NAPHTHA AND AROMATICS COMPLEX DUTY SPECIFICATION

INTRODUCTION 1.1 Unit Processing Objectives The Naphtha and Aromatics Complex shall be designed to process a stabilised feedstock of full range naphtha with the following objectives: •

NAPHTHA AND

AROMATICS COMPLEX

DUTY SPECIFICATION

A

FOSTER WHEELER ENERGY LTD PROCESS DOCUMENT

3550-8110-PD-040-0001 PAGE 2 OF 22

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4.7.15 Process Control, Safety and Shutdown Systems 15

4.7.16 Flare Loads and Flare Design 15

4.8 Utilities 15

4.8.1 Wash Water 16

4.9 Other Raw Material Requirements 16

5 BATTERY LIMIT CONDITIONS 17

6 PROCESS GUARANTEES 20

7 ATTACHMENTS 21

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1 INTRODUCTION

1.1 Unit Processing Objectives

The Naphtha and Aromatics Complex shall be designed to process a stabilised feedstock of full range naphtha with the following objectives:

• To maximise Paraxylene yield for product sale

• To produce a yield of Benzene for product sale

• To recover Liquefied Petroleum Gas (LPG) from the CCR Platforming Unit

• To produce an Isomerate stream for gasoline blending

• To produce a hydrotreated light and heavy naphtha stream to control the feedstock quality to the aromatics and isomerate producing units

• To produce Hydrogen at (99.9% mole) purity for use on other refinery units

• To have the facilities to route Toluene or HA column overheads to gasoline blending, if required

The overall design philosophy of the Naphtha and Aromatics Complex maximises economic Paraxylene production

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2 NAPHTHA AND AROMATICS COMPLEX SCHEMATIC

Figure 2-1 shows a schematic of the Naphtha and Aromatics Complex Licensor shall provide a process unit configuration to meet this duty specification

Heavy Aromatics

LPG

Isomerate LN

KHDS Naphtha

RHDS Naphtha

GOHDS Naphtha

LPG Recovery Unit

LPG LPG

FRN

HDS Off gases

NHT Off Gas

Aromatics Complex

LICENSOR SCOPE OF WORK

Hydrogen

H 2 Rich Gas

Raffinate

LPG Treater

ethaniser

De-H 2

H 2

H 2

Toluene / A9/A10

Heavy Aromatics

LPG

Isomerate LN

KHDS Naphtha

RHDS Naphtha

GOHDS Naphtha

LPG Recovery Unit

LPG LPG

FRN

HDS Off gases

NHT Off Gas

Aromatics Complex

LICENSOR SCOPE OF WORK

Hydrogen

H 2 Rich Gas

Raffinate

LPG Treater

ethaniser

De-H 2

H 2

H 2

Toluene / A9/A10

Figure 2-1 Naphtha and Aromatics Complex Schematic

The Naphtha and Aromatics Complex comprises of the following units:

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3 UNIT DEPENDENCE

The Naphtha and Aromatics Complex shall be capable of operating independently subject to the availability of hydrocarbon feedstocks, hydrogen make-up and utilities

Sufficient intermediate storage capacity will be available to enable continued production of Paraxylene and Benzene products in the event of either Naphtha Hydrotreater unit or CCR short term outage, and continued operation of the Naphtha and Aromatics Complex during short term outage of the CDU and LPG Recovery Unit

Paraxylene and Benzene products shall rundown cold to Product Storage

Isomerate shall rundown cold to Product Component Storage Heavy Aromatics shall rundown cold to Fuel Oil Blending storage Toluene and A9/A10 Aromatics shall normally be direct hot feed for the Tatoray Unit but shall also have the facilities to rundown cold to Product Component Storage

The following Intermediate, Product, and Product Component Storage Tanks will

be available and are excluded from Licensor’s scope:

• FRN (Full Range Naphtha) Tanks

• Desulphurised Heavy Naphtha Tank

• Reformate Tank

• Light Reformate Tank

• Heavy Reformate Tank

• Isomerate Tanks

• Heavy Aromatics Tanks (Toluene and A9/A10 Aromatics)

• Paraxylene Storage Tanks

• Benzene Storage Tanks

• Refinery or Utility Fuel Oil Tanks The Naphtha and Aromatics Complex will normally operate with 100% hot direct feeds to maximise energy efficiency, but provision shall be made to accept partial

or entire feed 'cold' from storage whilst meeting all product specifications

Similarly, Naphtha and Aromatics complex intermediates are normally rundown hot to the downstream units, but provision shall be made for intermediates to run down cold to available storage

