145 MM lbs/year Tertiary Amines Plant

International Process Plants

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Stock #600448

Brief Overview

Capacity: 145 MM lbs/year

Product: Tertiary Amines Built: 2000 (majority)

Shutdown: 2005 Technology: Olefin-Bromine Process (free & clear to practice worldwide) Raw Materials: Hydrogen, Bromine, DMA (di-methyl amine), Caustic and Olefins Utilities: Electricity, Steam, Water and Fuel gas

Key Points

Major Expansion in 2005 (Increase from 110 MM to 145 MM lbs/yr)

Plant is “overbuilt” with metallurgy, all explosion-proof motors, SS cooling water lines, SS conduit and SS insulation covering.

Plant has been very well maintained and obviously has no asbestos.

Honeywell 3000 Process Control System is available with plant

Major spare parts are available (over $1MM in new value)

Site is accessible by road, rail and port

Summary of Operations

Manpower required to operate the facility was five operators per shift. The total plant headcount was about 36 people, including staff and maintenance personnel. The plant originally produced 110 MM lbs/yr when first started up in 2000 but was expanded in 2005 to 145 MM lbs/yr of tertiary amines. The control room will stay since it is shared, but the Honeywell 3000 process control system and program can go with the plant.

Raw Materials

The liquid bromine is stored in a lead-lined CS storage tank. DMA comes in by rail and was stored in three horizontal CS storage tanks. Olefins of different chain lengths (typically C8 – C14) were brought in by rail and stored in large CS storage tanks. Ozone is generated from oxygen.

Summary of Operations

Process

The process consists of several different process steps which all operate in a continuous mode. Bromine and hydrogen are vaporized at 300°F and sent to one of three burners to produce hydrogen bromide (HBr) gas. The bromine vaporizer has Hastelloy tubes and a spare tube bundle. The HBr burners are made of Inconel 600 and are rated for 300 psig at 650°F.

The HBr is added with an olefin of varying chain length and ozone to the dominant bath reactor (DBR). The DBR is constructed of solid Hastelloy C-276. It is 7’-6” diameter by 17’ tall and is rated for 180 psig at 200°F. It has a Hastelloy B eductor on top which uses the high volume reactor recycle flow to draw in the ozone reactant. There is a spare eductor. The reactor recycle pump is a Goulds model 3180XL with a 200 hp drive motor. It pumps 3,600 gpm which turns the reactor over in one minute. There is an Alfa Laval plate exchanger used for cooling part of the reactor recycle stream. It has Hastelloy B plates with a total of 1,935 sq. ft. surface area. It is rated for 150 psig at 200°F. There is a complete spare set of plates.

Summary of Operations

The alkyl bromide product from the DBR is called “RBr”, with “R” denoting the specific olefin being used. It is mixed with water and di-methyl amine (DMA) and is sent to the amination reactors which are two tubular reactors running at 1,200 psig. The tubular reactors are 8” schedule 80 stainless steel pipe, 600’ and 800’ in length. Sundyne pumps are used to pump the feed stream up to reactor pressure.

The crude tertiary amine product from the amination reactor is mixed with 50% caustic and sent to the DMA stripper column for removal of the DMA. The DMA is recycled back to the beginning of the process. The stripper column is 60” diameter and 58’ tall with Koch-Glitsch packing. It is rated for 180 psi at 400°F and was built by Mueller out of 304L SS.

The process then goes to the 6,500 gallon capacity pressure settler. It is 84” (d) x 21’ (h). It is rated for 180 psig at 400°F and is constructed of 304L SS with 316L SS coalescing media. The amine solution flows out the top of the settler and a sodium bromide (NaBr) brine mixture leaves from the bottom.

Summary of Operations

The brine stream flows through carbon beds (retained by P&G) for purification and then to the brine stripper column for removal and recycle of the last amounts of DMA. The six carbon beds are rated for 180 psi at 400°F and made of 304L SS. They are 10’ (d) x 13’ (h).

The brine stripper column is 30” (d) x 55’ (h) and is made of 304L SS. It is packed with Koch Fleximax 200 packing. The brine continues to the two-effect evaporator and is then loaded into trucks and sent back to the bromine supplier for recovery of the bromine.

