Diesel Hydrodesulfurization

Submitted to:
Mr. Usman Hafeez
Senior Engineer

Submitted by:
Syed M Arsal Hashmi
Trainee Engineer
Contents:
INTRODUCTION…………………………………………………………………………………
PLANT DESIGN CONDITIONS………………………………………………………………
DESIGN BASIS………………………………………………………………………………
EURO SPECIFICATIONS……………………………………………………………………
DIESEL FEED SPECIFICATIONS…………………………………………………
DIESEL PRODUCT SPECIFICATION………………………………………………………
REACTOR CATALYST TYPE……………………………………………………………
PROCESS FLOW………………………………………………………………………
DIESEL CIRCUIT………………………………………………………………………
HYDROGEN CIRCUIT………………………………………………………………………
PLANT DESIGN AND OPERATIONAL CONDITIONS……………………………………
PUMPS DESIGN & OPERATIONAL CONDITIONS………………………………………
HEAT EXCHANGER DESIGN & OPERATIONAL CONDITIONS………………………
FIN-FAN COOLER DESIGN & OPERATIONAL CONDITIONS……………………………
 INTRODUCTION:

Hydrodesulfurization is a process used to remove impurities like organic sulfur, nitrogen, and
metal compounds from hydrocarbons. The HDS process typically involves passing the diesel oil
or other hydrocarbon feedstock over a fixed bed catalyst in the presence of hydrogen gas at high
temperatures and pressures. The sulfur compounds in the feedstock react with the hydrogen on
the catalyst surface, forming hydrogen sulfide (H2S), and nitrogen compounds react to form
ammonia (NH3), which can then be removed from the hydrocarbon stream. HDS is an important
process for reducing emissions of sulfur and nitrogen-containing pollutants from transportation
fuels and other hydrocarbon products. The HDS process is also helpful to saturate olefin and
aromatic compounds. The chemistry behind this HDS process involves the following given
reactions that take place in the reactor:

1. Olefin Saturation:
Olefins are less stable and unsaturated hydrocarbons that contain a double bond in their
structure, due to their highly reactive nature they tend to form polymers and gum
deposits, also form Ozon, and cause air pollution if contacted with atmospheric oxygen.
Olefins have lower cetane numbers than paraffin. The Olefin saturation process involves
the conversion of double-bond unsaturated hydrocarbons (olefins) into single-bond
saturated hydrocarbons (paraffins). Because of this reaction, we can limit the gum
deposits and it helps to enhance the cetane number for diesel. These reactions are highly
exothermic and release more energy as compared to other reactions. So, the concentration
of olefins directly relates to the reactor bed temperature profile. Higher the olefin
concentration, the higher the bed temperature rise.

2. Metals removal:
After the olefin saturation, metal removal reactions due to adsorption are the second least
difficult reactions. In this process. organo-metals (nickel, vanadium, and iron),
containments (sodium, calcium, and magnesium), and Filmer (phosphorus, silicon, and
lead) are removed which required 315 °C temperature for complete metals removal.
organo-metals may be present geologically in the oil and other processes like
transportation, refining, and extraction also contributes to the injection of metals. These
metals may cause fouling and leaves deposits in the engine so it is necessary to remove
them. Regeneration of the catalyst is not possible which is poisoned by metals and the
only solution is to replace the catalyst so rector guard or guard beds are used to absorb
these impurities to save the main catalyst. Metals concentration in the feed also relates to
the reactor temperature and catalyst life. Excessive increases in metals can decrease the
catalyst activity and life cycle.

3. Halides Removal:
Removal of halides like chlorides and bromides is the third least difficult reaction in this
chemistry. Halides-containing compounds react with hydrogen and form acids like HCl
which can react with the material body and leads to corrosion and wear and tear. Other
than that halide deposits cause fouling and decrease the over-quality of diesel fuel.
During the reactions, these acids react with ammonia and form ammonium chloride salts
and we remove these salts by dissolving in wash water.
4. Desulfurization:
Sulfur removal is one of the main reactions to meet the desired euro specification for fuel.
Our HDS plant at phase-1 follows the euro-2 standards which allows 500 ppm of sulfur
in the final diesel product, and our plant feed is designed for a maximum of 5000 ppm of
sulfur. Sulfur is naturally occurring in geological formation and it may present in sulfide
(RSR), disulfide (RSSR), and mercaptan form (RSH). Which reacts with hydrogen and
produces hydrogen sulfide as a by-product which is removed after further treatment upon
combustion of sulfur containing diesel it produces oxides of sulfur which cause air
pollution. Sulfur also causes corrosion in engines by forming sulfuric acid when reacted
with water. Higher sulfur in feed requires a higher amount of hydrogen and more
compressor load is needed and leading to a rise in reactor bed temperature.

5. Oxygen Removal:
Bounded oxygen which is present in fuel in the form of alcohol causes partial oxidation
or improper combustion of fuel because of the competition between inner oxygen and
fresh oxygen. For complete combustion, it is required to control air to fuel ratio, properly.
High fuel and less oxygen produce carbon monoxide due to incomplete combustion. Low
fuel and high oxygen content produce high temperature and thermal stress on the engine.
Due to this reason, we need to remove this bounded oxygen to stop CO and NOx
formation. CO and NOx formation produces smog and respiratory problems which lower
fuel efficiency and increases fuel consumption.

6. Denitrogenating:
Nitrogen removal is more difficult than sulfur removal because amines are more stable
than Sulfides and mercaptan so it requires more energy and a more complex process.
Nitrogen is naturally occurring in animals and plants. It produces nitrogen oxides upon
fuel combustion which causes smog, acid rain, and air pollution. This process involves
the reaction of nitrogen-containing compounds with hydrogen and produces ammonia
and alkanes. Ammonia reacts with halides and forms ammonium chlorides.

