1. INTRODUCTION .........................................................................................................

2. GENERAL DESCRIPTION OF CO2 RECOVERY UNIT ...............................................3

2.1. PROCESS DESCRIPTION .......................................................................................... 3

2.2. PROCESS CONSIDERATION .................................................................................... 5

3 START UP AND SHUT DOWN ..................................................................................10

3.1 INITIAL CHARGE OF KS-1 SOLUTION ................................................................. 10

3.2 START UP ................................................................................................................... 11
3.3 SHUT DOWN.............................................................................................................. 20
3.4 DRAIN OUT OF KS-1 SOLUTION ........................................................................... 22

4. NORMAL OPERATION .............................................................................................23

4.1. FLUE GAS SUPPLY SYSTEM .................................................................................. 23

4.2. FLUE GAS WASHING AND COOLING SYSTEM ................................................... 24
4.3. KS-1 SOLUTION CIRCULATION SYSTEM ............................................................ 25
4.4. TREATED FLUE GAS WASHING SYSTEM ............................................................ 26
4.5. REGENERATOR REFLUX SYSTEM ....................................................................... 27
4.6. ACTIVATED CARBON FILTER SYSTEM ............................................................... 27
4.7. REBOILER-STEAM SYSTEM .................................................................................. 28
4.8. OPPERATING LOAD................................................................................................. 29
4.9. RECLAIMING OPERATION ..................................................................................... 29
4.10. WASTE HEAT BOILER OPERATION ...................................................................... 32

5. SAMPLING AND ANALYSIS .....................................................................................33

5.1. LEAN KS-1 SOLUTION ............................................................................................ 33

5.2. RICH KS-1 SOLUTION ............................................................................................. 34
5.3. ABSOREBER WASH WATER .................................................................................... 34
5.4. SOX REMOVAL........................................................................................................... 34
5.5. MAKE UP KS-1 SOLUTION ..................................................................................... 34
5.6. FLUE GAS .................................................................................................................. 34
5.7. PRODUCT CO2 ........................................................................................................... 34

6. EMERGENCY SHUT DOWN .....................................................................................35

6.1. ELECTRIC POWER FAILURE ................................................................................. 35

6.2. STEAM FAILURE ...................................................................................................... 37
6.3. COOLING WATER FAILURE ................................................................................... 37
6.4. FAILURE OF STEAM CONDENSATE SUPPLY TO WASTE HEAT BOILER

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 (U-3001) ................................................................................................................................... 38
6.5. INSTRUMENTATION AIR FAILURE ...................................................................... 38
6.6. MECHANICAL TROUBLE OF ROTATING EQUIPMENT .................................... 39
6.7. MECHANICAL TROUBLE OF EQUIPMENT / PIPING......................................... 44

7. PREPARATION FOR INITIAL START UP..................................................................45

7.1. PROTECTION OF EQUIPMENT DURING CONSTRUCTION ............................. 45

7.2. CLEANING PRIOR TO START UP........................................................................... 45
7.3. ACTIVATED CARBON CHARGING......................................................................... 45

8. TROUBLES SHOOTING ...........................................................................................48

2
1. INTRODUCTION
This operation manual is written as an operations guide for the CO 2 Recovery plant of
Ruwais Fertilizer Industries (FERTIL). Detailed Engineering Contractor shall be
confirmed and verified during detailed engineering.

2. GENERAL DESCRIPTION OF CO2 RECOVERY UNIT

General description of the CO2 recovery plant is as follows.

2.1. PROCESS DESCRIPTION

CO2 recovery plant shall consist of three main sections; 1) Flue gas Cooling section,
2) CO2 recovery section, 3) Solvent regeneration section. The following block flow
diagram shows the plant configuration.

TREATED
FLUE GAS GENERATED STEAM
FROM SC

FLUE CO2 LEAN

(1)-1 (1)-2 (2) (3)
SOLVENT CO2
GAS Flue Gas Flue Gas CO2 Recovery Solvent
Cooling Cooling Regeneration PRODUCT
(Waste Heat Boiler) TO B/L
CO2 RICH
SOLVENT
SC

Figure 1 : Block Flow Diagram of the CO2 recovery plant

(1) Flue gas cooling

A flue duct will be installed to the existing stacks of the primary reformer and auxiliary
boiler of Fertil’s ammonia plant for flue gas extraction. The flue gas will be extracted
from the stacks through this duct and brought to CO2 recovery plant by Flue gas
blower (K-3001). The existing temperature of flue gas is too high to feed CO2
absorber(C-3001) as a lower flue gas temperature is preferred in terms of the
exothermic reaction of CO2 absorption and KS-1 solvent consumption. Therefore,
the hot flue gas shall be cooled to maximum 46C using the flue gas cooling system
prior to CO2 absorber(C-3001).

The flue gas temperature of 280°C at the primary reformer and auxiliary boiler shall be
used for generating steam from the steam condensate (SC) of the CO2 recovery plant
by Waste heat boiler unit(U-3001), and be cooled down to 170°C. Generated steam
shall be used for Regenerator reboiler(E-3005).

Flue gas quencher(Q-3001) shall be installed as a flue gas cooling facility and for SOx

3
removal. Flue gas quencher(Q-3001) shall be a packed column using structured
dimensionally configured packing. The flue gas shall be cooled in the upper packing
section of flue gas quencher(Q-3001) by direct contact saturation with water supplied
from top of the tower. Circulating water shall be cooled by Flue gas cooling water
cooler(E-3001).

The flue gas contains maximum 5 ppm of SOx. To minimize solvent degradation of
KS-1 solvent, SOx in the flue gas shall be reduced below 1 ppm before entering CO 2
absorber(C-3001). In the lower packing section of Flue gas quencher(Q-3001), SOx in
the flue gas is removed by caustic solution which is circulated by Flue gas wash water
pump(P-3009A/B).
Flue gas blower(K-3001) is required to draw the flue gas from the stack to overcome
the pressure drop across Flue gas quencher(Q-3001) and CO2 absorber(C-3001).
Flue gas blower(K-3001) shall be installed downstream of Flue gas
quencher(Q-3001).

(2) CO2 recovery

CO2 absorber(C-3001) shall use the structured packing in order to reduce the
pressure drop of flue gas inside the column. CO2 absorber (C-3001) consists of two
main sections, the CO2 absorption section in the lower part and the treated flue gas
washing section in the upper part.

The cooled flue gas from Flue gas quencher(Q-3001) shall be introduced into the
bottom section of CO2 absorber(C-3001) through the flue gas blower(K-3001). The
flue gas shall move upward through the packing, while the CO2 lean KS-1 solvent shall
be supplied from the top of the absorption section onto the packing. The flue gas
contacts with the KS-1 solvent on the surface of the packing, where CO2 in the flue
gas is absorbed by the KS-1 solvent. The flue gas then progresses upward into the
treated flue gas washing section in the upper part of the CO2 absorber(C-3001). This
section is similar to Flue gas quencher(Q-3001), where the flue gas shall contact with
water to be washed as well as to be cooled down to maintain water balance within the
system. The treated flue gas shall be exhausted from the top section of CO2 absorber
(C-3001) at sufficient height.

The rich solvent from the bottom of CO2 absorber(C-3001) is directed to the
Regenerator(C-3002) for regeneration by Rich solution pump(P-3003A/B) through
Solution heat exchanger(E-3003).

(3) Solvent Regeneration

Regenerator(C-3002) shall be a random packed column, where the rich solvent is

steam-stripped and CO2 is removed from the rich solvent.
The rich solvent heated by Solution heat exchanger(E-3003) with the lean solvent

4
 shall be introduced into the upper section of Regenerator(C-3002).
In order to utilize the waste heat of lean solvent and steam condensate for solvent
regeneration, the semi-lean solvent extracted from intermediary stage (2 stages) of
Regenerator(C-3002) shall be heated up with the lean solvent from bottom of
Regenerator(C-3002) and steam condensate from Regenerator reboiler(E-3005).
The rich solvent introduced to Regenerator(C-3002) contacts with steam and desorbs
CO2. The steam shall be produced by Regenerator reboiler(E-3005).
The overhead vapor is cooled to 45C by Regenerator condenser (E-3004). The
partially condensed water is returned from Regenerator reflux drum(V-3001) to the top
of Regenerator(C-3002) by Regenerator reflux pump(P-3004A/B).
The lean solvent shall be cooled to 45C by Solution heat exchanger (E-3003) and
Lean solution cooler (E-3006) is directed to the CO2 absorber (C-3001).
10% of the lean solution flows through a Carbon filter (S-3002). Oil contents, dust and
soluble organic compounds are removed in the Carbon filter (S-3002). Up/Down
stream guard filters (S-3001A/B /S-3003) are provided before and after Carbon filter
(S-3002) to remove insoluble particulate.

(4) Solvent reclaiming (Intermittent Operation)

SOx and NO2 reacts with the KS-1 solution in CO2 Absorber (C-3001), and this
reaction forms heat stable salts (HSS). The accumulation of HSS causes the
solution foaming. Reclaimer (E-3007) shall be provided in order to remove HSS
2
accumulated in the KS-1 solvent. It will be also used to reduce suspended solid (SS)
content in the KS-1 solvent.
Reclaimer (E-3007) shall be operated as a simple batch distiller. When the HSS
content or SS in the solvent reaches to the maximum limit, Reclaimer (E-3007) shall
be operated to heat the solvent with caustic soda and reflux water so that the part of
KS-1 solvent of which HSS will be released from HSS and the remains of HSS shall be
concentrated to sludge to be discharged. The part of NO 2 and SOx which is the
composition of HSS reacts with caustic soda in Reclaimer(E-3007), and this reaction
forms the salt and releases the part of KS-1 solvent form HSS. The salt and other
degradation products have higher boiling temperature than the KS-1 solvent.
Therefore, KS-1 solvent and water shall leave the kettle of Reclaimer (E-3007) in the
form of vapor, and the salt and other degradation products shall remain as reclaimed
waste in Reclaimer(E-3007).

2.2. PROCESS CONSIDERATION

2.2.1. Effect of impurities

(1) SO2
If SO2 is fed to CO2 absorber (C-3001) with the flue gas, SO2 reacts with the KS-1
solution and forms heat stable salt (HSS). KS-1 solution reacted with SO2 will be

5
 released from HSS and recovered by the reclaiming operation. However, SO 2 fed to
CO2 absorber (C-3001) will cause the increase of reclaiming operation frequency,
which will raise KS-1 consumption since the part of KS-1 solution fed to Reclaimer
(E-3007) is accompanied by reclaimer waste drained out to the outside of plant.

