Ethylene Plant Basis of Design No.: DDP-T-P-03205 Rev.

: 00

TABLE OF CONTENTS

1.0 SCOPE ............................................................................................................................ 3

2.0 ASSOCIATED GUIDELINES .......................................................................................... 3
3.0 ASSOCIATED DOCUMENTS ......................................................................................... 3
4.0 BACKGROUND .............................................................................................................. 4
5.0 REVISION HISTORY ...................................................................................................... 5
6.0 APPENDICES ................................................................................................................. 5
6.1 APPENDIX A: STANDARD BASIS OF PROCESS DESIGN .......................................... 1

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Ethylene Plant Basis of Design No.: DDP-T-P-03205 Rev.: 00

1.0 S COP E
Each ethylene plant design project must issue a Basis of Process Design (BOD).
The Basis of Process Design defines the basis by which the ethylene plant is to be
designed in accordance with client requirements and in agreement with Shaw
management. This Basis of Process Design (Generic) is in the format of the
individual project document and is used to generate the Basis of Process Design for
each individual project.
The Project Procedures and Specifications document (DTP-T-P-01001) has the
Purpose, Scope, Definitions, Responsibilities and Procedure for issuing the Basis of
Process Design document. There is some discussion in DTP-T-P-01001 of the
BOD content. This guideline is meant to be supplementary and more detailed.
2.0 AS S OCIATED GUIDELINES
Project Procedures and DTP-T-P-01001 Previously
Specifications 3_1_1/2/3WP1
Ethylene Plant Design Standards DTS-T-P-03001 Previously 3410P001A
Ethylene Plant Process Team DTP-T-P-03001 Previously 3410P002A
Guidelines (Generic)
3.0 AS S OCIATED DOCUMENTS
Invitation to Bid (ITB)/Proposal
Minutes of Meeting from Kick-off Meeting
Contractual information including Guarantees.
Correspondence with Client (as applicable)
Shaw Divisional Input
• Process Marketing
• Process Technology/Business Development
• Project Management
• Project Engineering
Input information shall include but is not limited to the following:
• Background and General Information
• Plant Capacity and Operating Factor
• Design and Rating Cases
• Feedstock Specifications
• Feedstock Contaminants (e.g. Hg, As, COS)
• Product Specifications
• Component Recovery Criteria
• Turndown Requirements
• Auxiliary and Start-up Material Specifications
• Battery Limit Conditions and Source/Destination for Feed and Products
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Ethylene Plant Basis of Design No.: DDP-T-P-03205 Rev.: 00

Revamp Considerations
• Other input information may be required for revamp work in addition to the
information mentioned above. Revamp input information may include but is
not limited to the following:
▬ Yields from existing (or planned) facilities.
▬ Philosophy and procedure to be used with proprietary equipment or
units licensed by others.
▬ Recycles or other feeds from outside units.
▬ Equipment or other physical constraints such as re-using existing
equipment or limited plot space.
▬ Existing equipment data sheets including compressor wheel curves and
tower/vessel internals .
▬ Existing equipment inspection data.
Team Guidelines
Project Design Data(PDD)
4.0 BACKGROUND
The Basis of Process Design is the central project document that relays contractual
obligations and performance guarantees to the process team. It is completed by
the Process Lead Engineer or his/her designee and approved by the Olefins
Section Manager. The Basis of Process Design is issued at the beginning of the
project prior to initiating the process engineering design effort. The Basis of
Process Design is not to state any design criteria that is stated in another
document, with the exception of compiling and repeating information given in one or
several client documents in order to have a single Shaw document with which to
work.
Often, the client’s ITB has a similar Basis of Design as the process BOD. It is
important that the Basis of Process Design be “owned” by the Shaw process team
instead of having it “owned” and approved by the client, even though the
information may be repeated.
The Basis of Process Design is meant to be “external” as well as “internal”; that is, it
is issued to Projects and the client and is often one of the first chapters of the Basic
Design Engineering Package (BDEP) produced for the project. It does not contain
proprietary information. It is a form of communication to the client in terms of
design criteria used.
There may be some information that normally written in the Team Guidelines (see
DTP-T-P-03001) that is moved to the Basis of Process Design due to client
preference (for instance, heat exchanger fouling resistances or pump efficiencies).
The lead or designee should try to minimize this in order to standardize the division
of these two documents for consistency.