7. Aromatic Saturation:
Aromatic saturation is the most difficult reaction of this HDS process. Aromatics are
highly exothermic and occur naturally by decomposition. The density of aromatics is
higher and makes higher deposits due to a higher tendency of soot formation (by
incomplete combustion). This saturation process involves the conversion of double
bounded aromatics hydrocarbons into cycloalkanes in this way we can enhance the cetane
number for diesel.
EURO Emission Standards:
The Euro emission standards are a set of regulations established by the European Union (EU) to
limit the levels of harmful pollutants that can be emitted from vehicles. These standards are
limits upon fuel emissions to improve air quality and health. The Euro emission standards
specify the maximum allowed levels of certain pollutants that a vehicle can emit, including:
1. Sulfur (S)
2. Nitrogen oxides (NOx)
3. Particulate matter (PM)
4. Carbon monoxide (CO)
5. Hydrocarbons (HC)
The Euro emission standards apply to different types of vehicles, including passenger cars, light-
duty vehicles, heavy-duty vehicles, motorcycles, and other types of vehicles. The standards have
been in place since 1992, with each new iteration of the standards becoming more stringent and
reducing the allowable levels of pollutants.
Table-1 Euro Emission Standards (Euro-1 to Phase-6)

Euro 1 2 3 4 5 6
Sulfur, ppm 1000 500 350 50 10 10
Nitrogen Oxides, g/km 0.97 0.79 0.5 0.25 0.18 0.08
Particulate Matter, g/km 0.14 0.08 0.05 0.025 0.005 0.005
Carbon Monoxide, g/km 2.72 1 0.66 0.5 0.5 0.5
Hydrocarbons, g/km  * * 0.56 0.3 0.23 0.17

PLANT DESIGN CONDITIONS:

This HDS plant is designed for two different phases. Phase-1 covers the euro-2 emission
standard while Phase-2 is for the euro-4 emissions standard. Phase 1 is based on a single reactor
but to meet phase 2 conditions another rector will be installed shortly to control the hydrogen gas
purity in the recycled gas stream of hydrogen which also contains some percentage of hydrogen
sulfide gas in it, a scrubber can be used.
 Table-1 Design Bases for Diesel Phase-1, Euro-2 and Phase-2, Euro-4

Phase-1 Euro-2 Specifications Phase-2 Euro-4 Specifications

Design Objectives Design Objectives

Cycle length for catalyst 24 months Cycle length for catalyst 24 months
Produces Low Sulfur Diesel Product (LSD) Produces Low Sulfur Diesel Product (LSD)
with sulfur < 500 ppm with sulfur < 50 ppm
Cetane Index (D-976): Minimum 46 Cetane Index (D-976): Minimum 51
Density in the range of (820-860) kg/m3 Density in the range of (820-845) kg/m3

Feed
60 vol. % Sweet straight run Diesel
24 vol. % Sour straight run Diesel
16 vol. % Heavy straight run Diesel
Total feed 12,500 BPSD

Hydrogen
Hydrogen purity Minimum 89 mol. %

DESIGN BASIS:

HDS plant is designed on the given parameters:

Table-1 Design Bases for Diesel Phase-1, Euro-2 and Phase-2, Euro-4

Case/Phase Phase 1 Phase 2

(Target)
Feed rate
BPSD 12,500 12,500
m3/h 82.8 82.8
t/h 71 71
Feed Distillate
Density, g/ml @ 15 °C 0.858 0.858
Sulfur, wt.% 0.5 0.5
Nitrogen, PPM 100 100
Bromine No. g/100g 0.5 0.5
Distillation ASTM D86
IBP 186 186
FBP 386 386
Product Distillate 150°C
99.62 99.51
 Yield, wt.% 0.846 0.845
Density @ 15 °C 500 50
Sulfur, PPM 52 52
Cetane Index 0.36 0.42
Chemical H2 consumption,
wt.%
Reaction
Hydrotreating LHSV, 1/h 2.56 0.99
Gas/HV. Nm /m
3 3
212 212
Makeup Gas purity, vol% 89 89
R Gas purity, vol% 79 79
Separator Pressure 40 40
Catalyst Graded/KF757 Graded/KF757
Catalyst Cycle (Months)
24 24

DIESEL FEED SPECIFICATIONS:

 Table-3 HDS Diesel Feed Specifications

Feedstock Sweet Heavy Sour Blend Operational

SRGO SRGO SRGO
Feed Rate
BPSD 7500 3000 2000 12,500
m3/h 49.7 19.9 13.3 82.8
t/h 42.1 17.5 11.4 71
Density @ 15°C 0.8476 0.8608 0.8808 0.8577
g/ml
Specific Gravity @ 0.848 0.881 0.861 0.858
60/60 °F
Sulfur, wt.% 0.11 0.42 0.2 0.5
Nitrogen, ppm 50 76 135 100
Bromine No. g/100g 0.5 0.5 0.5 0.5
Total Aromatics, Vol. 18.1 30.3 27.7 22.5
%
Total Aromatics, wt. 24.1 36.2 33.9 28.68
% 15.5 18.3 20.1 16.9
Mono 7.5 14.56 11.5 9.9
DI 1.07 3.34 2.3 1.8
Tri
Cold Flow Properties,
°C 8 8 11 9
Cloud Point 6 3 4 5
CFPP 2 -3 5 1
Pour Point
Color 0.5 1 1.5 <1.5
Flash Point, °C 66 98 78 79
Viscosity@ 40°C cst 3.3 4.8 4.7 3.8
Cetane Index 51.6 43.7 50.1 49.2
Distillation
IBP 180 214 202 186
FBP 369 397 400 386

DIESEL PRODUCT SPECIFICATION:

 Table-4 HDS Product Diesel Specifications

Diesel Operational
Specific Gravity @60/60 F 0.848
Sulfur PPM 500
Total Nitrogen PPM <50
CFPP °C 5–7
Color D1500 <2
Viscosity @ 40C Cst <3.8
Cetane Index D976 51.7
Flash Point 71
Distillation
IBP °C 191
°C 386
FBP

REACTOR CATALYST
A catalyst is a substance that changes the rate of reaction without itself being changed. It enables
a reaction to proceed at a faster rate by reducing the activation energy.
Catalyst compositions are:

CATALYST LOADING Bed No. SHAPE VOLUME,

METHOD
M3
KG-55 Sock 1A Pentaring 0.78
KF-542-9R Sock 1B Rings 0.78
KF-542-5R Sock 1C Rings 0.78
KF-841-3Q Sock 1D Quadra-lobe 1.9
KF-757-1.5E Dense 1E Tri-lobe 19.79
KF-841-3Q Sock 1F Quadra-lobe 0.59
3 mm Ceramic Balls 0.29
6 mm Ceramic Balls 0.29
Clearance 0.29
KF-841-3Q Sock 2A Quadra-lobe 0.59
KF-757-1.5E Dense 2B Tri-lobe 19.77
KF-841-3Q Sock 2C Quadra-lobe 0.57
3 mm Ceramic Balls 0.23
6 mm Ceramic Balls 0.21
19 mm Ceramic 0.58
Balls

