2le maldistri2ution of reactants4 <or example1 a li3uid$poor region may experience a higher temperature rise 2ecause slo*er mo(ing li3uid has more time to react and *ill li2erate more heat (local hot spot)4 &ressure drop across each reactor is monitored using differential pressure indicators (<irst Rx4&D+$9.?.1 Second Rx4&D+$9.92)4 !ormal operating conditions are S%R <irst reactor inlet pressure ('gGcm2g) <irst reactor outlet pressure ('gGcm2g) Second reactor inlet pressure ('gGcm2g) Second reactor outlet pressure ('gGcm2g) <irst reactor inlet temperature ( ) <irst reactor outlet temperature ( ) Second reactor inlet temperature ( ) Second reactor outlet temperature ( ) .24" -64> -64" -"4" "22 "-. "-. ".? E%R .24" -64> -64" -"4" "." "6? "6? "/?

Reactor effl%ent coolin& )he reactor effluent is split in to t*o4 +n order to maximi0e the heat reco(ery1 one part exchanges heat *ith the stripper feed in stripper feed preheat exchangers 66E" 5GD under temperature control of the stripper feed *hile the remaining part exchanges heat *ith the reactor feed in second feedG effluent exchanger 66E2 5GD4 )he t*o streams are mixed together 2efore entering 66E95GDG GDGEG< ()u2e side)4 <inal cooling of the reactor effluent is achie(ed in the effluent air condenser 66E-5GDG GD and then in the effluent trim condenser 66E.5GDG GD4 )he normal operating temperatures are S%R ( ) 66 ?" outlet ".? 2." 2/, 26> 99" >. .? 66 E?"5GD outlet 66 E?25GD outlet 66 E?95GDG GDGEG< inlet 66 E?95GDG GDGEG< outlet 66 E?- outlet 66 E?. outlet ASH A'(R S)S'(* E%R ( ) "/? 2-. "29 "?9 92? >. .?

)o a(oid ammonium salt deposits and ris' of corrosion1 *ater is in:ected at the inlet of the effluent air condenser 66E-5GDG GD on continuous flo* control (<+ 2??91 99m"Ghr for the design feed rate) 2y *ashing *ater pump 66A25GD4 )his *ashing *ater is a mixture of recycled *ater from the cold separator 66 and *ater reco(ered at coalescer 66 96 and at the stripperG sta2ili0er reflux drum66 9>4 )his mixture is collected in the *ashing *ater drum 66 >1 *hich is 'ept at 24? 'gGcm2g under fuel gas pressure to a(oid air entry4 &+ 2??9 controls the pressure of the drum4 )he effluent of trim condenser 66E.5GDG GD is collected in the cold separator 66 - *here three phases are separated4 )he sour *ater containing ammonium salts is partly recycled to the *ashing *ater drum 66 > under le(el

control of this drum (=+ 2??9) *hile the other part is sent to the sour *ater stripper under le(el control of cold separator 2oot (=+ 9>?.)4 C+,D S(P(RA'+R )he effluent of trim condenser 66E.5GDG GD is collected in the cold separator 66 - *here three phases are separated4 )he oil le(el in the cold separator (66 ?-) is controlled 2y a le(el controller =+ 9>?24 )he lo* lo* le(el shut do*n function shuts off the shut off (al(e BE9>?2 in the upstream of le(el controller1 *hich pre(ents high$pressure gases entering in to stripping section4 )he sour *ater containing ammonium salts is partly recycled to the *ashing *ater drum 66 > under le(el control of this drum (=+ 2??9) *hile the other part is sent to the sour *ater stripper under le(el control of cold separator 2oot (=+ 9>?.)4 =o* lo* le(el in the 2oot closes the shut off (al(e BE9>?" in the upstream of le(el controller4 )he relief (al(e for the H& section is located on the cold separator &SE9>?951 &SE9>?9D4 Reactor system pressure is controlled at the suction of the recycle gas compressor 2y manipulating the net flo* of ma'e$up hydrogen to the reactor section4 )he controller &+ $9>?9 set point should 2e ad:usted periodically to achie(e the desired pressure at the inlet of the first reactor4 5 high$set point pressure control loop is included on the recycle gas compressor suction line to ensure that pressure does not exceed the set pressure of the reactor loop &SE4 )he normal set pressure maintained at cold separator is "6'gGcm2g 4 )he pressure controller &+ $9>?9 is configured as a se3uence$type split range controller4 +t first opens the K5L (al(e1 *hich gi(es signal to &+ 9/?9 (spill 2ac' in the ma'e up gas compressor loop) and if pressure exceeds it opens the KDL (al(e located at H& a2sor2er outlet4 &+ 9>?9D relie(es the excess pressure 2y (enting H& gases either to flare or to fuel gas4 +n an emergency1 emergency dump (al(e BE9>?9 can 2e opened to 2egin depressuring the high$pressure loop4 )he (aria2le area restriction orifices set the

