INDIRECT ALKYLATION DUTY SPECIFICATION

INDIRECT ALKYLATION DUTY SPECIFICATION A FOSTER WHEELER ENERGY LTD PROCESS DOCUMENT 3550-8110-PD-028-0001 PAGE 2 OF 10 REV D1 INTRODUCTION 1.1 Unit Processing Objectives The Indirec

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INTRODUCTION

1.1 Unit Processing Objectives

The Indirect Alkylation (InAlk) Complex shall be designed to maximise production

of high octane, low vapour pressure, paraffinic gasoline blending component, similar in quality to traditional alkylate, using solid catalysts to react isobutylene with light olefins from the Residue Fluid Catalytic Cracker (RFCC) C4s stream

The primary objectives of the InAlk Complex are as follows:

• To produce gasoline blending alkylate

• To recover unreacted butanes for blending into LPG

1.2 Use of Document

This document specifies the basis for the proposed Licensor process design of the InAlk Complex for bid evaluation purposes This document shall be used as the basis of design for the process design of the InAlk Complex only

The design requirements specified in this document are considered to be the minimum required

2 UNIT INDEPENDENCE

The InAlk Complex is expected to comprise of the following main unit areas:

• Feed pre-treatment:

- Selective Hydrogenation Reactor

- Nitrile Removal Absorbers

• InAlk Unit

- Polymerisation Reactors

- Saturation Reactor

- Product Stripper

- Debutanizer

- Rerun Column The InAlk Complex shall be capable of operating independently at 100% capacity subject to the availability of hydrocarbon feedstocks, hydrogen make-up and utilities

The following feed and product tanks can be assumed to be available and are excluded from Licensor’s scope:

• Mixed (C4s) – InAlk feedstock

• Alkylate – InAlk product

• Butane – InAlk product Licensor is requested to provide recommended capacities for the storage tanks listed above and recommend any additional tankage required

The battery limit conditions required for each product and by product are outlined

in Section 4 below

The sketch below shows the scope of the InAlk Complex Licensor shall recommend a process unit configuration to meet this duty specification

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Figure 2-1 InAlk Unit Scope

3 BASIS OF DESIGN

3.1 Design Objective

The InAlk Complex shall be designed to process RFCC C4s to maximise production

of high octane Alkylate suitable for gasoline blending based on maximising octane-barrels

The Unit will also produce a mixed saturated C4s stream, which is sent to the LPG pool

3.2 Design Capacity

The InAlk Complex shall be designed to process the following quantities of the design feedstock

Table 3-1: Feedstocks to InAlk unit

Tonnes/hr

RFCC C4s 85 ( ~ 21,500 BPSD)

3.3 Design Feed Cases

There are two design cases for the InAlk Complex:- Case 1: Based on maximum propylene production in the RFCC (0.90 wt%

Butadiene) Case2: Based on maximum gasoline production in the RFCC The InAlk Complex shall be designed to run at 100% capacity with feed from storage whilst meeting all the product specifications

The feedstock pressures and temperatures are provided in section 4 Properties

of the InAlk Complex feedstock are given in Table 3-2 below

Feed Pre-treatment

H2

C4s

Butanes

Alkylate Unsat

Gas Plant

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3.4 Feedstock Properties

The specification of C4s stream to the InAlk Complex is detailed in Table 3-2 below Make-up hydrogen to the SHP reactor (pre-treatment Unit) and the saturation reactor (InAlk Unit) is specified in Table 3-3

Table 3-2: Properties of Feedstock to the InAlk Complex

Specific Gravity - 0.596 0.600 Molecular Weight

Sulphur wt-ppm 20 Max 20 Max

H2S wt-ppm 1 1 Basic N2 wt-ppm 1 Max 1 Max

Carbonyl Sulphur wt-ppm 1 Max 1 Max

Chloride, Fluoride wt-ppm 1 Max 1 Max

Total Oxygen wt-ppm 0.5 Max 0.5 Max

(NH3, Amines, caustic) wt-ppm 1 Max 1 Max

Metals wt-ppb 1 Max 1 Max

CO, CO2 wt-ppb 1 Max 1 Max

H2O No Free water No Free Water Alcohols wt-ppm 1 Max 1 Max

Acetonitrile wt-ppm 50 Max 50 Max

Acetone wt-ppm 75 Max 75 Max

C3 wt% 0.08 0.07

C3= wt% 0.06 0.06

i C4 wt% 22.30 14.98

n C4 wt% 6.02 5.87

1 C4= wt% 14.72 15.26 t-2 C4= wt% 21.02 22.32 c-2 C4= wt% 14.29 15.30 Iso C4= wt% 20.64 24.74 Butadiene wt% 0.37 0.9

C5+ wt% 0.50 0.50

Licensor to optimise the feed pre-treatment scheme to meet the requirement of the InAlk reaction section

