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GBH Enterprises, Ltd.
METHANOL PLANT - SHALE GAS FEED
PRETREATMENT
CASE STUDY #091406
Process Information Disclaimer
Information contained in this publication or as otherwise supplied to Users is
believed to be accurate and correct at time of going to press, and is given in
good faith, but it is for the User to satisfy itself of the suitability of the Product for
its own particular purpose. GBHE gives no warranty as to the fitness of the
Product for any particular purpose and any implied warranty or condition
(statutory or otherwise) is excluded except to the extent that exclusion is
prevented by law. GBHE accepts no liability for loss, damage or personnel injury
caused or resulting from reliance on this information. Freedom under Patent,
Copyright and Designs cannot be assumed.
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
Case Background
A Methanol plant operator would like to examine the technical feasibility of using
Shale Gas as a feedstock to their Methanol plant.
The first step in the Methanol production process is gas pretreatment. The
purpose of gas pretreatment is to make the gas suitable for the downstream
processes. There are two groups of compounds that are usually present in
natural gas and that should be removed during pretreatment—the associate NGL
and the sulfur-containing compounds. Some natural gas reservoirs may also
have other trace components that must be removed, but these are not discussed
here.
Desulfurization of Proposed Shale Gas
In large-scale Methanol facilities, desulfurization is typically performed by
passing the natural gas with a co-feed of hydrogen (H2) over a hydrotreating
catalyst, followed by desulfurization over a packed bed of porous “mixed-metal”-
containing zinc oxide (ZnO). The initial hydrotreating step is necessary to convert
sulfur in mercaptan (thiol) and sulfide (thioether) compounds to hydrogen sulfide
(H2S). The ZnO reacts with H2S to capture the sulfur as zinc sulfide (ZnS), and
the packed bed is typically operated at 350°C–400°C. Once the packed bed
reaches capacity, the ZnS can be regenerated by controlled oxidation. It is,
therefore, customary to apply two packed beds in series lead-lag.
Selecting ZnO-based desulfurization technology for methanol plants has some
implications:
• A source of pure H2 is required as utility. The issue is not H2 availability,
but rather the need to include an H2 purification unit, or an external source
of pure H2 in the design.
• During regeneration, a sulfur-dioxide-(SO2)-rich offgas is produced as
effluent. Depending on the location, the offgas can be disposed of through
a stack, or it can require gas treatment before release.
Other gas treatment strategies will have different requirements and implications.
For example, spent methanol synthesis catalyst makes a good sulfur trap. Gas
treatment and spent methanol synthesis catalyst disposal can be integrated,
instead of using ZnO.
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
This case study examines the impact of CO2 (Carbon Dioxide) on the pre-
treatment section design, performance and efficiency of ACME Methanol Plant’
feed gas pre-treatment section.
Case 1: Normal Shale Gas
Case 2: “Bad Gas”
Case 3: Low CO2
Case 4: High CO2
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
HDS VESSEL
