DEBNO PROJECT

• Design basis memorandum and project specifications for a 55 MMSCFD sour gas plant including fractionation and sulphur plants. Economic evaluation of 200 cum/d fractionation train options.
• Project management of a US $70 million gas plant development involving 21 wells and the production of 45 MMSCFD gas, 6000 bbl/d oil, 120 t/d sulphur, 600 bbl/d LPG and 200 bbl/d condensate.
• Fabrication and construction inspection.
• Pipeline system design and evaluation.
• HAZOP evaluation. Start-up and operations support.
• Training - plant management and Debno Plant Operations personnel.

Autor: P. Górski, archiwum PGNiG S.A. Oddział w Zielonej Górze

1. Inlet Manifold and Test Separator Building
   The building houses inlet manifolds for gathering lines from 22 well sites (at start-up), located in three oil and gas fields, and horizontal three-phase test and inlet separators.
2. Compressor Building
   There is one LP Compressor and two Refrigerant Propane Compressors in the building. The low-pressure compressor is a three-stage Dresser-Rand reciprocating compressor driven by a 970 kW motor. The first stage compresses gas from the Oil Stabilizer. Deethanizer overheads are added to the third stage.
   
   
   The Refrigerant Compressors are Mycom rotary screw compressors driven by 746 kW electric motors.
   
   
   Behind the building are the 1600 kW Refrigerant Condenser and the 1465 kW LP Compressor Cooler.
3. Gas Sweetening Building
   The amine plant sweetens up to 900 Nm³/min of sour natural gas containing 6.5% H2S. To the right of the building there are: 20-tray Amine Contactor, 55 m³ Amine Surge Tank, 50 m³ Amine Storage Tank. To the left of the building there are: 20-tray Amine Regenerator and 5-tray Water Wash column. Behind the building stand: 2786 kW Amine Reflux Condenser and 4980 kW Amine Trim Cooler. The building houses among others: Amine Flash Tank, 4303 kW Rich/Lean Exchanger, Amine Solids and Carbon Filters, 373 kW Amine Charge Pumps circulating 460 gpm of MDEA.
4. Stabilizer Building
   The Stabilizer Unit processes 1200 t/d of crude oil. The building houses 1120 kW Feed-Bottoms Exchanger, Stabilizer Feed Drum, 180 kW Oil Treater, 1910 kW Stabilizer Reboiler. To the right of the building there are: 20-tray Stabilizer column, 585 kW Stabilized Oil Cooler. The oil is stabilized to 12 RVP and <25 ppm H2S.
5. Gas Refrigeration Building
   To the left of the building there are: 200 kW Gas-Liquid and 2000 kW Gas-Gas Exchangers, 800 kW Propane Chiller, mole sieve LPG treating. To the right of the building there are: 30-tray Debutanizer and 1460 kW Debutanizer Reflux Condenser. In the building there are: LTS, packed Deethanizer column and 200 kW ethylene glycol regeneration. The liquid hydrocarbons are fractionated to up to 120 m³/d of LPG and 60 m³/d of condensate.
6. Sulfur Plant
   The main pieces of equipment are: 7470 kW Waste Heat Boiler, Reaction Furnace with 10000 kW burner, three-stage Claus Plant, tail gas unit (Super Claus), tail gas coalescer, incinerator and 45 m incinerator stack, 440 m³ sulfur pit,, Shell sulfur degassing, sulfur loading, The plant produces up to 130 t/d of sulfur.
7. Process Utilities Building
   The building contains boiler feed water treatment (chemical injection, deaeration), 25000 kg/h Auxiliary Steam Boiler, two Combustion Air Blowers for the Sulfur Plant, one electric and one steam driven. To the right of the building: Steam Boiler stack, Deaerator, 1172 kW Excess Steam Condenser/Condensate Cooler.
8. Boiler Blowdown Evaporation Pond
   The 6000 m³ evaporation pond collects blowdown water from the Sulfur Plant (Waste Heat Boiler, MP Steam Drum and Sulfur Condensers) and the Auxiliary Steam Boiler.
9. Storage Tank Area
   • Three oil storage tanks, two - 3500 m³, one 10000 m³.
   • Condensate storage tank 350 m³
   • Produced water tank 254 m³
   • Three LPG bullets to the right (not seen on the picture), 225 m³ each
   • Behind the storage tanks are LPG pumps and metering, VRU building, Oil/condensate pumps and metering
10. Fire Water Pump Building
    There are two skids in the building: fire water and water treatment.
    Fire water skid: two diesel driven vertical turbine fire water pumps, 795 m³/h capacity, and two electric driven vertical turbine jockey pumps, 11.35 m³/h capacity.
    Water treatment skid: multimedia filter, carbon filter, softener and reverse osmosis. The capacity of the skid is 76 l/min.
    
    
    The fire water pond has the capacity of 3020 m³.
11. Flare Stack
    The 45 m high flare stack is common to high and low pressure flare systems. The stack is equipped with three pilot tips with ignitors ignited by a John Zinc flame front generator.
12. Warehouse Building
    Spare parts in the building. To the left, not seen on the picture: utility/laboratory building, switchgear building, office/control room building.