Engineers India Limited

KNOWLEDGE SHARING SESSION ON P-25 PROJECT, PANIPAT & RHCU

15-Feb-2020

1
 PROJECTED GROWTH OF REFINED PRODUCTS
 Total global demand for refined products in 2030 is projected to be 42 percent above
2010 levels
 Global diesel/gas oil demand is forecast to grow 2.2%/year, increasing to over 13 MMBPD by 2030
 Asia will have the strongest growth (3.1%/year)

 Global gasoline demand is forecast to grow at an average rate of 1.3%/year, increasing to over 6
MMBPD by 2030
 Global residual fuel oil demand is forecast to grow by less than 1 MMBPD or 0.5%/year.

FEBRUARY 15, 2020 2

 FACTORS FAVOURING CAPACITY EXPANSION AT PANIPAT REFINERY

 Panipat refinery is strategically located to cater to the increasing demands of Northern India as compared to

meeting the demands by sourcing the products from Western Part.

 Adequate Land Availability for facilitating smooth execution of expansion project.

 Wide network of Pipeline connectivity catering to large area and adequate marketing terminal facilities

available for evacuation of products at minimal cost.

 Reliable availability of other associated infrastructure like water and power.

FEBRUARY 15, 2020 3

 PROJECT DETAILS & BRIEF SCOPE

 PROJECT : EXPANSION OF PANIPAT REFINERY FROM 15MMTPA TO 25MMTPA

(P-25 PROJECT)
 CLIENT : INDIAN OIL CORPORATION LIMITED (IOCL)
 TENDER : Consultancy for Overall Project management and EPCM services for
Capacity Expansion of Panipat Refinery from 15-MMTPA to 25-MMTPA
(Phase-1 FEL-2 Stage)
 DURATION and FEE:
PHASE OF PROJECT DURATION BRIEF SCOPE EIL FEE
(Rs.)
Phase -1, FEL-2 stage 6-Months +/- 20% Cost Estimate 30.72 Cr.

Phase -1, FEL-3 stage 6-Months +/- 10% Cost Estimate and DFR 27.27 Cr.

Phase -2 40 Months (MC)+ 3 Months Project Execution including 617 Cr.

Commissioning)+4 Months (Closure) Commissioning and Closure

FEL-FRONT END LOADING

FEBRUARY 15, 2020 4

 BRIEF ON FRONT END LOADING

 Front-end loading (FEL), also referred to as pre-project planning (PPP), feasibility analysis, conceptual

planning, programming/schematic design and early project planning, is the process for conceptual
development of projects in processing industries such as upstream oil and gas, petrochemical, natural
gas refining.
 It is common industry practice to divide front-end-loading activities into three stages: FEL-1, FEL-2, and
FEL-3. For each stage, typical deliverables are listed given below :

FEL-1 FEL-2 FEL-3

Material balance Preliminary equipment design Purchase-ready major equipment specifications

Energy balance Preliminary layout Definitive estimate (+/- 10%)

Project charter Preliminary schedule Project execution plan
Preliminary estimate (+/- 20%) Preliminary 3-D model
Line List

FEBRUARY 15, 2020 5

 PROJECT EXECUTION METHODOLOGY

 The total project is being executed in HYBRID MODE i.e. LSTK and Conventional mode.
 No. of LSTK/EPCM packages shall be finalised during DFR Stage.
 Few Units may also be clubbed together as Single LSTK Package

 EIL is OVERALL PMC for the project for PHASE-I and PHASE-II Activities. After DFR approval
EPCM Activities shall be divided among 3 EPCM consultants.

 The overall PMC i.e. EIL shall be responsible for EPCM-1 Activities and shall provide assistance in
lining of EPCM-2 and EPCM-3 consultants for the balance Units not covered under EPCM-1
 B269-999-81-41-00001 REV J.pdf

 OVERALL PLOT PLAN_PNCP Rev C.pdf

FEBRUARY 15, 2020 6

 PROJECT EXECUTION METHODOLOGY

Interface Management
PMC
OVERALL

EPCM-2 EPCM-3
EPCM-1 LSTK/LEPC

FEBRUARY 15, 2020 7

 BROAD EIL SCOPE OF WORK

INTERFACE INTERFACE
EPCM 1 for Open Art
PMC for LSTK/LEPC units MANAGEMENT for EPCM MANAGEMENT for EPCM
Units & Licensed Unit
2 3

Atmospheric Vacuum
VGO Hydro Treater Unit SR LPG Treater Unit Polypropylene Unit
Distillation Unit (AVU)
(PPU)
Sour Water Stripper
Unit INDMAX
Diesel Hydro Treater
Unit Alkylation Unit (including
Naphtha Hydro Treater n-Butane isomerization
Amine Recovery Unit
Unit Unit) & Sulphuric Acid
Regeneration Unit
Propylene Recovery RHCU Catalytic Cracking Unit
Unit (PRU) (CCRU)

Sulphur Recovery Unit – Hydrogen Generation Isomerization Unit CDW Unit/LOBS

Licensed Unit (SRU) Unit (LEPC) (ISOM)

FEBRUARY 15, 2020 8

 UNIT DETAILS
UNITS IN EPCM-1
UNIT MODE OF EXECUTION CAPACITY LICENSOR
AVU EPCM-1 10 MMTPA EIL
SWS EPCM-1 344+330 TPH (2 Trains) EIL
ARU EPCM-1 1350 TPH EIL
SRU EPCM-1 2 X 465 TPD Comprimo (JACOBS)
PRU EPCM-1 1.15 MMTPA EIL

