Preliminary Feasibility Report (PFR) for setting up of Petro-Resid Fludizied Catalytic Cracker at Mumbai Refinery.
1
Annexure B
Preliminary Feasibility Report (PFR)
for setting up of Petro-Resid Fludizied Catalytic Cracking
Unit (PRFCC)
at Mumbai Refinery.
APRIL 2018
Bharat Petroleum Corporation Limited.
Preliminary Project Feasibility Report (PFR) for setting up of Petro-Resid
Fludizied Catalytic Cracker at Mumbai Refinery.
Bharat Petroleum Corporation Limited, Mumbai Refinery Page 2 of 17
Table of Contents
1. Introduction
2. Objective
3. Scope of Facilities
4. Advantages of the project and technology high lights.
5. Potential Technology Licensors
6. Unit Design
7. Block Flow Diagram
8. Material balance
9. Location of Unit
10. Utility Systems
11. OSBL
12. Finincial Analysis
13. Project Implemenation Schedule
14. Health, Safety & Environment
Preliminary Project Feasibility Report (PFR) for setting up of Petro-Resid
Fludizied Catalytic Cracker at Mumbai Refinery.
Bharat Petroleum Corporation Limited, Mumbai Refinery Page 3 of 17
1 INTRODUCTION
Mumbai Refinery (MR) of Bharat Petroleum Corporation Limited (BPCL), has an
installed capacity of 12.0 Million Metric Tonnes per Annum (MMTPA) located at
Mahul, Mumbai, Maharashtra, India. The refinery was commissioned in 1955 with a
crude oil processing capacity of 2.2 MMTPA in a plot area of 450 acres. The refining
capacity has been augmented to 12.0 MMTPA through progressive revamps,
addition of various process units and incorporating advanced refining technologies.
Refinery processes various types of crudes which include Bombay High, East
African, Petronas, Kuwait, Arab mix, Arab medium, Basrah, Arab extra light, Murban,
Umm Shaif etc. The main products are LPG, Naphtha, MS, Benzene, Toluene,
Hexane, SBP, MTO, Kerosene, Jet Fuel, Diesel, Light Diesel Oil, Lubes, Fuel Oil,
LSHS and Bitumen.
While BPCL has already addressed the quality upgrade for gasoline and diesel fuel
products to meet BS-VI standards, BPCL wants to remain competitive, improve
refinery profitability further by improving the efficiency of older units and reducing fuel
& loss.
Feasibility study has been carried out by M/s Flour evaluating various options for
profitability improvement. One of the option was to replace existing CCU & FCCU
with new state of art, highly energy efficient and petro chemical based Petro Resid
Fludized Catalytic Cracker (PR FCC). Existing CCU is of Shell design installed in
1955 and FCCU of UOP design installed in 1985.
Installation of PRFCC would also enable MR to increase its high Sulphur crude
processing capability and target a production of about 450 KTPA of Propylene. This
new unit will be installed at Mumbai Refinery (MR) of Bharat Petroleum Corporation
Ltd. (BPCL)
MR currently has space constraints to accommodate Petro Chemical facilities and
hence is in the process of acquiring additional ~400 acres of land at Rasayani, which
is located at a distance of about 50 kms from MR. Utilizing this land and leveraging
Preliminary Project Feasibility Report (PFR) for setting up of Petro-Resid
Fludizied Catalytic Cracker at Mumbai Refinery.
Bharat Petroleum Corporation Limited, Mumbai Refinery Page 4 of 17
the Propylene from PRFCC, it is proposed to set up about 450 KTPA of
Polypropylene unit with associated facilities at Rasayani.
Based on the feasibility report from M/s Flour, M/s Bechtel Engineering And
Construction India Pvt Ltd (BECI) has been engaged by BPCL to develop a Detailed
Project Feasibility Report (PFR) with +/-20% cost estimate for the addition of PRFCC
and PP plants in the Mahul Refinery and Rasayani complex.
2 OBJECTIVE
The objective of the project is installation of PRFCC to replace the older units of
CCU & FCCU by latest state of the art technology, energy efficient, better yield unit.
This unit also provides opportunity for setting up a downstream petrochemical units
like Polypropylene based on propylene available from PRFCC).
