415 120 DB 0001

Refinery Fourth Expansion Project RFP-04-2018
KBR RESIDUE UPGRADING UNIT (VCC)

PAGE 1 OF 30
PROCESS DESIGN BASIS
10180-415-120-DB-0001 REV.: 01

415 - KBR RESIDUE UPGRADING UNIT (VCC) WITH INTEGRATED DIESEL HYDROTREATER
Document Category: 1
01 21-Mar-2019 Issued for FEED L. Veleda J. Y. Moro J. M. Muñoz
00 28-Sept-2018 Issued for Approval J. Seco J. Y. Moro J. M. Muñoz
REV. DATE ISSUE PREPARED BY CHECKED BY APPROVED BY
This document is property of Técnicas Reunidas. Its reproduction without previous permission in writing is strictly forbidden.
PAGE 2 OF 30
10180-415-120-DB-0001 REV.: 01
INDEX
1. GENERAL ....................................................................................................................... 3
2. CODES, STANDARD AND SPECIFICATIONS............................................................... 3
3. PROCESS BASIS OF DESIGN ....................................................................................... 4
3.1 UNIT CAPACITY ....................................................................................................... 4
3.1.1 Design Capacity ................................................................................................. 4
3.1.2 Turn Down Ratio ................................................................................................ 4
3.2 PROCESS FEEDSTOCK .......................................................................................... 4
3.2.1 Definitions of various design cases ................................................................. 4
3.2.2 Modes of Operation............................................................................................ 4
3.2.3 Feedstock Definition .......................................................................................... 5
3.3 PROCESS PRODUCT ............................................................................................ 11
3.4 BATTERY LIMIT CONDITIONS FOR PROCESS STREAMS ................................. 24
3.4.1 Feed Streams.................................................................................................... 24
3.4.2 Product Streams .............................................................................................. 25
3.5 BATTERY LIMIT CONDITIONS FOR UTILITY STREAMS ..................................... 26
3.6 ADDITIONAL CONSIDERATIONS ......................................................................... 26
3.6.1 Design pressure for Recycle Gas Compressor Circuit ................................. 26
3.6.2 Reactor Theoretical Yields .............................................................................. 26
4. GUARANTEED YIELDS AND PRODUCT INFORMATION........................................... 29
5. PROCESS ENERGY RECOVERY ................................................................................ 29
6. CATALYST INFORMATION ......................................................................................... 30
7. UNIT RUN LENGTH ...................................................................................................... 30
8. ENVIRONMENTAL EMISSIONS ................................................................................... 30
PAGE 3 OF 30
10180-415-120-DB-0001 REV.: 01
1. GENERAL
Jordan Petroleum Refinery Company Ltd. (JPRC), Amman—The Hashemite Kingdom of

Jordan, is planning a Refinery Fourth Expansion Project at the JPRC Refinery in Zarka City.
The objective of the Refinery Fourth Expansion Project (RFEP) is to enable the Refinery to
sustain its refining operations by competitively helping to meet the projected local demand for
gasoline and distillate products that meet the latest applicable European vehicle emission
standards.
The VCC™ process licensed by KBR is a residue upgrading technology used for processing
residuum into premium quality products. The JPRC VCCTM unit converts VR to lighter
product, sending an untreated VGO product OSBL to the Unicracker unit and then treats the
Naphtha and Diesel fractions such that the low Sulfur Diesel Product is sent to Diesel
product blending and Naphtha OSBL to the NHT unit.
2. CODES, STANDARD AND SPECIFICATIONS
In general, the Plant will be designed in accordance with internationally recognized codes
and standards, such as API, ASME, ANSI, IEC, ISA, NFPA, PIP. Jordanian Codes and
Standards, as well as local Laws and Safety Norms will also be considered where applicable.
The following project specification shall be also considered:
• Basic Engineering Design Data (Doc. Nº: 10180-000-120-GE-0001)
• Process Design Criteria (Doc. Nº: 10180-000-120-GE-0002)
• Isolation Philosophy (Doc. Nº: 10180-000-120-GE-0004)
• Drainage And Slops Philosophy (Doc. Nº: 10180-000-120-GE-0005)
• Sparing Philosophy (Doc. Nº: 10180-000-120-GE-0006)
• Flare and Vent Philosophy (Doc. Nº: 10180-000-120-GE-0008)
• Numbering Procedure (Doc. Nº: 10180-000-110-PD-0004)
PAGE 4 OF 30
10180-415-120-DB-0001 REV.: 01
3. PROCESS BASIS OF DESIGN
3.1 UNIT CAPACITY
3.1.1 Design Capacity
The VCC Unit (415) will be designed for processing 18902 BPSD for the Basrah Case and
18418 BPSD for the Arab Light Case. Design capacity is 110% of indicated capacity.
3.1.2 Turn Down Ratio
The Unit 415 will have a turndown ratio of 50%.
3.2 PROCESS FEEDSTOCK
3.2.1 Definitions of various design cases
The feed to the Refinery Complex will be Basrah Crude or Arab Light Crude coming from
floating roaf tanks. VCC Unit (415) will process the vacuum residue from existing VDU 2 Unit,
New VDU 3 Unit, Storage, and slurry from existing FCC Unit. Thus, it will consider two
possible feedstock compositions depending on the crude fed to the refinery. See Section
3.2.3 for each Feedstock composition.
Additionally, VCC Unit (415) will require a make-up of hydrogen, necessary for hydrocracking
reactions involved in the reactors, lean amine for treating the recycle gas and H2 rich gas,
and wash water to remove H2S and Ammonia from the process.
3.2.2 Modes of Operation
VCC Unit will have different modes of operation depending on the kind of crude fed to the
Refinery and the catalyst life time:
- Arab Light SOR

