Recovery of LPG

ETS LPG TECHNOLOGY Chapter 5 Recovery of LPG
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The classical process for the separation of

natural gas and LPG is oil absorption, the
prime step being the contacting of the gas with
diesel-type oil known as 'absorber oil'.
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Perhaps the commonest conversion process-

source of LPG is catalytic reforming.
The real object of the process is to produce C6
/C7 aromatics either as chemical intermediates
or more often, as a gasoline blendstock.
The feedstock is virgin naphtha obtained from
the crude oil fractionating tower or specially
purchased for the purpose (imports).
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The fixed bed 'reforming' process is one of

converting:
Paraffinic and
Naphthenic hydrocarbons
present in the naphtha to aromatics by:

Cyclization and
Dehydrogenation reactions
occurring simultaneously.
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Sulphur compounds which would poison the

catalyst are removed in a preliminary
hydrofining step.
In this, the naphtha and a hydrogen containing
refinery gas are passed (sometimes together
with sour LPG from the primary fractionating
tower), over a cobalt or nickel molybdate
catalyst at about 410°C and at raised pressure.
The sulphur compounds are converted to
hydrogen sulphide.
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This is removed together with other light gases

by 'flashing' before the naphtha enters a series
of reactors containing platinum catalyst, which
is regenerated periodically.
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The LPG which is also present in the products

of catalytic reforming is separated from the
principal C5+ product (i.e. the reformed
naphtha or reformate) by a distillation step
known as 'debutanization'.
It may be made to join the pipestill LPG stream

before or after the sour gas sweetening towers.
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A refinery which includes:

Only atmospheric distillation (no vacuum
step) and
Catalytic reforming (no cracking reactors)
among its main processing features
Is often called a 'hydroskimming' refinery.
In this, the twin tributary LPG streams from the

distillation and reforming units, suitably
purified, join for separation into propane and
butane products in the depropanizer tower.
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"Cat crackers' are installed along with catalytic

reformers at so called 'integrated' oil refineries
for the purpose of cutting down on the
production of middle distillates and producing
motor gasoline and unsaturated gases which
serve as intermediates for further chemical
processing.
The feedstock is usually heavy gas oil, even
wax, which if cracked at high temperature in
the presence of a silica-aluminate catalyst.
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Many large, modern 'cat crackers' are based on

the 'fluid catalytic' principle in which case, the
feedstock and fresh make-up catalyst are fed
continuously to the reactor tower from which,
at the same time, catalyst is being withdrawn
to a vessel regeneration for reactivation by hot-
air treatment.
The entire effluent from the reaction vessel is
fractionated in a primary separator into:
Light ends,
Middle distillate and
Heavy fractions.
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LP gases, together with methane, ethane and

catalytically cracked gasoline are taken off as
an overhead stream and separated in an
absorption tower by means of light absorbing
oil into a noncondensive gas stream (methane,
ethylene and ethane) and an absorbed fraction
consisting of LPG and gasoline.
The saturated absorbent, sometimes referred
to as 'fat oil' is stripped of its light end content
and the latter separated into a gasoline fraction
and LPG overhead in a 'debutanizer' tower.
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The propylene and butene components are

removed from the LPG stream by further
fractionating or chemical means but, depending
on the supply requirements of the separate
petrochemicals business at a given time, both
saturated and unsaturated C3/C4 gases may
find their way into the domestic or industrial
LPG tankage.
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One variant of the fluid catalytic cracking

process is known as 'hydrocracking', which
can take naphtha, light or heavy gas oils as
feedstock along with a hydrogen-rich diluent
gas to suppress overcracking and
polymerization side reactions.
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The process is one of removing sulphur

compounds from the sour streams
contributing to LPG production.
The object is to produce a non-corrosive, non-
toxic gas which is acceptable to domestic and
industrial markets.
The impurities to be removed include:
Hydrogen sulphide,
Methyl and ethyl mercaptans, and
Elemental sulphur.
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The processes adopted at the present time,