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Ethylene Plant Basis of Design No.: DDP-T-P-03205 Rev.: 00

5.0 REVIS ION HIS TORY

Revision Level Revision Description

Guideline is reformatted to match Shaw Aug. 2010 guideline template. Minor

00
updates in red font.
Prior 0 Previously issued as 3410P009A, Rev. 0, 04/30/97.

6.0 AP P ENDICES
6.1 APPENDIX A: STANDARD BASIS OF PROCESS DESIGN

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Ethylene Plant Basis of Design No.: DDP-T-P-03205 Rev.: 00

6.1 APPENDIX A: STANDARD BASIS OF PROCESS DESIGN

TITLE P AGE (TYP ICAL)

XZY CORP ORATION - XYZ ETHYLENE P ROJ ECT

BAS IS OF P ROCES S DES IGN

S HAW (LOGO c a n b e a d d e d )
J .O. No . 12345.10

REVISION 0 1 2 3 4 5
APPROVAL DATE
PREPARER
LEAD PROCESS ENGINEER
TECHNOLOGY
OLEFINS SECTION MANAGER

This document contains the proprietary and confidential information of The Shaw Group Inc. and is to be returned upon request. Its contents
may not be copied, disclosed to third parties, or used for other than the express purpose for which it has been provided without the written
consent of The Shaw Group Inc.

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Ethylene Plant Basis of Design No.: DDP-T-P-03205 Rev.: 00

TABLE OF CONTENTS

TITLE PAGE (TYPICAL) ........................................................................................................... 1

1. INTRODUCTION (TYPICAL) ................................................................................................. 3
2. PLANT DEFINITION (TYPICAL) ........................................................................................... 3
3. FEEDSTOCK DEFINITION (TYPICAL) .................................................................................. 3
3.1 FEEDS/DESIGN CASES ..................................................................................................... 3
3.2 VENT STREAMS/ADDITIONAL EXTERNAL FEEDS .......................................................... 7
3.3 FURNACE YIELDS .............................................................................................................. 8
4. PRODUCT DEFINITION AND SPECIFICATIONS (TYPICAL) .............................................. 9
5. DESIGN SPECIFICS (TYPICAL) ......................................................................................... 13
5.1 FURNACE SECTION ......................................................................................................... 13
5.2 FEED AND RECOVERY SECTIONS ................................................................................. 16
6. UTILITIES ............................................................................................................................ 18
7. EFFLUENTS (TYPICAL) ..................................................................................................... 18
8. BATTERY LIMIT CONDITIONS (TYPICAL) ........................................................................ 20

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Ethylene Plant Basis of Design No.: DDP-T-P-03205 Rev.: 00

1. INTRODUCTION (TYPICAL)
XYZ Corporation has requested that Shaw provide a Basic Engineering Package for an
ethylene plant to be located at their plant site in nowheresville, world.
The plant design shall include Shaw's proprietary Advanced Recovery System (ARS)
technology and the Olefins complex will include the following units:
1. The Ethylene Plant
2. Pyrolysis Gasoline Hydrotreating (PGH) Unit
3. C3 Hydrogenation Unit (Single Stage)
4. C4 Cut Hydrogenation Unit
The PDP packages for the PGH Unit, C3 Hydrogenation Unit (Single Stage), and the C4
Hydrogenation Unit will be developed by IFP and will be integrated into the complex by
Shaw. The design of the Ethylene Plant is to be carried out by Shaw. This Basis of
Design only addresses the Ethylene Plant.

2. PLANT DEFINITION (TYPICAL

Design Capacity: 450,000 MTA of ethylene
200,000 MTA of propylene

Stream Factor: 8445 hours per year

Run Length between Turnarounds: 3 years

Turndown: 70%

3. FEEDSTOCK DEFINITION (TYPICAL)

3.1 FEEDS/DESIGN CASES
3.1.1 Design Cases
100% Light Naphtha, 100% Algerian Condensate, and 50% LPG/50% Light Naphtha are
the different feed cases for the plant design. Shaw has provided a guarantee that the
Ethylene Plant will produce 450,000 metric tonnes/year of ethylene for the 100% Light
Naphtha case only. The revised Algerian Condensate feed and the 50% LPG/50% Light
Naphtha are alternate feeds.
For all the above cases ethane, propane, hydrogenated C4's and hydrogenated C5's from
the PGH Unit shall be recycled and cracked.
BASE CASE ALT. CASE AALT. CASE B
Light Naphtha 100% 50%
Algerian Condensate 100%
LPG 50%