The brine evaporation system is a double-effect system to increase the amount of evaporation per pound of steam used. The first effect of the evaporator was installed in 2000 with the original plant startup. The second effect was designed by Swenson and was installed in 2005 as part of the capacity expansion project. The second effect system is all modular and can easily be dismantled and shipped by truck. This system is all 304L SS and 316L SS, and there is a spare tube bundle for the first effect.

Summary of Operations

The 1st effect evaporator is heated using 150 psig steam in the tube bundle. The vapor (steam) generated in the 1st effect is then used as the heat source for the 2nd effect evaporator. In this manner, the heat in the original 150 psig steam is reused in the 2nd effect. The 37,000 lbs/hr of brine entering the 1st effect will normally be 20-25% NaBr. The 1st effect is designed to concentrate the brine to approx. 35% NaBr and operates at 310°F/45 psig. A level controller maintains the level in the 1st effect high enough to cover the tubes of the 1st effect tube bundle. The 2nd effect evaporator operates at atmospheric pressure and concentrates the NaBr from approx. 35% to a target of 45-50% NaBr. The overheads from the 2nd effect pass through (2) overhead condensers where the steam is condensed and sent to a condensate collection tank. The NaBr from the 2nd effect gravity flows through a cooler and into a storage tank for certification. The DCS control system is comprised of a Honeywell TDC 3000, Allen-Bradley PLC5, and Triconex TMR system.

The tertiary amine solution now called alkyl di-methyl amine (ADMA) exits the top of the pressure settler and proceeds to a sparger column where the last amounts of DMA are removed and recycled. The sparger was built in 2005 and constructed of Nickel 200. It is 24” (d) x 5’ (h) and rated for 180 psi at 400°F.

Summary of Operations The amine then goes through a flash still for removal of color bodies and water. The flash still has Hastelloy tubes in the preheater and both reboilers. The still is 108” (d) x 16’ (h) and is constructed of 304L SS. It is rated for 50 psi at 525°F. The vacuum is supplied by a Graham 4-stage ejector package. There is also a hammerhead condenser sitting on top of the flash still. It is 6’ (d) x 17’ (h) with 304L SS shell and tubes.

The product then goes to the topping column for olefin removal. The topping column has Koch-Glitsch packing (only 5 years old). It is 6’-6” (d) x 75.5’ (h) and is made of 316L SS. It is rated for 127 psi at 400°F. This is a versatile column which will separate light from heavy material and will segregate pure cuts of hydrocarbon material from a blended feed stock. It has been operating at a feed rate of 5,000 - 10,000lbs/hr with a finished product rate of 4,500 - 9,800 lbs/hr. The finished amine product from the topping column then goes to storage.

Process Flow Diagram

Major Equipment

Liquid Bromine Storage Tank (built 2005)

Horiz. tank, lead lined shell/heads. CS, 0.5” thick, 8’ (OD) x 23’-8” (tan/tan) with 3/8” thick homogeneous lead liner throughout all tank internal surfaces. All nozzles aligned with the vessel’s top center line. Rated 122 psi @ 150°F.

EQ4155 Dominant Bath Reactor (DBR) (built 2000)

7’-6” (D) by 17’ T/T. Rated for 180 psig @ 200°F. Constructed of Hastelloy C-276 with 0.336” wall thickness.

DBR Top

DBR Bottom

Major Equipment

EQ4160 Reactor Recycle Pump (built 2000)

Goulds Model 3180XL 10 X 12 – 22 Impeller. Rated for 3,600 gpm with 200 hp explosion proof motor.

EQ4161 Reactor Recycle Cooler (built 2000)

Alfa Laval plate exchanger with 59 0.6mm Hastelloy B plates approx. 72” x 46”. Total of 1,935 sq. ft. surface area. Rated for 150 psig at 200°F. Complete spare set of plates.

EQ4162 Reactor Eductor (built 2000)

Approximately 8” dia. by 90.5” long. Rated for 180 psig @ 200°F. Made of Hastelloy B. Complete spare in warehouse.

