15 Process Technic Manual of Reforming

SORALCHIN OIL REFINERY ENTERPRISE STANDARD
SRC/TE-SF-T-013-2005
Soralchin Oil Refinery
Catalytic Reforming Unit Processing

Technical Manual (Interim)
Issued on July 20, 2005 Implemented on July 20, 2005

Soralchin Oil Refinery Catalytic Reforming Unit Processing Technical Manual
ISSUED BY SORALCHIN OIL REFINERY
Preface
These Regulations bring forward detailed introductions to the profile of catalytic
reforming unit, production processes and technical principles, mass balance, dynamic
power consumption, three reagents application, as well as the attached major
instrumentation listing, equipment listing, technical principal flow charts, etc.
This Standard is proposed by Soralchin Oil Refinery.

This Standard is especially subsumed to Technology Dept of Soralchin Oil Refinery.
This Standard was drafted by Catalytic Reforming Unit of Soralchin Oil Refinery.
Prepared by: Zhijun Xiao
Verified by: Wei Chen, Technology Dept

Xudong Zeng, Production Dept
Yuanyi Ge, Mechanical & Dynamic Dept
Jingxin Su, Safety & Environmental Protection Dept
Approved by : Riyuan Zhang
2
Table of Contents
1 Applicable Scope ………………………………………………………………6
2 The Unit profile………………………………………………………………….6
3 Production Technical Process………………………………………………….7
3.1 Process Technology Features……………………………………………………7
3.2 Technical Principle and Major Operations Analysis…………………………9
3.2.1 Pretreatment System……………………………………………………....9
3.2.2 Reforming Reaction System…………………………………………….12
3.2.3 Toxic Substance Hazard to Reforming Catalysts………………………15
3.2.4 Reforming Catalyst Property Specifications……………………………17
3.3 Process Flows………………………………………………………………….19
3.3.1 Pretreatment Section………………………………………………………19
3.3.2 Reforming Section…………………………………………………………20
3.3.3 Tankage ……………………………………………………………………22
3.3.4 Ancillary Systems………………………………………………………….22
4 The Unit Mass Balance……………………………………………………….25
4.1 Mass Balance of the Unit……………………………………………………..25
4.1 Mass Balance of Pre-Fractionation Section …………………………………25
4.2 Mass Balance of Pre-Hydrogenation Section………………………………..26
5 Feedstock and Product Major Technical Specifications ……………………26
5.1 Feedstock Source and Processing Locations …………………………………26
5.2 Feedstock…………………………………………………………………….27
5.2.1 Crude Oil………………………………………………………………….27
5.3 Products……………………………………………………………………….32
5.3.1 Hydrogen-Containing Gas………………………………………………..32
5.3.2 Reformed Gasoline …………………………………………………………33
6 The Unit Processing Technical Plans and Major Operational Conditions …33
6.1 Processing Technical Plans …………………………………………………….33
6.2 Major Operational Conditions ……………………………………………….34
6.2.1 Pre-Hydrogenation ……………………………………………………34
6.2.2 Reforming ………………………………………………………………34
6.2.3 Starting and Shutdown…………………………………………………35
7 Production Control Analysis ………………………………………………36
8 The Unit Comprehensive Energy Consumption …………………………38
8.1 Utility Engineering Consumption …………………………………………38
8.1.1 Major Consumption Indexes……………………………………………38
3
8.1.2 Water Consumption…………………………………………………….40

8.1.3 Electricity Consumption ………………………………………………..41
8.1.4 Steam Consumption ……………………………………………………43
8.1.5 Compressed Air Consumption ………………………………………….44
8.1.6 Nitrogen Consumption …………………………………………………44
8.1.7 Fuel Gas Consumption…………………………………………………45
8.1.8 The Unit Comprehensive Energy Consumption ………………………45
9 Catalysts and Reagents ………………………………………………………46
9.1 Catalysts and Chemical Reagents Specifications ………………………….46
9.1.1 Catalyst …………………………………………………………………..46
9.1.2 Desulfurization Agent (CT8-3)………………………………………….47
9.1.3 Molecular Sieve Drying Agent………………………………………….47
9.1.4 Activated Carbon………………………………………………………..48
9.1.5 KT-1 Shoring Protective Agent …………………………………………48
9.1.6 Nitrogen and Hydrogen For Starting Operation………………………49
9.1.7 Chemical Reagents………………………………………………………49
9.1.8 Heat Carrier ……………………………………………………………..50
9.1.9 Catalyst and Chemical Reagent Application Volume ………………..51
10 Equipment of the Unit………………………………………………………52
10.1 Selection of Major Equipment ………………………………………..52
10.1.1 Reactors…………………………………………………………………52
10.1.2 Towers……………………………………………………………………52
10.1.3 Heaters…………………………………………………………………..52
10.1.4 Heat Exchangers ……………………………………………………….53
10.1.5 Compressors……………………………………………………………..53
10.1.6 Pumps……………………………………………………………………53
10.1.7 Vessels …………………………………………………………………….53
10.2 Equipment Listings …………………………………………………….54
10.2.1 Towers Listing……………………………………………………………54
10.2.2 Vessels Listing……………………………………………………………54
10.2.3 Pumps Listing ……………………………………………………………55
10.2.4 Coolers and Heat Exchangers Listing ………………………………….56
10.2.5 Compressors and Heater-Used Blowers ………………………………..57
10.2.6 Heaters …………………………………………………………………..57
10.2.7 Relief Valves ……………………………………………………………..58
10.2.8 Other Equipment…………………………………………………………59
4
10.3 Instrumentations Listings ………………………………………………...59

10.3.1 Major Control and Measuring Instrumentations………………………..59
11 Outline of DCS System…………………………………………………………62
12 Process Pipelines Specifications ……………………………………………….65
13 Environmental Protection and Three Wastes Treatment and Recycling …..87
13.1 Waste Gas…………………………………………………………………87
13.2 Effluent …………………………………………………………………..88
13.3 Three Wastes Treatment and Recycling ……………………………….89
13.3.1 Effluent Treatment………………………………………………………..89
13.3.2 Waste Gas Treatment……………………………………………………..89
13.3.3 Slag Treatment…………………………………………………………….90
13.3.4 Noise……………………………………………………………………….91
13.3.5 Professional Safety and Industrial Hygiene ……………………………92
13.3.6 Hazardous Feedstock and Products…………………………………….92
13.3.7 Hazardous Factors In Production Process……………………………..92
13.3.8 Major Countermeasures In Production Process ………………………93
13.3.9 Relevant Production Safety Codes For the Unit………………………..95
14 Annex Figures ………………………………………………………………99
Soralchin Oil Refinery Catalytic Reforming Unit Processing
5
Technical Regulations
1. Applicable Scope
These Regulations introduce the catalytic reforming unit profile, technical principle,
processing flows, technical conditions as well as major economic indexes, equipment
listings, safety code, etc.
These Regulations apply to operation posts at the catalytic reforming unit.
Referenced standard and basis of preparation:

1. General design plan. 2. Preliminary design instructions. 3. Technical package for
Hydrogen required during starting RIPP reforming unit.
2. The Unit Profile

Soralchin Oil Refinery (called “the Refinery”) catalytic reforming unit is designed by
East China Exploration & Design Institute under PetroChina and constructed by Jilin
Chemical Construction Co, Ltd under PetroChina. The catalytic reforming unit
reprocesses feedstock of straight-run naphtha produced from atmospheric unit, with
rated capacity of 100,000t/a. Main product lines are #96 premium gasoline
components and ordinary gasoline components, as well as byproducts such as
hydrogen, dry gas and LPG.
Pretreatment part of catalytic reforming unit adopts processing flows of fractionation

preceding hydrogenation. Reforming uses semi-regeneration fixed bed reforming
process with catalysts injected as per sections and two-section hydrogen-mixing
technologies involved. The catalytic reforming unit applies RIPP naphtha hydrogen-
making technology.
catalytic reforming unit is a newly established construction, situated the southernmost

part of production zone of the Refinery, and to the north there is atmospheric – gas
6
fractionating complex unit. The catalytic reforming unit is roughly divided into four
sections:
(1) Compressor house, located at north side of the shop of the Unit, is a two-storey
structure (open construction) equipped with an electric powered anti-explosion
overhead crane in service for installation and maintenance of the compressor and
motors.
(2) Along the south side of the shop, there are towers, vessels and cold exchange
framework that is three-layer structure in which reflux tank and heat exchangers
are mounted.
(3) The southern part of the Unit is pipeline zone, the process pipelines from and to
the Unit from west side, while utilities pipelines are connected with the Unit from
its east side. Air refrigeration unit is mounted above the pipelines and pumps are
installed beneath the lines.
(4) At the east part, north of the pipeline zone there are concentrated laid heaters,
reactor, vertical heat exchangers, etc. An electric hoist is equipped on framework
above the reactor.
These zones are separated by firefighting paths and maintenance aisles. The Unit
does not have independent power distribution house, instrumentation control room or
field operation room, instead, the Unit shares those functions with other units.
The Unit covers a space of 7,788m2, 118m in east-west direction; 66m in north-south.
3 Production Technical Process

3.1 Process Technology Features
(1) Pre-hydrogenation uses flow-through-once process, i.e. partial reforming
hydrogen flows through the pre-hydrogenation system at once, after being boosted by
pre-hydrogenation compressor, and then is sent by pre-hydrogenation liquid-gas
separator to fuel gas lines;
(2) The remaining reforming hydrogen discharged from reforming gas-liquid
7
separator to the fuel gas lines;

(3) The high-efficiency and high-velocity RS-1 pre-hydrogenation catalyst recently
developed by RIPP is used to increase air speed from conventional 2h -1 to 6h-1 so that
investment cost on pre-hydrogenation system equipment and expenses for catalysts
are reduced;
(4) The reforming part uses two-section hydrogen-mixing fixed bed semi-
regeneration technical process, equipped with four reactors. The first and second
reactors are axial reactor; the third and forth are radial reactor. Reforming catalyst is
applied per sections. Specifically, the first and second reactors use PRT-C catalyst and
operate in high air velocity and low-hydrogen-oil ratio conditions, while the third and
forth reactors use PRT-D catalyst, operating in low air velocity and high hydrogen-oil
ratio conditions. This technology allows variety of catalysts to make full use of their
activity, selectivity and stability characteristics in their respective reaction areas to
increase reforming liquid products yield rate, extend operation cycle and reduce the
Unit’s energy consumption.
(5) Two vertical counter-flow heat exchangers (reforming feeding heat exchanger and
two-section hydrogen-mixing heat exchanger) are employed for increased heat
exchanging intensity and reduced reforming section hydrogen system pressure drop;
(6) Reforming heater is a “4 in 1” type high-efficiency furnace to heat convection
section heat carrier and preheat air so as to raise heat efficiency;
(7) Reboilers at bottom of towers use heat carriers as heat source. Under normal
operation condition, the majority of heat carriers are heated by “4 in 1” heater and for
minority of them, the heat-carrier heater is to furnish the carriers with supplementary
heat;
(8) In order for pre-hydrogenation catalysts to increase their activity, there is pre-
sulfurization facility is available to pre-sulfurize the catalysts during starting
operation;
(9) Reforming section has a molecular sieve drying cycling hydrogen system to
dehydrate the system during starting operation.
8
3.2 Technical Principle and Major Operations Analysis

3.2.1 Pre-treatment system
3.2.1.1 Pre-fractionation system
The pre-fractionation’s objective is, by using the fractionating method, to separate the
overheads up to 65oC at dropping point from straight run naphtha downstream of
atmospheric unit so that the distillate components required for reforming reaction is
sorted out. In the meanwhile, a portion of water can be removed as well.
3.2.1.2 Pre-hydrogenation system

The pre-hydrogenation system is to hydrogenate and refine bottom distillates of pre-
fractionation tower by removing metal and nonmetal toxic matters from the bottom
heavy oil and making saturation of alkenes to meet stringent requirement in terms of
impurity contents of feedstock by catalytic reforming catalysts to prevent the catalysts
from contamination. Pre-hydrogenation feedstock is processed in the pre-
hydrogenation reactor mainly for reactions of desulfurization, denitrogenation,
deoxidization, removal of metals, saturation of alkenes, etc. Pre-hydrogenation
features a high degree of hydrogen consumption and heat release.
3.2.1.3 Major chemical reactions in Pre-hydrogenation

3.2.1.3.1 Desulfurization
In order for reforming catalysts to possess better selectivity and reliability, sulfur
concentration in reforming feedstock shall be strictly controlled. The low platinum-
rhenium catalyst, for example, requires less than 0.5ppm of sulfur contents. Because
desulfurization takes place rapidly, hydrogenating desulfurization is easier than the
reaction of hydrogenating denitrogenation and alkenes saturation. The hydrogenation
reaction produces hydrocarbons and hydrogen sulfide which is easy to be eliminated.
In general, nonmetals such as sulfur and nitrogen cause reforming catalysts to lose
activity temporarily, nevertheless, a prolonged duration of their contamination upon
the catalysts may perpetually impair the activity of the catalysts. Therefore, it is
necessary to monitor periodically if there is punch-through occurring in the layers of
9
hydrogenation catalyst bed.
diethyl disulfide ethane hydrogen sulfide
RSH + H2 → RH + H2S
Hydrosulfide alkane hydrogen sulfide
3.2.1.3.2 Denitrogenation
Reforming feedstock’s nitrogen existing in nitrogenated compounds is converted during
hydrogenation into ammonia and corresponding hydrocarbons, but denitrogenation is much more
tougher than desulfurization. For platinum-rhenium catalyst, nitrogen contents in feedstock shall
be less than 1.0ppm.
pyrrole butane ammonia
pyridine：
C6H5N+5H2—→C6H12+NH
Quinoline:
C9H7N+4H2—→C9H12+NH3
Comparison of nonmetals removing velocities in hydrogenation:

Desulfurization : alkenes saturation : denitrogenation = 70 : 40 : 1
3.2.1.3.3 Deoxidization
Deoxidization in feedstock: In hydrogenation condition, the oxygen-containing
10
compound reacts with hydrogen and produces corresponding hydrocarbon molecules.

