about

On
20 th June

By
P.Kannadoss

Naphtha PDS
Reformer
 DHDS BLOCK

DHDS SRU

Plant 76 Plant77(Diesel)

Naphtha PDSReformer
 PLANT-76

Consists of two major sections

1)PDS 2)Reformer unit

PDS
Objective: To produce low
sulphur (10ppm) naphtha from
feed naphtha (1000 ppm )

Reformer
Objective : To produce
hydrogen from sweet naphtha
feed
Product purity: 99.99%
(volume)
Capacity : 22,500 Nm3/hr of
hydrogen
Licensor : Reformer – KTI
PSA -- UOP
What is DHDS?
It is acronym of Diesel Hydro
De Sulphurisation

Why DHDS is needed in present

scenario?
- Aim of the unit is to reduce
‘S’ content from
1.86 wt% to 0.25 wt % in
reactor-I and
500ppm in reactor-II.
- To meet the environmental
control norms and
specifications.
- To maintain environment
clean and safe.
- Since diesel is widely used
fuel in developing countries
 like India, DHDS unit is more
important.

When the unit was

commissioned?
September 1999 with Reactor-I
2002 Reactor –II added.

Who are the licensors and

consultants?
Licensor – M/s IFP AXENS,
France.
Project management
consultant – M/s EIL, New Delhi

Hydro desulphurization :- It is
a catalytic process that
removes sulphur from the
hydro carbons by reacting
with hydrogen at high
pressure and temperature.

Feed stocks:-
• Straight run gas oils HSD
from Pt- 1, Pt-15, Pt- 201
• LCO and HCO from FCCU
• Gas oils from Visbreaker
unit
Product :-
Low sulphur Diesel
By product :-
Wild naphtha or Synthetic
naphtha
Feed +Hydrogen --> Low ‘S’ diesel
+
naphtha +
Recycle gas +
Acid gas to SRU

Process Description

Feed from OM&S tank 506

Filtered in the PALL filter
Hydrogen from RGC and Diesel From
Feed
 pumps are mixed in specified ratio
Mixing ensures adequate PP at the inlet
of
the reactor
Mixed stream is pre heated with the
reactor
effluent
 Pre heated mixture is heated in reactor
heater to required reactor inlet temp
Furnace outlet enter the first reactor
First reactor consists of three Nimo
catalyst
beds
Exothermic olefin saturation and hydro
de
sulphurisation reaction are taking
place in
1st reactor
To control the temperature raise
across the
beds quenching is done by recycle
gas
1st reactor O/L is the second reactor
inlet
2nd reactor has single catalytic bed of
Nimo
catalyst
The reactor effluent is exchanging heat
with
furnace feed and stripper feed(one
part)
Final cooling is achieved in air cooler
and
then in condenser
 The reactor effluent contains
ammonium
salts
To avoid ammonium salts deposition in
the
coolers and condenser the wash water
is
injected
Cooled and condensed effluent is
collected
in cold separator
Three phase are separated
i) Liquid hydrocarbon (diesel) --> stripper,
ii) recycle gas --> amine absorber,
iii) water with ammonium salts--> wash water
drum
To SRU ( partly)
Liquid hydrocarbon from cold
separator is
pre heated against stripper effluent
and
reactor effluent
Heated effluent is fed to stripper to
produce
diesel with correct flash point and H2S
content
 Stripping medium is super heated MP
steam

Stripper

Stripper bottom

Stripper bottom exchange heat with

feed
Sent to coalescer to separate entrained
 moisture content from stripper bottom
Water which is collected in coalescer is
routed to wash water drum
After removing water droplets the
effluent is
dried in vacuum dryer
 The product is cooled and sent to
storage

Stripper over head

Light ends and H2S taken from OVHD
Stripper OVHD is cooled and condensed
Three phases are separated from
condensed
OVHD
 Hydro carbon liquid for Reflux and
stabilized naphtha
 Water --> to wash water drum
Gas --> treated with lean DEA to
remove H2S

H2S free gas is lined up to FG header

H2S rich gas is sent to SRU

The gas from the cold separator is sent
to
HP amine absorber
The gas is treated with Lean DEA
(25 wt% DEA) to remove H2S
H2S free gas ie, recycle gas (0.5- 1wt% of
H2S)
is sent to the RGC
 H2S rich gas is sent to SRU along with
H2S
rich gas from LP amine absorber
Make up gas from upstream hydrogen
unit is
compressed and mixed with recycle
gas
Reactions
Desirable reactions