(2) NOx
Flue gas typically contains several oxides of nitrogen, but the main components are
NO2 and NO. NO fed to CO2 absorber (C-3001) except tiny amount absorbed
physically will be exhausted from the top of CO2 Absorber (C-3001). On the other
hand, some part of NO2 reacts with KS-1 solution to generate the degradation
products which is represented by heat-stable salts. Accordingly, NO2 fed to CO2
absorber (C-3001) will raise KS-1 consumption. Furthermore, NO absorbed
physically by KS-1 solution and small part of NO2 are accompanied by recovered CO2.

(3) O2
Unlike amines, KS-1 solution has some degree of resistance to oxygen of which the
concentration is the same level as air. Accordingly, it is not necessary to introduce
the inert gas for seal into the tanks or other processing equipment which handle KS-1
solution. However, heat-stable salts will be formed by contacting with oxygen in CO2
absorber (C-3001) for long time.

(4) Dust
The accumulation of dust in KS-1 solution may cause some troubles such as the
foaming, corrosion, increase of KS-1 consumption. In addition, the dust will block the
filter.

2.2.2 CO2 absorption

The efficiency of CO2 absorption will be influenced by the following items.
Furthermore, the countermeasures for decline of CO2 recovery rate are shown in
Clause 8 “Troubleshooting”.
- CO2 concentration of flue gas fed to CO2 absorber
- Temperature of flue gas fed to CO2 absorber
- Efficiency of gas-liquid contact

6
 - Flow rate of flue gas and KS-1 solution fed to CO2 absorber
- KS-1 concentration
- CO2 loading of lean KS-1 solution

2.2.3 Water balance

It is important to keep the water balance to maintain KS-1 concentration. The water
balance is automatically maintained by controlling the temperature of CO 2 Absorber
(C-3001)inlet gas or outlet gas to keep the level of KS-1solution at the bottom of CO2
absorber(C-3001) constant. To illustrate the above mechanism, the water balance is
decided by the amount of moisture fed to the CO2 absorber(C-3001) with flue gas,
moisture exhausted from the top of CO2 absorber(C-3001) and moisture accompanied
by product CO2. Furthermore, the amount of moisture fed to the CO 2
absorber(C-3001) will be controlled by the temperature of flue gas cooling water fed to
Flue gas quencher (Q-3001) since the temperature of flue gas is decided by the
temperature of flue gas cooling water. The amount of moisture exhausted from the
top of CO2 absorber(C-3001) will be controlled by the same mechanism as moisture
fed to the CO2 absorber (C-3001).
When the temperature of flue gas fed to CO2 Absorber (C-3001) is higher than the
treated flue gas exhausted from the top of CO2 Absorber (C-3001), the level at the
bottom of CO2 absorber (C-3001) will rise and KS-1 solution will dilute. In opposite
situation, KS-1 solution will get concentrated.

2.2.4. Wash section of CO2 absorber

The main purpose of wash section of CO2 absorber (C-3001) is to recover the
moisture generated with the exothermic reaction of CO 2 absorption and the vapor of
amine. The efficiency of recovering the vapor of amine is strongly influenced by KS-1
concentration of wash water and the temperature of treated flue gas at the outlet of
wash section. Two efficient points for inhibiting the emission of amine are as follows.

1) Feeding the reflux water to wash section

Some part of reflux water is fed to wash section of CO2 absorber (C-3001) to lower
KS-1 concentration of wash water. Specially, 50% of reflux water will be fed during
the normal operation and 30 - 40% will be fed during the reclaiming operation.

2) Lowering of the outlet temperature at the absorber wash section

7
 Lower flue gas temperature is preferred for inhibiting the emission of KS-1 solution.
Therefore, when the temperature of the cooling water is lower than usual because of
night time operation and winter season operation, the temperature of flue gas at the
outlet of wash section shall be lowered to accommodate it.

2.2.5 CO2 loading of lean KS-1 solution

CO2 loading of lean KS-1 solution is dependent upon the condition of KS-1 solution
and Regenerator operation. The method to lower CO 2 loading of lean KS-1 solution
loadings is shown in Clause 8 “Troubleshooting”.

2.2.6 Temperature of KS-1 solution at the bottom of Regenerator (C-3002)

The temperature of KS-1 solution at the bottom of Regenerator (C-3002) shall be kept
below the set point so that the degradation of KS-1 solvent is not promoted.
Although, the temperature of KS-1solution shall be kept above 110degree C to keep
the good performance of CO2 desorption. The temperature of KS-1 solution in
Regenerator (C-3002) will be adjusted by the pressure of Regenerator (C-3002).

2.2.7 KS-1 solution maintenance

Appropriate maintenance of KS-1 solution brings the low consumption of utility and
KS-1 solution and the consecutive stable operation.
The main items about KS-1 solution maintenance are shown below.

(1) Control of KS-1 concentration

Low KS-1 concentration results in high steam consumption since the circulation
amount of KS-1 solution increases. Therefore, KS-1 concentration shall be regularly
monitored and if necessary, the required amount of KS-1 solution shall be made up.

(2) Control of heat-stable salts content

When HSS content is high, the solvent degradation will be promoted and foaming will
occur more readily. Therefore, when the HSS content in KS-1 solution reaches the
limit (2.0 wt %), the reclaiming operation should be started.

(3) Removal of foaming factor

8
 The part of KS-1 solution fed to CO2 absorber (C-3001) is continuously introduced to
activated carbon to remove the foaming factor.
The adequate maintenance of activated carbon shall be carried out.

(4) Control of soluble iron content

When soluble iron content is high, as well as HSS, the solvent degradation can be
promoted and foaming can occur more readily. If soluble iron content reaches 10
ppm, the reclaiming operation shall be started. But, iron content basically doesn’t
reach 10 ppm.

2.2.8 Corrosion
The major causes of corrosion are poor maintenance of KS-1 solution and failure to
follow metallurgical guidelines. The areas where stainless steel is used to prevent
the corrosion are shown below.

(1) Areas exposed to acid gases or liquid. However, Carbon steel can be used in the
areas covered with KS-1.
(2) Areas where flushing occurs. Flushing occurs when carbon dioxide is released
from the solution due to high temperature or pressure reduction.
(3) Areas where the pipe flow velocity is high.

2.2.9 Economical operation

The considerations to achieve economical operation are shown below.

(1) Adjustment of KS-1 solution circulation

Excessive circulation of KS-1 solution leads to the excess consumption of power for
pumping KS-1 solution, steam and cooling water consumption. Accordingly, the
circulation rate of KS-1 solution should be adjusted depending on the operation.

(2) Adjustment of flue gas feeding

Excessive feeding of flue gas leads to the excess emission of KS-1 solution.
Accordingly, the feeding rate of flue gas should be adjusted depending on the
operation.

9
 (3) Cooling of flue gas
High temperature of flue gas fed to CO2 absorber results in low efficiency of CO2
absorption in order to keep the water balance. Furthermore, high temperature of flue
gas fed to CO2 absorber increases the emission of KS-1 solution because the
temperature of treated flue gas exhausted from the top of CO 2 absorber becomes
higher.

(4) Cleaning of Plate heat exchangers connected with Regenerator(C-3002)

When the plate of Solution heat exchanger (E-3003) is dirty, the performance of heat
transfer will be degraded and the steam consumption will increase since the
temperature of KS-1 solution fed to Regenerator (C-3002) will go down. If it has a
large impact upon the economical efficiency, E-3003 shall be washed. Much the same
in true on Semi-lean / lean upper exchanger (E-3008), Semi-lean / lean bottom
exchanger (E-3009), Semi-lean upper heater (E-3010) and Semi-lean bottom heater
(E-3011).

2.2.10 Dilution of KS-1 Solution

It is necessary to dilute KS-1 solution using the demineralized water without chemical
dosage. The water excluded impurities should be used to dilute KS-1 solution.

3 START UP AND SHUT DOWN

3.1 INITIAL CHARGE OF KS-1 SOLUTION
(1) Feed KS-1 solvent 70wt% to Solution sump tank (T-3002). In the case of restart,
make up necessary KS-1 solvent 70wt% after the measurement of KS-1
concentration.
(2) Feed desalinated water to T-3002 for adjusting KS-1 concentration.
(3) Circulate KS-1 solution between Solution storage tank (T-3001) and T-3002 by
Solution sump pump (P-3006) in order to mix KS-1 solvent and water sufficiently.
In the case of restart, it is not required to make up KS-1 solution, the above
operation is not required.
(4) Adjust the amount and concentration of KS-1 solution by the above operation (3.1
(1) and 3.1 (2)) during the circulation.

10
 (5) Stop the circulation after confirming that the amount and concentration of KS-1
solution meet the requirement.
(6) Confirm that the valves of semi-lean lines which are extracted from intermediary
stage (both upper and lower) of Regenerator (C-3002) are opened to fill the piping
and the equipment with KS-1 solution and the valves of semi-lean bypass lines are
closed.
(7) Fill up KS-1 solution into the suction line of Rich solution pump (P-3003A/B) by
Solution sump pump (P-3006) until the liquid level of bottom in CO2 absorber
(C-3001) reaches H.L.L.
(8) Fill up KS-1 solution to Regenerator (C-3002) by Rich solution pump so that the
liquid level of bottom of CO2 absorber (C-3001) doesn’t fall below L.L.L.
(9) Repeat the above operation (7) ~ (8) until the liquid level of Regenerator (C-3002)
reaches H.L.L.

3.2 START UP
3.2.1 Filling the desalinated water or the steam condensate
(1) SOx absorption section of Flue gas quencher (Q-3001)
Fill up the bottom of Q-3001 to H.L.L. with the desalinated water. In addition, open
the valve of circulation line to fill the piping with the desalinated water.
(2) Cooling section of Flue gas quencher (Q-3001)
Fill up the chimney tray of Q-3001 to N.L.L. with the desalinated water from the
suction of Flue gas cooling water pump (P-3001A/B). In addition, open the valve of
circulation line to fill the piping and Flue gas cooling water cooler (E-3001) with the
desalinated water.
(3) Regenerator reflux drum (V-3001)
Fill up V-3001 to H.L.L. with the desalinated water from the suction of Regenerator
reflux pump (P-3004A/B).
(4) Steam condensate drum (V-3002)
Fill up V-3002 to H.L.L. with the steam condensate of the Urea plant from the
suction of Steam condensate return pump (P-3008A/B).
(5) 1st wash section and 2nd wash section of CO2 absorber (C-3001)
Fill up the chimney tray of C-3001 to N.L.L. with the desalinated water from the
suction of 1st wash water circulation pump (P-3002A/B) and of 2nd wash water

11
 circulation pump (P-3007A/B). In addition, open the valves of circulation lines to fill
the piping and Wash water cooler (E-3002) with the desalinated water.

