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Separation Technolgy For HPI PDF
Separation Technolgy For HPI PDF
Separation Technology
for the Hydrocarbon Processing Industry
Technology Leadership
Application Know-How and Service are our Driving Force
0679 2001
Field Services
• Installation consulting,
inspection or supervision
• Full installation services
• Trouble shooting assistance
• Scanning
• Start-up assistance
Ethylene / Propylene Plants
Whatever your plans are, we have the right solution for every service
Hot section
Cracker/ Oil quench/Primary Water 3-stage gas Caustic 4th-stage gas
Furnace fractionator quench compression wash tower compression
Steam
Water
Dehydration unit
• Activated alumina
• Molsieves
• TEG system
Fuel oil
Aromatics
Refrigeration unit
ID ID
5500 4900
C2 Splitter and/or C3 Splitter with Shell HiFi trays
Objectives: +20 % feed rate, same product specification Benefits:
Initial design 1st Option: 1 for 1 retray 2nd Option: 4 for 3 retray • For higher capacity:
Replacement of existing trays enables
24.4 Gcal/hr 28.2 Gcal/hr 25.3 Gcal/hr handling of increased column loads at
higher exchanger duties.
• For higher capacity and / or higher
I.D. 4000 169 trays efficiency:
130 trays 130 trays 307 mm Replacement of existing trays by a
430 mm spacing spacing higher number of new high capacity
C3 feed C3 feed trays enables a reduction in reflux
C3 feed +20 % +20 % and load requirements, but puts
more emphasis on tray capacity and
4.6 I.D. 4000 4.6 4.6 efficiency at low tray spacing.
Gcal/hr 117 trays 150 trays
117 trays Gcal/hr Gcal/hr 350 mm spacing • For new columns:
457 mm spacing Technology can be used to minimize
20.9 Gcal/hr 24.2 Gcal/hr 21.4 Gcal/hr dimensions of new columns, such as
Propane the diameter and height.
Cold section
De-methanizer De-ethanizer C2 Splitter De-propanizer C3 Splitter De-butanizer
C2H2 Acetylene
C3H6
Acetylene recovery to EO-plant Propylene
C2H4
Ethylene
CH4,H2
C2H x C3Hx
C2H 6 C3H8
Ethane Propane
recycle
Ethylene Oxide and Derivates
- Antifreeze agent
- PET production
67% Ethylene Glycols - Polyester production
- Heat transfer liquid
- Plastizicer / softener
- Solvent Revamp of a CO2 absorption column
from high capacity trays to Mellapak
- Textile finishing
7% Ethanolamines - Cosmetics / Soaps Bevore revamp
- Detergents
- Gas purification Gas quantity (t/h) 110
EO CO2 at entry (vol. %) 4.7
- Brake fluid CO2 at exit (vol. %) 1.4
5% Glycol Ethers - Solvent for paint
- Detergents CO2 absorption (t/h) 7.1
- Gas purification
EO production
- Detergents
21% other Ethoxylates - Surfactants
- Emulsifiers
Wash
Know-how colunm CO 2 absorption / s
• Distillation of Ethylene
Oxide (EO)
• Technologies and key
components for:
- Ethylene Glycols
- Ethanolamines For various reaction technologies
- Glycol Ethers cooperating with experienced
- Alkylethanolamines partners
Reactor
Ethylene
Upgrade with Mellapak and MellapakPlus
Oxygen
Gasload 100 % 100 % 137 %
EO production 100 % 100 % 185 %
EO in outlet gas 250 ppm 22 ppm 100 ppm
Pressure drop 170 mbar 52 mbar 73 mbar
Process Features
• Continuous process
• Low by-product formation
• Flexible product ratio
• High yields on raw materials
• High recovery rates
After revamp • Low energy consumption
168 • Extremely low pressure drops
5.1 in the distillation section
• High product purity
0.3
• Joint developments
14.0
Ethanolamine production
Ammonia
Reactor
stripping
Water Ethanolamine
separation
stripping
Reactor
Synthesis Gas Application
Saturator
Cooler
2 ppmv H2S
147 oC 24 oC 32 bara
≈1400 wt
ppm COS
H2S -
Synthesis gas 1
23 oC 30 oC
5 mol % CO2 4.5 mol % CO2
9600 ppmv H2S 600 ppmv H2S
32.5 bara
rich amine
Compact Column Size Selective absorption of H2S with MDEA Tray column
Sulzer packings permit high gas and 60 % CO2 slippage
liquid throughputs resulting in small Mellapak 2 Vol ppm H2S
column diameters (important factor 90 % CO2 slippage
for pressurized columns or when 2 Vol ppm H2S
upgrading existing columns). High Lean MDEA
separation efficiency also allows Lean MDEA
Diameter 700 mm Diameter 1100 mm
the use of short-height columns. Height ca 11 m Height ca 15 m
New columns incorporating these
L/G ca 0.15 Pressure: 56 bar L/G ca 0.15
features result in large savings, Gas temperature: 30-35 oC
both in weight, volume and in
investment costs. Natural gas
with H2S + CO2
The increased selectivity leads to a ca 1 Vol %
higher CO2-slippage in the treated
gas and to a lower CO2 content in Rich MDEA Natural gas
with H2S + CO2
the acid gas which leads to a higher ca 1 Vol %
capacity of the existing Claus plant
or to lower CAPEX in case of a new
plant. Rich MDEA
