RESIDUE FLUIDISED CATALYTIC CRACKER DUTY SPECIFICATION

INTRODUCTION The objective of the Residue Fluidised Catalytic Cracker RFCC is to process hydrotreated atmospheric residue from the Residue Hydro-desulphuriser Unit RHDS to produce propy

RESIDUE FLUIDISED

CATALYTIC CRACKER

DUTY SPECIFICATION

A

FOSTER WHEELER ENERGY LTD PROCESS DOCUMENT PROCESS ENGINEERING

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3.7.21 Flare Loads and Flare Design 21

3.7.22 Additional Operational Requirements 21

3.8 Utilities 25

3.9 Other Raw Material Requirements 25

4 BATTERY LIMIT CONDITIONS 26

5 SYSTEM SKETCH 28

6 PROCESS GUARANTEES 29

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1 INTRODUCTION

The objective of the Residue Fluidised Catalytic Cracker (RFCC) is to process hydrotreated atmospheric residue from the Residue Hydro-desulphuriser Unit (RHDS) to produce propylene as feedstock for the Polypropylene Unit (PPU), light

& heavy FCC gasoline for the gasoline pool, propane, mixed Butane as feedstock for the Indirect Alkylation Unit (InAlk), light cycle oil as feedstock for the Gas Oil Desulphurization Unit (GOHDS), and clarified oil

The unit is also required to process 400-4000 kg/hr of returned purge gas from the Polypropylene Unit for recovery

The Unit will be designed to operate in maximum propylene and maximum gasoline modes

While operating in maximum propylene mode the production of propylene shall be approximately 48000 kg/hr (net from the RFCC, excluding PPU purge gas processing) This is intended to match the maximum capacity of a single train Polypropylene Unit

The RFCC unit will comprise the following unit operations:

• RFCC (including the reactor ,catalyst regeneration, catalyst storage &

handling, main fractionator, strippers, slurry filters, flue gas section

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• Gas concentration section (GCU) ( including the wet gas compressor, stripper, debutanizer, naphtha splitter, primary & secondary absorbers, fuel gas and amine treater)

• Steam generation facility including BFW treatment

The RFCC Unit is designed to process feedstocks from the Residue Hydrodesulphuriser (RHDS), and a propylene rich purge stream from the Polypropylene Unit, to produce maximum yields of propylene for the downstream petrochemical complex and Naphtha for the Gasoline pool

The Unit produces the following product streams:

• An amine treated LPG stream This LPG stream will be caustic treated (by others) to remove Mercaptans The mercaptan free LPG will be routed back to the RFCC C3/C4 splitter

• After mercaptan removal by others, the LPG stream will be split to produce

a propylene stream to the Polypropylene Unit, a mixed butane stream to Indirect Alkylation Unit , and a propane stream to the LPG pool

• Light FCC Gasoline (LFG) to the gasoline pool via caustic treating

• Heavy FCC Gasoline (HFG) to the gasoline pool

• Light cycle oil (LCO) product to the Gas Oil Hydrodesulphurisation Unit and/or fuel oil

• Clarified Oil (CLO) product to refinery fuel oil

The unit also produces the following by-products:

• Treated off gas to fuel gas

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• Sour water to sour water treatment

• Flue gas to atmosphere via stack The unit will be required to process a recycle Propane rich purge stream from the PPU

The RFCC shall be designed to process 80,000 BPSD of hydrotreated atmospheric residue as defined under section 3.4

In addition purge gas (400-4000 kg/hr) from the Aromatics Complex &

Polypropylene Units respectively will be processed

The unit will be designed with the flexibility to operate in both maximum propylene and maximum gasoline modes at the 80,000 BPSD capacity

Material balances and yields shall be developed for both design cases

The unit shall be designed to process desulphurised atmospheric residue from the RHDS The design capacity is provided in section 3.2 & the properties of the feedstock are given in Section 3.4 below

In addition to the design case, the following capability cases shall be included

Processing of full range naphtha from the RHDS, KHDS & GOHDS in the GCU section during the CDU shutdown and the overall refinery operation at a lower capacity

Processing of feed from RHDS & storage tanks with modified feed qualities during contingencies such as catalyst changeovers

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Hydrodesulphurised Atmospheric Residue From RHDS Unit

