DHDS BLOCK OPERATIONS.pptx

1

Soumen Mondal

18th Jan’2012

DHDS BLOCK Operations

2 204/08/2023

In a Complex Refinery with Separation Process and Secondary Conversion Processes………………..

Igniting Minds... Energizing Lives…Haldia Refinery

HALDIA REFINERY -PRODUCTS

LPG (Propane/Butane)GASOLINE (hundreds of blends)JET FUELSDIESEL FUELSHEATING OILSLUBRICATING OILSASPHALTSCOKE (not the kind you drink )


HALDIA REFINERY PRODUCT RANGE


HALDIA REFINERY PRODUCT YIELDS PATTARNS

LPG4%

OTHERS12%

MS9%

FO/LSHS11%

NAPHTHA9%

HSD37%

ATF / SKO11%

FUEL & LOSS7%


HALDIA REFINERY - PRODUCT PRICE

Product price, Rs/MT Product price, Rs/MT

LPG 29294 FO 20900

SRN 29265 CBFS 19483

MS(BS-II) 33412 Bitumen 16300

ATF 34514SK 31650

HSD(BS-II) 32353LOBS(500N) 31551

Crude: 20300 - 27300

Product Test Specification

LPG Weathering (+) 2 deg C

Cu Corrosion 1a

Naphtha(HPL) Density 0.67 – 0.71

Distillation 35 – 160 deg C

Paraffins 75% by Vol.

MS(Euro-III) RON 91.0 Min.

Sulphur 150 ppm. Max.

Benzene 1% max.

Product Quality


MS(Euro-IV) RON 91.0 Min.

Sulphur 50 ppm. Max.

Benzene 1% max.

ATF Freezing Point (-) 47 Deg C

Smoke Point 19 mm

Aromatics content 22% Max.

SKO(PDS) Flash Point 35 Deg C

Smoke Point 18 mm

Product Quality


HSD(Euro-III) Cetane No. 51 Min.

Pour Point Summer 15 deg C

Recovery 95% Min. at 360 Deg C

Sulphur 350 ppm Max.

Flash Point 35 Deg C Min

HSD(Euro-IV) Cetane No. 51 Min.

Pour Point Summer 15 degC

Recovery 95% Min. at 360 Deg C

Sulphur 50 ppm Max.

Product Quality


FO Flash Point 66 Deg C Min.

Density 0.991 Max.

Total Sulphur 4% Max.

HLD – BN Viscosity Index 90 Min.

Pour Point (-) 3 Deg C Max.

H-500 Gr-II LOBS Viscosity Index 105 Min.

Pour Point (-) 15 Max.

Product Quality

Haldia Refinery – Block Flow DiagramC

rude

HSD (BS-II, Euro-III ,Export)

FO (2 GRADES)Bitumen(3GRADES)

CDU

1

CDU

2

Fuel GasLPG

SRN

Kero CutSt.Run G.O

JBO

RCO

ATU&ARUSweet Fuel Gas

SRU Sulphur

LPGNaphtha

NHDT&CRU MS(BS-II, Euro-III ,Export)

KHDS

MTORTF/ATF

Kerosene

DHDS

HGU-I

H2

JBO (2 GRADES)

VDU 1

VDU2

IFO

GOSO

LO / IO / HO

SR

PDA

DAO

FEUNMP

SDU HFU

FCCU

Extract

Slack Wax

LO

Asphalt

VBUBTU

CBFS

MCW MCW

CDWU

MSQ

FCC Gasoline

H2

H2

H2

Reformate

HC

N

Off Gas

H2

100N/150N/500N/850N/150BN GR-I

LOBS

DC

O

Ext

ract 70N/100N/150N/500N/

850N/150BN GR-II LOBSH2

Bitumen Emulsion Bitumen Emulsion

VB Tar

Raffinate

Raffinate DWO

OHCUOHCU Bottoms

HGU-II

H2

FGSulphur

LPG

LCN

Kero

HS

D

ATU&SRU

HC

N

HAL DIA REFINERY BLOCK FLOW DIAGRAM

12

LUBE OIL BLOCK:VDU-1 PDAFEU SDULHFU VBU

NMPEU WHFUCDWU

FUEL OIL BLOCK:CDU-1CDU-IICRU

KHDS

DHDS BLOCK:DHDS HGU IRFCCU VDU II

MSQU SRU I / IIARU SWS

ETP

CPP-ITPS &

UTILITIES

OHCU BLOCK:OHCU HGU- II

CPP-IIGT-II/III

Haldia Refinery – At a glance


HALDIA REFINERY OPERATIONAL BLOCKS

FUEL OIL BLOCK

DHDS BLOCK

LUBE OIL BLOCK

OHCU BLOCK

OIL MOVEMENT & STORAGE


DHDS BLOCKHYDROGEN GENERATION UNIT( U-24)

