PAGE 2 OF 46

Case 1 - Normal Operation

Stream Number 0015 0016 0017 0018 0019 0020 0021 0023 0024 0025
WASH WATER OVHD VAPOR OVHD VAPOR LIQUID EXCESS REFLUX OFFGASES REBOILER REBOILER LEAN AMINE
TO FROM FROM FROM WATER TO TO TO (2-EA-002) (2-EA-002) FROM
2-DA-002 2-DA-002 2-EC-002 2-FA-001 OSBL 2-DA-002 INCINERATOR INLET OUTLET 2-EA-004

Case 1A 1A 1A 1A 1A 1A 1A 1A 1A 1A

Phase LIQUID VAPOR MIXED LIQUID LIQUID LIQUID VAPOR LIQUID MIXED LIQUID
mole %
METHANE 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
ETHANE 0.00 0.06 0.06 0.00 0.00 0.00 0.16 0.00 0.00 0.00
PROPANE 0.00 0.01 0.01 0.00 0.00 0.00 0.02 0.00 0.00 0.00
BUTANE 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
CARBON DIOXIDE 0.00 35.19 35.19 0.05 0.05 0.04 90.71 1.67 3.39 1.35
HYDROGEN SULFIDE 0.00 0.02 0.02 0.00 0.00 0.00 0.05 0.00 0.00 0.00
STEAM/WATER 99.99 64.69 64.69 99.91 99.91 99.92 9.05 88.11 96.56 86.52
DIGLYCOL AMINE 0.01 0.02 0.02 0.04 0.04 0.03 0.00 10.21 0.06 12.13

Mass Flow kg/hr 2,004 40,247 40,247 16,370 424 17,950 23,876 253,575 253,575 377,623
Molar Flow kg-mol/hr 111.15 1,479.72 1,479.72 906.18 23.48 993.85 573.53 9,270.43 9,270.43 13,049.04
Molecular Weight 18.03 27.19 27.19 18.07 18.07 18.06 41.62 27.35 18.94 28.94
Temperature °C 50.1 107.7 57.0 57.0 57.0 57.0 57.0 123.2 124.7 52.0
Pressure kg/cm2g 3.950 0.820 0.570 0.570 1.000 0.830 0.570 0.950 0.920 6.400

Vapor
Flow, mass kg/hr 0 40,247 23,876 0 0 0 23,876 0 50,712 0
Am3/hr 0 25,801 10,078 0 0 0 10,078 0 41,212 0
Molecular Weight 0.00 27.19 41.62 0.00 0.00 0.00 41.62 0.00 18.95 0.00
Density kg/m3 0.00 1.56 2.37 0.00 0.00 0.00 2.37 0.00 1.23 0.00
Viscosity cP 0.000 0.016 0.016 0.000 0.000 0.000 0.016 0.000 0.014 0.000
Cp/Cv 0.000 1.310 1.280 0.000 0.000 0.000 1.280 0.000 1.280 0.000
Compressibility 0.000 0.991 0.993 0.000 0.000 0.000 0.993 0.000 0.985 0.000

Liquid
Flow, mass kg/hr 2,004 0 16,370 16,370 424 17,950 0 253,575 202,863 377,623
m3/hr 2.03 0.00 16.58 16.58 0.43 18.67 0.00 260.07 209.29 363.79
Molecular Weight 18.03 0.00 18.07 18.07 18.07 18.06 0.00 27.35 29.01 28.94
Density kg/m3 986.0 0.0 987.2 987.2 987.2 961.7 0.0 975.0 969.3 1,038.0
Viscosity cP 1.01 0.00 0.52 0.52 0.52 0.52 0.00 0.39 0.40 1.67
Surface Tension dyne/cm 69.280 0.000 67.790 67.790 66.470 66.930 0.000 45.200 45.200 48.100

150898847-2.XLS ABB LUMMUS GLOBAL REV. 1

3.1.1 Interlock Description

Refer Appendix 9.5 for detailed interlock description of Ethylene Plant &
utilities.

3.2 Mercury Removal and Amine Treatment

3.2.1 Description

The feedstock contains a small amount of mercury, which can be removed in

the Mercury Removal Beds (2-FD-201A/B). The Mercury Removal Beds
(2-FD-201A/B) are located upstream of the amine absorber (2-DA-001). The
function of the Mercury Removal Beds is to absorb mercury from the C2/C3 feed
gas. Any mercury present in the C2/C3 feed gas, if allowed to pass into the
chilling train, would deposit in the brazed aluminum exchangers used in the
cold box, forming an aluminum-mercury amalgam. This mercury attack could
cause breach of pressure containment in the core exchangers, requiring
replacement of the cold box. There are two mercury removal carbon beds. One
is operating while the other is on standby. When the activated carbon bed life
expires, it must be disposed off and a new load of adsorbent must be utilized.
This can be done by switching operation to the equipment that is on standby.
The spent activated carbon can be discharged into drums or other suitable type
of container.