3.2.2 Start up of the circulation operation

(1) SOx absorption section of Flue gas quencher (Q-3001)
1) Confirm that the discharge valve of Flue gas wash water pump (P-3009A/B)
are closed.
2) Start P-3009A/B.
3) Open the discharge valve of P-3009A/B gradually so that the level of wash
water doesn’t fall below L.L.L and the current value of pump doesn’t exceed
the rated.
4) Confirm that the discharge valve and the mini flow valve of Waste water pump
(P-3012A/B) are closed.
5) Start P-3012A/B. Immediately, open the mini flow valve of P-3012A/B.
6) Open the discharge valve of P-3012A/B gradually.
7) Switch the level control of Q-3001 to the automatic mode and adjust the liquid
level to N.L.L.

(2) Cooling section of Flue gas quencher (Q-3001)

1) Confirm that the discharge valve and the mini flow valve of Flue gas cooling
water pump (P-3001A/B) are closed.
2) Start P-3001A/B. Immediately, open the mini flow valve of P-3001A/B.
3) Open the discharge valve of P-3001A/B gradually so that the liquid level of
chimney tray of Q-3001 doesn’t fall below L.L.L and the current value of pump
doesn’t exceed the rated. If necessary, supply the desalinated water to Q-3001
so that the liquid level will reach N.L.L.

(3) Regenerator reflux drum (V-3001)

1) Confirm that the discharge valve and the mini flow valve of Regenerator reflux
pump (P-3004A/B) are closed.
2) Start P-3004A/B. Immediately, open the mini flow valve of P-3004A/B.
3) Open the discharge valve of P-3004A/B gradually so that the level of reflux
water doesn’t fall below L.L.L and the current value doesn’t exceed the rated.

12
 4) Switch the level control of V-3001 to the automatic mode and adjust the set
point to N.L.L.

(4) Steam condensate drum (V-3002)

1) Confirm that the discharge valve and the mini flow valve of Steam condensate
return pump (P-3008A/B) are closed.
2) Start P-3008A/B. Immediately, open the mini flow valve of P-3008A/B.
3) Open the discharge valve of P-3008A/B gradually so that the level of steam
condensate doesn’t fall below L.L.L and the current value of pump doesn’t
exceed the rated.
4) Switch the level controller of V-3002 to the automatic mode and adjust the set
point to N.L.L.

(5) KS-1 solution circulation

1) Confirm that the valves of semi-lean lines which are extracted from
intermediary stage (both upper and lower) of Regenerator (C-3002) are closed
and the valves of semi-lean bypass lines are opened.
2) Confirm that the discharge valves and the mini flow valves of Rich solution
pump (P-3003A/B) and Lean solution pump (P-3005A/B) are closed.
3) Start P-3003A/B. Immediately, open the mini flow valve of P-3003A/B.
4) Open the discharge valve of P-3003A/B gradually.
5) Open the flow control valve installed in Regenerator feed line manually and
adjust the flow rate to the allowable minimum of P-3003A/B. After confirming
that the indication of flow meter is stable, switch the flow control to the
automatic mode.
6) Close the mini flow valve of P-3003A/B.
7) Start P-3005A/B in 1 minute after starting P-3003A/B. Immediately, open the
mini flow valve of P-3005A/B.
8) Open the discharge valve of P-3005A/B gradually.
9) Open the flow control valve installed in CO2 absorber feed line manually and
adjust the flow rate to the allowable minimum of P-3005A/B. After confirming
that the indication of flow meter is stable, switch the flow control to the
automatic mode.

13
 10) Close the mini flow valve of P-3005A/B.
11) Increase and adjust the flow rate of P-3003A/B and P-3005A/B gradually so
that the liquid level does not become unstable.
12) Switch the level control installed in bottom of Regenerator to automatic mode
under the condition that the liquid level of CO2 absorber (C-3001) and
Regenerator (C-3002) is stable.
13) Confirm that the discharge valve and the mini flow valve of Semi-lean upper
pump (P-3010A/B) are closed.
14) After closing the valve of upper semi-lean bypass line, open the valve of
semi-lean line which is extracted from upper stage of Regenerator (C-3002).
15) Start P-3010A/B. Immediately, open the mini flow valve of P-3010A/B.
16) Open the discharge valve of P-3010A/B gradually so that the liquid level of the
chimney tray does not fall below L.L.L and the current value of pump doesn’t
exceed the rated.
17) Open the flow control valve installed in P-3010 A/B discharge line manually
and adjust the flow rate to the same as KS-1 solution fed to Regenerator
(C-3002). After confirming that the indication of flow meter is stable, switch
the flow controller to the automatic mode.
18) Close the mini flow valve of P-3010A/B.
19) Confirm that the discharge valve and the mini flow valve of Semi-lean bottom
pump (P-3011A/B) are closed.
20) After closing the valve of lower semi-lean bypass line, open the valve of
semi-lean line which is extracted from lower stage of Regenerator (C-3002).
21) Start P-3011A/B. Immediately, open the mini flow valve of P-3011A/B.
22) Open the discharge valve of P-3011A/B gradually so that the liquid level of the
chimney tray does not fall below L.L.L.
23) Open the flow control valve installed in 3011 A/B the pump discharge line
manually and adjust the flow rate to the same as KS-1 solution fed to
Regenerator (C-3002). After confirming that the indication of flow meter is
stable, switch the flow control to the automatic mode.
24) Close the mini flow valve of P-3011A/B.

(6) Absorber 1st wash section

14
 1) Confirm that the discharge valve and the mini flow valve of 1st wash water
circulation pump (P-3002A/B) are closed.
2) Start P-3002A/B. Immediately, open the mini flow valve of P-3002A/B.
3) Open the discharge valve of P-3002A/B gradually so that the liquid level of
chimney tray does not fall below L.L.L and the current value doesn’t exceed
the rated. If necessary, feed the desalinated water to 1st wash section so
that the liquid level reaches N.L.L.
4) Close the mini flow valve of P-3002A/B.

(7) Absorber 2nd wash section

1) Confirm that the discharge valve and the mini flow valve of 2nd wash water
circulation pump (P-3007A/B) are closed.
2) Start P-3007A/B. Immediately, open the mini flow valve of P-3007A/B.
3) Open the discharge valve of P-3007A/B so that the liquid level of the chimney
tray does not reach L.L.L. and the current value of pump doesn’t exceed the
rated If necessary, feed the desalinated water to 1st wash section so that the
liquid level reaches N.L.L.
4) Close the mini flow valve of P-3007A/B.

3.2.3 Introduction of the solvent into the filter section

(1) Up stream guard filter (S-3001)
1) Confirm that the inlet and outlet valves of S-3001 are closed.
2) Open the upper air vent valve of S-3001.
3) Open the inlet valve of S-3001 slightly to fill S-3001 with the KS-1 solution.
4) Close the vent valve immediately after the liquid flows out from it.

(2) Carbon filter (S-3002)

1) Confirm that the inlet and outlet valves of S-3002 are closed.
2) Open the upper air vent valve of S-3002.
3) Open the inlet valve of S-3002 slightly to fill S-3002 with the KS-1 solution.
4) Close the vent valve immediately after the liquid flows out from it.

15
 (3) Down stream guard filter (S-3003)
1) Confirm that the inlet and outlet valves of S-3003 are closed.
2) Open the upper air vent valve of S-3003.
3) Open the inlet valve of S-3003 slightly to fill S-3003 with the KS-1 solution.
4) Close the vent valve immediately after the liquid flows out from it.

(4) Adjustment of the introduction of KS-1 solution

1) Open the inlet and outlet valves of S-3002 and the outlet valve of S-3003
fully.
2) While watching the flow meter installed in carbon filter line, adjust the inlet
valve of S-3001 to set the flow rate to normal rate (17.9 m3/h)

3.2.4 Introduction of the cooling water

Introduce the cooling water to Flue gas cooling water cooler (E-3001), Wash water
cooler (E-3002), Regenerator condenser (E-3004) and Lean solution cooler
(E-3006), Waste water cooler (E3012) and sample cooler for pH meter.
(1) Open the air vent valve and the inlet valve slightly to introduce the cooling water
(2) Close the vent valve immediately after the liquid flows out from it.
(3) Open the inlet and outlet valves of E-3001, E-3002 and E-3006 fully and switch
the flow control to the automatic mode. Outlet temperature of process side is set.
In addition, confirm that there is no leak in the process side by opening the drain
valve.
(4) Regarding E-3004, open the inlet valve fully and then open the outlet valve to
same degree. Adjust the opening of outlet valve by the outlet temperature of
cooling water and CO2 product after the operating condition of CO2 recovery unit
becomes stable.

(5) Regarding E-3013 and sample cooler for pH meter, open the inlet and outlet
valves fully.

3.2.5 Introduction of Boiler feed water to waste heat boiler

(1) Fill the waste heat boiler with steam condensate from the Urea plant up to LLL
on the steam drum.

16
 (2) Open the vent valve.
(3) Switch the level control of the steam drum to the automatic mode.

3.2.6 Introduction of the low pressure steam to Regenerator reboiler (E-3005)

(1) Confirm that CO2 product cut-off valve is closed and CO2 pressure release valve
is opened.
(2) Supply the steam condensate to desuperheater by Steam condensate return
pump (P-3008A/B).
(3) Open the drain and vent valves located at the low pressure steam line.
Introduce the low pressure steam to Regenerator reboiler (E-3005) by slightly
opening control valve installed in the low pressure steam line so that the low
pressure steam line is heated up and air is purged from Regenerator reboiler
(E-3005).
(4) Open the control valve manually to supply the steam at about 0.3 t/h
(5) Close the vent and drain valves, and then open the valve to steam trap.

3.2.7 Introduction of caustic soda solution

Caustic soda solution is introduced to Flue gas quencher (Q-3001) to absorb SOx in
flue gas.
(1) Confirm that Caustic storage tank (T-3003) is filled up to H.L.L with caustic soda
solution.
(2) Confirm that the discharge valve of Caustic make-up pump (P-3013A/B) is
closed.
(3) Start P-3013A/B. Immediately, open the discharge valve of P-3013A/B slightly.
(4) Set the flow rate of caustic soda solution to the required amount.

3.2.8 Introduction of the flue gas

(1) Preparation
1) Open the flue gas inlet damper fully.
2) Confirm that the cooling water is introduced to bearing of Flue gas blower
(K-3001).
3) Confirm that suction damper of K-3001 is fully closed.

17
 (2) Introduction of the flue gas
1) Start Flue gas blower (K-3001).
2) Open the suction damper promptly to the specified position in order to
avoid surging of the blower with monitoring operating condition of the
blower.
3) Confirm the liquid level of Flue gas quencher (Q-3001) and CO2 Absorber
(C-3001) so that these liquid levels don’t fall below L.L.L due to that the
hold up of packing increases by introducing the flue gas.
4) Switch the pH controller of Flue gas quencher (Q-3001) to the automatic
mode.