CATALYST TYPE SHAPE VOLUME, m3

KG-55 Alumina Silica N/A 0.76
KF-542-5R Ni & Co & Mo Rings 0.76
KF-542-9R Ni & Co & Mo Rings 0.76
KF-841-3Q Ni & Mo Quadra-lobe 3.61
KF-757-1.5E Co & Mo Quadra-lobe 39.53

PROCESS FLOW:
The complete process of Hydrodesulfurization (HDS) is divided into two different circuits:
 Diesel Circuit
 Hydrogen Circuit
Diesel Circuit is further divided into three different sections which are given below:

 Diesel Circuit

1. FEED SECTION:
 NDP Feed Tanks (HDS-TK-338/339)
 OSBL Pump (HDS-P-400)
 Feed Coalescer (HDS-ME-001)
 Fresh Feed – Stripper Bottom Exchanger (HDS-E-001)
 Feed Filter (HDS-ME-002)
 Feed Surge Drum (HDS-V-001)
 Charge Pumps (HDS-P-001 A/B)

2. REACTOR SECTION:
 Combined Feed Exchanger (HDS-CFE-002 A/B/C)
 Combined Feed Heater (HDS-H-001)
 Reactor (HDS-R-001)
 Product Condenser (HDS-EA-001)
 Separator (HDS-V-003)

3. FRACTIONATION SECTION:
 Flash Drum (HDS-V-004)
 Stripper Feed – Bottom Exchanger (HDS-E-003)
 Stripper (HDS-V-007)

3.1. STRIPPER TOP PRODUCT

 Stripper Condenser (HDS-EA-002A/B)
 Stripper Receiver (HDS-V-008)
 Stripper Reflux Pump (HDS-P-004A/B)
 3.2. Stripper Bottom Product:
 Stripper Bottom Pump (HDS-P-003)
 Stripper Reboiler (HDS-H-002)
 Stripper Feed – Bottom Exchanger (HDS-E-003)
 Fresh Feed – Stripper Bottom Exchanger (HDS-E-001)
 Stripper Bottom Cooler (HDS-EA-003A/B)
 Stripper Bottom Trim Cooler (HDS-E-004)

 HYDROGEN CIRCUIT

Hydrogen Circuit:
 Makeup Gas Cooler (HDS-E-006)
 Makeup Gas Compressor Suction Drum (HDS-V-006)
 Makeup Gas Compressor (HDS-C-001A/B)
 Recycle Gas Compressor Suction Drum (HDS-V-005)
 Recycle Gas Compressor (HDS-C-001A/B)

DIESEL CIRCUIT
 • FEED SECTION:
NDP Feed Tank (HDS-TK-338/339):
HDS plant is designed to remove contaminants like sulfur, nitrogen, and organ metals. TK 338
and 339 are used as storage tanks for diesel. These tanks are CRT (cone roof) type with a
capacity of 3181m3. A fuel gas blanketing is provided at the top to avoid any direct contact of
diesel with air otherwise gum formation and an increase in pressure drop across the strainers,
filters, and reactor may result in equipment fouling due to the oxidation and polymerization
reactions over the diesel’s surface in the presence of air, which is undesirable for any industrial
process. Nitrogen blanketing or using floating roof tanks is another solution for avoiding this
fouling.
These tanks are designed at atmospheric pressure and many safeties equipment is provided to
overcome the possibilities of implosion (under-pressurized) and explosion (over-pressurized)
conditions and for safe plant operation. To maintain tank inside pressure an air level is provided
having a density of 1.29kg/m3, at the top to overcome any pressure variation especially during
online and filling conditions. Below the air, fuel gas with a density of almost 700kg/m3 is used
to make a partition between air and diesel. The density of diesel is 845kg/m3 and it is maintained
below the fuel gas due to its higher density. The water content present in diesel, is denser than
above mentioned all with a density of 1000 kg/m3, so it can be drained from the bottom of the
tank to avoid any excessive pressure.
A breather valve which is also called a pressure/vacuum relief valve is provided on the tank's
roof which allows enough air to enter or leave when the tank is at IN and OUT breathing
position, to maintain the internal pressure. Its set point is (50 to 275) mmH 2O or (0.0050 to
0.0275) kg/cm2(g).
The emergency vent is also introduced at the top of the tank which operates in emergency
conditions like fire to release excessive pressure inside the tank. This vent operates when the
tanks inside pressure raise to the set point of 250 mmH2O.
A radar level gauge is used to indicate the level inside the tank. It transmits low-energy, high-
frequency electromagnetic signals through an oscillator. Distance is measured by considering the
oscillator as a reference point. Once the electromagnetic signals hit the fluid surface it reflects
pulsating signal to the radar antenna. Pressure Safety Valve with a set point of 3.5 kg/cm 2(g), is
also for the protection of pipe and tank against over-pressure.

Offside Battery Limit Pump (HDS-P-400A/B):

At the offside of the battery limit of the HDS plant, a Single stage centrifugal pump is introduced
which is a charge pump for the HDS plant, with a spill back line to maintain the flow rate and a
strainer at the suction side of a pump having a size of 8 inches and 30 mesh. This strainer
prevents the passage of any particulate. This pump takes feed at 1.1 kg/cm 2(g) of pressure at (1-
41) °C of temperature range and feed leave the pump with the discharge pressure of 8.5
kg/cm2(g).
 Design Parameter
Suction Pressure 1.1 kg/cm2(g) Differential Head 89.42m
Differential Pressure 7.5 kg/cm2 (g) Motor Power 46.2 KW
MCSF 69 m3/h NPSH(R)/NPSH(A) 3.96 m/12 m
MCTF 21.63 m /h
3
Ampere (MAX.) 122.6 A
Efficiency 75.10% Impeller Diameter 270 mm
RPM 2970 Ingress Protection IP 55
Operational Parameters
Suction Pressure 1.1 kg/cm2 (g) Discharge Pressure 8.5 kg/cm2 (g)
Differential Pressure 7.5 kg/cm2 (g) Ampere 75 A

Feed Coalescer (HDS-ME-001)

