DUNG QUAT REFINERY PROJECT MANAGEMENT BOARD 3rd TECHNOLOGY GROUP
RESIDUE FLUID CATALYSTIC CRACKING UNIT (RFCCU)
QUANG NGAI -2006
PRESENTATION CONTENTS
I.
INTR IN TROD ODUC UCTI TION ON;;
II.. II
BASI BA SIC C OF DES DESIG IGN; N;
III. PROCES PROCESS S DESCRI DESCRIPTION PTION;; IV. MATERI MATERIAL AL BALAN BALANCE CE (TYPI (TYPICAL); CAL); V.
SPECIFICATI SPECIF ICATION ON OF CATALY CATALYST ST AND CHEMIC CHEMICAL; AL;
VI. SAF SAFETY ETY..
PRESENTATION CONTENTS
I.
INTR IN TROD ODUC UCTI TION ON;;
II.. II
BASI BA SIC C OF DES DESIG IGN; N;
III. PROCES PROCESS S DESCRI DESCRIPTION PTION;; IV. MATERI MATERIAL AL BALAN BALANCE CE (TYPI (TYPICAL); CAL); V.
SPECIFICATI SPECIF ICATION ON OF CATALY CATALYST ST AND CHEMIC CHEMICAL; AL;
VI. SAF SAFETY ETY..
I- INT INTROD RODUCT UCTION ION
1.
Lice Li cens nsed ed by IF IFP/ P/AX AXEN ENS; S;
2.
Tech Te chno nolo logy gy:: R2 R2R; R;
3.
The rol rolee of RFC RFCC C in the Ref Refine inery; ry;
4.
Locati Loc ation on of RFC RFCC C in the Ref Refine inery. ry.
I.3 – THE ROLE OF RFCC IN THE REFINERY
I.4 – LOCATION OF RFCC IN THE REFINERY
II-BASIC OF DESIGN 1.
Unit objectives and capacity;
2.
Feedstock properties;
3.
Product specifications;
4.
Operating conditions;
5.
Battery limit conditions;
6.
Utility operating / Design conditions.
II.1 – UNIT OBJECTIVES AND CAPACITY a.
Objectives: Process: Bach Ho
Mixed BH/DB Off-gas LPG
Atmosphere Residue From CDU
Cracking
Lighter more valuable
Off gas HSO (5000BPSD) LSO (5000BPSD)
Products
From NHT From Refinery
b.
Capacity: 69700 BPSD (3 256 000 tonnes per year)
c.
Operational:
Maximum Gasoline;
Maximum Distillate.
Blending
Gasoline DO
II.2 – FEEDSTOCK PROPERTIES a.
Atmospheric residue properties; Crude Blend
100%BachHo
Cut range, TBP (oC)
370+
370+
Vol. % on crude
46.6
47.3
SG at 15/4oC
0.893
0.882
50
52
IBP
263
262
50%
475
480
Vol% above 550oC
32.4
32.5
Property
Pour point (oC) ASTM distillation @ 760 mmHg (oC
II.2 – FEEDSTOCK PROPERTIES (CONT.) b.
CDU stabilizer off-gas; 100% Dubai
100% Bach Ho
339.0
291.0
Flow rate (kg/h) Composition (mol%) C1
-
0.7
C2
6.3
4.8
C3
37.0
22.7
C4
54.9
69.5
C5
0.4
0.4
Molecular weight
50.6
52.6
II.2 – FEEDSTOCK PROPERTIES (CONT.) c.
NHT stripper off-gas to RFCC; H2O
(kg mol/h)
0.13
H2S
(kg mol/h)
0.32
H2
(kg mol/h)
13.17
C1
(kg mol/h)
1.69
C2
(kg mol/h)
1.37
C3
(kg mol/h)
0.83
C4
(kg mol/h)
0.46
C5
(kg mol/h)
0.24
C6+
(kg mol/h)
0.63
Total
(kg mol/h)
18.84
II.2 – FEEDSTOCK PROPERTIES (CONT.) d.