3.2.9 Start up of waste heat boiler

(1) Keep the vent valve and pressure control valve open to remove all air from
Steam drum (V-3003).
(2) Close the pressure control valve gradually and manually until the pressure of
drum reaches 5.0 kg/cm2G so that the increasing rate of water and steam
temperature doesn’t exceed 50 degree C /h.
(3) Switch the pressure control of the steam drum to the automatic mode.
(4) Open the valve connected to low pressure steam heater gradually and close
the vent valve fully.

3.2.10 Adjustment of operation

The procedure to adjust operation is illustrated below in an orderly sequence.

(1) Circulation rate

1) Open the discharge valve of Flue gas wash water pump (P-3009A/B)
gradually so that the current value of the pump motor doesn’t exceed the
rated.
2) Open the discharge valve of Flue gas cooling water pump (P-3001A/B)
gradually so that the current value of the pump motor doesn’t exceed the
rated.

18
 3) Open the discharge valve of 1st wash water circulation pump (P-3002A/B)
gradually so that the current value of the pump motor doesn’t exceed the
rated.
4) Open the discharge valve of 2nd wash water circulation pump
(P-3008A/B) gradually so that the current value of the pump motor doesn’t
exceed the rated.
5) Increase the circulation rate of KS-1 solution gradually to the normal so
that the liquid level of CO2 absorber and Regenerator doesn’t become
unstable.

(2) Flow rate of flue gas

Increase the flow rate of flue gas gradually by opening the suction damper of
K-3001 to the normal. At the same time, pay attention to the operating
condition of steam reformer and Auxiliary boiler.

(3) Flow rate of low pressure steam to Regenerator reboiler (E-3005)

1) After confirming that the indication of flow meter located at the low
pressure steam line is stable, switch the flow control to the automatic
mode. At the same time, switch the temperature controller of low
pressure steam fed to Regenerator Reboiler (E-3005) to the automatic
mode and set the temperature to 142 degree C.
2) Increase the flow rate of low pressure steam to the normal.
3) After confirming the flow rate of low pressure steam and the temperature
of steam condensate at the outlet of E-3010 are stable, open the block
valve locked at the steam condensate line from Semi-lean upper heat to
Waste heat boiler unit (U-3001).
4) Close the block valve located at the steam condensate line from the Urea
plant.

(4) Male up the reflux water to 2nd wash section

Make up 50% of reflux water to 2nd wash section by opening the flow control
valve.

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 (5) Water balance
1) In order to keep the water balance, switch the level controller of CO2
absorber bottom to the automatic mode and adjust the set point to N.L.L.
2) Switch the level controller of CO2 absorber bottom to the automatic mode.
3) Set the liquid level to N.L.L.

3.2.11 Discharge of product CO2

(1) Adjustment of the pressure of product CO2
1) Close the pressure control value of product CO2 gradually and set the
pressure of product CO2 0.5kg/cm2G.
2) Confirm that the indication of pressure controller is stable, and then switch
the pressure controller to the automatic mode.
3) Confirm that the temperature at the bottom of the Regenerator (C-3002) is
stable, and then increase the flow rate of low pressure steam fed to
Regenertor Reboiler (E-3005) to the normal.

(2) Discharge of product CO2

1) Confirm whether CO2 purity and impurity content is acceptable.
2) Confirm the operation condition of Urea plant.
3) Open the block valve of product CO2 gradually and send CO2 product to
Urea plant.

3.3 SHUT DOWN

Shut down procedure of CO2 recovery plant is shown below.

3.3.1 Release of product CO2

(1) Close the block valve of CO2 product with keeping the pressure of product CO2
(2) Open the pressure control valve of product CO2 gradually to release product
CO2 to the atmosphere.

3.3.2 Stop of flue gas supply

(1) Reduce the flow rate of flue gas to 50% turn down by closing the suction damper
of Flue gas blower (K-3001).

20
 (2) Switch the level control of CO2 absorber bottom from auto mode to manual mode
since the liquid level of CO2 absorber bottom is increased by the reduction of
hold up of the packing.
(3) Reduce the flow rate of low pressure steam fed to Regenerator Reboiler
(E-3005) to 50% turn down.
(4) Stop Fue gas blower (K-3001).
(5) Confirm that the blower is completely stopped and then close the suction
damper of Flue gas blower (K-3001) and the flue gas inlet damper at the bottom
of stack.

3.3.3 Shot down of Waste heat boiler unit (U-3001)

(1) Close the valve connected to low pressure steam header and open the vent
valve to isolate Waste heat boiler (U-3001) from low pressure steam header.
(2) Reduce the steam pressure of Steam drum (V-3003) by opening the pressure
control valve.
(3) Close the vent valve and introduce N2 into the water and steam side.
(4) Drain the remaining water by opening the drain valve at the bottom of Waste
heat boiler (U-3001).

3.3.4 Solvent regeneration

The circulation of KS-1 solution and the supply of the low pressure steam to
Regenerator reboiler (E-3005) shall be continued for 30 minutes in order to lower
CO2 concentration in KS-1 solution.

3.3.5 Stop of steam supply to Regenerator reboiler (E-3005)

(1) Close the control valve located at the low pressure steam line.
(2) Close the valve of desuperheater.

3.3.6 Pump stop

Stop all pumps.

3.3.7 Stop of cooling water supply

Stop the supply of the cooling water to all heat exchangers.

21
3.3.8 Drying of flue gas duct
(1) Confirm that the flue gas inlet damper is closed.
(2) Open the hatch located near the flue gas inlet damper to introduce air.
(3) Confirm that the cooling water is introduced to the bearing of Flue gas blower
(K-3001).
(4) Confirm that the suction damper is fully closed.
(5) Start Flue gas blower (K-3001).
(6) While paying attention to operating condition of the blower, open the suction
damper promptly to the specified position in order to avoid the surging of the
blower.
(7) While confirming the current value of the blower motor, open the suction damper
to adequate position.
(8) The blower operation is continued until the duct is dries. At this time, a small
amount of amine adhering on the surface of packings is emitted from the top of
CO2 absorber.

3.4 DRAIN OUT OF KS-1 SOLUTION

KS-1 solution shall be drained out for maintenance after the plant is stopped. Drain
out procedure is as follows.

3.4.1 Emission of product CO2 (See 3.3.1)

3.4.2 Stop of flue gas supply (See 3.3.2)

3.4.3 Solvent regeneration (See 3.3.3)

3.4.4 Stop of steam supply to Reboiler (See 3.3.4)

3.4.5 KS-1 solution cooling

Circulate KS-1 solution so that KS-1 solution is cooled to 60 degree C by Lean
solution cooler (E-3006).

22
3.4.6 Drain out of KS-1 solution
(1) After cooling KS-1 solution, KS-1 solution is drained out to Solution storage tank
(T-3001) through the blow down line located downstream of Lean solution cooler
(E-3006).
(2) When the liquid level of CO2 absorber and Regenerator reaches L.L.L, Rich
solution pump (P-3003A/B) and Lean solution pump (P-3005A/B) are stopped.
(3) The remaining KS-1 solution in the system is drained out to Solution sump tank
(T-3002) from each drain. At this time, each drain valve shall be controlled so
that the amount of KS-1 solution drained out to T-3002 does not exceed the
capacity of Solution sump pump (P-3006)
(4) KS-1 solution drained out to Solution sump tank (T-3002) is sent to Solution
storage tank (T-3001) by Solution Sump Pump (P-3006).

4. NORMAL OPERATION
The CO2 recovery plant shall be operated for the most efficient production and longest
equipment life. Main check points are described as follows. When there are some
deviations from specified operational conditions, the plant must be adjusted to keep the
specified conditions as far as possible.

4.1. FLUE GAS SUPPLY SYSTEM

4.1.1. Monitoring of flow rate, temperature, and pressure of flue gas
When the amount of flue gas is high, excessive emission of amine is caused and the
low flue gas flow rate results in low amount of product CO 2 or excessive low
pressure steam consumption to achieve specified CO2 production capacity.
Therefore, the flue gas rate shall be adjusted by the suction damper so that CO 2
recovery rate keeps around 90%

4.1.2. Monitoring of operating condition of Flue gas blower (K-3001)

The monitoring items and procedure about the blower shall be confirmed by
Detailed Engineering Contractor using the instruction manual submitted by blower
manufacturer.

23
4.2. FLUE GAS WASHING AND COOLING SYSTEM
4.2.1. pH value of circulation water in SOx absorption section
When pH value of circulation water in SOx absorption section is low, the
degradation of amine is promoted due to the increase of SO2 content in absorber
feed gas. When pH value of circulation water in SOx absorption section is high,
caustic soda solution supply is excessive. In such case, the flow meter, the flow
controller and pH meter shall be checked and adjusted.

4.2.2. Monitoring of stable operation of circulation water in SOx absorption section

The monitoring items and procedure about Flue gas wash water pump (P-3009A/B)
shall be confirmed by Detailed Engineering Contractor using the instruction manual
submitted by pump manufacturer.

4.2.3. Monitoring of stable operation and temperature of circulation water in cooling section
When the outlet temperature of Flue gas cooling water cooler (E-3001) is high, the
low efficiency of CO2 absorption and the excessive loss of amine are caused since
the temperature of absorber feed gas increases. In such case, the temperature
meter, the temperature controller and E-3001 shall be checked and adjusted. If
necessary, they shall be repaired and washed.
For each operation load, the amount of circulation water shall be optimized to
reduce the electric consumption of the pump. And the amount of circulation water
shall be determined after commissioning period.
The monitoring items and procedure about Flue gas cooling water pump
(P-3001A/B) shall be confirmed by Detailed Engineering Contractor using the
instruction manual submitted by pump manufacturer.

4.2.4. Pressure drop in packings of Flue gas quencher (Q-3001)

When the flooding occurs with the high amount of flue gas, the pressure drop in
packings rapidly increases. In such case, the flue gas rate shall be reduced by the
suction damper of blower.

4.2.5. Temperature of Q-3001 outlet

24
 When the temperature of Q-3001 outlet is high, low efficiency of CO2 absorption and
the excessive loss of amine are caused. In such case, the circulation water rate of
cooling section shall be increased, or the outlet temperature of Flue gas cooling
water cooler (E-3001) shall be lowered.

