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CHAPTER-1
DESIGN BASIS
1.1 GENERAL
Panipat refinery is designed to cater the demand of the petroleum products in the
northern region of India .The Panipat refinery consists of the following units:
The DHDS unit is set up to reduce sulfur content in the diesel and produce diesel with
0.25% Sulphur.
1. S.R.Gas oil
2. Vacuum Diesel
3. Vis-Breaker Gas Oil
4. Total Cycle Oil
The purpose of the section is to reduce 90% Sulphur in feed diesel using
hydrogen from Catalytic Reformer or Hydrogen Generation Units. In addition to
the deep desulfurisation, the diolefin and olefins will be saturated and a
denitrification will also occur.
Feedstocks are blended from various sources, straight run or cracked products
Sulfur and nitrogen contents are depending upon the crude. Cracked products are
characterized by the presence of unsaturated hydrocarbons (olefins, diolefins and
aromatics)
Nowadays, more and more stringent specifications are imposed upon sulfur
content of diesel delivered by refineries.
The presence of olefins or diolefins calls for additional bed installed in upstream
of the desulfurisation bed.
The unit is able to produce treated Diesel Oil with maximum sulfur content of
500 ppm by providing an additional second Reactor in series.
- HP Amine Absorber
- LP Amine Absorber
The DHDS unit is designed to hydrodesulfurise the two feedstock blends as in the
table named as “Feed 1” and “Feed 2” in section 1.4.1 and 1.4.2 respectively.
The characteristics of “Feed 3” used as check feed is given in 1.4.3.
The unit nameplate capacity is 700,000 MTPA with a stream factor of 8000 hours
per year. The design capacity is 770,000 MTPA.
In the case 2 with the installation of second reactor the sulphur in the feed is
reduced to 500 wt. ppm for the feeds 1 and 2.
The hydrogen required for the reactions is supplied either from the Catalytic
Reforming Unit or Hydrogen Generation Unit.
Nitrogen/air facilities for HR - 945 and HR-348 catalyst in-situ regeneration are
also provided.
Check Feed : 65% wt. of SRGO, 10% wt. of SRVD and 25% wt of
Total Cycle Oil
1.4.1 Feed 1
1.4.2 Feed 2
1.4.3 Feed 3
The hydrogen make-up is available at the battery limit with the following
composition:
Impurities ppm v
Chlorine & Chloride 2 max.
Impurities ppm v
CO + CO2 50 max.
The Desulfurised diesel is produced at the stripper bottom and dried in the
coalescer before being sent to storage.
Feed 1 Feed 2
Description
Case 1 Case 2 Case 1 Case 2
SPGR 0.841 0.838 0.842 0.839
Sulfur content, wt. ppm 1650 500 1810 500
Nitrogen content, wt. ppm 110 70 160 110
Water content, wt. ppm <500 <500 <500 <500
Bromine Number <1 <1 <1 <1
Cetane index 58 59 57 58
Pour Point oC Same as feed Same as feed Same as feed Same as feed
Flash point oC Same as feed Same as feed Same as feed Same as feed
Color Same as feed Same as feed Same as feed Same as feed
The naphtha recovered as liquid distillate from the stabilizer bottom is sent to the
naphtha storage.
Feed 1 Feed 2
Description
Case 1 Case 2 Case 1 Case 2
SPGR 0.750 0.748 0.750 0.747
H2S content wt ppm 10 5 10 5
Nitrogen wt ppm 2 1 2 1
max
RON 72 to 74 72 to 74 72 to 74 72 to 74
RVP 0.26 0.28 0.28 0.27
Sweet Fuel gas from LP amine is routed to FCC fuel gas header.
Feed 1 Feed 2
Description
Case 1 Case 2 Case 1 Case 2
H2 content, mol% 35 to 30 31 to 26 31 to 28 28 to 23
H2S content, ppm vol 100 100 100 100
H2O content, mol% 2 2 2 2
HC content, mol% 63 to 78 67 to 72 70 to 77 70 to 75
MW 19.3 to 20.9 20.4 to 22.4 20.3 to 21.6 21.2 to 22.9
Feed 1 Feed 2
Description
Case 1 Case 2 Case 1 Case 2
NH4SH, wt% 1.0 1.7 1.6 2.5
Properties:
Viscosity, cP : 0.14
Molecular weight : 17
The Dimethyl Disulfide is injected at the feed pump suction at 1 wt % rate in the
recirculating gas oil, during catalyst sulfiding
The antifouling agent is injected at the feed pump suction diluted at 10% in
straight run gasoil at the rate of 10 ppm of pure product compared to the feed.
