Hydrogen Plant based on Tail gas/Naphtha/LPG
Unit nameplate capacity: 18.5MMSCFD , H2 @ 95% purity.
The No.1 Hydrogen Generation Unit (HGU-1) plant was originally designed by MW Kellogg for 17.2 MMSCFD H2 production with either butane or propane/butane LPG as feedstock. It mainly comprises of a Desulphurization Unit, top fired Reformer by Kellogg, 2 stages of Shift Converters and CO2 Absorbers (CARACARB system by EICKMEYER) followed by METHANATOR. However, use of naphtha feed enables only 85% operation of the Hydrogen Plant. The plant can handle a feedstock containing small amounts of olefins and limited by maximum allowable temperature rise of through the feed hydrotreater.
An additional reboiler was installed in the CO2 absorption section to raise the unit’s H2 production to 19.0 MMSCFD H2 with LPG feed after the commissioning of CDU-2. With the commissioning of the Catalytic Reforming Unit, modifications were done for the plant to turn down at 30.9% of the full capacity while utilizing tail-gas from No. 1 Hydrogen Purification Unit in Cat Reforming Unit (CRU) as feedstock. Arabian Medium 95 RON-C, Iranian Heavy 95 RON-C and Iranian Heavy 85 RON-C were considered as the tail gas for the modification.
Over the years, deterioration in the unit was observed, affecting the reformer’s efficiency and ultimately the unit’s hydrogen production capability. More recently, the refinery carried out improvement projects on HGU-1, to restore the unit back to 19.0MMscfd H2 production. All burners in the reformer, which were replaced with John Zink design for better firing and the reformer roof top refractory was completely changed out to minimize heat loss and air ingress. As a result, reformer efficiency improved significantly.
H2 purity of HGU-1 is designed for 95%mole.
BFW(Boiler Feedwater):28T/H; Cooling water: 4.2T/H.
Raw material/feedstock: Tail gas/LPG/Naphtha
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