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Ethylene Plant Basis of Design No.: DDP-T-P-03205 Rev.: 00

3.1.2 Feeds
The quantities and specification of the fresh feeds and the supplemental feeds are listed
in the following tables:

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Ethylene Plant Basis of Design No.: DDP-T-P-03205 Rev.: 00

TABLE 3.1-1 LIGHT NAPHTHA

Specific gravity, 20/4 ºC .693

Total Sulfur, wt ppm 200 max

ASTM D86 Vol. % ºC

IBP 37
10 57
30 71
50 86
70 107
90 133
95 143
EP 171

PONA Analysis WT %
N-Paraffin 36.9
I-Paraffin 37.1
Naphthenes 20.7
Aromatics 5.3

CONTAMINANTS AVERAGE PEAK

MTBE 6 ppmw 120 ppmw
Methanol 6 ppmw 120 ppmw

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Ethylene Plant Basis of Design No.: DDP-T-P-03205 Rev.: 00

TABLE 3.1-2 ALGERIAN CONDENSATE

API Gravity 62.7

Density at 15°C 0.7288
Total Sulfur, wt% 0.035

Distillation ºC
IBP 34
5 46
10 54
30 81
50 114
70 155
90 240
95 277
FBP 317
RESIDUE, % 2.0
LOSS,% 3.0

PONA Analysis, WT%

n-Paraffins 37.87
i-Paraffins 35.45
Naphthenes 15.97
Aromatics 10.72

CONTAMINANTS AVERAGE PEAK

Mercury 50 ppbw 60 ppbw

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Ethylene Plant Basis of Design No.: DDP-T-P-03205 Rev.: 00

TABLE 3.1-3 LIQUIFIED PETROLEUM GAS (LPG)

COMPONENTS WT %
Propane 60
Isobutane 14
N-Butane 26

CONTAMINANTS VALUE
COS 10 ppmw
Arsenic 20 ppbw

NOTE: LPG should account for 50% of the fresh feed for
Alternative Feed Case.

3.1.3 Studies
Two studies will be performed during project execution:

Maximum Hydrogen Make Study: Determine the maximum hydrogen quantity

possible.

C3 Splitter Heat Pump Study: Determine whether the C3 Splitter has a heat
pump.

3.2 VENT STREAMS/ADDITIONAL EXTERNAL FEEDS

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Ethylene Plant Basis of Design No.: DDP-T-P-03205 Rev.: 00

TABLE 3.2-1 ETHYLENE STREAM RETURNED FROM POLYETHYLENE PLANTS

COMPONENTS VALUE

Ethane, % vol. 10.0

Hydrogen, % vol. 2.0
Nitrogen + Methane, vol.% 1.0
Ethylene Balance
Carbon Dioxide, ppmv 2000 max.
Carbon Monoxide, ppmv 50 max.
Oxygen, ppmv 5 max.
Water, ppmw 5 max.
Acetylene, ppm vol. 150 max.
Total Sulfur, ppm weight 10 max.
H2S, ppm weight 10 max.

Flow Rate - 15,000 tons/yr

TABLE 3.2-2 RECYCLE C5'S FROM PGH

COMPONENTS UNIT VALUE

N-Pentane wt% 9.51

N-Pentene wt% 17.26
I-Pentane wt% 4.45
I-Pentene wt% 22.40
Cyclopentane wt% 18.20
Cyclopentene wt% 28.18

Flow Rate - To be determined (use 45,000 MTA as an approximation for

now)

3.3 FURNACE YIELDS

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Ethylene Plant Basis of Design No.: DDP-T-P-03205 Rev.: 00

The furnace yields are to be included in the Basis of Process Design if a separate
Basis of Process Design is not prepared for the furnace section.

4. PRODUCT DEFINITION AND SPECIFICATIONS (TYPICAL)

In addition to ethylene and propylene the plant will produce the following products:

The product specifications are listed in the following tables:

TABLE 4.1-1 POLYMER-GRADE ETHYLENE

ANALYSES UNIT XYZ REFERENCE

SPECIFICATION

Ethylene % mole min. 99.94

Ethane ppm mole max. 500 G.C. Capilar
Methane ppm mole max. 100 G.C. Capilar
Propylene ppm mole max. 10 G.C. Capilar
Propane ppm mole max. 10 G.C. Capilar
Hydrogen ppm mole max. 10 ASTM D-2504
Nitrogen ppm mole max. 10 G.C. Capilar /ANTEK
7000N
Ammonia ppm wt max. 2 Calculation or Acid
Absorption
Total Oxygenates ppm wt max. 5 G.C. Capilar
NO, NO2 ppm wt max. 2 ASTM D-4629
Acetone ppm wt max. 2 G.C. Capilar
CONTAMINANTS
CO ppb mole max.300 ISO 6381 / ASTM 2504
CO2 ppm mole max. 2 ISO 6381 / ASTM
2504/2505
Acetylene ppm mole max. 5 G.C. Capilar
Water ppm wt max. 2 Automatic Dew Point

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Ethylene Plant Basis of Design No.: DDP-T-P-03205 Rev.: 00

TABLE 4.1-1 POLYMER-GRADE ETHYLENE

ANALYSES UNIT XYZ REFERENCE

SPECIFICATION

Ethylene % mole min. 99.94

Alcohol (MEOH, ETOH) ppm mole max. 2 G.C. Capilar
Total Sulfur ppm wt max. 1 ASTM D-4468
O2 ppm mole max. 2 Electrochemical Teledyne
COS ppb wt max.100 Calculation or G.C. FPD
Methyl Acetylene ppm mole max. 3 ASTM D-2505
Propadiene ppm mole max. 5 ASTM D-2505
Arsine ppb wt max. 30 G.C. Capilar
Phosphine ppb wt max.30 G.C. Capilar

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Ethylene Plant Basis of Design No.: DDP-T-P-03205 Rev.: 00

TABLE 4.1-2 POLYMER-GRADE PROPYLENE

ANALYSIS UNIT XYZ REFERENCE

SPECIFICATION

Propylene % mole min. 99.5

Propane ppm mole max. 5000 G.C. Capilar
Methane + Nitrogen ppm mole max. 100 ISO 6381
Ethane ppm mole max. 200 ISO 6381
Ethylene ppm mole max. 50 ISO 6381
Butenes ppm mole max. 100 G.C. Capilar
Butanes ppm mole max. 100 G.C. Capilar
C5 Total ppm mole max. 10 G.C. Capilar
Hydrogen ppm mole max. 5 ASTM D-2504
CONTAMINANT
Acetylene ppm mole max. 5 G.C. Capilar
Methyl Acetylene ppm mole max. 3 G.C. Capilar
Propadiene ppm mole max. 5 G.C. Capilar
Butadiene ppm mole max. 10 G.C. Capilar
C6+ (Including Green- ppm mole max. 20 G.C. Capilar
Oil)
Oxygen ppm mole max. 2 Electrochemical
Teledyne
CO ppb mole max. 100 ISO 6381
CO2 ppm mole max. 5 ISO 6381
COS ppb mole max. 20 Calculation or G.C.
FPD
Total Sulfur ppm wt max. 1 ASTM D-4468
Water ppm wt max. 2 Automatic Dew Point
Methanol ppm mole max. 5 G.C. Capilar
Other Alcohol ppm wt max. 15 G.C. Capilar
Arsine ppbw max. 30 G.C. Capilar
Phosphine ppbw max. 30 G.C. Capilar

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Ethylene Plant Basis of Design No.: DDP-T-P-03205 Rev.: 00

ANALYSIS UNIT XYZ REFERENCE

SPECIFICATION

Ammonia ppm wt max. 5 Calculation or acid

absorption
Cyclopentadiene ppm mole max. 50

TABLE 4.1-3 HYDROGEN PRODUCT

ANALYSIS UNIT XYZ REFERENCE

SPECIFICATION

Methane % mole balance G.C. Capilar

Hydrogen % mole 99.9 ASTM D-2504
CO ppm mole max. 1 ISO 6381
CO2 ppm mole max. 5 ISO 6381
Acetylene ppm mole max. 5 G.C. Capilar
Water ppm mole max. 2 Automatic Dew Point
O2 ppm mole max. 5 Electrochemical Teledyne
Nitrogen % mole balance G.C. Capilar
Total Sulfur ppm wt max. 2 Calculation or G.C. FPD

TABLE 4.1-4 LPG

Corrosion to copper (1 h at 37.8 ºC) Not more discoloration than

standard copper strip 1
Vapor pressure at 37.8 ºC, kg/cm2 15.0 max
Volatile sulfur, g/m3 0.36 max
95% BP at 760 mmHg, ºC 2 max
Water No free water