depressuri0ing rate at normal le(el44 )he hand s*itches (HS$9>?9) operate emergency relief (al(e to open or close the path to the orifices4 )he depressuring installations :oin in the relief header4 5 do*nstream pressure indicator (&+$9>?2) indicates the potential o(erpressurising of the relief header1 if any4 RE C =E A5S SCS)EM H& 5M+!E 5DS%RDER 5!D =E5! 5M+!E SCS)EM )he separator gas is sent for amine a2sorption to the H& amine a2sor2er 7% drum 66 ?6 and then is partly sent to H& amine a2sor2er 66 ?/4 =ean amine (2.@ *t DE5 solution) from off plot 5RB is recei(ed in the lean amine surge drum 66 ?,4 =ean amine from 66 ?, is pumped 2y 66A$?"5GD through <E$$96?9 and the shut off (al(e BE$96?" to H& amine a2sor2er 66 ?/4 )he lean amine flo* to the a2sor2er (,? m "Ghr4) is set to achie(e the desired degree of H 2S remo(al from the recycle gas4 5 shutoff (al(e BE96?" *ill close on lo*$lo* le(el in the surge drum 66 ?,4 )he lo* lo* le(el in the surge drum also stops the lean amine 2ooster pump 66A?"5GD )he temperature of the lean amine must 2e maintained . hotter than the feed (apor temperature to pre(ent any condensation of the (apor on contacting the lean amine4 )his is critical in pre(enting foaming in the a2sor2er4 5 differential temperature measurement ()D+ $96?9) is pro(ided for controlling the lean amine temperature4 4 H& H2S a2sor2er 66 ?/ rich amine le(el is controlled 2y the le(el control (al(e =E$96?9 at the 2ottom of a2sor2er to 2e fed to the =& amine a2sor2er 66 994 )he shut off (al(e BE96?2 closes *hen ?/ le(el goes to lo* lo* le(el to pre(ent high pressure entering in to =& a2sor2er section4 )he pressure drop across the trays1 measured 2y a differential pressure indicator &D+$96?>1 is the 2est indicator to detect foaming in the a2sor2er4 5 full line si0e hand controlled 2ypass of the H 2S a2sor2er H+ $96?9 is pro(ided at the top of H& amine a2sor2er4 )his 2ypasses the gases from cold separator partly to recycle gas compressor 7% drum 9"4 )his 2ypass allo*s for

control of H2S concentration in the recycle gas4 )he gas purge is pro(ides at the top of H& amine a2sor2er to control the 2uild up of hea(ies in the hydrogen gas recycle stream4 !ormally the flo* rate of this stream is 0ero4 66A$?"5GD is protected 2y a lo*$flo* spill2ac' system4 )he automated C5R85C (al(e spill2ac's the excess flo* to lean amine surge drum for maintaining minimum flo* through the pump4 )he high$pressure lean amine surge drum (66 ?,) pressure is controlled 2y a split$range pressure controller &+ $96?9 (on falling pressure1 fuel gas is 2rought inM on rising pressure1 fuel gas is (ented to flare)4 RE C =E A5S %M&RESS%R 6672 ?/ and the Hp a2sor2er 2ypassed gases

)he H2S remo(ed gases from

are sent to recycle gas compressor 7% drum 66 9" *here the entrained li3uid is remo(ed4 5 high$le(el trip *ill shut off the recycle compressor to pre(ent li3uid from reaching the recycle compressor4 )he recycle gas compressor (6672) circulates the recycle gas through the high$pressure system4 )he compressor is a t*o stage centrifugal compressor4 <irst stage discharge is cooled in the inter stage cooler 66E2? and the entrained li3uid in the first stage outlet is remo(ed in the interstage 7% drum 66 2"4 5 high le(el in 66 2" *ill shut off the recycle compressor to pre(ent li3uid from reaching the recycle compressor4 %ne part of compressor discharge :oins the Rx4oil feed going to 66E95GDG GDGEG<4 )he other part goes as 3uench gas to reactor 2eds as already descri2ed4 5ntisurge flo* controller <+ $9,?2 fixes the spill2ac' flo* (<+$9,?9) to 66E$?- to a(oid KsurgeL1 an unsta2le condition of *idely oscillating flo* rates that *ill damage the machine4 )here is almost no flo* through the spill2ac' line during normal plant operation4

