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DIESEL HYDRODESULPHURISATION UNIT

CHAPTER-1 DESIGN BASIS 1/27

CHAPTER-1

DESIGN BASIS

1.1 GENERAL

Panipat refinery is designed to cater the demand of the petroleum products in the

northern region of India .The Panipat refinery consists of the following units:

1. Atmospheric and Vacuum Unit.

2. Once Through Hydrocracker Unit

3. Catalytic Reformer Unit

4. Resid Fluid Catalytic Cracking Unit

5. Hydrogen Generation Unit

6. Visbreaking Unit

7. Bitumen Blowing Unit

8. Amine Regeneration Unit

9. Sour Water Stripper

1.2 PURPOSE OF THE DHDS PROCESS

The DHDS unit is set up to reduce sulfur content in the diesel and produce diesel with

0.25% Sulphur.

The unit treats the following gas-oils fractions.

1. S.R.Gas oil

2. Vacuum Diesel

3. Vis-Breaker Gas Oil

4. Total Cycle Oil

1.2.1 Hydrodesulfurisation Section

The purpose of the section is to reduce 90% Sulphur in feed diesel using

hydrogen from Catalytic Reformer or Hydrogen Generation Units. In addition to

the deep desulfurisation, the diolefin and olefins will be saturated and a

denitrification will also occur.

The choice of catalysts and operating conditions is made in order to avoid

hydrogenation of the aromatics.

Feedstocks are blended from various sources, straight run or cracked products

Sulfur and nitrogen contents are depending upon the crude. Cracked products are

characterized by the presence of unsaturated hydrocarbons (olefins, diolefins and

aromatics)

Nowadays, more and more stringent specifications are imposed upon sulfur

content of diesel delivered by refineries.



Denitrification improves the product stability.

The required level of desulfurisation is achieved by hydrotreating over a specially

selected catalyst.

The presence of olefins or diolefins calls for additional bed installed in upstream

of the desulfurisation bed.

In the present case, no aromatic hydrogenation is aimed at.

The unit is able to produce treated Diesel Oil with maximum sulfur content of

500 ppm by providing an additional second Reactor in series.

1.2.2 Amine Treatment Section

The Amine Treatment Section is designed to remove Hydrogen Sulfide (H2S)

from gaseous hydrocarbons effluents.

H2S removal from gaseous hydrocarbons effluents is achieved by means of a

continuous absorption/regeneration process using a 25% wt. Di-Ethanol Amine

(DEA) for H2S removal.

This section includes the following main equipments

- HP Amine Absorber

- LP Amine Absorber

1.3 CAPACITY AND TURNDOWN RATIO

The DHDS unit is designed to hydrodesulfurise the two feedstock blends as in the

table named as “Feed 1” and “Feed 2” in section 1.4.1 and 1.4.2 respectively.

The characteristics of “Feed 3” used as check feed is given in 1.4.3.

The unit nameplate capacity is 700,000 MTPA with a stream factor of 8000 hours

per year. The design capacity is 770,000 MTPA.

The unit turndown rate is 50% of the design capacity

The design covers 2 cases:

In the case 1, 90% of the feed sulphur is converted to H2S.

In the case 2 with the installation of second reactor the sulphur in the feed is

reduced to 500 wt. ppm for the feeds 1 and 2.



The hydrogen required for the reactions is supplied either from the Catalytic

Reforming Unit or Hydrogen Generation Unit.

Lean Amine is supplied from the Amine Regeneration Unit

Nitrogen/air facilities for HR - 945 and HR-348 catalyst in-situ regeneration are

also provided.