1.7.4 Antifoaming
The corrosion inhibitor is injected in the stripper and stabilizer overheads diluted
at 1% in stabilized naphtha at the rate of 6 wt. ppm of pure product compared to
the total column overhead.
1.7.7 Catalysts
Quantity :
Case 1 : 26.5 m3 3.3 m3
Case 2 : 61.1 m3 3.3 m3
It can be used in association with other NiMo type or CoMo type catalysts where
specific objectives are required.
TYPICAL PROPERTIES
Cylindrical extrudates
Diameter 1.2 mm
Nickel (NiO) 3.3 Wt%
Molybdenum (MoO3) 16.5 Wt%
Total pore volume 0.42 Cm3/g
Sock loading density 0.72 Kg/l
Dense loading density 0.82 Kg/l
Bulk crushing strength 1.49 MPa
HR 945 special design limits the polymerization of olefins and diolefins and
thus, the coke formation, even at low hydrogen partial pressure. The resulting
advantage is longer cycle operation.
TYPICAL PROPERTIES
Spheres
Diameter 2 to 4 mm
Surface area 140 m2/g
Total pore volume 0.4 cm3/g
Tapped bulk density 0.88 kg/l
Bulk crushing strength 1.55 mini. MPa
1.7.8.1 Absorbent
Type : 1” ½ or 50 mm
Quantity : 0.3 m3
Operating Design
Temp.(oC) Pressure Temp.(oC) Pressure
(kg/cm2g) (kg/cm2g)
Feed from storage 40 5.0 95 15.0
Feed from CDU 65 5.5 95 22.0
Feed from VDU 74 6.3 95 17.0
Feed from VBU 133 18.8 150 26.0
Feed from FCCU 87 3.9 105 13.5
Make-up H2 (HGU) 40 19.5 55 27.5
Makeup H2 (CRU) 40 20 55 27.5
Sour Water 50 5.0 65 6.0
Rich Amine 66.4 6.9 80 12.8
Lean Amine 40 8.0 65 12.6
Diesel to Storage 40 6.0 55 16.6
Offspec Diesel 40 6.0 55 16.6
Stabilized Naphtha 40 5.0 55 10.1
Naphtha to Slop 40 3.5 150 10.1
Spent Caustic 55 2.0 70 21.0
Caustic Solution 40 9.0 65 17.0
Sweet FG to RFCCU 50 3.0 65 6.6
FO Supply 210 10 260 15.0
FO Return 210 5.3-1.9 260 15.0
Flare Header AMB ATM-1.5 150 65.0
o
Temperature C 143 175 190 240
Medium Pressure
Return
Pressure Kg/cm2g 2.2 - 7.0
o
Temperature C 45 65
1.9.3 DM Water
1.9.5 Nitrogen
2) Meteorological Data
1.10.7 Drainage
Feed 1
Description Case 1 Case 2
SOR MOR EOR SOR MOR EOR
Feed 2
Description Case 1 Case 2
SOR MOR EOR SOR MOR EOR
1.11.2.1 Reactor
Feed 1
Description Case 1 Case 2
SOR MOR EOR SOR MOR EOR
Feed 2
Description Case 1 Case 2
SOR MOR EOR SOR MOR EOR
Feed 3 (check Feed) : The operating conditions are the same as for Feed 2 except
for space velocity which is increased by 10% due to the smaller flow rate.
The hydrogen recycle ratio is a measure of the hydrogen recycle through the
furnace to the reactor entry. It is expressed as the standard m3/hr of pure H2
recycled divided by the volume of HC liquid feed in m3/hr at 15 0C.
Pressure, kg/cm2 g : 50
1.11.2.3 Stripper
Reflux ratio:
Feed 1 Feed 2
Description Case 1 Case 2 Case 1 Case 2
SOR EOR SOR EOR SOR EOR SOR EOR
Reflux / feed (% wt) 5.37 5.60 5.24 6.08 6.92 7.05 6.77 7.44
The following table gives estimated utility consumption for DHDS plant.
1.13.1 Catalysts
Quantity :
Case 1 : 26.5 m3 3.3 m3
Case 2 : 61.1 m3 3.3 m3
Quantity :
1/4” diameter : Case 1 : 1.56 m3
: Case 2 : 2.02 m3
Type : 1½“ OR 50 mm
Quantity : 0.3 m3
2 Antifouling 7,700
3 Antifoaming 2,400 -
This spent caustic has to be sent to an oxidation plant with aeration by air in
presence of catalyst to oxidize the sulfites in sulfates.