Refinery Presentation On 07th July 07

Presentation on Overall Refinery Operation
Contents of today’s presentation

 Brief about Crude oil
 Different Refinery Configurations
 About Sohar Refinery Configuration
2017-09-12 1 Sohar Refinery Company

What is Crude Oil ?
 Crude oil is mixture of various hydrocarbons consisting of

Carbon 84-86 % , Hydrogen -10-14%,Other impurities like
Sulfur , Nitrogen , Oxygen , Heavy metal 3-5 %.
 The Hydrocarbons ( C1 to C70 ) present in crude oil in
Paraffinic , Cycloparaffinic ( Napththenic) , Aromatic or
Asphatinic form. Olefins does not present in crude oil.
 Depending on API gravity Crude oil termed as
Light Crude Oil with API more than 34
Medium Crude Oil with API 20 to 34
Heavy Crude Oil with API less than 20

What is Crude Oil ?
 Depending on total Sulfur content Crude oil termed as

High Sulfur Crude Oil with “S” more than 0.5 wt%
Low Sulfur Crude Oil with “S” less than 0.5 wt%
 Depending on Total Acid No. ( TAN) Crude oil

termed as
High Acidic Crude Oil TAN more than 1 mg KOH/gm
Low Acidic Crude Oil TAN less than 1 mg KOH/gm
 Depending on UOP K factor Crude oil termed as

Paraffinic Crude Oil UOP K more than 12.5
Naphthenic Crude Oil UOP K less than 10.0
Mixed base Crude Oil UOP K between 10-12.5

Crude Oil Samples

Paraffins & Iso Paraffins
Normal Paraffin Isoparaffin (Isoalkane)

Heptane, C7H16 Isooctane, C8H18
H H
H H H H H H H
H C H H C H
H C C C C C C C H
H H H
H H H H H H H
H C C C C C H
H H H
H C H H
H
0 RON 100 RON
CR02002.VSD
RON = Research Octane Number

Olefins
Heptene, C7H14 Isooctene, C8H16
H H
H H H H H H
H H C H H C H
C C C C C C C H
H H H
H H H H H H
H C C C C C
H
H H
H C H H
H
CR02004.VSD
55 RON 106 RON

Naphthenes
Methylcyclopentane, C6H12 Cyclohexane, C6H12
H2 H2
C C
H
H2C C H2C CH2
CH3
H2C CH2 H2C CH2
C
H2
91 RON CR02005.VSD
83 RON
80 MON 77 MON

Aromatics
Benzene, C6H6 Toluene, C7H8

H H
C C
HC CH HC C CH3
HC CH HC CH
C C
H H CR02006.VSD
115 RON 120 RON

Oxygenates
MTBE, CH3OC4H9 Ethanol, C2H5OH

Methyl Tertiary Butyl Ether Ethyl Alcohol
H
H H
H C H
H C C O H
H H
H H
H C C O C H
H H
H C H
CR02007.VSD
H
110 (R+M)/2 115 (R+M)/2

Major Refined Products
Gases (C4-)
- Fuel gas
- LPG
Naphtha
- JP-4, Air Force Jet
- Petrochemical
Gasoline
Kerosene
- Jet-A, Commercial
- JP-5 and JP-8, Navy Jet
Crude Oil Refining Gas Oil

- Diesel
- No. 2 Oil
- Home Heating Oil
Lube Oil
Fuel Oil (Residual)
- No. 6 Oil
- HSFO / LSFO
- Bunker
- IBF's
Asphalt
Coke

Different Refinery Products

Crude Oil Production

Refinery Configurations
Refinery Configuration is aimed with the objective of

 Maximizing of light distillate and middle distillate recovery
 Minimize Heavy Distillate Production
 Meet Stringent Fuel Spec.
 Compatible Residue up gradation
 Conversion Facility ( to enhance octane No.)
 Capital Investment & Margin
Depending on the combinations of different units Refinery Configurations
can be
 Topping Up Refinery
 Hydro skimming Refinery
 Complex Refinery
 Full Complex Refinery