Desulphurisation (Elimination of sulphur)

Mercaptans
R – SH + H2  R – H + H2 S
Sulphides
R –S – R + 2H2  2 R – H + H2S

Denitirification (Elimination of nitrogen)

Catalyst
(Ni3S2)
R-CH2CH2CH2NH2 + H2 ---------- R-CH2CH2CH3 + NH3
Amine Paraffin Ammonia

Hydrogenation of oxygenated compounds

Catalyst
(Ni3S2)
R¾CH2CH=CH2 + H2 --- R¾CH2CH2CH3

Olefin Paraffin

Demetalisation

Hydrogenation of olefins and diolefins

Undesirable reactions

Hydro cracking (reduces product yield and

consumes more Hydrogen)
Coking (coke deposit is the main cause of
catalyst activity reduction)

Catalyst Details

Two types of Nimo type catalyst are used in

reactor –I

HR 945 for hydrogenation of unsaturates

HR-348 for the hydrodesulfurization,
dearomatization and hydrodenitrification
of hydrocarbon

One type of Nimo type catalyst is used in

reactor –II

HR-448 for very high denitrification and

aromatichydrogenation activities and
desulfurisation activity equal to CoMo
catalysts.

Why two catalyst in one reactor?

 To achieve a high desulphurisation activity and
deep desulphurisation
Choice of catalyst

 Olefins
hydrogenation, denitrification and
desulphurisation rates
 Aromatics hydrogenation
 Cycle length

Recycle Gas Compressor

 Turbine driven compressor of 3784 KW and

11152RPM rated
Multi stage centrifugal compressor
System consists of lube oil, dry gas seal,
condensate recovery, vacuum ejector

Make Up Gas Compressor

 Two reciprocating compressors,electric

 motor driven
It is horizontal non -lubricated cylinder type,
single compression stage and double throw
Feed Filter
 This
unit is a duplex design filter
To remove suspended solid particles in the
feed above 25 microns.
Number of filter elements : 583 per filter
vessel

Furnace

The 77F1 heater is of conventional forced draft

cylindrical type.
The heater consists of three sections:

1) Firebox or radiant section

2) Convection

i)Process section

ii) Steam super heating section.

iii) Air preheater section

3) Stack.
Basic steps for the DHDS unit Start-
up
Air is purged from the H.P and LP Systems
with inert gas
Leak checking of HP and LP systems with
N2, HP system purging with H2
H2 gas circulation is started
Heater is fired up
Raw HSDO circulation is started through LP
side feed cut into reactor
Pressure and flows are brought to normal
operating values as the heater is brought up to
normal temperature

Basic steps for the DHDS unit Shut-

down
Decrease feed throughput to 60%
Shut off the diesel feed to unit
Keep recycle gas rate at minimum
Stop the wash water injection
Cut off stripping steam
 Drain the hydrocarbons from separator to
slop
Stop amine feed to HP amine absorber
Depressurise the HP system
Cut off the stripper feed and isolate
coalescer
Depressurise the stripper and reflux drum
and purge with nitrogen

Emergency Procedure
Initial steps to protect the Catalyst and
equipment from damage during almost any
upset.
 Reduce heat input to the reactors to
keep reactor temperatures under
Control
 Maintain recycle gas flow through the
equipment
 Limit hydrogen availability to minimize
heat release
Emergencies
GAS LEAK OR FIRE IN THE UNIT
RECYCLE GAS COMPRESSOR FAILURE
MAKE-UP GAS FAILURE
FEED FAILURE
There are two types of feed loss:
 - Loss of fresh feed to the feed surge drum

- Loss of feed pump

LOSS OF WASH WATER
LOSS OF AMINE TO SYSTEM
FURNACE COIL RUPTURE OR TUBE LEAK
HEAVY H2S LEAK
HEAVY SOUR WATER LEAK
PREHEAT EXCHANGER TUBE LEAK
TEMPERARUE EXCURSION IN THE
REACTOR BED
UTILITIES FAILURE