The feedstock contains a significant amount of carbon dioxide (CO2) as well as

some hydrogen sulfide (H2S) which is removed in the amine system using a
DGA solution.

The feedstock is contacted with a 45 wt% diglycolamine (DGA) solution in

countercurrent flow in the Acid Gas Absorber (2-DA-001). The treated
feedstock is then washed with water (condensate from the HP Steam
Blowdown Condensate Cooler 2-EA-131) in the top section of the absorber, to

Page 243 of 1363

 SECTION 3 - OPERATING VARIABLES & CONTROL

prevent DGA carryover, and then sent to the Cracking Heaters. The feedstock
leaves the absorber with the CO2 reduced down to a level of 100 ppmw and
saturated with water at the absorber temperature and pressure. The rich DGA
solution leaving the bottom of the absorber is heat exchanged with lean DGA,
stripped of CO2 and H2S in the Amine Stripper (2-DA-002), cooled and recycled
back to the absorber. The Amine Stripper operates at the lowest possible
pressure based on the operating pressure of the incinerator. The tower utilizes
air as the condensing medium and low pressure steam as the heating medium.
The desorbed light hydrocarbons and steam are routed to the incinerator
where they are burned. Provisions are included to remove any contaminants in
the DGA solution via the Amine Reclaimer (2-EA-003). This exchanger is used
to perform batch evaporation of the lean DGA, leaving behind the
contaminants to be disposed.

Make-up DGA is available to replace any DGA losses in the system. In order to
insure the stable operation of the system over the required plant run length,
antifoam injection will be used and a 20% slipstream of the lean amine solution
will be continuously filtered.

3.2.2 Operating Variable & Controls

The C2/C3 fresh feed coming from OSBL is send to mercury removal bed
(2-FD-201A/B) in order to remove traces of mercury. The inlet and outlet
mercury in the feed will be analysed by 2-AI-2013A/B. C2/C3 feed free from
mercury at ambient temperature, enters the bottom of the Acid Gas Absorber
(2-DA-001) on pressure control (2-PC-1077) to maintain the feedstock header
pressure. It passes first through the Feed K.O. Drum (2-FA-002) where any
condensate present will be separated and sent to the Wet Flare Drum on level
control (2-LC-0003). It then flows up through the column which is two beds
packed column. CO2 and H2S in the C2/C3 feedstock are removed by
countercurrent contact with 45 wt. % DGA solution recycled from the Amine

Page 244 of 1363

Stripper (2-DA-002) on flow control (2-FC-0006). The lean amine solution,
which is somewhat warmer than the feed gas to preclude the possibility of
condensing hydrocarbons in the solution, enters the Acid Gas Absorber below
the wash water draw-off tray. As it flows through the column, CO2 and H2S are
absorbed into the amine solution.

The heat of absorption raises the temperature of the solution as it flows down
the tower. The treated feedstock is passed through a demister pad and enters
the wash section at the top of the tower. The water wash section has three
bubble cap trays. Phosphate free boiler feed water (BFW) enters the top tray
on flow control (2-FC-0001) and flows countercurrent to the upward feedstock
flow to remove trace amounts of amine from it. The liquid from the water wash
section sump is sent on level control (2-LC-0001) to the Amine Stripper,
entering at the reflux line. In order to recover trace amounts of DGA in the
water, the C2/C3 vapor saturated with water is passed through a second
demister pad before going to the Ethane Feed Preheater (2-EA-130). A CO2
analyzer (2-AI-0003) is provided on this stream and another CO2 analyzer
(2-AI-0001) is provided on the C2/C3 feed line to the Acid Gas Absorber to
monitor the absorber performance.

Rich amine solution, containing up to 0.40 moles of CO2 per mole of DGA is
drawn from the sump of the Acid Gas Absorber on level control (2-LC-0005).
The pressure of the solution is reduced across the absorber level control valve
immediately before entering the Amine Stripper above the inlet distributor.
The rich amine solution increases in temperature as it passes through the
Lean/Rich amine Interchanger (2-EA-001A/B), entering the stripper at
101.7°C. As the solution flows down through the column, it contacts up flowing
steam stripping. This section of the stripper consists of two packed beds. Below
packed beds, lean amine solution is collected and drawn off to the Amine
Stripper Reboiler (2-EA-002A/B/C) which operates under thermosyphon
action. The Reboiler heating medium is desuperheated LP steam, which enters

Page 245 of 1363

on flow control (2-FC-0012) reset by the stripper overhead temperature
(2-TC-0015). Desuperheated steam is used to minimize amine degradation.
Hot solution at 124.7°C is returned to the base of the Stripper while the
stripping steam vapor produced in the reboiler flows back up the column.
Condensation of this steam supplies heat of desorption of CO2 from the rich
amine solution, while supplying sensible heat to the amine in the stripper
bottoms solution. The remainder of the steam is stripping vapor which dilutes
the vapor phase and lowers the partial pressure of CO2 to assist the stripping of
CO2 from the solution. The overhead temperature and pressure are controlled
to keep the CO2 partial pressure at its optimum value.

