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INTRODUCTION OF DUNG QUAT REFINERY
DUNG QUAT REFINERY
Site 12 km in the East of No 1 national
road 7 km from Chu Lai Airport, 100km
from Da Nang 38 km from Quang Ngai Town The Site is bounded by Dung Quat
Bay to the North and Viet Thanh Bay to the South
Quang Ngai ProvinceArea: 5,131.51 km2
Population: 1,198,500 (1999)
DUNG QUAT REFINERY
Capacity: 6.5 million tons crude oil/annum (148,000
BPSD)
Feedstock: Sweet case: Bach Ho Crude Oil Sour Case: Mix Bach Ho + Dubai (5.5/1)
Capital investment $3.0 billion.
DUNG QUAT REFINERY
Main products (meet ASEAN standards): LPG Polypropylene Unleaded Gasoline (RON 83 and 92) Jet Fuel (Jet A1)/ Burning Kerosene Auto Diesel and Industrial Diesel Fuel Oil
DUNG QUAT REFINERY
Package 1: Refinery Inside Battery Limit Package 2: Crude Tank Farm Package 3: Product Tankage, Truck Loading,
Interconnecting Pipeline, Product Export berth Package 4: Single Point Mooring (SPM) Package 5A: Breakwater Package 5B: Jetty Package 7: Administration Building
DUNG QUAT REFINERY
Plot Plant: 36 ha
40 ha 4 ha 27 ha 125 ha
232 ha
(Add. 135 ha for ProductHarbor Service Area)
DUNG QUAT REFINERY
EPC Package 1 (Refinery Inside Battery Limit) Includes: Process Units, Utility and Offsite facilities Main Process Units:
Crude Distillation Unit (CDU) Kerosene Treating Unit (KTU) Naphtha Hydrotreating Unit (NHT) Continuous Catalytic Reforming Unit (CCR) Residue Fluid Catalytic Cracking Unit (RFCC) LPG Treating Unit (LTU) RFCC Naphtha Treating Unit (NTU) Propylene Recovery Unit (PRU)
DUNG QUAT REFINERY
EPC Package 2: Crude Tankage
Stores Crude Oil imported through SPM Includes six floating roof tanks with total
working capacity: 390,000 m3
Capacity is equal to 11 day's operation at the design CDU feed rate ( 148,000 BPSD) + maximum parcel size (110,000 DWT).
DUNG QUAT REFINERY
EPC package 3: Product Tankage, Truck Loading, Jetty Topsides, Interconnecting pipeline
Stores and exports products Includes:
27 tanks with total working capacity: 397,000 m3 to store and dispatch products via Jetty Topsides, Truck Loading and Product Pipeline
Interconnecting Pipelines: totally 10 km (7km from the Refinery to the Product Tankage and 3km from the Product Tankage to the Product Export Berths
Jetty: Loading arms, MOV valves, slop tanks, drains, etc., as well as on-shore facilities including custody transfer flowmeters, safety valves, etc.
DUNG QUAT REFINERY
EPC Package 4: single point Mooring (SPM)
Import Crude Oil from Tanker The SPM Unit comprises of
Single Point Mooring Buoy Interconnecting hoses PLEM submarine pipeline
The SPM buoy is located approximately 3.2km off-shore in Viet Thanh bay.
DUNG QUAT REFINERY
EPC Package 5A: Beak water Keep the Loading Operations in good
condition The Breakwater of about 1.6km long
DUNG QUAT REFINERY
EPC Package 5B: Product Export Berths
Harbour for product export operations Includes:
2 Ocean Tankers Berths (Berths 1 and 2) provide capability for ocean tankers in the range of 15,000 to 30,000 dead weight tonnage (DWT) with facility expandable to 50,000 DWT.
4 Coastal Tankers Berths (Berths 3, 4, 5, 6) provide capability for coastal tankers in the range of 1,000 to 5,000 dead weight tonnage (DWT) with facility expandable to 30,000 DWT.