Table 3-3: Make-up Hydrogen Specification for SHP/saturation reactor

Hydrogen purity, min vol% 99.9

CO+CO2 content, max ppmv 10

Chlorides, max ppmv 1

Methane & Nitrogen Balance

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3.5 Product Specifications

For the design feedstock and flowrate, the InAlk Unit shall meet the product specifications outlined below

Alkylate

Table 3-4: Alkylate Product Specification (Note 1)

Appearance Clear and Free of

Sediment Visual Butanes wt% 1.5 max UOP 539 RON 97.6 ASTM D2699 MON 92.7 ASTM D2700

Total Sulphur content

wt-ppm <1 UOP 727 Product Distillation vol% ASTM D86

1 °C 38

5 °C 89.5

10 °C 102

30 °C 109.5

50 °C 112

70 °C 116

90 °C 170

95 °C 206.5t End point °C 205

SG (15.6°C/15.6°C) 0.697 ASTM D1298 RVP @ oC kPa 24.14 ASTM D4953/D 5191

Copper Corrosion (3hrs @ 50 o

C Report Oxidation Stability Report

Existent gum Wt% Report

Note 1 – Licensor to confirm product specifications

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LPG (Butanes) (Note 1, 2) Licensor is requested to provide the Mixed Butane product specifications from the InAlk Unit based on an optimised design to meet this duty specification

Specific Gravity gm/cc Report ASTM D-1657/

ASTM D-2598

Composition

Water wt% Report Nitrogen wt% Report Oxygen wt% Report ASTM D-2233 Hydrogen wt% Report ASTM D-2504 Methane wt% Report ASTM D-2163 Ethane wt% Report ASTM D-2163 Ethylene wt% Report ASTM D-2163 Propane wt% Report ASTM D-2163 Propylene wt% Report 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 1,2-Butadiene (Note 3) ppmw Report ASTM D-2163 1,3-Butadiene (Note 3) ppmw Report ASTM D-2163

C5+ wt% 1 max ASTM D-2163

Sulphur Dioxide ppmw Report Carbon Monoxide ppmw Report ASTM D-3416 Carbon Dioxide ppmw Report ASTM D-3416 Hydrogen Sulphide ppmw Report ASTM D-2420 Methyl Acetylene ppmw Report

Propadiene ppmw Report Total Mercaptans S ppmw Report ASTM D-3227 COS ppmw Report

CS2, ppmw Report Arsine ppbw Report ASTM E-819 Phosphine ppbw

NH3 ppmw Report Copper strip corrosion

(1h @ 38oC)

Report ASTM D-1838 Amine ppmw

Note 1 – Licensor to confirm product specifications Note 2 – Max Olefin content (incl Butedienes) shall be < 1 vol% (over 24 hrs) Note 3 – Max Butedienes content shall be < 100 wppm

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3.6 By-product Specifications

The following by-products are expected to be produced in the InAlk Complex:

• Off-gas to LRU/RFCC Amine Stripper

• Sour water to sour water stripping (SWS1)

• Oily contaminated water to Effluent Treatment Plant (ETP)

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

3.7 Specific Design Requirements

3.7.1 Feedstock specification

Licensor shall optimise the InAlk Complex design to process the feedstock as determined in Sections 3.3 and 3.4

Licensor is requested to provide a qualitative analysis regarding the flexibility of the proposed configuration in terms of changes in operation / feedstocks, particularly with respect to the RFCC mode of operation

3.7.2 On stream factor

The InAlk Complex shall be designed for a minimum on-stream factor of 0.95

This is equivalent to 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

3.7.3 Turndown

The InAlk Complex shall be designed to operate satisfactorily in all operating modes, as a minimum, in the range 40% to 100% of design feed rate for the feed cases defined in section 3.3 and 3.4 while meeting all product specifications

3.7.4 Cycle length

Licensor to specify cycle length All equipment shall be specified and spared to support maximum continuous operation between major turnarounds (4 years)