4.3. KS-1 SOLUTION CIRCULATION SYSTEM

4.3.1. Control of KS-1 concentration
When KS-1 concentration is low, the flow rate of KS-1 solution and the consumption
of the low pressure steam increase. If KS-1 concentration is low, KS-1 shall be
made up in the system by the following procedure.
(1) Analyze the concentration of KS-1 solution in the system, Solution storage tank
(T-3001) and Solution sump tank (T-3002).
(2) Calculate the necessary amount to make up KS-1 solution based on the above
analysis resultes.
(3) Fill the calculated necessary amount of KS-1 solution is introduced from T-3002
to the system by Solution Sump Pump (P-3006).

4.3.2. Monitoring of heat-stable salts content

When the concentration of heat stable salts in KS-1 solution exceeds about 2 wt%,
the reclaimer operation shall be started. The procedure for reclaiming operation is
shown in Item 4.9 “Reclaiming system”.

4.3.3. Monitoring of foaming in the tower (Monitoring of differential pressure in packings

and liquid level of the tower bottom)
When the foaming occurs, the liquid level of absorber bottom moves up-and-down
by the increase of pressure drop in packings. As a result, the efficiency of CO 2
absorption or CO2 desorption becomes unstable. Foaming results from the
presence of solids or degradation products. Foaming factor can be readily
removed by the activated carbon, but all may not be removed. If foaming occurs or
its symptoms are found, a reliable antifoam agent shall be injected from the anti
foam injection pot located at the suction of Rich solution pump (P-3003A/B). In this
time, the activated carbon system shall be isolated and antifoam agent shall be
injected steadily and little by little until the foaming is removed. Exceeding the

25
 recommended dosage can promote foam rather than remove it. If the foaming
frequently occurs, the activated carbon shall be replaced. In according to the
experience of the commercial plant, the silicon type is recommended as antifoam
agent.

4.3.4. Monitoring of the circulation amount , temperature, and stable operation of KS-1
solution
Circulation amount of KS-1 solution shall be optimized to reduce the steam
consumption of Regenerator reboiler (E-3005). And the optimized circulation
amount in each operation load shall be determined after commissioning period.
When the Regenerator (C-3002) bottom temperature is high, the solvent
degradation can be promoted. Therefore, the Regenerator (C-3002) bottom
temperature shall be kept below about 123 ℃. When the Regenerator (C-3002)
bottom temperature exceeds 123 ℃, the operating pressure of Regenerator
(C-3002) shall be reduced.
The monitoring items and procedure about Rich solution pump (P-3003A/B) and
Lean solution pump (P-3005A/B) shall be confirmed by Detailed Engineering
Contractor using the instruction manual submitted by pump manufacturer.

4.3.5. Monitoring of component of flue gas

CO2, SO2 and NOx content in flue gas shall be monitored in order to comprehend
the efficiency of CO2 absorption and the influence of solvent degradation.

4.4. TREATED FLUE GAS WASHING SYSTEM

4.4.1. Monitoring of KS-1 concentration in circulation water and stable operation
When KS-1 solvent concentration in circulation water of wash section is high, the
emission of amine can be increase. The solutions are given under Item 8
“Troubleshooting” later in this document.
For each operation load, the amount of circulation water shall be optimized to
reduce the electric consumption of 1st wash water circulation pump (P-3002A/B).
And the amount of circulation water shall be determined after commissioning period.
The monitoring items and procedure about 1st wash water circulation pump
(P-3002A/B) and 2nd wash water circulation pump (P-3008A/B) shall be confirmed

26
 by Detailed Engineering Contractor using the instruction manual submitted by pump
manufacturer.

4.4.2. Keeping make up water from the regenerator reflux

The amount of make up water from the regenerator reflux is adjusted to keep KS-1
concentration of circulation water of wash section lower than the specified value.
When the make up water from the regenerator reflux is low, the excessive loss of
amine is caused. Therefore, in the case of normal operation, the amount of make up
water shall be maintained to 50% of the amount of regenerator reflux water. In the
case of reclaiming operation, it shall be maintained to 30 – 40% of the amount of
regenerator reflux water.

4.4.3. Lowering of outlet temperature at the absorber wash section

For inhibiting the emission of amine, it is efficient that the outlet temperature of the
absorber wash section is lower. Therefore, when the temperature of the cooling
water is low because of winter season etc., the outlet temperature of the absorber
wash section shall be lowered according to it.

4.5. REGENERATOR REFLUX SYSTEM

In the case of normal operation, 50 percent of the regenerator reflux water is supplied
to Regenerator, and remaining 50 percent to 2nd wash section of CO 2 Absorber. In
the case of reclaiming operation, 30 percent is supplied to Reclaimer, 30 – 40 percent
to 2nd wash section of CO2 Absorber, and remaining 30 – 40 percent to Regenerator.
At this time, the minimum required flow rate for tray of Regenerator wash section shall
be kept.

4.6. ACTIVATED CARBON FILTER SYSTEM

4.6.1. Monitoring of differential pressure
S-3002 (Carbon Filter) and S-3001, S-3003 (Up-stream and Down-stream Guard
Filters) frequently pick up dust, etc. in the circulation system and become clogged,
especially soon after the initial start up and restart of operation beginning of the
operation. Therefore, it is necessary to pay sufficient attention to the differential
pressure.

27
4.6.2. Activated carbon replacement
When the pressure drop across the activated carbon exceeds the specified value, it
shall be replaced with fresh one.
The general procedure for replacing spent activated carbon is as follows:
(1) Close the inlet and outlet valves of the activated carbon to isolate the activated
carbon from the system.
(2) Draw out KS-1 solution in Carbon filter (S-3002) into the Solution Sump Tank
(T-3002).
(3) Fill Carbon filter (S-3002) with the demineralized water and then drain out the
water into T-3002 to recover the solvent adhering on the activated carbon
surface.
(4) Back wash the activated carbon to remove any contaminate. The detailed
method shall be specified at the Item 7.3.6.
(5) Take out the activated carbon from a manhole at the bottom of Carbon filter
(S-3002).
(6) Replace the activated carbon with fresh one.

4.6.3. Guard filters replacement

When the pressure drop across the guard filter exceeds the specified value, the
guard filter shall be replaced with fresh one.
The general procedure for replacing spent filter is as follows:
(1) Close the inlet and outlet valves of the filter to isolate the filter from the system.
(2) Drain out the KS-1 solution in the filter into the Solution Sump Tank (T-3002).
(3) Wash the filter with the demineralized water.
(4) Drain out the wash water T-3002 since the wash water contains a small
amount of KS-1 solvent.
(5) Take out the filter from the top of the filter and then replace it with fresh one.

4.7. REBOILER-STEAM SYSTEM

After optimizing the amount of flue gas and circulation of KS-1 solution for each CO2
product capacity, the amount of low pressure steam fed to the reboiler is adjusted to
achieve objective CO2 production capacity.

28
4.8. OPPERATING LOAD
Operating procedure for increase or decrease the CO2 production capacity is fellows.
4.8.1 Increase the CO2 production capacity
(1) Increase the flue gas suction damper opening to increase the flow rate of flue
gas gradually.
(2) Set the flow rate of flue gas at optimum value for the target of CO2 production
capacity.
(3) Increase the circulation rate of KS-1 solution gradually.
(4) Set the circulation rate of KS-1 solution at optimum value for the target of CO2
production capacity.
(5) Increase the flow rate of LP steam gradually.
(6) Adjust the flow rate of LP steam to achieve the target of CO2 production
capacity.

4.8.2 Decrease the CO2 production capacity

(1) Reduce the flow rate of LP steam to compensate for turndown of CO2
production capacity.
(2) Reduce the circulation rate of KS-1 solution gradually.
(3) Set the circulation rate of KS-1 solution at optimum value for the target of CO2
production capacity.
(4) Decrease the flue gas suction damper opening to decrease the flow rate of flue
gas gradually.
(5) Set the flow rate of flue gas at optimum value for the target of CO2 production
capacity.
(6) Readjust the flow rate of LP steam to achieve the target of CO2 production
capacity.

4.9. RECLAIMING OPERATION

The primary purpose of the reclaimer is to remove soluble solvent degradation
products and suspended solid (SS)2from the lean solution. These degradation
products include formamides, formates, oxalates and higher polymers of the solvent.
The reclaimer operates as a simple batch distiller, and since the solvent degradation
products have higher boiling temperatures than water or solvent, they remain in the

29
 reclaimer kettle. In the absence of liquid carryover, only vapors (water and KS-1)
leave the kettle through the reclaimer overhead.
The accumulation of solvent degradation products must be controlled at a low level by
operation of the activated carbon filtration systems and the reclaimer. The presence
of degradation products can increase corrosion rates, raise the viscosity of the
solution, and may cause solution foaming.
The primary solvent degradation product will be heat-stable salt complexes of amine.
Normally, the plant should operate safely with concentration of these salts below
2.0 wt%. When the concentration reaches 2.0 wt%, the reclaimer should be
2
operated until the level is reduced to about 0.7 wt%. In addition, the reclaimer should
be also operated when the SS content in the KS-1 solvent reaches to 100 mg/l.
General guidelines in the reclaimer operation are as follows:

4.9.1. Preparation
(1) Purge air from reclaimer by introducing the steam to the bottom of Reclaimer
(E-3007) and purging it from the vent.
Stop introducing the steam and close the vent value after completing air
purging. Open the block valve in the reclaimer vapor line connected with the
bottom of Regenerator (C-3002) closely to make the pressure of reclaimer
same as that of Regenerator.

(2) Introduce caustic soda 48 wt% solution by Reclaimer Caustic Feed Pump
(P-3014). At this time, it shall be confirmed that liquid level of Caustic Storage
Tank (T-3003) is enough. If necessary, caustic soda solution shall be
introduced to T-3003 from existing facility.
The initial charge amount of caustic soda is twice chemical equivalent to reduce
HSS, it’s concentration from 2.0 wt% to 0.7 wt%. For each 1.3 wt% heat-stable
salts (HSS from 2.0 wt% to 0.7 wt%) in 1.0 m3 of KS-1 solution. The
necessary amount of NaOH is calculated as follows:
0.013 (1.3 wt%) × 889 (constant) = 11.6 kg NaOH (100 % basis)
The quantity of hold up in the plant system is estimated to be about 116 m3.
So initial charge of NaOH to the Reclaimer (E-3007) is calculated as follows;
116m3 × 11.6 kg / 0.48 = 3.1 ton NaOH (48 wt% basis)

30
 (3) Add lean KS-1 and reflux water until minimum liquid level (upper of tube bundle)
is established. The flow ratio controller is activated to admit water and KS-1
solution on a 2-to-1 basis.