Naphthenic acid, the major content of oxygen-bearing compounds in feedstock, shall
be removed, or it will generate water when entering reforming reaction in the
presence of hydrogen to result in excessive water in the system, which may, on one
hand, cause the washing-away of chlorine in the catalysts, on the other, result in
agglomeration of the catalyst crystalline grains.
Phenol
Acid
3.2.1.3.4 Dehalogenation
Organic halogenated compounds in the presence of hydrogen can produce
corresponding hydrocarbons and hydrogen halide. Dehalogenation of organic
halogen compound is more difficult than desulfurization.
RCl + H2→RH + HCl
3.2.1.3.5 Alkenes saturation

Saturation of alkenes produces alkane at a bit slower rate than desulfurization. Owing
to alkane present in feedstock, carbon deposition upon the catalysts increases so that
production cycle is reduced.
CnH2n+H2→CnH2n+2
3.2.1.3.6 Dematallation
The feedstock contains compounds of impurity of arsenic, cupper, lead, mercury, iron,
11
etc which may cripple or even permanently expropriate the activity of reforming
catalysts if they come inside reactor. Among those compounds, arsenic is most
hazardous. It may adhere upon the reforming catalysts, and with reactions involving
the active components in the catalysts, generate platinum or rhenium alloys to cause
perpetual impairment of activity of the catalysts.
3.2.2 Reforming reaction system

3.2.2.1.1 Reforming reaction principle
Catalytic reforming is the process of aromatization and other reactions taking place in
the presence of petroleum fractions in a certain boiling range, effected by reforming
catalysts in hydrogen environment under desired temperature and pressure conditions.
The reforming allows small amount of aromatic hydrocarbon in the feedstock to
rearrange molecular structures and consequently generate isomerized alkane rich in
aromatic hydrocarbon. It is further processed to obtain gasoline components with
high octane. General requirements for reforming feedstock are: ideal reforming feed
should have a high extent of aromatic hydrocarbon potential contents (or reforming
index), whereas naphthene base material is the ideal feedstock for reforming unit.
Desired fraction components for yielding high octane gasoline are within the range of
65oC – 180oC.
3.2.2.1.2 Major chemical reactions

(1) Hexahydric polymethylene dehydrogenation
cyclohexane benzene hydrogen

C7H14 → C7H8 + 3H2
Reactions of this kind are rapid and draws considerable amount of heat. They are
main reaction of producing aromatic hydrocarbon.
12
(2) Five carbon ring alkane isomerization
pentacarbon alkane hexahydric alkane aromatic hydrocarbon

C6H12 →C6H12 →C6H6+3H2
Reactions of this kind take place relatively slower and draw heat, are main reaction in
generation of aromatic hydrocarbon. They take place in two steps. The first step is
isomerization which is slow and a key step in reaction; the second is dehydrogenation
and takes place rapidly.
(3) Alkane cyclization dehydrogenation
Alkane products of dehydrogenation isomerization
Reactions of this kind run slowly, draw heat and require stringent conditions, they are
main reactions in generating aromatic hydrocarbons. Alkane cyclization
dehydrogenation requires higher temperature and lower pressure to fetch a relatively
complete outcome. Outstanding catalysts can aid to these reactions to achieve
satisfactory performance. These reactions usually take place in after-reactors.
(4) Hydrogenation cracking reaction

The replacement of Alkane or alkyl ring pentane into aromatic hydrocarbon involves
tough experience of dehydrogenation and cyclization. It requires acidic catalyst
present in the reaction. Such reaction conditions also results in hydrogenation
13
cracking reaction.
Hydrogenation cracking reaction is a faster reaction process to which high pressure

and high temperature are conducive. In normal conditions, hydrogenation cracking
reaction should be minimized in catalytic reforming process because it affects and
reduces liquid yield rate as well as consuming hydrogen generated in reforming
reaction.
(5) Isomerization
C7H16 (n; normal) →C7H16 (isomerized)
These reactions are slow and heat-releasing (moderate amount), producing neither
hydrogen nor consuming hydrogen, conducive to the rise of octane numbers.
(6) Demethylation
Under austere catalytic reforming reaction conditions, demethylation may take place
if confronting high temperature and high pressure. In some conditions, it is more
likely occurring when catalyst is replaced or restarting the system after regeneration.
These reactions are triggered mainly by metals.
Demethylation
Usually, demethylation is undesired in the production and measures to restrain it from

happening are application of sulfur or second metal (dual metal catalyst) to deaden the
metal function.
(7) Aromatic hydrocarbon dealkylation is similar to demethylation. The difference
14
lies in that the former removes an alkyl from the lateral chain of aromatic
hydrocarbon instead of just a methyl.
Dealkylation
This kind of dealkylation reaction will take place if the lateral chain is long enough
and conditions of high temperature and high pressure are present.
In addition, there is polymerization coking reaction that is inevitable and the higher
the alkenes contents in feedstock, the more severe the polymerization coking reaction.
3.2.3 Reforming Catalyst Property Specifications

3.2.3.1 Arsenic (As)
Arsenic is the most hazardous toxic substance to reforming catalysts. It has a strong
affinity interaction with precious metals in catalyst. When interacting with platinum,
it deprives platinum activity for good and consequently expropriates catalyst activity
permanently. In addition, arsenic may produce AsCl 2 with chlorine, as a result, the
acidic components are weakened and catalysts’ dual function balance is ruined.
Arsenic hazard is leaching down along bed layers with weak penetration. In general,
the catalysts in the first reactor have the highest contents of arsenic and in the last
reactor the least contents.
Like arsenic, metal impurities such as lead, cupper, mercury, iron, etc are permanent
toxics, whereas the effect of permanently impaired activity of the catalyst can’t be
reversed via regeneration. If excessive metal impurities present on a long-term basis,
it may cause deposition of iron sulfide upon the top of the pre-hydrogenation reactor
and increment of the reactor discharge pressure. Therefore, removal of the deposition
on the reactor top is necessary whenever the system is shutdown.
15
3.2.3.2 Sulfur
Absorbed to the surface of catalyst, sulfur, together with platinum and rhenium,
produces compound to destroy the catalyst activity. Sulfur is a temporary toxic yet
has notorious strong penetration, capable of harming several reactors at once.
Sulfur poisoning can be relieved by regeneration and application of low-sulfur

feedstock to allow the catalysts restore their activity completely or partially.
H2S usually concentrates in the reflux tank on top of the pre-hydrogenation higher
fractions and reforming evaporation dehydration tower, the upper part of reforming
debutanation tower. During normal operation, close attention shall be paid to H 2S
concentration in the reforming circulating hydrogen, while over shutdown period,
FeS2 self combustion shall be concerned strictly.
3.2.3.3 Water (H2O)

Water concentration in gases in the reactor will rise if reforming feedstock has a high
content of water. High reactor temperature makes platinum grains in catalyst to
coagulate increasingly, causing chlorine loss in reforming catalyst, diminishing
catalyst acidic contents and destroying water-chlorine balance.
3.2.3.4 Nitrogen (N)

The nitrogen in organic nitrogen compound may, in reforming conditions, react with
hydrogen to generate NH3, which is able to neutralize acidic components in catalysts
to sabotage the balancing relationships between catalyst metal function and acidity
function. NH3’s presence is detrimental to the operation safety of the reforming
equipment. NH4Cl agglomeration in gigantic amount may cause increment of inlet-
outlet pressure differential of compressor to result in such frequent shifting that the
compressor operation safety is seriously impacted. On the other hand, it agglomerates
in huge volume at reforming unit cold exchange equipment and high fractions gas-
liquid separator, which is prone to produce blockage in pipelines.
16
3.2.4 Reforming catalyst performance specifications

3.2.4.1 Catalyst activity
Activity is an essential specification for reforming catalysts. The more active the
catalyst, the more feedstock replacement capacity and the more output of production
are produced over an equivalent reaction period. Therefore, reforming catalyst
activity is often measured in aromatic hydrocarbon yield rate.
3.2.4.2 Selectivity
Selectivity refers to the criterion of capability of the catalyst conducive to ideal
reaction. Very often, the catalyst triggers side reaction as well as accelerating the
desired reactions.
3.2.4.3 Stability
The catalyst activity and selectivity in process cycle will be weakened as time elapses.
This nature is depicted as catalyst stability, i.e. the smaller the stability value, the
better the stability.
3.2.4.4 Catalyst life

The number of cubic meters of feedstock processed by the catalyst in processing cycle
is called catalyst life. With process time passed, the catalyst activity is ever-
decreasing as a result of settled carbon and contamination until it’s no longer
workable and requires replacement by fresh catalyst to continue the process.
3.2.4.5 Platinum and rhenium functions

Platinum functions:
Platinum is metal activity center in reforming catalyst. Its most significant feature is
the strong ability to attract hydrogen atoms and as such it possesses catalysis property
for dehydrogenation isomerization reaction. Platinum in reforming catalyst mainly
functions to promote dehydrogenation – hydrogenation.
17
Relatively more platinum contents bring more anti-toxic ability to catalysts.
Rhenium functions:
Rhenium is to raise catalyst stability and restrain platinum grains from agglomerating.
Inclusion of rhenium lifts carbon-containing capability of sole platinum catalyst to 3 –
4 times. The catalyst stability is therefore increased, however, catalyst activity
remains unchanged.
Water and chlorine functions

The presence of water-chlorine is for the promotion of acidic functions of the catalysts
required for isomerization, cyclization and cracking reactions. Reforming catalyst
metal function (dehydrogenation) and acidic function are inter-matching and mutually
effected. Therefore, it is rather essential to maintain water-chlorine balance for fully
application of reforming catalyst performances. It is even more important for the
reforming unit with aromatic hydrocarbon potential contents in feedstock.
Excessive or inadequate amount of chlorine (water) is detrimental to the catalyst.

Chlorine injection usually causes severe chlorine corrosion the low-temperature part
of hydrogen system or ammonium Chloride blockage in downstream units. To maintain
water-chlorine balance, the key is smooth operation, even and continuous injection
without intense fluctuation of injection. During starting and shutdown operations,
stringent chlorine injection plan should be observed to avoid chlorine spill or escape,
otherwise, it may cause insufficient chlorine content and impact the optical operation
of the overall cycle. In addition, two-section chlorine injection procedures should be
followed in respect to two-section hydrogen-mixing process with no mutual
replacement permissible.
3.3 Process Flows
18
3.3.1 Pretreatment section

Straight-run naphtha from feedstock tankage (distillation range: dropping point up to
165oC) enters heat exchanger (E-202101/1-3) of pre-fractionation tower for heat
exchange, and then enters pre-fractionation tower (C-202101). The top distillates
from C202101 are cooled and condensed at air cooler (A-202101) and water cooler
(E-202107) of the pre-fractionation tower before entering into reflux tank (D-202102)
of the pre-fractionation tower. Uncondensed gas from D-202102 is discharged to fuel
gas system through pressure controls, while liquid phase components (light naphtha)
are split into two streams. One stream gets boosted by reflux pumps (P-202102/1, 2)
of the pre-fractionation tower and returned to the top of C-202101 as reflux; the other
stream is sent out of the unit [or is boosted by light naphtha pumps (P-202103/1, 2) to
the heat exchangers (E-202203/1-3) of stabilization tower as a stream of feedstock].
C-202101 bottom distillates (65-165oC fractions) are boosted by hydrogenation
feeding pumps (P-202104/1, 2) to E202103/1-3 for heat exchange against
hydrogenation reaction products prior to entering pre-hydrogenation furnace (F-
202101) where the bottom distillates are heated to reaction temperature and routed to
pre-hydrogenation reactor (R-202101) for desulfurization, denitrogenation and
dematallation reactions. The reacted products enter E-202103/1-3 to heat-exchange
against hydrogen, and then enter E-202101/1-3 to heat-exchange against feedstock of
pre-fractionation tower. The heat-exchanged feedstock is condensed and cooled by
pre-hydrogenation product air cooler (A-202102) and pre-hydrogenation product
water cooler (E-202108) before entering pre-hydrogenation gas-liquid separator (D-
202103) to separate gas from liquid. The separated gas is pumped to fuel gas pipeline
through pressure controls and bottom liquid feed is fed to the heat exchanger (E-
202104/1-3) of evaporation tower for heat exchanging against bottom distillate stream
before being routed into evaporation tower (C-202102). C-202102 top distillates are
condensed and cooled in evaporation tower air cooler (A202103) and water cooler (E-
202109) and then enter reflux tank (D-202104) of the evaporation tower. D-202104
uncondensed gas is boosted to catalytic cracking unit for desulfurization before being
19
vented to fuel gas lines, while majority of bottom distillates from D-202104 is boosted
by evaporation tower reflux pumps (P-202105/1, 2) to be sent back to the top of C-
202102 as reflux stream and minority of them is routed into catalytic cracking unit.
C-202102 bottom distillates (refined naphtha) enter into reforming section through
desulfurization tank (D-202105) and E-202104/1-3. C-202102 bottom distillates may
also taken as refined oil after being cooled by E-202106 and stored in refined naphtha
tanks. The Heat required by pre-fractionation tower reboiler (E-202102) and
evaporation tower reboiler (E-202105) comes from the heat recovered by 4 in 1 heater
counter-flow section.
In order for pre-hydrogenation catalyst to increase its stability and activity, there is a
sulfur injection line equipped at the inlet of P-202104 in initial starting period to
perform pre-sulfurization to the catalyst.
There is a desulfurization tank D-202105 constructed at the bottom of evaporation

dehydration tower (C-202102) to better protect reforming catalyst from contamination
by sulfur.
3.3.2 Reforming Section

The refined naphtha from pre-hydrogenation is boosted by reforming feeding pumps
(P-202201/1, 2) to merge into the circulating hydrogen stream (first section hydrogen
mixing) and enter reforming feeding heat exchanger (E-202201) piping range for heat
exchange against reforming reacted products, and then enter the following devices in
sequence: 1st reforming furnace (F-202201/1), 1st reforming reactor (R-202201), 2nd
reforming furnace (F-202201/2), 2nd reforming reactor (R-202202), thereafter they are
mixed with another stream of circulating hydrogen (second section hydrogen mixing)
boosted by K-202201/1-3. The remixed feed is routed into 3 rd reforming furnace (F-
202201/3), 3rd reforming reactor (R-202203), 4th reforming furnace (F-202201/4), 4th
reforming reactor (R-202204). R-202204 reacted products are split into two streams:
one stream is heat-exchanged against reforming feedstock in E-202201 housing range;
20
the other is heat-exchanged against second section mixing hydrogen in E-202202

housing range, and then two streams merge into one. It further enters reforming
products air cooler (A-202201), reforming products water cooler (E-202208) for
condensation and cooling before entering reforming gas-liquid separator (D-202201).
Hydrogen-containing gas withdrawn from the top of D-202201 enters liquid

separation tank (D-202202) located at the inlet of the compressor for liquid separation
and then is split into two portions: the majority is reforming circulating hydrogen,
being boosted by K2201/1, 2 as the first and second section mixing hydrogen; the
remainder portion of reforming generated hydrogen is sent to pretreatment section.
D-202201 bottom liquid phase (reforming generated oil) is boosted by stabilization

tower feeding pumps (P-202202/1, 2) to enter stabilization tower feeding heat
exchanger (E-202203/1-3) for heat exchange against bottom distillate stream of the
stabilization tower before entering the stabilization tower (C-202201). Top C 4-
distillate of C-202201 is condensed and cooled by stabilization tower air cooler (A-
202202) and water cooler (E-202209) before entering the stabilization tower reflux
tank (D-202203). D-202203 uncondensed gas enters fuel gas system through pressure
controls. D-202203 bottom liquid phase is boosted by stabilization tower reflux
pumps (P-202203/1, 2) and a portion of the liquid phase is returned to the top of C-
202201 as reflux while the other portion is sent out of the unit as LPG. C-202201
bottom distillate (debutanation oil) is heat-exchanged in E-202203/1-3 prior to being
cooled by reforming gasoline cooler (E-202205) and then sent out of the unit as high
octane gasoline blending component.
There are chlorine and water injection facilities in the reforming system to maintain
water-chlorine balance for the catalysts in normal operation.
During initial starting period, the pre-sulfurization facilities are employed at the inlet
of all reforming reactors to restrain cracking activity of fresh (or regenerated)
21
catalysts. These facilities are operated to utilize high-pressure nitrogen to force the
sulfides in D-202207, D-202208, D-202209 and D-202210 into the inlet of R-202201,
R-202202, R-202203 and R-202204 respectively.
During starting and abnormal operations the system contains high level of water
content. To remove and reduce system water content, there are molecular sieve
drying system and molecular regeneration system configured. Hydrogen-containing
gas from K2201/1, 2 enters D202204/1, 2 where water contents in circulating
hydrogen are absorbed upon the molecular sieves. The molecular sieve regeneration
system processes are as follows: after nitrogen is fed into F-202202 and heated, the
nitrogen enters D-202204/1, 2 to bring away the water contents in the molecular
sieves, the regeneration gas then enters E-202206 housing range to be cooled and
enters D-202206 for draining water, while nitrogen is recirculated for application.
3.3.3 Tankage
Reforming feedstock tankage, located in petroleum products tanks zone, includes 3
reforming feedstock tanks with unit capacity of 1,000m 3 and 1 refined oil tank of
1,000m3.
The naphtha with dropping point up to 165 oC from atmospheric distillation unit enters
reforming feedstock tank (T-30202 to T-30204) for natural settling dehydration and is
pumped by pre-fractionation feeding pumps (P-202101/1, 2) into the stream of pre-
fractionation feedstock.
In addition, for the needs of reforming starting operation, there are refined oil tank T-
30201 and specially equipped refined oil pump (P-30207) and pipelines to prevent the
refined oil from contamination.
3.3.4 Ancillary systems

3.3.4.1 Air system
22
The air system consists of purified air and non-purified air coming from outside of the
unit via pipelines. The purified air enters D-202219 and exits it through the top where
the purified air is allocated for applications of pre-hydrogenation catalyst
regeneration, instrumentation pneumatic regulating valves, K202101, unloading
devices K202201A-C, and clearance cavity. The non-purified air is routed to
reforming fractionation and hosing station at reactions zone as sweeping air.
3.3.4.2 Fresh water system

