Karbala Refinery Unit 02

General Process Overview

Project No.: MK200063 (PMC Phase 2)

Date: September 2017

The aim of this presentation is to provide a
general process overview of the Karbala
Refinery design for this Unit.
Additional information for each Unit is provided within issued project documentation.

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Reference:

Karbala Refinery Process Units Configuration

Overview dated 3rd June 2017
(147547-TP-SCOP-6552-PM)

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Agenda
• Purpose of Unit

• Positioning - Refinery
flow scheme, plot plan
and 3D Model

• Process Design

• Process Description

• Start-Up Dependencies

• Additional Information

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Purpose and Location

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Unit 02, 03, 04 : Naphtha Upgrading Block

Naphtha Upgrading Block

 Unit 02: Naphtha Hydrotreating Unit
 Unit 03: Isomerisation Unit
 Unit 04: Continuous Catalytic Reforming (CCR) Unit

Licensor
 UOP

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 LPG
LPG

Light Naphtha ISOM Isomerate

(Unit 03) Premium

Gasoline
LPG + NHT GASOLINE
Naphtha BLENDING
(Unit 02) Regular
Gasoline
Heavy Naphtha CCR Reformate

Unstabilized (Unit 04)

Naphtha
Poly
Gasoline
Straight run KHT Kerosene /
Kerosene
(Unit 05) ATK
Crude Oil CDU
(Unit 01) PNU
(Unit 09)

Straight run DHT Diesel

Diesel
(Unit 06)
Unsat. LPG
Heavy
Diesel
VGO Cracked Gasoline
Treated FCC
ATM
Residue
VGO
HDT VGO
(Unit 08) LCO / Slurry
VDU (Unit 07)
(Unit 01) Light Gasoil
FUEL OIL
BLENDING
Vacuum Residue

ABU Industrial /
(Unit 10) Paving Bitumen
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Purpose of Unit 02: Naphtha Hydrotreating Unit

Naphtha Hydrotreating Unit

 Unit 02 is regarded as a “clean-up” operation of refinery naphtha
 Purpose: Protect downstream Unit 03, 04 catalyst from poisoning
Meet Gasoline product specification
 Naphtha feed impurities: Organic sulfur, oxygen, nitrogen
compounds, organometallic
compounds, olefinic compounds
 Operating Principle: Naphtha feed combined with refinery
Hydrogen to decompose impurities, remove organometallic
compounds and saturate olefinic compounds

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Naphtha Feed to Unit 02

Refinery Naphtha Sources

 Unit 01 straight run naphtha
 Unit 07 unstabilized naphtha
 Straight-run naphtha (stabilized) from Unit 52 Tank Farm

5%

Unit 01 straight run naphtha

95%
Unit 07 unstabilized naphtha

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Purpose: Protecting downstream unit catalysts
Impurities and catalyst poisoning
 Organometallic compounds: Permanently poisons Unit 04
catalyst. Removal prolongs Unit 04 catalyst life
 Sulfur: Temporarily poisons Unit 04 catalyst. Also leads to
unfavourable product distribution and increases coke laydown in
Unit 04
 Organic nitrogen: Temporarily poisons Unit 04 catalyst. Small
concentration can cause large offset in product distribution.
Forms ammonium chloride salts in Unit 04 cold section
 Oxygen: Detrimental to Unit 04 catalyst. Converted to water,
which affects water/chloride balance in Unit 04 catalyst
 Olefins: Polymerize at downstream unit operating conditions.
Leads to fouling in downstream unit

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Purpose: Meeting gasoline specifications
Karbala refinery and gasoline specifications
 Karbala refinery is designed to meet Euro V gasoline specifications
 Meeting specification requires: Sulfur – 10 ppm max
Olefins – 18 vol% max

 Naphtha Hydrotreating Unit decomposes organic sulfur to

hydrogen sulfide, which is removed from naphtha
e.g. C-C-C-C-C-C-SH + H2 → C-C-C-C-C-C + H2S
 Naphtha Hydrotreating Unit saturates linear olefins to linear
paraffins (alkanes) and cyclic olefins to naphthenes (cycloalkanes)
e.g. C-C-C-C=C-C + H2 → C-C-C-C-C-C

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Unit 02 Location on Plot Plan

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Unit 02 Plot Plan

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Unit 02 3D Model

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Unit 02 3D Model

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Process Design and Description