CDU LPG rich steam. Crude (sour) Blend
100% Bach Ho
Flow rate (kg/h)
6206
2071
SG at 15oC
0.565
0.572
C2
1.2
0.8
C3
19.3
10.7
C4
78.2
87.1
C5+
1.3
1.4
Total
100
100
Composition (mol%)
II.3 – PRODUCT SPECIFICATIONS a.
LPG;
MMG
BMG
MMD
BMD
0.565
0.566
0.565
0.565
Mercaptans (wt ppm)
78
7.1
78
7.1
COS (wt ppm)
5.0
5.0
5.0
5.0
Total sulphur (wt ppm)
3768
332
4260
383
Butadiene (wt ppm)
3012
1647
1358
1063
PROPETIES
Sp. Gr 15/15
II.3 – PRODUCT SPECIFICATIONS (CONT.) b.
Gasoline (MG: C5-205oC; MD: C5-165oC); MMG
BMG
MMD
BMD
Sulphur (wt ppm)
340
10
230
10
RON clear
92.1
91.8
92.0
RVP (kPa)
32
34
48
51
0.736
0.732
0.719
0.715
IP
39
39
35
34
50%
90
87
72
70
EP
197
197
159
156
Olefins (wt%)
34
35
43
45
PROPERTIES
Sp. Gr. 15/15
91.7
II.3 – PRODUCT SPECIFICATIONS (CONT.) c.
LCO (MG: 205-360oC; MD: 165-390oC);
MMG
BMG
MMD
BMD
Sulphur (wt ppm)
0.619
0,055
0.45
0.04
Cetane number
24.4
28.1
33.9
Pour point (oC)
-12.8
-14.0
-17.3
-18.9
Flash point (oC)
76
74
67
67
Sp. Gr. 15/15
0.926
0.911
0.881
0.864
IP
188
180
189
189
50%
263
262
263
264
EP
353
353
373
374
PROPERTIES
38.4
II.3 – PRODUCT SPECIFICATIONS (CONT.) d.
Slurry (MG: 360+oC; MD: 390+oC);
MMG
BMG
MMD
BMD
Sp. Gr. 15/15
1.092
1.043
0.994
0.960
Sulphur (wt%)
1.03
0.10
0.835
Conradson carbon (wt%)
15.7
12.7
12.5
9.5
Viscosity @ 100oC (cSt)
160
140
110
45
15-20
15-20
15-20
15-20
PROPERTIES
Pour point (oC)
0.07
II.3 – PRODUCT SPECIFICATIONS (CONT.) e.
Decant Oil (after slurry separation):
f.
100
ppm wt max
Fuel Gas:
g.
Catalyst content:
H2S content:
50
ppm wt max
Flue Gas (after EP and DeSOx unit):
NOx:
1000
mg/Nm3 max
SOx:
500
mg/Nm3 max
Catalyst fines
50
mg/Nm3 max
CO content
300
mg/Nm3 max
II.4 – OPERATING CONDITIONS a.
Reaction/Regeneration Section;
MMG
BMG
MMD
BMD
Outlet temperature (oC)
520
518
511
505
Feed flow rate (ton/h)
407
407
524.1
524.1
Feed temperature (oC)
170
290
170
290
MTC
(ton/h)
76.4
0
0
0
MTC recycle temp. (oC)
181
0
0
0
5
5
5
5
170
170
170
170
79.94
80.76
62.60
61.88
RISER/REACTOR
HCO back flush (t/h) HCO back flush temp. (oC) Stand. conversion (wt%)
II.4 – OPERATING CONDITIONS (CONT.) a.