Refinery Configurations
Different Combinations possible :
 CDU
 CDU+Hydrodesulfurisation of naphtha,+Platformer (CCR )
 Base+Hydrocracker+Coker
 Base+FCC+Coker
 Base+Hydrocracker+FCC+Visbreaker
 Base+FCC+VB
 Base+Coker+FCC+Aromatic Complex
 Base+Coker+FCC+Aromatic+Power plant
 Base + RFCC+Conversion units ( SHP,TSHP,Inalk,TAME)

TOPPING REFINERY

FUEL GAS
LPG
C LIGHT NAPHTHA
HEAVY
D NAPHTHA
KEROSENE KEROSENE / ATF
MEROX
U HDS
CRUDE DIESEL DIESEL
LONG RESIDUE

HYDROSKIMMING
REFINERY

FUEL GAS
LPG
C LIGHT NAPHTHA
HEAVY
HDS Platformer
D NAPHTHA MOGAS
KEROSENE KEROSENE / ATF
MEROX
U HDS
CRUDE DIESEL DIESEL
LONG RESIDUE

FUEL GAS
LPG
C LIGHT NAPHTHA
HEAVY NAPHTHA
MS
HDS CCR
FUEL GAS
D KEROSENE KEROSENE
MEROX ATK
LPG
CRUDE
U DIESEL
HDS
DIESEL HYDRO
CRACKER
NAPHTHA
KEROSENE
HSD
FUEL GAS
V VGO LPG
D DELAYED
U MS
COKER
LONG RESIDUE KERO/HSD
COKE
2017-09-12
SHORT RESIDUE
23 Sohar Refinery Company
FUEL GAS
LPG
FUEL GAS
LIGHT NAPHTHA H2S+FG
C HEAVY NAPHTHA
HDS CCR MS
LPG F LPG
D KEROSENE
MEROX KERO/ATK
NAPHTHA C MS
U DIESEL
VGO
HDT GAS OIL
CRUDE HDS DIESEL C CYCLE
OIL
CLARIFIED
OIL
VGO
V
D
LONG RESIDUE FUEL GAS
U
LPG
DELAYED MS
SHORT RESIDUE COKER KERO+HSD

2017-09-12 25
COKE Sohar Refinery Company
FUEL GAS
LPG
FUEL GAS
C HEAVY NAPHTHA
HDS CCR MS
LPG F LPG
D KEROSENE
MEROX KERO/ATK
NAPHTHA MS
VGO C
CRUDE
U DIESEL
HDS DIESEL HDT GAS OIL
C OIL
CYCLE
CLARIFIED
OIL
V VGO
LONG RESIDUE D FUEL GAS
U
VISBREAKER NAPHTHA
SHORT RESIDUE
FUEL OIL

FUEL GAS BENZENE
LPG BENZENE
RECOVERY
TOLUENE
C P-XYLENE
XYLENE
LPG
D HEAVY NAPHTHA
HDS
RECOVERY
O-XYLENE
NAPHTHA
U CCR
VGO
HDT
CRUDE
SPLITTER FG
GAS OIL
LPG
MS
FCC
V VGO CYCLE
D OIL
U
CLO
LPG
DELAYED COKER
MS
SHORT RESIDUE KERO/HSD

2017-09-12 29
COKE Sohar Refinery Company
FUEL GAS
LPG
FUEL GAS
C HEAVY NAPHTHA
HDS CCR MS
LPG F LPG
D KEROSENE
MEROX KERO/ATK
NAPHTHA C MS
U DIESEL
VGO
HDT GAS OIL
CRUDE HDS DIESEL C CYCLE
OIL
CLARIFIED
OIL
V VGO
D
U
LPG ELECTRICAL
POWER
DELAYED MS PLANT POWER
COKER KERO+HSD
SHORT RESIDUE
2017-09-12 31
COKE
Sohar Refinery Company
 Capacity : 116,400 BPSD of Mixed Crude Oil.
 Feed Stock :
 Oman Export Blend Crude Oil (76,400 BPSD-65%)
 Atmospheric Residue from ORC (40,000 BPSD-35%)
 Products :
 LPG , Propylene
 Naphtha
 Regular/Premium Gasoline
 Aviation Fuel
 Low-Sulfur Gas Oil
 Fuel Oil
 Granulated Sulfur

PRODUCT YIELDS
Max Olefin & SOR (BPSD)
Electricity 20 MW
LPG 8,869 ( 7 %)
Propylene 14,583 (12 %)

