RFCC LIGHT GASOLINE TREATER UNIT

RFCC LIGHT GASOLINE TREATER UNIT DUTY SPECIFICATION A FOSTER WHEELER ENERGY LTD PROCESS DOCUMENT PROCESS ENGINEERING 3550-8110-PD-025-0001 PAGE 4 OF 12 REV D2 The Unit shall be desig

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RFCC LIGHT GASOLINE

TREATER UNIT

DUTY SPECIFICATION

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FOSTER WHEELER ENERGY LTD PROCESS DOCUMENT PROCESS ENGINEERING

3550-8110-PD-025-0001 PAGE 2 OF 12 REV D2

4.7.17 Process Control, Safety and Shutdown Systems 10

4.7.18 Purging, Flushing and Blanketing Requirements 10

4.8 Utilities 10

4.8.1 Make-up Water 10

4.8.2 Process Air 11

4.8.3 Fuel Gas 11

4.8.4 Other Requirements 11

5 BATTERY LIMIT CONDITIONS 11

6 PROCESS GUARANTEES 11

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3550-8110-PD-025-0001 PAGE 3 OF 12 REV D2

1 INTRODUCTION

1.1 Unit Processing Objectives

The primary objective of the Residue Fluidised Catalytic Cracker (RFCC) Light Gasoline Treater Unit is to reduce the Mercaptan and total sulphur content and remove H2S from the light gasoline obtained from the RFCC

The product will meet the quality requirement to produce treated light gasoline with

a maximum total sulphur specification of 35 ppmw (for feed containing 55 ppmw RSH-S) and 25 ppmw (for feed containing 15 ppmw RSH-S)

1.2 Use of Document

This document shall be used as the design basis for the process design of the RFCC Light Gasoline Treater Unit only

The design requirements specified in this document are considered to be the minimum required Where the Licensor has more onerous requirements than those specified in this document, these shall be notified to Employer prior to implementation

The RFCC Light Gasoline Treater Unit shall be capable of operating as an independent block subject to the availability of:

• Feed stocks

• Utilities and Process Chemicals

The Unit draws the RFCC light gasoline directly from the RFCC Unit

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3550-8110-PD-025-0001 PAGE 4 OF 12 REV D2

The Unit shall be designed to process RFCC light gasoline from the RFCC Light Gasoline Splitter The Unit shall process the feed to produce treated light gasoline with a maximum total sulphur specification of 35 ppmw (for feed containing 55 ppmw RSH-S) and 25 ppmw (for feed containing 15 ppmw RSH-S) The caustic shall be regenerated in RFCC LPG Treater Unit caustic treatment section and regenerated caustic shall be recycled back to the extraction section The RFCC Gasoline Splitter is outside of the Licensor scope

The design capacity of the RFCC Light Gasoline Treater Unit shall be 24,000 BPSD of light gasoline from the RFCC Unit

The Unit shall be design to meet a turndown of 40% of product design capacity whilst meeting all product specification requirements

Licensor is requested to provide a qualitative analysis regarding the flexibility of the proposed configuration in terms of changes in feedstock

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3550-8110-PD-025-0001 PAGE 5 OF 12 REV D2

4.3 Design Feed Cases

The Unit shall be designed for the design feedstock defined in Section 4.4

Material balance shall be provided for design case

4.4 Design Feedstock Properties

4.4.1 RFCC Light Gasoline Treater Unit feed

The RFCC Light Gasoline Treater Unit feed has the following properties

Total Mercaptan Sulphur

C1-SH

C2-SH

C3-SH

C4-SH

Nil

27 max

21 max

7 max

15 max Nil

7 max

6 max

2 max

Distillation (D86 vol%)

IBP

10

30

50

70

90

FBP

°C

22

40

44

50

60

77

88

22

40

44

50

60

77

88

4.4.2 Fresh Caustic Make-up

Make-up caustic will be available from the chemical storage unit at 20 °Be

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3550-8110-PD-025-0001 PAGE 6 OF 12 REV D2

4.5 Design Product Specifications

The light gasoline product specification is as below:

