GAS CONDITIONING

&
PROCESSING

PTP-19.2
Gas Sweetening

1
 TABLE OF CONTENTS

Contents Page number

1.0. Acid Gases in Natural Gas 03

2.0. AMINE TREATMENT 03

2.1. Alkanolamines 03

2.2. Basic Process 05

2.3. Process flow and Components 06

2.4. Antifoam Chemical Injection 11

2.5. Safety 05

2.6. Emergency Operations 12

2.7. Storing and Identifying Chemicals 13

2.8. Potential Hazardous 13

3.0. SULFEROX PROCESS 14

3.1. Introduction 14

3.2. Process Details 14

3.3. Drum Filter 18

3.4. Start up Operation 20

3.5. SulFerox Chemicals 21

GAS SWEETENING
1.0. Acid Gases in Natural Gas

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Natural gas often contains hydrogen sulfide (H2S) and Carbon Dioxide (CO2) and these
gases form acids when combined with water is called an acid gas. Hydrogen sulfide (H2S)
and carbon dioxide (CO2) combined with water form sulfuric acid and carbonic acid,
respectively and hence the name acid gas. Natural gas with H2S or other sulfur compounds
present is called "sour gas", while gas without H2S or other sulfur compounds are called
"sweet gas".

They occur in varying concentrations depending on the nature of the reservoir from which
the natural gas is produced. The acids formed can be very corrosive to equipment and
piping. Removal of both H2S and C02 from natural gas is one of the most common treating
problems for gas plants. Hydrogen sulfide must be removed due to its corrosiveness and
toxicity. When burned, it forms sulfur dioxide (SO2), which is another toxic gas. Carbon
dioxide must also be removed from natural gas due to its corrosiveness and lack of heating
value.

Gas Sweetening

The process of removing acid gases from natural gas is called gas sweetening. Although
there are several processes used in the petroleum industry for removing acid gases from
natural gas, the most common process is alkanolamine treatment or simply amine treatment.

2.0. AMINE TREATMENT

2.1. Alkanolamines

Alkanolamines, which are weak bases, react chemically with acid gases to form salt
complexes. These salt complexes can be regenerated so that the amine again free of acid
gases and can be recycled.

Amines are nitrogen-hydrocarbon (N-HC) compounds which are categorized as primary,

secondary, or tertiary depending on the number of hydrocarbon (HC) groups attached to the
nitrogen (N) atom. HC groups will vary depending on the type of amine, e.g., mono ethanol,
diethanol, triethanol , methyl diethanol , etc.

The most commonly used amines are:

Mono ethanol amine (MEA): A primary amine which has two hydrogen atoms and one HC
group attached to the N atom.

Diethanol amine (DEA): A secondary amine which has one hydrogen atom and two HC
groups attached to the N atom.

Triethanol amine (TEA), Methyl diethanol amine (MDEA) are tertiary amines which have
three HC groups and no hydrogen atoms attached to the N atom.
CHEMICAL FORMULA

H
MEA l
3
 HOCH2CH2 - N - H

H
DEA l
HOCH2CH2 - N - CH2CH2OH

CH3
MDEA l
HOCH2CH2 - N - CH2CH2OH

CH2CH2OH
TEA l
HOCH2CH2 - N - CH2CH2OH

MDEA has unique capability of selectively absorbing H2S from CO2-H2S mixture and will
be useful in the application of the removal of H2S. MDEA is a light colored liquid with
characteristic ammoniacal odor, is soluble in water. An aqueous solution of 50% is being
used in Yibal Khff Gas Treatment Plant.

Absorption

Much like a sponge, amine is used to absorb acid gases from natural gas. By mixing together
the sour gas and amine solution in a contactor column, the acid gases are absorbed by the
amine solution, thereby removing them from the natural gas.

Distillation

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In distillation, acid gases are removed from the amine solution by the use of heat. Sufficient
heat must be added to the rich amine solution to break the bonds between the acid gases and
the amine. This is generally done by using steam in a stripper column.

2.2. Basic Process

There are two purposes of an amine sweetening unit. The primary purpose is to remove acid
gases from natural gas before putting the natural gas into a pipeline. The other purpose is to
remove acid gases from the amine solution so that the amine can be used over and over again
in the sweetening process.