The two feedstock blends are a mixture of:

Feed 1 : 87% wt. of SRGO and 13% wt. of SRVD

Feed 2 : 70% wt. of SRGO, 10% wt. of SRVD, 3% wt. of VBGO

and 17% wt. of CGO

Check Feed : 65% wt. of SRGO, 10% wt. of SRVD and 25% wt of

Total Cycle Oil



1.4 FEED SPECIFICATIONS

1.4.1 Feed 1

The characteristics of the feed 1 to be treated is as follows ((value)=estimated)

DESCRIPTION SRGO SRVD FEED 1

% on feed mix (wt) 87 13 100

Sp. Gr. 0.850 0.860 0.851

% S. wt. 1.53 2.48 1.65

Nitrogen ppm wt. 165 250 176

Cetane number 52.8 52.8 52.8

Flash point,

oC 81 100 (81)

Dist. ASTM.

oC

- IBP 226.5 276.2 226

- 05% 246 294 243

- 10% 265.4 312.5 269

- 30% 302.7 331.7 306

- 50% 316.9 340.7 321

- 70% 333.4 352.1 336

- 90% 359.7 366.8 362

- 95% 381 373.7 383

- EP 399 379.2 404

Metal content, wt ppm

- Nickel 0.07 0.07 0.07

- Vanadium 0.13 0.13 0.13

Name plate capacity : 7,00,000 T/y

Design capacity : 7,70,000 T/y



1.4.2 Feed 2

The characteristics of the feed 2 to be treated is as follows ((value)=estimated)

DESCRIPTION SRGO SRVD VBGO CGO FEED 2

% on feed mix (wt) 70 10 3 17 100

Sp. Gr. 0.850 0.860 0.859 0.869 0.854

% S. wt. 1.53 2.48 2.4 2.44 1.81

Nitrogen ppm wt. 165 250 500 675 270

Bromine number 34 27.4 5.6

Cetane number 52.8 52.8 38.9 38.6 -

Flash point,

oC 81 100 65 (67)

Dist. ASTM.

oC

- IBP 226.5 276.2 168 (178.6) 172

- 5% 246 294 199 - 212

- 10% 265.4 312.5 216 (202.6) 253

- 30% 302.7 331.7 248 (228) 293

- 50% 316.9 340.7 280 (252.6) 313

- 70% 333.4 352.1 307 (279.5) 331

- 90% 359.7 366.8 348 (313) 358

- 95% 381 373.7 361 - 380

- EP 399 379.2 407 (349.1) 403

Metal content.Wt ppm

- Nickel 0.07 0.07 - -

- Vanadium 0.13 0.13 - -

Name plate capacity : 700,000 T/y

Design capacity : 770,000 T/y

1.4.3 Feed 3



The characteristics of the feed 3 used as check feed are as follows

((value)=estimated)

DESCRIPTION SRGO SRVD TCO FEED 3

% on feed mix (wt) 65 10 25 100

Sp. Gr. 0.850 0.860 0.861 0.854

% S. wt. 1.53 2.48 0.74 1.43

Nitrogen ppm wt. 165 250 260 200

Bromine number 8.7 2.2

Cetane number 52.8 52.8 33

Flash point,

oC 81 100 36 (36)

Dist. ASTM.

oC

- IBP 226.5 276.2 141 141

- 05% 246 294 151 195

- 10% 265.4 312.5 162 220

- 30% 302.7 331.7 199 282

- 50% 316.9 340.7 240 312

- 70% 333.4 352.1 278 332

- 90% 359.7 366.8 341 362

- 95% 381 373.7 362 375

- EP 399 379.2 382 403

Metal content.Wt ppm

- Nickel 0.07 0.07

- Vanadium 0.13 0.13

Name plate capacity: 690,000 T/Y

1.5 MAKE-UP HYDROGEN SPECIFICATIONS



The hydrogen make-up is available at the battery limit with the following

composition:

a. Hydrogen from Catalytic Reforming Unit

Molar Composition Vol. %

H2 90.0

Cl 6.2

C2 1.6

C3 0.8

C4 0.7

C5 + 0.7

Impurities ppm v

Chlorine & Chloride 2 max.

b. Hydrogen from Hydrogen Generation Unit

Molar Composition Vol. %

H2 99.9

Cl 0.1

Impurities ppm v

CO + CO2 50 max.



1.6 ESTIMATED PRODUCT SPECIFICATIONS

1.6.1 Desulfurised Diesel

The Desulfurised diesel is produced at the stripper bottom and dried in the

coalescer before being sent to storage.

