Chapter III

CHAPTER III
TECHNICAL DESIGN AND REQUIREMENTS
This chapter discusses the preparation of comprehensive plant cycle
cycles for three design options. This includes process flow diagram, mass
balance, energy balance, equipment and design specifications, technical
specifications, and standard requirements.
Equipment and Functions
A. Desalter
Figure 6 . Desalter
A crude oil desalter is a device used in petroleum refineries to
remove inorganic salts, water and sediment from the incoming petroleum crude
oil feedstock before it is refined. This article focuses on the use
of electrostatic desalters to produce a dehydrated, desalted crude oil with a low
sediment content. Almost all refineries now use electrostatic desalters. However,
there may still be a few refineries employing the older, less efficient method that
12
utilizes chemicals and settling tanks.
Design Specification
Equipment Category Treatment
Requirement 1
Capacity 21MT/day
Size 140 sq. m
Certification ISO9002, UKAS, NCS ISO 9001
Table 1. Desalter Specification
A. Pre-flash Vessel/Drum
Figure 7. Pre-flash Vessel/ Drum
A preflash drum/vessel creates foam that can affect measurement
accuracy of liquid levels and decrease distillate production in the
atmospheric column. Too low of a preflash drum level will cause pump
cavitation of the flashed crude. Too high of a level will cause liquid
carryover to the distillation column.

13
Design Specifications
Equipment Category Treatment
Requirement 1
Capacity 2-20 T/d
Size L*W – 12-25m
Table 2. Flash Drum Specification
B. Furnace
Figure 8. Furnace
An enclosed structure in which material can be heated to very high
temperatures.It is a forced and induced draught, multiple burner heater with
vertical firing in the radiant cell.
Equipment Category Heating
Requirement 1
Capacity 4500kg
Size 4000 sets/sets per year
Power requirement 750 kwh
Operating mode Induction mode
Certification CE ISO900/ CE and ISO
Table 3. Flash Drum Specification
14
C. Atmospheric Distillation Column
Figure 9. ADU
The purpose of atmospheric distillation is primary separation of
various fractions of hydrocarbons namely, fuel gases, LPG, naphtha,
kerosene, diesel and fuel oil. The heavy hydrocarbon residue left at the
bottom of the atmospheric distillation column is sent to vacuum distillation
column for further separation of hydrocarbons under reduced pressure.
Equipment Category Separation
Requirement 1
Capacity 20MT/day
Size 2200mm*6000mm*2500mm*8800m
m
Operating mode Batch type
Table 4. Atmospheric Distillation Specification
15
D. Gas Separation Unit
Figure 10. Gas
Separator
Gas separation units are used to separate various hydrocarbons
from the natural gas which in turn maximizes value of the gas.
Requirement 1
Flow Rate 3~5000Nm3/h
Capacity 50 Nm3/h
Production Rate 90%
Certification ISO, TUV, SGS
Table 5. Gas Separator Specification
E. Hydrotreater Unit
16
Figure 11. Hydrotreater unit
Hydrotreating is an established refinery process for reducing
sulphur, nitrogen and aromatics while enhancing cetane number, density
and smoke point.
Temperature 300-380 degrees Celsius
Pressure requirement 10-20 bar
Certification CE ISO / SGS
Table 6. Hydrotreater Unit Specification
F. Debutanizer Tower
Figure 12. Debutanizer Tower
17
Debutanizer is a type of fractional distillation column used to
separate butane from natural gas during the refining process. Distillation is
the process of heating a liquid to vapor and condensing the vapors back to
liquid in order to separate or purify the liquid. Examples include distilling
water to purify it and distilling liquor to make it stronger. Fractional
distillation, as occurs in a debutanizer, is the separation of a fraction — a
set of compounds that have a boiling point within a given range — from
the rest of the mixture.
Requirement 1
Temperature 260 degrees Celsius
Very high cat/oil ratio 15-25
Certification ISO9002, UKAS, NCS ISO
9001
Table 7. Debutanizer Specification
G. Hydrodesulfurization unit
18
Figure 13. HDS
Hydrodesulfurization Unit (HDS) is an equipment widely used to
remove sulfur (S) from natural gas and from refined petroleum products,
such as gasoline or petrol, jet fuel, kerosene, diesel fuel, and fuel oils. The
purpose of removing the sulfur, and creating products such as ultra-low-
sulfur diesel, is to reduce the sulfur dioxide (SO2) emissions that result
from using those fuels in automotive vehicles, aircraft, railroad
locomotives, ships, gas or oil burning power plants, residential and
industrial furnaces, and other forms of fuel combustion.
Design Specification
Requirement 1
Temperature 35 °C
Pressure requirement 3-5 atmospheres
Certification CE certificate
Table 8. Hydrodesulfurization Specification
H. Catalaytic Cracking Unit
Figure 14. Catalytic Cracking Unit
19
Fluid catalytic cracking (FCC) is one of the most important
conversion processes used in petroleum refineries. It is widely used to
convert the high-boiling, high-molecular weight hydrocarbon fractions of
petroleum crude oils into more valuable gasoline, olefinic gases, and other
products.
Design
Specification
Equipment Category Conversion
Requirement 1
Temperature 1.72 bar
Pressure 40-130 atm
Table 9. Catalytic Cracking Specification
I. Catalytic Reformer Unit
Figure 15. Catalytic Reforming Unit
Catalytic reforming is a chemical process used to convert
petroleum refinery naphthas distilled from crude oil (typically having low
octane ratings) into high-octane liquid products called reformates, which
are premium blending stocks for high-octane gasoline.

