Chapt

er1
I
ntr
oduct
ion
1.
1INTRODUCTI
ONOFCRUDEOI
L:

Cr
udeoi
li
soneoft
het
womaj
orf
ossi
lfuel
sonear
th,
theot
herbei
ngcoal
.Iti
sthemai
nand
costef
fect
iveener
gysour
cet
odayt
hroughef
for
tsar
eont
odi
scov
erot
hermeans.Cr
udeoi
l
s
v
arywi
del
yinappear
anceandconsi
stencyf
rom count
ryandf
rom f
iel
dtof
iel
d.Howev
er,al
l
cr
udeoi
l
sconsi
stessent
ial
l
yofhy
drocar
bons.

1.
2CLASSI
FICATI
ONOFCRUDEOI
L:

1.Basedont
henat
ureofhy
drocar
bons:

a)Par
aff
inbasedcr
udeoi
l
s:Theseconsi
stmai
nlyofpar
aff
ini
chy
drocar
bonsbutl
i
ttl
e/no
asphal
ti
cmat
ter
.Theyusual
l
ygi
vegoody
iel
dsofpar
aff
ini
cwax,
highgr
adeSKOandhi
gh
gr
adel
ubr
icat
ingoi
l
s.

b)Asphal
tbasedcr
udeoi
l
s:Theycont
ainl
i
ttl
e/nopar
aff
inwaxbutasphal
ti
cmat
eri
ali
s
usual
l
ypr
esenti
nlar
gepr
opor
ti
ons.Theyconsi
stofmost
lynapht
henes.Lubeoi
l
sof
t
hesecr
udeoi
l
sar
emor
esensi
ti
vet
otemper
atur
e.Thesecr
udeoi
l
sgi
vehi
ghqual
i
ty
gasol
i
ne.

c)Mi
xedbasecr
udeoi
l
s:Thesecr
udeoi
l
sexhi
bitconsi
der
abl
eov
erl
appi
ngoft
hebot
hty
pes
descr
ibedabov
e.

2.BasedonAPIgr
avi
ty:

Cr
udewi
thl
ow densi
ty(
highAPIgr
avi
ty)i
scal
l
edl
i
ghtcr
ude,whi
l
ethatwi
thhi
ghdensi
ty
(
lowAPIgr
avi
ty)i
scal
l
edheav
ycr
ude.

3.Basedonsul
furcont
ent
:

a)Lowsul
furcr
udeoi
l
:Cr
udeswi
thl
esst
han1wt
%sul
furar
ecal
l
edassweetcr
udes.

b)Hi
ghsul
furcr
udeoi
l
:Cr
udeswi
thmor
ethan1wt
%sul
furar
ecal
l
edassourcr
udes.
 TABLE-
1RANGEOFHYDROCARBONSPRESENTI
NTHEPRODUCTS

Gas c1-c4

Napht
ha/
str
aightr
ungasol
i
ne c4 -c12

Di
sti
l
lat
es(
ker
osene-di
esel
) c10 -c18

Gasoi
l c14 -c22

Lubeoi
ldi
sti
l
lat
e c16 -c26

Resi
duum (
Reducedcr
ude,
heav
yfuel
, c26+
asphal
tet
c)

1.
3INTRODUCTI
ONTOMS:

Mot
orspi
ri
torpet
rolorgasol
i
nei
sat
ranspar
ent
,pet
rol
eum der
ivedl
i
qui
dthati
sused
asf
ueli
nspar
kigni
tedi
nter
nalcombust
ionengi
nes.I
tconsi
stsofmost
lyor
gani
c
compoundsobt
ainedbyt
hef
ract
ionaldi
sti
l
lat
ionofpet
rol
eum,
enhancedwi
thav
ari
ety
ofaddi
ti
ves.Onav
erageof42gal
l
onbar
rel
sofcr
udeoi
l(159L)y
iel
dsabout19US
gal
l
onsofgasol
i
newhenpr
ocessedi
naoi
lref
iner
y.

Thechar
act
eri
sti
csofpar
ti
cul
argasol
i
nebl
endt
oresi
sti
gni
ti
ngt
ooear
ly(
causes
knocki
ngandr
educeef
fi
ci
encyi
nreci
procat
ingengi
ne)
.Gasol
i
nei
spr
oducedi
n
sev
eral
gradesofoct
aner
ati
ngs.

1.
3.1Oct
aner
ati
ngofgasol
i
ne:

Spar
kigni
ti
onengi
nesar
edesi
gnedt
obur
ngasol
i
nei
nacont
rol
l
edpr
ocesscal
l
ed
def
lagr
ati
on.Howev
ert
hebur
ningmi
xtur
emayaut
oigni
tebydet
onat
ionunder
pr
essur
eandheatal
one,
rat
hert
hani
gni
tef
rom spar
kpl
ugatt
her
ightt
ime.Thi
scan
r
api
dlyl
eadst
opr
essur
erai
sewhi
chcandamaget
heengi
ne.Thi
siscal
l
edknocki
ng.
Knocki
ngcanber
educedbyi
ncr
easi
ngt
hegasol
i
ner
esi
stancet
oaut
oigni
ti
on
whi
chi
sexpr
essedi
nter
msofoct
aner
ati
ngs.

Oct
aner
ati
ngi
smeasur
edr
elat
ivet
oami
xtur
eof2,2,4-
tr
imet
hyl
pent
aneandn-
pent
ane.Ther
ear
edi
ff
erentconv
ent
ionsf
orexpr
essi
ngoct
aner
ati
ngs,sot
hephy
sical
f
uelmayhav
edi
ff
erentoct
aner
ati
ngsbasedont
hemeasur
esused.Oneoft
hebesti
s
t
her
esear
choct
anenumber(
RON)
.

1.
3.2Const
it
uent
sofgasol
i
ne:

Thebul
koft
het
ypi
calgasol
i
neconsi
stsofhy
drocar
bonswi
thbet
ween4and12car
bon
at
omspermol
ecul
e(r
efer
red asC4 t
o C12)
.Iti
sa mi
xtur
eofpar
aff
ins(
alkene)
,
cy
cloal
kenes(
napt
henes)
,andol
efi
ns(
alkenes)
.

1.
3.3Chemi
cal
anal
ysi
sofGasol
i
ne:

Thebul
koft
hegasol
i
neconsi
stsofhy
drocar
bonswi
thbet
ween4and12car
bonat
oms
permol
ecul
e.I
tisami
xtur
eofpar
aff
ins,
cycl
oal
kanes,
olef
ins.Var
iousr
efi
ner
y
st
reamsar
ebl
endedt
omakegasol
i
nehav
ingdi
ff
erentchar
act
eri
sti
cs.

Somei
mpor
tantst
reamsar
e:

 St
rai
ghtr
ungasol
i
ne,commonl
yref
err
edasnapt
ha,i
sdi
sti
l
leddi
rect
lyf
rom
cr
udeoi
l
.Iti
slow i
nar
omat
ics,cont
aini
ngsomecy
cloal
kanesandnool
efi
ns.
Thechemi
calpr
oper
ti
esst
rai
ghtr
ungasol
i
necanbei
mpr
ovedbyi
somer
izat
ion
andr
efor
ming.

 Ref
ormat
e,pr
oducedi
nacat
aly
ticr
efor
merhasahi
gheroct
aner
ati
ngswi
th
hi
ghar
omat
iccont
entandr
elat
ivel
ylowol
efi
ncont
ent
.

 Cat
aly
ticcr
ackedgasol
i
neorcat
aly
ticcr
ackednapt
ha,
producedf
rom acat
aly
tic
cr
acker
,wi
thamoder
ateoct
aner
ati
ngs,hi
ghol
efi
nsandmoder
atear
omat
ics
l
evel
.

 Al
kyl
atei
spr
oducedi
nanal
kyl
ati
onuni
t,usi
ngasf
eedst
ocksi
sobut
aneand
al
kenes.
Alky
lat
econt
ainsnoar
omat
icsandal
kenesandhashi
ghMON.

 I
somer
ate,
isobt
ainedbyi
somer
izi
ngl
owoct
anest
rai
ghtr
ungasol
i
net
oiso-
par
aff
ins.I
somer
atehasmedi
um RON amd MON butni
lar
omat
icsand
ol
efi
ns.
  But
ane,i
susual
l
ybl
ended i
ngasol
i
nepoolal
thought
hequant
it
yoft
he
st
ream i
sli
mit
edbyRVPspeci
fi
cat
ions.

1.
3.4Ant
iknocki
ngAddi
ti
ves:

Ant
iknocki
ng agenti
sagasol
i
neaddi
ti
veused t
oreduceengi
neknocki
ng and
i
ncr
easef
uel
'
soct
aner
ati
ngs.Ty
pical
Ant
iknocki
ngagent
sar
e:

 Tet
raet
hyl
lead(
TEL)

 Oct
ane

 2,
2,4-
tr
imet
hyl
pent
ane

 Met
hyl
tet
rabut
ylet
her
(MTBE)

1.
4PURPOSEOFMSBLOCK:

MSi
sami
xedbl
endofdi
ff
erentt
ypesofNapht
ha(
i.
e.,bl
endedpr
oduct
).
Bef
ore
2010,BS-
1(Br
it
ishst
andar
ds)andBS-
2MS madebybl
endi
ngofSRN andCRN
di
rect
ly.Thi
sMSi
susedasf
uelf
oraut
omobi
l
es.Fr
om t
heaut
omobi
l
es,sul
fur
cont
enti
nMSi
soxi
dizedt
oSO2andemi
tt
edi
ntheat
mospher
e.Thi
siscausi
ng
pol
l
uti
onpr
obl
emsandr
aisi
ngenv
ironment
alconcer
ns.Tocont
rolSoxemi
ssi
on
gov
ernmenthasr
evi
sedMSspeci
fi
cat
ions(
i.
e.,EURO-
II
I/
EURO-
IVspeci
fi
cat
ions)
.For
r
eachi
ngEURO-
II
I/
EURO-
IVspeci
fi
cat
ionsMSBl
ocki
scommi
ssi
oned.

1.
4.1Adv
ant
agesofMSBl
ockSt
reams:

Lowersul
fur

 Hi
gherResear
chOct
aneNumber

 Lowerbenzene
  Lowerar
omat
iccont
entf
orsev
eral
str
eams(
LCN,
LN,
LI,
HI)

 Lowerol
efi
nsf
orsev
eral
str
eams(
Ref
ormat
e,LN,
LI,
HI)

1.
5MSBLENDI
NG:

Wi
tht
hei
ncr
easi
ngconcer
naboutt
heenv
ironmentandt
hedev
elopmentofl
ess
pol
l
uti
nggr
adef
uel
s,VRcl
eanf
uel
spr
ojectar
ecommi
ssi
onedt
omeett
henewer
MSgr
adenor
mswhi
char
emuchmor
est
ri
ngent
.Ascompar
edt
otheear
li
ert
ime,
wher
einonl
ySRN andCRN wer
ebl
endedt
opr
oduceMS,now ot
herst
reamsar
e
bei
ngusedbecauset
heaf
orement
ionedst
reamshav
enow becomef
eedt
othe
secondar
yuni
ts,
whosepr
oduct
sar
ebl
endedt
opr
oducenewgr
adesofMS.TheMS
bl
endpr
imar
il
yconsi
stsof
:Hy
drot
reat
edl
i
ghtnapt
ha,Ref
ormat
e,pr
imeG l
i
ght
napht
ha,
pri
meGheav
ynapht
haandr
efor
mat
e.Eachoft
heabov
est
reamshast
hei
r
own qual
i
typr
oper
ti
es and const
rai
nts pr
oper
ti
es.The bl
end i
s so cr
eat
ed t
o
opt
imi
zet
hequal
i
typr
oper
ti
esbyov
ercomi
ngt
heconst
rai
ntpr
oper
tyt
omeett
he
qual
i
tyasdesi
redbyt
hemar
ketwi
thoutanyqual
i
tygi
venaway
.

I
noper
ati
onspl
anni
ng,MSbl
endi
ngexcelsheeti
susedt
ocar
ryoutt
hisbl
endi
ng.A
t
heor
eti
cal
blendf
orapar
ti
cul
arbat
chi
spr
epar
edandt
hest
reamsar
erout
edasper
t
hebl
endi
ngr
ati
o.Thet
anki
sal
l
owedt
omi
xfor10-
12hour
saf
terwhi
chsampl
eis
sentf
orf
ull
test
.Bel
owst
reamsf
rom MSbl
ockar
eusedf
orMSbl
endi
ng:

1.CCRREFORMATE:Ref
ormat
ecanber
out
edt
obot
hMSbl
endheader
s.I
fBPC/
BRCi
s
onl
i
neexcessf
low wi
l
lgot
oref
ormat
est
oraget
ankorot
herMSheader
.Tot
al
r
efor
mat
ecanbeAI
ndust
ri
alRepor
tonHPCL26r
out
edt
oref
ormat
est
oraget
ank.

2.LIf
rom NI
U:LIber
out
edt
obot
hMS-bl
endheader
sanddi
rect
lycanber
out
edt
o
st
oraget
ankandot
herMSheader
.IfBPC/
BRCi
sonl
i
neexcessf
lowwi
l
lgot
ost
orage
t
ank.

3.HIf
rom NI
U:HIcanber
out
edt
obot
hMS-
blendheader
s.I
fBPC/
BRCi
sonl
i
neexcess
f
lowwi
l
lgot
oNapht
hapool
(HIj
oinsLNf
rom NHTheader
)orot
herMSheader
.
4.LCN:LCNcanber
out
edt
obot
hMSheader
.IfBPC/
BRCi
sonl
i
neexcessf
lowwi
l
lgo
t
o

MS-r
egul
arheader
.

5.HCN:HCNcanber
out
edt
obot
hheader
s.I
fBPC/
BRCi
sonl
i
neexcessf
lowwi
l
lgot
o
Napht
hapool
(HCNj
oinsLNf
rom NHTheader
)orot
herMSheader
.

6.LN:Li
ghtNapht
hacanber
out
edmanual
l
ytocont
rol
theRON.

Tabl
e-2MSEURO-
II
I/
IVSPECI
FICATI
ON

PARAMETER EUROI
II EUROI
V

Sul
phur
,maxppmw 150 50

Benzene%max 1.
0 1.
0

Ar
omat
ics(
%max) 42 35

Ol
efi
ns(
%max) 18 18

RONmi
n 95pr
emi
um 95pr
emi
um

91r
egul
ar 91r
egul
ar

MONmi
n 85pr
emi
um 85pr
emi
um

81r
egul
ar 81r
egul
ar

RVP,
kPamax 70 60

Leadcont
entg/
lmax 0.
013 0.
0103
 Oxy
gen(
%max
) 2.
7 2.
7

Et
her
s(%cont
aini
ng3or5C 15 15
at
oms)
%Di
sti
l
ledat100degC 46 46

%Di
sti
l
ledat150degC 75 75
 Chapt
er2
Li
ter
atur
eRevi
ew
2.
1Fl
uidCat
aly
ticCr
acki
ngandNapht
haHy
drot
reat
ingUni
t

2.
1.1I
ntr
oduct
ion:

Theobj
ect
iveofFCCNapht
haHy
drot
reat
ingUni
tist
opr
ocessFCCGasol
i
net
o
obt
ainpr
oductst
reams(
Lightgasol
i
neandHeav
yHy
drot
reat
edgasol
i
ne)wi
th
t
arget
ed qual
i
ties (
Eur
o-I
IIspeci
fi
cat
ions)ofoct
ane number
,sul
phurcont
ent
,
benzenecont
entandol
efi
nscont
ent
.

The uni
tis desi
gned f
or a st
ream f
act
or of 8000
hour
s/annum.Theuni
tcapaci
tyi
s893330MT/
yr.

2.
1.2Pr
ocessDesi
gnBasi
s:

Feedf
rom FCCUsi
sfi
rstpr
ocessedi
nSHUsect
ionwher
ehy
drogeni
ssuppl
i
edt
o
sat
urat
ethedi
-ol
efi
ns.Somel
i
ght
ersul
phurcompoundsar
econv
ert
edt
otheheav
ier
sul
phurcompounds.TheSHUr
eact
ordownst
ream spl
i
ttersepar
atesl
ow sul
phur
,
hi
ghRONLCNandt
hespl
i
tterbot
tom i
ssendt
otheHDSsect
ionwher
esul
phuri
sde
-sul
fur
izedandHCNi
ssentt
ost
abi
l
izer
.St
abi
l
izeri
sdesi
gnedt
ost
ri
p-of
fH2Sf
rom
HCN.I
tal
soconsi
stsofabsor
ber
.Iti
sdesi
gnedt
oreducet
heH2Scont
entofr
ecy
cle
gas.TheFCCNHThasacapaci
tyof0.
89MMTPAconsi
der
ingonst
ream f
act
orof8000
oper
ati
nghour
spery
ear
.

