1、天然气厂主体装置工艺流程及工艺原理 The Process Flow and Principle of Main Units in Gas Plant,脱硫 Sulfur Removal,脱水 Dehydration,硫磺回收 Sulfur Recovery,尾气处理 Tail Gas Treatment,主体工艺 Main Process,空氮站 Air & N2 Station,锅炉给水框架 Boiler Feedwater,燃料气系统 Fuel Gas Sys.,火炬及放空系统 Flare & Vent Sys.,硫磺成型及储存 Sulfur Storage & Forming,商业计量
2、站 Gas Commercial Metering Station,水处理系统 Water Treatment Sys.,气田水处理系统 Produced waterTreatment,公用工程及辅助设施 Utilities & Auxiliary Facilities,自控机柜间 Central Control Room,35kV变电站 35kV Substation,循环水系统 Cooling Water Sys.,消防水给水系统 Fire WaterSupply Sys.,天然气处理厂 Gas Treatment Plant 工厂组成 Plant Components,2,溶剂脱硫 Su
3、lfur Removal,脱水 Dehydration,硫磺回收 Sulfur Recovery,尾气处理 Tail Gas Treatment,主体工艺 Main Process,空氮站 Air & N2 Station,锅炉给水框架 Boiler Feedwater,燃料气系统 Fuel Gas Sys.,火炬及放空系统 Flare & Vent Sys.,硫磺成型及储存 Sulfur Storage & Forming,商业计量站 Gas Commercial Metering Station,水处理系统 Water Treatment Sys.,气田水处理系统 Produced wat
4、erTreatment,公用工程及辅助设施 Utilities & Auxiliary Facilities,自控机柜间 Central Control Room,35kV变电站 35kV Substation,循环水系统 Cooling Water Sys.,消防水给水系统 Fire WaterSupply Sys.,天然气处理厂 Gas Treatment Plant 工厂组成 Plant Components,3,Gas Plant overview,Sulfur Removal Unit 脱硫装置 (2),Tail Gas Treatment & Sour H2O Stripping
5、尾气处理&酸H2O汽提(1),Sulfur Recovery Unit硫磺回收装置 (1),Sulfur Removal Unit 脱硫装置( 1),Commercial Metering Station 商业计量站,Dehydration 三甘醇脱水,Liquid Sulfur Storage Tanks液硫储罐,Incinerator 灼烧炉,Sulfur Forming 硫成型,Incinerator 灼烧炉,Sulfur Recovery Unit 硫磺回收装置(2),Tail Gas Treatment & Sour Water Stripping尾气处理&酸H2O汽提(2),Fee
6、d Gas From Gas Terminal Station 来自末站的原料气,Wet Treated Gas 处理湿气,Acid Gas 酸气,Acid Gas 酸气,Acid Gas 酸气,Sales Gas to Grid 商品气至管网,Product Sulfur to Storage 硫磺产品储存,Vent to Atm.,Vent to Atm.,4,Acid Gas 酸气,脱硫单元 Sulfur Removal Unit,Gas Plant overview,Sulfur Removal Unit 脱硫装置 (2),Tail Gas Treatment & Sour H2O S
7、tripping 尾气处理&酸H2O汽提(1),Sulfur Recovery Unit硫磺回收装置 (1),Sulfur Removal Unit 脱硫装置( 1),Commercial Metering Station 商业计量站,Dehydration 三甘醇脱水,Liquid Sulfur Storage Tanks液硫储罐,Incinerator 灼烧炉,Sulfur Forming 硫成型,Incinerator 灼烧炉,Sulfur Recovery Unit 硫磺回收装置(2),Tail Gas Treatment & Sour Water Stripping尾气处理&酸H2O
8、汽提(2),Feed Gas From Gas Terminal Station 来自末站的原料气,Wet Treated Gas 处理湿气,Acid Gas 酸气,Acid Gas 酸气,Acid Gas 酸气,Sales Gas to Grid 商品气至管网,Product Sulfur to Storage 硫磺产品储存,Vent to Atm.,Vent to Atm.,6,Acid Gas 酸气,脱硫目的 Purpose,通过气-液吸收、气-固吸附和化学转化等途径除去天然气中的含硫化合物和部分CO2，使其达到商品天然气管输标准。 To remove sulfur compounds