20
Design
Specification
Requirement 1
Temperature 495-520 degrees Celsius
Pressure requirement 5-45 atm
Table 10. Catalytic Reformer Specification
J. Redistillation tower
The primary purpose of redistillation tower is to separate the liquids
into fractions to accumulate the desired products that had been processed
from hydrodesulfurization unit.
Design
Specification
Requirement 1
Capacity 20MT/day
Size 2200mm*6000mm*2500mm*8800mm

Operating mode Batch type
Table 11. Redistillation Tower Specification
H. Filter
21
Figure 16. Filter
Filters can capture mineral matter, such as scale and rust, which often foul
equipment and catalyst beds. Additionally, they can remove catalyst and coke
from and within various refinery-process units.
Requirement 1
Capacity 40,000 kg
Operating temperature 263.71 K – 272.04 K

Table 12. Filter Specification
I. LC FINING Unit
22
Figure 17. LC Fining Unit
LC Fining unit is designed to process heavy, high metals, and/or high
solid feeds. The heavy hydrocarbons are being treated with hydrogen to
produce low sulfur products. The LC-FINING process hydrocracks heavy
vacuum residue feeds to lighter distillates while simultaneously removing
sulfur, nitrogen, micro-carbon residue (MCRT), and metals containing
species.
Design
Specification
Requirement 1
Temperature 438 degrees Celsius (820 F)
Pressure requirement 3200 – 2700 psig
Table 13. LC Fining Unit Specification

J. Delayed Coker
23
Figure 18. Delayed Coker
A delayed coker is a type of coker whose process consists of
heating a residual oil feed to its thermal cracking temperature in a furnace
with multiple parallel passes. This cracks the heavy, long chain
hydrocarbon molecules of the residual oil into coker gas oil and petroleum
coke.
Design
Specification
Requirement 1
Temperature Above 482C (900F)
Size Diameter = 24’’ to 130’’
Pressure requirement 4,000 psig
Table 13. Delayed Coker Specification
Design Option 1
I. Process Design Layout

24
The oil and gas refinery plant will be consisting of series of processes in
order to obtain the light and heavy fuels as the final products. The diagram
below shows the flow of the process of the proposed plant design.
Figure 19. Oil and Gas Refinery Plant Process Flow Diagram
The crude oil is fed into the desalter with some brine to remove unwanted
inorganic salts, water and sediment. The brine will flow as discharge and the
desalted crude oil will pass through the furnace where it will be heated at high
temperature causing the crude oil to change into gas.
The refining begins with the process of distillation. The vapor enters as the
temperature of the crude oil in the distillation column rises, the crude oil
separates itself into different components called “fraction.” Each fraction
corresponds to a different type of petroleum product. The lighter distillates will
enter the hydrotreating unit to reduce sulphur, nitrogen and aromatics while
enhancing cetane number, density and smoke point. Next, it will enter the
25
debutanizer tower where butane is separated from natural gas during the refining
process. The overhead contains butane and lighter hydrocarbons which will go to
gas separator which is used to maximize the value of gas. It will then go to amine
gas treater that undergoes gas sweetening that uses aqueous solutions of
various alkylamines (commonly referred to simply as amines) to remove
hydrogen sulfide (H2S) and carbon dioxide (CO2) from gases. This can now be
sold to market as Liquefied Petroleum gas or LPG.
The bottom product from debutanizer will go through the splitter where the
bottom product will enter catalytic reformer unit where overhead products are
reformates which are premium blending stocks for high-octane gasoline.
Meanwhile, the bottom discharge product is residue.
For middle distillates, they will be introduced to Hydrodesulfurization unit
which is an equipment widely used to remove sulfur from kerosene, diesel, and
fuel oils. The purpose of removing the sulfur, and creating products such as ultra-
low-sulfur diesel, is to reduce the sulfur dioxide (SO2) emissions that result from
using those fuels in automotive vehicles, aircraft, railroad locomotives, ships, gas
or oil burning power plants, residential and industrial furnaces, and other forms of
fuel combustion. It will subsequently be fed to the redistillation column which
separates the kerosene from diesel.
Fuel oil from fractional distillation column will enter hydrotreater unit. The
feed is mixed with hydrogen gas and preheated to the appropriate reactor inlet
temperature. The process primarily removes sulfur as well as nitrogen and raise
26
cetane number. After desulphurization, it will enter to the FCC unit which is
important in converting in which heavy oil is passed through metal chambers
(called catalytic crackers or cat crackers) under pressure and high temperature in
the presence of catalysts such as alumina, silica, or zeolites. This boiling breaks
up heavy, large, and more complex long-chain oil molecules into lighter, smaller,
and simpler short-chain molecules such as those of gasoline. When blended with
additives, motor gasoline is produced and can be sold to market at different
grades.
Lastly the heaviest component or the residue will directly go to the tank
where it can be sold commercially.
II. Material Balance Calculation
Material balances are fundamental Sin the process control, particularly
in monitoring the yields of the output for each equipment. The material
balances can be used as basis to know if the equipment is functioning the
way they should. When any changes are implemented with the process, a
new material
balance is necessary.
Assumptions:
1. All flow rates are steady.
2. All gases behave ideally.
27
Raw Material Assumption
TARGET CAPACITY: 115,000 barrels daily = 4792 barrels per hour