OEB Crude Naphtha 12,612 (10 %)
76,400 bpsd
SRC Gasoline 44,752 (36 %)
Kerosene 8,976 ( 7 %)
116,400
Atm. Residue bpsd Gas Oil 30,397 (24 %)
40,000 bpsd Fuel Oil 5,105 ( 4 %)
Sulfur 155 t/d

Process Units (Functional)
 Primary Fractionation  Product Treating Units
 Crude Distillation Unit (CDU)  Gasoline Hydro Desulphurisation
(GHDS)
 Residue Upgrading  Diesel Hydro Desulphurisation Unit
(DHDS)
 RFCC RX-Regen Section
 Kerosene Merox Treating
 RFCC Main Frac. Section
 CDU LPG Merox Unit
 RFCC Gas Concentration
 RFCC LPG Merox Section
 RFCC Flue Gas Section
 Kerosene Merox Unit
 Conversion Units ( To enhance  Tail Gas Treating Unit (TGTU)
octane no. of gasoline)
 Indirect Alkylation Unit (InAlk)
 Tertiary Amyl Methyl Ether Unit
 Other Units
(TAME)  Sour Water Stripping Unit (SWS)
 SHP  Amine Regeneration Unit (ARU)
 TSHP  Hydrogen Generation Unit (HGU)
 Recovery Units  Sulfur Granulation Unit
 Propylene Recovery Unit (PRU)
 Sulfur Recovery Unit (SRU)

Process Areas
 Area 1:
 1100 Crude Distillation Unit CDU
 1200 CDU LPG Merox Unit CDU LPG Merox
 1300 Kerosene Merox Unit Kerosene Merox

 Area 2:
 2000 Resid FCC Reactor Regenerator Section RFCC RXRG
 2100 Resid FCC Main Fractionation Section RFCC MF
 2200 Resid FCC Gas Concentration Section RFCC GC
 2300 Resid FCC Flue Gas Section RFCC FLG
 2600 Resid FCC LPG Merox Process Unit RFCC LPG Merox
 2700 Propylene Recovery Unit PRU
 Area 3
 3200 Distillate Unionfining Process Unit DHDS
 4000 TSHP Unit TSHP
 4200 Gasoline Hydro-desulfurization Process Unit GHDS
 Area 4
 3300 Hydrogen Generation Unit HGU
 3400 Sour Water Stripping Unit SWS
 3500 Amine Recovery Unit ARU
 3600 Sulfur Recovery Unit Train 1 SRU-1
 3650 Sulfur Recovery Unit Train 2 SRU-2
 3700 Tail Gas Treating Unit TGT
 Area 5
 2800 Huels Selective Hydrogenation Process Unit SHP
 2900 Indirect Alkylation Unit INALK
 4100 TAME Unit TAME

LPG
LPG Sulfur
Sat. LPG
Merox LPG
PRU Propylene
SR Naphtha Unsat. LPG Merox
Mixed C4’s LPG
C Off
O
C r u d e
Kerosene ARU
D Gas Acid SRU SHP InAlk
U Gas
TGTU
i
Gas Oil
C4 Alkylate
LLG Regular
l
Light Gasoline
TSHP
Gasoline
Gasoline TAME
Blender
Atm Residue Etherified
RFCC
HLG Gasoline
Hydrotreated Gasoline
Hy Premium
Gasoline GHDS Gasoline
CFO
HGU
Kero LCO DHDS Gas Oil
Merox Fuel Oil
Naphtha
Aviation Fuel

Process Flow Diagram
Propylene
CDU LPG
Merox LPG
2,040 BPSD LPG
Propylene Recovery
Merox
29,500 BPSD 29,368 BPSD
Alkylate
Sel Hydro Gen (SHP) INALK
15,000 BPSD C4
15,000 BPSD
Naphtha
Crude
Distillation AGU Acid Gas Sulfur Sulfur
SWS Sulfur
Recovery Granulation
2,640 T/D 155 T/D x 2 80T/D x 3
Kerosene
Merox
116,400 BPSD 12,320 BPSD Gasoline
Regular
Gasoline
Blender
TSHP TAME
Residue 35,000 BPSD 1,800 T/D Premium
Fluid
Catalytic Gasoline HDS FCC
Cracker 26,500 BPSD
RFCC
HGU Aviation Fuel
75,260 BPSD Distillate Unionifining Gas Oil
30,000 BPSD
Fuel Oil

