Bashundhara Oil & Gas Company Ltd. Doc. No.

FR/TC-DC-02

Bashundhara Bitumen
Dt. Of Issue Plant
16-Feb-2020

Technical Department
Rev. No. 00

Last Dt. Of
Document Name : Rev. **/**/****
Project Synopsis

Plant Diagam at a Glance

Sketch of Bashundhara Bitumen Plant, associated units and respective raw and products are as below:
 Bashundhara Oil & Gas Company Ltd. Doc. No. FR/TC-DC-02

Dt. Of Issue 16-Feb-2020

Bashundhara Bitumen Plant
Technical Department Rev. No. 00

Document Name : Project Synopsis Last Dt. Of Rev. **/**/****

Process Capacity at a glance

There is always bitumen crisis in the country due to the gap between the demand and supply. To meet the demand of increasing fuel, associated petroleum products
(bitumen, lubricant etc.) and various petroleum products, Bashundhara Oil and Gas Company Limited (BOGCL) has taken an initiative to setup a Bitumen plant
(Bashundhara Bitumen/Asphalt production plant) at the location of South Keraniganj area of Dhaka District.

Operating Parameters Design Specifications

Sl. No. of
Unit Capacity Remarks
No. Equip.
Pr (Mpa) Temp. (C) Internal External

Atmospheric Distillation Unit 1 500 Kton/A

1 0.08 126-370 48 trays
(1700 Kton/A)
1 1200 Kton/A

1 320 Kton/A
2 Vacuum Distillation Unit (1120Kton/A) Full vacuum/ 390-370
0.003 Mpa
1 800 Kton/A

3 Bitumen Oxidization Unit 1 30 Kton/A

4 Rubber Powder Plant 1 160 Kton/annum

5 SBS MB Plant 1 160 Kton/annum

6 Emulsified Bitumen Plant 1 80 Kton/annum

7 Cut back Bitumen Plant 1 80 Kton/annum

4 20000 m3
Tank Feed rate from
Heating by Jetty-650
8 Crude Oil Tank (110,000 m3) 0.101325 40~50
Steam m3/hr.Process feed
2 15000m3 rate 62.5m3/hr.

Filling rate from

9 3000 m3 process 34-
Heating by 4m3/hr.Delivery rate
9 Bitumen Tank (37,000 m3) 0.101325 150
Thermal Oil 60 m3/hr
1 10000 m3

2 2000 m3 Filling rate from

Furnace oil/ Fuel Oil/ Heavy Oil Tank Farm- 1 process 5m3/hr.
10 0.101325 60~70
(22,000 m3) Delivery rate 60
4 5000 m3 m3/hr

Furnace oil/ Fuel Oil/ Heavy Oil Tank Farm- 2 Filling rate from
11 4 5000 m3
(20,000 m3) process 5m3/hr.
0.101325 60~70
Delivery rate 60
12 Furnace oil/ Fuel Oil/ Heavy Oil Tank Farm- 3 4 15000 m3 m3/hr
(60,000 m3)

1 500 m3
Heating by Delivery rate
13 Slop Tank (25,00 m3) 0.101325 60~70
Thermal Oil 60m3/hr
2 2000 m3

0.6 mm 150 kg Drum weight

14 Drum Production Unit 1 7-8 drum/min thickness CR 9.9 kg; 180 kg Drum
coil weight 11.5 kg

15 Drum Filling Unit 1 400 drums/hr 150 50 drums/nozle

Fuel Consumption -
16 ADU Furnace 1 8 MMkcal 0.2 365 60 hg/hr

Fuel Consumption -
17 VDU Furnace 1 3 MMKcal 0.01 365 24 hg/hr

18 Steam Boiler 1 10 ton/hr 1.25

19 Thermal Oil Boiler 1 3 MMKcal 320

20 Thermal Oil Boiler 1 6 MMKcal 320

21 Waste Water Treatment 1 300 ton/day

22 Fire Fighting Water Tank 2 2500 m3

 Bashundhara Oil & Gas Company Ltd. Doc. No. FR/TC-DC-02

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Bashundhara Bitumen Plant
Technical Department Rev. No. 00

Document Name : Project Synopsis Last Dt. Of Rev. **/**/****

Tank Firm Summary

The tank firm consist of different tanks of different volumes and types for raw, product and bi-product storage and blending purposes. The raw material is heavy
bituminous crude oil and the main product is high quality Bitumen. Also insignificant amount of naptha, diesel, furnace oil will be produced. A tank from by-product tanks
will be selected for necessary blending.