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 Unit 02 Process Flow Scheme
Fuel
Recycle Gas Recycle Gas Gas
Compressor Corrosion Inhibiter
Hydrogen Injection
(Unit 04,
13/14/15)

Sponge
Absorber

Separator Debutaniser
Charge Heater
LPG

Hydrotreating
Reactor
Light
Naphtha
ISOM
(Unit 03)
Combined FEED Reactor Effluent
Exchanger

Wash water
Injection

Naphtha
(Unit 01, 07,
Heavy CCR
Naphtha
Tank Farm) (Unit 04)
Naphtha Splitter

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Process Design Highlights

Unit 02 Feedstock
 Unit 01 straight run naphtha
 Unit 07 unstabilized naphtha
 Straight-run naphtha (stabilized) from Unit 52 Tank Farm

Feedstock cut-point
 Basrah/ Mishrif Base Cases: C3 – 175°C
 Basrah/ Mishrif ATK Cases: C3 – 155°C

Feedstock sulfur content

 Basrah Case: 136 ppm
 Mishrif Case: 952 ppm
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Process Design Highlights
Unit 02 Design Capacity and turndown

Basrah Mishrif
Design Capacity 41,500 bpd 37,800
Normal operating ~37,000 bpd ~33,000 bpd

 Unit turndown is specified as 50% design capacity

Unit 02 Hydrogen requirement

Basrah Mishrif
H2 Consumption ~1930 Nm3/h ~1920 Nm3/h
 Hydrogen is sourced from Unit 04 (CCR) – Hydrogen 91.1 vol%
 Back-up Hydrogen is sourced from Unit 13, 14, 15 (HPU) –
Hydrogen 99.9 vol%
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Process Design Highlights

Unit 02 Products

Basrah Mishrif Sulphur To

Light Naphtha ~11,600 bpd ~11,600 bpd 0.1 ppm max Unit 03
Heavy Naphtha ~23,900 bpd ~18,900 bpd 0.5 ppm max Unit 04

Basrah Mishrif To
LPG 12,130 kg/h 19,285 kg/h Unit 11
Fuel Gas 1,001 kg/h 1,507 kg/h Unit 16

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Process Design Highlights
Unit 02 Chemical consumption
 Continuous corrosion inhibiter injection in debutaniser overheads
 Intermittent sulfiding of catalyst using DMDS (prior to start-up)
 Intermittent caustic usage for catalyst regeneration

Unit 02 Utility requirements

 Unit 02 utilises electric power, HP and MP steam, fuel gas,
instrument air, cooling water, boiler feed water and service water
during normal operation
 Unit 02 utilises utility air and nitrogen during start-up / shutdown

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 Process Design Highlights
Charge Heater (02-H-001)
 Completely vaporise naphtha and
heat combined feed to temp
required for desired reactions
 Heater has 4 passes
 Horizontal tubes in convection
section (preheating feed)
 Vertical tubes in radiant section
 Fuel gas is only firing fuel. Offgas
from PNU also burned in heater
 4 forced draft, low NOx burners
 CEMS provided at stack for SO2,
O2, NOx continuous monitoring
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 Process Design Highlights
Hydrotreating Reactor (02-R-001)
 Downflow reactor with feed in
vapour phase
 Reactor is fabricated of killed
carbon steel with alloy lining
 Designed to ensure no catalyst
leaves with reactor effluent
 Isothermal: Inlet temp 338~340°C
Outlet temp 343°C
 Operating pressure: 29.4 kg/cm2g
 Inlet distributor provided to
prevent vapour disturbing catalyst
bed and enhance flow distribution

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 Process Design Highlights
Reactor (02-R-001) Catalyst
 46 m3 of catalyst and
inert balls required Bed 1A: Inert support material

Bed 1B: Olefins hydrogenation

 All catalyst is sock loaded
Bed 1C: Organometallic
 Mandatory supplier of contaminants removal; some
sulfur/nitrogen removal
catalyst is UOP
Bed 1D: Sulfur and nitrogen
 3, 6 and 9 mm Ceramic removal
balls are used
 Catalyst replaced approx.
Inert Ceramic balls
once every 5 years
 In-situ regeneration can
be carried out

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Process Design Highlights
Recycle compressor (02-K-001A/B)
 Single stage reciprocating type, motor-driven compressor