Benefits for Conversion Units CO - Conversion unit
• Reduced steam requirements, ≥ 188 oC
less energy consumption Steam
200 oC
• Lower OPEX
• Pay back time approx. 1 year
Saturator Saturator
• Less fouling problems No 1 No 2
≤ 70 oC Reactor
Converted gas CO converter
to CO2 amine unit: 65 oC
≤ 6 %wt CO
Removal unit ≥ 82 % wt CO2
212 oC ≈ 390 oC
Regenerator
Reboiler
lean amine
181 oC 188 oC
∆T ≥ 22 oC
∆T ≤ 12 oC
203 oC 200 oC
140 oC 134 oC
152 oC 146 oC
0698 2530-2
Tail Gas Treating
Com-
bustion
Acid gas
42 oC
Quench column
Sulfur
200 oC
Selective H 2S Regenerator
absorption
p = 1 bar
Sourwater stripper
10
Applications in Ammonia and Fertilizer Production
Condensate stripper
Exhaust gas
p = 2.5 bara
110 oC
Steam
128 oC
Formaldehyde Production
• Mellapak in the pump-around sections for Formaldehyde
the removal of the considerable amount of absorber Exhaust gas
absorption heat
• Trays or plastic gauze packing for top part
(final absorption with low water flow) Water
11
Methanol
Applications
• Methanol splitters with fixed
valve trays
• Methanol absorption columns
with structured packing
• Gas saturators with random or
structured packing
0605 2506
Fusel oil
Feed
Benefits with Sulzer high performance VGPlus trays in methanol splitters:
• Reduced column diameter due to greater capacity, compared to sieve
or valve tray
• Great fouling resistance
• Minimize vapor cross-flow channeling by improved liquid flow and
Water vapor/liquid contacting through lateral vapor release
12
DMF / DMAc Recovery and Heat Pump / Heat Integration
Feed
We deliver:
• Key-components such as
column internals, compressors
and heat exchangers
• Studies and basic engineering
for revamping existing units
• Basic engineering for new units
• Commissioning and start-up
Heavy end Product services
13
Treatment of Corrosive Products e.g. Cl2 and HCl
Hypochlorite tower
dry chlorine gas
Make up
H2SO4
0682 2020
Use of Packing and Internals in a highly corrosive milieu, HCI - recovery from phosgenation
e.g. in chlorine and HCl-columns.
Sulzer Packings and Internals are available in the fol- Pressure: approx. 1 bara
lowing corrosion resistant materials: Inerts
Plastics: PP, PVDF, PVC-C, PFA, Halar, PEEK Reflux
Mellacarbon: Graphite
Make up water
Mellapak: High-alloy steels, Hastelloy, Nickel, 80 90 100 110 120
Temp. oC
0%
Tantal, Zirconium, Titanium etc. Typical packing
height: 6 - 7 m
Typical diameter
21 %
0.3 - 1.5 m
H2O
Waste acid
0698 2511
14
Column Design and Process Simulation
Our main applications for which we • Direct Heat Exchange Do not hesitate to ask for design
offer our advantages of a theore- • Columns for DMF and DMAc possibilities or for our Engineering
tical study, based on special know- Recovery Services brochure. If there are no
ledge from field experiences and data available for the design of the
• Waste Water Treatment
pilot tests, are as follows: column, we are also able to offer
• Absorption of Formaldehyde experimental tests in our laboratory
• Columns for Olefin Plants
• Formaldehyde, Methanol, or in cooperation with external con-
• Recovery of Ethylene Oxide Methylal Purification sultants and universities.
• Columns for Ethylene Glycols, • Recovery of HCl
Ethanolamines and Glycolethers
• Removal of CO2 and H2S
15
Headquarters North and South America Asia Pacific
Sulzer Chemtech Ltd Sulzer Chemtech USA, Inc. Sulzer Chemtech Pte. Ltd.
P.O. Box 65 8505 E. North Belt Drive 10 Benoi Sector
8401 Winterthur, Switzerland Humble, TX 77396, USA Singapore 629845
Phone +41 52 262 50 28 Phone +1 281 441 5800 Phone +65 6515 5500
Fax +41 52 262 01 82 Fax +1 281 291 0207 Fax +65 6862 7563
chemtech@sulzer.com
www.sulzerchemtech.com
Sulzer Chemtech Ltd, a member of the Sulzer Corporation, with head- The activity program comprises:
quarters in Winterthur, Switzerland, is active in the field of process engi- • Process components such as trays, structured and random pa-
neering and employs some 2500 persons worldwide. ckings, internals for separation columns and reaction technology
Sulzer Chemtech is represented in all important industrial countries and • Engineering services for separation and reaction technology such
sets standards in the field of mass transfer and static mixing with its as optimizing energy consumption, plant optimization studies, pre-
advanced and economical solutions. engineering for governmental approval, basic engineering
• Separation and purification of organic chemicals by means of crys-
tallization and membranes
• Mixing and reaction technology with static mixers
• Mixing and Cartridges Technology
• Tower field services
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