Unit 01 Karbala Refinery Project - Sept 20 17 PDF

Karbala Refinery Unit 01
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)

Agenda
• Purpose of Unit
• Positioning - Refinery
flow scheme, plot plan
and 3D Model
• Process Design
• Process Description
• Start-Up Dependencies
• Additional Information

Purpose and Location

Purpose of Unit 01 (Crude/Vacuum Distillation)
Crude Distillation Unit (CDU)

Primary step of processing in the refinery.
Distillation tower operates at atmospheric pressure to separate crude
oil into various fractions by their boiling point differences:
 Unstabilized Naphtha, includes Off Gas
 Kerosene / Aviation Turbine Kerosene (ATK)
 Diesel
 Heavy Diesel
 Atmospheric Residue (AR)

Purpose of Unit 01 (Crude/Vacuum Distillation)
Vacuum Distillation Unit (VDU)

Second fractionation step at below atmospheric pressure to separate
heavy components in CDU Bottoms:
Enables recovery of valuable materials from reduced crude.
 Light Vacuum Gasoil (LVGO) / Heavy Vacuum Gasoil (HVGO)
 Further processing in VGO Hydrotreater (Unit 07) and FCCU (Unit 08).
 Vacuum Residue (VR)

 Heaviest material, used to produce Asphalt in ABU (Unit 10).
 Can also be blended into Heavy Fuel Oil (HFO).

Position on Refinery Flow scheme
to NHT
to Storage
to Storage
to Storage
to FCC
to Fuel Oil Blending
to Fuel Oil
Blending
and then to
HFO Storage

Site Plot Plan

UTILITIES
Site Plot Plan UTILITIES
SULPHUR/ASH DEPOT
LOADING LOADING
UTILITIES
PROCESS UNITS
ADMIN
PROCESS UNITS
DEPOT
STOR
UTILITIES
ADMIN
COMP. FINAL
STOR STOR
CRUDE
INT. WATER
STORAGE STOR TREAT. FLARE

Unit 01 Plot Plan

Unit 01 3D Model

Process Design and Description

Process Design Highlights
Overview
 Unit Capacity of 140,000 BPSD.

 Turndown Capacity of 70,000 BPSD (i.e. 50 %).
 CDU Feed:
 Basrah / Mishrif Crude.
 VDU Feed:
 Atmospheric Residue (AR) from CDU bottoms.
 Integrated CDU / VDU pre-heat trains.

Feed Properties and Conditions: Basrah Crude

Property Base Case Property ATK Mode
Flowrate (kg/h) 804,023 Flowrate (kg/h) 834,690
Temperature (°C) 25.0 Temperature (°C) 25.0
Pressure (kg/cm2g) 26.0 Pressure (kg/cm2g) 26.0
Composition (wt %) Composition (wt %)
C5 – 175 °C 19.3 C5 – 154 °C 16.1
175 °C – 250 °C 12.1 154 °C – 225 °C 11.1
250 °C – 350 °C 16.5 225 °C – 326 °C 16.4
350 °C – 541 °C 27.5 326 °C – 350 °C 4.3
541 °C + 22.5 350 °C – 541 °C 27.5
541 °C + 22.5
Feed Properties and Conditions: Mishrif Crude

Property Base Case Property ATK Mode
Flowrate (kg/h) 834,690 Flowrate (kg/h) 834,690
Temperature (°C) 25.0 Temperature (°C) 25.0
Pressure (kg/cm2g) 26.0 Pressure (kg/cm2g) 26.0
Composition (wt %) Composition (wt %)
C5 – 175 °C 15.2 C5 – 154 °C 12.5
175 °C – 250 °C 10.8 154 °C – 225 °C 9.5
250 °C – 350 °C 13.9 225 °C – 326 °C 14.0
350 °C – 541 °C 23.3 326 °C – 351 °C 4.0
541 °C + 35.0 351 °C – 502 °C 23.3
502 °C + 35.0
Products: Basrah Crude

Base Case ATK Mode Base Case ATK Mode
Cut
TBP Cut-Points (°C) Production Rate (kg/h)
Unstabilized Naphtha 175 – 154 – 171,639 144,712
Kerosene 175 – 250 154 – 225 95,260 89,016
Diesel 250 – 350 225 – 326 136,116 136,138
Heavy Diesel n/a 326 – 350 n/a 32,533
LVGO 350 – 393 350 – 394 54,235 55,204
HVGO 393 – 541 394 – 541 163,646 162,621
Vacuum Residue 541 + 541 + 179,950 179,951