4.9.2. Steam Supply

(1) Open the isolate valve located Steam Drum(V-3003). At the same time, purge
the air from the steam supply line to Reclaimer(E-3007) by opening the vent
valve slightly. After the end of air vent, the vent valve is closed.
(2) The steam shall be supplied to Recliamer (E-3007) from Steam drum (V-3003)
of Waste heat boiler (U-3001). The supply of steam shall be controlled by the
pressure control vale. During the reclaiming operation, the temperature of liquid
in Reclaimer will increase as HSS accumulates. Accordingly, the set point of
steam supply pressure shall be adjusted by the temperature of liquid in
Reclaimer to keep the temperature difference between steam and liquid inside
Reclaimer(E-3007). In addition, when the steam pressure at the inlet of
Reclaimer (E-3007) reaches to the specified pressure , the set point shall be
kept constant since high temperature on the skin of tube is avoided.

4.9.3. KS-1 solution and reflux water supply

(1) As KS-1 solution and reflux water are vaporized from the reclaimer, additional
KS-1 solution and water is admitted on level control via the flow ratio controller.
(2) Stop the supply of KS-1 solution when HSS concentration is reduced to around
0.7 wt%. However, if the liquid temperature in the reclaimer is raised to 150˚C
before HSS concentration reaches to 0.7 wt%, the supply of KS-1 solution shall
be stopped at the time.
(3) Continue to supply of water and steam to vaporize and recover residual KS-1
solution for about 24 hours.

4.9.4. Drain out of reclaimer sludge

(1) Stop the supply of reflux water.
(2) In order to reduce the amount of reclaimed waste, continue to supply of steam
until the liquid level of Reclaimer(E-3007) reaches L.L.L.
(3) Stop the supply of steam.

31
 (4) Close the blocked valve located at vapor return line from the reclaimer and
depress Reclaimer(E-3007) slowly by venting to atmosphere.
(5) Drain out reclaimer waste to drums after sufficient cooling.
(6) As option operation for reclaimer waste treatment, Drain out reclaimer waste to 2
Reclaimed waste tank (T-3004) using Reclaimed waste transfer pump
(P-3015).
(7) Send reclaimer waste to Mixing tank (T-3101) for dilution with desalinated water
using Reclaimed waste feed pump (P-3016).
(8) Send diluted reclaimer waste to Incinerator (H-3101) using Waste water pump
(P-3101). The detailed procedure for Incineration unit shall be developed by
Detailed Engineering Contractor using the instruction manual submitted by
Incinerator manufacturer.

4.9.5. Reclaimer washing

Inspect the shell inside of Reclaimer(E-3007) and flush it if necessary after
finishing reclaiming operation and draining out reclaimer waste. If necessary. It
might be necessary to pull the tube bundle of Reclaimer(E3007) to clean the
bundle and shell manually if there is significant solids accumulation.

4.10. WASTE HEAT BOILER OPERATION

The general operation of waste heat boiler is shown below. However, the detailed
procedure shall be developed by Detailed Engineering Contractor using the instruction
manual submitted by WHB manufacturer.

4.10.1. Superheater(E-3013), Evaporater(E-3014), Economizer(E-3015)

Check the pressure loss at gas side of the WHB (U-3001). Rising pressure loss at
gas side of the boiler indicates fouling of the bundle tubes. After shutting down the
plant, the nature of the fouling can be determined by opening the manholes at the gas
inlet and outlet chambers. If loose deposits are observed, remove it by means of a
wire brush which is attached to a flexible lance and blow tubes by air afterwards (from
inlet end to outlet end). If solid deposits are observed, remove it by means of the
rotary steel wire brush or by hydro jetting.

32
4.10.2. Steam drum (V-3003)
Check the general condition of Steam Drum (V-3003) regularly. Eliminate leaks at
valves and instrumentation fittings immediately. TAKE PARTICULARLY CAUTIOUS
WHEN WORKING AT LINES UNDER PRESSURE.
(1) Keep safety valves in good condition always. The safety valves are adjusted
with a set pressure above operating pressure.
(2) Check the pressure gauges for proper functioning regularly.
(3) Check valves, at level indicators, magnetic and electrical signal for proper
functioning. To avoid clogging, flush the indicator inside periodically by high
pressure water.
(4) Maintain normal water level in Steam Drum (V-3003). Adjust the water level
controller to maintain the normal water level without oscillating. Drum level
above designed normal water level may cause “CARRYOVER” of boiler water into
the steam. Oscillating of the water level may cause “foaming” with consequent
carryover.
(5) Check the function of the blow down valves at each blow down operation. Listen
for flow noise after opening the valve. If flow noise does not become silent after
closing the valve again, obstructions may have settled at the valve seat.
Operate valve several times for clearance. Touch the blow down lines carefully
sometimes. If there are leaking valves the blow down line will becomes hot.

5. SAMPLING AND ANALYSIS

Analysis items and frequency are shown below. The method of analysis is specified
at the Analytical Manual (0287 B406-00100).

5.1. LEAN KS-1 SOLUTION

< Analysis items> <Analysis frequency>
KS-1 concentration 2 times / week
*When the make up of KS-1 is carried out, it shall be analyzed separately.
CO2 loading 2 times / week
Heat-stable salts content 1 time / week
Soluble iron content 1 time / week

33
5.2. RICH KS-1 SOLUTION
< Analysis items> <Analysis frequency>
CO2 loading 1 time / week

5.3. ABSOREBER WASH WATER

< Analysis items> <Analysis frequency>
KS-1 concentration 2 times / week

5.4. SOx REMOVAL

< Analysis items> <Analysis frequency>
pH of circulation water 2 times / week
SS of circulation water if needed
COD of circulation water if needed

5.5. MAKE UP KS-1 SOLUTION

< Analysis items> <Analysis frequency>
KS-1 concentration at the time of KS-1 make up

5.6. FLUE GAS

< Analysis items> <Analysis frequency>
CO2 concentration at absorber inlet 2 times / week
CO2 concentration at absorber outlet 2 times / week
SO2 concentration at absorber inlet 1 time / month
NO2 concentration at absorber inlet 1 time / month

5.7. PRODUCT CO2

< Analysis items> <Analysis frequency>
CO2 purity 1 time / month

34
6. EMERGENCY SHUT DOWN
For the following reasons, there may be an emergency shutdown during the operation.
(1) Electric power failure
(2) Steam failure
(3) Cooling water failure
(4) Failure of steam condensate supply to Waste heat boiler (V-3001)
(5) Instrumentation air failure
(6) Mechanical trouble of rotating equipment
(7) Leakage of gas or liquid due to damaged equipment / piping etc.
The operation manual for each case is as follows.

6.1. ELECTRIC POWER FAILURE

6.1.1. Failure of low voltage power supply
(1) Result
All pumps are stopped.
(2) Action
1) Stop Flue gas blower (K-3001).
Since circulating water of SO2 absorption section and flue gas cooling section
are stopped, high temperature flue gas contaning SOx is supplied to CO2
Absorber (C-3001). Degradation and loss of KS-1 are promoted due to the
high temperature flue gas contaning SOx. Therefore, it is necessary to stop
Flue gas blower (K-3001).
When Flue gas blower (K-3001) is stopped, the following interlock systems are
worked.
• Trip for supply of low pressure steam
• Rich solution pump (P-3003A/B), Regenerator reflux pump (P-3004A/B),
Lean solution pump (P-3005A/B), Semi-lean upper pump (P-3010A/B) and
Semi-lean bottom pump (P-3011A/B) trip.
• Product CO2 line block valve is closed.
• Flue Gas cut off motor valve is closed.
2) Open the CO2 pressure release valve.

35
 The temperature and pressure of Regenerator (C-3002) gradually goes down
due to that the supply of steam is stopped. Therefore, the CO2 pressure
release valve is opened gradually and air is introduced to the Regenerator
(C-3002) to prevent vacuum condition.

6.1.2. Failure of high voltage power supply

(1) Result
1) Flue gas blower (K-3001) is stopped.
2) The supply of the flue gas is stopped.
3) The following interlock systems are worked due to that Flue gas blower
(K-3001) is stopped.
• Trip for supply of low pressure steam
• Rich solution pump (P-3003A/B), Regenerator reflux pump (P-3004A/B),
Lean solution pump (P-3005A/B), Semi-lean upper pump (P-3010A/B) and
Semi-lean bottom pump (P-3011A/B) trip.
• Product CO2 line block valve is closed.
• Flue Gas cut off motor valve is closed.
(2) Action
1) Open the CO2 pressure release valve.
2) Open the block valve in the steam condensate line from Urea Plant to
Waste heat Boiler (U-3001) to supply the steam condensate from Urea Plant.
3) Stop Flue gas Cooling water pump (P-3001A/B), 1st wash water
circulation pump (P-3002A/B) and 2nd wash water circulation pump
(P-3007A/B) when the liquid level reaches to L.L.L.
Since the gas flow is stopped in the chimney trays below flue gas cooling
packing, 1st water washing packing and 2nd washing packing by stopping
Flue gas blower (K-3001), a small portion of circulation water falling from the
packing goes through the opening area of chimney trays and the liquid levels
of chimney trays go down slowly.
Therefore, it is necessary to stop these pumps when the liquid level reaches to
L.L.L.

36
6.2. STEAM FAILURE
(1) Result
1) The production of CO2 gas is stopped.
(2) Action
1) Stop Regenerator Reflux Pump (P-3004A/B).
2) Close the product CO2 line block valve.
3) Open the CO2 pressure release valve.
4) Open the block valve in the steam condensate line from Urea Plant to Waste
heat Boiler (U-3001) to supply the steam condensate from Urea Plant.

6.3. COOLING WATER FAILURE

(1) Result
1) The shaft of Flue gas blower (K-3001) is not cooled.
2) All coolers become ineffective.
(2) Action
1) Stop Flue gas blower (K-3001).
Since the shaft cooling for Flue gas blower (K-3001) is stopped, it is necessary to
stop Flue gas blower (K-3001) immediately. In addition, since Flue gas cooling
water cooler (E-3001) becomes ineffective, high temperature flue gas is supplied
to CO2 absorber (C-3001) and the degradation and loss of KS-1 solution are
promoted. Therefore, it is necessary to stop Flue gas blower (K-3001).
When Flue gas blower (K-3001) is stopped, the following interlock systems are
worked.
• Trip for supply of low pressure steam
• Rich solution pump (P-3003A/B), Regenerator reflux pump (P-3004A/B),
Lean solution pump (P-3005A/B), Semi-lean upper pump (P-3010A/B) and
Semi-lean bottom pump (P-3011A/B) trip.
• Product CO2 line block valve is closed.
• Flue Gas cut off motor valve is closed.
2) Open the CO2 pressure release valve.
3) Stop Flue gas Cooling water pump(P-3007A/B), 1st wash water circulation
pump(P-3002A/B) and 2nd wash water circulation pump(P-3007A/B) when the liquid
level reaches to L.L.L.