A feed coalescer is a horizontal vessel that is used to remove particulate and water from diesel
feed. The fresh feed goes through filters to remove particulate matter and water droplets
entrapped in diesel oil. The feed filters can be replaceable. It consists of four cartridge-type
coalescer elements with a dimension of (6 inches outer diameter * 56 inches length), made of
glass fiber. When feed comes in contact with fibrous material of coalescer water droplets inside
the diesel coalescence and gets separated from the diesel. And two cartridge-type separator
elements with dimensions of (6 inches outer diameter * 43 inches length), made of Teflon
material. Twenty-five-micron filters can effectively remove most of the particulate matter that
could accumulate in the reactor and cause pressure drop buildup. These filters provide a total
filtration area of 3.2 m2. These coalescer filters are designed at a maximum pressure drop of 3.6
kg/cm2 (g). PDI is installed which indicates the pressure drop across the feed coalescer and when
the value reaches 1.5 kg/cm 2 (g) then these filters are replaced. Filter's life directly depends upon
the quality of diesel feed and the content of water and particulate matter in it. These filters are
reusable after washing through kerosene.

Design Parameter
Design Pressure 10.5 kg/cm2(g) Hydro Test Pressure 25.76 kg/cm2(g)
Design Temperature 140 °C Volume 0.848 m3
PSV (S.P) 10.5 kg/cm2 (g) Filter (Pressure Drop) 3.6 kg/cm2 (g)
Operational Parameters
Operational Pressure (5-7) kg/cm2 (g) Operational Temperature (30-35) °C

Fresh Feed – Stripper Bottom Exchanger (HDS-E-001):

After the ME-001 feed enters with the flow rate of 64 m3/h and pressure of 6.9 kg/cm2 (g) into
the shell side of single pass and U-shaped bundle of shell and tube heat exchanger where diesel
feed exchanges heat with stripper bottom product and reaches the temperature of almost (90-95)
°C from (30-35) °C. A flow control valve is provided before the inlet of the exchanger which
controls the feed flow according to the level of surge vessel V-001. At the tube side of this
exchanger, feed enters at 220°C and leaves at 165°C, to control the output temperature of diesel
feed at the shell side another control valve (TCV) is provided at the bypass line of the tube sides'
feed.

Design Parameter
Shell Side Tube Side
Design Pressure 15.5 kg/cm (g) 2
Design Pressure 20 kg/cm2 (g)
Design Temperature 140 °C Design Temperature 255 °C
Hydro Test Pressure 22.39 kg/cm2 (g) Hydro Test Pressure 29.66 kg/cm2(g)
No. of Passes 1 No. of Passes 2
PSV (S.P) 15.5 kg/cm2 (g)
Design Duty 2.522 MM Kcal. /h
Operational Parameter
Shell Side Tube Side
Pressure (5-7) kg/cm2 g) 2
Pressure 14.9 kg/cm2 (g)
Temperature (33inlet -93outlet) °C Temperature (220in -165out) °C
Flow Rate 64 m3/h

Feed Filter (HDS-ME-002):

A feed filter is a vertical vessel that is used to remove particulate matter from diesel. Fee enters
at (5-6) kg/cm2 (g) pressure and (90-95) °C. It consists of nineteen cartridge-type filter elements
with dimensions of (6 inches outer diameter * 43 inches length), made of Teflon material. These
filters have a size of twenty-five-micron are designed at a maximum pressure drop of 1.8 kg/cm 2
(g). PDI is installed which indicates the pressure drop across the feed coalescer and when the
value reaches 1.5 kg/cm2 (g) then these filters are replaced. These filters are reusable after
washing through kerosene.

Design Parameter
Design Pressure 10.7 kg/cm2 (g) Hydro Test Pressure 17.99 kg/cm2 (g)
Design Temperature 140 °C Volume 0.217 m3
PSV (S.P) 10.5 kg/cm2 (g) Filter (Pressure Drop) 1.8 kg/cm2 (g)
Operational Parameters
Operational Pressure (5-6) kg/cm2 (g) Operational Temperature (90-95) °C
Feed Surge Drum (HDS-V-001):
This vessel provides intermediate storage having a total volume of 51.53 m 3. The main purpose
of this additional storage is to maintain the head required for the charge pump and in case of any
emergency, this storage gives additional time to handle the situation. On a hundred percent plant
load of 82.8 m3/h, it gives 14.94 minutes of the plant running time, and with a sixty percent plant
load of 49.5 m3/h, it provides 24.98 minutes of running time. The level of this vessel is an
essential parameter that we need to control as it provides a suction head for the charge pump next
to this vessel. Nitrogen blanketing is provided at the top of this vessel to maintain an inside
pressure of 2.5 kg/cm2 (g). It is equipped with a pressure control system that allows for gas
make-up (nitrogen) or venting to the flare system. This vessel is constructed of killed carbon
steel and equipped with level gauges to give a tangent-to-tangent level indication. The normal
liquid hydrocarbon level is maintained by adjusting the feed flow rate from the Flow Control
valve (FCV-001). LT-003 tells the overall level of the vessel which is maintained at 70% and
LT-004A/B/C is to indicate alarm and tripping conditions due to low flow and low suction head
which may cause to cavitate the charge pump P-001A/B.
 Alarm at 50% level of LT-004A/B/C.
 Tripping at 40% level of LT-004A/B/C.

Design Parameter
Design Pressure 10.5 kg/cm2 (g) Hydro Test Pressure 13.65 kg/cm2 (g)
Design Temperature 140 °C Volume 51.53 m3
PSV (S.P) 10.5 kg/cm2 (g)
Operational Parameters
Operational Pressure 2.5 kg/cm2 (g) Operational Temperature 93 °C

Charge Pump (HDS-P-001A/B):

Multi-stage centrifugal pump is the main charge pump for the HDS plant, with a spill back line
through a flow control valve (FCV-003) to maintain the flow rate and a strainer at the suction
side of a pump having a size of 8 inches and 30 mesh. A PDI is used to measure the pressure
drop across this strainer. A non-return or unidirectional valve is available at discharge, to ensure
that the medium flows in the right direction. It causes a large pressure drop and prevents
backflow.
A feed sample point is available at the suction of the pump through the sample cooler and there
is another line of Dimethyl disulfide (DMDS) injection, which joins at the suction. The new
catalyst for the reactor is in metal oxide form which provides more stable handling during
transportation. So, it is necessary to convert this catalyst into the sulfide form, DMDS is used for
the sulfiding of a new catalyst which creates a layer of sulfur over the catalyst surface to make it
an active site for HDS reactions. Suction and discharge pressure for this pump is 2.5kg/cm2 (g)
and 64kg/cm2(g), respectively

