GAS TERMINAL PROCESS DESCRIPTION: The Hazira Onshore terminal begins where the South Bassein-Hazira Pipeline ends

and ends at the distribution outlet points for the gas and condensate streams. The terminal has facilities for receiving the twophase flow, separating into condensate and gas streams, condensate stabilization and distribution. The two-phase flow is received in the slug catcher, where the gas and condensate streams are separated. The gas is filtered, metered and sent to the GSU plants for further processing. The separated condensate from the slug catcher is metered and sent to the CFU plants for further treatment. The gas is supplied in the existing 36 pipeline and 42 pipeline. The following main equipments are provided at this terminal: -Pig receiver -Pressure reducing valves -Slug catcher -Filtering unit -Metering unit The pig-receiving trap makes it possible to recover the pig when scraping the line and to remove any foreign matter and residual solids entrained by the pig itself. There are pressure controllers downstream of the pig receiving stations. The sour gas (42) pipeline has downstream pressure control valve input depending on HBJ requirement.

Slug catcher unit: SCU

Three slug catchers in 3 phases (I, II&III). It is designed to handle associated gas coming from Bombay high field and from satellite fields to knock out the condensate from the incoming gas. The condensate free gas is either processed in gas processing plants or diverted to consumers. Separate pressure regulating skids are provided on the trunk BUT (Bombay High Uran trunk) to maintain GSU (Gas Sweetening Unit) inlet pressure i.e. the skid downstream pressure. Downstream of the control valves is the slug catcher, which has existing 48 fingers and new 6 fingers. During normal operation phase-I slug catcher (24 fingers) separate condensate from 25MMSCMD sour gas from 42 line. Phase-II slug catcher (24 fingers) separate gas and condensate from 36 line, suitable inter-connections have been envigsed in the existing line to hook up with the new line from offshore. However, during pigging of the 42 line, all the 48 fingers will be lined up to receive the liquid hold up in the 23 km line. During this time the 3.6 lines shall be lined up to the 6 new fingers to separate gas and condensate. Each finger is 498 mts long. Slug catcher consists of condensate storage section, separating section, primary riser, and secondary riser. Gas and condensate from pig receiver is fed to slug catcher separation section where the gas is separated. The separated gas goes to gas filtering unit through primary risers. Condensate, which is removed from gas, is stored in slug catcher and for further separations of the entrained gas. The separated gas from primary riser, secondary riser and equalizing riser combines together and goes to filtering unit through 26-P-04-219-D174.Slug catcher-III has 6 fingers.

GAS FILTERING UNIT:

The gas from the slug catcher is sent for filtration in which any condensate entrained along with the gas is separated. Sour gas from PhI slug catcher is sent for to existing filtration unit and sweet gas from Ph-II / Ph-III slug catcher is sent to new filtration unit. For normal operation, two filters will be operated to cover the 25MMSCMD of sour gas and one is standby. New filtration unit has three filters. Each filter can treat max.5800000SCMH sweet gas to remove 99% of 10Q solid particles. For normal operation, two filters are operated to cover sour gas. Sweet gas which is removed of solid particles goes to metering unit and then goes to DPD unit. Each filter is equipped with liquid automatic discharge, which is controlled by the liquid level inside the filter itself. The condensates from sweet and sour gas are metered separately. Gas filter separate from condensate or particle with principle of centrifuge. Gas filter has 200-2 dia cyclones. Feed is injected tangentially into the upper part of the gas filter section and develop a strong swirling, motion within the cyclone. Liquid containing the fine particles fraction is discharged out through the under flow. Gas filters equipped with differential pressure gauge to moniter the any leakage. The liquid coming out of the filters will be sent to a single collecting line, connected both with the line conveying the condensates to the blow down and with the feeding line of the stabilization plant. The condensates from sweet and sour gas are metered separately. Provision is kept for mixing the sweet gas condensate in the sour condensate, after which it goes to the sour condensate fractionation unit.

AIM:-To hold the slug fluid coming at uran at the time of pigging of the gas pipe lines. -To separate continuously coming condensate along with saturated gas.

-To partially stabilize the liquid condensate & inject into crude inlet to CSU, in case of CFU-I/II are down or running at maximum capacity. -To supply gas to GSU for sweetening. -Condensate from the associated gas compressors also can be stored in the slug catcher when CFU-I/II is not in operation.

GAS SWEETENING UNIT-GSU

DESIGN CAPACITY:
Two gas sweetening trains of Ph-III A(37& 38) can handle a total of 12.6 MMSCMD of sour gas.The remaining trains of GSU can handle 28 MMSCMD with 5 trains operating and one standby. This makes the total capacity 40.6 MMSCMD with one train of capacity 5.6 MMSCMD as standby.

