Dung Quat Oil Refinery I Introduction to Dung Quat Oil Refinery I 1 Introduction Dung Quat Refinery the first refinery in Vietnamin Dung Quat economic zone, Binh Son district, Quang Ngai province with[.]
Dung Quat Oil Refinery I Introduction to Dung Quat Oil Refinery I.1 Introduction Dung Quat Refinery: the first refinery in Vietnamin Dung Quat economic zone, Binh Son district, Quang Ngai province with capacity of 6.5 million tons of crude a year and has been in commercial operation sine 2010 (including Dung Quat Polypropylene with capacity of 150,000 tons of polypropylene products a year, has been in commercial operation sine 2010 The successful construction and put the Dung Quat oil refinery in operation meaning extremely important for ensuring energy security and contribute to speeding up industrialization and modernization of the country Company Limited Binh Son Oil Refinery (BSR) has the responsibility to receive, manage and operate the business Dung Quat oil refinery, the role of pioneer and laid the foundation for the development of the industry Vietnam oil refinery, and is where training high-quality human resources in this field Overview of sustainable development strategy of the company is : "Produce Safety always - always efficient business - always modern technology - HR professional always - always quality products - Services are varied environment friendly always - always reputable Cooperation - Opportunities always open - always cultural Conduct " Binh Son Refining and Petrochemical Company Limited + Founded on 09/05/2008 (Decision No 1018/QD-DKVN) + License number : 3,404,000,189 by the Department of Planning and Investment of Quang Ngai province level + Full name : Limited Liability Company a filter - member Binh Son Petrochemical + International Trade name : Binh Son Refining and Petrochemical Company Limited + English Abbreviation : BSR Co , Ltd + Headquarters: 208 - Hung Vuong street , city , Quang Ngai , Quang Ngai Province + Executive offices : the administrative area Dung Quat oil refinery , Binh Tri Commune , Binh Son District + Phone : ( 84-55 ) 825 3825 - Fax : ( 84-55 ) 826 3825 + Website : www.bsr.com.vn - Email : tmtt@bsr.com.vn I.2 The process of formation and development I.2.1 The period from 1977 to 1991: Project Petrochemical Refinery Complex by French company Beicip done at Nghi Son - Thanh Hoa and Lien Projects petrochemical complex due to perform in the Soviet Union of Tuy Ha Long Thanh district, Dong Nai province The refinery project started already in 1980s The refinery was planned to be construct near the port of Vũng Tàu, just 100 kilometres (60 mi) away from the offshore oil fields In 1988, the clearance of the construction site from unexploded wartime ordnance was started I.2.2 The period from 1992 to 1996: Continuing the search for joint venture partners to invest in the construction of oil refinery in Dung Quat - Quang Ngai I.2.3 The period from 1997 to 1998: Implementing a self-investment decision-TTg 514/QD of the Prime Minister In the early 1990s, Total S.A expressed interest to the project At the same time the Vietnamese government suggested to move the site to Van Phong bay, north of Nha Trang, and later further north to Dung Quat Followed this, in 1995 Total SA pulled out, claiming that the new site made no economic sense Total was replaced with a consortium of foreign investors, including LG Group and Petronas, but also this consortium withdraw two years later In 1998, establishment of VietRoss, a joint venture of Vietnam and Russia, was decided The intergovernmental agreement on the construction and operation of the refinery was signed on 25 August 1998 The Front End Engineering Design (FEED) Contract was signed between Petrovietnam, Zarubezhneft and Foster Wheeler Energy I.2.4 The period from 1999 to 2003: Cooperation with Russia thanhlap Joint Venture Refinery Vietnam - Russia (VIETROSS) to implement the project in the form of joint ventures with the capital contribution ratio 50/50 The Dung Quat Refinery was originally scheduled to start work in 2000, but the process was several times delayed.On 25 December 2002, the intergovernmental agreement between Vietnam and Russia was terminated, and the project continued as a solo project of Petrovietnam I.2.5 The period from 2003 to 2010: Back form of self-investment and deployment of plant theoquyet 546/QD - TTg of the Prime Minister On 24 October 2003, the project management consultancy services contract was signed with Stone & Webster, and on 27 February 2004 the contract for front end engineering design (FEED) development was signed with Technip.The construction started on 28 November 2005.The refinery was inaugurated by Vietnamese Prime Minister Nguyễn Tấn Dũng on 22 February 2009 + On 9/6/2008: Establishing Binh Son Refining and Petrochemical Company Limited + On 23/10/2009: Successful Operation 14/14 technology workshops + On 14/7/2010: PP unit for the first product + On 13/9/2011: Successful Launch refinery after two months of maintenance II Systems Dung Quat Oil