Quench Tower 2

7/30/2019 Quench Tower 2

1/16

Separation Technologyfor the

Hydrocarbon Processing Industry

Sulzer Chemtech


2/16

Sulzer Chemtech produces a wide array of towerinternals. With this broad spectrum of custom-designedfractionation trays, random and structured packing wecan meet any process requirement in any size tower

throughout the chemical, refining, petrochemical, andgas processing industries. For over 50 years, SulzerChemtech has been serving these industries withour innovations, which set a new standard in manyapplications.

Sulzer Chemtech Achievements:

1956 Nutter Float Valve trays in an olefin plant,among others for a 120 i.d. C2 Splitter

1964 BX gauze packing for Distillation of heatsensitive fragrances

1975 BX plastic gauze packing for HCl Absorptiontowers

1977 Nutter V-Grid trays for C3 Splitters

1985 Nutter Ring for Demethanizer

1985 Mellapak for Water Quench towers

1988 Design of Heat Pump systems

1988 Mellapak for Ethylene Oxide towers

1995 Mellagrid for Water Quench towers

1997 Katapak for Reactive Distillation of Methylal

2000 MellapakPlus for various applications

For classical column operations such as distillation,absorption, stripping and extraction, and for alternativessuch as crystallization, membrane permeation andreactive distillation, we are continuously developingnew product ideas to meet the economical andtechnical objectives of our customers. For numerousapplications Sulzer Chemtech provides superior plantperformance, improved product quality, increasedcapacity, and reduced energy consumption.

Sulzer Chemtech offers the full range of columninternals with trays, random and structured packingsoptimized through column simulation, process design,basic engineering and field services.

Sulzer Chemtech is a worldwide leading supplierfor separation technology; thanks to our customersand the confidence they instill into our products andcapabilities.From the very first to the very last of our more than30,000 columns in operation we have never stoppedlistening to our customers about their needs. At SulzerChemtech, we are eager to develop a successful appli -

cation for your needs.

Technology Leadership

Industrial Applications from A to Z

Ammonia and fertilizer production 11

DMF / DMAc recovery 13

Ethylene 4/5

Ethanolamine 6/7

Ethylene glycol 6/7

Ethylene oxide 6/7

Heat pump / heat integration 13

High pressure gas saturation 8/9

Methanol 12

Selective H2S absorption 8-10

Synthesis gas applications 8/9

Tail gas treating 10

Treatment of corrosive products 14

Color index of the diagrams

Structured packing

Trays

Random packing

2


3/16

Application Know-How and Service are our Driving Force

Sulzer Chemtech has 50 years ofaccumulated application know-how and experience in developing,designing, supplying and servicing

mass transfer equipment in theChemical, Petrochemical, Refining,Gas Processing and Specialityindustries. Only the very besttechnical solutions can secure thecompetitive advantages which ourcustomers need in todays highlydemanding conditions. Leadershipin technology and applicationknow-how is fundamental to oursuccess.

Technical and Process Support

Column simulations anddesign

Process simulations and plantoptimization

Feasibility studies for capacityand/or purity improvements

CFD modelling

Pilot plant testing

Field Services

Installation consulting,inspection or supervision

Full installation services

Trouble shooting assistance

Scanning

Start-up assistance

Replacement Service

Reliable and fast supply througha world-wide manufacturing

network of: any hardware

most valves

most tray decks

complete trays

R a n d o m p a c k i n g s

T r a y s

S t r u c t u r e d p a c k i n g s

S h e l l t r a y s

G r i d s

0695 2510-13

0 6 7 9 2 0 0 1

0 6 0 2 2 5 1 2

0 6 0 0 2 5 6 9 - 3 0 6 9 9 2 5 2 4

0694 2507

0601 2505-4

3


4/16

Ethylene Plants

Whatever your plans are, we have the right solution for every service

Caustic wash tower with Nutter rings or Mellapak

Benefits:

The revamp of the water quench towertrays and random packing to structured

packing Mellapak led to improvementsin capacity and in efficiency. In addition,energy costs were reduced considerablydue to the following reasons:

Less cooling energy requirementsand no steam consumption for thereboiler of the C3 Split ter, due to betterefficiency of structured packing.