(based on the target 25% market share)
Solving for the target hourly feed rate:
4 792 barrels x 0.14 tons of oil = 670. 88 tons/hr

feedstock
Hour 1 barrel of oil
For checking:
670.88 tons x 24 hrs x 330 days = 5 313 369.6 tons/yr

Hr day year
Mass Balance
Mass Balance Around Desalter (92% conversion efficiency)
m2
m1 m3
m4
m1 + m2 = m3 + m4
115 000 = m3 + m4
m4= 115 000 (.92)
m3 = 105 800 ( desalted crude oil)
m3= 115 000 – 105 800
m4= 9 200 (brine)
28
Mass Balance Around Preheater and Furnace (100% conversion
efficiency)
m3 m3
m3 = 105 800 (desalted crude oil)
Mass Balance Around the ADU (100% conversion efficiency
m5= 2 116
m6= 23 276
m7= 11 638
m8= 29 624
m9= 22 218
m10= 16 928
Mass Balance Around the HTU (96% conversion efficiency)
h1
m5 + m6 m11
S
m5 + m6 + h1= m11 + s
2 116 + 23 276 + 300 = m11 + s
S= .007 (2 116 + 23 276) (0.96)
29
S= 170. 63424
m11= 2 116 + 23 276 + 300 – 170. 63424
m11= 25 521. 36576
Mass Balance Around Debutanizer
m12
m11
m13
m13= 0.9 (12 760. 68258)
m13= 22 969. 22918
m12= 2 552. 136576
Mass Balance Around Gas Separator (91% conversion efficiency)
fuel gas
m12 m14
m14= 0.91(2,552. 1336576)
m14= 2 322. 444284
fuel gas= 229. 6922918

Mass Balance Around Amine Treater (98 % conversion efficiency
30
m14 LPG
s= 0.007 ( 2 322. 444284) .98
s= 15. 93196779
LPG= 2 322. 444284 – 15. 93196779
LPG= 2 306. 512316 bbl/ day

or
366 706. 165538 L/day
Mass Balance Around Splitter (100% conversion efficiency)
m15= 40%
m13= 50%
m16= 60%
m15= 4 593. 845836 (tank tops)
Mass Balance Around Catalytic Reformer (91% conversion efficiency)
cracked liquid
31
m16
residue
m16= 0.6 (11 484. 61459)
m16= 6 890. 768754 (reformates)
1 033. 615313 ( residue )
Mass Balance Around Hydraulic Desulfurization (94% conversion efficiency)
m7 m17
m8
m17= (m7 + m8 + H) – S
m17= (11 638 + 29 624 + 300) - 271. 50396
m17= 41 290. 49604
Mass Balance Around Redistillation Column (97% conversion efficient)
32
fuel gas kerosene
m17 LGO
HGO
m18= 0.40 (m17)
m18= 16 516. 19842 bbl/day (Kerosene)

or
2 625 865. 793060 L/day
m19= 0.30 (m17)
m19= 12 387. 14881 bbl/day (LGO)

or
1 969 399. 344000 L/day
m20 = 0.30 (m17)
m20= 12 387. 14881 bbl/day (HGO)
Mass Balance Around Filter (90% conversion efficient)
m18 m21
residue
m21= m18 (.90)
m21= 14 864.57858
residue= m18 – m21
33
residue= 1 651. 619842
Mass Balance Around Hydrotreater Unit (93% conversion efficient)
H
m9 m22
m22= (m9 + h) –s
s= 0.007(22 218).93
s= 144. 63198
m22= 22 373. 36082
Mass Balance Around Catalytic Cracking (95% conversion efficient)
m22 m24
m23
m24= m22 (.95)
m24= 22 373. 36082 (.95)
m24= 21 254. 69278 ( cracked gasoline )
m23= 1118. 66804 (gasoline tanks)

34
Energy Balance
Energy balances are used in the examination of the various stages of a
process, over the whole process and even extending over the total production
system from the raw material to the finished product.
Kuwait crude oil
SG = 0.8708
Cp = 2.13 kJ/kg K
Units used: m = kg/hr
Cp = kJ/kgK
T = Kelvin
1. Desalter
T1=298.15K Desalter T2=533.15K

