TAKREER Ruwais Refinery Expansion

1620
Ethylene Recovery Unit
 ERU - OVERVEIW

Capacity : 1,490 T/d of ROG feedstock from USGP

Main Feed : Refinery off-gas from the Fuel
Gas Absorber in the Unsaturated Gas Plant and
Deethanizer vent from PRU.
Objective : To recover polymer-grade ethylene
product after removing contaminants and
separating out fuel gas and C3+ streams.
Separation of Refinery Off Gas (ROG) into high
value products
 Polymer Grade Ethylene
 C3+ Stream(recycled to PRU For propylene recovery)
 By-product Fuel Gas
 Process requires removal of contaminants

Contaminants are removed by adsorption in:

 Dryers
 RSH/COS Removal Beds
– Dryers and the RSH/COS Removal Beds are
regenerated on a short cycle
– DeOxo Reactor is regenerated infrequently
 Arsine removal Beds
 Mercury removal beds
 Product specs are met by the Acetylene polishing
 Main Components of ERU

 Contaminant Removal Components

1. DeOxo Reactors
2. Caustic Tower
3. Dryer Beds
4. RSH/COS Removal Beds
5. Arsine Removal Bed
6. Mercury Removal Bed
7. Acetylene Polisher
Main Separation Components of ERU

1. Deethanizer

2. HRS Modules

3. Demethanizer

4. C2 Splitter

5. C2 Refrigeration

6. C3 RefrigerationSera3 Ref
 DeOxo Reactors

 Removes O2, NOx, and some acetylenes including

butadiene from ROG feedstock
 DMDS is injected to moderate the reactor
catalyst temperature and reduce undesirable
hydrogenation reaction
 DeOxo Steam heater – preheats feed stream to
190oC using superheated HP steam

 Catalyst requires regeneration after 18 months

 ROG outlet stream is cooled to 55 deg oC

before entering the Caustic Tower.
 Caustic Tower

Removes acid gases H2S and CO2 and

ammonia by reaction with caustic

PRU vent gas, containing some CO2, will be

added to the feed before it enters the Caustic Tower

ROG passing overhead is cooled by propylene

refrigerant and the condensed water is separated out
before it is reheated and routed to the dryers
 Dryer Beds

Two Dryer Beds provide uninterrupted

dehydration of treated ROG

While one bed is in service, the other is

regenerating or on standby

The switching and regenerating sequences are automatic

Each vessel operates on a minimum 36-hour drying cycle

 RSH / COS Removal Beds

Remove ammonia, mercaptans, COS, H2S, and CO2

A parallel vessel is provided for

regeneration while the other is in service

They are regenerated on a 72-hour cycle

 Arsine & Murcury Removal Bed

ARSINE REMOVAL BED :

Removes arsine and trace sulphur compounds by
a chemical reaction

Fixed, non-regenerable type bed consisting of R9-12

lead Oxides

MERCURY REMOVAL BED :

Removes mercury by adsorption

Fixed, non-regenerable type bed sulphur impregnated

carbon
 Deethanizer

Removes heavier components from ROG and routes

them to PRU

 Deethanizer overhead stream is essentially free of C3’s

Overhead stream is compressed in Deethanizer Heat

Pump, cooled, flashed, and used as Deethanizer and
Demethanizer reflux

 Heat source to the Deethanizer Reboiler is C3

refrigerant, which is being chilled in the reboiler

Deethanizer bottoms flow to PRU

 HRS Modules

Vapor from the Deethanizer Reflux Drum is partially

condensed with refrigerant and sends liquid to Demethanizer

Remaining vapor is split into two streams:

1. Sent to bottom of HRS Rectifier
2. Partially condensed with refrigerant and fed into HRS
Rectifier

 HRS Rectifier overhead stream is partially condensed with

the liquid used as reflux and the vapor routed into the
Demethanizer overhead stream

 HRS Rectifier bottoms flow to the Demethanizer

 Demethanizer

Demethanizer overhead stream is partially condensed

with refrigerant using a core-type exchanger in the top of
the column, with the liquid used as reflux and the vapor
expanded and used to condense HRS Rectifier overheads

