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Questions and Answers
What is the primary source for producing hydrogen in the Hydrogen Generation Unit?
steam reforming process with naphtha or natural gas feed
What type of reactor is the Technip Parallel Reactor (TPR)?
Process Monitoring Manual of HGU must be reviewed and updated quarterly.
False
Regarding confidentiality, the materials presented in the document are considered _____________.
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What is the range of temperature for the reactor?
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What impurity is adsorbed on ZnO reactor?
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The Pre-Reforming process converts heavy hydrocarbons to H2, CO, CO2, CH4, and ensure C2+ contents in outlet gas is ______.
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The hydrogen partial pressure in the reactor is less than 7.0 kg/cm2(g).
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What is the potential issue if there is a High Sulfur in Desulfurized Naphtha?
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What can cause Hydrogen Compressor Fluctuations?
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A potential issue in the Pre-Reformer unit is the Deactivation of the ____.
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A sudden drop in Inlet Temperature in MT/LT Shift Reactor is a common issue.
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What are the various feeds for the Hydrogen Generation Unit?
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Which process is involved in converting the Naphtha/NG to hydrogen?
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In the Feed Desulfurization process, sweet naphtha is used as feed for the hydrogen unit.
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The TPR® stands for Technip Parallel ____________.
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Match the following components with their descriptions:
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Study Notes
Process Monitoring Manual for Hydrogen Generation Unit (HGU)
Revision History and Purpose
- The document is a first release in June 2020, with a revision frequency of once a year.
- The manual aims to improve reliability, productivity, and safety of Refinery Processes and Equipment in Indian Oil.
Hydrogen Generation Unit (HGU)
- HGU caters to the hydrogen requirement of Hydroprocessing units.
- Hydrogen is produced using steam reforming process with naphtha or natural gas feed.
- Availability and reliability of the hydrogen unit are critical for the operation and performance of hydroprocessing units.
Process Monitoring Manual Content
- The manual covers standardized guidelines for effective monitoring of the HGU.
- It includes troubleshooting guidelines, major incidents, and learnings compiled from experts from IOCL Refineries and RHQ.
- The manual is reviewed and updated annually to incorporate new procedures, troubleshooting methods, and learning incidents.
Confidentiality
- The materials presented in this document are confidential and for the exclusive use of IOCL.
- The document should not be distributed or made available to any other person/s or company without the knowledge and written consent of the competent authority.
Abbreviations
- HGU: Hydrogen Generation Unit
- NG: Natural Gas
- IBP: Initial Boiling Point
- FBP: Final Boiling Point
- PDS: Pre-desulfurization Section
- FDS: Feed desulfurization Section
- COT: Coil Outlet Temperature
- CIT: Coil Inlet Temperature
- RG Boiler: Reformed Gas Boiler
- TPR: Technip Parallel Reformer
- HTCR: Haldor Topsoe Convection Reformer
- HT Shift: High Temperature Shift Reactor
- MT Shift: Medium Temperature Shift Reactor
- LT Shift: Low Temperature Shift Reactor
- PSA: Pressure Swing Adsorption
- DSN: Desulfurized Naphtha
- DMW: Demineralised Water
- BFW: Boiler Feed Water
- CBD: Continuous Blow Down / Closed Blow down
- IBD: Intermittent Blow down
- SRN: Straight Run Naphtha
- FD Fan: Forced Draft Fan
- ID Fan: Induced Draft Fan
- SOR: Start of Run
- EOR: End of Run
- DCU: Delayed Coker Unit
- CDU: Crude Distillation Unit
- MSQU: Motor Spirit Quality Upgradation
- OHCU: Once Through Hydrocracker Unit
- CCRU: Continuous Catalytic Cracking Unit
- VBN: Vis-Breaker Naphtha### Hydrogen Generation Unit (HGU)
- The HGU is designed to produce hydrogen for secondary hydro processing units.
- Various feedstocks can be used, including:
- Natural Gas (NG)
- Straight run naphtha
- Light naphtha
- Hydrocracked naphtha
- Coker Naphtha
Feed Pre-desulfurization
- Sour naphtha is desulfurized in a HDS unit to remove sulfur and produce sweet naphtha.
- Sweet naphtha is used as feed to the hydrogen unit and undergoes final desulfurization.
- Hydrogen required for sulfur conversion is provided from the hydrogen product.
Feed Desulfurization
- Sweet naphtha is passed through a final desulfurization step to remove sulfur and chloride.
- Natural Gas feed is directly processed in the Feed Desulfurization section for removal of sulfur.
- The desulfurization process involves the removal of impurities such as silicon, sulfur, chlorine, and nitrogen.
Pre-Reforming
- In the pre-reformer, naphtha/NG is reformed in the presence of steam to produce hydrogen, methane, carbon monoxide, and carbon dioxide under adiabatic conditions.
- The steam to carbon ratio is calculated based on the hydrocarbon weight flow/carbon content of the feed.
Reforming
- The pre-reformer effluent is reformed in catalyst-filled reformer tubes to produce hydrogen, methane, carbon monoxide, and carbon dioxide.
- The reformer is a fired furnace with tubes containing catalyst.
Parallel Reformer
- The TPR (Technip Parallel Reactor) is an unfired reformer that is installed parallel to the primary reformer.
- The TPR uses an increased steam to carbon ratio to ensure proper conversion of the feed.
Shift Conversion
- The reformer effluent is cooled and passed through a shift reactor section that converts carbon monoxide to carbon dioxide and hydrogen.
- The shift reactors can be a combination of HT (High Temperature), MT (Medium Temperature), and LT (Low Temperature) to ensure maximum conversion of carbon monoxide.
Hydrogen Purification (PSA)
- The process gas, after cooling and process condensate separation, is fed to the PSA unit and purified to produce hydrogen.
Steam System
- The steam system consists of the degasser, BFW system, steam generator, and steam superheater.
- Steam is generated from the convection coils of the reformer and also from the Reformed Gas (RG) Boiler.
Heat Supply and Flue Gas Heat Recovery
- The heat required for the reforming reactions in the steam methane reformer is supplied by purge gas fuel supplemented by vaporized sour naphtha/Natural Gas.
- Combustion air is supplied from Forced Draft (FD) fans, and heat is recovered from the flue gases through convection coils.
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This quiz assesses your understanding of the process monitoring manual, covering topics such as hydrogen generation units and process reliability. Test your knowledge of process monitoring and improvement.
