GAS CONCENTRATION UNIT

PROCESS GENERAL A Gas Concentration Unit (13 Unit) receives gasoline and all lighter products from a Fluid Catalytic Cracking Unit (FCC) and separates this mixture into stabilized gasoline, a liquefied petroleum gases (LPG) stream, and a non-condensable lean gas stream. The gasoline stream may be processed further, into heavy and light gasoline streams. The LPG stream is sent to an LPG treating unit for treating. After treating, the LPG stream is further separated into mixed C3 and mixed C4 streams. The components in the charge and products from a Gas Concentration Unit are summarized in the following table: Component Gasoline Normal Butane Isobutane Butylenes Propane Propylene Hydrogen Sulfide Ethane Ehtylene Methane Hydrogen Inerts Formula C5 + Hydrocarbons n-C4 H10 i-C4 H10 C4 H8 C3 H8 C3 H6 H2S C2 H6 C2 H4 CH4 H2 N2, CO, CO2 Boiling Point (@ 1 atm) 38-221 -0.6 -12 -7 to +4 -42 -48 -61 -88 -104 -162 -253 -196, -192, -78

1.4 PROCESS DESCRIPTION

The first step in the Gas Concentration process (see Figure 1) is the separation of the noncondensable lean gas from the heavier components. The lean gas can not be separated in conventional fractionation equipment unless refrigeration is used (even though the equipment may be operated at high pressure). A stripper- absorber system must therefore be used for this primary separation. Net gas from the FCC unit must first be compressed and cooled before entering the stripper-absorber system. A two-stage, Wet Gas Compressor (13-TC-301) is used for this purpose. The compressor raises the gas pressure and moves the net gas stream forward for processing in the stripper-absorber system. A spillback from the compressor is provided to prevent the compressor from surging during turndown operation. The compressor speed is varied to control the FCC Main Column Receiver(12-V-202) pressure. The heart of a stripper-absorber configuration is the high pressure cooler and receiver. The High Pressure Receiver (13-V-303) serves as both a surge vessel to dampen process upsets and as a water settler. All internal streams and all charge streams pass through the cooler/receiver except for the unstabilized cracked gasoline. Gas from the Wet Gas

Compressor(13-TC-301) joins the Primary Absorber(13-C-301) bottoms stream, the Stripper(13-C-303) overhead vapor stream, and the liquid from the Compressor Interstage suction Drum(13-V-302) to enter the High Pressure Condenser(13-EA-302), High Pressure Trim Condenser(13-E-302) and then the High Pressure Receiver(13-V-303). Gas from the High Pressure Receiver (referred to as rich gas) contains valuable products in the propane-butane range. The gas is washed with cracked gasoline from the FCC Main Column Receiver (12-V-202) to recover these products in the Primary Absorber(13-C-301). Stabilized gasoline can also be injected at the top of the Primary Absorber to increase the C3/C4 recovery. Heat is generated as the liquid streams flow down the column absorbing the lighter material from the rising gas stream. This heat is removed via intercoolers to increase absorption efficiency. The liquid hydrocarbon from the bottom of the Primary Absorber (13-C-301) is pumped to the High Pressure Condenser(13-EA-302). Figure 1

Typical Gas Concentration Unit

The gas stream from the Primary Absorber(13-C-301) exits from the top and flows to the bottom of the Sponge Absorber(13-C-302). The Sponge Absorber(13-C-302) is a packed tower where any remaining C5+ material is removed by countercurrent contact with a lean oil, normally Light Cycle Oil (LCO) from the FCC unit. The lean gas from the top of the