 Demethanizer bottoms flow to the C2 Spliter

 C2 Splitter

Separates ethylene from ethane

Overhead stream is partially condensed with liquid

C2 collecting the C2 Refrigerant Surge Drum for
reflux / withdrawal and the vapor feeding the third
stage of the C2 Refrigerant Compressor

Ethane from the bottom of the C2 Splitter is vaporized

by condensing part of the ethylene refrigerant and
is used for chilling the Deethanizer overhead
before being sent to Battery Limits as fuel gas
 C2 Refrigeration

.
A three-stage Ethylene Refrigerant Compressor
supplies refrigerant to various users
at the -61°C, -83°C and the -100°C levels, respectively

Ethylene from the final stage discharge is

desuperheated against propylene refrigerant with
part being condensed by reboiling the C2 Splitter
and part by vaporizing the C2 Splitter bottoms

The balance is condensed using -40°C propylene

refrigerant
 C3 Refrigeration

A three-stage Propylene Refrigerant

Compressor supplies refrigerant to various users

 at the 5°C, -19°C and the -40°C levels, respectively

 Propylene is condensed against cooling water

Catalyst Preparation & Regeneration

Deoxo Reactor-1620-D-002A/B
Are regenerated on an infrequent basis (once every
1-2 years)
Reactor is heated with N2 & then LP steam
superheated to 250 deg.C using Electric Heater 1620-
B-001.
The Air is supplied from plant air system
The carbon is burned off until there is no rise in bed
temp
After regeneration the catalyst required reduction
with N2 and H2
During reduction ,the gas is circulated using blower
1620-K-001 after being cooled in Air cooler 1620-EA-
002 and fed to KO drum1620-D-031.
Catalyst Preparation & Regeneration

Catalyst is fresh is requires both reduction and sulphiding.

DMDS is injected into N2/H2

The DMDS is dissociated into H2S when heated.

The hot N2/H2 and H2S are fed to the reactor and gas is
is circulated through the Air cooler 1620-EA-002,KO drum
1620-D-031 and Blower 1620-k-001

Sulphiding is done before off gas is charged to the

Caustic Tower
 Catalyst Preparation & Regeneration

ROG Dryer regeneration

The ROG Dryer are regenerated once every 36 hour
During the heating step, ERU Rasidue gas from Gas compressor
1620-K-002 to the Dryer regeneration steam heater 1620-E-026
The heating step heats the bed at a controlled rate with the max.
Temp. of the gas at 232 deg.C
The cooling step uses cold Regen Gas bypassing Regen Gas Steam
Heater via TV-257B

The hot regen gas is sent to the Fuel Gas Header

 Catalyst Preparation & Regeneration

RSH/COS Removal Beds

The dry ROG gas flows to the RSH/COS removal beds
1620-D-005A/B
Each vassel contain BASF Selexsorb Cos and Selexsorb CD
adsorbent
The RSH/COS Removal Beds are regenerated once every
72 hours
The regeneration gas is sent from residue gas compressor
1620-K-003 and electric heater 1620-B-001 to heat the gas
going to RHS/COS Bed

The peak temp. for regeneration will be 290 deg.C

Catalyst Preparation & Regeneration

Arsine removal Beds

The Arsine removal bed 1620-D-006 which is fixed
non regenerable type
The bed material consist pf R9-12 lead oxides

The Mercury removal beds

The Mercury removal bed 1620-D-007 which is contain
non regenerable fixed bad

The bed material consist of sulphur impregnated carbon

 Complex control in ERU

Total 15 no. complex control in ERU

1.Residue gas –compressor K-003 discharge temperature control
P &ID 5578-E2-1620-PRP-D-132

2.Regeneration system back pressure control

P &ID 5578-E2-1620-PRP-D-116

3.Regeration system differential Pressure Control

P &ID 5578-E2-1620-PRP-D-116

4.ROG Dryer D-004A/B Sequence control

P &ID 5578-E2-1620-PRP-D-109 & P &ID 5578-E2-1620-PRP-D-110
 Complex control in ERU