UNITS IN EPCM-2
UNIT MODE OF EXECUTION CAPACITY LICENSOR
INDMAX (FCCU) EPCM-2 2.5 MMTPA LUMMUS IOCL
NHT EPCM-2 0.83 MMTPA UOP HONEYWELL
CCR EPCM-2 0.624 MMTPA UOP HONEYWELL
ISOM EPCM-2 0.201 MMTPA UOP HONEYWELL
SR LPG TREATER EPCM-2 0.108 MMTPA IOCL R&D

FEBRUARY 15, 2020 9

 UNIT DETAILS
UNITS IN EPCM-3
UNIT MODE OF EXECUTION CAPACITY LICENSOR

PPU EPCM-3 0.45 MMTPA Lyondell Basell

ALKYLATION EPCM-3 670 TMTPA Under Finalization

SARU (Sulphuric Acid Regeneration Unit) 185 MTPD MECS
CDW/LOBS EPCM-3 0.56 MMTPA CLG

UNITS IN LSTK / LEPC

UNIT MODE OF EXECUTION CAPACITY LICENSOR
VGO-HDT LSTK 3.6 MMTPA UOP HONEYWELL
RHCU LSTK 3.3 MMTPA AXENS
DHDT LSTK 5 MMTPA SHELL
HGU LEPC 84 KTPA LEPC

FEBRUARY 15, 2020 1

0
 UTILITIES IN P-25

Cooling water Raw water Instrument Air / Plant Air Nitrogen

(60,000 M3/hr) (3,000 M3/hr) (26,200 NM3/HR) (7600 NM3/HR)
UTILITIES

Steam- VHP Steam –HP Power Condensate Polishing

(300 TPH) (160 TPH) (75 MW) (205 TPH)

New Hydrocarbon Flare

New Acid Flare system New integrated ETP New LPG Mounded Bullet
system
(16’’) (500 M3/HR) (01 No)
(56’’)

New MS Tank New HSD Tank New Naphtha Tank Propylene Bullets
(03 Nos) (01 No) (01 No) (072020
FEBRUARY 15, Nos) 1
1
 FEL-2 - SCOPE OF WORK

 Overall Project Management

 BDEP Preparation for OPEN ART Units.

 Finalization of design basis for all units and offsite facilities.

 Participation with Owner during BDEP preparation by Licensor right from KOM, PFD & P&ID

Review, finalization of equipment datasheets, finalization of plot plan etc.

 Finalization of Engineering Design Basis for all disciplines and offsite facilities.

 Finalization of project procedures, coordination plan, execution plan, schedule, construction

philosophy.
 Preparation of overall plot plan and indicative equipment layout based on Licensor’s input and

statutory norms (OISD, PESO)

FEBRUARY 15, 2020 12

 FEL-2 - SCOPE OF WORK

 Ensuring Completeness of Process Packages by Licensor.

 Planning & Control including development of Work Breakdown Structure.

 Tendering, Award and Lining of agencies for Soil Investigation, Topographical Survey, ODC

Route feasibility survey, Site Enabling works, development of construction power, benchmarking
of project.
 Review of Site data and reports.

 Finalization of MASTER VENDOR LIST

 Finalization of HSE Policy and CONTRACTING & PURCHASE PROCEDURE

 +/- 20% Cost Estimate and assistance to IOCL for getting approvals

 Conduct HAZID (Hazard Identification) and PHSSER ( Project HSSE Review Study)

FEBRUARY 15, 2020 13

 FEL-3 - SCOPE OF WORK

 Bid Document preparation for EPCM-2 & EPCM-3 Packages

 Tendering, Evaluation and Award recommendation for

I. All Units under LSTK mode of execution

II. LLI’s ( all disciplines i.e. Mechanical, Electrical, Instrumentation with delivery period more than
18 months)
III. Works Packages / contracts
 Preparation of +/- 10% cost estimate for total project.
 Assistance for DFR approval from IOCL Board
 Site survey for integration & finalization of Tie-ins of existing facilities with new facilities.
 FEED Preparation for the project
 Adequacy check for existing facilities
FEBRUARY 15, 2020 14
 FEL-3 - SCOPE OF WORK

 Preparation of DFR
 Carry out Residual Process Design & Engineering and development of FEED Packages based
on packages issued by Licensor
 Facilitate Project and statutory approvals
 Development of Project Constructability Plan
 Assistance to IOCL for EIA/RRA Studies for Environmental Clearance.
 Develop Risk Mitigation Plan, Risk Review .
 Develop Project Quality Assurance Plan.
 List of Hazardous Chemicals, catalyst, effluents etc.
 Hazid, Hazop & SIL Studies
 Overall Master Schedule Preparation
FEBRUARY 15, 2020 15
 FEL-3 - SCOPE OF WORK

 Develop QA/QC Plan and project procedures

 Finalization of equipment layouts for OPEN ART UNITS.
 Submission of Finalized PLOT PLAN for PESO APPROVAL.

