residue fluid catalystic cracking unit (rfccu)

QUANG NGAI -2006

DUNG QUAT REFINERY PROJECT

MANAGEMENT BOARD3rd TECHNOLOGY GROUP

RESIDUE FLUID CATALYSTIC

CRACKING UNIT (RFCCU)

2PRESENTATION CONTENTS

I. INTRODUCTION;

II. BASIC OF DESIGN;

III. PROCESS DESCRIPTION;

IV. MATERIAL BALANCE (TYPICAL);

V. SPECIFICATION OF CATALYST AND CHEMICAL;

VI. SAFETY.

3I- INTRODUCTION

1. Licensed by IFP/AXENS;

2. Technology: R2R;

3. The role of RFCC in the Refinery;

4. Location of RFCC in the Refinery.

4I.3 THE ROLE OF RFCC IN THE REFINERY

5I.4 LOCATION OF RFCC IN THE REFINERY

6II-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.

7II.1 UNIT OBJECTIVES AND CAPACITY

a. Objectives: Process:

b. Capacity: 69700 BPSD (3 256 000 tonnes per year)

c. Operational:

Maximum Gasoline;

Maximum Distillate.

Bach Ho Atmosphere

Residue

Cracking Lighter

more valuableProducts

Blending Gasoline

DO

Mixed BH/DB

Off-gasFrom CDU

LPG

Off gas From NHT

HSO (5000BPSD) From

RefineryLSO (5000BPSD)

8II.2 FEEDSTOCK PROPERTIES

a. Atmospheric residue properties;

Property 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

Pour point (oC) 50 52

ASTM distillation @ 760 mmHg (oC

IBP 263 262

50% 475 480

Vol% above 550oC 32.4 32.5

9II.2 FEEDSTOCK PROPERTIES (CONT.)

b. CDU stabilizer off-gas;

100% Dubai 100% Bach Ho

Flow rate (kg/h) 339.0 291.0

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

10

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

11

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

Composition (mol%)

C2 1.2 0.8

C3 19.3 10.7

C4 78.2 87.1

C5+ 1.3 1.4

Total 100 100

12

II.3 PRODUCT SPECIFICATIONS

a. LPG;

PROPETIES MMG BMG MMD BMD

Sp. Gr 15/15 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

13

II.3 PRODUCT SPECIFICATIONS (CONT.)

b. Gasoline (MG: C5-205oC; MD: C5-165

oC);

PROPERTIES MMG BMG MMD BMD

Sulphur (wt ppm) 340 10 230 10

RON clear 92.1 91.8 92.0 91.7

RVP (kPa) 32 34 48 51

Sp. Gr. 15/15 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

14


c. LCO (MG: 205-360oC; MD: 165-390oC);


Sulphur (wt ppm) 0.619 0,055 0.45 0.04

Cetane number 24.4 28.1 33.9 38.4

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

15


d. Slurry (MG: 360+oC; MD: 390+oC);


Sp. Gr. 15/15 1.092 1.043 0.994 0.960

Sulphur (wt%) 1.03 0.10 0.835 0.07

Conradson carbon (wt%) 15.7 12.7 12.5 9.5

Viscosity @ 100oC (cSt) 160 140 110 45

Pour point (oC) 15-20 15-20 15-20 15-20

16


e. Decant Oil (after slurry separation):

Catalyst content: 100 ppm wt max

f. Fuel Gas:

H2S content: 50 ppm wt max

g. 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

17

II.4 OPERATING CONDITIONS

a. Reaction/Regeneration Section;

RISER/REACTOR 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

HCO back flush (t/h) 5 5 5 5

HCO back flush temp. (oC) 170 170 170 170

Stand. conversion (wt%) 79.94 80.76 62.60 61.88

18

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

Coke burnt (%) 70 70 70 70

Cat. dry make-up (t/d) 15.2 5.5 15.2 5.5

SECOND REGENERATOR 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

19


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

Draw-off temperature (oC)

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

20


c. Gas Recovery Section;

PRIMARY ABSORBER MMG BMG MMD BMD


Top pressure (kg/cm2g) 14.8 14.8 14.8 14.8


Bot. pressure(kg/cm2g) 15.1 15.1 15.1 15.1

SECOND ABSORBER MMG BMG MMD BMD


Top pressure (kg/cm2g) 14.4 14.4 14.4 14.4



21


c. Gas Recovery Section (Cont.);

STRIPPER MMG BMG MMD BMD




Bottom pressure (kg/cm2g) 16 16 16 16

DEBUTANIZER MMG BMG MMD BMD





22


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

23

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

LPG rich stream from CDU 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

24

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

25

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

26

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

REFINERY NITROGEN 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

27

III - PROCESS DESCRIPTION

1. Reactor/Regeneration (Rx/Rg) - Catalyst handling;

2. Flue gas treatment;

3. Feed fractionation;

4. Gas Recovery section.

28

III.1 RX/RG CATALYST HANDLING

29

III.1.1 RX

Backflush Oil

To flue gas

LC

LC

TC

PdC

PC

LC

FC

FC

FC

FC

FC

FC

FC

FC

FC

FC

FC

MP Steam

Riser

1

Withdrawal wel

To main

fractionator

T1501

To flue gas

Combustion air

Combustion air

Plug valve

Lift air

Fluidization air

MTC

Standpipe

30

III.1.1 RX (CONT.)

Feed

Injecti

on

Riser

Outlet

MTC

Injecti

on

T

ELE

V

31

III.1.1 RX (CONT.)

