LNG Badak CO2 Removal Hystory

AGENDA
I. INTRODUCTION
II. STRESS CORROSION CRACKING WHEN USING
MEA
III. SOLVENT CONVERSION FROM MEA TO
FORMULATED UCARSOL CR-402
IV. EROSION CORROSION WITH UCARSOL CR-402
V. EFFORTS TO OVERCOME EROSION
CORROSION WITH UCARSOL CR-402
VI. SOLVENT CONVERSION FROM UCARSOL CR-
402 TO BASF aMDEA
VII. CONCLUSIONS
Introduction (Cont.)
? 1977 FIRST DROP OF LNG FROM TRAINS A AND B

? 1982 CONSTRUCTION OF TRAINS C AND D
? 1987 CONSTRUCTION OF TRAIN E
? 1991 CONSTRUCTION OF TRAIN F
? 1995 CONSTRUCTION OF TRAIN G
? 1997 CONSTRUCTION OF TRAIN H
? 2000 PLANT CAPACITIES :
EIGHT TRAINS (A-H)
LNG = 21.64 MM Tons/Year.
LPG = 1.25 MM Tons/Year (Propane + Butane)
Condensate = 10 MM Barrels/Year.
CO2 REMOVAL (AMINE) UNIT
ORIGINAL DESIGN (Trains A & B)

• Feed gas : 305,900 Nm3/h
• CO2 content in feed gas : 5.88% vol.
• Amine solution : MEA, strength max 20% wt.
• Amine circulation rate : 740 m 3/h
• Maximum CO2 slip : 50 ppmv
• Use corrosion inhibitor
AFTER REVAMP (Trains A-D)

• Feed gas: 495,000 nm3/h
• Maximum CO2 content in feed gas : 8% vol.
• Amine circulation rate : 1200 m3/h
• Maximum CO2 slip : 50 ppmv
• Use corrosion inhibitor
CO2 REMOVAL (AMINE) UNIT
TO DRIER
OVHD.COOLER
CARBON
OVHD.ACC. TREATER
OVHD.ACC.
OVHD.COOLER SURGE
TANK
MECH.
FILTER 1G-6
WASH
WATER
1G-1
AMINE STRIPPER
CO2
ABSORBER
LP STEAM
TRIM
COOLER
FEED GAS
FINFAN
COOLER
FLASH DRUM
REBOILER
CROSS
BOOSTER EXCHANGER
PUMP
II. STRESS CORROSION CRACKING
WITH MEA
TRAINS A & B
• STARTUP WITH MEA SOLUTION IN 1977
• JANUARY 1986, FIRST CRACK INCIDENT IN AMINE
STRIPPER ON THE LACE WELD WITHOUT STRESS
RELIEF
TRAINS C & D
• STARTUP WITH MEA IN 1983
• MAY 1986, CRACK WAS FOUND IN AMINE STRIPPER IN
TRAIN C NEAR THE MIDDLE CIRCUMFERENTIAL WELD
JANUARY 1986 - MAY 1989

10 UNSCHEDULED SHUTDOWNS BECAUSE OF SCC
III. SOLVENT CONVERSION FROM
MEA TO UCARSOL CR-402
SOLVENT CONVERSION
• TO PREVENT FURTHER LOSSES DUE TO SCC
• CARRIED OUT IN THE PERIOD OF 1990-1991
(TRAINS A-D)
• USED MEA WAS BURNED
• TRAINS E/F STARTED UP WITH UCARSOL CR-402
RESULTS
• NO SCC OCCURRED
• REDUCED STEAM CONSUMPTION
• CO2 SLIP IN TREATED GAS < 5 ppmv
SOLVENT CONVERSION … (Cont.)
Operating Conditions with UCARSOL CR-

402
• AMINE STRENGTH 35% WEIGHT
• AMINE CIRCULATION RATE 1050-1100 m3/h
VELOCITY IN PIPING 5-6 ft/sec (1.5-1.8 m/sec)
• MAXIMUM RICH LOADING 0.35 M/M
• MAXIMUM LEAN LOADING 0.02 M/M
• NO CORROSION INHIBITOR
• ANTIFOAM INJECTION RATE 5-6 LITERS/DAY
(50% Si-BASE AND 50% GLYCOL-BASE)
IV. EROSION CORROSION WITH
UCARSOL CR-402
IN 1995, LOST OF LNG PRODUCTION OPPORTUNITY

EQUIVALENT TO $24MM CAUSED BY:
• REDUCED LNG RATE FOR REPAIR ONE BANK CROSS
EXCHANGERS
• SHUTDOWN AMINE UNIT AND LNG PRODUCTION
USING CROSS LEAN GAS FROM OTHER TRAIN
• EXTENDED DOWNTIME FOR EQUIPMENT REPAIR
Erosion Corrosion ... (Cont.)
Metal Content in Solution
UCARSOL CR-402
140
Train E Train A Train B
120
Train C
Iron Content (ppm)
100 Train F Train D
80
60
40
20
0
0 2 4 6 8 10 12 14 16
Month
Erosion Corrosion … (Cont.)
Equipment Inspection Results
AMINE STRIPPER DAMAGE