The lean amine solution from the bottom of the Amine Stripper flows through
the Lean/Rich Amine Interchanger (2-EA-001,A,B) is pumped back to the Acid
Gas Absorber on flow control (2-FC-0006) and cooled down to 57°C in the Lean
Amine Cooler (2-EC-001A/B) where the cooling medium is air, and then is
cooled further to 52°C in the Lean Amine Trim Cooler (2-EA-004) where the
cooling medium is cooling water.

The stripper overhead product, CO2 and water vapor, is cooled and partially
condensed in the Amine Stripper Condenser (2-EC-002A/B), then enters the
Amine Stripper Reflux Drum (2-FA-001). The liquid from this reflux drum is
returned as reflux on flow control (2-FC-0011) with reset from the reflux drum
level controller (2-LC-0010) to the Amine Stripper top liquid distributor, which
is located above the top tray. The excess condensate is sent to waste water
treatment on flow control (2-FC-0014). The stripper overhead pressure is
controlled by venting the CO2 to the incinerator through the "B" pressure
controller (2-PC-0023) on high pressure, or drawing in nitrogen through the
"A" pressure controller (2-PC-0023) on low pressure. The Amine Reclaimer
(2-EA-003) is a kettle type heat exchanger which removes solution heat stable
salts, along with decomposition and degradation products from the circulating
amine. The reclaimer processes, in a semi-continuous operation, a slip stream

Page 246 of 1363

(approx. 2%) of lean amine which enters from the stripper bottom on level
control (2-LC-0008). Caustic solution is manually added to the reclaimer feed
to decompose any heat stable salts. The reclaimer can also process a slip
stream from the Amine Sump or the Amine Storage tank. The reclaimer utilizes
saturated HP steam, which enters on flow control (2-FC-0010) as the heating
medium to vaporize the liquid in this kettle. Due to accumulation of sludge and
decomposition by-products, the boiling temperature increases with time.
When the temperature reaches 143°C, the feed and HP steam are turned off
and desuperheated LP steam is introduced to remove the remaining free DGA.
Finally, the reclaimer is removed from service and cleaned with BFW. The
resulting sludge is discharged into drums for disposal via the drain valves. A
slip stream (approx. 20%) is manually taken from the discharge of the Lean
Amine Circulating Pumps (2-GA-001A/B) and directed through the Amine
Prefilter (2-FD-004) and Amine Filter (2-FD-001). These are followed by a
Mechanical Filter (2-FD-002) to catch any particles from the carbon filter. The
Amine Prefilter (2-FD-004) & Amine Filter (2-FD-001) contains a bed of
activated carbon and is provided to remove suspended solids such as salts,
corrosion products and polymers. The Amine Mechanical Filter (2-FD-002) is a
bag-type filter and is provided to remove any activated carbon fines as well as
some particulates in the amine solution. The filtered amine rejoins the
circulation loop. The amine filter has provisions for manual back flushing using
steam condensate as necessary. Normally the backwashing is required at
startup or at bed replacement. Occasionally, it is advantageous to backwash
during normal operation to prolong the carbon bed life. The Antifoam Injection
System (2-PA-003) injects antifoam agent as needed by adjusting the
injection pump stroke into the suction line of the Lean Amine Circulation Pump,
and into the reflux line to the Amine Stripper to assure Acid Gas Absorber and
Amine Stripper capacity and efficiency. The amine storage system consists of
Amine Storage Tank (2-FB-001) and Amine Makeup Pump (2-GA-003A/B).

Page 247 of 1363

Concentrated DGA is received from an outside source into the storage tank and
then blended with BFW to provide the 45% amine solution for the system. The
tank which operates under a slight positive pressure using nitrogen is sized to
provide storage for the system inventory which enters from the Lean Amine
Circulation Pump discharge during the shutdown periods for system cleanout,
maintenance, etc. The amine solution is then pumped to the lean amine
solution leaving the Stripper. The Amine Makeup Pump is also used to mix the
contents of the storage tank and to send spent amine solution to the reclaimer
for recovery of DGA. The Amine Sump Tank (2-FB-002) and Amine Sump
Pump (2-GA-004) are supplied to receive and dispose of amine from the amine
drain system. The sump tank operates under a slight positive pressure using
nitrogen and is provided with internal steam heating coils. The spent amine
from the sump pump can either be routed to the Amine Storage Tank if clean,
to the reclaimer for recovery of DGA or to drums for disposal.