The process, while it may seem somewhat complicated, is actually quite simple. Sour gas
has acid gases removed from it by an absorption process. The amine solution absorbs acid
gases from the natural gas, leaving sweet gas. The rich (containing acid gases) amine
solution then goes through a process of distillation where the acid gases are removed. The
lean (not containing acid gases) amine solution is then sent back to function again in the
sweetening of natural gas. In this manner, amine is recycled.

BASIC PROCESS

SWEET GAS ACID

GAS
LEAN AMINE

SOUR
GAS RICH
AMINE
HEAT
ABSORPTION DISTILLATION

2.3. PROCESS FLOW AND COMPONENTS

Overview
A typical amine sweetening process schematic is shown in the next page. This is a typical
example of the Yibal Khuff Plant. This sweetening process uses an aqueous amine solvent.
The solvent utilized is Methyl Di-Ethanol Amine (MDEA). The solvent strength is 50%
(w/w). The Natural Gas being treated is the sour gas from the Khuff oil separators. The plant

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consists of the following components: inlet gas cooler, inlet separator, contactor column,
outlet scrubber, flash tank, filters, stripper column, reflux condenser, accumulator, pumps ,
amine heater, lean/ rich heat exchanger, circulation pumps and trim cooler.

Depending on the type of alkanolamine used, the amine sweetening unit at your location may
vary slightly from this typical unit. However, the process will be very similar to the one
shown.

Inlet Gas Cooler

The gas is initially cooled in an inlet air cooler and the temperature is controlled by a
temperature controller. Temperature should not be too low so that hydrates should not form.
The approximate hydrate formation temperature is 15°C at 4000 kPa (g). On the other hand
if the temperature is higher than the amine in the contactor , then the gas will cool down in
the contactor and hence lighter hydrocarbons will condense and may leads to unstable
operation conditions. So temperature control of the inlet gas is very important in the amine
treatment plants.

AMINE TREATMENT PLANT

INLET
GAS COOLER SWEET GAS
CONTACTOR
GAS
SCRUBBER CARBON
ACID GAS
FILTER
AMINE
STILL REFLUX
COLUMN ACCUMULATOR

FLASHED
GAS

FLASH
TANK

SOCK FURNACE
FILTER

HEAT
EXCHANGER

Inlet Separator

Gas flows from the cooler to the separator or scrubber, where solids and free liquids are
removed from the gas. This separator can be an integral part of the contactor unit or it can be
a separate vessel.

Within the separator, baffles allow most of the liquids to be removed. A mist extractor,
located near the gas outlet, traps liquids entrained in the gas before it leaves the vessel.

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Efficient removal of solids, such as iron sulfide, from the gas prior to the absorption process
can minimize many operational and maintenance problems such as foaming, erosion and high
corrosion rates. These problems usually result in amine loss, equipment failure, and
difficulty in meeting sweet gas specifications.

Contactor Column

In this vertical pressure vessel, sometimes called an absorber, sour gas comes in contact with
amine solution. Contactor columns operate at a pressures in the range of 1300 to 4000 kPa..

There are two types of contactor columns commonly used: the tray column and the packed
column.

In a tray column, which is more commonly used than a packed column, the liquid level is
maintained on each tray by a weir on the down comer.

The number of trays or height of packing helps to determine the degree of sweetening.
Twenty trays are common. Bubble cap trays or valve trays are used for good liquid and gas
contact.

In a packed column the amine solution contacts the gas stream by forming a film over the
packing. Thus, a large surface is available for C02 and H2S to transfer from the gas to the
amine solution.

Since tray columns are more common, we will discuss flow through this type of column from
here on. Sour gas, which is preferably kept at a temperature between 35 and 45°C , enters
the bottom of the contractor, it begins to rise through the bubble caps on each tray. At the
same time, lean amine, which has entered from the top, flows downward counter-current to
the gas flow. The temperature of the lean amine should be kept 6°C above the natural gas
temperature to prevent hydrocarbon condensation.