FEBRUARY 15, 2020 16

 Phase-II - SCOPE OF WORK as OVERALL PMC

 Overall Project Management

 PMC for LSTK/LEPC Units
 To coordinate with EPCM-2 and EPCM-3 for finalization of all battery limit interface and utilities
for EPCM-2 and EPCM-3 units
 Conducting weekly coordination meeting with EPCM-2 and EPCM-3
 To plan, initiate, coordinate and control the entire project implementation activities
 Procurement of commonly shared utilities, equipment’s , substation’s equipment’s, centralised
control room facilities (DCS, PLC, PA, CCTV, UPS, Battery charger, clean agent etc.)
 Guiding IOCL on key matters to ensure project is completed within time, cost and quality
targets.

FEBRUARY 15, 2020 17

 Phase-II - SCOPE OF WORK as EPCM-1

 Residual Engineering for all project facilities under EPCM-1 Package (AVU, PRU, SWS,
ARU,SRU and Offsite & Utilities)
 Detail Design Engineering & drawing, issue of AFC drawings, datasheets to EPCM work Package
Contractors. 3-D modelling of the units including U&O.
 Review of project schedules, Project Procedures and project execution plan
 Procurement and Expediting Services
 Expediting the deliveries of LLI’s. (These LLI’s shall be issued as FIM to EPCM-1,2 and 3 and
LSTK & LEPC contractors)
 Tendering of balance materials/ service contracts
 Construction Management including supervision and assistance in commissioning & pre-
commissioning

FEBRUARY 15, 2020 18

 Residue HydroCracker Unit (RHCU)

Indian Oil Corporation Limited (IOCL) is considering a new Resid Hydrocracker Unit (RHCU) of
2.5 MMTPA (based on 8000 hours of operation) with the following design cases:
Design Case 1 – Mainly middle eastern crude derived VR (Vacuum Residue) at 75 wt %
conversion (net)
Design Case 2 –72 wt % conversion (net) of feed blend consisting of 76 vol% Design Case 1 feed
with the balance consisting of West African crude derived VR

RHCU comprises of the following FOUR Sections:

 RHCU Reaction Section

 RHCU Fractionation Section

 RHCU Gas Plant Section

 RHCU Catalyst Handling Section

FEBRUARY 15, 2020 19

 RHCU FEED
FEEDSTOCK TEMPERATURE at Battery Limit (in PRESSURE at Battery Limit
Degree C) (in Kg/cm2 g)
Vacuum Residue (VR) from AVU-3 200 5
Vacuum Residue from Storage 150 5
CLO from RFCC Unit 07 80 5
CLO from Indmax 80-200 5

UTILITIES REQUIRED
Hydrogen make up
Fresh Caustic from TPS
Lean amine from new ARU
Stripped Sour Water from SWS
Start-up Naphtha from Storage
Start-up Diesel from Storage
Start-up/Emergency VGO from Storage

FEBRUARY 15, 2020 20

BLOCK DIAGRAM- REFINERY

12/19/2020 2
1
RHCU : Standard Flow Scheme

Make-Up HP Fuel
2nd 3rd Membrane PSA Gas
H2 1st
Stage Stage Stage

HP Amine
HP Air
Absorber
Cooler
Inter Stage
Separator HP-HT
Separator
HP-LT
Heater Separator

MP Air MP Amine
Absorber
Cooler

Spent
MP-LT
Catalyst
MP-HT Separator
Separator
Sour Gas
Atmospheric & Naphtha
Resid Vacuum Diesel
Fractionation
Feed Heater Fresh VGO UCO
H-Oil®
Reactors Catalyst

22
 RHCU REACTION SECTION
RHCU REACTION SECTION can be sub-divided into the following sections:

FEED SECTION
FEED HEATING SECTION
REACTION SECTION
HP SEPARATION SECTION
COLD SEPARATION SECTION
AMINE ABSORBER SECTION
HYDROGEN PURIFICATION SECTION
MAKE-UP HYDROGEN COMPRESSORS SECTION
UTILITIES SECTION
EFFLUENTS SECTION
SEAL OIL SECTION

FEBRUARY 15, 2020 23

 RHCU REACTION SECTION-Block Diagram
19Kg @ 45 Deg.C H2 to 1 st stage reactor @ 186kg and 117Deg C 360 Deg C 540 Deg C

KOD
Hydrogen
Hydrogen
Make-Up
Make-Up Hydrogen
Hydrogen H2
H2 to
to 22nd stage
nd
stage
Compressors
Compressors (Recip.
(Recip. EXCHANGERS
EXCHANGERS Hydrogen
Hydrogen
reactor
reactor
Type)
Type) Heater
Heater

COLD FEED SURGE DRUM

11stst
FEED
FEEDMIXER
MIXER
Stage
Stage
React
React

HOT FEED SURGE DRUM

or
or

245 Deg.C 306 Deg.C 341 Deg C

EXCHANGERS
EXCHANGERS Oil
Oil Feed
Feed
Heater
Heater

H-CAT
H-CAT
186 Deg.C EXCHANGER
EXCHANGER 245 Deg.C
TRAIN
TRAIN in
FEED FEED
in
UNIT-402
UNIT-402 FEED
FEED
FEED PUMP
BOOSTER PUMP
BOOSTER
PUMP
PUMP

VR
VR CLO
CLO CLO
CLO
from VR
VR from
from from from
from from from
AVU Storage
Storage RFCC INDMAX
AVU RFCC INDMAX

FEBRUARY 15, 2020 24

 RHCU REACTION SECTION
HHPS/ISS Vapor for H2 & Feed
Heating Exchangers HMPS VAPOR
Hot HP Separator (HHPS) @ 268 Deg.C
Inter Stage HMPS
HMPS VAPOR
VAPOR STEAM
STEAM HP
HP
Separator (ISS) STEAM
1 stage Reactor
st STEAM GENERATOR
GENERATOR