• INLET DISTRIBUTOR COLLAPSE
• UPPER TRAY DAMAGE
• VESSEL WALL LEAK
CAUSE
• POOR DESIGN INLET DISTRIBUTOR
• VIBRATION
• CORROSIVE SOLVENT
Equipment Inspection Results
AMINE/AMINE CROSS EXCHANGER DAMAGE

• EROSION CORROSION OF THE CARBON STEEL
CHANNEL BOX, FLOATING HEAD COVER, AND FIXED
TUBESHEETS
• THINNING OF 304 SS TUBES
• SCALE FORMATION INSIDE TUBES
AMINE FLASH DRUM DAMAGE

• EROSION CORROSION ON INTERNAL WALL
• POOR DESIGN OF INLET DISTRIBUTOR
HEAT STABLE AMINE SALTS (HSAS)
• PRIMARILY ACETATE, GLYCOLATE, AND FORMATE

• MAXIMUM ALLOWABLE 0.25% WEIGHT
• NEUTRALIZATION USING CAUSTIC
CAUSE
• OXYGEN INGRESS INTO THE SYSTEM
• RETURNING LEAKING SOLUTION INTO THE SYSTEM
PREVENTION
• NITROGEN BLANKETING
Lean Amine Side Corrosion
LOW-PRESSURE RELATED REGIMES SUCH AS:

• DOWNSTREAM CONTROL VALVE
• INSIDE OF ELBOWS
• INLET TUBES OF FIN FAN HEAT EXCHANGER
V. EFFORTS TO OVERCOME
UCARSOL CR-402 EROSION CORROSION
CHANGING OPERATING CONDITIONS

• INCREASE OPERATING PRESSURE OF AMINE FLASH
DRUM
• REDUCE THE RICH AMINE TEMPERATURE OUTLET
CROSS EXCHANGER
EQUIPMENT MODIFICATIONS
• PARTIAL UPGRADE PIPING MATERIAL FROM CS TO SS
• IMPROVE DESIGN OF INLET DISTRIBUTOR AMINE
FLASH DRUM AND AMINE STRIPPER
• IMPROVE MECHANICAL SUPPORT OF AMINE STRIPPER
INLET DISTRIBUTOR
Amine Flash Drum
Liquid
Wire Screen Level
Splash Baffle
Corrosion
Areas
After Modification
Before Modification with Perforated Pipe
(A) (B)
Efforts … (Cont.)
HIGHER AMINE STRENGTH
INCREASE AMINE CONCENTRATION FROM 35% WT TO

45-50% WT TO REDUCE AMINE CIRCULATION RATE
PROBLEMS
• FOAMING IN CO2 ABSORBER VERY FREQUENTLY
• AMINE STRIPPER LEVEL CYCLING
• EXCESSIVE SCALE FORMATION IN STRIPPER
REBOILER
• EROSION CORROSION WAS STILL OBSERVED DURING
INSPECTION AFTER ONE YEAR
• STRENGTH WAS REDUCED BACK TO 35% WT
VI. SOLVENT CONVERSION FROM
UCARSOL CR-402 TO BASF aMDEA
SELECTION OF ALTERNATE SOLVENT

• Corrosion problem is the driving force for solvent
conversion
• Several alternate solvents were evaluated
• Comparison study with reference plants using the
alternate solvent in the U.S. And Europe
SELECTED BASF aMDEA

• Minimum equipment modification is a must
• Test in one train for 18 months, with internal inspection
after 12 months
• Tighter guarantee figures:
- 20 mpy max corrosion rate by coupon
- 100 ppmw max iron content in solution
- No defect found after one year test
Solvent Conversion … (Cont.)
TEST PREPARATION FOR THE

SELECTED SOLVENT
• MAJOR EQUIPMENT INSPECTION FOR BASE LINE

• INSTALL TWO NEW BUNDLES OF CROSS EXCHANGER
TO MEASURE TUBE THINNING RATE & SCALE
FORMATION
• INSTALL THREADED CONNECTIONS ON PIPING FOR
COMPARISON WITH UCARSOL CR-402
• CHEMICAL CLEANING WITH CAUSTIC 2% WT (pH 12)
• STEAM CONDENSATE FLUSHING FINISH
NEW OPERATING CONDITIONS
• SOLUTION STRENGTH 40% WT

• AMINE CIRCULATION RATE : 750 m3/h, LIMITED BY
CO2 SLIPPAGE INSTEAD OF RICH LOADING
• NO CORROSION INHIBITOR
• MAXIMUM RICH AMINE LOADING : 0.62 M/M
• MAXIMUM LEAN AMINE LOADING : 0.03 M/M
• ANTIFOAM INJECTION RATE 5 LITER/DAY
(GLYCOL TO SILICON BASE 50:50)
AMINE CIRCULATION RATE
• DESIGN AMINE CIRCULATION: 1200 m3/h