TABLE 4.1-5 RAW C4 CUT

C3s and Lighter 0.15 mol% max

C5s and Heavier 0.3 % wt max

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Ethylene Plant Basis of Design No.: DDP-T-P-03205 Rev.: 00

TABLE 4.1-6 RAW PYROLYSIS GASOLINE

C4s and Lighter 0.8 mol% max

TABLE 4.1-7 FUEL OIL PRODUCT

HFO will be mixed with about 10% LFO to meet viscosity and storage requirements

ANALYSIS UNITS TYPICAL SPEC. REFERENCE

VALUE

Specific Gravity 20/4°C >1.1 To be ASTM D-1298

specified
Flash Point °C >100 To be ASTM D-93
specified
Viscosity @ 98.9°C cst 200+ To be Saybolt
specified
Viscosity @ 48.9°C cst - To be Saybolt
specified
Sulfur wt % 0.5 To be ASTM D-129
specified
BMCI - >125 To be BMCI
specified
Water & Sediments vol % <0.1 < 0.1 ASTM D-96

The quality of Fuel Oil has changed from combined LFO and HFO to only HFO, as the
LFO will be used as fuel in the Gas-turbine.

5. DESIGN SPECIFICS (TYPICAL)

5.1 FURNACE SECTION

Normally, a separate Basis of Process Design is prepared for the furnace section,
the only information to be repeated in this document is the dilution steam-to-
hydrocarbon ratios. If a separate Basis of Process Design is not prepared for the
furnace section, then this section is to be included in the Basis of Process Design

5.1.1 Furnace System Selected

For the 100% Light Naphtha feed case 6 USC-96U furnaces shall be used for cracking
liquids and one USC-M furnace shall be used for cracking recycle ethane. Normal
operation will require operating all the six USC-U furnaces and the recycle furnace,
except when one of the USC-U furnace is undergoing decoking. At this time the furnace

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Ethylene Plant Basis of Design No.: DDP-T-P-03205 Rev.: 00

section will still produce the same hourly rate of ethylene using only 5 USC-U furnaces
and the recycle furnace, by increasing the loading of the operating liquid cracking USC-
U furnace.
For the 100% Algerian Condensate feed case, 5 of the 6 USC-U furnaces will be
cracking Light Condensate and the 6th furnace will crack the Heavy Condensate. When
one of the 5 furnaces cracking the Light Condensate is undergoing decoking, the other
4 furnaces will increase their ethylene production to compensate for the decoking
furnace. When the Heavy Condensate furnace is undergoing decoking, the 5 furnaces
cracking the Light Condensate will increase their ethylene production to achieve the
same ethylene hourly rate. The fractionated Heavy Condensate will be sent to the
Heavy Condensate day tank, which shall have the necessary capacity to store the
heavy condensate while the Heavy Condensate furnace is out of operation.
For the 50% LPG/50% Light Naphtha feed case, the LPG cracking furnaces shall
receive the LPG as a vapor stream.
Each USC-96U furnace shall be of twin-cell design with two radiant boxes, each with 48
radiant coils. There will be a common convection box for the two radiant boxes. There
are three different types of furnaces in this plant:
Five USC-96U furnaces with capability to handle gas-turbine exhaust(GTE) and capable
of cracking Light Naphtha liquid feed, or Light Condensate liquid feed, or LPG vapor
feed.
One USC-96U furnace with capability to handle gas-turbine exhaust(GTE) and capable
of cracking Light Naphtha liquid feed, or Heavy Condensate liquid feed.
One recycle USC-8M furnace capable of cracking the ethane recycle with a design to
use ambient air ONLY for fuel combustion.
Gas-turbine exhaust will be ducted to only 4 USC-96U furnaces. In the future, when
another gas turbine is installed all other furnaces except the recycle furnaces will have
the capability to be ducted. Presently it has not been finalized as to the type of burners
that will be used for the furnaces which are not presently ducted with the GTE.
Any excess Gas-turbine exhaust for the initial design will be sent to a waste-heat
recovery exchanger before atmospheric discharge.
When the ethane recycle furnace is out of service for decoking or mechanical cleaning,
the ethane recycle can be evenly distributed to three liquid cracking furnaces and co-
cracked with the liquid feeds.

