DUNG QUẤT REFINERY

DUNG QUẤT REFINERY

INTRODUCTION OF DUNG QUAT

REFINERY

DUNG QUAT REFINERY

 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 Province

Area: 5,131.51 km 2

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

(Add 135 ha for Product

Harbor 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 m 3

 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

 Jetty: Loading arms, MOV valves, slop tanks, drains, etc., as well as shore facilities including custody transfer flowmeters, safety valves, etc.

on-DUNG QUAT REFINERY

EPC Package 4: single point Mooring (SPM)

 Import Crude Oil from Tanker

 The SPM Unit comprises of

 Single Point Mooring Buoy

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

Gasoline A92 (unlead) 1,407,667 1,952,333 1,534,333 2,081,667

DUNG QUAT REFINERY

PROCESS UNITS

DUNG QUAT REFINERY

Note : Stabiliser and Naphtha Splitter are parts of CDU

Jet A1 Kerosene

Residue LCO

DCO RFCC Naphtha

LPG LPG

C3

Mix C4LPG

Treated HN Reformate

Treated RFCC Naphtha

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)

oxygen, metallic compounds in heavy

protect CCR catalyst by Hydrotreating

Naphtha Hydrotreating Unit

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

 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)

activated carbon, salt, Attapulgus clay

EXL, ARI-120L), MEA 50%

Residue Fluid Catalytic Cracker

(RFCC)

residue into value products (lighter

compounds) by catalytic cracking process

Residue Fluid Catalytic Cracker

RFCC Gas Plant

 Process the following streams:

 CDU Stabilizer Off-gas

 CDU LPG rich stream

Residue Fluid Catalytic Cracker

 Light Cycle Oil (LCO): To Diesel Blending

 Decant Oil (DCO): To Fuel Oil Blending

 Other streams:

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 NH 3 and H 2 S dissolved in sour water

collected from CDU, NHT and RFCC Unit

 Surge drum + a single stripping column

 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

 Duty: Neutralize and remove phenolic and naphthenic oils from various spent caustic streams (KTU, LTU,

NTU caustic; ETP Water; NHT alkaline water)

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

Propylene Recovery Unit

(PRU)

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

(BFW) in Process Steam Generators

 Collection, storage and treatment of Power Generation Plant steam condensate for reuse as HHP BFW in

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

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

Nitrogen System

 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

Fuel Gas

 Other users:

 Refinery Flare System

 Product Tankage (Flare system, steam regenerators)

Refinery Fuel Oil

within Refinery

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

solution to all consumers within Refinery

Power Generation &

Distribution

facilities

grid

Refinery Tankage

 Duty: Stores and handles the intermediates and

finished products of the Refinery:

 1 Off-spec Propylene Sphere

Product Blending

 Consists of a number of separate systems and

associated components for blending the final products

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

Flushing Oil

 Source of Flushing Oil:

 For Process units and Offsite pipework:

 LCO from LCO Intermediate Storage Tank

 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

vol.)

Effluent Treatment Plant

(ETP)

environment protection requirements

 Primary, secondary and tertiary treatment facilities to remove oils, solids and organics

Primary 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