The gas disperses through the amine in the form of bubbles. A froth is formed. The gas
disengages from the froth, travels through a vapor space and up through the liquid on the
next tray. Entrained amine solution falls back onto the tray and then flows down through the
down comer to the next tray. Nearly all absorption of H2S and some C02 takes place on the
trays and not in the vapor space between the trays.
One of the more likely operating difficulties which can occur in the contactor is the hold up
of the amine liquid on the trays due to excessive amine foaming in the trays. The differential
pressure across the trays will increase during such instances. Anti-foam chemical injection to
be started immediately and the reason for foaming to be rectified.
At the top of the contactor , an upper chimney tray with two trays are provided in the Yibal
Khuff plant. This is to wash out the gas so that the entrained amine will be retained in the
chimney tray. In some other cases a demister pad is provided at the top of the column. In
both the cases the purpose is to reduce the amine loss.

While sweet gas is leaving the top of the contactor, rich amine solution, which contains
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H2S and C02, is discharged from the base of the contactor.

The sweetened outlet gas from the amine contactor flows in to the outlet scrubber . This
scrubber is designed to receive any amine liquid carryover from the contactor . It has a wire
mesh mist pad to remove entrained amine droplets from the out going sweet gas. Liquid
amine flows back into the flash tank along with the amine from the contactor. Thus any
amine carry-over from the contactor is returned to the system. Normally there will not be
much liquid collection in this vessel. During operational upsets such as foaming in the
contactor , more liquid will be collected in this vessel.

Flash Tank
Rich amine solution leaves the bottom of the contactor and flows to the flash tank .It
operates at a pressure of 500 to 600 kPa(g) with a back pressure control valve where a large
portion of the physically absorbed gases are flashed off. The flash tank should be operated at
the lowest possible pressure to maintain amine flow to the stripper and to flash off maximum
possible gases. Tank vapors, which are usually H2S and CO2 are normally flared. The
heavier hydrocarbons separated from the amine and form a separate liquid layer on top of the
amine solution. They are skimmed off and the amine is drained from the bottom of the tank
with the help of level control valve.

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From the flash tank , the rich amine flows through the filters to the Heat Exchanger. There
are sample points at the inlet and on the vessel to check the amine for foam or hydrocarbon
liquid. Frequent checking of the amine quality at these points is essential for the smooth
operation of the plant.

PC TANK
FLASH TANK VAPOUR

RICH
AMINE Mist mat

RICH AMINE
Oil

Filters

Filtering the amine solution to remove solid matters and entrained hydrocarbons is essential
for proper operation. Filtering can be done several ways. The rich amine can be filtered
downstream of the flash tank and upstream of the lean/rich heat exchanger. If filtering is
done at this point, normally a full-flow mechanical (sock) filter is used. Delta pressure
across this filter should be bellow 35 kPa (g). If it is more than 70 kPa(g) the filter element to
be changed. For the purpose of filter element change , no need to shut down the plant. Filter
can be by-passed for a short time for the above purpose.

Another type of filter used in the amine regeneration process is activated carbon filters. The
activated carbon filter is used to remove entrained hydrocarbons. Entrained hydrocarbon
liquid will tempt amine to foam in the contactor. Monitoring the d/p is important in the
process. If the d/p is high , filter can be by-passed and the activated carbon can be replaced.
It is also possible to re-generate it by using steam purge to drive off the hydrocarbons
adsorbed by the activated carbon.

Lean/Rich Heat Exchanger

From the sock filter, amine flows to the heat exchanger, which rises the temperature of the
rich amine by exchange of heat with hot lean amine from the still column. An anti-foam
injection point is located in the rich amine outlet line . This point would be the preferred
injection point if primary foaming problem is in the still.

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Amine Still
WATER VAPOUR
and
ACID GASES

#1
FEFLUX

RICH
AMINE

HOT AMINE

LEAN
AMINE

The stripper column or still is commonly referred to as the regenerator because it is in this
vessel that acid gases are removed from the rich amine, making the amine solution once
again lean. Like the contactor, a stripper column is either a tray or packed column.
However, strippers operate near atmospheric pressure.

Rich amine enters at the top and flows downward. The rich amine solution is further
heated by steam entering the bottom of the stripper and flowing upward through the
descending amine solution.