- Arab Light EOR
- Basrah SOR
- Basrah EOR
Additional check cases will be considered, as required by KBR to ensure operability of the
unit, and may affect the equipment design; examples include start-up case, low conversion
case, etc.
PAGE 5 OF 30
10180-415-120-DB-0001 REV.: 01
3.2.3 Feedstock Definition
The feed characterization for the Arab Light Design Case is shown in table below:
Referenc VR 1 VR 2 Existing
Parameters e UOM (Existing (New FCC BLEND 1
Method VDU 2) VDU3) Slurry
Total Feed Rate MTPD 527 2457 34 3018
Volumetric Feed Rate 4 Calc m3/hr 21.62 99.4 1.31 122.3
Volumetric Feed Rate 4 Calc bpsd 3255 14966 197 18418
Specific Gravity @
Calc - 1.015 1.030 1.071 1.028
15ºC
ASTM
Sulfur wt% 4.144 4.35 3.315 4.302
D4294
ASTM
Nitrogen ppmw 2961 3386 1900 3295
D4629
Oxygen ppmw 3000 3 3000 3 1190 3 2980 3
ASTM
CON Carbon wt% 17.62 21 2.7 20.2
D4530
UOP K Calc 11.59 11.58 N/A
Nickel IP 501 ppmw 21.25 26 0.8 24.6
Vanadium IP 501 ppmw 55.93 67 2.8 65.4
Iron ppmw 7.36 3 8.95 3 0.28 3 8.57 3
Asphaltenes (heptane
IP 143 wt% 5.93 7.2 0.12 6.90
insoluble asphaltene)
ASTM
Hydrogen Content wt% 10.52 3 10.44 3 7.20 3 10.42 3
D5291
Chloride Content5 Calc ppmw 40 27 N/A
Arsenic2 IP 501 ppmw Nil Nil Nil Nil
2
Silicon IP 501 ppmw Nil Nil Nil Nil
Solids wt% N/A N/A N/A
Viscosity @ 104 ºF
cSt 62979.7 389175.7 142.4 79265.3
(40ºC)
Viscosity @ 122 ºF
cSt 10131.5 40202.3 72.4 28003.5
(50ºC)
Viscosity @ 212ºF
cSt 380.9 938.9 7.2 741.2
(100ºC)
Viscosity @ 284ºF
cSt 77.2 151.1 1.4 124.4
(140ºC)
PAGE 6 OF 30
10180-415-120-DB-0001 REV.: 01
VR 1 VR 2 Existing
Reference
Parameters UOM (Existing (New FCC BLEND1
Method
VDU 2) VDU3) Slurry
ASTM Distillation D2887/ TBP @ 760
D2887 D2887 D1160
Method D1160/TBP mmHg
Initial Boiling Point ºC 449.6 478.1 306 451
5% Point ºC 508.9 538.6 351 525
10% Point ºC 527.4 557.1 356 547
20% Point ºC 553.1 584.5 364
30% Point ºC 576.4 613.7 373 604
50% Point ºC 642.5 672.3 406 666
70% Point ºC 721.4 749.6 442 743
80% Point ºC 780.5 811.2 467
85% Point ºC 835.7 862.1 N/A
90% Point ºC 888.3 911.4 508 907
95% Point ºC 957.6 970.1 N/A 967
End Point ºC 1031.3 1031.3 541 1031
Notes:
1. Blend information by KBR.
2. Arsenic and Silicon are “non-detectable”, as confirmed via communication RE: H122-
KJ-L-0007 KBR / JPRC questions to UOP, dated 9-Nov-2017.
3. Estimated values.
4. Volumetric flowrate is slightly different from the UOP estimates due to conversion
factor.
5. Chloride based on 1ptb residual salt in new crude unit and 3 ptb in existing CDU III
desalted crude.
PAGE 7 OF 30
10180-415-120-DB-0001 REV.: 01
The feed characterization for the Basrah Design Case is shown in table below:
VR 1 VR 2 Existing
Referenc
Parameters UOM (Existing (New FCC BLEND 1
e Method
VDU 2) VDU3) Slurry
Total Feed Rate MTPD 556 2547 34 3137
Volumetric Feed Rate 4 Calc m3/hr 22.59 101.65 1.31 125.6
Volumetric Feed Rate 4 Calc bpsd 3401 15304 197 18902
Specific Gravity @
Calc - 1.026 1.044 1.071 1.041
15ºC
ASTM
Sulfur wt% 4.72 5.06 3.315 4.984
D4294
ASTM
Nitrogen ppmw 3542 3985 3500 3901
D4629
Oxygen ppmw 2200 3 2343 3 1190 3 2305 3
ASTM
CON Carbon wt% 19.57 23.8 2.7 22.8
D4530
UOP K Calc 11.4 11.42 N/A
Nickel IP 501 ppmw 26.97 34 0.8 32.2
Vanadium IP 501 ppmw 95.42 119 2.8 113.7
Iron ppmw 8.39 10.2 0.25 3 9.77 3
Asphaltenes (heptane
IP 143 wt% 9.19 11.5 0.12 10.99
insoluble asphaltene)
ASTM
Hydrogen Content wt% 10.08 9.99 7.20 9.98
D5291
Chloride Content5 Calc ppmw 40 25 N/A
Arsenic2 IP 501 ppmw Nil Nil Nil Nil
Silicon2 IP 501 ppmw Nil Nil Nil Nil
Solids wt% N/A N/A N/A
Viscosity @ 104 ºF
cSt 102136.2 1005319.6 142.4 2714020.8
(40ºC)
Viscosity @ 122 ºF
cSt 88969 859623.2 72.4 544123.7
(50ºC)
Viscosity @ 212ºF
cSt 1176.2 3309.2 7.2 2447.9
(100ºC)
Viscosity @ 284ºF
cSt 122.5 275.4 1.4 217.8
(140ºC)
PAGE 8 OF 30
10180-415-120-DB-0001 REV.: 01
VR 1 VR 2 Existing
Reference
Parameters UOM (Existing (New FCC BLEND1
Method
VDU 2) VDU3) Slurry
ASTM Distillation D2887/ TBP @ 760
D2887 D2887 D1160
Method D1160/TBP mmHg
Initial Boiling Point ºC 453.6 477 306 456
5% Point ºC 509.3 536.5 351 524
10% Point ºC 525.1 552.2 356 543
20% Point ºC 548.6 574.5 364
30% Point ºC 566.3 600.6 373 593
50% Point ºC 626.8 672.9 406 663
70% Point ºC 725.1 756.4 442 750
80% Point ºC 780.3 803.4 467
85% Point ºC 825.7 852.4 N/A
90% Point ºC 869.2 896.4 508 892
95% Point ºC 947.9 970.4 N/A 965
End Point ºC 1093.3 1093.3 541 1092
Notes:
1. Blend information by KBR.
2. Arsenic and Silicon are “non-detectable”, as confirmed via communication RE: H122-
KJ-L-0007 KBR / JPRC questions to UOP, dated 9-Nov-2017.
3. Estimated values.
4. Volumetric flowrate is slightly different from the UOP estimates due to conversion
factor.
5. Chloride based on 1ptb residual salt in new crude unit and 3 ptb in existing CDU III
desalted crude.
PAGE 9 OF 30
10180-415-120-DB-0001 REV.: 01
Makeup Hydrogen is required to convert and treat the unit feed to clean transportation fuels.
The makeup rate depends on unit feed rates, properties and catalyst life time. The table
below lists the makeup hydrogen composition for the different cases.
Arab Light Basrah

