Hydrogen Purification Regeneration

Process Description
The Petrochemical polymer units require hydrogen as a chain-terminating agent. This polymer grade
hydrogen has the following specifications:

Product Composition
Hydrogen %vol 99.9
CO + CO2 PPMV <1
Water PPMV <1

During regular operation, a DFCU unit supplies high-purity hydrogen. However, in the event of any
operational disruption, alternative hydrogen sources become necessary for the polymer unit.
The refinery hydrogen currently, has the following specification:

Component UOM
Main fluid - Hydrogen
Temperature °C Ambient
Pressure Kg/cm2g 60 – 65
MW g/mol 2
Flow (design) Kg/h 220
Mass Flow (normal) Kg/h 200
Allowable Pressure
Kg/cm2 2
drop

Feed Composition
Hydrogen %vol 99.9
Methane %vol Balance
Inerts PPMV 50
CO + CO2 PPMV 20
Water PPMV 50

The above Hydrogen quality does not meet the required specifications of the Petchem polymer
units. So, refinery hydrogen is not fit to be used in Petchem Polymer units. In order to use the
refinery Hydrogen in the Petchem polymer units the refinery Hydrogen must be purified to meet the
Petchem required standard.

So, it is proposed to install a new skid mounted Hydrogen Purification System (934-LZ-7002) for
purification of Hydrogen.
The Hydrogen purification skid will contain the following equipments:
 1. Electrical Heater - 1 nos.
2. Methanator bed - 1 nos.
3. Hairpin Heat exchanger - 1 nos.
4. Moisture removal beds - 2 nos.
5. Guard filters - 2 nos.
6. Analyzers - 2 nos.
7. Instrumentations - As required
8. Safety equipment - As required
9. Catalyst and Adsorbent - As required

Hydrogen from header will be supplied to the skid at 60-65 kg/cm2g pressure at ambient
temperature (max. 46 °C and min. 1 °C) with maximum flow of 200 kg/hr. At first the Hydrogen will
enter the Electrical heater which will preheat the incoming Hydrogen at 230 °C and feed it into the
Methanator bed. The Methanator bed contains catalyst that performs the following reactions to
convert CO and CO2 to CH4 and H2O.
CO + 3H2  CH4 + H2O
CO2 + 4H2  CH4 + 2H2O
The reacted hydrogen gas then passes through a hairpin heat exchanger to reduce its temperature
to 45 °C and proceeds to a set of two dryer beds designed to eliminate moisture from the hydrogen
gas. These beds contain moisture adsorbents that can be periodically regenerated using nitrogen.
One bed operates while the other undergoes regeneration/stands by using nitrogen from an existing
regeneration system in a closed loop.
The dry hydrogen from the dryers moves through a pair of guard filters to prevent any solid particle
carryover into the downstream system.
Additionally, there are CO/CO2 and H2O analyzers placed at seven specific points to monitor the
composition at various stages of the purification process.
1. Electrical Heater inlet - CO/CO2 analyzer
2. Methanator bed Body - CO/CO2 analyzer
3. Methanator bed outlet - CO/CO2 analyzer
4. Dryer bed inlet - H2O analyzer
5. Dryer bed A - H2O analyzer
6. Dryer bed B - H2O analyzer
7. Dryer bed outlet - H2O analyzer

As per our information BASF and Sud-Chemie can provide the catalyst and adsorbent required for
the proposed Hydrogen Purification System.
The necessary equipment for this system will be mounted on skids and transported to the site by
the vendor. End USer will solely handle the connection and startup of this system upon receipt from
the vendor, without making any modifications to the skid.