Steam, generated in the bottom, adds sufficient heat to the amine solution to strip acid gases
from the amine solution. In addition, steam helps to sweep the liberated acid gases out of the
stripper.

Rich amine enters tray 20 of the amine still and is distributed on to tray 20 with a feed baffle.
The still stripping trays consists of 20 valve trays and 2 reflux trays at the top.

As the amine flows downward to each trays 20 to 1 , it is stripped of more H2S and CO2 on
each tray by the rising steam created by the heat input to the amine by the heater. The still
operates at a constant pressure of approximately 70 kPa (g) below bottom tray number 1.
This pressure is controlled by the back pressure controller in the acid vapor outlet line. The
normal differential pressure drop across these 20 trays is 20 kPa (g). If a high differential
pressure exists across these 20 trays means foaming inside the column.

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Acid gas and steam flows upwards through reflux trays 21 and 22 and out the top of the still
to Reflux Condenser . Water is returned to the system as reflux through pumps and enters
the still on tray 22 .

The hot, regenerated (lean) amine solution leaves the bottom of the stripper and flows to the
Amine Heater and Heat Exchanger with the help of a centrifugal pump.

Reflux Condenser/Accumulator

Overhead vapors from the stripper, consisting essentially of water vapour and acid gases,
pass through the reflux condenser to recover water and the small amount of amine which
may have vaporized in the stripper. Some of the water vapor is condensed so it can be
separated and pumped back to the stripper for reflux.

The condenser effluent then flows to the reflux accumulator for separation of the water and
acid gases. The water is returned to the stripper by the reflux pump. Acid gases may be
sent to the flare.

Amine Heater

The stripper bottoms are heated by the amine heater. Amine heater is a forced draft heater.
To ensure adequate stripping steam flow in the still , the amine is heated up to 165°C in the
heater . Pressure is held on the amine heater to ensure that it should remains as a single
liquid-phase . This is achieved by a flow control valve. The FCV is in the amine outlet of the
heater and is very close to the still bottom . As the solvent flash to the still pressure across the
FCV, steam is generated to provide the stripping media for the still.

Trim Cooler

The lean amine solution in the contactor column should be hotter than the sour gas being
treated, however, high amine temperatures affect the amount of acid gas removal. A trim
cooler is used to control the temperature of the lean amine solution coming from the Heat
Exchanger.

2.4. Antifoam Chemical Injection.

The anti foam chosen for MDEA system is Union Carbide SAG GT-101. This chemical can
be injected at 100% strength or it can be mixed with the 50% MDEA solvent to dilute the
mixture. It is a popular misconception that too much of the silicone antifoam chemical will
actually induce foaming. This is not true, but normally a total of 1% of the system volume
should not be exceeded and should more than sufficient. WHEN LARGE AMOUNT OF
HYDROCARBON ARE PRESENT, HOWEVER, NO AMOUNT OF ANTIFOAM CAN
KEEP FOAMING UNDER CONTROL.

2.5. SAFETY

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 This section deals in general with plant safety.

GENERAL

Definite safety procedures should be prepared for the plant. Plant supervision should make
certain that employees understand their duties and responsibilities. Employees should
understand that it is their personal responsibility to report to their immediate supervisor any
abnormal circumstances, such as:

1.Leaks
2.Accumulation of gas or vapor.
3.Defective or damaged equipment.
4.Abnormal conditions such as excessively high or low temperature or pressure.
5.Unauthorized hot work.
6.Unauthorized vehicles or personnel in the area.

Operating personnel should be familiar with location of fire protection and first aid
equipment in the area and trained in the use of such equipment. Employees should know
how to report a fire or an emergency and have a clear understanding of their duties during
such emergencies.

NORMAL OPERATION

Plant manuals and PEFS to be available in the plant control room.

. Procedures covering the starting up and shutting down of processing equipment and units
should be made and explained thoroughly by those responsible for operation of the
equipment.

2.6. EMERGENCY OPERATIONS

General

When flammable liquids or vapors escape from tanks, vessels, or lines,wear BA set
immediately and shut down the plant. All available means should be used for limiting their
spread and preventing their ignition. The extent of the contaminated area should first be
defined and the area identified by suitable warning signs, and patrolled. Spills should be
cleaned up as soon as possible.

