RFCC LPG TREATER DUTY SPECIFICATION

RFCC LPG TREATER DUTY SPECIFICATION A FOSTER WHEELER ENERGY LTD PROCESS DOCUMENT 3550-8110-PD-024-0001 PAGE 4 OF 13 REV D2 Residue Fluidized Catalytic Cracker Reactor Unsat Gas P

Trang 2

RFCC LPG TREATER

DUTY SPECIFICATION

A

FOSTER WHEELER ENERGY LTD PROCESS DOCUMENT

3550-8110-PD-024-0001 PAGE 2 OF 13

REV D2

4.7.15 Flare Loads and Flare Design 11

4.7.16 Effluents and Emissions 11

4.7.17 Start-up and Shutdown 11

4.7.18 Process Control, Safety and Shutdown Systems 11

4.7.19 Purging, Flushing and Blanketing Requirements 11

4.8 Utilities 12

4.8.1 Make-up Water 12

4.8.2 Process Air 12

4.8.3 Fuel Gas 12

4.8.4 Other Requirements 12

5 BATTERY LIMIT CONDITIONS 12

6 PROCESS GUARANTEES 13

Trang 3

A

3550-8110-PD-024-0001 PAGE 3 OF 13

REV D2

1 INTRODUCTION

The primary objective of the RFCC LPG Treater Unit is to reduce the Mercaptans, total sulphur content, and remove H2S from the LPG obtained from the Residue Fluid Catalytic Cracker Unit (RFCC) The product specifications need to meet the processing requirements of downstream processing (Alkylation and Polypropylene Units) and LPG sales

The product will meet the quality requirement to produce treated LPG with maximum total mercaptans content of 3 ppmw with maximum total sulphur of 10 ppmw

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

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

The RFCC LPG 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 RFCC LPG directly from the Unsaturated Gas Plant at the RFCC Unit

Trang 4

A

3550-8110-PD-024-0001 PAGE 4 OF 13

REV D2

Residue

Fluidized

Catalytic

Cracker

Reactor

Unsat Gas Plant Propane

Polypropylene Unit

Mixed butanes Alkylation

Treated LPG Untreated

LPG

Propylene

LPG

RFCC LPG Treater

Licensor scope

Fresh Caustic

Spent caustic

Chemicals

Storage

Foul Air

CDU Heater (or) RFCC CO Boiler (or) Sulphur Recovery Unit (or)

HC Flare

Disulphide Oil

Naphtha Hydrotreating Unit (or) Slop Tank

Fresh Solvent

Waste Water Storage

Effluent Treatment Plant

LP BFW Utility

Effluent Treatment

Plant

The Unit is designed to process LPG feedstock from the RFCC Unit after amine scrubbing The Unit shall process the feed to produce treated LPG with a maximum total mercaptans content of 3 ppmw with maximum total sulphur of 10 ppmw Spent caustic treatment design shall be part of the scope of work and shall include the spent caustic from RFCC Light Gasoline Treater Unit for treatment

Regenerated caustic shall be recycled back to the extraction section

The RFCC LPG Treater Unit shall be designed to process 43,000 BPSD of LPG 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

Trang 5

A

3550-8110-PD-024-0001 PAGE 5 OF 13

REV D2

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

Material balance shall be provided for design case

4.4.1 RFCC LPG Treater Unit feed

The RFCC LPG Treater Unit feed has the following properties:

Mercaptans Sulphur, as Sulphur ppmw 120 max

Copper strip corrosion (1 hr 38°C) 1 max

Trang 6

A

3550-8110-PD-024-0001 PAGE 6 OF 13

REV D2

4.4.2 Fresh Caustic Make-up

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

4.4.3 Fresh Solvent

Desulphurised Heavy Naphtha from storage will be available as fresh solvent

Licensor is requested to confirm the solvent specification and provide required flow rate

The Desulphurised Heavy Naphtha has the following properties

ASTM D-86 Distillation, °C IBP

10%

30%

50%

70%

90%

FBP

89.7 99.3 108.3 116.5 139.2 164.0 183.6

(1) Licensor to define.

For the design feedstock and flow rate, the RFCC LPG Treater Unit shall be designed to maximise treated LPG product with the specifications outlined below:

Density (@15°C) kg/l 0.5 min ASTM D-1657 or

ASTM D-2598 Composition

Ethane Ethylene Propane Propylene n-Butane Iso-Butane 1-Butene Isobutylene Trans-2-butene Cis-2-buene

C5+

wt%

Report Report Report Report Report Report Report Report Report Report Report

ASTM D-2163 ASTM D-2163 ASTM D-2163 ASTM D-2163 ASTM D-2163 ASTM D-2163 ASTM D-2163 ASTM D-2163 ASTM D-2163 ASTM D-2163 ASTM D-2163 Olefin content vol % Report ASTM D-2163

Trang 7

A

3550-8110-PD-024-0001 PAGE 7 OF 13

REV D2

Composition of 100 ml vaporized residue ml 0.05 max ASTM D-2158 Copper strip corrosion