Operating Conditions
Feed surge drum
Pressure (kg/cm2g) 1.5

Reaction section SOR EOR

·
Pressure (kg/cm2g)
 Reactor inlet: 48.3 48.3

Reactor outlet : 43.3 43.3

·
Temperature (°C)
*
Reactor inlet: 322 353

Reactor outlet : 350 380

HP separator
·
Pressure (kg/cm2g 36.9

Temperature (°C) 50

Stripper/stabilizer/coalescer section

Pressure profiles (kg/cm2g) 5.0

Reflux drum 6.0

Stripper Bottom 6.3

Stabiliser Top 6.0

Stabiliser Bottom 6.3

Coalescer 4.0

Temperature profile (°C) SOR EOR

Reflux drum 40
Stripper Top 158 159
Stripper Feed 250 250
Stripper Bottom 246 246
Stabiliser Top 183 171
Stabiliser Feed 141 135
Stabiliser Bottom 231 233
Coalescer 97 96

Control Philosophy Of The

Process
Feed Flow rate
Reaction section Pressure control
-controlled by the pressure at the cold
separator
Reactor beds temp control
-inlet temp of the reactor beds controlled by
quench injection
Operating parameters

Reactor weight average bed temp (WABT)

- temp increase favors all the hydrogenation
reaction
The hydrogen PP at the outlet of the reactor
- It is function of purge, the recycle gas
flow, temp at reactor O/L the composition of
the effluent and the reactor O/L pressure
- PP H2 outlet of the reactor must be above
30 kg/cm2
- PP H2 enhances reaction, reduces coke
formation