Hydrogen Composition
SOR EOR SOR EOR
Mole % Mole % Mole % Mole %
WATER 0.0082% 0.0082% 0.0082% 0.0079%
AMMONIA 0.0000% 0.0000% 0.0000% 0.0000%
OXYGEN 0.0000% 0.0000% 0.0000% 0.0000%
NITROGEN 0.0000% 0.0000% 0.0000% 0.0000%
HYDROGEN SULFIDE 0.0000% 0.0000% 0.0000% 0.0000%
HYDROGEN 99.3675% 99.3699% 99.3677% 99.3872%
METHANE 0.4031% 0.4017% 0.4030% 0.3919%
ETHANE 0.1577% 0.1570% 0.1576% 0.1519%
PROPANE 0.0451% 0.0449% 0.0450% 0.0434%
ISOBUTANE 0.0082% 0.0082% 0.0082% 0.0079%
n-BUTANE 0.0102% 0.0102% 0.0102% 0.0099%
ISOPENTANE 0.0000% 0.0000% 0.0000% 0.0000%
n-PENTANE 0.0000% 0.0000% 0.0000% 0.0000%
2-METHYLPENTANE 0.0000% 0.0000% 0.0000% 0.0000%
n-HEXANE 0.0000% 0.0000% 0.0000% 0.0000%
METHYLCYCLOPENTANE 0.0000% 0.0000% 0.0000% 0.0000%
CYCLOHEXANE 0.0000% 0.0000% 0.0000% 0.0000%
BENZENE 0.0000% 0.0000% 0.0000% 0.0000%
MDEA will be used in the amine treating of the recycle gas and H2 rich gas. The amine
quality and loadings will be as follows.
Amine Information
Type MDEA
Concentration 35% wt
Lean Loading Max, mol H2S / mol Amine 0.01
Rich Loading Max, mol H2S / mol Amine 0.41
PAGE 10 OF 30
10180-415-120-DB-0001 REV.: 01
Wash Water is required in the VCCTM process to remove H2S and Ammonia from the
process before they form salts in the equipment and pipe lines which could lead to corrosion
and eventual loss of containment. The wash water rates vary depending on various process
parameters including Nitrogen, Sulfur and Chlorides in the feed, treat gas rate. The
controlling parameter for this unit is salt concentration in the resulting sour water. The unit is
designed for less than 3.5 wt% salt concentration.
At least 25% of the total wash water to the unit should be clean fresh water (including DHT
Stripper and DHT fractionator condensate). A maximum of 75% of the total wash water may
be Non-Phenolic stripped water from a sour water stripper that handles sour water produced
from hydroprocessing units only (i.e., no FCC sour water should be processed in the sour
water stripper). The Fresh Water line needs to be sized to handle 100% of the wash water
requirement in case the Non-Phenolic stripped sour water is not available.
The recommended wash water requirements are listed below:
Maximum
Parameter UOM Allowable
Limits
Total Dissolved Solids ppmw 25
Chlorides ppmw 5
Oxygen ppbw 50
NH3 ppmw 100
H2S ppmw 100
pH 7-9
To achieve the quality specified above cold condensate will be used as clean fresh water.
PAGE 11 OF 30
10180-415-120-DB-0001 REV.: 01
3.3 PROCESS PRODUCT
The VCC Unit will be designed to recover the products listed below:
SWEET LOW PRESSURE OFFGAS SPECIFICATION
Basrah Arab Light

Property Units SOR EOR SOR EOR
Flow Rate Nm3/hr 2447 2470 2317 2331
Flow Rate kg/hr 1993 2042 1776 1835
Density @ Flowing conditions kg/m3 5.25 5.33 4.93 5.07
Molecular Weight kg/kg-mole 18.26 18.53 17.18 17.65
Water wt% 1.91 1.90 2.00 1.98
Hydrogen wt% 4.80 4.67 5.52 5.31
Methane wt% 15.36 14.92 15.33 14.60
Ethane wt% 46.42 46.22 46.61 45.24
Propane wt% 7.34 7.94 7.65 7.83
i-Butane wt% 0.26 0.26 0.25 0.23
n-Butane wt% 1.14 1.14 1.21 1.19
C5+ wt% 22.77 22.95 21.45 23.61
H2S ppmw 97 96 103 100
NH3 ppmw Negligible Negligible Negligible Negligible
Sulfur ppmw 103 102 110 107
Mercaptan Sulfur ppmw <5 <5 <5 <5
Nitrogen ppmw < 0.1 < 0.1 < 0.1 < 0.1
PAGE 12 OF 30
10180-415-120-DB-0001 REV.: 01
SWEET H2 RICH OFFGAS
Basrah Arab Light