Products: Mishrif Crude

Base Case ATK Mode Base Case ATK Mode
Cut
TBP Cut-Points (°C) Production Rate (kg/h)
Unstabilized Naphtha 175 – 154 – 141,778 117,424
Kerosene 175 – 250 154 – 225 83,533 79,255
Diesel 250 – 351 225 – 326 123,866 120,820
Heavy Diesel n/a 326 – 351 n/a 31,385
LVGO 351 – 393 351 – 392 53,217 53,107
HVGO 393 – 502 392 – 502 137,232 137,274
Vacuum Residue 502 + 502 + 292,194 292,204

Battery Limit Conditions

Key Products Destination Temperature (°C) Pressure (kg/cm2g)
CDU Off Gas To Gas Sweetening (Unit 16) 38 7.5
Unstabilized Naphtha To NHT (Unit 02) 38 7.3
To KHT (Unit 05) 105 - 140 7.5
Kerosene
To Storage 38 7.0
To DHT (Unit 06) 140 - 175 9.0
Diesel
To Storage 40 7.0
Heavy Diesel To Storage 40 7.0
To VGO HT (Unit 07) 170 - 180 9.0
VGO
To Storage 75 7.0
To ABU (Unit 10) 200 10.0
Vacuum Residue
To Storage 180 5.0

Utilities Required: Basrah Base Case

Normal Operating Conditions
Service Consumption * (t/h)
Press. (kg/cm2g) Temp. (°C)
HP | MP | LP Steam 40 | 15 | 5 400 | 250 | 210 2.34 | 33.35 | 4.50
MP BFW 26 140 25.05
CW Supply / Return 4 / 2.5 32 / 43 4,536
PWA | SWA | DWA 2.5 | 4 | 6 25 | 35 | 35 0 | 4.18 | 0 (m3/h)
Fuel Gas 4 64 80.1 (Gcal/h)
IA | PA | N2 7|7|7 <50 | <50 | >10 316 | 0 | 5 (Nm3/h)
* Source: IONE-1C01-CN-PR-0003 Rev 1, UTILITIES CONSUMPTION SUMMARY FOR UNIT 01

Chemicals Required:
Item No. Chemical Type Consumption * (t/year)
01-PK-001 Corrosion Inhibitor 21.4
01-PK-002 Neutralizing Amine 15.2
01-PK-003 Filming Amine 8.9
01-PK-004 Demulsifier 32.7
01-PK-005 Phosphate 7.0
01-PK-006 Caustic Solution 792
01-PK-007 Caustic Replacer 317
NB: Consumptions to be confirmed.
* Source: IONE-1C01-CN-PR-0004 Rev 0, CATALYST & CHEMICALS CONSUMPTION SUMMARY FOR UNIT 01

Process Description Highlights
Crude Pre-heating Concept Effluent to WWT (U51)
B.L.
U52 U01
Crude Oil Crude Oil

1st Pre-heat
Storage Desalter
Train
(52-TK-101) (01-V-001)
Crude to Atmospheric
Tower (01-T-001) Crude Heater 2nd Pre-heat
(01-H-001) Train

First Crude Pre-heating Train
 Crude pumped from storage to Unit 01 Battery Limit.

 Heated against Unit 01 product streams to reach operating
temperature (130 °C) of Crude Oil Desalter (01-V-001 A/B).
 Added complexity due to integration of CDU/VDU systems
in preheat trains.
 One exchanger (01-E-002) relies on VDU product (LVGO).
 No duty performed in this exchanger during Start-Up (SU) or CDU
Single Operation.

LVGO from VDU

Crude Oil Desalter (01-V-001 A/B)

 Removes salt (in solution with water) from Crude Oil.

 Protects downstream equipment from corrosion issues.
 High voltage (3,000 volts per inch) applied across cross

section of vessel by electrodes.
 Preheated crude emulsified before 1st stage.
 Oil/water separation in 01-V-001 A by electrostatic coalescence.
 Treated oil from 1st stage emulsified again before 2nd stage.
 Oil/water separation in 01-V-001 B by electrostatic coalescence.
 Treated oil to second crude preheat train.
 Oil and water phases flow counter-currently.
 Effluent (salty water) to Waste Water Treatment (WWT)


to second preheat train
from first preheat train
Effluent
to WWT Unit 51 Stripped Sour Water
from SWS Unit 17

Second Crude Pre-heating Train
 Heated against Unit 01 product streams up to 278 °C

(Basrah Base Case) then fed to Crude Heater (01-H-001).
 Three exchangers rely on VDU products streams.
 AR routed to these exchangers during SU / CDU Single Operation.
from Desalter

Crude Heater (01-H-001)

 Pass balance control for outlet temperature equalization.