AR
From Off-Gas to FUEL CDU
ORC LPG LPG MEROX
GAS SYSTEM
2,040 BPSD
LPG to
Storage
Mixed CDU SRN to

Crude 116,400 Storage
BPSD KEROSENE
Kerosene MEROX
12,320 BPSD
Gas Oil to
OMANI DHDS & Aviation Fuel
Crude Intermediate to Storage
From LR to RFCC Storage
ORC

Crude Distillation Unit (Unit 1100)
 The purpose is to produce a long residue, as a RFCC feedstock
 CDU is designed to process 116,400 BPSD of Mixed Crude

40,000 BPSD of long residue
76,400 BPSD of Oman Export Blend Crude
 CDU also produces LPG, naphtha, kerosene and gas oil.
 CDU consists of Preheating section, heaters, Desalters,

Main Fractionation and Stabilizer section.

CDU / RFCC LPG Merox Process Unit (Unit 1200 / 2600)
 The purpose is to remove hydrogen sulfide (H2S) and

mercaptans (R-SH) in the LPG from the bottom of
the Amine Absorber at CDU unit and in the LPG from
RFCC Unit.
 LPG Merox utilizes UOP’s Merox process,

their design feed rate are 2,040 / 29,500 BPSD.
 LPG Merox consists of a pre-treatment section,

an extraction section and caustic regeneration section.

Kerosene Merox Process Unit (Unit 1300)
 The purpose is to produce Jet A-1 grade product by remov

ing naphthenic compounds and free water in the kerosene
from CDU unit, and converting mercaptans into disulfide.
 Kerosene Merox utilizes UOP’s Merox process,

design feed rate is 12,320 BPSD.
 Kerosene Merox consists of a pre-treatment section

and a sweetening section.
 2R´SH + 2RSH + O2  2 R´SSR + 2 H2O

Off-Gas to C3 to Storage
FUEL GAS
SYSTEM
AR RFCC LPG C3 & PRU
From LPG MEROX C4 1,220 T/D
CDU 29,500 BPSD
RFCC Light Gasoline TSHP C4

RX / RG
75,260 BPSD
Heavy Gasoline
MAIN FRAC. SHP
LCO
GAS CON. GHDS
FLUE GAS Diesel
DHDS
Fuel Oil to
2017-09-12
Storage
43 Sohar Refinery Company
Residue Fluid Catalyst Cracking Unit (Unit 2000/2100/2200/2300)
 The purpose is to convert the heavy residual oils into lighter,

more valuable hydrocarbons such as LPG, gasoline and light
cycle oil products.
 RFCC utilizes the principles of UOP’s fluid catalytic cracking

process, it is designed to process 75,260 BPSD of Oman long
residue feed from the upstream CDU process unit.
 RFCC consists of Reactor and Regenerator Section,

Main Fractionator Section, Gas Concentration Section
and Flue Gas Section.

Propylene Recovery Unit (Unit 2700)
 The purpose is to recover polymer grade propylene from

C3/C4 mixture of the RFCC unit. The recovered propylene
is to be used as the feedstock for a Polypropylene plant.
 PRU is designed to process 29,368 BPSD of a mixture of

C3 and C4 hydrocarbons. PRU can also handle 257 T/D of
Carrier/Purge Fluid from the Polypropylene plant.
 PRU consists of a depropanizer, a deethanizer, propylene-

propane splitter, COS/Arsine treaters and a dryer.

Light Gasoline
From RFCC Light Light Gasoline to
TAME
Heavy Light
TSHP Gasoline
35,000 BPSD
Heavy Gasoline GHDS

From RFCC 26,500 BPSD
Hydrotreated GASOLINE
H2 From HGU
Gasoline BLINDER
DHDS
30,000 BPSD Diesel to
Storage
LCO From Gas Oil From CDU

RFCC
Distillate Unionfining Process Unit (Unit 3200)
 The purpose is to remove sulfur and nitrogen as a

hydrogen sulfide (H2S) and ammonia (NH3), from
a mixture of straight run gas oil from CDU and LCO
from RFCC and produce diesel oil product with improved
combustion properties.
 DHDS utilizes UOP’s Distillate Unionfining process and

its feed throughput is 30,000 BPSD.
 DHDS unit consists of a reactor section and

a fractionation section.