Space velocity
- Increased space velocity results in lower
reaction rate
Process description
FEED SECTION
The feed to the DHDS Unit is a blend of straight run and cracked gas oils.
The DHDS unit receives feed from three different sources
1. Straight run gas oil from OM&S tank 506
2. LCO and HCO from FCCU unit
3. Cracked gas oil from Vis breaker unit of refinery III
Tank 506 of OM&S receives feed from
1. High sulfur diesel from plant 1
2. High sulfur diesel from plant 15
3. High sulfur diesel from plant 201 of refinery III
Cracked gas oil from FCCU and VBU unit is directly brought to the DHDS unit.
Whereas straight run gas oil is fed to the unit from storage under feed surge
drum 77C01 level control LIC1101.
UV1101 is the shut off valve which shuts when C01 level goes to high high.
UV1102 in FCCU line shuts off the feed for the similar causes. Then UV 5801
shuts off VBU feed when C01 level goes high.
The feed is combined and the blend is filtered through feed filter package
77T1 and sent to feed surge drum. The detail about the feed filter is described in
special equipments chapter,
The pressure of the surge drum 1.5 kg/cm2g is maintained by fuel gas
blanketing using a split range pressure controller PIC1101. When the pressure
drops the fuel gas is brought in and venting through flare controls the excess
pressure. Feed surge drum gives a surge time of 20 minutes and provides NPSH
facility and spill back to 77G01A/B feed pump
FEED PUMPS
Reactor Feed Pump 77G-01A/B is a high-pressure multistage
centrifugal pump driven by the HT motor. The pump boosts the diesel feed from
2.0 Kg/cm2 to 66 Kg/cm2, to enable the oil feed to flow through the high-pressure
reaction section. Total oil feed rate to the reactor is set by a flow controller
FIC--1201. To maintain minimum flow of the pump, the flow from discharge is
sent back to the feed surge drum 77C-01 by automatic valve (YARWAY) and
ensures minimum flow through the pump at all times, thus preventing mechanical
damage. Feed flow controller FIC-1201 is provided with low flow alarm. UV1202
shut off valve closes when feed pump trips to prevent pump damage from the
reverse flow by high pressure recycle gas. Polymerization inhibitor (antifouling
agent) is injected in the fresh feed at feed pump suction.
FEED PREHEAT AND FURNACE
The liquid feed is then mixed with the recycle gas and the combined mixture
is fed into the preheat exchanger train. The mixing of recycle hydrogen with feed
ensures an adequate hydrogen partial pressure at the inlet of the reactor.
The mixed stream is heated in first feed/effluent exchanger 77E1
A/B/C/D/E/F then in second feed/effluent exchanger 77E2A/B and finally in the
reactor heater 77F01 to the required reactor inlet temperature. The reactor inlet
temperature is controlled by TIC1501 which in turn controlling the fuel oil/fuel gas
pressure to the heater burners (PIC1403/PIC1401).
REACTOR SYSTEM
77F-01 O/L oil-gas mixture enters first reactor 77C02 then to second
reactor C03. In the reactors the exothermic olefin saturation and
Hydrodesulphurisation reactions taking place in presence of catalyst, result in a
slight heat release that increases the temperature of the reactants. This
increased temperature further increases the rate of reaction. This heat release
therefore results in temperature rise across each bed.
In order to control this temperature rise and, likewise, the rate of reaction, a
series of reactor temperature controllers is provided to control the temperature
profile through the reactors:
First Rx . 2nd bed I/L - TIC--1515
First Rx. 3rd bed I/L - TIC--1524
Second Rx. I/L - TIC--1534
Temperature control is accomplished by manipulating the flow of “cold”
quench gas that is introduced between the catalyst beds in each reactor. The
temperature O/L at each bed O/L should be maintained same, which may vary
slightly depending upon the reaction rate in each bed. The bed O/L is quenched
using cold quench gas In order to measure the temperatures in the reactors;
thermocouples are placed in the catalyst beds. 12 thermocouples in the first bed
of the first reactor, nine in second and third bed of first reactor and fifteen in
second reactors.
In addition to providing temperature control, the temperatures measured at
the top and bottom of each bed in each reactor can be used to monitor reaction
progress and to indicate the location and extent of possible channeling of
reactants. Temperatures measured at different heights but at the same
circumferential position (i.e., temperature difference across a bed) indicate the
extent of reaction in the bed. Temperatures measured at the same height but at
different circumferential positions in the bed can indicate the location and extent
of possible maldistribution of reactants. For example, a liquid-poor region may
experience a higher temperature rise because slower moving liquid has more
time to react and will liberate more heat (local hot spot).
Pressure drop across each reactor is monitored using differential pressure
indicators (First Rx.PDI-1505, Second Rx.PDI-1512).
Normal operating conditions are
SOR EOR
First reactor inlet pressure (kg/cm2g) 52.3 52.3
First reactor outlet pressure (kg/cm2g) 47.6 47.6
Second reactor inlet pressure (kg/cm2g) 47.3 47.3
Second reactor outlet pressure (kg/cm2g) 43.3 43.3
First reactor inlet temperature (°C) 322 353
First reactor outlet temperature (°C) 345 370
Second reactor inlet temperature (°C) 345 370
Second reactor outlet temperature (°C) 350 380
Reactor effluent cooling
The reactor effluent is split in to two. In order to maximize the heat
recovery, one part exchanges heat with the stripper feed in stripper feed preheat
exchangers 77E3 A/B under temperature control of the stripper feed while the
remaining part exchanges heat with the reactor feed in second feed/ effluent
exchanger 77E2 A/B. The two streams are mixed together before entering
77E1A/B/C/D/E/F (Tube side). Final cooling of the reactor effluent is achieved in
the effluent air condenser 77E4A/B/C/D and then in the effluent trim condenser
77E5A/B/C/D.
The normal operating temperatures are
SOR (°C) EOR (°C)
77 C03 outlet 350 380
77 E03A/B outlet 253 245
77 E02A/B outlet 289 321
77 E01A/B/C/D/E/F inlet 276 301
77 E01A/B/C/D/E/F outlet 113 120
77 E04 outlet 65 65
77 E05 outlet 50 50
WASH WATER SYSTEM
To avoid ammonium salt deposits and risk of corrosion, water is injected
at the inlet of the effluent air condenser 77E4A/B/C/D on continuous flow control
(FIC2001, 11m3/hr for the design feed rate) by washing water pump 77G2A/B.
This washing water is a mixture of recycled water from the cold separator 77C4
and water recovered at coalescer 77C17 and at the stripper/ stabilizer reflux
drum77C16. This mixture is collected in the washing water drum 77C6, which is
kept at 2.0 kg/cm2g under fuel gas pressure to avoid air entry. PIC2001 controls
the pressure of the drum.
The effluent of trim condenser 77E5A/B/C/D is collected in the cold
separator 77C4 where three phases are separated. The sour water containing
ammonium salts is partly recycled to the washing water drum 77C6 under level
control of this drum (LIC2001) while the other part is sent to the sour water
stripper under level control of cold separator boot (LIC1605).
COLD SEPERATOR
The effluent of trim condenser 77E5A/B/C/D is collected in the cold
separator 77C4 where three phases are separated.
The oil level in the cold separator (77C04) is controlled by a level
controller LIC1602. The low low level shut down function shuts off the shut off
valve UV1602 in the upstream of level controller, which prevents high-pressure
gases entering in to stripping section.
The sour water containing ammonium salts is partly recycled to the
washing water drum 77C6 under level control of this drum (LIC2001) while the
other part is sent to the sour water stripper under level control of cold separator
boot (LIC1605). Low low level in the boot closes the shut off valve UV1603 in the
upstream of level controller.
The relief valve for the HP section is located on the cold separator
PSV1601A, PSV1601B.
Reactor system pressure is controlled at the suction of the recycle gas
compressor by manipulating the net flow of make-up hydrogen to the reactor
section. The controller PIC-1601 set point should be adjusted periodically to
achieve the desired pressure at the inlet of the first reactor. A high-set point
pressure control loop is included on the recycle gas compressor suction line to
ensure that pressure does not exceed the set pressure of the reactor loop PSV.
The normal set pressure maintained at cold separator is 37kg/cm2g
. The pressure controller PIC-1601 is configured as a sequence-type split
range controller. It first opens the “A” valve, which gives signal to PIC1801 (spill
back in the make up gas compressor loop) and if pressure exceeds it opens the
“B” valve located at HP absorber outlet. PIC1601B relieves the excess pressure
by venting HP gases either to flare or to fuel gas.
In an emergency, emergency dump valve UV1601 can be opened to begin
depressuring the high-pressure loop. The variable area restriction orifices set the
depressurizing rate at normal level.. The hand switches (HS-1601) operate
emergency relief valve to open or close the path to the orifices.
The depressuring installations join in the relief header. A downstream pressure
indicator (PI-1602) indicates the potential overpressurising of the relief header, if
any.