DUNG QUAT REFINERY
EPC Package 7: Administration Building
Operation Supports Consists of:
Administration Building Fire Station/Gas Rescue Station Canteen/Shop/ Laundry Building First Aid Station Maintenance Shop; Garage Facilities/Motor Pool Building
DUNG QUAT REFINERY
Products Balance, tons/year
BMD BMG MMD MMGPropylene 108,333 157,000 111,000 147,666LPG 286,000 343,667 276,333 307,000Gasoline A92 (unlead) 1,407,667 1,952,333 1,534,333 2,081,667Gasoline A83 (unlead) 534,667 718,000 407,667 515,667Kerosene/Jet A1 282,333 219,667 219,667 219,667Auto Diesel 2,084,333 2,115,667 2,225,333 2,321,000Industrial Diesel 1,327,000 430,000 252,000 30,000FO 115,667 177,000 1,131,667 466,000Product Total 6,146,000 6,113,000 6,158,000 6,088,667Lost and consumed 354,000 386,667 342,000 441,333Total 6,500,000 6,500,000 6,500,000 6,500,000
DUNG QUAT REFINERY
PROCESS UNITS
DUNG QUAT REFINERY
Note : Stabiliser and Naphtha Splitter are parts of CDU
SPM
Crude Tankage
CD
U
LTU RFCC Gas Plant
RFCC
NHT CCR
KTU
NTU
Propylene
LPG
Mogas 92/83
Jet A1
Kerosene
Auto/Ind. Diesel
FO
LPG + FG
LN
HN
Kerosene
LGO
HGO
Residue LCO
DCO
RFCC Naphtha
LPG LPG
C3 Mix C4
LPG
Treated HN Reformate
Treated RFCC Naphtha
Sta
bili
ser
Sp
litte
r Note
Note
PRU
Crude Distillation Unit (CDU)
Capacity: 148,000 BPSD (6.5 millions TPA) Duty: Split Crude Oil into a number of hydrocarbon
fractions by distillation process System:
Desalter Fired Heater Main Fractionators & associated Strippers Stabilizers and Splitters
Crude Distillation Unit (CDU)
Product Streams: Light Ends: To RFCC Gas Plant Light Naphtha: To Mogas Blending Heavy Naphtha: To NHT Kerosene: To KTU/Kerosene Tankage Light Gas Oil: To Diesel Blending Heavy Gas Oil: To Diesel/Fuel Oil Blending Residue: To RFCC
Naphtha Hydrotreating Unit (NHT)
Capacity: 21,000 BPSD Licensed by: UOP Duty: Remove sulfur, chlorite,
nitrogen, oxygen, metallic compounds in heavy naphtha stream taken from CDU process to protect CCR catalyst by Hydrotreating
Naphtha Hydrotreating Unit (NHT)
A single fixed bed catalyst reactor Catalyst: Co + Mo + Al2O3
Catalyst regeneration cycle life: >2 years Treated naphtha: To CCR Off-gas: To FG Amine
Absorber at RFCC Gas Plant
Continuous Catalytic Reformer (CCR)
Capacity: 21,000 BPSD Licensed by: UOP Duty: Reform heavy naphtha straight-run from
NHT to High Octane Mogas Blending components (Reformat)
Catalyst: Pt/Al2O3
Continuous Catalytic Reformer (CCR)
Systems: 4 Reactors (Platformer) Continuous Catalyst Regenerator (Cycle Max) Combined Exchangers
Reformat: To Mogas Blending Un-stabilized LPG: Blended with Refinery
LPG stream and routed to LPG storage
Kerosene Treating Unit (KTU)
Capacity: 10,000 BPSD Licensed by: MERICHEM Duty: Treat kerosene stream taken from CDU to
meet Jet A1 specifications Technology: FIBER-FILM Contactor
Kerosene Treating Unit (KTU)
System: NAPFINING: Naphthenic acid extraction MERICAT II: Mercaptan oxidation AQUAFINING: Water washing
Remove Na+
Salt Dryer: Remove trace of free water and dry kerosene below saturation
Clay Filter: Remove remaining solids, moistures, soaps, emulsions and surfactant
Kerosene Treating Unit (KTU)
Treating reagents: NaOH 200 and 50 Be, activated carbon, salt, Attapulgus clay
Catalyst: Cobalt Phthalocyanine (ARI-100 EXL, ARI-120L), MEA 50%
Treated kerosene: To Jet A1 Storage Spent caustic: To CNU Alkaline water: To ETP
Residue Fluid Catalytic Cracker (RFCC)