Description

Feed 1

Feed 2

Case 1 Case 2 Case 1 Case 2

SPGR 0.841 0.838 0.842 0.839

Sulfur content, wt. ppm 1650 500 1810 500

Nitrogen content, wt. ppm 110 70 160 110

Water content, wt. ppm <500 <500 <500 <500

Bromine Number <1 <1 <1 <1

Cetane index 58 59 57 58

Pour Point oC Same as feed Same as feed Same as feed Same as feed

Flash point oC Same as feed Same as feed Same as feed Same as feed

Color Same as feed Same as feed Same as feed Same as feed

1.6.2 Stabilized Naphtha

The naphtha recovered as liquid distillate from the stabilizer bottom is sent to the

naphtha storage.

Description

Feed 1

Feed 2


SPGR 0.750 0.748 0.750 0.747

H2S content wt ppm

Nitrogen wt ppm

max

10

2

5

1

10

2

5

1

RON 72 to 74 72 to 74 72 to 74 72 to 74

RVP 0.26 0.28 0.28 0.27



1.6.3 Sweet Fuel Gas from LP Amine Absorber

Sweet Fuel gas from LP amine is routed to FCC fuel gas header.

Description

Feed 1

Feed 2


H2 content, mol% 35 to 30 31 to 26 31 to 28 28 to 23

H2S content, ppm vol 100 100 100 100

H2O content, mol% 2 2 2 2

HC content, mol% 63 to 78 67 to 72 70 to 77 70 to 75

MW 19.3 to 20.9 20.4 to 22.4 20.3 to 21.6 21.2 to 22.9

1.6.4 Purge Gas from HP Amine Absorber

Normally this flow is zero.

1.6.5 Sour Water from Cold Separator

Description

Feed 1

Feed 2


NH4SH, wt% 1.0 1.7 1.6 2.5

This sour water is oversaturated with hydrocarbon and excess of H2S :

HC content : 600 wt. ppm

H2S content : 150 to 300 wt. ppm



1.7 CHEMICALS, CATALYSTS AND OTHER ITEMS

1.7.1 Anhydrous Ammonia

During in-situ catalyst regeneration under nitrogen/air atmosphere anhydrous

ammonia is injected at the reactor bottom at a rate of 100 wt ppm (compare to gas

at reactor inlet).

Properties:

Density, kg/m3 : 636

Viscosity, cP : 0.14

Molecular weight : 17

1.7.2 Dimethyl Disulfide(DMDS)

The Dimethyl Disulfide is injected at the feed pump suction at 1 wt % rate in the

recirculating gas oil, during catalyst sulfiding

Estimated DMDS consumption per catalyst sulfiding is about 3500 kg (Provision

for dense loading included).

1.7.3 Antifouling Agent

The antifouling agent is injected at the feed pump suction diluted at 10% in

straight run gasoil at the rate of 10 ppm of pure product compared to the feed.

Type : CHIMEC 3033 or equivalent

Estimated Annual consumption = 7700 kg

1.7.4 Antifoaming

The antifoaming is injected at the 52-PA-CF-107 suction, 52-CC-00-103 feed and

52-CC-00-104 feed, diluted at 10% in demineralised water at the rate of 20 wt.

ppm of pure product compared to each stream.


Estimated annual consumption = 2400 kg



1.7.5 Corrosion Inhibitor Solution

The corrosion inhibitor is injected in the stripper and stabilizer overheads diluted

at 1% in stabilized naphtha at the rate of 6 wt. ppm of pure product compared to

the total column overhead.


Estimated annual consumption = 600 kg

1.7.6 Caustic Soda Solution

During in-situ Catalyst regeneration under nitrogen/air atmosphere, a 10% wt.

Caustic soda solution is injected downstream of reactor effluent water cooler 52-

EE-00-104 at a rate of 0.7 wt.% of pure caustic (compare to gas at reactor inlet).

Estimated pure NaOH consumption per catalyst regeneration = 71,000 kg

1.7.7 Catalysts

Type : HR - 348 HR-945

Manufacturer : PROCATALYSE PROCATALYSE

Quantity :

Case 1 : 26.5 m3 3.3 m3

Case 2 : 61.1 m3 3.3 m3

1.7.7.1 Catalyst HR 348 1.2 Deep Hydrorefining of Petroleum Cuts

HR 348 1.2 presents very high denitrification and aromatic hydrogenation

activities as well as desulfurization activity better than common NiMo catalysts.