Feed Unit Design

Value

Test Method

Aniline Point oC 99 ASTM D-611

TAN mgKOH/g Nil

.Note: During the tankage switchover sulphur level of 0.42 Wt % and total metals of 17

ppmw expected for a short duration

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Monomer Purge Gas From the Polypropylene Unit:

Component Unit Design Value

Hydrogen Mole % 8.26 Ethane Mole % 0.93 Propylene Mole % 75.06 Propane Mole % 15.75 Total 100.0

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Intermediate, LPG from caustic treatment

Specific Gravity gm/cc Report ASTM D-1657/ASTM D-2598

Copper strip corrosion (1hr @38oC) 1 max ASTM D-1838

Water at operating conditions No free entrained

Note: Relevant properties of LPG from caustic treatment to be confirmed by the licensor of

the Caustic treatment Unit

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For the design feedstocks and flow rate, the RFCC shall meet the following product

specifications

Intermediate, LPG to caustic treatment

Specific Gravity gm/cc Report ASTM D-1657/ASTM D-2598

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Propylene Component/property Unit Specification Test Method

Specific Gravity gm/cc Report ASTM D-1657/

ASTM D-2598

Composition

Water mol ppm 2 max

Nitrogen mol ppm Report

Oxygen mol ppm 5 max ASTM D-2233

Hydrogen mol ppm 5 max ASTM D-2504

Methane mol ppm 100 max ASTM D-2712

Ethane mol ppm 200 max ASTM D-2712

Ethylene mol ppm 100 max ASTM D-2712

Propylene mol % 99.6 Min ASTM D-2712

Propane+ Cyclopropane mol % 0.4 max ASTM D-2712

Butane and butenes mol ppm 10 max ASTM D-2712

1,3-Butadiene mol ppm 5 max (1) ASTM D-2712

Saturated C5 mol ppm Report ASTM D-2712

Green Oils (C6-C12) mol ppm Report

Sulphur Dioxide mol ppm Report

Carbon Monoxide mol ppm 0.1 max ASTM D-3416

Carbon Dioxide mol ppm 4 max ASTM D-3416

Hydrogen Sulphide Ppm w Report ASTM D-2420

Acetylene mol ppm 5 max (1) ASTM D-2505

Methyl Acetylene mol ppm 5 max (1) ASTM D-2712

Propadiene mol ppm 5 max (1) ASTM D-2712

Total S Ppmw 1 max as H2S ASTM D-3246

Total Mercaptans S Ppmw Report ASTM D-3227

COS (Carbonyl Sulphide) mol ppm 0.05 max

CS2, Ppmw Report

Arsine (ArH3) Ppmw 0.03 max ASTM E-819

Phosphine Ppbw Report

NH3 Ppmw Report

Oxygenated organic compounds mol ppm 5 max ASTM D-4864

Copper strip corrosion (1hr @ 38oC) 1 max ASTM D-1838

Polymerisation test Good

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Propane Composition/Property Unit Specification Test Method

Specific Gravity gm/cc Report ASTM D-1657/

n-Butane wt% Report(1) ASTM D-2163

iso-Butane wt% Report(1) ASTM D-2163

1-Butene wt% Report(1) ASTM D-2163

t-2-Butene wt% Report(1) ASTM D-2163

c-2-Butene wt% Report(1) ASTM D-2163

iso-Butene wt% Report(1) ASTM D-2163

1,2-Butadiene wt% Report(1) ASTM D-2163

1,3-Butadiene wt% Report(1) ASTM D-2163

C5+ wt% Report(1) ASTM D-2163

Sulphur Dioxide ppmw Report

Carbon Monoxide ppmw Report ASTM D-3416

Carbon Dioxide ppmw Report ASTM D-3416

Hydrogen Sulphide ppmw Nil ASTM D-2420

Methyl Acetylene ppmw Report

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Methane wt% Report ASTM D-2163 Ethane wt% Report ASTM D-2163 Ethylene wt% Report ASTM D-2163 Propane wt% Report (2) ASTM D-2163

