

3550-8110-PD-0005

1. PROJECT DESCRIPTION

The refinery will process 200,000 BPSD of imported Kuwait Export Crude (KEC)
oil. The Aromatics Complex produces Paraxylene and Benzene. A key product
from the Residue Catalytic Cracker Unit is Propylene which is used to produce
Polypropylene product.

Nhà máy sẽ chế biến 200.000 BPSD dầu thô Kuwait nhập khẩu. Tổ hợp
Aromatics sản xuất Paraxylene và Benzene. Sán phẩm chính thừ RFCC là
propylene được dùng sản xuất PP.

2. REFINERY PROCESS UNITS

2.1 Crude Distillation Unit (CDU)

The CDU processes 100 % Kuwait Export Crude oil to produce a range of straight-
run distillate products plus atmospheric residue; these are routed to further
processing within the complex.

The Unit produces the following streams:

A sour overheads gas stream routed to the LPG Recovery Unit.

A full-range unstabilised naphtha stream routed to the LPG Recovery Unit.
A kerosene stream routed to the Kerosene Hydrodesulphuriser Unit
(KHDS) and to product blending.
A combined gas oil stream routed to Gas Oil Hydrodesulphuriser Unit
(GOHDS) or to GOHDS inter-unit tankage.
An atmospheric residue stream routed to the Residue Hydrodesulphuriser
Unit (RHDS) or to RHDS inter-unit tankage.

Các dòng đầu ra của phân xưởng CDU bao gồm:

- Dòng khí chua overhead đến LPG Recovery Unit.
- Dòng full-range naphtha không ổn định đến LRU.
- Dòng kerosene đến KHDS và đến pha trộn sản phẩm.
- Dòng Hỗn hợp gasoil đến GOHDS hoặc đến GOHDS inter-unit tankage.
- Cặn chân không đến RHDS hoặc đến RHDS inter-unit tankage.

2.2 LPG Recovery Unit

The LPG Recovery Unit is designed as a common saturated gas plant; it collects
and processes saturated feed streams (off-gas, LPG and naphtha) received from
the Crude Distillation Unit, the Naphtha Hydrotreater, the CCR, the Isomerisation
Unit and the three Hydrodesulphuriser Units (KHDS, GOHDS & RHDS).
The unit produces the following products:
Produce an off-gas which is sent to the Refinery Fuel Gas System after
hydrogen sulphide removal.
Produce separate Propane and Butane LPG product streams which are
routed to Inter Unit storage.
Produce stabilised full-range naphtha which is routed as feedstock to the

3550-8110-PD-0005 DSN: 478

 
3550-8110-PD-0005
Naphtha Hydrotreater Unit.

2.3 Saturated LPG Treater Unit

The Unit is designed to process mixed LPG feedstock from the amine extractor in
the LPG Recovery Unit to produce treated LPG with a maximum total mercaptans
sulphur content of 5 ppm wt. The Unit designs include facilities for spent caustic
treatment and recycle. The treated LPG product returns to the LPG Recovery Unit
for C3/C4 separation.

2.4 Kerosene Hydrodesulphuriser Unit (KHDS)

The Kerosene Hydrodesulphuriser Unit (KHDS) processes the kerosene fraction

from the Crude Distillation Unit (CDU) and produces desulphurised Kerosene /Jet
Fuel with max. 50 ppm wt sulphur content and max. 0.003 wt% mercaptan sulphur
content.

The Unit also produces a number of by-product streams:

Unstabilised Naphtha, which is sent to the Crude Distillation Unit

Sour off-gas sent to the LPG Recovery Unit.

Sour water sent to the Sour Water Stripping Unit (SWS-1).

2.5 Gasoil Hydrodesulphuriser Unit (GOHDS)

The Gasoil Hydrodesulphuriser Unit (GOHDS) processes atmospheric Gas Oil

from the Crude Distillation Unit (CDU) and Light Cycle Oil from the RFCC. The
unit desulphurises these feeds to produce low sulphur (max 50 ppm wt) diesel
blendstock.