3 SCOPE OF FACILITIES
The scope of the project is to install a Petro Resid Fluidized Catalytic Cracker Unit
(PRFCC) along with a Propylene Recovery Unit to provide raw material for
downstream petrochemical units and processing of vacuum residues. Major process
units proposed under configuration are:
Unit Code Name TPD
PRFCC Petro Resid Fluid Catalytic Cracker 9000
PRU (Note 1) Propylene Recovery Unit 1073
PRFCC SWS Sour Water Stripper 1300
ARU Amine Regeneration Unit 1440
SRU Sulphur Recovery Unit 165
Note 1. Capacity is amount of Polymer grade Propylene
produced.
Preliminary Project Feasibility Report (PFR) for setting up of Petro-Resid
Fludizied Catalytic Cracker at Mumbai Refinery.
Bharat Petroleum Corporation Limited, Mumbai Refinery Page 5 of 17
4 ADVANTAGES OF THE PROJECT AND TECHNOLOGY HIGH LIGHTS.
Unit Replaces the old CCU and FCCU unit with a high efficient unit using
latest technology.
Tighter heat integration with production of high pressure steam from process
flue gas heat recovery.
A power recovery turbine of around 18 MW during normal operation from the
exhaust flue gas from the PRFCC.
DeNOX facility to reduce NOx emission using a combination of SCNR and
SCR technology along with Low NOx burners.
Produce feedstock for downstream petrochemical units to meet the increasing
demand for petrochemical products.
5 POTENTIAL TECHNOLOGY LICENSORS
The potential licensors for PRFCC and associated units are given below:
AXENS
CB&I
UOP
KBR
While all the above are potential licensors for PRFCC, some of them may not have
the technologies for associated units. However, they can liaison with licensors of
associated units with them being the lead licensor. It is recommended that a single
licensor design basis be developed for PRFCC and associated units with PRFCC
licensor being the single point of contact.
6 UNIT DESIGN
The following new process facilities are envisaged as part of the various units under
PRFCC complex:
Preliminary Project Feasibility Report (PFR) for setting up of Petro-Resid
Fludizied Catalytic Cracker at Mumbai Refinery.
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PRFCC Reactor & Regeneration
PRFCC Main Fractionator & Unsaturated Gas Plant (USGP)
Flue Gas Treatment Facilities
Propylene Recovery Unit (PRU)
Unsaturated LPG Treating Unit (LTU)
RFCC Sour Water Stripping Unit (SWS)
Amine Regeneration Unit (ARU)
Sulphur Recovery Unit (SRU)
The following new / additional Utilities and Offsite facilities are envisaged post
PRFCC:
New Sea Water Cooling Water System
New Condensate Polishing Unit facilities with tankages
Additional Instrument & Plant Air generation facilities.
Additional BFW generation facilities
New Flare System.
6.1 FEED TO THE UNIT
The feed stock to the PRFCC complex is a blend of following intermediates from
Vacuum Distillation Units and VGO Hydrocracker:
Vacuum Residue (VR) 2455 TPD From CDU/VDU-3 & 4
Vacuum Gas Oil (VGO) 6426 TPD From CDU/VDU-3 & 4
Preliminary Project Feasibility Report (PFR) for setting up of Petro-Resid
Fludizied Catalytic Cracker at Mumbai Refinery.
Bharat Petroleum Corporation Limited, Mumbai Refinery Page 7 of 17
Unconverted Cycle Oil (UCO) 119 TPD From Hydrocracker
Blend 9000 TPD To PRFCC Complex
The crude processing capacity of the refinery is 12 MMTPA. The refinery is
processing a blend of the following crudes:
Crude Type Percentage
Bombay High 21%
Azeri 11%
Saharan 11%
-Arab Extra Light 29%
Murban 14%
Arab Mix (65-35) 14%
Total 100%
6.2 PRFCC REACTOR AND REGENERATION
The purpose of PRFCC unit is to convert a mix feed of Vacuum Residue / Vacuum
Gas Oil (VGO) from Vacuum Distillation Unit (VDU) and Unconverted Cycle Oil
(UCO) from hydrocracker into Propylene rich light gases and high-octane gasoline.
The intent is to maximize Propylene production. Licensor shall configure the design
to maximize propylene yields.
The PRFCC Reactor & Regeneration shall typically include the following:
Reactor
Regenerator
Preliminary Project Feasibility Report (PFR) for setting up of Petro-Resid
Fludizied Catalytic Cracker at Mumbai Refinery.