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
ZNO VESSEL
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
Purification Calculation Summary: [Cases 1 – 4 Cross Checks]
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
APPENDIX
FEEDSTOCK CHARACTERIZATION
Component Units NG CO2
Process
Steam
Recycle NG CO2 Recycle
Stream Stream Stream Stream Stream Stream
Data from Stream Mixer mol% mol% mol% mol% mol% mol% mol% mol% kmol/hr mol % kmol/hr
Paraffins Note: Okay Okay Okay Okay
CH4 mol% 55.32 55.32 0.00 0.00 55.321 2115.76 55.323 2115.76
C2H6 mol% 1.18 1.18 0.00 0.00 1.180 45.130 1.180 45.130
C3H8 mol% 0.23 0.23 0.00 0.00 0.230 8.797 0.230 8.797
C4H10 mol% 0.05 0.05 0.00 0.00 0.050 1.912 0.050 1.912
C5H12 mol% 0.01 0.01 0.00 0.00 0.005 0.191 0.005 0.191
C6H14 mol% 0.24 0.24 0.00 0.00 0.240 9.179 0.240 9.179
C7H16 mol% 0.00 0.00 0.00 0.000 0.000 0.000 0.000
C8H18 mol% 0.00 0.00 0.00 0.000 0.000 0.000 0.000
C9H20 mol% 0.00 0.00 0.00 0.000 0.000 0.000 0.000
Olefins
C2H2 Acetylene mol% 0.00 0.00 0.00 0.000 0.000 0.000 0.000
C2H4 mol% 0.00 0.00 0.00 0.000 0.000 0.000 0.000
C3H6 mol% 0.00 0.00 0.00 0.000 0.000 0.000 0.000
C4H8 Butene mol% 0.00 0.00 0.00 0.000 0.000 0.000 0.000
C4H6 Butadiene mol% 0.00 0.00 0.00 0.000 0.000 0.000 0.000
C5H10 mol% 0.00 0.00 0.00 0.000 0.000 0.000 0.000
C6H12 Hexene mol% 0.00 0.00 0.00 0.000 0.000 0.000 0.000
Naphthenes
C6H12 Cyclohexane mol% 0.00 0.00 0.00 0.000 0.000 0.000 0.000
Aromatics
C6H6 Benzene mol% 0.00 0.00 0.00 0.000 0.000 0.000 0.000
Inerts & Others
CO mol% 0.00 0.00 0.00 0.00 0.000 0.000 0.000 0.000
CO2 mol% 25.06 100.00 25.06 100.00 0.00 25.061 958.439 25.061 958.439
N2 mol% 15.41 15.41 0.00 0.00 15.410 589.367 15.411 589.367
Ar mol% 0.00 0.00 0.00 0.00 0.000 0.000 0.000 0.000
H2 mol% 2.50 100 2.50 0.00 100.00 2.500 95.614 2.500 95.614
NH3 Ammonia mol% 0.00 0.00 0.00 0.00 0.000 0.000 0.000 0.000
H2O mol% 0.00 100 0.00 0.00 0.00 0.003 0.115
Total 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 3824.50 100.00 3824.39
Organic Carbon Factor 0.6004 0.0000 0.0000 0.0000 0.6004 0.0000 0.0000 0.6004 0.6004 0.6004 0.6004
Inorganic Carbon Factor 0.8510 1.0000 0.0000 0.0000 0.8510 1.0000 0.0000 0.8510 10.1848 0.8510 10.1848
Molecular Weight kg/kmol 24.9677 44.0098 18.0152 2.0158 24.9677 44.0098 2.0158 24.9677 24.9677 24.9679 24.9679
Error Warning Note: Okay Okay Okay Okay
Flowrate Nm³/hr
Flowrate kg/hr
Flowrate kmol/hr 3824.5 0 0 29.966
Gas Flowrate Nm3
/hr 85722 0 0 0 85722 0 0 85722 85720
kg/hr 95488.8 0.0 0.0 0.0 95488.8 0.0 0.0 95488.8 95486.7
kmol/hr 3824.5 0.0 0.0 0.0 3824.5 0.0 0.0 3824.50 3824.39
Calculated Steam to Carbon mol/mol 0.0000
Model C5's + as C4's No
C5's + as C4's mol% 0.00 0.00 0.00 0.000 0.000
New C4 Flowrate kmol/hr 0.00 0.00 0.00 1.912 1.912
New Total Flowrate kmol/hr 3815.13 3815.02
Total Total Total Total
Sulfur Speciation Note:
ppm mol ppm mol ppm mol ppm mol
mg
S/Nm3
mol %
component
kmol/hr
H2S ppm v 5.27 5.270 0.000 0.000 5.270 7.5 0.000527 0.020155
COS ppm v 1.32 1.320 0.000 0.000 1.320 1.9 0.000132 0.005048
CS2 ppm v 0.000 0.000 0.000 0.000 0.0 0.000000 0.000000
Mercaptans
CH3SH ppm v 0.000 0.000 0.000 0.000 0.0 0.000000 0.000000
C2H5SH ppm v 0.000 0.000 0.000 0.000 0.0 0.000000 0.000000
C3H7SH ppm v 0.000 0.000 0.000 0.000 0.0 0.000000 0.000000
n-C4H9SH ppm v 0.000 0.000 0.000 0.000 0.0 0.000000 0.000000
Mixed Gas (Wet) Mixed Gas (Dry)