Q=mCp∆T
T1= 1.2 atm P2= 1.2 atm
Qin = Qout
Qin = mCpΔTcrude oil
Qout = 562,231.32 (2.13) (393.15 – 298.15)
kJ
Qout= 113.7675076 x 106 hr
35
2. Furnace
T1=533.15K T2=633.15 K
Furnace
Q= mCp∆T
P1= 1 atm P2= 1 atm
Qin = Qout
Qout = 518,172.81 (2.13) (633.15 – 533.15)
Qin = 110.3708085 x 106 kJ/hr
Qout = 110.3708085 x 106 kJ/hr
3. ADU
T1= 623.15K ADU T2= varies
Q=mCp∆T
P1= 1.2 atm P1= 1.2 atm
Qin = Qout
Qout = [10363.46(1.8)(302.59 – 623.15)] + [113,998.02(1.72)
(358.15 – 623.15)] + [56,999.01(1.75)(573.15 – 623.15)] + [145,088.39(2.01)
(523.15 – 623.15)] + [(108,816.29)(2.22)(730 – 623.15)] + [82,907.65 (2.8) (840 –
273.15)]
Qout = 65.311073 x 106 kJ/hr
Qin = 65.311073 x 106 kJ/hr
4. Hydrotreating
T1=375.65 T2=573.15
Hydrotreating
Q= mCp∆T
P1= 1 atm P2= 1 atm
36
Qin = Qout
Qin = [(124,995.06)(2.3)(573.15 – 375.65)] + [(835.71(0.0071)(197.5)]
Qin = 56.780178 x 106 kJ/hr
Qout = 56.780178 x 106 kJ/hr
5. Debutanizer
T1=573.15 T2=533.15
Debutanizer
Q= mCp∆T
P1= 1.2 atm P2= 1.2 atm
Qin = Qout
Qin = [(12,499.51)(1.8)(533.15 – 573.15)] + [(112,495.56)(1.72)(533.15 –
573.15)]
Qin = -8.639659 x 106 kJ/hr
Qout = -8.639659 x 106 kJ/hr
6. Gas Separation Unit
T1=533.15 T2=298.15
Gas Separator
Q= mCp∆T
P1= 1.2 atm P2= 1.2 atm
Qin = Qout
Qout = [(11,374.55)(1.8)(298.15 – 533.15)] + [(1124.96)(2.22)( 298.15 –
533.15)]
Qout = -5.398326 x 106 kJ/hr
Qin = -5.398326 x 106 kJ/hr
7. Amine treater
T1=298.15 T2=399.15
Amine treater
Q= mCp∆T
P1= 1.2 atm P2= 1.2 atm
37
Qin = Qout
Qin = [(11,296.52)(2.4)(399.15 – 298.15)] + [(78.03)(0.0071)(399.15 –
298.15)]
Qin = 2.738332 x 106 kJ/hr
Qout = 2.738332 x 106 kJ/hr
8. Splitter
T1=533.15 T2=643.15
Splitter
Q= mCp∆T
P1= 1.2 atm P2= 1.2 atm
Qin = Qout
Qin = [(22,499.11)(1.72)(643.15 – 533.15)] + 33748.67(1.72)( 643.15 –
533.15)]
Qin = 10.642080 x 106 kJ/hr
Qout = 10.642080 x 106 kJ/hr
9. Catalytic Reformer
T1=643.15 T2=768.15
Catalytic
Reformer
P1= 1.2 atm Q= mCp∆T P2= 1.2 atm
Qin = Qout
Qin = [(30,711.29)(1.72)(768.15 – 643.15)] + [(3,037.38)(1.8)(768.15 –
643.15)
Qin = 7.286338 x 106 kJ/hr
38
Qout = 7.286338 x 106 kJ/hr
10. Hydrodesulphurization Unit
T1=548.15 T2=308.15
HDS unit
Q= mCp∆T
P1= 1.2 atm P2= 1.2 atm
Qin = Qout
Qin = 202,226.96(1.75)(308.15 – 548.15) + 3,037(1.72)(308.15 – 548.15)
Qin = -86.188997 x 106 kJ/hr
Qout = -86.188997 x 106 kJ/hr
11. Redistillation column
T1=308.15 T2=616.483
Redistillation
column
Qin = Qout
Qin = [(80,890.78)(2.01)(616.483 – 308.15)] + [(121,336.18)(1.75)(308.3)]
Qin = 115.59591 x 106 kJ/hr
Qout = 115.59591 x 106 kJ/hr
12. Filter
T1=616.483 T2=399.15
Amine treater
Q= mCp∆T
P1= 1.2 atm P2= 1.2 atm
Qin = Qout
Qin = [(72,801.71)(2.22)(399.15 – 616.483) + [8089.08(2.5)(-217.333)]
Qin = -39.520375 x 106 kJ/hr
Qout = -39.520375 x 106 kJ/hr
13. Hydrotreater Unit
T1=730 T2=573.15
Amine treater
39 Q= mCp∆T
P1= 1.2 atm P2= 1.2 atm
Qin = Qout
Qout = [(109,577.20)(2.22)(573.15 – 730)] + [(708.36)(0.0071)(-156.85)
Qin = -38.156337 x 106 kJ/hr
Qout = -38.156337 x 106 kJ/hr
14. Catalytic cracking
T1=808.15 T2=988.15
Catalytic
cracking
Qin = Qout
Qin = [(104,098.34)(2.22)(988.15 – 808.15)] + [(5478.86)(2.22)(180)]
Qin = 43.787049 x 106 kJ/hr
Qout = 43.787049 kJ/hr
DESIGN OPTION 2
40
Figure 20 . MTM Oil and Gas Refinery Plant Process Flow Diagram
Figure 21. Piping and Instrumentation Diagram
From the crude tanks, the feed will enter the desalter to remove the salt.
Next, the desalted crude will be preheated in the heater to a temperature. It will
go to the atmospheric distillation unit. The petroleum products obtained from the
distillation process are light, medium, and heavy naphtha, kerosene, diesel, and
oil residue. The first two light gases will enter the hydrotreating unit for reducing
sulphur, nitrogen and aromatics while enhancing cetane number, density and
smoke point. It will next enter the debutanizer to recover light gases (C1-C4) and
Liquefied Petroleum Gas (LPG) from the overhead distillate before producing
light naphtha during the refining process. The lightest gas will enter the gas
separator for separating a well stream into gaseous and liquid components. The
lighter gas will enter the splitter to provide a minimal level of processing to
condensate, turning it into other products such as naptha. The lightest gas will
41
enter the amine treater to remove hydrogen sulfide (H 2S) and carbon dioxide
(CO2) from gases. Then the gas from the splitter will enter to reforms lighter
hydrocarbons into higher octane molecules and hydrogen and to the catalytic
reformer to convert petroleum refinery naphtha distilled from crude oil into high-
octane liquid products.
The kerosene and gas oil will enter the hydrodesulphurization to
remove sulfur (S) from natural gas and from refined petroleum products, such
as gasoline or petrol, jet fuel, kerosene, diesel fuel, and fuel oils. It will go again
through redistillation column separate a mixture of two (or more) components into
its virgin state by heating the mixture to a temperature between their respective
boiling points.
The heavy gas will enter the catalytic hydrotreating unit to remove about
90% of contaminants such as nitrogen, sulfur, oxygen, and metals from liquid
petroleum fractions.
Lastly, the heaviest component or the residue will directly go to the
storage tank where it can be sold commercially.
Mass Balance
m2
m1 m3
42
m4
m1 + m2 = m3 + m4
115 000 = m3 + m4
m4= 115 000 (.92)
m3= 115 000 – 105 800
m4= 9 200 (brine)