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Catalyst Cooler (Licensor to confirm requirement)
Main Air Blower
CO Boiler
Power Recovery Turbine
Catalyst Storage and Handling Facilities
6.3 MAIN FRACTIONATOR AND UNSATURATED GAS PLANT (USGP)
The Main Fractionator and Unsaturated Gas Plant (USGP) shall typically include the
following:
Main Fractionator and associated systems
Wet Gas Compressor
Stripper and Absorber System
Cracked Naphtha Debutanizer
LPG and Off Gas Amine Absorber
6.4 FLUE GAS TREATMENT FACILITIES
Flue Gas treatment facilities will be provided as part of PRFCC to scrub the
regenerator flue gas and reduce SOx, NOx and particulate emissions.
6.5 UNSATURATED LPG TREATING UNIT
The purpose of the Unsaturated LPG Treating Unit (ULTU) is to remove sulfur
compounds (mercaptans, H2S and COS) from amine treated LPG received from
PRFCC.
The Unsaturated LPG Treating Unit ( ULTU) shall typically include the following:
Preliminary Project Feasibility Report (PFR) for setting up of Petro-Resid
Fludizied Catalytic Cracker at Mumbai Refinery.
Bharat Petroleum Corporation Limited, Mumbai Refinery Page 9 of 17
Caustic wash section
Water wash section
Caustic regeneration section
Spent Caustic Degassing
6.6 PROPYLENE RECOVERY UNIT
The Propylene Recovery unit separates mix LPG’s into polymer grade Propylene,
Propane and Mixed C4’s.
The Propylene Recovery Unit (PRU) will typically include the following:
C3/C4 Splitter
Dryer and Contaminant Removal facilities
Deethaniser
C3 Splitter with Heat Pump Compressor
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Fludizied Catalytic Cracker at Mumbai Refinery.
Bharat Petroleum Corporation Limited, Mumbai Refinery Page 10 of 17
7 BLOCK FLOW DIAGRAM
Preliminary Project Feasibility Report (PFR) for setting up of Petro-Resid
Fludizied Catalytic Cracker at Mumbai Refinery.
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8 MATERIAL BALANCE (MT/D)
9 LOCATION OF UNIT
Location of PR FCC will be well within Refinery permsis. Old units CDU 1 & 2 which
have been decommissioned after commissioning of CDU 4 are in the process of
dismanteling. As per preliminary assessment, PRFCC can be accommodated within
this plot. Exact plot space required and equipment locations will be carried out in
detail during DFR. Location of PRFCC plot in MR is shown as below.
PR
FCC
(9000 MT/D)
OFF GAS 655 (7.28%)
PROPYLENE 1106 (12.28%)
PROPANE 137 (1.52%)
LPG 1371 (15.23 %)
GASOLINE 2718 (30.2%) TO GTU
LCO 1459 (16.21%) TO FO/HSD
SLURRY OIL 746 (8.29%) TO FO
COKE 808 (8.98 %)
HCU UCO 119
VGO 6426
VR 2455
Preliminary Project Feasibility Report (PFR) for setting up of Petro-Resid
Fludizied Catalytic Cracker at Mumbai Refinery.
Bharat Petroleum Corporation Limited, Mumbai Refinery Page 12 of 17
10 UTILITY SYSTEMS
Existing utility facilities shall be utilized for PRFCC and capacities shall be
augmented wherever required. Since PRFCC is replacement for CCU & FCCU, it is
expected that most of the utiiltes can be met from exisiting systems. The additional
utilites envisaged for PRFCC are as follows:
a. Sea Cooling Water Circulation Unit: A dedicated Sea Cooling Water system for
PRFCC and associated units will be provided. The new sea cooling water system
will be a closed loop circulating system with sea water makeup from the existing sea
water intake facilities. The blowdown from the new sea water cooling system will be
sent to the existing sea water outfall.
The sea cooling water requirements for PRFCC and associated units is estimated to
be around 23,000 m3/h. The design circulation capacity is considered to be around
26,000 m3/h. During DFR, adequacy of existing sea cooling water will be checked in
lieu of dismanteling of CCU and FCCU.
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Fludizied Catalytic Cracker at Mumbai Refinery.
