REFINERY PROJECT2018

30,000 BPD full conversion refinery

REFINERY PROJECT

UNITS UNITS DESIGNMAX

m3/D

CRUDE 4,700

NHT 1,800

PLATFORMER - UOP 1,307

PENEX - UOP 500

DHT 1,275

FCCU - UOP 2,000

POLY -UOP 402

FCC MEROX - UOP 868

LDL MEROX - UOP 846

SAT LPG MEROX - UOP 138

UNSAT LPG MEROX -UOP 509

REFINERY PROJECT

• SITE ACERAGE

•

• ACRES Hectares•

• TERMINAL 6.52 2.63• TANK FARM 169.21 68.48• PROCESS AREA 46.24 18.72

• ADMINISTRATION 6.26 2.54• PONDS 21.00 8.49•

• TOTALS 249.20 100.86

Full Conversion Refinery

• The purpose of a full conversion refinery is to utilize as much of the crude oil in to make as much clear product as possible. Clear product is gasoline and diesel.

• These units are also designed to treat each individual product to that it meets or exceeds the required specification.

• A full conversion plant will make the products:

• Off gas- used to fire the heater furnaces

• Propane and Butane. Butane can be added to gasoline for specifications and propane is sold.

Full Conversion Refinery

• LSR – Light Strait Run Gasoline that is hydrotreated and then octane is improved through the Penex unit and then goes to the gasoline pool.

• HSR – Heavy Straight Run Gasoline is hydrotreated and then sent to the Reformer for Octane specification.

• Light Diesel-Kerosene-Jet Fuel goes into the diesel pool or is sold as individual products.

• Regular Diesel is hydrotreated and sent to storage for distribution.

• Atmosphic Gas Oil- AGO is sent to the FCCU again to split the bottom product into LPG’S, two different cuts of gasoline and a diesel product. All of these products are put into the gasoline and diesel pools.

Full Conversion Refinery

• The bottom of the crude tower will then go to the vacuum tower where Light vacuum gasoil, heavy vacuum oil along with the bottom of this tower will go to the FCCU unit.

• All of these different products will have specification and limitation as per the actual design of the refinery.

• This is just a very brief summary of the operation and capabilities of the refinery package.

• The following sheet is a simplified process flow sheet showing the product flows.

C

R

U

D

E

U

N

I

T

Saturated

Gas Plant

Naphtha

Hydrotreater

Kerosene

Merox

Distillate

Hydrotreater

Fluid

Catalytic

Cracker

Amine

Treating

Merox

Treating

Penex

Unit

Platformer

LPG.

Merox

FCCU Gas

Merox

Fuel Gas

Butane and

Propane

Gasoline

Diesel Fuel

Heavy Fuel

Oil

AsphaltVacuum

Unit

Deasphalter

Unit

Sulphur

Plant

Butane

Polymerization

Unit

Refinery Simulation

• The following slides will show a simply refinery Simulation program for optimization purposes.

• The initial crude feed is critical to determine optimization of the plant.

• The following is a example of a full distillation of a crude.