Fresh water comes from outside the unit and is used for washing water in compressor
room. The fresh water enters pre-fractionation tower heat exchanger (E-202101/1-3)
as water conveying media and is sent to reforming reaction hosing station as rinsing
water.
3.3.4.3 Recirculating water system

Coming from outside the unit, recirculating water goes to K202101, K202201,
E202106,E202107,E202108,E202109,E202205,E202206,E202207,E202208,E202209
,E202210 and K202202 as cooling water for traction blower, pumps and oil samplers.
After completion of the cooling the recirculated water is returned to recirculated water
plant. In addition, it is routed to reaction zone sampling device as temporary coolant.
3.3.4.4 Fuel gas system

High-pressure gas (natural gas), coming from outside of the unit, goes through gas
pressure control valve and joins the gas streams from reforming D202102, D202203
and D202104, and the jointly they are routed into gas liquid separation tank
(D202214) where bottom condensates draining is performed before top gas is sent to
F202101, F202201 (A-D), F202202 and F202203 as fuel gas. If D202214 pressure is
out of control specification, the gas in D202214 can return the gas line outside of the
unit. D202214 has heat coils at its bottom to heat up condensates to be evaporated,
while the un-evaporated portion is discharged into effluent, contaminated oil system.
23
3.3.4.5 Nitrogen system

The nitrogen, supplied from outside pipelines, has two specifications of 0.25mPa and
0.8mPa. 2.5mPa is mainly for the following purposes: nitrogen injection and
replacement at K202101 and K202201, pressure supplement at D202104 and
D202203 and emergency nitrogen and sweeping gas for pre-hydrogenation section.
0.8mPa is for emergency sweeping and replacement applications at reforming reaction
section and hosing station.
3.3.4.6 1.0mPa steam system

1.0mPa steam is supplied by hydrogenation unit for the applications of the following
sections:
（1）M202201,M202202 air draft
（2）C202101,C202102,C202201 sweeping and firefighting
（3）Temporary sweeping for all hosing stations
（ 4 ） F202101,F202201,F202202,F202203 furnace stack extinguishing, sweeping
and firefighting
（5）Reaction zone firefighting and reaction zone hosing stations
（6）D202214 heating gas
3.3.4.7 Desalting water

The desalting water from hydrogenation unit enters D202106 (sulfur injection tank) as
the diluent for alkaline injection.
3.3.4.8 Heat carrier system

The heat carrier from atmospheric unit enters D202215 and goes through dehydration
by circulating constant temperature dewatering device, and then is boosted by
P202205/1, 2 into counter-flow compartment of reforming 4 in 1 furnace and heater
of heat carrier for heating up before being sent to E202102, E202105 and E202204 as
heat source. Thereafter the heat carrier leaves reboiler for D202215 for recirculating
applications. Oxidation metamorphism of the heat carrier may be discharged out of
24
the unit via contaminated oil lines.
4. The Unit Mass Balance

4.1 Mass Balance of the Unit
Table 4.1 Overall Mass Balance
Data
Name Yield rate wt% Remarks
kg/h t/d 104t/a
Feeding
Naphtha 100 14500 348 11.6
Total 100 14500 348 11.6
Fuel gas + loss 10.32 1496 35.904 1.20
LPG 1.13 164 3.936 0.13

Output
Light naphtha 18.78 2723 65.352 2.19
Stable gasoline 69.77 10117 242.808 8.09
Total 100 14500 348 11.6
4.1 Mass Balance of Pre-Fractionation Section

Table 4.2 Pre-fractionation Mass Balance
Data
Name Yield rate wt% Remarks
kg/h t/d 104t/a
Feeding Naphtha 100 14500 348 11.6
Total 100 14500 348 11.6
Light naphtha 16.69 2420 58.08 1.94
Output Pre-hydrogenat
83.38 12080 289.92 9.66
feeding
Total 100 14500 348 11.6
4.2 Mass Balance of Pre-Hydrogenation Section

Table 4.3 Pre-hydrogenation & Reforming Mass Balance
25
Yield rate wt Data

Name Remarks
% kg/h t/d 104t/a
Pre-
Feeding
hydrogenation 100.00 12080 289.92 9.66
feeding
Total 100.00 12080 289.92 9.66
Gas rich in H2 +
12.38 1496 35.904 1.20
loss
Output
LPG 1.36 164 3.94 0.13
Light naphtha 2.51 303 7.27 0.24
Stable gasoline 83.75 10117 242.808 8.09
Total 100.00 12080 289.92 9.66
5 Feedstock and Products Major Technical Specifications

5.1 Feedstock Source and Processing Locations
Feedstock used in this unit is straight run naphtha of OTRA #1 crude oil.
The feedstock is transferred through pipelines pumped up from straight run naphtha
tankage to the unit.
The unit mainly produces RON96 high-octane gasoline components, by-product of

light naphtha, hydrogen-containing gas and liquid hydrocarbons. All the products are
delivered via pipelines out of the unit.
Gasoline and light naphtha are sent to gasoline tankage. Hydrogen-bearing light
naphtha generated at the evaporation tower top is routed to catalytic cracking unit.
LPG is pumped to gas fractionation section in atmospheric unit or feedstock tankage
of gas fractionation. Since there is no hydrogenation facilities in the Refinery, all the
by-product hydrogen is combined into the Refinery-wide fuel gas lines (evaporation
tower top gas enters catalytic cracking unit for desulfurization before entering the fuel
26
gas lines).
5.2 Feedstock
5.2.1 Crude oil
(1) Feedstock for pretreatment section: distillates with dropping point up to 165 oC.
Refer to Table 5.1 for their properties and Table 5.2 for their family compositions.
Table 5.1 OTR-#1 Crude Produced Gasoline Distillates Properties
Analysis item Analysis result
Boiling range ℃ IBP～165
Yield rate Wt% 19.77
Vol% 23.11
API° 65.05
Density(20℃) kg/l 0.7154
Acidic value mgKOH／g <0.02
Mercaptan sulfur ppm 11
S content Wt% 0.01
N content ppm 2.50
Corrosion (Cu strip，50℃,3h) Grade 1a
n-normal alkane Wt% 31.0
isomerized alkane Wt% 34.4
naphthene Wt% 30.5
alkenes Wt% 0.09
aromatic hydrocarbon Wt% 3.68
IBP 45
10％ 73
30% 93
27
Analysis item Analysis result
distillation range，℃ 50% 110
70% 127
90% 146
95% 153
end point 161
d-character factor 12.2
correlation index 11.3
Table 5.2 OTR-#1 Crude Produced Gasoline Distillate Composition, dropping

point up to 165oC
carbon No alkane naphthene alkenes arene total
C4 1.37 1.37
C5 8.82 0.55 0.05 9.42
C6 12.15 4.65 0.02 0.10 16.92
C7 12.66 9.26 0.02 0.50 22.44
C8 14.13 8.04 1.34 23.51
C9 10.78 7.13 1.64 19.55
C10 5.00 0.90 0.10 6.00
C11 0.49 0.49
total 65.40 30.53 0.09 3.68 99.70
(2) Feedstock for reforming section: 65-165oC distillates. Refer to Table 5.3 for
properties and Table 5.4 for family composition.
Table 5.3 OTR-#1 Crude Produced Reforming Feedstock Distillates Properties
28
Analysis
65～165℃
Item
Yield rate Wt% 16.47
Vol% 18.80
API° 60.98
Density(20
kg/l 0.7307
℃)
Acidic value mgKOH／g <0.02
Sulfur Wt% 0.01
Nitrogen ppm 2.30
Corrosion (copper
1a
strip，50℃,3h) grade
d-character
12.1
factor
correlation
15.08
index(BMCI)
IBP 84
10％ 98
30% 107
distillation
50％ 118
range，℃
70% 131
90％ 148
95% 154
end point 162
n-normal alkane 26.37
isomerized alkane 33.63
Compositio Wt% naphthene 35.35
29
Analysis
65～165℃
Item
n analysis
alkenes 0.07
arene 4.21
As Ppb 15
Table 5.4 OTR-#1 Crude Produced Gasoline Distillates Group Composition 65-165oc
carbon No alkane naphthene alkenes arene total
C4 0.10 0.10
C5 0.38 0.13 0.51 0.51
C6 8.49 4.78 0.04 0.09 13.40
C7 15.24 11.27 0.03 0.60 27.14
C8 17.11 9.74 1.51 28.36
C9 12.35 8.38 1.89 22.62
C10 5.79 1.05 0.12 6.96
C11 0.54 0.54
total 60.00 35.35 0.07 4.21 99.63
(3) Refined naphtha

Refer to Table 5.5 for refined naphtha properties and Table 5.6 for impurity
specifications.
Table 5.5 Refined Naphtha Properties and Composition
Item Datum
Density（20℃），kg/m3 730.7
IBP 84
10％ 98
30
Item Datum
30％ 107
ASTM D－86 50％ 118
distillation range，℃ 70％ 131
90％ 148
95％ 154
end point 162
Family composition w ％ P N A
C4 0.10 －－
C5 0.38 0.13 －
C6 8.53 4.78 0.09
Family composition w％ P N A
C7 15.27 11.27 0.60
C8 17.11 9.74 1.51
C9 12.35 8.38 1.89
C10 5.79 1.05 0.12
C11 0.54 －－
C12+ 0.37 －－
total 60.44 35.35 4.21
Arene potential content，w% 37.42
Table 5.6 Refined Naphtha Impurity Concentration Specifications *
Item Specification
S ppm <0.5
N ppm <0.5
H2O ppm <5
As ppb <1
31
Item Specification
Pb ppb <10
Cu ppb <10
(4) Reforming circulating hydrogen

Refer to Table 5.7 for reforming circulating hydrogen composition.
Table 5.7 Reforming Circulating Hydrogen Composition
Componen H2 C1 C2 C3 C4 C5+ total
Mol% 84.02 4.36 4.13 3.63 2.14 1.72 100
Mean molecular weight M=7.923.
5.3 Products
5.3.1 Hydrogen-containing gas
Table 5.8 Composition of Hydrogen Discharged By Pre-Hydrogenation Gas-Liquid Separator
Mol% 88.59 4.37 3.50 2.13 0.06 1.35 100
Table 5.9 Composition of Hydrogen Discharged By Reforming Liquid-Gas Separator

Mol% 84.02 4.36 4.13 3.63 2.14 1.72 100
5.3.2 Reformed gasoline

C4(wt)%≯1%, RON is 96, density is 793kg/m3 when light naphtha is not present.
32
6 The Unit Processing Technical Plans and Major Operational Conditions

6.1 Processing Technical Plans
Pretreatment of the unit adopts the processing flows of fractionation preceding
hydrogenation. Oil feedstock (dropping point up to 165 oC straight run naphtha) is
firstly fractionated light naphtha (dropping point up to 65oC) and heavy naphtha
(dropping range 65-165oC). Heavy naphtha is hydrogenation-treated to meet desired
requirements for reforming operation in terms of impurity contents. Pre-
hydrogenation is a flow-through-once process, i.e. part of reforming hydrogen is
quantified as per needed hydrogen-oil ratio to be mixed with heavy naphtha for
hydrogenation refining reaction. The remaining hydrogen is discharged by hydrogen-
liquid separator to fuel gas lines.
Reforming uses semi-regeneration fixed bed reforming, catalysts addition per sections
and two-section hydrogen-mixing technologies. The application of abovementioned
technologies enables catalysts’ specific characteristics to be fully used in different
reaction stages and conducive to improvement of liquid products and yield rate and
extension of cycle and reduction of energy consumption.
RIPP heavy benzine hydrogen making technology is adopted to provide hydrogen

required for starting.
6.2 Major Operational Conditions

6.2.1 Pre-hydrogenation
Catalyst RS-1
Pre-hydrogenation distributed high pressure 1.9mPa(g)
Reaction temperature 280 (initial) 320 (ending) oC
Reaction volume air velocity 6 h-1
Hydrogen-volume ratio 90 : 1
33
6.2.2 Reforming
(1) Reforming reaction
Table 6.1 Reforming Reaction Conditions
1st reactor 2nd reactor 3rd reactor 4th reactor
Media Hydrogen + oil gas
Catalyst PRT-C PRT-D
Mean reaction
1.35
pressure，mPa(g)
Reaction temp，℃ 492 492 492 492
Catalyst add rate % 10 15 25 50
Repetitive air speed，h-1 1.2
Gasoline volume ratio 600 1200
(2) Reforming gas-liquid separator

Pressure 1.2mPa (g)
Temperature 40oC
(3) Operation conditions of towers
Table 6.2 Operation Conditions of the Towers

Pre-fractionation tower Evaporation tower Stabilization tower
Bottom temp，℃ 101 91 70
Bottom temp，℃ 178 207 207
Operation
0.35 0.9 1.1
pressure，mPa(g)
Reflux ratio(to
0.3 0.35 0.43
feeding)
6.2.3 Starting and shutdown
34
6.2.3.1 Heavy benzine hydrogen making technology is adopted to furnish hydrogen

and refined naphtha to starting and shutdown operations.
6.2.3.2 Pre-hydrogenation portion may form a close loop via pre-hydrogenation

compressor to satisfy the needs of normal operation, starting, shutdown operations
and accident handling, pre-hydrogenation catalyst regeneration and catalyst pre-
sulfurization. The equipment on standby can be utilized as circulating gas compressor
and for application of molecular sieves regeneration.
6.2.3.3 The reforming circulating hydrogen system is equipped with two conversable
molecular sieve drying tanks used for absorbing catalyst reduction products and water
in the system generated during initial starting period. There is circulating system
established for molecular sieve regeneration, consisting of heater, cooler and water
distribution tanks.
6.2.3.4 Reforming system is equipped with chlorine and water injection facilities to
maintain catalyst water-chlorine balance during normal operation. There are sulfur
and chlorine injection facilities to provide pre-sulfurization in starting operation and
chlorination renewal after catalyst regeneration.
6.2.3.5 There is no nitrogen storage facility in the unit. Nitrogen required for
starting and shutdown operations and accident handling is supplied from the
Refinery’s nitrogen lines.
6.2.3.6 Water, electricity, gas, compressed air and fuel are supplied by the Refinery.
Chemical reagents are delivered to the unit prior to starting. Nitrogen needed in
starting meets requirements.
7 Production Controls Analysis

Refer to 7.1 for details of production controls analysis.
35
Table 7.1 Production Control Analysis
Sample
pre-hydrogenation discharging hydrogen
reforming circulating hydrogen

stabilization tower bottom oil
evaporation tower bottom oil
Analysis
stabilization tower top gas

pre-fraction tower top gas
stabilization tower reflux

pre-fraction tower reflux
evaporation tower reflux

pre-fraction feed (tank)
pre-fraction bottom oil
fuel unit for heaters

Frequency evaporation top gas
Analysis Item
distillation range B A A A E E B
Relative Density B B A A B B B B B E
Content, As, Pb, Cu E E C
S and H2O in oil D B A E
N in oil D B B
Cl in oil E
Oil family composition E E C E E E
Single hydrocarbon composition E E C E
Octane value E C B
Bromine No C C E
Doctor test E
36
Sample
pre-hydrogenation discharging hydrogen
reforming circulating hydrogen

stabilization tower bottom oil
evaporation tower bottom oil
Analysis
stabilization tower top gas

pre-fraction tower top gas
stabilization tower reflux

pre-fraction tower reflux
evaporation tower reflux

pre-fraction feed (tank)
pre-fraction bottom oil
fuel unit for heaters

evaporation top gas
Frequency
Analysis Item
Gas composition B B B B B E
Water in air B
Sulfur in air B B B B B
Chlorine in air B B
Arene %
Refractive index nD20 B B B B
Note：A-once/shift，B-once/d，C-once/w，D-once/tank，E-infinitively
Table 7.2 Continuous Production Control Analysis
sample evaporation hydrogen reforming

Stabilization tower feeding
pre-hydrogenation reaction
Analysis
Reforming feeding
tower making reaction