5.1.2 Cracking Severities

In all cases, feedstocks are cracked at severities consistent with reliable and continuous
furnace system operation so as to minimize the requirement of fresh feedstock.
The cracking severities (KSF), or conversion, for the different feeds shall be as follows
for each case:
Base Case Alt Case A Alt Case B
Light Naphtha, KSF-A 3.8 N/A 3.8
Light Algerian Condensate, KSF-A N/A 3.8 N/A
Heavy Algerian Condensate, KSF-A N/A 2.0 N/A
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Ethylene Plant Basis of Design No.: DDP-T-P-03205 Rev.: 00

LPG, (% C4 Conv.) N/A N/A 96.0

Base Case Alt Case A Alt Case B

Recycle Ethane, % Conv. 70.0 70.0 70.0
Recycle C3's, % C4 Conv. N/A N/A 96.0
Recycle C4's, % Conv. 98.0 98.0 98.0
Recycle C5's, KSF-A 3.8 3.8 3.8

5.1.3 Furnace Run Length

The feeds shall be cracked in the furnaces so that with five operating furnaces at
maximum coil loading the continuous average furnace run length shall be 20 days. End
of Run (EOR) shall be defined as furnace with radiant coil tube metal temperature
(TMT) of 1100 °C. Based on a typical 95% furnace availability, with all the six furnaces
operating for nearly 70% of the time, and hence a lower coil loading, the continuous run
length will be in the order of 40 days. Overall, the time between decokes, effective run
length, shall be 35 days. The radiant coils will be specified for 100,000 hours of
operating life with mechanical design temperature of 1125°C.

5.1.4 Dilution Steam Ratio

Dilution steam to hydrocarbon weight ratios for the different feeds shall be as follows:
Light Naphtha 0.6
Light or Heavy Condensate 0.6
LPG 0.5
Recycle C4s & C5s 0.6
Recycle ethane 0.3
Recycle propane 0.5

5.1.5 Miscellaneous Furnaces/Gas Turbine Information

The pressure at the USC-U SLE outlet shall be 0.67 kg/cm2G. In the case of the recycle
furnace the USC-M USX outlet shall be at 0.70 kg/cm2G.
Four of the six liquid cracking furnaces USC-96U will be integrated with a gas-turbine
for this plant. The gas-turbine's exhaust will be routed to the fireboxes of the liquid
crackers as combustion air. This will permit the plant to operate more efficiently and will
allow exporting electrical power to the rest of the complex.
Light Fuel Oil (LFO) and fuel gas generated by the plant will be used as fuel in the
gas-turbine. The ratio of LFO and fuel gas to the gas-turbine will be in the 80:20 to
20:80 LFO:Fuel gas range. The gas turbine will operate on a continuous basis with dual
fuel feed firing. Startup fuel to be LPG. If the fuel generated by the Ethylene Plant is
insufficient, an LPG system for providing the fuel will be used.
The boiler feed water (BFW) inlet temperature to the plant is 147°C.
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Ethylene Plant Basis of Design No.: DDP-T-P-03205 Rev.: 00

Cracking furnace decoking effluent will be routed back to the furnace fire box.

5.2 FEED AND RECOVERY SECTIONS

5.2.1 Feed Treatment

XYZ will install three new tanks in the area 31 for naphtha and raw Algerian Condensate
storage, two new day tanks in area 32 - one for fractionated Light Condensate and the
other one for fractionated Heavy Condensate. All these tanks are in the OSBL area. The
pumps for using the Light Naphtha, raw Algerian Condensate, Light Condensate and
the Heavy Condensate will be located in the ISBL area. Use of wet pit pumps for
pumping the feeds is acceptable to XYZ. The recycle C5s will be recycled to any of
these tanks, except the Heavy Condensate tank.
A mercury removal system shall be installed for treating the Algerian Condensate Feed
at the inlet to the Ethylene Plant.
The treated Algerian Condensate shall be fractionated to separate the Light and the
Heavy Condensate to achieve an overhead product with an ASTM end point (EP) of
about 230°C. The Condensate Fractionator products shall be sent to the day storage
tank.
Facilities to remove arsine and vaporize the LPG to meet the needs defined by the
Alternate Case B feed requirements shall be provided.
LPG feed distribution piping for the furnaces shall be provided so that the LPG can be
cracked in the Liquid furnaces. The LPG stream will replace the naphtha to the USC-
96U furnaces and will be provided as a vapor feed.

