OPERATING MANUAL VOLUME 13 LIGHT NAPHTA ISOMERIZATION UNIT

PROCESS DATA SHEET Project N° - Unit Doc. type Equipment N° Serial N° Rev. index CLIENT Page LOCATION UNIT Rev. A Rev. Page Page X X X X X X X X X X X X X X X A Rev. Document revisions PDS94 - Rev. 4 - ANG - XL97 H:\projet\8475M-DQR-POC\08-Process\Operating Manuals\operating manual - DQR\ISOM\[8474L-023-ML-001-A.xls]PAGE A PD094A14 ISSUE FOR REVIEW Description Op. Center JOB N o . Op. Center Doc. N o . 27-JUL-07 Date DD-MMM-YY C. VERDON Written by J-P. BINET Checked by R. LEFEBVRE Approved by Ch 11 Ch 12 Ch 13 Ch 14 Ch 7 Ch 8 Ch 9 Ch 10 Ch 3 Ch 4 Ch 5 Ch 6 Ch 1 Ch 2 023 PENEX A A PENEX UNIT (023) OPERATING MANUAL PETROVIETNAM DUNG QUAT VIETNAM A8474L-023 ML 001 FEED Doc. N o . DOCUMENT CLASS X VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM) DUNG QUAT REFINERY OPERATING MANUAL VOLUME 13 LIGHT NAPHTA ISOMERIZATION UNIT UNIT 023 BOOK 1/2 Rev. 0 VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM) March 2007 DUNG QUAT REFINERY Rev. : 0 OPERATING MANUAL Chapter : 1 UNIT ISOM (023) Page : 1 / 2 CONTENTS CHAPTER 1 BASIS OF DESIGN 1. DUTY OF THE PLANT 2. ENVIRONMENTAL CONDITIONS 3. FEEDSTOCKS AND PRODUCTS SPECIFICATIONS 4. OVERALL MATERIAL BALANCE OF THE UNIT 5. BATTERY LIMIT CONDITIONS 6. DESIGN FEATURES 7. GAS AND LIQUID EFFLUENTS CHAPTER 2 PROCESS DESCRIPTION 1. PROCESS THEORY 2. DESCRIPTION OF FLOW CHAPTER 3 DESCRIPTION OF UNIT CONTROL 1. DESCRIPTION OF FLOW WITH CONTROLS 2. OPERATING CONDITIONS 3. PROCESS VARIABLES 4. INTER-UNIT CONTROL SCHEME 5. UNINTERRUPTIBLE POWER SUPPLY (UPS) 6. COMPLEX CONTROL DESCRIPTION CHAPTER 4 UILITY, CHEMICAL AND CATALYST REQUIREMENTS 1. UTILITIES 2. CHEMICALS CONSUMPTION CHAPTER 5 PREPARATION FOR INITIAL START-UP 1. PLANT CHECK-OUT 2. LINE FLUSHING 3. WATER CIRCULATION 4. LEAK TESTING 5. HEATER DRY-OUT 6. LOADING OF METHANATOR, DRIERS, SCRUBBER AND REACTORS 7. CHEMICAL CLEANING CHAPTER 6 INITIAL AND NORMAL START-UP 1. SUMMARY OF START-UP 2. PURGING AND GAS BLANKETING 3. METHANATOR START-UP 4. HYDROCARBON CIRCULATION AND INITIAL DRYDOWN 5. ACIDIZING AND FINAL DRYDOWN 6. CATALYST LOADING 7. INITIAL START-UP 8. NORMAL START-UP 9. DEISOHEXANIZER START-UP 10. NORMAL OPERATION CHAPTER 7 NORMAL SHUTDOWN 1. NORMAL SHUTDOWN PROCEDURES VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM) March 2007 DUNG QUAT REFINERY Rev. : 0 OPERATING MANUAL Chapter : 1 UNIT ISOM (023) Page : 2 / 2 2. CATALYST UNLOADING AND HANDLING PROCEDURES 3. SPECIAL PROCEDURES CHAPTER 8 EMERGENCY SHUTDOWN PROCEDURES 1. INTRODUCTION 2. EMERGENCY FUNCTIONS PHILOSOPHY 3. PROCESS FAILURES 4. UTILITY FAILURES 5. MAJOR UPSETS CHAPTER 9 SAFETY EQUIPMENT AND PROCEDURES 1. PRESSURE SAFETY DEVICES 2. ALARM SETTINGS 3. TRIP SETTINGS 4. TRIP SYSTEM CHART 5. CAUSE AND EFFECT DIAGRAM 6. MATERIAL HAZARD DATA SHEETS 7. SAFEGUARDING MEMORANDUM CHAPTER 10 INSTRUMENT DATA 1. CONTROL VALVES AND INSTRUMENTS 2. ORIFICE PLATES CHAPTER 11 SUMMARY OF MAJOR EQUIPMENT 1. EQUIPMENT LIST 2. LARGE ROTATING EQUIPMENTS 3. HEATERS 4. OTHER VENDOR INFORMATION CHAPTER 12 ANALYSIS 1. INTRODUCTION 2. SAMPLING SCHEDULES / APPROVED TEST METHODS 3. ANALYTICAL METHODS 4. ON-LINE ANALYZERS CHAPTER 13 PROCESS CONTROL 1. DISTRIBUTED SYSTEM CONTROL (DCS) CHAPTER 14 DRAWINGS 1. PLOT PLAN AND HAZARDOUS CLASSIFICATION 2. PROCESS FLOW DIAGRAMS AND MATERIAL SELECTION DIAGRAMS 3. PIPING AND INSTRUENTATION DIAGRAMS 4. OTHER DRAWINGS VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM) March 2007 DUNG QUAT REFINERY Rev. : 0 OPERATING MANUAL Chapter : 1 UNIT ISOM (023) Page : 1 / 16 CHAPTER 1 BASIS OF DESIGN CONTENTS 1. DUTY OF THE PLANT 1.1 LICENSOR 1.2 FUNCTION OF THE UNIT 2. ENVIRONMENTAL CONDITIONS 2.1 AIR