CRUDE FEED

Bonny Light Whole Crude Properties

G ravity, API° 35.30

G ravity SG 0.85

Sulfur, wt% 0.15

Total Nitrogen, ppm 1084.85

Acid Number, mg KOH /g 0.23

Pour Point, °C -11.48

Charact. Factor (K-FACTOR) 11.72

Viscos ity, cSt at 40°C (104°F) 3.28

Viscos ity, cSt at 50°C (122°F) 2.73

Vanadium, ppm 0.44

Nickel, ppm 4.13

MCR, wt% 1.24

Ramsbottom Carbon, wt% 1.02

Asphaltenes, (H .C7) wt% 0.01

Bonny Light SUMMARY OF MAJOR CUTS

Whole Light Medium H eavy Kero Atm Light H eavy Vacuum Atm

Crude Naphtha Naphtha Naphtha G as Oil VG O VG O Res id Res id

TBP Temp At Start, °C Start 10 80 150 200 260 340 450 570 340

TBP Temp At End, °C End 80 150 200 260 340 450 570 End End

TBP Temp At Start, °F Start 55 175 300 400 500 650 850 1050 650

TBP Temp At End, °F End 175 300 400 500 650 850 1050 End End

Yield at Start, vol% 2.2 8.6 25.9 35.4 48.2 68.5 87.2 95.3 68.5

Yield at End, vol% 8.6 25.9 35.4 48.2 68.5 87.2 95.3 100.0 100.0

Yield of Cut (wt% of Crude) 5.1 15.6 9.1 12.8 21.0 20.2 9.1 5.7 35.0

Yield of Cut (vol% of Crude) 6.5 17.2 9.5 12.8 20.4 18.7 8.1 4.7 31.5

G ravity, °API 35.3 81.6 53.5 43.4 36.0 30.6 23.4 16.7 7.0 19.0

Specific G ravity 0.85 0.66 0.76 0.81 0.84 0.87 0.91 0.96 1.02 0.94

Sulfur, wt% 0.15 0.00 0.00 0.01 0.05 0.13 0.23 0.35 0.61 0.32

Mercaptan Sulfur, ppm 0 1 2 3

Nitrogen, ppm 1085 0 0 1 8 93 875 3248 10428 3041

H ydrogen, wt% 16.1 14.2 14.0 13.4 12.9 12.5 11.8

Viscos ity @ 40 °C (104 °F), cSt 3.28 0.42 0.62 1.04 1.93 4.65 33.51 1.18E+03 2.E+07 2.08E+02

Viscos ity @ 50 °C (122 °F), cSt 2.73 0.40 0.57 0.91 1.65 3.72 21.93 5.14E+02 2.E+06 1.14E+02

Viscos ity @ 100 °C (212 °F), cSt 1.32 0.31 0.40 0.57 0.89 1.58 5.07 3.32E+01 5.E+03 1.50E+01

Viscos ity @ 135 °C (275 °F), cSt 0.93 0.28 0.35 0.46 0.67 1.04 2.63 1.10E+01 4.E+02 6.31E+00

Freeze Point, °C 34 -125 -100 -74 -44 -6 30 53 71 51

Freeze Point, °F 92 -192 -147 -101 -48 22 85 128 159 123

Pour Point, °C -11 -131 -105 -76 -47 -10 27 49 75 35

Pour Point, °F 11 -203 -157 -106 -53 14 80 120 167 95

Smoke Point, mm (ASTM) 10 36 32 27 20 14 8 4 2 4

Aniline Point, °C 68 71 54 54 58 67 79 85 91 82

Aniline Point, °F 154 160 129 129 136 153 174 185 195 180

Total Acid Number, mg KOH /g 0.2 0.0 0.0 0.0 0.0 0.1 0.2 0.2 0.2 0.2

Cetane Index, ASTM D4737 33 39 48

Diesel Index 54 131 69 56 49 47 41 31 14 34

Characterization Factor (K Factor) 11.7 12.6 11.6 11.5 11.5 11.6 11.6 11.7 11.6 11.6

Research Octane Number, Clear 75.5 65.1 37.4

Motor Octane Number, Clear 73.1 63.2

Paraffins , vol% 83.3 39.7 28.7 24.2

Naphthenes , vol% 16.7 46.4 57.2 57.1

Aromatics , vol% 0.0 13.9 14.1 18.7

Thiophenes , vol%

Molecular Weight 196 102 114 140 172 218 306 437 693 347

G ross H eating Value, MM BTU/bbl 5.83 4.85 5.39 5.63 5.81 5.95 6.14 6.32 6.57 6.26

G ross H eating Value, kcal/kg 10915 11584 11189 11038 10911 10816 10668 10508 10215 10562