2nd Stage
HOT MP
Reactor
SEPARATOR
(HMPS)
432 Deg.C 409 Deg.C

444 Deg.C

HOT
HOT FRACTIONATOR
FRACTIONATOR
FEED
FEED
H2
H2and
andoil
oil FEED
421 Deg.C FEED 169.4 Kg /385 Deg.C 247 Deg.C
mixed
mixedfeed
feed MIXER
MIXER
2nd Stage
Ebullating Pump
175.5KG 1st stage 2nd stage Reactor treat gas H2
361 Deg C Ebullating Pump compressor
WHPS VAPOR @ 268 Deg.C

HVGO Quench at 91 Deg C WHPS

WHPS VAPOR
VAPOR STEAM
STEAM
HP
HP STEAM
STEAM 223 C
COLD
COLD FRACTIONATOR
FRACTIONATOR
GENERATOR
GENERATOR Warm CMPS from
FRACTIONATOR SECTION
FEED
FEED

HHPS/ISS VAPOR
COOLED TO ACT AS
WHPS INLET WARM HP Warm CMPS/WHPS exchanger
SEPARATOR (WHPS)

FEBRUARY 15, 2020 25

 RHCU REACTION SECTION
HP Sweet Gas HP
WARM CMPS @ 45 Deg.C from HP Lean Amine membrane
HMPS Vapor @ stage-1
FRACTIONATOR SECTION 22 stage
stage HP
HP
268 Deg.C Permeate
53 Deg.C Membrane
Membrane

HP Amine ABSORBER
HP
Air
Air Condenser
Condenser Membrane
Stage-2
EXCHANGERS Permeate
EXCHANGERS
HP Lean Amine

ABSORBER KOD

Column
HP AMINE
WARM CMPS @ HP Sour Gas
MP Lean Amine
199 Deg C
COLD HP MP Sweet Gas Purified H2
SEPARATOR Gas to H2
Compressor
WHPS Vapor Air
Air 161.4 Kg 55 Deg.C PSA Tail Gas to
@ 183 Deg.C PSA
PSA Fractionator
Condenser

ABSORBER Column
Condenser Section

ABSORBER KOD
MP Lean Amine
MP Sour Gas

MP Amine

MP Amine
PSA
HP Rich Condensate
Amine PRT to
Cold MP Separator Fractionator
(CMPS) Section

CMPS Liquid

CMPS Water

MP Rich Amine

FEBRUARY 15, 2020 26

 RHCU REACTION SECTION
The VR feed is preheated before being routed to the two stage ebullating bed reactors.

HVGO quench facilities are provided between the reactors.

Hydrogen rich gas is separated from reactor liquid effluent. Hydrogen rich gas is purified in amine absorber
column and then in a two stage HP membrane unit.

Low purity gas from membrane is routed to PSA units while permeate gas is compressed and mixed with
fresh make up hydrogen to the reactors.

Reactors liquid effluents are routed to the RHCU Fractionation Section at different temperature: hot and cold
fractionator feed.

FEBRUARY 15, 2020 27

 RHCU REACTION SECTION
Crictical /ODC equipments in Reaction Section
S.No Equipment Qty Type Dia. TL-TL Design Design Temp. MOC
Name/Tag mm Length mm Pressure (Deg.C)
(Kg/Cm2 G)
1 Hot Feed Surge 1 Vertical 4800 14700 3.5+F V 400 CS
Drum
2 1st Stage Reactor 1 4440 20300 185.5 470 2 ¼ Cr+1Mo+1/4 V
3 2nd Stage Reactor 1 4440 20300 185.5 470 2 ¼ Cr+1Mo+1/4 V
4 Oil Feed Heater 1 Process absorbed 19.98 266.5 DEC SS 347H
design duty
(10^6 kcal/h)

5 Hydrogen Heater 1 Process absorbed 8.57 196.5 DEC SS 347H

design duty
(10^6 kcal/h)

FEBRUARY 15, 2020 28

 RHCU REACTION SECTION
Crictical /ODC equipments in Reaction Section
S.No Equipment Qty Type Pumping Temp Design Est. MOC Remark’s
Name/Tag (Deg.C) Flow Power
(M3/Hr) (Kw)
1 1st stage EB Pump 1 Cent. 432 2818 DEC Pump casing: 347 Motor casing
SS. Impeller, trim design pressure:
and cover: 316 SS 185.5 kg/cm2 g.
2 1st stage EB Pump 1 Cent. 438 2818 DEC Pump casing: 347 Motor casing
SS. Impeller, trim design pressure:
and cover: 316 SS 185.5 kg/cm2 g.
3 Make-Up 3 Recip Stage 1: 41.1 9370 3 stage
Compressor Stage 2: 89.5 compressor
Stage 3: 187.5 2 O +1 Spare
(Discharge
Pressure)

FEBRUARY 15, 2020 29

 RHCU FRACTIONATION SECTION

RHCU FRACTIONATION SECTION can be sub-divided into the following sections:

ATMOSPHERIC DISTILLATION
VACUUM DISTILLATION
TEMPERED WATER LOOP
VACUUM OFF-GAS SECTION

FEBRUARY 15, 2020 30

 RHCU FRACTIONATION SECTION
OVERHEAD
COMPRESSOR
14.1KG, 119 C COMPRESSOR
COMPRESSOR
SUCTION KOD

KOD
Air
Air Condenser
Condenser DISCHARGE
DISCHARGE TO
TO GAS
GAS
PLANT SECTION
PLANT SECTION
FRACTIONATOR
OVERHEAD VAPOR103 C FRACTIONATOR
FRACTIONATOR
FRACTIONATOR OVERHEAD
OVERHEAD
REFLUX DRUM COMPRESSOR
COMPRESSOR (Recip.
(Recip.
Fractionator Reflux Type)
Type)
Sour Water to Pumps
REACTION
ATMOSPHERIC SECTION Fractionator Sour
FRACTIONATOR Water Pumps

WILD
WILD NAPTHA
NAPTHA TO
TO
GAS
GAS PLANT SECTION
PLANT SECTION
DIESEL SIDE STRIPPER OVERHEAD, 205 C
DIESEL SIDE
DIESEL PUMP AROUND STRIPPER DIESEL
DIESELPRODUCT
PRODUCT
DIESEL DRAW, 208 C DIESEL LLP
LLP STEAM
STEAM
PRODUCT GENERATOR
GENERATOR
DIESEL REFLUX PUMP
DIESEL PA
PUMP HOT DIESEL PUMP
HOT FRACTIONATOR
235 C AROUND, 208 C
FEED (394 C) HAGO,365 C HAGO SIDE 217C
217C
STRIPPER EXCHANGERS
EXCHANGERS
HAGO
HAGO MP STEAM
MP STEAM HAGO
HAGO LLP
LLPSTEAM
STEAM
GENERATOR
GENERATOR GENERATOR
GENERATOR
HAGO
SUPER HEATED LLP Air
Air Cooler
Cooler
PRODUCT
STEAM
PUMP 241C 286 C
FRACTIONATOR
344 C
HAGO
HAGO
BOTTOM PUMP
EXCHANGERS
EXCHANGERS
HOT COLD
COLD
COLD FRACTIONATOR FRACTIONATOR
HOT DIESEL
DIESEL
TO DIESEL
DIESEL TO
TO
FEED BOTTOM PRODUCT 223 C TO DHDT
DHDT
STORAGE
STORAGE

FEBRUARY 15, 2020 31

 RHCU FRACTIONATION SECTION
COLD
COLD
LVGO
LVGO
VACUUM TOWER
HOT LVGO
OVERHEAD
LVGO PUMP
AROUND

HAGO
HAGO from
from HOT
HOT
ATMOSPHERIC
ATMOSPHERIC
Condenser
Condenser
132
132 CC FRACTIONATOR
HAGO
HAGO
FRACTIONATOR

HVGO PUMP AROUND HVGO

LVGO PUMP HVGO LLP
LLP STEAM
STEAM
AROUND PUMP GENERATOR
GENERATOR
LVGO EB PUMP HVGO Draw, 285 C HVGO PUMP AROUND PUMP HVGO
HVGO MP
MP STEAM
STEAM
SEAL OIL GENERATOR
GENERATOR
Superheated
Velocity MP HVGO REFLUX
Steam EXCHANGERS 160 C
EXCHANGERS
272 C EXCHANGERS
EXCHANGERS
375 C
OVERFLASH Cold
365 C OVERFLASH
OVERFLASH MP
MP STEAM
STEAM
GENERATOR Fractionator COLD
COLD
GENERATOR
Residue Vacuum Tower HVGO HVGO
HVGO
Oil
Oil Feed
Feed Recirculation Overflash Pump
Heater
Heater

Seal Oil for Catalyst Handling

Superheated Pump , Booster Pump, Feed
LLP Steam Pump
VACUUM and Fractionation Pump
Fractionator
Fractionator RESIDUE Vacuum
VR BOOSTER Instrument Purging in HOT
HOT VGO
VGO
Vacuum EXCHANGERS
EXCHANGERS PUMP EXCHANGERS
EXCHANGERS
Bottom
Bottom Product
Product (VR) Bottom
Bottom Filter
Filter
Reaction and Fractionator TO
TO
section
VGO_HDT
VGO_HDT
VR PUMP
HOT
HOT UCO
UCO to
to
VACUUM
VACUUM COKER COLD
COLD UCO
UCO
COKER
FRACTIONATOR
FRACTIONATOR to STORAGE
to STORAGE

FEBRUARY 15, 2020 32

 RHCU FRACTIONATION SECTION

HOT
HOT
HAGO
HAGO
EXCHANGERS
EXCHANGERS

COLD
COLD
HVGO
HVGO

COLD
COLD
LVGO
LVGO

COLD
COLD VGO
VGO to
to STORAGE
STORAGE

FEBRUARY 15, 2020 33

 RHCU FRACTIONATION SECTION
The objective of the fractionation section is to separate the reactor effluents into petroleum cuts (off-gas, sour
water, unstabilized naphtha, diesel, vacuum gasoil and unconverted oil) by atmospheric and vacuum
distillations.
Hot Feed, Warm Feed and the Cold Feed from the reaction section are feeding the Fractionation section.
Fractionator off-gas is sent to the Gas Plant Section in order to be treated to produce fuel gas according to
the required specifications. Vacuum Fractionator off-gas is sent to flare.
A Diesel cut is withdrawn from the Fractionator under level control, and then stripped in the Diesel Side
Stripper using stripping steam to remove the light components. The stripped diesel is then pumped to the
HDT-3 Unit or to storage.
Heavy Atmospheric Gasoil (HAGO) cut is withdrawn from the main fractionator under level control, and then
stripped in the HAGO Side Stripper using stripping steam to remove some remaining light diesel components
and further improve the separation between the diesel and the HAGO. The stripped HAGO is then blended
with Light Vacuum Gasoil (LVGO) and Heavy Vacuum Gasoil (HVGO) from the Vacuum Fractionator. This
Vacuum Gasoil (VGO) mix is then delivered to VGO HT Unit (Hot VGO) or to storage (Cold VGO).