Refinery II.1 Dung Quat Oil Refinery complex area The Dung Quat refinery complex area comprises: Overall Refinery Process, Utility and Offsites Facilities: about 110 ha; Crude Tank Farm and Flare Area: about 42 ha; Product Tank Farm: about 36 ha; Seawater intake, Waste Water and Crude Oil Pipelines: about ha; Interconnecting Pipelines, road and right of Way: about 40 ha; Product Harbor Service Area: about 135 Ground factory includes mean areas: Refinery Inside Battery Limit Crude Oil Tank Farm Product Tankage, Truck Loading, Interconnecting Pipeline, Product Export berth Single Point Mooring, Jetty, Breakwave II.2 Introduce about Units in Dung Quat Oil Refinery Dung Quat refinery has 14 techonology units and 10 energy units,… II.2.1 Unit – Crude Distillation The Crude Distillation Unit (CDU) provides primary separation of crude oil feedstocks: Crude oil is first preheated against product and pumparound streams before being routed to a fire heater Then the primary fractionation is carried out in the main crude column fractionator and associated side stream strippers The CDU produces Naphtha (Overhead naphtha from the main fractionator is further processed in the naphtha stabilizer column), Light Gas Oil & Heavy Gas Oil (LGO and HGO streams are vacuum dried prior to rundown), Kerosene and residue II.2.2 Unit – Naphtha Hydro Treater The Naphtha Hydro Treater (NHT) processes the straight run Naphtha from the CDU and the intermediate storage The Naphtha Hydrotreating Process is a catalytic refining process employing a select catalyst and a hydrogen rich gas stream fed from unit (CCR) to decompose organic sulfur, oxygen and nitrogen compounds contained in hydrocarbon fractions In addition, hydrotreating removes organo-metallic compounds and saturates olefinic compounds II.2.3 Unit – Continuous Catalytic Reformer The CCR is divided in sections: Reaction Section or Platforming, which processes the hydrotreated straight run heavy naphtha from the Naphtha splitter of unit to produce a high octane gasoline blending component This is achieved by using a catalyst refining process to transform naphtenes into aromatics while minimizing the conversion of paraffins and aromatics The main by-product of this process, hydrogen, is then used in unit Regeneration section, which continuously regenerate the catalyst in steps: • Burning of the accumulated coke • Oxychlorination – To disperse the catalyst metals and adjusting the catalyst chloride content • Catalyst Drying • Reduction – To change the catalyst metals to the reduced state II.2.4 Unit – Kerosene Treater The Kerosene Treater Unit (KTU) provides caustic treatment to the kerosene from the CDU: • Caustic Washing to remove naphtenic acids • Oxidative caustic treating to convert the mercaptan sulphur into disulfide oil • Water washing to remove sodium salts • Salt & clay filtration to remove free water and surfactants The treated kerosene is then stored as finished product for sale and is used in the auto blending II.2.5 Unit – Residue Fluid Catalytic Craking The Residue Fluid Catalytic Cracking (RFCC) converts various residue from CDU to lower boiling, high value products: Naphtha sent to NTU & Light Cycle Oil sent to LCO HDT and intermediate storage Using vapor phase chemical reactions in the presence of specialized FCC cracking catalyst, the long molecular chain FCC feedstock is cracked to shorter chain molecules Heat for the cracking process is supplied by the hot regenerated catalyst which vaporizes the finely atomized oil feed and ensures the selective cracking process in roughly two seconds As by-products of the reaction, fuel gas, slurry oil, and coke are also generated in the reactor-riser Decanted Cycle Oil (DCO) will then be incorporated in the fuel oil blend The majority of the FCC equipment handles catalyst / vapor product separation and removal of the coke from the catalyst, while only a small portion of the system is directly used for the cracking reaction II.2.6 Unit – LPG Treater The LPG Treater Unit (LTU) ensures the extraction of H2S and mercaptans contained in the LPG stream from RFCC, NHT & CDU with caustic The process used is a stage (prewash & extraction with caustic) non dispersing mixing process The treated LPG is then fed to the PRU for further separation II.2.7 Unit – RFCC Naphtha Treater The RFCC Naphtha Treater Unit (NTU) ensures the extraction of H2S and mercaptans contained in the Naphtha stream from RFCC with caustic The process used is a single stage (extraction with caustic and oxidation of the mercaptans with air) non dispersing mixing process The treated Naphtha is then sent to storage before being used for the MoGas 90/92/95 blends II.2.8 Unit – Sour Water Treating The Sour Water Stripping Unit (SWS) treats combined sour water from the CDU, the NHT, the RFCC the LCO HDT, the Sour Flare and the CCR units The treated water is then discharged either to the CDU for use as desalter wash water or the effluent treatment plant ETP II.2.9 Unit – Amine Regeneration Unit The Amine Regeneration Unit (ARU) removes H2S