Thr
eeoper
ati
ngcasesar
econsi
der
eddur
ingdesi
gnoft
heuni
t,namel
y:
Not
icei
nvi
ti
ngt
endercase(
NIT)-Hi
ghsul
phurandhi
ghol
efi
ns
Ar
abMi
xcase(
AM)-Hi
ghsul
phur
BombayHi
ghcase(
BH)-l
owsul
phur

2.
1.3TheUni
tconsi
stsoff
oll
owi
ngsect
ion:

1.Sel
ect
iveHy
drogenat
ionUni
t

2.Spl
it
ter
3.HydroDe-
Sul
phuri
sat
ion
4.Amineabsor
berandr
ecycl
ecompr
essi
on

5. St
abi
l
izer
2.
2SHUCHEMI
CALREACTOI
NS:

1.Di
olef
inshy
drogenat
ion

2.Ol
efi
nshy
drogenat
ion

3.Ol
efi
nsi
somer
izat
ion

4.Sul
phurr
eact
ion

2.
2.1 Hy
drogenat
ionofDi
olef
ins(
Diol
efi
nSat
urat
iont
oOl
efi
n):

Di
olef
insar
ehy
drogenat
edi
ntocor
respondi
ngol
efi
nsandsomeoft
heol
efi
nsar
e
hy
drogenat
ed i
ntocor
respondi
ngpar
aff
in’
s.

 NormalDi
olef
ins–Exampl
e

CH3-
CH=CH-
CH2-
CH2-
CH=CH2+H2 CH3-
CH=CH-
CH2-
CH2-
CH3

 Cycl
odi
olef
ins–Exampl
e

 Hy
drogenat
ionofOl
efi
ns:

Theser
eact
ionsar
eundesi
rabl
ebecauset
heyr
educet
heoct
anenumber
.
Hy
drogenat
ionofol
efi
nsi
ntopar
aff
in’
s

R-
C=C-
R’+H2 R-
C-C-
R’
 Ol
efi
nsdoubl
ebondi
somer
izat
ion:

I
ncr
easeol
efi
nsoct
anenumberReact
ionundert
her
mody
nami
ccont
rol
.

CH2=CH-
CH2-
CH2-
CH2-
CH3 CH3-
CH=CH2-
CH-
CH2-
CH3

 Sul
phurr
eact
ions:

I
n cr
acked napht
has(
FCC gasol
i
neand py
rol
ysi
sgasol
i
ne)
,thepr
inci
pal
sul
fur compounds i
ncl
ude mer
capt
ans (
RSH)
,al
i
phat
ic sul
fi
des (
RSR)
,
al
i
phat
icdi
sul
fi
deandt
hiophenes.Ov
ersel
ect
ivehy
drogenat
ioncat
aly
sts,
l
i
ghtmer
capt
ansandl
i
ghtsul
fi
desar
econv
ert
edt
oheav
iersul
furspeci
es.I
n
addi
ti
on,H2Si
sal
soconv
ert
edt
oheav
iersul
furcompounds.Appr
oxi
mat
ely
95-
98%oft
hel
i
ghtmer
capt
ansar
econv
ert
edi
ntheSel
ect
iveHy
drogenat
ion
r
eact
or.Car
bony
lsul
fi
de (
COS)and car
bon di
sul
fi
de (
CS2)wi
l
lal
so be
conv
ert
edt
onearext
inct
ion.Di
-met
hylsul
fi
de(
DMS)andet
hyl
-met
hylsul
fi
de
(
EMS)conv
ersi
oni
sli
mit
edatappr
oxi
mat
ely50-
70%.

 CONVERSI
ONOFLI
GHTMERCAPTANSTOHEAVI
ERSULFI
DES

RSH+R'
(C5t
oC7ol
efi
n) RSR'

 CONVERSI
ONOFLI
GHTMERCAPTANSTOHEAVI
ERMERCAPTANS

RSH+H2 RH+H2S
2.
3PLANTCHEMI
CALS:

2.
3.1Chemi
cal
dur
ingnor
mal
plantoper
ati
on:

Cor
rosi
oni
nhi
bit
oragent
:
Thecor
rosi
oni
nhi
bit
oragenti
sinj
ect
edanddi
l
utedat10%wti
ndesul
fur
izedheav
y
napht
ha.Oncei
nject
edi
nthepr
ocessst
ream,t
hecor
rosi
oni
nhi
bit
oragenti
sat
10ppm wtofpr
ocessst
ream
TYPE:CHI
MEC1044
Est
imat
edconsumpt
ion:
832kg/
year

Theal
ter
nat
eChemi
cal
sforusageascor
rosi
oni
nhi
bit
oragentar
ephi
l
m pl
us5K7
andNal
coEC-
1070A.Theconcent
rat
ionandconsumpt
ionr
emai
nst
hesame.

Chemi
cal
dur
ingTr
ansi
entoper
ati
on:

Sul
phi
dingagent
:
Thesul
phi
dingagenti
sinj
ect
edatr
eact
orsi
nlet
sdur
ingst
art
-up(
fi
rstst
art
-upand
dur
ingi
n-si
tucat
aly
str
egener
ati
on)i
nor
dert
osul
fur
izet
hecat
aly
st.I
tshal
lbe
i
nject
edpur
e.

TYPE:
DI-
METHYLDISULPHI
DE(
DMDS)
DMDSi
sinj
ect
eddur
ingt
wo12hour
s(maxi
mum 18hour
s)per
iod.React
orsul
phi
ding
i
sdoneonebyone.

Est
imat
edconsumpt
ionf
ori
nit
ial
cat
aly
stl
oadi
ng:
SHUReact
or-4620kg
HDSReact
or-1290kg
2.
4CATALYSTSUSEDI
NPLANT

HR-845:
Rel
evantt
o-Sel
ect
ivehy
drogenat
ionr
eact
or(
SHU)75-
R-01
Tr
ademar
k-HR-845manuf
act
uredbyAx
enspr
ocat
aly
sedcat
aly
stand
absor
bent
sShapeanddi
amet
er-spher
es,
diamet
er3mm (
2to4mm)
Loadedcat
aly
stv
olume-32m3

Cat
aly
stcy
clel
engt
handest
imat
edl
i
fet
imei
sdi
ff
erentf
ordi
ff
erentcases:
NI
Tcase:
Est
imat
edcy
clel
i
fe=3y
ear
s,Est
imat
edl
i
fet
ime=5y
ear
s
AM case:
Est
imat
edcy
clel
i
fe=1.
5year
s,Est
imat
edl
i
fet
ime=2.
5year
s
BHcase:
Est
imat
edcy
clel
i
fe=3y
ear
s,Est
imat
edl
i
fet
ime=3y
ear
s

Thesecy
clel
engt
hsandl
i
fet
imeswer
edef
inedoni
so-
capaci
ty(
111666kg/
hr)
75-
R-01i
sdesi
gnedt
ohav
eapr
ovi
si
oni
nther
eact
ort
ohav
eforf
utur
eloadi
ng.
Addi
ti
onalcat
aly
stv
olume49.
5m3al
l
owst
oincr
easecat
aly
stcy
clel
engt
handl
i
fe
t
imef
orAM casef
eed.

HR-845i
saNi
-Mo(
Nickel-Mol
ybdenum)basedcat
aly
stusedf
ordesul
phur
izat
ion
ofFCCgasol
i
ne.I
tist
hebestcat
aly
stofchoi
cei
nthePRI
MEG+

HR-806:
Rel
evantt
o-Fi
rstHy
drodesul
phur
izat
ion(
HDS)r
eact
or,
75-
R-02
Tr
ademar
k-HR-806,
manuf
act
uredbyAxenspr
ocat
aly
sedcat
aly
stsandadsor
bent
s
Appear
ance-spher
es,
diamet
er3mm
Loadedcat
aly
stv
olume-23.
9m3
HR-
806i
saCo-
Mot
ypecat
aly
stusedf
orsel
ect
ivehy
drogenat
ionofcr
ackedgasol
i
nesuchas
FCCgasol
i
ne.

HR-841:
Rel
evantt
o-secondHy
drodesul
phur
izat
ionr
eact
or
Tr
ademar
k-HR-
806,
Manuf
act
uredbyAx
enspr
ocat
aly
sedcat
aly
stsandAdsor
bent
s
Al
lthesecat
aly
stshoul
dbeoper
atedi
nsul
phi
dingst
ateasanact
ivat
orf
ort
he
cat
aly
stt
ooper
ateunderr
equi
redspeci
fi
cat
ionst
omeett
hepr
oductunderl
ow
sul
furcont
ent
.Socat
aly
stsul
phi
dingshoul
dbedonet
othecat
aly
statt
het
imeof
st
artupandaddi
ti
onoff
reshcat
aly
st.Sosul
phi
dingi
nject
ionf
aci
l
iti
esar
epr
ovi
dedt
o
meett
hisr
equi
rement
.DMDSi
susedf
orsul
phi
dingofcat
aly
stasi
tcont
ainsmaxi
mum
sul
fi
decont
ent
.
 Chapt
er3

Det
ail
edFl
owsheet
& Pr
ocessDescr
ipt
ion
.
1Pr
ocessDescr
ipt
ionofSHU

Thef
eedi
sdi
rect
lyt
akent
otheSHUSur
geDr
um.Thepr
essur
eint
hesur
gedr
um i
s
mai
ntai
nedbyspl
i
trangecont
rolofhy
drogenandv
ent
ingt
ofuelgasheader
.The
f
eedi
spumpedbySHUFeedPumpsunderf
low cont
roli
ncascadewi
tht
hesur
ge
dr
um l
evelcont
rol
.Thehy
drogenmake-
upf
rom I
somer
izat
ionuni
tandsentt
othe
uni
tunderr
ati
ofl
owcont
rolt
othehy
drocar
bonf
eedf
lowandmi
xedwi
tht
hef
resh
f
eedbef
oreent
eri
ngt
ubesi
deofSHUf
eed/
HDSEf
fl
uentex
changer
.

Thef
eedandhy
drogenmi
xtur
eisheat
edbyexchangi
ngheatwi
tht
heSHUFeed/
HDSEf
fl
uentExchanger
.Inaddi
ti
on,t
hef
eedi
sfur
therheat
edbyt
heSHUFeed/
Ef
fl
uentEx
changer
.Thef
inalheat
-upoft
hef
eedt
oreacht
hepr
operr
eact
ori
nlet
t
emper
atur
eisachi
evedi
ntheSHUPr
eheat
er.Toal
l
ow agoodcont
roloft
heSHU
r
eact
ori
nlett
emper
atur
e,ami
nimum t
emper
atur
ei easeof50oCmustbedonei
ncr n
t
hest
eam pr
eheat
er.

FI
GURE-
1SELECTI
VEHYDROGENATI
ONUNI
T
 Theheat
edf
eed/hy
drocar
bonmi
xtur
efl
owst
othet
opoft
heSHUr
eact
or.The
r
eact
orcont
ainst
wobedsofHR-
845cat
aly
st.Oper
ati
ngcondi
ti
onsandcat
aly
star
e
opt
imi
zedt
opr
ovi
desel
ect
ivehy
drogenat
ionofdi
olef
insi
nthef
eedandconv
ert
l
i
ghtmer
capt
ansi
ntoheav
ierboi
l
ingt
emper
atur
esul
phurcompounds.Aby
passl
i
ne
oft
hef
ir
stbedwaspr
ovi
dedi
ncaseofanypr
essur
edr
opbui
l
d-upi
ntheSHU
r
eact
or.Theef
fl
uentf
rom t
heSHUr
eact
orf
lowst
hrought
heSHUFeed/Ef
fl
uent
Exchangerandi
ntot
heSpl
i
tter
,underpr
essur
econt
rol
.NOTE:t
hehy
drogenat
ionof
di
olef
inst
akespl
acei
nor
dert
oav
oidgum pr
oduct
ion.

.
2Pr
ocessDescr
ipt
ionofSpl
i
tterSect
ion

3.
2.1 OBEJCTI
VE:

I
nthi
scol
umnf
ract
ionat
etheSHUef
fl
uenti
ntoLCN&HCN.Fr
om t
hespl
i
tterone
opt
ional
cuti
.
e.,
benzenehear
tcut
.

PROPERTI
ESOFLCN,
HCNANDBENZENEHEARTCUT

LCN-
LightCr
ackedNapht
ha(
SideDr
aw)t
oMSpool

 Lowsul
phurcont
ent

 Nodi
olef
ins

 Ver
ylowornomer
capt
anscont
ent

 Hi
ghol
efi
nscont
ent
 HCN–Heav
yCr
ackedNapht
ha-
Spl
i
tterBot
toms–t
oHDSsect
ion

Hi
ghsul
phurcont
ent
3 Hi
. ghsul
phurcont
ent

Lowdi
olef
inscont
ent

Lowmer
capt
anscont
ent

Moder
ateol
efi
nscont
ent

Fr
om t
hespl
i
tter
,1opt
ional
cut
:benzenehear
tcut
:

.
3.01.
1 Dr
awni
ncaseofhi
ghconcent
rat
ionbenz
enei
nthef
eed

.
3.01.
2 Fl
owr
ateadj
ust
edt
oachi
evebenzenecont
enti
ngasol
i
nepool
(<0.
9
%v
oli
nHCN+LCNmi
xtur
e)

Pr
ocessDescr
ipt
ion:

TheSpl
i
tterhas52t
ray
sandt
hef
eedent
erst
hecol
umnatt
ray19(
number
ingf
rom
bot
tom)
.Thepur
poseoft
heSpl
i
tteri
stof
ract
ionat
ethef
eedandpr
oduceLi
ghtCr
acked
Napht
ha(
LCN)andaHeav
yCr
ackedNapht
ha(
HCN)
.TheLCN/Hear
tcutgasol
i
necut
poi
nti
sadj
ust
edt
opr
oduceal
ow-
sul
phurLCNwhi
l
esi
mul
taneousl
yrecov
eri
ngal
arge
por
ti
onofol
efi
ns.Thi
sispossi
blesi
ncet
heheav
ierboi
l
ing
component
scont
ain ahi
gh di
spr
opor
ti
onat
eamountofsul
phurr
elat
ivet
olow
ol
efi
nscont
ent
.

TheSpl
i
tterov
erheadi
sal
mostt
otal
l
ycondensedbyai
r-
cool
i
ngi
ntheSpl
i
tterOv
erhead
Ai
rCondenser
.Vapour(
excesshy
drogenandl
i
ghtends)i
ssepar
atedf
rom t
her
efl
ux
l
i
qui
dint
heSpl
i
tterRef
luxDr
um.

TheSpl
i
tterPostCondensercool
sthev
apourpur
get
obat
ter
yli
mitcondi
ti
onsi
nor
der
t
orecov
erl
i
ghtendsf
rom t
hepur
ge.Thespl
i
tterpr
essur
eiscont
rol
l
edbyt
hespl
i
t
r
angecont
rolofpr
essur
izi
nghy
drogen(
nor
mal
l
ynof
low)andv
ent
ingt
ofuelgas
header
.Thel
i
qui
dispumpedbyt
heSpl
i
tterRef
luxPumpsandr
etur
nedt
othet
opofas
r
efl
ux,
underf
lowcont
rol
incascadewi
tht
her
efl
uxdr
um l
evel
cont
rol
.
TheLCN pr
oducti
sdr
awnf
rom t
heaccumul
atort
raynumber48oft
heSpl
i
tter
(
number
ingf
rom bot
tom)
.Iti
scool
edwi
tht
hel
i
ghtgasol
i
neAi
rcool
erunderf
low
cont
roli
ncascadewi
tht
hespl
i
ttert
ray44t
emper
atur
econt
rolofl
i
ght
ersul
phur
compoundsconcent
rat
edi
ntheLCN.

TheSpl
i
tterbot
tom i
sreboi
l
edwi
thHPst
eam r
eboi
l
er.Ther
eboi
l
ingst
eam r
atei
s
underf
lowcont
roli
ncascadewi
tht
heSpl
i
tterr
efl
uxf
low.Heav
ynapht
haf
rom t
he
spl
i
tterbot
tom i
ssentt
oHDSsect
ionunderf
lowcont
roli
ncascadewi
tht
hespl
i
tter
bot
tomsl
evel
cont
rol
.

One benzene hear

t-
cuti
sfor
eseen i
n or
dert
oreduce benz
ene cont
enti
nthe
gasol
i
nepooli
ncaseofhi
ghconcent
rat
ionbenz
enei
nthePRI
MEG +f
eed.The
hear
t-
cutbenz
enei
sdr
awnf
rom t
heaccumul
atort
raynumber36.Thehear
t-
cut
st
ream i
scool
edbyl
i
ghtgasol
i
neai
rcool
erandpumpedbyt
ost
orageaf
terf
inal
cool
i
ngi
nunderf
lowcont
rol
resetby31stt
rayt
emper
atur
econt
rol
.

NOTE:
thepur
poseofr
eboi
l
eri
stogetdesi
gnr
efl
uxr
ati
oandgoodf
ract
ionat
ion

HDSSect
ion

 Maxi
mize Desul
fur
izat
ion Mi
nimi
zi
ng Whi
l
e Ol
efi
n Sat
urat
ion and Hy
drogen
Consumpt
ion.

 Decr
easesul
phurcont
entt
ospeci
fi
cat
ion(
Organi
csul
phuri
str
ansf
ormedi
ntoH2S
i
nvapourphaser
eact
ion)

 Pr
eser
veoct
anenumber

 Li
mithy
drogenconsumpt
ion

 Recoverheatf
rom r
eact
oref
fl
uent
Pr
ocessDescr
ipt
ion:

Theheav
ynapht
haf
rom Spl
i
tteri
spumpedbyHDSFeedPumpsunderf
lowcont
rol
i
ncascadewi
tht
hespl
i
tterl
evelcont
rol
.Themai
npar
tofHCNf
eedi
smi
xedwi
th
t
her
ecy
clehy
drogenbef
oreent
eri
ngt
heFi
rstHDSFeed/Ef
fl
uentEx
changer
.