DIESEL HYDRO DESULPHURISATION UNIT (U-25)

RFCCU(U-17,18,19)

VACUUM DISTILLATION UNIT(U-82)

MSQ UPGRADATION UNIT (U-85,86 & 87)

SULPHUR RECOVERY UNIT(U-28,83,95)

AMINE REGENARATION UNIT(U-26& 93)

SOUR WATER STRIPPER UNIT(U-29& 94)

PDS FDS

Reformer

Pre Reformer

M TShiftPSA

Naphtha

Steam

Pure H2 to DHDS

S = 1000 ppmS = 1000 ppm S = 5 ppmS = 5 ppm

S = 50 ppbS = 50 ppb

H2 = 99.5%H2 = 99.5%

HYDROGEN GENERATION UNITHYDROGEN GENERATION UNITDHDS BLOCK - HGU FLOWSHEET

DHDS -HYDROTREATMENT:GENERAL FLOWSHEET

Feed

M/U H2

M/U Compressor

Reactor feed heater

Reactor(s)

Hot separator

Cold separator

Amine Wash

Purge

Hydrotreated Product to Distillation

Quench

Recycle Gas Recycle

Compressor

DHDS-PFD

DHDS BLOCK -DHDS UNIT

DHDS PROCESS DESCRIPTION - Haldia• Unit Capacity = 1.2 MMTPA (Haldia)

• Design Feed S content = 1.79 (Wt %)• Design Product S content = 0.05

(Wt %)• Reaction Pressure 39.5 Kg/Cm2

(g)• Reaction Temperature 363/377

°C• Feed Rate = 188.7 M3/Hr• H2 Makeup rate = 1221/1329

Kg/Hr

DHDS BLOCK- DHDS UNIT


DHDS BLOCK- DHDS UNIT

HydrodesulfurizationRemove sulfur compoundsSulphur is present mainly as Thiophenes, Benzothiophenes and Dibenzothiophenes Minimum conversion of feed to lighter products10% to 20% conversion

Sulfur is converted to hydrogen sulfide (H2S)Added hydrogen breaks carbon-sulfur bonds &

saturates remaining hydrocarbon chainsCreates some light ends

C‑C‑C‑C‑SH + H2 C‑C‑C‑C + H2S

(Mercaptan)

C‑C‑S‑C‑C + 2 H2 2 C‑C + H2S

(Sulphide)

C‑C‑S-S‑C‑C + 3 H2 2 C‑C + 2 H2S

(Disulphide)

(Cyclic Sulphide)

(Thiophenic Sulphur)

DHDS BLOCK –DHDS REACTIONS

• De-nitro genation is generally more difficult than desulphurization.

• Nitrogen compounds more difficult to hydrogenate than the original reactants.

(Pyridine) Other reactions are:• Olefin Saturation• Aromatic Saturation• Oxygen removal

DHDS BLOCK –DHDS REACTIONS

DHDS BLOCK - AMINE REGENERATION UNIT

26V01

26E01

26AC05

26E02

RICH AMINE FROMCDWU,DHDS

26E03

CONDENSATE

26AC06

26E04

26V02

26P01A/B 26P02A/B

26P03A/B

TO FLARE

26C01

MP STEAMTO SRU

LEAN AMINE

TO FLARE

PFD OF U26(AMINE REGENERATION UNIT)

LEAN AMINEFROM E01

CONDENSATE

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15 1617

26FS 01/02/03

18

DHDS BLOCK - SWS UNIT

28E01

28E02

28K01 A/BAir blower

28E06

Air to super Claus

28E03

28E1028E11 28E12

28R03

28R0228R01

28E04 28E05

28E14WHB

Stac

k

28E15

28K02 A/BIncinerator air blower

28V04Process gas coalescer

28V01Acid Gas

Air

Air

28E13Process gas reheator

28R04Super Claus reactor

Drain

28F01&F02 MCC

Sulphur condenser

Process gas reheatorProcess gas reheator

Process gas reheator

Sulphur condenser Sulphur condenser Sulphur condenser

28F03&04Incinerator

28R01, 28R02 & 28R03: Claus reactors

SulphurTo pit Sulphur to pit

Sulphur to pit

Sulphur to pitSulphur to pit Sulphur

to pit

Fuel gas to unit

Static mixer

Fuel gas

H2S + O2 SO2 + H2S + H2O H2S + SO2 S2 + H2O

DHDS BLOCK –SRU FLOWSHEET

DHDS BLOCK –SRU REACTIONS

Claus Reactions• The main reaction (PARTIAL OXIDATION) in the main burner is :

H2S + 3 O2 ------> SO2 + H2O + heat 2 • The major part of the residual H2S combines with the SO2 to form

sulphur, according to the equilibrium reaction :

2H2S + SO2 < -------> 3 S2 + 2H2O - heat 2• By this reaction , known as the Claus reaction, sulphur is formed in

vapour phase in the main burner and combustion chamber.