9、and excessive CO2 from sour natural gas by means of gas-liquid absorption, gas-solid adsorption and chemical conversions so that the gas meets the pipeline transportation specifications.,脱硫工艺方法,本厂使用砜胺溶液Sulfinol-M（萨菲诺-M）进行脱硫 The plant uses Sulfinol-M to remove sulfur.溶液組份：甲基二乙醇胺50%，环丁砜15%， 水35%。 Comp
10、osition of the Solvent: 50% MDEA, 15% sulfolane, 35% water,Sulfur Removal Unit脱硫装置,原料气脱硫 Feed gas sulfur removal,回流泵,分离部分 Separation Section 去除原料气中的大量水和杂质 Remove water and impurities from the feed gas,吸收部分 Absorption Sectin 砜胺溶液和原料气在吸收内逆向接触，吸收H2S、CO2和部分有机硫（脱硫） The sulfinol-M countercurrents with fee
11、d gas and absorbs H2S, CO2 and part of organic sulfur (sulfur removal),闪蒸部分 Flash Section 闪蒸出砜胺富液中夹带的碳氢化合物 Flash hydrocarbon out of the rich sulfinol-M,再生部分 Regeneration Section 用加热的方式解析出富液中的酸气， The rich sulfinol-M is regenerated by heating it to drive off acid gas,富液再生 Rich sulfinol-M regeneration,
12、将再生后的贫液打回吸收塔循环使用 The lean sulfinol-M regenerated is routed to absorber for recycling,湿净化气去脱水单元 Wet Treated gas to dehydration unit,解析出的酸气送入硫磺回收单元 Acid gas to sulfur recovery unit,Sulfur Removal Unit,脱硫设备清单 塔 脱硫吸收塔 闪蒸气吸收塔 再生塔 罐 原料气分离器 湿净化气分离器 闪蒸罐 回流罐 砜胺液排放罐 凝结水分离器,10,Equipment List -Sulfur Removal Co
13、lumns Main Absorber Column Flash Gas Absorber Column Regenerator Column Drums Feed Gas Separator Drum Wet Treated Gas K. O. Drum Flash Drum Reflux Drum Sulfinol Drain Drum Condensate Water Separator,Sulfur Removal Unit,11,换热器和冷凝器 贫富砜胺液换热器 贫砜胺液冷却器 贫砜胺液后冷却器 再生塔重沸器 塔顶冷凝器 塔顶后冷器 过滤器 原料气过滤分离器 砜胺液机械过滤器 活性炭
14、过滤器 砜胺液后过滤器 排放溶液过滤器,Exchangers & Coolers Lean/Rich Sulfinol Exchangers Lean Sulfinol Cooler Lean Sulfinol Trim Cooler Regenerator Reboiler Overhead Condenser Overhead Trim Cooler Filters Feed Gas Filters Lean Sulfinol Filter Activated Carbon Filter Sulfinol Trim Filter Drained Sulfinol Filter,Sulfur
15、 Removal Unit,Pumps & Drivers Low Pressure Lean Sulfinol Pumps High Pressure Lean Sulfinol Pumps Reflux Pumps Drained Sulfinol Pump Power Recovery Turbine,12,泵和驱动器 低压贫砜胺液泵 高压贫砜胺液泵 回流泵 排放溶液泵 富砜胺液能量回收透平 ）,ENVIRONMENT FOCUS 环保关注点,气体污染： H2S 泄漏、含硫闪蒸气泄漏 Gas pollution: H2S leakage, flash gas leakage 固体污染：固
16、废物堆放、 Solid pollution: solid waste piles 液体污染： 脱硫溶液泄漏、化学药剂泄漏、 Liquid pollution: desulfurization solution leakage, chemical leakage 热辐射：换热器、重沸器、蒸汽泄漏 Heat Radiation: heat exchanger, re-boiler and steam leakage 噪声污染：管线噪声、机械噪声 Noise pollution: duct noise, mechanical noise,脱水单元 Dehydration Unit,Gas Plant
