INDIAN OIL CORPORATION LIMITED BARAUNI REFINERYenvironmentclearance.nic.in/writereaddata/Online/... · 3 Chapter 1 Executive Summary Indian oil Corporation limited (IOCL) owns and

1

PRE-FEASIBILTY REPORT

ON

COKE CHAMBER REPLACEMENT AND ALLIED MODERNIZATION

AT BARAUNI REFINERY

INDIAN OIL CORPORATION LIMITED BARAUNI REFINERY

2

Index

S. No Topic Page no

Chapter 1 Executive summary Page 3

Chapter 2 Introduction / Back ground information Page 4

Chapter 3 Project Description Page 5

Chapter 4 Site analysis & Infrastructure Page 6

Chapter 5 Planning Brief Page 7

Chapter 6 Rehabilitation and Resettlement plan Page 8

Chapter 7 Project Schedule & Cost estimate Page 9

Chapter 8 Analysis of Proposal Page 10

3

Chapter 1

Executive Summary

Indian oil Corporation limited (IOCL) owns and operates a 6.0 MMTPA refinery at Barauni in

Begusarai district of Bihar. Coker-A unit was originally designed and commissioned by Russian in

1964 for processing of low sulfur RCO (0.5 wt %) of Assam Crude.

Original 04 Coke drums of the unit were commissioned in 1964. These Coke chambers were

replaced in 1983 i.e. after 19 years of service with 04 new Coke drums at the same location. The

metallurgy of the Coke drums is SA 387 Gr. 12 Cl-2 (1Cr 0.5 Mo) and these have been in operation

since past 30 years.

Under the present project, IOCL Barauni intends to replace the present four Coke drums by two

new coke drums of a bigger size at a new location.

4

Chapter 2

Introduction of Project / Background Information In Barauni Refinery there are two Coker units Coker-A and Coker-B. Coker-A unit was originally

designed by Russians and commissioned in 1964 for processing of low sulphur RCO (0.5% wt

sulphur) of Assam crude. Coker-B unit was designed by EIL and commissioned in 1986. This unit

was also designed to process low sulphur RCO + VR (0.5% wt sulphur).

Due to non-availability of Assam crude, Haldia-Barauni Crude Pipeline (HBCPL) was commissioned

in Feb’99 and processing of imported crude was started. Sulphur content in the VR of many

imported low sulphur crude. Hence, Coker-A unit was revamped in 1999-2000 with a new furnace,

main fractionator and feed pre-heat circuit. This revamp was carried out for improvement of

distillate yield, energy optimization and for overall reliability improvement. Metallurgy of all new

equipment was upgraded to process high sulphur feed (5 wt% sulphur). However, there was no

change in the reactors and blowdown circuit and no metallurgy up-gradation was carried out in

this circuit. Accordingly operation of Coker-A unit operation was restricted to 0.9%wt of feed

sulphur level.

Original coke drum metallurgy was carbon steel with internal lining of A-410 SS and these were

replaced in 1983 after around 19 years of service due to deformation and diametrical growth in

shell and frequent cracking of weld joint and parent metal. Changed metallurgy of the coke drums

are SA 387 Gr.12 Cl-2 (1 Cr 0.5 Mo). These coke drums have been in operation for last 30 years and

outlived its life. Replacement of old outlived reactors of Coker-A has been recommended by

Inspection due to the following reasons :

Frequent development of cracks in the skirt to shell joint of the reactors which has

propagated into the parent metal.

Crack was also found in welded joint of lifting lugs, which also propagated into parent

metal.

Frequent development of crack in the welding joint (inner side) of bottom cover plate

with the nozzle. Recently such crack was developed in R1 reactor on 5th

Feb’11 and in

R4 reactor on 10th

Feb’11 which was urgently repaired during reactor change over.

Thickness loss of around 3 mm was observed at top dish end of reactor shells.

Service life of the reactors is already around 28 years. Hence, the reactors outlived its

life.

Bulging of reactors in conical portion. ID growth was found to be more than 25 mm

for reactor R3.

As per API coke drum survey for Chrome-Moly drums, through wall cracks are

generally observed after around 3570 cycles of operation. If cracks are repaired, then

for 50% of cases there are recurrences of cracks. Coke drums of Coker-A unit were

already operated for around 30 years and experienced cracking. Hence, the coke

drums are required to be replaced at the earliest.

MOC of the existing coke drums is SA 387 Gr.12 Cl-2 (1 Cr 0.5 Mo) which is an obsolete metallurgy

and not suitable for processing of feed stream containing more than 0.9 %wt of sulphur. To

resolve these issues, IOCL has approached EIL to study the feasibility of revamping the unit for the

replacement of existing coke drums along with latest modernization and energy optimization

measures.

5

Chapter 3

Project Description In view of ageing of reactors, cracks in the reactors, deformation of reactor metallurgy and

inspection recommendations to restore metallurgical integrity, reliability and safety of operations it is

proposed to replace all the existing four reactors and install two new higher sized reactors at a new

location with upgraded metallurgy. Proposed reactor MOC is 1.25 Cr 0.5 Mo + 410 SS cladding which is

suitable for processing of high sulphur coker feed upto 5.1 %wt of sulphur.

Along with replacement of reactors following changes are also proposed to be taken-up at Coker-A for

unit modernization/ reliability improvement :

a) Installation of automatic heading/ unheading devices for the proposed two new reactors

b) Installation of automatic coke drums level indication.

c) Removal of Quench Column and RFO Generation.

d) Reduction of recycle ratio and one furnace operation.

e) Preheat improvement and energy optimization.

6

CHAPTER 4

Site Analysis and Infrastructure Land:

The new Coke Chambers will be located in the vacant area near the western side of the existing

Coker furnaces. Other allied facilities will be located within the existing area of Coker-A unit only.

Environment

The subject project additionally envisages stoppage of one of the existing furnaces. Hence, there

will be reduction in emission from the heater stacks.

7

CHAPTER 5

Planning Brief

It is proposed to carry-out Civil and Mechanical execution of new facilities in a new location

without affecting Coker-A unit operation. New area is a vacant space with approach available from

peripheral road. Following activities are proposed to be completed before taking shutdown of

Coker-A unit –

Construction of new reactor platform (RCC and Steel structure of area 25M X 16M

approx).

Erection of two new reactors.

Construction of new coke pit/ maze.

Construction of new coke settler for water reuse system.

Installation of new heading/ unheading device.

Installation of new lift and bridge crane.

Installation of new coke cutting water pumps.

Erection of all new piping in new area (except old area piping and hook-ups).

Erection and execution of all Electrical jobs (except hook-ups).

Erection and execution of all instrumentation jobs (except hook-ups) etc.

Shutdown Activities

Following major activities are planned during shutdown of Coker-A unit –

Dismantling, relocation and erection of coke cutting system.

Erection of new transfer line, vapour line and other required piping inside existing Coker-A

unit.

Installation of shield tray and main fractionators bottom recirculation system with pump

and filter.

Relocation of hydrocyclone pump and hydrocyclone system.

All piping, instrumentation and electrical hook-ups.

Shutdown duration is expected to be of around 60 days.

8

CHAPTER 6

Rehabilitation and Resettlement plan:

The new Coke Chamber replacement and Allied modernization project in existing Coker-A Unit will be

installed inside the refinery premises near to existing Coke Chambers. No new land is occupied for the

purpose. Thus, no person will be affected by the project.

9

CHAPTER 7

Project schedule and Cost estimate:

Total project is expected to be completed within 26 months from the date of approval of investment

proposal. The estimated cost of carrying out the above modifications has been worked out at 480.31

crores with a foreign exchange component of 146.09 crores.

10

CHAPTER 8

Analysis of the proposal: Two new reactors along with allied facilities will be installed in the available vacant space at the

western side of the existing Coker furnace. As the present Coke drums have been in operation for last

30 years and has already outlived its life, replacement of existing Coke drums is envisaged to ensure

better reliability and smooth operation of the refinery.

Basic Design and Engineering Package

for

Installation of Biturox Unit

at

Barauni Refinery

INDIAN OIL CORPORATION LIMITED BARAUNI REFINERY

BITUROX PROJECT

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plant 603 – Biturox Unit Kunden Nr.

client code

1 Final Issue of BDEP 26.07.13/Kracher 26.07.13/Foltyn 26.07.13/Filz

0 First Complete Issue 19.04.13/Kracher 19.04.13/Foltyn 19.04.13/Filz

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Pörner Ingenieurges.m.b.H./ FILE: T18-603-PDB-CV001-1_Design Basis.doc

Design Basis

of

603 – Biturox Unit

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Table of content

1 INTRODUCTION ................................................................................................................................ 3

2 DESIGN BASIS .................................................................................................................................. 3

2.1 Duty and Capacity ........................................................................................................................... 3

2.2 Feed material .................................................................................................................................. 3 2.2.1 Vacuum Residue .......................................................................................................................... 3 2.2.2 Vacuum Gas Oil ........................................................................................................................... 5

2.3 Product Specification ....................................................................................................................... 6

2.4 Process Parameters ........................................................................................................................ 7

2.5 Sizing of Biturox® Reactor ............................................................................................................... 8

2.6 Operating Parameters and Throughputs – Normal Operation ........................................................ 8

2.7 Operating Parameters and Throughputs – Turn Down Operation .................................................. 9

2.8 Battery Limit Conditions – Process Streams ................................................................................... 9

3 UTILITIES ......................................................................................................................................... 10

3.1 Medium Pressure Steam ............................................................................................................... 10

3.2 Low Pressure Steam ..................................................................................................................... 10

3.3 Boiler Feed Water ......................................................................................................................... 10

3.4 Process Water ............................................................................................................................... 11

3.5 Raw Water ..................................................................................................................................... 11

3.6 Process Air .................................................................................................................................... 11

3.7 Plant Air ......................................................................................................................................... 11

3.8 Instrument Air ................................................................................................................................ 11

3.9 Nitrogen ......................................................................................................................................... 11

3.10 Fuel Gas ...................................................................................................................................... 12

3.11 Flushing Oil .................................................................................................................................. 12

3.12 Flushing Oil Return ...................................................................................................................... 13

3.13 Caustic Soda ............................................................................................................................... 13

4 SITE CONDITIONS .......................................................................................................................... 14

4.1 Wind .............................................................................................................................................. 14

4.2 Air Temperature ............................................................................................................................ 14

4.3 Relative Humidity ........................................................................................................................... 14

4.4 Rainfall ........................................................................................................................................... 14

4.5 Barometric Pressure ...................................................................................................................... 14

4.6 Snowfall ......................................................................................................................................... 15

4.7 Altitude ........................................................................................................................................... 15

4.8 Earthquake Rating ......................................................................................................................... 15

4.9 Site Information ............................................................................................................................. 15

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1 INTRODUCTION

This Design Basis is a part of the basic engineering works that applies to the Biturox Unit (Unit No. 603) for bitumen production at the Barauni Refinery of the INDIAN OIL CORPORATION LTD (IOCL), India.

The Biturox unit shall be designed for production of viscosity graded paving bitumen VG10, VG20, VG30 and VG40 using Biturox process by oxidation of the Vacuum Residue and VGO obtained from the Vacuum Unit of the refinery.

The Design Basis includes the basis for the unit design, the basic information about utilities and side conditions.

2 DESIGN BASIS

2.1 Duty and Capacity

The unit is designed for a design capacity of 150000 TPA considering

the quality of the feed material as defined in Fig. 1and Fig. 2

the specification of the design product grade VG30 and the alternative grades VG10, VG20

and VG40 as defined in Fig. 3

continuous production of 24 hours per day and 8000 operating hours per year.

Based on this the design throughput related to the design product grade VG30 is 18.750 MTH.

The Biturox unit is designed for continuous production. The turn down rate for production of the design product grade VG30 is 75% (see Fig. 7 for other grades).

2.2 Feed material

The feed components for bitumen production are the vacuum residue and the vacuum gas oil obtained from the VDU by processing of the high sulphur crudes as Basrah Light, Arab Mix (a mixture of 20% Arab Light and 80% Arab Heavy), Upper Zakum, Kuwait, Iran Mix (a mixture of 25% Iran Light and 75% Iran Heavy) or a blend thereof.

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2.2.1 Vacuum Residue

The main feedstock for bitumen production is the Vacuum Residue produced in the vacuum unit of the refinery with the following specification.

VACUUM RESIDUE (MAIN FEED COMPONENT)

CHARACTERISTICS UNIT Sample

Analysis 1)

LKNr. 2013/002218 Range

2)

Penetration @ 25°C 0.1 mm 177 150-200

Softening Point °C 37.8 36-40

Density @ 15°C g/cm3 1.0298 1.028 – 1.032

API Gravity API° 5.8 5.5 – 6.1

Kin. Viscosity @ 100°C mm2/s 1357.00 1200 - 1700

Kin. Viscosity @ 135°C mm2/s 203.10 180 – 240


Dynamic Viscosity @ 60°C Pa.s 53.4 40 - 65

Flash Point COC °C 342 min. 300

Asphaltenes (nC7-insoluble) mass % 7.66 6.5 – 8.5

Paraffin Content (EN 12606-1) mass % 1.90 max. 2.2

Sulfur Content mass % 4.5580 4.0 – 5.0

Heating Test RTFOT

- Change of mass % 0.05 max. 0.07

- Retained Penetration @ 25°C 0.1 mm 113 -

- Retained Penetration @ 25°C % of origin 63.8 min. 60

- Softening Point after RTFOT °C 42.4 -

- Increase of Softening Point °C 4.6 max. 5

- Viscosity @ 60°C after RTFOT Pa.s 87.2 -

- Viscosity Ratio @ 60°C - 1.63 max. 2

Distillation Analysis ASTM D 7169, ASTM D 6352

- 0 mass% (IBP) °C 415.8 -

- 10 mass% °C 516.8 500 - 520

- 20 mass% °C 548.0 -

- 30 mass% °C 571.4 -

- 40 mass% °C 591.8 -

- 50 mass% °C 612.0 -

- 70 mass% °C 656.6 -

- 90 mass% °C 714.0 -

Fig. 1 1) As analysed within the laboratory tests in Vienna. 2) Specified range related to the penetration value of +/- 15% of tested VR.

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2.2.2 Vacuum Gas Oil

Fig. 2 shows the specification of the VGO that will be used as a flux component if required to fulfil the requirements on the feed material.