The main fractionator bottom is heated in the Vacuum heater and used as feed in the Vacuum Fractionator.
The vacuum residue and the vacuum overflash streams, withdrawn from Vacuum tower, are mixed and
routed to Delayed Coker Unit.

FEBRUARY 15, 2020 34

 RHCU FRACTIONATION SECTION

The RHCU Fractionation Section is designed to fractionate the effluent of the reaction section into
the following products:
 Wet gas and liquid distillate from the Fractionator Reflux Drum, which feed the Gas Plant, after
compression or pumping,

 Sour diesel product which is routed to the DHT unit (or to storage).

 Heavy Atmospheric Gasoil, HAGO, which is part of the total unit VGO stream.

 Light Vacuum Gasoil, LVGO, which is part of the total unit VGO stream.

 Heavy Vacuum Gasoil, HVGO, which is part of the total unit VGO stream.

 Unconverted Oil, UCO, which is routed to the Delayed Coker in the refinery (or to storage).

FEBRUARY 15, 2020 35

 RHCU FRACTIONATION SECTION
Crictical /ODC equipments in Fractionation Section

S.No Equipment Qty Section Dia. TL-TL Length Design Design MOC
Name/Tag mm mm Pressure Temp.
(Kg/Cm2 G) (Deg.C)
1 Atmospheric 1 Top 3800 41400 3.5+F V 330-420 Shell- CS
Fractionator (41 Trays) Tray- Monel
Top sec. ht-
Bottom 3800 37800
Bottom Sec.
ht- 3800
2 Vacuum 1 38300 185.5 255-395 Shell- CS (wet H2S
Fractionator Res.)
1st sec. 4500 4500 (1 tray) Tray- SS 410
2nd sec. 6400 20100 (2 Tray)
3rd sec. 3300 10700 (11 tray)
4th sec. 1200 2600

FEBRUARY 15, 2020 36

 RHCU FRACTIONATION SECTION
Crictical /ODC equipments in Fractionation Section
S.No Equipment Qty Type Pumping Temp Design Est. MOC Remark’s
Name/Tag (Deg.C) Flow Power
(M3/Hr) (Kw)
1 Diesel PA pumps 2 Cent. 209 590.5 180 DEC
2 HAGO Product 2 Cent. 350 64 75 DEC
Pumps
3 Fractionator 2 Recip Stage 1: 4.4 Stage 1: 2500 2 stage
Overhead Stage 2: 15.1 20150 compressor
Compressor (Discharge Stage 2: 1 O +1 Spare
Pressure) 5480

4 Vacuum Off-Gas 2 Recip 4.2 Discharge 400.3 45 1 O +1 Spare

Compressor . Pressure

FEBRUARY 15, 2020 37

 RHCU GAS PLANT SECTION
RHCU GAS PLANT SECTION can be sub-divided into the following sections:

LPG ABSORBER / STRIPPER SECTION

ABSORBER AND OFF GAS SECTION
DEBUTANIZER SECTION
LPG AMINE TREATMENT
CAUSTIC WASH SECTION
LPG WASH SECTION

FEBRUARY 15, 2020 38

 RHCU GAS PLANT
Absorber Reflux Drum Off-Gas
Absorber Overhead
OFF-GAS TREATED
TREATED
Wild Naptha from Fractionation KOD
De Ethanizer Section and recycle Naptha
Absrober OFF-GAS
OFF-GAS
to
to FUEL
FUEL
Absorber
Absorber Reflux GAS
GAS
Compressor
Discharge from 90 C LP RICH
Fractionator
Section, 119 C De Butanizer Reflux drum AMINE
De Ethanizer
Water Decantation
Warm Diesel Pot Sour Water to
PA, 186 C
Fractionation
HotDiesel 153 C Section
PA, 208 C
SOUR
SOUR
De Ethanizer LPG
LPG
Recontacting
Reboiler De Butanizer De Butanizer
Cooler De Butanizer
Reflux Pump Distillate
88 C Reboiler
Pump
Recontacting drum Hot Debutanizer Naptha
190 C

Recontacting
Sour Water, 40 C
40
40 CC

Warm Debutanizer 6 Kg, 40 C

De Ethanizer Naptha 127 C Naptha 65 C
NapthaAir
Air
Feed Pump Cooler
Cooler
Naptha Trim
Cooler
NAPTHA
NAPTHA to
to NAPTHA
Recycle Naptha
NAPTHA
NAPTHA to
to NAPTHA
DHDT
DHDT toStorage
NHT-MS
NHT-MS Block
Block toStorage

FEBRUARY 15, 2020 39

 RHCU GAS PLANT
LPG/Amine
LPG/Amine
Static
Static Mixer
Mixer
Sweet LPG LPG
LPG Water
Water Washed LPG Coelescer
Caustic Drum Package
Caustic Wash
Wash Static
Static Mixer
Mixer
Static
Static Mixer
Mixer
Lean Amine LPG Amine
from Reaction Settler LPG Water
Caustic Wash
Settler
Section Drum

SOUR LPG Amine Recycle

Pump Water Recycle
Lean Amine Caustic Wash
Recycle Pump Pump
Absorber

LPG Rich LPG

Fresh Caustic LPG TO
TO
Amine
Tank STORAGE,
STORAGE,
Caustic Make-Up 19
19 Kg,
Kg, 40
40 C
C
Pumps

Make-Up Water Fresh Caustic 20% wt.