TheHDSr
eact
ori
sdi
vi
dedi
n3bedsofHR806cat
aly
st.Thecat
aly
sti
nthesecondHDS
r
eact
ori
sHR-841.
Theov
eral
ltemper
atur
eri
sei
nther
eact
ori
scont
rol
l
edbyt
wo
i
nject
ionofr
ecy
clel
i
qui
dquenchf
rom t
hesepar
atordr
um bet
weent
het
hreebeds.The
HDSef
fl
uenti
sfur
therheat
edi
nHDSheat
er.Theheat
eroper
atesi
nvapourphase
andt
hef
eedHDSr
eact
ori
nlett
emper
atur
eiscont
rol
l
edv
iaf
uelgascont
rol
.The
ef
fl
uentf
rom t
heheat
eri
sthencool
edbyt
heHDSf
eed/ef
fl
uentex
changer
sandby
exchangerwi
tht
he SHU r
eact
orf
eed/
HDS ef
fl
uentex
changer
.Fi
nalcool
i
ng i
s
achi
evedi
ntheHDSef
fl
uentai
rA I
ndust
ri
alRepor
tonHPCL36cool
erandt
he
r
eact
oref
fl
uentt
ri
m cool
ers.

Ani
nter
mit
tentwashi
ngwat
eri
nject
ionpoi
ntupst
ream t
heHDSef
fl
uentai
rcondenser
enabl
est
ofl
usht
hisequi
pmentf
rom sal
tdeposi
tthatmayhav
ebeenf
ormedatl
ow
t
emper
atur
e.The hy
drocar
bon l
i
qui
dis par
ti
all
ypumped back t
othe HDS sect
ion
t
hroughquenchpumps.Ther
emai
ningpar
toft
hel
i
qui
disr
out
edt
othest
abi
l
izer
sect
ionunderf
lowcont
rol
resetbyl
evel
cont
rol
.

.
NOTE:
React
ionsconsumeH2andar
eexot
her
mic.

Maj
ori
tyoft
heH2consumpt
ioni
sduet
otheol
efi
nssat
urat
ion.
Maj
ori
tyoft
her
eact
orexot
her
mici
sduet
otheol
efi
nssat
urat
ion.
H2f
lowr
atecompensat
eH2chemi
cal
consumpt
iont
omai
ntai
nreact
orpr
essur
e.

Ami
neAbsor
berandRecy
cleCompr
essi
onSect
ion
Obj
ect
ive:
H2Si
sremov
edf
rom t
her
ecy
clegasbyusi
ngDEPr
ocessDescr
ipt
ion:

The v
apourent
erst
he ami
ne KO dr
um wher
eiti
sfr
eed f
rom condensed l
i
qui
d
hy
drocar
bonpar
ti
clesduet
oawi
remesh.
Int
heami
neabsor
bert
her
ecy
clegasi
s
cont
act
edwi
tha25%wtl
eanDEAsol
uti
oncomi
ngf
rom bat
ter
yli
mit
s.Thel
eanDEAi
s
pr
e-heat
edi
nthel
eanami
nepr
eheat
er,
thusmai
ntai
ninga10°
Ctemper
atur
edi
ff
erence
bet
weent
hegasand t
heami
ne.
TheH2S enr
iched DEA,col
l
ect
ed i
ntheabsor
ber
bot
toms,
andi
sthenr
out
edt
otheDEAr
egener
ati
onuni
tunderami
neabsor
berbot
toms
l
evel
cont
rol
.

Thesweet
enedgasi
smi
xedwi
tht
heH2makeup,andt
henf
lowst
other
ecy
cle
compr
essorK.
O.dr
um wher
eiti
sfr
eedf
rom anyl
i
qui
dami
neent
rai
nmentt
hatmay
hav
eoccur
red.Par
toft
hegasi
sthenpur
gedt
othef
uelgasnet
wor
kunderf
low
cont
rolt
opr
eventanyl
i
ghtendconcent
rat
ioni
nther
ecy
clel
oop.Ther
emai
ningpar
t
oft
hegasi
scompr
essedbackt
othei
nletbyt
her
ecy
clecompr
essor
.

St
abi
l
izerSect
ion
Obj
ect
ive:Separ
atet
hel
i
qui
dphase,
wat
erphaseandpur
gegasi
nst
abi
l
izerr
efl
ux.

Pr
ocessDescr
ipt
ion:
The l
i
qui
dfr
om t
he separ
atori
sheat
ed t
hrough t
he st
abi
l
iserf
eed/
bot
tomsheat
exchanger
s and ent
erst
he St
abi
l
isercol
umn.
The ov
erhead oft
he st
abi
l
izeri
s
condensedt
hrought
hest
abi
l
izerov
erheadai
rcondenserandaddi
ti
onal
l
ycool
edi
n
st
abi
l
izerov
erheadt
ri
m cool
ers.Thel
i
qui
dphase,t
hewat
erphase(
ifany
)andt
he
v
apourphasesepar
atei
nthest
abi
l
izerr
efl
uxdr
um ,
thepr
essur
eofwhi
chi
scont
rol
l
ed
byt
hepur
gegasf
low.Thewat
ercol
l
ect
edi
nthebooti
ssentt
othesourwat
er
t
reat
mentunderbootl
evel
cont
rol
.

Thel
i
qui
disr
out
edbackt
othecol
umnasr
efl
uxbyt
hest
abi
l
izerr
efl
uxpumpsunder
f
lowcont
rolr
esetbyr
efl
uxdr
um l
evelcont
rol
.Thest
abi
l
izerov
erheadi
spr
otect
ed
f
rom cor
rosi
onbycor
rosi
oni
nhi
bit
ori
nject
ionf
rom t
hecor
rosi
oni
nhi
bit
orpackage
(
drum +met
eri
ngpump)i
ntot
hest
abi
l
izerov
erheadl
i
ne.

Thest
abi
l
izerbot
tom i
sreboi
l
edbyHPst
eam r
eboi
l
er,t
hedut
yofwhi
chi
sadj
ust
edby
HPst
eam f
lowr
ater
esetbyst
abi
l
izersensi
ti
vet
raycont
rol
.Thebot
tom oft
hest
abi
l
izer
(
treat
edheav
ygasol
i
ne)i
ssentt
o st
orageunderf
low cont
rolr
esetby st
abi
l
izer
bot
tomsl
evel
cont
rol
.Thecool
i
ngdownoft
hest
abi
l
izeri
sensur
edf
ir
stbyt
hest
abi
l
izer
f
eed/
bot
tomsheatexchangerandbyt
heheav
ygasol
i
neai
rcool
erheav
ygasol
i
net
ri
m
cool
er

.
 Chapt
er4
Mat
eri
alandener
gyBal
ance
on

S.
H.U.
Hy
drogenr
equi
rement
sinSel
ect
iveHy
drogenat
ionReact
or(
SHU)

Ol
efi
nshy
drogenat
ion:
(thi
samountwi
l
lbesamei
nal
lcases)
Sel
ect
iveHy
drogenat
ionofdi
olef
ins(
taki
ng85%conv
ersi
on)
Di
olef
insi
nfeed=(
111666)
*0.
02=2233.
32kg/
h.
C7di
olef
inshy
drogenat
ion:

CH3-
CH=CH-
CH2-
CH2-
CH=CH2+H2 CH3-
CH2CH2CH2CH2CH=CH2

Hy
drogenr
equi
red(
kg/
h)=2233.
32*
(2/
96)
*0.
85

=39.
55kg/
h

C6di
olef
inshy
drogenat
ion:

CH3-
CH=CH-
CH2-
CH=CH2+H2 CH3-
CH2CH2CH2CH=CH2

Hy
drogenr
equi
redf
orC6sat
urat
ion=2233.
32*
(2/
82)
*0.
85

=46.
09(
kg/
h)

CH3-
CH=CH2-
CH=CH2+H2 CH3-
CH2CH2CH=CH2

Hy
drogenr
equi
redf
orC5sat
urat
ion=2233.
32*
(2/
68)
*0.
85

=55.
85(
kg/
h)

CH2=CH-
CH=CH2+H2 CH3-
CH2-
CH=CH2

Hy
drogenr
equi
redf
orC4sat
urat
ion=2233.
32*
(2/
54)
*0.
85

=70.
30(
kg/
h)

Onanav
erageHy
drogenr
equi
red=(
39.
55+46.
09+55.
85+70.
3)/
4
 =52.
95kg/
h

TheOl
efi
nsf
ormedbyhy
drogenat
ionoft
hesedi
olef
inswi
l
lagai
ngetsat
urat
ed
byH2Taki
ng85%conv
ersi
on:

Av
erageHy
drogenr
equi
redi
nsecondar
yreact
ions=(
73+57.
51+47.
45+
40.
40)
/4=54.
6kg/
hrespect
ivel
y.

Hy
drogenr
equi
redi
nol
efi
nssat
urat
ional
readypr
esenti
nfeed(
Arabmi
x
case-conv
ersi
on50%)

Ol
efi
nsi
nfeed=35.
5%(
byv
olumeoff
eed)=(
0.355)
*152.
3=54.
10m3

=54.
10*densi
ty=54.
10*
733.
4=39652(
kg/
h)

C2Ol
efi
ns:

CH2=CH2+H2 CH3-
CH3

Amountofhy
drogenr
equi
red=39652*
(2/
28)
*0.
5=1416.
2
(
kg/
h)C3Ol
efi
ns
CH3-
CH=CH2+H2 CH3-
CH2-
CH3

Amountofhy
drogenr
equi
red=39652*
(2/
42)
*0.
5=944
(
kg/
h)C4ol
efi
ns
CH3-
CH2-
CH=CH2+H2 CH3-
CH2-
CH2-
CH3

Amountofhy
drogenr
equi
red=39652*
(2/
56)
*0.
5=
708.
1(kg/
h)C5Ol
efi
ns
CH3-
CH2-
CH2-
CH=CH2+H2 CH3-
CH2-
CH2-
CH2-
CH3

Amountofhy
drogenr
equi
red=39652*
(2/
70)
*0.
5=
566.
5(kg/
h)C6Ol
efi
ns
CH3-
CH2-
CH2-
CH2-
CH=CH2+H2 CH3-
CH2-
CH2-
CH2-
CH2-
CH3
Amountofhy
drogenr
equi
red=39652*
(2/
84)
*0.
5=
472.
1(kg/
h)C7Ol
efi
ns

CH3-
CH2CH2CH2CH2-
CH=CH2+H2 CH3CH2CH2CH2CH2CH2CH3
Amountofhy
drogenr
equi
red=39652*
(2/
98)
*0.
5=404.
6(kg/
h)
Av
erageH2r
equi
rement=(
404.
6+472.
1+566.
5+708.
1+944+1416.
2)=
752kg/
h

Hy
drogenr
equi
redi
nol
efi
nssat
urat
ional
readypr
esenti
nfeed
(
BombayHi
ghCase)
:

Ol
efi
nsi
nfeed=(
0.385)
*156=60.
10m3

=60.
10*densi
ty=54.
10*=43032(
kg/
h)
Car
boncont
enti
nol
efi
nsv
ari
esf
rom C2t
oC7
C2Ol
efi
ns:
CH2=CH2+H2 CH3-
CH3

Amountofhy
drogenr
equi
red=43032*
(2/
28)
*0.
5=1537
(
kg/
h)C3Ol
efi
ns
CH3-
CH=CH2+H2 CH3-
CH2-
CH3

Amountofhy
drogenr
equi
red=43032*
(2/
42)
*0.
5=
1024.
5(kg/
h)C4ol
efi
ns
CH3-
CH2-
CH=CH2+H2 CH3-
CH2-
CH2-
CH3

Amountofhy
drogenr
equi
red=43032*
(2/
56)
*0.
5=768.
4
(
kg/
h)C5Ol
efi
ns
CH3-
CH2-
CH2-
CH=CH2+H2 CH3-
CH2-
CH2-
CH2-
CH3

Amountofhy
drogenr
equi
red=43032*
(2/
70)
*0.
5=614.
7
(
kg/
h)C6Ol
efi
ns
CH3-
CH2-
CH2-
CH2-
CH=CH2+H2 CH3-
CH2-
CH2-
CH2-
CH2-
CH3
Amountofhy
drogenr
equi
red=43032*
(2/
84)
*0.
5=512.
3(kg/
h)

4
C7Ol
efi
ns

CH3-
CH2CH2CH2CH2-
CH=CH2+H2 CH3CH2CH2CH2CH2CH2CH3

Amountofhy
drogenr
equi
red=43032*
(2/
98)
*0.
5=439(
kg/
h)

Hy
drogenr
equi
redi
nol
efi
nssat
urat
ional
readypr
esenti
n
f
eed(
Not
iceI
nvi
ti
ngTender
):

Ol
efi
nsi
nfeed=38.
5%(
byv
olumeoff
eed)=(
0.5447)
*152. 23m3
8=83.

=83.
23*densi
ty=83.
23*
731=60841(
kg/
h)
Car
boncont
enti
nol
efi
nsv
ari
esf
rom C2t
oC7
C2Ol
efi
ns:
CH2=CH2+H2 CH3-
CH3

Amountofhy
drogenr
equi
red=60841*
(2/
28)
*0.
5=2173
(
kg/
h)C3Ol
efi
ns
CH3-
CH=CH2+H2 CH3-
CH2-
CH3

Amountofhy
drogenr
equi
red=60841*
(2/
42)
*0.
5=1487
(
kg/
h)C4ol
efi
ns
CH3-
CH2-
CH=CH2+H2 CH3-
CH2-
CH2-
CH3

Amountofhy
drogenr
equi
red=60841*
(2/
56)
*0.
5=
1086.
4(kg/
h)C5Ol
efi
ns
CH3-
CH2-
CH2-
CH=CH2+H2CH3-
CH2-
CH2-
CH2-
CH3

Amountofhy
drogenr
equi
red=60841*
(2/
70)
*0.
5=
869.
15(
kg/
h)C6Ol
efi
ns
CH3-
CH2-
CH2-
CH2-
CH=CH2+H2 CH3-
CH2-
CH2-
CH2-
CH2-
CH3

Amountofhy
drogenr
equi
red=60841*
(2/
84)
*0.
5=724.
25(
kg/
h)
C7Ol
efi
ns

CH3-
CH2CH2CH2CH2-
CH=CH2+H2 CH3CH2CH2CH2CH2CH2CH3

Amountofhy
drogenr
equi
red=60841*
(2/
98)
*0.
5=620.
8(kg/
h)

Hy
drogenr
equi
rement
sindi
ff
erentcasesf
orpl
antcapaci
tyof
2450TPD:

Ar
ab-
mixcase BombayHi
gh N.
I.
T.Case

Di
olef
ins+ 52.
95 52.
95 52.
95
ol
efi
ns
54.
60 54.
60 54.
60

Ol
efi
ns(
alr
eady
i
nfeed)
752 816 1160

Tot
alH2 52.
95+54.
6 52.
95+54.
60+816 52.
95+54.
6+1160
r
equi
red(
kg/
h) +752
=923.
55 =1267.
55
=859.
55
I
nter
pol
atedSHUDat
atakenf
rom Pl
antf
or2680TPD Capaci
ty:

Not
iceI
nvi
ti
ng BOMBAY ARABMI
XCASE
TenderCase HI
GHCASE

Feed(
kg/
h) S.
O.R. E.
O.R. S.
O.R. E.
O.R. S.
O.R. E.
O.R.