Density (@15°C) kg/l Report Report ASTM D-1298 or

ASTM D-4502

Mercaptans Sulphur,

C1-SH

C2-SH

C3-SH

ppmw

Report Report Report

ASTM D-3227

H2S content, max ppmw Nil Nil

Total Sulphur ppmw 35 max 25 max ASTM D-2622/

ASTM D-5453

Copper strip corrosion

ASTM D-3606

ASTM D-5191

ASTM D-6839

Distillation (D86 vol%)

IBP

5

10

30

50

80

90

95

FBP

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3550-8110-PD-025-0001 PAGE 7 OF 12 REV D2

4.6 By-product Specification

The following by-products are expected to be produced the RFCC Light Gasoline Treater Unit:

• Spent Caustic & Waste water to the Effluent Treatment Plant

Licensor is requested to provide the process conditions and composition of the below streams in addition to any further by-product streams not stated below

Licensor shall provide below specifications as minimum

4.6.1 Waste Water

Waste water shall be sent to the Effluent Treatment Plant Flow rate, composition, operating condition and pH of waste water should be defined by Licensor

4.6.2 Spent Caustic

Spent Caustic shall be sent to the Effluent Treatment Plant Flow rate, composition and operating condition of spent caustic should be defined by Licensor

4.7 Specific Design Requirements

4.7.1 Feedstock Specification

Licensor shall specify the RFCC Light Gasoline Treater Unit design to process the feedstock as determined in Section 4.4 above

4.7.2 On-stream factor

The RFCC Light Gasoline Treater Unit shall be designed for a 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) = 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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3550-8110-PD-025-0001 PAGE 8 OF 12 REV D2

4.7.3 Turndown

The Unit is designed to meet a turndown of 40%design feed for the design cases specified, whilst meeting all product specification requirements Any additional facilities or deviation from standard operation required to achieve this shall be clearly identified and incorporated

4.7.4 Cycle Length

The RFCC Light Gasoline Treater Unit shall be designed for a minimum operating cycle length of 4 years between major turnarounds All fixed bed catalysts catalysts systems shall be designed to operate for a minimum of 4 years without regeneration or catalyst change out being required

4.7.5 Energy Efficiency

• Licensor’s design shall optimise the consumption of energy and utilities It is expected that Licensor’s proposed process will incorporate a high level of heat integration in order to provide optimum refinery efficiency

• Licensor shall investigate the potential for recovery of low grade heat from the process unit and utilities systems

• Licensor shall base the inclusion of energy integration processes against a payback time of 8 years

• Licensor shall comment on opportunities to improve process and energy efficiency by use of Advanced Process Control

• Steam is expected to be used for reboiler duties, Licensor to specify any reboilers where an alternative heating medium is proposed

4.7.6 Design Guidelines for Process and Equipment

Guidelines for the design of process and equipment are detailed in the Process Engineering Design Guidelines, Document, No.: 3550-8110-PD-0007 The guidelines are used to achieve a consistent design approach across the project

These are not intended to supersede the Licensor design requirements, or any criteria which may impact the Licensor guarantees

4.7.7 Caustic Treatment

The spent caustic treatment for removal of sulphur from caustic shall be combined with caustic treatment system in RFCC LPG Treater Unit Regenerated caustic shall be recycled back to the extraction section

4.7.8 Water Wash or Coalescer

Licensor is requested to provide a wash water system or Coalescer for reducing of caustic content in the treated RFCC Light Gasoline

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3550-8110-PD-025-0001 PAGE 9 OF 12 REV D2 4.7.9 Material Selection and Corrosion Inhibition

Licensor shall specify any particular metallurgical, corrosion inhibition monitoring

or injection requirements

4.7.10 Catalyst Type and Regeneration (if applicable)

Licensor is request to advise all applicable catalyst type for the RFCC Light Gasoline treatment process including the advantage and the disadvantage of each type of catalyst

The Unit shall not be designed for in-situ catalyst regeneration If required, Licensor shall provide details and costs of suitable regeneration facilities for this project

4.7.11 Catalyst Handling

Licensor shall specify all permanent facilities required to load and unload catalysts Licensor shall provide guidance as to any special conditions relating to these operations and any effluent problems that might be expected

4.7.12 Catalyst Solvent Handling

Licensor shall specify all permanent facilities required to load solvent from drums

Licensor shall provide guidance as to any special conditions relating to these operations and any effluent problems that might be expected