Frequency feeding reaction products
products
products
Analysis Item
distillation range A A A E E E
Relative Density A A A E E E
Content, As, Pb, Cu C
S and H2O in oil A A A
N in oil C
37
sample evaporation hydrogen reforming
Stabilization tower feeding
pre-hydrogenation reaction
Analysis
Reforming feeding
tower making reaction
Frequency feeding reaction products
products
products
Analysis Item
Cl in oil
Oil family composition C C C E E E
Single hydrocarbon composition C C C E E E
Octane value
Bromine No
Doctor test
Gas composition E E E
Water in air
Sulfur in air
Chlorine in air
Arene %
Refractive index nD20 B B B
Note：A-once/shift，B-once/d，C-once/w，D-once/tank，E-infinitively
8 The Unit Comprehensive Energy Consumption

8.1 Utility Engineering Consumption
8.1.1 Major consumption indexes
Refer to Table 8.1 for major consumption indexes.
Table 8.1 The Unit Major Consumption Indexes

No Item Spec Unit Qty Source Remarks
I Water
consumption
1 Recirculating 0.45 mPa,32℃ t/h 150.52 Refinery-wide
38
water system lines
2 Fresh water 0.45 mPa, ATM t/h (17.0) Refinery-wide intermittent
system lines ，max
3 Softened water 0.5 mPa,40℃ t/h （1.5） Refinery-wide
system lines
II Power
consumption
1 6,000V KW 660 Integration
distribution
room
2 380V KW 318.46 Integration
distribution
room
3 220V KW 36 Integration intermittent
distribution
room
III Steam
consumption
1 1.0 mPa,250℃ t/h (1.3) Refinery-wide intermittent
lines
IV Fuel gas 0.35 mPa, room kg/h 811 Refinery-wide
temp lines
V Compressed air Refinery-wide
lines
1 Purified 0.6 mPa, room Nm3/ 120 Refinery-wide
compressed air temp h lines
2 Non-purified 0.6 mPa, room Nm3/ (840) Refinery-wide intermittent，ma
compressed air temp h lines x
VI Nitrogen Refinery-wide
39
lines
1 High-pressure 2.5 mPa, room Nm3/ (600) Refinery-wide intermittent，ma
nitrogen temp h lines x
2 Low-pressure 0.8 mPa, room Nm3/ 4.5 Refinery-wide
nitrogen temp h lines
8.1.2 Water consumption
Table 8.2 Water Consumption
Supply rate t/h Drainage rate t/h
No User Softened Fresh Recircu Recircu Oily Household Remarks
water water cold water hot water effluent effluent
1 E-202205 19.95 19.95 continuous
2 E-202107 7.57 7.57 continuous
3 E-202108 17.72 17.72 continuous
4 E-202109 11.44 11.44 continuous
5 E-202208/1,2 43.52 43.52 continuous
6 E-202209 18.32 18.32 continuous
7 K-202101/1,2 12.0 12.0 continuous
8 K-202201/1,2,3 14.5 14.5 continuous
F-202201 induction
9 1.0 1.0 continuous
blower
10 Pump cooling 4.5 3.5 1.0 continuous
11 E-202106 (22.41) (22.41) intermittent
12 E-202206 (15.24) (15.24) intermittent
13 E-202207 (67.84) (67.84) intermittent
14 Sampling cooler (1.0) (1.0) intermittent
C-202101 starting
15 (15.0) (15.0) intermittent
water transmit
40
Supply rate t/h Drainage rate t/h
No User Softened Fresh Recircu Recircu Oily Household Remarks
water water cold water hot water effluent effluent
16 D-202107 (1.5) intermittent
Hose station (2.0) (2.0) intermittent
Total 150.52 149.52 1.0 continuous
(17.0) (106.49) (105.49) (16.0) (2.0) intermittent
8.1.3 Electricity consumption
Table 8.3 Electricity Consumption
Annual Annual
Shaft working power
No User Volt Qty (unit) Capacity (kW) power hours consume Remarks
V Run standby Run standby kW h 104kw.h
1 P-202102/1.2 380 1 1 7.50 7.50 3.40 8,000 2.72 continuo
2 P-202103/1.2 380 1 1 (7.50) (7.50) (5.46) intermitt

us
3 P-202104/1.2 380 1 1 75.00 75.00 31.00 8,000 24.80 continuo

ent
4 P-202105/1.2 380 1 1 7.50 7.50 3.52 8,000 2.82 continuo

us
5 P-202201/1.2 380 1 1 37.00 37.00 16.90 8,000 13.52 continuo

us
6 P-202202/1.2 380 1 1 11.00 11.00 4.50 8,000 3.60 continuo

us
7 P-202203/1.2 380 1 1 11.00 11.00 3.74 8,000 2.99 continuo

us
8 P-202204 380 2 0.18 0.10 8,000 0.08 continuo

us
9 P-202205/1.2 380 1 1 90.00 90.00 70.00 8,000 56.00 continuo

us
10 P-202206 380 1 (7.50) (4.20) intermitt

us
11 P-202207 380 1 (0.18) (0.10) intermitt

ent
12 P-202208/1.2 380 2 0.18 0.10 8,000 0.08 continuo

ent
13 P-202210 380 1 (0.55) (0.50) intermitt

us
14 P-202211 380 1 (5.50) (4.00) intermitt

ent
ent
41
Annual Annual
Shaft working power
No User Volt Qty (unit) Capacity (kW) power hours consume Remarks
V Run standby Run standby kW h 104kw.h
15 A-202101/1.2 380 1 37.00 26.80 8,000 21.44 continuo
16 A-202102/1.2 380 1 37.00 26.70 8,000 21.36 continuo

us
17 A-202103/1.2 380 1 37.00 26.70 8,000 21.36 continuo

us
18 A-202201/1.2 380 1 37.00 27.00 8,000 21.60 continuo

us
19 A-202202 380 2 11×2 14.00 8,000 11.20 continuo

us
20 K-202101/1,2 6,000 1 1 200.00 200.00 128 8,000 128.00 continuo

us
Lube pump motor 380 2 2 8.00 8.00 6.00 8,000 4.80 continuo
us
Oil inject motor 380 2 1.10 1.10 8,000 0.88 continuo

us
Turn-gear motor 380 2 (4.40) intermitt

us
Electric heater 220 2 (1.60) intermitt

ent
Oil injector heater 220 2 (0.40) intermitt

ent
21 K-202201/1,2,3 6,000 2 1 333×2 333.00 400 8,000 320 continuo

ent
Lube pump motor 380 6 4 22.00 22.00 18.80 8,000 15.04 continuo
us
Turn-gear motor 380 3 (9.00) intermitt

us
Electric heater 220 3 (18.00) intermitt

ent
Main motor cavity heater 220 3 (3.60) intermitt

ent
Oil injector heater 220 3 (0.60) intermitt

ent
22 F-202201 blower 380 1 1 55.00 55.00 38.10 8,000 30.48 continuo

ent
23 Crane 380 1 (10.00) intermitt

us
24 Hoist 380 1 (3.40) ent
25 Illumination 220 (45.00) 36.00 3,500 12.60 intermitt
total 220 (69.20) 36.00 3,500 12.60 intermitt

ent
380 473.46 324.00 318.46 8,000 254.77 continuo

ent
380 (40.53) (7.50) 14.26 intermitt

us
6,000 866.00 533.00 660.00 8,000 422.4 continuo

ent
us
42
8.1.4 Steam consumption
Table 8.4 Steam Consumption
1.0mPa steam consumption t/h

No User Remarks
Normal Max
1 F-202101 (10) intermittent
2 M-202203 (0.5) intermittent
3 M-202204 (0.5) intermittent
Traced heat (0.3) intermittent
Total (1.3) (10) intermittent
8.1.5 Compressed air consumption
Table 8.5 Compressed Air Consumption
Compressed air consumption Nm3/min
No User & applications Non-purified air Purified air Remarks
Normal max Normal max
Compressed air for

1 2 4 continuous
instrumentations
2 Pre-hydrogenation catalyst (4) intermittent
3 Reforming catalyst regeneration (10) intermittent
4 Sweeping (7)
total 2 4 continuous
(7) (14) intermittent
8.1.6 Nitrogen consumption
Table 8.6 Nitrogen Consumption
consumption Nm3/min Pressure Purity

No User & applications Remarks
Normal max mPa(g) required
43
1 Compressor sealing 0.075 0.8 >99.5% continuous
Starting pressure supplement,
replacement seal, drying,

2 (10) 2.5 >99.5% intermittent
nitrogen used at accident,
catalyst regeneration, etc
total 0.075 continuous
(10) intermittent
8.1.7 Fuel gas consumption
Table 8.7 Fuel Gas Consumption
Consumption kg/h
No User and applications Remarks
Normal max
1 F-202101 69 continuous
2 F-202201/1～4 644 continuous
3 F-202202 (55) intermittent
4 F-202203 98 continuous
total 811 continuous
(55) intermittent
8.1.8 The unit comprehensive energy consumption
Table 8.8 The Unit Energy Consumption
Energy consumption Calculated

Annual consumption
No Utility index consumption
Value Unit Qty Unit 104MJ/a
2 Recircu water 120.42 104t/a 4.19 mJ/t 504.56
3 Oily effluent 0.8 104t/a 33.49 mJ/t 26.79
44
4 Electricity 689.77 104kw.h 11.84 mJ/kW.h 8,168.88
5 Purified air 96.00 104Nm3/a 1.59 mJ/Nm3 152.64
6 Nitrogen 3.6 104Nm3/a 6.28 mJ/Nm3 22.61
7 Fuel gas 0.65 104t/a 41,868 mJ/t 27,214.20
Total 36,089.68
The design energy consumption value for the unit is 36,089.68 × 10 4mJ/a, an
equivalent of 3,734.45mJ per ton of reforming feedstock (89.20 × 10 4kCal per ton of
reforming feedstock).
9 Catalysts and Reagents

9.1 Catalysts and Chemical Reagents Specifications
9.1.1 Catalysts
Table 9.1 Catalyst Specifications
catalyst Pre-hydrogenation Reforming Reforming Hydrogen
catalyst catalyst catalyst making

Item catalyst
RS-1 PRT-C PRT-D High platinum
beads
composition wt NiO≥2.0 Pt 0.25 Pt 0.22 Pt 0.5
% WO3≥19.0 Re 0.26 Re 0.46
CoO≥0.03
Adjuvant≥0.7
Supporter Al2O3 Al2O3 Al2O3 Al2O3
Grain mm 1.5 1.2×3～6 1.2×3～6 1.5～3.0
Strength ≥16N/mm >3(kg/granule)
Bulk Density 0.88 0.74 0.74 0.80
g/ml
Proportional ≥130 255
45
catalyst Pre-hydrogenation Reforming Reforming Hydrogen
catalyst catalyst catalyst making

Item catalyst
RS-1 PRT-C PRT-D High platinum
beads
surface area
m2/g
Porous volume ≥0.27 0.351
ml/g
9.1.2 Desulfurization agent (CT8-3)
Table 9.2 Desulfurizer
Item contents
Major chemical composition wt CuO 40～47
% NiO 15～22
Al2O3 15～17
SiO2 15～22
Granule mm （1.1～1.5）×（5～10）strip
Side pressure strength N/cm >40
Proportional surface area m2/g 40～50
Bulk Density kg/m3 1,000～1150
9.1.3 Molecular sieve drying agent
Table 9.3 Molecular Sieve Drying Agent
Drying agent
5 A(Ca) 4 A(Na)
Item
Porous diameter A 4.9～5.5 4.2～4.7
Grain mm 4～6 4～6
46
Bulk Density g/ml ≥0.68 ≥0.68
Static water absorption % ≥21 ≥20.5
Compressive strength ≥60 ≥80
N/granule
9.1.4 Activated carbon
Table 9.4 Activated Carbon Specifications
Item Description
Shape mm Prism Ф1.5×(2～4)
Bulk Density kg/m3 495
Water wt% 8～10
Ash content wt% <30
Iodine mg/g 859.8
Proportional surface area m2/g 962
C3～C6 mean absorption： 0.07kg/kg(C2 and above components complete absorption
basically required)
9.1.5 KT-1 Shoring protective agent specifications
Table 9.5 KT-1 Shoring Protective Agent Specifications

Item Description
Appearance Porous sphere granules
Major chemical contents Al2O3（Wt% >40%）
Adjuvant wt% 1～3
Acid-proof wt% ≥98
Alkali-proof wt% ≥85
Temperature sudden alteration >800
resistance ℃
Compressive strength 300～2,000（depending on different spec）
47
Item Description
Appearance Porous sphere granules
Major chemical contents Al2O3（Wt% >40%）
Adjuvant wt% 1～3
Acid-proof wt% ≥98
Alkali-proof wt% ≥85
Temperature sudden alteration >800
resistance ℃
N/granule
Bulk Density kg/m3 1,200～1,500
Ф5 and Ф18 specifications are used.
9.1.6 Nitrogen and hydrogen for starting operation

1) Nitrogen
Composition N2 O2
Mol% ≮99.5 ≯0.1
2) Hydrogen for starting operation*

Composition H2 C2+ H2O H2S
Mol% >98.5% <0.5% <50ppm <1ppm
9.1.7 Chemical reagents
Table 9.6 Chemical Reagents Specifications
Dimethyl Carbon Ethylene Corrosion

Item Ethyl
disulfide tetrachloride chloride inhibitor
Relative
1.0625 1.594 1.2351 0.7892
Densityd20
Boiling pt ℃ 109.7 75.5～77.5 83.47 78.29
Melting pt ℃ -84.72 -23 -35.67 -114.39
48
Dimethyl Carbon Ethylene Corrosion

Item Ethyl
disulfide tetrachloride chloride inhibitor
Refractive index
1.5259 1.4607 1.4448 1.36143
n20D
Molecular weight
94.20 153.82 98.96 46.07
M
Purity grade Industrial Industrial Analysis Analysis
Flash pt (open)
Non-flammable 21 11～13
℃
Auto –
Non-flammable 449 425
combustion pt ℃
Explosion limit% Non-flammable 62～15.9 3.1～20
Colorless,
Colorless, Colorless,
transparent,
transparent, transparent,
Property Toxic volatile,
volatile, toxic volatile,
toxic,
gas inflammable
excitability
Remarks Nonmetal impurity, fluoride
9.1.8 Heat carrier

Distillate range 300-360oC fraction straight run oil, from OTRA #1 Crude
Relative density d204 0.85
Character factor K 12.1
Molecular weight 292
o
Viscosity C 50 80
mm2/s 14.5 7.8
9.1.9 Catalyst and chemical reagent application volume
Table 9.7 Catalyst & Chemical Reagent Consumptions
49
Annual
Expected
No Name Spec/model consume One dose t Remarks
life (y)
t
Pre-hydrogenation
1 RS-1 3.79 6 Surfurized
catalyst
PRT-C 3.455 5 Reduced

2 Reforming catalyst
PRT-D 9.948 5 Reduced
High
Hydrogen making
3 platinum 0.377 5 Reduced
catalyst
beads
Protective agent CT8-7 1.32 5
Molecular sieve
4 4A，5A 13 3 50% each
drying agent
5 Desulfurizer CT8-3 3 3 Reduction type
6 Activated carbon 1.8 3
KT-1 shoring
7 Φ15，Φ18 25 5 50% each
protective agent
PRT-C，PRT-D
Carbon Industrial
8 0.1 Chlorination
tetrachloride application
renewal
PRT-C，PRT-
Industrial
9 Dimethyl disulfide 0.4 D，RS-1 for pre-
use
sulfurization
PRT-C，PRT-D
Analytical
10 dichloroethane 0.6 Normal chlorine
purity
supplement
PRT-C，PRT-D
11 Ethanol Industrial 0.7 Normal water
supplement
12 Corrosion inhibitor SF-121G 1.0 Tower top anti-
50
Annual
Expected
No Name Spec/model consume One dose t Remarks
life (y)
t
corrosion
ATM-3 300～360℃
13 Heat carrier 150
sideline fractions
10 Equipment of the Unit