FCC-
Napht
ha 111666 111666 111666 111666 111666 111666

Makeup 277 323 224 284 245 286

hydr
ogen
Tot
al(
feed
+hy
drogen)
111943 111943 111890 111950 111911 111952

1.ARAB-
MIXCASE-Tot
alhy
drogenconsumed=859.
55kg/
h
MakeupHy
drogenneeded(
atSt
artofRun)=245kg/
h
Hy
drogent
ober
ecy
cled=(
859.
55–245)kg/
h=614.
55kg/
h

2.BOMBAYHI
GHCASE-Tot
alhy
drogenconsumed=923.
55kg/
h
Hy
drogent
ober
ecy
cled=(
923.
55–224)=699.
55kg/
h
3N.
I.
T.CASE-Tot
alhy
drogenconsumed=1267.
55kg/
h
Hy
drogent
ober
ecy
cled=(
1267.
55–277)=990.
55kg/
h
 BALANCEONSHU

Ar
abmi
xcase:

Sel
ect
iveHy
drogenat
ionofdi
olef
insandol
efi
ns(t
hoser
esul
ti
ngf
rom
di
olef
ins)

Di
olef
insi
nfeed=(
111666)
*0.
02=2233.
32kg/
h. (
Conver
sion=85%)
C7di
olef
inshy
drogenat
ion:
CH3-
CH=CH-
CH2-
CH2-
CH=CH2+H2 CH3-
CH2CH2CH2CH2CH=CH2

Ol
efi
nsf
ormed(
kg/
h)=2233.
32*
(98/
96)*
0.85=1938kg/
h
C6di
olef
inshy
drogenat
ion:
CH3-
CH=CH-
CH2-
CH=CH2+H2 CH3-
CH2-
CH2-
CH2-
CH=CH2

Ol
efi
nsf
ormedbasedonC6car
bondi
olef
ins
component
s=2233.
32*
(84/
82)
*0.
85

=1944.
62(
kg/
h)

CH3-
CH=CH2-
CH=CH2+H2 CH3-
CH2-
CH2-
CH=CH2

Ol
efi
nsf
ormedbasedonC5car
bondi
olef
ins
component
s=2233.
32*
(70/
68)
*0.
85

=1954.
2(kg/
h)

CH2=CH-
CH=CH2+H2 CH3-
CH2-
CH=CH2

Ol
efi
nsf
ormedbasedonC4car
bondi
olef
ins
component
s=2233.
32*
(56/
54)
*0.
85

=1969(
kg/
h)
Ol
efi
nsf
ormedbyhy
drogenat
ionoft
hesedi
olef
inswi
l
lagai
ngetsat
urat
ed
byH2Taki
ng85%conv
ersi
on:

C7par
aff
ins=1938*
(100/
98)
*0.
85=1681(
kg/
h)

C6par
aff
ins=1944.
62*(
86/
84)
*0.
85=1692(
kg/
h)

C5par
aff
ins=1954.
2*(
72/
70)*
0.85 =1709(
kg/
h)

C4par
aff
ins=1969*(
58/
56)*0.
85 =1733(
kg/
h)
Onanav
eraget
otal
par
aff
insf
ormed=(
1681+1692+1709+1733)
/4=
1704kg/
h

Sel
ect
iveHy
drogenat
ionofOl
efi
nsal
readypr
esenti
nfeed(
50%

conv
ersi
on)

Ol
efi
nsi
nfeed=35.
5%(
byv
olumeoff
eed)=(
0.355)
*152.
3=54.
10m3

=54.
10*densi
ty=54.
10*
733.
4=39652(
kg/
h)

C2Ol
efi
ns:

CH2=CH2+H2 CH3-
CH3

AmountofC2par
aff
insf
ormed=39652*
(30/
28)
*0.
55=(
kg/
h)
C3Ol
efi
ns
CH3-
CH=CH2+H2 CH3-
CH2-
CH3

AmountofC3par
aff
insf
ormed=39652*
(44/
42)
*0.
55=
(
kg/
h)C4ol
efi
ns
CH3-
CH2-
CH=CH2+H2 CH3-
CH2-
CH2-
CH3

AmountofC4par
aff
insf
ormed=39652*
(58/
56)
*0.
55=
(
kg/
h)C5Ol
efi
ns
CH3-
CH2-
CH2-
CH=CH2+H2 CH3-
CH2-
CH2-
CH2-
CH3

AmountofC5par
aff
insf
ormed=39652*
(72/
70)
*0.
55=
(
kg/
h)C6Ol
efi
ns
CH3-
CH2-
CH2-
CH2-
CH=CH2+H2 CH3-
CH2-
CH2-
CH2-
CH2-
CH3

AmountofC6par
aff
insf
ormed=39652*
(86/
84)
*0.
55=(
kg/
h)
C7Ol
efi
ns

CH3-
CH2CH2CH2CH2-
CH=CH2+H2 CH3CH2CH2CH2CH2CH2CH3

AmountofC7par
aff
insf
ormed=39652*
(100/
98)
*0.
55=(
kg/
h)

Onanav
eraget
otal
par
aff
insf
ormed=(
1/6)
*(23,
366.
36+22,
847.
11+
22,
587.
5+22,
432+22,
328+22,
254)

=22,
636(
kg/
h)

BombayHi
ghCase:

Di
olef
insi
nfeed=(
111666)
*0.
02=2233.
32kg/
h.
C7di
olef
inshy
drogenat
ion:
CH3-
CH=CH-
CH2-
CH2-
CH=CH2+H2 CH3-
CH2CH2CH2CH2CH=CH2

Ol
efi
nsf
ormed(
kg/
h)=2233.
32*
(98/
96)*
0.85

=1938kg/
h
C6di
olef
inshy
drogenat
ion:
CH3-
CH=CH-
CH2-
CH=CH2+H2 CH3-
CH2CH2CH2CH=CH2

Ol
efi
nsf
ormedbasedonC6car
bondi
olef
ins
component
s=2233.
32*
(84/
82)
*0.
85

=1944.
62(
kg/
h)
CH3-
CH=CH2-
CH=CH2+H2 CH3-
CH2CH2CH=CH2

Ol
efi
nsf
ormedbasedonC5car
bondi
olef
ins
component
s=2233.
32*
(70/
68)
*0.
85

=1954.
20(
kg/
h)

CH2=CH-
CH=CH2+H2 CH3-
CH2-
CH=CH2

Ol
efi
nsf
ormedbasedonC4car
bondi
olef
ins
component
s=2233.
32*
(56/
54)
*0.
85

=1969(
kg/
h)
Ol
efi
nsf
ormedbyhy
drogenat
ionoft
hesedi
olef
inswi
l
lagai
ngetsat
urat
ed
byH2Taki
ng85%conv
ersi
on:

C7par
aff
ins=1938*
(100/
98)*
0.85=1681kg/
h

C6 par
aff
ins = 1944.
62*(
86/
84)*
0.85 =1692
kg/
h C5 par
aff
ins = 1954.
2*(
72/
70)*
0.85 =
1709(
kg/
h)C4par
aff
ins=1969*(
58/
56)*
0.85=
1733(
kg/
h)
Onanav
eraget
otal
par
aff
insf
ormed=(
1681+1692+1709+1733)=
1704kg/
h

Wehav
ethesamecal
cul
atedv
alueofpar
aff
insasi
nAr
abmi
xcase.

Sel
ect
iveHy
drogenat
ionofOl
efi
nsal
readypr
esenti
nfeedOl
efi
nsi
n
f
eed=38.
5%(
byv
olumeoff
eed)=(
0.385)
*156=60.
10m3
=60.
10*densi
ty=54.
10*=43032(
kg/
h)
Car
boncont
enti
nol
efi
nsv
ari
esf
rom C2t
oC7
C2Ol
efi
ns:

CH2=CH2+H2 CH3-
CH3

AmountofC2par
aff
insf
ormed=43032*
(30/
28)
*0.
55=23,
358
(
kg/
h)C3Ol
efi
ns
CH3-
CH=CH2+H2 CH3-
CH2-
CH3

AmountofC3par
aff
insf
ormed=43032*
(44/
42)*
0.55=24,
795
(
kg/
h)C4ol
efi
ns
CH3-
CH2-
CH=CH2+H2 CH3-
CH2-
CH2-
CH3

AmountofC4par
aff
insf
ormed=43032*
(58/
56)
*0.
55=24,
513
(
kg/
h)C5Ol
efi
ns
CH3-
CH2-
CH2-
CH=CH2+H2 CH3-
CH2-
CH2-
CH2-
CH3
 11

AmountofC5par
aff
insf
ormed=43032*
(72/
70)*
0.55=24,
344(
kg/
h)

C6Ol
efi
ns
CH3-
CH2-
CH2-
CH2-
CH=CH2+H2 CH3-
CH2-
CH2-
CH2-
CH2-
CH3

AmountofC6par
aff
insf
ormed=43032*
(86/
84)*
0.55=24,
231
(
kg/
h)C7Ol
efi
ns
CH3-
CH2CH2CH2CH2-
CH=CH2+H2 CH3CH2CH2CH2CH2CH2CH3

AmountofC7par
aff
insf
ormed=43032*
(100/
98)
*0.
55=24,
150(
kg/
h)
Onanav
eraget
otal
par
aff
insf
ormed=25,
565(
kg/
h)
Not
iceI
nvi
ti
ngTenderCase:

Di
olef
ini
ccont
enti
ssamebutol
efi
niccont
enti
ssomewher
e
gr
eat
ert
hanpr
evi
oust
wocases(
i.
e.Ar
abmi
xcaseandBombay
Hi
ghcase)

Theol
efi
niccont
enti
nthi
scasei
s54.
47%(
V/V)

Sel
ect
iveHy
drogenat
ionofOl
efi
nsal
readypr
esenti
nfeed:

Ol
efi
nsi
nfeed=38.
5%(
byv
olumeoff
eed)=(
0.5447)
*152.
8=83.
23m3

=83.
23*densi
ty=83.
23*
731=60841(
kg/
h)
Car
boncont
enti
nol
efi
nsv
ari
esf
rom C2t
oC7
C2Ol
efi
ns:

CH2=CH2+H2 CH3-
CH3

AmountofC2par
aff
insf
ormed=60841*
(30/
28)
*0.
55=35,
853
(
kg/
h)C3Ol
efi
ns
CH3-
CH=CH2+H2 CH3-
CH2-
CH3

AmountofC3par
aff
insf
ormed=60841*
(44/
42)
*0.
55=35,
056
(
kg/
h)C4ol
efi
ns

CH3-
CH2-
CH=CH2+H2 CH3-
CH2-
CH2-
CH3

AmountofC4par
aff
insf
ormed=60841*
(58/
56)*
0.55=34,
658
(
kg/
h)C5Ol
efi
ns
CH3-
CH2-
CH2-
CH=CH2+H2 CH3-
CH2-
CH2-
CH2-
CH3

AmountofC5par
aff
insf
ormed=60841*
(72/
70)
*0.
55=34,
419
(
kg/
h)C6Ol
efi
ns
CH3-
CH2-
CH2-
CH2-
CH=CH2+H2 CH3-
CH2-
CH2-
CH2-
CH2-
CH3

AmountofC6par
aff
insf
ormed=60841*
(86/
84)
*0.
55=34,
259
(
kg/
h)C7Ol
efi
ns
CH3-
CH2CH2CH2CH2-
CH=CH2+H2 CH3CH2CH2CH2CH2CH2CH3

AmountofC7par
aff
insf
ormed=60841*(
100/
98)
*0.
55=34,
146(
kg/
h)
Onanav
eragepar
aff
insf
ormed
=34,
732(
kg/
h)
4.

Cal
cul
ati
onofheatdut
yoft
hreeheatexchanger
sforpr
eheat
ingt
he
f
eed: T=219C

(
T=188C)

(
T=155C)

(
m=111666kg/
h)

T=188C

Cp=0.
54
kcal
/kgCm =
111666kg/
h
Q=m *Cp*(
T1–T2)

=111666*0.
54*(
188–155)

=1,
989,
888Kcal
/h
 T=211C

(
T=155C)

(T=66C)

(
m=111666kg/
h)
T=156C
Cp=0.
54
(
kcal
/kgC) m=
111,
666kg/
h
Q=m *Cp*(
T1–T2)

=111666*0.
54*(
155–66)

=5,
366,
668Kcal
/h

Fi
g2.Schemat
icdi
agr
am ofSHUFeed/HDSef
fl
uentshel
landt
ubeheatex
changer
 Desuper
heat
edst
eam

(
T=193C)

(
T=188C)

(
m=111666kg/
h)

Condensat
eTsat=100C
Cp=0.
54k
c al
/kgC
m =111666kg/
h
Q=m *Cp*(
T1–T2)

=111666*0.
54*(
193–188)

=301,
498Kcal
/h

Amountofst
eam r
equi
red:

(
Massofst
eam)*(
lat
entheatofcondensat
ion)=301,
498Kcal
/hMassofst
eam (
kg/
h)*
540(
inKcal
/kg)=301,
498(
kcal
/h)
Massofst
eam (
kg/
h)=301,
498/
540=558.
33(
kg/
h)
 SHUFeed/
HDSEf
fl
uentHeatexchanger

PARAMETER Shel
lsi
de Tubesi
de
Desi
gn 29 37
Pr
essur
e(kg/
cm2g)
Desi
gn 240 150
Temper
atur
e(C)
Oper
ati
ng 211(
inl
et) 66(
inl
et)
Temper
atur
e(C)
156(
out
let
)

155(
out
let
)
Cal
cul
atedheatdut
y=5366668kcal
/h
 SHUFeed/SHUEf
fl
uentHeatexchanger

PARAMETER SHELLSI
DE TUBESI
DE

Desi
gn 37 37
pr
essur
e(kg/
cm2g)
Desi
gnt
emper
atur
e 235 215

Oper
ati
ng 219(
inl
et) 155(
inl
et)
Temper
atur
e
188(
out
let
) 188(
out
let
)
Cal
cul
atedheatdut
y=1989888Kcal
/h
Shel
landTubeexchangercondensi
ngDesuper
heat
edSt
eam

PARAMETER SHELLSI
DE TUBESI
DE

Desi
gnPr
essur
e 32 32

(
Kg/
cm2g)
Desi
gnTemper
atur
e 238 238
(
DegC)

Oper
ati
ng 190(
Inl
et) 188(
Inl
et)
Temper
atur
e

(
DegC)
100(
Out
let
) 193
(
Out
let
)
Cal
cul
atedheatdut
y=301,
498Kcal
/h
 Chapt
er5

Over
allMat
eri
alBal
ance
Maxi
mum av
ail
abl
erat
e(kg/
h)=111,
666Densi
ty=733.
40(
kg/
m3)

St
andar
dVol
ume(
V)=(
111,
666/
733.
4)=152.
3(m3)

Tot
alsul
phur
(wppm)=2400=0.
24%=(
111,
666*
(0.
24/
100)
)

=268(
kg/
h)

Par
aff
inspr
esenti
nthef
eed=29.
5% =(
152.
3*0.
295)

=44.
93(
m3/
h)

Ol
efi
nspr
esenti
nthef
eed= 35.
5% =(
152.
3*0.
355)

=54.
10(
m3/
h)

Di
olef
insi
nfeed =2.
0(wt%) =(
0.02)*(
111,
666)

=2233.
32(
kg/
h)

Napht
henes =10.
70(
vol
%) =(0.
107*152.
3)

=16.
30(
m3/
h)

Benzene(
vol
%) = 1.
80 =(
1.8/
100)
*152.
3

=2.
74(
m3/
h)
Pr
oduct
s:

Hy
drot
reat
edLi
ghtCr
ackedNapht
ha:
Max
imum av
ail
abl
erat
e=49,
027(
kg/
h)
Densi
ty(
rho)=664(
kg/
m3)
Vol
ume(
V)=(
49,
027/
664)

=73.
83(
m3)

Mol
ecul
arwei
ght
(M)=74.
30(
kg/
kmol
)
Sul
phur
(wppm)=240
Par
aff
ins(
vol
%)=34.
4%=(
73.
83)*(
0.344)

=25.
42(
m3/
h)

Ol
efi
ns(
vol
%)=61.
2%=(
0.612*
73.
83)

=45.
20(
m3/
h)

Di
olef
ins-
-compl
etel
yremov
ed

Napht
henes(
vol
%)=2.
90=(
(2.
9/100)
*(73.
83))

=2.
141(
m3/
h)

Benzene(
vol
%)=0.
76=(
(0.
76/
100)*73.
83)

=0.
561(
m3/
h)

R.
O.N.=94.
6

M.
O.N.=81.
8
 Hy
drot
reat
edHeav
yCr
ackedNapht
ha

Maxi
mum av
ail
bler
ate=62,
468(
kg/
h)
Densi
ty=794(
kg/
m3)

Vol
ume(
V)=(
62,
468/794)=78.
67(
m3/
h)

Sul
phur(
wppm)=10

Par
aff
ins(
vol
%)=62.
6=(
0.626*78.
67)=49.
25(
m3/
h)

Ol
efi
ns(
vol
%)=1.
0=(
0.01*78.
67)=
0.
78(
m3/
h)Di
olef
inst
otal
l
yremov
ed
Napht
henes(
vol
%)=9.
9=7.
78(
m3/
h)

Benzene(
vol
%)=26.
5%=(
0.265*78.
67)=20.
84(
m3/
h)

Par
aff
insi
nthef
eed=44.
93(
m3/
h)

=(
44.
93)*(
733.
4)

=32,
951.
662(
kg/
h)

Par
aff
insi
npr
oduct

(
a)Hy
drot
reat
edLCN– (
25.
40)*(
664)=16,
865.
60(
kg/
h)

(
b)Hy
drot
reat
edHCN-
-(49.
25)*(
794)=39,
104.
5(kg/
h)
Tot
alpar
aff
insi
nthepr
oduct=(
16,
865.
60+39,
104.
50)

= 55,
970(
kg/
h)

Par
aff
insf
ormedduet
oSel
ect
iveHy
drogenat
ionofol
efi
nsanddi
olef
inswi
l
lbe-

= (55,
970–32,
951.
662)(
kg/
h)

= 23018.
34(
kg/
h)
Ol
efi
nsi
nthef
eed(
35.
5%byv
olume)

=(
54.
10)*(
733.
4)

=39,
676.
94(
kg/
h)

Di
olef
insi
nthef
eed=(
2%bywei
ght
)

=2233.
32(
kg/
h)

Tot
al(
olef
ins+di
olef
ins)i
nthef
eed=(
39,
676.
94+2233.
32)
=41,
910.
26(
kg/
h)

Per
cent
ageconv
ersi
on(
olef
ins+di
olef
ins)t
opar
aff
inswi
l
lbe-

=(
23,
018.
44/
41,
910.
26)*100

= 54.
923%(
around55%)
 Bal
anceonSul
phur

Feed:

1.Ar
abmi
xcase-

Tot
alsul
phur=2400(
wppm)

=0.
24%bywei
ght

=(
0.24/
100)
*(111,
666)

=2.
68(
kg/
h)

2.BombayHi
ghcase-

Tot
alsul
phur=180(
wppm)

=0.
018%(bywei
ght
)

=(
0.018/
100)*(
111,
666)

=0.
201(
kg/
h)

3.Not
iceI
nvi
ti
ng
Tender
Tot
alSul
phur=
1133(
wppm)
=(
1133/
10^8)*
(111,
666)

=1.
265(
kg/
h)
Pr
oduct:

(
A) Heav
yhy
drot
reat
edCr
ackednapht
ha

1)Arabmi
xcase:

Tot
alSul
phur=200ppmw

=(
200/
10^8)
*(62,
468)

=0.
125(
kg/
h)