Reg. Cat. From Second StageRegenerator

MP Steam

Feed

MTC(MMG)

Backflush Oil

Vapor Pro. To Frac. Section

Spent Cat. To First Stage

Regenerator

Riser OutletSeperation System

32

III.1.2 RG

Flue gas to COB/WHB

Combustion Air

Lift Air

Spent Cat From Stripper

(Reactor).

Reg. Cat. To Riser

33

III.2 FLUE GAS TREATMENT

34

III.3 FEED FRACTIONATION

35

III.3 FEED FRACTIONATION (CONT.)

36

III.4 GAS RECOVERY

37

IV- MATERIAL BALANCE (TYPICAL)

FEED (KG/HR) PRODUCTS (KG/HR)

Residue 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)

38

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:

a. Antimony (Nickel passivator)

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.

39

V- SPECIFICATION OF CATALYST AND CHEMICAL

a. Corrosion Inhibitor:

Used in: Fractionator overhead ; Type: CHIMEC 1430; Normal consumption (kg/day): 60; Max consumption (kg/day): 120.

b. Amine Antifoaming Agent:

Used in: FG/LPG amine absorbers; Type: CHIMEC 8045; Normal consumption (kg/day): 10; Max consumption (kg/day): 20.

40

VI - SAFETY

1. Precaution for entering vessels;

2. High temperature precautions;

3. Chemical hazards.

41

VI.1-PRECAUTION FOR ENTERING VESSELS

a. The Reactor must be cooled to below 150oC before any manways or nozzles are opened.

b. The following precautions should be followed to prevent the personnelentering a vessel:

The vessels should be isolated by positive action;

An air mover should be installed at the vessels manway to sweepaway any vapors and provide a continuous supply of fresh air;

Responsible personnel must test the atmosphere in the vessel forexplosiveness, toxic fumes, oxygen content, dust, etc;

Personnel entering the vessel must be equipped with a pressuredemand respirator that is in proper working condition, and isconnected to a suitable fresh air supply;

Separate air supplies which are independent of electrical powershould be available for immediate use and transfer to personnel inthe vessel.;

Personnel entering the vessel should wear a safety harnesswith a properly attached safety line.

42

VI.1-PRECAUTION FOR ENTERING VESSELS (CONT.)

If the work is to be performed at a high level above the bottom ofthe 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 vesselmanway in continuous surveillance of the personnel in the vessel.

There should be spare pressure demand respirators, complete withtheir 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 orcontaminated atmosphere not be permitted to move too far away

from the entryway, or into any tight areas, such as through a

fractionator tray manway;

43

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.

44

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. Whenunloading catalyst cars, drawing samples, etc., goggles or a face

shield, a dust mask should be worn;

When drawing hot regenerated catalyst samples, gloves and longsleeved clothing should always be worn.

Personnel should not walk over or work around piles of spilledcatalyst.

45

VI.3 CHEMICAL HAZARDS (CONT.)

a. Iron Sulfide:

Iron sulfide has pyrophoric properties. It will ignitespontaneously when exposed to air, which is most likely to occur inrecently opened refinery vessels.

A vessel suspected of containing iron sulfide must be thoroughlysteamed out and washed with water before air is permitted to enter.

b. Heavy Cracked Hydrocarbons:

Heavy cracked oils are skin irritants. In case of actual contact, theskin should be thoroughly washed with hot soapy water, and anyoil-saturated clothing should be removed;

Should any hydrocarbon enter the eye, First Aid is to wash with acopious amount of clean water and obtain trained medicalassistance as quickly as possible.

46


a. Light Cracked Hydrocarbon Liquids:

Those gasoline streams which contain aromatics will be particularlydangerous. Benzene is a poison, and heavier aromatics have a

narcotic effect;

In case of exposure, no time should be lost in removing anygasoline-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.

b. Aromatic Hydrocarbons:

Benzene:

Benzene has carcinogenic effect on the bodys blood-formingorgans, 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.

47


o Avoid draining benzene on the ground or into the sewerswhere it can vaporize and create a health hazard. If you mustenter an area of high benzene vapor concentration resultingfrom a spill, wear a pressure demand respirator.

Toluene, Xylenes, and Heavier Aromatics:

o These aromatic compounds principal effect is skin, eye, andrespiratory irritation. Avoid breathing aromatic vapors;

o All employees should be alerted as to the early signs andsymptoms of excessive absorption of aromatics, and allworkers should report such symptoms to the MedicalDepartment.

a. 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 shouldbe removed from the area and kept warm and quiet. If necessary,artificial respiration with or without the use of oxygen should beadministered and medical aid summoned. Professional medicalattention should be obtained at once.

48


a. Hydrogen Sulfide:

Hydrogen sulfide is one of the most poisonous gases known.Exposure to an atmosphere containing less than 0.1% H2S may befatal in 30 minutes or less;

A person exposed to H2S may become excited or dizzy, maystagger, and can ultimately lose consciousness. First Aid consists ofremoval from the area and the administration of artificial respirationwith or without oxygen if breathing has stopped. The patient shouldbe kept warm and medical aid summoned.

b. Flue Gas:

Flue gas from the regenerator can cause asphyxiation if a personenters an improperly ventilated duct or a low area where the highdensity of flue gas;

Symptoms of asphyxiation may be dizziness, headache, orshortness of breath;

49


RCC flue gas is very dangerous since it contains carbonmonoxide, 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 poisoningconsists of keeping the victim warm and administering

artificial respiration and oxygen, if necessary, obtain

professional medical attention immediately.

residue fluid catalystic cracking unit (rfccu)

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