GAS FEEDSTOCK SPECIFICATIONS:

The following mixed gas composition has been considered for the design of GSU and GDU.

COMPOSITION:
COMPONENTS N CO HS Cl C C iC nC C C C C C DESIGN CASE(MOLE%) 0.21 6.00 0.137 79.84 7.48 4.14 0.18 0.17 0.22 0.05 0.01 0.002 0.001 CHECK CASE(MOLE%) 0.19 6.50 0.137 78.596 7.41 4.54 0.23 0.22 0.15 0.11 0.05 0.01 -

The design composition of sour gas is as per the Material balance given by SNEA after the test runs. Additionally the design shall be check case composition containing 6.5% (mole) CO by adjusting methane content. Pressure at battery limits : 96-54 kg/cmabs Temperature at battery limits : 20-33 C Gas sweetening train will have a maximum operating pressure of 77 kg/cma. A pressure control valve and heating device upstream of the pressure valve will prevent hydrate formation. H S and CO content will vary depending on conditions. PRODUCT SPECIFICATIONS: The product from each gas sweetening train will meet the following specification. Sweet and dry gas: HS content Pressure at battery limits Temperature at battery limits Rich MDEA flash gas: HS content Pressure at battery limits Temperature at battery limits Acid gas: 4 ppm vol.Max 74.9-51.9 kg/cmabs 40C 4 ppm vol.Max 4.5 kg/cmabs 48-55C

Hydrocarbon content will be minimized Pressure at battery limits 1.9 kg/cmabs Temperature at battery limits 50C

PROCESS DESCRIPTION GENERAL In the sweetening process, gas is washed with aqueous solutions of MdeA. The MDEA and TEG trains are connected with one another by a pipie rack supplying products and required utilities. GAS SWEETENING UNIT The main purpose of this gas treatment step is to remove the H S from the sour gas with a high severity, and at same time the CO co-absorption to the minimum required and in any case, to not more than 32%. MDEA PROCESS PRINCIPLES The selective removal of HS is made by washing the sour gas with an aqueous solution of Methyl-Di-Ethanol-Amine. The process principles are similar to the well known SNPA-DEA process.The only difference is the behavior of the ethanolamine used. Methyl-Di-Ethanol-Amine(MDEA) is a tertiary amine, which does not react easily with CO .The selectiveity is so promoted by using the differences in reaction rates between both H S and CO and the tertiary amine. First the case of a primary or secondary amine whose reactions with the acid components H S and CO are similar, is investigated. HS reacts to give amine hydrosulfide: H S + R NH HS , R NH

CO can react directly with amine to form an amine carbonate: CO + 2R NH R NCOO , R NH

But CO can react with water or hydroxyl ions to form carbonic acid or bicarbonate ions:

CO + H O CO + HO

H CO HCO

There are basically two units: 1) High pressure absorption. 2) Amine regeneration. 1) High pressure absorption:-

- Sour gas liberated from CFU also joins this stream under flow control. - This combined sour gas comes in counter current contact with lean amine solution (MDEA:-Methyl Di Ethanol Amine) in absorption column having 14 type trays. - The sweet gas leaves from the top of the column with 4 PPM H2S which is cooled and routed to GSU/LPG units through knock out drum (KOD).

- The rich amine from the column to medium pressure absorber/flash drum. The flash gases go to fuel header and rich amine (containing H2S) passes through the plate heat exchanger before it enters the regeneration column having 21 trays for regeneration of amines. - Regenerated lean amine from the bottom goes back to the MDEA tank and is recycled in the process. - Acid gas consists of 98% of carbon dioxide and 2% of hydrogen sulphide. - It is liberated from the top of the regenerator column for sulfur recovery. AIM:- To reduce the hydrogen sulphide content of sour gas to 4PPM. - To limit the carbon dioxide co-operation to the minimum required no more than 32%. Principle involved:- Counter current absorption using aqueous solution of MDEA. - Regeneration of rich MDEA solution to lean MDEA solution in two stages. STAGE I:Flashing of intermediate pressure in MP flash drum to regenerate fuel gas. STAGE II:Reboiling of rich MDEA in regenerator to generation acid gas to SRU.

SULPHUR RECOVERY UNIT:Capacity: The SRU is designed to treat 35,000 NM/Hr of acid gas originating from the gas sweetening unit. Each train is capable of treating up to 7000 NM/Hr of acid gas with a hydrogen sulphide concentration ranging between .3 and 5.2 mole percent i.e. 3000 to 52000 ppm of H S.The sulphur production will range between 0.7 and 12.2 metric tons per day per train .Under normal circumstances four trains will operate at full capacity while two remains on standby/under maintenance.