RECYCLE GAS SYSTEM

HP AMINE ABSORBER AND LEAN AMINE SYSTEM

The separator gas is sent for amine absorption to the HP amine absorber
KO drum 77C07 and then is partly sent to HP amine absorber 77C08. Lean
amine (25% wt DEA solution) from off plot ARU is received in the lean amine
surge drum 77C09. Lean amine from 77C09 is pumped by 77G-03A/B through
FV--1701 and the shut off valve UV-1703 to HP amine absorber 77C08. The lean
amine flow to the absorber (90 m 3/hr.) is set to achieve the desired degree of H 2S
removal from the recycle gas. A shutoff valve UV1703 will close on low-low level
in the surge drum 77C09. The low low level in the surge drum also stops the lean
amine booster pump 77G03A/B
The temperature of the lean amine must be maintained 5°C hotter than the
feed vapor temperature to prevent any condensation of the vapor on contacting
the lean amine. This is critical in preventing foaming in the absorber. A
differential temperature measurement (TDIC-1701) is provided for controlling the
lean amine temperature. .
HP H2S absorber 77C08 rich amine level is controlled by the level control
valve LV-1701 at the bottom of absorber to be fed to the LP amine absorber
77C11. The shut off valve UV1702 closes when C08 level goes to low low level
to prevent high pressure entering in to LP absorber section. The pressure drop
across the trays, measured by a differential pressure indicator PDI-1706, is the
best indicator to detect foaming in the absorber.
A full line size hand controlled bypass of the H 2S absorber HIC-1701 is
provided at the top of HP amine absorber. This bypasses the gases from cold
separator partly to recycle gas compressor KO drum C13. This bypass allows for
control of H2S concentration in the recycle gas. The gas purge is provides at the
top of HP amine absorber to control the build up of heavies in the hydrogen gas
recycle stream. Normally the flow rate of this stream is zero.
77G-03A/B is protected by a low-flow spillback system. The automated
YARWAY valve spillbacks the excess flow to lean amine surge drum for
maintaining minimum flow through the pump.
The high-pressure lean amine surge drum (77C09) pressure is controlled by
a split-range pressure controller PIC-1701 (on falling pressure, fuel gas is
brought in; on rising pressure, fuel gas is vented to flare).