Sl. No. Units V- 2401~2408 V- 2201~2204 V- 2301~2304 V- 2205~2206 V- 2305 V- 2101~2104 Remarks

1 Fluid Bitumen Diesel Furnace Oil Naphtha Unqualified Oil Crude

Internal Floating Inner Floating Inner Floating Inner Floating

2 Tank Type Dome Roof Dome Roof
Roof Roof Roof Roof

3 Number Of Tank 8 4 4 2 1 4

4 Height, m 13.4 13.6 13.6 13.4 10.1 23.5

5 Nominal Height, m 10.8 10.5 10.5 11.3 8.92 18.2

6 Diameter, m 20 25 25 16 8.92 38

7 Tank Capacity, m3 3393 5154 5154 2272 557 20641

8 Tank Capacity (Calibrated) m3 3388 5126 5126 2259 - 20491

9 Cross sectional area, m2 314 491 491 201 62 1134

10 Circumference, m 63 79 79 50 28 119

11 Maximum filling Height, m 10.6 10 10.4 10.7 - 17.5

12 Maximum filling Capacity, m3 3344 4894 5089 2160 0 19803

13 Maximum flow rate, m3/hr 26 10 10 10 - 650

14 Safe Filling Height, m 10 9.8 9.8 10.5 - 17.1

15 Safe Filling Height, % 94 98 95 98 - 98

16 Safe Filling Capacity, m3 3142 4811 4811 2111 0 19337

17
Time Required To Safe Filling
Height, hr
121 481 481 211 - 30

18 Increment Rate, m/min 0.0014 0.0003 0.0003 0.0008 0 0.0096

19
Difference In Height Between
Max & Safe Filling Height, m
0.65 0.17 0.57 0.24 - 0.41

20
Time Required To Reach Safe To
Maximum Filling Height, min
467.62 500.69 1672.9 293.15 - 43.03

21 Area Of Shell, m2 842 1068 1068 674 283 2805

22 Thermal Insulation/thikness - - Rock Wool/80 - Rock Wool/80 -

Prortective layer (Galvanized
23 Yes No Yes No Yes No
Steel Sheet) 󠆶δ =0.5mm

Product flow required to implement response action, t= 467 min

Maximum flow rate into tank, F= 163.54 bbl/hr

Total TankHeight. H= 34.9156 ft

Tank rated capacity, C= 21310.52 BBL

Differential Height, h= 25 inch
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Drum Plant Summary

The produced bitumen will be transferred from bitumen storage tanks to drum production unit and refilled into drums of different dimensions and
sizes for loading to customer ends.

Bitumen Production Capacity Bitumen Storage Capacity

Phase-1 : 300,000 ton/year Phase 1 08 Tanks 3000 m3 24000 ton

Phase-2 : 700,000 ton/year 01 tanks 10000 m3 10000 ton

Phase 2
Total : 1,000,000 ton/year 01 tanks 3000 m3 3000 ton

Drums Production Phase 1 Phase 1 & 2

Capacity
900 tons/day 3000 tons/day Considering Safe operating height 90%

38 tons/hr 125 tons/hr Deadstock 10%

Considering 01 tons/min 02 tons/min Phase 1 Phase 1 & 2

150 kg drum 03 drums/min 14 drums/min Operable capacity 19200 ton 29600 ton

180 kg drum 03 drums/min 12 drums/min Maximum Hold-up Days 21 days 10 days

Drum Requirement/Day Drum Production Capacity

Considering Phase 1 Phase 2 Drum Production Capacity 7pcs/min

150kg drum 6000 drums 20000 drums No. of working shift 3

180kg drum 5000 drums 16667 drums Unit efficiency 100%

OR No. of working days 7 day

150kg drum 180kg drum No. of Drum produced per day 10080 Pcs
Mix Delivery
100% 0%

Phase 1 6000 drums 0 drum Drum requirement per day Phase 1 Phase 1 & 2

Phase 1 & 2 20000 drums 0 drum 6000 pcs 20000 pcs

Filling Line Drum Transportation

Number of filling nozzles 17 pcs Large Medium Small

Filling nozzle capacity 7500 kg/hr Dimension 52'x16' 30'x14' 22'x14'