10.1 Selection of Major Equipment
10.1.1 Reactors
The hot-wall structure is adopted for pre-hydrogenation, hydrogen-making and
reforming reactors in order to ensure long cycle safe operation of the unit. Since there
is less pressure drop and less amount of catalyst addition needed for 1 st and 2nd
reactors, the axial reactor design is selected. For 3 rd and 4th reactors, catalyst addition
is in larger quantity, radial reactor design is chosen for reduction of pressure drop in
the reforming system.
10.1.2 Towers
Pre-fractionation tower, evaporation tower and stabilization tower all have extended
bore at feeding inlet, therefore, the ballast tray design is selected.
10.1.3 Heaters
In order to improve heater efficiency, reduce floor space and steel materials, a “4 in 1”
furnace is designed for the reforming section. The furnace is supplied with preheated
air and its counter-flow section heats up the heat-carriers and the counter-flow top is
equipped with air pre-heater. Pre-hydrogenation furnace and heat-carrier heater are
cylindrical radiation-counter flow structure. The molecular sieve regeneration heater
is small in loading, a cylindrical radiation design is selected.
10.1.4 Heat exchangers
51
For the purposes of increasing heat exchange rate and reduction of system pressure
drop, the reverse osmosis single line vertical heat-exchange is designed for reforming
feeding heat exchanger and two-section hydrogen-mixing heat exchanger.
10.1.5 Compressors
There are two hydrogenation compressors (on in service and the other on standby) and
three circulating hydrogen compressors (two in operation while one standby), which
are all adoptions of electric driven reciprocating compressor.
10.1.6 Pumps
Oil pumps are high-efficiency centrifugal pumps and reagent injection pumps are
dosing pumps. For discharge of contaminated oil from the underground oil sumps,
anti-corrosive submergible pumps are selected. All motors are outdoor anti-explosion
motors and all dosing pumps are equipped with anti-explosion motors.
10.1.6 Pumps
Oil pumps are selections of high-efficiency centrifugal pumps. Chemical reagent
injection pumps are dosing pumps. Anti-corrosion submersible pumps are selected
for contaminated oil pumping of the underground dirty oil tanks.
10.1.7 Vessels
There are altogether 26 units of containers in this unit. Their materials are selected in
accordance with different media and operational conditions. Refer to Equipment
Listing for details.
10.2 Equipment Listings

10.2.1 Towers listing
Table 10.1 Towers Listing
52
No Equipment Item No Spec/model
1 pre-fractionation tower C-202101 ∮1,000/∮1,200×38,785
2 evaporation dehydration tower C-202102 ∮800/∮1,200×33,335
3 stabilization tower C-202201 ∮800/∮1,000×40,237
10.2.2 Vessels listing
Table 10.2 Vessel Equipment Listing
1 pre-fractionation tower reflux tank D-202102 ∮1,200×4,000(tan)horizontal
pre-hydrogenation high molecular

2 D-202103 ∮1,600×6,000(tan)horizontal
tank
3 Evaporation tower reflux tank D-202104 ∮1,200×4,000(tan)horizontal
4 Desulfurization tank D-202105 ∮1,400×4,000(tan)vertical
5 Sulfur injection tank D-202106 ∮800×1,000(tan)vertical
pre-hydrogenation water injection

6 D202107 ∮800×1,000(tan)vertical
tank
7 reforming high molecular tank D-202201 ∮600×1,400(tan)vertical
compressor inlet liquid distribution

8 D-202202 ∮1,200×3,000(tan)vertical
tank
9 stabilization tower reflux tank D-202203 ∮1,000×4,000(tan)horizontal
10 molecular sieve tank D-202204/1-2 ∮1,400×6,000(tan)vertical
11 Active carbon tank D-202205 ∮1,000×4,200(tan)vertical
molecular sieve regeneration water

12 D-202206 ∮800×2,500(tan)vertical
distribution tank
reforming 1st reactor S-injection, Cl

13 D-202207 ∮159×1,150(tan)vertical
inject tank
reforming 2nd reactor S-injection,

14 D-202208 ∮159×1,150(tan)vertical
Cl inject tank
15 reforming 3rd reactor S-injection, Cl D-202209 ∮219×1,050(tan)vertical
53
inject tank
reforming 4th reactor S-injection, Cl

16 D-202210 ∮219×1,050(tan)vertical
injection tank
17 Alkylol injection tank D-202211/1-2 ∮500×1,050(tan)vertical
18 Cl inject tank D-202212/1-2 ∮500×1,050(tan)vertical
19 Corrosion inhibitor injection tank D-202203 ∮219×1,050(tan)vertical
20 fuel gas-liquid distribution tank D-202214 ∮1,000×3,000(tan)vertical
21 Heat carrier tank D-202215 ∮34,000×12,000(tan)vertical
22 Slightly-contaminated oil tank D-202216 ∮1,400×3,000(tan)horizontal
Low pressure flare gas condensed

23 D-202217 ∮2,000×6,000(tan)horizontal
liquid tank
24 Steam water distribution tank D-202218 ∮500×650(tan)vertical
25 Purified air tank D-202219 ∮1,600×5,000(tan)vertical
Hydrogen-making dechlorination
26 D-202108 ∮1,800×4,800(tan)vertical
tank
10.2.3 Pumps listing
Table 10.3 Pumps Listing
1 pre-fractionation tower feeding P-202101/1-
2 pre-fractionation tower reflux pump P-202102/1-

pump 2
3 light naphtha pump P-202103/1-

2
4 pre-hydrogenation feeding pump P-202104/1-

2
5 evaporation tower reflux pump P-202105/1-

2
6 pre-hydrogenation water inject pump P-202106

2
7 reforming reaction feeding pump P-202201/1-
8 stabilization tower feeding pump P-202202/1-

2
9 stabilization tower reflux pump P-202203/1-

2
2
54
10 Alkylol injection tank P-202204/1-
11 heat carrier pump P-202205/1-

2
12 Dirty oil pump P-202206

2
13 Corrosion inhibitor injection pump P-202207
14 Chlorine injection pump P-202208/1-
15 Pneumatic pump P-202209

2
16 S-injection pump P-202210
10.2.4 Coolers and heat exchangers listing
Table 10.4 Cooler & Heat Exchanger Listing
1 pre-fractionation tower top air refrigerator A-202101 6×6
2 pre-hydrogenation products air refrigerator A-202102 6×6
3 evaporation tower top air refrigerator A-202103 6×6
4 reforming products air refrigerator A-202201 6×6
5 stabilization tower top air refrigerator A-202202 6×3
6 pre-fractionation tower feeding heat exchanger E-202101/1-3 U TUBE/DN500
7 pre-fractionation tower bottom reboiler E-202102 floating head/DN600
8 pre-hydrogenation feeding heat exchanger E-202103/1-3 U TUBE/DN500
9 evaporation tower feeding heat exchanger E-202104/1-3 U TUBE/DN500
10 evaporation tower bottom reboiler E-202105 floating head/DN600
11 starting/shutdown cooler E-202106 floating head/DN600
12 pre-fractionation tower top aftercooler E-202107 floating head/DN600
13 pre-hydrogenation products aftercooler E-202108 floating head/DN800
14 evaporation tower top aftercooler E-202109 floating head/DN600
15 reforming feeding heat exchanger E-202201 vertical/DN900
16 Two-section H mixing heat exchanger E-202202 vertical/DN600
55
17 stabilization tower feeding heat exchanger E-202203/1-3 U tube/DN500
18 stabilization tower bottom reboiler E-202204 floating head/DN700
19 stabilized gasoline cooler E-202205 floating head/DN600
20 molecular sieve regeneration cooler E-202206 floating head/DN600
21 heat carrier cooler E-202207 floating head/DN600
22 reforming products aftercooler E-202208 floating head/DN800
23 stabilization tower top aftercooler E-202209 floating head/DN700
10.2.5 Compressors and heater blowers
Table 10.5 Compressor & Furnace Blowers Listing
1 pre-hydrogenation pressure booster K-202101/1-2
2 reforming circulating hydrogen compressor K-202201/1-3
3 reforming heater blower K-202202
10.2.6 Heaters
Table 10.6 Heaters
1 pre-hydrogenation heater F-202101 Cylindrical furnace, total load 0.67Mw
2 reforming heater F-202201/A-D Square vertical, total load 6.738Mw
3 heat carrier furnace F-202203 Cylindrical furnace, total load
0.973Mw
4 molecular regeneration heater F-202202 Cylindrical furnace, total load 0.35Mw
10.2.7 Relief valves
Table 10.7 Relief Valves Summary
56
Process conditions
Calculated
Install Gas molecular
Discharge Discharge Pressure
No Item No Discharge Nozzle area
location weight & relative volume temp Back
media Relief cm2
density kg/h ℃ pressure
1 PSV-202102/1.2 C - 2 0 2 1 0 1 oil gas 6,771 101 0.63 0.03 13.2
2 PSV-202103/1.2 D - 2 0 2 1 0 3 contain hydrogen 1,068 40 2.18 0.03 2.14
3 PSV-202104/1.2 C - 2 0 2 1 0 2 oil gas 4,974 88 1.18 0.03 5.67
4 PSV-202201/1.2 D - 2 0 2 2 0 1 contain hydrogen 8,941 40 1.48 0.03 22.4
5 PSV-202202/1.2 C-202201 oil gas 4,842 70 1.38 0.03 4.6
6 PSV-202203/1~4D - 2 0 2 2 0 4 / 1 , 2contain hydrogen 5,470 74 2.38 0.03 9.0
7 PSV-202204/1.2 D-202205 contain hydrogen 400 40 1.78 0.13 1.22
8 PSV-202205/1.2 D-202214 fuel gas 1,200 40 0.53 0.03 7.4
9 PSV-202207/1.2 D-202215 fuel gas 750 60 0.68 0.03 2.01
10 PSV-2208/1.2 D-202219 purified air 777 30 0.88 0.03 1.53
11
Selection of relief valve We i g h t

No Qty Remarks
Rated P Spring No Unit
Model To t a l
mPa(A) (mPa) weight
1 NPS4” 0.63 0.6～0.8 2 NPS4”×6”
2 NPS2” 2.18 2.0～2.5 2 NPS2”×3”
3 NPS3” 1.18 1～1.3 2 NPS3”×4”
4 NPS4” 1.48 1.3～1.6 2 NPS4”×6”
5 NPS3” 1.38 1.3～1.6 2 NPS3”×4”
6 NPS3” 2.38 2.0～2.5 4 NPS3”×4”
7 NPS1½” 1.78 1.6～2.0 2 NPS1½”×2”
8 NPS3” 0.53 0.5～0.6 2 NPS3”×4”
9 NPS2” 0.68 0.6～0.8 2 NPS2”×3”
10 NPS2” 0.88 0.8～1.0 2 NPS2”×3”
57
11
10.2.8 Other equipment
Table 10.8 Other Equipment
reforming steam
1 M-202201
extractor
molecular sieve steam

2 M-202202
extractor
10.3 Instrumentation Listing

10.3.1 Major control and measuring instrumentations
Table 10.9 Temperature Instrumentations
No Tag No Measurement, control object
1 TIC-30611 C202101 reboiler gas phase temp control, back to tower
2 TIC-30701 pre-hydrogenation heater outlet temp control
3 TIC-30711 R202101 inlet temp control/alarm
4 TIC-30921 E202105 outlet temp adjusting
5 TIC-31001 F202201A outlet temp adjusting
6 TIC-31002 F202201B outlet temp adjusting
7 TIC-31003 F202201C outlet temp adjusting
8 TIC-31004 F202201D outlet temp adjusting
9 TIC-31221 E202204 outlet temp adjusting
10 TIC-31311 F202202 outlet temp adjusting
Table 10.10 Pressure Instrumentations
1 PIC-30622 D202102 top pressure control
58
4 PIC-31021 F202201 furnace stack negative pressure control
8 PIC-31522 heat carrier pressure control
9 PICA-31661 fuel gas tank pressure control
10 PIC-31663 fuel gas unit inlet pressure indication/alarm
11 PIC-31665 F202101 negative pressure adjustment
12 PIC-31672 F202203 negative pressure adjustment
Table 10.11 Flow Instrumentations

1 FIC-30601 pre-fractionation feeding flow control
2 FIC-30602 C202101 top reflux flow control
3 FIC-30604 pre-hydrogenation feeding flow control
4 FIQ-30608 straight-run naphtha to unit flow for accumulation
5 FIC-30801 pre-hydrogenation H2 mixing volume control

6 FIC-30802 D202103 liquid control cascade
7 FIC-30902 C202102reflux flow control
8 FICQ-31101 reforming feeding control accumulation
9 FIA3-1102 hydrogen flow indication/alarm
10 FIA-31103 hydrogen flow indication/alarm
11 FIC-3 1201 D202201 liquid control cascade
12 FIC-31202 C202201 top reflux flow control
13 FIQ-31206 Gasoline leaving unit for accumulation
14 FICA-31502 heat carrier flow control alarm
15 FIQ-31601 fuel gas to unit for accumulation
16 FIQ-31602 fuel gas to heater zone for accumulation
17 FIC-31603 F202101fuel gas control
18 FIC-31604 F202201Afuel gas control
19 FIC-31605 F202201Bfuel gas control
59

20 FIC-31606 F202201Cfuel gas control
21 FIC-31607 F202201Dfuel gas control
Table 10.12 Fluid Level & Proximity Instrumentations
1 LICA-30612 pre-fractionation tower bottom liquid control
2 LICA-30613 pre-fractionation tower reflux tank liquid control
3 LICA-30803 pre-hydrogenation high fraction liquid control
4 LIA-30911 evaporation tower bottom fluid level indication/alarm
5 LICA-30912 evaporation tower top reflux tank liquid control
6 LICA-31111 reforming high fraction liquid control
7 LICA-31211 stabilization tower bottom liquid control
8 LICA-31212 stabilization tower reflux tank liquid control
9 LIA-31511 heat carrier tank fluid level indication/alarm
Table 10.13 Online Instrumentations
1 AIC-31001 F202201 flue gas O2 content indication/adjust
2 AI-31002 F202201 flue gas O2 content indication
3 AI-31101 Hydrogen purity online analysis
4 AI-31102 Online analysis of water content in gas
Table 10.14 Manual Operating Instrumentations
Tag No Measurement, control object

HIC-31601 F202202 flue duct baffle manual control
11 Outline of DCS System

DCS (Distributed Control System) control system developed in mid 1970s is
microcomputer application technology control system, featuring distributed control,
60
high demand of safety and concentrated information management and conducive to

the control at higher level. DCS control functions bring up dispersion configuration
and apply redundancy technology so that system reliability and security is further
improved. In addition, by means of integration of all control stations connected by
communications network, a dispersion control system is realized. DCS integrates
microcomputer technology, measurement and control technologies, communication
technology and graphic technology into one system and forms a modern process
control and management equipment.
Generally, DCS consists of the following segments:

1) Control station to complete field data collection and control functions, which is
the core part of the system.
2) A man-machine interface, usually is CRT-based operation station to complete
process management function.
3) Communication network to connect all equipment.
Compared with conventional instrumentations, DCS has the following advantages:

1) Complete control functions. It can function from single loop adjustment to
complex multi-variable optical control, execute conventional PID calculation and
feed-forward/feedback combination adjustment and automatic control
calculations, perform continuous feedback control and intermittent sequence
control, batch control, logic control, carry out data auto collection and satisfy
operation requirements of monitoring, display, printing, alarm, history data, etc.
2) Convenience of data processing. Besides calculation of control variables, other
process data can be input into computer for DCS to realize variety of data
processing.
3) Concentrated display of operations. The display and manipulation of operation
display is done by video monitor, operator keyboard and mouse to indicate all
data of the processes in front of operators in an envisage and easy-apprehensive
manner in order for the operators to manipulate overall condition and operate
61
conveniently.
4) Good flexibility and extensibility. As for modification of control plans, there is
no additional equipment or extra wiring required, instead, only an alteration of
configuration is needed to serve the purpose. When extension of equipment is
needed, just hook them up with the communications network without any
alterations made to existing equipment.
5) The system owns self-diagnosis function, i.e. automatic alarming, display and
printing performances will be activated in case of malfunction detected in the
system.
6) Event recording function. All parameter settings are automatically recorded in
the system and the settings may be output via display or printing.
7) Redundancy technology. It includes power source redundancy, controller
redundancy, I/O card redundancy and network redundancy. In case of equipment
and card malfunctioning, the redundant equipment or cards are capable of
replacing the malfunctioning ones to fetch a more secured and reliable system.
8) Ease of connection with host so that the Refinery-wide computer integrated
management in operation plan and production dispatching can be achieved.
TPS control system produced by US Honeywell Co is used as the control system at

this unit, its application will benefit new unit’s safe, smooth and reliable long-cycle
operation, while laying down an outstanding foundation for future optical control
work. This system is mainly comprised of two networks of UCN and LCN and their
network equipment:
1) UCN (Universal Control Network) is a control network capable of
communicating and protocol conversion with LCN through NIM (Network
Interface Module). UCN network components include: mains cable, branch
cable, TAP and terminal resistance. The most important equipment in UCN is
HPM (High Performance Process Manager) that completes control and logic
calculation by collecting field data by I/O processor card, and inputs control
signals to the field.
62
2) LCN (local Control Network) communicates with UCN via NIM. LCN’s key
equipment includes: GUS (Global User Station) – man-machine interface,
supporting process operation and process engineering configuration; HM (History
Module) – file server, saving history data. NIM provides the interface for LCN to
access UCN network. Convert communication protocol of LCN into
communication protocol of UCN.
The system structure schematic is shown as below:
field process field execution
data mechanism
↓ ↑
HPM
↑↓
UCN bus
↑↓
NIM
↑↓
LCN bus
↑↓
GUS
12 Process Pipeline Specifications
Table 12.1 Process Pipeline Specifications
Heat
Operation
Media & start/ end Operation Nominal insul
Pipe No Start point End point pressuremP
point temp℃ diameter thick
a(G)
mm
P-1101 refined naphtha pipe P-1145 pump P-202201/2 40 0.8 4"
63
Heat
Operation
a(G)
mm
P-1102 naphtha tankage E-202101/1～3 40 0.95 4"
pre-fractionation
P-1103 pipe P-1119 pipe P-1178 178 2.86 2"
tower bottom oil
sulfur-contain
P-1104 light naphtha to 40 1.3 1"
catalytic
P-1105 naphtha E-202101/1～3 C-202101 159 0.5 3" 30
P-1106 naphtha pipe P-1105 C-202101 159 0.5 3" 30
P-1107 naphtha pipe P-1105 C-202101 159 0.5 3" 30
P-1108 light naphtha C-202101 A-202101 101 0.35 6"
P-1109 light naphtha A-202101 E-202107 60 0.32 4"
P-1110 light naphtha E-202107 D-202102 40 0.3 4"
P-1111 light naphtha D-202102 pump P-202102/1 40 0.3 3"
P-1112 light naphtha pump P-202102/1 C-202101 40 0.73 2"
P-1113 light naphtha pipe P-1111 pump P-202102/2 40 0.3 3"
P-1114 light naphtha pump P-202102/2 pipe P-1112 40 0.73 2"
P-1115 light naphtha pipe P-1112 leaving unit 40 0.73 1½"
P-1116 naphtha C-202101 E-202102 178 0.4 10" 50
P-1117 naphtha E-202102 C-202101 190 0.4 14" 50
P-1118 naphtha pipe P-1116 pump P-202104/1 178 0.4 4" 40
P-1119 naphtha pump P-202104/1 E-202103/1～3 178 2.86 3"/6" 30/40
P-1120 naphtha pipe P-1118 pump P-202104/2 178 0.4 4" 40
P-1121 naphtha pump P-202104/2 pipe P-1119 178 2.86 3" 30
gasoline ， hydrog
P-1122 E-202103/1～3 F-202101 253 2.3 6" 50
en
P-1123 gasoline ， hydrog F-202101 R-202101 510* 2.2 6" 60
64
Heat
Operation
a(G)
mm
en
gasoline ， hydrog
P-1124 R-202101 E-202103/1～3 510* 2.1 6" 60
en
gasoline ， hydrog
P-1125 E-202103/1～3 E-202101/1～3 197 2.05 6" 50
en
gasoline ， hydrog
P-1126 E-202101/1～3 A-202102 107 2 6" PP-30
en
gasoline ， hydrog
P-1127 A-202102 E-202108 60 1.95 6"
en
gasoline ， hydrog
P-1128 E-202108 D-202103 40 1.9 4"
en
P-1129 gasoline D-202103 E-202104/1～3 40 1.9 4"
P-1130 gasoline E-202104/1～3 C-202102 176 1.1 4" 40
P-1131 light naphtha C-202102 A-202103 91 0.9 4"
P-1132 light naphtha A-202103 E-202109 60 0.87 3"
P-1133 light naphtha E-202109 D-202104 40 0.85 3"
P-1134 light naphtha D-202104 pump P-202105/1 40 0.85 3"
P-1135 light naphtha pump P-202105/1 C-202102 40 1.3 2"
P-1138 light naphtha pipe P-1135 pipe P-1115 40 1.3 1"
P-1139 refined naphtha C-202102 E-202105 207 0.95 12" 60
P-1140 refined naphtha E-202105 C-202102 215 0.95 16" 70
P-1141 refined naphtha pipe P-1139 D-202105 207 0.95 4" 50
P-1142 refined naphtha D-202105 E-202104/1～3 207 0.9 4" 50
P-1143 refined naphtha pipe P-1141 pipe P-1142 207 0.95 4" 50
P-1144 refined naphtha E-202104/1～3 pump P-202201/1 86 0.8 4" 20
65
Heat
Operation
a(G)
mm
P-1145 refined naphtha unit boundary pump P-202104/2 40 0.8 4"
P-1146 refined naphtha pump P-202104/2 pipe P-2237 40 2.86 3"
P-1147 refined naphtha pipe P-1118 pipe P-1119 178 2.86 2" 30
P-1148 gasoline pump P-202104/1 pipe P-1161 178 2.86 3" 20
P-1149 light naphtha pipe P-1115 pipe P-1163 40 0.73 1½"
P-1151 light naphtha pump P-202103/1 pipe P-2246 40 1.64 1½"
P-1153 light naphtha pump P-202103/2 pipe P-1151 40 1.64 1½"
hydrogen making
P-1154 pipe P-1123 R-202102 510* 2.2 6" 70
feeding
hydrogen-making
P-1155 R-202102 pipe P-1124 510* 2.2 6" 70
products
P-1158 refined naphtha pipe P-1146 pipe P-1129 40 2.86 3"
P-1159 gasoline pipe P-1129 pipe P-1163 40 1.9 4"
P-1160 gasoline pipe P-1148 pipe P-1129 178 2.86 4" 20
P-1161 gasoline pipe P-1144 E-202106 86 0.8 3" PP-30
P-1162 refined naphtha E-202106 pipe P-1145 40 0.5 3"
P-1163 gasoline pipe P-1162 Feedstock bank 40 0.5 3"
P-1164 gasoline pipe P-1162 pipe SLO-2402 40 0.5 2"
P-1165 fuel gas pump P-202105/1 pipe GF-2402 40 1.3 1"
P-1166 fuel gas pump P-202105/2 pipe P-1165 40 1.3 1"
P-1168 refined naphtha pipe P-1144 D-202211 86 0.8 ½" PP-30
P-1169 refined naphtha pipe P-1167 D-202213 86 0.8 ½" PP-30
P-1171 refined naphtha pipe P-2201 pipe P-1161 95 2.18 3" PP-30
66
Heat
Operation
a(G)
mm
Sulfurization
P-1173 pipe P-1129 pipe P-1118 40 1.9 4"
circulating oil
gasoline ， hydrog
P-1178 pipe P-1155 pipe P-1123 510* 2.2 6" 70
en
P-2201 refined naphtha pump P-202201/1 E-202201 95 2.18 3"/10" 20/20
P-2202 refined naphtha pipe P-1144 pump P-202201/2 86 0.8 4" 20
P-2203 refined naphtha pump P-202201/2 pipe P-2201 95 2.18 3" 20
reforming
P-2204 E-202201 F-202201/1 420 1.75 12" 80
feeding
reforming
P-2205 F-202201/1 R-202201 492 1.7 12" 80
feeding
reforming
P-2206 R-202201 F-202201/2 400 1.65 12" 80
feeding
reforming
P-2207 F-202201/2 R-202202 492 1.6 12" 80
feeding
reforming
P-2208 R-202202 F-202201/3 448 1.55 12" 80
feeding
reforming
P-2209 F-202201/3 R-202203 492 1.5 12" 80
feeding
reforming
P-2211 F-202201/4 R-202204 492 1.4 12" 80
feeding
reforming
P-2212 R-202204 E-202201 471 1.35 12" 80
products
P-2213 reforming pipe P-2212 E-202202 471 1.35 8" 80
67
Heat
Operation
a(G)
mm
products
reforming
P-2214 E-202201 A-202201 106 1.3 10"/12" 80
products
reforming
P-2215 E-202202 pipe P-2214 110 1.3 8" 80
products
reforming
P-2216 A-202201 E-202208/1 60 1.25 8"
products
reforming
P-2217 A-202201 E-202208/2 60 1.25 8"
products
reforming
P-2218 E-202208/1 pipe P-2220 40 1.2 8"
products
reforming
P-2219 E-202208/2 pipe P-2220 40 1.2 8"
products
reforming
P-2220 pipe P-2216,2217 D-202201 40 1.2 12"
products
reforming
P-2221 D-202201 pump P-202202/1 40 1.2 3"
generated oil
reforming
P-2222 E-202203/1～3 C-202201 170 1.25 4" 40
generated oil
reforming
P-2223 pipe P-2222 C-202201 170 1.25 4" 40
generated oil
Butane distillated
P-2224 C-202201 A-202202 70 1.1 3"
oil
Butane distillated
P-2225 A-202202 E-202209 60 1.07 3"
oil
68
Heat
Operation
a(G)
mm
Butane distillated
P-2226 E-202209 D-202203 40 1.05 3"
oil
P-2227 LPG D-202203 pump P-202203/1 40 1.05 3"
P-2228 LPG pump P-202203/1 C-202201 40 1.52 2"
P-2229 LPG pipe P-2227 pump P-202203/2 40 1.05 3"
P-2230 LPG pump P-202203/2 pipe P-2228 40 1.52 2"
P-2231 LPG pipe P-2228 unit boundary 40 1.52 1½"
P-2232 stabilized gasoline C-202201 E-202204 207 1.15 10" 60
P-2233 stabilized gasoline E-202204 C-202201 218 1.15 14" 60
P-2234 stabilized gasoline pipe P-2232 E-202203/1～3 207 1.15 3" 40
P-2236 stabilized gasoline E-202203/1～3 E-202205 83 1.1 3" PP-30
gas fractionation
P-2239 LPG pipe P-2231 40 1.52 1½"
unit
P-2240 LPG pipe P-2228 pipe GF-2402 40 1.52 1"
P-2241 LPG pipe P-2230 pipe P-2240 40 1.52 1"
reforming
P-2243 E-202205 unit boundary 40 0.7 3"
gasoline
reforming
P-2244 pipe P-2243 pipe P-1163 40 0.7 3"
gasoline
P-2245 condensed liquid pipe SLO-2427 pipe P-2221 40 1.2 1½"
reforming
P-2246 pump P-202202/1 E-202203/1～3 40 1.69 3"
products
P-2247 reforming pipe P-2221 pump P-202202/2 40 1.2 3"
69
Heat
Operation
a(G)
mm
products
reforming
P-2248 pump P-202202/2 pipe P-2246 40 1.69 3"
products
P-2401 diesel fuel out of unit pipe P-2418 60 0.5 3" 20
P-2402 diesel fuel D-202215 pump P-202205/1 250 0.4 10" 60
F-
P-2403 diesel fuel pump P-202205/1 202201counterflow 250 1.33 8" 60
chamber
P-2406 diesel fuel pipe P-2403 F-202203 250 1.33 6" 50
P-2407 diesel fuel F-202203 pipe P-2408 270 0.9 6" 50
F-
P-2408 diesel fuel 202201counterflow pipe P-2409 270 0.9 6" 60
chamber
P-2409 diesel fuel pipe P-2407,2408 reboiler 270 0.9 8" 60
P-2410 diesel fuel pipe P-2409 E-202102 270 0.9 4" 50
P-2411 diesel fuel E-202102 pipe P-2412 219 0.7 4" 50
P-2412 diesel fuel reboiler main pipe 250 0.5 8" 60
P-2417 diesel fuel pipe P-2409 pipe P-2412 270 0.9 3" 40
P-2418 diesel fuel pipe P-2412 D-202215 250 0.5 8" 60
P-2420 diesel fuel pipe P-2403 pipe P-2419 250 1.33 3" 40
P-2421 diesel fuel E-202207 leaving unit 60 0.5 3"
70
Heat
Operation
a(G)
mm
P-2422 diesel fuel pipe P-2421 pipe P-2401 60 0.5 3"
P-2423 diesel fuel pump P-202205/1,2 pipe P-2421 60 1.33 2"
GF-2101 fuel gas PSV-202101/1,2 pipe GF-2402 40 0.03 3"
GF-2102 fuel gas pipe GH-1106 pipe GF-2101 40 0.03 2"
GF-2104 fuel gas D-202102 pipe GF-2401 40 0.25 1"
GF-2105 fuel gas pipe GF-2104 pipe GF-2402 40 0.03 1"
GF-2106 hydrogen PSV-202103/1,2 pipe GF-2402 40 0.03 3"
GF-2107 hydrogen pipe GH-2106 pipe GF-2402 40 0.03 4"
GF-2111 fuel gas pipe GF-2113 pipe GF-2401 40 0.4 1½"
GF-2112 fuel gas pipe GF-2113 pipe GF-2402 40 0.03 1½"
GF-2113 fuel gas D-202104 catalytic unit 40 0.85 1½"
GF-2202 hydrogen PSV-202201/1,2 pipe GF-2402 40 0.03 6"
GF-2203 LPG PSV-202202/1,2 pipe GF-2402 40 0.03 3"
GF-2204 fuel gas pipe GF-2205 pipe GF-2402 40 0.03 1"
hydrogen or
GF-2207 PSV-202208/1,2 pipe GF-2402 40 0.03 4"
nitrogen
hydrogen or
GF-2208 PSV-202204/1,2 pipe GF-2402 40 0.03 2"
nitrogen
GF-2209 hydrogen or pipe GH-2236 pipe GF-2402 40 0.03 3"
71
Heat
Operation
a(G)
mm
nitrogen
GF-2401 fuel gas out of unit D-202214 40 0.35 6"
GF-2402 fuel gas Emission outlets D-202217 40 0.03 12"
GF-2403 fuel gas D-202214 Heaters 40 0.35 6"
GF-2404 fuel gas pipe GF-2403 F-202101 40 0.35 2"
GF-2405 fuel gas pipe GF-2403 F-202201/1 40 0.35 2"
GF-2409 fuel gas pipe GF-2403 F-202203 40 0.35 2"
GF-2410 fuel gas pipe GF-2403 F-202202 40 0.35 1½"
room
GF-2411 natural gas out of unit pipe GF-2401 0.8 4"
temp
GF-2413 fuel gas D-202217 out of unit 40 0.03 12"
GF-2416 fuel gas D-202216 pipe GF-2402 40 0.03 1½"
Flares conjunction
GF-2419 fuel gas pipe GF-2401 40 0.35 2"
tubing
GF-2420 fuel gas pipe GF-2419 F2101-flare 40 0.35 1"
GF-2421 fuel gas pipe GF-2419 F2201/1-flare 40 0.35 1"
72
Heat
Operation
a(G)
mm
reforming
GH-1101 pipe GH-2203 K-202101/1 40 1.2 6"
hydrogen
reforming
GH-1102 K-202101/1 pipe P-1119 90 2.35 6" 40
hydrogen
reforming
GH-1103 pipe GH-2203 K-202101/2 40 1.2 6"
hydrogen
reforming
GH-1104 K-202101/2 pipe GH-1102 90 2.35 6" 40
hydrogen
reforming
GH-1105 pipe GH-1102 pipe P-1126 90 2.35 3"
hydrogen
GH-1106 hydrogen D-202103 D-202108 40 1.9 4"
GH-1107 hydrogen pipe GH-1106 pipe GH-2203 40 1.9 4"
pipe GH- pipe GH-1107(after