Design Parameter
Suction Pressure 2.474 kg/cm2 (g) Differential Head 772.7 m
Differential Pressure 60.1 kg/cm2 (g) Motor Power 232 KW
MCSF 34.42 m3/h NPSH(R)/NPSH(A) 3.3 m/43.7 m
Capacity 99.1 m3/h Ampere (MAX.) 27.3 A
Efficiency 70% Impeller Diameter 244 mm
RPM 2964 Ingress Protection IP 55
No. of Impellers 11
Operational Parameters
Suction Pressure 2.5 kg/cm2 (g) Discharge Pressure 64 kg/cm2 (g)
Differential Pressure 60.1 kg/cm2 (g) Ampere 24 A
Flow Rate 62 m3/h

• Reactor Section
Combined feed Exchanger (HDS-CFE-002C/B/A):
After the feed charge pump diesel enters at shell side of the combined feed exchangers (CFE) of
the shell and tube heat exchanger where diesel feed exchanges heat with the reactor's effluent
and reaches the temperature of almost 280°C from 93°C with the pressure of 51 kg/cm2 (g). At
the tube side of this exchanger, feed enters at 340°C and leaves at 170°C with a pressure of 42
kg/cm2 (g). A temperature control valve (TCV) is also provided at the bypass line. Reactor
temperatures are controlled from CFE especially inlet temperature for the reactor's feed. At
normal conditions flow rate through the CFE is almost 64 m3/h. before entering the CFE diesel
feed combines with the hydrogen feed and then both of the reactants get heated at the desired
temperature. CFE and charge heater both help to meet the requirement for desired heater inlet
temperature.

Design Parameter
Shell Side Tube Side
Design Pressure 66.5 kg/cm (g)
2
Design Pressure 48 kg/cm2 (g)
Design Temperature 370 °C Design Temperature 415 °C
No. of Passes 1 No. of Passes 2
 Design Duty 12.32 MM Kcal. /h
Operational Parameter
Shell Side Tube Side
Pressure 51 kg/cm (g)2
Pressure 42 kg/cm2 (g)
Temperature (93inlet -280outlet) °C Temperature (340inlet -170outlet) °C

Combined Feed Heater (HDS-H-001):

After passing through the combined feed exchanger (CFE 002) feed (diesel and hydrogen) enters
into a heater at almost 280°C and 47 kg/cm2 (g) of pressure to reach the desired temperature by
the combustion of fuel, for the reactor inlet. It has four main fuel gas burners with four pilot
burners. Fuel burns right after the burner and process fluid travels through the tubes inside the
heater. Heat is transferred through different modes of heat transfer like radiation, convection, and
conduction.
Heater tubes that carry the process fluid are made of seamless austenitic steel which can
withstand higher temperature conditions. The design temperature for the tube is 605°C but our
feed outlet temperature is 325°C at 4a kg/cm2 (g) of pressure.

Design Parameter
Pressure 65 kg/cm2 (g) Design Duty 4.53 MM Kcal/h
Temperature 605 °C Tube thickness 8.18 mm
Height 30850 mm Diameter 5450 mm
Operational Parameters
Pressure (IN) 47 kg/cm2 (g) Pressure (OUT) 44 kg/cm2 (g)
Temperature (IN) 280 °C Temperature (OUT) 325 °C

Reactor (HDS-R-001):
Once the feed and hydrogen gas has been heated to the desired temperature by Combined Feed
Exchanger (HDS-E-002A/B/C) and Combined Feed Heater (HDS-H-001), the reactants enter the
top of the reactor at 323°C and 44 kg/cm 2 (g). As the reactants flow downward through the
catalyst bed, various exothermic chemical reactions occur, and the temperature increases.
This reactor is a catalytic plug flow reactor and contains two beds of catalyst separated by a
quench zone and ceramic balls. Several exothermic reactions take place in the presence of a
catalyst. Each bed contains three elements of radial thermocouple assembly at the top and
periodic levels down through the bed. Total 3 sets of radial thermocouple assemblies are
installed in the reactor. Reactor skin thermocouples are provided at the bottom of each bed and
on the bottom reactor head, for monitoring the reactor wall temperature. The purpose of these
thermocouples is to observe the exotherm of the reactor and to monitor average bed temperatures
which further helps to understand the overall performance and activity of the catalyst.
The reaction which is involved to remove the undesired impurities from diesel, inside the reactor
is given below:
• Olefin Saturation • Desulfurization
• Nitrogen Removal • Halides removal
• Oxygen removal • Metal Removal
• Aromatic Saturation

A graded catalyst bed is installed at the top of the first catalyst bed to collect corrosion products
and other particulates without an excessive increase in pressure drop. Nickel & Molybdenum
catalysts are used to assist with nitrogen removal reactions and cobalt & Molybdenum for sulfur
removal reactions.
During the denitrogenating and halides removal reaction ammonia and halides are formed this
ammonia makes ammonium chloride salts which may deposit in the tubes of exchangers and fin-
fan cooler to cause fouling and may lead to pressure drop. To avoid this wash water minimum of
5 vol. % of feed is added to the reactor effluent. This water dissolves these salts and prevents the
salt's deposition across the tubes. This sour water can be drained from the flash drum vessel and
also from the stripper overhead receiver and processed to the Sour water unit for further
treatment.

Product Condenser (HDS-EA-001A/B/C/D):

The reactor's effluent with wash water then enters the tube side of CFE to preheat the feed (diesel
& hydrogen) and then it goes into the fin fan cooler where its temperature further decreases to
almost 58°C.