The Unit also produces a number of by-product streams:

Unstabilised Naphtha sent to the Crude Distillation Unit

Treated off- gas sent to the LPG Recovery Unit

Sweet gas to the HCDS for hydrogen recovery in a PSA

Sour water sent to the Sour Water Stripping Unit (SWS-1)

2.6 Residue Hydrodesulphuriser Unit (RHDS)

The RHDS is designed to process atmospheric residue from the Crude Distillation
Unit to produce a feedstock suitable for processing in a downstream RFCC.

The unit produces the following product streams:

Desulphurised atmospheric residue to the RFCC

Unstabilised Naphtha to the LPG Recovery Unit

Desulphurised RHDS diesel to the diesel pool.

3550-8110-PD-0005 DSN: 478

 
3550-8110-PD-0005
The Unit also produces the following by-products:

Off-gas from the product recovery section to the LPG Recovery Unit

Off-gas from the reactor section to HCDS for hydrogen recovery.

REFINERY DESIGN FOSTER WHEELER ENERGY LTD PAGE 15 OF 33

BASIS - OVERALL PROCESS ENGINEERING REV D7

2.7 Residue Fluid Catalytic Cracker Unit (RFCC)

The RFCC is designed to process the RHDS residue stream received from the
Residue Hydrodesulphuriser (RHDS). The RFCC is designed for two modes of
operation: maximum olefin (propylene) and maximum gasoline.

The Unit produces the following product streams:

An amine treated LPG stream. This LPG stream will be caustic treated
(RFCC LPG Treater – Unit 024) to remove Mercaptans. The mercaptan
free LPG will be routed back to the RFCC C3/C4 splitter.

After mercaptan removal, the LPG stream will be split to produce a

propylene stream to the Polypropylene Unit, a mixed butane stream to
Indirect Alkylation Unit, and a propane stream to the LPG pool.

Light FCC gasoline (LFG) to the gasoline pool via a Caustic Treating Unit.

Heavy FCC gasoline (HFG) to the gasoline pool.

Light cycle oil (LCO) product to the Gas Oil Hydrodesulphurisation Unit
and/or fuel oil

Clarified Oil (CLO) product to refinery fuel oil

The Unit also produces the following by-products:

Treated off-gas sent to the refinery fuel gas system.

Sour water sent to Sour Water Stripping Unit (SWS-2).
Regenerator flue gas which is sent to atmosphere via a stack.

The RFCC unit includes dedicated amine absorber/extractor/regenerator facilities

to serve the RFCC Unit only.

2.8 Propylene Recovery Unit (PRU)

The Propylene Recovery Unit (PRU) is designed to recover high-purity propylene

from the mixed C3 feedstock received from the RFCC.

The propylene product is fed forward to the Polypropylene Unit (PPU). The PRU

3550-8110-PD-0005 DSN: 478

 
3550-8110-PD-0005
also produces a propane by-product stream which is routed to LPG product
blending and storage.

The Propylene Recovery Unit is designed by the licensor of the RFCC Unit and
hence the design basis for the Propylene Recovery Unit is described in Doc. No.
REFINERY DESIGN FOSTER WHEELER ENERGY LTD PAGE 16 OF 33
BASIS - OVERALL PROCESS ENGINEERING REV D7

3550-8110-PD-022-0001, Residue Fluid Catalytic Cracker Design Basis, issued

separately.

2.9 RFCC LPG Treater Unit

The Unit is designed to process LPG feedstock from the RFCC unit after amine
scrubbing. The Unit produces treated LPG with a maximum total mercaptans
content of 3 ppm wt. The designs include facilities for spent caustic treatment and
recycle.

2.10 RFCC Light Gasoline Treater Unit

The Unit is designed to process RFCC light gasoline from the RFCC Gasoline
Splitter. The Unit produces treated Light Gasoline with minimum 90% of
mercaptans extraction from feed. The designs include facilities for spent caustic
treatment and recycle.

2.11 Indirect Alkylation Unit (InAlk)

This Unit comprises three separate process units: a Selective Hydrogenation

Process (SHP), a Nitrile Removal Unit (NRU) and an Indirect Alkylation Unit
(InAlk) designed to maximise the production of high octane alkylate suitable for
gasoline blending based on maximising octane-barrels.
The feed to the units is the mixed butane/butene product from the RFCC. This
stream is first processed in the SHP to remove dienes and then into the NRU to
remove nitriles before passing to the InAlk unit where isobutylene is reacted with
light olefins to yield iso-octane rich alkylate product. The hydrogen requirement for
the SHP and InAlk units is taken from the Hydrogen Compression and Distribution
System. The InAlk unit also produces a mixed C4s stream (unreacted butanes)
which is sent to the LPG pool.