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
NG CO2
Process
Steam
Recycle
Mixed Gas
(Wet)
Mixed Gas
(Dry)
Color Scheme
Calculations…………….………….………….…………….………….…………. Mol Wt User Input
mass mass mass mass mass mass (kg/kmol) Fixed Input
Paraffins Calculation
CH4 887.4944 0 0 887.494413 887.521008 CH4 16.0426 Warning
C2H6 35.4826 0 0 35.4826029 35.4836662 C2H6 30.0694 Atomic Weights
C3H8 10.14233 0 0 10.1423292 10.1426331 C3H8 44.0962 Hydrogen 1.0079
C4H10 2.906208 0 0 2.90620823 2.90629531 C4H10 58.123 Carbon 12.011
C5H12 0.360756 0 0 0.36075623 0.36076704 C5H12 72.1498 Nitrogen 14.0067
C6H14 20.6828 0 0 20.6827984 20.6834182 C6H14 86.1766 Oxygen 15.9994
C7H16 0 0 0 0 0 C7H16 100.2034 Sulfur 32.066
C8H18 0 0 0 0 0 C8H18 114.2302 Argon 39.948
C9H20 0 0 0 0 0 C9H20 128.257
Olefins
C2H2 Acet 0 0 0 0 0 C2H2 Acetylene 26.0378
C2H4 0 0 0 0 0 C2H4 28.0536
C3H6 0 0 0 0 0 C3H6 42.0804
C4H8 Buten 0 0 0 0 0 C4H8 Butene 56.1072
C4H6 Butad 0 0 0 0 0 C4H6 Butadiene 54.0914
C5H10 0 0 0 0 0 C5H10 70.134
C6H12 He 0 0 0 0 0 C6H12 Hexene 84.1608
Naphthenes
C6H12 Cycl 0 0 0 0 0 C6H12 Cyclohexane 84.1608
Aromatics
C6H6 Benz 0 0 0 0 0 C6H6 Benzene 78.1134
Inerts & Others
CO 0 0 0 0 0 CO 28.0104
CO2 1102.908 4400.98 0 1102.90768 1102.94074 CO2 44.0098
N2 431.6951 0 0 431.695143 431.708079 N2 28.0134
Ar 0 0 0 0 0 Ar 39.948
H2 5.039601 0 201.58 5.03960097 5.03975199 H2 2.0158
NH3 Ammon 0 0 0 0 0 NH3 Ammonia 28.0134
H2O 0.053984 0 1801.52 0 0.05398406 H2O 18.0152
Total 2496.766 4400.98 1801.52 201.58 2496.76552 2496.78635 Convert degC to degK 273.151
2296.08458 kg/hr C
0.11 kg/hr C
0.09 kg/hr steam
6.59 ppm mol
19.396 kg/day S
S kg/hr
as S
S kg/hr
as S
S kg/hr
as S
S kg/hr
as S
% mass of
component
ppm wt of
component
H2S 0.646303 0 0 0.646303 0.01796189 179.6 H2S 34.0818
COS 0.161882 0 0 0.161882 0.00793043 79.3 COS 60.0764
CS2 0 0 0 0 0 0.0 CS2 76.143
Mercaptans
CH3SH 0 0 0 0 0 0.0 CH3SH 48.1086
C2H5SH 0 0 0 0 0 0.0 C2H5SH 62.1354
C3H7SH 0 0 0 0 0 0.0 C3H7SH 76.1622
n-C4H9SH 0 0 0 0 0 0.0 n-C4H9SH 90.189
i-C4H9SH 0 0 0 0 0 0.0 i-C4H9SH 90.189
C6H11SH 0 0 0 0 0 0.0 C6H11SH 118.2426
C6H5SH 0 0 0 0 0 0.0 C6H5SH 110.1794
RSH 0 0 0 0 0 0.0 RSH 48.1086
Sulfides
(CH3)2S 0 0 0 0 0 0.0 (CH3)2S 47.1007
(C2H5)2S 0 0 0 0 0 0.0 (C2H5)2S 61.1275
(C6H5)2S 0 0 0 0 0 0.0 (C6H5)2S 186.277
C6H5SC6H1 0 0 0 0 0 0.0 C6H5SC6H11 192.3244
R2S 0 0 0 0 0 0.0 R2S 47.1007
Disulfides
(CH3)2SS 0 0 0 0 0 0.0 (CH3)2SS 79.1667
(C2H5)2SS 0 0 0 0 0 0.0 (C2H5)2SS 93.1935
Thiophenes
(CH3)2C4H4S 0 0 0 0 0 0.0 (CH3)2C4H4S 114.211
C4H4S 0 0 0 0 0 0.0 C4H4S 84.1416
Other S as S 0 0 0 0 0 0.0 Other S as S 32.066
Total S as S 0.808185 0 0 0.808185 0.02589232 258.915415
Mixed Gas
(Dry)
NG CO2
Process
Steam
Mixed
Gas
Mixed Gas
(Dry)
Amount of S to be removed
Steam injection required for COS/CS2 hydrolysis
Sulphur concentration as H2S
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
HDS CATALYST
HDS Catalyst Volume Calculation : Nat Gas, Refinery Gases & LPG Feedstocks
See Vulcan Design Manual Section 1
Title: ACME Methanol
Total S to be treated 1.3 ppm mol 0.1619 kg/hr as S Estimated Catalyst volume 19.21 m
3
VULCAN™VHT-S101 recommended
Carbon Number 1.0000 Pressure correction
Revised Volume required 19.2 m
3
T-S101
Spillage allowance 2.00%
Order 19.6 m
3
VULCAN™VHT-S101
Guaranteed Life up to 3 years Catalyst Density 700 kg/m³
