Ras Lanuf Complex - Phase II LSTK-1 - PETROCHEMICAL PLANT Part 2 - Technical Proposal Page 6 - 1 SECTION 6 6.2 6.3 6.4 6.5 UNIT 2290 - BENZENE INTRODUCTION AND DESIGN BASIS 6.1.1 Introduction 6.1.2 Design Basis PROCESS DESCRIPTION 6.2.1 Process Features 6.2.2 Unit Description 6.2.3 Process Controls 6.2.4 Safety Considerations 6.2.5 Material Balance SPECIFICATIONS OR RAW, AUXILIARY MATERIALS AND UTILITIES 6.3.1 Raw Materials Specifications 6.3.2 Chemicals Specifications 6.3.3 Utilities Specifications EXPECTED UNIT PERFORMANCES 6.4.1 Production Capacity 6.4.2 Product Characteristics 6.4.3 Expected Consumptions and Recoveries 6.4.4 Chemicals and Auxiliary Material Requirements 6.4.5 Alternative Specification Case aRas Lanuf Complex - Phase II LSTK-1 - PETROCHEMICAL PLANT Part 2 - Technical Proposal Page 6 - 2 6.6 6.7 6.8 6.9 6.10 OTHER INFORMATION 6.6.1 Data on Releases to Flare System 6.6.2 Recommendations for Products Storage and Handling 6.6.3 Health Considerations EQUIPMENT LIST 6.7.1 General 6.7.2 Equipment List EQUIPMENT CHARACTERISTICS 6.8.1 General 6.8.2 Process Data Sheets LIST OF CRITICAL ITENSRas Lanuf Complex - Phase II LSTK-1 - PETROCHEMICAL PLANT Part 2 - Technical Proposal Page 6 - 3 6.1 6.1.1 INTRODUCTION AND DESIGN BASIS Introduction The FORMEX Process covers the extraction and purification of aromatics from feedstocks of different origins such as Reformed Gasoline and Hydrogenated Py-Gasoline in the Cp-Cy cuts by using an aqueous solution of Foraylmorpholine as a solvent. In this specific case, as the only aromatic product to be produced is Benzene, the Py-Gasoline is fractionated into a Light cut containing the Benzene and light non aromatic hydrocarbons and a heavy cut containing Toluene and Xylenes. The Benzene is separated from the non-aromatics hydrocarbons in the presence of the solvent in an extractive column. The rich solvent, containing the benzene, is then sent to a stripper, where the lean solvent is recovered as bottom product and recycled back to the extractive column. The benzene is recovered as extract from the top of the stripper. The extract and Raffinate are finally washed to eliminate possible Formylmorpholine or Morpholine traces -Ras Lanuf Complex - Phase IT LSTK-1 - PETROCHEMICAL PLANT Part 2 - Technical Proposal Page 6 - 4 6.1.2 Design Basis The Unit has been designed on the basis of 8,000 full operating hours per year to produce 88,000 t/year of Benzene having the specifications listed under following para. 6.4.2.1. The feedstock shall be as specified in following para. 6.3.1.1. ‘The Unit has been designed to allow the operation in the range from 40 to 110 percent of design flow rate indicated at para. 6.4.3.1. The Unit shall be able to accomodate moderate variations on the composition of the feedstock of the expense of the production rate but not at the expense of the product quality. However, in case the actual feedstock shall be not in accordance to the feed specification, stated in para, 6.3.1.1, the CONTRACTOR reserve the right to review the process guarantees Pa( ( Ras Lanuf Complex - Phase II LSTK-1 - PETROCHEMICAL PLANT Part 2 - Technical Proposal Page 6 - 5 6.2 PROCESS DESCRIPTION 6.2.1 Process Features ‘The FORMEX, Aromatics Extraction Process, is based on the use of a solvent (N-formylmorpholine) which displays excellent solvent power and selectivity. This process has proved to be very suitable for the separation of the aromatics from hydrocarbon mixtures. One additional feature of the Formylmorpholine is a quite good thermal stability; furthermore, it is not corrosive, thus enabling the use of carbon steel as material for the equipment. 