efficiency)
m3 m3
m3 = 105 800 (desalted crude oil)
Mass Balance Around the ADU (100% conversion efficiency)
m5= 2 116
m6= 23 276
m7= 11 638
m8= 29 624
m9= 22 218
m10= 16 928
43
h1
m5 + m6 m11
m5 + m6 + h1= m11 + s
2 116 + 23 276 + 300 = m11 + s
S= .007 (2 116 + 23 276) (0.96)
S= 170. 63424
m11= 2 116 + 23 276 + 300 – 170. 63424
m11= 25 521. 36576
m12
m11
m13
m13= 0.9 (12 760. 68258)
m13= 22 969. 22918
m12= 2 552. 136576
fuel gas
44
m12 m14
m14= 0.91( 2 552. 1336576)
m14= 2 322. 444284
fuel gas= 229. 6922918
Mass Balance Around Amine Treater (98 % conversion efficiency)
m14 LPG
s= 0.007 ( 2 322. 444284) .98
s= 15. 93196779
LPG= 2 322. 444284 – 15. 93196779
LPG= 2 306. 512316 bbl/ day

or
366 706. 165538 L/day

45
m15= 40%
m13= 50%
m16= 60%
m15= 4 593. 845836 (tank tops)
cracked liquid
m16
residue
m16= 0.6 (11 484. 61459)
m16= 6 890. 768754 (reformates)
1 033. 615313 ( residue )
m7 m17
m8
46
m17= (m7 + m8 + H) – S
m17= (11 638 + 29 624 + 300) - 271. 50396
m17= 41 290. 49604
fuel gas kerosene
m17 LGO
HGO
m18= 0.40 (m17)
m18= 16 516. 19842 bbl/day (Kerosene)

or
2 625 865. 793060 L/day
m19= 0.30 (m17)
m19= 12 387. 14881 bbl/day (LGO)

or
1 969 399. 344000 L/day
m20 = 0.30 (m17)
m20= 12 387. 14881 bbl/day (LGO)

or
1 969 399. 344000 L/day
H
m9 m21
47
S
m21= (m9 + h) –s
s= .007(22 218).93
s= 144. 63198
m21= 22 373. 36082
m21 m23
m22
m23= m21 (.95)
m23= 22 373. 36082 (.95)
m23= 21 254. 69278 ( cracked gasoline )
m22= 1118. 66804 (gasoline tanks)
Energy Balance
48
1. Desalter