 Optimal heat transfer, decreased rate of coking.
 Crude is partially vaporized, outlet temperature of 364 °C.

 Dual fuel: Fuel Gas (primary), Fuel Oil (secondary).
 Sweetened VDU Off Gas used in addition to Fuel Gas.
 24 forced draft, low NOx burners.

 Hot Crude Oil sent to Atmospheric Tower (01-T-001).


Atmospheric Tower (01-T-001)

Valve trays in Rectifying section
Sieve trays in Stripping section


 Top of column operating pressure = 1.5 kg/cm2g.
 Has a total of 48 trays, total pressure drop = 0.55 kg/cm2g.
 Superheated steam from heater convection section used
for stripping in tower bottom. Drained from Reflux Drum.
 Includes 2 pump-around (PA) circuits for heat recovery.
 Diesel PA and Kerosene PA.
 All side products are first stabilized in side strippers before

further processing in downstream units.
 Heavy Diesel, Diesel and Kerosene.

OVHDs, contains Naphtha, LPG, Off Gas
Reflux
Crude
Stripping
steam
Heavy Diesel Diesel Kerosene

Atmospheric Residue
to Vacuum Tower

 Tower overheads on temperature control:
 Defines Naphtha cut point.
 Controls bypass rate of Crude Oil around Crude / CDU OVHD
Exchanger (01-E-003 A-H).
 Condensed overheads separated from Off Gas and pumped

to NHT (Unit 02) for clean-up as Untabilized Naphtha.
 Off Gas pressurised up to 8.6 kg/cm2g in a two-stage
reciprocating machine (01-K-001 A/B).
 Includes interstage condenser and K.O. drum.
 Off Gas sent to ARU (Unit 16) for sweetening.

OVHDs from Atmospheric Tower
Reflux to Atmospheric Tower

Vacuum Tower (01-T-051)

 Atmospheric Residue is first heated to 405 °C in Vacuum
Heater (01-H-051).
 High efficiency structured packing in top section.
 Has 6 sieve trays in stripping section.
 Top section operating pressure of 30 mmHg.
 Includes 2 pump-around (PA) circuits for heat recovery.
 HVGO PA and LVGO PA.
 Superheated steam from heater (01-H-051) convection

section used as stripping medium in tower bottom.

High Efficiency Structured Packing


 Most of the overhead vapours are condensed and then
separated from Off Gas in Vacuum Hot Well (01-V-051).
 Includes condensed water due to stripping steam.
 Sour Off Gas is treated in Vacuum Off Gas Amine Absorber.

 Used as supplementary fuel in Crude Heater (01-H-001).
 Can be vented to atmosphere at safe location if required.
 Heater failure case.
 Start-up when heater is not online.


 LVGO and HVGO are mixed together and sent to VGO
Hydrotreating Unit (Unit 07) and to Storage (Unit 52).
 Vacuum Residue sent to Asphalt Blowing Unit (Unit 10) and
Vacuum Residue Storage Tanks (52-TK-209 A/B).
 VR cooled against BFW to produce steam in 01-E-051 A-D.
 VR further cooled against cold condensate to produce Tempered
Water in 01-E-056.

Additional Considerations

Start-up Dependencies
Requirements for Unit start-up

 Flare system and all PSVs are online.
 Undergrounds 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.
 Tempered water system is fully commissioned.
 Initial start-up of chemical injection systems.

Requirements for Unit start-up

 Unit feed and flushing oil for start-up is available.
 Product routes to storage / downstream units are lined-up.
 NHT unit to be available to receive Atmospheric Tower
OVHDs and Off Gas destination to be available (Unit 16).
 SR Naphtha storage (52-TK-201 A/B) to be available.
 Initiate start-up as per procedure in U01 Operating Manual.

Start-up considerations
 Max. Operating Pressure and Vacuum leak testing required.
 Remove/avoid free-water:
 Cold crude oil circulation step - approx. 48 hour duration.
 Warm-up of stripping steam lines, avoid column internals damage.
 Avoid coking in Vacuum Heater by using velocity steam.

 Reduced Crude Tanks (52-TK-308 A/B) used during start-up.
 Also for CDU Single Operation.

Start-up Sequence
 CDU Cold circulation

 Long circulation: AR recycled back to Crude Oil tanks.
 Closed circulation: AR recycled back to first preheat train.
 CDU Hot circulation

 Up to 120 °C: Establish reflux in Atmospheric Tower.
 Up to 250 °C: Establish pump-arounds.
 Up to 365 °C: Start side strippers and OVHDs compressor.
 CDU Single Operation: AR routed to Reduced Crude Tanks (52-TK-
308 A/B). Can then be sent for blending into Heavy Fuel Oil (HFO).