5.2.2 Quench Section

The recycle gas furnace effluent shall be used to strip the Heavy Fuel Oil (HFO) in the
Heavy Fuel Oil Stripper (HFOS). When the ethane recycle furnace is off-line, quench oil
stripping in the HFOS will be accomplished using superheated high pressure steam.
LFO feed will be sent to the Light Fuel Oil Stripper (LFOS) for stripping the light gases.
This is required to provide sufficient liquid fuel to the gas-turbine. Please refer to Section
9 for definition of composition and rate.
This plant will have separate LFO and HFO products. The LFO will be used in the
gas-turbine and the HFO with appropriate amounts of LFO (approximately 10:1
HFO:LFO) will be sent off the ISBL plot as product.
DEA shall be used for quench water pH control.

5.2.3 Cracked Gas Compression

A five (5) stage cracked gas compressor is to be used; pressure ratios are selected
based on Shaw’s standard design practices. Drying and air-blowing of the plant will be
done using the cracked gas compressor.

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Ethylene Plant Basis of Design No.: DDP-T-P-03205 Rev.: 00

BFW/condensate injection nozzles are to be provided. Compressor casing shall be

specified with BFW/condensate injection (which shall remain plugged during normal
operation). The material balances shall not include wash oil or water injection.
Spent caustic shall be washed with aromatic gasoline and sent to the spent caustic
oxidation unit for treatment.
The supplemental feeds to the plant shall be treated for contaminant removal.
Anti-fouling chemical injection facilities for the HP/LP Depropanizers will be provided.

5.2.4 Cold Fractionation

Shaw's standard design practices shall be applied for the design of the Advanced
Recovery System (ARS).
Design of the plant hydrogen recovery system will include a PSA Unit to ensure that a
high purity hydrogen stream is available for hydrogenation. The plant shall be self-
sufficient in hydrogen.
For the ethylene and propylene refrigerant and the heat pump compressors, dry gas
seals shall be used.
The ethylene product is produced as a vapor and also as a liquid. The ethylene product
system shall be capable of producing 100% of the product as vapor and up to 30% of
product as liquid. Normal plant operation shall consist of producing 30% of ethylene as
liquid product. The ethylene product run down exchangers to cool the ethylene product
to storage will be designed to handle 50% of the plant capacity. This overcapacity is
only on the heat exchangers, control valves and the lines. It will not impact the ethylene
refrigerant compressor.
5.2.5 Hot Fractionation
The propylene product run down facilities should be designed to send a maximum of
50% of the product to refrigerated storage. Under normal operation 100% of the product
will be sent out as a product.
The C4 Hydrogenation and the Pyrolysis Gasoline Hydrotreating Units (PGH) are
outside Shaw’s PDP scope of work. They are of part of IFP's scope of work, but Shaw is
responsible for integrating these units with the Ethylene plant for P&IDs and other parts
of the Basic Engineering effort. Shaw is responsible for integration and consolidation of
the PDP package portion of the IFP work into the Shaw documents. Shaw will be
responsible for providing the feeds to IFP and incorporating their effluents into the
Ethylene complex.
IFP's C3 Hydrogenation process has been selected to hydrogenate the Methyl
Acetylene and Propadiene, and forms part of Shaw scope of work. The MAPD reactor
shall be a single stage reactor system, as the MAPD slippage will be handled by
propylene purification system, which shall produce a 99.5% pure propylene. For more
information see Basis of Process Design for the C3 Hydrogenation Unit.
The propylene tower bottoms shall be exported as a LPG product from the plant, except
in the case of the Alternate Case B - 50% LPG/50% Light Naphtha, when the propylene
tower bottoms will be recycled to the LPG vaporizer.
For the C4 Complex the processing scheme provided by XYZ shall be used. Please see
Basis of Process Design for the C4 Hydrogenation Unit.
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Ethylene Plant Basis of Design No.: DDP-T-P-03205 Rev.: 00

The scope of work of Shaw in the PGH Unit is to develop P&IDs from the PDP package
provided to Shaw by IFP for the PGH unit. In addition the interaction of this unit for the
overall material balance with the Ethylene plant will be part of Shaw’s scope. Hence, an
understanding of the raw pyrolysis gasoline (RPG) processing scheme is essential.
Please see Basis of Process Design for the PGH Unit.
Shaw’s scope of work is to ensure that the proper streams are interconnected between
the Ethylene unit and incorporate the IFP's PDP package into the P&IDs.