Flow Rate 3
Nm /hr 5969 5991 6085 6126
Flow Rate kg/hr 2588 2617 2539 2580
Water wt% 1.14 1.16 1.21 1.19
Hydrogen wt% 14.46 14.31 15.46 15.28
Methane wt% 25.29 25.02 23.75 23.37
Ethane wt% 24.04 24.36 23.69 23.90
Propane wt% 19.10 19.17 19.48 19.56
i-Butane wt% 3.28 3.29 2.78 2.79
n-Butane wt% 6.82 6.83 7.04 7.08
C5+ wt% 5.86 5.85 6.58 6.81
H2S ppmw 60 59 62 61
NH3 ppmw Negligible Negligible Negligible Negligible
Sulfur ppmw 63 63 66 65
Nitrogen ppmw < 0.1 < 0.1 < 0.1 < 0.1
PAGE 13 OF 30
10180-415-120-DB-0001 REV.: 01
RICH AMINE
Basrah Arab Light

Property Unit SOR EOR SOR EOR
Flow Rate @ P & T 1 m3/hr 139.36 139.40 118.73 118.79
Flow Rate kg/hr 139551 139555 118855 118856
Density @ P & T 1 kg/m3 1001.4 1001.1 1001.1 1000.5
Specific Gravity @ 15 °C 1.022 1.021 1.022 1.022
H2O wt% 62.7 62.7 62.7 62.7
NH3 wt% 0.001 0.001 0.002 0.001
H2S wt% 3.5 3.5 3.5 3.5
H2 wt% 0.002 0.002 0.002 0.002
N2 wt% 0.00 0.00 0.00 0.00
C1 wt% 0.002 0.002 0.002 0.002
C2 wt% 0.003 0.003 0.003 0.003
C3 wt% 0.002 0.002 0.002 0.002
IC4 wt% 0.00 0.00 0.00 0.00
NC4 wt% 0.00 0.00 0.00 0.00
MDEA wt% 33.8 33.8 33.8 33.8
ADDITIVE wt% 0.00 0.00 0.00 0.00
RESID FEED wt% 0.00 0.00 0.00 0.00
NAPHTHA (C5 - 145C) wt% 0.00 0.00 0.00 0.00
DIESEL (145C - 375C) wt% 0.00 0.00 0.00 0.00
VGO (375C-525C) wt% 0.00 0.00 0.00 0.00
UNCONVERTED RESID (525C+) wt% 0.00 0.00 0.00 0.00
PAGE 14 OF 30
10180-415-120-DB-0001 REV.: 01
MEMBRANE PERMEATE GAS
Basrah Arab Light

Flow Rate Nm3/hr 26327 26937 28569 29228
Flow Rate kg/hr 2756 2820 2991 3060
Water wt% 0.38 0.38 0.38 0.38
Hydrogen wt% 84.16 84.16 84.16 84.16
Methane wt% 12.10 12.10 12.10 12.10
Ethane wt% 1.92 1.92 1.92 1.92
Propane wt% 0.94 0.94 0.94 0.94
i-Butane wt% 0.25 0.25 0.25 0.25
n-Butane wt% 0.25 0.25 0.25 0.25
C5+ wt% 0.0029 0.0029 0.0029 0.0029
H2S ppmw 29 29 29 29
NH3 ppmw <1 <1 <1 <1
Sulfur ppmw < 33 < 33 < 33 < 33
Nitrogen ppmw < 0.1 < 0.1 < 0.1 < 0.1
PAGE 15 OF 30
10180-415-120-DB-0001 REV.: 01
MEMBRANE NON PERMEATE GAS
Basrah Arab Light

Flow Rate Nm3/hr 9628 9895 9966 10245
Flow Rate kg/hr 5901 6107 5991 6221
Water wt% 0.54 0.54 0.56 0.56
Hydrogen wt% 6.94 6.86 7.41 7.31
Methane wt% 39.19 38.76 37.15 36.55
Ethane wt% 24.35 24.75 24.67 24.98
Propane wt% 15.56 15.64 16.17 16.27
i-Butane wt% 2.49 2.51 2.11 2.12
n-Butane wt% 5.92 5.93 6.46 6.49
C5+ wt% 5.01 5.02 5.46 5.72
H2S ppmw 25 25 24 24
NH3 ppmw <2 <2 <2 <2
Sulfur ppmw < 51 < 52 < 51 < 52
Nitrogen ppmw < 0.1 < 0.1 < 0.1 < 0.1
PAGE 16 OF 30
10180-415-120-DB-0001 REV.: 01
LPG
Basrah Arab Light

Property Units Specs SOR EOR SOR EOR
Flow Rate @ P & T m3/hr 8.6 8.6 7.8 7.8
Flow Rate kg/hr 4395 4423 3999 3989
Density @ P & T kg/m3 513.1 513.1 513.3 513.4
Water ppmw <3 <3 <3 <3
Hydrogen wt% 0 0 0 0
Methane wt% 0 0 0 0
Ethane wt% 0.10 0.10 0.10 0.10
Propane wt% 40.84 40.71 41.16 41.02
i-Butane wt% 15.02 15.09 12.57 12.59
n-Butane wt% 43.13 43.20 45.34 45.43
0.5
C5+ wt% 0.49 0.47 0.50 0.50
(Max)
H2S wt% Report 0.41 0.43 0.33 0.35
NH3 ppmw 15 14 24 25
Sulfur wt% 0.39 0.41 0.31 0.33
Mercaptan Sulfur ppmw < 10 < 10 < 10 < 10
Nitrogen ppmw <1 <1 <1 <1
Vapor Pressure 37.8 °C kg/cm2 < 14.6 8.2 8.2 8.2 8.2
Volatile Residue:
Evaporated Temperature °C < 2.2 < 2.2 < 2.2 < 2.2 < 2.2
@ 95%
Residues in LPG ml < 0.05 < 0.05 < 0.05 < 0.05 < 0.05
Free Water Content Free Free Free Free Free
PAGE 17 OF 30
10180-415-120-DB-0001 REV.: 01
NAPHTHA
Basrah Arab Light