Less energy requirements for thecompression stage due to low pressuredrop in the packed bed.

Benefits of structured packing:

Smaller column diameter, due to higher

capacity

Reduced packing height, due to higherseparation efficiency

Lower pressure drop

Reduced foaming tendency, due to lessturbulences

Less entrainment

Higher fouling resistance

Water quench tower with Mellapak/Mellagrid

Before revamp

Random

packing

Trays

230 t/h99 oC

Cracker/Furnace

37 oC920 m3/h29 oC

1230 m3/h57 oC

70 oC

T = 8 oC35 oC

1250 m3/h33 oC

Mellapak

1050 m3/h, 59 oC

Mellapak +

Mellagrid

80 oC

T = 2 oC

After revamp+70% higher capacity

Oil quench/Primaryfractionator

Waterquench

3-stage gascompression

Causticwash tower

4th-stage gascompression

Feedstock (e.g. Naphtha,Gas oil, Ethane)

Steam

Fuel oil

Olefins

Water

Aromatics

Dehydration unit Activated alumina Molsieves TEG system

Refrigeration unit

Hot section

Random

packing

9 m

9 m

Water

NaOH

ID5500

ID4900

7.5 m

7.5 m

Water

NaOH

Mellapak

400 t/h94 oC

p 100 mbar p = 10 mbar

4


5/16

Benefits:

For higher capacity:Replacement of existing trays enables

handling of increased column loads athigher exchanger duties.

For higher capacity and / or higherefficiency:Replacement of existing trays by ahigher number of new high capacitytrays enables a reduction in refluxand load requirements, but putsmore emphasis on tray capacity andefficiency at low tray spacing.

For new columns:Technology can be used to minimizedimensions of new columns, such asthe diameter and height.

High performance MVGT trays allowthe reuse of the existing tower without

replacing it by a new one.

The advantages of MVGT:

Higher capacity at same efficiency

Tray spacing can be kept

No welding to column shell, as existingattachments can be reused

Minimized plant shut down time

Lower revamp costs

De-methanizer De-ethanizer C2 splitter De-propanizer De-butanizerC3 splitter

CH4,H2

C2Hx

C2H2 Acetylene

Acetylene recoveryC2H4Ethylene

to EO-plantC3H6Propylene

C2H6Ethanerecycle

C3Hx

C3H8Propane

C2+ C3+ C4+ C5+

Cold section

C2 splitter and/or C3 splitter with Shell HiFi traysObjectives: +20 % feed rate, same product specification

Initial design 1st Option: 1 for 1 retray 2nd Option: 4 for 3 retray

C3 feed

4.6Gcal/hr

I.D. 4000117 trays457 mm spacing

24.4 Gcal/hr 28.2 Gcal/hr 25.3 Gcal/hr

I.D. 4000130 trays430 mm spacing

130 trays169 trays307 mmspacing

C3 feed+20 %

C3 feed+20 %

117 trays 150 trays350 mm spacing

20.9 Gcal/hrPropane

24.2 Gcal/hr 21.4 Gcal/hr

New C3 splitter withconventional trays

Reuse of existing C3 splitterwith MVGT trays

Feed

ID 3600 mm

120 trays450 mm spacing


Feed

ID 3200 mm



4.6Gcal/hr

4.6Gcal/hr

5


6/16

Ethylene Oxide and Derivates

Bevore revamp

Gas quantity (t/h) 110

CO2 at entry (vol. %) 4.7

CO2 at exit (vol. %) 1.4

CO2 absorption (t/h) 7.1

Revamp of a CO2 absorption column

from high capacity trays to Mellapak

- Antifreeze agent- PET production- Polyester production- Heat transfer liquid

- Plastizicer / softener- Solvent

- Textile finishing- Cosmetics / Soaps- Detergents- Gas purification

- Brake fluid- Solvent for paint- Detergents

- Gas purification

- Detergents- Surfactants- Emulsifiers

Know-how

Distillation of EthyleneOxide (EO)

