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