Property Unit Spec SOR EOR SOR EOR
Flow Rate @ P & T 1 m3/hr 19.08 19.24 18.45 18.34
Flow Rate kg/hr 13736 13886 13108 12974
Cut Range (TBP) °C C5 - 145 C5 - 145 C5 - 145 C5 - 145 C5 - 145
Density @ P & T 1 kg/m3 719.9 721.6 705.7 707.4
kg/kg-
Molecular Weight 101 101 101 101
mole
Sulfur ppmw <4 <4 <4 <4 <4
Total Nitrogen ppmw <2 <2 <2 <2 <2
Paraffins 2 wt% 58.2 60.5 70.3 73.7
Naphthenes 2 wt% 33.8 30.4 23.9 19.8
Aromatics 2 wt% 8 9.1 5.8 6.6
RVP kg/cm2 0.23 0.23 0.25 0.25
Water wt% 0.08 0.06 0.11 0.11
Hydrogen wt% 0.00 0.00 0.00 0.00
Nitrogen wt% 0.00 0.00 0.00 0.00
Methane wt% 0.00 0.00 0.00 0.00
Ethane wt% 0.00 0.00 0.00 0.00
Propane wt% 0.001 0.001 0.001 0.001
i-Butane wt% 0.5 0.01 0.01 0.01 0.01
n-Butane wt% (Max) 0.09 0.08 0.10 0.10
C5+ wt% 99.82 99.85 99.78 99.79
H2S ppmw 0.20 0.20 0.21 0.21
Distillation (D86 LV %) °C
1% 71 71 72 71
5% 84 84 82 83
10% 87 87 84 84
30% 100 100 97 98
50% 110 110 108 108
70% 117 117 114 114
90% 128 129 129 129
95% 134 134 135 135
98% 137 137 137 137
PAGE 18 OF 30
10180-415-120-DB-0001 REV.: 01
NAPHTHA (Cont.)
Basrah Arab Light

Property Unit Spec SOR EOR SOR EOR
Distillation (TBP WT %) °C
1% 40 41 41 40
5% 63 63 61 61
10% 67 67 64 64
30% 95 95 92 92
50% 111 111 109 109
70% 122 122 119 119
90% 139 139 139 139
95% 144 144 144 144
98% 147 147 146 146
Basrah Arab Light

Carbon
P/N/A SOR EOR SOR EOR
Number
Paraffins - - - -
4 Naphthenes - - - -
Aromatics - - - -
Paraffins 8.7 10.7 11.9 14.9
5 Naphthenes 1.8 2 1.4 1.5
Aromatics 0 0 0 0
Paraffins 17.9 18 22.4 22.6
6 Naphthenes 9.2 8.1 7.1 5.7
Aromatics 1.6 1.8 0.8 0.9
Paraffins 16 16.1 19 19.1
7 Naphthenes 11 9.8 8.1 6.6
Aromatics 2.4 2.7 2 2.3
Paraffins 15.6 15.7 17 17.1
8 Naphthenes 11.8 10.5 7.3 5.9
Aromatics 4 4.6 3 3.4
Paraffins 0 0 0 0
9 Naphthenes 0 0 0 0
Aromatics 0 0 0 0
Paraffins 58.2 60.5 70.3 73.7
Total Naphthenes 33.8 30.4 23.9 19.8
Aromatics 8 9.1 5.8 6.6
Notes:
1. Density and volumetric flow rate given at 5 kg/cm2g & 40°C.
2. PNA shown is approximate. To be confirmed by pilot plant test.
PAGE 19 OF 30
10180-415-120-DB-0001 REV.: 01
DIESEL
Basrah Arab Light

Property Unit Specs SOR EOR SOR EOR
Flow Rate @ P & T 1 m3/hr 73.1 72.3 74.4 73.8
Flow Rate kg/hr 59159 58562 59303 58883
Cut Point (TBP) °C 145 - 375 145 - 375 145 - 375 145 - 375 145 - 375
Density @ P & T 1 kg/m3 809.4 810.1 796.7 797.9
820 (Min)-
Density @ 15 °C kg/m3 832.5 833.2 820.0 821.0
845 (Max)
Molecular Weight kg/kg-mole 197 195 208 206
2 (Min)-4.5
Viscosity at 40 °C cSt 2.33 2.27 2.48 2.56
(Max)
Viscosity at 50 °C cSt 1.97 1.92 2.09 2.06
Sulfur ppmw 10 (Max) < 10 < 10 < 10 < 10
Total Nitrogen ppmw < 10 < 10 < 10 < 10
Aromatics % wt < 15 < 15 < 15 < 15
Flash Point °C 56 56 56 56
Cloud Point °C -11 -11 -15 -15
Pour Point °C -16 -16 -20 -20
Cetane Index 45 (Min) 50 48 57 56
Cetane Number 51 (Min) 51 51 58 57
Polycyclic Aromatics % wt 8 (Max) <8 <8 <8 <8
Water Content ppmw 200 (Max) < 100 < 100 < 100 < 100
< 0.30 (on
Carbon Residue wt% 10% < 0.30 < 0.30 < 0.30 < 0.30
Distillation)
Copper Strip Corrosion Class 1 Class 1 Class 1 Class 1
Lubricity 2 640 640 640 640
Ash wt% 0.01 (Max) < 0.01 < 0.01 < 0.01 < 0.01
Total Contamination mg/kg 24 (Max) < 24 < 24 < 24 < 24
Oxygen Stability gm3 25 (Max) < 25 < 25 < 25 < 25
1% 178 178 177 176
5% 184 184 184 184
10% 191 190 195 194
30% 220 218 229 228
50% 251 247 261 259
70% 284 281 294 291
90% 336 335 340 339
95% 345 344 348 347
98% 358 357 360 359
PAGE 20 OF 30
10180-415-120-DB-0001 REV.: 01
DIESEL (Cont.)
Basrah Arab Light