Design Parameter
Pressure 46 kg/cm2 (g) Design Duty 6.92 MM Kcal/h
Temperature 365 °C No. of passes 4
No. of tubes 224
Operational Parameters
Pressure (IN) 41.5 kg/cm2 (g) Pressure (OUT) 40.8 kg/cm2 (g)
Temperature (IN) 170 °C Temperature (OUT) 58 °C
Flash Drum (HDS-V-003):
This is a killed carbon steel horizontal vessel with a water boot. The purpose of the Separator is
to separate the recycled gas, water, and hydrocarbon from the reactor effluent. This vessel
contains a mesh blanket which helps to remove liquid droplets from the recycle gas and helps
water droplets in the hydrocarbon phase to coalesce. The bottom half of the separator is lined
with a 3 mm layer of stainless steel for corrosion protection. The reactor effluent typically enters
the separator through a slotted inlet distributor at one end. The hydrocarbon outlet is at the
opposite end of the vessel to provide the maximum amount of residence time for effective
hydrocarbon-water separation. Feed enters the separator at 58°C and the pressure of the separator
is at 40.8 kg/cm2 (g). At this pressure, hydrogen sulfide form in the reactor remains in the
dissolved form in diesel, and hydrogen gets separated from the top of the separator with some
traces of hydrogen sulfide. This separator plays an important role to maintain the pressure of the
overall system.
Water removed from this separator is reinjected into the next coming vessel, flash drum HDS-V-
004 because soluble hydrocarbons in the water phase from the high-pressure separator are
reflashes in the low-pressure drum to remove hydrocarbons.

Design Parameter
Design Pressure 45 kg/cm2 (g) Hydro Test Pressure 58.5 kg/cm2 (g)
Design Temperature 270 °C Volume 17.958 m3
PSV (S.P) 45 kg/cm2 (g)
Operational Parameters
Operational Pressure 40.8 kg/cm2 (g) Operational Temperature 58 °C

 Fractionation Section
Separator (HDS-V-004):
The purpose of the Flash Drum is to remove dissolved gases and flash low boiling range material
from the separator liquid. Feed enters the separator at 58°C and the pressure of the separator is at
9.5 kg/cm2 (g). The design (construction materials and internals) of this vessel is the same as the
Separator. The flash drum receives sour water from the separator and drains vessel 006 and
vessel 006, via a connection to the bottom of the flash drum. This allows the recovery of
dissolved gases from the sour water at a lower pressure before sending it to sour water treatment.

Design Parameter
Design Pressure 11.5 kg/cm2 (g) Hydro Test Pressure 15.06 kg/cm2 (g)
Design Temperature 270 °C Volume 34.4459 m3
Operational Parameters
Operational Pressure 9.5 kg/cm2 (g) Operational Temperature 58 °C

Stripper Feed – Bottom Exchanger (HDS-E-003):

After the V-004 feed enters into the shell side of the shell and tube heat exchanger where the
feed (diesel & H2S) exchanges heat with the stripper bottom product and reaches the temperature
of almost 215°C from 58°C. At the tube side of this exchanger, feed enters at 350°C and leaves
at 220°C, with a pressure of 15.3 kg/cm2 (g).

Design Parameter
Shell Side Tube Side
Design Pressure 15.5 kg/cm (g) 2
Design Pressure 20 kg/cm2 (g)
Design Temperature 245 °C Design Temperature 380 °C
No. of Passes 1 No. of Passes 4
PSV (S.P) 15.5 kg/cm2 (g)
Design Duty 6.027 MM Kcal. /h
Operational Parameter
Shell Side Tube Side
Pressure 9.5 kg/cm (g)2
Pressure 15.3 kg/cm2 (g)
Temperature (58inlet -215outlet) °C Temperature (220inlet -165outlet) °C

Stripper (HDS-V-007):
Stripper is a vertical vessel constructed of killed carbon steel. Feed is introduced in the stripper at
almost 215 degrees Celsius with a pressure of 5.2 kg/cm2 (g) towards the column. The top and
bottom temperatures of the stripper column are 137°C and 350°C, respectively. Stripper consists
of 30 valve-type trays which help to achieve better fractionation efficiency throughout the
column. Feed is introduced at the 5th tray. This stripper separation becomes possible at low
pressure and high temperature. Some part of the bottom level of diesel in the stripper enters the
stripper reboiler after passing through the pump P-003A/B at almost 350°C to reach the desired
temperature by the combustion of fuel, to reflux back to the stripper which helps to strip out the
lighters like H2S.
Our feed (diesel and H2S) enters the stripper and it creates a level of liquid at the bottom due to
flash at the flash zone vapor content in the feed moves in the upward direction, and due to this a
vapor flow is created. And heavy diesel in liquid form moves downward to the bottom of the
stripper due to density which creates a liquid flow toward the bottom of the stripper column. A
reflux line from the bottom blows the 30 th tray of column is provided which is a diesel heated at
almost 370°C. this stream enhances the separation efficiency for columns as it helps to strip out
the lighters which are entrapped to the liquid diesel due to high downward flow.
H2S is separated from the top of the stripper which goes into the amine unit for further
processing after passing through a stripper recovery.
Contaminated or processed diesel is withdrawn from the bottom of the stripper which goes into
the storage after exchanging the heat to preheat the feed diesel.

Design Parameter
Design Pressure 8.5 kg/cm2 (g) Hydro Test Pressure 13.65 kg/cm2 (g)
Design Temperature 390 °C Volume 100.38 m3
 PSV (S.P) 8.5 kg/cm2(g) PSV (S.P) 8.9 kg/cm2 (g)
Operational Parameters
Pressure (IN) 5.5 kg/cm2 (g) Pressure (OUT) 5.1 kg/cm2 (g)
Temperature (IN) 215 °C Temperature (TOP) 137°C
Temperature (BOTTOM) 350 °C

STRIPPER TOP PRODUCT

Stripper Condenser (HDS-EA-002A/B):
The top product of the stripper which mostly contains hydrogen sulfide enters the fin-fan cooler
where it releases some of its heat. Feed enters with the pressure of 5.2 kg/cm 2 (g) at the
temperature reaches 40°C from 137°C.