Major Equipment

EQ4201 DMA Stripper Column (built 2000)

42” – 60” (D) x 58’ (W) 0.625” wall thickness. Koch-Glitsch packing. rated for 180 psi @ 400°F. Built by Mueller out of 304L SS. Capacity is 5,000 gal. Top packing bed 9’ x 5’ Fleximax 200 316L SS, Lower packing bed 27’-6” x 3’-6” Fleximax 200 316L SS. Column operates at 60 psig with a pressure drop across the column equal to 40” of water.

EQ4203 DMA Stripper Receiver (built 2000)

3’ (d) x 4’-3” (h) and 0.375” wall thickness. Made of 304L SS. Rated for 170 psi @ 400°F.

Major Equipment

EQ4205 Pressure Settler (built 2000)

6,500 gal. capacity, 84” (ID) x 249” (Tan/Tan), 0.75” wall thickness, MAWP; 180/FV @ 400°F, Internal liquid/liquid coalescer 316L SS, MOC SA-240Tp.304L.

EQ4206 DMA/Water Mix Cooler (built 2003)

Constructed of 304L SS and rated for 180 psi @ 400°F on both sides. 29” (D) x 12’ (L).

Pressure Settler

Major Equipment

EQ4208 Amination Tubular Reactor (built 2000)

8” Schedule 80 pipe with 0.5” wall thickness. Two sets- 600’ and 800’. Rated for 1,234 psig @ 400°F. Made of 304L SS.

EQ4214 DMA Surge Tank

CS, 0.75” wall thickness. 12’ (D) x 24’. Rated for 50 psi @ 300°F. 21,000 gallon capacity. Fall Protection Work Platform.

Amination Tubular Reactor

Major Equipment

EQ4300 Flash Evaporator Vessel (built 2000)

108” (D) x 16’, 304L SS. Rated for 50 psi @ 525°F. 8,000 gal. capacity. With Graham Corp. 4-Stage Ejector. Package Consisting Of; Hammerhead Condenser (see EQ4303), 17,582.3 gpm/hr, (1) Critical Spare Heat Exchanger; 2,957,740 BTU/Hr, Manning & Lewis 600 lb. Steam Re-Boiler (see EQ4302). The Flash Still was fabricated by Paul Mueller and the internal packing by Koch-Glitsch.

EQ4302 Flash Evaporator Reboiler (built 2000)

2’ (D) x 172” (L) rated for 700 psi @ 600°F (both sides). 155 – ¾” 14 ga Hastelloy C276 tubes and 316L SS shell.

Q4303 Flash Evaporator Condenser (Hammerhead) (built 2000)

304L SS shell/tubes. 6’ (D) x 14’ (L) tube, 17’ (L) overall. 0.5” thick shell wall.

Flash Still

Major Equipment

EQ4501 Brine Cooler (built 2000)

26” (D) x 143” (L) w/ 782- ½” tubes. Rated for 180 @ 400°F, 304L SS on both sides.

EQ4516 Brine Stripper Column (built 2000)

Paul Mueller Company Vertical Column 55” (T-T) x 30” (OD) MOC SA-240-304L SS. MAWP: 180/-14.7 at 400/400°F.; FV Capacity-297 cu. ft. (2) Packing beds, 19’-3” x 30” ea. Koch Fleximax 200 Flow Rates: 4,000 lb/h Vapor and 32,000 lb/hr Liquid.

EQ6307 (6) Rich DMA + Misc Tanks (built 2000)

10’ (D) x 17’ (H). Rated for 150 psi @ 450°F. 9/16” thick walls, 304L SS. Shell wall is 0.5” thick.

Brine Stripper

Major Equipment

EQ6316 Brine Stripper Condenser (built 2000) 1’ (D) X 12’ (L). 304L SS on both sides

EQ6340 HBr Burners (built 1998)

Shell is 5/16” thick Inconel 600 rated for 300 psig @ 850°F. Inconel helical coil internals. Two burners in service with one new installed spare. These units have a burning chamber where bromine and hydrogen are mixed to form an HBr vapor composition; Manufactured by Precision Stainless Inc. 24’ tall.

HBr Burners

Major Equipment

EQ6370 Sparger Column (built 2005)

24” (D) x 8’ (H) made of 3/8” thick Nickel 200. Rated for 180 psi @ 400°F, w/ internal tube bundle.