FEED SPECIFICATION: The acid gas composition will vary with the variation in sour gas throughout, arrival pressure and temperature at hazira. The acid gas has the following properties: COMPOSITION H2S CO2 H2O Hydrocarbons Pressure(kg/cm) Temperature(C) Flow(NM/Hr) Source VOLUME % 0.3-5.2 92.5-8.5 6.9-8.5 0.5-1.0 0.8-1.0 45-50 7000 per train MDEA regenerator in GSU

PRODUCT SPECIFICATIONS: Sulphur produced by the SRU is a consequence of meeting an environmentally acceptable gaseous effluent. The sulphur is expected to have the following characteristics:-

Sulphur purity Moisture Ash Organics As,Se,Te Fe Form Packaging PROCESS DESIGN:

99.9% 0.1% Less than 400 ppm Less than 500 ppm Commercial Nil 250 ppm max. Solid, in flakes form 25-30 kg bags

The locant unit will reduce the H S by 99.9% from 5.2% to 10 ppmv.The locant unit works by contacting the H S with a liquid phase catalytic reagent, which absorbs the H S and converts it to elemental sulphur and H O.Details of thetheory and operation of the locant unit designed for this application are contained in the following sections. THEORY OF OPERATION: The locant process brings about the following reactions to produce solid elemental sulphur from hydrogen sulphide gas. Absorption: H S + H O (liquid) First ionization: H S (liquid) Second ionization: HS H + S..... (3) ): ... (4) H + HS..... (2) H S (liquid) + H O (liquid)... (1)

Oxidation by metal ions(Fe S + 2Fe Overall reaction:

S (solid) + 2Fe

H S (gas) + 2Fe

2H + S + 2Fe

.... (5)

The metal ions must then be deoxidized in the regeneration part of the process using oxygen from either ambient air (anaerobic process) or the process gas itself (aerobic process). Absorption: O (gas) + 2H O O (liquid) + 2H O...... (6)

Regeneration of metal ions: O (liquid) + H O + 2Fe Overall Reaction: O (gas) + H O + 2Fe 2(OH) + 2Fe ... (8) 2(OH) + 2Fe . (7)

Now ,adding equations (5) and (8) together gives H S (gas) + O (gas) + H O S (solid) + 2H O (liquid)

In this overall reaction, the metal serves to transport electrons from the absorber side of the reaction to the regeneration side, and it is necessary to supply at least two metal ions per atom of sulphur made. In this sense, the metal ions are a reagent. However, they are not used up in the overall reaction and serve as a catalyst for the reaction of catalyst for the reaction of H S and O .Because of this dual function, the metal ion concentrate, ARI-310 solution is described as a catalyst reagent. The auto circulation LO-CAT unit addressed in this manner utilizes the differential density between two aerated liquid phases at different aeration rates to circulate ARI-310 solution from the oxidizer section to the absorber section of the vessel. The solution absorbs HS and small amounts of CO and is returned to the oxidizer. Air is introduced in the oxidizer section of the vessel, whose oxygen is absorbed into the solution.This absorbed oxygen regenerates the catalyst. Equation (9) indicates that there is no net production of H ions of OH ions and the pH of the solution is not changed by the basic reaction. However, several competing side reactions do go on to a limited extent, and

require the addition of KOH. Or other alkaline material to maintain the pH of the solution high enough to give good HS absorption. The side reactions are less clearly defined from a chemical standpoint, but may be represented by the following generalized reaction: 2HS + 2O S O +H O

When this is combined with the ionization reactions, it is apparent that there is a net production of H ions whenever S O is produced. This would lead to a decrease in the pH of he solution, and to prevent this, it is necessary to add an alkaline reagent such as KOH either continuously or intermittently to control the pH of the solution. Usually pH values in the mildly alkaline range between 7.5 and 8.5 are satisfactory for most applications. The exact pH required will vary with the type of absorber and absorber efficiency required. Operation at an excessively high pH will encourage the formation of thiosulphate ions even though a larger fraction of the dissolved H S will be in the form of s ions at high pH values. Operation at abnormally low pH of the solution. To prevent this form happening, it is necessary to further buffer the solution with an alkaline reagent such as KOH.As a general rule, a concentration of 10wt% KOH is required in the circulating solution for a gas steam containing solution for a gas stream containing 1 atmos partial pressure of CO .This will give a solution pH of between 7.5 and 8.5.Batch or continuous make up will be required to overcome the withdrawal losses from the system. It is apparent that the formation of sulphate and thiosulphate and addition of alkaline reagents to control the pH will lead to increasing concentrations of dissolved salts in the ARI-310 solution with time.