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Basic Information Package: This Information Briefly Describes the Refinery Process Equipment and Its Capabilities

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Basic Information Package: This Information Briefly Describes the Refinery Process Equipment and Its Capabilities Basic Information Package: This information briefly describes the refinery process equipment and its capabilities. The refinery is a fully integrated plant, comprised of several major process units, all interconnected via the central computerized control system. Each unit includes a large number of vessels and other equipment. Crude Processing and Vacuum Units - 30,000 B.P.D. Crude oil contains all of the components necessary to make any petroleum product. The crude and vacuum units separate crude oil into various components for further processing. Crude oil is heated in a system of heat exchangers and a furnace and introduced to a tower where the different components, which have different boiling ranges, are separated by fractional distillation. The products from this unit include (from top to bottom of the tower). Tower overheads which go on to butane/propane recovery and the refinery fuel system. Naphtha which goes on to hydrotreating and fuel oil production. Kerosene which goes to Merox treating and jet fuel production. Diesel which goes to hydrotreating and fuel oil production. Gas oils which go the FCCU (fluid catalytic cracking unit) for further refining. Saturated Gas Plant - 2,100 B.P.D. This unit splits the light hydrocarbon stream from the crude unit, as well as from the FCCU and Platformer units, into propane and butane products. Ethane and methane are removed and eventually used as fuel gas, with the balance of propane and butane sent to storage. Fuel Gas Treating Unit - 4.5 MMSCFD 96,000 #/hr DEA Circ. To reduce sulphur dioxide emissions, hydrogen sulfide is removed from the fuel gas before it is burned in any refinery process furnace. Amine is used to absorb the hydrogen sulfide from the gas. The hydrogen sulfide is boiled off the amine and sent to the adjacent Petrogas Processing plant to make sulphur. Merox Unit - 4 Units Unsat LPG (2,600 B.P.D.) Sat LPG (900 B.P.D.) Kerosene (6,000 B.P.D.) FCCU Gas (6,000 B.P.D.) These units produce products which are non-corrosive, with a sweet or low-odor level and free from dirt and moisture. Various treatment processes involving washing, filtering and chemical reactions are used. Naphtha Hydrotreater - 11,300 B.P.D. (700 psi) In this unit sour naphtha containing sulphur and nitrogen is treated for the removal of these two components. Platformer - 8,200 B.P.D. (180 psi) This unit increases the octane of the naphtha received from the naphtha hydrotreater. The product from the Platformer, called Platformate, provides the bulk of the high octane components for gasoline sales. Diesel Hydrotreater - 8,000 B.P.D. (1,000 psi) This unit removes sulphur and nitrogen contained in diesel produced by the Crude Processing Unit. These compounds, if not removed, would cause plugging, fouling and noxious fumes when diesel is combusted in a diesel engine. Fluid Catalytic Cracking Unit (FCCU) - 11,500 B.P.D. Gas oils and heavy fuel components are upgraded with the aid of this unit into gasoline and other light products. Residual processing capability with catalyst cooling and lift gas technologies is installed on the unit. Polymerization Unit - 2,530 B.P.D. (Chamber Unit) This unit produces a gasoline blending product with a high octane rating which is necessary in producing various blends of gasoline. Penex - 3,000 B.P.D. UOP This unit reformulates pentanes and hexanes to increase octane for unleaded gasoline. Sour Water Stripping Unit Water which is used in the various process units becomes saturated with hydrogen sulfide and ammonia. This unit is designed to eliminate such gases picked