Q=mCp∆T
T1= 1.2 atm P2= 1.2 atm
Qin = Qout
Qout = 562,231.32 (2.13) (393.15 – 298.15)
kJ
Qout= 113.7675076 x 106 hr
2. Furnace
T1=533.15K T2=633.15 K
Furnace
Q= mCp∆T
P1= 1 atm P2= 1 atm
Qin = Qout
Qout = 518,172.81 (2.13) (633.15 – 533.15)
Qout = 110.3708085 x 106 kJ/hr
3. ADU
Q=mCp∆T
P1= 1.2 atm P1= 1.2 atm
Qin = Qout
49
Qout = [10363.46(1.8)(302.59 – 623.15)] + [113,998.02(1.72)
(358.15 – 623.15)] + [56,999.01(1.75)(573.15 – 623.15)] + [145,088.39(2.01)
(523.15 – 623.15)] + [(108,816.29)(2.22)(730 – 623.15)] + [82,907.65 (2.8) (840 –
273.15)]
Qout = 65.311073 x 106 kJ/hr
Qin = 65.311073 x 106 kJ/hr
4. Hydrotreating
T1=375.65 T2=573.15
Hydrotreating
Q= mCp∆T
P1= 1 atm P2= 1 atm
Qin = Qout
Qin = [(124,995.06)(2.3)(573.15 – 375.65)] + [(835.71(0.0071)(197.5)]
Qin = 56.780178 x 106 kJ/hr
Qout = 56.780178 x 106 kJ/hr
5. Debutanizer
T1=573.15 T2=533.15
Debutanizer
Q= mCp∆T
P1= 1.2 atm P2= 1.2 atm
Qin = Qout
Qin = [(12,499.51)(1.8)(533.15 – 573.15)] + [(112,495.56)(1.72)(533.15 –
573.15)]
Qin = -8.639659 x 106 kJ/hr
Qout = -8.639659 x 106 kJ/hr
50
T1=533.15 T2=298.15
Gas Separator
Q= mCp∆T
P1= 1.2 atm P2= 1.2 atm
Qin = Qout
Qout = [(11,374.55)(1.8)(298.15 – 533.15)] + [(1124.96)(2.22)( 298.15 –
533.15)]
Qout = -5.398326 x 106 kJ/hr
Qin = -5.398326 x 106 kJ/hr
7. Amine treater
T1=298.15 T2=399.15
Amine treater
Q= mCp∆T
P1= 1.2 atm P2= 1.2 atm
Qin = Qout
Qin = [(11,296.52)(2.4)(399.15 – 298.15)] + [(78.03)(0.0071)(399.15 –
298.15)]
Qin = 2.738332 x 106 kJ/hr
Qout = 2.738332 x 106 kJ/hr
8. Splitter
T1=533.15 T2=643.15
Splitter
Q= mCp∆T
P1= 1.2 atm P2= 1.2 atm
Qin = Qout
Qin = [(22,499.11)(1.72)(643.15 – 533.15)] + 33748.67(1.72)( 643.15 –
533.15)]
51
Qin = 10.642080 x 106 kJ/hr
Qout = 10.642080 x 106 kJ/hr
T1=643.15 T2=768.15
Catalytic
Reformer
Qin = Qout
Qin = [(30,711.29)(1.72)(768.15 – 643.15)] + [(3,037.38)(1.8)(768.15 –
643.15)
Qin = 7.286338 x 106 kJ/hr
Qout = 7.286338 x 106 kJ/hr

T1=548.15 T2=308.15
HDS unit
Q= mCp∆T
P1= 1.2 atm P2= 1.2 atm
Qin = Qout
Qin = 202,226.96(1.75)(308.15 – 548.15) + 3,037(1.72)(308.15 – 548.15)
Qin = -86.188997 x 106 kJ/hr
Qout = -86.188997 x 106 kJ/hr
T1=308.15 T2=616.483
Redistillation
column
Qin = Qout
Qin = [(80,890.78)(2.01)(616.483 – 308.15)] + [(121,336.18)(1.75)(308.3)]
Qin = 115.59591 x 106 kJ/hr
Qout = 115.59591 x 106 kJ/hr
52
T1=730 T2=573.15
Amine treater
Q= mCp∆T
P1= 1.2 atm P2= 1.2 atm
Qin = Qout
Qout = [(106 667.94)(2.22)(573.15 – 730)] + [(689.55)(0.0071)(-156.85)
Qin = -37.143291 x 106 kJ/hr
Qout = -37.143291 x 106 kJ/hr
T1=808.15 T2=988.15
Catalytic
cracking
Qin = Qout
Qin = [(101 334.54)(2.22)(988.15 – 808.15)] + [(5 333.40)(2.22)(180)]
Qin = 42.624509 x 106 kJ/hr
Qout = 42.624509 x 106 kJ/hr
53
DESIGN OPTION 3
Figure 22. Oil and Gas Refinery Plant Process Flow Diagram
In this design option, the main difference from other options is the
processing of residues, transforming them into products that have higher value
such as kerosene and diesel. The lowest tray collects heaviest component called
residue which will enter the LC Fining unit where the processed crude will enter
the hydrodesulphurization unit. The residue from LC fining unit will be processed
again by the delayed coker unit where different fractions will be processed by
HDS unit and shall enter redistillation column to separate the products into
kerosene, light gas oil, and heavy gas oil.
54
The residue from catalytic cracker will be introduced to delayed coker to
experience the same process of desulphurization and separation.
Mass balance
m2
m1 m3
m4
m1 + m2 = m3 + m4
115 000 + 5 000 = m3 + m4
m4= 120 000 (.92)
m3= 120 000 – 110,400
m4= 9,600 (brine)

efficiency)
m3 m3
55
m3 = 110,400 (desalted crude oil)
Mass Balance Around the ADU (100% conversion efficiency)
m5 = 2,208
m6 = 24,288
m7= 12,144
m8= 30,912
m9= 23,184
m10= 17,664
h1
m5 + m6 m11
m5 + m6 + h1= m11 + s
2,208 + 24,288 + 300 = m11 + s
S= .007 (2,208 + 24,288) (0.96)
S= 178.05312
m11= 2,208 + 24,288 + 300 – 178.05312
m11= 26617.94688
56
m12
m11
m13
m13= 0.9 (26617.94688)
m13= 23,956.15219
m12= 2,661.794688
fuel gas
m12 m14
m14= 0.91(2,661.794688)
m14= 2422.233166
fuel gas= 239.5615
Mass Balance Around Amine Treater (98 % conversion efficiency)
m14 LPG
57
S
s= 0.007 ( 2422.233166) .98
s= 16.6165
LPG= 2422.233166 – 16.6165
LPG= 2405.6167 bbl/ day