whether the LPG be natural gas or crude oil-
derived, include the following:
H2S
:caustic soda wash
H2S and elemental sulphur
: mono- or di-or triethanolamines extraction
(Girbotol process)
Mercaptans
: caustic soda wash
: "Merox" extraction
H2S and light mercaptans
: Absorption on 'molecular sieves'
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Caustic Wash
The caustic solution (NaOH or KOH) reacts
with the H2S which is dissolved in the liquid
LPG.
H2S is a weak acid, and its removal is nearly
quantitative even in a single stage.
The extraction of mercaptans, however, is

equilibrium-limited and is dependent on:
Strength of alkali used,
Ratio of alkali to LPG,
Operating temperature and pressure, and
Molecular weight of the mercaptans, etc
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Twin towers may be used in series:
The first to remove the bulk of the H2S and

The second to deal with the mercaptans.
Commonly used is a 5-20% strength caustic
solution.
Spent caustic solution is not usually

regenerated and its disposal often presents a
problem to the oil refiner.
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Measures adopted to cut down on caustic

consumption include:
q Partial recycle of spent solution to the

wash tower and
q Batch washing with intermittent
replacement of caustic rather than a
continuous countercurrent flow operation.
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Girbotol Process
If a relatively large amount of H2S is present in
the sour LPG, it may conveniently and more
economically be removed by extraction with
monoethanolamine (MEA) or diethanolamine
(DEA), which is regenerated by heating at 95°C
in a separate vessel, followed by stream
stripping and recycle to process.
Extraction takes place at 40-60°C under vapour

pressure in a packed tower, countercurrent
fashion.
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This amine solution method avoids the use of

aqueous alkali, effectively removes:
Carbon dioxide and, if present, also
Elemental sulphur.
But is not very effective in removing
mercaptans.
Hence, a refinery LPG sweetening package
may be found to comprise:
An amine extraction tower followed by
A caustic trimming washer and
A 'Merox' unit (for mercaptans removal).
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Merox Extraction
The Universal Oil Company's (UOP) Merox
process is one of oxidation of the mercaptans
with air and a relatively small amount of alkali
in the presence of chelated iron compound
catalysts.
The mercaptans are converted to disulphides

which are relatively:
Odorless,
Non-corrosive compounds.
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A small amount may remain in the treated LPG

but the bulk is transferred with the caustic to a
regenerator where sulphur compounds are
stripped by hot-air treatment and the alkali
returned to process along with some make-up
solution.
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Molecular Sieve Adsorption

The use of a dry 'molecular sieve' process
obviates the caustic disposal or recovery
problems.
Molecular sieves are synthetic metal
aluminosilicates having a three-dimensional
pore structure and a one to three micron
particle diameter.
They are manufactured as pellets sized 1/16 in
or 1/8 in for easy handling and use.
The size and position of the metal ions in the
crystal control the effective diameter of the
interconnecting channels. 43
The separation of the sulphur compounds

depends therefore on selective adsorption due
to the higher polarity of these compounds
rather than on conventional molecular sieve
action.
The adsorptive capacity for:

H2S is about 1% by weight and
Lower mercaptans, 0.5%.
Higher sulphides and disulphides are not
removed.
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The plant consists of twin towers alternating

the processes of adsorption and bed
regeneration.
The cycle might be (typically):

q 8 hr service at 30°C followed by
q 8 hr regeneration (using sweet product
gas or refinery gas, or nitrogen, heated to
260°C) and
q 8 hr cooling to adsorption temperature.
Sour regeneration gas is flared.
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LPG sweetened by molecular sieves will at the

same time be dried by the same process of
adsorption.
The preferred feedstock is an LPG stream

containing saturated hydrocarbons, the H2S
and a relatively small amount of mercaptans.
Typically, a regenerative unit might be sized

for 40 gal/min throughput with a product
specification of 1-2 ppm H2S or mercaptans
and 10 ppm maximum outlet water
concentration.
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The object is to produce LPG which do not

deposit the dissolved water left over from an
aqueous sweetening process on liquid
temperature reduction or vapour expansion.
Not all LPG need to be dried but those
marketed in cold climates, propane grades in
particular, invariably are.
The process is one of percolating the liquid