2)BombayHi
ghcaseTot
alsul
phur=290ppmw
=(
290/
10^8)
*(62,
468)=0.
1812(
kg/
h)

3)
Not
iceI
nvi
ti
ngTenderCase

Tot
alsul
phur=100ppmw
=(
100/
10^8)*(
62,
468)

=0.
0624(
kg/
h)
B)L
( i
ghtHy
drot
reat
edCr
ackedNapht
ha

1.Ar
abmi
xCase:

Tot
alSul
phur=240ppmw

=(
240/10^
8)*(
49,
027)

=0.
12(
kg/
h)

2.BombayHi
ghCase:

Tot
alSul
phur=270ppmw

=(
270/
10^8)*(
49,
027)

=0.
132(
kg/
h)
3.Not
iceI
nvi
ti
ngTender
:

Tot
alSul
phur=15ppmw

=(
15/10^
8)*49,
027

=0.
0073(
kg/
h)

Chapt
er6
Desi
gnofHeatexchanger

(
2-4&2-
8ty
pe)
DESI
GNOFSHUFEED-
HDSEFFLUENTHEATEXCHANGER

Shel
lsi
de:211°
Cto
156°
CTubesi
de:66°
Cto
155°
C
f
lowr
ateofSHUf
eed:111,
666
kg/
h

Cr
ackedNapht
hapr
oper
ti
es:

Mol
ecul
arwei
ght=(
100-
215)g/
mol
Speci
fi
cGr
avi
ty=(
0.75-
0.85)
Boi
l
ingpoi
nt=(
70-
430)
°F
K=0.
15W/
m-K

Cp=2259.
36J/
Kg°
C

Vi
scosi
ty=2.
645Cent
ipoi
se
2-
2-8SHELLANDTUBETYPEHEATEXCHANGER

LMTD-
Cal
cul
ati
on:

d(
T1)=(
155-
66)=89°
C
d(
T2)=(
211-
156)=55°
C
R=0.
6292

S=0.
6138

LMTD=70.
642°
C
Ft=0.
9575
Cor
rect
edLMTD=(
70.
642)
*(0.
9575)

Hence,

Cor
rect
edLMTD=67.
64°
C
Cp=2259.
36J/
Kg°
C
m =111666(
Kg/
h)

Q=m*
Cp*
dT

=(
111,
666/
3600)
*(2259.
36)
*(89)

Q=6237261J/
s
ForNapht
hacool
er: (
U=312.
31-369.
087)

(
W/m2k
)
LetU=340.
69(
W/m2K)
Af
tersol
vi
ngwegett
hev
aluesasf
oll
ows:
A=268.
420m2
Do=0.
0254
m t=0.
00419
m Di
=0.
0170
m L=6m
So,

N=268.
43/(
3.14*
.0254*
6)

(
N=561t
ubes)

Cal
cul
ati
onofBundl
edi
amet
er:
Db=d0*
1/
n
(
Nt/
K) Fort
ri
angul
arpi
tch:
k=.
0365
n=2.
67
1/
2.67
Db=0.
0254*
(561/
.0365)
 =0.
93945m

=939.
45mm

Pi
tch(
Ptt=1.
25*
d0)
Ptt=0.
03175m
Dshell=Dbundle+cl
ear
ance
=(
939.
45+67)
m

=1006.
45mm

TUBESI
DE:
Ai(insidearea)=2. 10-4m2
27*

Numberofpasses=8

Tot
alf
lowar
eaperpassAa=70.
115
I
nsi
dear 015916m2
ea=0.
Massf
lowr
ateGs=(
m/A)
=7015958.
789(k
g/hm2)Li
nearv
eloci
ty
u=(
Gs/
densi
ty)=2.
564m/
s

Nre=(
(760*
2.564*
.0254)
/(0.
002645)
)
Nre=18,
713
Npr=39.
84
.
33 .14
Nu=hi
*di
/k=j
h*Re*
Pr *(
u/uw)
Neel
ect
ingVi
scosi
tyv
ari
ati
ont
erm
L/
D=352.
941
Si
nce(Re>10000)
;(0.
7<Pr
<160)
;(di/
L<0.
1)
Usi
ngdi
tt
usboel
ter
:hi=564.
175(
W/mK)
SHELLSI
DE:
Baf
fl
espaci
ng,
Lb=(
Ds/
5)=0.
216
TubePi
tch=1.
25*
Do=0.
03175m
Gr
ossf
lowar
eaAc=(Pt-
D0/
p)*
Ds*
Lb
046656m2
=0.
 De=4*
(ar
ea/
wet
ted-
per
imet
er)
Taki
ngt
ri
angul
arpi
tch:
De=0.
01838m
Gs=m/
As=664.
831kg/
s
u=0.
875(
m/s)
Nre=G*
D/u=4619.
88
Pr
=39.
84

BYKERNMETHOD

Re.
55 .33
h0*
De/
k=.
36* *Pr
.
14
(
u/u
w) h o=1027. m2c
31W/
St
ainl
essst
eel
K=16W/
m°C
FORANEW HEATEXCHANGER:
1/
Uo=1/
h0+(
A0/
Ai)
*1/
hi+(
A0/
Ai)
*(Do-
Di)
/2k
Gi
ves,
Uo=396. m2K
495W/
Tocheckwhet
herui
swi
thi
nper
missi
blel
i
mitornot
(
(Uassumed-
Uo)
/Uassumed)*100=16.
38%(
lesst
han30%)
Tubesi
depr
essur
edr
opcal
cul
ati
ons:
D(
pt)=Np(
8*j
f*(
L/di
)(
mu/
mu(
w))
^(-
m))+
2.
5)*
((r
ho*
u*u)
/2)Wher
e Np(
numberofpasses)
m =0.
25(
forl
ami
nar
)
m =0.
14(
fort
urbul
ent
)
Nowf
orst
ainl
essst
eel
roughness=(
0.03*
10^
-3)
(
Mu/
rho)
=(3.
48*
10^
(-6)
)
(
K/Di
)=(
1.76*
10^
(-3)
)

So,
f=0.
02885(
canbeobt
ainedf
rom moodychar
t)
Tot
alpr
essur
edr
opf
orsi
ngl
epasst
ubesi
dewi
l
lbe-
1)pr
essur
edr
opi
nnozz
le=382.
51(
N/m^
2)

2)pr
essur
edr
opt
hrought
ubebundl
e=20,
772(
N/m^
2)
3)pr
essur
edr
opduet
obendi
ngl
osses=
8160(
N/m2)Hence,
tot
alpr
essur
edr
op(
tubesi
de)
wi
l
lbe
=29,
314.
51N/
m2(accept
abl
e)

(
Sincet
otalaccept
abl
epr
essur
edr
opt
ubesi
deshoul
dnotexceed10psi
)

Shel
lsi
depr
essur
edr
op

Nr
e=4619.
88

Numberofbaf
fl
es=(
tubel
engt
h/baf
fl
espaci
ng)

=(
6/0.
2160)=27.
78

Numberofbaf
fl
es=28
Taki
ngsegment
albaf
fl
es:
Jf
=5.
5*10^
(-2;
)(usi
ngsegment
al-
cut
t
abl
e)
Fr
om npt
el,
wehav
ethef
ormul
aas-
D(
P)=(
f*j
h*Gs^
2*Dsi
(Nb+1)
)/(
2g*
rho*
De*
(Vi
scosi
tyef
fectt
erm)
)

D(
P)=2778.
1063(
N/m2)

2-
4ty
peheatexchanger

LMTD=70.
642°
C
Ft=0.
9575
Cor
rect
edLMTD=(
70.
642*0.
9575)=67.
64°
C
Cp=2259.
36J/
kg°
C
m =111,
666(
kg/
h)
Q=m*
Cp*d(
T)
Q=(
111,
666/
3600)
*(2259.
36)
*(89)

=6237260.
762(
J/s)

Assume U=340W/
m^2K
A=271.
213m^
2
N*
pi*
Do*
L=271.
213

N=566

Cal
cul
ati
onofBundl
eDi
amet
er-
Db=0.
872m =872.
6m
Pi
tch=Do*1.
25=(
0.0254*
1.25)=0.
03175m

Dshel
l=Dbundl
e+cl
ear
ance

=872.
6+67=939.
6mm

Tubei
nsi
dear
ea(
Ai)=2.
27*
10^
(-4)m^
2
Numberofpasses=4
Numberoft
ubesperpass=141

I
nnercr
oss-
sect
ional
area=0.
032m^
2
Gs=3489562.
50(kg/
h.m^
2)
u=1.
275(
m/s)
Nr
e=9356.
5
Npr=39.
84

Now,
usi
ngDi
tt
us-
Boel
terequat
ion-
hi
=1331.
58(
W/mK)
Shel
lsi
de-

Lb=(
0.2)
*Ds=0.
188m
Pt=0.
03175m
Cr
osssect
ional
area=(
(Pt-do)
/Pt
)*Ds*
Lb

=0.
0353m^
2.

De(
equi
val
entdi
amet
er)=4*
(ar
ea/
wet
terper
imet
er)

=0.
018m

Gs=m/
As=(
111,
666/
(3600*
0.0353)
)=878.
70
(
kg/
s)u=(
878.
7/760)=1.
156(
m/s)
Nr
e=5991

Npr=39.
76

hscal
cul
ated=1514.
87(
W/mK)

Si
mil
art
opr
evi
ouscase,
over
all
heatt
ransf
ercoef
fi
ci
entascal
cul
ated
wi
l
lbe-

Uo=351(
W/m^
2K)

Now,

(
(Uass-Uo)
/Uass)=3.
04%(l
esst
han30%)(
Accept
ed)
)
Cal
cul
ati
onoft
ubesi
depr
essur
edr
op:

Np=4

St
ainl
essst
eel
roughness=(
0.03*
10^
(-3)
)
(
Mu/
rho)=3.
48*
10^
(-6)
;
(
K/Di
)=(
1.76*10^
(-3)
);

Jf=0.
02885(
usi
ngMoody
'schar
t)
Cal
cul
atedpr
essur
edr
op(
dP)wi
l
lbe-
dP=11.
81psi
(t
ubesi
de)
Si
mil
arl
y,

dP=53.
987psi
(shel
lsi
de)

Si
ncet
hepr
essur
edr
opobt
ainedi
sver
yhi
ghsot
hiscanber
educedby
i
ncr
easi
ngt
hebaf
fl
epi
tch.
.

LetPt(
new)=2*Pt
(ol
d).
.

Doubl
i
ngt
hepi
tchhal
vest
heshel
lsi
dev
eloci
ty,
whi
chr
educest
he
pr
essur
edr
opbyaf
act
orof(
0.5)
^2.
So,

(
Del
P)new=(
372.
233/
4)=93.
05KPa=13.
59psi

And,

ho=1514.
87*(
0.5)
^0.
8

=870.
06(
W/m^
2K)

(
1/Uo)=(
1/870.
06)+(
0.0254/
0.017)
^2*
(1/
1331)+(
0.0254/
0.0170)
^2
*
((0.
0254-
0.017)
/(2*
1.6)
);

Whi
chgi
ves,
Uo=293.
04W/
m^2K
I
nthi
snewcase,
theov
eral
lcoef
fi
cient(
Uo)wi
l
lbe-293.
04(
W/m^
2K)
Whi
chmeans-
(
(340-
293.
04)
/340)
*100=13.
80%(
(accept
abl
e))
Compar
sionbet
ween2-
4ty
peheatexchangerand2-
8ty
peheat

Basi
s 2-
4ty
peheat 2-
8ty
peheat
exchanger exchanger
Tot
alnumberoft
ubes
566 561

Tot
alar
eaf
orheat
exchange 43m2
268. 21m2
271.

Numberoft
ubesper
pass
141 70

I
nsi
deheatt
ransf
er 564.
17(
w/m^2K)
1331.
58(
w/m^2K)
coef
fi
cientoft
ube

870.
06(
w/m^2K) 1027.
31(
w/m^2K)
Shel
lsi
deheatt
ransf
er
coef
fi
cient

Over
allheatt
ransf
er 293.
04(w/
m^2K) 296.
49(
w/m^2K)
coef
fi
cient
 16.
38%
{
(UassumeU0)
*100}
/Uassume 13.
04%

Tot
alpr
essur
edr
op
t
ubesi
de 29314.
5N/
m^2
75834N/
m^2
 Chapt
er7
Desi
gnofnapht
ha
spl
i
tter
Desi
gnofNapt
haSpl
i
tterCol
umn(
Assumi
ngf
eedasami
xtur
eof5
hy
drocar
boncomponent
s):

Tops(
50934.
035kg/
h)

Feed(
111,
943kg/
h)

P=120.
3PSI

Bot
toms(
61,
009.
965kg/
h

AssumedRef
luxr
ati
o(R)=
2.
5
 Feed(
F) Tops(
d) Bot
toms(
b)

Pr
opane(
C1) 5597.
15 5597.
15 0

i
-but
ane(
iC4) 16,
791.
45 16,
791.
45 0

n-
but
ane(
nC4) 27,
985.
75 27,
426.
035(
98% 560.
715
i
ntop)

i
-pent
ane(
iC5) 22,
388.
60 1119.
40 21269.
20

n-
pent
ane(
nC5) 39,
180.
05 0 39,
180.
05

Nowmaki
nguseofant
oineequat
ions,
De-
pri
est
erchar
twehavecal
cul
atedt
he
bubbl
eanddewpoi
ntt
emper
atur
esas65°
Cand120°
Crespect
ivel
y.

i
.e.t
emper
atur
eatt
opofcol
umn=65°
C
t
emper
atur
eatt
hebot
tom =120°
C

“Kv
aluest
abl
e” Top(
65°
C) Bot
tom (
120°
C)

Pr
opane(
C3 2.
5 5.
0

i
-but
ane(
iC4) 1.
3 2.
8

n-
but
ane(
nC4) 0.
96 2.
3
 i
-pent
ane(
iC5) 0.
46 1.
25

n-
pent
ane(
nC5) 0.
37 1.
10

Now,
ther
elat
ivev
olat
il
it
yofi
ndi
vi
dual
hydr
ocar
boncanbe
f
oundbydi
vi
dingt
he“
Ki”v
aluesofi
ndi
vi
dual
hydr
ocar
bonsby
t
heKv
alueoft
heHeav
ykey(
i.
e.,
iC5).al
pha=Ki
/K(
heav
y
key
)

Al
phav
alue Al
phaval
ue Av
g
(
at65°
C) (
At120°
C) al
pha(
takenas
Hy
drocar
bon
G.
M.)

C3 5.
43 4.
00 4.
66

i
C4 2.
83 2.
24 2.
52
nC4(
LightKey
) 2.
08 1.
84 1.
96
i
C5(
Heav
yKey
) 1.
00 1.
00 1.
00

nC5 0.
81 0.
88 0.
84

Cal
cul
ati
onofNon-
keyf
lows

Al
phai Di Li
=di
/(@- v
i=(
li+di
)
1)

C3 4.
66 5597.
15 1529.
20 7126.
35

i
C4 2.
52 16,
791.
45 11,
047 27,
838.
45
Tot
alLi
=12,
576.
20(
kg/
h)
Tot
alv
i =34,
964.
80(
kg/
h)
 Al
phai Bi Vi
’ Li
’

nC5 0.
844 39,
180.
05 29,
630.
791 68,
811

Wher
e,

Vi
=(al
phai
*bi
)/(
alpha(
LK)
-al
pha(
i)
)Vi
=(
(0.
844*
39,
180.
05)
/ (
1.960–0.
844)
)
Vi
=29,
630.
791(
kg/
h)
Rect
if
yingsect
ion

Le=L–(
summat
ionofLi
)
Ve=V–(
summat
ionof
Vi
)
LeandVear
etheest
imat
edf
lowr
atesofcombi
nedkey
s

(
Li,
Vi)–l
i
mit
ingl
i
qui
dandv
apourr
atesofcomponent
sli
ght
er
t
hant
hekey
sinr
ect
if
yingset
ion.

Le=(
2.5*
50,
934.
035)–12,
576.
20

Le=114,
758.
88(
kg/
h)

Ve=(
2.5+1)
*(50,
934.
035)–34,
964.
80

Ve=143304.
322(
kg/
h)
St
ri
ppi
ngsect
ion

Le’
=L’
–(summat
ionofl
i
’)
Ve’
=V’
–(summat
ionof
v
i’
)
Wher
eli
’andv
i’ar
ethel
i
mit
ingl
i
qui
dandv
apourr
atesof
component
sheav
iert
hant
hekey
sinst
ri
ppi
ngsect
ion.