Capacity: 69,700 BPSD Licensed by: IFP Duty: Converts heavy compounds of
CDU residue into value products (lighter compounds) by catalytic cracking process
Catalyst: Zeolite
Residue Fluid Catalytic Cracker (RFCC)
Operation mode: Max Gasoline Max Distillate
System: Reactor and 2-stage catalyst regenerator Main Fractionator Gas Recovery Section (Gas Plant)
RFCC Gas Plant
Process the following streams: CDU Stabilizer Off-gas CDU LPG rich stream NHT Off-gas Wet gas from RFCC Fractionator
Duty: Recovers C3/C4
Removes H2S, CO2 from LPG and fuel gas by DEA absorbers
Residue Fluid Catalytic Cracker (RFCC)
Product streams: Unsaturated off-gas:To Refinery Fuel gas Mix C3/C4: To LTU Naphtha: To NTU Light Cycle Oil (LCO): To Diesel Blending Decant Oil (DCO): To Fuel Oil Blending
Other streams: Sour water: To SWS Rich amine: To ARU
LPG Treating Unit (LTU)
Capacity: 21,000 BPSD Licensed by: MERICHEM Duty: Remove Mercaptan, COS, H2S from
LPG stream of RFCC Gas Plant Technology: FIBER-FILM Contactor 2-stage THIOLEX extraction system
LPG Treating Unit (LTU)
Treating reagents: NaOH 200 Be Catalyst: MEA 50%wt Treated LPG: To PRU/Storage Spent caustic: To CNU
RFCC Naphtha Treating Unit (NTU)
Capacity: 45,000 BPSD Licensed by: MERICHEM Duty: Remove H2S, Mercaptan and other acidic
compounds in Naphtha stream of RFCC Unit Technology: FIBER-FILM Contactor 1-stage MERICAT caustic treating system
RFCC Naphtha Treating Unit (NTU)
Catalyst: Cobalt Phthalocyanine Treating reagents: NaOH 200 Be Treated naphtha: To Mogas Blending Spent caustic: To CNU
Sour Water Stripper (SWS)
Duty: Strip NH3 and H2S dissolved in sour water collected from CDU, NHT and RFCC Unit
Surge drum + a single stripping column Sour gases: To SRU Stripped water: To ETP/CDU Desalter
Amine Regeneration Unit (ARU)
Duty: Skim hydrocarbon and strip sour gas (H2S) from rich amine stream of RFCC Unit
Feed surge drum + a regeneration column Skimmed oil: To Light slops Sour gases: To SRU Stripped lean amine: To H2S absorber on
RFCC
Spent Caustic Neutralization Unit (CNU)
Capacity: 1.5 m3/h mixed caustic stream Licensed by: MERICHEM Duty: Neutralize and remove phenolic and
naphthenic oils from various spent caustic streams (KTU, LTU, NTU caustic; ETP Water; NHT alkaline water)
Technology:FIBER-FILM Contactor
Spent Caustic Neutralisation Unit (CNU)
Caustic Deep Neutralization: Neutralize by sulphuric acid 96% and remove acid gases,
naphthenic, phenolic acids from the brine Neutralization and Phenol Extraction:
Neutralize to pH=7 and extract phenol from acidic brine by solvent (Kerosene)
Treating reagents: H2SO4 96%, NaOH 50Be, Neutralized brine: To ETP Off-gas: To SRU Acid Oils/Kerosene: To Fuel Oil Blending
Propylene Recovery Unit (PRU)
Capacity: 21.000 BPSD Duty: Separate and purify propylene
from the mixed C3/C4 stream of LTU to polymer grade (99.6 wt%) specification
Product stream: Propylene: To Propylene Tankage/PP Plant C3/C4: To LPG Blending
Propylene Recovery Unit (PRU)
System: C3/C4 Splitter: Remove C4’s from LPG Propane/propylene splitting facility:
De-ethaniser: Release product lighter than propylene Propane/Propylene splitting column
Propylene purification: Carbonyl sulfide removal Arsenic, phosphorous and antimony removal
Sulfur Recovery Unit (SRU)
Licensed unit Capacity:
Sweet case: 3 tons/day Sour case: 36 tons/day