Technologies and keycomponents for:- Ethylene Glycols- Ethanolamines- Glycol Ethers- Alkylethanolamines

For various reaction technologiescooperating with experiencedpartners

Gasload 100 % 100 % 137 %

EO production 100 % 100 % 185 %

EO in outlet gas 250 ppm 22 ppm 100 ppm

Pressure drop 170 mbar 52 mbar 73 mbar

Upgrade with Mellapak and MellapakPlus

67% Ethylene Glycols

7% Ethanolamines

5% Glycol Ethers

21% other Ethoxylates

2.0 vol % EO 2.0 vol % EO 2.7 vol % EO

35 MD trays 2 x 7 mMellapakM 250.Y

2 x 7 mMellapakPlusM 252.Y

Wash

colunm

Reactor

Ethylene

Oxygen

EO absorp

CO2 absorpt

EO production

EO

6


7/16

After revamp

168

5.1

0.3

14.0

Process Features

Continuous process

Low by-product formation

Flexible product ratio

High yields on raw materials

High recovery rates

Low energy consumption

Extremely low pressure dropsin the distillation section

High product purity

Joint developments

ping

EO distillation

ing

Reactor

Reactor

Ammonia

H2O MEA DEA TEA

Water

separation

Ethanolamine

separation

H2O MEG DEG TEG

Water separation Glycol separation

Ethanolamine production

Glycol production

7


8/16

1

1

Synthesis Gas Application

Compact Column Size

Sulzer packings permit high gas andliquid throughputs resulting in smallcolumn diameters (important factorfor pressurized columns or whenupgrading existing columns). High

separation efficiency also allowsthe use of short-height columns.New columns incorporating thesefeatures result in large savings,both in weight, volume and ininvestment costs.

The increased selectivity leads to ahigher CO2-slippage in the treatedgas and to a lower CO2 content inthe acid gas which leads to a highercapacity of the existing Claus plantor to lower CAPEX in case of a new

plant.

COS - Conversion unit

28 oC

30 oC

147 oC

Cooler

Water87 oC

72 oC

Heater

to H2S removal unit 15 wt ppm COS

ReactorCOS converterH2S Hydrolysis

Saturator

24 oC 32 bara

1400 wtppm COS

90% CO2 - Slippage200 ppmv H2S

Selective H2SAbsorber No 1

Synthesis gas

23 oC5 mol % CO29600 ppmv H2S32.5 bara

Selective H2SAbsorber No 2

30 oC4.5 mol % CO2600 ppmv H2S

rich amin

2 ppmv H2S

H

COS + H2O = > H2S + CO2

Selective absorption of H2S with MDEA Tray column60 % CO2 slippage2 Vol ppm H2SMellapak

90 % CO2 slippage2 Vol ppm H2S

Diameter 700 mmHeight ca 11 mL/G ca 0.15

Natural gaswith H2S + CO2ca 1 Vol %

Rich MDEA Natural gaswith H2S + CO2ca 1 Vol %

Rich MDEA

Diameter 1100 mmHeight ca 15 mL/G ca 0.15Pressure: 56 bar

Gas temperature: 30-35 oC

Lean MDEA

Lean MDEA

8


9/16

Benefits for Conversion Units

Reduced steam requirements,less energy consumption

Lower OPEX

Pay back time approx. 1 year

Less fouling problems

lean amine

oval unit

Acid gas

to Claus plant(see also tailgas treatingon next page)

Regenerator

Reboiler

Solvent heat exchanger

CO - Conversion unit

SaturatorNo 1

SaturatorNo 2

Converted gasto CO2 amine unit:

6 %wt CO

82 % wt CO2

70 oC

Cooler

65 oC

110 oC

212 oC 390oC

CO + H2O = > CO2+ H2

Steam

188 oC

ReactorCO converter

203 oC

Pall ring 3"