Propylene wt% Report (2) ASTM D-2163

n-Butane wt% Report ASTM D-2163

iso-Butane wt% Report ASTM D-2163

1-Butene wt% Report ASTM D-2163

t-2-Butene wt% Report ASTM D-2163

c-2-Butene wt% Report ASTM D-2163

iso-Butene wt% Report ASTM D-2163

Butadienes wt% 0.6 max ASTM D-2163

Carbon Monoxide+ Carbon Ppmw < 1 ASTM D-3416

Hydrogen Sulphide Ppmw < 1.0 (1) ASTM D-2420

Methyl Acetylene Ppmw Report

1.) To be ensured by Licensor of LPG sweetening unit

2.) Propane & propylene content to be less than 0.15

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Light FCC Gasoline (LFG) Parameters Unit Specification (1) Test method

Cut range oC C5 -90oC (3)

Specific gravity gm/cc Report ASTM D-1298

Total Sulphur content Ppmw <15 ASTM D-2622/ASTM D-5453

H2S Ppmw Report

Mercaptans Sulphur Ppmw <8 ASTM D-3227

Methanethiol Ppmw Report ASTM D-3227

Ethanethiol Ppmw Report ASTM D-3227

Propanethiol Ppmw Report ASTM D-3227

Butanethiol Ppmw Report ASTM D-3227

CS2 Ppmw Report ASTM D-3227

Thiophenes Ppmw <10 ASTM D-3227

RON 96.0/94.8 (4) ASTM D-2699/ASTM D-2700

MON 80.5/80.1 (4) ASTM D-2699/ASTM D-2700

Benzene wt% Report ASTM D-3606/ASTM D-5580

RVP @ 38ºC kPa Report (2) ASTM D4953/ASTM D 5191

Copper Corrosion (3hrs @ Report ASTM D-130

Oxidation stability Minutes Report (3) ASTM D-525

Aromatics vol% Report ASTM D-6293

Olefins vol% Report ASTM D-6293

Existent gum mg/100ml Report ASTM D-381

1.) Licensor to provide full component breakdown which is to include definition of olefins,

naphthenes, aromatics, paraffins and distribution of sulphur compounds Octane curve to be

included

2.) Light cracked gasoline will be routed directly to tankage via treating RVP to be low enough to

enable this

3.) Alternate gasoline splitter cut point 70 OC

4.) Max propylene/max gasoline cases

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Heavy FCC Gasoline (HFG) Parameters Unit Specification (1) Test method

Cut range oC 90 – 210oC

Specific gravity Gm/cc Report ASTM D-1298

Total Sulphur content Ppmw <114 ASTM D-2622)/ASTM D-5453

H2S Ppmw Report

Mercaptans Sulphur ppmw Report ASTM D-3227

Methanethiol ppmw Report ASTM D-3227

Ethanethiol ppmw Report ASTM D-3227

Propanethiol ppmw Report ASTM D-3227

Butanethiol ppmw Report ASTM D-3227

CS2 ppmw Report ASTM D-3227 Thiophenes ppmw Report ASTM D-3227

RON 95.7/91.6 (3) ASTM D-2699/ASTM D-2700

MON 83.5/80.6 (3) ASTM D-2699/ASTM D-2700

Benzene wt% Report ASTM D-3606/ASTM D-5580

RVP @ 38ºC kPa Report ASTM D4953/ASTM D 5191

Copper Corrosion (3hrs @ 1 max ASTM D-130

Oxidation stability minutes 480 min ASTM D-525

Paraffins Report ASTM D-6293 Aromatics vol% Report ASTM D-6293

Light naphthenes Report ASTM D-6293

Heavy naphthenes Report ASTM D-6293

Olefins vol% Report ASTM D-6293

Existent gum mg/100ml 4 max ASTM D-381

1.) Licensor to provide full component breakdown which is to include definition of olefins,

naphthenes, aromatics, and paraffins and distribution of sulphur compounds Octane curve to

be included

2.) Alternative gasoline splitter cut points 70-210 oC

3.) Max propylene/max gasoline cases

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Light Cycle Oil (LCO)

Specific gravity Gm/cc Report ASTM D-1298/ASTM D-4052

API Report ASTM D-1298/ASTM D-4052

Sulphur Wt % <0.9 ASTM D-2622/ASTM D-5453

Nitrogen Ppmw Report ASTM D-5762

Silicon Ppmw Report ASTM D-5185

Cetane Index >22 ASTM D-976

Cetane number Report ASTM D-613

Flash point oC >90 ASTM D-3828/ASTM D-93

Kinetic Viscosity (@ 40oC) cP Report ASTM D-445

CCR (on 10% distillation residue) wt % Report ASTM D-189/ASTM D-4530

Pour point oC Report ASTM D-97

Ash wt % Report ASTM D-482

Water mg/kg Report ASTM E-203

Sediment mg/l Report ASTM D-2276 Copper strip corrosion (3hrs @ 50oC) Report ASTM D-130