Sponge Absorber is then sent to an Fuel Gas Absorber (16-C-601) through Lean Gas Knockout Drum(13-V-304) for H2S removal. A portion of the untreated lean gas may be recycled to the Reactor (11-R-101) riser in the FCC unit as lift media. The LCO (Rich Oil) is pumped back to the Main Column(12-C-201). Unfortunately, absorption is not as selective an operation as fractionation. As such, the rich oil contains not only the desired C3s and C4s, but also a considerable quantity of the unwanted ethane (C2), methane (C1) and hydrogen sulfide (H2S). These components are removed by charging the High Pressure Receiver (13-V-303) liquid to the Stripper (13-C303). Stripper Reboilers (13-E-309/310) heat is used to strip out the correct quantity of material from the Stripper charge by having the stripper overhead vapor flow reset the reboilers heat input. The stripper overhead vapor returns to the High Pressure Receiver and High Pressure Condensers from which the lighter gases again enter the bottom of the Primary Absorber (13-C-301). The Stripper(13-C-303) bottoms contains a reduced concentration of H2S and C2- material that permits handling this stream in conventional fractionation equipment. The Stripper bottoms material is separated in the Debutanizer (13-V-304) into LPG and gasoline. The Debutanizer(13-C-304) is operated to control the Reid Vapor Pressure (RVP) of the gasoline product. Heat to the Debutanizer Reboiler (13-E-312) is supplied from circulating FCC heavy cycle oil. The LPG stream is generally sent to a LPG Merox Unit to remove sulfur compounds prior to further processing. The Debutanizer bottoms is removed to either net gasoline, to treating, or recycle gasoline to the Primary Absorber.

PROCESS VARIABLES
The purpose of the Gas Concentration Unit is to separate gasoline, LPG and light gases produced in the FCC Unit. The purpose of the Stripper(13-C-303) column is to separate C 2and H2S from the gasoline, while maximizing C3 recovery. The unit is controlled by observing the C3 content of the lean gas from Sponge Absorber(13-C-302) and the H2S content of the LPG stream. In practice, as the C3 content of the lean gas increases, the H2S content of the LPG stream decreases, and vice versa. For convenient control it is necessary to observe only one of these concentrations. Since a Tutweiler H2S determination on the LPG stream can easily be carried out at the plant, this is generally used for control purposes. The optimum concentration of H2S in the LPG stream is usually one of the control points set by the refinery supervision after an economic study. The main operating variable is the Flow Recorder Controller(13-FIC-314) in the Stripper(13-C-303) overhead vapor line that controls the flow of light cycle oil through the stripper reboiler tubes. This vapor rate is the primary control in the recovery section of the Gas Concentration Unit. Increasing this vapor flow will decrease the H2S content of the Stripper(13-C-303) bottoms but will increase the propylene and propane content of the lean gas from the Sponge Absorber(13-C-302). The vapor flow should be adjusted to give a minimal content of H2S in the Debutanizer(13-C-304) overhead with a minimal content of propylene and propane in the Sponge Absorber(13-C-302) off-gas.

It is possible to build up a liquid recycle in the absorption section and overload the Stripper and absorber with liquid. For example, if the stripping rate becomes excessive, the Stripper vapors will contain heavier than desired components that end up as a liquid in the High Pressure Receiver(13-V-303). This will increase the feedrate to the stripper and increase the liquid loading, and consequently, the pressure drop across the column. These conditions tend to increase liquid entrainment back to the High Pressure Receiver magnifying the problem. This may cause liquid entrainment from the Primary Absorber where it will be returned to the FCC Main Column(12-C-201) with the rich sponge oil from Sponge Absorber. The above condition of C3 internal recycle due to overstripping, is easily recognized since there will be a reduction in the quantity of light FCC gasoline to treating. Levels tend to build in the High Pressure Receiver(13-V-303) and FCC Main Column Receiver(12-V202). Also, it is possible to build up a cycle whereby the levels in these vessels will continue to build with the pertinent control valves wide open. The best immediate action to rectify the situation is to drastically reduce the heat input to the reboiler of the stripper by lowering the setting on the stripper vapor flow controller until the upset condition is corrected. A sudden increase in the H2S level of the LPG stream should not be construed as being a result of lower stripping alone. For example, if the sulfur content of the FCC Unit charge increases, the H2S content of all the streams will increase in roughly the same proportion. On the other hand, if the H2S of the LPG stream is held constant by changing the stripping rate, the propane content of the lean gas will increase. Since our objective is to maximize recovery of C3 and minimize the H2S content of the LPG stream, let us examine what variables control the H2S rejection.
LEAN OIL FLOW TO THE ABSORBER

3.1.1 Primary Absorber(13-C-301) Lean oil flow (unstabilized gasoline) from the FCC Main Column(12-C-201) is not a variable that operators can control. Recycled gasoline from the Debutanizer(13-C-304) bottoms can be adjusted to increase C3/C4 recoveries. However, caution must be exercised to avoid liquid flooding at high throughputs. 3.1.2 Sponge Absorber(13-C-302) Increasing the sponge oil flow rate tends to increase the absorption efficiency of the Sponge Absorber. Changes in sponge oil flow rates have only a slight effect on C3 recovery, but the effect is more noticeable on the recovery of heavier components.