T 40 mbar

200 oC

Mellapak

T 10 mbar

140 oC

152 oC 146 oC

134 oC

181 oC 188 oC

T 12 oC

Saturator No. 2 Diameter: 2.94 m

T 22 oC

from H2S removalp = 29.9 bara82% wt CO 28 oC

200 oC

0 6 9 8 2 5 3 0 - 2

9


10/16

Tail Gas Treating

High Selectivity

The higher selectivity of structu-red packing over other compo-nents results in the following ad-vantages:

Reduction of CO2 concentrationin acid gas which leads to

Reduction of pressure drop ofthe Claus plant which leads to

Increase of capacity of theClaus plant

Quench for tail gas treating unitColumn diameter 6.1 mPressure AtmosphericGas flow rate 260,000 kg/h

Trays Random packing Mellapak

Pressure drop 70 25 9(mbar)

Energy savings - 2.8 3.9(milions kWh/year)

Cost reduction - 180,000 260,000

(US$/year)

Low Pressure drop withMellapak

means smaller blowers or compres-sors power compared with traysand random packing, as well asadvantages for the upstream Clausprocess stages.

Com-

bustion

Claus-

plant

Hydro-

genation

Selective H2S

absorptionp = 1 bar

Regenerator

Quench column

H2S SO2 H2S

Sulfur

Acid gas

200 oC

42 oC

Sourwater stripper

10


11/16

Applications in Ammonia and Fertilizer Production

Formaldehyde Production

Revamping of processcondensate strippers (improvingof efficiency)

High pressure ammoniaabsorbers

Waste water strippers

Ammonia strippers inammonium nitrate production

Mellapak in the pump-around sections forthe removal of the considerable amount ofabsorption heat

Trays or plastic gauze packing for top part(final absorption with low water flow)

Further Process Technologies:

Katapak for Methanol separation from bottomformaldehyde product

Katapak for production of acetals

Original column Revamp

Type of packing Pall ring 2" Mellapak

Flow (t/h) 65 - 75 65 - 75

NH3 outlet (ppm) 10 - 30


12/16

Methanol

Applications

Methanol splitters with fixedvalve trays

Methanol absorption columnswith structured packing

Gas saturators with random orstructured packing

Methanol distillation unit

Benefits with Sulzer fixed valveMVG trays in methanol splitters:

Reduced column diameter dueto greater capacity, comparedto sieve or valve tray

Great fouling resistance

Minimize vapor cross-flowchanneling by improvedliquid flow and vapor/liquidcontacting through lateral

vapor release

Toppingcolumn

Light ends Pressurecolumn

Refiningcolumn

Crudemethanol

Puremethanol

Processwater

Fusel oil

0 6 0 0 2 5 1 8 - 1 0

12


13/16

DMF / DMAc Recovery and Heat Pump / Heat Integration

Multi-effect distillation systems:

Reduced energy consumptiondue to high efficiency structuredpackings

Increase of capacity withMellapakPlus

Low consumption of coolingwater

Heat pump technology allows:

90% energy saving

No steam consumption

Higher cooling watertemperature

We deliver:

Key-components such ascolumn internals, compressorsand heat exchangers

Studies and basic engineeringfor revamping existing units

Basic engineering for new units

Commissioning and start-up

services

Feed

Light end

Heavy end Product

C.W

D M A c r e c o v e r y p l a n tB u t e n e - 1 p l a n t w i t h h e a t p u m p s y s t e m

0690 4504 0697 2501-1

13


14/16

Treatment of Corrosive Products e.g. Cl2 and HCl

Features of CorrosionResistant Packings

High efficiency even at lowliquid loads

High capacity Over 200 columns in operation

Use of Packing and Internals in a highly corrosive milieu,e.g. in chlorine and HCl-columns.Sulzer Packings and Internals are available in the fol-lowing corrosion resistant materials:Plastics: PP, PVDF, PVC- C, PFA, HalarMellacarbon: GraphiteMellapak: High-alloy steels, Hastelloy, Nickel,

Tantal, Zirconium, Titanium etc.