*A-( UP .AS C+*PR(SS+R )he hydrogen ma'e up gas coming from 2attery limit is routed through chlorine adsor2ent pot 66 2? to the ma'e up 74% drum 66 .4 )he high high le(el in . trips the ma'e up gas compressor 667?95GD4 +t is then compressed 9/?9) 2y means of a compressor spill2ac'1 *hich is 2y the ma'e up compressor 6679 5GD4 )he ma'e up gas flo* rate to the reaction section is controlled (<+ sent 2ac' to the ma'e up 74% drum after cooling through spill2ac' *ater cooler 66E>4 )he ma'e up gas :oins the recycle and 3uench gas upstream to the recycle 74% drum 66 9"4 )he com2ined ma'e up + recycle+3uench stream is routed (ia the recycle gas compressor 66724 S'R/PP/N. S(C'/+N S'R/PP(R 0((D PR(H(A' AND S'R/PP(R )he hydrocar2on li3uid phase from the cold separator is routed under flo* control <+ 9>?9 reset 2y cold separator drum le(el =+ 9>?2 to the stripper feedG2ottom exchanger 66E?65GDG GD4 )his stripper feed is first preheated 2y heat exchange against stripper 2ottom product in the stripper feedG2ottom exchanger 66E?65GDG GD and then 2y heat exchange against the reactor effluent in the stripper feed exchanger 66E?"5GD in order to reach the re3uired stripper inlet temperature4 )+ 29?9 controls the stripper inlet temperature 2y 2ypassing reactor effluent4 )he normal operating temperatures are S%R( ) 66 ?- outlet 66E?65GDG GD outlet 66E?"5GD outlet ." 9,2.? E%R ( ) ." 9,2 2.?

)he outlet of 6>E?" is fed to stripper (66 9-) in order to produce a diesel *ith a correct flash point and H2S content4 )he stripper is a (al(e tray to*er consists of 2. trays4 )he feed enters at 9>th tray of stripper4 Medium pressure steam superheated in the reactor hater 66<?9 is in:ected into stripper under flo* control <+ 9-?9 as stripping steam4 Stripper feed

temperature and correct flo* of stripping steam is to 2e maintained in order to produce diesel *ith a correct flash point and H2S content4 )he stripper pressure is controlled 2y &E22?9 located at the o(erhead line of =& a2sor2er 994 )he normal operating conditions are Stripper inlet temperature Stripping steam rate Stripper pressure Stri$$er o1er !ead stripperGsta2ili0er reflux drum (66 9>) =ight ends and H2s gather at the top of the stripper4 Stripper o(erhead and sta2ili0er o(erhead are mixed 2efore 2eing partly condensed in the stripperGsta2ili0er air condenser 66E?, and then in the stripperGsta2ili0er trim condenser 66 E9?4 orrosion inhi2itor is in:ected into the stripper o(erhead line 2efore mixing *ith sta2ili0er o(er head4 )he stripperGsta2ili0er trim condenser outlet comprising of three phases is separated in the stripper reflux drum 66 9>M a hydrocar2on li3uid phase (*ild naphtha)1 a free li3uid *ater phase and a (apour stream4 )he decanted *ater from 66 9>2oot is sent under 2oot le(el control =+ 22?9 to the *ashing *ater drum 66 ?>4 )he hydrocar2on li3uid phase is split into reflux1 *hich is returned to the stripper under flo* control and li3uid distillate (*ild naphtha)1 *hich is routed to the sta2ili0er feed 2ottom exchanger4 )he reflux is pumped 2y reflux pump 66A?-5GD to stripper and is controlled 2y flo* controller <+ 22?24 )he normal operating conditions are )he stripper o(erhead temperature ( ) )he stripper o(erhead pressure 'gGcm2g E?, outlet temperature E9? outlet temperature ( ) ( ) 9.?$9>? .4? >. -? ( ) 'gGhr 'gGcm2g 2.? .??? .4?

Reflux ratio NAPH'HA S'A2/,/3(R

(@*t)

-4?