3.2 PRIMARY ABSORBER(13-C-301) TEMPERATURE

Low temperatures favor absorption, however, absorber temperature is not normally considered to be a variable. The intercoolers(13-E-303/304) are generally operated at less than 38C (100F). When starting up a Gas concentration Unit, experienced operators will, however, frequently leave the water shut off on the intercooler until the unit is steady so that the H2S rejection is favored. This operation will not scale the coolers because absorber temperatures are not high enough to precipitate scale from good cooling water.

3.3 HIGH PRESSURE RECEIVER(13-V-303) TEMPERATUARE

Generally, the High Pressure Receiver temperature is held close to 38C (100F). Variations of this temperature will result in large variations in the stripping and absorption rates. Also, the inlet temperature of the hydrocarbon to this cooler is high enough to scale the tubes should the water flow be restricted.

3.4 STRIPPER(13-C-303) VAPOR RATE

This is the primary control on the Gas Concentration Unit. Normally all other variables are held constant and this vapor rate is varied to control either H2S or the C2 content of the LPG.

3.5 SYSTEM PRESSURE

The Sponge Absorber(13-C-302) pressure control maintains a constant pressure on all vessels in the Gas Concentration Unit, except the debutanizer. The system pressure is a secondary control which, though not normally used for day to day operation, can be used to keep the necessary Stripper vapor rate in a convenient range. It may sometimes be desirable to lower the system pressure when the cracking unit swings to a high sulfur chargestock because the Stripper column will be more efficient (the system pressure must always be high enough to charge the Debutanizer). It should also be noted that the absorption efficiency decreases as the pressure decreases. Thus more H2S will be rejected, but the LPG recovery will decrease.

3.6 FUEL GAS ABSORBER(16-C-601)

The absorption of H2S from the Sponge Absorber(13-C-302) lean gas into the amine solution is favored by: 1 Low Temperature 2 Low Acid Gas (H2S) Loading 3 High Amine concentration 3.6.1 Low Temperature A low amine temperature favors H2S removal. When treating a hydrocarbon gas, however, the lean amine temperature must be maintained 3C (5F) higher than the temperature of the gas feed stream to avoid any possible condensation of these hydrocarbon vapors. The lean amine is usually cooled to between 27-49C (80 and 105F). 3.6.2 Acid Gas Loading Efficient acid gas removal depends on good amine solution regeneration, as will be discussed later. However, it also depends on restricting the H2S loading in the rich amine to favor the forward direction of the reaction given in equation (1). The H2S loading of the

amine solution is controlled by adjustment of the amine circulation rate. In most cases, unless special design considerations have been employed, the rich amine acid gas loading (H2S plus CO2) should not exceed 0.3 to 0.4 mols total acid gas per mol of amine present. For MEA : HOCH2CH2NH2 + H2S HOCH2CH2NH3SH (1) For DEA : (HOCH2CH2)2NH + H2S (HOCH2CH2)2NH2SH (1a)

3.6.3 High Amine Concentration The concentration of uncombined amine is favored by high amine concentration in the amine solution, good regeneration, and freedom from strong acids. Practical and economical considerations confirmed by field experience have generally shown that the optimum amine concentration is between 15 and 35 wt-% amine, with target values of 15 wt-% for MEA, 20 wt-% DEA, and 35 wt-% for MDEA. This is based on the lowest heat requirement for the desired H2S removal, the lowest chemical losses, and the fewest operational problems. Amine regeneration efficiency and control significantly effects the lean amine concentration. The lower the sulfide content of the lean amine, the greater the available amine concentration for removal of H2S. In most cases, properly regenerated lean amine will not contain more than 0.1 mol CO2 per mol amine.

