Normal Operation

MRPL Phase III Refinery Project

Hydrogen Generation Unit

Normal Operation
General Information
Operator has to:

keep operating conditions normal

keep operating conditions stable

- avoid sudden changes in temperature

- avoid sudden changes in pressure

avoid that mechanical design limits are exceeded

Normal Operation

Feed flow pressure to the unit is controlled automatically to meet the
requirement of the reforming section

Control hydrogen recycle to keep 0.2 Nm3 H2/kg naphtha feed

Control hydrogen recycle to keep 0.04 Nm³ H2/kg natural gas feed

Sulphur content to be analysed on weekly basis. Min. 2-5 ppm wt S in

feed, DMDS addition if necessary
– Risk of exothermic cracking
– Break through of unreacted organic sulphur

Feed composition to be analysed on weekly basis

– Determination of carbon no. for S/C calculation
– C/H ratio and molecular weight for naphtha

1
 Normal Operation
Hydrogenator, DC-32301:

Control inlet temperature to about 350°C-380°C via steam to naphtha

feed preheater, EA-32302 A/B
– Higher temperature:

Higher activity of TK-250

Higher absorption capacity of ZnO absorbent

– Too high temperature gives risk of polymerisation

Monitor pressure drop

- Increasing pressure drop => coking

Normal Operation
Hydrogenator, DC-32301: (continued)

Content of H2S and total S to be analysed weekly to check for

complete hydrogenation

In case of failure:
- Check operating temperature
- Check hydrogen recycle
- Check S content in feed (>2-5 ppm ?)
- Check for coking (pressure drop)

Normal Operation
Chloride/Sulphur Absorbers, DC-32302 A/B:

Content of H2S and chloride to be analysed weekly

6 sample points:
– Two interbed and outlet of 1st reactor
– Two interbed and outlet of 2nd reactor

Replace catalyst in first reactor at leakage of H2S or chloride

2
 Normal Operation
Replacement of Catalyst in DC-32302 A/B:

Open bypass around DC-32302 A to DC-32302 B

Close inlet and outlet of DC-32302A

Depressurise

Purge with nitrogen

Turn blinds at inlet and outlet

Connect DC-32302A to the start up circuit

Cool down in circulating or once-through nitrogen

Unload catalyst

Clean and inspect reactor

Normal Operation
Replacement of Catalyst in DC-32302A:(continued)

Reload

Purge/Pressurise with nitrogen to atmosphere
– Heat in circulating nitrogen
– Disconnect SU circuit and turn the blinds
– Turn blinds in inlet and out
– Pressurise with process gas through bypass
– Open block valves in inlet and outlet

Normal Operation

Prereformer, DC-32303:

Control feed flow to meet the load requirement

Control steam flow to keep S/C at 2.5
– Below 1.5 risk of carbon formation

Adjust steam quench and/or tubular reformer firing profile if required to
control prereformer inlet temperature at about 490°C
– Below 470°C decreased activity and risk of gum formation
– Too high temperature may lead to carbon formation

3
 Normal Operation

Prereformer, DC-32303: (continued)

Monitor the temperature profile in prereformer

– 6 thermocouples at different heights (Z-90 plot)

Indication of development of catalyst deactivation

Fast downwards movement indicates operational problems:
Poisoning (check desulphurization)
Carbon formation (check S/C)
Gum formation (check operating temperature)

Pressure drop increase is indication of:

– Carbon formation
– Disintegration/oxidation

Normal Operation
Prereformer, DC-32303: (continued)

Composition of prereformed process gas to be analysed:

– Weekly at converter exit
- Monthly at catalyst bed
- Leakage of higher hydrocarbons indicates problem with operation
– Risk of carbon formation in tubular reformer

Normal Operation
Tubular Reformer, BA-32301:

Control tubular reformer to maximize energy efficiency

– Keep process gas outlet temperature high (910°C)
– Keep operating pressure low
– Keep Steam/Carbon as low as possible

Control heat input
– 360 burners in 6 rows
– Bottom row burners designed for 50% firing
– Control of fuel and air is done globally
– Profiling by controlling header pressure

4
 Normal Operation

Control combustion air header pressure to keep an O2 content of 1.7-
1.8 vol% (dry) in the flue gas
– Reducing atmosphere will destroy the protective chromium oxide layer on
the tubes

Adjust draught to keep about 5 mm WG vacuum in radiant chambers

Monitor pressure drop

– Increase as catalyst ages
– Sudden increase indicates operating problems/carbon formation

Normal Operation

Tubular Reformer Fuel System: (continued)

Composition of PSA off-gas and fuel gas to be analysed

every shift and LHV value in DCS to be updated

Composition of naphtha fuel to be analysed on weekly

basis and LHV value in DCS to be updated

Normal Operation
MT Shift, DC-32304 and LT Shift, DC-32305:

Control inlet temperature to the reactors:

– Higher temperature:

Higher catalyst activity

Lower equilibrium conversion
– Optimum temperature depends on catalyst age/activity

Monitor outlet temperature

– Temperature drop at constant inlet temperature indicates decrease in
catalyst activity

5
 Normal Operation
CO-Conversion, DC-32304 and DC-32305: (continued)

Monitor temperature profile in the catalyst bed
– Downwards movement of profile to be followed (ageing)

– Sudden increase in movement rate indicates operating problems:

Poisoning

Water condensation

Normal Operation
DMW, BFW and Steam System:

Supply and deaeration of DMW is controlled automatically

Supply and preheat of BFW is controlled automatically

Final preheat temperature to be controlled by automatic BFW bypass

of 3rd BFW preheater

Normal Operation
DMW, BFW and Steam System: (continued)

Quality of the condensate, DMW, BFW and BW must be monitored

closely

– Avoid that poisons enter reforming section with the steam

– Salts, especially Cl-, causes stress corrosion problems

6
 Normal Operation
DMW, BFW and Steam System: (continued)

Steam
– Analysis of pH, TDS, and conductivity every shift
– Analysis of S and SiO2 every day

DMW
– Analysis of O2 and Cl- at BL

BFW
– Analysis of pH, TDS and conductivity every shift
– Analysis of S, SiO2, Cl-, O2 on daily basis

Normal Operation
DMW, BFW and Steam System: (continued)

Boiler Blow-down
– Analysis of pH and conductivity every shift
– Analysis of TDS, S, SiO2, Cl-, PO43- on a daily basis

Measures of adjustment
– Ammonia water addition to deaerator for pH control
– PO43- addition for decrease of hardness/protection of magnetite
layer in steam drum
– Hydrazine dosing for removal of oxygen from boiler feed water

Normal Operation
Load Changes:

Increase load gradually in small steps by:

1. Increase steam flow
2. Increase feed flow
3. Increase combustion air header pressure
4. Increase heat input

Decrease load gradually in small steps by:

1. Decrease heat input
2. Decrease combustion air header pressure
3. Decrease feed flow
4. Decrease steam flow