6.2.2 Unit Description (Reference is made to Process Flow Diagram DWG GD-12E-04506-0) ‘The Benzene Unit includes the following sections: 6.2.2.1 Splitter Section The charge, consisting of a C,-Cg hydrogenated fraction, coming from the Battery Limits, is stored in the feed surge drum, V-18. Hence it is pumped by feed pump P-19 A/S, under flow control, to exchangers X-01/X-04, where it gets preheated exchanging respectively with T-01 bottom product and the solvent coming from the stripper vmRas Lanuf Complex - Phase IT LSTK~1 - PETROCHEMICAL PLANT Part 2 - Technical Proposal Page 6 - 6 The T-O1 feed temperature is controlled acting on x-O4 by-pass, solvent side. Feed splitter column T-01 is fed at tray No. 24 or, alternatively, at tray No. 18 or 30. ‘The separation between the Benzene and heavier aromatics contained in the charge takes place within column T-01, thus producing a top stream mainly consisting of Benzene and light non aromatic hydrocarbons and a bottom stream containing Toluene, Xylenes and heavy non aromatic hydrocarbons. The Bottom stream, under level control, is cooled off by exchanging heat with the feedstock in X-O1 and with cooling water in X-02 then, it is send to Battery Limits. The splitter, column is provided with a recirculating reboiler, X-05. Medium pressure steam is used as a heating medium, the quantity of steam is controlled by the reboiler return temperature which acts in cascade on the flow rate controller. ‘The T-01 overhead vapours are condensed and subcooled in air cooler X-03. The condensate is sent to splitter overhead accumulator V-01. A pressure controller is installed on V-Ol, acting in split range, to discharge excess vapour to flare or to request nitrogen as blanket gas The hydrocarbons from V-01 are sent, by splitter reflux pumps P-02 A/S, partly as reflux to column T-01 controlled by the overhead column temperature gradient which acts in cascade on the flowrate controller, partly as feedstock to the extractive distillation section. The flow controller set point is automatically adjusted by V-01 level controller. 4Ras Lanuf Complex - Phase II LSTK-1 - PETROCHEMICAL PLANT Part 2 - Technical Proposal Page 6 - 7 6.2.2.2 Extractive Distillation Section The feedstock to the extractive distillation section is preheated by the solvent in X-06. A temperature controller, acting on the by-pass, solvent side, maintains the stream near its boiling point. ‘The stream enters extractive distillation colum T-02 at tray No. 15. In this column the hydrocarbons get into contact with the solvent, fed onto tray No. 33, which extracts the Benzene as bottom product. ‘The temperature of the solvent is controlled by a dedicated instrument acting on fan pitch of solvent aircooler X-07. The overhead vapours, consisting of Paraffinic hydrocarbons, water and traces of solvent, are condensed and subcooled in air cooler X-08. ‘The condensate is collected in overhead accumulator V-02 where the two phases separate: the aqueous phase is withdrawn by reflux pumps P-04 A/S, and returns to the tower under interphase level control to minimize the solvent entrained in the overhead vapours. The light phase is withdrawn by raffinate pump P-05 A/S, cooled off in cooler X-09 and then sent to raffinate washing tower T-O4. A pressure control is provided on V-02, acting in split range, requests nitrogen to blanket the tower or discharges excess vapour to sump tank V-06, where solvent droplets, possibly entrained, are collected. Column T-02 is provided with a once-through reboiler, X-10. 4Ras Lanuf Complex - Phase II LSTK-1 - PETROCHEMICAL PLANT Part 2 - Technical Proposal Page 6 - 8 6.2.2.3 2 Medium pressure steam, depressurized to 9 kg/cn’g and desuperheated, is used as a heating medium, the quantity of steam is controlled by the reboiler return temperature which acts in cascade on the flow rate controller. Benzene Stripping Section ‘The extractive distillation bottom product, mainly consisting of solvent and Benzene, is withdrawn by bottoms pumps P-03 A/S and fed to tray No. 20 of stripper column T-03. ‘The section of the tower above the feeding point has the task to remove the solvent from the hydrocarbons using an aqueous flow, whereas in the section below the feeding point the solvent is stripped. ‘The overhead vapours, consisting of water, Benzene and traces of solvent, are condensed and subcooled in air cooler X-11. A pressure control provided on V-03, acting in split range, requests nitrogen to blanket the tower or discharges excess vapour to sump tank V-06 where solvent droplets are collected. The OVHD Condensate is collected in overhead accumulator V-03, where the two phases separate. The aqueous phase is refluxed into the tower by pumps P-07 A/S under V-03 interface level control which acts in cascade on a flow controller. The organic phase, consisting of the extracted Benzene, is sent to air cooler X-12 and subsequently to the washing tower 7-05 by pumps P-08 A/S. ‘The bottom stripper temperature is maintained at the value necessary to obtain an almost complete Benzene stripping. 