Expected Life 5 years Loaded weight 13445.03 kg
Bed Dimensions
Process Conditions Aspect ratio required Yes
Pressure 26.9 bara Gas Viscosity 0.000025 N.s/m2
0.025 cP Bed diameter 3.300 m
Temperature 370 degC Gas Density 12.560 kg/m³ Bed height 2.246 m 19.21
Flowrate (Dry Gas) 85720 Nm
3
/hr Molecular Weight 24.968 kg/kmole Actual Aspect Ratio (L/D) 0.681
Flowrate (Wet Gas) 85722 Nm
3
/hr Mass flux 3.101 kg/s m2
Steam: Dry Gas ratio 3E-05 Velocity Head 0.383 kg/m s2
2.00% per year bar kg/cm2
psi
Reynolds Number #N/A Bed PD after settling = #N/A #N/A #N/A
Bed friction factor #N/A 1 year = #N/A #N/A #N/A
Compute Desired Space Velocity 2 years = #N/A #N/A #N/A
Space Velocity 4463 hr-1 3 years = #N/A #N/A #N/A
Catalyst Parameters 4 years = #N/A #N/A #N/A
Bed Voidage #N/A Calculate the equivalent sphere diameter for the pellet 5 years = #N/A #N/A #N/A
Pellet Diameter #N/A mm Area #N/A mm
2
6 years = #N/A #N/A #N/A
Pellet Length #N/A mm Volume #N/A mm
3
7 years = #N/A #N/A #N/A
# holes #N/A #N/A m 8 years = #N/A #N/A #N/A
Hole diameter #N/A 9 years = #N/A #N/A #N/A
Pellet voidage #N/A 10 years = #N/A #N/A #N/A
Assuming a particle breakage of
Olefins hydrogenation is not a problem
Feed classified as
HDS not required
Beware possible Methanation reaction - Temp rise = 1,504 degC based on [CO]+[CO2]
Bed PD after
Bed PD after
Bed PD after
Same vessel as ZnO bed?
Bed PD after
Bed PD after
Bed PD after
Bed PD after
Recycle Hydrogen OK
Refinery Off Gas
Bed PD after
Bed PD after
Diameter Equiv Sphere
Bed PD after
CHLORIDE GURAD
Chloride Guard Catalyst Volume Calculation : Nat Gas, Refinery Gases & LPG Feedstocks
See Catalyst Design Manual Section 2
Title: ACME Methanol
ppm mol Mass equivalent 0.0 ppm wt Estimated Catalyst volume 0.00 m
3
VULCAN™ VGP CRT-3000 recommended
ppm wt Molar equivalent 0.0 ppm mol Design HCl pickup capacit kg Cl/ m3
absorbent
Life required 365 days Spillage allowance 2.00%
Lead/Lag? (Y/N) Yes Catalyst Volume Correction Factor 0 Order 0.0 m
3
VULCAN™ VGP CRT-3000
Process Conditions
Pressure 33.75 bara Gas Viscosity 0.000025 N.s/m2 0.025 cP Guaranteed Life #DIV/0! months
Temperature 380 degC Gas Density 15.517 kg/m³ Expected Life #DIV/0! months
Molecular Weight 24.968 kg/kmole Guaranteed Slip 0.10 ppm mol
Flowrate (Dry Gas) 85720 Nm3/hr Mass flux 3.101 kg/s m2 Expected Slip 0.01 ppm mol
Flowrate (Wet Gas) 85722 Nm3/hr Velocity Head 0.310 kg/m s2
Reynolds Number #N/A Pressure Drop prediction
Bed friction factor #N/A 2.00% per year bar kg/cm2
psi
Bed Dimensions Bed PD after settling = #N/A #N/A #N/A
Aspect Ratio desired 0.463 Catalyst Density 900 kg/m³ 1 year = #N/A #N/A #N/A
Bed diameter 3.300 m Loaded weight 0 kg 0.00 2 years = #N/A #N/A #N/A
Bed height 0.000 m Space Velocity #DIV/0! hr-1
3 years = #N/A #N/A #N/A
Actual Aspect Ratio (L/D) 0.000 4 years = #N/A #N/A #N/A
5 years = #N/A #N/A #N/A
Absorbent Parameters 6 years = #N/A #N/A #N/A
Bed Voidage #N/A Calculate the equivalent sphere diameter for the pellet 7 years = #N/A #N/A #N/A
Pellet Diameter #N/A mm Area #N/A mm
2
8 years = #N/A #N/A #N/A
Pellet Length #N/A mm Volume #N/A mm
3
9 years = #N/A #N/A #N/A
# holes #N/A
Diameter Equiv
S h
#N/A m 10 years = #N/A #N/A #N/A
Hole diameter #N/A
Pellet voidage #N/A
Guard Volume 17.14 m
3
VULCAN™ VGP CRT-3000
Guard Volume Life #DIV/0! months
Bed PD after
Bed PD after
Bed PD after
Bed PD after
Bed PD after
#DIV/0!