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b. Raw Water/ DM Water & BFW: Requirement of Raw Water, DM water and Boiler
Feed water (BFW) is expected to be met from existing facilities since PRFCC is
replacement of CCU & FCCU. Exact additional quantity will be worked out during
DFR. Raw water is know as DM water after treatement in DM plants. This DM water
after treatement in Dearators know as Boiler Feed Water (BFW) is used in three
number of boilers, three HRSGs of Gas Turbines GT 1,2 & 3 and in waste heat
steam generators in process plants. The DM water & BFW can be met from
existing facilities however detailed adequacy check will be done in DFR
c. Instrument Air / Plant Air (IA/PA) Unit: Since unit is replacement for CCU & FCCU,
it is expected that IA & PA can be met from existing system. The installed Instrument
air drying capacity in the refinery is 25,200 Nm3/h of which one dryer capacity of
4500 Nm3/h is considered under maintenance.The current normal and peak
Instrument Air consumption in the refinery are 15,409 Nm3/h and 22,575 Nm3/h
respectively. For the new PRFCC units, 1897 Nm3/h of Instrument Air (for
Instruments) is required.
During normal demands, there is adequate capacity in the existing Instrument air
dryers for catering to additional demands from PRFCC and associated units.
d. Nitrogen System: Nitrogen consumption is expected to be intermittent for PRFCC
and associated units usually during start-up and shutdown. Also nitrogen
consumption for CCU & FCCU will be saved as PRFCC is replacement for these
units. Estimated peak Nitrogen requirement is 7407 Nm3/h. The intermittent
requirements are met from existing Liquid Nitrogen storage facilities for existing
refinery units which will also apply for the new units. Existing facilities have a liquid
Nitrogen storage volume of 660 m3. Approximate liquid Nitrogen volume estimated
for PRFCC and associated units is 70 m3 which can be sourced from the existing
Liquid Nitrogen facilities.
No Nitrogen facility shall be required as nitrogen required for startup and shut down
shall be made available by trucks supplying liquid Nitrogen which can be vaporized
in the existing set up.
Preliminary Project Feasibility Report (PFR) for setting up of Petro-Resid
Fludizied Catalytic Cracker at Mumbai Refinery.
Bharat Petroleum Corporation Limited, Mumbai Refinery Page 14 of 17
e. Fuel Gas System: PRFCC is net exporter of fuel gas. During normal operation, unit
can generate around 17 MT/D of FG and consumption will be around 10 MT/D.
Hence 7 MT/D can be exported to Refinery FG system. During start up of unit, RLNG
is available as make up to FG system.
f. Steam System: Steam generation from refinery process units post addition of
PRFCC and associated units is estimated to be 641 TPH. This includes a net steam
export of 127 TPH from PRFCC Unit.Steam Consumption in refinery process units
post addition of PRFCC and associated units is estimated to be 941 TPH.The net
Steam demand of 300 TPH will be met by the existing HEBs and HRSGs. No
additional boilers will be required.
g. Power: The present refinery power consumption is around 115 MW. The maximum
power generation from the Gas Turbines in the existing refinery is 76 MW. The
balance power is sourced from the grid. Power requirement in refinery post addition
of PRFCC and associated units is estimated to be around 176 MW. Hence an
additional power of 61 MW will need to be sourced from the grid.
A Power Recovery Turbine(PRT) is envisaged in PRFCC to extract power from Flue
gases. During normal operation, Flue Gas Power Recovery Turbine in PRFCC is
estimated to generate around 18 MW power, which will reduce the net power
demand to 43 MW.
11 OSBL FACILITIES:
Hydrocarbon Storage & Movement: The storage requirements can be mostly met
from existing tanks as per initial preliminary study. Existing fuel oil tanks 701 & 702
can be used as PRFCC feed tanks, existing propylene bullets V7 & V8 can be used
for propylene ex PRFCC also, existing Naphtha tanks 527 & 528 can be used for
naphtha storge ex PRFCC, existing tanks 705 & 715 can be used for LCO and 601 &
602 for clarified slurry oil. Required pipelines need to be installed to send the
products to existing storage and distribution facility. During DFR, tankage
requirement can be worked out in detail. New bullets may be required for Propylene
and LPG as the yield is getting increased.
Preliminary Project Feasibility Report (PFR) for setting up of Petro-Resid
Fludizied Catalytic Cracker at Mumbai Refinery.