Ve’
=(2.
5+1)
*(50934.
035)–29,
630.
791
Ve‘
=148,
638.
33(
kg/
h)
Le’
=(2.
5+1)
*(50,
934.
035)+61,
009.
965–68,
811
Le’
=170,
468.
10(
kg/
h)

Sl
opeofoper
ati
ngl
i
ne(
Le/
Ve)= 0.
801(
forenr
ichi
ng
sect
ion)Sl
opeofoper
ati
ngl
i
ne(
Le’
/Ve’
)=1.
15 (
for
st
ri
ppi
ngsect
ion)

Xb=(
(fl
owLK)
/(Fl
owLK+HK)
)

Xb =560.
715/
(560.
715+21,
269.
2)

Xb=0.
026
Xd=(
(27426.
035/
(27,
426.
035+1119.
40)
)
Xd=0.
961
 Xf=(
(27,
985.
75/
(27985.
75+22,
388.
60)
)
Xf=0.
55

Togener
atet
hey
-xequi
l
bri
um cur
ve

Y=(
(al
phaLK)
*(X)
/(1+(
alphaLK-
1)*
X)

Y=(
(1.
96*
X/(
1+0.
96X)
)

\
 X Y

0.
10 0.
17

0.
20 0.
32

0.
30 0.
45

0.
40 0.
56

0.
50 0.
66

0.
60 0.
75

0.
80 0.
88

0.
90 0.
94
1.
00 1.
00
Sl
opeoft
opoper
ati
ngl
i
ne=0.
81
Xi
nter
cept=0.
16(
ony
-axi
s)
Sl
opeofbot
tom oper
ati
ngl
i
ne=1.
15(
tan
49)Tan(
41)=X/
(1-0.
025)
Gi
vesX=0.
830
I
nter
ceptonX-
axi
satt
opwi
l
lbe-

=0.
83+0.
025

Gi
ves-(
X=0.
855)

Whenf
eedi
ssat
urat
ed{
i.
e.q=1}her
e.
Numberofpl
ates=15.
Whenf
eedi
sami
xtur
eofl
i
qui
dandv
apour
f
orm Numberofpl
ates=16.

CALCULATI
ONOFACTUALNO.OFTRAYS

Theef
fi
ciencyv
ari
esf
rom r
ange(
0.50–0.
70)

(
1) Whenf
eedi
ssat
urat
edl
i
qui
d(q=1)
Numberoft
heor
eti
cal
tray
s=15
Numberofact
ual
tray
s=(
15/
0.65)=
23

(
2) Whenf
eedi
sami
xtur
eofl
i
qui
dandv
apour(
0<q<1)
Numberoft
heor
eti
cal
tray
s=16

Numberofact
ual
tray
s=(
16/
0.65)=24
Cal
cul
ati
onofmi
nimum numberofpl
ates
Nm =l
n((
Xlk/
Xhk)
*(Xhk/
Xlk)
)/l
n(2.
1)
Nm =l
n((
27426/
1119.
4)*
(21269/
560.
71)
)/l
n(2.
1)
Nm =9.
2

Cal
cul
ati
onofRmi
nbyanal
yti
calmet
hod:
Under
woodequat
ion-
∑(
(αi
*xi
d)/
(αi
–θ)
)=Rmi
n+1;

Wher
eθl
i
esbet
ween(
αlkandαhk)(
canbef
oundbyt
ri
al
and-er
rormet
hod.

Xi
f αi αi
*Xi
f Θ=1.
5 Θ=1.
3 Θ=1.
35

0.
055 4.
66 0.
256 0.
081 0.
076 0.
077

0.
167 2.
52 0.
420 0.
41 0.
34 0.
35
 0.
270 1.
96 0.
520 1.
13 0.
78 0.
85

0.
220 1.
00 0.
220 -
0.44 -
0.73 -
0.62

0390 0.
84 0.
320 -
0.48 -
0.69 -
0.62

∑=0.
70 ∑=-
0.29 ∑=0.
037

NowSol
vef
or∑(
(αi
*Xi
f)
/(αi
-θ)
)=
0

assume(
θ=1.
35)

xi
d αi αi
*xi
d αi
*xi
d/(
αi-
θ)
0.
107 4.
66 0.
498 0.
150

0.
320 2.
53 0.
806 0.
688

0.
510 1.
96 0.
999 1.
680

0.
063 1.
00 0.
063 -
0.180

0.
000 0.
84 .
000 0.
00
Rmi
n+1=2.
338

Gi
ves,

Rmi
n=1.
338

Feedpoi
ntl
ocat
ion(
Kir
kbr
ideequat
ion)
Log(
Nr/Ns)=0.
206l
og(
(B/
D)*
(xf
hk/
xfl
k)*
(xb,
lk/
xdhk)
^2)
Nr(
noofst
agesabov
efeedpl
ate)
Ns(
noofst
agesbel
owf
eedpl
ate)
B(
mol
arf
lowr
ateofbot
tom
pr
oduct
)D(
mol
arf
lowr
ateoft
op
pr
oduct
)Log(
Nr/
Ns)=
0.
206l
og(
(61/
50.
93)
*(0.
9/0.
24)
*(0.
009/
0.021)
^2

Whi
chgi
ves

Nr
/Ns=0.
703…….
(a)
Ns+Nr=15 (
b)

Ns=8.
8==9,

So9thpl
atei
sthef
eedpl
ate.
 Chapt
er6
Economi
cAnal
ysi
s
 Est
imat
ionofequi
pmentcost

Costofequi
pment
siscal
cul
atedusi
ngf
oll
owi
ngcostcor
rel
ati
ons:

Ce=a+bSn
Ce=CSn
Wher
e,Ce=pur
chasedequi
pment
a,
b,C=costconst
ant
s
S=si
zepar
amet
er

n=exponentf
ort
hatt
ypeofequi
pment

Chemi
cal
Engi
neer
ingPl
antCostI
ndex2010=532.
9
Chemi
cal
Engi
neer
ingPl
antCostI
ndex2019=603.
1
Chemi
cal
Engi
neer
ingPl
antCostI
ndex2004=457.
4
Costofequi
pmenti
n2019i
scal
cul
atedas:
Costi
n2019=(
Costi
n2010)
(CEPCIi
n2019)
/(CEPCIi
n2010)

1.HeatExchanger
Ar 43m2
ea=268.
a=28000
b=268.
43

n=1.
2

So,
Ce=2840000+54*
(268.
43)
^1.
2

=Rs4341596.
838

Costi
n2019=4341596.
838*
603.
1/532.
9

=Rs4913524.
212

Repeat
ingabov
epr
ocedur
eforal
lequi
pmentused,
weget
:
 Equi
pment Costof Numberof Tot
alCost
Equi
pment Equi
pment (
LakhRs)
Sr
.No.
(
LakhRs)
1 Fi
l
ter 50.
52 1 50.
52

2 Pump 12.
20 8 97.
66

3 HeatExchanger 49.
13 13 638.
69

4 Tanks 5.
78 7 40.
46

5 Reboi
l
er 59.
39 3 178.
19

6 Col
umn 215.
86 3 647.
59

7 React
or 36.
18 3 108.
54

8 Ai
rCool
er 28.
09 7 196.
64

9 Fur
nace 86.
65 1 86.
65

10 Compr
essor 16.
57 1 16.
57

TOTAL(
E) 2061.
41
 Est
imat
ionofFi
xedCapi
tal
Inv
est
ment
:

1)Di
rectCost
1. Pur
casedEqui
pmentCost
,E 06X108
=Rs2.

2. Equi
pmentI
nst
all
ati
onCost
,39%ofE 82X107
=Rs7.

3. I
nst
rument
ati
on(
inst
all
ed)
,28%E 62X107
=Rs5.

4. El
ect
ri
cal
inst
all
ed,
10%E 006X107
=Rs2.

5. Pi
ping(
inst
all
ed)
,31%E 22X107
=Rs6.

6. Bui
l
dingsi
ncl
udi
ngser
vices,
22%E 413X107
=Rs4.

7. Ser
vicef
aci
l
iti
esi
nst
all
ed,
55%E 133X108
=Rs1.

8. LandRequi
si
ti
on,
4%E 03X106
=Rs8.

TOTAL,
D 792Xb108
=Rs.3.

2)I
ndi
rectCost

1. Engi
neer
ingandSuper
visi
on,
32%ofE 42X107
=Rs6.

2. Const
ruct
ionexpenses,
34%ofE 82X107
=Rs6.

3. Cont
ract
orsf
ee‘
s,5%D 89X107
=Rs1.

4. Cont
ingency
,10%D 79X107
=Rs3.

TOTAL,
I =Rs.1.
892X1
Fi
xedCapi
talI
nvest
ment =D+I

792X108+1.
=3. 892X108

684X108
=Rs5.

Wor
kingCapi
talCost =15%ofFCI

=0. 684X108
15X5.

853X108
=Rs0.

Tot
al Capi
tal I
nvest
ment =FCI+WCI

91X108+1.
=8. 33X108

54X108
=Rs6.
 Est
imat
ionofTot
alPr
oductCost
:

Manuf
act
uri
ngcost=Di
rectpr
oduct
ioncost+Fi
xedchar
ges+Pl
antov
erheadcost
.

A.Fi
xedChar
ges:
(10-
20%t
otal
productcost
)

I
.Depr
eci
ati
on:
(dependsonl
i
feper
iod,
sal
vagev
alueandmet
hodofcal
cul
ati
on-
about13%ofFCIf
ormachi
ner
yandequi
pmentand2-
3%f
orBui
l
dingVal
uef
or
Bui
l
dings)
.Consi
derdepr
eci
ati
on=10%ofFCIf
ormachi
ner
yandequi
pmentand
3%f
orBui
l
dingVal
uef
orBui
l
dings)i
.e.
,Depr
eci
ati 654X108
on=Rs.0.

i
i
.Local
Taxes:
(1-
4%off
ixedcapi
tal
inv
est
ment
)Consi
dert
hel
ocal
tax
esof
4%off
ixedcapi
tal
inv
est
menti
.
e.Local
Tax 274X107
es=Rs2.

i
i
i.I
nsur
ances:
(0.
4-1%off
ixedcapi
tal
inv
est
ment
)Consi
dert
heI
nsur
ance=0.
6%
off
ixedcapi
tal
inv
est
menti
.e.I
nsur
ance=Rs.
3.41*
10^
6

i
v.Rent
:(8-
12%ofv
alueofr
ent
edl
andandbui
l
dings)Consi
derr
ent=
10%ofv
alueof(
rent
edl
and+bui
l
dings)Rent=Rs5.
684×10^
7

Fi
xedChar
ges=Depr
eci
ati
on+LocalTaxes+I
nsur
ance+Rent

=0.654x108+2.
274x107+3.
41x107+5.
684x108

48x108
=Rs1.

B.Di
rectPr
oduct
ionCost
:(about60%oft
otal
productcost
)

Lett
het
otal
productcostbeX

i
. RawMat
eri
als:
(10-
50%oft
otal
productcost
)

Consi
dert
hecostofr
awmat
eri
als=25%oft
otal
productcost
Rawmat
eri
alcost=Rs.
0.25X
i
i
. Oper
ati
ngLabor(
OL)
:(10-
20%oft
otal
productcost
)
 Consi
dert
hecostofoper
ati
ngl
abor=15%oft
otal
productcost
Oper
ati
ngLaborCost=Rs.
0.15X
i
i
i. Di
rectSuper
visor
yandCl
eri
cal
Labor(
DS&CL)
:(10-
25%ofOL)
Consi
dert
hecostf
orDi
rectsuper
visor
yandcl
eri
cal
labor=12%ofOL
Di
rectsuper
visor
yandcl
eri
cal
laborcost=Rs.
0.018X
i
v. Ut
il
it
ies:
(10-
20%oft
otal
productcost
)

Consi
dert
hecostofUt
il
it
ies=15%oft
otal
productcost
Ut
il
it
iescost=0.
15X
v. Mai
ntenanceandr
epai
rs(
M &R)
:(2-
10%off
ixedcapi
tal
inv
est
ment
)
Consi
dert
hemai
ntenanceandr
epai
rcost=5%off
ixedcapi
tal
inv
est
ment
Mai
ntenanceandr
epai 21x107
rcost=Rs5.
vi
. Oper
ati
ngSuppl
i
es:
(10-
20%ofM &Ror0.
5-1%ofFCI
)
Consi
dert
hecostofOper
ati
ngsuppl
i
es=15%ofM &R
Oper
ati
ngsuppl
i 82x106
escost=Rs7.
vi
i
. Labor
ator
yChar
ges:
(10-
20%ofOL)Consi
der
t
heLabor
ator
ychar
ges=15%ofOL
Labor
ator
ychar
ges=Rs.
0.0225X
vi
i
i. Pat
entandRoy
alt
ies:
(0-
6%oft
otal
productcost
)

Consi
dert
hecostofPat
entandr
oyal
ti
es=5%oft
otal
productcost
Pat
entandRoy
alt
iescost=Rs.
0.05X

Di
rectPr
oduct
ionCost=I+i
i+i
i
i+i
v+v+v
i+v
ii+v
ii
i

=0.
25X+0.
15X+0.
018X+0. 842x107+4.
15X+2. 26x106+
0.
0725X
 =Rs.(
0.6405X+(
32.
68×10^
6))

C.Pl
antOv
erheadCost
:

(
50-
70% ofOper
ati
ngl
abor
,super
visi
on,andmai
ntenanceor5-
15% oft
otalpr
oduct
cost
);i
ncl
udesf
ort
hef
oll
owi
ng:gener
alpl
antupkeepandov
erhead,pay
rol
lov
erhead,
packagi
ng,medi
calser
vices,saf
etyandpr
otect
ion,r
est
aur
ant
s,r
ecr
eat
ion,sal
vage,
l
abor
ator
ies,
andst
oragef
aci
l
iti
es.

Pl
antOv
erheadCost=60%ofLabor&Mai
ntenancecost

=0.
6(0. 21x107)
15X+5.

12x107+0.
=Rs3. 09X

Tot
alPr
oductCost=A+B+C

=(
1.48x108)
+( 68x106+0.
32. 6405X) 12x107+0.
+(3. 09X)

=(
2.12x108)+0.
7305X

=Rs.2.
45*(
10^
9)
Tot
alI
ncome:

Pr
oduct1:
LightFCCGasol
i
ne

Li
ghtFCCGasol
i
nei
ssentt
otheMSPool
forbl
endi
ngandt
hensol
dto
mar
ket
.Lett
hecont
ri
but
ionofLi
ghtFCCGasol
i
nei
s60%.
CostofGasol
i
neperl
i
teri
nIndi
a =Rs74
Pr
oduct
ionofLi
ghtGasol
i
neperannum =590400000
l
i
ter
I
ncome =74x
0.60x590400000

62x1010
=Rs2.

Pr
oduct2:
Heav
yDe-
sul
fur
isedGasol
i
ne

Heav
yDe-
sul
fur
isedGasol
i
nei
ssentt
otheMSPool
forbl
endi
ngandt
hensol
dtot
he
mar
ket
.
Lett
hecont
ri
but
ionofHeav
yDe-
sul
fur
isedGasol
i
nei
s15%.

Pr
oduct
ionofHeav
yDe-
sul
fur
isedGasol
i
neperannum =630400000l
i
ter
I
ncome =0.
2x74x630400000
99x109
=Rs6.

Pr
oduct3:
Pur
geGas

Pur
geGasi
sobt
ainedat648kg/
hrwhi
chcanbeusedasaf
uel
forf
urnace.

Tot
alI
ncome 62x1010+6.
=2. 99x109

19x109
=Rs33.

Gr
ossPr
ofi
t =Tot
alI
ncome–Tot
alPr
oductCost

19x109-2.
=33. 45x109

74x109
=Rs30.
 Chapt
er7

Saf
ety&Pol
l
uti
onCont
rol
The Env
ironmentHeal
th Saf
ety(
EHS)Gui
del
i
nes f
orPet
rol
eum Ref
ini
ng cov
er
pr
ocessi
ngoper
ati
onsf
rom cr
udeoi
ltof
ini
shedl
i
qui
dpr
oduct
s,i
ncl
udi
ngl
i
quef
ied
pet
rol
eum gas(
LPG)
,Mo-
Gas(
mot
orgasol
i
ne)
,ker
osene,di
eseloi
l
,heat
ingoi
l
,fuel
oi
l
,bi
tumen,asphal
t,sul
phur
,andi
nter
medi
atepr
oduct
s(e.
g.pr
opane/pr
opy
lene
mi
xtur
es, v
irgi
n napht
ha, mi
ddl
e di
sti
l
lat
e and v
acuum di
sti
l
lat
e) f
or t
he
pet
rochemi
cali
ndust
ry.Fur
theri
nfor
mat
iononEHSi
ssuesr
elat
edt
ost
oraget
ank
f
armsi
spr
ovi
ded i
ntheEHS Gui
del
i
nesf
orCr
udeOi
land Pet
rol
eum Pr
oduct
Ter
minal
s.

Thef
oll
owi
ngsect
ionpr
ovi
desasummar
yofEHSi
ssuesassoci
atedwi
thpet
rol
eum
r
efi
ningwhi
choccurdur
ingt
heoper
ati
onalphase,al
ongwi
thr
ecommendat
ionsf
or
t
hei
rmanagement
.Recommendat
ionsf
ort
hemanagementofEHSi
ssuescommon
t
o mostl
argei
ndust
ri
alf
aci
l
iti
esdur
ing t
heconst
ruct
ionand decommi
ssi
oni
ng
phasesar
epr
ovi
dedi
ntheGener
alEHSGui
del
i
nes.

Envi
ronment
al

Pot
ent
ial
env
ironment
ali
ssuesassoci
atedwi
thpet
rol
eum r
efi
ningi
ncl
udet
hef
oll
owi
ng:

 Ai
remi
ssi
ons

 Wast
ewat
er

 Hazar
dousmat
eri
als

 Wast
es

 Noi
se

Ai
rEmi
ssi
ons

ExhaustGases

Exhaustgasandf
luegasemi
ssi
ons(
car
bondi
oxi
de(
CO2)
,ni
tr
ogenox
ides(
NOX)
and car
bon monoxi
de (
CO)i
nthe pet
rol
eum r
efi
ning sect
orr
esul
tfr
om t
he
combust
ionofgasandf
ueloi
lordi
eseli
ntur
bines,boi
l
ers,compr
essor
sandot
her
engi
nesf
orpowerandheatgener
ati
on.Fl
uegasi
sal
sogener
atedi
nwast
eheat
boi
l
ersassoci
atedwi
thsomepr
ocessuni
tsdur
ingcont
inuouscat
aly
str
egener
ati
on
orf
lui
dpet
rol
eum cokecombust
ion.Ai
rqual
i
tyi
mpact
sshoul
dbeest
imat
edbyt
he
useofbasel
i
neai
rqual
i
tyassessment
sandat
mospher
icdi
sper
sionmodel
sto
est
abl
i
shpot
ent
ialgr
oundl
evelambi
entai
rconcent
rat
ionsdur
ingf
aci
l
itydesi
gnand
oper
ati
onspl
anni
ng.