Liquid Leaks

If a break or serious leak occurs in a liquid line, the plant should be shut down and block
valves closed.
In the case of very light leaks which give off quantities of vapor, the procedures listed for gas
leaks should also be followed.

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 Gas Leaks

In the event of a break to a gas or amine line or vessel, emergency shut down of the plant to
be initiated. Before operations are resumed, tests should be made at pits, trenches, or dikes
where gas might accumulate. Portable gas indicators for making such tests will indicate if a
flammable gas or vapor is present. If it is minor leak and the section can be isolated , it can
be done so , with BA set and buddy system.

Equipment

1. Inspect all personnel protective equipment daily.

2.7. Storing and Identifying Chemicals

1. Adequately label or mark bottles and containers to identify the chemical within.

2. Keep chemicals stored in their proper place. Solvents should not be brought into the
control room. Keep volatile combustible liquids in safety containers and away from
direct flames or sources of heat.

3. When handling chemicals, always wear protective clothing and eye protection.

4. If acids or caustics enter the eye, flush with plenty of water and report immediately for
first aid treatment.

5 .Wash hands immediately after handling chemicals bearing poison labels.

6. Refer to vendor information for specifics on the safe handling

of individual types of chemicals, and first aid steps for accidents involving them.

7. Keep chemical data sheets at the places of storage, make-up and sampling.

2.8. SOME POTENTIAL HAZARDS AROUND AMINE/ACID GAS

TREATING PLANTS

AMINE (MDEA): Amine is a mild alkaline material which in the pure form can cause
minor irritation to the skin. If contact is made, wash the area thoroughly with soap and
water. Avoid contact with eyes and do not take internally. Follow the manufacturer's
recommended handling procedures.

(H2S) Hydrogen sulfide: is an extremely toxic gas. Extreme caution should

be used whenever the presence of H2S is suspected. Do not work alone. Follow buddy
system. Have emergency breathing equipment available.

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Hot Equipment: The process of regenerating an amine solution necessitates certain pieces
of equipment operate above 65°C. Exercise caution when opening valves or maintaining
equipment in these areas. Serious burns can result from liquid or vapour discharge. Avoid
contact of hot surfaces.

3.0. GAS SWEETENING – SULFEROX PROCESS

3.1. Introduction

H2S is a colourless inflammable and highly toxic gas.

In Lekhwair field the present concentration is +/- 50 ppm and is likely to increase to about
500 ppm.
In the overall policy of gas conservation it has been decided to treat the gas free of H2S and
export it to Yibal and Fahud after controlling the dew-point for pipe line use.

The sulFerox is a sour gas treatening process designed by SIPM to reduce the H2S
concentration in the gas from 500 ppm to 5 ppm. The process outline follows.

The temperature of the sour gas is raised by 5C by heating in the sour gas super heater to
prevent hydrocarbon liquid condensation from the gas. Then gas flows to gas/sulFerox
contactors where H2S in the gas is absorbed by chemical reaction between H2S and ferric
ions in the sulFerox solution. Elemental sulphur is formed by the process and is removed in
the vacuum filter system.

14
Treated gas from the contactor passes through the separator and KO vessel and enters for
dew point correction. The sulFerox solution carrying sulphur particles flows to the flash
vessels and then goes to the regeneration.

The regeneration solution is pumped back to the contactor . The bottom product of the
regeneration vessel is sent to the vacuum filter where the sulphur particles are filtered from
the sulFerox solution and disposed of in the form of wet sulphur cake.

3.2. Process Details ( Process in Lekhwair Production Station ).

A schematic of the SulFerox process is shown in the next page.

SulFerox

It is a trade neme- an acronym for Sulphur removal by Ferric Ion and Oxidation. The name
applies both to the process itself and to the chelate solution used in the process.

The sour HP gas from the gas lift compression unit flows to SulFerox unit through 27-US-
601 for removal of H2S. When the sulFerox unit is shutdown HP gas flows to gas distribution
bypassing the SulFerox unit through 26-US-602.