3Ras Lanuf Complex - Phase IT LSTK-1 - PETROCHEMICAL PLANT Part 2 - Technical Proposal Page 6 - 9 6.2.2.4 ‘The temperature must be carefully controlled, avoiding values beyond which solvent decomposition would set in, along with corrosion phenomena. To this purpose, a temperature controller is provided, which acts in cascade on the vapour flowrate to reboiler X-13, once-through type. ‘The solvent is withdrawn from the stripper bottom by pumps P-06 A/S and routed, under level control in cascade on a flow controller, to exchangers X-O4 and X-06, where it exchanges heat with the T-01 and T-02 charges respectively, gets further cooled under temperature control in air cooler X-07 and is finally fed to tray No. 33 of Extractive Distillation Column T-02. Extract and Raffinate Washing Section ‘The raffinate is countercurrent water-washed in tower T-Ol in order to get rid of the residue Morpholine traces and subsequently is sent to Battery Limits. Part of the washing water is sent to the solvent circuit to maintain the current solvent/water ratio; part is drained into the oily sewer under T-O4 interface level control. ‘The Benzene is washed with water in countercurrent inside tower 1-05 for residual Morpholine traces removal and subsequently is sent to clay treatment under V-03 hydrocarbon level com PRas Lanuf Complex - Phase II LSTK-1 - PETROCHEMICAL PLANT Part 2 - Technical Proposal Page 6 - 10 6.2.2.5 Clay Treatment and Storage Aim of this section is to clean up the Benzene to meet the restrictive product specifications. Benzene coming from T-05 is sent to X-20 A/B, where it is pre-heated by Clay Treatment effluent and through X-21 where it is heated by Medium Pressure Steam, The hot feed passes down through Clay towers T-06 A/B. Normally only one clay is used, but provision is made to run both towers in series or parallel operation. After the Clay tower the effluent is cooled by exchange with the cold feed and finally in the X-22 water cooler. The Benzene Product is continuously analyzed by a chromatograph; if the Benzene stream does not meet the specifications, it is recycled to the Unit. From $-01 and S-02 the Benzene is withdrawn by pump P-17 A/S and conveyed to the Unit Battery Limits. Benzene to storage pumps are designed to empty the daily tank (24 hours’ production) in 8 hours. ‘The Off-Spec Benzene may be sent, by the same pumps P-17 A/S, to the following points of the Unit: - feed surge drum V-18 if it is Off-Spec because of excess Toluene - as feedstock to T-02, if it is Off-Spec for excess non Aromatic Hydrocarbons. -Ras Lanuf Complex - Phase II LSTK-1 - PETROCHEMICAL PLANT Part 2 - Technical Proposal Page 6 - 11 6.2.2.6 Solvent Filtration and Regeneration Provision is made to withdraw from the discharge of the stripper bottoms pumps P-06 A/S a portion of solvent which is sent to solvent filter F-Ol A/S after cooling in X-14. Filters eliminate the possibly entrained solid particles from the solvent. A high differential pressure alarm indicates that the filter in operation is plugged. The cooled solvent is recycled back to the bottom of the T-03 as a quench to minimize thermal degradation of the solvent itself. Morpholine and Formic Acid are present in the solvent in equilibrium with Formylmorpholine. If the quantities present to the equilibrium decrease either because the Formic Acid decomposes due to the temperature effect, or for Morpholine losses with Raffinate and Extract a further Formylmorpholine decomposition takes place. ‘The quantities of