Aditya Pradikta Novianto

REFINERY IV
310902 / D
 Background
• The need of fuel in Indonesia increase because of
Indonesian people increament

• To incease the fuel production and to support the building of

a new Residual Catalytic Cracking Unit.
Objective
• From performance side, designing of tank and
vessel can make optimum capability.

• From economic side, designing of tank and vessel

have the profit in economic evaluation value.

• From maintenance side, designing of tank and

vessel can make the maintenance becomes
easier.

• From safety side, designing of tank and vessel

can fulfill the safety standart in operation
condition.
 Constraint of Problem

• The step of Designing Crude Distilling Unit.

• The calculation of capacity and number of tank.
• The calculation of dimension and plate that we use
• The calculation of bundwall and tank installation layout.
• The calculation of process that take place in vessel.
• The calculation of vessel dimension.
• The calculation of tank and vessel economic side, and
CDU
The step of Designing
The Basic Unit of Designing :
1) Feed = Panyu Crude Oil
2) Product = Gas, Naphta, Kerosine,
Diesel dan Residu
3) Capacity = 125 MBSD
TRUE BOILING POINT DISTILLATION
28,99 °API PANYU CRUDE OIL
TEMPERATURE YIELD ON CRUDE
FRAKSI
RANGE, °C %VOL %WT
Light End Comp C1 - C5 1,0 0,74
Naphtha C5 - 150 2,59 2,20
Kerosine 150 - 250 10,04 8,91
Gasoil 250 - 350 19,93 18,77
ATM Residue > 350 66,44 69.38
Total 100 100
Simplified Flow Diagram of CDU
TANK

• Tanks is very important in oil refinery.

• Too much tank can make the higher cost
• Too little tank can make trouble in unit and
obstruct the oil distribution.
• The cost of tank, may be on the order of 25-35%
of the capital cost of the plant. (UOP : 319)
TANK STANDARD CODE
UOP uses :
• API 650 for oil storage

Other Standart :
• National Fire Protection Association 30
TANK Pre Designing Tank
• Capacity = 137.500 BPSD
• Tanks
Feed Tank : Crude Oil Tank
Product Tank : Naphta Tank,
Kerosine Tank,
Gasoil Tank,
Residue Tank
TANK Steps of Pre Designing

Crude Oil Tank

1) Determine the kind of tank

1) From This Chart :

2) Type of the Tank is “Floating
3) Roof Tank”
TANK Steps of Pre Designing

2) The Dimension of tank

Unit Capacity = 137 MBSD
Stock = 15 days
Tank quantity = 6 tanks
Plate size = 6 x 20 ft
Height = 60 ft ( 10 course )
Diameter = 216,516 ft
Volume = 2.208.917,197 ft3
= 62.597,632 m3
TANK Steps of Pre Designing

3) Calculation of shell thickness :

Using “One Foot Method” API Standard 650
• Design Shell Thickness
2,6 x D x (H - 1) x G
td   CA
Sd

• Hydrostatic Test Shell Thickness

2,6 x D x (H - 1)
tt 
St
TANK Steps of Pre Designing
Calculation Result :
Td Adopted Thickness
Course X : 0,2137” 5/8”
Course IX : 0,3200” 11/16”
Course VIII : 0,4264” 3/4"
Course VII : 0,5328” 13/16”
Course VI : 0,6392” 7/8”
Course V : 0,7456” 15/16”
Course IV : 0,8519” 17/16”
Course III : 0,9583” 17/16”
Course II : 1,0647” 9/8”
Course I : 1,1711 “ 19/16”
Material : ASTM A 537M Grade 1
TANK Steps of Pre Designing
4) Calculation of Bottom and Roof thickness :
Based on API Standard 650 ( include corrosion allowance):
Bottom = 0,45” ( 11,43 mm )
Roof = 0,3125 ( 7,935 mm )

5) Bundwall Tank Design

Based on standard from NFPA 30
 TANK Steps of Pre Designing
Bundwall Crude Oil Tank Design