The sour HP Gas is pre-cooled in sour gas/sweet gas exchanger E-2761 and flows to
SulFerox inlet KO vessel V-2761. Separator liquid from V-2761 flows to NGL first stage
flash vessel V-2785. Gas from V-2761 flows to the SulFerox contactors C-2770/71/72 for
de-sulphurisation through the sour gas super heater E-2762. The temperature of sour gas is
raised to 5C above its dew point in E-2762 to prevent hydrocarbon liquid condensation from
the gas. Liquid hydrocarbons in SulFerox solution cause foaming and system blockages in
the SulFerox unit due to the formation of "sticky" sulphur.
Gas enters the contactors from the bottom. A SulFerox solution is pumped concurrently via
a spray nozzle into the contactors. The column is equipped with a proprietary packing which
reduces the risk of solution blocking the column. A pressure drop of approximately 300 kPa
should be maintained over the spray nozzle to ensure that the spray covers the complete
packing. A minimum liquid / gas volumetric ratio (3-4% of actual gas volume) ensures
adequate wetting of the packing.
The SulFerox fluid reacts with the H2S as follows:
2 Fe + + + (L) + H2S (g) = 2 Fe+ + (L) + S(s) + 2 H+ (L) (1)
The L stands for Ligand, which is also called a chelate. This is an organic molecule, which
is used to maintain a high concentration of iron in solution, and protects the iron from
precipitation as sulphide (FeS) or hydroxide (Fe(OH)3).

The design residence time of gas in the contactor is about 2 seconds. The gas and SulFerox
slurry flow into the treated gas separator V-2770 where the solids / liquids are separated from
the gas. The gas flows to the treated gas knock out vessel V-2771.

The solid / liquid mixture from vessel V-2770 and V-2771, which both operate at the
compressor discharge pressure, flow to V-2772, the medium pressure flash vessel. The gas
which flashes from the solid / liquid slurry flows either the LP flare or to the LP fuel system.
The pressure in the vessel is controlled at approximately 750 kPa(g).
15
 SIMPLIFIED SCHEMATIC OF GAS SWEETENING SULFEROX

GAS SWEETENING SULFEROX SCRUBBER SWEET GAS

TO LP FLARE

TO LP FUEL
TO LP FLARE
FLASH
VESSEL
SEPARATOR FLASH
VESSEL

HIGH PRESSURE
CONTACTOR
COLUMN

HOT
OIL TO REGENERATION

SOUR
GAS
REGENERATED SOLUTION

16
SULFEROX REGENERATION
17
The solid / liquid mixture from V-2772 is flashed off again at 255 kPa (g) in vessel V-2773.
The vapour leaving this vessel is routed to the LP flare.
The solid / liquid mixture flows to the SulFerox regeneration vessel V-2775 where air is
blown into the slurry, which reacts as follows:

4 Fe++ (L) + 02(g) + 4 H+ (L) ) = 4 Fe+++ (L) + 2H20(l) (2)

The regenerated SulFerox solution is pumped from V-2775 by pumps P-2772 A/B/C back to
the contactors.

The sulphur / SulFerox slurry is pumped from the bottom of the V-2275 by pumps P-2775
A/B to the sulphur vacuum drum filter S-2775. The slurry is separated into sulphur cake and
disposed as wet cake and SulFerox filtrate, which flows to filtrate receiver V-2776.

Water is added to the vacuum filter to remove as much SulFerox solution as possible from
the sulphur cake. The make-up water has to be free of chlorides (<10ppm) to prevent stress
corrosion cracking of the stainless steel. Corrosion coupons are installed to detect stress
corrosion cracking at an early stage.

Air and water vapour are drawn from the SulFerox filtrate in the filtrate receiver by the
SulFerox filter vacuum pump K-2776. The SulFerox solution is then pumped back to vessel
V-2775.