VGO (FLUX COMPONENT)

CHARACTERISTICS UNIT Sample

Analysis 1)

LKNr. 2013/02221

Range 2)

Density @ 15°C g/cm3 0.9285 0.925 – 0.930





Flash Point °C 188.5 min. 185

Sulfur Content mass% 2.8620 2.3 – 3.4

DISTILATION ANALYSIS: ASTM D 7169, ASTM D 6352

- 0 mass% (IBP) °C 294.2

- 10 mass% °C 387.8 370 – 400

- 20 mass% °C 414.2

- 30 mass% °C 432.0

- 40 mass% °C 448.0

- 50 mass% °C 463.4

- 60 mass% °C 478.6

- 70 mass% °C 494.8

- 80 mass% °C 513.4

- 90 mass% °C 539.2 530 - 550

- 100 mass% °C 637.4

Fig. 2 1) As analysed within the laboratory tests in Vienna. 2) Specified range related to the viscosity values of approx. +/-15% of tested VGO.

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2.3 Product Specification

The Biturox unit shall be capable of producing the grades VG10, VG20, VG30 and VG40 with the

specifications shown in Fig. 3 as defined in the License and Guarantee Agreement.

PRODUCT SPECIFICATION

PAVING GRADES

CHARACTERISTICS UNIT TEST METHOD VG10 VG20 VG30 VG40

1. Absolute Viscosity @ 60°C Poise IS-1206 (Part II) 800-1200 1600-2400 2400-3600 3200-4800

2. Kinematic Viscosity @ 135°C, (min.) cSt IS-1206 (Part III) 250 300 350 400

3. Flash Point COC, (min.) °C IS-1209A 220 220 220 220

4. Solubility in Trichloroethylene, (min.) mass % IS-1216 99.0 99.0 99.0 99.0

5. Penetration @ 25°C, 100g, 5s, (min) 0.1 mm IS-1203 80 60 45 35

6. Softening Point (R&B), (min.) °C IS-1205 40 45 47 50

7. Tests on residue after RTFOT (Rolling Thin Film Oven Test):

a) Viscosity Ratio @ 60°C, (max.) 1)

- IS 1206 (Pt II) 4.0 4.0 4.0 4.0

b) Ductility @ 25°C, (min.) cm IS-1208 75 50 40 25

Fig. 3

Note 1: Viscosity Ratio calculated as follows:

Viscosity of RTFOT bitumen Viscosity Ratio = -------------------------------------------- Viscosity of neat bitumen

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2.4 Process Parameters

Additionally to the plant capacity, product throughput, feed and product specification, the process parameters - as feed blending rate, process temperature, pressure, specific air rate and retention time are required for reactor and plant design.

Fig. 4 shows a summary of the design parameters based on the results of the Biturox laboratory tests and considered for reactor and unit design.

DESIGN PARAMETERS FOR BITUMEN PRODUCTION

CHARACTERISTICS UNIT VG10 VG20

VG30

DESIGN

GRADE 1)

VG40

BASIS (Test Run No.) - 2900 2899 2899 2897

FEED PARAMETERS

- Vacuum residue mass % 93 95 95 100

- VGO mass % 7 5 5 0

Density @15°C g/cm3 1.0227 1.0247 1.0247 1.0298

Penetration @25°C mm/10 400 3)

306 306 177

Softening Point R&B °C 32 33.6 33.6 36.7

Dyn. viscosity @ 60°C Pa.s 21.5 26.4 26.4 53.4

Kin. Viscosity @ 100°C cSt 727.30 878.70 878.70 1357.00



PROCESS CONDITIONS

Process Temperature °C 250 250 250 250

Process Pressure bar g 2 2 2 2

Sp. Process Air Rate 2)

Nm3/h/t 30 30 30 30

Retention Time h 1.5 1.6 1.8 1.6

Yield mass % 98.7 99.0 99.0 99.3

PRODUCT PARAMETERS

Density @ 15°C g/cm3 1.0275 1.0308 1.0313 1.0325

Density @ 25°C g/cm3 1.0214 1.0247 1.0252 1.0264

Penetration @ 25°C 0.1 mm 112 77 61 50

Softening Point (R&B) °C 42.8 46 48.2 50.6

Kinematic Viscosity @ 100°C cSt 2027.00 2875.00 3776.00 4898.00



Fig. 4

1) The parameters for the design grade VG30 are the basis for reactor size calculation as shown in Fig. 5. 2) Related to the reactor content. 3) Calculated value

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2.5 Sizing of Biturox® Reactor

Based on the design data related to the feed & product parameters, production capacity and

process parameters described in the chapters 2.1 - 2.4 and summarized in Fig. 4 the reactor size has been calculated as shown in Fig. 5.

REACTOR SIZING

CHARACTERISTICS UNIT VALUE

Design Product - VG30

Design Product Throughput TPH 18.75

Retention Time h 1.8

Yield mass % 99.0

Nominal Reactor Capacity (NET) tons 34.1

Fig. 5

The reactor is designed with a following capacity range:

nominal capacity: 34.1 tons (related to nominal liquid level)

minimum capacity: 28.3 tons (related to minimal liquid level and 80% of nominal capacity)

maximum capacity: 41.6 tons (related to maximal liquid level and 120% of nominal capacity).

2.6 Operating Parameters and Throughputs – Normal Operation

Fig. 6 shows an overview of the operating parameters (feed and product rates, reactor capacity, retention time and yield) for normal operation of the single products using the standard process parameters (process temperature of 250°C, process pressure of 2 kg/cm

2 g and specific process

air rate of 30 Nm3/h/t.

OPERATING PARAMETERS – NORMAL OPERATION

PRODUCT GRADE mF VRBR VGOBR RC tR VPA Y mP DC

VG10 18.997 93 7 28.5 1.5 860 98.7 18.75 100

VG20 18.939 95 5 30.3 1.6 910 99.0 18.75 100

VG30 (Design Case) 18.939 95 5 34.1 1.8 1030 99.0 18.75 100

VG40 18.882 100 0 30.2 1.6 910 99.3 18.75 100

Fig. 6

mF – feed rate (MTH)

VRBR – VR blending rate (mass %)

VGOBR – VGO blending rate (mass %)

RC – reactor capacity (tons)

tR – retention time (h)

VPA – process air rate (Nm3/h)

Y – yield (mass %)

mP – product rate (MTH)

DC – % related to design capacity

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2.7 Operating Parameters and Throughputs – Turn Down Operation

Fig. 7 shows an overview of the operating parameters (feed and product rates, retention time and turn down rates) for a turn down operation of the single products using the turn down conditions:

reactor level reduced to minimal working level (capacity of 28.3 tons)

process temperature reduced to 240°C

process pressure reduced to 1.0-1.5 kg/cm2 g and

specific process air rate reduced to 25 Nm3/h/t

OPERATING PARAMETERS – TURN DOWN OPERATION

PRODUCT GRADE mF VRBR VGOBR RC tR VPA Y mP TDR

VG10 16.150 93 7 28.3 1.75 710 98.7 15.94 85 %

VG20 15.152 95 5 28.3 1.87 710 99.0 15.00 80 %

VG30 (Design Case) 14.202 95 5 28.3 2.0 710 99.0 14.06 75 %

VG40 15.106 100 0 28.3 1.87 710 99.3 15.00 80 %

Fig. 7

As seen in Fig. 7 to achieve the turn down production the process air rate, process temperature, process pressure and the reactor liquid level were decreased.

For extension of retention time a softer feed material could be used for turn down regime additionally. But as the rate of VGO should be kept to a minimum from the economic point of view, the blending rates of the flux component VGO have not been increased compared to the normal operation.

2.8 Battery Limit Conditions – Process Streams

Fig. 8 shows a list of the process streams with the battery limit conditions.

BATTERY LIMIT CONDITIONS

PROCESS STREAM in/out Temperature °C

Pressure kg/cm

2 g

Vacuum Residue Hot from AVU III in 150 10

Vacuum Residue Cold from Storage in 90 8

VGO Hot in 200 5/5 1)

VGO Cold in 90 5

Bitumen to Storage out 150-160 15

Slop Oil out max. 80 5

Spent Caustic (pH=8) out 50 2

Flue Gas to stack out 65 atm.

Fig. 8

1) The pressure of the hot VGO shall be reduced to 5 kg/cm2 g upstream the B.L. (OSBL) of the Biturox Unit.

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3 UTILITIES

(See the UTILITY SUMMARY, Document No. T18-603-UTS-LV002, for battery limit conditions and utility consumption)

3.1 Medium Pressure Steam

The medium pressure steam is available at the B.L. and is used for:

Heating purposes – the feed and product pumps, heat tracing

For steaming of the vessels, cleaning of equipment; can be also used for line flushing after mechanical erection and comprehensive mechanic service of pipelines to assure adequate cleanness of pipe internals.

Heating of the boiler water in the MP-Steam Drum 603-V-502 during plant shut down

The generated and superheated MP-Steam is connected to MP-Steam header in the Biturox Unit and exported to the refinery net.

The medium pressure condensate is collected and sent back to B.L.

3.2 Low Pressure Steam

The low pressure steam is available at the B.L. and is used for:

purging of the nozzle N28 at the top of the Biturox Reactor 603-R-501 to prevent deposits on the rupture disc

quenching of the reactor vapour space - nozzle N8 (for emergency use only)

Velocity Seal 603-X-502 installed in the off gas line upstream the Incinerator 603-IN-501

quenching of pump mechanical seals (if required)

heat tracing of lines: Slop oil, Flushing oil return (Black slop)

heating of the Slop Oil Pumps 603-P-502A/B

heating of the NaOH tank 603-T-511

utility stations at the bottom / top of the reactor

Low pressure steam can be also used for line flushing after mechanical erection and comprehensive mechanic service of pipelines using low pressure steam to assure adequate cleanness of pipe internals.

The low pressure condensate is collected and sent back to B.L.

3.3 Boiler Feed Water

Boiler feed water (BFW) is available at B.L. and is used for

MP-Steam generation in the Heat recovery downstream the Incinerator 603-IN-501

MP-Steam conditioning in MP-Steam Desuperheater 603-X-504

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3.4 Process Water

Demineralized water is available at B.L. and is used

as process water for cooling of the Biturox reactor content during oxidation process

for cooling of the off gas by injection into the off gas line

as make up water to equalize the wash water losses due to evaporation in the scrubber section.

3.5 Raw Water

Raw water is available at B.L. and is used for

cooling of blow down water in the Blow Down Cooler 603-V-504.

3.6 Process Air

The process air used for oxidation process is produced I.S.B.L. by process air compressors 603-KA-511A/B (1 in operation + 1 stand by).

Alternatively process air can be supplied from the refinery using the existing compressors 830-K-01A/B.

3.7 Plant Air

The plant air is available at B.L. and is used as service air for the utility stations.

3.8 Instrument Air

The instrument air is available at B.L. and is used for pneumatic controllers.

3.9 Nitrogen

Gaseous nitrogen is available at B.L. and can be used for blow out the product and feed lines before flushing and inertization of the reactor before start up.

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3.10 Fuel Gas

Fuel Gas is available at B.L. and is used as fuel for the burner of the incinerator 603-IN-501. The

specification of the fuel gas for two cases is provided in Fig. 9. CASE 1 with higher H2S content was used for Mass and Heat Balance of the unit, to obtain a design basis for desulphurization process in the flue gas scrubber.

FUEL GAS

CHARACTERISTICS UNIT CASE 1 1)

CASE 2

Composition:

H2 Vol. % 14.09 25.00

CH4 Vol. % 60.40 36.00

C2H6 Vol. % 20.31 16.00

C2H4 Vol. % 0.00 11.80

C3H8 Vol. % 0.09 1.50

C3H6 Vol. % 0.03 1.70

C4H10 Vol. % 0.80 0.75

C4H8 Vol. % 0.00 0.16

C5+ Vol. % 0.00 0.31

N2 Vol. % 0.00 6.50

CO2 Vol. % 0.48 0.00

CO Vol. % 0.73 0.00

O2 Vol. % 0.28 0.06

H2S Vol. % 2.78 0.22

Total Vol. % 99.99 100.00

Mol. Weight kg/kmol 18.07 18.45

Heating Value kcal/kg 11240.1 10811.9

Heating Value kcal/Nm3 9062.3 8901.8

Fig. 9

1) Used in the Mass & Heat Balance

3.11 Flushing Oil

Flushing oil is available at B.L. and is required during commissioning period of the unit when the equipment is initially tested and partly operated during the mock operation phase.

Later, when the unit is already in normal operation, flushing oil is required when the unit is shut down and the lines and equipment internals are cleaned from bitumen residues.

The product pumps, slop oil pumps and heat exchangers are connected directly to the flushing oil header for separate flushing.

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As Flushing oil mainly the gas oils from:

the Crude Distillation Units (Light Gas Oil, Heavy Gas Oil, Light Vacuum Gas Oil) and

the Fluid Catalytic Cracking Unit (Light Cycle Oil)

are used. Depending on availability, any of these may be routed to the Flushing Oil header.

Flushing oil properties to be considered for design of the related equipment:

Density @ 40°C: 835 kg/m3

Kinematic viscosity @ 40°C: 3.5822 cSt

Distillation Analysis ASTM D86:

IBP 190°C

5% 230°C

50% 296°C

95% 370°C

FBP 390°C

3.12 Flushing Oil Return

The fluids arising during flushing of the unit are collected in the flushing oil return (black slop) header and sent to B.L.

3.13 Caustic Soda

NaOH Solution is available at B.L. with a concentration of 20 mass % and is foreseen as caustic solution (Make up NaOH) for desulfurization process in the scrubber.