These features are particularly interesting in the treatment of feedstocks coming

from thermal and catalytic conversion processes.

It can be used in association with other NiMo type or CoMo type catalysts where

specific objectives are required.

HR 348 1.2 is either delivered under oxide form to be sulfided in-situ, or

presulfurized ex-situ by SULFICAT

process.



TYPICAL PROPERTIES

Nickel and molybdenum oxides on very high purity alumina

Cylindrical extrudates

Diameter

1.2

mm

Nickel (NiO) 3.3 Wt%

Molybdenum (MoO3) 16.5 Wt%

Total pore volume 0.42 Cm3/g

Sock loading density 0.72 Kg/l

Dense loading density 0.82 Kg/l

Bulk crushing strength 1.49 MPa

1.7.7.2 Catalyst HR 945 Hydrotreatment of Cuts Containing Olefins

HR 945 is a NiMo type catalyst to be used in front of hydrotreatment catalysts to

protect them against deactivation by unsaturated compounds generally contained

in cracked stocks.

HR 945 special design limits the polymerization of olefins and diolefins and

thus, the coke formation, even at low hydrogen partial pressure. The resulting

advantage is longer cycle operation.

It can be used in combination with any HR series catalysts.

HR 945 is either delivered under oxide form to be sulfided in-situ, or

presulfurized ex-situ by SULFICAT

process.

TYPICAL PROPERTIES

Nickel and molybdenum oxides on very high purity alumina

Spheres

Diameter 2 to 4 mm

Surface area 140 m2/g

Total pore volume 0.4 cm3/g

Tapped bulk density 0.88 kg/l

Bulk crushing strength 1.55 mini. MPa

1.7.8 Other Items



1.7.8.1 Absorbent

Type : Puraspec 2110 Puraspec 2240

Manufacturer : ICI-Katalco ICI-Katalco

Quantity : 1.9 m3 3.6 m3

1.7.8.2 Alumina Balls

Type : Mullite or equivalent

Quantity : 1/4” diameter Case 1 : 1.56 m3

Case 2 : 2.02 m3

3/4” diameter Case 1 : 2.08 m3

Case 2 : 3.27 m3

1.7.8.3 Ceramic Balls

Type : 1” ½ or 50 mm

Quantity : 0.3 m3

1.8 BATTERY LIMIT CONDITIONS - PROCESS

Operating Design

Temp.(oC) Pressure

(kg/cm2g)

Temp.(oC) Pressure

(kg/cm2g)