Reaction/Regeneration Section (Cont.);
FIRST REGENERATOR
MMG
BMG
MMD
BMD
Dilute temperature (oC)
678
646
641
631
Dense temperature (oC)
683
651
646
636
Dilute pressure(kg/cm2g)
2.28
2.28
2.28
2.28
70
70
70
70
15.2
5.5
15.2
5.5
MMG
BMG
MMD
BMD
Dilute temperature (oC)
772
734
733
720
Dense temperature (oC)
762
713
712
695
Dilute pressure (kg/cm2g)
1.3
1.3
1.3
1.3
Coke burnt (%) Cat. dry make-up (t/d) SECOND REGENERATOR
II.4 – OPERATING CONDITIONS (CONT.) b.
Fractionation Section;
MAIN FRACTIONATOR
MMG
BMG
MMD
BMD
Top temperature (oC)
103
102
100
96
Top pressure(kg/cm2g)
0.85
0.85
0.85
0.85
Heavy naphtha
156
152
162
161
LCO
218
210
230
230
Bottom temperature (oC)
340
340
340
340
Bottom pressure (kg/cm2g)
1.15
1.15
1.15
1.15
Draw-off temperature ( oC)
II.4 – OPERATING CONDITIONS (CONT.) c.
Gas Recovery Section;
PRIMARY ABSORBER
MMG
BMG
MMD
BMD
Top temperature (oC)
51
49
50
48
Top pressure (kg/cm2g)
14.8
14.8
14.8
14.8
Bottom temperature (oC)
59
58
58
58
Bot. pressure(kg/cm2g)
15.1
15.1
15.1
15.1
SECOND ABSORBER
MMG
BMG
MMD
BMD
Top temperature (oC)
50
47
47
45
Top pressure (kg/cm2g)
14.4
14.4
14.4
14.4
Bottom temperature (oC)
60
58
59
59
Bottom pressure (kg/cm2g)
14.7
14.7
14.7
14.7
II.4 – OPERATING CONDITIONS (CONT.) c.
Gas Recovery Section (Cont.);
STRIPPER
MMG
BMG
MMD
BMD
59
59
60
60
Top pressure(kg/cm2g)
15.7
15.7
15.7
15.7
Bottom temperature (oC)
120
122
122
126
Bottom pressure (kg/cm2g)
16
16
16
16
MMG
BMG
MMD
BMD
68
68
68
68
Top pressure(kg/cm2g)
11.7
11.7
11.7
11.7
Bottom temperature (oC)
180
178
172
171
Bottom pressure (kg/cm2g)
12.1
12.1
12.1
12.1
Top temperature (oC)
DEBUTANIZER
Top temperature (oC)
II.4 – OPERATING CONDITIONS (CONT.) c.
Gas Recovery Section (Cont.);
Fuel Gas Absorber o
Top temperature (oC)
56
o
Top pressure (kg/cm2g)
13.7
o
Bottom temperature (oC)
61
o
Bottom pressure (kg/cm2g)
14
LPG Amine Absorber o
Top temperature (oC)
40
o
Top pressure (kg/cm2g)
17.9
o
Bottom temperature (oC)
42
o
Bottom pressure (kg/cm2g)
19.7
II.5 – BATTERY LIMIT CONDITIONS
STREAM
TEMP. (oC)
PRES.(kg/cm2g)
Atmospheric residue from CDU
115
4.5
Atmospheric residue from storage
70
4.5
46-52
20
Off gas from CDU
50
0.7
Off gas from NHT
40
0.6
Lean amine from ARU
55
22.6
Light slops from off-site
50 max
3.5
Heavy slops from off-site
70 max
3.5
LPG rich stream from CDU
II.5 – BATTERY LIMIT CONDITIONS (CONT.)