TEMPERATURE 2.2 RELATIVE HUMIDITY 2.3 RAINFALL 2.4 SNOWFALL 2.5 AIR BAROMETRIC PRESSURE 2.6 WIND 2.7 ATMOSPHERE 2.8 MISCELLANEOUS DATA 3. FEEDSTOCKS AND PRODUCTS SPECIFICATIONS 3.1 FEEDS CHARACTERISTICS 3.1.1 HYDROTREATED LIGHT NAPHTHA 3.1.2 MAKEUP GAS 3.2 PRODUCTS SPECIFICATIONS 3.2.1 ISOMERATE 3.2.2 NET GAS 4. OVERALL MATERIAL BALANCE OF THE UNIT 4.1 PROCESS INLET VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM) March 2007 DUNG QUAT REFINERY Rev. : 0 OPERATING MANUAL Chapter : 1 UNIT ISOM (023) Page : 2 / 16 4.2 PROCESS OUTLET 5. BATTERY LIMIT CONDITIONS 5.1 FEEDSTOCKS BATTERY LIMIT CONDITIONS 5.2 PRODUCTS BATTERY LIMIT CONDITIONS 5.3 UTILITIES BATTERY LIMIT CONDITIONS 6. DESIGN FEATURES 6.1 EQUIPMENT OUTSIDE LICENSOR SCOPE 6.2 MANDATORY SUPPLY 6.2.1 SULFUR ABSORPTION AND METHANATION CATALYSTS 6.2.2 ISOMERIZATION REACTOR CATALYST 6.2.3 MOLECULAR SIEVES 6.2.4 DRCS 7. GAS AND LIQUID EFFLUENTS VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM) March 2007 DUNG QUAT REFINERY Rev. : 0 OPERATING MANUAL Chapter : 1 UNIT ISOM (023) Page : 3 / 16 1. DUTY OF THE PLANT 1.1 LICENSOR The Penex / DIH Process (Unit 023) is based on the UOP (Universal Oil Products) process. The Licensor has issued the following documents: ♦ UOP Project Specification (Project 928504). ♦ UOP Penex Process Hydrogen Once Through: General Operating Manual. ♦ UOP Deisohexanizer: General Operating Manual. ♦ UOP Methanator Information (Additional section of the Penex Process Hydrogen Once Through General Operating Manual). 1.2 FUNCTION OF THE UNIT The function of the Penex / DIH Unit is to process straight run light naphtha from the overhead of the Naphtha Splitter column T-1202 (Unit 012) to produce a high octane isomerate naphtha product. The light straight run naphtha is derived from either 100% Bach Ho Crude or Mixed Crude (85% Bach Ho / 15% Arabian Light). The Penex unit is designed for a capacity of 231 613 metric tonnes per year (equivalent to 6500 BPSD). The UOP Penex Process is a continuous catalytic isomerization of pentanes, hexanes and mixtures thereof, based on an equilibrium reaction. The reactions take place in a hydrogen atmosphere, over a fixed bed of catalyst and at operating conditions, which promote isomerization and minimize hydrocracking. This product is a mixture of iso- paraffins with a high octane number. The process is simple and straightforward in design and operation and trouble-free in performance permitting a minimum of staffing and supervision. Operating conditions are not severe as reflected by moderate operating pressure, low temperature, high catalyst space velocity and low hydrogen partial pressure requirements. Except for normal hydrotreating, the PENEX Process requires neither special feed pretreatment nor especially sharp prefractionation for removal of C 6 cyclics or C 7 + . Penex affords the refiner considerable flexibility in the choice of feedstocks both at the time of design or after the unit is constructed. The major elements of the Penex / DIH Unit are the liquid feed and make-up gas driers, the methanator, the feed surge drum, the reactors and associated heater and exchangers, the product stabilizer, the net gas scrubber and the deisohexanizer. Although not essential to the success of the process, the Penex system will normally employ two reactors in a series flow configuration with the total required catalyst loading being equally distributed between the vessels. Valving and piping are provided which permit reversal of the processing positions of the vessels and the isolation of either for partial catalyst replacement. With time, the Penex catalyst will become deactivated by water, not hydrocarbon. Because the water