from rich amine returning from the amine absorbers in the RFCC and LCO HDT by means of stripping steam in a single column The treated amine, or lean amine, is then returned back to these units II.2.10 Unit 10 – Spent Caustic Neutralization The Caustic Neutralization Unit (CNU) processes caustic streams from LTU, KTU, RFCC & NTU, as well as phenolic water from ETP and alkaline water from regeneration of the NHT II.2.11 Unit 11 – Propylene Recovery Unit The Propylene Recovery Unit (PRU) fractionate the treated C3/C4LPG from the LTU into mixed C4’s, propane and propylene in stages: • C3/C4 separation • De-ethanization of the separated C3 • Propane/Propylene splitting The propylene is further purified in a catalytic process to achieve grade polymer specification II.2.12 Unit 12 – Sulphur Recovery The Sulphur recovery Unit (SRU) has been designed for the Bach Ho crude operation to convert all suphur compounds present in the acid gas feed from the ARU and the SWS into liquid elemental sulphur II.2.13 Unit 13 – Light Naphtha Isomerisation The Light Naphtha Isomerisation Unit (ISOM) processes straight run light naphtha from Unit 012 to produce a high octane isomerate naphtha product used in the MoGas 90/92/95 blends The process is a continuous catalytic isomerization of pentanes, hexanes and mixtures thereof under a hydrogen atmosphere, over a fixed bed of catalyst and at operating conditions, This process promotes isomerization and minimize hydrocracking, leading to a mixture of iso-paraffins with a high octane number II.2.14 Unit 14 – LCO Hydrotreater The operation of the LCO Hydro Treater eliminates metals, sulfur, nitrogen & oxygen in the gas oil fed to the unit and saturates olefins and diolefins by reaction with hydrogen from CCR The feed to the unit 014 is a combination of LGO & HGO from the CDU and LCO from the RFCC Beside, Dung Quat Refinery also has 10 energy uints: Unit 31 – Water System Unit 32 – Steam, Boiler Feed Water & Condensate System Unit 33 – Cooling Water System Unit 34 – Sea Water Intake System Unit 35 – Plant & Instrument Air System Unit 36 – Nitrogen System Unit 37 – Fuel Gas System Unit 38 – Fuel Oil System Unit 39 – Caustic Supply Unit 40 – Power & Steam Generation III Source of supply and products of Dung Quat Refimery III.1 Source of supply • In period 1: Processing from 100% Bach Ho – Viet Nam crude oil • In period 2: Processing from mix oils: 50% Bach Ho – Viet Nam crude oil and 50% Dubai – MidEast III.2 Products Products: LPG, Unleaded Gasoline (RON 92; 95); Jet-A1; Diesel; FO; Polypropylene Sulphur The capacity by specific products as bellow table: No Products LPG Quantity (BPSD) 11,100 Regular Gasoline Premium Gasoline Jet A-1/Kerosene Diesel Fuel Oil Polypropylene Sulfur Total Liquid Product IV Dung Quat production details and capacity 44,100 21,800 5,300 53,200 7,000 450 TBD TPD 142,400 The capacity of the refinery in 6,5 milion tons, of low sulphur a year(5,5 milion tons of the Bach Ho crude oil from Viet Nam and one million tons of middle East sour crude a year _ 130000bdp) using deep and modern processing configurations including: a continuos catalytic reformer(CCR) and residual fluid catalytic cracking(RFCC), and a benzene , toluene ,xylene (BTX) plant When the plant runs at full capacity, product will include : about 23000t LPG, unleaded petrol , kerosene/30000t of jel fuel, feedstock for the propylene plant about 25000t of FO, 240000t of diesel(industrial and production each month.The products from the refinery are expected to meet about 30℅ of domestic requirement Future Projects of the government The government has also phanned the construction of two more refineries within the same timescale as Dung Quat The second installation will be at Nghi Son in Thanh Hoa about 1200 km north of the oifields- still a logistical transport problem for crdude feedstock and refined products Petrovietnam, Kuwait and Japanese partners signed and agreement in in march 2007 for the Ngi Son refinery with an initial refining capacity of about ten million tons annually In February 2010 foster wheeler won the contract for providing technical and commercial services for the refinery foster wheeler will manage the bidding process for the new refinery The third planed refinery Long Son, will be located in the south at Vung Tau Which is closer to the oilfields and has a better chance of being economically viable The Long Son refinery will begin operation in 2015 ... Successful Launch refinery after two months of maintenance II Systems Dung Quat Oil Refinery II.1 Dung Quat Oil Refinery complex area The Dung Quat refinery complex area comprises: Overall Refinery Process,... Export berth Single Point Mooring, Jetty, Breakwave II.2 Introduce about Units in Dung Quat Oil Refinery Dung Quat refinery has 14 techonology units and 10 energy units,… II.2.1 Unit – Crude Distillation... thanhlap Joint Venture Refinery Vietnam - Russia (VIETROSS) to implement the project in the form of joint ventures with the capital contribution ratio 50/50 The Dung Quat Refinery was originally