STREAM
TEMP. (oC)
PRES.(kg/cm2g)
Unsaturated off gas
54
4.5
LPG to LTU
40
18
RFCC naphtha to NTU
40
9.5
LCO to LCO Unit/ Storage
50
6.0
DCO to blending
90
8.0
Sour water to SWS
42
3.5
Rich amine to ARU
41-50
7.0
II.6 – UTILITY OPERATING/DESIGN CONDITIONS SERVICE
NORMAL
MAXIMUM
MINIMUM
DESIGN
NORMAL
MAXIMUM
MINIMUM
DESIGN
HHP STEAM
105.5
107.5
103.5
112.9
500
510
490
535
HP STEAM
42.3
44.3
40.3
48.3
380
400
360
450
MP STEAM
14.1
15.1
13.1
16.8
250
270
230
320
POWER STATION LP STEAM
4.1
4.6
3.6
6.3
160
180
148
230
LP STEAM
3.6
4.6
3.6
6.3
160
180
148
230
POWER STATION LP STEAM
4.1
4.6
3.6
6.3
160
180
148
230
SERVICE WATER
5
7
1.5
9.3
30
35
15
60
POTABLE WATER
2
2.5
0.5
4.2
30
35
15
60
DEMIN WATER
5
7
1.5
9.3
30
35
15
60
HHP BFW
130
135
110
141.8
112
131
105
160
HP BFW
60
66
58
89.2
112
131
105
160
LP BFW
22
24
20
37.5
112
131
105
160
COLD BFW
4
6
4
9.3
60
90
50
115
FRESH CW SUPPLY
4.5
5.5
4
9.2
32
34
25
70
FRESH CW RETURN
1.5
2.5
1
9.2
47
60
25
70
SEA CW SUPPLY
3.8
4.8
3.3
7.4
30
30
20
70
SEA CW RETURN
0.8
1.3
0.8
7.4
38
40
20
70
REFINERY FIRE WATER
7
15
3
19.3
30
35
15
60
SALT FIRE WATER
10
15
6
19.3
30
30
20
70
II.6 – UTILITY OPERATING/DESIGN CONDITIONS
SERVICE
NORMAL
MAXIMUM
MINIMUM
DESIGN
NORMAL
MAXIMUM
MINIMUM
DESIGN
HP CONDENSATE
7.5
48.3
170
450
MP CONDENSATE
7.5
16.8
170
320
LP CONDENSATE
2
63
133
230
VACUUM CONDENSATE
2.5
3
2
4.7
50
80
50
110
INST AIR/PLANT AIR
7.5
8
7
10.6
35
40
10
65
7
9
6.5
11.7
30
40
10
65
CCR NITROGEN
8.5
9
8
11.7
30
40
10
65
FUEL GAS COLLECTION
3.8
4
3.5
6.7
46
53
38
75
FUEL GAS SUPPLY
3.3
3.5
3
6.7
46
53
38
75
REFINERY FUEL OIL
16
17.5
14
30.5
90
100
50
125
50 Be’ CAUSTIC
3
4
1
6.3
40
45
30
70
20 Be` CAUSTIC
1.5
2
1
5.5
40
45
30
70
14 Be` CAUSTIC
2
3
1
6.3
40
45
30
70
5 Be` CAUSTIC
1.5
2
1
4.3
40
45
30
70
REFINERY NITROGEN
III - PROCESS DESCRIPTION 1.
Reactor/Regeneration (Rx/Rg) - Catalyst handling;
2.
Flue gas treatment;
3.
Feed fractionation;
4.
Gas Recovery section.
III.1 – RX/RG – CATALYST HANDLING
III.1.1 – RX To flue gas
To main fractionator T1501 TC Withdrawal wel
MP Steam
LC FC
LC PdC
Combustion air
FC FC 1
To flue gas
FC PC FC Standpipe
FC
Backflush Oil
FC FC
LC
Riser
Combustion air Fluidization air Lift air
FC FC FC
Plug valve
MTC
III.1.1 – RX (CONT.)
T
Feed MTC Injecti Injecti on on
Riser Outlet
ELE V
III.1.1 – RX (CONT.) Vapor Pro. To Frac. Section Riser Outlet Seperation System
Spent Cat. To First Stage Regenerator Reg. Cat. From Second Stage Regenerator
Backflush Oil MTC(MMG) Feed
MP Steam
III.1.2 – RG Flue gas to COB/WHB
Reg. Cat. To Riser Combustion Air Spent Cat From Stripper
.