Gross H eating Value, MJ/kg 45.7 48.5 46.8 46.2 45.7 45.3 44.6 44.0 42.7 44.2

H eptane Asphaltenes, wt% 0.0 0.2 0.0

Micro Carbon Res idue, wt% 1.2 20.0 3.5

Ramsbottom Carbon, wt% 1.0 16.4 2.9

Vanadium, ppm 0 8 1

Nickel, ppm 4 72 12

Iron, ppm 1 20 3

Date Assayed

2/7/2010

Crude

Bonny Light Whole Crude Properties

Gravity, API° 35.30

Gravity SG 0.85

Sulfur, wt% 0.15

Total Nitrogen, ppm 1084.85

Acid Number, mg KOH/g 0.23

Pour Point, °C -11.48

Charact. Factor (K-FACTOR) 11.72

Viscosity, cSt at 40°C (104°F) 3.28

Viscosity, cSt at 50°C (122°F) 2.73

Vanadium, ppm 0.44

Nickel, ppm 4.13

MCR, wt% 1.24

Ramsbottom Carbon, wt% 1.02

Asphaltenes, (H.C7) wt% 0.01

Bonny Light SUMMARY OF MAJOR CUTS

Whole Light Medium Heavy Kero Atm Light Heavy Vacuum Atm

Crude Naphtha Naphtha Naphtha Gas Oil VGO VGO Resid Resid

TBP Temp At Start, °C Start 10 80 150 200 260 340 450 570 340

TBP Temp At End, °C End 80 150 200 260 340 450 570 End End

TBP Temp At Start, °F Start 55 175 300 400 500 650 850 1050 650

TBP Temp At End, °F End 175 300 400 500 650 850 1050 End End

Yield at Start, vol% 2.2 8.6 25.9 35.4 48.2 68.5 87.2 95.3 68.5

Yield at End, vol% 8.6 25.9 35.4 48.2 68.5 87.2 95.3 100.0 100.0

Yield of Cut (wt% of Crude) 5.1 15.6 9.1 12.8 21.0 20.2 9.1 5.7 35.0

Yield of Cut (vol% of Crude) 6.5 17.2 9.5 12.8 20.4 18.7 8.1 4.7 31.5

Gravity, °API 35.3 81.6 53.5 43.4 36.0 30.6 23.4 16.7 7.0 19.0

Specific Gravity 0.85 0.66 0.76 0.81 0.84 0.87 0.91 0.96 1.02 0.94

Sulfur, wt% 0.15 0.00 0.00 0.01 0.05 0.13 0.23 0.35 0.61 0.32

Mercaptan Sulfur, ppm 0 1 2 3

Nitrogen, ppm 1085 0 0 1 8 93 875 3248 10428 3041

Hydrogen, wt% 16.1 14.2 14.0 13.4 12.9 12.5 11.8

Viscosity @ 40 °C (104 °F), cSt 3.28 0.42 0.62 1.04 1.93 4.65 33.51 1.18E+03 2.E+07 2.08E+02

Viscosity @ 50 °C (122 °F), cSt 2.73 0.40 0.57 0.91 1.65 3.72 21.93 5.14E+02 2.E+06 1.14E+02

Viscosity @ 100 °C (212 °F), cSt 1.32 0.31 0.40 0.57 0.89 1.58 5.07 3.32E+01 5.E+03 1.50E+01

Viscosity @ 135 °C (275 °F), cSt 0.93 0.28 0.35 0.46 0.67 1.04 2.63 1.10E+01 4.E+02 6.31E+00

Freeze Point, °C 34 -125 -100 -74 -44 -6 30 53 71 51

Freeze Point, °F 92 -192 -147 -101 -48 22 85 128 159 123

Pour Point, °C -11 -131 -105 -76 -47 -10 27 49 75 35

Pour Point, °F 11 -203 -157 -106 -53 14 80 120 167 95

Smoke Point, mm (ASTM) 10 36 32 27 20 14 8 4 2 4

Aniline Point, °C 68 71 54 54 58 67 79 85 91 82

Aniline Point, °F 154 160 129 129 136 153 174 185 195 180

Total Acid Number, mg KOH/g 0.2 0.0 0.0 0.0 0.0 0.1 0.2 0.2 0.2 0.2

Cetane Index, ASTM D4737 33 39 48

Diesel Index 54 131 69 56 49 47 41 31 14 34

Characterization Factor (K Factor) 11.7 12.6 11.6 11.5 11.5 11.6 11.6 11.7 11.6 11.6