EQ7204 (3) Brine + Misc API Tanks (built 2000)

12’ (D) x 26’ (H). API tanks made of 304L SS.

Sparger Column

Major Equipment

EQ2550 Topping Column (Fractionation Column) (built 1987)

6’-6” (D) x 75.5’ (H) made of 316L SS. Wall thickness of 0.625”. Rated for 127 psi @ 400°F. Koch packing. This column is designed for full vacuum and consists of 4 sections: upper, middle, lower, and the pot with three packing beds. The column will separate light from heavy material, and will segregate pure cuts of hydrocarbon material from a blended feed stock. The performance of the column is determined by the type of packing and pump size. This column has been operating at a feed rate of 5,000 - 10,000 lbs/hr with a finished product rate of 4,500 to 9,800 lbs/hr.

Topping Column

Major Equipment

Evaporator System (all 304L SS unless noted otherwise)

Swenson Package on modular frame as follows: Paget Eq 1st Effect Evaporator (EQ7313), built 2003, 6’ (D) x 10” (H), 304 SS, 150 psig @ 375°F. Tube Bundle 399 - ¾” 16 ga U-tubes, SA789 UNS#31803; 2003 Benicia Fab. Spare Tube Bundle, Tubes .75”, SA-249-TP316L, 399 U-Tubes.

Swenson Package: Modular construction, built in 2000. Circulation Heater (EQ4523; 45” dia.), Overheads Condenser (EQ4524), Evaporator, Vacuum System, Circulation Pump, Product Transfer Pump, Condensate Collection Tank (30” dia.; 850 lbs), Condensate Pump, NaBr Transfer Pump, and modular structure. 2nd effect body (EQ4521; 66” dia.)

Brine Evaporation Details-- The Brine Evaporation system is a double-effect type system to increase the amount of evaporation per lb. of steam used.

2-Effect Evaporator System

Major Equipment

Evaporator System (continued)

The 1st Effect Evaporator is heated using 150# steam in the tube bundle. The vapor (steam) generated in the first effect is then used as the heat source for the 2nd Effect Evaporator. In this manner, the heat in the original 150# steam is reused in the Second Effect. The brine entering the 1st Effect will normally be 20-25% NaBr. The 1st Effect is designed to concentrate the brine to approx. 35% NaBr and operates at 310°F/45 PSIG. In addition, the 1st Effect generates steam that is used in the 2nd Effect. A level controller maintains the level in the 1st Effect that is high enough to cover the tubes of the 1st Effect tube bundle. The 150# steam flow to the 1st Effect is controlled by a FCV.

The 2nd Effect Evaporator concentrates the NaBr from approx. 35% to a target of 45-50% NaBr. The overheads from the Second Effect pass through two overheads condensers where the steam is condensed to liquid and sent to a condensate collection tank. The NaBr from the Second Effect gravity flows through a cooler and into a storage tank for certification.

1st Effect Evaporator

Major Equipment

Evaporator System (continued)

Performance: Concentrate a 37,000 lb/hr steam at 24% by weight brine to a 48% strength DCS control system is comprised of a Honeywell TDC 3000, Allen-Bradley PLC5 and Triconex TMR system. All steam tracing MOC is 3/8” SS tubing Area Classification: 1D1 through out Maximum lifting weight of each module is 38,000 lbs and lifting and trailing lugs are integrated into the modular design Structure is designed for Seismic Zone 2A, and to withstand a 90 mph wind load per ASCE7-95.

2nd Effect Evaporator

2nd Effect Evaporator Pump

Major Equipment

Emergency Generator (built 1998)

Kohler with 776 Total Run Hours, Natural Gas, 175kW Output, 60hz, 480vac, 3-Phase, With Block Heater, Battery Charger, Automatic Microprocessor Controlled, NEMA 3 Enclosure, Outdoor Weather Housing, Residential Exhaust Silencer, 400 Amps, 3-20 Second Time Delay Normal To Emergency, 4-Position (Test, With Load, Auto, Off, Engine Start), Pilot Lights For Normal Or Emergency Source, Engine Model/Type; Detroit Diesel (converted to natural gas) S50G, 4-Cycle, Turbocharged, 1800rpm, Serial number: GEN9706.

