Hydrocarbon Processing - December 2020 - 42

Plant Design, Engineering and Construction
H2 purification. The gasified syngas will
be used to provide H2 for hydrocracker
use, HP fuel for power generation and
LP tail gas for SAGD steam generation.
The design capacity of syngas processing
is approximately 8.64 MMm3d, which is
approximately 78% utilization of the total syngas available from the four asphaltene gasifier trains in operation.
To properly evaluate the operation
and to establish a design basis for the
debottlenecking, operating data from
the PSA H2 system were collected from
January 2014 to December 2015. The
performance data were analyzed and are
summarized in TABLE 1 and in FIG. 3 and
FIG. 4. The design data in TABLE 1 show
that this PSA system has a low-feed H2
concentration of around 45%, a higher
desorption pressure of 265 kPag and a
high adsorption pressure of 5.4 MPag.

shows the PSA feed H2 and CO
concentration profiles. FIG. 4 lists the H2
recoveries, as well as feed load and H2
product ratios over the design. Operating data shows that actual PSA operations were underperforming, with much
lower H2 recovery and production rates.
Analysis results of historical operating
data led to the following findings for the
original design deficiency:
1. A low-reliability issue was
evident for the programming
switch valves due to the
high-pressure drops and shorter
cycle times of around 25 sec
2. Higher tail gas flows resulted
in higher pressure drops
and hydraulic limitations in
existing tail gas piping
3. Lower H2 recoveries were
seen due to higher desorption
FIG. 3

TABLE 1. Comparison of actual performance with original design for PSA system
Item description

Original design

Actual performance

Feed/design ratio, %

100

70-95

Feed H2 concentration, mol%

44.6

43.3

Feed CO concentration, mol%

53.7

51

3

H2 products, sm /hr

110, 528

H2 product/design ratio, %

100

54-85

H2 purity, mol%

99.8

99.8

H2 recovery, %

73

54-60

Adsorption pressure, MPag

5.4

5.4

Tail gas pressure, kPag

265

315

Tail gas flow/design ratio, %

100

105

80

H2 concentration
CO concentration
Average H2
Average CO

PSA feed H2 and CO, mol%

70

Evaluation of debottlenecking options. Based on preliminary studies by

60

50

40

30

20
Jan.-14

April-14

July-14

Nov.-14

Feb.-15
Dates

FIG. 3. PSA feed H2 and CO concentration.

42

DECEMBER 2020 | HydrocarbonProcessing.com

May-15

Sept.-15

Dec.-15

pressure of 265 kPag and
less adsorbent volumes
4. The existing PSA unit is
incapable of supplying H2
at required design rates.
Depending on the severity of the hydrocracker, the targeted PSC API specification is in the range of 33-44. In this
study, a maximum-severity case targeting
a maximum of 44 API PSC was considered for the debottlenecking design of
the H2 system. According to the performance estimate from the hydrocracker
vendor and catalyst supplier, the required
H2 makeup rate for the 44 API PSC is
approximately 100.2% over the original
design rate. Therefore, the chosen debottlenecking option should offer the
following targeted priorities:
1. Meeting the targeted H2 demand
of 100.2% over the design rate
while only three gasifier trains
are in operation, with one
spare. In this way, the targeted
syngas usage ratios over the
total available syngas should
be less than 75%.
2. Maximizing the HP syngas fuel
supply to the gas turbines.
3. Resolving the reliability problem
of PSA switching valves.
4. Eliminating the hydraulic
limitation of the tail gas
piping lines.
5. Minimizing the incremental
capital cost of technically
viable options.
6. Maximizing incremental
operating margins of
technically viable options.