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4 SITE CONDITIONS

4.1 Wind

Annual prevailing direction: East to west in summer; West to East in winter

Maximum wind velocity: 47 m/s

Normal wind velocity: 17 km/h

4.2 Air Temperature

Maximum temperature: 46°C

Design maximum ambient temperature: 46°C

Minimum temperature: 5°C

Winterizing temperature: 5°C

Design minimum temperature (MDMT): 5°C

Design dry bulb temperature: 46°C

Design wet bulb temperature: 29°C

Design Air Temperature:

For HVAC system: 46°C

For air compressor: 46°C

For air coolers: 42°C

For electrical system: 46°C

4.3 Relative Humidity

Relative humidity: max. 65%

Maximum humidity: 96%

Minimum humidity: 60%

Average maximum: 90%

Average minimum: 70%

4.4 Rainfall

Maximum rainfall in 24 hours: 487 mm

Maximum rainfall in 1 hour: 55 mm

Design rainfall intensity (1 hour): 120 mm/h

4.5 Barometric Pressure

Absolute average: 750 mmHg

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4.6 Snowfall

Design snow loading: not applicable

4.7 Altitude

Altitude above mean sea level: 42.75 m

4.8 Earthquake Rating

Seismic zone Seismic Zone- IV

Basic earthquake coefficient (Design earthquake factor as per IS 1893): XX

4.9 Site Information

State: Bihar

Nearest important town & distance: Patna; 120 km

Nearest railway station & distance: Barauni; 10 Km

BITUROX PROJECT

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Pörner Ingenieurges.m.b.H./ FILE: T18-603-PD-CV007-1_ProcessDescription.doc

Process Description

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Table of content

1 INTRODUCTION ................................................................................................................................. 3

2 PROCESS AND UNIT DESCRIPTION ............................................................................................... 3

2.1 General about Biturox.......................................................................................................................... 3

2.2 Biturox Reactor .................................................................................................................................... 3

2.2.1 Process Air Dispersion ........................................................................................................................ 4

2.2.2 Process Temperature .......................................................................................................................... 4

2.2.3 Process Pressure ................................................................................................................................ 5

2.2.4 Liquid Level ......................................................................................................................................... 5

2.3 Feed Supply ........................................................................................................................................ 6

2.4 Feed Heating and Product Cooling ..................................................................................................... 6

2.5 Process Air System ............................................................................................................................. 8

2.6 Process Water ..................................................................................................................................... 8

2.7 Off Gas Section ................................................................................................................................... 9

2.7.1 Off gas characteristics ......................................................................................................................... 9

2.7.2 Knock Out Drum .................................................................................................................................. 9

2.7.3 Incinerator............................................................................................................................................ 9

2.7.4 Heat Recovery ................................................................................................................................... 10

2.7.5 NaOH Scrubber ................................................................................................................................. 10

2.7.6 NaOH Supply ..................................................................................................................................... 11

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1 INTRODUCTION

This Process Description is a part of the basic engineering works that applies to the Biturox Unit (Unit No. 603) for bitumen production at the Barauni Refinery of the INDIAN OIL CORPORATION LTD (IOCL), India.

The 603 - Biturox Unit consists of the following sections: feed blending, feed/product HE, Biturox reactor, process air/water supply, off gas treatment section with knock out drum, incinerator, heat recovery (steam generation), NaOH scrubber and related facilities.

This document shall be studied in conjunction with the Process Flow and Process & Instrumentation Diagrams with the following document numbers:

T18-603-PFD-1151 Process Flow Diagram – Process Unit

T18-603-PFD-1152 Process Flow Diagram – Off Gas Section

T18-603-PID-1151 to -1166 Process & Instrumentation Diagrams

2 PROCESS AND UNIT DESCRIPTION

2.1 General about Biturox

Biturox is a process for production of blown bitumen. Various qualities of bitumen can be made out of different residues - with or without blending components - under atmospheric conditions or with elevated pressure.

Biturox process is oxidation of feed material at an operating temperature between 240 - 270°C and pressure up to 2.0 kg/cm

2 g.

To reach high efficiency of the reaction between feed stock and oxygen a large reaction surface of the air bubbles is required. For that reason the Biturox reactor 603-R-501 is equipped with a three - stage agitator 603-AG-501 to break up the incoming air bubbles. To ensure a small bubble size through the whole length of liquid column in the guiding cylinder the air bubbles are collected by coalescing plates under each agitator disc to break them up again whereby the reaction surface is renewed.

On the other hand, due to the large size of the air pipes the process air is introduced into the liquid product in a form of big bubbles with a small reaction surface. This prevents a fast start of the reaction between fresh feed and oxygen and prevents coke formation. So the Biturox reactor has low servicing needs and this effects minimum operating costs.

This technique replaces the conventional air pipes with small openings which are closed due to coke formation within short time.

2.2 Biturox Reactor

The reactor section, where the Biturox Process occurs, consists of three main components:

Biturox Reactor 603-R-501

Agitator, with three stages of disc mixers 603-AG-501

The guiding cylinder, located concentric to the shell and containing two coalescing plates, one is located under the middle disc mixer and the other under the upper disc mixer.

Controlled amount of feedstock, air and water are simultaneously fed into and processed within the reactor unit.

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2.2.1 Process Air Dispersion

Compressed air is fed into the guiding cylinder through the vertical air injection pipes and flows down through the pipes to the bottom of the reactor, where it is blown into the incoming feed. As the air injection pipes are large in diameter (3”), the air bubbles created at the bottom of the pipes are large and as such, minimize the amount of available oxygen at the air inlet, which prevents overheating and coke formation at this point.

To increase the amount of available oxygen and to be able to achieve maximum oxygen utilization, it is necessary to reduce the size of the air bubbles; it means to increase the reaction surface, thus releasing more oxygen to the process.

As the large air bubbles are introduced to the process at the bottom of the reactor they begin to rise and are immediately dispersed by the first disc mixer. At that point an intensive reaction begins - involving the combination of feed stock, small air bubbles and steam. The small bubbles continue to rise inside the guiding cylinder, become large, are again collected by the coalescing plates and are again broken up and dispersed by the next stage of mixer.

The sequence of movement mentioned before continues in stages, as the material being processed circulates rapidly upstream within the guiding cylinder and then continues downstream between the outside wall of the guiding cylinder and the reactor shell. This continuous circulation, together with the dynamics of the process, ensures a uniform reaction and consistently offers the best in product quality.

2.2.2 Process Temperature

The standard liquid temperature used for Biturox process is 250°C.

As the process is an exothermic one, it is important that the operating temperature within the reactor is tightly controlled. This is accomplished by injecting of process water into the air pipes. As the water vaporizes in the air pipes it cools the content of the reactor making it possible to maintain precise temperature control.

Additionally the light hydrocarbons are stripped out of the product by the vaporized water, which is injected into the air. This effect is increased by reaction water created during the chemical reactions.

The temperature in the vapour space is indicated by the redundant temperature transmitters at the top of the reactor. 603-TI-5510 triggers alarms H and L and 603-TI-5509 activates the Interlock 603-I-1001 and triggers an alarm HH.

The temperature of the liquid phase is indicated by the temperature transmitter 603-TI-5502 which triggers the alarms H and L.

In principle the temperature in the vapour space of the reactor is approximately 50-70°C below the bitumen temperature during normal operation.

In case of high temperature in the vapour space of ≥ 240°C the LP-Steam can be fed into the vapour space for quenching purposes. The reactor quench steam valve 603-HV-5501 is operated by the hand button 603-HS-5501 installed in the control room.

In case the temperature in the vapour space will reach 250°C the Interlock 603-I-1001 will be activated and Biturox section will be shut down.

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2.2.3 Process Pressure

The process pressure is measured in the off gas line and controlled by the pressure controller 603-PIC-6101 with the pressure control valve 603-PV-6101. The Biturox Unit is designed for normal operating pressure of 2.0 kg/cm

2 g (means pressure in the off gas space).

Additionally at the top part of the reactor the pressure transmitter 603-PI-5502B with pressure alarm H and L is installed.

To prevent an over pressure of the reactor, the rupture discs (RD) 603-PSE-505A/B in combination with the safety valves 603-PSV-504A/B are foreseen at the top of the reactor.

The maximum operating pressure of the reactor is 90% of the burst pressure of the rupture disc. If this percentage is exceeded, the rupture disc is damaged and may burst under normal operating pressure. A pressure alarm H 603-PICAH-6101/603-PIAH-5502B indicates the high pressure before the burst pressure is reached and prevents RD damage.

Bursting of the RD is indicated by pressure gauges with alarm H signal 603-PAH-5504A/B, located between RD and safety valve.

The RD outlets are sealed by the safety valves 603-PSV-504A/B with a set pressure related to the reactor design pressure. If the rupture disc bursts due to high operating pressure, the safety valve keeps the operating pressure in the vessel to enable the operators to adjust the correct operating pressure. If the pressure could be adjusted, it is possible to continue with the operation.

The RD can be changed during the next planned shutdown of the reactor.

The pressure alarm HH 603-PSHH-5503 is foreseen to prevent releasing of the safety valve and is activated, if the pressure in reactor exceeds 90% of set pressure of 603-PSV-504A/B. In that case the interlock 603-I-1001 is triggered and an emergency stop of the reactor section follows. Process air, process water, feed and product flow are shut-off.

If the operating pressure reaches the PSV set pressure, the safety valve releases the over pressure to the atmosphere via the Blow Down Pit 603-X-501 whereas the liquid phase is collected.

2.2.4 Liquid Level

The reactor level controller 603-LYIC-5502 is based on a measurement of the liquid column hydrostatic pressure. The level is determined from the differential pressure between bottom 603-PT-5502A and top of the reactor 603-PT-5502B. The actual density of the liquid product used for the level calculation will be determined under actual operating conditions to increase level calculation accuracy. For this purpose the differential pressure of a defined height (2 m) of liquid column 603-DT-5502 (installed at N23A/B) will be used to calculate the liquid density.

The level controller 603-LYIC-5502 acts on the level control valve 603-LV-5502 installed in the product discharge line upstream the Feed/Product Heat Exchanger 603-E-501A/B/C.

During operation five temperature transmitters are indicating important points of the liquid level and additionally supervise the liquid level. The level indication is based on the temperature difference between the liquid and gas phase of approximately 50 to 70°C.

603-TI-5503 installed at N12 (minimal working level)

603-TI-5504 installed at N13 (intermediate working level)

603-TI-5505 installed at N14 (nominal working level)

603-TI-5506 installed at N15 (intermediate working level)

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603-TI-5507 installed at N16 (maximal working level)

The temperature transmitter 603-TI-5508 installed at N17 triggers an alarm H, which has a function of a level alarm H.

To prevent spill over of the reactor while operating, the level switch 603-LS-5504 is foreseen that triggers a level alarm HH. For Interlock that activates shut down of the reactor section at level HH a second level indication 603-LYI-5501 determined from the pressure difference between bottom 603-PT-5501A and top of the reactor 603-PT-5501B is foreseen.

A low liquid level has a negative influence on the circulation inside the reactor, thus it is indicated during the reactor filling and operation by the level switch 603-LS-5503 and triggers a level alarm LL.

2.3 Feed Supply

The feed components –Vacuum Residue and VGO - are supplied to the Biturox Unit as follows:

Vacuum Residue 90°C, 8.0 kg/cm2 g

150°C, 10.0 kg/cm2 g

VGO 90°C, 5.0 kg/cm2 g

200°C, 20.0 kg/cm2 g

In the hot VGO supply line a PCV is installed to reduce the high pressure of the hot VGO to the pressure level of the cold VGO, i.e. from 20 to 5 kg/cm

2g.

The feed components are led to the feed blending section. The total feed flow and the VGO ratio are entered into the ratio controller 603-FFY-5201 which calculates the flow of VR and VGO and gives the set points to the designated flow controller 603-FIC-5201A (VR) and 603-FIC-5201B (VGO). The VR flow controller 603-FIC-5201A acts on the flow control valve 603-FV-5201A and the VGO flow controller 603-FIC-5201B acts on the flow control valve 603-FV-5201B. The total flow of the feed blend is measured at the inlet of the reactor and indicated by 603-FI-5401 and summarised by 603-FQI-5401.

The VR is routed via the Feed/Product Heat Exchanger 603-E-501A/B/C and the Feed Heater 603-EE-507 to the Biturox Reactor 603-R-501. Because of the VGO low pressure of 5 kg/cm

2 g,

the VGO is blended to the VR upstream the Biturox Reactor 603-R-501.

2.4 Feed Heating and Product Cooling

Feed Heating

The Feed is heated up in two steps: in the Feed/Product HE 603-E-501A/B/C and Feed Heater 603-EE-507 (electrical heater).

The table below summarizes all feed temperature cases and their impact on the feed heating and heat exchanger duties.

Feed heating is described in detail for production of design case VG30 (CASE 3):

At the first step the Feed is led to the Feed/Product HE 603-E-501A/B/C, where it is heated from 90°C to 204°C by the hot product coming from the reactor with a temperature of 250°C. The outlet feed temperature results from the controlled product cooling to 150°C (see below description of Product Cooling for details).

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At the second step it is heated up from 204°C to 216°C by the Feed Heater 603-EE-507. The VR is blended downstream 603-EE-507 with the VGO whereas it is cooled down by the colder VGO to the required Feed temperature of 210°C.

The temperature of the Feed which enters the Biturox Reactor is controlled by 603-TIC-5402 that acts on the control unit of the heating cartridges of 603-EE-507.

CASE

No.

Product

CASE

VR/VGO

Temp.

at B.L.

Feed

Heating in

603-E-501 1)

Duty in

603-E-501

Feed

heating in

603-EE-507 1)

Duty in

603-EE-507

Product Cooling

in

603-E-501

(°C) (°C) (MMkcal/h) (°C) (MMkcal/h) (°C)

1 VG10 90 / 90 90 -> 206 1.025 206 ->219.0 0.128 (149 kW) 250 ->150

2 VG20 90 / 90 90 -> 204 1.022 204 ->216.3 0.124 (144 kW) 250 ->150

3 VG30 90 / 90 90 -> 204 1.022 204 ->216.3 0.125 (145 kW) 250 ->150

4 2)

VG40 90 / 90 90 -> 189.6 0.926 189.6 ->210 0.210 (245 kW) 250 ->160

5 VG10 150 / 90 150 -> 219 0.649 Not used 0 250 ->188.6

6 VG20 150 / 90 150 -> 216.3 0.634 Not used 0 250 ->190

7 VG30 150 / 90 150 -> 216.3 0.633 Not used 0 250 ->190

8 VG40 150 / 90 150 -> 210 0.598 Not used 0 250 ->193.4

9 VG10 90 / 200 90 -> 206 1.025 206 ->210.8 0.046 (54 kW) 250 ->150

10 VG20 90 / 200 90 -> 203.9 1.022 203.9 –>210.5 0.066 (77 kW) 250 ->150

11 VG30 90 / 200 90 -> 203.9 1.022 203.9 –>210.5 0.066 (77 kW) 250 ->150

12 2)

VG40 90 / 200 90 -> 189.5 0.926 189.5 ->210 0.211 (245 kW) 250 ->160

13 VG10 150 / 200 150 -> 210.8 0.567 Not used 0 250 ->196.7

14 VG20 150 / 200 150 -> 210.5 0.575 Not used 0 250 ->195.7

15 VG30 150 / 200 150 -> 210.5 0.575 Not used 0 250 ->195.7

16 VG40 150 / 200 150 -> 210 0.598 Not used 0 250 ->193.4

1)

The temperature of 210°C required at inlet of the reactor will be achieved by blending of VGO to VR. 2)

The design case for the Feed Heater is the CASE 4 (=CASE 12) with max. duty of 245kW (cold VR and VG40 production, where product is cooled down to 160°C only).

