DOC. NO. PDRP0456-8110-PD-106-0002 REV.

O1
HDO DOC. NO. A4-2100866-106-BEP-Vol I-002
PROCESS DESCRIPTION
PARADIP REFINERY PROJECT CONDENSATE RECOVERY SYSTEM
FOR
INDIAN OIL CORPORATION LIMITED
CONSULTANT: -
FOSTER WHEELER (INDIA)
SUBMITTED
BY

DORR-OLIVER HOUSE,
CHAKALA, ANDHERI (EAST), MUMBAI 400099
INDIA
TEL. NO. :-022 28359400
FAX NO. :- 022 28365659

R1 10.06.2010 ISSUED FOR APPROVAL PRB TM RK

PREPARED CHECKED APPROVED
REV. DATE REVISIONS
BY BY BY
HINDUSTAN DORR OLIVER LTD.

PROCESS DESCRIPTION

General:
Condensate generated in the refinery units is mainly from the process heaters, reboilers etc. Within the
refinery units, HP and MP condensate are flashed in LP flash drum and LP condensate is flashed in
atmospheric flash drums generating LLP condensate which is pumped back to Unit 106. As there is a
chance of contamination in the generated condensate from the process units, this suspect condensate
needs to be treated in Condensate Recovery Unit (unit 106) before using it in the boiler units. The
condensate polishing plant reduces very small quantities of contaminants that can appear in the
condensate. The contaminants like NaCl, KCl, silica etc. besides being traces of impurities
produced during turbine operations, may include residual impurities in the make-up water and
can also appear as a result of leakage of cooling water into the condensers. Such contaminants
can accumulate and cause corrosion of boiler tubes and the formation of deposits in turbines. These
effects are minimized by the condensate polishing plant. The condensate polishing is done by Ion
Exchange process with resins.

Condensate Collection And Transfer unit:

HP and MP suspect condensate is collected from each unit (or group of near by units) in the suspect
condensate header and routed to a local LP suspect condensate flash drum. The LP suspect condensate
flash drums operate at LP steam pressure and the flashed steam goes to the LP steam header. The
condensate from the LP suspect condensate flash drum is routed to Atmospheric suspect condensate
flash drums (AFDs) on level control. The LP suspect condensate flash drums and the atmospheric
suspect condensate flash drums are located within the process unit (or group of nearby process units).
However, if the quantity of condensate is low, one drum can cater for more than one unit. Depending on
the quality, quantity and location, the LLP steam (generated from the atmospheric flash drum) may be
utilised in the refinery or condensed back into the system. The LLP condensate from the AFDs is
pumped back through the suspect condensate collection header to the suspect condensate tank (106-TK-
001).

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The suspect condensate pressure required at each of the refinery unit battery limit is 7.7 kg/cmg.
Since there is always a possibility of condensate becoming contaminated due to leakage from the
process and utility systems, online conductivity, hydrocarbon and pH analysers shall be provided on the
LLP suspect condensate return pump discharge line from respective process units or a group of units.

The collection header for the steam traps will be dedicated for steam traps only and shall be sized based
on an assumption of 10% of steam trap failing. The dedicated steam trap collection headers shall be
flashed either in dedicated or in the condensate flash drums in the process units and pumped to the
return LLP condensate header. Mixing of un-flashed condensate from steam traps with pumped
condensate in the return line is not permitted. Collection, flashing and return of the steam trap
condensate are in the scope of the respective process units.

Condensate Recovery System:

The LLP condensate from each of the process units will be collected in a header and routed to
Condensate Recovery Unit (Unit 106). The pressure of LLP condensate at Condensate Recovery Unit
battery limit is estimated to be 3.5 Kg/cm2g. In the condensate recovery unit, suspect condensate is first
cooled in the DM Water Heater (106-E-001). In this exchanger, DM water is preheated before feeding
to the deaerators using the recovered heat from the suspect condensate. The DM water enters into the
CPP battery limit at around 68C. The suspect condensate is then further cooled in the clean condensate
heater (106-E-002). The clean condensate which is pumped from the clean condensate storage tank
to the CPP battery limit is heated in this exchanger to 64C. A final trim cooling of the suspect
condensate is done in the condensate trim cooler (106-E-003) before it is sent to the centralized suspect
condensate tank (106-TK-001).

Provision for monitoring the level of contamination in the suspect condensate at the inlet of the
condensate polishing unit (CPU) is included. Online conductivity, hydrocarbon and pH analysers are
installed at the discharge of the Unpolished Condensate Feed Pumps(106-P-001A/B/C). If excessive
contamination is detected, provision for dumping the suspect condensate is also provided. Excessive
contaminated condensate is to be automatically diverted to the oily water sewer (OWS) system

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for disposal. Fire water will be provided to be used as quench automatically when hot condensate is
dumped to cool the flow to drain. This centralised online analysing system is in addition with the
analysers located in the respective process units.