5. RSH/COS Removal bed D-005A/B Sequence control

P&ID 5578-E2-1620-PRP-D-111 & P&ID 5578-E2-1620-PRP-D-112

6.Deoxo Reactor Steam heater E-002 Control

P&ID 5578-E2-1620-PRP-D-102

7.Fresh Caustic Dosing Control

P&ID 5578-E2-1620-PRP-D-105 & P&ID 5578-E2-1620-PRP-D-107

8.Regeneration Gas Steam Heater E-026 Control

P&ID 5578-E2-1620-PRP-D-114
 Complex control in ERU

 9.RSH/COS Regeneration Gas Electric Heater B-001 control

P&ID 5578-E2-1620-PRP-D-114

10.E-016 Chiller Overheads Bypass Control

P&ID 5578-E2-1620-PRP-D-127

11.Residue Gas Expander EX-003 Capacity Control

P&ID 5578-E2-1620-PRP-D-131

12.C2 Splitter Reflux Ration Control

P&ID 5578-E2-1620-PRP-D-135
 Complex control in ERU

13.Acetylene Polisher ROG temperature control

P &ID 5578-E2-1620-PRP-D-113
14.Treated ROG Bypass Control
P &ID 5578-E2-1620-PRP-D-113B
15.Caustic Tower wash water make-up cooler temperature
Control
P &ID 5578-E2-1620-PRP-D-205
 REFERENCE DOCUMENTS
1. PFDs
2. P&IDS
3. CAUSE & EFFECT
4. EQUIPMENT DATA SHEET CLICK ON DOCUMENT
5. O & M MANUAL NAME TO OPEN
6. PROCESS DESIGN BASIS
7. COMPLEX CONTROL
8. CATALYST & CHEMICAL SUMMERY
9. PLOT PLAN
10. PROCESS EQUIPMENT LIST
Cause & Effect

 ESD001-Deoxo reactor shutdown 1 FOR DETAIL SEE THE C& E

 ESD002-Deoxo reactor shutdown 2
ESD003- ROG to Deoxo reactor 1620-D-002A/B Press. Low low
ESD004-Deoxo reactor regeneration shut down for
Reactor bed temp high high 2oo12
ESD005-Deoxo reactor regeneration shutdownfor control valve
Diff. pressure
ESD006-Deoxo reactor regeneration shutdown for heater
Temp. high high
ESD007 –Regeneration Blower 1620-K-001 trip
ESD008-Deoxo reactor regeneration shutdown for KO drum
level high high
Cause & Effect

ESD034-Deoxo reactor regeneration shutdown for regeneration

Blower flow low low
ESD035-Deoxo reactor regeneration shutdown for N2 flow
Low low
ESD012-Low temp protection for Fuel gas & borouge plant
Feed line
ESD013-High temp protection for regeneration gas line
ESD014- Regen gas 1620-B-001 elect. Heater temp high high
ESD017- Residue gas expander/Comp. trip
ESD018-Low temp. protection for regeneration/fuel gas line
ESD020-1620-K-004 Ethylene refrig comp trip
Cause & Effect

ESD021-1620G-007A/B Ethylene product pump isolation

ESD022-1620-K-005 C3 refrigeration comp. trip
ESD023-Caustic tower low level trip 1620-C-001
ESD024-Caustic dryer feed KO drum low level trip
ESD025-Deethaniser low level trip 1620-C-002
ESD026-Deethaniser reflux drum low level trip
ESD027 –C2R Surge drum low level trip
ESD028 –Caustic tank high temp trip
ESD033- Demethaniser low level trip
ESD029-Acetelene polisher high temp trip
ESD030-Acetylene polisher shutdown
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 Cause & Effect

ESD031- Acetylen polisher N2 purge

ESD032- High temp protection for condensate line
ESD201- Reactor/Caustic & Dryer system isolate
ESD202-C2R System isolate blow down & de pressure
ESD203-C2R Surge C2 splitter isolate
ESD204-1620-EX-003/K003 isolate & de pressure
ESD207-C3 Refrigeration System isolate & blow down
ESD011-1620-K-002 Deethaniser heat pump trip
ESD212-Deethaniser isolation & depressurization
ESD213-Demethaniser isolate & depressure
ESD214-LP flare drum condensate pump start/stop
ESD300/301- Unit shutdown/Depressurization
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