or
382,462.5 L/day
m15= 40%
m13= 50%
m16= 60%
m15= 4,791.2304 (tank tops)
cracked liquid
m16
residue
m16= 0.6 (11 484. 61459)
m16= 6540.029548 (reformates)
646.8161091 ( residue )
58
Mass Balance around LC Fining unit (94% conversion efficiency)
m19
M10
m18
M19 = 0.94 (m10)
M19 = 0.94 (17,664)
M19 = 16,604.16
Residue = 706.56 = m18
Mass Balance Around Delayed Coker (99% efficiency)
m18 M20
Anode coke
m20 = 0.99 (m18)
m20 = 699.4944
59
anode coke = 7.0656
m7+m8 m17
m19+m20
m17= (m7 + m8 +m19 + m20 + H) – S
m17= (12,144 + 30,912 + 16,604.16 + 699.4944 + 300) - S
S = 0.007 (60,359.6544)(0.94)
S = 397.166526
M17 = 60,262.48787
fuel gas kerosene
m17 LGO
HGO
M25= 0.40 (m17)
60
M25= 24,104.99515 bbl/day (Kerosene)
or
3,832,388 L/day
M26 = 0.30(m17)
M26 = 18,078.74636 (LGO)
M26= 18,078.74636 bbl/day (LGO)

or
2,874,291 L/day
m20 = 0.30 (m17)
m27= 18,078.74636 bbl/day (LGO)

or
2,874,291 L/day
H
m9 m21
m21= (m9 + h) –s
s= .007 (23,184) (0.93)
s= 150.92784
m21= 23,333.07216
m21 m23
61
m22
m23= m21 (.95)
m23= 23,333.07216 (.95)
m23= 22,166.41855 ( cracked gasoline )
m22= 1166.65361 (gasoline tanks)
Energy Balance
1. Desalter

Q=mCp∆T
T1= 1.2 atm P2= 1.2 atm
Qin = Qout
Qin = [(548 277.62)(2.13)(393.15 – 298.15)] + [23 838.16(3.93)
( 393.15 – 298.15)]
6
Qin = 119.833836 x 10 kJ/hr = Qout
2. Furnace
62
T1=533.15K T2=633.15 K
Furnace
Q= mCp∆T
P1= 1 atm P2= 1 atm
Qin = Qout
Qout = 526 346.52 (2.13) (633.15 – 533.15)
Qout = 110.3708085 x 106 kJ/hr
Qin = 110.3708085 x 106 kJ/hr
3. ADU
Q=mCp∆T
P1= 1.2 atm P1= 1.2 atm
63
Qin = Qout
Qout = [10,526.93(1.8)(302.59 – 623.15)] + [115 796.23 (1.72)
(358.15 – 623.15)] + [57,898.12(1.75)(573.15 – 623.15)] + [147,377.03 (2.01)
(523.15 – 623.15)] + [(110,532.77)(2.22)(730 – 623.15)] + [84 215.44 (2.8) (840 –
273.15)]
Qout = 66.341296 x 106 kJ/hr
Qin = 66.341296 x 106 kJ/hr
4. Hydrotreating
T1=375.65 T2=573.15
Hydrotreating
Q= mCp∆T
P1= 1 atm P2= 1 atm
Qin = Qout
Qin = [(10,526.93)(1.8)(573.15 – 375.65)] + [(115 796.23)(1.72)(197.5)+
[(1,430.29)(14.46)(573.15 – 375.65)]
Qin = 47.162997 x 106 kJ/hr
Qout = 47.162997 x 106 kJ/hr
5. Debutanizer
T1=573.15 T2=533.15
Debutanizer
Q= mCp∆T
P1= 1.2 atm P2= 1.2 atm
Qin = Qout
Qin = [(126,904.56)(1.8)(533.15 – 573.15)]
Qin = -9.137128 x 106 kJ/hr
64
Qout = -9.137128 x 106 kJ/hr
T1=533.15 T2=298.15
Gas Separator
Q= mCp∆T
P1= 1.2 atm P2= 1.2 atm
Qin = Qout
Qout = [(12 690.46)(1.8)(298.15 – 533.15)]
Qout = -5.368065 x 106 kJ/hr
Qin = -5.368065 x 106 kJ/hr
7. Amine treater
T1=298.15 T2=399.15
Amine treater
Q= mCp∆T
P1= 1.2 atm P2= 1.2 atm
Qin = Qout
Qin = [(11,548.32)(2.4)(399.15 – 298.15)]
Qin = 2.799313 x 106 kJ/hr
Qout = 2.799313 x 106 kJ/hr
8. Splitter
T1=533.15 T2=643.15
Splitter
Q= mCp∆T
P1= 1.2 atm P2= 1.2 atm
Qin = Qout
Qin = [(57 107.05)(1.72)(643.15 – 533.15)]
Qin = 10.804654 x 106 kJ/hr
Qout = 10.804654 x 106 kJ/hr
65
T1=643.15 T2=768.15
Catalytic
Reformer
Qin = Qout
Qin = [(31 180.45)(1.72)(768.15 – 643.15)]
Qin = 6.703796 x 106 kJ/hr
Qout = 6.703796 x 106 kJ/hr