No of working shift 3 Delivered/lorry 277 Pcs 140 Pcs 102 Pcs

Unit efficiency 100% No. of vehicles required

No of working days 7 day Phase 1 22 43 59

Total filling capacity/day 3060 ton Phase 1 & 2 72 143 196

Gross weight in (ton) = drum weight + product weight

Phase 1 Phase 2 For 150 kg Drum 45 ton 23 ton 17 ton

Total filling
requirement/day
900 ton 3000 ton For 180 kg Drum 55 ton 28 ton 20 ton
 Bashundhara Oil & Gas Company Ltd. Doc. No. FR/TC-DC-02

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Jetty at a glance

Bitumen Plant of Bashundhara Oil and Gas Company Ltd. has got a 220 meter long jetty for loading & unloading of petroleum products. It has the
capacity to berth two 5000DWT oil ships at the same time. There are three DN300 and one DN200 loading & unloading arms for loading & unloading
operation.

Design Parameters

Diameter DN300/DN200

Design temperature -10℃ ~100℃

Design pressure 1.6MPa

Pipe material 20# steel

Flange standard（To HG/T20592-2009B
dock）
Drive method Electric hydraulic driving
Inner, outer arm drifting Max.135°
range
Alarm grade 1: 122° ； Alarm grade 2:
133°（release）
Horizontal drifting range Max.±42°
Alarm grade 1: 32° ； Alarm grade 2:
40°（release）
Weight 26T
 Bashundhara Oil & Gas Company Ltd. Doc. No. FR/TC-DC-02

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Maintenance (Electrical)

There are 1 main substation and 5 distribution substation for power supply at different locations of BOGCL plant.

Serial no. Equipment Name Quantity Remarks

Emergency DG Set

1 Capacity: 1500 KVA 1 set

Voltage: 11 KV

10/14 MVA Transformer

2 33/11 KV 1 set

Dyn 11

33 KV Switchboard

3 I/C Feeder -01, 1 set

O/G Feeder -03

11 KV Switchboard

4 I/C Feeder -02, 01 set

O/G Feeder -04

5 Total Sanction Load 5 MW

6 Total Connected Load 7.8 MW

 Bashundhara Oil & Gas Company Ltd. Doc. No. FR/TC-DC-02

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DCS Control Room Summary

BOGCL operation will be carried out from the fire proof control room through DCS (Distributed Control System). Both phase-1
and 2 operation facilities are accomodated from the same control room.

Brand : Hollysys
Number of Operator Panel : 5
Number of Control Cabinet : 2
Number of Extension Cabinet : 1
Number of Operating Station : 3
Number of Historical Station : 1
Number of Engineering Work Station : 1
Number of HMI’s : 3
For Phase 1: 1 Nos
For Phase 2: 1 Nos
For Camera : 1 Nos
 Bashundhara Oil & Gas Company Ltd.
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Maintenance (Mechanical)

The purpose of the mechanical workshop is to carry-out the routine maintenance of the stationary and rotating
equipment and troubleshoot while necessary. BOGCL maintenance workshop is facilitated with the following machine
and tools.

SL. No. Equipment Name Quantity Remarks

1 Lathe machine 3

2   Shaping Machine 1

3 Plano Milling Machine 1

4 Slotting Machine 1

5 Radial Drilling Machine 1

6 Portable Hydraulic Press 1

7     Drilling Machine: 1

8    Bench grinder 2

9 Balancing Machine 1

10 Slotting Machine 1
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Utlility at a glance

BOGCL utility consists of Fresh water supply, Reverse Osmosis unit, three boilers (one thermal and two steam), compressor unit and
cooling tower.

Fresh Water Reverse Osmosis

Source : Underground Water Capacity : 20 Ton/Hour
Two Submersible Pumps Recovery Rate : ≥70% (at ≥ 25°C)
1. Power : 3% decrease for every 1°C temp. decrease
2. Flow Rate : Desalinization Rate : ≥97%
Storage :
Two Circulating Pumps :
1. Power :
2. Flow Rate :

Reverse Osmosis Diagram

Steam Boiler (1) Thermal Boiler (2)

Capacity : 10 T/H Capacity of Boiler in KCal 3million 6million

Heating Surface : 2840 ft2 HFO/diesel HFO/diesel

Firing Medium (fuel) gas, diesel,
HFO or combination
Steam Pressure : 1 MPa combination
Thermal oil operating
Steam Temperature : 193°C 320℃
temperature
Fuel Consumption : 588.8 kg/h Thermos oil tank 30m3 sharing with 6million k.cal thermos boiler

Boiler Drum Capacity : 20 T Expansion tank 4.5m3 10m3

Boiler Hydro test Pressure: 1.65Mpa Circulation pump 200m3/h, 60m head

Economizer: 92.8m2 Control system with PLC PLC+Touch screen

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Waste Water Treatment Plant Quality
The goal of wastewater treatment is to transform raw sewage into water clean enough to be discharged into a lake or stream without
causing harmful environmental or ecological consequences. Dhaka Refinery of BOGCL is zero discharge plant. The Design Scale of the WWTP
is 300 ton/day (12.5 m3/hr).

