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INTRODUCTION OF DUNG QUAT REFINERY

DUNG QUAT REFINERY

Site

12 km in the East of No 1 national road 7 km from Chu Lai Airport, 100km from Da Nang 38 km from Quang Ngai Town The Site is bounded by Dung Quat Bay to the North and Viet Thanh Bay to the South

Quang Ngai Province


Area: 5,131.51 km2 Population: 1,198,500 (1999)

DUNG QUAT REFINERY Capacity:

6.5 million tons crude oil/annum (148,000 BPSD) Sweet case: Bach Ho Crude Oil Sour Case: Mix Bach Ho + Dubai (5.5/1)

Feedstock:

Capital investment $3.0 billion.

DUNG QUAT REFINERY Main products (meet ASEAN standards): LPG Polypropylene Unleaded Gasoline (RON 83 and 92) Jet Fuel (Jet A1)/ Burning Kerosene Auto Diesel and Industrial Diesel Fuel Oil

DUNG QUAT REFINERY


Package 1: Refinery Inside Battery Limit Package 2: Crude Tank Farm Package 3: Product Tankage, Truck Loading, Interconnecting Pipeline, Product Export berth Package 4: Single Point Mooring (SPM) Package 5A: Breakwater Package 5B: Jetty Package 7: Administration Building

DUNG QUAT REFINERY


Plot Plant:
36 ha 40 ha 4 ha 27 ha 125 ha 232 ha (Add. 135 ha for Product Harbor Service Area)

DUNG QUAT REFINERY


EPC Package 1 (Refinery Inside Battery Limit) Includes: Process Units, Utility and Offsite facilities Main Process Units:

Crude Distillation Unit (CDU) Kerosene Treating Unit (KTU) Naphtha Hydrotreating Unit (NHT) Continuous Catalytic Reforming Unit (CCR) Residue Fluid Catalytic Cracking Unit (RFCC) LPG Treating Unit (LTU) RFCC Naphtha Treating Unit (NTU) Propylene Recovery Unit (PRU)

DUNG QUAT REFINERY

EPC Package 2: Crude Tankage


Stores Crude Oil imported through SPM Includes six floating roof tanks with total working capacity: 390,000 m3 Capacity is equal to 11 day's operation at the design CDU feed rate ( 148,000 BPSD) + maximum parcel size (110,000 DWT).

DUNG QUAT REFINERY


EPC package 3: Product Tankage, Truck Loading, Jetty Topsides, Interconnecting pipeline Stores and exports products Includes:

27 tanks with total working capacity: 397,000 m3 to store and dispatch products via Jetty Topsides, Truck Loading and Product Pipeline Interconnecting Pipelines: totally 10 km (7km from the Refinery to the Product Tankage and 3km from the Product Tankage to the Product Export Berths Jetty: Loading arms, MOV valves, slop tanks, drains, etc., as well as on-shore facilities including custody transfer flowmeters, safety valves, etc.

DUNG QUAT REFINERY

EPC Package 4: single point Mooring (SPM)


Import Crude Oil from Tanker The SPM Unit comprises of

Single Point Mooring Buoy Interconnecting hoses PLEM submarine pipeline

The SPM buoy is located approximately 3.2km off-shore in Viet Thanh bay.

DUNG QUAT REFINERY

EPC Package 5A: Beak water


Keep the Loading Operations in good condition The Breakwater of about 1.6km long

DUNG QUAT REFINERY EPC Package 5B: Product Export Berths


Harbour for product export operations Includes: 2 Ocean Tankers Berths (Berths 1 and 2) provide capability for ocean tankers in the range of 15,000 to 30,000 dead weight tonnage (DWT) with facility expandable to 50,000 DWT. 4 Coastal Tankers Berths (Berths 3, 4, 5, 6) provide capability for coastal tankers in the range of 1,000 to 5,000 dead weight tonnage (DWT) with facility expandable to 30,000 DWT.