Design Parameter
Pressure 8.5 kg/cm2 (g) Design Duty 1.04 MM Kcal/h
Temperature 145 °C No. of passes 2
No. of tubes 213
Operational Parameters
Pressure (IN) 5.5 kg/cm2 (g) Pressure (OUT) 5 kg/cm2 (g)
Temperature (IN) 137 °C Temperature (OUT) 40 °C

Stripper Receiver (HDS-V-008):

This is a horizontal vessel constructed of killed carbon steel which has a water
draw-off boot. It has an inlet distributor attached to the inlet nozzle to facilitate
water and hydrocarbon separation. Feed enters with a pressure of 6.55 kg/cm2 (g) and
at 40°C of temperature.
H2S gas is removed from the top of the vessel and it goes towards the amine unit
for further treatment. Sour water is removed from the boot which is at the bottom
of the vessel. The hydrocarbon outlet is at the opposite end of the vessel from the
inlet distributor which is used as a reflux which is introduced at the top tray of the
stripper to control the column temperature through the pump P-004A/B, next to the
receiver.
Design Parameter
Design Pressure 9 kg/cm2 (g) Hydro Test Pressure 11.7 kg/cm2 (g)
Design Temperature 145 °C Volume 5.429 m3
 Operational Parameters
Pressure (IN) 6.55 kg/cm2 (g) Temperature 40 °C

Stripper Reflux Pump (HDS-P-004A/B):

A Single stage centrifugal pump is introduced which is the reflux pump for a stripper. This pump
is also used to transfer unestablished lighters if there are any, to the crude distillation unit.

Design Parameter
6.188 kg/cm2
Suction Pressure Differential Head 105.9 m
(g)
Differential Pressure 6.6 kg/cm2 (g) Motor Power 22 KW
MCSF 10.09 m3/h NPSH(R)/NPSH(A) 1.69 m/2.6m
MCTF 3.36 m3/h Ampere (MAX.) 36.8 A
Efficiency 21.50% Impeller Diameter 310 mm
RPM 2950 Ingress Protection IP 55
Operational Parameters
Suction Pressure 6.5 kg/cm2 (g) Discharge Pressure 12.6 kg/cm2 (g)
Differential Pressure 6.6 kg/cm2 (g) Ampere 25

STRIPPER BOTTOM PRODUCT

HDS-P-003A/B
It is a centrifugal pump to transport the stripper bottom product toward the reboiler so it could be
utilized to carry on stripping after achieving desired temperature through the reboiler or heater. A
second output of this pump leads the diesel product towards the different heat exchangers and
fin-fan cooler to lower the temperature of the final product. And this heat is utilized to preheat
the feed. A strainer at the suction side of a pump has a size of 8 inches and 30 mesh which helps
to prevent the passage of any undesired particulate matter. Suction and discharge pressure are 6.5
kg/cm2 (g) and 15 kg/cm2 (g), respectively.

Design Parameter
6.718 kg/cm2
Suction Pressure Differential Head 153.7m
(g)
Differential Pressure 8.68 kg/cm2 (g) Motor Power 330 KW
MCSF 371.1 m3/h NPSH(R)/NPSH(A) m/4 m
MCTF m3/h Ampere (MAX.) 35.5 A
Efficiency Impeller Diameter 160.1 mm
RPM 1484 Ingress Protection IP 55
Operational Parameters
 Suction Pressure 1.1 kg/cm2 (g) Discharge Pressure 8.5 kg/cm2 (g)
Differential Pressure 7.5 kg/cm2 (g) Ampere 25 A

Stripper Reboiler (HDS-H-002):

Stripper bottom product enters the stripper reboiler after passing through the pump P-003A/B at
almost 350°C to reach the desired temperature by the combustion of fuel, to reflux back to the
stripper which helps to strip out the lighters like H 2S. It has six main fuel gas and Fuel burners
with six fuel gas pilot burners. Fuel burns right after the burner and process fluid travels through
the tubes inside the heater. Heat is transferred through different modes of heat transfer like
radiation, convection, and conduction.
Heater tubes that carry the process fluid are made of seamless austenitic steel which can
withstand higher temperature conditions. The design temperature for the tube is 555°C but our
feed outlet temperature is near about 370°C.

Design Parameter
Pressure 23 kg/cm2 (g) Design Duty 9.47 MM Kcal/h
Temperature 555 °C Tube thickness 8.18 mm
Height 39550 mm Diameter 6200 mm
Hydro Test Pressure 51.8 kg/cm (g)
2

Operational Parameters
Pressure (IN) 17 kg/cm2 (g) Pressure (OUT) 15 kg/cm2 (g)
Temperature (IN) 350 °C Temperature (OUT) 370 °C

The bottom of the stripper is divided into two streams after passing through a pump (HDS-P-
003A/B). One of the streams enters into a second heater at 350 degrees Celsius and leaves the
heater at 370 degrees Celsius, which is used for stripping purposes. The second stream of the
stripper's bottom is treated diesel but at a higher temperature and we need to cool down it before
it leaves the battery limit of the plant. For this reason, we allow this diesel to pass through the
exchangers (HDS-E-003), (HDS-E-001), fin-fan cooler (HDS-EA-003A/B), and final trim cooler
(HDS-E-004). So, it could exchange its heat with the feed.

HYDROGEN CIRCUIT
HDS plant is designed for a minimum of 89% of purity of makeup hydrogen and 79% purity for
recycled hydrogen gas. Hydrogen can be used either from the hydrogen plant which gives
99.99% of purity or from the reformer unit which gives 91% of purity. Hydrogen enters the
battery limit of the HDS plant at almost 58°C temperature and pressure of 23 kg/cm2(g). First of
all, hydrogen feed enters into a shell side of the shell and tube heat exchanger (HDS-E-006)
where hydrogen feed exchanges the heat with the water, which is flowing through the tube side
of the exchanger and reaches the 28°C temperature. And after passing through the exchanger, it
enters into a makeup gas vessel (HDS-V-006). After the vessel, gas is compressed through a
reciprocating compressor which transports the gas with the required pressure at discharge.
Snubbers which are like small storage vessels are provided at suction and discharge of the
compressor to minimize the fluctuation or pulsating in flow. The main parameters during
compression are discharge pressure and discharge temperature. Excessive discharge pressure or
compression ratio may cause to rise in temperature or mechanical damage to the equipment.
Recycle gas helps to control the excessive temperature of beds by quenching and it also gives
excess amount of hydrogen to overcome the consumption and losses during the complete cycle.
The main focus is to control the gas-to-oil ratio or hydrogen-to-hydrocarbon ratio. A minimum
of 212m3 of hydrogen is required for 1m3 of diesel. If the value goes below, it means enough
amount of hydrogen is not available to complete the reaction or remove the impurities to the
desired level. An excessive gas-to-oil ratio may increase the load on the compressor and an
excessive amount of hydrogen will decrease the bed temperature.
The separator vessel plays a vital role to manage the system pressure when H2S, diesel, and salty
water enter the separator, it helps to separate the maximum hydrogen back as a recycle gas. The
separator pressure is 40.8kg/cm2(g). At this pressure, H2S is dissolved in liquid and only allows
hydrogen to pass as a recycle stream. Some of the H2S may cause lower hydrogen purity but we
can control this amount by venting off some of the gas.