1% 143 143 141 141
5% 157 157 155 155
10% 170 170 175 174
30% 218 216 228 227
50% 260 256 271 269
70% 301 297 310 308
90% 351 349 357 355
95% 367 366 371 370
98% 394 393 394 394
Notes:
2. Estimate provided for Lubricity. Lubricity additive needs to be added in order to meet
final diesel product specifications.
PAGE 21 OF 30
10180-415-120-DB-0001 REV.: 01
VGO
Basrah Arab Light

Flow Rate @ Flowing
m3/hr 37.2 37.2 34.1 34.1
conditions 1
Flow Rate kg/hr 35443 35439 31898 31893
Cut Range (TBP) °C 375 - 530 375 - 525 375 - 525 375 - 525 375 - 525
Density @ Flowing conditions 1 kg/m3 952.9 952.9 935.3 935.3
Viscosity at 40 °C cSt 104 104 92.3 92.3
Viscosity at 50 °C cSt 53.6 53.6 49 49
Sulfur % wt 2.835 2.835 2.2 2.2
Total Nitrogen ppmw 4891 4891 3395 3395
Ni + V ppmw <2 <2 <2 <2 <2
Asphaltenes ppmw < 500 < 500 < 500 < 500 < 500
CCR wt% <1 <1 <1 <1 <1
Aromatics % wt 25 - 30 25 - 30 22 - 28 22 - 28
Flash Point °C 171 171 127 171
Cloud Point °C 40 40 40 40
Pour Point °C 37 37 37 37
Cetane Index 29.6 29.6 31.7 31.7
1% 355 355 354 354
5% 372 372 372 372
10% 381 381 381 381
30% 403 403 403 403
50% 422 422 421 421
70% 449 449 451 451
90% 488 488 496 496
95% 506 506 516 516
98% 522 522 529 529
PAGE 22 OF 30
10180-415-120-DB-0001 REV.: 01
VGO (Cont.)
Basrah Arab Light

1% 330 330 330 330
5% 358 358 360 360
10% 374 374 374 374
30% 400 400 399 399
50% 423 423 422 422
70% 450 450 452 452
90% 489 489 497 497
95% 507 507 517 517
98% 522 522 530 530
Notes:
PAGE 23 OF 30
10180-415-120-DB-0001 REV.: 01
PITCH
Basrah Arab Light

Property 1 Unit SOR EOR SOR EOR
Flow Rate m3/hr 7.2 7.2 7.1 7.1
Flow Rate kg/hr 8000 8000 7700 7700
Cut Point (TBP) °C 525+ 525+ 525+ 525+
Specific Gravity @ 15 °C 2 - 1.184 1.184 1.153 1.153
Carbon % wt 86.74 86.74 87.85 87.85
Hydrogen % wt 6.21 6.21 6.91 6.91
Sulfur % wt 3.22 3.22 2.13 2.13
Total Nitrogen % wt 0.63 0.63 0.18 0.18
Pour Point 3 °C N/A N/A N/A N/A
CCR % wt 41.1 41.1 49.89 49.89
TAN mg KOH/g < 0.3 < 0.3 < 0.3 < 0.3
Nickel % wt 0.07 0.07 0.04 0.04
Vanadium % wt 0.23 0.23 0.11 0.11
C7 Insoluble % wt 20 20 14.97 14.97
Ash % wt 2.1 2.1 2.1 2.1
80-
Softening Point °C 80-130 80-130 80-130
130
Heating Value kcal / kg 8600 8600 8600 8600
Notes:
1. Pitch Properties to be confirmed by Pilot Plant Testing.
2. Oil only specific gravity
3. Pitch will be solidified within the VCCTM Unit.
PAGE 24 OF 30
10180-415-120-DB-0001 REV.: 01
3.4 BATTERY LIMIT CONDITIONS FOR PROCESS STREAMS
3.4.1 Feed Streams
Next table shows operating and design conditions of all Feeds to VCC Unit (415) at the
battery limit of the unit, with pressure at grade.
Normal Conditions1 Design Conditions

Stream Source P P
T 0C T 0C
kg/cm2g kg/cm2g
VDU 2, VDU 3, FCC,
Combined VR Feed 2 167.9 2 9.5 230 38.33
Storage
Additive 40 0 - -
Amine Regeneration
Lean Amine 57 12.5 120 31.73
Unit
Non-phenolic Sour
Stripper Sour Water 55 5 160 10.8 3
Water Stripper
Fresh Wash Water Cold Condensate 55 5 120 10
OSBL Make-up Gas

Make-up hydrogen 74 237 120 262
Compressors
OSBL Hydrogen
Hydrogen for Blanketing 45 24.5 120 28.5
Distribution
Notes:
1. Normal Pressure and Temperature at Battery Limit of VCCTM Unit.
2. The three feeds to the unit combine outside the battery limit. The temperature of the
combined stream is 30ºC lower than normal to account for cold feed from storage.
3. Estimated shut-off pressure. To be confirmed by DEC.
4. Deleted
PAGE 25 OF 30
10180-415-120-DB-0001 REV.: 01
3.4.2 Product Streams
Next table shows operating and design conditions of all products generated in VCC Unit
(415).
Normal Conditions 1 Design Conditions