DUNG QUAT REFINERY

EPC Package 7: Administration Building


Operation Supports Consists of:

Administration Building Fire Station/Gas Rescue Station Canteen/Shop/ Laundry Building First Aid Station Maintenance Shop; Garage Facilities/Motor Pool Building

DUNG QUAT REFINERY


Products Balance, tons/year
Propylene LPG Gasoline A92 (unlead) Gasoline A83 (unlead) Kerosene/Jet A1 Auto Diesel Industrial Diesel FO Product Total Lost and consumed Total BMD 108,333 286,000 1,407,667 534,667 282,333 2,084,333 1,327,000 115,667 6,146,000 354,000 6,500,000 BMG 157,000 343,667 1,952,333 718,000 219,667 2,115,667 430,000 177,000 6,113,000 386,667 6,500,000 MMD 111,000 276,333 1,534,333 407,667 219,667 2,225,333 252,000 1,131,667 6,158,000 342,000 6,500,000 MMG 147,666 307,000 2,081,667 515,667 219,667 2,321,000 30,000 466,000 6,088,667 441,333 6,500,000

DUNG QUAT REFINERY

PROCESS UNITS

DUNG QUAT REFINERY

LPG + FG
Note

Stabiliser

RFCC Gas Pl ant


LN HN

LPG

LTU

LPG LPG

PRU
C3

Mix C 4

Propylene LPG Mogas 92/83

Splitter

Note

NHT

Treated HN

CCRReformate
Treated RFCC Naphtha

SPM CDU

Kerosene

KTU

Jet A1 Kerosene

LGO
HGO RFCC Naphtha LCO

Crude Tankage

NTU
Auto/Ind. Diesel FO

Residue

RFCC
DCO

Note : Stabiliser and Naphtha Splitter are parts of CDU

Crude Distillation Unit (CDU)


Capacity: 148,000 BPSD (6.5 millions TPA) Duty: Split Crude Oil into a number of hydrocarbon fractions by distillation process System:

Desalter Fired Heater Main Fractionators & associated Strippers Stabilizers and Splitters

Crude Distillation Unit (CDU)


Product Streams:

Light Ends: Light Naphtha: Heavy Naphtha: Kerosene: Light Gas Oil: Heavy Gas Oil: Residue:

To RFCC Gas Plant To Mogas Blending To NHT To KTU/Kerosene Tankage To Diesel Blending To Diesel/Fuel Oil Blending To RFCC

Naphtha Hydrotreating Unit (NHT)


Capacity: 21,000 BPSD Licensed by: UOP Duty: Remove sulfur, chlorite, nitrogen, oxygen, metallic compounds in heavy naphtha stream taken from CDU process to

protect CCR catalyst by Hydrotreating

Naphtha Hydrotreating Unit (NHT)


A single fixed bed catalyst reactor
Catalyst: Co + Mo + Al2O3 Catalyst regeneration cycle life: >2 years Treated naphtha: To CCR Off-gas: To FG Amine Absorber at RFCC Gas Plant

Continuous Catalytic Reformer (CCR)


Capacity: 21,000 BPSD Licensed by: UOP Duty: Reform heavy naphtha straight-run from NHT to High Octane Mogas Blending components (Reformat) Catalyst: Pt/Al2O3

Continuous Catalytic Reformer (CCR)


Systems:

4 Reactors (Platformer) Continuous Catalyst Regenerator (Cycle Max) Combined Exchangers

Reformat: To Mogas Blending Un-stabilized LPG: Blended with Refinery LPG stream and routed to LPG storage

Kerosene Treating Unit (KTU)


Capacity: 10,000 BPSD Licensed by: MERICHEM Duty: Treat kerosene stream taken from CDU to meet Jet A1 specifications Technology: FIBER-FILM Contactor

Kerosene Treating Unit (KTU)


System:

NAPFINING: Naphthenic acid extraction MERICAT II: Mercaptan oxidation AQUAFINING: Water washing