17、 overview,Sulfur Removal Unit 脱硫装置 (2),Tail Gas Treatment & Sour H2O Stripping 尾气处理&酸H2O汽提(1),Sulfur Recovery Unit硫磺回收装置 (1),Sulfur Removal Unit 脱硫装置( 1),Commercial Metering Station 商业计量站,Dehydration 三甘醇脱水,Liquid Sulfur Storage Tanks液硫储罐,Incinerator 灼烧炉,Sulfur Forming 硫成型,Incinerator 灼烧炉,Sulfur Reco
18、very Unit 硫磺回收装置(2),Tail Gas Treatment & Sour Water Stripping尾气处理&酸H2O汽提(2),Feed Gas From Gas Terminal Station 来自末站的原料气,Wet Treated Gas 处理湿气,Acid Gas 酸气,Acid Gas 酸气,Acid Gas 酸气,Sales Gas to Grid 商品气至管网,Product Sulfur to Storage 硫磺产品储存,Vent to Atm.,Vent to Atm.,15,Acid Gas 酸气,脱水目的 Purpose,采用不同工艺脱除天然气
19、中水份，使其达到商品天然气管输标准中水露点。 To remove water from gas by different methods to ensure the gas is within dew point specification for sales gas pipeline transportation.,脱水工艺方法,（ 本厂使用TEG（三甘醇）脱水 The plant uses TEG for dehydration. OH），在结构上与水相似，甘醇的羟基与水分子可以形成氢键，由于缔合分子的键长很长，键能小，因此缔合分子是可逆的，并且可在低于甘醇沸点，高于水的沸点温度下再生提纯
20、以供循环使用。,18,Dehydration脱水,Critical Equipment Table TEG Absorber Product Gas K.O. Drum TEG Flash Drum Buffer Container TEG Recovery Tank Off Gas K.O. Drum TEG Reserve Tank Fuel Gas Buffer Drum TEG Cooler Rich TEG Heater Lean/Rich TEG Heat Exchanger,关键设备列表 TEG吸收塔 产品气分离器 TEG 闪蒸罐 缓冲罐 TEG 回收罐 废气分液罐 TEG 储罐
21、 燃气缓冲罐 TEG 冷却器 富液加热盘管 TEG贫/富液换热器,19,Dehydration脱水,关键设备列表 TEG 重沸器 TEG 预过滤器 活性炭过滤器 TEG 后过滤器 TEG 贫液循环泵 TEG 回收泵 TEG 补充泵 TEG 回收总管 燃气/商业气计量系统 火炬,Critical Equipment Table TEG Reboiler TEG Pre-Filter Activated Carbon Filter TEG Trim Filter Lean TEG Circulation Pump TEG Recovery Pump TEG Make-up Pump TEG Rec
22、overy Header Fuel/Commercial Gas Metering System Flares ESD Narrative Reference,20,Dehydration脱水,Critical Equipment Table TEG Absorber Product Gas K.O. Drum TEG Flash Drum Buffer Container TEG Recovery Tank Off Gas K.O. Drum TEG Reserve Tank Fuel Gas Buffer Drum TEG Cooler Rich TEG Heater Lean/Rich
23、TEG Heat Exchanger,关键设备列表 TEG吸收塔 产品气分离器 TEG 闪蒸罐 缓冲罐 TEG 回收罐 废气分液罐 TEG 储罐 燃气缓冲罐 TEG 冷却器 富液加热盘管 TEG贫/富液换热器,TEG Dehydration Unit ( one per train) 三甘醇脱水装置（一列一套）,21,K.O. Drum 产品气气液分离罐,Flash Drum闪蒸罐,TEG,Absorber 吸收塔,Reboiler 重沸器,Wet Treated Gas 处理湿气,Product gas 产品气,Flash gas to fuel gas system 到燃料气系统的闪蒸气,
24、Off gas to Incinerator 不合格气体到灼烧炉,Lean-Rich exchanger 贫富液交换器,TEG Pump TEG泵,Buffer tank 缓冲罐,MP steam 中压蒸气,Stripping gas 汽提气,Lean TEG 贫液,Rich TEG 富液,ENVIRONMENT FOCUS 环保关注点,液体污染： TEG溶液泄漏、化学药剂泄 Liquid pollution: TEG leakage, chemical leakage 热辐射：换热器、重沸器、蒸汽泄漏 Heat Radiation: heat exchanger, re-boiler and