Feed from storage 40 5.0 95 15.0

Feed from CDU 65 5.5 95 22.0

Feed from VDU 74 6.3 95 17.0

Feed from VBU 133 18.8 150 26.0

Feed from FCCU 87 3.9 105 13.5

Make-up H2 (HGU) 40 19.5 55 27.5

Makeup H2 (CRU) 40 20 55 27.5

Sour Water 50 5.0 65 6.0

Rich Amine 66.4 6.9 80 12.8

Lean Amine 40 8.0 65 12.6

Diesel to Storage 40 6.0 55 16.6

Offspec Diesel 40 6.0 55 16.6

Stabilized Naphtha 40 5.0 55 10.1

Naphtha to Slop 40 3.5 150 10.1

Spent Caustic 55 2.0 70 21.0

Caustic Solution 40 9.0 65 17.0

Sweet FG to RFCCU 50 3.0 65 6.6

FO Supply 210 10 260 15.0

FO Return 210 5.3-1.9 260 15.0

Flare Header AMB ATM-1.5 150 65.0

1.9 BATTERY LIMIT CONDITIONS - UTILITIES



1.9.1 Steam and Condensate

Units Min. Normal Max. Mech. Design

Low Pressure

Pressure Kg/cm2g 3.0 4.0 5.0 7.0

Temperature

oC 143 175 190 240

Medium Pressure

Pressure Kg/cm2g 12.0 14.0 15.0 18.0

Temperature

oC 210 290 305 350

Condensate

Pressure Kg/cm2g 5.0 8.0 10.0 16.0

Temperature

oC 50 100 150 180

1.9.2 Cooling Water


Supply

Pressure Kg/cm

2g 3.8 - 4.5 7.0

Temperature

oC 33 65

Return

Pressure Kg/cm

2g 2.2 - 7.0

Temperature

oC 45 65



1.9.3 DM Water


Pressure Kg/cm

2g 4.0 7.5 8.0 12.0

Temperature oC Ambient 65

1.9.4 Boiler Feed Water


Pressure Kg/cm2g 28 40

Temperature oC 100-110 150

1.9.5 Nitrogen


Pressure Kg/cm2g 6.0 10.5

Temperature oC ambient 65

1.9.6 Service/Plant Air


Pressure Kg/cm

2g 7.0 10.0

Temperature

oC ambient 65



1.9.7 Instrument Air


Pressure Kg/cm

2g 7.0 10

Temperature oC 40 65

Dew Point at Atm. pressure = -40oC

1.9.8 Fuel Gas from B/L to Unit, from Unit to B/L


Pressure Kg/cm2g 3.0 3.5 6.2

Temperature oC 40 65

1.10.0 SITE DATA AND OTHER INFORMATION

1.10.1 Reference Documents

1) Survey of India Maps

2) Meteorological Data

1.10.2 Site Location

1 State where located Haryana

2 Nearest important town and distance Panipat

3 Nearest railway station and distance Panipat

4 Railway approach Gharonda

5 Nearest port -

6 Nearest airport and distance Delhi

7 Nearest highway milestone and distance NH-1

8 Approach road - Existing

- Planned

-

From NH-1, 8 km



1.10.3 Geographical Data

1 Geographic bearing of site -

2 Height above mean sea level 238 M

3 Bench mark level and location Plate no.136, 238.33

M.WL, Behind Canal Rest

House at app. S-1570.00

and W-140.00 co-ordinates

4 Site characteristics (Terrain Type) Flat land

5. Grade variation low point/high point 236.60 m/238.30 m

1.10.4 Meteorological Data

1 Climate of area Moderate

2 Air Temperature

Maximum/min. Dry bulb temperature 38.3

oC/6.8

oC

Design dry bulb/Wet bulb temperature 39

oC/27.5

oC

Ambient Temperature max./min. 46.6oC/(-)0.7oC

3 Rainfall

Maximum recorded in 1 hour 72 mm

Maximum recorded in 24 hours 218 mm

Annual max./min./Avg. 705 mm/307 mm/709.36

mm

Design intensity for surface 72

water drainage (MM/HR)

4 Rainy season June - September

5 HFL data for last 20 years and

maximum HFL recorded

237.72 m

6 Relative humidity – Maximum 94%

Normal

19%



7

Wind velocity and direction

- Wind velocity - Maximum 168 km/hr as a height of

30 mtr.

- Wind direction and % age Mor. SE (28.4%) to NW

(25.0 %), Eve.

NW(35.5%)to SE (27.0 %)