(Reactor)
Lift Air
III.2 – FLUE GAS TREATMENT
III.3 – FEED FRACTIONATION
III.3 – FEED FRACTIONATION (CONT.)
III.4 – GAS RECOVERY
IV- MATERIAL BALANCE (TYPICAL)
FEED (KG/HR)
Residue
PRODUCTS (KG/HR)
407000
Fuel gas
9812
CDU LPG
2071
LPG
77250
CDU off gas
291
Naphtha (RFCC)
216962
NHT off gas
243
LCO
56889
Light/Heavy slops
(NNF)
DCO
29574
Total
409605
Total:
390487(Loss 9118)
V- SPECIFICATION OF CATALYST AND CHEMICAL 1.
Catalyst;
a. Used in: Reaction/Regeneration section ; b. Type of catalyst: RE-USY; c. Catalyst inventory: 600 tons; d. Addition rate (ton/day): 15.2(Mixed)/5.5(BachHo). 2. Chemicals: Antimony (Nickel passivator) a.
Used in: RFCC feed section; Type: NALCO EC919ZA or equivalent; Antimony content(%): 23; Injection rate: Ratio Sb/Ni in feed: 0.5; Normal consumption (kg/day):109(Mixed)/0(Bach Ho); Max consumption (kg/h): 15.
V- SPECIFICATION OF CATALYST AND CHEMICAL a.
Corrosion Inhibitor:
b.
Used in: Fractionator overhead ; Type: CHIMEC 1430; Normal consumption (kg/day): 60; Max consumption (kg/day): 120. Amine Antifoaming Agent:
Used in: FG/LPG amine absorbers; Type: CHIMEC 8045; Normal consumption (kg/day): 10; Max consumption (kg/day): 20.
VI - SAFETY 1.
Precaution for entering vessels;
2.
High temperature precautions;
3.
Chemical hazards.
VI.1-PRECAUTION FOR ENTERING VESSELS a. b.
The Reactor must be cooled to below 150oC before any manways or nozzles are opened. The following precautions should be followed to prevent the personnel entering a vessel: The vessels should be isolated by positive action; An air mover should be installed at the vessel’s manway to sweep away any vapors and provide a continuous supply of fresh air; Responsible personnel must test the atmosphere in the vessel for explosiveness, toxic fumes, oxygen content, dust, etc; Personnel entering the vessel must be equipped with a pressure demand respirator that is in proper working condition, and is connected to a suitable fresh air supply; Separate air supplies which are independent of electrical power should be available for immediate use and transfer to personnel in the vessel.;
Personnel entering the vessel should wear a safety harness with a properly attached safety line.
VI.1-PRECAUTION FOR ENTERING VESSELS (CONT.)
If the work is to be performed at a high level above the bottom of the vessel, such as cyclone inspection, scaffolding and support flooring must be built to prevent fall;
There should be a minimum of two backup men at the vessel manway in continuous surveillance of the personnel in the vessel.
There should be spare pressure demand respirators, complete with their own separate air supplies, to allow backup personnel to enter the vessel quickly in case of an emergency.
any personnel working in a vessel which has an inert or contaminated atmosphere not be permitted to move too far away from the entryway, or into any tight areas, such as through a fractionator tray manway;
VI.2 – HIGH TEMPERATURE PRECAUTIONS a.
Anyone working around the uninsulated lines or vessels should be warned that these will get hot. Combustible materials and trash should be kept away from the unloading lines and equilibrium catalyst hoppers.
VI.3 – CHEMICAL HAZARDS 1.
If the hydrocarbons, catalyst, and chemicals are mishandled, or allowed to escape into the atmosphere, some of them may be a hazard to the health of anyone in the area;
2.
Should be carefully for Hazardous materials present in the RCC Unit, as follows: a.
