MEROX

Merox is an acronym for MERcaptan OXidation. It is a proprietary catalytic chemical process developed by UOP used at National Refinery to remove mercaptans from LPG, propane, butanes, light naphthas, heavy naphthas and kerosene by converting them to liquid hydrocarbon disulfides. The Merox process requires an alkaline environment which is provided by an aqueous solution of sodium hydroxide (NaOH), a strong base, commonly referred to as caustic. The catalyst is impregnated onto charcoal granules. UOP has developed many versions of the Merox process for various applications. Presently three types of MEROX processes are being used at the fuel refinery. 1. Conventional Merox for extraction of mercaptans from LPG, propane, butanes or light naphthas. 2. Conventional extraction plus sweetening Merox for heacy naphthas. 3. Conventional fixed-bed catalytic Merox for sweetening of kerosene.

106 LPG MEROX (EXTRACTION)

Design process capacity = 1200 BPSD Extraction is used for low molecular weight mercaptans that can easily be removed from the feed streams at low temperatures and pressures. Extraction converts the mercaptans into disulphides in the presence of an alkaline environment such as caustic. Regeneration is an integral section which is followed by extraction. The 106 unit comprises of the following sections; 1. Pre-washing 2. Extraction 3. Settler 4. Sand Filter

PRE-WASHING LPG obtained from 101 unit is the feed stream of 106 unit. LPG from 101 LCV-246 is directed to the 106 unit where the flow to the pre washing section is controlled by an FCV-203. Prewashing is used to removed the presence of H 2S that would otherwise react with the circulating caustic in the extractor and would interfere with merox reactions. Caustic used for this purpose is of 10 oBaume strength which is sufficient for the absorption of trapped H2S contents. Feed now free from H2S is feed into the extractor. The reaction followed in this step is as follows; H2S + 2NaOH EXTRACTOR The extractor is a 43 ft high tower which is fitted with 7 trays which are used to provide intimate contact between the circulation caustic and LPG. Feed from the pre washing section enters at the bottom of the tower from the 7th tray where as the circulating caustic which is of strength 20 o Baume is introduced from the top of the 1 st tray. The counter-current flow provides maximum possible contact between LPG and caustic and the mercaptan sulpur present is converted into sodium mercaptan. The reaction is followed as; 2RSH + NaOH 2NaSR + 2H2O Na2S + 2H2O

The mercaptant rich caustic is now sent to the regeneration section, controlled by LCV-207, in order to recover the caustic solution. CAUSTIC SETTLER The stream free from mercaptant is now fed into a caustic settler from top of the extractor. The settler works as a knock out vessel which is used to remove any entrained caustic in the product stream. The entrained caustic is also sent to the regeneration section. SAND FILTER Sand filter is installed to meet the product specification and ensures that if any water or caustic trapped in the product is further filtered out and marketed. The pressure required to keep LPG in liquid form is controlled through PCV-211 before sending it down to the storage.

107 HEAVY NAPHTHA MEROX (EXTRACTION + SWEETENING)

Design process capacity = 2600 BPSD The heavy naphtha merox comprises of the following sections; 1. Pre washing 2. Extraction 3. Merox Reactor 4. Settler 5. Sand Filter The pre washing and the extraction stages of 107 unit are the same as that of 106 unit. Since mercaptants present in heavy naphtha are of higher molecular weight, there both extraction plus sweetening is utililized in this unit. NAPHTHA MEROX REACTOR The naphtha from top of the extractor enters into the reactor (R7) which is loaded with a catalyst which is activated charcoal, impregnated with merox reagent. Controlled quantity of air is injected from FCV-238 to the reactor feed to supply oxygen needed for oxidation of mercaptants to disulfides. Following chemical reaction takes place in the reactor; 4RSH + O2 SETTLER Sweetened naphtha comes out from the bottom of the reactor and enters a horizontal vessel called the settler to minimize any chances of caustic entrainment with naphtha. SAND FILTER Sand filter is installed to meet the product specification and ensures that if any water or caustic trapped in the product is further filtered out and marketed. The rundown pressure of nahptha is controlled through PCV-244 which is now sent to storage. 2RSSR + 2H2O