- Prevailing wind direction Mor SE to NW

Eve NW to SE

8. Barometric Pressure

- Maximum 988.4 mb

- Minimum 967.3 mb

- Average 978.675 mb

9. Earthquake design As per IS:1893 Zone IV

1.10.5 Site Grading

1.10.5.1 Design HFL for grading : 237.72 M

1.10.5.2 Borrow area location/details : Across Western Jamuna Canal

1.10.5.3 Proposed FGL : 237.72 / 238.02/238.32

1.10.6 Roads and Pavements

1.10.6.1 C.B.R. Value of soil:

1.10.7 Drainage

Storm water disposal point and

distance : To main drain no. 2 at RD 33650

Approx. distance from refinery: 800M

1.10.8 Water Supply

1.10.8.1 Source of water : Munak head works

1.10.8.2 Quality of water : Potable

1.11.0 OPERATING CONDITIONS AND YIELDS



1.11.1 Estimated ex-reactor yields (% wt. of liquid HC feed)

Feed 1

Description Case 1 Case 2

SOR MOR EOR SOR MOR EOR

H2S 1.59 1.59 1.59 1.7 1.7 1.7

NH3 0.008 0.008 0.008 0.013 0.013 0.013

C1 0.01 0.02 0.04 0.020 0.033 0.06

C2 0.02 0.03 0.05 0.020 0.036 0.07

C3 0.020 0.033 0.06 0.03 0.053 0.1

C4 0.020 0.036 0.07 0.03 0.053 0.1

C5 - 150 0.700 0.900 1.300 0.840 1.026 1.4

150+ 98.042 97.803 97.322 97.847 97.596 97.087

Total 100.41 100.42 100.44 100.50 100.51 100.53

H2 Chemical

Consumption

0.41 0.353 0.44 0.5 0.51 0.53



1.11.1 Estimated ex-reactor yields (% wt. of liquid HC feed) (Contd.)

Feed 2



H2S 1.74 1.74 1.74 1.87 1.87 1.87

NH3 0.013 0.013 0.013 0.02 0.02 0.02

C1 0.01 0.02 0.04 0.02 0.036 0.07

C2 0.02 0.03 0.05 0.03 0.047 0.08

C3 0.020 0.033 0.06 0.03 0.056 0.11

C4 0.020 0.036 0.07 0.04 0.067 0.12

C5 - 150 0.7 0.9 1.3 0.90 1.117 1.55

150+ 97.997 97.758 97.277 97.70 97.407 96.82

Total 100.52 100.53 100.55 100.610 100.620 100.640

H2 Chemical

Consumption

0.52 0.53 0.55 0.610 0.620 0.640



1.11.2 Operating conditions

1.11.2.1 Reactor

Feed 1



R01 inlet temperature, 0C 326 341 356 326 341 356

R01 outlet temperature, 0C 343 358 373 343 358 373

R01 WABT, 0C 335 350 365 335 350 365

Inlet pressure, kg/cm2 g 60.6 60.6 60.6 63.8 63.8 63.8

Outlet pressure, kg/cm2 g 56.6 56.6 56.6 59.8 59.8 59.8

R02 inlet temperature, 0C 330 345 360

R02 outlet temperature, 0C 338 353 368

R02 WABT, 0C 334 349 364

Inlet pressure, kg/cm2 g 59.6 59.6 59.6

Outlet pressure, kg/cm2 g 56.6 56.6 56.6

Space velocity 3.8 3.8 3.8 1.75 1.75 1.75

H2 recycle ratio, Sm3/m

3 150 150 150 150 150 150

H2 partial press., kg/cm2

Minimum recommended

35 35 35 35 35 35



1.11.2.1 Reactor (Contd.)

Feed 2



R01 inlet temperature, 0C 323 338 353 323 338 353

R01 outlet temperature, 0C 346 361 376 346 361 376

R01 WABT, 0C 335 350 365 335 350 365

Inlet pressure, kg/cm2 g 60.6 60.6 60.6 63.8 63.8 63.8

Outlet pressure, kg/cm2 g 56.6 56.6 56.6 59.8 59.8 59.8

R02 inlet temperature, 0C 336 351 366

R02 outlet temperature, 0C 343 358 373

R02 WABT, 0C 340 355 370

Inlet pressure, kg/cm2 g 59.6 59.6 59.6

Outlet pressure, kg/cm2 g 56.6 56.6 56.6

Space velocity 3.8 3.8 3.8 1.75 1.75 1.75

H2 recycle ratio, Sm3/m

3 150 150 150 150 150 150

H2 partial press., kg/cm2

Minimum recommended

35 35 35 35 35 35

Feed 3 (check Feed) : The operating conditions are the same as for Feed 2 except

for space velocity which is increased by 10% due to the smaller flow rate.

The Space velocity (LHSV) is the volume of liquid HC feed at 15 0C in m

3/hr

divided by the volume of catalyst.

The hydrogen recycle ratio is a measure of the hydrogen recycle through the

furnace to the reactor entry. It is expressed as the standard m3/hr of pure H2

recycled divided by the volume of HC liquid feed in m3/hr at 15

0C.



The minimum hydrogen recycle ratio = 150 Sm3/m

3.