PROCESS FLOW AND CONTROL

The Gas Concentration Unit can be divided into two general areas known as the Recovery Section and the Fractionation Section. In the Recovery Section, ethane and lighter components and hydrogen sulfide are removed from the feed stream. The principle pieces of equipment are the Wet Gas Compressor(13-TC-301), High Pressure Receiver(13-V-303), Primary Absorber(13-C-301), Sponge Absorber(13-C-302), Fuel Gas Absorber(16-C-601) and the Stripper(13-C-303). The Fractionation Section in its most basic form has a Debutanizer(13-C-304) to split the unstable gasoline into liquefied petroleum gases (LPG) and stable gasoline.

RECOVERY SECTION
The charge streams to the recovery section of the Gas Concentration Unit usually consist of the gas and unstabilized gasoline from the main column overhead receiver in the FCC Unit as shown in Figure 2.

Figure 2 Main Column Overhead System

The Wet Gas Compressor(13-TC-301) flow and control is shown in Figure 3. Vapor from the Main Colum Receiver(12-V-202) is compressed to 16 kg/cm2 using two separate stages by the compressor. The gas is cooled after each stage to remove heat of compression allowing heavier components to condense out of the gas stream. The gas flows from the Main Column Receiver(12-V-202) through a Compressor Suction Drum(13-V-301) to the first stage of compression of a centrifugal gas compressor. The suction drum contains a wire mesh blanket (demister pad) to trap entrained liquid droplets that could damage the compressor. Any liquid that collects in the first stage suction drum is pumped forward to the Main Colum Condenser(12-EA-203). The first stage discharge flows through the Compressor Interstage Cooler(13-EA-301) and Compressor Interstage Trim Cooler(13-EA-301) to the Compressor Interstage Suction Drum(13-V-302). Gas from the first stage discharge may also return to the FCC Main Column Trim Condenser(12-E-208) to prevent compressor surge or to maintain receiver pressure. Wash water is injected to the Compressor Interstage Cooler,13-EA-301 (see Figure 4) to prevent the buildup of salts such as ammonium chloride. Typical injection rates are in the range of 6-7 vol% of the FCC charge rate. The Compressor Interstage Suction Drum(13-V-302) gas outlet is also covered with a demister pad to trap any entrained liquid. The liquid collecting in the Compressor Interstage Suction Drum(13-V-302) (hydrocarbon and wash water) is pumped on level control to the inlet of the High Pressure Condenser(13EA-302). From the top of the Compressor Interstage Suction Drum(13-V-302), gas flows to the second stage suction of the gas compressor then on through the High Pressure

Condenser(13-EA-302) and High Perssure Trim Condenser(13-E-302)to the High Pressure Receiver(13-V-303). The overhead vapor stream from the Stripper(13-C-303), the interstage condensate and the rich oil from the Primary Absorber(13-C-301) join the second stage discharge gas upstream of the High Pressure Condenser(13-EA-302). Spillback gas from the compressor second stage also joins the first stage discharge upstream of the Compressor Interstage Cooler(13-EA-301). This protects the second stage of the compressor from surge.

Figure 3

Wet Gas Compressor Flow and Control

As previously mentioned, wash water (injected at the Wet Gas Compressor first stage discharge)

flows through the Compressor Interstage Cooler(13-EA-301), the Compressor Insterage Trim Cooler(13-E-301), the High Pressure Condenser(13-EA-302) and High Pressure Trim Condenser(13-E-302) to the High Pressure Receiver(13-V-303) with the hydrocarbon streams. Wash water is used to prevent the deposition of ammonium chloride in the coolers and the receivers. The water is collected in the water boot of the High Pressure receiver and is pressured to the Main Column Receiver(12-V-202) of the FCC Unit on interface level control.