10. LC Fining unit
T1=840 T2=711.15
LC Fining Unit
Q= mCp∆T
P1= 1.2 atm P2= 1.2 atm
Qin = Qout
Qin = [(84,215.44)(2.6)(711.15 – 840)]
Qin = - 28.213015 x 106 kJ/hr
Qout = - 28.213015 x 106 kJ/hr
11. Delayed Coker
T1=711.15 T2=758.15
Delayed Coker
Q= mCp∆T
P1= 1.2 atm P2= 1.2 atm
Qin = Qout
Qin = [(3 368.62)(2.6)(758.15 – 711.15)
Qin = 411.645.364 x 103 kJ/hr
Qout = 411.645.364 x 103 kJ/hr
T1=548.15 T2=308.15
HDS unit
Q= mCp∆T
P1= 1.2 atm P2= 1.2 atm
66
Qin = Qout
Qin = [(57 898.12 (1.75)(573.15 – 548.15)] + [(147 377.03)(2.01)(523.15–
548.15)] + [(82 497.45)(2.6)(573.15- 758.15)] + [(1,430.29)(14.51)(308.15-
20.28)
Qin = - 38.579614 x 106 kJ/hr
Qout = - 38.579614 x 106 kJ/hr
T1=308.15 T2=616.483
Redistillation
column
Qin = Qout
Qin = [(287,309.34)(2.01)(616.483 – 308.15)]
Qin = 178.059771 x 106 kJ/hr
Qout = 178.059771 x 106 kJ/hr
T1=730 T2=573.15
Amine treater
Q= mCp∆T
P1= 1.2 atm P2= 1.2 atm
Qin = Qout
Qout = [(110,532.77)(2.22)(573.15 – 730)] + [(1,430.29)(14.77)(-156.85)]
Qin = -41.801801 x 106 kJ/hr
Qout = -41.801801 x 106 kJ/hr
T1=808.15 T2=988.15
Catalytic
cracking
Qin = Qout
67
Qin = [(111 243.49)(2.22)(988.15 – 808.15)]
Qin = 44.452899 x 106 kJ/hr
Qout = 44.452899 x 106 kJ/hr
68

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Chapter III

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CHAPTER III

TECHNICAL DESIGN AND REQUIREMENTS

This chapter discusses the preparation of comprehensive plant cycle

balance, energy balance, equipment and design specifications, technical

specifications, and standard requirements.

Equipment and Functions

A crude oil desalter is a device used in petroleum refineries to

oil feedstock before it is refined. This article focuses on the use

of electrostatic desalters to produce a dehydrated, desalted crude oil with a low

Figure 7. Pre-flash Vessel/ Drum

A preflash drum/vessel creates foam that can affect measurement

accuracy of liquid levels and decrease distillate production in the

carryover to the distillation column.

An enclosed structure in which material can be heated to very high

temperatures.It is a forced and induced draught, multiple burner heater with

vertical firing in the radiant cell.

The purpose of atmospheric distillation is primary separation of

various fractions of hydrocarbons namely, fuel gases, LPG, naphtha,

bottom of the atmospheric distillation column is sent to vacuum distillation

column for further separation of hydrocarbons under reduced pressure.

Figure 10. Gas

Gas separation units are used to separate various hydrocarbons

Hydrotreating is an established refinery process for reducing

sulphur, nitrogen and aromatics while enhancing cetane number, density

and smoke point.

liquid in order to separate or purify the liquid. Examples include distilling

water to purify it and distilling liquor to make it stronger. Fractional

distillation, as occurs in a debutanizer, is the separation of a fraction — a

the rest of the mixture.

Hydrodesulfurization Unit (HDS) is an equipment widely used to

purpose of removing the sulfur, and creating products such as ultra-low-

from using those fuels in automotive vehicles, aircraft, railroad

locomotives, ships, gas or oil burning power plants, residential and

industrial furnaces, and other forms of fuel combustion.

H. Catalaytic Cracking Unit

Figure 14. Catalytic Cracking Unit

conversion processes used in petroleum refineries. It is widely used to

convert the high-boiling, high-molecular weight hydrocarbon fractions of

I. Catalytic Reformer Unit

Figure 15. Catalytic Reforming Unit

Catalytic reforming is a chemical process used to convert

octane ratings) into high-octane liquid products called reformates, which

are premium blending stocks for high-octane gasoline.

The primary purpose of redistillation tower is to separate the liquids

from hydrodesulfurization unit.

Power requirement 15 kwh

from and within various refinery-process units.

Power requirement 15 kwh

LC Fining unit is designed to process heavy, high metals, and/or high

produce low sulfur products. The LC-FINING process hydrocracks heavy

vacuum residue feeds to lighter distillates while simultaneously removing

sulfur, nitrogen, micro-carbon residue (MCRT), and metals containing

Table 13. LC Fining Unit Specification

A delayed coker is a type of coker whose process consists of

heating a residual oil feed to its thermal cracking temperature in a furnace

I. Process Design Layout

temperature causing the crude oil to change into gas.

separates itself into different components called “fraction.” Each fraction

corresponds to a different type of petroleum product. The lighter distillates will

various alkylamines (commonly referred to simply as amines) to remove

sold to market as Liquefied Petroleum gas or LPG.

reformates which are premium blending stocks for high-octane gasoline.

Meanwhile, the bottom discharge product is residue.