deactivation proceeds as a sharp front, which moves down the bed in a piston-like fashion, catalyst downstream of the front remains unaffected. When catalyst in the lead reactor is spent, the reactor is taken off line for reloading. During the short period of time the reactor is out of service, the second reactor is capable of maintaining continuous operation at design throughput and yield; conversion is moderately lower. After catalyst reloading is completed, the processing positions of the two reactors may be reversed. The two reactor design permits essentially 100% unit onstream efficiency and reduces catalyst consumption costs by making partial catalyst replacements practical. It also permits the unit to be designed for a smaller catalyst inventory (higher space velocity) thus reducing catalyst capital requirements. Isomerization and benzene hydrogenation reactions are both exothermic and the temperature increases across the reactor. Equilibrium requires that the outlet temperature be as low as the activity of the catalyst VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM) March 2007 DUNG QUAT REFINERY Rev. : 0 OPERATING MANUAL Chapter : 1 UNIT ISOM (023) Page : 4 / 16 permits. With a single reactor, this would lead to a low inlet temperature and low isomerization rates in part of the catalyst bed. The two reactor system permits the imposition of an inverse temperature gradient by cooling between reactors through exchange against cold feed. The first reactor may, therefore, be operated at a higher temperature and achieve a higher reaction rate. This reduces the inventory of catalyst and the reactor size required. Most of the isomerization is thus accomplished at high rate in the first reactor and the final portion is performed at a lower temperature to take advantage of the more favorable equilibrium. Not all catalysts are suitable for application of the inverse temperature gradient principle. Some might coke or sludge if operated at a higher inlet temperature, or else they might promote excessive hydrocracking and yield loss. Since the Penex catalyst does neither of these, the inverse gradient can be applied to economic advantage. Chloride promoter (perchloroethylene) is added continuously with the feed and is converted to hydrogen chloride in the reactor. Since the catalyst functions with very small amounts of promoter (measured in parts per million), it is not necessary to provide separate equipment for recovery and re-use of hydrogen chloride. It is permitted to leave the unit by way of the stabilizer gas. The quantity of stabilizer gas is small, due to the selective nature of the catalyst, which permits very little hydrocracking of the pentane/hexane charge to take place. To protect the catalyst, the liquid feed is first charged to the feed dryers and then to the charge surge drum. Hydrogen make-up gas is sent to a methanator to remove trace levels of CO, CO 2 and H 2 S and then onto the make-up gas dryers prior to be mixed with the combined feed from the charge surge drum and sent to the reactors. The effluent from the reactor is charged to a stabilizer to remove the residual hydrogen from the reaction and the light gases (C 1 through C 4 ) introduced with the make-up gas and produced in the reactor as a result of cracking. The stabilizer gas is scrubbed for hydrogen chloride removal before entering the refinery fuel gas system (Unit 037). The catalyst itself is non-corrosive in the plant and, despite the presence of small amounts of hydrogen chloride during operation, the dryness of the system permits construction of carbon steel. Bottom stream from the stabilizer is sent to the deisohexanizer (DIH) column. The DIH