Gasoline Hydro-Desulfurization Process Unit (Unit 4200)
 The purpose of GHDS is to remove sulfur as a hydrogen sulfide

from a mixture of HLG from TSHP unit and HG from RFCC unit
and to pass doctor test negative in the product.
 The desulfurization level of product is 20 wtppm.
 GHDS utilizes Axens’ hydro-desulfurization process and its

feed throughput is 26,500 BPSD.
 GHDS consists of a reactor section, which includes a HDS

reactor and a finishing reactor, and a stabilizer section.

TAME Selective Hydrogenation Unit (Unit 4000)
 The purpose is to remove all dienes for the TAME unit feed
and to convert the light mercaptane compounds (R-SH) into
heavy ones to be sent to GHDS for further removal of sulfur.
 TSHP utilizes Axens’ selective hydrogenation process and

its feed throughput is 35,000 BPSD.
 TSHP consists of a reactor section and a splitter section.
 TSHP produces Light Light Gasoline (LLG) and

Heavy Light Gasoline (HLG) from Light Gasoline.

C4 From PRU
INALK Light Alkylate

SHP 15,000 BPSD
C4=
15,000 BPSD
C4 GASOLINE
H2 From HGU BLENDER
Light Light Gasoline TAME Etherified

From TSHP 1,800 T/D Gasoline
Methanol

Selective Hydrogenation Unit (Unit 2800)
 The purpose is to hydrogenate essentially all the butadiene in

the feed in order to minimize catalyst deactivation in the
Indirect Alkylation unit and to increase the octane of the
Indirect Alkylation unit’s product by increasing
the concentration of 2-butene in the SHP product.
 SHP utilizes UOP’s selective hydrogenation process and

its feed throughput is 15,000 BPSD of a mixed C4.
 SHP consists of a reactor section and a stripper section.

UOP Indirect Alkylation (InAlK) Unit (Unit 2900)
 The purpose is to produce high-octane gasoline blending

component similar to Motor Alkylate from butane/butene
feedstock from RFCC Unit.
 InAlk utilizes UOP’s indirect alkylation process and its feed

throughput is 15,000 BPSD of mixed C4 which is treated
by SHP.
 InAlk consists of a polymerization section, a hydrotreating

section and a fractionation section.

TAME Unit (Unit 4100)
 The purpose of TAME is to produce etherified gasoline as a

gasoline blending component by removing of reactive olefins
in the LLG.
 TAME utilizes Fortum (Neste)’s etherification process and

its design capacity is 1,800 ton/day.
 TAME consists of a rector section, a fractionation section

and a closed slop system to recover any methanol.

CDU LPG
Rich Amine
MEROX
RFCC LPG
ARU MEROX
149 T/D Lean
Amine RFCC GC
GHDS
DHDS
Amine Acid Gas
to SRU TGTU

Amine Regeneration Unit (Unit 3500)
 The purpose of ARU is to remove hydrogen sulfide (H2S) from

the rich amine streams produced in RFCC, RFCC LPG Merox,
DHDS and GHDS.
 The regenerated lean amine can be returned to the various user.
 The amine is a 35 wt.% solution of Di-isopropanol amine (DIPA)

in water.
 The regeneration is accomplished by sending preheated

rich amine to the Amine Regenerator.

2. PROCESS UNITS BLOCK DIAGRAM – AREA 400
TSHP
GHDS
Natural
HGU
Gas From DHDS
1.9 MMNm3/d
Utilities
SHP
INALK
OPP
HP Steam (Header: HGU / Utility)

Hydrogen Generation Unit (Unit 3300)
 HGU is designed to produce 1,900,000 Nm3/day of hydrogen

with 99.9 % purity from Natural Gas.
 HGU has been designed by TECHNIP.
 HGU involves the steam reforming reaction of Natural Gas into

hydrogen rich stream followed by PSA purification process.