C A = 216.561 ft = 66.00764 m
B
B = 72.187 ft = 22.0025 m
D A
C = 40.5 ft = 12.344 m
D = 60.5 ft = 18.44 m
Bundwall Length = 915.055 ft
= 278.908 m
Bundwall Width = 586.308 ft
= 178.706 m
Wide of Bundwall = 536.504,053 ft2
= 52.508,24 m2

D
VESSEl

Vessel  Accumulator Overhead Fractionator

Temperature = 60 oC
= 140 oF
Pressure = 1,0546 kg/cm 2a
= 15 psia
VESSEl Mass Balance
Inlet from Top Fractionator Outlet Off Gas
Qfeed = 608,370 m3/jam Qgas = 9,108 m3/jam
= 453.844,05 kg/jam = 495,38 kg/jam
BM = 46,22 BM = 42,83
Density (ρ) = 746,00 kg/m3 Density (ρ) = 54,39 kg/m3
= 46,57 lb/ft3 = 3,40 lb/ft3

Outlet Water ke SWS Outlet to Stabilizer dan Reflux

Qwater = 73,027 m3/jam = Qliquid = 599,260 m3/jam
73.028,189 kg/jam = 380.320,715 kg/jam
BM = 18,02 BM = 104,075
Density (ρ) = 1000,019 kg/m3 Density (ρ) = 634,649 kg/m3
= 62,429 lb/ft3 = 39,619 lb/ft3
VESSEl Pre Designing Accumulator

Dimension
a) Allowable Vapour Velocity

Va = 1,951 ft/sec

b) Required Separation Area

As = 3,059 ft2
VESSEl Pre Designing Accumulator

c) Required Diameter

AT = 38,237 ft2

D = 6,98 ft
= 83,76 inch = 2,127 m
VESSEl Pre Designing Accumulator

d) Settling Velocity

V = 157,859 ft/jam
= 2,63 ft/min
e) Retention Time

Ho = 4,451 ft
tys = 1,692 min
VESSEl Pre Designing Accumulator

e) Accumulator Length

Ls = 19,032 ft
= 20 ft
VESSEl Pre Designing Accumulator

Dimension of Accumulator
L = 7174 mm
L = 6096 mm
inlet gas outlet

HLL
2159 mm ID

NLL
1524 mm

4,763 mm
(min thick) outlet

L = 1426 mm
 Economic Evaluation
• To evaluate the economic side for planning investigating
project
• Economic evaluation is based on the calculation from
CDU design.
• The calculation is based on the price from each
equipment and auxilary facility.
• The purpose is to know the feasibility value from the
activity that based on the economic.
Price
• Price for Tanks
= US$ 17.705.500,00
• Price for accumulator
= US$ 18.102,23
No Peralatan Harga US $
1 Kolom Fractionator dan Stripper 697.267,89
2 Kolom Stabilizer 187.571,18
3 Heater 620.304,21
4 Reboiler 9.500,00
5 Heat Exchanger 2.069.440,00
6 Pompa 605.856,00
7 Tangki 17.705.500,00
8 Pressure Vessel 22.672,80
9 Desalter 101.218,11
Total Price of Equipment 21.413.474,19
Economic Evaluation Parameter

- Pay Out Time (POT) = 5,42 years

- Rate of Return (ROR) = 15,67 %/year

- Break Even Point (BEP) = 69,00 %

- Net Present Value (NPV) = US$ 135.399.624,56

- Internal Rate of Return (IRR) = 23.43 %/year

SUMMARY

CONCLUSION & SUGGESTION

• From that analysis, we know that the investment for building a

new Crude Distilling Unit is feasible and profitable
• This design and cost based on Study Estimate. If we want to
continue this project, we have to do considerabilty study further
• To increase the use of equipment, we have to work based on
Standing Operating Procedure (SOP)
• To support the built of CDU and make it more profitable, we have
to build a new Residual Calatalytic Cracking Unit.