Duty: Recover Sulfur in Refinery off-gas to meet environment protection requirements (SO2 concentration)
Product: Sulfur Powder
Polypropylene (PP) Plant
Licensed unit Capacity: 150,000 tons PP/annum Duty: Produce PP from Propylene product of
the Refinery by polymerization process Product: Unpainted heat and light stabilized
Polypropylene pellets Detailed Feasibility Study (DFS) completion
Water System
Duty: Produce and distribute various grade of water to users within Refinery and Product Tank Farm (PTF) as follows: Service water to users at Refinery and PTF Make-up supply to freshwater cooling system Make-up supply to Refinery potable water system Make-up supply to dematerialized water system Make-up supply to Refinery fire water system
Steam and Condensate
Provides: HP, MP, LP Steam to and subsequent distribution
within Refinery Collection, storage and treatment of Refinery steam
condensate for reuse as HP & MP boiler feedwater (BFW) in Process Steam Generators
Collection, storage and treatment of Power Generation Plant steam condensate for reuse as HHP BFW in Power Generation Plant
Steam and Condensate
Comprise of: Steam producing equipment Distribution Pipework HP to MP and MP to LP letdown stations Condensate collection and treatment facilities Dearators Associated chemical dosing package
Cooling Water
Duty: Supply cooling water to all users in process and utility units (except the condensers in Power Station)
A closed fresh water system, cooled by once-through sea water
Cooling Water
Comprise of: Cooling Water Circulation Pumps Plate Heat Exchanger Expansion Tank Expansion Tank Oil Skimmer Chemical Dosing Package
Sea Water Intake
Provides: Seawater to Power Station for once-through cooling in
Vacuum Condensers Seawater to seawater/freshwater exchanger for cooling
the closed loop cooling water system
Sea Water Intake
Consists of: Seawater Intake box (located offshore) Seawater Intake Basin Inlet Line Seawater Intake Basin (located onshore) Seawater circulation pumps Hypochlorite dosing Discharge facilities
Hypochlorite for seawater chlorination is generated on site by electrolysis of seawater
Plant and Instrument Air
Duty: Provides Plant and Instrument Air for demand of Refinery
System: 3 Air Compressors Wet Air Receivers: Remove condensed
water 2 refrigeration-type dryers 2 Instrument Air Receivers
Nitrogen System
Provides: Gaseous nitrogen to process users in normal operation Liquid nitrogen for storage and subsequent
vaporisation to meet peak loads and startup demands Dedicated liquid nitrogen for storage and subsequent
vaporisation for use in CCR Regeneration Section Independent high pressure system for leak testing of
process equipment/pipelines
Nitrogen System
Comprises of: Nitrogen Generation Package Liquid Nitrogen Storage Vaporisation Package
Method of generation: Cryogenic Air Separation
Nitrogen purity: 96% volume
Fuel Gas
Duty: Provide Fuel Gas to process unit fired heaters and HHP Boilers at Power Station
Major users of fuel gas: CDU charge heater RFCC process heaters NHT charge heater CCR process heaters Power Station Boilers
Fuel Gas
Other users: Refinery Flare System Product Tankage (Flare system, steam regenerators)
Comprises of: Fuel Gas Mix Drums Vaporiser Package
Vaporise LPG/Propylene for use at Startup,disposal of LPG/Propylene off-spec., low FG pressure or emergency event
Fuel Gas collection/distribution pipework
Refinery Fuel Oil