Sour Gas to SRU

CDU
RFCC CDU DESALTER
PRU Sour SWS

GHDS Water 2,640 T/D Stripped Water
DHDS WWT
SRU (OFF-SITE)
TGTU

Sour Water Stripping Unit (Unit 3400)
 The purpose of Sour Water Stripping unit is to remove

hydrogen sulfide (H2S) and ammonia (NH3) from various
sour waters from upstream process units, and produce
stripped water.
 The SWS is designed to treat 2,640 metric tones per day

of sour waters.
 The SWS unit consists of a storage tank, a feed drum and

a distillation tower system.

Acid Gas From THERMAL

ARU Off Gas
INCINIRATOR
Sour SRU
Gas Tail Gas TGTU
155 T/D
From
SWS
H2S
Liquid Sulfur to
SGU (OFF-SITE)

Sulfur Recovery Unit (Unit 3600/3650)
 The purpose of the Sulfur Recovery Unit is to recover elemental

sulfur from hydrogen sulfide in the acid gas from ARU, SWS and
the Tail Gas Treating Unit (TGT).
 SRU utilizes Stork's modified Claus process and comprises two (2) ident
ical trains each having 75 % of total capacity of 155 tons/day of recove
red sulfur.
 SRU consists of a thermal stage and two catalytic stages.
 The recovered sulphur, liquid phase, from sulfur condensers

contains 300 wtppm of hydrogen sulfide (H2S), partly dissolved and par
tly present in the form of polysulfides (H2Sx).
 The Shell Sulfur degasification process has been developed to

degasify liquid sulfur to 10 wtppm H2S/H2Sx, which is the safe level to
avoid exceeding of the lower explosive limit.

Tail Gas Treating Unit (Unit 3700)
 The purpose is to remove the sulfur compounds from the SRU’s

tail gas and the vent gas of sulfur pit.
 TGT consists of the “SCOT (Shell Claus Off-gas Treating)” section

and the incinerator section.
 The SCOT section consists of a reduction section, followed by

an absorption section.
 The reduction section of the TGT converts the sulfur remaining

in the SRU’s tail gas to hydrogen sulfide (H2S), which is recovered
in the absorption section of the TGT and is recycled to the SRU.
 In the incinerator (F-3704), the combustible components in the

process gas from the SCOT absorber and the vent gas of sulfur
pit are oxidized at a temperature of 760oC within excess air
to meet local environmental regulations on SOx, NOx, particulates
and H2S emission.

Sulfur Granulation Unit (Unit 3800)
 The purpose is to produce dry sulfur pastilles from

degassed liquid sulfur produced in the SRU and to
package the pastilles in 1 ton bags for storing and shipping.
 The solidification facility shall have three trains (one spare)

of steel-belt-cooler type sulfur granulators, which produce
minimum 80 tons/day/train dry sulfur pastilles.
 The dry pastilles is stored in the silo, which has a two-days

storage capacity at the design sulfur production,
and will be transferred to the packaging and palletizing facility

Product Quality
LPG Gasoline
RVP, barg : 0.62 max :
Vapor Pressure @ 38 C, Benzene, vol % : 1.0 max
barg : 6.7 max. Olefin , vol % : 18 max.
Cu strip :No.1 Aromatic, vol %: 35 max.
RON: 90 min (reg.)/95min(sup)
MON: 80 min (reg.)/85min(sup)
Propylene
Aviation Fuel (Jet A-1)
Propylene, wt % : 99.5 min Sp. Gr.: 0.775 - 0.84
Freezing Pt. ℃: - 47 max
FBP ℃ : 300 max
Naphtha
Gas Oil
Sp. Gr 0.65 – 0.74 Flash Pt. ℃ : 62 min
IBP ℃ 25 min Cetane No. : 50 min
FBP ℃ 204 max Pour Pt. ℃ : -10 max

Theory of Distillation Column
Vapor Liquid Equilibrium
A : High Boiling Point Component

B : Low Boiling Point Components
Decrease
a b Temperature
Pressure
Heated
Feed AB
Distillation Increase
Column

RFCC Reactor & Regenerator Section

Main Fractionator

Gas Concentration Section

B/L Conditions
Press., barg Temp., ℃
C3= to PP Plant 40 20~40

H2 to PP Plant 47 38
Utilities to PP Plant
HP STM 42.3 385
MP STM 21.0 320
LP STM 10.6 220
LLP STM 3.5 180
Plant Air 7.0 50