Catalyst:
FCC is a fine dust capable of causing eye and Lung irritation. When unloading catalyst cars, drawing samples, etc., goggles or a face shield, a dust mask should be worn;
When drawing hot regenerated catalyst samples, gloves and long sleeved clothing should always be worn.
Personnel should not walk over or work around piles of spilled catalyst.
VI.3 – CHEMICAL HAZARDS (CONT.) a.
b.
Iron Sulfide: Iron sulfide has “pyrophoric” properties. It will ignite spontaneously when exposed to air, which is most likely to occur in recently opened refinery vessels. A vessel suspected of containing iron sulfide must be thoroughly steamed out and washed with water before air is permitted to enter. Heavy Cracked Hydrocarbons: Heavy cracked oils are skin irritants. In case of actual contact, the skin should be thoroughly washed with hot soapy water, and any oil-saturated clothing should be removed; Should any hydrocarbon enter the eye, First Aid is to wash with a copious amount of clean water and obtain trained medical assistance as quickly as possible.
VI.3 – CHEMICAL HAZARDS (CONT.) a.
b.
Light Cracked Hydrocarbon Liquids:
Those gasoline streams which contain aromatics will be particularly dangerous. Benzene is a poison, and heavier aromatics have a narcotic effect;
In case of exposure, no time should be lost in removing any gasoline-soaked clothing and washing the skin with hot soapy water. First Aid for eye injuries is the same as that discussed above under “Heavy Cracked Hydrocarbons.”
Aromatic Hydrocarbons:
Benzene:
Benzene has carcinogenic effect on the body’s blood-forming organs, an effect which is cumulative with each exposure;
If clothing, including gloves, becomes wet from benzene, immediately remove the clothing. Wash the skin areas exposed to benzene with soap and water. The person will inhale benzene vapors over a long period of time with serious hazard to health.
VI.3 – CHEMICAL HAZARDS (CONT.) o
a.
Avoid draining benzene on the ground or into the sewers where it can vaporize and create a health hazard. If you must enter an area of high benzene vapor concentration resulting from a spill, wear a pressure demand respirator. Toluene, Xylenes, and Heavier Aromatics: o These aromatic compounds principal effect is skin, eye, and respiratory irritation. Avoid breathing aromatic vapors; o All employees should be alerted as to the early signs and symptoms of excessive absorption of aromatics, and all workers should report such symptoms to the Medical Department. Light Hydrocarbon Vapors: These vapors can be toxic, since they may contain aromatics, H2S, or other lethal compounds. A person who has breathed quantities of hydrocarbon vapors should be removed from the area and kept warm and quiet. If necessary, artificial respiration with or without the use of oxygen should be administered and medical aid summoned. Professional medical attention should be obtained at once.
VI.3 – CHEMICAL HAZARDS (CONT.) a.
b.
Hydrogen Sulfide: Hydrogen sulfide is one of the most poisonous gases known. Exposure to an atmosphere containing less than 0.1% H2S may be fatal in 30 minutes or less; A person exposed to H2S may become excited or dizzy, may stagger, and can ultimately lose consciousness. First Aid consists of removal from the area and the administration of artificial respiration with or without oxygen if breathing has stopped. The patient should be kept warm and medical aid summoned. Flue Gas: Flue gas from the regenerator can cause asphyxiation if a person enters an improperly ventilated duct or a low area where the high density of flue gas; Symptoms of asphyxiation may be dizziness, headache, or shortness of breath;
VI.3 – CHEMICAL HAZARDS (CONT.)
RCC flue gas is very dangerous since it contains carbon monoxide, which is toxic. A concentration of 0.4% can be fatal in about one hour. One visible symptom of carbon monoxide poisoning is a bluish-red color of the skin;
First Aid in cases of flue gas asphyxiation or poisoning consists of keeping the victim warm and administering artificial respiration and oxygen, if necessary, obtain professional medical attention immediately.