108 A KEROSENE MEROX

Design process capacity = 8840 BPSD The 108 A merox comprises of the following sections; 1. Pre washing 2. Sand Filter 3. Merox Reactor 4. Settler 5. Water Filter 6. Salt Filter 7. Clay Filter KEROSENE MEROX REACTORS Kerosene from the sand filter enters two parallel reactors from the top. Controlled quantity of air is injected from FCV-115 at the inlet of the reactors. The reactors are loaded with activated charcoal catalyst impregnated with merox reagent. Following reaction takes place in the reactor; 4RSH + O2 SETTLER Sweet kerosene comes out from the bottom of the reactor and enters the settler to minimize the chances of caustic with naphtha product. WATER WASH Kerosene from settler enters a water wash vessel which is operated at 50% full of water to absorb any impurities and merox catalyst entrained with kerosene. SALT FILTER 2RSSR + 2H2O

Sweet kerosene from top of the water wash vessel is although free of caustic but if now contains traces of water, is undesirable. Therefore it is passed through a salt filter which absorbs moisture from kerosene.

CLAY FILTER After salt filter the product may still contain some gum forming compounds which are objectionable for blending. These impurities are removed by passing kerosene through a clay filter. Kerosene from salt filter enters the top of clay filter fitted with 30 60 mesh Fullers Earth type Clay. Finally the kerosene product is now sent for storage controlled through PCV-132A.

108 B LIGHT NAPHTHA MEROX

Design Process Capacity = 8840 BPSD The light naphtha merox comprises of following sections; 1. Pre Washing 2. Merox Reactor 3. Settler 4. Sand Filter PRE-WASHING Pre-washing is used to removed the presence of H2S that would otherwise interfere with merox reactions. Caustic used for this purpose is of 10 oBaume strength which is sufficient for the absorption of trapped H2S contents. The reaction followed in this step is as follows; H2S + 2NaOH MEROX REACTOR After pre washing light naphtha enters the reactor R3C. Controlled quantity of air is injected at the inlet of the reactor. The reactor is loaded with activated charcoal catalyst impregnated with merox reagent. Following reaction takes place in the reactor; Na2S + 2H2O

4RSH + O2 CAUSTIC SETTLER

2RSSR + 2H2O

The stream free from mercaptant is now fed into a caustic settler. The settler works as a knock out vessel which is used to remove any entrained caustic in the product stream. SAND FILTER Sand filter is installed to meet the product specification and ensures that if any water or caustic trapped in the product is further filtered out and marketed. The run down pressure is controlled through PCV-132B before sending it down to the storage.

CAUSTIC REGENERATION SECTION

Circulating caustic from 106 and 107 extractors is first heated to a certain temperature in heat exchanger 107 E1 through steam which is required to meet the oxidation conditions. Now the preheated caustic is introduced into an oxidizer, 107 V4, which is packed bed to keep caustic and water insoluble disulphide well contacted and mixed. Air required for oxidation is injected from FCV-226 at the inlet of oxidizer. Following reaction takes place in the oxidizer; 4NaSR + O2 + 2H2O 2RSSR + 4NaOH

This mixture now enters a horizontal vessel called the disulphide separator, 107 V5, which is fitted with rachig rings which provide contact area in order for caustic to settle down at the bottom of the vessel from where it is pumped out again for circulation through pumps 107 P1 A/B whereas the oily disulphide floats on top. The disulphide pressure is controlled through PCV-234 and the contaminated air moves into a flame arrestor to minimize the chances of ignition of air with combustible mercaptides.

MEROX UNITS
MEROX UNITS 106 LPG 107 Heavy Naphtha 108 A Kerosene 108 B Light Naphtha CAPACITY PSV POPUPS 1200 BPSD 2600 BPSD 8840 BPSD 8840 BPSD 237 psi 160 psi 173 psi 170 psi

PUMPS AND THEIR TRIPPING

PUMPS 108 P1 A/B 108 P2 A/B 108 P4 A 108 P4B/C 107 P1 A/B 119 P1 A/B DISCHAGE PRESSURE OPERATING AMPERES TRIPPING 6 barg 6 barg 11 barg 11 barg 10 barg 9 barg 20 45 40 50 30 70 32 80 80 105 50 125

COMPRESSORS AND THEIR SAFETIES

COMPRESSORS ONLOAD OFFLOAD 108 K1 A /B 108 K1 C 142 PSIG 146 PSIG 148 PSIG 152 PSIG

LINEUP REPORT OF 106, 107, 108A AND 108 B MEROXS