25、 steam leakage 噪声污染：管线噪声、机械噪声 Noise pollution: duct noise, mechanical noise,硫磺回收单元 Sulfur Recovery Unit(SRU),23,Gas Plant overview,Sulfur Removal Unit 脱硫装置 (2),Tail Gas Treatment & Sour H2O Stripping 尾气处理&酸H2O汽提(1),Sulfur Recovery Unit硫磺回收装置 (1),Sulfur Removal Unit 脱硫装置( 1),Commercial Metering Stati
26、on 商业计量站,Dehydration 三甘醇脱水,Liquid Sulfur Storage Tanks液硫储罐,Incinerator 灼烧炉,Sulfur Forming 硫成型,Incinerator 灼烧炉,Sulfur Recovery Unit 硫磺回收装置(2),Tail Gas Treatment & Sour Water Stripping尾气处理&酸H2O汽提(2),Feed Gas From Gas Terminal Station 来自末站的原料气,Wet Treated Gas 处理湿气,Acid Gas 酸气,Acid Gas 酸气,Acid Gas 酸气,Sa
27、les Gas to Grid 商品气至管网,Product Sulfur to Storage 硫磺产品储存,Vent to Atm.,Vent to Atm.,24,Acid Gas 酸气,硫磺回收,工艺描述 硫磺回收装置的三个部分： 克劳斯热反应部分 克劳斯催化反应部分 脱气部分,25,Process Description Three sections that make up the Sulfur Recovery Unit: Claus Thermal Reaction section Claus Catalytic Reaction section Degassing secti
28、on,硫磺回收,热化学反应（克劳斯反应） 热化学反应阶段由主燃烧器，燃烧室，余热锅炉和一级硫磺冷凝冷却器组成。主燃烧器中的来料酸气与空气进行不完全燃烧（即次化学当量）。 进料酸气中三分之一的H2S 以这种方式燃烧生成SO2 ，而其它杂质，碳氢化合物则完全燃烧，变成二氧化碳和水。 余下三分之二的H2S与SO2反应，转化为硫。 这个平衡反应称为克劳斯反应。克劳斯反应的主要特点是H2S 与SO2之间2:1的比例。这个比例在整个过程中是恒定的，并通过在主燃烧器中适量空气的燃烧来控制。 一些硫直接在主燃烧器火焰上形成，这就是所谓的硫化氢自动分解反应。,26,Thermal Reaction Stage（
29、 Claus reaction ） The thermal stage consists of the main burner, combustion chamber, waste heat boiler and first sulfur condenser. In the main burner the sour gas feed is burnt substoichiometrically (= shortage of oxygen) with air. One-third of the H2S present in the sour gas feed is combusted in th
30、is way, whereas the several feed gas impurities, hydrocarbons, are burnt completely to carbon dioxide and water. The major part of the remaining two-thirds of H2S is thermally converted into sulfur by the reaction with SO2. This equilibrium reaction is called the Claus reaction. The characteristic f
31、eature of the Claus reaction is the 2:1 ratio between H2S and SO2. This ratio is constant throughout the process and is obtained by proper combustion air control at the main burner. Some sulfur is directly formed in the main burner flame by the so-called auto-dissociation reaction of H2S, and under
32、formation of hydrogen.,硫磺回收,催化反应 下游催化反应阶部分，在低温情况下，在随后的两级反应阶段通过采用一种特殊的催化剂（三氧化二铝）来继续克劳斯平衡反应。 脱气 硫磺回收装置产生的硫含有大约300 ppm wt H2S，部分化学反应生成的硫化物 (H2Sx)，以及部分发生物理溶解的硫。为从液体硫中脱除H2S和H2Sx ，消除在处理，运输和储存液体硫磺时潜在的毒性和爆炸风险，“壳牌硫磺脱气工艺”应运而生。采用壳牌脱气工艺的脱气流程能将H2S 含量减至10 ppm wt以下。 通过喷淋器将空气注入液体硫中，实现脱气反应，一部分溶解的H2S从硫磺中被汽提出，一部分H2S发生