primarily separates C 5 , 2,2-dimethylbutane and 2,3-dimethylbutane from the other C 6 isomers and heavier components of the isomerate. The benefit of the addition of a DIH column is to upgrade to a product with an octane value of 88.0 - 90.0 RONC. Compared to a maximum research octane number of approximately 84.0 RONC for a hydrocarbon once-through operation, this is a significant increase. More benefits from a DIH column are derived as the C 5 /C 6 ratio of the fresh charge decreases since the nC 5 is not recycled back to the reactor section for further isomerization. The DIH overhead product, composed primarily of C 5 's and dimethylbutanes, is sent to storage for gasoline blending. The bottoms, flow-controlled at a small rate, are also typically sent to storage with the DIH overhead product; however, the bottoms should be evaluated as potential reformer feedstock as well. The bottoms draw is necessary to avoid a build-up of heavies in the reactor section charge. The DIH side draw, composed primarily of methylpentanes, some dimethylbutanes and nC 6 , is recycled back on flow control to the isomerization unit upstream of the reactors. Hereafter are supplied the following documents:  Diagrams showing all process and utilities connections with other units  Overall block flow diagram of the Refinery VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM) March 2007 DUNG QUAT REFINERY Rev. : 0 OPERATING MANUAL Chapter : 1 UNIT ISOM (023) Page : 5 / 16 PENEX / DIH PROCESS (UNIT 023) Isomerate to TK-5106 A/B Net gas to FG (unit 037) Light naphtha from unit 012 Make-up gas from unit 012 Potable water Plant Air Instrument air Refinery Nitrogen Cold BFW Service water CW supply LP steam MP steam 20°Be Caustic from unit 039 Flare to unit 057 CW return LP condensate MP condensate Oily water PENEX / DIH PROCESS (UNIT 023) VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM) March 2007 DUNG QUAT REFINERY Rev. : 0 OPERATING MANUAL Chapter : 1 UNIT ISOM (023) Page : 6 / 16 2. ENVIRONMENTAL CONDITIONS 2.1 AIR TEMPERATURE a. Maximum recorded 41.4 °C b. Minimum recorded 12.4 °C c. Maximum monthly average 34.4 °C d. Minimum monthly average 18.9 °C e. Design maximum 36.0 °C f. Design minimum 16.0°C 2.2 RELATIVE HUMIDITY a. Maximum monthly average 89% b. Minimum monthly average 80% c. Average monthly humidity 85% d. Design maximum 100% e. Design minimum 40% 2.3 RAINFALL a. Maximum recorded annual 3052 mm b. Minimum recorded annual 1374 mm c. Average annual 2268 mm d. Maximum recorded in 24 hours 525 mm e. Maximum rainfall intensity 40 mm for 10 min period 60 mm for 30 min period 108.1mm for 60 min period 2.4 SNOWFALL Not applicable 2.5 AIR BAROMETRIC PRESSURE a. Maximum 1023.6 mbar b. Minimum 988.8 mbar c. Average 1009 mbar d. Design 1013 mbar 2.6 WIND a. Average velocity 3.2 m/s b. Maximum hourly velocity 42 m/s Direction % of time for each Quadrant No wind 43.8 N/NE 9.7/6.2 W/NW 4.1/14.3 E/SE 12.8/6.7 S/SW 1.1/1.0 The maximum velocity over a 2 minutes is 41.6 m/s for a return period of 50 years. The maximum velocity over a 2 minutes is 32.7 m/s for a return period of 20 years 2.7 ATMOSPHERE a. Extreme moisture - tropical climate b. Marine exposure - salt spray c. Sand storms - not applicable d. Copper-attacking fumes - sulphur [...]