CAUTION: (HAZOP Recommendation No. 24)

The operator should never change the set point of PC-0049 below the
maximum back pressure of wet flare header.

Page 248 of 1363

3.2.3 Normal Operating Conditions:

Pressure,
Service Temperature, °C Flow, kg/hr
kg/cm2g

Case Case 2 Cases 1&2 Case 1 Case2

C2/C3 Feed 30.0 30.0 6.58 104,368 98,071

2-DA-001 Overhead 44.0 44.0 6.23 82,176 76,482

2-DA-001 Bottom 78.6 78 6.58 399,919 399,477

Lean Amine 52.0 52.0 6.4 377,623 377,787

Wash Water In 41.0 41.0 9.47 2,108 2036

Wash Water Out 41.0 41.0 6.25 2,004 1,935

2-DA-002 Overhead 107.7 107.7 0.67 40,247 39,108

2-DA-002 Bottom 124.7 124.6 0.92 377,623 377,787

Rich Amine Feed 101.7 101.9 0.81 399,919 399,477

Reflux to 2-DA-002 57 57 0.75 15946 15472

Total Reflux to
57 57 0.83 17,950 17,408
2-DA-002

Amine Stripper Reflux

57 57 0.57 40,247 39,106
Drum 2-FA-001 Feed

Amine Stripper Reflux

Drum 2-FA-001 57 57 0.57 23,876 23,209
Overhead

Amine Stripper Reflux

57 57 0.57 16,370 15,896
Drum 2-FA-001 Bottom

Page 249 of 1363

Water To OSBL 57 57 1 424 424

Lean/Rich Amine
Interchanger 2-EA-001 96.0 130 0.52 377,623 377,787
A/B Lean Amine (Out)

Lean Amine Cooler

2-EC-001 A/B Lean 57 57 7.100 377,623 377,787
Amine (Out)

Lean Amine Trim cooler

2-EA-004 Lean Amine 52 52 6.400 377,623 377,787
(Out)

Amine stripper Reboiler

2-EA-002 A/B/C 124.7 124.6 0.920 253,575 245,716
Reboiler Effluent

Nitrogen Mercury
Removal Bed 20 20 36.59 117,521 114,493
2-FD-201A/B

Lean Amine Cooler

2-EC-001 A/B Lean 57 57 7.100 377,623 377,787
Amine (Out)

Page 250 of 1363

3.3 Feed Handling

3.3.1 Description
The purpose of this section is to insure a continuous, controllable flow of C2/C3
vapor feed to the Cracking Heaters at the conditions specified in the process
design. Treated fresh C2/C3 feed saturated with water, along with back-up
ethane feed and ethane recycle are preheated with quench water in the Ethane
Feed Preheater (2-EA-130) to a temperature of 60 °C, before entering the
preheat section of the cracking heaters. Sulfur as DMDS is injected individually
to each heater feed after the preheater.

3.3.2 Operating Variable & Controls

Recycle ethane from the Ethylene Fractionator that has been vaporized in the
Ethane Vaporizer (2-EA-301), is preheated in off-gas exchangers of the cold
box and combined with the treated fresh C2/C3 feed from the Acid Gas
Absorber (2-DA-001).The combined C2/C3 stream is heated in the Ethane Feed
Preheater (2-EA-130) with quench water on temperature control (2-TC-1003)
to 60° C. The fresh feed from battery limit is introduced on pressure control
through the pressure control valve (2-PC-1077). Back-up ethane feed will be
supplied through the (2-PV-1001A) if the pressure in the feed line to the
Cracking Heaters is too low. The back-up ethane feed can be supplied for up to
48 hours of continuous operation in case there is no fresh feed available. The
ethane recycle from the Ethylene Fractionator is on flow control (2-FC-4018),
reset by level (2-LC-4013).

The DMDS Injection System (2-PA-103) injects DMDS, by adjusting the

injection pump stroke, into the individual heater C2/C3 feed line downstream of
the Ethane Feed Preheater. This reduces coke formation in the radiant section
of the heater and controls the formation of carbon oxides. Normal injection
rate is 25 ppmw of the ethane feed.

Page 251 of 1363

3.3.3 Normal Operating Conditions

Service Flow, kg/hr

Case 1 Case 2

Fresh C2/C3 Feed 82,176 76,482

Ethane Recycle 36,167 38,504

Quench Water 87,000 86,667

Page 252 of 1363