Operating Experience of BASF Amdea in a CO2 Removal System

Operating Experience of BASF aMDEA in a CO₂ Removal System

Date	April 3rd, 2013
Author	Muhammad Bin Khamis Butt, Bilal Mustafa, Muddassar Rathore
Company	Engro Fertilizers Ltd. Pakistan
Company address	ECPL, Daharki, Distt. Ghotki, Sindh. Postal Code 65020.
Business Tel.	+92-723-641001 Ext 4402
E-Mail	mkbutt@engro.com

 

Abstract:

This paper shares Engro's experience of BASF aMDEA in a CO2 removal system of this new Ammonia Plant.  It also shares the problems encountered during pre-commissioning, commissioning and normal operation phase with aMDEA system. The commissioning & stabilization of aMDEA unit has been a roaring success. With concerted efforts, excellent planning and preparations, the new CO2 removal system's commissioning was not only accomplished well within the scheduled time but also in-house optimization efforts proved successful in realizing its excellent performance. The decision to rely on in house operational capabilities while identifying the leading limiting areas and their subsequent stepwise improvement paid heavy dividends.

       

No doubt, some problems were faced during the course of the project and the team got stuck at some points but they got thru with continuous zeal and efforts. Still aMDEA operations have some unrevealed areas and the team is putting efforts to get hold on them for achieving excellence in the operations domain

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To give you an idea regarding content of the paper, please find the following highlights.      
Comparison of CO2 removal system in Engro:

Engro Fertilizers Limited operates two ammonia plants. Both plants have design capacity of 1550 MTPD and 2190 MTPD respectively and they use natural gas as feedstock and fuel. The first plant was uses a hot potassium carbonate system (Catacarb) for CO2 removal. However for the second plant BASF aMDEA system was chosen

Journey of aMDEA Operation at Engro:

1.      Pre-commissioning of aMDEA system

a.       Pre-cleaning of tower's packing (external cleaning)

b.      Water flushing, purge and tightness test of all vessels

c.       Flushing with potassium solution

d.      Two consecutives flushing with demineralized water

e.       Preparation of aMDEA solution

2.      Commissioning / Operating experience

a.       Antifoam dosing issues

b.      Extensive foaming in columns

c.       Amine smell

d.      Vibration issues in piping & pumps

e.       Recycle gas compressor problematic operation

Flooding Incident (aMDEA showering):
On 2nd April, 2011 sudden fluctuation in level of LP Flash Drum occurred followed by rapid level increase in overhead separator, V-303 and downstream K.O drum, V-19. Finally high level in V-19, CO2 Compressor suction KO Vessel tripped CO2 compressor and I-4 (trip of aMDEA circulation pump) was manually activated at 1636 hrs. i.e. 15 min and 30 sec after the fluctuation commenced. Significant amount of aMDEA discharged through the CO2 vent downstream of overhead separator, V-303 during the incident. Sequences of events that pursued are mentioned below

Modifications in the System:

To ensure safety & integrity of the unit modifications have been made based on operating experiences & issues faced during the course of commissioning