Previous page shows a schematic of the SulFerox regeneration system. The following
chemicals are used within the SulFerox process:

* IC 110 is the iron chelate, which forms the active part of the SulFerox fluid.
* IC 210 additional concentrated chelate solution, added to replace chelate lost
due to thermal or oxidative degradation.
*CA 100 in situ cleaning agent consisting of bisulfite to remove elemental sulphur, chelate
make-up to remove Fe solids and cationic surfactant to remove oil. All products are
compatible with SulFerox chemicals and do not have to be rigorously removed after
cleaning.
* CA 200 chemical added to ensure correct sulphur properties, and prevent solution
foaming and fouling.
* it wets the sulphur particles to make it sink.
* it agglomerates the small sulphur particles to about 50 microns so that they sink
more rapidly and can be filtered off.
*its defoaming properties promote the rapid release of trapped air from the fine sulphur
particles and prevent the aqueous solution from excessive foaming.
* CA 300 stabilizer, added to minimize oxidative degradation of the chelate.

Further details on the SulFerox plant are available in Shell SulFerox Process Standard Operating
Manual.

The SulFerox Unit has its own drain system consisting of a hydrocarbon drain header, an LP drain
header, and a drain sump.

18
Solutions free of hydrocarbon gas are recovered in the LP drain header, which is a tundish
drain line. The sources feeding this LP drain system are P-2772 A/B/C, P-2775A/B, V-2775,
P-2776A/B, S-2775, V-2776, P-2774A/B, T-2771 and T-2776.

Solutions containing hydrocarbon gas are collected in the hydrocarbon drain header. Gas is
flashed off to atmospheric vent before the solution enters the SulFerox drain sump. A liquid
seal is maintained on the hydrocarbon gas with air in the sump. The sump is equipped with a
pump to recover the SulFerox solution to either the inventory storage tank or the drum filter.

The liquid seal must be established before commissioning the plant and regularly checked.
All drains to the sump are manually opened. If the level in sump rises above the alarm level,
the operator must stop and slow down the manual drain and investigate pump operation.

The drain sump has 2 flame arrestors on the venting system. They should be checked
regularly for plugging. High pressure drop may cause back flow through the LP drain
header.

3.3. Drum Filter

Cross section of Drum Filter

Filter medium
Lead Pipe
Trail Internal Piping
Pipe typical of
all sections
Drum Shell
Vacuum applied
DRY ZONE

Valve Air Blow for

Cake discvharge Scrapper

Vacuum applied

Form Zone
Rotation

Slurry Level Filter Tank

Working principle of the Filter.

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Slurry is pumped to the trough by a slurry pump. The slurry level is maintained at a preset
level by means of an adjustable overflow pipe. The over flow is returned to the vessel V
2775. This implies that the Filter must be located above the vessel.
A drain is also located at the bottom of the trough so for any maintenance job it can be
drained to the same vessel.

The slurry is maintained in suspension by means of a slow speed agitator bar, which rocks to
and fro along the bottom of the trough.

The filter drum is fixed to a shaft, which is free to rotate.

VENT SULFEROX REGENERATION

AIR
FROM FLASH
VESSEL AIR
FILTER
REGENERATION
WATER
VESSEL

SULPHUR
CAKE

VACUUM
VENT

PUMP
SLURRY FILTERATE RETURN
TO PUMP
CONTACTOR
PUMP

The sulphur / sulferox slurry is pumped from the bottom of the V-2775 by pumps P-2775
A/B to the sulphur vacuum drum filter S-2775. The slurry is separated into sulphur cake and
disposed as wet cake and sulFerox filtrate, which flows to filtrate receiver V-2776 .

Water is added to the vacuum filter to remove as much sulFerox solution as possible from
the sulphur cake. The make up water has to be free of chlorides (less than 10 ppm) to
prevent stress corrosion cracking of the stainless steel.

Air and water vapour are drawn from the SulFerox filtrate in the filtrate receiver by the
sulFerox filter vacuum pump k-2776. The SulFerox solution is then pumped back to vessel
V-2775

3.4. LPS, SulFerox Plant : Start up operations.

(Read along with the PEFS)
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1) Pressurize slowly the plant as follows,
a) Contactors C-2770/71/72, V-2770 and V-2771 to 1200 kPa
b) V-2772 to 600 kPa
c) V-2773 to 250 kPa
2) Start purge air fan K-2777 A/B and select one as Stand by.

3) Reset SulFerox unit from DCS screen.