The design and operational parameters for this above-mentioned circuit is given below:
EQUIPMENT DESIGN OPER. DESIGN OPERATION
PRESSURE PRESSURE TEMP. AL TEMP.
kg/cm2 (g) kg/cm2 (g) °C °C
HDS-E-006 25.5 23 140 58
HDS-V-006 25.5 22.8 120 27
MU-SUCTION SNUBBER 23.2 24 44 27
MU-C001A/B
MU-DISCHARGE SNUBBER 42.3 42 101 93
HDS-V 005 45 40.8 175 67
RECYCLE H2 - 40.8 - 52
RG-SUCTION SNUBBER 41.5 42 65 62
RG-C001A/B
RG-DISCHARGE SNUBBER 61.5 52 93 90
HYDROGEN - 51 - 90

PLANT DESIGN AND OPERATIONAL CONDITIONS:

EQUIPMENT DESIGN / OPERATIONA DESIGN OPERATIONAL

DIFFERENTIA L PRESSURE TEMPERATUR TEMPERATUR
L PRESSURE kg/cm2 (g) E E
 kg/cm2 (g) °C °C
TK-338/339 1.03 30-35
P-400A/B 7.5 (DIFF.) 8.5 1-41 30-35
HDS-ME-001 10.5 7.2 140 30-35
HDS-E-001 15.5 6.9 120 90-95
HDS-ME-002 10.5 6 140 90-95
HDS-V-001 10.5 2.5 140 90-95
HDS-P-001A/B 60.1 (DIFF.) 64 111 90-95
HDS-CFE-002- 66.5 51 370 270-285
C/B/A (S.S)
HDS-H-001 65 47 605 320-325
HDS-R-001 62 44 415 335-340
HDS-CFE-002- 48 42 415/375/320 170
A/B/C (T.S)
HDS-EA-001A/ 46 41.5 365 55-60
B/C/D
HDS-V-003 45 40.8 270 55-60
HDS-V-004 11.5 9.5 270 55-60
HDS-E-003 (S.S) 15.5 8.3 245 215
HDS-V-007 8.5 5.5 390 215/137/350
F.Z/TOP/
BOTTOM
STRIPPER TOP PRODUCT
HDS-EA-002A/B 8.5 5.2 145 137in – 40out
HDS-V-008 9 5 145 40
HDS-P-004
STRIPPER BOTTOM PRODUCT
HDS-P-003
HDS-H-002 23 15 555 370

HDS-E-003 (T.S) 20 15.3 380 220

HDS-E-00 (T.S) 20 14.9 255 165
HDS-EA-003A/B 20 12.51 195
HDS-E-004 (T.S) 20 10.1 149 27
PUMPS DESIGN CONDITIONS:

P-400A/B P-001A/B P-003 A/B P-004 A/B

Suction Pressure, kg/cm (g)
2
1.1 2.474 6.718 6.188
Differential Pressure, kg/cm2(g) 7.5 60.1 8.68 6.6
Discharge Pressure, kg/cm2 (g) 8.6
Differential Head, m 89.42 772.7 153.7 105.9
Impeller Dia. mm 270 244 632 310
MCSF, m3/h 69 34.42 371.1 10.09
MCTF, m3/h 21.63 3.36
NPSH(R)/NPSH(A) / 12 3.3/43.7 2.7 / 4 1.69 / 2.6
RPM 2970 2964 1484 2950
Motor Power, KW 46.2 232 330 22
Ampere max./normal 126 / 75 27.3 / 24 35.5 / 25 36.8 / 25
Enclosure IP 55 IP 55 IP 55 IP 55
Efficiency, % 75.1 70 72 21.5

HEAT EXCHANGER DESIGN & OPERATIONAL CONDITIONS:

HEAT HDS-E-001 HDS-E-002 HDS-E-003 HDS-E-004 HDS-E-005
EXCHANGERS
FLUID (S.S) Fresh Feed HC + H2 Stripper Feed Stripper MU Gas
Bottom
FLUID (T.S) Stripper Reactor Stripper CWS Cooling
Bottom Effluent Bottom water
NO. OF TUBES 254 856 702 1276 9
PASSES
SHELL 1 1 1 1 1
TUBE 2 2 4 6 1
DESIGN TEMP. 120/255 370/415 245/380 120/149 140/149
°C (S/T)
OPERATIONA 33/93 93/280 58/215 60/27 52/28
L TEMP. °C
(S.S)
IN/OUT
OPERATIONA 220/165 340/170 370/220 13.5/22 13.5/16
L TEMP. °C
(T.S)
IN/OUT
DESIGN 15.5/20 66.5/48 15.5/20 20/15.5 25.5/20
PRESSURE.
kg/cm2 (g) (S/T)
OPERATIONA 6.9/14.9 51/42 8.5/15.3 10.1/ 23/5.7
L PRESSURE.
kg/cm2(g) (S/T)
DESIGN DUTY 2.522 12.32 6.027 0.7524 0.04551
(MM Kcal/h)
FIN-FAN COOLER DESIGN & OPERATIONAL CONDITIONS:
HDS-EA-001A/B/ HDS-EA-002A/B HDS-EA-003A/B
C/D
FLUID (T.S) HC + H2S + H2 Lighters + H2S Diesel
FLUID (O.S) Air Air Air
PASSES 4 2 4
TUBES 224 213 420
DESIGN TEMP. °C 365 145 195
OP. TEMP (IN/OUT) 170/58 137/40 165/60
DESIGN PRESSURE 46 8.5 20
kg/cm2(g)
OPERATIONAL 42/41.5 5.25/5.21 14.9/12.51
PRESSURE
(IN/OUT) kg/cm2 (g)
DESIGN DUTY 6.92 1.04 3.85

References:
https://www.rac.co.uk/drive/advice/emissions/euro-emissions-standards/
https://www.theaa.com/driving-advice/fuels-environment/euro-emissions-standards