Research Octane Number, Clear 75.5 65.1 37.4

Motor Octane Number, Clear 73.1 63.2

Paraffins, vol% 83.3 39.7 28.7 24.2

Naphthenes, vol% 16.7 46.4 57.2 57.1

Aromatics, vol% 0.0 13.9 14.1 18.7

Thiophenes, vol%

Molecular Weight 196 102 114 140 172 218 306 437 693 347

Gross Heating Value, MM BTU/bbl 5.83 4.85 5.39 5.63 5.81 5.95 6.14 6.32 6.57 6.26

Gross Heating Value, kcal/kg 10915 11584 11189 11038 10911 10816 10668 10508 10215 10562

Gross Heating Value, MJ/kg 45.7 48.5 46.8 46.2 45.7 45.3 44.6 44.0 42.7 44.2

Heptane Asphaltenes, wt% 0.0 0.2 0.0

Micro Carbon Residue, wt% 1.2 20.0 3.5

Ramsbottom Carbon, wt% 1.0 16.4 2.9

Vanadium, ppm 0 8 1

Nickel, ppm 4 72 12

Iron, ppm 1 20 3

Simulation Model

• The following is a typical model looking at the production, costs and product amounts for optimization of the process equipment.

REFINERY ECONOMICS REVIEW

REFERENCE PRICE

Bonney Light 0 PLATFORMING OPERATION

0 Enter the desired factor

POF (2) 0.83

BUY Volume m3/d Tons/d COST US/m3 TOTAL US

Bonney Light 4770.0 3776.9 0.0 0.00

0.0 0.0 0.0 0.00

Others

TOTAL 4770 3776.9 0.00 Capacity Utilization

CRUDE FEED 100.0 OK

VACUUM 98.3 OK

SELL Volume m3/d Tons/d PRICE US/m3 TOTAL US FCC FEED 79.5 OK

Propane 125.3 63.6 0.0 0.00 CC in FCC feed 0.66 OK

Butane 162.1 94.7 0.0 0.00

Premium Gasoline 212.1 168.3 0.0 0.00 NHT 80

Regular Gasoline 1918.7 1523.1 0.0 0.00 Diesel HTU 97

Low Oct. Gasoline 0.0 0.0 0.0 0.00 Platforming 68.1

Jet 751.5 607.3 0.0 0.00 Penex 111

Diesel 1253.3 1056.8 0.0 0.00 Poly 72

Mazut (1) 157.3 166.7 0.0 0.00

Asphaltenes 130.8 137.4 0.0 0.00 Overall Yield % 98.8

TOTAL 4711.0 3817.9 0.00

PRODUCT MARGIN 0.00

MARGIN/m3 CRUDE 0.00

NOTES:

(1) Mazut: Cat slurry oil + Vacuum Bottoms. Does not meet Mazut specifications.