• In the SUPERCLAUSR stage the remaining H2S is selectively oxidised to sulphur,

• It is essential that the combustion in the main burner is such that the downstream of the third reactor stage the amount of H2S is in the range of 0.5 – 0.7 vol.% and that the SO2 concentration is as low as possible.

• Before it enters the reactor a controlled amount of air is added. Proper mixing is obtained in a static mixer, in the reactor H2S reacts with oxygen to sulphur according to the reaction:

2H2S + O2 2 S8 + 2H2O + heat

8

DHDS BLOCK –SRU REACTIONS

Typical FCC/RFCC Unit

DHDS BLOCK -FCCU

•To produce High RON gasoline.

•To produce LPG.•To produce Petro chemical feed stock.

•Key process dictating refinery product pattern.

DHDS BLOCK - Role of FCC/RFCC

UNIT CAPACITY LICENSOR

R.F.C.C.WITH AMINE TREATER

0.700 MMTPA M/S SWEC , USA

LPG TREATER 0.130 MMTPA M/S MERICHEMUSA

GASOLINE TREATER

0.200 MMTPA M/S MERICHEMUSA

FLUE GAS SCRUBBER

119.5 MT/Hr M/S BELCOUSA

DHDS BLOCK – RFCCU (INSIDE)

Feed Section Reactor / Regeneration section (R-

R) Main Fractionation Section Gas separation section

DHDS BLOCK –FCCU SECTIONS

Typical FCC Feed Blend

WT % KVSO 2.1 2.5LO 20.0 5.5 - 6.5IO 44.8 12.15HO 2.6 22 - 27DAO 6.2 40 - 45SR 11.0SL WAX 6.8EXTRACT 2.1RCO 5.0

AVERAGE FOR THE YEAR 2008 - 2009

FEED PROPERTIESTYPE OF FEED / FEED COMPOSITION

DHDS BLOCK – RFCCU FEED

DHDS BLOCK – RFCCU

ATTRIBUTE RFCC VGO ACTUAL

1 Feed Preheat Temp°C 188 338 195-215

2 Riser Outlet Temp°C 510 488 510

3 Reactor Outlet Temp°C 510(MAX 552)

488(MAX 552)

510

4 1st Stage Regenerator Temp°C

659(Max.746)

613(Max.746)

658

5 2nd Stage Regenerator Temp°C

730(Max.802)

677(Max.802)

747

6 Cat/Oil ratio 6.87 5.48 6.5

7 1st Regen combustion, % 67 67

8 CO/CO2 ratio in 1st stage regenerator

0.36 0.49 0.52

DHDS BLOCK – RFCCU OPERATING PARAMETERS

FEED RATE,m3/hr 93.2 105PRODUCT,WT%ACID GAS 1.20

1.00/0.85DRY GAS 3.00

3.1/3.1LPG 12.50 14.5/18.7LCN 18.6

31.0/34.1TCO (INCL HCN) 46.45

35.0/29.3DCO 10.82

10.2/9.5COKE 7.43

5.2/ 4.55

DESIGN (RFCC) ACTUAL

DHDS BLOCK – RFCCU PRODUCT YIELD


SWEC R-R Design




Cyclones



Cracking Reactions



FUNCTION OF CATALYST HYDROTHERMAL STABILITY HIGH OCTANE REQUIREMENT METAL RESISTANCE BOTTOM CONVERTION CHARACTERISTICS COKE BURNING ABILITY DESULFURISATION ABILITY FLUIDISATION CHARACTERISTICS HIGHER RESISTANCE

DHDS BLOCK – RFCCU CATALYST


CHAIN STRUCTURES

Paraffin

HH HH

H H H H

RR

HHH H H H

RING STRUCTURES

H H H H

Olefin

H HH

RR

HHH H H

Naphthene

H

HH

HR

HH H

H H

H H

R

H H

HH H H

H

Alkylaromatic

H

HH

HH

H H H H

RR

H H

H

Hydrocarbon Types

FCC Reactions – An overview

Crackability (Conversion): Paraffinic > Naphthenic > Aromatic


DHDS BLOCK – RFCCU REACTIONS







Belco

Spray TowerAbsorber Section

Stack Emissions: SOx removal < / = 219 kg/hr (based on 2.5 kg/ton of feed for 0.7 MMTPA) Particulate outlet </= 50 mg/Nm3-dry

DHDS BLOCK – BELCO

FLUE GAS SCRUBBING UNITOBJECTIVE : TO REDUCE SO2 EMISSION TO REDUCE PARTICULATE EMISSIONCHEMISTRY:

• SO2+H2O-> H2SO3• H2SO3 + 2NaOH Na2SO3 + 2H2O• SO3+H2O-> H2SO4• H2SO4 + 2NaOH Na2SO4 + 2H2O• H2SO3 + NaOH NaHSO3 + H2O• NaOH + CO2 -> NaHCO3• 2NaOH + CO2--- Na2CO3+ H2O

DHDS BLOCK -Mericam UnitDHDS BLOCK – BELCO

FCC GASOFLINE TREATING UNIT• OBJECTIVE : IMPURITIES TO BE REMOVED * MERCAPTAN * H2S• CHEMISTRY2H2S + 4 NaOH -----.> 2Na2S + 4H 2O2Na2S + 2O2 + H2O+*---Na2S2O3 +2NaOH2H2S + 2O2 + 2NaOH +*----Na2S2O3 +3H2O2RSH + 2NaOH ---- 2NaSR + 2H2O2NaSR + ½ O2 +H2O+*--- RSSR(DSO) + 2NaOH2RSH + ½ O2+*----- RSSR +H2OROH +NaOH ---- RONa + H2OCO2 + 2NaOH ----- Na2CO3 + H2O• *CAT : Cobalt Phthalocynine• ARI – 100L or ARI –100EXL

DHDS BLOCK – MERICAM/MERICAT


Vacuum

Distillation

Column

Ejectors

Spindle Oil

Light Oil

Inter Oil

Heavy Oil

Vacuum residue

RCO Feed

Vacuum Distillation Unit – Flow sheetDHDS BLOCK – VDU-II FLOW SHEET


DHDS BLOCK-VDU-II OBJECTIVESFuel based VDU– Prepares

feedstock to FCC, Hydrocracker

Products– Diesel– Light Vacuum

Gas Oil (LVGO)– Heavy Vacuum

Gas Oil (HVGO)– Slop Distillate– Vacuum Residue

Lube based VDU– Prepares

feedstock to Lube plant

Products– Spindle oil

– Light Neutral

– Intermediate

Neutral

– Heavy Neutral

– Slop

– Vacuum Residue


TOP PRESSURE - 20 To 60 mmHg

BOTTOM PRESSURE - 30 To 90 mmHg

COT - 395-405 Deg C

TOP TEMPERATURE - 55-60 Deg C

DHDS BLOCK-VDU-II OBJECTIVES


NHDT unit (385TMT/yr):

ISOM unit (122TMT/yr) :

Prime G+ (200TMT/yr)

Reformate Splitter (184TMT/yr)

DHDS BLOCK-MSQ UNITS


DHDS BLOCK-MSQ UNIT OBJECTIVESQUALITY EURO III EURO IV

BS-II

SULPHUR (ppmw) max 150 50 500

RON min 91 92 88

BENZENE,(vol.%), max 1 1 3

AROMATICS (vol. %) max 42 42 NO SPEC

OLEFINS (vol. %) max 21 18 NO SPEC


DHDS U-85 FLOW DIAGRAM


DHDS BLOCK- ISOM FLOW SHEET


The reactions are carried out in three steps

1st step : Sulfur removal (HR 448) {in NHDT}

2nd step : Hydrogenation of benzene (LD 412).

3rd step : Isomerization of normal paraffins (IS 614 A).

DHDS BLOCK-ISOM REACTION STEPS


DHDS BLOCK-ISOM REACTIONS


Tetra chloroethylene (C2Cl4) is the chloriding agent for fresh catalyst

C2Cl4 is fully converted to HCl at reactor normal operating conditions.

HCl reacts with the -OH groups at the catalyst surface to form -Cl groups and establish the catalyst acidity.

DHDS BLOCK-ISOM CHEMICAL INJECTION


DHDS BLOCK-PRIMEG FLOW DIAGRAM


DHDS BLOCK –FCC GASOLINE TREATMENT

High sulfur content in LCN can be due to a higher ‘S’ / mercaptans content in feed

More light RSH in feed contributes more RSH/’S’ in LCN (@ const. conversion)

Measure the S & RSH content in the feed. Conduct ‘S’ species analysis (if possible)

Reduce LCN cut point (decrease the heavy RSH & thiophene content present in feed)


DHDS BLOCK –FCC GASOLINE PROPERTIES


SHU Reactor sectionIn the reactor section, main regulations

are :Inlet T of the reactor : this temperature is regulated steam flow rate to feed preheater

Temperature Light mercaptan conversion Hydrogenation

Hydrogenation selectivity

(diolefin / olefin) Polymerization of gum

precursors



Change Result Effect

Increase LCN cut pointLCN sulfur

Olefins in untreated HCN

Decrease LCN cut point

LCN sulfur Olefins in untreated HCN

LCN/Feed Draw Rate (at constant Reflux/Feed Ratio)


77 7704/08/2023

Thank you

Documents

DHDS BLOCK OPERATIONS.pptx