Vent
ingandFl
ari
ng
Vent
ingandf
lar
ingar
eimpor
tantoper
ati
onalandsaf
etymeasur
esusedi
npet
rol
eum
r
efi
ning f
aci
l
iti
es t
o ensur
ethatv
apor
s gases ar
e saf
elydi
sposed of
.Pet
rol
eum
hy
drocar
bonsar
eemi
tt
edf
rom emer
gencypr
ocessv
ent
sandsaf
etyv
alv
esdi
schar
ges.
Thesear
ecol
l
ect
edi
ntot
hebl
ow-
downnet
wor
ktobef
lar
ed.

Excessgasshoul
dnotbev
ent
ed,buti
nst
eadsentt
oanef
fi
cientf
lar
egassy
stem f
or
di
sposal
.Emer
gencyv
ent
ingmaybeaccept
abl
eunderspeci
fi
ccondi
ti
onswher
efl
ari
ng
oft
hegasst
ream i
snotpossi
ble,
ont
hebasi
sofanaccur
ater
iskanal
ysi
sandi
ntegr
it
y
oft
hesy
stem needst
obepr
otect
ed.Just
if
icat
ionf
ornotusi
ngagasf
lar
ingsy
stem
shoul
dbef
ull
ydocument
edbef
oreanemer
gencygasv
ent
ingf
aci
l
ityi
sconsi
der
ed.

Bef
oref
lar
ingi
sadopt
ed,f
easi
bleal
ter
nat
ivesf
ort
heuseoft
hegasshoul
dbe
ev
aluat
edandi
ntegr
atedi
ntopr
oduct
iondesi
gnt
othemax
imum ex
tentpossi
ble.
Fl
ari
ng v
olumes f
or new f
aci
l
iti
es shoul
d be est
imat
ed dur
ing t
he i
nit
ial
commi
ssi
oni
ngper
iodsot
hatf
ixedv
olumef
lar
ingt
arget
scanbedev
eloped.The
v
olumesofgasf
lar
ed f
oral
lfl
ari
ng ev
ent
sshoul
d be r
ecor
ded and r
epor
ted.
Cont
inuousi
mpr
ovementoff
lar
ingt
hroughi
mpl
ement
ati
onofbestpr
act
icesand
newt
echnol
ogi
esshoul
dbedemonst
rat
ed.

Thef
oll
owi
ngpol
l
uti
onpr
event
ionandcont
rolmeasur
esshoul
dbeconsi
der
edf
orgas
f
lar
ing:

 I
mpl
ement
ati
onofsour
cegasr
educt
ionmeasur
est
othemax
imum ex
tent
possi
ble

 Useofef
fi
cientf
lar
eti
ps,
andopt
imi
zat
ionoft
hesi
zeandnumberofbur
ning
nozz
les

 Maxi
mizi
ngf
lar
ecombust
ionef
fi
ci
encybycont
rol
l
ingandopt
imi
zi
ngf
lar
e
f
uel/ai
rst
eam f
lowr
atest
oensur
ethecor
rectr
ati
oofassi
stst
ream t
ofl
are
st
ream

 Mi
nimi
zi
ng f
lar
ing f
rom pur
ges and pi
l
ots,wi
thoutcompr
omi
sing saf
ety
,
t
hroughmeasur
esi
ncl
udi
ngi
nst
all
ati
onofpur
gegasr
educt
iondev
ices,f
lar
e
gasr
ecov
eryuni
ts,i
ner
tpur
gegasandsof
tseatv
alv
etechnol
ogywher
e
appr
opr
iat
e,andi
nst
all
ati
onofconser
vat
ionpi
l
ots
 Mi
nimi
zi
ng r
iskofpi
l
otbl
ow-
outbyensur
ing suf
fi
cientex
itv
eloci
tyand
pr
ovi
ding wi
ndguar
ds

 Useofar
eli
abl
epi
l
oti
gni
ti
onsy
stem

 I
nst
all
ati
onofhi
ghi
ntegr
it
yinst
rumentpr
essur
epr
otect
ionsy
stems,
wher
e
 appr
opr
iat
e,t
oreduceov
erpr
essur
eev
ent
sandav
oidorr
educef
lar
ingsi
tuat
ions

 I
nst
all
ati
on of knock-
outdr
ums t
o pr
eventcondensat
e emi
ssi
ons,wher
e
appr
opr
iat
e

 Mi
nimi
zi
ngl
i
qui
dcar
ry-
overandent
rai
nmenti
nthegasf
lar
est
ream wi
tha
sui
tabl
eli
qui
dsepar
ati
onsy
stem

 Mi
nimi
zi
ngf
lamel
i
ftof
fand/orf
lamel
i
c k

 Oper
ati
ngf
lar
etocont
rolodorandv
isi
blesmokeemi
ssi
ons(
nov
isi
blebl
ack
smoke)

 Locat
ingf
lar
eatasaf
edi
stancef
rom l
ocalcommuni
ti
esandt
hewor
kfor
ce
i
ncl
udi
ngwor
kfor
ceaccommodat
ionuni
ts

 I
mpl
ement
ati
onofbur
nermai
ntenanceandr
epl
acementpr
ogr
amst
oensur
e
cont
inuousmaxi
mum f
lar
eef
fi
ci
ency

 Met
eri
ng f
lar
e gas.To mi
nimi
ze f
lar
ing ev
ent
s as a r
esul
tofequi
pment
br
eakdowns and pl
antupset
s,pl
antr
eli
abi
l
ityshoul
d be hi
gh (
>95 %)
,and
pr
ovi
si
onshoul
dbemadef
orequi
pmentspar
ingandpl
antt
urndownpr
otocol
s.

Fumi
gat
iveEmi
ssi
ons

Fugi
ti
veemi
ssi
onsi
npet
rol
eum r
efi
ningf
aci
l
iti
esar
eassoci
atedwi
thv
ent
s,l
eaki
ng
t
ubi
ng,
val
ves,
connect
ions,
flanges,
packi
ng,
open-
endedl
i
nes,
float
ingr
oofst
orage
t
anksandpumpseal
s,gasconv
eyancesy
stems,compr
essorseal
s,pr
essur
erel
i
ef
v
alv
es,t
anksoropenpi
ts/cont
ainment
s,andl
oadi
ngandunl
oadi
ngoper
ati
onsof
hy
drocar
bons.Dependi
ngont
her
efi
ner
ypr
ocessscheme,f
ugi
ti
veemi
ssi
onsmay
i
ncl
ude:

 Hy
drogen

 Met
hane

 Vol
ati
l
eor
gani
ccompounds(
VOCs)
,(e.
g.et
hane,et
hyl
ene,pr
opane,pr
opy
lene,
but
anes,
but
ylenes,
pent
anes,
pent
ene,
C6-
C9al
kyl
ate,
benzene,
tol
uene,
xyl
enes,
 phenol
,andC9ar
omat
ics)

 Pol
ycy
cli
c ar
omat
ic hy
drocar
bons (
PAHs)and ot
hersemiv
olat
il
e or
gani
c
compounds
  I
nor
gani
cgases,i
ncl
udi
nghy
drof
luor
icaci
dfr
om hy
drogenf
luor
ideal
kyl
ati
on,
hy
drogensul
fi
de,ammoni
a,car
bondi
oxi
de,car
bonmonoxi
de,sul
furdi
oxi
deand
sul
furt
ri
oxi
def
rom sul
fur
icaci
dregener
ati
on i
nthesul
fur
icaci
d al
kyl
ati
on
pr
ocess,NOX,met
hylt
ert
-but
ylet
her(
MTBE)
,et
hylt
ert
iar
ybut
ylet
her(
ETBE)
,t-
amy
lmet
hyl
ether(
TAME)
,met
hanol
,andet
hanol
.

Themai
nsour
cesofconcer
nincl
udeVOCemi
ssi
onsf
rom coner
oofst
oraget
anks
dur
ingl
oadi
ngandduet
oout
-br
eat
hing;
fugi
ti
veemi
ssi
onsofhy
drocar
bonst
hrought
he
f
loat
ingr
oofseal
soff
loat
ingr
oofst
oraget
anks;f
ugi
ti
ve emi
ssi
ons f
rom f
langes
and/
orv
alv
esandmachi
ner
yseal
s;VOCemi
ssi
onsf
rom bl
endi
ngt
anks,
val
ves,
pumps
andmi
xi
ngoper
ati
ons;
andVOCemi
ssi
onsf
rom oi
l
ysewageandwast
ewat
ert
reat
ment
sy
stems.Ni
tr
ogen f
rom bi
tumen st
orage t
anks may al
so be emi
tt
ed, possi
bly
cont
aini
nghy
drocar
bonsandsul
furcompoundsi
nthef
orm ofaer
osol
s.Ot
herpot
ent
ial
f
ugi
ti
veemi
ssi
onsour
cesi
ncl
udet
heVapourRecov
eryUni
tvent
sandgasemi
ssi
on
f
rom caust
icoxi
dat
ion.

Recommendat
ionst
opr
eventandcont
rol
fugi
ti
veemi
ssi
onsi
ncl
udet
hef
oll
owi
ng:

 Basedonr
evi
ew ofPr
ocessandI
nst
rument
ati
onDi
agr
ams(
P&I
Ds)
,ident
if
y
st
reams and equi
pment(
e.g.f
rom pi
pes,v
alv
es,seal
s,t
anks and ot
her
i
nfr
ast
ruct
ure component
s)l
i
kel
ytol
ead t
ofugi
ti
ve VOC emi
ssi
ons and
pr
ior
it
izet
hei
rmoni
tor
ing wi
thv
apourdet
ect
ion equi
pmentf
oll
owed by
mai
ntenanceorr
epl
acementofcomponent
sasneeded

 Hy
drocar
bonv
apor
sshoul
dbeei
thercont
ainedorr
out
edbackt
othepr
ocess
sy
stem wher
ethepr
essur
elev
elal
l
ows

 Thesel
ect
ionofappr
opr
iat
eval
ves,
flanges,
fit
ti
ngs,
seal
sandpacki
ngshoul
dbe
basedont
hei
rcapaci
tyt
oreducegasl
eaksandf
ugi
ti
veemi
ssi
ons

 Useofv
entgasscr
ubber
sshoul
dbeconsi
der
edt
oremov
eoi
landot
her
oxi
dat
ion pr
oduct
sfr
om ov
erhead v
apor
sin speci
fi
c uni
ts(
e.g.bi
tumen
pr
oduct
ion)

 I
nci
ner
ati
onofgasshoul
dbeconduct
edathi
ght
emper
atur
e(appr
oxi
mat
ely
800°
C)t
o ensur
ecompl
etedest
ruct
ion ofmi
norcomponent
s(e.
g.H2S,
al
dehy
des,or
gani
caci
dsandphenol
i
ccomponent
s)andmi
nimi
zeemi
ssi
ons
 andodouri
mpact
s

 neut
ral
i
zedf
orHFr
emov
ali
nascr
ubberbef
orebei
ngsentt
ofl
ar
Sul
furOxi
des

Sul
furoxi
des(
SOx)andhy
drogensul
fi
demaybeemi
tt
edf
rom boi
l
ers,heat
ers,and
ot
herpr
ocessequi
pment
,basedont
hesul
furcont
entoft
hepr
ocessedcr
udeoi
l
.
Sul
furdi
oxi
deandsul
furt
ri
oxi
demaybeemi
tt
edf
rom sul
fur
icaci
dregener
ati
oni
n
t
hesul
fur
icaci
dal
kyl
ati
onpr
ocess.Sul
furdi
oxi
dei
nref
iner
ywast
egasesmayhav
e
pr
e-abat
ementconcent
rat
ion l
evel
s of1500 -
7500 mi
l
li
grams percubi
c met
er
(
mg/
m3)
.

Recommendedpol
l
uti
onpr
event
ionandmi
nimi
zat
ionmeasur
esi
ncl
udet
hef
oll
owi
ng:

 Mi
nimi
ze SOX emi
ssi
ons t
hrough desul
fur
izat
ion off
uel
s,t
othe ex
tent
f
easi
ble,
orbydi
rect
ingt
heuseofhi
gh-
sul
furf
uel
stouni
tsequi
ppedwi
thSOX
emi
ssi
oncont
rol
s

 Recov
ersul
furf
rom t
ailgasesusi
nghi
ghef
fi
ciencysul
furr
ecov
eryuni
ts(
e.g.
Cl
ausuni
ts)

 I
nst
allmi
stpr
eci
pit
ator
s(e.
g.el
ect
rost
ati
cpr
eci
pit
ator
sorbr
inkdemi
ster
s)
t
oremov
esul
fur
icaci
dmi
st

 I
nst
allscr
ubber
swi
thcaust
icsodasol
uti
ont
otr
eatf
luegasesf
rom t
he
al
kyl
ati
onuni
tabsor
pti
ont
ower
s.

Par
ti
cul
ateMat
ter

Par
ti
cul
ateemi
ssi
onsf
rom r
efi
ner
yuni
tsar
eassoci
atedwi
thf
luegasf
rom f
urnaces;
cat
aly
stf
inesemi
tt
edf
rom f
lui
dizedcat
aly
ticcr
acki
ngr
egener
ati
onuni
tsandot
her
cat
aly
stbasedpr
ocesses;t
hehandl
i
ngofcoke;andf
inesandashgener
ateddur
ing
i
nci
ner
ati
onofsl
udge.Par
ti
cul
atesmaycont
ainmet
als(
e.g.v
anadi
um,ni
ckel
s).
Measur
est
ocont
rolpar
ti
cul
atemayal
socont
ri
but
etocont
rolofmet
alemi
ssi
ons
f
rom pet
rol
eum r
efi
ning.

Recommendedpol
l
uti
onpr
event
ionandmi
nimi
zat
ionmeasur
esi
ncl
udet
hef
oll
owi
ng:

 I
nst
allcy
clones,el
ect
rost
ati
cpr
eci
pit
ator
s,bagf
il
ter
s,and/
orwetscr
ubber
s
t
oreduceemi
ssi
onsofpar
ti
cul
atesf
rom poi
ntsour
ces.A combi
nat
ionof
 t
heset
echni
quesmayachi
eve>99per
centabat
ementofpar
ti
cul
atemat
ter

 I
mpl
ementpar
ti
cul
ate emi
ssi
on r
educt
ion t
echni
ques dur
ing coke handl
i
ng,
i
ncl
udi
ng:
 o Keepcokeconst
ant
lywet

o Cutcokei
nacr
usherandconv
eyi
ttoani
nter
medi
atest
oragesi
l
o
(
hydr
obi
ns)

o Spr
ayt
hecokewi
thaf
inel
ayerofoi
l
,tost
ickt
hedustf
inest
othecoke

o Usecov
eredandconv
eyorbel
tswi
thext
ract
ionsy
stemst
omai
ntai
n
negat
ivepr
essur
e

o Useaspi
rat
ionsy
stemst
oext
ractandcol
l
ectcokedust

o Pneumat
ical
l
yconv
eyt
hef
inescol
l
ect
edf
rom t
hecy
clonesi
ntoasi
l
o
f
it
tedwi
thexi
tai
rfi
l
ter
s,andr
ecy
clet
hecol
l
ect
edf
inest
ost
orage.

Gr
eenhouseGases(
GHGs)

Car
bondi
oxi
de(
CO2)maybepr
oducedi
nsi
gni
fi
cantamount
sdur
ingpet
rol
eum r
efi
ning
f
rom combust
ionpr
ocesses(
e.g.el
ect
ri
cpowerpr
oduct
ion)
,fl
aresandhy
drogenpl
ant
s.
Car
bondi
oxi
deandot
hergases(
e.g.ni
tr
ogenoxi
desandcar
bonmonoxi
de)maybe
di
schar
gedt
oat
mospher
edur
ingi
n-si
tucat
aly
str
egener
ati
onofnobl
emet
als.

Oper
ator
s shoul
d ai
m t
o maxi
miz
e ener
gyef
fi
ciencyand desi
gn f
aci
l
iti
es (
e.g.
oppor
tuni
ti
es f
or ef
fi
ci
ency i
mpr
ovement
sin ut
il
it
ies,f
ir
ed heat
ers,pr
ocess
opt
imi
zat
ion,heatexchanger
s,mot
orandmot
orappl
i
cat
ions)t
omi
nimi
zeener
gy
use.Theov
eral
lobj
ect
iveshoul
dbet
oreduceai
remi
ssi
onsandev
aluat
ecost
-
ef
fect
iveopt
ionsf
orr
educi
ngemi
ssi
onst
hatar
etechni
cal
l
yfeasi
ble.