37
6.4. FAILURE OF STEAM CONDENSATE SUPPLY TO WASTE HEAT BOILER (U-3001)
(1) Result
1) In case of complete dry operation of the system, heavy damage will result to the
boiler, i.e. bending of boiler tubes, rupture of boiler tubes out of tube sheet, leaking
tube to tube sheet welds etc.
2) High temperature flue gas is supplied to Flue gas quencher (Q-3001).
(2) Action
1) Stop Flue gas blower (K-3001)
When Flue gas blower (K-3001) is stopped, the following interlock systems are
worked.
• Trip for supply of low pressure steam
• Rich solution pump (P-3003A/B), Regenerator reflux pump (P-3004A/B),
Lean solution pump (P-3005A/B), Semi-lean upper pump (P-3010A/B) and
Semi-lean bottom pump (P-3011A/B) trip.
• Product CO2 line block valve is closed.
• Flue Gas cut off motor valve is closed.
2) Open the CO2 pressure release valve
3) Stop Flue gas Cooling water pump(P-3007A/B), 1st wash water circulation
pump(P-3002A/B) and 2nd wash water circulation pump(P-3007A/B) when the
liquid level reaches to L.L.L.

6.5. INSTRUMENTATION AIR FAILURE

(1) Result
1) When instrumentation air is stopped, the following interlock systems are
worked.
• Flue gas blower (K-3001) is stopped.
• Trip for supply of low pressure steam
• Rich solution pump (P-3003A/B), Regenerator reflux pump (P-3004A/B),
Lean solution pump (P-3005A/B), Semi-lean upper pump (P-3010A/B) and
Semi-lean bottom pump (P-3011A/B) trip.
• Product CO2 line block valve is closed.

38
 • Flue Gas cut off motor valve is closed.
Each control valve will be completely opened or completely closed or does not
change the position during operation depending on the condition of each control
valve.
(2) Action
1) Open the CO2 pressure release valve.
2) Stop all pumps.
3) Stop Flue gas Cooling water pump(P-3007A/B), 1st wash water circulation
pump(P-3002A/B) and 2nd wash water circulation pump(P-3007A/B) when the liquid
level reaches to L.L.L.

6.6. MECHANICAL TROUBLE OF ROTATING EQUIPMENT

6.6.1. Flue Gas Blower (K-3001)
(1) Result
1) Supply of flue gas is stopped.
2) When Flue gas blower (K-3001) is stopped, the following interlock systems are
worked.
• Trip for supply of low pressure steam
• Rich solution pump (P-3003A/B), Regenerator reflux pump (P-3004A/B),
Lean solution pump (P-3005A/B), Semi-lean upper pump (P-3010A/B) and
Semi-lean bottom pump (P-3011A/B) trip.
• Product CO2 line block valve is closed.
• Flue Gas cut off motor valve is closed.
(2) Action
1) Open the CO2 pressure release valve.
2) Stop Flue gas Cooling water pump (P-3007A/B), 1st wash water circulation pump
(P-3002A/B) and 2nd wash water circulation pump (P-3007A/B) when the liquid
level reaches to L.L.L.

6.6.2. Flue gas wash water pump (P-3009A/B)

(1) Result
1) The flue gas containing SOx is supplied to CO2 Absorber (C-3001).
(2) Action

39
 1) Stop Flue gas blower (K-3001).
Since Flue gas wash water pump (P-3009A/B) is stopped, flue gas containing SOx
is supplied to CO2 Absorber (C-3001). Degradation and loss of KS-1 are promoted
due to the flue gas containing SOx. Therefore, it is necessary to stop Flue gas
blower (K-3001). However, it is not necessary to stop Flue gas blower (K-3001) if
the concentration of SOx is less than 1 ppm.
When Flue gas blower (K-3001) is stopped, the following interlock systems are
worked.
• Trip for supply of low pressure steam
• Rich solution pump (P-3003A/B), Regenerator reflux pump (P-3004A/B),
Lean solution pump (P-3005A/B), Semi-lean upper pump (P-3010A/B) and
Semi-lean bottom pump (P-3011A/B) trip.
• Product CO2 line block valve is closed.
• Flue Gas cut off motor valve is closed.
2) Open the CO2 pressure release valve.
3) Stop Flue gas Cooling water pump(P-3007A/B), 1st wash water circulation
pump(P-3002A/B) and 2nd wash water circulation pump(P-3007A/B) when the liquid
level reaches to L.L.L.

6.6.3. Flue gas cooling water pump (P-3001A/B)

(1) Result
1) High temperature flue gas is supplied to CO2 Absorber (C-3001).
(2) Action
1) Stop Flue gas blower (K-3001).
Degradation and loss of KS-1 are promoted due to high temperature of the flue gas.
Therefore, it is necessary to stop Flue gas blower (K-3001).
When Flue gas blower (K-3001) is stopped, the following interlock systems are
worked.
• Trip for supply of low pressure steam
• Rich solution pump (P-3003A/B), Regenerator reflux pump (P-3004A/B),
Lean solution pump (P-3005A/B), Semi-lean upper pump (P-3010A/B) and
Semi-lean bottom pump (P-3011A/B) trip.
• Product CO2 line block valve is closed.

40
 • Flue Gas cut off motor valve is closed.
2) Open the CO2 pressure release valve.
3) Stop Flue gas Cooling water pump(P-3007A/B), 1st wash water circulation
pump(P-3002A/B) and 2nd wash water circulation pump(P-3007A/B) when the liquid
level reaches to L.L.L.

6.6.4. 1st wash water circulation pump (P-3002A/B)

(1) Result
1) High temperature treated Flue gas is exhausted from CO2 Absorber(C-3001).
(2) Action
1) Stop Flue gas blower (K-3001).
KS-1 solvent is concentrated since the recovery of water by cooling the treated
gas is stopped. Furthermore, the emission of KS-1 solution is increased since
temperature of treated gas increases. Therefore, it is necessary to stop Flue gas
blower (K-3001).
When Flue gas blower (K-3001) is stopped, the following interlock systems are
worked.
• Trip for supply of low pressure steam
• Rich solution pump (P-3003A/B), Regenerator reflux pump (P-3004A/B),
Lean solution pump (P-3005A/B), Semi-lean upper pump (P-3010A/B) and
Semi-lean bottom pump (P-3011A/B) trip.
• Product CO2 line block valve is closed.
• Flue Gas cut off motor valve is closed.
2) Open the CO2 pressure release valve.
3) Stop Flue gas Cooling water pump(P-3007A/B), 1st wash water circulation
pump(P-3002A/B) and 2nd wash water circulation pump(P-3007A/B) when the
liquid level reaches to L.L.L.

6.6.5. 2nd wash water circulation pump (P-3007A/B)

(1) Result
1) The emission of KS-1 solution is increased.
(2) Action
Although the emission of KS-1 solution is increased by stop of 2nd wash water

41
 circulation pump (P-3007A/B), the economical efficiency of CO2 recovery unit does
not deteriorate significantly. Therefore, it is possible to continue operation.
However, this operation is performed for only unavoidable case, it is not
recommended in normal operation.

6.6.6. Rich solution pump (P-3003A/B)

(1) Result
1) The production of CO2 is stopped.
2) Liquid level of CO2 absorber (C-3001) goes up.
3) Liquid level of Regenerator (C-3002) goes down
(2) Action
1) Stop Lean solution pump (P-3005A/B), Semi-Lean upper pump(P-3010A/B) and
Semi-Lean Bottom Pump(P-3011A/B)
2) Stop the supply of low pressure steam.
3) Close the product CO2 line block valve.
4) Open the CO2 pressure release valve.
5) Stop Regenerator reflux pump (P-3004A/B).

6.6.7. Regenerator reflux pump (P-3004A/B)

(1) Result
1) Liquid level of Regenerator reflux drum (V-3001) goes up.
2) The concentration of KS-1 solution in the recovered CO2 gas increases.
(2) Action
1) Stop the supply of low pressure steam.
2) Open the block valve in the steam condensate line from Urea Plant to Waste
heat Boiler (U-3001) to supply the steam condensate from Urea Plant.
3) Close the product CO2 line block valve.
4) Open the CO2 pressure release valve.

6.6.8. Lean solution pump (P-3005A/B)

(1) Result
・ Liquid level of CO2 absorber (C-3001) goes down.
・ Liquid level of Regenerator (C-3002) goes up.

42
 (2) Action
1) Stop Rich solution pump (P-3003A/B), Semi-lean upper pump(P-3010A/B) and
Semi-lean bottom pump(P-3011A/B)
2) Stop the supply of low pressure steam.
3) Close the product CO2 line block valve.
4) Open the CO2 pressure release valve.
5) Stop Regenerator reflux pump (P-3004A/B).
6) Open the block valve in the steam condensate line from Urea Plant to Waste
heat Boiler (U-3001) to supply the steam condensate from Urea Plant.

6.6.9. Steam condensate return pump (P-3008A/B)

(1) Result
1) Liquid level of Steam condensate drum (V-3002) goes up.
2) The supply of steam condensate is to Waste heat boiler (U-3001) stopped.
(2) Action
1) Stop the supply of low pressure steam.
2) Close the product CO2 line block valve.
3) Stop Regenerator reflux pump(P-3004A/B)
4) Open the CO2 pressure release valve.
5) Open the block valve in the steam Urea plant to waste heat Boiler(U-3001) to
supply the steam condensate from Urea plant.

6.6.10. Semi-lean upper pump (P-3010A/B)

(1) Result
・ Liquid level of upper chimney tray in Regenerator (C-3002) goes up.
(2) Action
1) Open the bypass valve located at the semi-lean line to the distributor of middle
packing.
2) Even if Semi-lean upper pump (P-3010A/B) is stopped, it hardly influences
operation. Therefore, it is possible to continue operation.

6.6.11. Semi-lean bottom pump (P-3011A/B)

(1) Result

43
 ・ Liquid level of bottom chimney tray in Regenerator (C-3002) goes up.
(2) Action
1) Open the bypass valve located at the semi-lean line to the distributor of bottom
packing.
2) Even if Semi-lean bottom pump (P-3011A/B) is stopped, it hardly influences
operation. Therefore, it is possible to continue operation.