2.12 Hydrogen Manufacturing Unit (HMU)

The Hydrogen Manufacturing Unit (HMU) utilises steam-methane reforming of

hydrocarbon feedstock (refinery fuel gas and LPG) to produce a hydrogen-rich
gas product which is purified in a Pressure Swing Adsorption (PSA) to yield
hydrogen with a minimum purity of 99.9 vol% hydrogen.
REFINERY DESIGN FOSTER WHEELER ENERGY LTD PAGE 17 OF 33
BASIS - OVERALL PROCESS ENGINEERING REV D7

The hydrogen product is routed to the RHDS unit with the balance of production
distributed throughout the complex via the Hydrogen Compression and
Distribution System (HCDS).

3550-8110-PD-0005 DSN: 478

 
3550-8110-PD-0005
The HMU generates a substantial quantity of high pressure steam from waste
heat and this steam makes a significant contribution to the refinery steam
balance.

2.13 Hydrogen Compression and Distribution System (HCDS)

The Hydrogen Compression and Distribution System (HCDS) receives high-purity

hydrogen from two sources: the Hydrogen Manufacturing Unit (HMU) and the PSA
section within the Catalytic Reformer (CCR) in the Naphtha and Aromatics
Complex. In addition, a PSA unit shall be installed within HCDS which shall
recover pure H2 from the RHDS & GOHDS H2 rich off-gases.

The objective of the HCDS is to compress and distribute high purity hydrogen to
the following units at the required battery limit pressures:

Kerosene Hydrodesulphuriser

Gas Oil Hydrodesulphuriser

Selective Hydrogenation / Indirect Alkylation

Units Isomar
Tatoray
Normally the Hydrogen requirement to the Polypropylene (PP) Unit shall be met
by the H2 from the CCR Patforming PSA Unit.

The hydrogen treat-gas requirements within the Naphtha & Aromatics Complex
(i.e. the Naphtha Hydrotreater and Isomerisation units) are fed directly by
hydrogen-rich gas produced in the CCR, hence, these Units are not normally
served by the HCDS.

2.14 Sour Water Stripper Units (SWS)

The objective of the SWS Unit is to treat refinery sour water streams such that the
quality of stripped water enables it to be reused as wash water within the refinery
and/or discharged to the Effluent Treatment Plant for final clean-up.

The sour gases (H2S and NH3) stripped from the sour water in the SWS are
routed to the Sulphur Recovery Unit for further treatment.
REFINERY DESIGN FOSTER WHEELER ENERGY LTD PAGE 18 OF 33
BASIS - OVERALL PROCESS ENGINEERING REV D7

The SWS is configured as two separate trains in order to segregate the treatment
of sour waters from different sources; the routings of the most significant sour
water streams are indicated here:

SWS Train 1 : All sour water production except RFCC

SWS Train 2 : Dedicated RFCC

The design basis for the SWS unit is described in Doc. No. 3550-8110-PD-080-
0001, Sour Water Stripper Unit Design Basis, issued separately.

3550-8110-PD-0005 DSN: 478

 
3550-8110-PD-0005

2.15 Amine Regeneration Unit (ARU)

The objective of the common Amine Regeneration Unit (ARU) is to strip hydrogen
sulphide from the rich amine solvent (MDEA) returned from amine
absorbers/extractors located within the following refinery units:

 The LPG Recovery Unit

 The Hydrodesulphuriser Units (GOHDS & RHDS)

The various gas and LPG streams requiring treatment within the above units are
essentially free of problematic trace components, such as cyanides and phenols,
which might otherwise be a cause of cross-contamination between processes via
the circulating solvent. Such ‘clean’ systems permit use of a common ARU, and
thus a single ARU train is selected to serve these units.

The design basis for the common Amine Regeneration Unit is described in Doc.
No. 3550-8110-PD-084-0007, Amine Regeneration Unit Design Basis, issued
separately.