Total Chloride to be treated
Bed PD after
Bed PD after
Assuming a particle breakage of
Bed PD after
Bed PD after
Bed PD after
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
ZNO ABSORBENT BEDS
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
APPENDIX: Vulcan Hybrid Purification Systems
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
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METHANOL PLANT - SHALE GAS FEED PRETREATMENT

  • 1. GBH Enterprises, Ltd. METHANOL PLANT - SHALE GAS FEED PRETREATMENT CASE STUDY #091406 Process Information Disclaimer Information contained in this publication or as otherwise supplied to Users is believed to be accurate and correct at time of going to press, and is given in good faith, but it is for the User to satisfy itself of the suitability of the Product for its own particular purpose. GBHE gives no warranty as to the fitness of the Product for any particular purpose and any implied warranty or condition (statutory or otherwise) is excluded except to the extent that exclusion is prevented by law. GBHE accepts no liability for loss, damage or personnel injury caused or resulting from reliance on this information. Freedom under Patent, Copyright and Designs cannot be assumed. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 2. Case Background A Methanol plant operator would like to examine the technical feasibility of using Shale Gas as a feedstock to their Methanol plant. The first step in the Methanol production process is gas pretreatment. The purpose of gas pretreatment is to make the gas suitable for the downstream processes. There are two groups of compounds that are usually present in natural gas and that should be removed during pretreatment—the associate NGL and the sulfur-containing compounds. Some natural gas reservoirs may also have other trace components that must be removed, but these are not discussed here. Desulfurization of Proposed Shale Gas In large-scale Methanol facilities, desulfurization is typically performed by passing the natural gas with a co-feed of hydrogen (H2) over a hydrotreating catalyst, followed by desulfurization over a packed bed of porous “mixed-metal”- containing zinc oxide (ZnO). The initial hydrotreating step is necessary to convert sulfur in mercaptan (thiol) and sulfide (thioether) compounds to hydrogen sulfide (H2S). The ZnO reacts with H2S to capture the sulfur as zinc sulfide (ZnS), and the packed bed is typically operated at 350°C–400°C. Once the packed bed reaches capacity, the ZnS can be regenerated by controlled oxidation. It is, therefore, customary to apply two packed beds in series lead-lag. Selecting ZnO-based desulfurization technology for methanol plants has some implications: • A source of pure H2 is required as utility. The issue is not H2 availability, but rather the need to include an H2 purification unit, or an external source of pure H2 in the design. • During regeneration, a sulfur-dioxide-(SO2)-rich offgas is produced as effluent. Depending on the location, the offgas can be disposed of through a stack, or it can require gas treatment before release. Other gas treatment strategies will have different requirements and implications. For example, spent methanol synthesis catalyst makes a good sulfur trap. Gas treatment and spent methanol synthesis catalyst disposal can be integrated, instead of using ZnO. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 3. This case study examines the impact of CO2 (Carbon Dioxide) on the pre- treatment section design, performance and efficiency of ACME Methanol Plant’ feed gas pre-treatment section. Case 1: Normal Shale Gas Case 2: “Bad Gas” Case 3: Low CO2 Case 4: High CO2 Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 4. HDS VESSEL Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 5. ZNO VESSEL Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 6. Purification Calculation Summary: [Cases 1 – 4 Cross Checks] Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 7. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 8. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 9. APPENDIX FEEDSTOCK CHARACTERIZATION Component Units NG CO2 Process Steam Recycle NG CO2 Recycle Stream Stream Stream Stream Stream Stream Data from Stream Mixer mol% mol% mol% mol% mol% mol% mol% mol% kmol/hr mol % kmol/hr Paraffins Note: Okay Okay Okay Okay CH4 mol% 55.32 55.32 0.00 0.00 55.321 2115.76 55.323 2115.76 C2H6 mol% 1.18 1.18 0.00 0.00 1.180 45.130 1.180 45.130 C3H8 mol% 0.23 0.23 0.00 0.00 0.230 8.797 0.230 8.797 C4H10 mol% 0.05 0.05 0.00 0.00 0.050 1.912 0.050 1.912 C5H12 mol% 0.01 0.01 0.00 0.00 0.005 0.191 0.005 0.191 C6H14 mol% 0.24 0.24 0.00 0.00 0.240 9.179 0.240 9.179 C7H16 mol% 0.00 0.00 0.00 0.000 0.000 0.000 0.000 C8H18 mol% 0.00 0.00 0.00 0.000 0.000 0.000 0.000 C9H20 mol% 0.00 0.00 0.00 0.000 0.000 0.000 0.000 Olefins C2H2 Acetylene mol% 0.00 0.00 0.00 0.000 0.000 0.000 0.000 C2H4 mol% 0.00 0.00 0.00 0.000 0.000 0.000 0.000 C3H6 mol% 0.00 0.00 0.00 0.000 0.000 0.000 0.000 C4H8 Butene mol% 0.00 0.00 0.00 0.000 0.000 0.000 0.000 C4H6 Butadiene mol% 0.00 0.00 0.00 0.000 0.000 0.000 0.000 C5H10 mol% 0.00 0.00 0.00 0.000 0.000 0.000 0.000 C6H12 Hexene mol% 0.00 0.00 0.00 0.000 0.000 0.000 0.000 Naphthenes C6H12 Cyclohexane mol% 0.00 0.00 0.00 0.000 0.000 0.000 0.000 Aromatics C6H6 Benzene mol% 0.00 0.00 0.00 0.000 0.000 0.000 0.000 Inerts & Others CO mol% 0.00 0.00 0.00 0.00 0.000 0.000 0.000 0.000 CO2 mol% 25.06 100.00 25.06 100.00 0.00 25.061 958.439 25.061 958.439 N2 mol% 15.41 15.41 0.00 0.00 15.410 589.367 15.411 589.367 Ar mol% 0.00 0.00 0.00 0.00 0.000 0.000 0.000 0.000 H2 mol% 2.50 100 2.50 0.00 100.00 2.500 95.614 2.500 95.614 NH3 Ammonia mol% 0.00 0.00 0.00 0.00 0.000 0.000 0.000 0.000 H2O mol% 0.00 100 0.00 0.00 0.00 0.003 0.115 Total 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 3824.50 100.00 3824.39 Organic Carbon Factor 0.6004 0.0000 0.0000 0.0000 0.6004 0.0000 0.0000 0.6004 0.6004 0.6004 0.6004 Inorganic Carbon Factor 0.8510 1.0000 0.0000 0.0000 0.8510 1.0000 0.0000 0.8510 10.1848 0.8510 10.1848 Molecular Weight kg/kmol 24.9677 44.0098 18.0152 2.0158 24.9677 44.0098 2.0158 24.9677 24.9677 24.9679 24.9679 Error Warning Note: Okay Okay Okay Okay Flowrate Nm³/hr Flowrate kg/hr Flowrate kmol/hr 3824.5 0 0 29.966 Gas Flowrate Nm3 /hr 85722 0 0 0 85722 0 0 85722 85720 kg/hr 95488.8 0.0 0.0 0.0 95488.8 0.0 0.0 95488.8 95486.7 kmol/hr 3824.5 0.0 0.0 0.0 3824.5 0.0 0.0 3824.50 3824.39 Calculated Steam to Carbon mol/mol 0.0000 Model C5's + as C4's No C5's + as C4's mol% 0.00 0.00 0.00 0.000 0.000 New C4 Flowrate kmol/hr 0.00 0.00 0.00 1.912 1.912 New Total Flowrate kmol/hr 3815.13 3815.02 Total Total Total Total Sulfur Speciation Note: ppm mol ppm mol ppm mol ppm mol mg S/Nm3 mol % component kmol/hr H2S ppm v 5.27 5.270 0.000 0.000 5.270 7.5 0.000527 0.020155 COS ppm v 1.32 1.320 0.000 0.000 1.320 1.9 0.000132 0.005048 CS2 ppm v 0.000 0.000 0.000 0.000 0.0 0.000000 0.000000 Mercaptans CH3SH ppm v 0.000 0.000 0.000 0.000 0.0 0.000000 0.000000 C2H5SH ppm v 0.000 0.000 0.000 0.000 0.0 0.000000 0.000000 C3H7SH ppm v 0.000 0.000 0.000 0.000 0.0 0.000000 0.000000 n-C4H9SH ppm v 0.000 0.000 0.000 0.000 0.0 0.000000 0.000000 Mixed Gas (Wet) Mixed Gas (Dry) Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 10. NG CO2 Process Steam Recycle Mixed Gas (Wet) Mixed Gas (Dry) Color Scheme Calculations…………….