Stream Destination P P
T 0C T 0C
kg/cm2g kg/cm2g
Saturate Gas Concentration
Sweet LP Offgas 57 6.5 120 9
Unit
Sweet H2 Rich ROG PSA Unit 57 8.2 165 31.5
Offgas
Membrane
Make-up Gas Compressors 90 55 165 80
Permeate Gas
Membrane Reject
ROG PSA Unit (HCK Unit) 74 40 165 80
Gas
LPG LPG Merox Unit 42 22 120 28.8 2
Naphtha Hydrotreating Unit 75 9
Naphtha 120 23.5 2
Storage 40 5
Diesel Diesel Pool (Storage) 51 5 165 17 2
Unicracking Unit 190 6 250
VGO 24.8 2
Storage 80 5 205
Pitch Solidification Ambient 0 - -
Non-phenolic Sour
Non-phenolic SWS Unit 51 5 165 10.5
Water
Phenolic Sour
Phenolic SWS Unit 53 5 165 10.5
Water
Rich Amine Amine Regeneration Unit 63 5 165 12.6
Notas:
1. Normal pressure and temperature at Battery Limit of VCCTM Unit.
2. Estimated shut-off pressure. To be confirmed by DEC.
PAGE 26 OF 30
10180-415-120-DB-0001 REV.: 01
3.5 BATTERY LIMIT CONDITIONS FOR UTILITY STREAMS
Utility supply conditions are included in the Basic Engineering Design Data (Doc. Nº: 10180-
000-120-GE-0001).
3.6 ADDITIONAL CONSIDERATIONS
3.6.1 Design pressure for Recycle Gas Compressor Circuit
For the Recycle Gas Compressor high pressure loop (RGC, 415-C-01), the following design
guideline has been applied by Licensor to specify design pressures:
The design pressure profile for the individual equipment in this system is based on the
settling out pressure (SOP) estimated by Licensor and considers the normal operating
pressure drops of the circuit.
3.6.2 Reactor Theoretical Yields
Theoretical Reactor Yields are given in the tables below based on perfect square cuts of
products. In the design of the unit, these were adjusted as a result of imperfect separation of
the materials in the fractionation towers and separation drums.
Arab Light Case
Feed UOM SOR EOR

VR wt% 100.00 100.00
Additive wt% 1.00 1.00
H2-Cons wt% 3.01 2.90
Total wt% 104.01 103.90
Products
H2S wt% 3.85 3.85
NH3 wt% 0.28 0.28
H2O wt% 0.24 0.24
C1's wt% 2.57 2.62
C2's wt% 2.24 2.32
C3's wt% 2.57 2.61
C4's wt% 2.49 2.52
Naphtha (C5+ - 1450C) wt% 12.12 12.15
Diesel (1450C - 3750C) wt% 46.89 46.55
VGO (3750C - 5250C) wt% 24.75 24.75
Residue (5250C+) wt% 4.36 4.36
Solids wt% 1.65 1.65
Total wt% 104.01 103.90
PAGE 27 OF 30
10180-415-120-DB-0001 REV.: 01
Basrah Case
Feed UOM SOR EOR

VR wt% 100.00 100.00
Additive wt% 1.00 1.00
H2-Cons wt% 3.41 3.31
Total wt% 104.41 104.31
Products
H2S wt% 4.30 4.30
NH3 wt% 0.29 0.29
H2O wt% 0.16 0.16
C1's wt% 2.58 2.63
C2's wt% 2.20 2.29
C3's wt% 2.55 2.60
C4's wt% 2.58 2.62
Naphtha (C5+ - 1450C) wt% 12.26 12.37
Diesel (1450C - 3750C) wt% 45.48 45.05
VGO (3750C - 5250C) wt% 25.99 25.99
Residue (5250C+) wt% 4.36 4.36
Solids wt% 1.65 1.65
Total wt% 104.41 104.31
The operating conditions for the reactors of the unit and for each design case are as follow.
Arab Light Case – LPH Reactors Operating Conditions
SOR EOR
No. of Vessels 3 3
Overall WHSV, h-1 0.5 0.5
Inlet Pressure, kg/cm2(g) 219.3 219.3
Weighted Average Bed Temperature, °C 470 470
Chemical H2 Consumption, Nm3/ton 235 235
Inlet Treat Gas Rate, Nm3/MT Fresh Feed 750 750
PAGE 28 OF 30
10180-415-120-DB-0001 REV.: 01
Arab Light Case – DHT Reactor
SOR EOR
No. of Vessels 1 1
Overall SV, ton/m3/hr 1.51 1.51
Chemical H2 Consumption, Nm3/ton 140.3 119.5
Treat Gas Rate 1, Nm3/ton 1593 1596
Cycle Length, months > 48
Note 1: This treat gas rate is resultant from the LPH Reactor treat and quench gas and the
DHT oil feed. During Start-up, the minimum recommended treat gas rate is 800 Nm3/ton.
Basrah Case – LPH Reactors
SOR EOR
No. of Vessels 3 3
Overall WHSV, h-1 0.5 0.5
Chemical H2 Consumption, Nm3/ton 264 264
Inlet Treat Gas Rate, Nm3/MT Fresh Feed 750 750
Basrah Case – DHT Reactor
SOR EOR
No. of Vessels 1 1
Overall SV, ton/m3/hr 1.54 1.54
Chemical H2 Consumption, Nm3/ton 165.1 147.6
Treat Gas Rate 1, Nm3/ton 1737 1736
Cycle Length, months > 48
PAGE 29 OF 30
10180-415-120-DB-0001 REV.: 01
4. GUARANTEED YIELDS AND PRODUCT INFORMATION
The VCC™ has the following processing objectives:

- Crack Residue Feed to Naphtha, Diesel and Gas Oil product with 95 wt% conversion
in the LPH Reactors.
- Produce Naphtha product that will contain less than 4 ppmw Sulfur, and a Diesel
product that will meet 2013 EN 590 (Euro V) specifications from the DHT Section.
- Produce a LPG Stream which will be treated OSBL by Amine Treating and a
Mercaptan Removal Unit.
- Minimize hydrogen consumption.
- Minimize water usage including cooling water.
KBR and OWNER expect to enter into a Guarantee Agreement which will contain the
following performance guarantee parameters for VCC unit:
- Capacity
- Turndown
- Hydrogen consumption
- Products specification
- Catalyst Cycle Length
- Utility Consumption
5. PROCESS ENERGY RECOVERY
The VCC unit will be heat integrated as per Licensor design to an extent consistent with
technical limitations and OWNER´s economic preferences relating to the tradeoff between
capital and utilities. The treat gas stream that joins downstream of the LPH Reactor Effluent /
Fresh Feed Exchanger (415-E-01A/B) is a clear example of process heat recovery in the
unit.
During the BEP Licensor has evaluated fired heater heat recovery schemes such as pre-
heating cold streams, generating and superheating steam and air pre-heat. Licensor has
also looked at combining the flue gas from several heaters together to allow more
economical heat recovery for generating steam. As a result of the economic feasibility study
performed by Licensor, a combined Waste Heat Boiler Package (415-ME-50) has been
specified.
In order to maintain the required purity of hydrogen in the gas recycle loop a continuous
purge is carried out. Hydrogen Production is an expensive process from an energy point of
view. Therefore, a Membrane (415-ME-02) is used to increase the purity of the purge stream.
Thus, part of the recycle gas purge is fed back to the intermediate stage of the OSBL
Makeup Gas Compressor package. Membrane Non Permeate Gas goes to the OSBL ROG
PSA Unit.
PAGE 30 OF 30
10180-415-120-DB-0001 REV.: 01
6. CATALYST INFORMATION
Refer to KBR RESIDUE UPGRADING UNIT (VCC) CATALYST AND CHEMICAL

SUMMARY (Document No. 10180-415-120-CC-0001).
7. UNIT RUN LENGTH
The unit 415 shall have an on-stream factor of 8400 hours per year (350 days/year). Catalyst
cycle length is four years.
8. ENVIRONMENTAL EMISSIONS
Rich amine will be routed to the Amine Treating Unit. Sour water containing H2S and NH3 will
be routed to the non-phenolic Sour Water Unit and phenolic sour water will be routed to the
Phenolic Sour Water Unit.
For other effluents refer to KBR RESIDUE UPGRADING UNIT (VCC) EFFLUENTS
SUMMARY (Document No. 10180-415-120-AC-0001).

415 120 DB 0001

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415 120 DB 0001

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Refinery Fourth Expansion Project RFP-04-2018

KBR RESIDUE UPGRADING UNIT (VCC)

PROCESS DESIGN BASIS

01 21-Mar-2019 Issued for FEED L. Veleda J. Y. Moro J. M. Muñoz

00 28-Sept-2018 Issued for Approval J. Seco J. Y. Moro J. M. Muñoz

REV. DATE ISSUE PREPARED BY CHECKED BY APPROVED BY

Jordan Petroleum Refinery Company Ltd. (JPRC), Amman—The Hashemite Kingdom of

2. CODES, STANDARD AND SPECIFICATIONS

• Basic Engineering Design Data (Doc. Nº: 10180-000-120-GE-0001)

• Process Design Criteria (Doc. Nº: 10180-000-120-GE-0002)

• Isolation Philosophy (Doc. Nº: 10180-000-120-GE-0004)

• Drainage And Slops Philosophy (Doc. Nº: 10180-000-120-GE-0005)

• Sparing Philosophy (Doc. Nº: 10180-000-120-GE-0006)

• Flare and Vent Philosophy (Doc. Nº: 10180-000-120-GE-0008)

• Numbering Procedure (Doc. Nº: 10180-000-110-PD-0004)

3. PROCESS BASIS OF DESIGN

3.1 UNIT CAPACITY

3.1.1 Design Capacity

3.1.2 Turn Down Ratio

The Unit 415 will have a turndown ratio of 50%.

3.2 PROCESS FEEDSTOCK

3.2.1 Definitions of various design cases

3.2.2 Modes of Operation

- Arab Light SOR

3.2.3 Feedstock Definition

Arab Light Basrah

3.3 PROCESS PRODUCT

SWEET LOW PRESSURE OFFGAS SPECIFICATION

Basrah Arab Light

SWEET H2 RICH OFFGAS

Basrah Arab Light

Basrah Arab Light

MEMBRANE PERMEATE GAS

Basrah Arab Light

MEMBRANE NON PERMEATE GAS

Basrah Arab Light

Basrah Arab Light

Basrah Arab Light

Basrah Arab Light

Basrah Arab Light

Basrah Arab Light

Basrah Arab Light

Basrah Arab Light

Basrah Arab Light

Basrah Arab Light

3.4 BATTERY LIMIT CONDITIONS FOR PROCESS STREAMS

3.4.1 Feed Streams

Normal Conditions1 Design Conditions

OSBL Make-up Gas

3.4.2 Product Streams

Normal Conditions 1 Design Conditions

3.5 BATTERY LIMIT CONDITIONS FOR UTILITY STREAMS

3.6 ADDITIONAL CONSIDERATIONS

3.6.1 Design pressure for Recycle Gas Compressor Circuit

3.6.2 Reactor Theoretical Yields

Arab Light Case

Feed UOM SOR EOR

Feed UOM SOR EOR

Arab Light Case – LPH Reactors Operating Conditions

Arab Light Case – DHT Reactor

Basrah Case – LPH Reactors

Basrah Case – DHT Reactor

4. GUARANTEED YIELDS AND PRODUCT INFORMATION