... (PETROVIETNAM) DUNG QUAT REFINERY OPERATING MANUAL UNIT ISOM (023) 5 March 2007 Rev :0 Chapter : 1 Page : 12 / 16 BATTERY LIMIT CONDITIONS The total refinery site is divided in blocks Every block contains one or more units The isomerization unit is situated together with NHT and CCR units (012 and 013) Because of this construction there are two types of battery limits: battery limits for units and battery limits... QUAT REFINERY OPERATING MANUAL UNIT ISOM (023) UTILITIES RETURN MP Condensate LP condensate Cooling Water Oily Water Flare OSBL OSBL OSBL OSBL OSBL 16.8 6.3 9.2 4.7 3.5 320 230 70 65 210 7.5 (3) 2 (3) 2.2 (3) 3.5 (3) 0.2 (1) Notes: (1) At grade – Units 012/ 013/ 023 Battery Limit elevation is 15 m (2) At grade – Units 012/ 013/ 023 Battery Limit elevation is 12 m (3) At grade – Units 012/ 013/ 023 Battery... GAS CORPORATION (PETROVIETNAM) DUNG QUAT REFINERY OPERATING MANUAL UNIT ISOM (023) March 2007 Rev :0 Chapter : 1 Page : 8 / 16 3 FEEDSTOCKS AND PRODUCTS SPECIFICATIONS 3.1 FEEDS CHARACTERISTICS 3.1.1 HYDROTREATED LIGHT NAPHTHA The Penex / DIH unit is designed to process straight run hydrotreated light naphtha, coming from Naphtha hydrotreating unit (Unit 012), derived from 100% Bach Ho or Mixed crude... CORPORATION (PETROVIETNAM) DUNG QUAT REFINERY OPERATING MANUAL UNIT ISOM (023) 3.1.2 March 2007 Rev :0 Chapter : 1 Page : 9 / 16 MAKEUP GAS Make-up gas for the Penex / DIH Unit is delivered from the 3rd stage discharge of the make-up gas multi-stage compressors C-1202A/B/C (Unit 012) at a pressure of 42.3 kg/cm2 (g) It is a product of CCR platforming unit (Unit 013) The composition of hydrogen is the following... Limit elevation is 12 m (3) At grade – Units 012/ 013/ 023 Battery Limit elevation is 9 m (4) At grade – Units 012/ 013/ 023 Battery Limit elevation is 6 m March 2007 Rev :0 Chapter : 1 Page : 13 / 16 170 133 47 36 38 VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM) DUNG QUAT REFINERY OPERATING MANUAL UNIT ISOM (023) 6 March 2007 Rev :0 Chapter : 1 Page : 14 / 16 DESIGN FEATURES 6.1 EQUIPMENT OUTSIDE LICENSOR... QUAT REFINERY OPERATING MANUAL UNIT ISOM (023) March 2007 Rev :0 Chapter : 2 Page :5 / 31 1.2 REACTION MECHANISMS Paraffin isomerization catalysts fall mainly into either of two principal categories: 1 Those based on Friedel-Crafts catalysts as classically typified by aluminum chloride/hydrogen chloride 2 Dual-function hydro -isomerization catalysts The catalyst used in this isomerization unit is of the... VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM) DUNG QUAT REFINERY OPERATING MANUAL UNIT ISOM (023) 7 March 2007 Rev :0 Chapter : 1 Page : 16 / 16 GAS AND LIQUID EFFLUENTS Refer to attached document: “Effluent Summary Table” – 8474L-200-NM-6200-002 VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM) DUNG QUAT REFINERY OPERATING MANUAL UNIT ISOM (023) CHAPTER 2 DESCRIPTION OF PROCESS CONTENTS 1 PROCESS... Hydrocracking to light gases is generally slight, so liquid product yields are high As stated before, it is this type of catalyst that is used in the Isomerization Unit 023 1.4 OTHER REACTIONS Apart from the paraffin isomerization reactions which were discussed in detail in the proceeding pages, there are several other important reactions including: 1 Naphthene ring opening 2 Naphthene isomerization 3... heavier boiling components, like cyclohexane and C7+ VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM) DUNG QUAT REFINERY OPERATING MANUAL UNIT ISOM (023) Figure 2.1.1 March 2007 Rev :0 Chapter : 2 Page :15 / 31 VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM) DUNG QUAT REFINERY OPERATING MANUAL UNIT ISOM (023) Figure 2.1.2 March 2007 Rev :0 Chapter : 2 Page :16 / 31 ... TEMPERATURE PRESSURE (1) TEMPERATURE Kg/cm2 (g) 16.0 (°C) 120 Kg/cm2 (g) 7.0 (°C) 38 Unit 012 48.0 160 42.3 38 PRODUCTS BATTERY LIMIT CONDITIONS DESTINATION Isomerate Net gas OPERATING CONDITIONS AT B/L Unit 012 Hydrotreated light naphtha Makeup gas 5.2 DESIGN CONDITIONS AT B/L U051 U037 (Fuel Gas) DESIGN CONDITIONS AT B/L OPERATING CONDITIONS AT B/L PRESSURE (1) TEMPERATURE PRESSURE (1) TEMPERATURE Kg/cm2