This will open the following valves,
a) Hot oil return E-2775 ………...27-US-704
b) Potable water to T-2775 ……...27-US-775
c) Liquid o/l V-2772……………..27-US-703
d) Liquid o/l V-2773 …………….27-US-705
e) Liquid o/l V-2770 …………….27-US-707
f) Liquid o/l V-2771 …………….27-US-718

4) Make sure T-2775 water tank is filled to 85%. Start one seal water pump P-2771 A/B and
select the other as standby from DCS.
5) Make sure T-2770 SulFerox inventory tank is filled with SulFerox solution.(approx.
38m3)
6) Start the agitator for the inventory tank T-2770 from DCS.
7) Fill V-2776 SulFerox Filtrate receiver with SulFerox solution using P-2776 from T-2770.
8) Fill V-2775 SulFerox regenerator vessel with SulFerox solution from T-2770 by using P-
2776 up to 80%.
9) Select P-2776 B running in recycle mode, taking suction from V-2776 by selecting 27-
LICA-719 to Auto 50% level. P-2776 A select to standby.

10) Line up SulFerox solution pumps P-2772 A/B/C and start circulation through one
contactor. The flow establishes to V-2770 to V-2772 to E-2775 to V-2773 and to V-2775
and back to the pump.
@ set the following level controllers to auto,
V-2770 27-LIC-700 to 20%
V-2771 27-LIC-704 to 35%
V-2772 27-LIC-707 to 20%

11) Set the pressure controllers of V-2772 @27-PICA-712 to 650 kPa and V-2773 @27-
PICA-714 to 250 kPa respectively.
12) Maintain a steady SulFerox solution flow.
13) The E-2775 heater on line, slowly raise the 27-TICA-701 V-2773 inlet temperature to
51C.
14) Start SulFerox slurry pump P-2775 on recycle mode back to the regenerator vessel V-
2775 by selecting the 3-way valve back to regenerator vessel.

15) Slowly pressurise the unit to the normal operating pressure by opening the main valves,
@ 16” inlet to SulFerox unit d/s of 27-US-709 and 16” outlet from SulFerox to E-2763.

16) Prior to this, gas conditioning to be pressurised and start gas flow through gas
conditioning unit, bypassing SulFerox unit.

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17) Once gas conditioning unit has established gas flow, slowly bring flow to the SulFerox
unit as follows,
a) Confirm Regenerator blower K-2775 is ON, select the other as stand by.
b) Set air flow around 300 m3/hr and pressure 8.3 kPa.
c) Ensure that the contactor inlet flow controller 27-FIC-701 is Manually Closed fully. The
gas should be bypassing SulFerox unit through SulFerox bypass 27-PDIC-717.
d) Ensure that the inlet gas temperature controllers are set as per design.
e) Energise FCV(Start Treatment) from DCS and energise 2” pressurising line (Enable
Press).
f) Start slowly closing SulFerox bypass 27-PDIC-717 and start slowly opening column inlet
control valve 27-FCV-701 and establish flow.
g) Close the bypass fully to normalize the flow.

18) Start filtration unit by normalising the 3-way valve and starting filter motor from the
field.
19) Start vacuum unit .
20) Start the second contactor and stabilise the plant.

3.5. SULFEROX CHEMICALS

(SULphur removal by FERric ion & Oxidation)

TRADE NAME FUNCTION

IC 110 IRON CHELATE Active material used in sulferox

(to increase total iron content)

IC 210 CHELATE or LEGAND Organic binding agent. It react with

Iron and protect it from precipitation.
(Added to replace the loss due to
Thermal & oxidative degradation)

CA 100 STABILISER To minimise oxidative degradation of

Iron chelate.

CA 299 & SULPHUR CONDITIONER To ensure correct Sulphur properties

CA 2102 & prevent solution foaming, fouling &
Sticking sulphur.

CA 100 CLEANING AGENT React with sulphur and other deposits

& facilitate in-site cleaning of
equipment.

NaOH CAUSTIC SODA To control pH

STANDARD BATCH IC110: IC210: CA110

(4Drums) (1 Drum) (1 Drum)

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CA299 (Continuous injection) 200 ml/day (After mixing with water)
CA2102 (Continuous injection) 600 ml/day
Caustic Soda (Intermittently) 500 kg/month.

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