Remove Na+

Salt Dryer: Remove trace of free water and dry kerosene below saturation Clay Filter: Remove remaining solids, moistures, soaps, emulsions and surfactant

Kerosene Treating Unit (KTU)


Treating reagents: NaOH 200 and 50 Be, activated carbon, salt, Attapulgus clay Catalyst: Cobalt Phthalocyanine (ARI100 EXL, ARI-120L), MEA 50% Treated kerosene: To Jet A1 Storage Spent caustic: To CNU Alkaline water: To ETP

Residue Fluid Catalytic Cracker (RFCC)


Capacity: 69,700 BPSD Licensed by: IFP Duty: Converts heavy compounds of CDU residue into value products (lighter compounds) by catalytic cracking process Catalyst: Zeolite

Residue Fluid Catalytic Cracker (RFCC)


Operation mode:

Max Gasoline Max Distillate Reactor and 2-stage catalyst regenerator Main Fractionator Gas Recovery Section (Gas Plant)

System:

RFCC Gas Plant


Process the following streams:

CDU Stabilizer Off-gas CDU LPG rich stream NHT Off-gas Wet gas from RFCC Fractionator

Duty:

Recovers C3/C4 Removes H2S, CO2 from LPG and fuel gas by DEA absorbers

Residue Fluid Catalytic Cracker (RFCC)


Product streams:

Unsaturated off-gas: To Refinery Fuel gas Mix C3/C4: To LTU Naphtha: To NTU Light Cycle Oil (LCO): To Diesel Blending Decant Oil (DCO): To Fuel Oil Blending Sour water: Rich amine: To SWS To ARU

Other streams:

LPG Treating Unit (LTU)


Capacity: 21,000 BPSD Licensed by: MERICHEM Duty: Remove Mercaptan, COS, H2S from LPG stream of RFCC Gas Plant Technology: FIBER-FILM Contactor 2-stage THIOLEX extraction system

LPG Treating Unit (LTU)


Treating reagents: NaOH 200 Be Catalyst: MEA 50%wt Treated LPG: To PRU/Storage Spent caustic: To CNU

RFCC Naphtha Treating Unit (NTU)


Capacity: 45,000 BPSD Licensed by: MERICHEM Duty: Remove H2S, Mercaptan and other acidic compounds in Naphtha stream of RFCC Unit Technology: FIBER-FILM Contactor 1-stage MERICAT caustic treating system

RFCC Naphtha Treating Unit (NTU)


Catalyst: Cobalt Phthalocyanine Treating reagents: NaOH 200 Be

Treated naphtha: To Mogas Blending Spent caustic: To CNU

Sour Water Stripper (SWS)


Duty: Strip NH3 and H2S dissolved in sour water collected from CDU, NHT and RFCC Unit Surge drum + a single stripping column Sour gases: To SRU Stripped water: To ETP/CDU Desalter

Amine Regeneration Unit (ARU)


Duty: Skim hydrocarbon and strip sour gas (H2S) from rich amine stream of RFCC Unit Feed surge drum + a regeneration column Skimmed oil: To Light slops Sour gases: To SRU Stripped lean amine: To H2S absorber on RFCC

Spent Caustic Neutralization Unit (CNU)


Capacity: 1.5 m3/h mixed caustic stream Licensed by: MERICHEM Duty: Neutralize and remove phenolic and naphthenic oils from various spent caustic streams (KTU, LTU, NTU caustic; ETP Water; NHT alkaline water)

Technology:

FIBER-FILM Contactor

Spent Caustic Neutralisation Unit (CNU)


Caustic Deep Neutralization:

Neutralize by sulphuric acid 96% and remove acid gases, naphthenic, phenolic acids from the brine Neutralize to pH=7 and extract phenol from acidic brine by solvent (Kerosene)

Neutralization and Phenol Extraction:

Treating reagents: Neutralized brine: Off-gas: Acid Oils/Kerosene:

H2SO4 96%, NaOH 50Be, To ETP To SRU To Fuel Oil Blending

Propylene Recovery Unit (PRU)


Capacity: 21.000 BPSD Duty: Separate and purify propylene from the mixed C3/C4 stream of LTU to polymer grade (99.6 wt%) specification Product stream:

Propylene: To Propylene Tankage/PP Plant C3/C4: To LPG Blending

Propylene Recovery Unit (PRU)


System:

C3/C4 Splitter: Remove C4s from LPG Propane/propylene splitting facility:


De-ethaniser: Release product lighter than propylene Propane/Propylene splitting column

Propylene purification:

Carbonyl sulfide removal Arsenic, phosphorous and antimony removal

Sulfur Recovery Unit (SRU)


Licensed unit Capacity:

Sweet case: Sour case:

3 tons/day 36 tons/day

Duty: Recover Sulfur in Refinery off-gas to meet environment protection requirements (SO2 concentration) Product: Sulfur Powder

Polypropylene (PP) Plant


Licensed unit Capacity: 150,000 tons PP/annum Duty: Produce PP from Propylene product of the Refinery by polymerization process Product: Unpainted heat and light stabilized Polypropylene pellets Detailed Feasibility Study (DFS) completion

Water System
Duty: Produce and distribute various grade of water to users within Refinery and Product Tank Farm (PTF) as follows:

Service water to users at Refinery and PTF Make-up supply to freshwater cooling system Make-up supply to Refinery potable water system Make-up supply to dematerialized water system Make-up supply to Refinery fire water system

Steam and Condensate


Provides:

HP, MP, LP Steam to and subsequent distribution within Refinery Collection, storage and treatment of Refinery steam condensate for reuse as HP & MP boiler feedwater (BFW) in Process Steam Generators Collection, storage and treatment of Power Generation Plant steam condensate for reuse as HHP BFW in Power Generation Plant

Steam and Condensate


Comprise of:

Steam producing equipment Distribution Pipework HP to MP and MP to LP letdown stations Condensate collection and treatment facilities Dearators Associated chemical dosing package

Cooling Water
Duty: Supply cooling water to all users in process and utility units (except the condensers in Power Station) A closed fresh water system, cooled by oncethrough sea water

Cooling Water
Comprise of:

Cooling Water Circulation Pumps Plate Heat Exchanger Expansion Tank Expansion Tank Oil Skimmer Chemical Dosing Package

Sea Water Intake


Provides:

Seawater to Power Station for once-through cooling in Vacuum Condensers Seawater to seawater/freshwater exchanger for cooling the closed loop cooling water system

Sea Water Intake


Consists of:

Seawater Intake box (located offshore) Seawater Intake Basin Inlet Line Seawater Intake Basin (located onshore) Seawater circulation pumps Hypochlorite dosing Discharge facilities

Hypochlorite for seawater chlorination is generated on site by electrolysis of seawater

Plant and Instrument Air


Duty: Provides Plant and Instrument Air for demand of Refinery System:

3 Air Compressors Wet Air Receivers: Remove condensed water 2 refrigeration-type dryers 2 Instrument Air Receivers

Nitrogen System
Provides:

Gaseous nitrogen to process users in normal operation Liquid nitrogen for storage and subsequent vaporisation to meet peak loads and startup demands Dedicated liquid nitrogen for storage and subsequent vaporisation for use in CCR Regeneration Section Independent high pressure system for leak testing of process equipment/pipelines

Nitrogen System
Comprises of:

Nitrogen Generation Package Liquid Nitrogen Storage Vaporisation Package Cryogenic Air Separation

Method of generation:

Nitrogen purity: 96% volume

Fuel Gas
Duty: Provide Fuel Gas to process unit fired heaters and HHP Boilers at Power Station Major users of fuel gas:

CDU charge heater RFCC process heaters NHT charge heater CCR process heaters Power Station Boilers

Fuel Gas
Other users:

Refinery Flare System Product Tankage (Flare system, steam regenerators) Fuel Gas Mix Drums Vaporiser Package

Comprises of:

Vaporise LPG/Propylene for use at Startup,disposal of LPG/Propylene off-spec., low FG pressure or emergency event

Fuel Gas collection/distribution pipework

Refinery Fuel Oil


Duty: Supply Fuel Oil to all consumers within Refinery Comprises of:

2 Refinery Fuel Oil Storage Tanks Fuel Oil Pumps Fuel Oil Heater Supply and return pipework

Refinery Fuel Oil


Source of Refinery Fuel Oil:

In normal operation: Decant Oil (DCO) from RFCC For Refinery Startup: Imported via SPM Outages of RFCC: Heavy Gas Oil (HGO) and/or CDU residue from CDU

Caustic Supply
Duty: Make up and provide caustic (NaOH) solution to all consumers within Refinery Comprises of:
Dissolving Sump: dilutes solid caustic pellets Storage Tanks Pumping Facilities

Caustic Supply
Concentrations of NaOH solution are made up, stored and distributed on site:

500 Be (49.5 wt%)

Made up by dissolving solid caustic in demin. water Made up by diluting 500 Be caustic in demin. water Made up by diluting 500 Be caustic in demin. water

200 Be (14.4 wt%)

50 Be (3.4 wt%)

Power Generation & Distribution


Provide:

Electrical Power to Refinery and all associated facilities Steam and condensate to Refinery

4 15 MW Steam Turbine TurboGenerators Ability to import/export power from/to EVN grid

Refinery Tankage
Duty: Stores and handles the intermediates and finished products of the Refinery:

1 Off-spec Propylene Sphere 1 RFCC Feed Tank 2 NHT Feed Tanks 1 Off-spec RFCC Naphtha Tank 1 Reformate Tank

1 2 1 2

Light Naphtha Tank Mix C4s Spheres HGO Tank LCO Tanks

Product Blending
Consists of a number of separate systems and associated components for blending the final products of Refinery:

92 RON Mogas 83 RON Mogas Auto Diesel Industrial Diesel Fuel Oil

Flushing Oil
Unit number: 055 Provides:

Flushing Oil for process units and Offsite pipework


Contains catalyst fines Pour point is higher than minimum daily ambient temp.

Flushing Oil for SPM loop Facilities for flushing process units Separated facilities for flushing SPM loop

Consists of:

Flushing Oil
Source of Flushing Oil:

For Process units and Offsite pipework:

LCO from LCO Intermediate Storage Tank LGO from SPM Flushing Oil Tank as a slip stream from CDU rundown

For SPM loop:

SPM loop is flushed immediately before and after each transfer operation

Slops
Duty: Collects, Stores light and heavy slops from Refinery process units and Offsite areas for subsequent reprocessing in CDU or RFCC Oily Water: To Refinery ETP for further treatment Alternative disposal route for heavy slops: Refinery Fuel Oil System

Flare System
Consists of:

Refinery Flare System Product Tank Farm Flare System Main Flare Stack Sour Gas Flare Riser (handle all discharges containing H2S at levels higher than 10% vol.)

Each Flare System comprises of:


Effluent Treatment Plant (ETP)


Duty: Treat effluent streams to meet environment protection requirements Consists of:

Refinery ETP

Primary, secondary and tertiary treatment facilities to remove oils, solids and organics Primary treatment for removing oil and solids

Product Tankage ETP

Effluent Treatment Plant (ETP)


Products stream:

Treated effluent: discharged to the sea Recovered slop oil: pumped to Refinery Heavy Slops tank for re-processing Digested biological sludge: Buried in Dedicated Area De-watered, de-oiled refinery sludge: To other facilities for special treatment

Fire Water System


Duty: Supply water for firefighting Comprises of 2 separate firewater systems:

Refinery and nearby facilities Product Tank Farm, Truck Loading and Jetty Topsides

Firewater was taken from the sea at Jetty