 Circulates hydrogen rich gas through reaction circuit

 Critical for maintaining reaction circuit pressure

 Rated capacity: 25,700 Nm3/h. Machine designed to operate at 0, 50, 75 and 100% of
design capacity

 Motor rated power: 650 kW

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Process Design Highlights
Debutanizer (02-T-001)
 Designed to remove H2S and water
from light naphtha stream
 Designed for maximum economical
propane and butane recovery (LPG)
i.e. max 1 vol% C5+ in LPG
 Upper part of tower narrower than
lower part (Upper ID: 2700 mm /
Lower ID : 3700 mm)
 Tower is fabricated of killed carbon
steel
 Tower has 35 stainless steel valve
trays
 HP steam is used in tower reboiler
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Process Design Highlights
Sponge absorber (02-T-002)
 Designed to recover naphtha
fractions entrained in debutanizer
off-gas (sent to Unit 16)
 Off-gas contacted with heavy
naphtha from 02-T-003 to recover
naphtha fractions
 Upper part of tower narrower than
lower part (Upper ID: 800 mm /
Lower ID : 1200 mm)
 Tower is fabricated of killed carbon
steel
 Tower has 20 stainless steel valve
trays

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Process Design Highlights
Naphtha Splitter (02-T-003)
 Designed to separate light naphtha
(feed to Unit 03) and heavy naphtha
(feed to Unit 04)
 C6 and lighters maximised in
overheads. C7 and heavier in bottoms
 Upper part of tower narrower than
lower part (Upper ID: 3400 mm /
Lower ID : 4000 mm)
 Tower is fabricated of carbon steel
 Tower has 46 carbon steel valve trays
 MP steam is used in tower reboiler

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Additional Considerations

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Start-up Dependencies

Requirements for Unit start-up

 Commissioning of utilities
 Pressure test equipment
 Acid cleaning of compressor lines
 Dry out fired heater
 Reactor circuit dry out
 Sulfiding of Hydrotreating catalyst

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Start-up Dependencies

Requirements for Unit start-up

 Flare system and all PSVs are online.
 Underground systems are clear and unobstructed to avoid
potential backflow / flooding.
 Slops system is commissioned and is available.
 Utilities are available and headers are at correct pressure.
 Cooling water flow to all exchangers at correct flowrate.

 Initial start-up of chemical injection systems.

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Start-up Dependencies

Requirements for Unit start-up

 Unit 01 under normal operation
 Hydrogen Production Unit (Units 13/14/15) operating to
supply hydrogen
 Product routes to storage / downstream units are lined-up.
 Off Gas destination to be available (Unit 16).
 Initiate start-up as per procedure in Unit 02 Operating
Manual.

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Start-up Dependencies
Start-up considerations
 During Sulfiding H2S is released. Safety procedures for
handling H2S need to be adhered to.
 Reactor circuit temperature is increased incrementally over
time to avoid thermal shocks / stresses
 Operate at lower pressures initially to ensure Charge Heater
(02-H-001) feed is in vapor phase at lower temperature
 Reactor circuit pressure is maintained from Hydrogen. Ensure
hydrogen to hydrocarbon ratio is min. 35 Nm3/m3
 Debutaniser (02-T-001) may already be in operation with Unit
01 start-up to stabilise straight run naphtha and send to
storage

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Operating Considerations
 Avoid exceeding reactor set temperature. As H2S produced
can react with olefinic compounds to produce mercaptans
 Ensure correct hydrogen to hydrocarbon ratio is maintained.
This maintains catalyst life and avoids coke formation
 Ensure wash water is injected at desired rates to absorb
ammonia and hydrogen halides formed in reactor.
 Ensure corrosion inhibitor is injected at desired rate
 As catalyst ages, increasing reactor temperature may correct
product quality
 Catalyst deterioration, scale and polymer formation at top of
reactor bed cause high pressure drop. This will cause
channelling and impact product quality
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Shutdown Highlights
Planned shutdown
 Reduce reactor temperature and feed flowrate incrementally
 Stop naphtha feed and allow recycle gas to sweep any
hydrocarbons
 Cool down columns by stopping reboiler heat input
 Shutdown recycle gas compressor when reactor is cooled
down
 Unit 03 and 04 will also have to be shutdown as feed for
these units is only provided via Unit 02 and not storage

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