up in the water wash streams. Steam Three gas fired boilers, capable of producing 45,000 pounds of steam per hour each, provide the main steam supply. Steam is used for refining processes, for heating and to drive turbines. Steam is also produced by three waste heat converters in the process area, minimizing energy waste. Air Air compressors are used to supply dry air to run instruments and to supply power to air driven tools and equipment. DESIGN THROUGHPUT The plant is a grass roots, modularly designed plant. The design throughout on the Crude Unit is 30,000 BPD or 4.700 m3/D. Actual achievable throughput is 4.950 m3/D. We have processed over 5.000m3/D for short periods of time (3-5 days). Sustained maximum throughput on an annual basis is considered to be 4.800 m3/D. PROCESS UNITS DESIGN ACHIEVABLE UNITS MAX MIN MAX m3/D m3/D m3/D CRUDE 4,700 2,500 4,950 NHT -UOP 1,800 900 1,930 PLATFORMER - UOP 1,307 550 1,425 PENEX - UOP 500 250 550 DHT 1,275 650 1,400 FCCU - UOP 2,000 1,050 1,850 POLY -UOP 402 200 440 FCC MEROX - UOP 868 368 800 LDL MEROX - UOP 846 200 850 SAT LPG MEROX - UOP 138 UNSAT LPG MEROX -UOP 509 * Lower with recycle DISTRIBUTED CONTROL SYSTEM HONEYWELL'S Plantscape release, four operator stations. The system has approximately 1,800 points and 700 control loops. The plant also has a MODICON PLC in place. Both of these systems have been revamped and are new, (Never Used) UNIT YIELDS Crude CONDENSATE % % CRUDE Density@15c (kg/m3) 830.30 716.60 Sulphur wt% 0.39 0.21 Propane 0.50 0.50 Butane 1.50 1.50 Vacuum Bottoms 4.15 LSR ( 62c@90%) 4.57 35.54 LSR/HSR (130c@90%) 23.56 80.72 (140c@90%) 25.00 81.95 (160c@90%) 30.74 84.67 (175c@90%) 32.18 86.64 LSR/HSR/LDL (250c@95%) 48.06 94.57 HDL (280c@95%) 5.07 3.43 (290c@95%) 6.25 (300c@95%) 7.44 (320c@95%) 10.14 (340c@95%) 13.18 (380c@95%) 15.89 GO (280c@95%) 40.72 (290c@95%) 39.54 (300c@95%) 38.35 (320c@95%) 35.65 (340c@95%) 32.61 (360c@95%) 29.90 TYPICAL REFINERY YIELDS ACTUAL 1991 % Inputs Crude 89.4 Condensate 9.1 Purch. Butane 1.5 Products Gasoline 58.2 Clean Pdt Diesel 34.5 92.7 Propane 1.2 Butane 0.6 Clarified oil 2.3 96.8 Gasoline yield can range as high as 65% depending on HSR cutpoint and condensate % in feed. Diesel yield can range from 31 - 40% depending on HDL and LCO cutpoints. UNIT SUMMARIES CRUDE Crude unit consists of atmospheric crude and vacuum towers. The crude unit has 3 side draws c/w steam side strippers (LDL,HDL,AGO) a top P/A draw and a partial condenser on the O/H. The vacuum tower is equipped with mechanical vacuum system. Reduced crude can be processed through the vacuum unit to yield LVGO, HVGO, and vacuum bottoms or routed directly to the FCCU. NHT Pressure - 5585 kPa Catalyst - Shell 424: sulfur removal to 0.5 wppm . Designed for 10 wppm nitrogen in coker naphtha, maximum EP of feed 193 C. Currently all straight run gasoline is treated in the NHT, then split with LSR 30-62 C sent to the Penex and HSR 62-190 C sent to the Platformer. PLAT. UOP licensed semi-regenerative unit using bimetallic R16G catalyst. PENEX UOP licensed: catalyst 1-8 Pressure - 4033 kPa DHT Pressure - 6900 kPa Catalyst S16 FCCU UOP licensed high-efficiency regenerator. This unit was revamped in 1989 with the following UOP technology: Lift gas system on the riser Close-coupled cyclone at the reactor inlet Catalyst cooler technology for 600 psi steam production c/w fired superheater. POLY UOP licensed non-regenerative fixed bed unit. MEROX UOP Licensed UNITS Sat and Unsat LPG units - extractors FCC - Minalk fixed bed LDL - conventional fixed bed AUXILARY UNITS Gas plant c/w deethanizer, 2 depropanizers, C3 driers and amine H2S removal system. FCC Gas Concentration unit c/w primary absorber, sponge absorber, stripper and debutanizer to prepare FCC gasoline. Steam Plant c/w 3 Foster-Wheeler 45.000 lb/hr @525 psi and 78 F degree superheat packaged boilers. .
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