During the start-up procedure no hot product is available. Therefore the Feed Heater 603-EE-507 can be used for heating up the Feed. The heating procedure during the start-up begins with Feed preheating in the Feed Heater during filling of the reactor. Then the reactor content (nominal capacity of 34 tons) will be circulated by the Product Pump 603-P-501A/B via the Feed Heater 603-EE-507 until the temperature of the feed material in the reactor is increased to approx. 210°C (initial temperature for start of the oxidation process).

The Feed Heater 603-EE-507 can also be used to compensate the heat losses during the Hot Stop operation (Biturox process is stopped as no Process Air is introduced to the reactor).

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Therefore to keep the unit warm, the product is circulated via 603-E-501A/B/C and 603-EE-507 back to the Biturox Reactor.

Product Cooling

The Product from the Biturox process leaves the reactor with a temperature of 250°C. The product is discharged from the reactor 603-R-501 by the Product Pump 603-P-501A/B (positive displacement pump) to the Feed/Product Heat Exchanger 603-E-501A/B/C via the level control valve 603-LV-5502. The surplus of the constant product flow pumped by the Product Pump 603-P-501A/B is led back to the reactor via the pressure control valve 603-PV-5804 controlled by 603-PIC-5804. The temperature of the Product discharged to the storage is controlled by 603-TIC-5306 that acts on the 3-way temperature control valve 603-TV-5306 installed in the Feed line upstream of 603-E-501A/B/C.

2.5 Process Air System

The Process Air for the Biturox process is produced I.S.B.L. by the Process Air Compressor 603-KA-511A/B. The compressed air with the pressure of 7.5 kg/cm

2 g (min. required pressure of

process air is 7.0 kg/cm2 g) is supplied through the Process Air Receiver 603-V-512 and is

charged on flow control 603-FIC-5601 via the flow control valve 603-FV-5601 to the reactor top.

The flow of the Process Air has to be adjusted so that the residual oxygen in the off gas (measured downstream the Knock Out Drum 603-V-501) is settled about 3 – 7 Vol. %.

Remark:

Alternatively the Process Air can be supplied by the existing compressors 27-KA-001A/B and charged to the Process Air Receiver 603-V-512 with a pressure of 7.0 kg/cm

2 g.

2.6 Process Water

DM water is available at the B.L. with a pressure of 4.0 kg/cm2 g (norm.) and a temperature of

40°C (norm.). The DM water is used as Process Water in the Biturox Process, as Injection Water for Off Gas cooling and as Make Up Water in the scrubber section.

It is supplied by the Process Water Receiver 603-V-511 and charged to the unit by the Process Water Pumps 603-P-511A/B. To assure a minimal required flow of the Process Water Pump 603-P-511A/B of 5 m

3/h the flow controller 603-FIC-6002 is installed that acts on the flow control valve

603-FV-6002 installed in the return line back to the Process Water Receiver 603-V-511.

The Process Water charged to the reactor is controlled by 603-FIC-5602 that acts on the flow control valve 603-FV-5602. To achieve an optimal water spray into the air pipes, two spray nozzles are serving each air pipe. Additionally, depending on the process water amount, the open/close valves 603-HV-5602A-F are used to adjust the number of the spray nozzles in operation and to optimize the spray effect. The open/close valves are operated by solenoid valves 603-HX-5602A/B/C.

In emergency situation when the interlock 603-I-1001 is activated, the open/close valve 603-HV-5601 installed in the process water supply line is closed by the interlock.

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2.7 Off Gas Section

2.7.1 Off gas characteristics

The off gas coming from the Biturox Process consists mainly of nitrogen and steam (> 90 Vol. %). Due to the strip effect of these two components, light hydrocarbons will be stripped out of the liquid product. Other reaction products as CO2, CO, SO2, H2S, R-SH and light alcohols, ketones and aldehydes will be discharged together with nitrogen and steam from the reactor. Due to an effective oxygen utilisation in oxidation process the content of the residual oxygen in the off gas is about 3 - 7 Vol. %.

2.7.2 Knock Out Drum

The off gas leaves the Biturox Reactor with a temperature of 180 - 210°C and is led via the pressure control valve 603-PV-6101 to the off gas section.

In order to recover a part of the hydrocarbons from the off gas and to ensure stable conditions at incinerator inlet, the off gas is cooled down before it enters the Knock Out Drum 603-V-501.

For this purpose the DM water is injected into the off gas to cool it down from 180 - 210°C to ~145°C measured downstream the Knock Out Drum. The injection nozzle is installed upstream the pressure control valve 603-PV-6101. The cooling of the off gas is controlled by temperature controller 603-TIC-6105 (master) that acts on the flow controller of Injection Water 603-FIC-6103 (slave).

The cooling of the off gas is made by evaporation of the injected water, while a part of the hydrocarbons condense due to the cooling effect. The cooled off gas is then led to the Knock Out Drum 603-V-501, where the condensed liquid hydrocarbons (slop oil) are separated.

The collected slop oil is discharged discontinuously (stop and go operation controlled by 603-LIS-6104, switched between LSH and LSL) to the B.L. by the Slop Oil Pump 603-P-502A/B via the Slop Oil Cooler 603-E-502 (Shell & Tube), where it is cooled to max. 80°C. As cooling medium the wash water from the scrubber cycle with 50°C will be used. The temperature of the wash water ensures that also in case of “no slop oil flow” through the cooler, temperature of the slop oil cannot fall down below 50°C. The wash water flow through the cooler is adjusted to 10000 kg/h by means of the manual valve and flow indication 603-FI-6104 and can be kept constant.

After separation of the liquid phase the Off Gas is led to the Incinerator 603-IN-501 to burn the waste components.

2.7.3 Incinerator

The off gas coming from the Knock Out Drum 603-V-501 is led continuously to the Incinerator 603-IN-501 to burn the residual light hydrocarbons, H2S, R-SH and CO at a temperature of min. 850°C and convert them to CO2, SO2 and H2O.

Because of the relatively high heating value of the off gas coming from the KO Drum (350 to 550 kcal/Nm

3, depending on production case), the fuel gas fired burner will run at turn down duty.

The temperature in the combustion chamber is controlled by temperature controller 603-TIC-6203A that acts on the fuel gas control valve 603-TV-6203. The fuel gas is combusted with a stoichiometric excess of combustion air that is supplied by Combustion/Quench Air Blower 603-FD-501A/B and controlled by flow controller 603-FIC-6201. The stoichiometric excess of combustion air is ensured by the fuel gas flow indication 603-FI-6202 that is the basis for the calculation of the set point of 603-FIC-6201.

Process Description

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PD-CV007

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The second part of the air charged by the blower 603-FD-501A/B is led into the combustion chamber as combustion air for combustion of the off gas resp. the quench air to control the combustion temperature in case of energy excess.

The oxygen content in the flue gas is controlled by 603-AIC-6301, which ensures the specified minimal required oxygen content in the flue gas at the outlet of the combustion chamber. In case - when the burner is operated at minimum duty because of the high heating value of the off gas from the Biturox process - this air has a function of quench (cooling) air. The air control valve 603-AV-6301 is controlled by 603-TIC-6203B whereas the oxygen content is higher than min. required.

In cases, when the off gas load is lower and burner has to be operated with increased duty to reach the required combustion temperature, the air valve 603-AV-6301 is controlled by 603-AIC-6301.

2.7.4 Heat Recovery

The Flue Gas with a temperature of 850°C is led to the heat recovery for heat utilization by producing MP Steam.

The Flue Gas leaves the combustion chamber with a temperature of 850°C and is led to the heat recovery section consisting of:

MP-Steam Generator I & II (603-E-503 & 603-E-505)

MP-Steam Superheater 603-E-504

Combustion/Quench Air Preheater 603-E-506

Steam Drum 603-V-502

The generated superheated MP-steam is supplied to the MP-Steam header of the Biturox Unit with a temperature of 275°C and a pressure of 13.5 kg/cm

2 g.

After the heat recovery the Flue Gas with a temperature of 280°C is led to the scrubber section.

2.7.5 NaOH Scrubber

The flue gas containing SO2/SO3 after incineration of the sulphur components is led to the Scrubber 603-V-503 installed downstream the heat recovery, to reduce the sulphur emissions by washing with NaOH solution (pH 8). The scrubber is operated on jet principle, where gas and liquid are routed co current.

By means of the wash water that is injected into the jet pipe of the scrubber the off gas is cooled down from 280°C to 60-65°C that is required for absorption process. The injection of the wash water into the flue gas creates a large contact surface between the gas and liquid phase which is necessary for absorption of SO2/SO3 into the wash water. Then the absorbed SO2/SO3 reacts with NaOH to Natrium sulphite, hydrosulfite and sulphate (Na2SO3, NaHSO3, and Na2SO4). The sulfite and hydrosulfite are oxidized to natrium sulfate (Na2SO4) by the oxygen from the flue gas.

In order to assure optimal conditions for the caustic process, the pH value of the wash water is indicated and controlled by the pH-controller 603-AIC-6502 (master) which acts on the flow controller 603-FIC-6502 (slave) that controls the throughput by adjusting the frequency of the NaOH Dosing Pumps 603-P-512A/B.

After the gas and liquid mixture leaves the quench pipe of the scrubber they will be separated from each other. The separated liquid phase is collected at the vessel bottom. From here and after adding of NaOH Make Up it is circulated by the Wash Water Circulation Pump 603-P-503A/B to the Wash Water Cooler 603-AC-501 and back to the scrubber.

Process Description

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T18-603-

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In the Wash Water Cooler 603-AC-501 designed as an air cooler the washing solution is cooled to 50°C and then led on flow control 603-FIC-6403 via the flow control valve 603-FV-6403 back to the injection nozzles at the top of the scrubber. A part of the wash water is led to the Slop Oil Cooler 603-E-502 where it is used for cooling of the slop oil. The Wash Water Return with a slightly increased temperature of approx. 53°C is led back to the wash water cycle upstream the flow meter 603-FT-6403, is mixed with the main stream of the wash water and is led to the scrubber spray nozzles.

The level in the scrubber is controlled by 603-LIC-6404. The surplus of the wash water is sent via the level control valve 603-LV-6404 to the Underground Caustic Drainage System.

To prevent dropping of the level in the scrubber that could be caused by loses of water by evaporating into the flue gas, a Make-Up Water is foreseen to the section. On the other hand the desulphurisation products have limited solubility in the water, so increasing of their concentration in the waste water has to be avoided to prevent creating of solid sulfate. Therefore a constant Waste Water flow of 1000 kg/h leaving the Wash Water Circle to the Caustic Drainage System is assured by the flow controller 603-FIC-6402 that acts on the flow control valve 603-FV-6402 installed at the Make Up Water supply line.

The washed off gas leaves the scrubber at the top with a temperature of 60-65°C and is led to the stack 603-SK-501 and to the atmosphere.

2.7.6 NaOH Supply

The Caustic Soda (20wt% NaOH) is stored at the NaOH Storage Tank 603-T-511 and supplied to the scrubber section by the NaOH Dosing Pumps 603-P-512A/B.

The charged NaOH flow to 603-T-511 is indicated by 603-FI-6501 and totalized by 603-FQI-6501.

2

1

0Rev.

Rev.Beschreibung

description


prepared, date/name


checked, date/name


approved, date/name

19.04.13 / Blazej 19.04.13 / Foltyn 19.04.13 / Filz

First Issue

First Complete Issue


Mass and Heat Balance

Final Issue of BDEP 26.07.13 / Blazej 26.07.13 / Foltyn 26.07.13 / Filz

Kunde

clientIOCL, Barauni Refinery

Anlage

plant603 – Biturox Unit

Kunden Nr.

client code

Product Grade VG10

BITUROX PROJECT

Projekt Nr.

project code T18

Dokument Nr.

Document No.

T18-603-

HMB-CV002

Seite

page1 of 4

PRODUCT GRADE VG10 (LIQUID STREAMS)

STREAM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Stream DescriptionVR VR VR VGO Feed Blend Product VG10

Product VG10

returnProduct VG10 Product VG10

DM

Water

DM

Water

DM

Water

DM

WaterSlop Oil Slop Oil Slop Oil

from from from from to from to to to from to to to from to to

B.L. 603-E-501 603-EE-507 B.L. 603-R-501 603-P-501 603-R-501 603-E-501 B.L. 603-P-511 603-R-501 Off Gas Line 603-V-503 603-V-501 603-E-502 B.L.