Make-Up BFW Trim Cooler 6Kg, 40 C
25Kg, 110 C 40 C

FEBRUARY 15, 2020 40

 RHCU GAS PLANT

The RHCU Gas Plant processes the wet gas and the liquid distillate from the Fractionator Reflux Drum along
with tail gas from PSA desorption step.

The objective of the gas plant is to separate the feeds in to the following products:
 Sweet Off-Gas which it is routed to the refinery fuel gas network,
 Sweet LPG routed to storage.
 Stabilized naphtha which feeds the NHDT Unit in MS Block (or DHDT3 or storage tank).

Amine sweetening is performed on fuel gas and LPG streams.

FEBRUARY 15, 2020 41

 RHCU CATALYST HANDLING SECTION
 Automation operation = three sequences including all required procedures to replace
the targeted quantity of catalyst in 24 hours :
1. Transfer of Fresh Catalyst from storage to Hoppers
2. Catalyst addition and withdrawal operations :
a) Fresh catalyst addition to 2nd Reactor (R-02)
b) Catalyst withdrawal from 2nd Reactor (R-02)
c) Spent catalyst addition to 1st Reactor (R-01)
d) Catalyst withdrawal from 1st Reactor (R-01)
3. Cooling of Spent Catalyst in Spent Catalyst Cooling Drum (V-05) and Dump to Spent Catalyst Hopper (V-06)
 Possibility to launch the three sequences in parallel under some conditions
 If significant loss of activity in the 1st reactor : Dump Mode option (addition of fresh
catalyst in both reactors)

 Initial Catalyst Loading per reactor- 86 Tonnes

 Daily Catalyst Replacement Rate – 4.8 Tonnes per day.

FEBRUARY 15, 2020 42

 RHCU CATALYST HANDLING SECTION
CRITERION TEX-2910 CY (1.0)
Ebullated Bed Resid Catalyst

TYPICAL PROPERTIES
Nickel and molybdenum oxides on alumina
Cylindrical extrudates

Average Diameter 1.08 mm

PROPRIETARY AND CONFIDENTIAL

Shipping Information

PACKAGING: MANUFACTURING:
Big Bags. Net 760 kg Medicine Hat (Canada)
Michigan City (USA)
Flow Bins or Truck Trailers. By arrangement Azusa (USA) Pittsburg (USA) Ghent
(Belgium)

FEBRUARY 15, 2020 43

 RHCU CATALYST HANDLING SECTION
 a. Addition to 2nd Reactor
i. Catalyst Transfer
ii. Warm-up
iii. Pressurization
iv. Addition
v. Flushing

b. Withdrawal from 2nd Reactor

i. Depressurization
ii. Flushing
iii. Withdrawal
iv. Flushing

FEBRUARY 15, 2020 44

 RHCU CHEMICALS SUMMARY

SERVICE SUPPLIER PRODUCT NAME (1) ESTIMATED ANNUAL CONSUMPTION ESTIMATED INITIAL START-UP
(kg/yr) (13) REQUIREMENTS (kg) (3)

CATALYST AXENS HCAT 151 520 (2) 13 630 (3)

PRECURSOR

CHIMEC CHIMEC 8049 36 800 (4) 3 300 (4)

ANTI-FOAMING
AGENT
NALCO NALCO EC9079A 36 800 (4) 3 300 (4)

CHIMEC CHIMEC 1829 ENW 19 200 (7) 1 750 (7)

CORROSION
INHIBITOR
NALCO NALCO EC1010A / 8 000 (8) 700 (8)
EC1010B

CHIMEC CHIMEC 5334 212 000 (10) 19 100 (10)

ANTI-FOULING
AGENT
NALCO NALCO EC3404A / 151 200 (11) 13 600 (11)
EC3405A

FEBRUARY 15, 2020 45

 RHCU PRODUCTS
PRODUCTS TEMPERATURE at Battery Limit (in PRESSURE at Battery Limit
Degree C) (in Kg/cm2 g)

Treated Off-Gas 45 6
LPG Product 40 19
Sour Naphtha to NHDT (MS-Block) / 40 6
DHDT- 3 / Storage
Sour Diesel to DHDT-3 unit 121-123 8.5
Diesel to DHT feed storage tank 45 5.5
VGO to VGO HT unit 150 12
VGO to VGO storage tank 150 5.5
UCO to Delayed Coker Unit 198-205 12
UCO to Storage 150 12
Rich amine 53 9
Sour water 47 9

FEBRUARY 15, 2020 46

 Engineers India Limited

! THANK YOU !

FEBRUARY 15, 2020 4

7
 Why the need of Residue HydroCracker Unit (RHCU)
With the recent downturn in crude oil prices, the incentive to upgrade residues has also shifted
as upgrading margins have been compressed. To maximise upgrading margins, technology
solutions that maximise high quality, high hydrogen content transportation fuels (gasoline,
kerosene, and diesel) and minimise unconverted residues are required.