Generator

Major Equipment

Trane Chillers (3) (built 1996 – 2003)

Chiller #1- Trane RTHB-255 SN U96H-06429 (Built 1996)

Chiller #2- Trane RTHB-255 SN U96H-06439 (Built 1996)

Chiller #3- Trane RTHC SN RTHC1D1FOD1L3E1LFVQUCO (Built 2000)

Maintained through annual service agreements by Trane technicians. Annual PV inspections. R-134A Refrigerant Chiller #1 has 48,209 hours of compressor running time. Chiller #2 has 54,053 hours of compressor running time. Chiller #3 has 60,801 hours of compressor running time.

Trane Chiller

Major Equipment

Flare Stack (built 2003)

100’ (H) x 11’ (D) Base, Stream Flow Rate; 100,00 Lbs/Hr, Temp. 70°F, Waste Vapor DMA, 100 SCFH Per Pilot, 110v, (3) Continuous Pilot Burners, Velocity Type Purge Reduction Seal. The stack is 304 SS and 316 SS, depending on the section. The access ladder and work platforms are galvanized. Control Panel/Ignitions System Consisting Of; Self-Inspirated Flame Front Generator (SI-FFG), Auto Re-Ignition, Thermocouple, Ignition Fuel Gas Valves, Pressure Regulators, Pressure Indicators, Fuel Gas/Air Mixing Chamber, Ignition Chamber With Spark Igniting Device, Ignition Transformers, Emergency Shut Off Push Button, Control System Pre-Wired, Pre-Piped And Rack Mounted, Galvanized Caged Ladder, With (3) 360° Platforms.

Sundyne Pumps (2) (built 2000)

Model LMV-341 Pumps, 316 SS, With Reliance XEX Motors, 250 hp, 460 v, 3-Phase, 3,570 rpm, 255 gpm

Ozone Generator (built 2000)

Model CFL-10/SP-31-D, rated 370 lb/d.

Major Equipment

Spare Steam Heat Exchangers (2) (built 1999-#2) & (built 2002-#1)

#1 Manufactured by Southern Heat Exchanger Corp. (35) U-tubes, 5/8” OD, SB-163 Nickel Alloy 201 (N02201). Tubesheet SB-160 Nickel Alloy 200; Shell SA-240-304L.

#2 Manufactured by Manning & Lewis. Same spec’s as #1 (except 70 U-tubes)

East Cooling Tower

Fan Tower, Gear Boxes, ratio: 7.1/1, fans; 6-Blade, 192HP71, 12° Pitch, 227 rpm,

Goulds Model VIT Cooling Tower Pumps (2) (built 2000)

6,500 gpm, w/400 hp, 1800 rpm motors, 3-Phase, with (3) Spare GE Model 5K511GT6011P, 400 hp Motor, 3-Phase, 1785 rpm, 60hz, 460v

Major Equipment

West Cooling Tower (built 1998)

Hudson Tuf-Lite Fan, 4000 Series Hub, 16’ Fan, Gear Reducer 7.7/1 Ratio.

Motor Control Center

Furnas System 89, (8) Multi-Bank Motor Control Centers, Each With 42,000 Amp PLC Racks, (7) With 300 Amp Vertical Bus Rating, (1) With 800 Amp Horizontal Rating, Misc. Buckets, Starters, Disconnects, Breaker Panels, Power Distribution Panels, (6) Square D 45kva 3-Phase Insulated Transformers, HV=480v, LV=208Y/120, (1) Square D 75kva 3-Phase Insulated Transformer, HV=480v, LV=208Y/120, (1) Square D 25kva Single Phase General Transformer, HV=240-480v, LV=120/240, (4) Allen-Bradley 1336Plus Sensorless Vector Variable Frequency Drives, (2) 18-Bank Panels.

Photos

Photos

MICHAEL JOACHIM DIRECTOR, PLANTS DEPT. Tele: 609-838-5930 (direct)

Mobile: 609-516-9107 MichaelJ@ippe.com

SANJEEV REGE VP, GLOBAL PLANT SALES Tele: 609-838-5938 (direct)

Mobile: 609-510-2616 SanjeevR@ippe.com

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