Khark Petrochemical Company Production Process

A step-by-step overview of the feedstock flow to final products. Click the arrow below each stage to view full details.

Feedstock — Sour Gas
The plant feedstock consists of rich sour gas containing hydrocarbons from C1 to C8, as well as significant amounts of H₂S and CO₂. It is supplied via 19 subsea pipelines from wells located about 100 km offshore in the Persian Gulf.
Feed condition and pipeline safety
The incoming feed is continuously monitored: gas composition, pressure, and flow rate of each pipeline are recorded. Safety and anti-corrosion systems are in place to handle H₂S hazards.
Pressure Reduction & Amine Unit (Sweetening)
After pressure regulation, the sour gas enters the Amine Unit. In HP and LP contact towers, it is sweetened using 20–25 wt% DEA (Diethanolamine) solution to remove H₂S and CO₂.
Removal of H₂S and CO₂
In the contact towers, DEA absorbs H₂S and CO₂ from the gas stream. The output is “sweet gas” with significantly reduced acid gas content.
Amine Regeneration
Rich amine leaving the towers is sent to the Regenerator (stripper) where H₂S and CO₂ are separated, and the lean amine is recovered for reuse.
Amine recycle & acid gas stream
In the regenerator, the amine is stripped using heat/steam and returned for reuse. The separated acid gas (about 60% H₂S) is directed to the Sulfur Recovery Unit (SRU).
Sulfur Recovery & Granulation
The acid gas is processed in the Sulfur Recovery Unit, producing molten sulfur, which is then granulated for storage and export.
Conversion of acid gas to export product
Molten sulfur is solidified and granulated for safe handling and long-term storage. Final product quality is tested before being sent to export terminals.
Dehydration with TEG
The sweetened gas is dehydrated in the Glycol Unit by contacting Triethylene Glycol (TEG), which absorbs water and delivers a dry gas stream.
Removal of water vapor
Saturated TEG is regenerated and recycled for continuous use. The dry gas stream is suitable for downstream hydrocarbon separation.
Lean Oil Absorption & Fractionation
The dry gas undergoes Lean Oil absorption, followed by fractionation in DeC2, Stabilizer, Depropanizer, and Debutanizer towers to separate C3, C4, and Naphtha streams.
Separation of propane, butane, and naphtha
Heavier hydrocarbons are absorbed and fractionated. Propane, butane, and naphtha are separated, while C1/C2 gases are directed to fuel systems or the Methanol Unit.
LPG Purification (DMD & Treaters)
LPG streams are treated in DMD and treater units to remove sulfur compounds and water, ensuring product purity.
Quality assurance for LPG
LPG is purified, stored in daily tanks, and sent to export storage after laboratory testing confirms compliance with specifications.
Methanol Production from C1/C2 Off-Gases
Excess C1 and C2 gases are processed in the Methanol Unit. After compression, desulfurization, and reforming, they are converted into syngas and synthesized into methanol.
Valorization of off-gas
The gases are reformed into CO, CO₂, and H₂, then fed to the synthesis loop where methanol and water are produced. Unreacted gas is recycled, and methanol is purified in the distillation unit.
Storage, Quality Control & Export
Final products (LPG, Methanol, Naphtha, Sulfur) are stored in dedicated tanks, quality-tested, and transferred to export facilities.
Laboratory control & shipment
Sampling and daily lab tests ensure compliance. Certified cargoes are transferred to export tanks and shipped to international customers.
Energy Efficiency, Safety & Sustainability
Energy optimization, emission reduction, occupational safety, and environmental protection are core priorities at Khark Petrochemical.
Emission control & sustainable growth
Flare minimization projects and advanced technologies reduce emissions. Employee safety and environmental stewardship remain top priorities of the company.