free Morpholine/Formic Acid are, therefore, to be kept under control by adding Formic Acid/Morpholine whichever necessary. To this purpose, from pumps P-06 A/S delivery a slim portion of solvent is withdrawn which is mixed with a proper dose of Formic Acid/Morpholine withdrawn from Formic Acid/Morpholine drum V-05 by pump P-10; this stream is then sent to solvent correction vessel V-10 dimensioned with the residence time necessary to reach the equilibrium between Formic Acid/Morpholine and Formylmorpholine. Provision is made for the treated solvent to flow back upstream of cooler X-07. This discontinuous operation is fRas Lanuf Complex - Phase II LSTK-1 - PETROCHEMICAL PLANT Part 2 - Technical Proposal Page 6 - 12 carried out every time the content of free Norpholine/Formic Acid in the solvent shows a tendency to increase. As an alternative, a slip stream of solvent may be sent to preheater X-17 and then to regenerator V-07 where is evaporated under vacuum. Vapours are condensed in water condenser X-16 and the regenerated solvent, withdrawn by pump P-13, is sent to storage tank S-03 under level control of an accumulator boot of X-16. This operation, carried out periodically, allows the elimination of polymers formed due to the temperature effect; these polymers are drained from the bottom of regenerator v-o7. ‘The Unit filling and make-up operations are carried out flowing the solvent from tank S-03 to sump tank V-06; hence the solvent is sent upstream of cooler X-07 via vertical pump P-09. ‘The filling of the solvent storage tank is performed by P-09, which takes suction of the solvent from V-06 through a( Ras Lanuf Complex - Phase II LSTK-1 - PETROCHEMICAL PLANT Part 2 - Technical Proposal Page 6 - 13 6.2.2.7 Drainage Recovery System Provision has been made for two separate drainage recovery systems. One collects the drainage from column T-01 and dedicated equipment, along with the drainage of storage tanks S-Ol and S-02. ‘These drainages, consisting of hydrocarbons which have not yet got into contact with the solvent, are collected and conveyed to Py-Gasoline sump tank V-11, which receives also the vents of the same pieces of equipment. ‘The liquid phase separated in V-11 is sent to feed surge drum V-18 for treatment by vertical pump P-14. Vapours are sent to flare. The second system collects the drainage of the remainder Unit equipment (S-03 included) which contains, or may contain, solvent. Drainages of this second system are collected and sent to sump tank V-06, which also receives the vents from the sane equipment and the blanketing system balancing line header. The liquid phase separated in V-06 is conveyed upstream of X-07 for treatment or, alternatively, to tank S-03, by pump P-09 activated by high level within V-06. Due to the possible presence for Formylmorpholine which has a quite high freezing point, provision has been made for a heating coil in V-06. xRas Lanuf Complex - Phase II LSTK-1 - PETROCHEMICAL PLANT Part 2 - Technical Proposal Page 6 - 14 6.2.2.8 Steam and Condensate Recovery System Medium pressure stean is used to reboil splitter coluan 7-01. To minimize solvent corrosion and decomposition phenomena, columns T-02 and T-03 are reboiled with steam pressured down tod kg/en?g and desuperheated. ‘The mean pressure steam condensate coming from X-05 and those from X-10, X-13 and X-16/X-17, when in use, and X-21, are collected into medium condensate flash drum Y-12, where they expand to 4.5/5.8 kg/en”. The produced steam is routed to the ow pressure steam system. The condensate is fed, under level control, to low condensate flash drum V-13, which also receives the condensates from the low pressure steam users. The steam liberated in V-13 is condensed in air condenser X-18 and the condensate flows back into V-13. Provision is made for a pressure controller in V-13, which overflows steam to the atmosphere. The recovered condensate is withdrawn by pump P-20 and partially recycled back to the MP Stean desuperheater W-01. the remainder is cooled in X-19 and sent to B.L. The recovered condensate is