PLANT OPERATIONS DEPARTMENT

Installation of Triethylene Glycol Contactor Overhead Knock Out Drum in the Propylene

Carbonate system at Process Plant Specialists (P.P.S), Savonetta

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ORGANIZATION CHART OF PLANT OPERATION DEPARTMENT

Chief Engineers

Process Consultant

General Manager

Ornella Ramsarran

Steffon Mohammed

Dylan Dhanpaul

Crystalgail Ali Khan

Monique LaFoucad

e

19-Nov-13

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To define the activities and equipment required for the installation and commission of a Triethylene Glycol (TEG) Knock Out (K.O) Drum.

TEG K.O Drum serves to monitor and control the level of glycol.

Plant Operation Department projected precise and minimal cost of the project.

19-Nov-13

TECHNICAL PROPOSAL

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Outline of presentation: The Problem: Carryover of TEG into the PC

system.

Implemented Solution: TEG Knockout Drum

Details of Solution: I. ProcedureII. CostIII. Benefits

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SCOPE

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To determine the problem experienced at the Savonetta plant, several studies and tests were conducted.

It was concluded that TEG was being carried over to the Propylene Carbonate (PC) system.

The operating temperatures of the TEG contactors were causing an increased viscosity of the TEG.

The increased viscosity prevented the elimination of TEG prior to the PC system entrance. The TEG was then able to escape into the PC system.

It was found that continuous degradation of the TEG was occurring. This gave rise to large amounts of suspended solids in the glycol.

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BACKGROUND

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This resulted in a deficiency in the CO2 removal process in the PC system increasing the overall temperatures within the methanator system.

Through this contamination an increased consumption of TEG was being experienced. Also PC losses and general excess expenditure was being suffered.

Due to the deficiency in the PC system an average production loss of 15 tons of ammonia was being experienced daily.

Historical data of TEG, PC and H2O were observed.

It was confirmed that a loss of 90 drums of TEG averaging a value of US$36,000.00 was being suffered yearly. Remediation costs of the PC in the region of US$20,0000.00 yearly was also being suffered.

19-Nov-13

BACKGROUND

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After in- depth study and analysis the origin of the problems were found to be within the Glycol Stripping Air system of the PC system.

It was concluded that a TEG Knockout Drum system would be a successful implementation to the PC system.

To implement the new system properly, specifics of pipes, nozzles and valves with high pressure. Conditions have been calculated and sized to be installed prior to initializing the TEG Knockout drum.

All calculations were done at an earlier time before the arrival of the drum, so the incorporation of the new upgrade into the existing system was an uninterrupted process.

19-Nov-13

SOLUTION

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Performed inspection checks on the existing system.

Inlet and outlet valves were installed before the plant was brought back up.

Support landing was constructed at the work shop to secure and mount the K.O. Drum for smooth operation and maintenance.

Installation was readily done downstream to the existing glycol contactor without upsetting the already existing system production.

The TEG K.O. Drum level control system was equipped with high and low alarm switches.

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DETAILS OF SOLUTION

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DETAILS OF SOLUTION

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FIGURE 1: Shows design view of TEG Contactor K.O Drum

DETAILS OF SOLUTION

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DETAILS OF SOLUTION

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HORIZONTAL CONTACTOR KNOCKOUT DRUM

42” OD X 10 ‘ × 150 PSIG

EST WT: 4,400 LBS

Dry air and TEG enters

Dry air leaves and goes to CO2 Stripper

Nameplate

¼” Weep Hole below inside Nozzle

Removable Dacron Mesh

Removable Vane Type

Drain

Cleanout w/PLG

LC/LG Bridle

LC/LG Bridle

Pressure Saftey Valve / Manway Inlet

Outlet

FIGURE 2: SHOWS TEG K.O DRUM

DETAILS OF SOLUTION

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Production Cost Production Cost/Value

MT / day increase in production

75 Drums PC saving /year

27.00

TOTAL increase in production for year

$ 2,738.00 Per Drum $ 675.00

Contribution 1 $ 88.50 $ 18,225.00

SAVING /Year $ 242,268.75

IRR –5 Year Forecast

95%

Drums of Glycol saving /year

20.00 NPV After 5 Years $ 514,737.72

Per Drum $ 525.00

Savings /year $ 10,500.00 PAYBACK PERIOD 13 MONTHS

Total Savings Per Year $ 270,993.75

19-Nov-13

DETAILS OF SOLUTIONTABLE: Shows Project Upgrade Economics

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Main Benefits Gained by Usage of the TEG K.O Drum:

Reduced the amount of process gas vented.

With the vessel in series the glycol and moisture carryover was minimal.

With the contactor bypassed, on–line cleaning of its internals can be performed without affecting the plant operation.

The piping has been configured for the vessel to operate in series as well as bypass for the existing contactor.

Production increased by 15 tons per day.

Payback Time of 13 months .

Production increased by 75 metric tons per day with $270,000.00 saving per year.

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DETAILS OF SOLUTION

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Plant Operation Department guarantees that the project has been completed in accordance with the requirements of the Contract.

We guarantee the project to be free of defects in workmanship, equipment and materials.

Our department agrees to repair or replace any and all components of the project, that may have been damaged or displaced within a two (2) year period.

No expense whatsoever will be charged to Process Plant Specialists under the warranty.

19-Nov-13

CONCLUSION

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Problem: TEG was being carried over to the PC system.

Solution: Relevant tests and calculations were meticulously carried out in order to begin implementation of the TEG K.O Drum system.

Benefit: The Savonetta plant was able to cut financial losses and excess expenditure, thanks to the initial capital invested in the TEG K.O Drum.

CONCLUSION

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ANY QUESTIONS ON CONTENT OF PRESENTATION?