LPG from the CCR shall be routed to the De-ethaniser in the LPG Recovery Unit (outside the scope of Licensor) Offgas from the NHT shall be fed to the LPG Recovery Unit (outside the scope of Licensor)

The battery limit conditions required for each intermediate, product and by-product are outlined in Section 5 below

The CCR of the complex will produce hydrogen with a purity of 99.9 mol% that will

be routed to the refinery Hydrogen Compression and Distribution System for use throughout the refinery

LPG from the CCR shall be routed to the De-ethaniser in the LPG Recovery Unit

The design philosophy of the Naphtha and Aromatics Complex is to maximise economic Paraxylene production Benzene is treated as a paraxylene by-product and is 2nd priority Benzene production should float in favour of paraxylene.

There is no target for Isomerate production volume, the isomerate production volume can decrease in favour of paraxylene and benzene production

Production of Heavy Aromatics should be minimised to obtain further paraxylene and benzene production

4.2 Design Capacity

The Naphtha and Aromatics Complex shall be designed to process the following quantities of the design feedstock

Table 4-1: Feedstocks to the Naphtha Hydrotreater

Feedstock Flow rate, te/

stream day

The properties of the above feedstock are listed below in Table 4-2 below

4.3 Design Feed Cases

The design feed case for the Naphtha and Aromatics Complex is 100% straight run naphtha with the feed specifications as shown in Table 4-1

For the Naphtha Hydrotreater, an alternative (C4 spike) design case is required for the design of the Naphtha Stripper and associated equipment The basis for the C4 spike case is 1 vol% of C4 in the feed

An additional (rich) design case for the CCR Platforming Unit is required The basis for the Rich feed case is 10% additional Naphthenes (on a PONA basis) in the CCR Platforming Unit feed

REV D2 The Naphtha and Aromatics Complex will normally operate with 100% hot direct feed from the LPG Recovery Unit to maximise energy efficiency, but provision shall be made to accept partial or entire feed 'cold' from storage whilst meeting all product specifications The design basis for Hot and Cold Feeds is provided in section 4.7.4 below

The feedstock pressures and temperatures are provided in section 5 below

Properties of the Naphtha and Aromatics Complex feedstock are given in Section Table 4-2 below

It should be noted that the Licensor may be requested, during the Licensor PDP phase, to provide estimates of product yields and main properties, operation conditions, probable bottlenecks (identification of constraining equipment) and maximum throughput for various Performance Cases These Performance Cases may concern feeds or operating objectives different from the Design Case

4.4 Feedstock Properties

The design properties of the 100% straight run, full range naphtha feedstock to the Naphtha and Aromatics Complex, processed from Kuwait Export Crude, are detailed in Table 4-2 and Table 4-3 below

Table 4-2: Properties of Naphtha feed to the Naphtha Hydrotreater

Parameter Units

Full Range Naphtha

API Gravity API 64.8 Nominal Cut Range °C C5 - 180

D-86 90% °C 164 D-86 95% °C

D-86 FBP °C 180 Paraffins wt%

Olefins wt%

Naphthenes wt%

See Table 4-3 below

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Parameter Units

Full Range Naphtha

Table 4-3: Estimated wt% PIONA of Feedstocks to the Naphtha Hydrotreater Unit

on the properties and PIONA distribution above

Table 4-4: Paraxylene Product Specification

Note 1: Paraxylene purity is linked to 97% recovery from Parex-Isomar loop at design Naphtha feed rate

4.5.2 Benzene

For the design feedstock and flowrate, the Naphtha and Aromatics Complex shall meet the Benzene product specifications outlined below in Table 4-5

Table 4-5: Benzene Product Specification

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4.5.3 Component Blend Products

Licensor shall target the following component blend products to be of suitable blend quality to meet the gasoline product specification shown in section 7:

• Isomerate from the Penex unit

• Toluene from the BT Fractionation Unit (Normally No Flow)

• A9/A10 Stream from Heavy Aromatics Column overheads (Normally No Flow)

During Normal Operation the Toluene and A9/A10 streams will form feeds to the Tatoray Unit

In addition, the Isomerate from the Penex unit shall have a minimum RON of 88 and the ASTM D86 endpoint of the A9/A10 stream shall be less than 210 °C

REV D2 4.5.4 Heavy Aromatics Stream

The Heavy Aromatics produced in the Naphtha and Aromatics Complex will be used as fuel oil and routed to the Refinery Fuel Oil Tank