Instrument Air 7.0 50
Natural Gas 31.0 22

Fuel Gas 3.5 38
Nitrogen 7.0 Amb.
Sea Water 2.5 34

UTILITY FACILITIES

Utility Facilities
 Unit 5100 : Power Plant, Electricity Receiving

and Distribution System.
 Unit 5200: Sea Water Intake Station
 Unit 5300: Water system.
 Unit 5400: Steam and Condensate system.
 Unit 5500: Fuel Gas and Natural Gas System.
 Unit 5600: Instrument Air and Plant Air system.
 Unit 5700: Nitrogen System.
 Unit 5800: Chemicals Preparation and
Injection Facilities

Utility - Facilities
Facilities Capacity
GTG : 20 MW x 2
STG : 32.9 MW x 2
EDG: 2.1 MW
Boiler: 60 T/H x 2
SWI: 59,100 T/D
Desalination: 165 T/H x 3
Deminalization: 240 T/D x 2
Deaerator: 490 T/H x 2
2ndary C.W.: 2260 T/H
Others: Sub-station,
Fuel gas System,
Caustic System, etc.

Utility - Power Balance
 The estimated electric power balance is as follows:
Generation MW Consumption MW
Steam Turbine Generators 65.8 Sohar Refinery 59.0
Gas Turbine Generators 40.0 Polypropylene plant 23.0
Total 105.8 Export to National Grid 23.8
Total 105.8

Utility Facilities
Unit 5200 - Sea Water Intake Station
 This system is designed to take sea water and distribute to

the Refinery and Polypropylene plant users.
 Sea water return and outfall facilities are also included in the
system. Sea water is used for cooling water medium and source
of desalinated water.
 Sea water supply pumps and sea water pipe from the intake
structure to the refinery and return pipeline up to the main
return header are designed to handle 59,100 T/D of sea water
(excluding amount of return water from Polypropylene plant).

Utility - Fuel Balance
 The estimated fuel and natural gas balance is as follows:
Import/Generation T/h Consumption T/h
Natural gas from 28.6 Natural gas to HGU as Feed 22.8

Pipeline Natural gas to Pilot burners 0.4
Fuel gas from 38.4 Natural gas to GTG 5.4

On-Site Process Fuel gas to Utility 12.2
Boiler & GTG
Total 67.0
Fuel gas to Area 1 7.3
Fuel gas to Flare system 0.5
Total 67.0

Utility - Steam Balance
 The estimated steam balance is as follows:
Generation T/h Consumption T/h

Utility Boiler 100 Steam Turbine Generator 364
Gas Turbine Generator (GTG) 70 Main Air Blower (K-2301) 129
CO Boiler (WHB-2301) 300 Wet Gas Compressor (K-2201) 58
RFCC Cat-cooler (E-2001/2002) 140 Process Steam Heaters 42
RFCC Steam Generators 46 Turbine (HP to LLP) 137
HGU Reformer (F-3307) 112 Turbine (HP to LP) 27
TGT Incinerator (E-3707) 6 Letdown (HP to MP) 0
Total 774 Loss at GTG 17
Total 774

Utility - Water Balance
 The estimated water balance is as follows:
Generation T/h Consumption T/h

Sea Water from Intake 552.0 Reject sea water to Outfall 325.0
Cold Condensate 425.0 Service water to On-site, Of 7.0
Clean Condensate 151.0 f-site and PP plat
Suspected Condensate 40.0 HP BFW to Utility boiler 101.0
LLP steam for Deaerator 63.2 HP BFW to Process boiler 727.0

make-up MP BFW to Process boiler 31.0
Total 1231.2 LP BFW to Process (SHP) 33.4
Demine water to PP plant 3.0
Import/GenerationT/Demine 3.0
water for Storage
Venting from Deaerator 0.8
Total 1231.2

OFFSITES AREA

OFFSITES AREA ( Facilities )
Feedstock & Slops Tankage

Product Tankage
Marine Loading
Truck Loading
Waste Water Treating System
Sulfur Granulation
and Bagging System
Flare

Offsites Area Definition
 Feed Stock / Intermediate / Slops Tankage

 Area 6100
 Component / Product Tankage
 Area 6200
 Waste Water
 Truck Loading Treatment
 Area 6300
 Area 6500
 Fire Fighting
System
 Area 9100
 Sulfur Granulation
 Flare Unit Sulfur
 Area 3800
 Area 6900

OFFSITES AREA ( Hydrocarbon Flare )
Flare Philosophy
 The Flare is designed to handle the Relief Load

of 1,002 Tons/hr. of hydrocarbon in case of
Total Power Failure.
 Relief Load from OPP’s Polypropylene Unit is

also handle by this Flare.
 Following are some of the cases to determine

the design load of Flare
 Total Power Failure
 Partial Power Failure
 Sea Water Failure
 Instrument Air Failure
 External Fire etc.