Lubricity μm Report ASTM D-6079

Total Aromatics Wt % Report

Mono Aromatics Wt % Report

Di Aromatics Wt % Report

Poly aromatic Wt % Report ASTM D-1319/ASTM D-6379

Colour Report ASTM D-1500 Existent gum mg/100ml Report ASTM D-381

Oxidation stability mg/100ml Report ASTM D-2274

Appearance Report ASTM D-4176 ASTM Distillation (Vol%)

IBP ºC Report ASTM D-86

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Clarified Oil (CLO)

Properties Unit Value Test Method

Specific gravity gm/cc Report ASTM D-1298/ASTM D-4052

API Report ASTM D-1298/ASTM D-4052

Kinematic viscosity @ 50oC cSt Report ASTM D-445

@ 100oC Report

Catalyst fines mg/l < 50

Sulphur Wt % 1.0 max

Pour Point ºC Report

Flash Point ºC Report

Vanadium + Sodium Ppm w Report

Heat of combustion Kcal/kg report

NOx mg/Nm³ 450 max SOx mg/Nm³ 500 max

1.) Specifications are point source limits Lower values are required to meet the ground level concentration requirements

Licensor to provide the flue gas composition, including hydrocarbon breakdown, between each unit operation in the flue gas treatment system

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REV D2 Licensor to also provide solids loading and particle size distribution at the outlet of each unit operation in the flue gas clean up system (DeNOx, DeSOx, Economizer and Reheat)

Licensor to advise acid gas dew point of flue gas to atmosphere

Off gas to Fuel Gas Properties Unit

Molecular weight kg/kmol Report

Oxygen and other

contaminants (including COS

The FCCU shall be designed for minimum on-stream factor of 0.95 This is based

on 8320 hours operation per calendar year On stream factor is defined as follows:

On stream Factor = (1) (1) + (2) (1) = total duration of productive operation (2) = total duration for repairs and maintenance including turnaround, catalyst change-out and typical trip outage

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REV D2 3.7.2 Turndown

The unit shall be designed to operate satisfactorily in the range 50% to 100% of design feed rate for the feed defined in section 3.4 while meeting all product specifications

Licensor to provide detailed schematic of the proposed reactor/regenerator system including the following details:

1 Reactor/regenerator dimensions

2 Number of cyclones

3 Riser dimensions

4 Feed injection details

5 Slide valve arrangement/location Licensor to provide details of the following operating conditions including:-

1 Cat/Oil ratio

2 Reactor/regenerator temperatures and pressures

3 Catalyst make-up/withdrawal rates and inventory

4 Equilibrium catalyst requirement at start-up

5 Regenerator and purge air requirements

6 Metals level on catalyst

7 Catalyst MAT

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3.7.5 Optimum Reactor Operating Pressure & validation of Coke yields

RFCC licensor to design for operation with a minimum reactor pressure

3.7.6 Cut Point Flexibility for the Main Fractionator

,Licensor shall provide the following cut point flexibility

Flexibility range oC LFG/HFG 70-90oC

HFG/LCO 190-210oC LCO/CLO 360-380oC The LFG/HFG & HFG/LCO cut point flexibility provides a means to control total sulphur levels in full range cracked gasoline and to control the sulphur compounds

in light cracked gasoline (mercaptans/thiophenes)

LCO/CO cut point flexibility is provided to achieve a CLO viscosity of < 40 cSt @

100 °C from the main fractionator column

3.7.7 Facility for steam generation

The facility for the steam generation in the RFCC unit shall include deaeration &

chemical treatment of the feed demineralised water

3.7.8 C3 Splitter and De-Ethaniser

Licensor to include the C3 splitter in the RFCC scope Licensor is advised that the

C3 splitter or the de-ethaniser will include a recycle C3 purge stream from the PP unit, capacity to be confirmed prior to final design

Licensor shall base the inclusion of energy integration processes against a