C02 Removal Section Limitations

&
Plausible solutions

1
 Objective

To Address the Key Factors Effecting

CO2 Removal Section Performance
For Maximizing Its Efficiency And
Reliability
Contents
Brief description

Limitations of CO2
Removal Section

Remedial Options

Cost benefit Analysis

Recommendations

Q&A Session
 Brief description of CO2 Removal Section
Regeneration CO2 to UREA
Wash Gas to R-4311 Temp
30231 Nmc/hr.
40 °C , 0.2 kg/cm2 40 °C
BFW 97.3 °C
0.2 kg/cm2
Lean Sol
246,700 kg/hr.
50 °C C-4301
C-4302 K-4301

V-4301
Semi Lean Process Gas inlet
Sol
E-4215

Process Gas outlet

Recycle Gas V-4302
S-4301
18.34 %
E-4301
CO2

DHTP-4301 E-4306
Process Gas
P-4301 P-4302
164,832 Nmc/hr. P-4308
75 °C A.C Filter E-4303
26.9 kg/cm2
P-4303
 Limitations of CO2 Removal Section

CO Slippage
2

Low Gradual rise in

Urea
loss
Regeneration Heat Stable
Temperature Salts
NH3
loss
 Effect of Low Regeneration Temperature
105 1.00
Regeneration Temp design = 97 °C
103 CO2 in Lean Solution design= 0.3% 0.95
Regeneration Temperature

101 0.90
99 0.85

CO2 in Lean Solution

97 0.80
95 0.75
93 0.70
91 0.65
89 0.60
87 0.55
85 0.50
1 1 2 2 2 3 3 4 4 4 5 5 6 6 7 7 7 8 8 9 9 9
r-1 g-1 n-1 n-1 v-1 r-1 p-1 b-1 l-1 c-1 y-1 t-1 r-1 g-1 n-1 n-1 v-1 r-1 p-1 b-1 l-1 c-1
a u c a u
M Au Ja Ju No Ap Se Fe J De Ma O M Au Ja Ju No Ap Se Fe J De
Reasons of Low Regeneration Temperature

1
E-4301 Choking

2
E-4215 Fouling
Reasons of E-4301 Choking & E-4215 Fouling

1 Contaminants with Process Gas

2 Corrosion/Erosion Products

3 Deposition of Antifoam

Degraded Amines
4
 Effect of E-4301 Choking on Regeneration Temperature
110

105

100
Temperature (°C)

95

E-4301 Plate pack

90 replaced

85

80

75
0 0 1 2 2 3 4 4 5 6 7 7 8 9 9
ar
-1 v -1
u l-1 p r-1 c -1 g -1
p r-1 c -1 p -1 y -1 n -1 p -1 y -1 b -1
c t-1
M o J A D e u A D e S e a J a S e a F e O
N A M M
Chemical Cleaning Semi Lean to C-4301 Temp (C) Regeneration Temp (C)
E-4215 Low Performance
E-4215 Low Performance
E-4215 Low Performance
E-4215 Low Performance
E-4215 Low Performance
Remedial Options for E-4301 Choking

Installation of Cartridge
1 filter at C-4301 outlet

Replacement of CS
2
Packing with SS

Frequent Chemical
3
Cleaning of E-4301
 Remedial Options for E-4301 Choking
Cartridge Filter at Packing Frequent Chemical
E-4301 upstream Replacement with SS Cleaning of E-4301

E-4301 Effective
Higher Light
less
chocking
Filtration Chemical deposits
Tendency
Capacity Less CS Cleaning
Corrosion Volume
Products 82%

High Booster Chemical

Pressure Pumps Cleaning Parallel
drop Required Frequency Installation
to be
increase

Capital Operating Total Cost Flexibility

Cost Cost / Long of
~ PKR 283
~ PKR year Downtime Chemical/
million mechanical
49.8 ~ PKR 8
million million cleaning
 Payback of Parallel exchanger installation

Estimated Cost Urea Production Payback Period

~ 25 Saving ~ 3Years
Million PKR ~ 8.2 Million
per year
 Heat Stable Salts (Degraded amines)

Thermal Heat Stable Oxidative

Degradation Salts(Degraded Degradation
Amines)
(Formic, oxalic, acetic
acid)

Effects of HSS

Foaming Heat Exchanger Low Absorption

aMDEA Loss Corrosion
Fouling Capacity
 Deactivated amine Concentration
6.00 44.00

5.50 43.00

5.00 42.00

4.50 41.00

4.00 40.00

3.50 39.00

3.00 38.00

2.50 37.00

2.00 36.00
2008 2013 2015 2017 2019

Deactivated Amines, % Active Amines, %

 Remedial Options For Heat Stable Salts Problem

Replacement Online removal of

of aMDEA HSS by ion
Solution with exchange
New Charge technology

~ 178
Temporary Million
PKR

20
 Working & Benefits of Ion Exchange System
Regeneration
Cycle Start
Ion Dilute NaOH More active amines
Exchange (aMDEA Saving)
System

Reduce filtration
cost
Benefits
Waster water Reduce Foaming

Purified Solution Proven Performance

Loading Cycle Worldwide=70 units
Pakistan= 2 units
Lean Solution from Stripper
 Recommendations

Installation of New exchanger in

parallel to existing E-4301

E-4215 Mechanical Cleaning

(If performance not improved)
Recommendations Replacement to be planned

Installation of advance ion

exchange technology for
HSS Removal
 Yo u
an k
T h
23
QUESTIO
NS
Benefits of Parallel exchanger installation

Improve Regeneration
Temperature

Urea Production
Saving

Effective Chemical
Cleaning
 Reasons of Corrosion Products

Why High Iron (Fe)?

Corrosion CS
particles Packing Inadequate
Filtration
Contaminant
s with
Process gas Erosion/
Corrosion in
piping

CS Packing

High Iron Contents

 Iron Content Profile
TA 2002 TA 2008 TA 2015 TA 2018
24

21
Design Value
Iron Content (ppm)

18 10 ppm

15

12