Figure 4

Water Wash

Rich Gas flows from the High Pressure Receiver(13-V-303) to the Primary Absorber(13-C301) for C3/C4 recovery. The absorbers are shown in Figure 5. The gas flows upward through the Primary Absorber(13-C-301) contacting a downflow of unstabilized gasoline from the FCC Unit Main Column Receiver(12-V-202) that is introduced into the Primary Absorber at Tray 9. A slipstream of stabilized gasoline from the Debutanizer(13-C-304) is admitted to the top tray of the Primary Absorber. The addition of stabilized gasoline to the Primary Absorber significantly increases C3/C4 recovery. Off-gas exits the top of the Primary Absorber and flows to the bottom of the Sponge Absorber(13-C-302) for final recovery of any C5+ material and some C3/C4 components. The gas flows upward through the Sponge Absorber where it is contacted with a downflow of lean sponge oil (LCO) which enters the column on flow control above the packing. The lean gas leaves the top of the Sponge Absorber and enters a Lean Gas Knockout Drum(13-V-304) which removes any entrained liquid. The gas exits the top of the Lean Gas Knockout Drum(13-V-304) and flows to the bottom of the Fuel Gas Absorber(16-C-601). A portion of the sponge gas will be recycled to the FCC Unit as lift media. In the Fuel Gas Absorber(16-C-601) the gas is contacted with a downflow of lean amine for H2S removal. The amine enters the column on flow control. The treated gas exits the top of Fuel Gas Absorber(16-C-601) and enters a Treated Gas Knockout Drum(16-V-607) that removes any entrained amine. The sponge gas leaves the Treated Gas Knockout Drum(16-V-607) on pressure control to the refinery Fuel Gas System. Light cycle oil (LCO) from the FCC supplies lean oil to the Sponge Absorber. A slipstream of LCO is sent to the Sponge Absorber as lean oil. This lean oil is cooled by heat exchange with rich oil from the bottom of the Sponge Absorber and a Sponge Absorber Lean Oil Cooler(13-E-306). The LCO is pumped on flow control into the top of the tower above the packing. The lean sponge oil flows downward through the absorber contacting the upward flow of gas. From the absorber bottom, the rich oil (flowing on level control) is heated by the lean oil before returning to the FCC Main Column(12-C-201) via the LCO pumparound. The unstabilized gasoline from the FCC Main Column Receiver(12-V-202), which is pumped on level control direct to the Primary Absorber, flows down through the column contacting the upward flow of gas. Some of the heat of absorption transferred to the liquid is removed by pumping a stream of the liquid (rich gasoline) from the column through the intercoolers(13-E-303/304) and back to the column. At the bottom of the Primary Absorber, the rich gasoline is pumped on level control through the High Pressure Condenser(13-EA302) and High Pressure Trim Condenser(13-E-302) into the High Hressure Receiver(13-V303) as previously mentioned. Liquid hydrocarbon from the High Pressure Receiver(13-V-303) is pumped to the Stripper(13-C-303) where hydrogen sulfide (H2S), ethane and lighter components are stripped out. The Stripper flow is shown in Figure 6. Feed to the Stripper is heated using the total Debutanizer(13-C-304) bottoms stream. Stripper charge enters the column above the top tray. Stripping action is provided via a Stripper Reboiler Exchanger(13-E-310) at

the bottom of the column through which heat is supplied from the Debutanizer bottoms stream and a Stripper Reboiler(13-E-309). Circulating LCO flows through the tube side of the Stripper Reboiler with its flow regulated by a flow controller(13-FIC-313) that is reset by the stripper overhead vapor rate. The overhead vapor is returned to the High Pressure Condenser(13-EA-302). Bottoms material is pressured to the Debutanizer(13-C-304) on level control. Figure 5

Absorbers

FRACTIONATION SECTION

As shown in Figure 6, the feed to the Fractionation Section is the Stripper(13-C-303) bottoms stream that is pressured into the Debutanizer(13-C-304). Heat is supplied via a