ASTM D-6667 Hydrogen Sulphide ppmw 0.5 max ASTM D-2420 Sulphur dioxide ppmw Report

Total Mercaptans S ppmw 3 max ASTM D-3227

Oxygenated Organic ppmmol Report

The following by-products are expected to be produced in the RFCC LPG Treater Unit:

• Foul Air to the CDU Heaters or RFCC CO Boiler or Incinerators located at the Sulphur Recovery Unit (SRU) or HC Flare

• Disulphide Oil (DSO) to Naphtha Hydrotreting Unit (NHT) or Slop Tank

• 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 Foul Air

Trang 8

A

3550-8110-PD-024-0001 PAGE 8 OF 13

REV D2

Water @ operating conditions mol% Report

Total Mercaptans (S) ppmw Report

4.6.2 Disulphide Oil (DSO)

4.6.4 Waste Water

Waste water from wash water section will be sent to the Effluent Treatment Plant

Flow rate, composition, operating condition and pH of waste water should be defined by Licensor

4.6.5 Spent Caustic

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

4.7.1 Feedstock Specification

Licensor shall specify the RFCC LPG Treater Unit design to process the feedstock

as determined in Section 4.4 above

Trang 9

A

3550-8110-PD-024-0001 PAGE 9 OF 13

REV D2

4.7.2 On-Stream Factor

The on stream time for the Unit shall be 8320 hours per calendar year, equivalent

to an on-stream factor 0.95 where:

On stream Factor = (1)

(1) = total duration of productive operation

(2) = total duration for repairs and maintenance including turnaround and typical trip outage

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 Unit cycle length will be 4 years between scheduled turnarounds All fixed bed 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 contained 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

Trang 10

A

3550-8110-PD-024-0001 PAGE 10 OF 13

REV D2 4.7.7 Caustic Treatment

The Unit design shall incorporate spent caustic treatment for removal of sulphur from caustic, in order to reduce caustic consumption The caustic treatment system shall be common for RFCC LPG Treater Unit and RFCC Light Gasoline Treater Unit Regenerated caustic shall be recycled back to the extraction section

Licensor to consider sending the Foul Air to the CDU Heaters or RFCC CO Boiler

or Incinerator located in the SRU A connection to the HC Flare shall be provided

Disulphide Oil will be normally routed to Naphtha Hydrotreating Unit (NHT) A connection to Slop tank is to be provided

4.7.8 Spent Caustic Drum

Licensor shall design spent caustic drum for bleed stream from caustic treatment section

4.7.9 Water Wash Drum

Licensor shall provide a wash water system for reducing of caustic content in the treated RFCC LPG

4.7.10 Material Selection and Corrosion Inhibition

Licensor shall specify any particular metallurgical, corrosion inhibition monitoring

or injection requirements

4.7.11 Catalyst Type and Regeneration (if applicable)

Licensor is request to advise all applicable catalyst type for LPG 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

4.7.12 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

Trang 11

A

3550-8110-PD-024-0001 PAGE 11 OF 13

REV D2

4.7.13 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

4.7.14 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 start-up, 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

4.7.15 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)

4.7.16 Effluents and Emissions

Licensor shall identify all effluent streams (gaseous, liquid and solid) arising from the process during normal operation and significant abnormal operations

Estimated rates and compositions shall be provided for each stream, together with recommendations for safe treatment and disposal This should include all transient and intermittent operations such as start-up and shutdown, catalyst loading/unloading etc

4.7.17 Start-up and Shutdown

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

4.7.18 Process Control, Safety and Shutdown Systems

The Unit design shall incorporate the use of modern state-of-the-art process control systems and shutdown logic systems Licensor shall specify all necessary process control systems and safety shutdown logic systems required to support the safe operation and maintenance of the Unit

4.7.19 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

Trang 12

A

3550-8110-PD-024-0001 PAGE 12 OF 13

REV D2

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 LPG Treater Unit in accordance with recommendations established by the Licensor

4.8.2 Process Air

Licensor shall include an Air Compressor Package for supply of air to caustic treatment section Plant air will be available as a back-up

4.8.3 Fuel Gas

Fuel gas should be considered for purge foul air from caustic treatment section

4.8.4 Other Requirements

Licensor shall specify all other raw materials required for the RFCC LPG Treater 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

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

Gas Plant

RFCC LPG

Treater Unit

RFCC Unsat

(1)

Heavy Naphtha

RFCC LPG

Treater Unit

Trang 13

A

3550-8110-PD-024-0001 PAGE 13 OF 13

REV D2

Treater Unit

CDU / RFCC /

(1)

Treater Unit

(1) To be advised / confirmed by Licensor

Complete definitive guarantee statements for the RFCC LPG Treatre 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

Nevertheless, for the benefit of users of this document, Licensor shall provide a list

of guarantees which shall apply to design case

The minimum scope shall include:

• Unit design capacity as per section 4.2

• Product specifications as per section 4.5

• Unit Turndown capability (40%)

• Consumption of Catalyst, Solvent and Caustic

• Cycle length

• Catalyst life

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

Định dạng
Số trang	13
Dung lượng	277,39 KB