………….………….…………….………….…………. Mol Wt User Input mass mass mass mass mass mass (kg/kmol) Fixed Input Paraffins Calculation CH4 887.4944 0 0 887.494413 887.521008 CH4 16.0426 Warning C2H6 35.4826 0 0 35.4826029 35.4836662 C2H6 30.0694 Atomic Weights C3H8 10.14233 0 0 10.1423292 10.1426331 C3H8 44.0962 Hydrogen 1.0079 C4H10 2.906208 0 0 2.90620823 2.90629531 C4H10 58.123 Carbon 12.011 C5H12 0.360756 0 0 0.36075623 0.36076704 C5H12 72.1498 Nitrogen 14.0067 C6H14 20.6828 0 0 20.6827984 20.6834182 C6H14 86.1766 Oxygen 15.9994 C7H16 0 0 0 0 0 C7H16 100.2034 Sulfur 32.066 C8H18 0 0 0 0 0 C8H18 114.2302 Argon 39.948 C9H20 0 0 0 0 0 C9H20 128.257 Olefins C2H2 Acet 0 0 0 0 0 C2H2 Acetylene 26.0378 C2H4 0 0 0 0 0 C2H4 28.0536 C3H6 0 0 0 0 0 C3H6 42.0804 C4H8 Buten 0 0 0 0 0 C4H8 Butene 56.1072 C4H6 Butad 0 0 0 0 0 C4H6 Butadiene 54.0914 C5H10 0 0 0 0 0 C5H10 70.134 C6H12 He 0 0 0 0 0 C6H12 Hexene 84.1608 Naphthenes C6H12 Cycl 0 0 0 0 0 C6H12 Cyclohexane 84.1608 Aromatics C6H6 Benz 0 0 0 0 0 C6H6 Benzene 78.1134 Inerts & Others CO 0 0 0 0 0 CO 28.0104 CO2 1102.908 4400.98 0 1102.90768 1102.94074 CO2 44.0098 N2 431.6951 0 0 431.695143 431.708079 N2 28.0134 Ar 0 0 0 0 0 Ar 39.948 H2 5.039601 0 201.58 5.03960097 5.03975199 H2 2.0158 NH3 Ammon 0 0 0 0 0 NH3 Ammonia 28.0134 H2O 0.053984 0 1801.52 0 0.05398406 H2O 18.0152 Total 2496.766 4400.98 1801.52 201.58 2496.76552 2496.78635 Convert degC to degK 273.151 2296.08458 kg/hr C 0.11 kg/hr C 0.09 kg/hr steam 6.59 ppm mol 19.396 kg/day S S kg/hr as S S kg/hr as S S kg/hr as S S kg/hr as S % mass of component ppm wt of component H2S 0.646303 0 0 0.646303 0.01796189 179.6 H2S 34.0818 COS 0.161882 0 0 0.161882 0.00793043 79.3 COS 60.0764 CS2 0 0 0 0 0 0.0 CS2 76.143 Mercaptans CH3SH 0 0 0 0 0 0.0 CH3SH 48.1086 C2H5SH 0 0 0 0 0 0.0 C2H5SH 62.1354 C3H7SH 0 0 0 0 0 0.0 C3H7SH 76.1622 n-C4H9SH 0 0 0 0 0 0.0 n-C4H9SH 90.189 i-C4H9SH 0 0 0 0 0 0.0 i-C4H9SH 90.189 C6H11SH 0 0 0 0 0 0.0 C6H11SH 118.2426 C6H5SH 0 0 0 0 0 0.0 C6H5SH 110.1794 RSH 0 0 0 0 0 0.0 RSH 48.1086 Sulfides (CH3)2S 0 0 0 0 0 0.0 (CH3)2S 47.1007 (C2H5)2S 0 0 0 0 0 0.0 (C2H5)2S 61.1275 (C6H5)2S 0 0 0 0 0 0.0 (C6H5)2S 186.277 C6H5SC6H1 0 0 0 0 0 0.0 C6H5SC6H11 192.3244 R2S 0 0 0 0 0 0.0 R2S 47.1007 Disulfides (CH3)2SS 0 0 0 0 0 0.0 (CH3)2SS 79.1667 (C2H5)2SS 0 0 0 0 0 0.0 (C2H5)2SS 93.1935 Thiophenes (CH3)2C4H4S 0 0 0 0 0 0.0 (CH3)2C4H4S 114.211 C4H4S 0 0 0 0 0 0.0 C4H4S 84.1416 Other S as S 0 0 0 0 0 0.0 Other S as S 32.066 Total S as S 0.808185 0 0 0.808185 0.02589232 258.915415 Mixed Gas (Dry) NG CO2 Process Steam Mixed Gas Mixed Gas (Dry) Amount of S to be removed Steam injection required for COS/CS2 hydrolysis Sulphur concentration as H2S Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 11. HDS CATALYST HDS Catalyst Volume Calculation : Nat Gas, Refinery Gases & LPG Feedstocks See Vulcan Design Manual Section 1 Title: ACME Methanol Total S to be treated 1.3 ppm mol 0.1619 kg/hr as S Estimated Catalyst volume 19.21 m 3 VULCAN™VHT-S101 recommended Carbon Number 1.0000 Pressure correction Revised Volume required 19.2 m 3 T-S101 Spillage allowance 2.00% Order 19.6 m 3 VULCAN™VHT-S101 Guaranteed Life up to 3 years Catalyst Density 700 kg/m³ Expected Life 5 years Loaded weight 13445.03 kg Bed Dimensions Process Conditions Aspect ratio required Yes Pressure 26.9 bara Gas Viscosity 0.000025 N.s/m2 0.025 cP Bed diameter 3.300 m Temperature 370 degC Gas Density 12.560 kg/m³ Bed height 2.246 m 19.21 Flowrate (Dry Gas) 85720 Nm 3 /hr Molecular Weight 24.968 kg/kmole Actual Aspect Ratio (L/D) 0.681 Flowrate (Wet Gas) 