Vapour Fraction 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

Temperature (°C) 90.0 206.0 219.0 90.0 210.0 250.0 250.0 250.0 150.0 40 40 40 40 145 145 80

Pressure (kg/cm2 g) 8.0 4.0 3.0 5.0 3.0 23.0 23.0 18.0 15.0 11.0 11.0 11.0 11.0 0.4 6.4 5.0

Std. Liquid Density @ 15°C (kg/m3) 1029.8 1029.8 1029.8 928.5 1022.7 1027.5 1027.5 1027.5 1027.5 998.0 998.0 998.0 998.0 870.5 870.5 870.5

Mass Density (kg/m3) 984.80 915.18 907.38 879.75 903.75 884.14 884.14 884.14 945.15 992.50 992.50 992.50 992.50 796.20 796.20 834.30

Mass Heat Capacity (kcal/kg °C) 0.449 0.551 0.562 0.485 0.557 0.591 0.591 0.591 0.503 0.998 0.998 0.998 0.998 0.572 0.570 0.506

Viscosity (cP) 2682.980 19.922 15.109 11.159 14.044 10.080 10.080 10.080 137.488 0.651 0.651 0.651 0.651 1.315 1.342 4.523

Kinematic Viscosity (cSt) 2724.4 21.8 16.7 12.7 15.5 11.4 11.4 11.4 145.5 0.7 0.7 0.7 0.7 1.7 1.7 5.4

Thermal Conductivity (W/m°C) 0.109 0.101 0.101 0.120 0.102 0.099 0.099 0.099 0.105 0.632 0.632 0.632 0.632 0.127 0.126 0.138

Thermal Conductivity (kcal/hm°C) 0.093 0.087 0.087 0.103 0.088 0.085 0.085 0.085 0.090 0.543 0.543 0.543 0.543 0.109 0.109 0.119

Molecular Weight (kg/kmol) - - - - - - - - - 18.0 18.0 18.0 18.0 303.9 303.9 303.9

Mass Flow (kg/h) 17667.2 17667.2 17667.2 1329.8 18997.0 22987.8 4237.8 18750.0 18750.0 1021.3 500.0 44.5 476.8 139.4 796.2 1) 796.2

Molar Flow (kmol/h) 56.68 27.75 2.47 26.46 0.46 2.62

Std. Liquid Volume Flow (m3/h) 17.16 17.16 17.16 1.43 18.58 22.37 4.12 18.25 18.25 1.02 0.50 0.04 0.48 0.16 0.91 0.91

Actual Volume Flow (m3/h) 17.94 19.30 19.47 1.51 21.02 26.00 4.79 21.21 19.84 1.03 0.50 0.04 0.48 0.18 1.00 0.95

Normal Gas Flow (Nm3/h) - - - - - - - - - - - - - - - -

Enthalpy Difference - - - - - - - - - -

Between streams (MMkcal/h) - - - - - - - - - - - - - -

STREAM NO. 17 18 19 20 21 22 23 24 25 26 27 28

Stream Description

NaOH

20 Mass%Wash Water Wash Water Wash Water Wash Water Wash Water Wash Water BFW BFW BFW Raw Water Blow Down Water

to to from to from to to to to to to from

603-P-503 603-AC-501 603-AC-501 603-E-502 603-E-502 B.L. 603-V-503 603-U-501 MP-Steam 603-V-502 603-V-504 603-V-504

Vapour Fraction 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

Temperature (°C) 45.0 62.0 50.0 50.1 52.8 50.0 50.5 100.0 100.0 100.0 40.0 60.0

Pressure (kg/cm2 g) 2.0 9.5 8.5 8.5 4.0 2.0 3.0 22.0 22.0 22.0 4.0 0.0

Std. Liquid Density @ 15°C (kg/m3) 1222.0 998.0 998.0 998.0 998.0 998.0 998.0 998.0 998.0 998.0 998.0 998.0

Mass Density (kg/m3) 1204.10 984.90 988.30 988.20 987.50 988.20 988.10 960.60 960.60 960.60 992.20 982.90

Mass Heat Capacity (kcal/kg °C) 0.878 1.034 1.032 1.032 1.033 1.032 1.032 1.004 1.004 1.004 0.998 1.000

Viscosity (cP) 2.200 0.441 0.536 0.536 0.511 0.536 0.531 0.279 0.279 0.279 0.651 0.463

Kinematic Viscosity (cSt) 1.8 0.4 0.5 0.5 0.5 0.5 0.5 0.3 0.3 0.3 0.7 0.5

Thermal Conductivity (kcal/hm°C) 0.6 0.558 0.547 0.547 0.550 0.547 0.549 0.585 0.585 0.585 0.543 0.562

Molecular Weight (kg/kmol) - 18.0 18.0 18.0 18.0 18.0 18.0 18.0 18.0 18.0 18.0 18.0

Mass Flow (kg/h) 50.7 60995.2 60995.2 10000.0 10000.0 1000.0 60000.0 2030.9 42.3 1988.5 441.9 501.6

Molar Flow (kmol/h) - 3384.9 3384.9 554.9 554.9 55.5 3329.6 112.7 2.3 110.4 24.5 27.8

Std. Liquid Volume Flow (m3/h) 0.041 61.12 61.12 10.02 10.02 1.00 60.12 2.03 0.04 1.99 0.44 0.50

Actual Volume Flow (m3/h) 0.042 61.93 61.72 10.12 10.13 1.01 60.72 2.11 0.04 2.07 0.45 0.51

Normal Gas Flow (Nm3/h) - - - - - - - - - - - -

Enthalpy Difference - - - - - - - -

Between streams (MMkcal/h) - - - - - - - - - - - -

Notes:

T18

2 Final Issue of BDEP T18-603-HMB-CV002

1 First Complete Issue

0 First Issue

Rev.

Rev.

Beschreibung

description

Kunde:

Client: IOCL, Barauni Refinery

Anlage

plant

Seite

page2 of 4



603 – Biturox UnitErstellt, Datum/Name

prepared, date/name


checked, date/name


approved, date/name


0.028

Dokument Nr.

Document No.

Projekt Nr.

project code Mass and Heat Balance

Product Grade VG10

1.025 1.025 0.028

0.128

0.754

1) The Slop Oil Pump 603-P-502 A/B is designed with a capacity of 1 m3/h for ON/OFF operation between LSH and LSL.

PRODUCT GRADE VG10 (GAS STREAMS)

STREAM NO. 31 32 35 36 37 38 39 40 41 42

Stream DescriptionProcess Air LP-Steam Off Gas LP-Steam

Off Gas +

LP-SteamFuel Gas

Combustion/

Quench Air

Combustion/

Quench Air

Combustion

Air

Combustion/

Quench Air

to to from to to to to from to to

603-R-501 603-R-501 603-V-501 Velocity seal 603-IN-501 603-IN-501 603-E-506 603-FD-501 Burner 603-IN-501

Vapour Fraction 1.000 1.000 0.995 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000

Temperature (°C) 60.0 180.0 180.0 180.0 145.0 145.0 145.0 180.0 149.1 40.0 20.0 80.0 80.0 80.0

Pressure (kg/cm2 g) 7.5 3.5 2.0 2.0 0.1 0.1 0.1 3.5 0.0 1.8 0.0 0.060 3) 0.010 3) 0.010 3)

Std. Liquid Density @ 15°C (kg/m3) - - - 871.2 - 870.5 - - - - - - - -

Mass Density (kg/m3) 8.73 2.19 1.87 775.50 0.74 796.20 0.74 2.19 0.65 1.94 1.20 1.05 1.01 1.01

Mass Heat Capacity (kcal/kg °C) 0.245 0.521 0.370 0.604 0.365 0.572 0.365 0.521 0.376 0.526 0.241 0.242 0.242 0.242

Viscosity (cP) 0.021 0.015 0.016 0.810 0.015 1.315 0.015 0.015 0.014 0.012 0.019 0.021 0.021 0.021

Kinematic Viscosity (cSt) 2.4 6.9 8.8 1.0 19.9 1.7 19.9 6.9 21.6 6.1 15.5 20.2 21.2 21.2

Thermal Conductivity (kcal/hm°C) 0.025 0.028 0.028 0.103 0.026 0.109 0.026 0.028 0.026 0.036 0.022 0.025 0.025 0.025

Molecular Weight (kg/kmol) 28.9 18.0 23.5 307.0 23.1 303.9 23.1 18.0 22.4 18.1 28.9 28.9 28.9 28.9

Mass Flow (kg/h) 1104.7 200.0 1938.4 113.3 1956.8 139.4 1956.8 250.0 2206.8 38.2 4792.8 4792.8 875.0 3917.8

Molar Flow (kmol/h) 38.29 11.10 82.34 0.37 84.71 0.46 84.71 13.87 98.60 2.12 166.13 166.13 30.33 135.80

Std. Liquid Volume Flow (m3/h) - - - 0.13 - 0.16 - - - - - - - -

Actual Volume Flow (m3/h) 126.51 91.37 1035.46 0.15 2640.7 0.18 2640.69 114.21 3371.14 19.71 3994.00 4547.25 870.65 3898.31

Normal Gas Flow (Nm3/h) 858.26 248.77 1845.67 - 1898.6 - 1898.64 310.96 2210.10 47.44 3723.60 3723.60 679.80 3043.80

Enthalpy Difference - - - - - - - - - - - -


Composition [Vol%]

- N2 79.00 0.00 36.74 - 35.71 - 35.71 0.00 30.68 0.00 79.00 79.00 79.00 79.00

- O2 21.00 0.00 1.38 - 1.34 - 1.34 0.00 1.15 0.28 21.00 21.00 21.00 21.00

- H2O 0.00 100.00 60.29 - 61.50 - 61.50 100.00 66.92 0.00 0.00 0.00 0.00 0.00

- CO2 0.00 0.00 0.59 - 0.57 - 0.57 0.00 0.49 0.48 0.00 0.00 0.00 0.00

- CO 0.00 0.00 0.04 - 0.04 - 0.04 0.00 0.03 0.73 0.00 0.00 0.00 0.00

- C1 0.00 0.00 0.12 - 0.11 - 0.11 0.00 0.10 60.41 0.00 0.00 0.00 0.00

- C2 0.00 0.00 0.02 - 0.02 - 0.02 0.00 0.02 20.31 0.00 0.00 0.00 0.00

- C3 0.00 0.00 0.02 - 0.02 - 0.02 0.00 0.02 0.12 0.00 0.00 0.00 0.00

- C4 0.00 0.00 0.01 - 0.01 - 0.01 0.00 0.01 0.80 0.00 0.00 0.00 0.00

- C5 0.00 0.00 0.00 - 0.00 - 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

- Sum of C1 - C5 0.00 0.00 0.17 - 0.16 - 0.16 0.00 0.14 81.64 0.00 0.00 0.00 0.00

- C5 + 0.00 0.00 0.76 1) - 0.64 2) - 0.64 0.00 0.55 0.00 0.00 0.00 0.00 0.00

- H2S (vppm) 0.00 0.00 395.0 - 384.00 - 384.00 0.00 330.00 27803.00 0.00 0.00 0.00 0.00

- SO2 (vppm) 0.00 0.00 21.0 - 21.00 - 21.00 0.00 18.00 0.00 0.00 0.00 0.00 0.00

- H2 0.00 0.00 0.00 - 0.00 - 0.00 0.00 0.00 14.09 0.00 0.00 0.00 0.00

Total 100.00 100.00 100.00 - 100.00 - 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00

Composition [Mass %]

- N2 76.71 0.00 43.71 - 43.31 - 43.31 0.00 38.40 0.00 76.71 76.71 76.71 76.71

- O2 23.29 0.00 1.87 - 1.85 - 1.85 0.00 1.64 0.50 23.29 23.29 23.29 23.29

- H2O 0.00 100.00 46.13 - 47.97 - 47.97 100.00 53.86 0.00 0.00 0.00 0.00 0.00

- CO2 0.00 0.00 1.10 - 1.09 - 1.09 0.00 0.97 1.17 0.00 0.00 0.00 0.00

- CO 0.00 0.00 0.05 - 0.05 - 0.05 0.00 0.04 1.13 0.00 0.00 0.00 0.00

- C1 0.00 0.00 0.08 - 0.08 - 0.08 0.00 0.07 53.68 0.00 0.00 0.00 0.00

- C2 0.00 0.00 0.03 - 0.02 - 0.02 0.00 0.02 33.83 0.00 0.00 0.00 0.00

- C3 0.00 0.00 0.04 - 0.04 - 0.04 0.00 0.03 0.29 0.00 0.00 0.00 0.00

- C4 0.00 0.00 0.03 - 0.03 - 0.03 0.00 0.03 2.58 0.00 0.00 0.00 0.00

- C5 0.00 0.00 0.00 - 0.00 - 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

- Sum of C1 - C5 0.00 0.00 0.17 - 0.17 - 0.17 0.00 0.15 90.38 0.00 0.00 0.00 0.00

- C5 + 0.00 0.00 6.90 1) - 5.50 2) - 5.50 0.00 4.88 0.00 0.00 0.00 0.00 0.00

- H2S (ppm) 0.00 0.00 572.00 - 566.00 - 566.00 0.00 502.00 52478.00 0.00 0.00 0.00 0.00

- SO2 (ppm) 0.00 0.00 58.00 - 58.00 - 58.00 0.00 51.00 0.00 0.00 0.00 0.00 0.00

- H2 0.00 0.00 0.00 - 0.00 - 0.00 0.00 0.00 1.57 0.00 0.00 0.00 0.00

Total 100.00 100.00 100.00 - 100.00 - 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00

Notes:

T18



0 First Issue

Rev.

Rev.

Beschreibung

description

Kunde:

Client:IOCL, Barauni Refinery

Anlage:

Plant:

Seite

page3 of 4

26.07.13 / Foltyn 26.07.13 / Filz

33

from to

603-V-501

34

0.996

603-R-501

Off Gas

Gas Phase / Liquid Phase

Off Gas


0.070

603 – Biturox UnitGeprüft, Datum/Name

checked, date/name


approved, date/name


prepared, date/name

1) C5+ as C16 (C16 average mol. weight)

04.04.13 / Filz

19.04.13 / Blazej 19.04.13 / Foltyn

Dokument Nr.

Document No.

Projekt Nr.


Product Grade VG10


04.04.13 / Blazej 04.04.13 / Foltyn

3) Pressure values inside incinerator package are only estimations. To be verified during detail engineering.

19.04.13 / Filz

26.07.13 / Blazej


STREAM NO. 43 44 45 46 47 48 49 50 51 52 54 55 56 57

Stream DescriptionFlue Gas Flue Gas Flue Gas Flue Gas Flue Gas Flue Gas MP-Steam MP-Steam MP-Steam MP-Steam

from from from from from from from to from to

603-IN-501 603-E-503 603-E-504 603-E-505 603-E-506 603-V-503 603-V-502 603-E-504 603-E-504 B.L.