(2) Platforming Operation Factor = RON 97 Platf operation / Platf operation

(3) Assumed price for Asphaltenes is 105 US/M3

REMARKS: No Extra Vacuum Capacity

CRUDE DISTILLATION UNIT

OVER HEAD 1589 OK

MAX CAP 2000

MIN CAP 1000

T end °C Yields %vol Vol

3.50 167

95 11.66 556

Bonney Light % 175 18.14 865

4770 100.0

250 15.76 752

4770 360 19.87 948

0 0.0

375 2.22 106

MAX CAP 4770

MIN CAP 3800

OK

Cap util 100.0 Con SG

510 16.40 782 0.01 1.217 0.10

SG 0.7918 550 4.06 194 0.65 0.957 1.20

550 + 8.40 401 12.75 0.999 51.07

28.86

VACUUM 1377 OK

MAX CAP 1400

MIN CAP 1000

Cap util 98.3

NOTES: 0

(1) All volumes in m3/d Con SG

0 12.54 1.1167

0.0

LPG

LN

KER

HDSL

LVGO

HVGO

VRC

CDUFEED

HN

AGO

To Mazut

To FCC

FLUID CATALYTIC CRACKING UNIT

Yields %vol Volume

Volume 106

C Carbon 0.01

SG 1.1486

7.6121 102.9

Volume 782 1.7279 23.4

C Carbon 0.01 287.5 7.08642 95.8

SG 1.2166 21% 3.73409 50.5

1.10949 15.0

Volume 194

C Carbon 0.65 52.15 704.8

SG 0.9570

21.7 293.3

Feed 1351

VCR C Carbon 0.66

Volume 68 SG 1.1234 11.64 157.3

C Carbon 12.75

SG 0.9990 Max Feed 1700

Min Feed 1200 OK

Aspheltene Content1.25 %w Max C Carbon 3.09

Min C Carbon 0.05 OK

DAO

Volume 202 Abottoms

C Carbon 0.01 VCR Volume 361.21 299.883

SG 0.9500 Feed 1644.4 1477.362

C Carbon 2.62 2.43

Atmospheric Bottoms SG 1.1012 1.2081

Volume 0.0

C Carbon 12.54 Cap util 79.5

SG 1.1167

NOTES:

(1) All volumes in m3/d

(2) Maximizing VRC to FCC, limitation ConCarbon Content

LVGO

HVGO

VRC

FEED

FCC

F GAS

C3

N CRAC

LCO

SLURRY

1. To Calculate DAO and Max Atmospheric Bottoms as a feed to FCC regarding

ConCarbon content and FCC Cap

C4=

C3=

iC4

nC4

Unsat LPG

AGO

2. To Calculate MAX VRC as a feed to FCC regarding

ConCarbon content and

FCC Cap

% Vol yield Volume To FCC

60.7 201.7 202

Feed

401 332.5 0.0

Resid From Vacuum

Tower

SG 0.999

Asphaltenes 1.25

39.3 130.8

68.3

68.32

0.0 0.0

NOTES: Max Cap 332.5

(1) All volumes in m3/d

De Asphalting

Unit

DAO

Asphaltenes

To Mazut

To FCC

To Mazut

DIESEL HYDROTREATER UNIT

Yields %vol Volume

Volume 948

SG 0.8200

Sulphur 0.550 2.0 24.8

2.0 24.8

Volume 293

SG 0.8709

Sulphur 0.500 101.0 1253.3

Feed 1241

SG 0.8320

S 0.54

Cap util 97.3

NOTES:

(1) All volumes in m3/d

HDSL

LCOHTU

LPG

To Naphtha HTU

DSL

CATALYTIC POLYMERIZATION UNIT

23.4

50.5

15.0

Flow 88.8

Volume

102.9 99.3

23.4

95.8

50.5

15.0

Cap util 71.5

NOTES:

(1) All volumes in m3/d

C3

C4=

C3=

iC4

nC4

Unsat LPGPOLY

LPG

Poly Gasoline

C3iC4

nC4

C5/C6 PENEX UNIT

551

556

Max Capacity 500

Capacity util 111

NOTES:

(1) All volumes in m3/d

ISOMER

ISOMERATE

LN

Case 2: Octane 97 2 Yields %vol Volume

0.745 5.5 776.1

0.529 3.9

Cap utilization 68.1

714 0.466 3.4

20

86.0 631.5

OCTANE 97

POF (2) 0.83

PLATFHN

C3

iC4

nC4

Platformate

nC4

Platformate

Nafta fromDHTU

LPG

Volume

167 125.27

24.8

13.9 162.1

88.8

NOTES:

(1) All volumes in m3/d

From CDU

From Diesel HTU

From Platformer

From Poly

C3's

C4'sLPG

BENZENE BLEND

Benzene - Premium 95.0

% Volumes to blend

14.1 From FCC 29.9

14.1 From Poly 29.9

66.9 From Platf. RON97 141.9

0.0 From Platf. RON90 0.0 212.1

0.0 From Platf. RON60 0.0

4.9 From Penex 10.3

Benzene - Regular 91.0

% Volumes to blend

40.9 From FCC 674.8

4.2 From Poly 69.4

29.7 From Platf. RON97 489.6

0.0 From Platf. RON90 0.0 1650.6

0.0 From Platf. RON60 0.0

25.2 From Penex 416.8

Benzene - Premium RON 95

Benzene - RegularRON 91

Benzene

Benzene

PLOT PLAN

Construction

• The refinery complex should be constructed as close to possible to utilize all the engineering and drawings as possible.