4.7.13 Chemicals

Licensor shall specify consumption and facilities for the storage and preparation of chemicals (if any) required for the normal operation of the Unit, or required to facilitate Unit shutdown and maintenance Licensor shall identify estimated consumption rates for all chemicals and make recommendations for the treatment

of all waste effluent streams arising from the use of such chemical

4.7.14 Flare Loads and Flare Design

Licensor shall specify all safety/ pressure relief valves required to protect plant and equipment within the Unit Licensor shall also quantify the relief loads arising from controlling and significant relief scenarios for each safety/ pressure relief valve (e.g utility failure, blocked-in, external fire, etc)

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3550-8110-PD-025-0001 PAGE 10 OF 12 REV D2

4.7.15 Effluents and Emissions

Licensor shall identify all effluent streams (gaseous, liquid) arising from the process during normal operation and significant abnormal operations Estimated rates and compositions shall be provided for each stream, together with facilities for safe treatment and disposal This should include all transient and intermittent operations such as start-up and shutdown, catalyst loading/unloading etc

Licensor shall identify and quantify all solid wastes that will be produced by the Unit (e.g spent catalysts) and recommend disposal method

Licensor is to present this information in the specific format required by the relevant authorities

4.7.16 Start-up and Shutdown

Licensor shall provide any special facilities required to facilitate smooth and safe start-up of the Unit, and Unit shutdown

4.7.17 Process Control, Safety and Shutdown Systems

The Licensor design shall incorporate the use of modern state-of-the-art process control systems and shutdown logic systems Licensor shall design (based on Licensor’s recommendations) all necessary process control systems and safety shutdown logic systems required to support the safe operation and maintenance

of the Unit

4.7.18 Purging, Flushing and Blanketing Requirements

Licensor shall specify any special facilities required for the purging and flushing of equipment and instruments Licensor shall identify purging and flushing mediums and estimated rates of consumption

4.8 Utilities

Design data for available utility supplies are given in the Basic Engineering Design Data (BEDD), Document No.: 3550-8820-SP-0001

Licensor shall identify all utility consumption requirements and provide estimated rates of consumption for normal operation and for significant abnormal operations

4.8.1 Make-up Water

LP Boiler Feed Water will be available as make up water in the RFCC Light Gasoline Treater Unit in accordance with recommendations established by the Licensor

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3550-8110-PD-025-0001 PAGE 11 OF 12 REV D2 4.8.2 Process Air

Any air requirement shall be provided by the Air Compressor Package in the RFCC LPG Treater Unit Plant air will be available as a back-up

4.8.3 Fuel Gas

Fuel gas should be considered as blanketing gas

4.8.4 Other Requirements

Licensor shall specify all other raw materials required for the Unit in addition to the feedstock, catalysts, chemicals and utilities discussed in this document This specification shall include materials, hazard data, method of use, frequency of use and consumption The design shall include all specialised equipment required for their use

5 BATTERY LIMIT CONDITIONS

When the Unit is operating at design throughput the temperature and pressure of the feeds and products at the battery limits of the block are specified as follows:

kPa (g)

Temperature,

°C

Feed RFCC Light Gasoline Unit RFCC

RFCC Light Gasoline Treater Unit

780 42

Treated RFCC Light Gasoline Unit

Storage 400(1) 42(1) Fresh Caustic Utility Plant

295 40 Waste Water

Effluent Treatment Plant

400(1) 42(1) Spent Caustic

Effluent Treatment Plant

400(1) 42(1)

(1) To be advised / confirmed by Licensor

The definitive guarantee statements for the RFCC Light Gasoline Treater Unit shall be specified by the Licensor in the Guarantee Agreement between Licensor and Employer to which reference shall be made in respect of contractual obligations

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3550-8110-PD-025-0001 PAGE 12 OF 12 REV D2

The minimum scope of the Licensor’s guarantee shall include the following:

• Unit design capacity as per section 4.2

• Product specification as per section 4.5

• Unit Turndown capability (40%)

• Consumption of Catalyst, Solvent and Caustic

• Cycle length

• Catalyst life

• Consumption of Caustic, Catalyst and Solvent

• Utility consumption based on the utility summary at completion of design

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