Debutanizer Reboiler(13-E-312). The heating oil to the reboiler is heavy cycle oil from the FCC Unit. The HCO is regulated by a flow recording controller(13-FIC-316). Overhead vapors (C3s and C4s) are condensed by an air Debutanizer Condenser(13-EA-304) and then collected in the Debutanizer Receiver(13-V-305). Debutanizer feed is preheated by circulating LCOfrom the FCC. The net production of light FCC gasoline is pressured from the Debutanizer on level control to the LPG Merox Unit. A recycle stream of stabilized gasoline is also sent to the Primary Absorber to increase the absorption efficiency of C3/C4. A portion of the total overhead is pumped back to the column as reflux. The quantity of reflux is regulated by a flow recording controller(13-FIC-317) which is typically reset by the Tray 9 13-TIC-334 in the top of the column. The net overhead liquid product is pumped out on flow control that is reset by the level controller(13-LIC-322) on the Debutanizer Receiver(13-V-305). The Debutanizer column pressure is controlled by a pressure recording controller (13-PIC333) on the overhead vapor line and by a pressure differential indicator controller (13PDIC-334) in the vapor bypass line. The 13-PIC-333 controls vapor flow to condenser to control the column pressure. The 13-PDIC-334 keeps the receiver pressure from dropping too low, bypassing some vapor that keeps the 13-PV-333A valve in range. The receiver pressure is not always constant and will change with changes in the weather conditions. A drag line is provided to vent non-condensables from the top of the Debutanizer Receiver(13-V-305). Column pressure control will not work properly if non-condensables are present. If they are present, first the 13-PDV-334 control valve will close, then the column pressure will exceed the setpoint. The Debutanizer overhead product is pumped to the LPG Treating Unit(14 Unit) for mercaptan sulfur removal.

Figure 6 Stripper/Debutanizer Flow 5.0 PROCESS EQUIPMENT

Circulating LCO

Circulating LCO

5.1 WET GAS COMPRESSOR(13-TC-301)

The Wet Gas Compressor separates the relatively low pressure of the FCC Main Column(12-C-201) from the high pressure gas concentration unit. A centrifugal compressor is used for this service. Centrifugal Wet Gas Compressors are multi-stage machines, contained within two external stages. Each of the two stages is protected by an anti-surge device that will override normal controls to protect the compressor. Gas leakage out of the casing is prevented by suction and discharge end labyrinth seals. These seals are backed by either buffer gas. The seal

system must be kept in operation while the casing is under pressure or gas will leak out. Figure 8

Centrifugal Compressor

5.2 COMPRESSOR SUCTION DRUM AND COMPRESSOR INTERSTAGE SUCTION DRUM(13-V-301/302) A sketch of the compressor suction drum is presented below. Both first and interstage suction drums are made of carbon steel with a stainless steel mesh blanket (demister pad) to remove any entrained droplets. Mesh blankets provide a large surface area for any entrained liquid to coalesce on and be removed from the gas stream. Figure 9

Compressor Suction Drum

5.3 WASH WATER The overhead stream from the Main Column(12-C-201) contains various contaminants that may cause corrosion, plugging or fouling. These would include ammonia, sulfides, cyanides, chlorides and phenols. A wash water stream is used to remove these contaminants since most are ionic or polar species, and are readily soluble in water. Typical flow rates run 2 gpm water/1000 BPD feed (6.5-7 vol-%), though less may be used if it does the job. The water should be clean, preferably steam condensate, to prevent adding more problems such as salts or dissolved oxygen to the system. The water is injected after the compressor first stage and is pumped out of the interstage suction drum to the inlet of the High Pressure Condenser. The water is collected in the water boot of the High Pressure Receiver and then pressured back to the FCC Main Column overhead condensing system. There is always water present in the FCC Main Column and gas concentration section from

reactor stripping stream and other sources. If the wash water is not used to flush out the sulfides, ammonia, cyanides and other species, the water present can be highly corrosive from absorption of these contaminants. Sulfide levels of greater than 20,000 ppm have been reported in the Main Colum Receiver(12-V-202) water. Hydrogen blistering and general corrosive attack may become quite severe, especially if feed sulfur is greater than 1%, or feed nitrogen is greater than 1000 ppm. Also, while the Main Column Receiver water may be basic, most of the ammonia that is responsible for this will drop out in the Main Column Receiver. The water in the gas concentration section may become acidic from H2S and CN. If there is any oxygen present, elemental sulfur may be formed from oxidation of the sulfides. This will cause problems in meeting gasoline product specifications. Wash water will solve many of these problems by diluting the corrosives and keeping the water pH at 8-9 where sulfide oxidation is greatly reduced.