• Tank farm. The original plant had about 1.3 million barrels of total capacity. The refinery package has about one half of this capacity that will have to be constructed.

• We have a new AutoCAD drawing of the tank farm but before this is finalized, a technical review should be completed for optimized utilization of this area.

• The following is a Construction schedule.

0

100

200

300

400

500

600

700

800

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Manmonths

Months

CONSTRUCTION SCHEDULE

• All the utilities will have to be connected – steam, sewer system, fire water hydrant system, DCS system, flare.

• Tankage. There is about 400,000 barrel capacity included. Rolled

• Laboratory equipment for testing. Octane testing equipment, distillation machine, sulphur indication, cloud and pour cooler, flash equipment and may others.

• It is standard to have a product release form and retain program.

• There are chemicals that can be added to increase the octane such as MTBE, MMT, TAME. Here are may fact’s that must be considered as maximum addition rates, government regulations, cost and availability.

DRAWINGS AND DOCUMENTATION

• 3200 drawings of piping locations, undergrounds, electrical, instrumentation, foundations.

• Another 1500 drawings of vendor or as built drawings.

• Spool drawings

• Isometric drawings.

• P&ID drawings, mechanical drawings and as built,

• These drawings are not replaceable so that we must have control at all times so that they are under strict control.

• A copy machine will have to be available fro copying these drawings.

Piping Specifications

• Line list of all lines and specifications.

• Detailed list of all specifications related to material required for these line requirements.

• On P&IDs all lines have 36” PBA and number. These numbers can be related back so that you can see exactly the service of the line and what it is used for.

• We also have the engineering Specification book that is used for quality control in all aspects of the refinery equipment.

Match Marking

• When the refinery was taken down an engineering company did the match marking for the complete faculty.

• Pictures of all different pieces.

• Detailed location of the pieces.

• Set of drawings to match the pictures and documentation.

• All this information can be cross referenced.

Undergrounds

• We have a complete set of these drawings.

• We must use these drawings as a guideline but then incorporate the other areas that we must include.

• We must also look at what is required to complete these systems.

• There were some fire water hydrants brought with the refinery package but a review will have to be completed so that the full scope if covered to complete these systems for the refinery and the extra equipment that will be added.

Environmental

• We have the following for reference.

• Water permit usage and release.

• Flare release guidelines.

• Fugitive emissions permit and release guidelines.

• We have completed a emission study of the products and tanks emissions.

• Chemical usage

Catalysts and chemicals

• Catalysts for the equipment will be important. We will use the catalyst and chemical suppliers to give us the best product for the material and specifications that we require.

Spare Parts

• Spare parts inventory will be very important.

• We have the inventory records that were kept by part number and this can be referenced to each individual piece of equipment by equipment numbers.

• This information also indicates the frequency that they parts were used.

Storage Tanks

• A refinery of this size will have about 1.3 million barrels of capacity but will depend on many things.

• How is the crude coming in.

• How is the product going out.

• What tanks are needed for normal operations.

• An evaluation should be done when we know all of this information.

• We have to have a tank monitoring system – System like a Varec system or do in put it onto the Honeywell system.

Laboratory Equipment.

• What do we need to complete all tests.

• We must know the regulations or specifications required.

• We have a list of all equipment that was used in the past.

Buildings

• Office building

• Maintenance building

• Lunch rooms, washrooms.

• Control Building.

• We have the floor plan drawings for these buildings.

Utilities

• Water requirements

• Power requirements

• Fuel gas requirements over and above the amount that is produced in the plant.

• Nitrogen

• Hydrogen

Security and people

• Fence to isolate the facility.

• Security for the plant.

• How do handle fire protection and what is required.

• Foam systems deluge systems.

• These plants require trained experienced personal to operate them correctly.

Operation

• We have a team of individuals that have worked at the plant that will help with the construction, commissioning and start up of the facility.

• These individuals will train and work with in country employees.

• All start up, shut down and emergency procedures are available.