GH-1108 hydrogen 40 1.9 4"
1107(before valve) valve)
GH-1110 hydrogen pipe GH-1106 pipe GN-2209 40 1.9 2"
GH-1115 hydrogen D-202108 fuel gas pipelines 40 0.6 4"
GH-1116 hydrogen GH-1106 GH-1115 40 1.9 4"
GH-2201 hydrogen D-202201 D-202202 40 1.2 12"
GH-2202 hydrogen D-202202 pipe GH-2205,GH- 40 1.2 12"
73
Heat
Operation
a(G)
mm
2206
pipe GH-1101,GH-
GH-2203 hydrogen pipe GH-2202 40 1.2 6"
1103
GH-2204 hydrogen K-202201/2 E-202202 74 1.8 6" 20
GH-2205 hydrogen pipe GH-2202 K-202201/1 40 1.2 8"
GH-2207 hydrogen pipe GH-2206 pipe GH-2212 40 1.2 1½"
GH-2208 hydrogen pipe GH-2209,2226 pipe P-2201 74 1.8 6" 20
GH-2209 hydrogen K-202201/1 pipe GH-2208 74 1.8 6" 20
GH-2212 hydrogen K-202101/1,2 pipe GF-2402 40 0.1 6"
GH-2213 hydrogen pipe GH-2208 D-202204/1 74 1.8 6" 20
GH-2214 hydrogen D-202204/1 pipe GH-2208 74 1.8 6" 20
GH-2217 hydrogen pipe GH-2201 pipe GF-2401 40 1.2 3"
GH-2218 hydrogen pipe GH-2217 pipe GF-2402 40 0.03 2"
GH-2219 hydrogen pipe GH-2201 M-2201 40 1.9 3"
GH-2221 hydrogen pipe GH-2213 D-202204/2 74 1.8 6" 20
GH-2222 hydrogen D-202204/2 pipe GH-2214 74 1.8 6" 20
GH-2224 hydrogen E-202202 pipe P-2208 415 1.55 6" 70
GH-2225 hydrogen pipe GH-2226 pipe GH-2204 74 1.8 6" 20
GH-2226 hydrogen K-202201/3 pipe GH-2208 74 1.8 6" 20
74
Heat
Operation
a(G)
mm
GH-2227 hydrogen pipe GH-2226 pipe GH-2212 74 1.8 1½" 20
GH-2233 hydrogen pipe GH-2204 pipe P-2214 74 1.8 1½"
GH-2235 hydrogen pipe GH-2226 pipe GH-2233 74 1.8 1½" 20
GH-2236 hydrogen D-202205 pipe GH-2221 74 1.8 3"
GN-2101 nitrogen pipe GN-2226 pipe P-1155 40 0.9 1"
GN-2102 nitrogen pipe GN-2226 pipe GF-2104 40 0.9 1"
GN-2103 nitrogen pipelines pipe GH-1101 40 2.5 1½"
GN-2104 nitrogen pipe GN-2103 pipe GH-1102 40 2.5 1½"
GN-2108 nitrogen pipe GN-2226 D-202108 40 0.9 2"
molecular sieve
GN-2201 D-202206 pipe GH-1101 40 0.7 4"
regenerated N
molecular sieve
GN-2202 pipe GH-1102 F-202202 80 2.35 4" 20
regenerated N
GN-2203 molecular sieve F-202202 pipe GH-2214 400 0.6 4" 60
75
Heat
Operation
a(G)
mm
regenerated N
GN-2204 nitrogen pipe GH-2213 E-202206 400 0.6 4" PP-30
GN-2205 nitrogen E-202206 D-202206 40 0.6 4"
hydrogen or
GN-2206 pipe GN-2201 pipe GF-2402 40 0.7 4"
nitrogen
GN-2207 nitrogen pipe GH-2213 M-2203 74 1.8 3"
GN-2208 nitrogen pipe GN-2203 pipe GH-2236 140 0.9 3" 30
GN-2209 nitrogen D-202205 pipe GN-2204 140 0.9 3" PP-30
GN-2213 nitrogen pipelines pipe GH-2223 40 2.5 1½"
molecular sieve
GN-2215 pipe GN-2201 pipe GH-1103 40 0.7 4"
regenerated N
molecular sieve
GN-2216 pipe GH-1104 pipe GN-2202 80 2.35 4"
regenerated N
GN-2217 nitrogen pipe GN-2203 pipe GH-2222 400 0.6 4" 60
GN-2218 nitrogen pipe GH-2221 pipe GN-2204 400 0.6 4" PP-30
GN-2220 nitrogen pipe GN-2226 pipe GN-2202 40 0.9 1½"
D-202207~D-
GN-2221 nitrogen pipe GN-2103 40 2.5 ½"
202210
GN-2222 nitrogen pipe GN-2221 D-202208 40 2.5 ½"
GN-2225 nitrogen pipe GN-2226 pipe GF-2414 40 0.9 1½"
76
Heat
Operation
a(G)
mm
GN-2226 nitrogen pipelines main pipe 40 0.9 2"
CL-2201 Dimethyl disulfide D-202106 pump -2210 25 0.9 ½"
CL-2202 Dimethyl disulfide pump -2210 pipe P-1118 25 4 ½"
room
CL-2203 sulfide D-202207 pipe P-2205 2.5 ½"
temp
room
temp
room
CL-2205 sulfide pipe CL-2203 pipe P-2205 2.5 ½"
temp
room
temp
room
temp
room
temp
ethanol or water or room

CL-2209 D-202211 pump P-202204 ATM ½"
chloride temp

CL-2210 pump P-202204 pipe CL-2212 2.5 ½"
chloride temp

CL-2211 pipe CL-2209 pump P-202208 ATM ½"
chloride temp
CL-2212 ethanol or water or pump P-202208 pipe P-2201 room 2.5 ½"
77
Heat
Operation
a(G)
mm
chloride temp

CL-2213 pipe CL-2210 pipe CL-2214 2.5 ½"
chloride temp

CL-2214 pipe CL-2212 pipe P-2201 2.5 ½"
chloride temp

CL-2215 pipe CL-2214 pipe CL-2220 2.5 ½"
chloride temp

CL-2216 pipe CL-2215 pipe CL-2221 2.5 ½"
chloride temp
room
CL-2217 corrosion inhibitor D-202213 pump P-202207 ATM ½"
temp
room
CL-2218 corrosion inhibitor pump P-202207 pipe P-1131 2.5 ½"
temp
room
CL-2219 corrosion inhibitor pipe CL-2218 pipe P-2224 2.5 ½"
temp
room
temp
room
temp
CL-2222 Dimethyl disulfide pipe CL-2202 pipe P-1118 25 4 ½"
ethanol or water room

CL-2223 pipe CL-2213 pipe CL-2215 2.5 ½"
or chloride temp
IA-2201 regeneration air D-202219 pipe GH-2202 150* 0.6 2"
IA-2202 regeneration air pipe IA-2201 pipe GH-2203 150* 0.6 2"
IA-2302 purified air System D-202219 150* 0.6 2"
78
Heat
Operation
a(G)
mm
room
PA-2301 Non-purified air From system 0.6 2"
temp
SLO- slightly-polluted room

main pipe D-202216 free flow 3"
2401 oil temp

pump P-202206 leaving unit 0.51 3"
2402 oil temp

D-202102 pipe SLO-2401 free flow 1½"
2403 oil temp

pipe P-1116 pipe SLO-2401 free flow 2"
2404 oil temp
SLO- slightly-polluted
pipe P-1138 pipe SLO-2401 40 free flow 1"
2406 oil

SCD-2105 pipe SLO-2401 free flow 1½"
2407 oil temp

2408 oil temp

2410 oil temp

D-202104 pipe SLO-2401 free flow 2"
2412 oil temp

2414 oil temp

2415 oil temp
79
Heat
Operation
a(G)
mm

2416 oil temp

2417 oil temp

2422 oil temp

2423 oil temp

2424 oil temp

2425 oil temp

2426 oil temp

2427 oil temp

2428 oil temp

pipe P-1155 pipe SLO-2401 free flow 1½"
2430 oil temp
SOW- room
oily effluent pipe P-1116 pipelines free flow 3"
2411 temp
SOW- room
oily effluent D-202102 pipelines free flow 3"
2412 temp
SOW- oily effluent D-202103 pipelines room free flow 3"
80
Heat
Operation
a(G)
mm
2413 temp
SOW- room
2414 temp
SOW- room
2415 temp
SOW- room
2416 temp
SOW- room
2417 temp
SOW- room
2418 temp
SOW- room
2419 temp
SOW- room
oily effluent D-202206 pipelines free flow 1½"
2420 temp
SOW- room
2421 temp
SOW- room
oily effluent D-202217 pipelines free flow 1½"
2422 temp
sulfur-contain
ASW- effluent to acidic

40 1.9 1"
2101 water stripping
unit
ASW-
Acidic water D-202104 pipe ASW-2101 40 0.85 1"
2102
81
Heat
Operation
a(G)
mm
Recirculating cold
CW-2410 pipe CW-2414 E-202106 30 0.4 3"
water
recirculating cold
CW-2411 pipe CW-2414 E-202205 30 0.4 4"
water
recirculating cold
CW-2412 pipe CW-2414 E-202206 30 0.4 3"
water
recirculating cold
CW-2413 pipe CW-2414 E-202207 30 0.4 6"
water
recirculating cold
CW-2414 30 0.4 6"
water main pipe
recirculating cold
CW-2415 pipe CW-2414 E-202107 30 0.4 2"
water
recirculating cold
CW-2416 pipe CW-2414 E-202108 30 0.4 4"
water
recirculating cold
CW-2417 pipe CW-2414 E-202109 30 0.4 3"
water
recirculating cold
CW-2418 pipe CW-2414 E-202208/1 30 0.4 4"
water
recirculating cold
CW-2419 pipe CW-2414 E-202208/2 30 0.4 4"
water
recirculating cold
CW-2420 pipe CW-2414 E-202209 30 0.4 4"
water
recirculating hot
RW-2410 E-202106 pipe RW-2414 40 0.2 3"
water
RW-2411 recirculating hot E-202205 pipe RW-2414 40 0.2 4"
82
Heat
Operation
a(G)
mm
water
recirculating hot
RW-2412 E-202206 pipe RW-2414 40 0.2 3"
water
recirculating hot
RW-2413 E-202207 pipe RW-2414 40 0.2 6"
water
recirculating hot
RW-2414 40 0.2 6"
water main pipe
recirculating hot
RW-2415 E-202107 pipe RW-2414 40 0.2 2"
water
recirculating hot
RW-2416 E-202108 pipe RW-2414 40 0.2 4"
water
recirculating cold
RW-2417 E-202109 pipe RW-2414 40 0.2 3"
water
recirculating hot
RW-2418 E-202208/1 pipe RW-2414 40 0.2 4"
water
recirculating hot
RW-2419 E-202208/2 pipe RW-2414 40 0.2 4"
water
recirculating cold
RW-2420 E-202209 pipe RW-2414 40 0.2 4"
water
SW-2101 softened water pipe SW-2301 D-202107 40 0.6 1½"
SW-2102 softened water D-202107 pump P-202106 40 ATM 1½"
SW-2103 softened water pump P-202106 pipe P-1124 40 2.2 1"
SW-2104 softened water pipe SW-2103 pipe P-1125 40 2.2 1"
SW-2105 softened water D-202107 40 free flow 2"
SW-2301 softened water 40 0.6 2"
83
Heat
Operation
a(G)
mm
main pipe
low-pressure
LS-2410 pipe LS-2420 pipe P-1116 250 1 1½" 40
steam
low-pressure
LS-2411 pipe LS-2420 D-202107 250 1 1" 40
steam
low-pressure
LS-2412 pipe LS-2420 pipe P-1102 250 1 1½" 40
steam
low-pressure
LS-2413 pipe LS-2420 pipe P-1139 250 1 1½" 40
steam
low-pressure
LS-2414 pipe LS-2420 M-2201 250 1 2" 40
steam
low-pressure
LS-2415 pipe LS-2420 pipe P-2232 250 1 1½" 40
steam
low-pressure
LS-2416 pipe LS-2420 M-2203 250 1 2" 40
steam
low-pressure
LS-2417 pipe LS-2418 pipe P-2404 250 1 1½" 40
steam
low-pressure
LS-2418 pipe LS-2420 pipe P-2402 250 1 1½" 40
steam
low-pressure
LS-2419 pipe LS-2420 D-202214 250 1 1" 40
steam
low-pressure
LS-2420 250 1 3" 40
steam main pipe
SCW- steam condensed

D-202107 pipe SCW-2419 250 1 1" 30
2411 water
84
Heat
Operation
a(G)
mm
SCW- steam condensed

D-202214 pipelines 250 1 1" 30
2419 water
FW-2410 fresh water pipelines pipe P-1102 25 0.4 3"
13. Environmental Protection and “Three wastes” Treatment and Recycling
Pollutants from this unit include waste gas, effluent, scum, noise, etc.
13.1 Waste Gas

Major waste gas sources are light hydrocarbon gas and flue gas from heaters.
Table 13.1 Waste Gas Emission and Remedial Measures Summary
Emission Hazardous contents

Emission
No Emission point Gas emitted volume Countermeasures
SO2 Hydrocarbons type
kg/h
1 F-202101～F- Burnt flue gas 14,550 3ppm(wt) continuou Aloft emission
202203 s
3 C-202101 oil gas (6,770) 100% accident to flare stack
4 contain
D-202103 (1,067) accident to flare stack
hydrogen
5 C-202102 oil gas (4,974) 100% accident to flare stack
6 contain
D-202201 (9,841) accident to flare stack
hydrogen
7 C-202201 oil gas （4,842) 100% accident to flare stack
8 D-202204/1,2 contain (5,470) accident to flare stack
85
Emission Hazardous contents Emission

No Emission point Gas emitted Countermeasures
volume SO2 Hydrocarbons type
hydrogen
9 contain
D-202205 (650) accident to flare stack
hydrogen
10 D-202214 fuel gas (1,200) accident to flare stack
11 D-202215 fuel gas (750) accident to flare stack
13.2 Effluent
Table 13.2 Effluent Discharge and Remedial Measures
Emission Hazardous contents

N Emission Gas Emission
volume BOD5 Contain Countermeasures
o point emitted Oils Sulfide type
kg/h /COD Phenol
oily To Refinery effluent

1 Pump cooling 1.0 60/150 <10 continuous
effluent treatment plant
Sampling oily To Refinery effluent

2 （1.0） 60/150 <10 intermittent
cooler effluent treatment plant
oily To Refinery effluent

3 Hose stn （2.0） 60/150 <10 intermittent
effluent treatment plant
Slightly
0.5t/ To contaminated oil
4 Vessels polluted intermittent
time * tank
oil
13.3 Three Wastes Treatment and Recycling

13.3.1 Effluent treatment
The effluent from production processes is split into clean and contaminated streams
and pumped to treatment systems of sulfur-containing effluent, oily effluent, etc.
respectively.
86
(1) Sulfur-containing effluent system

Evaporation tower reflux tank and pre-hydrogenation high-molecular discharge water
are sulfur-containing effluent, which is sent to effluent stripping unit for treatment.
(2) Oily effluent system
Oil containing effluents discharged from pump cooling, sampler cooler, floor
washing, and oil-containing precipitation are discharged into system lines and
furthered to effluent treatment plant for treatment.
13.3.2 Waste gas treatment

(1) Major waste gas pollution sources in this unit are burnt flue gas from heaters,
therefore, burning low-sulfur fuel is the fundamental measure to minimize SO 2
pollution. This unit uses fuel of gas supplied by the Refinery’s gas system, after
desulfurization. So that pollutant concentrations are low in burnt flue gas to meet the
Third Grade of emission requirement set forth in GB9078-1996 “Industrial Furnace
Atmospheric Pollutants Emission Standard”, and then is emitted from stacks into
atmosphere.
(2) Oil gas released from relief valves in abnormal operation conditions is routed the
flare stack system for treatment.
13.3.3 Slag treatment
Table 13.3 Waste Slag Discharge and Remedial Measures
Discharge Discharge Counter-