• THREE CIRCULATING PUMPS, TWO RUN
• PUMP CAPACITY: 400-800 M3/H EACH
• REQUIRED CIRCULATION RATE BY PROCESS: 750 M3/H
• PUMP LIMITATION
RUNNING 1 PUMP: LOW PLANT RELIABILITY
RUNNING 2 PUMPS: CLOSE TO MINIMUM FLOW
• TEMPORARY SOLUTION: INCREASE AMINE
CIRCULATION RATE TO 850-900 m3/h
IRON CONTENT IN aMDEA BASFSOLUTION
4
Fe content (ppmw)
0
ONE YEAR WARRANTY SHUTDOWN
• NEGLIGIBLE CORROSION ATTACK

• GOOD CONDITION OF THREE THREADED CONNECTIONS
• NO THINNING TUBES IN CROSS EXCHANGER
• NO SCALE FORMATION INSIDE CROSS EXCHANGER
TUBES
ADVANTAGES OF OPERATING WITH

BASF aMDEA
• AMINE CIRCULATION RATE

28% LOWER THAN UCARSOL CR-402
25% LOWER THAN MEA
• CORROSION RATE
3 MPY MAX CORROSION RATE BY COUPON
MEASURED EVERY 4 WEEKS FOR 6 TIMES
• SOLVENT LOSSES
46% LOWER THAN UCARSOL CR-402
67% LOWER THAN MEA
ADVANTAGES ...
160
UCARSOL
Iron Content (ppmw)
120
80
40
aMDEA BASF
0
ADVANTAGES...
COMPARISON OF OPERATING CONDITIONS IN MEA,

Ucarsol AND aMDEA BASF
OPERATING CONDITIONS MEA Ucarsol aMDEA BASF
LNG Rate, m 3 /h 620 725 725
CO2 Slipage, ppmv 15 <10 <10
Amine Circulation Rate, m 3 /h 1000 1050 750
Concentration, %(wt) 20 35 40
Lean Loading, m/m 0.12 0.019 0.012
Rich Loading, m/m 0.41 0.34 0.42
Steam Consumption, Tons/h 125 120 96
Amine Make up, drums/month 23 14 7.5
CONCLUSIONS
• MEA in 1977-1989: SCC occurred in CO2 Absorber and

Amine Stripper and caused 10 unscheduled shutdowns
in January 1986 - May 1989
• UCARSOL CR-402 eliminated SCC but Erosion Corrosion
was prominent. The suspected cause:
CO2 liberation on rich amine side
Vena contracta effect on lean amine side
High linear velocity
• Efforts to control erosion corrosion UCARSOL CR-402 :
Changing operating conditions
Modifying equipment
Upgrading materials
CONCLUSIONS
• Solvent conversion from UCARSOL CR-402 to BASF

aMDEA was successful.
Meet the specified absorption capability
Low corrosion rate by coupon
Lower iron content in solution
Lower steam consumption
Lower solvent makeup
• Lower amine circulation rate could not be maintained
because of pump limitation. Evaluation is being
continued.

LNG Badak CO2 Removal Hystory

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LNG Badak CO2 Removal Hystory

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AGENDA

? 1977 FIRST DROP OF LNG FROM TRAINS A AND B

CO2 REMOVAL (AMINE) UNIT

ORIGINAL DESIGN (Trains A & B)

AFTER REVAMP (Trains A-D)

CO2 REMOVAL (AMINE) UNIT

JANUARY 1986 - MAY 1989

Operating Conditions with UCARSOL CR-

IN 1995, LOST OF LNG PRODUCTION OPPORTUNITY

100 Train F Train D

Equipment Inspection Results

AMINE STRIPPER DAMAGE

Equipment Inspection Results

AMINE/AMINE CROSS EXCHANGER DAMAGE

AMINE FLASH DRUM DAMAGE

HEAT STABLE AMINE SALTS (HSAS)

• PRIMARILY ACETATE, GLYCOLATE, AND FORMATE

Lean Amine Side Corrosion

LOW-PRESSURE RELATED REGIMES SUCH AS:

CHANGING OPERATING CONDITIONS

HIGHER AMINE STRENGTH

INCREASE AMINE CONCENTRATION FROM 35% WT TO

SELECTION OF ALTERNATE SOLVENT

SELECTED BASF aMDEA

TEST PREPARATION FOR THE

• MAJOR EQUIPMENT INSPECTION FOR BASE LINE

NEW OPERATING CONDITIONS

• SOLUTION STRENGTH 40% WT

AMINE CIRCULATION RATE

• DESIGN AMINE CIRCULATION: 1200 m3/h

IRON CONTENT IN aMDEA BASFSOLUTION

ONE YEAR WARRANTY SHUTDOWN

• NEGLIGIBLE CORROSION ATTACK

ADVANTAGES OF OPERATING WITH

• AMINE CIRCULATION RATE

COMPARISON OF OPERATING CONDITIONS IN MEA,

• MEA in 1977-1989: SCC occurred in CO2 Absorber and

• Solvent conversion from UCARSOL CR-402 to BASF

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