Several technologies are available for residue upgrading, broadly characterised as carbon
rejection technologies or hydrogen addition technologies. The principal residue conversion
based on carbon rejection technology is delayed coking. Delayed coking is simple, robust, and
can handle very high levels of feed contaminants. Roughly 25-30% of the residue is rejected as
petroleum coke, or petcoke.

Amongst hydrogen addition technologies, the principal ones are residue desulphurisation
technologies (ARDS, VRDS, UFR, and OCR) and residue hydrocracking technologies such as
LC-Fining by CLG (Chevron Lummus Global) and H-OIL BY AXENS. These technologies are
well established and have proven to be efficient and reliable processes.

Residue hydrocracking’s main advantage is that its unconverted residue product is typically
much higher in value than coke.

FEBRUARY 15, 2020 48

 Why the need of Residue HydroCracker Unit (RHCU)

Historically, residue hydrocracking has had a slight capital cost premium and required more
hydrogen because all products, including the bottoms, are hydrogenated.

In recent years, the cost for high pressure equipment has gone down very significantly as has the
cost of natural gas required to produce hydrogen.

This reduces the capital cost gap between high pressure residue hydrocracking and low pressure
processes such as delayed coking. It should be mentioned that the cost of a delayed coking
project geared towards maximum diesel production has to factor in the cost of upgrading the
coker gasoils and the hydrogen consumption in the hydrocracker. The global market for high
sulphur residue is expected to decline in the long term with environmental regulations becoming
increasingly stringent.

All of these factors support high conversion residue hydrocracking solutions, which will have the
best opportunity to meet future residue upgrading projects’ requirements.

FEBRUARY 15, 2020 49

 Market Over View
 Asia andthe Middle East will continue to lead world demand growth for refined
products.
 Product demand growth in the most developed markets over the medium to long term will be
dampened by measures to improve vehicle efficiencies and control of green house gas
emissions.
 Ongoing refining capacity developments are expected to be located in the Middle East and Asia.

 Investment in new refining capacity has slowed in most regions.

 Increased production of biofuels will reduce demand for gasoline.

FEBRUARY 15, 2020 50

 Why the need of Residue HydroCracker Unit (RHCU)

 The RHCU has a higher capital investment cost and hydrogen costs than a Delayed Coker
(DCU).  However with increased availability of natural gas which brings about a lower price and
reductions in the cost of the required high-pressure equipment, the return on investment (ROI)
swings in favour of RHCU when compared to a DCU with a hydrotreating unit.  With the non-
destruction of hydrogen in the RHU, it achieves a higher conversion at 85% (and up to 95%)
compared to 65% for the DCU. The RHU can also be integrated successfully with an existing
delayed coking unit to create a powerful combination.

FEBRUARY 15, 2020 51

 BRIEF DETAILS OF COOLING TOWER

UTILITIES DESCRIPTION Remarks

COOLING TOWER 1. 6+1 Cells (4000m3/Hr each) 1. For AVU, DHDT, RHCU, MS Block, HGU, SR
LPG, CDW/LOBS, N2 Plant, CR)

2. 10+2 Cells (4000m3/Hr each) 2. For INDMAX, PRU, VGO-HDT, SRU,

Alkylation)

52
 RHCU CATALYST HANDLING SECTION
 The hot catalyst previously withdrawn from the 2nd Reactor is loaded directly
into the 1st Reactor
 Fresh catalyst loading and warm-up is not required
Pressurization
› Increase pressure to ~3.5 kg/cm2 above 1st Reactor top pressure using hydrogen
› The pressure will already be high from previous step

ii. Catalyst Addition

› Pressurize and flush the daily addition transfer line from the HVGO Surge Drum (V-09) to the 1st
Reactor (R-01)
› Start catalyst batch transfer to the 1st Reactor (R-01)
› HVGO Temp is 285°C and Flow is 15.0 m3/h
iii. Flushing
› Stop catalyst transfer and maintain HVGO flow to flush the transfer line from the HVGO Surge Drum
to the 1st Reactor

FEBRUARY 15, 2020 53

 RHCU CATALYST HANDLING SECTION
The RHCU Catalyst Handling Section is designed to allow the daily replacement of the catalyst to ensure
steady performances of the unit.
A part of the reactor catalyst inventory is removed from the unit with a dedicated PLC sequence and is
replaced by fresh catalyst to maintain catalyst activity in an equilibrium.

FEBRUARY 15, 2020 54

 RHCU - CONCEPT

Crudes CDU

VDU
Atmospheric
Residue

Sour Gas
Naphtha
Vacuum RHCU Diesel
Residue VGO
UCO

55
 Why the need of Residue HydroCracker Unit (RHCU)

 With changes in crude prices and the increased global production of heavy crude oil, refineries
need to look toward other processes and technology to boost their global competitiveness.
Residue HydroCracking (RHC) is one solution. Resid Hydrocracking processes heavier feeds to
maximize diesel production. This process also has the flexibility to use non-standard feeds, such
as Heavy Coker Gas Oil (HCGO) and DeAsphalted Oil (DAO).

 Due to the continual supply of fresh catalyst, the Residuum HydroCracking Unit (RHU) produces
a constant yield of high-quality products. Middle distillates can be blended into jet fuel and diesel
fuel. Other benefits include significantly increased liquid yields; high volume of kerosene and light
gasoil; a wide range of other products and a low sulphur content.

FEBRUARY 15, 2020 56