RECYCLE GAS COMPRESSOR 77K2

The H2S removed gases from C08 and the Hp absorber bypassed gases
are sent to recycle gas compressor KO drum 77C13 where the entrained liquid is
removed. A high-level trip will shut off the recycle compressor to prevent liquid
from reaching the recycle compressor.
The recycle gas compressor (77K2) circulates the recycle gas through the
high-pressure system.
The compressor is a two stage centrifugal compressor. First stage
discharge is cooled in the inter stage cooler 77E20 and the entrained liquid in the
first stage outlet is removed in the interstage KO drum 77C23. A high level in
77C23 will shut off the recycle compressor to prevent liquid from reaching the
recycle compressor.
One part of compressor discharge joins the Rx.oil feed going to
77E1A/B/C/D/E/F. The other part goes as quench gas to reactor beds as already
described. Antisurge flow controller FIC-1902 fixes the spillback flow (FI-1901) to
77E-04 to avoid “surge”, an unstable condition of widely oscillating flow rates that
will damage the machine. There is almost no flow through the spillback line
during normal plant operation.
MAKE UP GAS COMPRESSOR
The hydrogen make up gas coming from battery limit is routed through
chlorine adsorbent pot 77C20 to the make up K.O drum 77C5. The high high
level in C5 trips the make up gas compressor 77K01A/B. It is then compressed
by the make up compressor 77K1 A/B. The make up gas flow rate to the reaction
section is controlled (FIC 1801) by means of a compressor spillback, which is
sent back to the make up K.O drum after cooling through spillback water cooler
77E6. The make up gas joins the recycle and quench gas upstream to the
recycle K.O drum 77C13. The combined make up + recycle+quench stream is
routed via the recycle gas compressor 77K2.

STRIPPING SECTION
STRIPPER FEED PREHEAT AND STRIPPER
The hydrocarbon liquid phase from the cold separator is routed under flow
control FIC1601 reset by cold separator drum level LIC1602 to the stripper
feed/bottom exchanger 77E07A/B/C/D. This stripper feed is first preheated by
heat exchange against stripper bottom product in the stripper feed/bottom
exchanger 77E07A/B/C/D and then by heat exchange against the reactor effluent
in the stripper feed exchanger 77E03A/B in order to reach the required stripper
inlet temperature. TIC2101 controls the stripper inlet temperature by bypassing
reactor effluent.
The normal operating temperatures are
SOR(°C) EOR (°C)
77C04 outlet 53 53
77E07A/B/C/D outlet 194 192
77E03A/B outlet 250 250
The outlet of 76E03 is fed to stripper (77C14) in order to produce a diesel
with a correct flash point and H2S content. The stripper is a valve tray tower
consists of 25 trays. The feed enters at 16th tray of stripper.
Medium pressure steam superheated in the reactor hater 77F01 is injected
into stripper under flow control FIC1401 as stripping steam. Stripper feed
temperature and correct flow of stripping steam is to be maintained in order to
produce diesel with a correct flash point and H2S content.
The stripper pressure is controlled by PV2201 located at the overhead line
of LP absorber C11.
The normal operating conditions are
Stripper inlet temperature (°C) 250
Stripping steam rate kg/hr 5000
Stripper pressure kg/cm2g 5.0

Stripper over head

stripper/stabilizer reflux drum (77C16)

Light ends and H2s gather at the top of the stripper. Stripper
overhead and stabilizer overhead are mixed before being partly condensed in the
stripper/stabilizer air condenser 77E09 and then in the stripper/stabilizer trim
condenser 77 E10. Corrosion inhibitor is injected into the stripper overhead line
before mixing with stabilizer over head. The stripper/stabilizer trim condenser
outlet comprising of three phases is separated in the stripper reflux drum 77C16;
a hydrocarbon liquid phase (wild naphtha), a free liquid water phase and a
vapour stream.
The decanted water from 77C16boot is sent under boot level control LIC
2201 to the washing water drum 77C06.
The hydrocarbon liquid phase is split into reflux, which is returned to the
stripper under flow control and liquid distillate (wild naphtha), which is routed to
the stabilizer feed bottom exchanger. The reflux is pumped by reflux pump
77G04A/B to stripper and is controlled by flow controller FIC2202.
The normal operating conditions are
The stripper overhead temperature (°C) 150-160
The stripper overhead pressure kg/cm2g 5.0
E09 outlet temperature (°C) 65
E10 outlet temperature (°C) 40
Reflux ratio (%wt) 4.0