In series SPA reactor arrangement to be used to permit catalyst change out while the unit is in operation to achieve the required period between major turnarounds

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PAGE 8 OF 10 REV D1 3.7.5 Specific Design Features

Alkylation reaction temperatures to be optimised to achieve optimum octane barrel production The Complex is to be capable of operating in maximum alkylate mode

if required Facilities to monitor and control alkylate conversion shall be included

Facilities to monitor and control water injection shall be included

Licensor to design the Complex to minimise off spec alkylate production (e.g at start up) and include necessary facilities to enable reprocessing The Complex should be designed to produce saturated LPG That is, to route all product from the SPA reactors through to the saturation reactor

3.7.6 Direct Feed and Feed from Storage

The InAlk Complex shall be designed to run at 100% capacity with feed directly from RFCC or storage

3.7.7 Process and 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

3.7.8 Design Guidelines for Process and Equipment

Guidelines for the design of process and equipment are listed in document 3550- 8110-PD-0006 The guidelines are used to achieve a consistent design approach across the project These are not intended to supersede the Licensors design requirements, or any criteria which may impact the Licensors guarantees

3.7.9 Material Selection and Corrosion Inhibition

Licensor shall specify any particular metallurgical, corrosion inhibition monitoring

or injection requirements

3.7.10 Major Compressor Driver Selection

Major compressor driver selection shall be specified by the Licensor with justification for the selection between steam turbine and motor drives

3.7.11 Catalyst Regeneration

Licensor shall specify the required method for regeneration and replacement of all catalysts used in the InAlk Complex

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PAGE 9 OF 10 REV D1 The units that require in-situ catalyst regeneration shall be designed accordingly, including any additional equipment if required

3.7.12 Catalyst Handling

Licensor shall specify all permanent facilities required to load and unload catalysts, including all equipment required for pre-sulphiding/hydrartion/reduction of catalysts

in situ, if required Licensor shall provide guidance as to any special conditions relating to these operations and any effluent problems that might be expected

Licensor to recommend catalyst disposal method to avoid disposal of catalyst to land fill

3.7.13 Chemicals

Licensor shall specify facilities for the storage and preparation of chemicals required for the normal operation of the complex, or required to facilitate the Complex shutdown and maintenance

3.7.14 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 & intermittent operations such as start-up and shutdown, catalyst loading/unloading etc

Specifically vent gas and wastewater streams should be treated to remove dioxins,

if present, within the licensed units

3.7.15 Purging and flushing

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

3.7.16 Start-up and shutdown

Licensor shall specify any special facilities required to facilitate smooth and safe start-up/shutdown of the InAlk Complex This shall include shutdown of individual units where the process allows

3.7.17 Process Control, Safety and Shutdown Systems

The InAlk Complex 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 InAlk Complex

3.7.18 Flare Loads and Flare Design

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

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3.8 Utilities

Design data for available utility supplies are given in the Basic Engineering Design Data (BEDD) document 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

Licensor shall specify all other raw materials required for the InAlk Complex in addition to the feedstock, hydrogen, 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

4 BATTERY LIMIT CONDITIONS

Table 4-1 shows the envisaged key battery limit stream conditions for the InAlk Complex The table is not intended to be exhaustive and Licensor is requested to provide a full list of battery limit streams and conditions

These battery limit conditions shall apply when the InAlk Complex is operating at design throughput

Table 4-1: InAlk Complex Battery Limit Conditions

RFCC Olefin Feed Storage SHP Unit 800 42

RFCC Olefin Feed RFCC C3/C4 Splitter SHP Unit 650 42

Make-up Hydrogen Hydrogen

Distribution SHP Unit 4000 55 Product Alkylate Rerun Column Alkylate Storage 600 42

Product Butane Debutanizer LPG Storage 800 42

Heavy Oil/Off-spec

Alkylate Rerun Column

RFCC Gasoline Slop Tank 600 42 Heavy Oil Rerun Column RHDS Diesel

Storage 600 42 Wastewater SHP Unit Sour Water Stripping

(SWS1) 600 42 Wastewater SHP Unit Effluent Treatment

Plant (ETP) 600 42 Off-gas Unit LRU/RFCC Amine

Stripper 1000 44

5 PROCESS GUARANTEES

A complete definitive list of process performance guarantees for the InAlk Complex

is specified in the guarantee agreements