Wast
ewat
er

I
ndust
ri
alPr
ocessWast
ewat
er

Thel
argestv
olumeef
fl
uent
sinpet
rol
eum r
efi
ningi
ncl
ude―sour
‖pr
ocesswat
erand
nonoi
l
y/non-
sourbuthi
ghl
yal
kal
i
ne pr
ocesswat
er.Sourwat
eri
sgener
ated f
rom
desal
ti
ng,t
oppi
ng,v
acuum di
sti
l
lat
ion,pr
e-t
reat
ing,l
i
ght and mi
ddl
e di
sti
l
lat
e
hy
drodesul
phur
izat
ion,hy
drocr
acki
ng,cat
aly
ticcr
acki
ng,coki
ng,v
isbr
eaki
ng/t
her
mal
cr
acki
ng.Sourwat
ermay be cont
ami
nat
ed wi
th hy
drocar
bons,hy
drogen sul
fi
de,
ammoni
a,or
gani
csul
furcompounds,or
gani
caci
ds,and phenol
.Pr
ocesswat
eri
s
t
reat
edi
nthesourwat
erst
ri
pperuni
t(SWS)t
oremov
ehy
drocar
bons,
hydr
ogensul
fi
de,
ammoni
aandot
hercompounds,bef
orer
ecy
cli
ngf
ori
nter
nalpr
ocessuses,orf
inal
t
reat
mentanddi
sposalt
hroughanonsi
tewast
ewat
ert
reat
mentuni
t.Non-
oil
y/non-
sourbuthi
ghl
yal
kal
i
nepr
ocesswat
erhast
hepot
ent
ial
tocauseWast
eWat
er
Tr
eat
mentPl
antupset
s.Boi
l
erbl
owdownanddemi
ner
ali
zat
ionpl
antr
ejectst
reams
i
npar
ti
cul
ar,i
fincor
rect
lyneut
ral
i
zed,hav
ethepot
ent
ialt
oex
tractphenol
i
csf
rom
t
heoi
lphasei
ntot
hewat
erphase,aswel
lascauseemul
sionsi
ntheWWTP.Li
qui
d
ef
fl
uentmayal
sor
esul
tfr
om acci
dent
alr
eleasesorl
eaksofsmal
lquant
it
iesof
pr
oduct
sfr
om pr
ocessequi
pment
,machi
ner
yandst
oragear
eas/
tanks.

Recommendedpr
ocesswast
ewat
ermanagementpr
act
icesi
ncl
ude:

 Pr
event
ion and cont
rolofacci
dent
alr
eleases ofl
i
qui
ds t
hrough r
egul
ar
i
nspect
ionsandmai
ntenanceofst
oragesandconv
eyancesy
stems,
incl
udi
ng
st
uff
ingbox
esonpumpsandv
alv
esandot
herpot
ent
iall
eakagepoi
nts,as
wel
last
hei
mpl
ement
ati
onofspi
l
lresponsepl
ans.Pr
ovi
sionofsuf
fi
cient
pr
ocessf
lui
dsl
et-
downcapaci
tyt
omaxi
miz
erecov
eryi
ntot
hepr
ocessand
av
oid massi
ve di
schar
ge ofpr
ocess l
i
qui
ds i
ntot
he oi
l
ywat
erdr
ainage
sy
stem

 Desi
gn and const
ruct
ion ofwast
ewat
erand haz
ardousmat
eri
alsst
orage
cont
ainmentbasi
ns wi
thi
mper
vious sur
faces t
o pr
eventi
nfi
l
trat
ion of
cont
ami
nat
edwat
eri
ntosoi
landgr
oundwat
er

 Segr
egat
ion of pr
ocess wat
er f
rom st
orm wat
er and segr
egat
ion of
wast
ewat
erandhaz
ardousmat
eri
alscont
ainmentbasi
ns

 I
mpl
ement
ati
on of good housekeepi
ng pr
act
ices,i
ncl
udi
ng conduct
ing
pr
oductt
ransf
eract
ivi
ti
esov
erpav
edar
easandpr
omptcol
l
ect
ionofsmal
l
spi
l
ls.

Pr
ocessWast
ewat
erTr
eat
ment

Techni
quesf
ort
reat
ingi
ndust
ri
alpr
ocesswast
ewat
eri
nthi
ssect
ori
ncl
udesour
ce
segr
egat
ion and pr
e-t
reat
ment of concent
rat
ed wast
ewat
er st
reams.Ty
pical
wast
ewat
ert
reat
mentst
epsi
ncl
ude:gr
easet
raps,
ski
mmer
s,di
ssol
vedai
rfl
oat
ati
on
oroi
lwat
ersepar
ator
sforsepar
ati
onofoi
l
sandf
loat
abl
esol
i
ds;f
il
tr
ati
onf
or
separ
ati
on off
il
ter
abl
e sol
i
ds;f
low and l
oad equal
i
zat
ion;sedi
ment
ati
on f
or
suspendedsol
i
dsr
educt
ionusi
ngcl
ari
fi
ers;bi
ologi
calt
reat
ment
,ty
pical
l
yaer
obi
c
t
reat
ment
,forr
educt
ionofsol
ubl
eor
gani
cmat
ter(
BOD)
;chemi
calorbi
ologi
cal
nut
ri
entr
emov
alf
orr
educt
ioni
nni
tr
ogenandphosphor
us;chl
ori
nat
ionofef
fl
uent
whendi
sinf
ect
ioni
srequi
red;dewat
eri
nganddi
sposalofr
esi
dual
sindesi
gnat
ed
hazar
douswast
elandf
il
ls.Addi
ti
onal
engi
neer
ingcont
rol
smayber
equi
redf
or

1)Cont
ainmentandt
reat
mentofv
olat
il
eor
gani
csst
ri
ppedf
rom v
ari
ousuni
t
oper
ati
onsi
nthewast
ewat
ert
reat
mentsy
stem

2)Adv
ancedmet
alsr
emov
alusi
ngmembr
anef
il
tr
ati
onorot
herphy
sical
/chemi
cal
 t
reat
mentt
echnol
ogi
es

3)Remov
alofr
ecal
cit
rantor
gani
csandnon-
biodegr
adabl
eCODusi
ngact
ivat
ed
car
bonoradv
ancedchemi
cal
oxi
dat
ion

4)Reduct
ioni
nef
fl
uentt
oxi
cit
yusi
ngappr
opr
iat
etechnol
ogy(
suchasr
ever
se
osmosi
s,i
onexchange,
act
ivat
edcar
bon,
etc.
),and

5)Cont
ainmentandneut
ral
i
zat
ionofnui
sanceodour
s.

Wast
es

Hazar
dousWast
es:
SpentCat
aly
sts

Spentcat
aly
stsr
esul
tfr
om sev
eralpr
ocessuni
tsi
npet
rol
eum r
efi
ningi
ncl
udi
ngt
he
pr
etr
eat
ingandcat
aly
ticr
efor
mer
;li
ghtandmi
ddl
edi
sti
l
lat
ehy
drodesul
phur
izat
ion;t
he
hy
drocr
acker
;fl
uid cat
aly
tic cr
acki
ng (
FCCU)
;resi
due cat
aly
tic cr
acki
ng (
RCCU)
;
MTBE/
ETBEandTAMEpr
oduct
ion;but
anesi
somer
izat
ion;t
hedi
eneshy
drogenat
ion
andbut
yleneshy
droi
somer
izat
ionuni
t;sul
fur
icaci
dregener
ati
on.

Non-
hazar
dousWast
es

Hy
drof
luor
icaci
d al
kyl
ati
on pr
oducesneut
ral
i
zat
ion sl
udgeswhi
ch maycont
ain
cal
cium f
luor
ide,cal
ci
um hy
droxi
de,cal
cium car
bonat
e,magnesi
um f
luor
ide,
magnesi
um hy
drox
ideandmagnesi
um car
bonat
e.Af
terdr
yingandcompr
essi
on,
t
heymaybemar
ket
edf
orst
eelmi
l
lsuseorl
andf
il
led.Det
ail
edgui
danceont
he
st
orage,handl
i
ng,t
reat
ment
,anddi
sposalofnon-
haz
ardouswast
esi
spr
ovi
dedi
n
t
heGener
alEHSGui
del
i
nes.

Occupat
ional
Heal
thandSaf
ety

Faci
l
ity
-speci
fi
coccupat
ionalheal
thandsaf
etyi
ssuesshoul
dbei
dent
if
iedbasedon
j
obsaf
etyanal
ysi
sorcompr
ehensi
vehazar
dorr
iskassessment
,usi
ngest
abl
i
shed
met
hodol
ogi
essuchasahazar
dident
if
icat
ionst
udy[
HAZI
D],
haz
ardandoper
abi
l
ity
st
udy[
HAZOP]
,oraquant
it
ati
ver
iskassessment[
QRA]
.Asagener
alappr
oach,
heal
thandsaf
etymanagementpl
anni
ngshoul
dincl
udet
headopt
ionofasy
stemat
ic
andst
ruct
uredappr
oachf
orpr
event
ionandcont
rolofphy
sical
,chemi
cal
,bi
ologi
cal
,
andr
adi
ologi
calheal
thandsaf
etyhazar
dsdescr
ibedi
ntheGener
alEHSGui
del
i
nes.
The mostsi
gni
fi
cantoccupat
ionalheal
th and saf
etyhaz
ards occurdur
ing t
he
oper
ati
onal
phaseofapet
rol
eum r
efi
ningf
aci
l
ityandpr
imar
il
yincl
ude:

 Pr
ocessSaf
ety
  Oxy
gen-
def
ici
entat
mospher
e

 Chemi
cal
hazar
ds

 Fi
reandexpl
osi
ons

Pr
ocessSaf
ety

Pr
ocess saf
ety pr
ogr
ams shoul
d be i
mpl
ement
ed,due t
o i
ndust
ry-
speci
fi
c
char
act
eri
sti
cs,i
ncl
udi
ngcompl
exchemi
calr
eact
ions,useofhaz
ardousmat
eri
als
(
e.g.t
oxi
c,r
eact
ive,f
lammabl
eorexpl
osi
vecompounds)
,andmul
ti
-st
epr
eact
ions.
Pr
ocesssaf
etymanagementi
ncl
udest
hef
oll
owi
ngact
ions:

 Phy
sical
hazar
dtest
ingofmat
eri
alsandr
eact
ions

 Hazar
danal
ysi
sst
udi
est
orev
iew t
hepr
ocesschemi
str
yandengi
neer
ing
pr
act
ices,
incl
udi
ngt
her
mody
nami
csandki
net
ics

 Exami
nat
ion ofpr
event
ive mai
ntenance and mechani
cali
ntegr
it
y oft
he
pr
ocessequi
pmentandut
il
it
ies

 Wor
kert
rai
ning

 Dev
elopmentofoper
ati
ngi
nst
ruct
ionsandemer
gencyr
esponsepr
ocedur
es.

Oxy
gen-
Def
ici
entAt
mospher
e

Thepot
ent
ial
rel
easeandaccumul
ati
onofni
tr
ogengasi
ntowor
kar
easmayr
esul
tin
t
he cr
eat
ion ofasphy
xiat
ing condi
ti
ons due t
othe di
spl
acementofox
ygen.
Pr
event
ionandcont
rol
measur
est
oreducer
isksofasphy
xiat
edgasr
eleasei
ncl
ude:

 Desi
gnandpl
acementofni
tr
ogenv
ent
ingsy
stemsaccor
dingt
oindust
ry
st
andar
ds

 I
nst
all
ati
onofanaut
omat
icEmer
gencyShut
downSy
stem t
hatcandet
ectand
war
noft
heuncont
rol
l
edr
eleaseofni
tr
ogen(
incl
udi
ngt
hepr
esenceofox
ygen
def
ici
entat
mospher
es i
n wor
king ar
eas6)
,ini
ti
atef
orced v
ent
il
ati
on,and
mi
nimi
zet
hedur
ati
onofr
eleases
  I
mpl
ement
ati
onofconf
inedspaceent
rypr
ocedur
es.

Chemi
cal
Hazar
ds

Rel
easesofhy
drof
luor
icaci
d,car
bonmonoxi
de,
met
hanol
andhy
drogensul
fi
demay
pr
esentoccupat
ionalexposur
ehazar
ds.Hy
drogensul
fi
del
eakagemayoccurf
rom
ami
ner
egener
ati
oni
nami
net
reat
mentuni
tsand sul
furr
ecov
eryuni
ts.Car
bon
monox
ide l
eakage may occurf
rom Hy
drot
reat
ing Uni
tand f
rom t
he sy
ngas
pr
oduct
ionsect
ionoft
heHy
drogenPl
ant
.Car
bonmonox
ide/ai
rmi
xtur
esar
e
expl
osi
veandspont
aneous/expl
osi
ver
e-i
gni
ti
onmayoccur
.Hy
drogensul
fi
de
posesani
mmedi
atef
ir
ehazar
dwhenmi
xedwi
thai
r.

Wor
ker
smaybeexposedt
opot
ent
iali
nhal
ati
onhazar
ds(
e.g.hy
drogensul
fi
de,car
bon
monoxi
de,VOCs,pol
ycy
cli
c ar
omat
ic hy
drocar
bons (
PAHs)dur
ing r
out
ine pl
ant
oper
ati
ons.Der
malhazar
dsmayi
ncl
udecont
actwi
thaci
ds,st
eam,andhotsur
faces.
Chemi
calhazar
dsshoul
dbemanagedbasedont
her
esul
tsofaj
obsaf
etyanal
ysi
sand
i
ndust
ri
alhy
gienesur
veyandaccor
dingt
otheoccupat
ionalheal
thandsaf
etygui
dance
pr
ovi
dedi
ntheGener
alEHSGui
del
i
nes.Pr
otect
ionmeasur
esi
ncl
udewor
kert
rai
ning,
wor
kper
mitsy
stems,use ofper
sonalpr
otect
ive equi
pment(
PPE)
,and t
oxi
cgas
det
ect
ionsy
stemswi
thal
arms.

Fi
reandExpl
osi
ons

Fi
reandexpl
osi
onhazar
dsgener
atedbypr
ocessoper
ati
onsi
ncl
udet
heacci
dent
al
r
eleaseofsy
ngas(
cont
aini
ngcar
bonmonox
ideandhy
drogen)
,ox
ygen,met
hanol
,
andr
efi
ner
ygases.Ref
iner
ygasr
eleasesmaycausej
etf
ir
es,
ifi
gni
tedi
nther
elease
sect
ion,orgi
ver
ise t
oav
apourcl
oud ex
plosi
on (
VCE)
,fi
rebal
lorf
lash f
ir
e,
dependi
ng on t
he quant
it
yoff
lammabl
e mat
eri
ali
nvol
ved and t
he degr
ee of
conf
inementoft
hecl
oud.Met
hane,hy
drogen,car
bon monoxi
de,and hy
drogen
sul
fi
demayi
gni
teev
eni
ntheabsenceofi
gni
ti
onsour
ces,i
fthei
rtemper
atur
eis
hi
ghert
hant
hei
raut
oigni
ti
ont
emper
atur
esof580°
C,500°
C,609°
C,and260°
C
r
espect
ivel
y.Fl
ammabl
eli
qui
dspi
l
lspr
esenti
npet
rol
eum r
efi
ningf
aci
l
iti
esmay
causepoolf
ir
es.Expl
osi
vehaz
ardsmayal
sobeassoci
atedwi
thaccumul
ati
onof
v
apour
sinst
oraget
anks(
e.g.sul
fur
icaci
dandbi
tumen)
.

Recommended measur
est
o pr
eventand cont
rolf
ir
e and ex
plosi
on r
isksf
rom
pr
ocessoper
ati
onsi
ncl
udet
hef
oll
owi
ng:

 Desi
gni
ng,const
ruct
ing,and oper
ati
ng pet
rol
eum r
efi
ner
ies accor
ding t
o
i
nter
nat
ionalst
andar
dsf
ort
hepr
event
ionandcont
roloff
ir
eandex
plosi
on
hazar
ds,i
ncl
udi
ngpr
ovi
si
onsf
orsegr
egat
ionofpr
ocess,st
orage,ut
il
it
y,and
saf
ear
eas.Saf
etydi
stancescanbeder
ivedf
rom speci
fi
csaf
etyanal
ysesf
or
t
hef
aci
l
ity
,andt
hroughappl
i
cat
ionofi
nter
nat
ional
l
yrecogni
zedf
ir
esaf
ety
st
andar
ds
 Pr
ovi
dingear
lyr
eleasedet
ect
ion,suchaspr
essur
emoni
tor
ingofgasand
l
i
qui
dconv
eyancesy
stems,
inaddi
ti
ont
osmokeandheatdet
ect
ionf
orf
ir
es

 Ev
aluat
ion ofpot
ent
ialf
orv
apouraccumul
ati
on i
n st
orage t
anks and
i
mpl
ement
ati
onofpr
event
ionandcont
rolt
echni
ques(
e.g.ni
tr
ogenbl
anket
ing
f
orsul
fur
icaci
dandbi
tumenst
orage)

 Av
oidi
ngpot
ent
ialsour
cesofi
gni
ti
on(
e.g.byconf
igur
ingt
hel
ayoutofpi
ping
t
oav
oidspi
l
lsov
erhi
ght
emper
atur
epi
ping,equi
pment
,and/orr
otat
ing
machi
nes)

 Pr
ovi
dingpassi
vef
ir
epr
otect
ionmeasur
eswi
thi
nthemodel
edf
ir
ezonet
hat
i
scapabl
eofwi
thst
andi
ngt
hef
ir
etemper
atur
eforat
imesuf
fi
cientt
oal
l
ow
t
heoper
atort
oimpl
ementt
heappr
opr
iat
efi
remi
ti
gat
ionst
rat
egy
.