GLOBAL LEADER
ERC Refinery Project
Contents
1. Process Unit Purpose 2. Unit Description & Capacity 3. Overall Block Diagram 4. Unit Schematics
ERC Refinery Project
1) PROCESS UNIT PURPOSE
GLOBAL LEADER
TO CONVERT HEAVY INTERMEDIATE PRODUCT OF LOW ECONOMIC VALUE INTO MIDDLE DISTILLATE OF HIGH ECONOMIC VALUE
ATMOSPHERIC RESIDUE
SEPARATION / CRACKING
VDU/ DCU/ HCU
LPG NAPHTHA KEROSENE DIESEL
TO MEET SALES PRODUCTION BY HYDROTREATING, REFORMING AND BLENDING. NAPHTHA
HYDROTREATING/ REFORMING NHT/CCR HYDROTREATING DHT SEPARATION DEU
REFORMATE ( RON 102) DIESEL (S : 10wt ppm) LPG
SOUR DIESEL SOUR LPG
TO SUPPORT PROCESS UNIT
HYDROGEN PRODUCTION UNIT AMINE REGENERATION UNIT SOUR WATER STRIPPING UNIT SULPHUR RECOVERY UNIT ERC Refinery Project UTILITY SYSTEMS TANKAGE
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2) UNIT DESCRIPTION AND CAPACITY
GLOBAL LEADER
Capacity Unit No. Unit Name TON/HR 11 12 / 13 14 15 16 21 22 23 25 26 27 28 80, 81, 82, 83 85 Naphtha Hydrotreating Unit Reformer & CCR Unit Diesel Hydrotreating Unit Hydrocracker Unit Hydrogen Production Unit Vacuum Distillation Unit Delayed Coker Unit De-ethanizer Unit Sour Water Stripping Unit No.1 Sour Water Stripping Unit No.2 Amine Treatment and Regeneration Unit No.1 Amine Treatment and Regeneration Unit No.2 Sulfur Recovery Unit (COMMON, No.1, No.2, No.3) Tail Gas Treating Unit 105.5 71.2 182.0 250.3 100 kNm3/h 514.5 171.7 16.7 126.0 39.0 495.0 m3/h (Amine Circ.) 71.9 m3/h (Amine Circ.) 162.5 Ton/D X 50% X 3 Train 325 Ton/D 81500 25000 BPSD 22600 14100 32100 40800 Axens Axens Axens Axens KTI GS Conocophillips GS GS GS GS GS TKT (KTI) TKT (KTI) Remarks
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3) OVERALL BLOCK DIAGRAM
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4) UNIT SCHEMATICS VDU & DCU
VACUMN DISTILLATION UNIT (VDU)
TO SEPARATE ATMOSPHERIC RESIDUE INTO, LVGO (FEED FOR DHT UNIT) MVGO/ HVGO (FEED FOR HCU UNIT)
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VR (FEED FOR DCU UNIT)
VDU
DELAYED COKER UNIT (DCU)
TO CONVERT VACUMN RESIDUE(VR) BY THERMAL CRACKING INTO,
SOUR NAPHTHA (FEED FOR NHT UNIT) SOUR LPG (FEED FOR NHT UNIT) LCGO (FEED FOR DHT UNIT) HCGO (FEED FOR HCU UNIT) COKE AS SIDE PRODUCT
DCU
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Vacuum Distillation Unit (VDU)
steam
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60 40 mmHg
vacuum ejector
Off Gas
Vacuum Tower
Slop & Sour Water LVGO to DHT
Heater
AR Feed 412 309.4 9.2 kg/cm2g stripping steam 205 mmHg
MVGO & HVGO to HCU
VR to DCU
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Delayed Coker Unit (DCU)
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127
38 Off Gas
0.20
1.0
0.55
LPG Naphtha
Coke Drum
Fractionator
198
LCGO
Decoking
40
Operation
446 0.80 291 336 HCGO
302 495
Cokes
Heater
LEGEND Kg/cm2g VR from VDU
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4) UNIT SCHEMATICS NHT, Reformer/CCR, DHT
NAPHTHA HYDROTREATING (NHT) & REFORMER /CCR UNIT
TO REMOVE SULPHUR AND NITROGEN IN NAPHTHA TO MEET REFORMER UNIT REQUIREMENT
GLOBAL LEADER
TO INCREASE OCTANE NUMBER (RON :102) BY REFORMING
CONTINUOUS CATALYST REGENERATION IN ORDER TO MAINTAIN CATALYST ACTIVITY
NHT
CCR
DIESEL HYDROTREATING UNIT (DHT)
TO REMOVE SULPHUR(10wt ppm) TO MEET FLASH POINT REQUIREMENT (55)
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Naphtha Hydrotreating
270 290 46.8
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LEGEND Kg/cm2g
Reactor 48.9 243 275 300 330