2.16 Sulphur Recovery Unit (SRU) and Tail Gas Treating Unit (TGTU)

The Sulphur Recovery Unit (SRU) is designed to recover elemental sulphur from
the acid gas feed streams received from the common Amine Regeneration Unit,
from the Amine Regenerator within the RFCC Unit and from the Sour Water
Stripper Unit.

Molten sulphur product is sent to the Sulphur Forming and Storage Facility

The SRU is configured as follows:

3 x 40% Claus trains (total 120% providing +20% design margin)

2 x 80% TGT trains (ie. each designed to service two Claus trains)
2 x 80% incinerators (i.e. each matched to one TGTU)
REFINERY DESIGN FOSTER WHEELER ENERGY LTD PAGE 19 OF 33
BASIS - OVERALL PROCESS ENGINEERING REV D7

Associated sulphur degassing and molten sulphur storage facilities are provided.

3. PETROCHEMICAL PROCESS UNITS

3.1 Naphtha and Aromatics Complex (NAC)

The Naphtha and Aromatics Complex (NAC) is designed to process a full-range

naphtha feedstock to produce Paraxylene and Benzene products at a purity
suitable for sale, plus heavy aromatics (subject to quality) and isomerate streams
suitable for gasoline blending. The design philosophy of the complex is to
maximise economic Paraxylene production.

The Aromatics Complex comprises the following process units:

3550-8110-PD-0005 DSN: 478

 
3550-8110-PD-0005
Naphtha Hydrotreater (including naphtha splitter)

CCR Platformer / CCR Regenerator section (incl. reformate splitter)

Sulfolane (Aromatics Extraction)

Benzene / Toluene Fractionation

Isomar (Xylenes Isomerisation)

Tatoray (Toluene Transalkylation)

Xylene Fractionation
Parex (Paraxylene Separation)

Penex (Isomerisation)

The NAC feedstock is full-range naphtha produced in the LPG Recovery Unit.

Fresh naphtha feedstock (and recycled raffinate from the Sulfolane Unit) is
processed in the Naphtha Hydrotreater. Treated naphtha product is then sent to
the Naphtha Splitter where it is fractionated into two streams: light naphtha as
feed to the Penex Unit and heavy naphtha to the CCR Platformer. The heavy
naphtha is processed in the CCR Platformer and the resultant reformate is then
routed to the Aromatics units for production of Paraxylene, Benzene and gasoline
blending components.

The primary products from the Naphtha and Aromatics Complex are:

Paraxylene – sent to paraxylene product storage

Benzene – sent to benzene product storage.

An isomerate stream – sent to gasoline blending.

By-products include:
REFINERY DESIGN FOSTER WHEELER ENERGY LTD PAGE 20 OF 33
BASIS - OVERALL PROCESS ENGINEERING REV D7

A raffinate stream from the Sulfolane Unit – which is totally recycled to the
Naphtha Hydrotreater.

A toluene stream – can be produced, if required, for gasoline blending

A C9/C10 aromatics stream (Aromatic Gasoline) from the Heavy Aromatic
column overheads – to gasoline blending, if required.
A heavy aromatics stream (A10+) from the Heavy Aromatic column bottoms
– to refinery fuel oil blending.

LPG from the CCR Platformer – to the LPG Recovery Unit.

A hydrogen-rich gas stream from the CCR Platformer PSA Unit – part of
which is consumed internally within the NAC with the remainder routed to
the refinery’s Hydrogen Compression and Distribution System.

3.2 Polypropylene Unit (PPU)

3550-8110-PD-0005 DSN: 478

 
3550-8110-PD-0005

The Polypropylene Unit is designed to produce Polypropylene from propylene

feedstock and hydrogen.

Propylene feed is obtained from the Propylene Recovery Unit within the RFCC
Unit. Hydrogen feed gas is supplied from the CCR.

The primary product from the PP is polypropylene homopolymer. A minor purge

gas stream is recycled back to the Propylene Recovery Unit.

Polypropylene product is bagged and loaded into containers on-plot for despatch
by road to the dockside where containers are transferred to ships.

The design basis for the Polypropylene Unit is described in Doc. No. 3550-8110-
PD-061-0001, Polypropylene Unit Design Basis, issued separately.

3550-8110-PD-0005 DSN: 478