analyzed on a continuous basis downstream of P-20 and, should it shows hydrocarbon presence, is drained to the oily sewer after cooling off in water cooler X-19. Interception of the condensate line to the steam generation system and the opening of the valve on the draining line to oily sewer are rouRas Lanuf Complex - Phase II LSTK-1 - PETROCHEMICAL PLANT Part 2 - Technical Proposal Page 6 - 15 6.2.3 6.2.3.1 Process Controls ‘The Unit has been provided with the normal controls over the operating variables in order to maintain the unit itself as close as possible to the design parameters and to check the main performances of the unit. ‘As On-Line gas-chromatograph has been provided to check the purity of the Benzene to Storage and its content of toluene and other non-Aromatics Hydrocarbons ‘The process controls of the unit are shown in detail in the Process Flow Diagram and in the Piping and Instrument Diagrams (see following para. 6.10.). Supervised Variables For the Splitter Section beside the normal controls, the unit has been provided with additional instrumentation to realize a Feed-Forward control. ‘The main facility is the On-Line gas-chromatographic Analysis of the feedstock. ‘The Combination of the normal controls along with the Feed- Forward Controls can be considered a low level Advanced Control System (A.C.S.). Such a system is to be realized with minimum impact either on the cost or on the reliability of D.C.S Scope of the A.C.S. is to maintain the product quality and benzene recovery targets in the following cases: - Sudden changes in the Feedstock, either in Composition or Flow rate. - Changes in the temperature profile of the cum 2DRas Lanuf Complex - Phase II LSTK-1 - PETROCHEMICAL PLANT Part 2 - Technical Proposal Page 6 - 16 6.2.4 6.2.5 Safety Considerations ‘The Unit has been designed with the utmost care as far as safety is concerned. Particularly: - continuous process gaseous discharges are conveyed to the blow-down system; - discontinuous drainages and vents (see maintenance, etc.) are routed to two closed drain systems which are, in turn, connected to blow-down by a header; - prevision is made for the installation of 30 gas detectors to detect release or accumulation of toxic and flammable gases; Material Balance ‘The enclosed Table 6.2.5.1 shows the overall material balance of the Benzene Unit. As to the number of streams see PFD e-ecues-e.CMRP ASCO- SPLAT | 213/64 | 2250 _ Snamprogetti "ang AUF COMPLEX PHASE TE SPCNo.Tabée 6.2.5.4. PROJECT/UNIT Rev Page 6-17 | Ur 2290 -BENZENE — |wA a2. TTT HEAT AND MATERIAL BALANCE TABLE Ret. PFO No: STREAM No 4 2 3 4 6 € B NAME ‘COMPONENT WATER = ca - = lau = [4uz | FORTY -MORPHOLINE - = - - 78375| - 78375 BENZENE OFS | W053 | 22 53 |Il008 | 1000| 8 OTHER aRoraTics |¢60ss| 0-6 |eos44| - | O6 | a6 | = How AROrIATIES HC| 10557 |3937-4|6619-6| 3926 | 11-4 | 1-4 = Tosa Liquid Mass Fow -ta/h | 2?6Q7| 14991 | 12696 | 397.9 [93512 | 11012 | 82500 [rompers Pe 35| 90 | 40 | 6s |i27 | ¢5 [iss Pressure “Kgdnig| 5-7 [0-76 | 7-0 | 0-2 | 0-9 | 0-2 |o- 3 | Standardtig. Density ko/ni = = = ici Lia DDE, shai? | 834 | 759 | 845 | 67/ | 1005 | 835 |1023 Vapor MW ‘Vapor compressibiliy factor = = = = 4 a | 7 | ae ea [27-07-93] new Deserpion Prepared | Checked | Approved | ate Sa om coge: OAT PT BMT 0001 ShOv/Rev O92 Fie code BLNODEVOAT ‘Tus doruents ne property a! Shamprogetiwho wil slegutra a ng accorang oe ew! and pena provision of hea.738 UTS Snamprogett 213164 | 2230 Page 6 - 18 SPC No. Tabée 6.2.5.4 242 sr B, ot HEAT AND MATERIAL BALANCE TABLE — Ret. PFD No ‘STREAM No 8 9 NAME ‘COMPONENT WATER - [- FORMyL-HORPHOLINE | = = i | BENZENE hooo| 53 1 OTHER AROrmTIES | 0-6 | — now ARormaTics He | 11-4 | 3926 Total Liquid Mass Flow -ka/h Temperature “Cc Pressure “Kylatg| 0-0 | 7-0 Siandard.iq, Density -kg/mt | — = a Actuallig.Densty _—-kg/m™ | BGO _| 680 Vapor Mii = = ‘Vapor compressibility factor SOTTO oor ——a— oa Fam came OAT TeMTOODT S/R Tin cots UNOOEZOAT cure ‘J Rrloocoment sth propery ol Snamproget. wo wil slaquara ts rght according oe ctl and penal provson of ne tw