4.5.5 Hydrogen Product

Hydrogen produced in the Naphtha and Aromatics Complex will be routed to the refinery Hydrogen Compression and Distribution system (HCDS) The hydrogen sent to HCDS shall meet the specification as detailed in Table 4-6 below

Table 4-6: Hydrogen Specification

Hydrogen purity, min vol% 99.9 CO+CO2 content ppmv 10 max

in the LPG Recovery Unit

The CCR Platforming Unit LPG should contain less than 1.1mol% C5+

4.6 By-product Specifications

The following by-products are expected to be produced in the Naphtha and Aromatics Complex:

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• Off-gas from NHT Unit to LPG Recovery Unit (by others)

• Fuel Gas from Isomar and Tatoray Units to the Fuel Gas Distribution (by others)

• Tail Gas from the PSA unit within the CCR Platforming Unit to the Hydrogen Manufacturing Unit (by others)

• Sour water and water contaminated with hazardous hydrocarbons to treatment facilities

• Flue Gas from fired heaters within the Naphtha and Aromatics Complex

• Vent Gas from CCR Platforming Regeneration Section Licensor shall provide the process conditions and composition of the above streams in addition to any further by-product streams not stated above

For Flue Gases, particulate emission shall be restricted to less than 50mg/Nm³ max

Removal of Chlorides and HCl from the CCR Platforming Regeneration Section Vent Gas by ChlorsorbTM shall be a minimum of 97 wt%

Table 4-7 below shows the specifications required for Fuel Gas Fuel gas streams from the Naphtha and Aromatics Complex are required to meet this specification

Table 4-7: Fuel Gas Specification

(2) =total duration for repairs and maintenance including turnaround, catalyst change-out and typical trip outage

Licensor to advise minimum unit downtime required for catalyst replacement

REV D2 4.7.2 Turndown

The Naphtha and Aromatics Complex shall be designed to operate satisfactorily in the range 50% to 100% of design feed rate for the feed cases defined in section 4.3 and 4.4 while meeting all product specifications

4.7.3 Cycle length

Catalysts shall be specified for a minimum of 4 years operation between major turnarounds All equipment shall be specified and spared to support 4 years continuous operation

Paraxylene adsorbent shall be designed for a minimum of three full cycle lengths (12 years) without changeout

4.7.4 Hot and cold feeds

Normal operation will utilise hot feed The basis for hot and cold feeds is outlined below in Table 4-8

Table 4-8: Hot and Cold Feed Design Basis

Normal operation

Turndown operation (50%) for the S/U

Hot / Cold Design Case

REV D2 4.7.6 Process and Heater Efficiency

The Licensor’s design shall optimise the consumption of energy and utilities

Licensor’s process design shall incorporate a high level of heat integration in order

to contribute to optimum refinery efficiency

Fired heaters shall be specified with air preheat facilitates using waste heat available from flue gas, unless Licensor demonstrates the addition of air preheat is uneconomic or detrimental to the unit operation

Steam is expected to be used for reboiler duties, where heat integration with process streams is not possible

4.7.7 Purification of Off-gas Streams

The use of amine absorbers for removal of H2S from sour off-gas streams is excluded from the Naphtha and Aromatics Complex scope

4.7.8 Design Guidelines for Process and Equipment

Guidelines for the design of process and equipment are listed in Doc No 8110-PD-0007 The guidelines are used to achieve a consistent design approach across the project These are not intended to supersede the Licensor’s design requirements, or any criteria which may impact the Licensor’s guarantees

3550-4.7.9 Major Compressor Driver Selection

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

4.7.10 Catalyst Regeneration and Handling

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

Licensor shall specify all permanent facilities required for storage, loading and unloading of catalysts Licensor to advise any plot layout/space required for new catalyst handling

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

The units that require in-situ catalyst regeneration, or pre-sulphiding shall be designed accordingly, including any additional equipment if required

4.7.11 Chemicals

Licensor shall specify facilities for the storage and preparation of chemicals (if any) required for the normal operation of the complex, or required to facilitate unit shutdown and maintenance

REV D2 4.7.12 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

Specifically vent gas and wastewater streams should be treated to remove dioxins, if present, within the Licensor’s units

4.7.13 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

4.7.14 Start-up and shutdown

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

Licensor to advise procedures associated with these activities, especially sulphiding and oil purging

Licensor shall advise expected start-up and shutdown periods (including heat up and cool down time/rates)

4.7.15 Process Control, Safety and Shutdown Systems

The Naphtha and Aromatics 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 complex

4.7.16 Flare Loads and Flare Design

Licensor shall specify all safety / pressure relief valves required to protect plant and equipment within the complex Licensor shall 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)