1.

Feed Filters: cartridge type 10-25 microns-not recommended due disposal issue or
automatic backwash systems 20-30 microns, very flexible & low maintenance but CAPEX
intensive, feed filtration is a must to avoid fouling and deposits

2. Feed pump: a beast with discharge pressure up to 200 barg, multistage high head
centrifugal with steam turbine / electrical motor, should be never operating below
min flow

3. Feed/Reactor Effluent HX: special design due to effluent characteristics & high
operating p & T 400°C / 190 barg, traditional or modified “D” TEMA type not
recommended due to maintenance / reliability issues, but special type from Lummus
Breech-lock high pressure is mandatory due to safe, easy & reliable conferred by
new breech lock pressure closure system

4. Fired Heater combined feed recommended due to high thermal efficiency, natural
draft or forced/induced usually gas fired. The heat distribution is approximately
70-73% in radiation section and the rest in convection with flame T 1800°C, bridge
wall T 780°C and Stack 205°C. Combined fired heater preferred option vs recycle gas
furnace because operates in elastic region & if thermal excursion occurs shall
remain in elastic region while the gas recycle furnace operates in creep region
with negative well known consequences

5. Reactors: ID up to 6.5-6.8 m with 400 mm wall thickness need to be forged ring

welded with mass flux impacting the ID, weight of reactor could arrive at 1100 MT
just to have an idea of magnitude. Inlet diffuser, top distribution tray quench
zone & mixing chamber, outlet collector are mandatory for a robust design

6. Hot HP Separator: vertical vessel operates up to 315°C minimize the downstream

air cooler size due to liquid separation, could be filled with a catalyst bed

7. High pressure Air Cooler: cool down 230-250°C the reactor effluent, wash water
at inlet is a must & the inlet/outlet manifolds shall assure proper distribution /
velocity to avoid corrosion issues

8. Low pressure Separator horizontal type operate at 55-60°C & 25-35 barg provide
adequate separation of hc vapor & gas & water-SS lined

9. Recycle Gas Compressor centrifugal not spare due to higher reliability but the
CAPEX is high powered by steam turbine / electrical motor

10. Stripper 32 real trays with 70% efficiency, main goal to stripp H2S by steam to
avoid downstream corrosion, must maintain a top T with 15-20°C higher than H2O dew
point & provision for corrosion inhibitor injection is a must

11. Main Column: 52 real trays, separate gas, LPG, Kerosene, Diesel & UCO, with the
main portion of UCO recycle back to 3rd hydrocracker reactor & the rest purged out
from system. 1.4 barg / 155°C on top, 2.0 barg / 262°C in bottom. The main
technical issue is the management of HPNA (heavy polynuclear aromatics) – at 350C
are in solution, at 200-210C start to drop from solution and at lower T 50C shall
agglomerate providing fouling.