)he other part of the reflux (*ild naphtha) *hich is routed to the sta2ili0er feedG2ottom exchanger 66E99 under flo* control <+ 22?9 reset 2y the le(el control on stripperGsta2ili0er reflux drum4 )he 66E99 effluent is fed to the top of the naphtha sta2ili0er 66 9.4 =ight ends and H2S gather at the top of the sta2ili0er and are routed after in:ection of corrosion inhi2itor to the top of the stripper to 2e mixed *ith its o(erhead4 )he naphtha sta2ili0er is re2oiled 2y the sta2ili0er re2oiler 66E92 *here heat is exchanged against a part of the stripper 2ottom4 )+ 2"?9 controls the sta2ili0er "rd )ray temperature4 )he sta2ili0ed naphtha exchanges heat *ith sta2ili0er feed in 66E99 and cooled in the sta2ili0ed naphtha *ater cooler 66E9" and sent to storage or slop (ia sta2ili0er le(el controller =+ 2"?9 2y sta2ili0ed naphtha pump 66A?/5GD4 )he normal operating conditions are Sta2ili0er feed temperature Sta2ili0er 2ottom temperature E99 outlet temperature E9" outlet temperature Sta2ili0er pressure ,P A*/N( A2S+R2(R )he (apour stream from stripper o(erhead after mixing *ith a sour gas from the Hydrogen unit is sent to the =& amine a2sor2er 74%4drum 66 9? *here entrained li3uid is 'noc'ed out4 )his stream is then fed to the =& amine a2sor2er 66 994)he (apour fed to the =& amine a2sor2er and (apour generated from flashing of rich amine from H& amine a2sor2er is *ashed 2y a lean DE5 solution to remo(e the H2S4)he lean DE5 to *hich anti$foaming agent is in:ected is fed at the top of the column under flo* control <+ 2/?94)he rich DE5 solution is *ithdra*n under le(el control at the 2ottom of the =& amine a2sor2er =+ 2/?9 to ( ) ( ) ( ) ( ) 'gGcm2g 9". 2"9 996 -? .4?

2e sent to the amine regenerator section4 )he (apour from =& amine a2sor2er then goes to the stac'ed =& amine a2sor2er 74%4 drum 66 924 &ressure control is achie(ed in the stripping section (& amine must 2e maintained . on (apour from reflux drum) 2y acting on the fuel gas rate from =& amine a2sor2er 74% drum4 )he temperature of the lean hotter than the feed (apor temperature to pre(ent

any condensation of the (apor on contacting the lean amine4 )his is critical in pre(enting foaming in the a2sor2er4 5 differential temperature measurement ()D+ $2/?9) is pro(ided for controlling the lean amine temperature S'R/PP(R 2+''+* 5 part of the stripper 2ottom product goes to re2oil the sta2ili0er 2ottom4 +t is then mixed again *ith the stream 2ypassing the sta2ili0er re2oiler4 )he stripper 2ottom product is then di(ided again in t*o streamsM 94 %ne of the t*o streams is cooled against the stripper feed in 66E?65GDG GD to ,> and sent to the coalescer 66 96 24 )he other stream is mixed *ith the outlet hydrocar2on stream of the coalescer4 )he flo* rate of the second stream is controlled 2y the inlet temperature of the dryer 66 9/4 Dy )+ C+A,(SC(R )he coalescer is a hori0ontal (essel separates entrained moisture content from the stripper 2ottom product4 )he *ater droplets coalesced through the element gets collected in the hori0ontal sump pro(ided at the 2ottom and thereafter drained to the *ashing *ater drum through coalescer 2oot =+ 2-?94 )he coalescer element consists of cylindrical 2ed of glass fi2er and SS 'nitted mesh4 5ll the solid particles 2.$2? microns and a2o(e are trapped in the element4 )he normal operating conditions are oalescer pressure oalescer inletGoutlet D& Maximum allo*a2le Dp !ormal operating temperature "4? 'gGcm2g ?4.'gGcm2g 94? 'gGcm2g ,> 2.?94

DR)(R4 )he flo* rate of the dryer inlet stream is controlled 2y the stripper 2ottom le(el controller =+ 29?9 +n the (acuum dryer most of the *ater is (apourised as *ell as some amount of light gas oil fractions4 5ll these (apors are cooled and partially condensed in the dryer o(erhead *ater condenser 66E9-4 )his condenser is connected to t*o stage (acuum system using e:ectors (66H9 and 66H2) operating *ith medium pressure steam4 )he dryer pressure is controlled 2y gas spill2ac' from e:ector discharge to the dryer o(erhead &+ 2.?94 )he dryer first and second stage condensers 66E9. (intermediate *ater condenser) and 66E9>(final *ater condenser)4 =i3uid and *ater condensate from *ater condensers 66E9-1 66E9. and 66E9> are collected in the dryer o(erhead drum 66 9,4 )he uncondensa2les are routed to safe location4 )he decanted a3ueous phase is pumped from 2affled dryer o(erhead drum 2y oily *ater pump 66A>5GD and sent under le(el control of the drum (=+ 26?9) to the *ashing *ater drum 66 > or to the 2ottom of sour *ater stripper (out of the DHDS Bnit 2attery limit)4 =i3uid hydrocar2on phase is pumped from 66 9, 2y the dryer o(erhead diesel pump 66A65GD and recycled to the coalescer feed 2y oil le(el controller =+ 26?24 )he dryer 2ottom product is pumped 2y dryer rundo*n pump 66A?.5GD to storage after cooling 2y air cooler 66E9/ and product *ater cooler 66E9,5GDG GD4 )he product flo* rate is controlled 2y dryer le(el controller =+ 2.?94