33、氧化反应，产生单质硫。而且，从硫磺中脱除H2S能促进H2Sx分解成H2S和硫,27,Catalytic Reaction Stage In the downstream catalytic reaction stages the Claus equilibrium reaction is continued at lower temperature by means of using a special catalyst in two subsequent reactor stages. Degassing Stage The sulfur produced in the SRU contai
34、ns about 300 ppm wt H2S, partly chemically bound as polysulfides (H2Sx) and partly physically dissolved. To remove H2S and H2Sx from liquid sulfur, eliminating potential toxic and explosion hazard associated with handling, transport and storage of liquid sulfur, the Shell Sulfur Degassing Process ha
35、s been developed. Degasification by means of the Shell degassing process reduces the H2S content to less than 10 ppm wt. Degasification is obtained by injecting air via spargers in the liquid sulfur, thereby partly stripping the dissolved H2S from the sulfur and partly oxidizing it to elemental sulf
36、ur. Furthermore, the removal of H2S from the sulfur promotes the decomposition of the polysulfides into H2S and sulfur,硫磺回收,28,热反应部分 主风机透平和减温器 主风机透平 主风机电机 酸气分离器和酸水泵（ 高级燃烧器控制 酸气压力和流量控制 空气需求量控制 燃料气流量控制 蒸汽/燃料气流量比控制（低压蒸汽用于冷却） 氮气流量控制（用于启动吹扫）主燃烧器和燃烧室 余热锅炉 和排污罐,Thermal Reaction Section Main Air Blower- Tur
37、bine & De-Superheater Main Air Blower- Turbine Main Air Blower- Electric Motor Acid Gas Knockout and Condensate Pumps Advanced Burner Control Acid Gas Pressure and Flow Control Air Demand Control Fuel Gas Flow Control Steam/Fuel Gas Flow Ratio Control (LP Steam for cooling) Nitrogen Flow Control (fo
38、r start-up purge) Main Burner and Combustion Chamber Waste Heat Boiler and Blowdown Drum,硫磺回收,29,催化反应部分 一级硫磺冷凝冷却器 一级再热器和反应器 二级硫磺冷凝冷却器 二级再热器和反应器 三级硫磺冷凝冷却器 尾气控制 和旁通 一级/二级/三级液硫封,Catalytic Reaction Section First Sulfur Condenser First Reheater and Reactor Second Sulfur Condenser Second Reheater and Reac
39、tor Third Sulfur Condenser Tail Gas Control and Bypass First/Second/Third Sulfur Locks,Sulfur Recovery Unit,30,脱气部分 液硫池和控制 喷射器/泵/液硫池蒸汽盘管 凝结水闪蒸罐 排污罐,Degassing Section Sulfur Pit and Control Ejector/Pumps/Steam Coil Condensate Flash Drum Boiler Blowdown Drum,Thermal Stage: 热反应段 In the main burner some
40、 of the acid gas feed and air are burnt. 在主燃烧器，会有酸气供给，空气燃烧。H2S + 1 O2 - SO2 + H2O + heat 生热The air to the acid gas ratio is controlled such that in total 1/3 of all hydrogen sulfide (H2S) is converted to SO2. This is a strongly exothermic and promotes the following Claus reaction: 空气在酸气中的比率需控制以让1/3的
41、H2S能转化为SO2。这是一个强烈的放热反应：2 H2S + SO2 3 S + 2 H2O,Sulfur Recovery Unit硫回收装置 (Claus),31,Main Burner 主燃烧器,1st Condenser 一级凝结器,Fuel Gas 燃料气,Acid Gas 酸气,Air空气,Liquid Sulfur 液硫,MP Steam废热锅炉产生中压蒸汽,LP Steam 冷凝器产生低压蒸汽,Acid Gas 酸气组成 H2S C02 H20 压力0.07MPag,198C,Approx 70%of the sulfur is obtained in the thermal