Vapour Fraction 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 0.180

Temperature (°C) 850.0 468.10 415.80 313.1 280.0 62.0 203.5 197.5 300.0 275.0 111.4 111.4

Pressure (kg/cm2 g) 0.010 1) 0.007 1) 0.005 1) 0.002 1) 0.0 0.0 16.0 13.5 13.5 13.5 0.5 0.5

Std. Liquid Density @ 15°C (kg/m3) - - - - - - - - - - - 998.0

Mass Density (kg/m3) 0.29 0.43 0.46 0.54 0.57 0.98 8.43 7.19 5.59 5.89 0.86 949.30


Viscosity (cP) 0.042 0.031 0.029 0.026 0.025 0.017 0.016 0.016 0.020 0.019 0.012 0.249



Molecular Weight (kg/kmol) 26.0 26.0 26.0 26.0 26.0 26.9 18.0 18.0 18.0 18.0 18.0 18.0

Mass Flow (kg/h) 7037.7 7037.7 7037.7 7037.7 7037.7 6565.2 1928.9 1928.9 1928.9 1971.2 10.7 48.9

Molar Flow (kmol/h) 270.47 270.47 270.47 270.47 270.47 244.52 107.04 107.04 107.04 109.39 0.60 2.71

Std. Liquid Volume Flow (m3/h) - - - - - - - - - - - -


Normal Gas Flow (Nm3/h) 6062.38 6062.38 6062.38 6062.38 6062.38 5480.57 2399.18 2399.18 2399.18 2451.86 13.35 -

Enthalpy Difference - - - - - -

Between streams (MMkcal/h) - - - - - - - -

Composition [Vol%]

- N2 59.72 59.72 59.72 59.72 59.72 66.04 0.00 0.00 0.00 0.00 0.00 -

- O2 7.20 7.20 7.20 7.20 7.20 7.96 0.00 0.00 0.00 0.00 0.00 -

- H2O 29.14 29.14 29.14 29.14 29.14 21.68 100.00 100.00 100.00 100.00 100.00 -

- CO2 3.91 3.91 3.91 3.91 3.91 4.31 0.00 0.00 0.00 0.00 0.00 -

- CO 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C1 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C2 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C3 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C4 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C5 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- Sum of C1 - C5 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C5 + 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- H2S (vppm) 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- SO2 (vppm) 344.00 344.00 344.00 344.00 344.00 15.00 0.00 0.00 0.00 0.00 0.00 -

- H2 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

Total 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 -


- N2 64.28 64.28 64.28 64.28 64.28 68.90 0.00 0.00 0.00 0.00 0.00 -

- O2 8.85 8.85 8.85 8.85 8.85 9.49 0.00 0.00 0.00 0.00 0.00 -

- H2O 20.17 20.17 20.17 20.17 20.17 14.55 100.00 100.00 100.00 100.00 100.00 -

- CO2 6.61 6.61 6.61 6.61 6.61 7.06 0.00 0.00 0.00 0.00 0.00 -

- CO 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C1 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C2 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C3 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C4 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C5 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- Sum of C1 - C5 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C5 + 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- H2S (ppm) 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- SO2 (ppm) 848.00 848.00 848.00 848.00 848.00 36.00 0.00 0.00 0.00 0.00 0.00 -

- H2 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

Total 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 -


T18



0 First Issue

Rev.

Rev.

Beschreibung

description

Kunde

client IOCL, Barauni Refinery

Anlage

plant

Seite

page4 of 4


53


Notes:

to

603-V-504


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approved, date/name



Projekt Nr.

project code

Dokument Nr.

Document No.


Product Grade VG10

Blow Down

Gas Phase/Liquid Phase

0.114 0.070 0.114

0.877 0.220

2

1

0Rev.

Rev.Beschreibung

description


prepared, date/name


checked, date/name


approved, date/name


First Issue





Kunde


Anlage


Kunden Nr.

client code

Product Grade VG20

BITUROX PROJECT

Projekt Nr.

project code T18

Dokument Nr.

Document No.

T18-603-

HMB-CV003

Seite

page1 of 4


STREAM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16


Product VG20


DM

Water

DM

Water

DM

Water

DM




Vapour Fraction 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

Temperature (°C) 90.0 203.87 216.32 90.0 210.0 250.0 250.0 250.0 150.0 40 40 40 40 145 145 80

Pressure (kg/cm2 g) 8.0 4.0 3.0 5.0 3.0 23.0 23.0 18.0 15.0 11.0 11.0 11.0 11.0 0.4 6.4 5.0


Mass Density (kg/m3) 984.80 916.48 909.01 879.75 905.70 887.44 887.44 887.44 948.45 992.50 992.50 992.50 992.50 799.90 799.90 837.60


Viscosity (cP) 2682.980 20.928 15.967 11.159 14.935 11.223 11.223 11.223 172.683 0.651 0.651 0.651 0.651 1.428 1.464 5.133





Mass Flow (kg/h) 17992.4 17992.4 17992.4 947.0 18939.4 23073.6 4323.6 18750.0 18750.0 969.7 600.0 45.7 324.03 95.5 799.9 1) 799.9

Molar Flow (kmol/h) 53.81 33.30 2.54 17.98 0.31 2.56






STREAM NO. 17 18 19 20 21 22 23 24 25 26 27 28

Stream Description

NaOH




Vapour Fraction 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

Temperature (°C) 45.0 63.1 50.0 50.1 52.8 50.0 50.5 100.0 100.0 100.0 40.0 60.0

Pressure (kg/cm2 g) 2.0 9.5 8.5 8.5 4.0 2.0 3.0 22.0 22.0 22.0 4.0 0.0


Mass Density (kg/m3) 1204.10 984.60 988.30 988.20 987.50 988.20 988.10 960.60 960.60 960.60 992.20 982.90


Viscosity (cP) 2.200 0.434 0.536 0.536 0.511 0.536 0.531 0.279 0.279 0.279 0.651 0.463




Mass Flow (kg/h) 39.0 60993.8 60993.8 10000.0 10000.0 1000.0 60000.0 1925.3 40.1 1885.1 418.9 475.5

Molar Flow (kmol/h) - 3384.8 3384.8 554.9 554.9 55.5 3329.6 106.8 2.2 104.6 23.2 26.4






Notes:

T18



0 First Issue

Rev.

Rev.

Beschreibung

description

Kunde:


Anlage

plant

Seite

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04.04.13 / Filz


prepared, date/name


checked, date/name


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1.0224 1.0224 0.028

0.1242

0.823


0.028


Dokument Nr.

Document No.

Projekt Nr.


Product Grade VG20



STREAM NO. 31 32 35 36 37 38 39 40 41 42


Off Gas +

LP-SteamFuel Gas

Combustion/

Quench Air

Combustion/

Quench Air

Combustion

Air

Combustion/

Quench Air



Vapour Fraction 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000

Temperature (°C) 60.0 180.0 180.0 180.0 145.0 145.0 145.0 180.0 148.8 40.0 20.0 80.0 80.0 80.0

Pressure (kg/cm2 g) 7.5 3.5 2.0 2.0 0.1 0.1 0.1 3.5 0.0 1.8 0.0 0.060 3) 0.010 3) 0.010 3)


Mass Density (kg/m3) 8.73 2.19 1.84 780.00 0.73 799.90 0.73 2.19 0.65 1.94 1.20 1.05 1.01 1.01


Viscosity (cP) 0.021 0.015 0.016 0.874 0.015 1.428 0.015 0.015 0.014 0.012 0.019 0.021 0.021 0.021




Mass Flow (kg/h) 1174.5 200.0 2090.3 73.6 2114.1 95.5 2114.1 250.0 2364.1 41.9 4047.7 4047.7 959.9 3087.8

Molar Flow (kmol/h) 40.71 11.10 90.49 0.23 92.97 0.31 92.97 13.87 106.88 2.32 140.30 140.30 33.27 107.03






Composition [Vol%]

- N2 79.00 0.00 35.54 - 34.59 - 34.59 0.00 30.10 0.00 79.00 79.00 79.00 79.00

- O2 21.00 0.00 1.33 - 1.29 - 1.29 0.00 1.13 0.28 21.00 21.00 21.00 21.00

- H2O 0.00 100.00 61.74 - 62.82 - 62.82 100.00 67.65 0.00 0.00 0.00 0.00 0.00

- CO2 0.00 0.00 0.57 - 0.56 - 0.56 0.00 0.48 0.48 0.00 0.00 0.00 0.00

- CO 0.00 0.00 0.04 - 0.04 - 0.04 0.00 0.03 0.73 0.00 0.00 0.00 0.00

- C1 0.00 0.00 0.11 - 0.11 - 0.11 0.00 0.10 60.41 0.00 0.00 0.00 0.00

- C2 0.00 0.00 0.02 - 0.02 - 0.02 0.00 0.02 20.31 0.00 0.00 0.00 0.00

- C3 0.00 0.00 0.02 - 0.02 - 0.02 0.00 0.02 0.12 0.00 0.00 0.00 0.00

- C4 0.00 0.00 0.01 - 0.01 - 0.01 0.00 0.01 0.80 0.00 0.00 0.00 0.00

- C5 0.00 0.00 0.00 - 0.00 - 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

- Sum of C1 - C5 0.00 0.00 0.16 - 0.16 - 0.16 0.00 0.14 81.64 0.00 0.00 0.00 0.00

- C5 + 0.00 0.00 0.58 1) - 0.51 2) - 0.51 0.00 0.44 0.00 0.00 0.00 0.00 0.00

- H2S (vppm) 0.00 0.00 382.0 - 372.00 - 372.00 0.00 324.00 27803.00 0.00 0.00 0.00 0.00

- SO2 (vppm) 0.00 0.00 21.0 - 20.00 - 20.00 0.00 18.00 0.00 0.00 0.00 0.00 0.00

- H2 0.00 0.00 0.00 - 0.00 - 0.00 0.00 0.00 14.09 0.00 0.00 0.00 0.00

Total 100.00 100.00 100.00 - 100.00 - 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00


- N2 76.71 0.00 43.10 - 42.61 - 42.61 0.00 38.11 0.00 76.71 76.71 76.71 76.71

- O2 23.29 0.00 1.84 - 1.82 - 1.82 0.00 1.63 0.50 23.29 23.29 23.29 23.29

- H2O 0.00 100.00 48.15 - 49.77 - 49.77 100.00 55.08 0.00 0.00 0.00 0.00 0.00

- CO2 0.00 0.00 1.09 - 1.08 - 1.08 0.00 0.96 1.17 0.00 0.00 0.00 0.00

- CO 0.00 0.00 0.05 - 0.05 - 0.05 0.00 0.04 1.13 0.00 0.00 0.00 0.00

- C1 0.00 0.00 0.08 - 0.08 - 0.08 0.00 0.07 53.68 0.00 0.00 0.00 0.00

- C2 0.00 0.00 0.02 - 0.02 - 0.02 0.00 0.02 33.83 0.00 0.00 0.00 0.00

- C3 0.00 0.00 0.04 - 0.04 - 0.04 0.00 0.03 0.29 0.00 0.00 0.00 0.00

- C4 0.00 0.00 0.03 - 0.03 - 0.03 0.00 0.03 2.58 0.00 0.00 0.00 0.00

- C5 0.00 0.00 0.00 - 0.00 - 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

- Sum of C1 - C5 0.00 0.00 0.17 - 0.17 - 0.17 0.00 0.15 90.38 0.00 0.00 0.00 0.00

- C5 + 0.00 0.00 5.54 1) - 4.44 2) - 4.44 0.00 3.97 0.00 0.00 0.00 0.00 0.00

- H2S (ppm) 0.00 0.00 564.00 - 557.00 - 557.00 0.00 498.00 52478.00 0.00 0.00 0.00 0.00

- SO2 (ppm) 0.00 0.00 58.00 - 57.00 - 57.00 0.00 51.00 0.00 0.00 0.00 0.00 0.00

- H2 0.00 0.00 0.00 - 0.00 - 0.00 0.00 0.00 1.57 0.00 0.00 0.00 0.00

Total 100.00 100.00 100.00 - 100.00 - 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00

Notes:

T18



0 First Issue

Rev.

Rev.

Beschreibung

description

Kunde:


Anlage:

Plant:

Seite

page3 of 4

26.07.13 / Filz

0.997

603-R-501

Off Gas


Off Gas



prepared, date/name


04.04.13 / Filz

19.04.13 / Blazej

26.07.13 / Blazej 26.07.13 / Foltyn


0.059

33

from to

603-V-501

34

19.04.13 / Foltyn 19.04.13 / Filz

0.998

Dokument Nr.

Document No.

Projekt Nr.


Product Grade VG20



checked, date/name


approved, date/name

04.04.13 / Blazej 04.04.13 / Foltyn



STREAM NO. 43 44 45 46 47 48 49 50 51 52 54 55 56 57



603-IN-501 603-E-503 603-E-504 603-E-505 603-E-506 603-V-503 603-V-502 603-E-504 603-E-504 B.L.

Vapour Fraction 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000

Temperature (°C) 850.0 465.90 413.20 309.7 280.0 63.1 203.5 197.5 300.0 275.0 111.4 111.4

Pressure (kg/cm2 g) 0.010 1) 0.007 1) 0.005 1) 0.002 1) 0.0 0.0 16.0 13.5 13.5 13.5 0.5 0.5


Mass Density (kg/m3) 0.28 0.42 0.46 0.54 0.56 0.97 8.43 7.19 5.59 5.89 0.86 949.30


Viscosity (cP) 0.041 0.030 0.029 0.025 0.024 0.017 0.016 0.016 0.020 0.019 0.012 0.249




Mass Flow (kg/h) 6453.7 6453.7 6453.7 6453.7 6453.7 5816.7 1828.6 1828.6 1828.6 1868.7 10.2 46.4

Molar Flow (kmol/h) 252.59 252.59 252.59 252.59 252.59 217.53 101.47 101.47 101.47 103.70 0.56 2.57






Composition [Vol%]

- N2 56.60 56.60 56.60 56.60 56.60 65.74 0.00 0.00 0.00 0.00 0.00 -

- O2 6.00 6.00 6.00 6.00 6.00 6.97 0.00 0.00 0.00 0.00 0.00 -

- H2O 33.45 33.45 33.45 33.45 33.45 22.75 100.00 100.00 100.00 100.00 100.00 -

- CO2 3.91 3.91 3.91 3.91 3.91 4.54 0.00 0.00 0.00 0.00 0.00 -

- CO 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C1 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C2 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C3 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C4 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C5 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- Sum of C1 - C5 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C5 + 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- H2S (vppm) 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- SO2 (vppm) 400.00 400.00 400.00 400.00 400.00 19.00 0.00 0.00 0.00 0.00 0.00 -

- H2 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

Total 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 -


- N2 62.07 62.07 62.07 62.07 62.07 68.86 0.00 0.00 0.00 0.00 0.00 -

- O2 7.51 7.51 7.51 7.51 7.51 8.34 0.00 0.00 0.00 0.00 0.00 -

- H2O 23.58 23.58 23.58 23.58 23.58 15.32 100.00 100.00 100.00 100.00 100.00 -

- CO2 6.73 6.73 6.73 6.73 6.73 7.47 0.00 0.00 0.00 0.00 0.00 -

- CO 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C1 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C2 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C3 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C4 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C5 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- Sum of C1 - C5 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C5 + 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- H2S (ppm) 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- SO2 (ppm) 1003.00 1003.00 1003.00 1003.00 1003.00 45.00 0.00 0.00 0.00 0.00 0.00 -

- H2 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

Total 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 -


T18



0 First Issue

Rev.

Rev.

Beschreibung

description

Kunde


Anlage

plant

Seite

page4 of 4

26.07.13 / Foltyn 26.07.13 / Filz

Projekt Nr.

project code

Dokument Nr.

Document No.