T h e p r e s s u r e s w i n g d i s t i l l a t i o n s y s t e m f o r

h y d r o c h l o r i c a c i d p r o d u c e s p u r e H C l g a s

w i t h o u t a n y c o n t a m i n a t i o n t h r o u g h b y -

p r o d u c t s

T h e M e l l a c a r b o n

p a c k i n g i s a k e y

c o m p o n e n t i n t h e H C l

d i s t i l l a t i o n c o l u m n

P l a s t i c g a u z e p a c k i n g B X e n a b l i n g l o w

s p e c i c l i q u i d l o a d s d u e t o g o o d w e t t i n g

p r o p e r t i e s .

Production of chlorine gas

Brine Electrolytic cells

Inerts

NaOH 20 %

wet chlorine gas

Hypochlorite tower

HypochloriteNaOHNaCIO

dry chlorine gas

Make upH2SO4

Drying towersCooler

Condensate dilute H2SO4

HCI - recovery from phosgenation

Pressure: approx. 1 bara

Make up water

Typical packingheight: 6 - 7 m

Typical diameter0.3 - 1.5 m

Inerts

Reflux

Temp. oC0 %

21 %

32 %

80 90 100 110 120

wt % HCI

30 - 32 % HCI

HCI - gas fromphosgenation90 - 100 %

Pressure: 2 - 6 bara HCI gas Pressure: 100 mbar

Waste acid

H2O

0 6 8 2 2 0 2 0

0 6 9 7 2 5 2 2 - 1

0 6 9 8 2 5 1 1

14


15/16

Column Design and Process Simulation

Sulzer Chemtech is your idealpartner for the design of yourseparation columns. We are ableto assist you in the calculation of a

new column, or determine potentialadvantages of a revamp for highercapacity, higher purity or newprocess conditions. The study iscarried out with modern simulationtools based on data from ourlaboratory, literature, databank andfield data.

The calculated number of theoreti-cal stages will then be convertedinto a packing height or number oftrays. In addition to Sulzers highcapacity trays, further capacity isachievable through our alliancewith Shell Global Solutions. Theresult of a study is of course not

only the number of trays but alsoa design of column internals orspecial recommendations for therunning of the plant.

Our main applications for which weoffer our advantages of a theore-tical study, based on special know-ledge from field experiences andpilot tests, are as follows:

Columns for Olefin Plants

Recovery of Ethylene Oxide

Columns for Ethylene Glycols,Ethanolamines and Glycolethers

Direct Heat Exchange

Columns for DMF and DMAcRecovery

Waste Water Treatment

Absorption of Formaldehyde

Formaldehyde, Methanol,Methylal Purification

Recovery of HCl

Removal of CO2 and H2S

Do not hesitate to ask for designpossibilities or for our EngineeringServices brochure. If there areno data available for the designof the column, we are also ableto offer experimental tests inour laboratory or in cooperationwith external consultants anduniversities.

15


16/16

Sulzer Chemtech LtdP.O. Box 65

CH-8404 Winterthur, SwitzerlandPhone +41 (52) 262 50 28Fax +41 (52) 262 01 82E-mail [email protected] www.sulzerchemtech.com

Sulzer Chemtech USA, Inc.4106 New West DriveUSA-Pasadena, TX 77507Phone +1 (281) 604 4100Fax +1 (281) 291 0207

Sulzer Chemtech Pte. Ltd.11 Tuas Avenue 18SGP-63 88 95 Singapore

Phone +65 6863 75 60Fax +65 6861 15 16

Sulzer Chemtech Ltd, a member of the Sulzer Corporation, withheadquarters in Winterthur, Switzerland, is active in the field of process

engineering and employs some 1200 persons worldwide.

Sulzer Chemtech is represented in all important industrial countriesand sets standards in the field of mass transfer with its advanced andeconomical solutions.

The activity program comprises:

Process components such as trays, structured and random packings,internals for separation columns and reaction technology

Engineering services for separation and reaction technology suchas optimizing energy consumption, plant optimization studies, pre-engineering for governmental approval, basic engineering

Separation and purification of organic chemicals by means ofcrystallization and membranes

Mixing and reaction technology with static mixers

Distributed by:

534

Documents

Quench Tower 2