OFFSITES AREA ( Hydrocarbon Flare )
Flare Process Flow
 Flare header is sloped towards K.O. Pot
 Flare headers are sized to keep the buildup
back pressure at each relief valve.
 Fuel Gas is used for sweeping the Flare header.
 LP steam is added to the tip of Flare for
smokeless flame. F
 Height of the Flare is enough to take care of L
Radiation heat intensity A
 Allowable safe concentration of R
sulfides/oxides at ground level is maintained. E
Hydrocarbon Relief
Liquid
from Process Units
Seal
Flare
To Wet Slops K.O. Pot

Q & A Session

Refinery Presentation On 07th July 07

Uploaded by

Copyright:

Available Formats

You might also like

Refinery Presentation On 07th July 07

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Refinery Presentation On 07th July 07

Uploaded by

Copyright:

Available Formats

Presentation on Overall Refinery Operation

Contents of today’s presentation

2017-09-12 1 Sohar Refinery Company

 Crude oil is mixture of various hydrocarbons consisting of

2017-09-12 2 Sohar Refinery Company

 Depending on total Sulfur content Crude oil termed as

 Depending on Total Acid No. ( TAN) Crude oil

 Depending on UOP K factor Crude oil termed as

2017-09-12 3 Sohar Refinery Company

2017-09-12 4 Sohar Refinery Company

Normal Paraffin Isoparaffin (Isoalkane)

2017-09-12 5 Sohar Refinery Company

Heptene, C7H14 Isooctene, C8H16

55 RON 106 RON

2017-09-12 6 Sohar Refinery Company

Methylcyclopentane, C6H12 Cyclohexane, C6H12

2017-09-12 7 Sohar Refinery Company

Benzene, C6H6 Toluene, C7H8

115 RON 120 RON

2017-09-12 8 Sohar Refinery Company

MTBE, CH3OC4H9 Ethanol, C2H5OH

2017-09-12 9 Sohar Refinery Company

Crude Oil Refining Gas Oil

2017-09-12 10 Sohar Refinery Company

2017-09-12 11 Sohar Refinery Company

2017-09-12 13 Sohar Refinery Company

Refinery Configuration is aimed with the objective of

2017-09-12 15 Sohar Refinery Company

2017-09-12 16 Sohar Refinery Company

Different Combinations possible :

2017-09-12 17 Sohar Refinery Company

2017-09-12 18 Sohar Refinery Company

2017-09-12 19 Sohar Refinery Company

2017-09-12 20 Sohar Refinery Company

2017-09-12 21 Sohar Refinery Company

SHORT RESIDUE COKER KERO+HSD

2017-09-12 27 Sohar Refinery Company

SHORT RESIDUE KERO/HSD

2017-09-12 33 Sohar Refinery Company

Max Olefin & SOR (BPSD)

Propylene 14,583 (12 %)

Sulfur 155 t/d

2017-09-12 34 Sohar Refinery Company

2017-09-12 35 Sohar Refinery Company

2017-09-12 36 Sohar Refinery Company

2017-09-12 37 Sohar Refinery Company

2017-09-12 38 Sohar Refinery Company

Mixed CDU SRN to

2017-09-12 39 Sohar Refinery Company

 The purpose is to produce a long residue, as a RFCC feedstock

 CDU is designed to process 116,400 BPSD of Mixed Crude

 CDU also produces LPG, naphtha, kerosene and gas oil.

 CDU consists of Preheating section, heaters, Desalters,

2017-09-12 40 Sohar Refinery Company

 The purpose is to remove hydrogen sulfide (H2S) and

 LPG Merox utilizes UOP’s Merox process,

 LPG Merox consists of a pre-treatment section,