NAPHTHA STABILIZER
The other part of the reflux (wild naphtha) which is routed to the stabilizer
feed/bottom exchanger 77E11 under flow control FIC2201 reset by the level
control on stripper/stabilizer reflux drum. The 77E11 effluent is fed to the top of
the naphtha stabilizer 77C15. Light ends and H2S gather at the top of the
stabilizer and are routed after injection of corrosion inhibitor to the top of the
stripper to be mixed with its overhead. The naphtha stabilizer is reboiled by the
stabilizer reboiler 77E12 where heat is exchanged against a part of the stripper
bottom. TIC 2301 controls the stabilizer 3rd
Tray temperature. The stabilized naphtha exchanges heat with stabilizer feed in
77E11 and cooled in the stabilized naphtha water cooler 77E13 and sent to
storage or slop via stabilizer level controller LIC2301 by stabilized naphtha pump
77G08A/B.
The normal operating conditions are
Stabilizer feed temperature (°C) 135
Stabilizer bottom temperature (°C) 231
E11 outlet temperature (°C) 117
E13 outlet temperature (°C) 40
Stabilizer pressure kg/cm2g 5.0

LP AMINE ABSORBER
The vapour stream from stripper overhead after mixing with a sour gas
from the Hydrogen unit is sent to the LP amine absorber K.O.drum 77C10 where
entrained liquid is knocked out. This stream is then fed to the LP amine absorber
77C11.The vapour fed to the LP amine absorber and vapour generated from
flashing of rich amine from HP amine absorber is washed by a lean DEA solution
to remove the H2S.The lean DEA to which anti-foaming agent is injected is fed at
the top of the column under flow control FIC2801.The rich DEA solution is
withdrawn under level control at the bottom of the LP amine absorber LIC2801 to
be sent to the amine regenerator section. The vapour from LP amine absorber
then goes to the stacked LP amine absorber K.O. drum 77C12. Pressure control
is achieved in the stripping section (PC on vapour from reflux drum) by acting on
the fuel gas rate from LP amine absorber K.O drum. The temperature of the lean
amine must be maintained 5°C hotter than the feed vapor temperature to prevent
any condensation of the vapor on contacting the lean amine. This is critical in
preventing foaming in the absorber. A differential temperature measurement
(TDIC-2801) is provided for controlling the lean amine temperature

STRIPPER BOTTOM
A part of the stripper bottom product goes to reboil the stabilizer bottom. It is
then mixed again with the stream bypassing the stabilizer reboiler. The stripper
bottom product is then divided again in two streams;
1. One of the two streams is cooled against the stripper feed in
77E07A/B/C/D to 96°C and sent to the coalescer 77C17
2. The other stream is mixed with the outlet hydrocarbon stream of the
coalescer. The flow rate of the second stream is controlled by the inlet
temperature of the dryer 77C18. By TIC 2501.

COALESCER
The coalescer is a horizontal vessel separates entrained moisture content from
the stripper bottom product. The water droplets coalesced through the element
gets collected in the horizontal sump provided at the bottom and thereafter
drained to the washing water drum through coalescer boot LIC 2401. The
coalescer element consists of cylindrical bed of glass fiber and SS knitted mesh.
All the solid particles 25-20 microns and above are trapped in the element.
The normal operating conditions are
Coalescer pressure 3.0 kg/cm2g
Coalescer inlet/outlet DP 0.5kg/cm2g
Maximum allowable Dp 1.0 kg/cm2g
Normal operating temperature 96°C
DRYER.
The flow rate of the dryer inlet stream is controlled by the stripper bottom
level controller LIC2101
In the vacuum dryer most of the water is vapourised as well as some
amount of light gas oil fractions. All these vapors are cooled and partially
condensed in the dryer overhead water condenser 77E14. This condenser is
connected to two stage vacuum system using ejectors (77H1 and 77H2)
operating with medium pressure steam. The dryer pressure is controlled by gas
spillback from ejector discharge to the dryer overhead PIC2501. The dryer first
and second stage condensers 77E15 (intermediate water condenser) and
77E16(final water condenser).
Liquid and water condensate from water condensers 77E14, 77E15 and
77E16 are collected in the dryer overhead drum 77C19. The uncondensables are
routed to safe location. The decanted aqueous phase is pumped from baffled
dryer overhead drum by oily water pump 77G6A/B and sent under level control of
the drum (LIC2701) to the washing water drum 77C6 or to the bottom of sour
water stripper (out of the DHDS Unit battery limit).
Liquid hydrocarbon phase is pumped from 77C19 by the dryer overhead
diesel pump 77G7A/B and recycled to the coalescer feed by oil level controller
LIC2702.
The dryer bottom product is pumped by dryer rundown pump 77G05A/B to
storage after cooling by air cooler 77E18 and product water cooler
77E19A/B/C/D. The product flow rate is controlled by dryer level controller
LIC2501.