42、process step, and condensed to liquid state in the 1st condensor. 大概70%的硫磺在这个步骤中产生，并在一级冷凝器中冷暖成液硫。,Acid Gas Sources 酸气来源 Sulfur Removal Unit 脱硫装置 Tail Gas Treatement Unit 尾气处理装置 Produced water stripper 产品气汽提),Claus Process 克劳斯工艺 Two stages 两级 1. Thermal 热反应段 2. Catalytic 催化反应,Sulfur Recovery Unit硫回收装
43、置 (Claus),32,Main Burner 主燃烧器,1st Condenser 一级冷凝器,1st Reactor 一级反应器,Fuel Gas 燃料气,Acid Gas 酸气,Air 空气,Liquid Sulfur 液硫,1st reheater 一级再热器,MP Steam,MP Steam 1t/h,Acid Gas 67% H2S 29% C024% H20,LP Steam,Catalytic step催化阶段 The Claus reaction continues in the catalytic step with activated, and serves to b
44、oost the sulfur yield. More hydrogen sulfide (H2S) reacts with the SO2 formed during combustion in the main burner, and results in gaseous, elemental sulfur. 在活性氧化铝催化剂的作用下，克劳斯反应在催化阶段继续，产生硫磺。在主燃烧器燃烧阶段，更多的H2S和SO2 反应，产生气态元素硫。2 H2S + SO2 3 S + 2 H2O The catalytic step consists of three substeps: 催化阶段由以下
45、3个分部组成： 1) heating to prevent sulfur condensation in the catalyst bed, which can lead to catalyst fouling, 过程气再热，获得反应器合适的温度，以及防止硫磺在催化剂床凝结导致催化剂污染。 2) catalytic reaction and 催化反应 3) cooling plus condensation. 硫磺冷凝,2nd Condenser 二级冷凝器,Sulfur Recovery Unit硫回收装置 (Claus),33,Main Burner主燃烧器,1st Condenser 一
46、级冷凝器,1st Reactor 一级反应器,2nd Condenser 二级凝结器,Tail Gasto TGTU 到尾气处理装置的尾气,2nd reheater二级再热器,2nd Reactor 二级反应器,Fuel Gas燃料气,Acid Gas酸气,Air空气,Liquid Sulfur液硫,1st reheater 一级再热器,3rd Condenser 三级凝结器,MP Steam,MP Steam,Analyzers for H2S and SO2 on Tail Gas control the amount of air to the Main burner to mainta
47、in the 2:1 Ratio. 三级冷凝器出口的H2S 和SO2 分析仪控制到主燃烧器的空气比率为：。,Acid Gas 67% H2S 29% C024% H20,LP Steam,330C,Liquid Sulfur De-gasing,液硫脱气,34,液流来自液硫封 Liquid sulfur from sulfur locks,液流池Sulfur Pit,脱气后的液流去硫磺厂储罐 degassed liquid sulfur to the tanks in sulfur plant,鼓泡空气 Air bubble,ENVIRONMENT FOCUS 环保关注点,气体污染：酸气(H2
48、S, SO2) 泄漏 Gas pollution: acid gas (H2S, SO2) leakage 固体污染：固废物堆放、催化剂储存及填装时的粉尘 Solid pollution: solid waste piles, dust when storing and filling catalyst 液体污染：锅炉排污、冷凝器排污、液硫及液硫池泄漏 Liquid pollution: boiler blowdown, condenser blowdown, liquid sulfur leakage, and sulfur pit leakage 热辐射：燃烧炉、再热炉、冷凝器、反应器、蒸汽泄漏 Heat radiation: burner, reheating furnace, condenser, reactor and steam leakage 噪声污染：管线噪声、机械噪声 Noise pollution: duct pollution, mechanical pollution,尾气处理单元 Tail Gas Treatment Unit(TGTU),