Low concentration wastewater High concentration wastewater

Low concentration wastewater quantity is high (80% of the total discharged)
Low concentration wastewater mainly contains oily sewage
Oily sewage generated by equipment, waste water produced in circulating
water field, rain and water leakage caused by leakage of underground oily
sewage pipeline.
High concentration wastewater quantity is low.
High concentration wastewater mainly contains acid water
Acid water generated by
Crude Oil Separated Water: High oil content oil and high COD
Electric desalting wastewater: High salinity and high COD
concentration ( Demulsifier Injection).
ADU & VDU top condensate water: High sulfur content

The Design Scale of the WWTP is 300 ton/day (12.5 m3/hr).

Quality of Waste Water Major Units of WWTP

CODcr: ≤2500mg/L; BOD: ≤700mg/L; Desulfurization pool, Hydrolytic acidification tank

Oil: ≤800mg/L; Sulfide: ≤30mg/L. Grid canals, Secondary sedimentation tank

NH-N: ≤120mg/L; - Suspended solids: ≤500mg/L; Two Stage oil-separated sedimentation tank

pH: 6-9; Volatile phenol: ≤50mg/L; Anoxic tank, Aerobic tank

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Laboratory Facilities

The following experiments and characterizations of raw and products are available under BOGCL QC department.