Product Grade VG20

0.180

to

603-V-504

0.108


approved, date/name

04.04.13 / Blazej 04.04.13 / Foltyn 04.04.13 / FilzErstellt, Datum/Name

prepared, date/name

0.108

0.832 0.208

0.059

26.07.13 / Blazej

53


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checked, date/name


Blow Down


2

1

0Rev.

Rev.Beschreibung

description


prepared, date/name


checked, date/name


approved, date/name


First Issue





Kunde


Anlage


Kunden Nr.

client code

Product Grade VG30 (Design Case)

BITUROX PROJECT

Projekt Nr.

project code T18

Dokument Nr.

Document No.

T18-603-

HMB-CV004

Seite

page1 of 4


STREAM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16


Product VG30


DM

Water

DM

Water

DM

Water

DM




Vapour Fraction 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

Temperature (°C) 90.0 203.8 216.3 90.0 210.0 250.0 250.0 250.0 150.0 40 40 40 40 145 145 80

Pressure (kg/cm2 g) 8.0 4.0 3.0 5.0 3.0 23.0 23.0 18.0 15.0 11.0 11.0 11.0 11.0 0.4 6.4 5.0


Mass Density (kg/m3) 984.80 916.50 909.01 879.75 905.70 887.94 887.94 887.94 948.95 992.50 992.50 992.50 992.50 801.10 801.10 838.70


Viscosity (cP) 2682.980 20.949 15.967 11.159 14.935 12.620 12.620 12.620 201.945 0.651 0.651 0.651 0.651 1.469 1.509 5.360





Mass Flow (kg/h) 17992.4 17992.4 17992.4 947.0 18939.4 23086.6 4336.6 18750.0 18750.0 1064.7 700.0 50.3 314.4 91.9 801.1 1) 801.1

Molar Flow (kmol/h) 59.08 38.85 2.79 17.44 0.29 2.54






STREAM NO. 17 18 19 20 21 22 23 24 25 26 27 28

Stream Description

NaOH




Vapour Fraction 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

Temperature (°C) 45.0 63.8 50.0 50.1 52.8 50.0 50.5 100.0 100.0 100.0 40.0 60.0

Pressure (kg/cm2 g) 2.0 9.5 8.5 8.5 4.0 2.0 3.0 22.0 22.0 22.0 4.0 0.0


Mass Density (kg/m3) 1204.10 984.40 988.30 988.20 987.50 988.20 988.10 960.60 960.60 960.60 992.20 982.90


Viscosity (cP) 2.200 0.430 0.536 0.536 0.511 0.536 0.531 0.279 0.279 0.279 0.651 0.463




Mass Flow (kg/h) 42.8 60992.7 60992.7 10000.0 10000.0 1000.0 60000.0 2126.6 44.3 2082.3 462.7 525.2

Molar Flow (kmol/h) - 3384.7 3384.7 554.9 554.9 55.5 3329.6 118.0 2.5 115.6 25.7 29.1






Notes:

T18



0 First Issue

Rev.

Rev.

Beschreibung

description

Kunde:


Anlage

plant

Seite

page2 of 4




prepared, date/name


checked, date/name


approved, date/name


0.028

Dokument Nr.

Document No.

Projekt Nr.



1.022 1.022 0.028

0.125

0.868



STREAM NO. 31 32 35 36 37 38 39 40 41 42


Off Gas +

LP-SteamFuel Gas

Combustion/

Quench Air

Combustion/

Quench Air

Combustion

Air

Combustion/

Quench Air



Vapour Fraction 1.000 1.000 0.997 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000

Temperature (°C) 60.0 180.0 180.0 180.0 145.0 145.0 145.0 180.0 148.4 40.0 20.0 80.0 80.0 80.0

Pressure (kg/cm2 g) 7.5 3.5 2.0 2.0 0.1 0.1 0.1 3.5 0.0 1.8 0.0 0.060 3) 0.010 3) 0.010 3)


Mass Density (kg/m3) 8.73 2.19 1.84 781.40 0.73 801.10 0.73 2.19 0.65 1.94 1.20 1.05 1.01 1.01


Viscosity (cP) 0.021 0.015 0.016 0.898 0.015 1.469 0.015 0.015 0.014 0.012 0.019 0.021 0.021 0.021




Mass Flow (kg/h) 1321.8 200.0 2341.7 69.5 2369.6 91.9 2369.6 250.0 2619.6 51.1 4471.0 4471.0 1169.8 3301.2

Molar Flow (kmol/h) 45.82 11.10 101.37 0.22 104.16 0.29 104.16 13.87 118.00 2.83 154.97 154.97 40.55 114.43






Composition [Vol%]

- N2 79.00 0.00 35.70 - 34.76 - 34.76 0.00 30.67 0.00 79.00 79.00 79.00 79.00

- O2 21.00 0.00 1.34 - 1.31 - 1.31 0.00 1.15 0.28 21.00 21.00 21.00 21.00

- H2O 0.00 100.00 61.35 - 62.42 - 62.42 100.00 66.84 0.00 0.00 0.00 0.00 0.00

- CO2 0.00 0.00 0.83 - 0.81 - 0.81 0.00 0.71 0.48 0.00 0.00 0.00 0.00

- CO 0.00 0.00 0.04 - 0.04 - 0.04 0.00 0.03 0.73 0.00 0.00 0.00 0.00

- C1 0.00 0.00 0.12 - 0.11 - 0.11 0.00 0.10 60.41 0.00 0.00 0.00 0.00

- C2 0.00 0.00 0.02 - 0.02 - 0.02 0.00 0.02 20.31 0.00 0.00 0.00 0.00

- C3 0.00 0.00 0.02 - 0.02 - 0.02 0.00 0.02 0.12 0.00 0.00 0.00 0.00

- C4 0.00 0.00 0.01 - 0.01 - 0.01 0.00 0.01 0.80 0.00 0.00 0.00 0.00

- C5 0.00 0.00 0.00 - 0.00 - 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

- Sum of C1 - C5 0.00 0.00 0.17 - 0.16 - 0.16 0.00 0.14 81.64 0.00 0.00 0.00 0.00

- C5 + 0.00 0.00 0.54 1) - 0.47 2) - 0.47 0.00 0.42 0.00 0.00 0.00 0.00 0.00

- H2S (vppm) 0.00 0.00 386.0 - 376.00 - 376.00 0.00 331.00 27800.00 0.00 0.00 0.00 0.00

- SO2 (vppm) 0.00 0.00 21.0 - 20.00 - 20.00 0.00 18.00 0.00 0.00 0.00 0.00 0.00

- H2 0.00 0.00 0.00 - 0.00 - 0.00 0.00 0.00 14.09 0.00 0.00 0.00 0.00

Total 100.00 100.00 100.00 - 100.00 - 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00


- N2 76.71 0.00 43.30 - 42.79 - 42.79 0.00 38.70 0.00 76.71 76.71 76.71 76.71

- O2 23.29 0.00 1.86 - 1.84 - 1.84 0.00 1.66 0.50 23.29 23.29 23.29 23.29

- H2O 0.00 100.00 47.86 - 49.42 - 49.42 100.00 54.24 0.00 0.00 0.00 0.00 0.00

- CO2 0.00 0.00 1.58 - 1.56 - 1.56 0.00 1.41 1.17 0.00 0.00 0.00 0.00

- CO 0.00 0.00 0.05 - 0.05 - 0.05 0.00 0.04 1.13 0.00 0.00 0.00 0.00

- C1 0.00 0.00 0.08 - 0.08 - 0.08 0.00 0.07 53.68 0.00 0.00 0.00 0.00

- C2 0.00 0.00 0.03 - 0.02 - 0.02 0.00 0.02 33.83 0.00 0.00 0.00 0.00

- C3 0.00 0.00 0.04 - 0.04 - 0.04 0.00 0.03 0.29 0.00 0.00 0.00 0.00

- C4 0.00 0.00 0.03 - 0.03 - 0.03 0.00 0.03 2.58 0.00 0.00 0.00 0.00

- C5 0.00 0.00 0.00 - 0.00 - 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

- Sum of C1 - C5 0.00 0.00 0.17 - 0.17 - 0.17 0.00 0.15 90.38 0.00 0.00 0.00 0.00

- C5 + 0.00 0.00 5.12 1) - 4.12 2) - 4.12 0.00 3.72 0.00 0.00 0.00 0.00 0.00

- H2S (ppm) 0.00 0.00 569.00 - 562.00 - 562.00 0.00 509.00 52500.00 0.00 0.00 0.00 0.00

- SO2 (ppm) 0.00 0.00 58.00 - 57.00 - 57.00 0.00 52.00 0.00 0.00 0.00 0.00 0.00

- H2 0.00 0.00 0.00 - 0.00 - 0.00 0.00 0.00 1.57 0.00 0.00 0.00 0.00

Total 100.00 100.00 100.00 - 100.00 - 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00

Notes:

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603 – Biturox UnitGeprüft, Datum/Name

checked, date/name


approved, date/name


prepared, date/name


04.04.13 / Filz

19.04.13 / Blazej 19.04.13 / Foltyn

Dokument Nr.

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04.04.13 / Blazej 04.04.13 / Foltyn


19.04.13 / Filz

26.07.13 / Blazej


STREAM NO. 43 44 45 46 47 48 49 50 51 52 54 55 56 57



603-IN-501 603-E-503 603-E-504 603-E-505 603-E-506 603-V-503 603-V-502 603-E-504 603-E-504 B.L.

Vapour Fraction 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 0.180

Temperature (°C) 850.0 465.90 413.20 309.7 280.0 63.8 203.5 197.5 300.0 275.0 111.4 111.4

Pressure (kg/cm2 g) 0.010 1) 0.007 1) 0.005 1) 0.002 1) 0.0 0.0 16.0 13.5 13.5 13.5 0.5 0.5


Mass Density (kg/m3) 0.28 0.42 0.46 0.54 0.56 0.97 8.43 7.19 5.59 5.89 0.86 949.30


Viscosity (cP) 0.041 0.030 0.029 0.025 0.024 0.017 0.016 0.016 0.020 0.019 0.012 0.249




Mass Flow (kg/h) 7141.7 7141.7 7141.7 7141.7 7141.7 6498.9 2019.8 2019.8 2019.8 2064.2 11.2 51.2

Molar Flow (kmol/h) 279.08 279.08 279.08 279.08 279.08 243.68 112.09 112.09 112.09 114.55 0.62 2.84






Composition [Vol%]

- N2 56.83 56.83 56.83 56.83 56.83 65.08 0.00 0.00 0.00 0.00 0.00 -

- O2 6.00 6.00 6.00 6.00 6.00 6.87 0.00 0.00 0.00 0.00 0.00 -

- H2O 33.16 33.16 33.16 33.16 33.16 23.50 100.00 100.00 100.00 100.00 100.00 -

- CO2 3.97 3.97 3.97 3.97 3.97 4.55 0.00 0.00 0.00 0.00 0.00 -

- CO 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C1 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C2 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C3 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C4 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C5 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- Sum of C1 - C5 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C5 + 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- H2S (vppm) 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- SO2 (vppm) 429.00 429.00 429.00 429.00 429.00 20.00 0.00 0.00 0.00 0.00 0.00 -

- H2 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

Total 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 -


- N2 62.22 62.22 62.22 62.22 62.22 68.37 0.00 0.00 0.00 0.00 0.00 -

- O2 7.50 7.50 7.50 7.50 7.50 8.25 0.00 0.00 0.00 0.00 0.00 -

- H2O 23.35 23.35 23.35 23.35 23.35 15.88 100.00 100.00 100.00 100.00 100.00 -

- CO2 6.83 6.83 6.83 6.83 6.83 7.50 0.00 0.00 0.00 0.00 0.00 -

- CO 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C1 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C2 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C3 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C4 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C5 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- Sum of C1 - C5 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C5 + 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- H2S (ppm) 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- SO2 (ppm) 1074.00 1074.00 1074.00 1074.00 1074.00 47.00 0.00 0.00 0.00 0.00 0.00 -

- H2 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

Total 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 -


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client code

Product Grade VG40

BITUROX PROJECT

Projekt Nr.

project code T18

Dokument Nr.

Document No.

T18-603-

HMB-CV005

Seite

page1 of 4


STREAM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16


Product VG40


DM

Water

DM

Water

DM

Water

DM




Vapour Fraction 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

Temperature (°C) 90.0 189.6 210.0 90.0 210.0 250.0 250.0 250.0 160.0 40 40 40 40 145 145 80

Pressure (kg/cm2 g) 8.0 4.0 3.0 5.0 3.0 23.0 23.0 18.0 15.0 11.0 11.0 11.0 11.0 0.4 6.4 5.0

Std. Liquid Dens. @ 15°C (kg/m3) 1029.8 1029.8 1029.8 928.5 1029.8 1032.5 1032.5 1032.5 1032.5 998.0 998.0 998.0 998.0 876.9 876.9 876.9

Mass Density (kg/m3) 984.80 925.06 912.80 879.75 912.80 889.14 889.14 889.14 944.05 992.50 992.50 992.50 992.50 803.70 803.70 841.00


Viscosity (cP) 2682.980 29.716 18.250 11.159 18.250 12.257 12.257 12.257 148.794 0.651 0.651 0.651 0.651 1.567 1.614 5.915





Mass Flow (kg/h) 18882.2 18882.2 18882.2 0.0 18882.2 23117.8 4367.8 18750.0 18750.0 949.2 600.0 43.3 305.90 58.8 803.7 1) 803.7

Molar Flow (kmol/h) 52.67 33.30 2.40 16.98 0.18 2.50

Std Liquid Volume Flow (m3/h) 18.34 18.34 18.34 0.00 18.34 22.39 4.23 18.16 18.16 0.95 0.60 0.04 0.31 0.07 0.92 0.92





STREAM NO. 17 18 19 20 21 22 23 24 25 26 27 28

Stream Description

NaOH




Vapour Fraction 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

Temperature (°C) 45.0 63.1 50.0 50.1 52.8 50.0 50.5 100.0 100.0 100.0 40.0 60.0

Pressure (kg/cm2 g) 2.0 9.5 8.5 8.5 4.0 2.0 3.0 22.0 22.0 22.0 4.0 0.0

Std. Liquid Dens. @ 15°C (kg/m3) 1222.0 998.0 998.0 998.0 998.0 998.0 998.0 998.0 998.0 998.0 998.0 998.0

Mass Density (kg/m3) 1204.10 984.60 988.30 988.20 987.50 988.20 988.10 960.60 960.60 960.60 992.20 982.90