5.2.6 Miscellaneous
6. UTILITIES
Refer to Project Design Data for utilities (steam, BFW, cooling water, machine cooling
water, service water, fire fighting water, drinking water, instrument air, service air, inert
gas, and electricity). PROCESS WILL NOT INCLUDE UTILITY DATA. PROJECT
MUST PREPARE UTILITY DATA.

7. EFFLUENTS (TYPICAL)
Normally, a separate Environmental Basis of Design will be issued for each project
and/or Project Design Data will contain environmental information. If a separate
Environmental Basis of Design is not prepared, then this section may be included in the
Process Basis of Design.

Table 7.1-1 describes the organic liquid effluents.

TABLE 7.1-1 REQUIRED ORGANIC LIQUID EFFLUENT SPECIFICATION

PARAMETERS LIMITS

pH 6 - 10
Temperature up to 50oC

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Ethylene Plant Basis of Design No.: DDP-T-P-03205 Rev.: 00

TABLE 7.1-1 (CONT.) REQUIRED ORGANIC LIQUID EFFLUENT SPECIFICATION

PARAMETERS STANDARD OF DAILY CONCENTRATION

LOAD STANDARD

TSS 260 kg 100 mg/l

TDS 2600 kg 1000 mg/l

TOC XYZ to provide 340 mg/l

COD 2400 kg 900 mg/l

BOD XYZ to provide 220 mg/l

OG - 60 mg/l

Phenols - 50 mg/l

Chlorides 100 kg 100 mg/l

Cyanides 25 mg 0.05 mg/l

NH3-N 30 kg 30 mg/l

NO3-N 1.0 kg 1.0 mg/l

TKN 150 kg 90 mg/l

Phosphorus 10 kg 10 mg/l

Sulfate 1000 kg 1500 mg/l

Sulfide - 5.0 mg/l

Ag 42 g 0.05 mg/l

Al 3.2 kg 5.0 mg/l

As - 0.50 mg/l

Ba - 5.0 mg/l

Cd 34 g 0.05 mg/l

Cr Total 130 mg 0.20 mg/l

Cu 90 g 0.20 mg/l

Fe 12 kg 7.0 mg/l

Hg 1.3 g 1.0 mg/l

Mn 400 g 0.50 mg/l

Ni 180 g 0.10 mg/l

Pb 420 g 0.20 mg/l

Se - 0.05 mg/l

Ti 1.3 kg 0.50 mg/l

Zn 1.7 kg 1.0 mg/l

V - 1.0 mg/l

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Ethylene Plant Basis of Design No.: DDP-T-P-03205 Rev.: 00

B - 5.0 mg/l

Sn - 4.0 mg/l

Fluoride - 10 mg/l

Floating solids - nil

8. BATTERY LIMIT CONDITIONS (TYPICAL)

Table 8.1.-1 shows the BATTERY LIMIT conditions for the feeds.

TABLE 8.1-1 NORMAL CONDITIONS AT BATTERY LIMITS OF FEEDS

2
FEED SCOPE TEMP. (C) PRESSURE (KG/CM G) STATE
RESPONS.

Light Naphtha Shaw 38 0.176 Liquid

Algerian Condensate Shaw 38 5.3 Liquid

LPG Shaw 38 15.0 Liquid

Ethylene from Polyethylene Plant Shaw 38 13.0 Liquid

Recycle C5's from PGH Shaw 38 Based on recycle going Liquid

to storage tanks

Table 8.1.-2 shows the BATTERY LIMIT conditions for the products.

TABLE 8.1-2 NORMAL CONDITIONS AT BATTERY LIMITS OF PRODUCTS

PRODUCT SCOPE TEMP (°C) PRESSURE STATE
2
RESPONSIBLE (KG/CM G)

Hydrogen Shaw 36 29.5 Vapor

Ethylene Shaw
To Storage -97 18.5 Liquid
To Complex 38 42.5 Vapor

Propylene Shaw
To Storage 12.5 24.1 Liquid
To Complex 38 32.0 Liquid

Propane Shaw 38 18.5 Liquid

Butene-1 Shaw 38 6.0 Liquid

C4 Cut IFP 44 6.0 Liquid

C5 Cut IFP 38 5.0 Liquid

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Ethylene Plant Basis of Design No.: DDP-T-P-03205 Rev.: 00

C6 Cut IFP 38 5.0 Liquid

C7-C8 Cut IFP 38 5.0 Liquid

C9-220 IFP 38 5.0 Liquid

C10+ IFP 38 5.0 Liquid

Fuel Oil Product Shaw 90 5.0 Liquid

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