Duty: Supply Fuel Oil to all consumers within Refinery
Comprises of: 2 Refinery Fuel Oil Storage Tanks Fuel Oil Pumps Fuel Oil Heater Supply and return pipework
Refinery Fuel Oil
Source of Refinery Fuel Oil: In normal operation: Decant Oil (DCO) from
RFCC For Refinery Startup: Imported via SPM Outages of RFCC: Heavy Gas Oil (HGO) and/or
CDU residue from CDU
Caustic Supply
Duty: Make up and provide caustic (NaOH) solution to all consumers within Refinery
Comprises of: Dissolving Sump: dilutes solid caustic
pellets Storage Tanks Pumping Facilities
Caustic Supply
Concentrations of NaOH solution are made up, stored and distributed on site: 500 Be (49.5 wt%)
Made up by dissolving solid caustic in demin. water 200 Be (14.4 wt%)
Made up by diluting 500 Be caustic in demin. water 50 Be (3.4 wt%)
Made up by diluting 500 Be caustic in demin. water
Power Generation & Distribution
Provide: Electrical Power to Refinery and all associated
facilities Steam and condensate to Refinery
4 15 MW Steam Turbine Turbo-Generators
Ability to import/export power from/to EVN grid
Refinery Tankage
Duty: Stores and handles the intermediates and finished products of the Refinery:
1 Off-spec Propylene Sphere 1 RFCC Feed Tank 2 NHT Feed Tanks 1 Off-spec RFCC Naphtha Tank 1 Reformate Tank
1 Light Naphtha Tank
2 Mix C4’s Spheres 1 HGO Tank 2 LCO Tanks
Product Blending
Consists of a number of separate systems and associated components for blending the final products of Refinery: 92 RON Mogas 83 RON Mogas Auto Diesel Industrial Diesel Fuel Oil
Flushing Oil
Unit number: 055 Provides:
Flushing Oil for process units and Offsite pipework Contains catalyst fines Pour point is higher than minimum daily ambient temp.
Flushing Oil for SPM loop Consists of:
Facilities for flushing process units Separated facilities for flushing SPM loop
Flushing Oil
Source of Flushing Oil: For Process units and Offsite pipework:
LCO from LCO Intermediate Storage Tank For SPM loop:
LGO from SPM Flushing Oil Tank as a slip stream from CDU rundown
SPM loop is flushed immediately before and after each transfer operation
Slops
Duty: Collects, Stores light and heavy slops from Refinery process units and Offsite areas for subsequent reprocessing in CDU or RFCC
Oily Water: To Refinery ETP for further treatment
Alternative disposal route for heavy slops: Refinery Fuel Oil System
Flare System
Consists of: Refinery Flare System Product Tank Farm Flare System
Each Flare System comprises of: Main Flare Stack Sour Gas Flare Riser (handle all discharges
containing H2S at levels higher than 10% vol.)
Effluent Treatment Plant (ETP)
Duty: Treat effluent streams to meet environment protection requirements
Consists of: Refinery ETP
Primary, secondary and tertiary treatment facilities to remove oils, solids and organics
Product Tankage ETPPrimary treatment for removing oil and solids
Effluent Treatment Plant (ETP)
“Products” stream: Treated effluent: discharged to the sea Recovered slop oil: pumped to Refinery Heavy
Slops tank for re-processing Digested biological sludge: Buried in Dedicated
Area De-watered, de-oiled refinery sludge: To other
facilities for special treatment
Fire Water System
Duty: Supply water for firefighting Comprises of 2 separate firewater systems:
Refinery and nearby facilities Product Tank Farm, Truck Loading and Jetty
Topsides Firewater was taken from the sea at Jetty