6.6.12. Waste water pump (P-3012A/B)

(1) Result
・ Liquid level of Flue gas quencher (Q-3001) goes up.
(2) Action
1) Stop Flue gas blower (K-3001).
If liquid level of Flue gas quencher (Q-3001) continues to go up, the circulation
wash water in Flue gas quencher (Q-3001) enters the flue gas duct. Therefore,
Flue gas blower (K-3001) is stopped.
When Flue gas blower (K-3001) is stopped, the following interlock systems are
worked.
• Trip for supply of low pressure steam
• Rich solution pump (P-3003A/B), Regenerator reflux pump (P-3004A/B),
Lean solution pump (P-3005A/B), Semi-lean upper pump (P-3010A/B) and
Semi-lean bottom pump (P-3011A/B) trip.
• Product CO2 line block valve is closed.
• Flue Gas cut off motor valve is closed.
2) Open the CO2 pressure release valve.
3) Stop Flue gas Cooling water pump(P-3001A/B), 1st wash water circulation
pump(P-3002A/B) and 2nd wash water circulation pump(P-3007A/B) when the
liquid level reaches to L.L.L

6.7. MECHANICAL TROUBLE OF EQUIPMENT / PIPING

If a part of the equipment or piping leaks during the operation, it is necessary to have
shutdown depending on the relevance of condition of each malfunction.

44
7. PREPARATION FOR INITIAL START UP
7.1. PROTECTION OF EQUIPMENT DURING CONSTRUCTION
Since system cleanliness is extremely important for satisfactory operation, diligence
must be exercised during construction and plant commissioning to avoid unnecessary
generation and/or accumulation of rust, dirt and construction debris in and on equipment
internals.

7.2. CLEANING PRIOR TO START UP

7.2.1. Removal of rust and/or scale
Rust and/or scale shall be removed as much as possible by wire brushing or other
method before equipment closure.

7.2.2. Water flushing

The equipment and piping shall be cleaned by circulating water to remove any
foreign materials that are remaining. Before water flushing, it will be confirmed
the followings.
- All flow meters and control valves are taken off.
- The temporary suction strainers shall be installed at inlet of pumps and plate
heat exchangers.

7.2.3. Chemical washing

The packing shall be degreased with caustic soda solution (approx. 3wt%). It is
necessary to carry out this degreasing whenever the packing is exchanged (Refer
to 0287 B407-00100).

7.2.4. Rinse washing

After the degreasing operation, caustic soda solution will be remaining in the
system. Rinse washing shall be carried out to remove the remaining soda from the
system by water circulation operation (Refer to 0287 B407-00100).

7.3. ACTIVATED CARBON CHARGING

7.3.1. Preparation

45
 The activated carbon filter is isolated from the system by closing its inlet and outlet
valves.

7.3.2. Blocking off of the solvent inlet nozzle

To prevent any activated carbon getting into the inlet nozzle at the time of
recharging of activated carbon filter, block off its open end with vinyl sheet.

7.3.3. Water charging

Since the charging is carried out from upper side of manhole, there is a possibility
of the activated carbon pieces getting shattered by the shock during the initial
charging. To prevent this, it is recommended that water is filled to about 1/2 - 1/3
height of the filter in prior to the introduction of the activated carbon.

7.3.4. Water level adjustment

After completion of the activated carbon charging, water is filled to the level near
KS-1 solution inlet nozzle. Then the vinyl sheet or the line, which was used to
block off the inlet nozzle, is removed.

7.3.5. Deaeration
Since air exists in the minute pores of the supplied activated carbon, the air does
not get replaced immediately even when the activated carbon is soaked in water or
KS-1 solution. Hence, if actual fluid is introduced into the activated carbon bed
without deaeration of the pores (replacement of air), the following problems would
occur:
Air in the pores gradually forms into fine bubbles with the elapse of time and
adheres on the activated carbon surface. Therefore, these bubbles prevent the
uniform flow of KS-1 solution in the activated carbon and the efficient contact
between KS-1 solution and the activated carbon. The procedure of deaeration is
shown below.

(1) After water charging, the upper manhole is closed and the manhole vent valve
is opened.

46
 (2) The activated carbon is kept soaked under this condition for more than 24
hours.
(3) Backwash is carried out to remove air trapped in the activated carbon bed and
the fine particles in sequence.

7.3.6. Removal of fine carbon particles (back wash)

Normally fine activated carbon particles adhere on the surface of the activated
carbon pieces and it is necessary to prevent flow loss being caused by these fine
particles. Therefore, cartridge filter is provided additionally at the outlet of the
activated carbon filter. The procedure of backwash is shown blow;
(1) The deaerated activated carbon is subjected to backwash within the activated
carbon bed where the fine particle bloats up, become fluid and eventually flows
out of the layer with the flowing liquid.
(2) Close the manhole vent valve of Carbon Filter (S-3002) and open the drain
valve of KS-1 inlet line.
(3) Fill the demineralized water to S-3002 from KS-1 outlet line.
(4) Stop the supply of the demineralized water after confirming that the
demineralized water starts to flow out from the drain valve of KS-1 inlet line.
(5) Discharge out washing water from the drain valve of S-3002 bottom. During
discharging, the manhole vent valve of S-3002 is opened.
(6) The above operation is repeatedly carried out for 2 hours.

47
 8. TROUBLES SHOOTING
Problems which may arise within the plant, these probable causes and solutions are
shown as follows.

Problems Causes Countermeasure

(1) Low CO2 1. Low KS-1 concentration • Add KS-1 solution. See (4.3.1).
absorption 2. High CO2 Loading of Lean
• See (2) poor CO2 stripping.
Solvent
3. Low CO2 concentration in flue gas • Check the combustion air flow of Boiler.
• Check Lean Solution Pump (P-3005A/B).
4. Low circulation rate of KS-1
• Check the control valve.
solution flow rate
• Check the flow meter.
• Check Flue Gas Blower (K-3001).
5. Low flow rate of flue gas • Check the inlet damper.
• Check the flow meter.
• Check the liquid distribution of
absorption section.
• Check the gas distribution of absorption
6. Poor liquid/gas contacting
section.
• Check the packing condition of
absorption section.
7. Foaming in CO2 Absorber • see (3) Foaming
8. High temperature of flue gas fed • Increase the circulation rate of cooling
to CO2 Absorber (C-3001) water.
• Reduce the temperature of cooling
water.
• Check the flue gas inlet temperature of
Flue gas quencher (Q-3001).
• Check H2O concentration of Flue gas
quencher (Q-3001).
• Check the liquid distribution of cooling
section.
• Check the gas distribution of cooling
section.
• Check the packing condition of cooling
section.

48
Problems Causes Countermeasure
9. High temperature of Lean KS-1 • Check the control valve.
solution fed to CO2 Absorber • Clean Lean Solution Cooler (E-3006).
(C-3001).

(2) Degradation of 1. Low flow rate of flue gas • Check the control valve.
CO2 stripping • Check the flow meter.

2. Low temperature of KS-1 solution • Clean Solution Heat Exchanger

fed to Regenerator (E-3003).
• Check any leak of Solution Heat
Exchanger (E-3003).
3. Low pressure of Regenerator • Increase the pressure of product CO2.
• Check the purging valve.
4. Low temperature of Regenerator • Increase the pressure of Regenerator
Bottom • Check KS-1 concentration.
5. Poor gas/liquid contacting • Check the liquid distribution of
Regenerator.
• Check the gas distribution of
Regenerator.
• Check the packing condition of
Regenerator.
(3) Foaming 1. High concentration of solvent • Check the activated carbon or replace it
degradation in KS-1 solution with new one.
• Inject the antifoam agent.
• Start reclaiming.
2
2. High concentration of solid or SS • Check the filter or replace it with new
in KS-1 solution one.
• Check the activated carbon or replace it
with new one.
3. Contamination of caustic soda in • Inject the antifoam agent.
KS-1 solution • Start reclaiming.
(4) Excessive loss 1. High flow rate of flue gas • Adjust flue gas flow.
of KS-1 2. High temperature of treated flue • Increase the circulation rate of 1st water
solution gas exhausted from CO2 wash section
Absorber. • Decrease the temperature of wash
water.
• Check the liquid distribution of 1st water
wash section.
• Check the gas distribution of 1st water
wash Section.

49
Problems Causes Countermeasure
• Check the packing condition of 1st water
wash section.
3. High concentration of KS-1 • Check the reflux water flow.
solution in 2nd wash water • Check the demisters in Absorber
• Check the operating condition in 1st
water wash section. See 9. (4) 2
4. Leaks • Stop the leak.

(5) High 1. High concentration of solvent Start reclaiming.

degradation degradation
rate of solvent 2. High concentration of SOx in the • Increase the flow rate to supply caustic
flue gas fed to CO2 Absorber soda to the circulation water of SOx
absorption section.
• Increase the circulation rate of SOx
absorption section.
• Check the liquid distribution of SOx
absorption section.
• Check the gas distribution of SOx
absorption section.
• Check the packing condition of SOx
absorption section.
3. High concentration of NOx in the • Check the combustive condition of boiler.
flue gas fed to CO2 Absorber
4. High skin temperature of reboiler • Reduce the pressure of low pressure
tube steam.
5. High operating temperature of • Reduce pressure in Regenerator.
Regenerator
6. High concentration of soluble iron • Start reclaiming.

(6) High corrosion 1. High concentration of solvent • Check the activated carbon or replace it
degradation with new one.
• Start reclaiming.
2. High concentration of chloride • Start reclaiming.
iron. • Check demineralized water.
2
3. High concentration of SS in KS-1 • Start reclaiming.
solution • Check the filter or replace it with new
one.

50
Problems Causes Countermeasure
(7) High KS-1 1. Failure of water balance control • If outlet temperature of Wash Water
concentration Cooler (E-3002) is too low, increase the
temperature.
• Reconsider the parameter of CO2
Absorber bottom level control.

[Link] temperature of treated flue • See 9. (4) 2

gas exhausted from CO2
Absorber
3. High temperature of product CO2 • Increase the flow rate of cooling water
fed to Regenerator Condenser (E-3004).
• Clean Regenerator Condenser (E-3004).
4. High concentration of mist in the • Check Absorber outlet demister.
treated flue gas exhausted from • Check the liquid distribution of 2nd water
CO2 Absorber wash section.
• Check the gas distribution of 2nd water
wash section.
• Check the packing condition of 2nd
water wash section.
5. High concentration of mists in • Check the top demister of Regenerator
product CO2 Reflux Drum (V-3001).
(8) Excessive 1. Excessive circulation of solvent • Adjust the circulation flow of solvent
steam 2. Low CO2 Loading of rich solvent • See 9. (1)
consumption
[Link] temperature of KS-1 solution • See 9.(2) 2
fed to Regenerator
4. Low concentration of KS-1 • Add KS-1 solution and/or additive. See
solution (4.3.1).
(9) High pressure 1. Foaming • See 9.(3).
drop in tower 2. Plugging of packing. • Check the packing.

3. Excessive gas or liquid rates • Reduce the flow.

4. Collapse or degradation of • Check the packing.

packing
5. Plugging of demister. • Check the demister.

51