Start-up Sequence
 VDU Cold circulation

 Fill VDU with Flushing Oil, circulate BTMs through Vacuum Heater.
 VDU Hot circulation

 Establish LVGO/HVGO pump-arounds.
 Build up heavy components in Vacuum Tower by injecting Reduced
Crude intermittently (use 4” bypass valve not 14” main valve).
 CDU/VDU Integration
 Start Vacuum System Package to create vacuum in the tower.
 Route Reduced Crude to Vacuum Tower using main 14” valve.
 Send VGO/VR to appropriate products tanks once on-spec.
Operating Considerations
Special Operating Procedures: Decoking

 Heater passes individually decoked by blowing steam
through heating coils.
 Avoid excessive steam velocities: Coke particles are very abrasive.
 Avoid excessive temperatures:
 Perform at night, easier to distinguish colour of hot coils.
 Beware of hot-spots, normally where coke is present in coil.
 Do not exceed MDMT of coils to prevent rupture.
 After decoking, cool down gradually at 50 – 100 °C per hour.

Shutdown Highlights
Planned Shutdown
 Atmospheric Tower inventory routed to Slops.

 Space required in Light Slop Oil Tank (52-TK-001)
 Operate at turndown (50 %) before shutdown.
 For CDU inventory, ensure temperature is below 40 °C.

 Any shutdown of CDU would mean loss of feed to rest of
refinery and ultimately result in refinery wide shutdown.
 VDU shutdown: CDU Single Operation still possible.
 CDU operating at 60% capacity.
 Atmospheric Residue sent to storage (Reduced Crude tanks).
Maintenance Highlights
Integrated CDU/VDU System Complications:
 Incomplete VDU maintenance during VDU shutdown mode

as exchangers 01-E-008 / 010 / 011, which are in VDU
service are required during CDU Single Operation.
 e.g.1: Crude / LVGO Exchanger (01-E-002 A/B/C).
 Maintenance bypasses for both Crude and LVGO sides.
 CDU Single Operation: No duty performed by exchanger.
 Can be taken offline for maintenance.
 e.g.2: 1st Crude / HVGO Exchanger (01-E-008 A-D).

 No maintenance bypasses for either Crude or HVGO sides.
 CDU Single Operation: AR directed through HVGO route.
 Cannot be taken offline for maintenance.

Maintenance Highlights
Integrated CDU/VDU System Complications:
 e.g.3: 2nd Crude / HVGO Exchanger (01-E-010 A-H).

 Maintenance bypasses for both Crude and HVGO sides.
 CDU Single Operation mode: AR directed through HVGO route.
 e.g.4: Crude / Vacuum Residue Exchanger (01-E-011 A-D).

 Maintenance bypasses for both Crude and VR sides.
 CDU Single Operation mode: AR directed through VR route.

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Karbala Refinery Unit 01

General Process Overview

Date: September 2017

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Karbala Refinery Process Units Configuration

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Crude Distillation Unit (CDU)

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Vacuum Distillation Unit (VDU)

 Vacuum Residue (VR)

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to Fuel Oil Blending

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 Unit Capacity of 140,000 BPSD.

 Integrated CDU / VDU pre-heat trains.

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Feed Properties and Conditions: Basrah Crude

Feed Properties and Conditions: Mishrif Crude

Products: Basrah Crude

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Products: Mishrif Crude

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Battery Limit Conditions

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Utilities Required: Basrah Base Case

* Source: IONE-1C01-CN-PR-0003 Rev 1, UTILITIES CONSUMPTION SUMMARY FOR UNIT 01

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Crude Pre-heating Concept Effluent to WWT (U51)

Crude Oil Crude Oil

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First Crude Pre-heating Train

 Crude pumped from storage to Unit 01 Battery Limit.

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LVGO from VDU

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Crude Oil Desalter (01-V-001 A/B)

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Crude Oil Desalter (01-V-001 A/B)

 Removes salt (in solution with water) from Crude Oil.

 High voltage (3,000 volts per inch) applied across cross

Crude Oil Desalter (01-V-001 A/B)

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Crude Oil Desalter (01-V-001 A/B)

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Second Crude Pre-heating Train

 Heated against Unit 01 product streams up to 278 °C

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Crude Heater (01-H-001)

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Crude Heater (01-H-001)

 Pass balance control for outlet temperature equalization.

 Crude is partially vaporized, outlet temperature of 364 °C.

 24 forced draft, low NOx burners.

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Crude Heater (01-H-001)