Mar.-16

EPCs, the licensor inputs and the catalyst/
adsorbent suppliers' offers, three technically viable debottlenecking options on
the existing gasification-based H2 system
were selected for analysis. Based on phase,
chemical and reaction equilibrium, the
simulation models for the asphaltene gasifier unit, CO shift reactors and PSA unit
were developed and validated by plant
operating data. These models are used for
the mass balance evaluation to screen and
analyze the process performance of the
three revamp options.
Option 1: New PSA2 train in parallel to existing PSA1. Referring to the
debottlenecking sketch in FIG. 5, revamp


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Hydrocarbon Processing - December 2020

Table of Contents for the Digital Edition of Hydrocarbon Processing - December 2020

Contents
Hydrocarbon Processing - December 2020 - Intro
Hydrocarbon Processing - December 2020 - Cover1
Hydrocarbon Processing - December 2020 - Cover2
Hydrocarbon Processing - December 2020 - Contents
Hydrocarbon Processing - December 2020 - 4
Hydrocarbon Processing - December 2020 - 5
Hydrocarbon Processing - December 2020 - 6
Hydrocarbon Processing - December 2020 - 7
Hydrocarbon Processing - December 2020 - 8
Hydrocarbon Processing - December 2020 - 9
Hydrocarbon Processing - December 2020 - 10
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Hydrocarbon Processing - December 2020 - 42
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Hydrocarbon Processing - December 2020 - 79
Hydrocarbon Processing - December 2020 - 80
Hydrocarbon Processing - December 2020 - 80A
Hydrocarbon Processing - December 2020 - 80B
Hydrocarbon Processing - December 2020 - 81
Hydrocarbon Processing - December 2020 - 82
Hydrocarbon Processing - December 2020 - Cover3
Hydrocarbon Processing - December 2020 - Cover4
Hydrocarbon Processing - December 2020 - GP-1
Hydrocarbon Processing - December 2020 - GP-2
Hydrocarbon Processing - December 2020 - GP-3
Hydrocarbon Processing - December 2020 - GP-4
Hydrocarbon Processing - December 2020 - GP-5
Hydrocarbon Processing - December 2020 - GP-6
Hydrocarbon Processing - December 2020 - GP-7
Hydrocarbon Processing - December 2020 - GP-8
Hydrocarbon Processing - December 2020 - GP-9
Hydrocarbon Processing - December 2020 - GP-10
Hydrocarbon Processing - December 2020 - GP-11
Hydrocarbon Processing - December 2020 - GP-12
Hydrocarbon Processing - December 2020 - GP-13
Hydrocarbon Processing - December 2020 - GP-14
Hydrocarbon Processing - December 2020 - GP-15
Hydrocarbon Processing - December 2020 - GP-16
Hydrocarbon Processing - December 2020 - GP-17
Hydrocarbon Processing - December 2020 - GP-18
Hydrocarbon Processing - December 2020 - GP-19
Hydrocarbon Processing - December 2020 - GP-20
Hydrocarbon Processing - December 2020 - GP-21
Hydrocarbon Processing - December 2020 - GP-22
Hydrocarbon Processing - December 2020 - GP-23
Hydrocarbon Processing - December 2020 - GP-24
Hydrocarbon Processing - December 2020 - GP-25
Hydrocarbon Processing - December 2020 - GP-26
Hydrocarbon Processing - December 2020 - GP-27
Hydrocarbon Processing - December 2020 - GP-28
Hydrocarbon Processing - December 2020 - GP-29
Hydrocarbon Processing - December 2020 - GP-30
Hydrocarbon Processing - December 2020 - GP-31
Hydrocarbon Processing - December 2020 - GP-32
Hydrocarbon Processing - December 2020 - GP-33
Hydrocarbon Processing - December 2020 - GP-34
Hydrocarbon Processing - December 2020 - GP-35
Hydrocarbon Processing - December 2020 - GP-36
Hydrocarbon Processing - December 2020 - GP-37
Hydrocarbon Processing - December 2020 - GP-38
Hydrocarbon Processing - December 2020 - GP-39
Hydrocarbon Processing - December 2020 - GP-40
Hydrocarbon Processing - December 2020 - GP-41
Hydrocarbon Processing - December 2020 - GP-42
Hydrocarbon Processing - December 2020 - GP-43
Hydrocarbon Processing - December 2020 - GP-44
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