5.4 HIGH PRESSURE RECEIVER(13-V-303)

The High Pressure Receiver collects the liquid streams from the Compressor Interstage Suction Drum(13-V-302) and Primary Absorber(13-C-301) bottoms and the gas streams from the second stage compressor discharge and the Stripper(13-C-303) overhead. Water is separated from the hydrocarbon stream and collected in the receiver water boot. The sour water is pressured from the boot to the Main Column overhead on level control. The hydrocarbon liquid stream is pumped to the Stripper(13-C-303) on level control. The separated gas is sent to the Primary Absorber(13-C-301). The Primary Absorber(13-C-301) floats on the High Pressure Receiver(13-V-303) pressure. The vessel is killed carbon steel. The design operating pressure is 16 kg/cm2(g). A slotted pipe distributor is provided to minimize liquid level disturbances due to the incoming gas/liquid stream.

5.5 PRIMARY ABSORBER(13-C-301)

The function of the Primary Absorber is to absorb most of the propylene, propane, butylene and butane components in the rich gas stream from the High Pressure Receiver(13-V-303). The column is killed carbon steel with 40 carbon steel trays. Valuable light products such as LPG are absorbed from the gas as it reveals from the bottom to the top outlet. The tower design uses two intercoolers to remove the heat of gas absorption from the gasoline as it flows down the tower. The temperature rise is about 14C. These intercoolers are located roughly one-third and two-thirds of the way down the tower. The circulating gasoline is pumped through the water coolers. Debutanized gasoline is introduced at the top of the column as a final wash of the gas stream. Improved C3/C4 recoveries result from the use of recycle gasoline although if the C3/C4 recovery is adequate it may be more economical not to recycle gasoline. The gasoline from the bottom of the column is pumped to the High Pressure Condenser(13-EA-302) while the gas goes to the Sponge Absorber(13-C-302).

5.6 SPONGE ABSORBER(13-C-302)

Depending on the absorption efficiency in the Primary Absorber, 5-10% of the propane and

heavier components can be lost to the fuel gas system if a secondary absorber is not used. The Sponge Absorber is a guard tower that uses light cycle oil to absorb any remaining liquid from the gas. If any significant quantities of C5 or C6 remain in the gas stream, these will cause problems with treating. If the gas is sent directly to the fuel gas system, condensation of heavy material is dangerous. The Sponge Absorber is half as big as the Primary Absorber. It is a killed carbon steel column filled with packing to provide intimate contact between the lean oil and the gas. A type 304 stainless demister pad, at the top of the absorber, traps any entrained liquid.

5.8 STRIPPER(13-C-303)
The purpose of this column is to strip off the light ends (C2-) plus the bulk of the hydrogen sulfide that is present in the gas and liquid streams from the FCC Unit. The charge to the column enters through two distributors that discharge onto the top tray. The stripped vapors leave the top of the column. The heat input to the column is controlled by the top vapor rate. The Stripper bottoms liquid is sent to the Debutanizer on reboiler level control. The gasoline stream from the Debutanizer bottoms provides preheat to the gasoline feed stream. The Stripper is made of killed carbon steel with 36 carbon steel trays. Tray fittings are type 410 stainless. The reboiler is carbon steel, but may be 5% Cr 1/2% Mo in cases where severe corrosion has occurred. This corrosion is not common and can usually be corrected without the additional expense of a chrome alloy reboiler.

5.9 DEBUTANIZER(13-C-304)
The stripped gasoline from the recovery section has to be debutanized for vapor pressure adjustment. In the Debutanizer, a majority of the C3 and C4 components are taken overhead. This is the LPG product stream that can be sent for further treating. The gasoline from Debutanizer bottoms usually requires treatment for removal of sulfur and the addition of inhibitors to upgrade its storage quality. The Debutanizer is killed carbon steel with 40 carbon steel trays. Tray fittings are type 410 stainless. The overhead system is usually carbon steel, with inhibited Admiralty brass tubes in the water condenser. The shell of the reboiler is carbon steel, the tubes, tube sheet and floating headcover are 5% Cr 1/2% Mo. Carbon steel clad with type 410 stainless may be used instead of 5% Cr. Hot fluid flow is through the tubes.