No media Discharge point Frequency
type volume measures
Spent pre- Once

pre-hydrogenation
1 hydrogenation intermittent 3.79 t/time every 6 recycled
reactor
catalyst years
2 spent reforming reforming reactor intermittent 13.403 Once recycled
catalyst t/time every 5
87
Discharge Discharge Counter-

No media Discharge point Frequency
type volume measures
years
Once
Spent hydrogen- hydrogen making 0.377
3 intermittent every 5 recycled
making catalyst reactor t/time
years
Once
Spent protective hydrogen making taken as trash
4 intermittent 1.32 t/time every 5
agent reactor after sweeping
years
Once
Spent molecular molecular sieve taken as trash
sieve drying tank after sweeping
years
Spent Once
taken as trash
6 desulfurizaiton desulfur tank intermittent 4.0 t/time every 3
after sweeping
agent years
Once
Spent activated active carbon taken as trash
carbon absorb tank after sweeping
years
Once
Spent shoring reactor, drying taken as trash
8 intermittent 25 t/time every 5
protective agent tank after sweeping
years
Hydrogen-making Dechlorination Once a taken as trash

9 intermittent 8t/time
deoxidizing agent tank year after sweeping
13.3.4 Noise
Noise at the unit comes mainly from heaters, compressors, pump motors, refrigeration
blowers, etc. The following measures will be taken to address noise problem:
(1) Select low-noise, high-efficiency motors for all pump motors. Equip sound
insulation shell for large pump motors and use only low-noise motors. Select low-
88
revolution, wide-blade and low-noise blowers and low-noise high-efficiency motors

for air refrigerator.
(2) The heater burners are installed of sound shroud and heaters are equipped with
enclosed duct for both recovery of residual heat and reduction of noise.
(3) Steam jet drawing device is equipped with muffler at its outlet.
By taking the above measures, the noise level satisfies specifications of the
regulations.
13.3.5 Professional safety and industrial hygiene

13.3.6 Hazardous feedstock and products
The majority of feedstock, intermediate products and finished products in catalytic
reforming unit are inflammable and explosive substances so that the unit is classified
as A-grade fire hazard. The varieties of feedstock are processed in a high temperature
and medium pressure environment. When ambient temperature exceeds auto-
combustion point and presence of leaking media, fire is likely to take place.
Therefore, considerations of fire hazard associated with materials are fully taken in
course of designing.
Table 13.4 Classifications of Fire Hazard from Major Feedstock, Intermediate

Products and Finished Products in Operation Process
Substance Flash pt (℃) Fire hazard classification
Feedstock straight-run naphtha ＜28 AB
Light naphtha ＜28 AB
Intermediate product Dry gas A
Gas containing H2 A
stabilized gasoline ＜28 AB
Finished product
liquefied gas AA
13.3.7 Hazardous factors in production process

13.3.7.1 Fire and explosion hazards
89
The catalytic reforming unit fire hazard is A-grade. The unit may produce
inflammable and explosive gases and has fired equipment (e.g. heaters). The most
devastating dangers are fire and explosion. All of the feedstock and products are
combustible, inflammable and explosive matters. Preventions of fire and explosion
are therefore the main tasks of professional safety and industrial hygiene.
Catalytic reforming unit major hazardous equipment includes reactors, fractionation

tower, hydrogen compressor, heaters, etc.
13.3.7.2 Prevention of scorching in high-temperature condition

Attention shall be paid to prevent personal scorch during operations in this unit.
13.3.7.3 Toxic substances

Part of chemical reagents used in this unit is corrosive or poisonous. Protective
measures must be taken in production process.
The majority of hazardous gases emitted from this unit are low molecular
hydrocarbons, gas containing H2S and flue gas. Low molecular hydrocarbons and
H2S containing gas come mainly from leakage of pipelines and valves. Flue gas is
mainly from the emission of industrial furnaces.
13.3.7.4 Noise hazard

Noise is mainly from pumps, air refrigerator, heaters and emission of pipelines and
machineries of the unit and utilities.
13.3.8 Major countermeasures in production process

13.3.8.1 Major designed protective measures for safety and hygiene
(1) The unit production process safety and hygiene design
In order to prevent equipment from overpressure caused by power failure, water-
supply failure, false operation or fire in the hazardous production process, all pressure
90
vessels and pressure systems such as equipment, pipelines and pumps are equipped
with relief valves and pressure relief devices in compliance with relevant regulations.
Pre-hydrogenation and reforming gas-liquid separator is furnished with emergency

relief duct and high/low fluid level alarming system. Relief valve with handle type is
selected in designing for all relief valves to allow manual manipulation of the valves
in case of an emergency.
Pre-hydrogenation and reforming compressor inlet and outlet are furnished with
emergency nitrogen filling and nitrogen replacement measures. The above two
hydrogen systems and air ducting used for catalytic coking are equipped with “8”-
shape blind flange at duct connections to prevent the system from air invasion.
In order to ensure the safety during starting, shutdown and maintenance of the unit,
relative equipment and pipelines are installed of fixed or semi-fixed sweeping joints
and trip valves and blind flanges are mounted in main process pipelines along the
boundary of the unit.
At conjunctions between utility lines and inflammable and explosive lines there are
three-valve sets, check valves or blind flanges equipped to prevent process media
reversing.
Plan layout was conducted in strict accordance with relevant firefighting regulations
and in considerations of ease of operation and maintenance. As for the factors of
seismic proofing and pipeline vibration, brittle fracture, temperature difference stress
destruction, stability failure, high creep fracture, corrosive fracture, sealing failure,
etc. the design has given an integrated consideration to safety measures to control
hazards, as well as equipment selection, calculation, foundation designing, process
lines designing and installation.
91
(2) Hydrocarbon gas, flue gas and hazardous gas prevention

Hydrocarbon gas and H2S-containing gas.
Some hydrocarbons and H2S gas are leaking in the unit. To prevent hydrocarbon from
polluting atmosphere, the design took a full consideration of leakage problem in
equipment, pipelines and instrumentations to collect the gas from systems’ separation
and discharge for fuel gas so as to prevent atmospheric pollution.
13.3.9 Relevant production safety codes for the unit

13.3.9.1 Fourteen Don’ts in production zone
(1) Strengthen open fire management, smoking is prohibited in fire prevention and
explosion prevention zones;
(2) Children are not admissible to production zone;
(3) Vehicles without flame arrestor are not allowed to enter fire-restriction zone;
(4) Sleeping, private work, absence of post and matters irrelative to production in
working hours are prohibited;
(5) Drinking alcohol before or on shift is not allowed;
(6) Wiping equipment, tools or clothing with gasoline or other volatile liquid is
prohibited;
(7) No admission of production post to the personnel without wearing protective
equipment;
(8) Equipment with incomplete safety device is forbidden for operation;
(9) The person has no permission to access those equipment or tooling for which
he/she is not responsible;
(10)No maintenance is allowed without implementation of safety measures;
(11) Serviced equipment after shutdown is not allowed to be started without thorough
inspections performed;
(12) High-rise operation is not permitted without wearing safety belt;
(13)High-rise operation is not permitted without catwalk and plank secured;
(14)It is prohibited to step on asbestos tiles without planks equipped.
92
13.3.9.2 Operator six stringencies

(1) Stringently conduct shift change;
(2) Stringently perform roving inspection;
(3) Stringently control process specifications;
(4) Stringently implement operation sheet instructions;
(5) Stringently observe labor disciplines;
(6) Stringently execute relevant safety regulations.
13.3.9.3 Six prohibitions for prevention of unauthorized fire use

(1) Any fire setting without approved fire use permits is prohibited;
(2) Any fire setting without isolating from production systems is prohibited;
(3) Any fire setting without prior cleaning and replacement to standard is prohibited;
(4) Any fire setting without surrounding inflammables removed is prohibited;
(5) Any fire setting beyond designated timeframe is prohibited;
(6) Any fire setting without firefighting measures prepared and guardianship is
prohibited.
13.3.9.4 Eight musts for entering vessel and equipment

(1) Must apply for the entry and obtain approval;
(2) Must perform safety partitioning;
(3) Must conduct displacement and ventilating;
(4) Must carry out safety analysis per timeframe requirement;
(5) Must wear protective equipment;
(6) Must have guardian staying outside of vessel to fulfill guardianship;
(7) Must have rescue backup measures;
(8) Guardian must keep his post.
13.3.9.5 Workshop safe production responsibility system

(1) Personnel on duty must carry “Safety Operation Certificate” and perform
operation pursuant to “Safety Technical Regulations”;
(2) Newly employed staffs and apprentices must receive safety educations by the
93
Refinery, workshop and team and obtain qualification certificate before learning and
operating under the guidance and leadership of the experienced staffs;
(3) At least two persons shall be involved in important operations (except for normal
instrumentation calibration) if staffing condition permits, while one in operation and
the other on guardianship;
(4) All production safety prohibitions and fire-prevention regulations shall be
observed;
(5) Field safety facility management regulations must be implemented to correctly
use site firefighting equipment and safety protective equipment;
(6) Unauthorized dismantling of operating equipment, spare equipment and
firefighting equipment is not allowed without consent of workshop and relative
departments;
(7) In case of an emergency occurs inter-post communications must be strengthened
to timely adjust operation and immediately report to team leader, workshop and the
Refinery Dispatching Room or safety department;
(8) In case of serious casualty, fire or equipment accident emergency measures must
be taken immediately to avoid extension of the accident. The scene must be well
protected while records being properly maintained. In the meanwhile, the accident
shall be reported immediately to workshop, the Refinery Dispatching Room or safety
dept;
(9) Roving inspections in toxic or hazardous section requires special guardian(s);
(10)For any accident happened, it must be handled in conformity with principle of
“No Four Let-Offs”;
(11) Personnel on duty have rights to reject any directions or instructions violating
relevant regulations.
13.3.9.6 Personal safety ten prohibitions

(1) The person failed to pass safety education test is prohibited to independently
operate equipment;
(2) The person wearing clothing in violating regulations or drinking alcohol before
94
shift is prohibited to enter production or construction zone;

(3) The person without wearing safety helmet is prohibited to enter production or
construction zone;
(4) The person without high-altitude operation permit or without wearing safety belt
is prohibited to perform such operations;
(5) The person without high-altitude operation permit is prohibited to enter such site;
(6) The person without maintenance certificate is prohibited to disassemble or shut
pipelines, pumps or valves which are connected with systems;
(7) The person without electric operation “three permits” is prohibited to conduct
electric operations;
(8) The person without construction earth excavation permit is prohibited to perform
such tasks;
(9) Use of equipment with incomplete protective device is prohibited;
(10)Wiping, cleaning or disassembling of rotating part of equipment is prohibited.
13.3.9.7 Fire and explosion prevention – ten prohibitions

(1) Smoking in the Refinery is prohibited. It is prohibited to bring in the Refinery
cigarette tinder, inflammable, explosive, poisonous substances;
(2) It is prohibited to issue fire-setting operation permits against regulations, to set
fire in construction site for living purpose;
(3) It is prohibited to wear static-generating clothing in explosive hazardous
worksite;
(4) It is prohibited to wear shoes with steel nails into explosive hazardous worksite;
(5) It is prohibited to use gasoline or other volatile solvent to wipe or clean
equipment, clothing, tools or floor, etc;
(6) Admission of motor vehicles into explosive hazardous workplace without
approval is prohibited;
(7) It is prohibited to place inflammable, explosive and other hazardous chemicals in
unauthorized locations;
(8) It is prohibited to use non explosive-proof equipment, facilities and tools in
95
explosive hazardous worksite;

(9) It is prohibited to block firefighting aisles or misuse or damage firefighting
equipment;
(10) It is prohibited to vandalize varieties of firefighting and anti-explosive facilities.
13.3.9.8 Prevention of poisoning and chock – ten provisions

(1) Personnel working in poisoning and chocking hazardous environment must have
guardians designated to conduct such tasks;
(2) Prior to work, the operators and guardians must be trained in regard to toxic
prevention and first-aid knowledge;
(3) Personnel working in poisoning and chocking hazardous environment must wear
reliable protective equipment;
(4) When entering into confined enclosure in toxic hazardous and oxygen deficit
environment, its connecting pipes shall be baffled with blind flanges;
(5) Toxic or chocking hazardous posts shall be risk-assessed and prepare emergency
plans and equipped with necessary protective equipment;
(6) Toxic and chocking hazardous workplace shall be periodically inspected and
steps are taken to meet National Standards;
(7) Special personnel must be designated to take charge of management and regular
inspection of varieties of toxic substances and poison-protective equipment;
(8) Instruments used for testing or measuring toxic substance shall be periodically
inspected and calibrated to ensure their proper conditions;
(9) In case of personal poisoning or chocking, medical treatment and rescue shall be
carried out immediately, conveniently and correctly. Toxic substances
management regulations shall be improved and implemented strictly.
14 Annex Figures
96

15 Process Technic Manual of Reforming

Uploaded by

Document Information

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

15 Process Technic Manual of Reforming

Uploaded by

Copyright:

Available Formats

SORALCHIN OIL REFINERY ENTERPRISE STANDARD

Soralchin Oil Refinery

Catalytic Reforming Unit Processing

Issued on July 20, 2005 Implemented on July 20, 2005

ISSUED BY SORALCHIN OIL REFINERY

This Standard is proposed by Soralchin Oil Refinery.

Prepared by: Zhijun Xiao

Verified by: Wei Chen, Technology Dept

Approved by : Riyuan Zhang

8.1.2 Water Consumption…………………………………………………….40

10.3 Instrumentations Listings ………………………………………………...59

Soralchin Oil Refinery Catalytic Reforming Unit Processing

These Regulations apply to operation posts at the catalytic reforming unit.

Referenced standard and basis of preparation:

2. The Unit Profile

Pretreatment part of catalytic reforming unit adopts processing flows of fractionation

catalytic reforming unit is a newly established construction, situated the southernmost

3 Production Technical Process

separator to the fuel gas lines;

3.2 Technical Principle and Major Operations Analysis

3.2.1.2 Pre-hydrogenation system

3.2.1.3 Major chemical reactions in Pre-hydrogenation

hydrogenation catalyst bed.

diethyl disulfide ethane hydrogen sulfide

Hydrosulfide alkane hydrogen sulfide

be less than 1.0ppm.

pyrrole butane ammonia

Comparison of nonmetals removing velocities in hydrogenation:

compound reacts with hydrogen and produces corresponding hydrocarbon molecules.

RCl + H2→RH + HCl

3.2.1.3.5 Alkenes saturation

3.2.2 Reforming reaction system

3.2.2.1.2 Major chemical reactions

cyclohexane benzene hydrogen

(2) Five carbon ring alkane isomerization

pentacarbon alkane hexahydric alkane aromatic hydrocarbon

(3) Alkane cyclization dehydrogenation

Alkane products of dehydrogenation isomerization

(4) Hydrogenation cracking reaction

Hydrogenation cracking reaction is a faster reaction process to which high pressure

Usually, demethylation is undesired in the production and measures to restrain it from

(7) Aromatic hydrocarbon dealkylation is similar to demethylation. The difference

3.2.3 Reforming Catalyst Property Specifications

Sulfur poisoning can be relieved by regeneration and application of low-sulfur

3.2.3.3 Water (H2O)

3.2.3.4 Nitrogen (N)

3.2.4 Reforming catalyst performance specifications

3.2.4.4 Catalyst life

3.2.4.5 Platinum and rhenium functions

Relatively more platinum contents bring more anti-toxic ability to catalysts.

Water and chlorine functions

Excessive or inadequate amount of chlorine (water) is detrimental to the catalyst.

3.3 Process Flows

3.3.1 Pretreatment section

There is a desulfurization tank D-202105 constructed at the bottom of evaporation

3.3.2 Reforming Section

the other is heat-exchanged against second section mixing hydrogen in E-202202

Hydrogen-containing gas withdrawn from the top of D-202201 enters liquid

D-202201 bottom liquid phase (reforming generated oil) is boosted by stabilization

3.3.4 Ancillary systems

3.3.4.2 Fresh water system

3.3.4.3 Recirculating water system

3.3.4.4 Fuel gas system