CO₂ Recovery Unit for By-product Gas From Petrochemical Plants
Introduction
The CO₂ Recovery Unit for Petrochemical By-product Gas is designed to recover, purify, and liquefy carbon dioxide from industrial gas streams, including ethylene oxide off-gas, synthetic ammonia tail gas, and hydrogen plant vents.
Technical Specifications of the CO₂ Recovery Unit
|
Technical Parameter |
Standard Range / Specification |
|
Nominal Processing Capacity |
1,000–10,000 kg/h |
|
Inlet CO₂ Concentration |
30%–95% (v/v) |
|
Inlet Operating Pressure |
0.02–0.50 MPa(g) |
|
Inlet Operating Temperature |
20–45°C |
|
CO₂ Delivery State |
Gaseous or liquid |
|
CO₂ Delivery Pressure |
Gaseous: 1.5–2.5 MPa(g); liquid: 1.8–2.2 MPa(g) |
|
CO₂ Recovery Rate |
85%–98% |
|
Final CO₂ Purity |
Industrial grade: ≥99.9%; higher purity up to 99.99% |
|
Compression System |
Multi-stage reciprocating or oil-free screw compressor |
|
Refrigeration System |
Closed-loop R717 or R404A |
|
Equipment Configuration |
Skid-mounted modules for smaller capacities |
|
Electrical Supply |
380 V–11 kV, 50–60 Hz |
|
Applicable Design Codes |
ASME Section VIII Division 1, GB 150, or PED 2014/68/EU |
Typical Feed Gas Composition
|
Gas Component |
Typical Concentration Range |
Engineering Consideration |
|
Carbon Dioxide (CO₂) |
30%–95% (v/v) |
Determines recovery process and equipment sizing |
|
Hydrogen (H₂) |
0.5%–15% (v/v) |
Requires non-condensable gas separation |
|
Methane and Light Alkanes |
0.1%–10% (v/v) |
Affects refrigeration and separation requirements |
|
Carbon Monoxide (CO) |
0.1%–5% (v/v) |
May require catalytic treatment, depending on product requirements |
|
Nitrogen and Argon (N₂ + Ar) |
0.5%–8% (v/v) |
Affects non-condensable gas removal |
|
Oxygen (O₂) |
Trace to 1.5% (v/v) |
May require dedicated treatment based on feed composition and process safety review |
|
Sulfur Compounds |
Total sulfur: <5–500 ppm |
Determines desulfurization requirements |
|
Moisture |
Based on feed conditions |
Removed through separation and drying before low-temperature processing |
Operating Conditions
Operating flexibility: The stated design range is 50%–110% of nominal throughput, subject to confirmation for the selected configuration.
Feed variations: Pressure variations of ±15% and temperature changes of ±10°C from baseline require verification against the project design basis.
Feed analysis: The buyer should provide validated gas chromatography (GC) results, including gas composition, sulfur compounds, moisture, pressure, temperature, and flow rate.
CO₂ Product Purity & Impurity Limits
|
Quality Parameter |
Industrial Grade Target |
High-Purity / Food-Grade Option |
Analytical Method |
|
CO₂ Concentration |
≥99.9% (v/v) |
≥99.99% (v/v) |
Gas chromatography (TCD) |
|
Moisture Content |
≤20 ppm (v/v) |
≤10 ppm (v/v) |
Quartz crystal or chilled-mirror hygrometer |
|
Total Sulfur (H₂S + COS) |
≤1 ppm (v/v) |
≤0.1 ppm (v/v) |
Lead acetate method or GC with sulfur detection |
|
Non-condensable Gases |
≤500 ppm (v/v) |
≤50 ppm (v/v), with O₂ ≤10 ppm |
Gas chromatography |
|
Total Hydrocarbons |
≤50 ppm (v/v) |
≤5 ppm (v/v), expressed as CH₄ |
Flame ionization detector (FID) |
Plant Integration & Automatic Control
Plant interfaces: Flanged connections are provided for feed gas, CO₂ product, cooling water, instrument air, and drains according to the agreed piping standards and battery limits.
Control system: PLC or DCS integration, communication protocols, and supported platforms are selected according to project specifications.
Safety & monitoring: Instrumentation monitors key operating parameters, including pressure, temperature, dryer differential pressure, and liquid storage levels. ESD and pressure protection systems are configured according to the approved safety design.
Supply boundaries: The manufacturer and buyer/EPC agree on terminal valves, utility tie-ins, civil foundations, external piping, electrical supply, and field cabling before contract execution.
Engineering deliverables: Documentation may include P&IDs, I/O lists, control narratives, cause-and-effect matrices, and panel layout drawings.
Commissioning & Warranty
Scope of Supply: The manufacturer provides the agreed process skids, compression equipment, distillation modules, skid piping, and control cabinets.
Commissioning Support: Field services may include equipment alignment, interface checks, loop testing, commissioning, and start-up supervision.
Performance Acceptance: Agreed test procedures verify throughput, product purity, recovery, and specific power consumption.
Guarantee Conditions: Guarantees apply under the agreed feed composition, pressure, temperature, utility conditions, and operating procedures.
Warranty: Warranty terms are defined in the contract, typically covering 12 months of operation or 18 months from shipment, whichever comes first. Initial remote technical support is targeted within 24 hours of written notification.
FAQ
Q: What is the typical project lead time?
A: A 3 t/h unit typically requires 6–8 months for delivery, while a 10 t/h unit requires 9–12 months. Installation takes 4–8 weeks, followed by 3–4 weeks for commissioning and performance testing.
Q: Should I choose R717 or R404A refrigeration?
A: R717 ammonia refrigeration uses less power and suits plants above 3 t/h, provided appropriate safety measures are in place. R404A is suitable for smaller units or sites where ammonia is not permitted, although its high GWP may be subject to phase-down requirements.
Q: How much electricity does the unit consume?
A: At 99.9% purity, liquid CO₂ production typically requires 130–200 kWh/t. Gaseous CO₂ at 2.0 MPa(g), without liquefaction, requires approximately 70–110 kWh/t.
Q: What is the service life of the main components?
A: Compressor valves and rings are serviced every 8,000–12,000 hours. Dryer adsorbent, desulfurization media, and deoxygenation catalyst typically last 3–5 years.
Q: Can certifications and quality documents be verified?
A: Yes. ISO 9001, ASME U Stamp, PED or GB pressure-vessel certificates, and EN 10204 3.1 material certificates can be verified with the issuing body. Third-party witnessing by organizations such as SGS or TÜV is also available.
Q: How are oxygen and flammable gases handled safely?
A: Feeds containing oxygen and combustible gases are treated by catalytic deoxygenation or nitrogen dilution. Oxygen analyzers and interlocks shut down the compressors if oxygen levels rise above the set limit, and a HAZOP review is completed before design finalization.
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