SL. No. Instrument Name Method Test Name Remarks

1 Salt content tester ASTM D6470 Salt Content

2 Copper corrosion tester ASTM D130 Copper Corrosion

3 Distilled water GB Method -

4 Cetane number tester ASTM D613 Cetane number

5 Cetane Index (calculated) ASTM D976,D4737 Cetane Index

6 Marshall Stability tester ASTM D6927 Marshall stability

7 Marshall hammer (Compactor) ASTM D1557-70 Marshall hammer compactor

8 Automatic vapor pressure tester ASTM D323 Vapor pressure

9 Conradson carbon residue tester ASTM D189 Carbon residue

10 GC (Gas Chromatography) GB Method Qualitative/Quantative analysis

11 Distillation Range instrument ASTM D86 Distillation

12 Vacuum Distillation range Instrument ASTM D1160 Vacuum Distillation

13 Water content analyser ASTM D95 watter content

14 Brookfield viscosity tester ASTM D789,D4878 Viscosity

15 Kinamatic viscosity tester ASTM D445 Viscosity

16 High speed shearing machine GB Method -

17 Blender GB Method -

18 Engler viscosity tester GB/T266 Viscosity

19 Color meter ASTM D1500 Color

20 Sulfur (chlorine) content tester GB Method Sulphur/Chlorine

21 Calorific value tester ASTM D240 Calorific value

22 Mechanical impurities tester GB/T511 Impurities

23 Open cup flash point (Clevland ) ASTM D92 Flash point

24 Closed cup flash point (PM) ASTM D93 Flash point

25 Softening point tester ASTM D36 Softening point

26 Penetrometer ASTM D5 Penetration

27 Ductility tester ASTM D113 Ductility

28 Drying oven GB Method -

29 Densimeter ASTM D1298 Density

 SL. No. Instrument Name Method Test Name Remarks

30 Acid value ASTM D974 Acidity

31 High temperature furnace ASTM D482 -

32 Circulating water bath GB Method -

33 Constant temperature water bath GB Method -

34 Oxidation stability tester ASTM D2274 Oxidation Stability

35 Asphalt content tester GB/T3536 Asphalt content

36 Solidifying point tester ASTM D97 Solidifying point

37 Ash content tester ASTM D482 Ash content

38 Rut test ASTM E1703 Rut test

39 Mixing Machine GB Method -

40 Thin film oven (Aging Test) ASTM D1754 Aging test

41 Ordinary electronic balance GB Method -

42 1/10000 balance GB Method -

43 Electric stove GB Method -

44 Rutting forming machine GB Method -

45 Sulfur content tester (Lamp Method) GB/T380 Sulphur content

46 Alkalinity hardness machine GB Method Alkalinity, Hardness

47 Multi-parameter water quality analyzer GB Method **

48 Multi-parameter combination analyzer GB Method ***

49 PH meter GB Method pH

50 Dissolved oxygen meter GB Method D.O

51 Infrared oil content analyzer GB Method Oil content

52 BOD analysis instrument GB Method BOD

53 Total Kjeldahl nitrogen/TKN GB Method TKN

** COD, Ammonia nitrogen, Total Phosphorus, Total nitrogen, Chromaticity, Turbidity, suspended solid Iron, Hexavalent chromium, Total
chromium, Zn,Cu, Ni, F, CN.

*** Chloride, Sulfide, Phenol, Aniline, Mn, Hg, Pb, Al, SS, Ad-Anaonic detergent.
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Emergency Fire Management System

The purpose of emmergency fire management system is to suuport the plant for incident free operation and ensure proper respose during any emmergency. The capacity of
the fire management system is as below:

SL No. Fire Fighting Equipment Quantity Capacity Specifications Remarks

Fire Water Reservoir 5 9450 m3 two 2500m3 fire water reservoir, one 2300m3 fresh water pool &
two rainwater pool of 2150m3 (1800m3 + 350m3)

Working pressure: 16 Bar

Fire water Hydrant 110 Operation Height of Opening: ≥50
1 Flow rate: <31.5L/s

Max Range: 65m,

Working pressure: 16 Bar
Fire Monitors 32 Range of motion: -45°~+90°Vert , Flow rate: 30-40-50L/s
360°Rot

Mixing Ratio: 6%,

Flow rate: 48-80 L/s,
Foam Bladder Tank 3 each bladder tank is 10m3. Working pressure range: .6 ~ 1.2 Mpa
2 Suitable foam type: P Type

Working pressure: 16 Bar

Foam Hydrant 34 Operation Height of Opening: ≥51
Flow rate: <31.5L/s

Power: 11.95 kW
Pressure stabilizer pump 2 Flow rate: 30m3/h Head: 100m

3
Electric Pump 2   Flow rate: 432m3/h    Power: 220 kW
Head: 100m
    Power: 280 kW
Diesel Engine pump 2 Flow rate: 432m3/h Head: 105m

Each circle
Water Spray System
4 (Only in Crude Tank)
contains 80 6 L/min Working pressure: 2 Bar
sprays

Spray Duration (s) :.12 sec

153 10 L Working range(m) : 3 m

Foam Extinguisher
Spray Duration (s) :.30 sec
31 25 L
Working range(m) : 6 m

Spray Duration (s) :.12 sec

5 210 5 kg
Working range(m) : 3 m
DCP Extinguisher
Spray Duration (s) :.30 sec
15 25 Kg Working range(m) : 6 m

Spray Duration (s) :.12 sec

164 5 kg Working range(m) : 3-4 m
CO2 Extinguisher

8 25 kg Spray Duration (s) :.35 sec

Working range(m) : 6-10 m

Water discharge range: 65m Horizontal rotation angle: 150-160 Degree

6 Fire Cannon tower 4 Foam discharge range : 58 m Follow angle adjustable: -15° to +60°

Water tanker capacity : 10000 L Water flow rate: 50 L/s

7 Fire Fighting Truck 1
Foam flow rate : 48 L/s
Foam tanker capacity : 5000 L

13 Explosion-proof camera

15 Explosion proof acousto-optic alarm

Fire monitoring & covers all around the plant to monitor and announce if any fire
announcing system incident happens in the plant

8
SL No. Fire Fighting Equipment Quantity Capacity Specifications Remarks
Fire monitoring & covers all around the plant to monitor and announce if any fire
announcing system Explosion-proof manual fire alarm incident happens in the plant
39 button
8
6 Water and dust proof camera

9 Manual fire alarm button

Fire monitoring & covers all around the plant to monitor and announce if any fire
announcing system incident happens in the plant
5 Acousto-optic alarm

Detects Flammable Gas ( like

9 Gas Detector 50 CH4,C2H6,C2H4,C3H6,C2H2,C3H4 etc.) covers Process area, Crude & Diesel Tank zone
& Toxic Gas (H2,H2S, PH3)

All the Fire Pannel, Smoke Detector, Heat

Smoke & Heat Detection covers office building and all the enclosed places of all over the
10 System
enclosed Detector, Manual Call Point, Bell,
plant
building Sprinkler etc.