Sour Gas
55 55
Charge Heater
10.1
40 40
1.0
Stripper
Naphtha Splitter
118 118
Reboiler 40.2 Reboiler
55
193 193 1.6 152 152
10.8 Separator 50.9
Feed
H2 Make-up
LPG
Heavy Naphtha
Light Naphtha
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Reformer & CCR (CCR)
Charge Heater 507 538 507 538 507 538 507 538 64 65 Fuel Gas 12 40 Stabilizer Receiver
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LEGEND Kg/cm2g
4th Reactor 3.3 1st Reactor 411 444 2nd Reactor 3rd Reactor 460 494
Net Gas Comp. Combined Feed Exchanger
Stabilizer Chloride Absorber Stabilizer Reboiler 12.3
2.3 40
KO Drum 22.5 2.3
12.0 Separator
FEED from NHT
40 6.0 Chlorine Absorber
98 98
Chiller
H2 Rich Gas. Reformate LPG
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4) UNIT SCHEMATICS HCU & HPU
HYDROCRACKER UNIT (HCU)
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PRODUCING MAXIMUM AMOUNT OF KEROSENE AND DIESEL, COMPLYING WITH KEROSENE AND DIESEL SPECIFICATION CONVERSION: 96.5 WT% MIN. KEROSENE SULPHUR CONTENT: 10 WT PPM MAX. DIESEL SULPHUR CONTENT: 10 WT PPM MAX.
HYDROGEN PRODUCTION UNIT(HPU)
HCU
TO CONVERT NATURAL GAS INTO HYDROGEN IN ORDER TO SUPPLY REACTION SOURCE TO HYDROTREATING AND HYDROCRACKING UNITS
TO RECOVER HYDROGEN RICH GAS FROM CCR AND PURGE GAS FROM HCU TO HYDROGEN
HPU
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Hydrocracker Unit (HCU)
SOR EOR
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Temp. (oC)
SOR EOR
Press. (kg/cm2g)
Sour Gas 161.9 167.1 8.0 Cracking Reactor 13.3 1.0 Sour Gas
373 409 Charge Heater
Stripper Naphtha Stripper Fractionator Kerosene Stripper
HDT Reactor
144.0 260 372 370 Gasoil Stripper
H2 M/U Comp.
1.5 HP Separator
MP Separator
FEED H2 Make-up Naphtha UCU Gasoil Kero
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Hydrogen Production Unit (HPU)
SOR EOR Temp. (oC)
Sweet Gas
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SOR EOR
Press. (kg/cm2g)
538 560
25.2 Steam Reformer Boosting Compressor
Steam Drum
Hydrogen Product
852 860
22.2
PSA Unit
380 28.7 28.6
Process Gas Boiler
39 HT Shift 40 Converter
19.8
Condensate Separator
Hydrogenator Desulphurizers
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4) UNIT SCHEMATICS SWS, ARU, SRU & TGTU
SWS, ARU, SRU
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SWS
TO TREAT SOUR WATER BY STEAM STRIPPING COMPLYING WITH WASH WATER FOR HYDROTREATING AND WWT FEED REQUIREMENT PHENOLIC SOUR WATER AND NON-PHENOLIC SOUR WATER
ARU
TO REGENERATE RICH AMINE TO LEAN AMINE, IN ORDER TO MEET SPECIFICATION REQUIRED FOR UPSTREAM ABSORBER SATURATED GAS AND UNSATURATED GAS ARU
SRU & TGTU
TO CONVERT H2S INTO SULPHUR IN ORDER TO MINIMIZE ENVIRONMENTAL POLLUTION
SRU
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Sulfur Recovery Unit (SRU)
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Acid Gas
Steam
NG
Reducing gas gen.
NH3 Rich Gas
1355
tail gas
0.63 kg/cm2g Sulfur
Furnace
condensed sulfur
Flake PKG.
Hydrogenation reactor
Lean Amine
Sulfur Pit
Amine absorber
650 0.01 kg/cm2g
Rich Amine
Incinerator
Contact condenser
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4) UNIT SCHEMATICS UTILITY AND OFFSITE
UTILITY AND OFFSITE
RAW WATER TREATMENT SYSTEM COOLING WATER SYSTEM STEAM AND CONDENSATE SYSTEM / BOILER FEED WATER SYSTEM AIR SYSTEM NITROGEN SYSTEM REFINERY FUEL GAS SYSTEM FLARE SYSTEM WASTE WATER SYSTEM TANKAGE FIREFIGHTING SYSTEM INTERCONNECTION
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