LPG through solid absorbents for water.
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The cheapest is often found to be a once-

through system using calcium chloride.
Other absorbents in common use on a

regenerative basis in refineries at the present
time are alumina, silica gel or 4A molecular
sieves.
In all such absorption processes, the packed

towers are protected from slop water carry
over by upstream separator-cum-coalescer
drums.
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Refinery LPG which is stored at atmospheric

pressure, as distinct from at its saturated
vapour pressure, has to be refrigerated to near
its true boiling point.
For this purpose, the LPG needs to be dried by

an absorption process.
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Drying with Calcium Chloride

The liquid LPG to be dried passes into one of
two drying towers connected in series.
Initially, dissolved water is removed in the first

tower and the second has no effect.
As the desiccant in the first tower is used up,

dissolving to form heavy brine containing
about 25% calcium chloride, the second tower
takes over.
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At this point, the first tower is recharged with

fresh calcium chloride containing about 72%
calcium chloride, and the flows are reversed.
The brine formed during operation is normally

drained off once per eight-hour shift.
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The amount of calcium chloride required can

be calculated from the original and final water
concentrations in the LPG, the water content of
the saturated absorbent and a predetermined
bed life, say six months.
On the basis of reducing an inlet water

concentration of 300 ppm weight in propane at
100°F to 20 ppm outlet water concentration, the
weight of water to be removed is 0-5 Ib (0.25
kg) approximately per ton of LPG.
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Taking the calcium chloride content of fresh

and spent calcium chloride as 72 and 25%,
respectively, the consumption of drying agent
works out at one pound per pound of water, i.e.
0.5 Ib/tone of propane (45 lb/1000 barrels).
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Regenerative Drying
The twin tower principle is employed with the
service tower on drying duty for, say, 24 hr and
the other engaged for a similar time on
regeneration and cooling.
During regeneration, hot purge gas (which can

be vaporized LPG) removes liquid LPG and
water from the spent service tower.
The effluent is cooled and the LPG separated

and re-used.
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Alternatively, one or more service towers are

fitted with internal steam coils which are
brought on during regeneration after the liquid
LPG has been removed by pressure reduction,
this being usually achieved by means of a
steam ejector.
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Recovery of LPG

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Recovery of LPG

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ETS LPG TECHNOLOGY Chapter 5 Recovery of LPG

The classical process for the separation of

Perhaps the commonest conversion process-

The fixed bed 'reforming' process is one of

present in the naphtha to aromatics by:

Sulphur compounds which would poison the

This is removed together with other light gases

The LPG which is also present in the products

It may be made to join the pipestill LPG stream

A refinery which includes:

In this, the twin tributary LPG streams from the

"Cat crackers' are installed along with catalytic

Many large, modern 'cat crackers' are based on

LP gases, together with methane, ethane and

The propylene and butene components are

One variant of the fluid catalytic cracking

The process is one of removing sulphur

The processes adopted at the present time,

The extraction of mercaptans, however, is

Twin towers may be used in series:

The first to remove the bulk of the H2S and

Spent caustic solution is not usually

Measures adopted to cut down on caustic

q Partial recycle of spent solution to the

Extraction takes place at 40-60°C under vapour

This amine solution method avoids the use of

The mercaptans are converted to disulphides

A small amount may remain in the treated LPG

Molecular Sieve Adsorption

The separation of the sulphur compounds

The adsorptive capacity for:

The plant consists of twin towers alternating

The cycle might be (typically):

LPG sweetened by molecular sieves will at the

The preferred feedstock is an LPG stream

Typically, a regenerative unit might be sized

The object is to produce LPG which do not

The process is one of percolating the liquid

The cheapest is often found to be a once-

Other absorbents in common use on a

In all such absorption processes, the packed

Refinery LPG which is stored at atmospheric

For this purpose, the LPG needs to be dried by

Drying with Calcium Chloride

Initially, dissolved water is removed in the first

As the desiccant in the first tower is used up,

At this point, the first tower is recharged with

The brine formed during operation is normally

The amount of calcium chloride required can

On the basis of reducing an inlet water

Taking the calcium chloride content of fresh

During regeneration, hot purge gas (which can

The effluent is cooled and the LPG separated

Alternatively, one or more service towers are

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