Bharat Petroleum Corporation Limited, Mumbai Refinery Page 15 of 17
a. Flare: The existing refinery flare has three independent demountable type flare
stacks and KOD’s located adjacent to each other. The stacks are designed to
normally operate in 2 operating and 1 standby mode of taking care of all possible
hydrocarbon loads from the refinery complex. Existing flare system is fully utilized
hence new flare is expected to be installed to cater PRFCC to safely dispose of the
relieving materials during any upset scenarios and to allow safe venting of the
equipment/process systems. However during DFR, adequacy check up of exising
flare system will be carried out with different mitigitation measures to avoid new flare
system. Also flare load due to CCU & FCCU will be nil post commissioning of
PRFCCU. .
b. Effluent Processing: The effluent generation ex PRFCC can be processed in
existing WWTP. The WWTP has surplus capacity of 50 M3/hr. WWTP needs to be
evaluated once exact quality and quantity of effluent ex PRFCC is known. No new
effluent storage tank is envisaged as per preliminary study.
c. Sour Water Processig: The sour water generated ex Fractionator overhead and
unsaturated gas plant has to be treated for H2S and NH3. The treated water can be
sent to desalter of CDUs. One new two stage SWS of approximate capacity 1300
TPD is envisaged. Sour water generation ex CCU & FCCU will be nil as these
plants will be decommissioned after PRFCC commissioning.
d. Fire Water Network: Fire water requirement needs to be worked out and fire water
network analysis needs to be carried out. It is expected that existing fire water
system will be adequate since fire water requirement for CCU & FCCU will be nil.
e. Civil Jobs: Requirements for buildings like substations, control rooms, process
operator cabins, warehouse, fire & safety building and mechanical workshop needs
to be studied for adequacy.
f. Analysis: Requirement of enhancement of existing laboratory needs to be further
explored.
Preliminary Project Feasibility Report (PFR) for setting up of Petro-Resid
Fludizied Catalytic Cracker at Mumbai Refinery.
Bharat Petroleum Corporation Limited, Mumbai Refinery Page 16 of 17
12 FININCIAL ANALYSIS
As per the preliminary estimates, the total project cost including all associated
facilities is expected to be in the range of Rs 7500 to 8500 Crores. Estimate with +/-
20% will be known during DFR. Considering the current cost of crude & products and
approximate yield from PRFCC, the approximate return on investment (ROI) is
expected to be 15%.
13 PROJECT IMPLEMENTATION SCHEDULE
An EPCM mode of construction is envisaged for the project.. Total project
implementation schedule after getting Environmental clearance, other statutory
approvals and final investment approval is expected to be around 36 Months.
14 HEALTH SAFETY & ENVIRONMENT
The unit shall be designed in accordance with local regulations, international industry
standards and codes.During DFR, priority will be given to maximize heat recovery by
means of heat integration with process streams which will reduce cooling water and
fan power consumption in rundown coolers.
It will be ensured that the addition of PRFCC and associated facilities shall not
exceed the SOx Emission rates beyond the current stipulated value of 10.4 TPD.
A flue gas scrubber will be provided to reduce the SOx and particulate emissions
from flue gases to local emissions stipulations. Combination of SCNR and SCR
technologies along with low NOx burners will be explored for use in CO incinerators
to reduce NOx emissions.
Water used for scrubbing will be sourced from stripped water coming out of
existingnonphenolic sour water stripper units thereby avoiding additional raw water
consumption. The purge water after treatment to remove solids will be sent to ETP.
Stripped water from new Sour water stripper will be routed to existing CDU desalters
due to presence of phenols and cyanides. This will also not be used in flue gas
scrubbers due to the contaminants mentioned.
Preliminary Project Feasibility Report (PFR) for setting up of Petro-Resid
Fludizied Catalytic Cracker at Mumbai Refinery.
Bharat Petroleum Corporation Limited, Mumbai Refinery Page 17 of 17
Sea water blowdown from sea water cooling towers will be sent to existing sea water
outfall. Steam Condensate blowdowns will be cooled and sent to existing ETP.
Solid wastes primarily comprise of catalysts collected in Third and Fourth Stage
Separators and Flue Gas scrubber. Additionally, spent catalysts are periodically
withdrawn. These solid wastes are usually used for landfilling or in cement
industries.
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