The hydrogen partial pressure is measured at the reactor outlet.

The minimum hydrogen partial pressure = 35 kg/cm2.

1.11.2.2 Cold Separator

Temperature, 0C : 50

Pressure, kg/cm2 g : 50

1.11.2.3 Stripper

Stripper feed temperature, 0C : 262 to 265

Stripper reflux drum temperature, 0C : 40

Stripper reflux drum Pressure, kg/cm2 g : 5.0

Stripping ratio = Stripping steam (kg / h) : 22 to 24

Stripper feed (t / h)

Reflux ratio:

Feed 1 Feed 2

Description Case 1 Case 2 Case 1 Case 2

SOR EOR SOR EOR SOR EOR SOR EOR

Reflux / feed (% wt) 5.37 5.60 5.24 6.08 6.92 7.05 6.77 7.44



1.12.0 ESTIMATED UTILITIES CONSUMPTION

The following table gives estimated utility consumption for DHDS plant.

S.No. UTILITY CONSUMPTION

1 Cooling Water, m3/hr. 710

2 Boiler Feed Water Unit, kg/hr 500

3 D.M. Water, m3/hr. Intermittent use

4 Service Water, m3/hr. 10

5 Condensate flowrate(condensate pump) 2970

6 LP Steam consumed, kg/hr. 2260

7 MP Steam Consumed, kg/hr. 12130

8 Power Consumed, KW 1340

9 Fuel, MG Kcal./hr. 4.34



1.13 ESTIMATED CATALYST, ALUMINA BALLS, CERAMIC BALLS,

CONSUMPTION

1.13.1 Catalysts

Type : HR - 348 HR - 945

Manufacturer : PROCATALYSE PROCATALYSE

Quantity :

Case 1 : 26.5 m3 3.3 m

3

Case 2 : 61.1 m3 3.3 m

3

1.13.2 Alumina balls

Type : Mullite or equivalent

Quantity :

1/4” diameter : Case 1 : 1.56 m3

: Case 2 : 2.02 m3

3/4” diameter : Case 1 : 2.08 m3

: Case 2 : 3.27 m3

1.13.3 Ceramic Balls

Type : 1½“ OR 50 mm

Quantity : 0.3 m3



1.14.0 ESTIMATED CHEMICALS CONSUMPTION

1.14.1 Chemicals used during normal operation

S. No CHEMICALS CONSUMPTION

Kg/year

REMARKS

1 Corrosion Inhibitor 600 -

2 Antifouling 7,700

3 Antifoaming 2,400 -

1.14.2 Chemicals used during transient/catalyst regeneration operation

S. No CHEMICALS CONSUMPTION

Kg.

REMARKS

1 DMDS 6,400 Consumption per

catalyst sulfiding

2 Anhydrous Ammonia 580 Consumption per

catalyst regeneration

3 NaOH (pure) 71,000 Consumption per

Catalyst regeneration



1.15.0 WASTE EFFLUENTS

1.15.1 Off-gases to Atmosphere

1.15.1.1 Flue Gas from Fired Heater

Continuous flow : About 4000 Sm3/h. H2S content depends on FG quality.

1.15.1.2 N2 Bleed during regeneration

Once every 2 years. Duration : about 8 days

Flow rate : Max. 615 kg/h

Composition N2 : 91% wt.

CO2: 7% wt.

1.15.2 Aqueous Effluent

1.15.2.1 The sour water is the purge of the SWS unit.

1.15.2.2 Water from fired heater decoking

Once every 4 years. Duration about 2 days.

Content : Coke, SO2, H2S, NH3

1.15.2.3 Spent caustic during regeneration

Once every 2 years. Duration about 8 days.

Flowrate of water : 2440 kg/h

content (NH4)2SO4 : 12 kg/h

Na2CO3 : 210

Na2SO3 : 107

This spent caustic has to be sent to an oxidation plant with aeration by air in

presence of catalyst to oxidize the sulfites in sulfates.

1.15.2.4 Waste Water during Sulfiding

Once every 2 years. Duration about 8 hours.

Flow rate : 270 kg/h, H2S content : Up to 0.2% wt.