85722 Nm 3 /hr Mass flux 3.101 kg/s m2 Steam: Dry Gas ratio 3E-05 Velocity Head 0.383 kg/m s2 2.00% per year bar kg/cm2 psi Reynolds Number #N/A Bed PD after settling = #N/A #N/A #N/A Bed friction factor #N/A 1 year = #N/A #N/A #N/A Compute Desired Space Velocity 2 years = #N/A #N/A #N/A Space Velocity 4463 hr-1 3 years = #N/A #N/A #N/A Catalyst Parameters 4 years = #N/A #N/A #N/A Bed Voidage #N/A Calculate the equivalent sphere diameter for the pellet 5 years = #N/A #N/A #N/A Pellet Diameter #N/A mm Area #N/A mm 2 6 years = #N/A #N/A #N/A Pellet Length #N/A mm Volume #N/A mm 3 7 years = #N/A #N/A #N/A # holes #N/A #N/A m 8 years = #N/A #N/A #N/A Hole diameter #N/A 9 years = #N/A #N/A #N/A Pellet voidage #N/A 10 years = #N/A #N/A #N/A Assuming a particle breakage of Olefins hydrogenation is not a problem Feed classified as HDS not required Beware possible Methanation reaction - Temp rise = 1,504 degC based on [CO]+[CO2] Bed PD after Bed PD after Bed PD after Same vessel as ZnO bed? Bed PD after Bed PD after Bed PD after Bed PD after Recycle Hydrogen OK Refinery Off Gas Bed PD after Bed PD after Diameter Equiv Sphere Bed PD after CHLORIDE GURAD Chloride Guard Catalyst Volume Calculation : Nat Gas, Refinery Gases & LPG Feedstocks See Catalyst Design Manual Section 2 Title: ACME Methanol ppm mol Mass equivalent 0.0 ppm wt Estimated Catalyst volume 0.00 m 3 VULCAN™ VGP CRT-3000 recommended ppm wt Molar equivalent 0.0 ppm mol Design HCl pickup capacit kg Cl/ m3 absorbent Life required 365 days Spillage allowance 2.00% Lead/Lag? (Y/N) Yes Catalyst Volume Correction Factor 0 Order 0.0 m 3 VULCAN™ VGP CRT-3000 Process Conditions Pressure 33.75 bara Gas Viscosity 0.000025 N.s/m2 0.025 cP Guaranteed Life #DIV/0! months Temperature 380 degC Gas Density 15.517 kg/m³ Expected Life #DIV/0! months Molecular Weight 24.968 kg/kmole Guaranteed Slip 0.10 ppm mol Flowrate (Dry Gas) 85720 Nm3/hr Mass flux 3.101 kg/s m2 Expected Slip 0.01 ppm mol Flowrate (Wet Gas) 85722 Nm3/hr Velocity Head 0.310 kg/m s2 Reynolds Number #N/A Pressure Drop prediction Bed friction factor #N/A 2.00% per year bar kg/cm2 psi Bed Dimensions Bed PD after settling = #N/A #N/A #N/A Aspect Ratio desired 0.463 Catalyst Density 900 kg/m³ 1 year = #N/A #N/A #N/A Bed diameter 3.300 m Loaded weight 0 kg 0.00 2 years = #N/A #N/A #N/A Bed height 0.000 m Space Velocity #DIV/0! hr-1 3 years = #N/A #N/A #N/A Actual Aspect Ratio (L/D) 0.000 4 years = #N/A #N/A #N/A 5 years = #N/A #N/A #N/A Absorbent Parameters 6 years = #N/A #N/A #N/A Bed Voidage #N/A Calculate the equivalent sphere diameter for the pellet 7 years = #N/A #N/A #N/A Pellet Diameter #N/A mm Area #N/A mm 2 8 years = #N/A #N/A #N/A Pellet Length #N/A mm Volume #N/A mm 3 9 years = #N/A #N/A #N/A # holes #N/A Diameter Equiv S h #N/A m 10 years = #N/A #N/A #N/A Hole diameter #N/A Pellet voidage #N/A Guard Volume 17.14 m 3 VULCAN™ VGP CRT-3000 Guard Volume Life #DIV/0! months Bed PD after Bed PD after Bed PD after Bed PD after Bed PD after #DIV/0! Total Chloride to be treated Bed PD after Bed PD after Assuming a particle breakage of Bed PD after Bed PD after Bed PD after Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 12. ZNO ABSORBENT BEDS Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 13. APPENDIX: Vulcan Hybrid Purification Systems Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 14. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 15. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 16. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 17. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com
  • 18. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com