Based on the above consideration, the centralised suspect condensate storage tank (106-TK-001) is
designed for 6.4 hours storage of recovered suspect condensate in the full refinery based on 90%
recovery of condensate. For the fuel refinery configuration, the tank hold up capacity is around 8.4
hours. The tank net capacity is 8312 m3. Three x 50% Unpolished Condensate Feed Pumps (106-P-
001A/B/C) shall be provided to pump the suspect condensate from suspect condensate tank (106-TK-
001) to condensate polishing unit which comprises of Oil coalescer (106-V
003A/B/C/D/E/F/G/H/J/K/L), Activated Carbon Filter (106-V-004 A/B/C/D/E/F/G/H/J), Cartridge Filter
(106-GN-001) and Mixed bed Exchanger (106-V-005A/B/C/D). Oil coalescer (106-V-003
A/B/C/D/E/F/G/H/J/K/L) removes Oil and suspended solids, Activated Carbon Filter (106-V-004
A/B/C/D/E/F/G/H/J) removes hydrocarbons and Mixed Bed Exchanger (106-V-005A/B/C/D) removes
inorganic Contaminants. The media in the coalescing and carbon filters must be selected to avoid
leaching of silica into the filtered water. The spare train is always available for polishing in case any one
of the operating trains malfunction and is taken for maintenance. To cater for the increased condensate
load of the deferred process units of the Full refinery one extra identical CPU train is to be added in the
same package and to be integrated to the present scheme. For backwashing of the exhaust CPU unit, two
x 100% CPU Backwash Pumps (106- P-002 A/B) are to be installed. Condensate from the centralised
clean condensate tank (106-TK-002) is pumped to the CPU for back wash and the back washed
condensate is drained to OWS. A CPU Backwash Cooler (106-E-004) is to be installed at the CPU
Backwash Pump discharge, to ensure that the water supplied for backwash is cooled to a temperature
below 50C before it enters the CPU.

Chemical Reactions:
The impurities removed from condensate by ion exchange resin (in the form of small beads) consist in
general of salts and other substances (e.g. NaCl, Na2SO4) that, when dissolved in water,
dissociate into cations (Na) respectively, in case of above examples and anions (Cl, SO4OH in
the same case). In the polisher unit, which contains a mixture of cations and anions resins, the
above cation should be exchanged for the Hydrogen (H+) cations with which the cation resin is

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loaded, and above anions would be exchanged for Hydroxil (OH-) anions with which the anion
resin is loaded.

The following examples of some chemical reactions that take place in the polisher units
demonstrate how the resin (R) changes the raw condensate into the required polished condensate.
In the case of sodium chloride, shown in the example as NaCl, it can be seen that the cation
resin RH collects sodium cation and becomes RNa, and the anion resin R (OH) collects the
chloride anion from the HCl, so that R(OH) + HCl becomes RCl + H2O.

Polishing process:
Cation exchange during service cycle
RH + NaCl = RNa + HCl
Resin with Sodium Resin with Hydrochloric
Hydrogen Chloride Sodium Cation acid
cation
2RH + Na2SO4 = 2RNa + H2SO4
Resin with Sodium Resin with Sulphuric
Hydrogen Sulphate Sodium Cation acid

Anion exchange during service cycle

R(OH) + HCl = RCl + H2O

Resin with Hydrochloric Resin with Water
Hydroxyl anion acid Chloride anion

2R(OH) + H2SO4 = R2SO4 + 2H2O

Resin with Sulphuric Resin with Water
Hydroxyl anion acid Sulphate anion

During a service run, the resin, shown above as 2 RNa and RCl gradually becomes exhausted
and can collect no more Na and Cl. They then require regeneration, which is demonstrated by
further examples below. It can be seen that regeneration of resins with HCL returns it to its
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original form, shown as RH, and regeneration of the anion with NaOH, without the Sulphation
Stages, returns to its original form as R(OH).

Exhausted Resin regeneration:

Regeneration is done by separating the cation resin from the anion resin by passing up flow
water through the mixed resins. The higher specific gravity cation resin settles to the bottom of the
layer of anion resin in a Resin Separation Tank. The two resins are separated; each is separately
regenerated and washed; then mixed and kept ready in CRT vessel as stand-by charge.

1) Cation resin Regeneration

Regeneration of the cation resin is done with an acid (Example : HCl)

C.R. + H.A. H.R. + Acid + C.A
Exhausted An acid Hydrogen form Excess Mineral
cation resin Cation resin acid

2) Anion resin regeneration:

Regeneration of the anion resin is done with an alkali (Example: NaOH)

A.R. + OH.C OH.R + OH.C + C.A.

Exhausted Alkali Hydroxide form Excess Mineral
anion resin anion resin alkali

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