Viscosity (cP) 2.200 0.434 0.536 0.536 0.511 0.536 0.531 0.279 0.279 0.279 0.651 0.463




Mass Flow (kg/h) 49.8 60992.2 60992.2 10000.0 10000.0 1000.0 60000.0 1928.8 40.2 1888.6 419.7 476.4

Molar Flow (kmol/h) - 3384.7 3384.7 554.9 554.9 55.5 3329.6 107.0 2.2 104.8 23.3 26.4

Std Liquid Volume Flow (m3/h) 0.041 61.11 61.11 10.02 10.02 1.00 60.12 1.93 0.04 1.89 0.42 0.48





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0.210

0.827



STREAM NO. 31 32 35 36 37 38 39 40 41 42


Off Gas +

LP-SteamFuel Gas

Combustion/

Quench Air

Combustion/

Quench Air

Combustion

Air

Combustion/

Quench Air



Vapour Fraction 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000

Temperature (°C) 60.0 180.0 180.0 180.0 145.0 145.0 145.0 180.0 148.8 40.0 20.0 80.0 80.0 80.0

Pressure (kg/cm2 g) 7.5 3.5 2.0 2.0 0.1 0.1 0.1 3.5 0.0 1.8 0.0 0.060 3) 0.010 3) 0.010 3)

Std. Liquid Dens. @ 15°C (kg/m3) - - - 878.4 - 876.9 - - - - - - - -

Mass Density (kg/m3) 8.73 2.19 1.82 784.70 0.72 803.70 0.72 2.19 0.64 1.94 1.20 1.05 1.01 1.01


Viscosity (cP) 0.021 0.015 0.016 0.953 0.014 1.567 0.014 0.015 0.014 0.012 0.019 0.021 0.021 0.021




Mass Flow (kg/h) 1170.6 200.0 2060.1 42.5 2087.0 58.8 2087.0 250.0 2337.0 61.8 4062.6 4062.6 1415.5 2647.1

Molar Flow (kmol/h) 40.58 11.10 90.20 0.13 92.59 0.18 92.59 13.87 106.47 3.42 140.82 140.82 49.06 91.76

Std Liquid Volume Flow (m3/h) - - - 0.05 - 0.07 - - - - - - - -





Composition [Vol%]

- N2 79.00 0.00 35.53 - 34.62 - 34.62 0.00 30.11 0.00 79.00 79.00 79.00 79.00

- O2 21.00 0.00 1.33 - 1.30 - 1.30 0.00 1.13 0.28 21.00 21.00 21.00 21.00

- H2O 0.00 100.00 61.88 - 62.89 - 62.89 100.00 67.73 0.00 0.00 0.00 0.00 0.00

- CO2 0.00 0.00 0.57 - 0.56 - 0.56 0.00 0.48 0.48 0.00 0.00 0.00 0.00

- CO 0.00 0.00 0.04 - 0.04 - 0.04 0.00 0.03 0.73 0.00 0.00 0.00 0.00

- C1 0.00 0.00 0.11 - 0.11 - 0.11 0.00 0.10 60.41 0.00 0.00 0.00 0.00

- C2 0.00 0.00 0.02 - 0.02 - 0.02 0.00 0.02 20.31 0.00 0.00 0.00 0.00

- C3 0.00 0.00 0.02 - 0.02 - 0.02 0.00 0.02 0.12 0.00 0.00 0.00 0.00

- C4 0.00 0.00 0.01 - 0.01 - 0.01 0.00 0.01 0.80 0.00 0.00 0.00 0.00

- C5 0.00 0.00 0.00 - 0.00 - 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

- Sum of C1 - C5 0.00 0.00 0.16 - 0.16 - 0.16 0.00 0.14 81.64 0.00 0.00 0.00 0.00

- C5 + 0.00 0.00 0.44 1) - 0.40 2) - 0.40 0.00 0.35 0.00 0.00 0.00 0.00 0.00

- H2S (vppm) 0.00 0.00 382.0 - 372.00 - 372.00 0.00 324.00 27803.00 0.00 0.00 0.00 0.00

- SO2 (vppm) 0.00 0.00 21.0 - 20.00 - 20.00 0.00 18.00 0.00 0.00 0.00 0.00 0.00

- H2 0.00 0.00 0.00 - 0.00 - 0.00 0.00 0.00 14.09 0.00 0.00 0.00 0.00

Total 100.00 100.00 100.00 - 100.00 - 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00


- N2 76.71 0.00 43.59 - 43.02 - 43.02 0.00 38.42 0.00 76.71 76.71 76.71 76.71

- O2 23.29 0.00 1.86 - 1.84 - 1.84 0.00 1.64 0.50 23.29 23.29 23.29 23.29

- H2O 0.00 100.00 48.81 - 50.26 - 50.26 100.00 55.58 0.00 0.00 0.00 0.00 0.00

- CO2 0.00 0.00 1.10 - 1.09 - 1.09 0.00 0.97 1.17 0.00 0.00 0.00 0.00

- CO 0.00 0.00 0.05 - 0.05 - 0.05 0.00 0.04 1.13 0.00 0.00 0.00 0.00

- C1 0.00 0.00 0.08 - 0.08 - 0.08 0.00 0.07 53.68 0.00 0.00 0.00 0.00

- C2 0.00 0.00 0.03 - 0.02 - 0.02 0.00 0.02 33.83 0.00 0.00 0.00 0.00

- C3 0.00 0.00 0.04 - 0.04 - 0.04 0.00 0.03 0.29 0.00 0.00 0.00 0.00

- C4 0.00 0.00 0.03 - 0.03 - 0.03 0.00 0.03 2.58 0.00 0.00 0.00 0.00

- C5 0.00 0.00 0.00 - 0.00 - 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

- Sum of C1 - C5 0.00 0.00 0.17 - 0.17 - 0.17 0.00 0.15 90.38 0.00 0.00 0.00 0.00

- C5 + 0.00 0.00 4.36 1) - 3.52 2) - 3.52 0.00 3.14 0.00 0.00 0.00 0.00 0.00

- H2S (ppm) 0.00 0.00 570.00 - 562.00 - 562.00 0.00 502.00 52478.00 0.00 0.00 0.00 0.00

- SO2 (ppm) 0.00 0.00 58.00 - 58.00 - 58.00 0.00 51.00 0.00 0.00 0.00 0.00 0.00

- H2 0.00 0.00 0.00 - 0.00 - 0.00 0.00 0.00 1.57 0.00 0.00 0.00 0.00

Total 100.00 100.00 100.00 - 100.00 - 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00

Notes:

T18



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Rev.

Beschreibung

description

Kunde:


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Plant:

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26.07.13 / Filz

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Off Gas



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0.999 0.998

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Dokument Nr.

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checked, date/name


approved, date/name

04.04.13 / Blazej 04.04.13 / Foltyn



STREAM NO. 43 44 45 46 47 48 49 50 51 52 54 55 56 57



603-IN-501 603-E-503 603-E-504 603-E-505 603-E-506 603-V-503 603-V-502 603-E-504 603-E-504 B.L.

Vapour Fraction 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000

Temperature (°C) 850.0 465.90 413.20 309.7 280.0 63.2 203.5 197.5 300.0 275.0 111.4 111.4

Pressure (kg/cm2 g) 0.010 1) 0.007 1) 0.005 1) 0.002 1) 0.0 0.0 16.0 13.5 13.5 13.5 0.5 0.5

Std. Liquid Dens. @ 15°C (kg/m3) - - - - - - - - - - - 998.0

Mass Density (kg/m3) 0.28 0.42 0.46 0.53 0.56 0.97 8.43 7.19 5.59 5.89 0.86 949.30


Viscosity (cP) 0.041 0.030 0.029 0.025 0.024 0.017 0.016 0.016 0.020 0.019 0.012 0.249




Mass Flow (kg/h) 6461.4 6461.4 6461.4 6461.4 6461.4 5817.1 1832.0 1832.0 1832.0 1872.2 10.2 46.5

Molar Flow (kmol/h) 253.19 253.19 253.19 253.19 253.19 217.79 101.66 101.66 101.66 103.89 0.57 2.58

Std Liquid Volume Flow (m3/h) - - - - - - - - - - - -





Composition [Vol%]

- N2 56.60 56.60 56.60 56.60 56.60 65.81 0.00 0.00 0.00 0.00 0.00 -

- O2 6.00 6.00 6.00 6.00 6.00 6.98 0.00 0.00 0.00 0.00 0.00 -

- H2O 33.57 33.57 33.57 33.57 33.57 22.82 100.00 100.00 100.00 100.00 100.00 -

- CO2 3.78 3.78 3.78 3.78 3.78 4.40 0.00 0.00 0.00 0.00 0.00 -

- CO 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C1 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C2 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C3 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C4 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C5 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- Sum of C1 - C5 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C5 + 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- H2S (vppm) 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- SO2 (vppm) 519.00 519.00 519.00 519.00 519.00 23.00 0.00 0.00 0.00 0.00 0.00 -

- H2 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

Total 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 -


- N2 62.13 62.13 62.13 62.13 62.13 69.01 0.00 0.00 0.00 0.00 0.00 -

- O2 7.52 7.52 7.52 7.52 7.52 8.36 0.00 0.00 0.00 0.00 0.00 -

- H2O 23.70 23.70 23.70 23.70 23.70 15.39 100.00 100.00 100.00 100.00 100.00 -

- CO2 6.52 6.52 6.52 6.52 6.52 7.24 0.00 0.00 0.00 0.00 0.00 -

- CO 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C1 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C2 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C3 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C4 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C5 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- Sum of C1 - C5 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- C5 + 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- H2S (ppm) 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

- SO2 (ppm) 1304.00 1304.00 1304.00 1304.00 1304.00 56.00 0.00 0.00 0.00 0.00 0.00 -

- H2 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -

Total 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 -


T18



0 First Issue

Rev.

Rev.

Beschreibung

description

Kunde


Anlage

plant

Seite

page4 of 4

53


Notes:

0.180

to


prepared, date/name

26.07.13 / Blazej


0.209

19.04.13 / Blazej 19.04.13 / Filz

26.07.13 / Foltyn 26.07.13 / Filz

Projekt Nr.

project code

Dokument Nr.

Document No.


Product Grade VG40

603-V-504


checked, date/name


approved, date/name

0.059

19.04.13 / Foltyn

Blow Down


0.108

0.833

0.108

ATM

603-KA-511A/B

603-V-501

NC

FV

LV

603-

AG-5

01

603-R-501

603-P-511A/B

PV

PV

ATM

BATT

ERY

LIMIT

NC

BATT

ERY

LIMIT

FV

FV

603-E-502

TV

LP-STEAM180°C

3.5 kg/cm² g

DM WATER40°C

4.0 kg/cm² g

VACUUM RESIDUE150°C

10.0 kg/cm² g

VGO200°C

20.0 kg/cm² g

SLOP OILMAX. 80°C5.0 kg/cm² g

BITUMEN TO STORAGE150-170°C15.0 kg/cm² g

603-P-501A/B

603-P-502A/B

ATM

603-EE-507

FV

FV

603-X-501

PFD-1152WASH WATER SUPPLY

FROM 603-V-503

PFD-1152LP-STEAM

TO VELOCITY SEAL

PFD-1152MAKE UP WATER

TO 603-V-503

PFD-1152OFF GAS

TO 603-IN-501

PFD-1152WASH WATER RETURN

TO 603-V-503

BATT

ERY

LIMIT

603-V-512

603-V-511

ATM

PLOT DATE:CAD-FILE:

DWG-No.:

PROJECT CODE:

SCALE:

DRAWN

CHECKED

APPROVED

TITLE:

DATE NAMEA-1050 Vienna

Hamburgerstraße 9

Tel.:+43(5) 05899-0

Fax:+43(5) 05899-99

[email protected]

06.06.2013T18-603-PFD-1151-3_PROCESS UNIT.DWG

T18-

22.02.2013 FILZ

22.02.2013

22.02.2013

BATIK

KRACHER

PFD-1151603 - BITUROX UNITPROCESS FLOW DIAGRAM

PROCESS UNIT

PREPAREDISSUE DESCRIPTION DATE CHECKED APPROVED

INDIAN OILCORPORATION LIMITED

Barauni Refinery

BATIKFIRST ISSUE 22.02.2013 KRACHER FILZREV 0

NUHSBAUMERFIRST ISSUE - REVISION 04.04.2013 KRACHER FILZREV 1

NUHSBAUMERFIRST COMPLETE ISSUE 19.04.2013 KRACHER FILZREV 2

NUHSBAUMERFINAL ISSUE OF BDEP 26.07.2013 KRACHER FILZREV 3

HV

VACUUM RESIDUE90°C

8.0 kg/cm² g

VGO90°C

5.0 kg/cm² g

2

89

1

4

10 11

12

31

32

33 34

35

14 15 16

6

OF 603-IN-501ATM

CONTROLSECTION

7

3 5

13

36

DESIGN

GRA

DE V

G30

xx

17992.4 17992.4 17992.4 947.0 18939.4 23086.6 4336.6 18750.0 18750.0 1064.7 700.0 50.3 314.4 91.9 801.1 801.1 42.8 60992.7 60992.7 10000.0 10000.0 1000.0 60000.0 2126.6 44.3 2082.3 462.7 525.2

90.0 203.8 216.3 90.0 210.0 250.0 250.0 250.0 150.0 40.0 40.0 40.0 40.0 145.0 145.0 80.0 45.0 63.8 50.0 50.1 52.8 50.0 50.5 100.0 100.0 100.0 40.0 60.08.0 4.0 3.0 5.0 3.0 23.0 23.0 18.0 15.0 11.0 11.0 11.0 11.0 0.4 6.4 5.0 2.0 9.5 8.5 8.5 4.0 2.0 3.0 22.0 22.0 22.0 4.0 0.0

0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

1321.8 200.0 2411.2 2461.5 2369.6 250.0 2619.6 51.1 4471.0 4471.0 1169.8 3301.2 7141.7 7141.7 7141.7 7141.7 7141.7 6498.9 2019.8 2019.8 2019.8 2064.2 62.5

60.0 180.0 180.0 145.0 145.0 180.0 148.4 40.0 20.0 80.0 80.0 80.0 850.0 465.9 413.2 309.7 280.0 63.8 203.5 197.5 300.0 275.0 111.47.5 3.5 2.0 0.1 0.1 3.5 0.0 1.8 0.0 0.060 0.010 0.010 0.010 0.007 0.005 0.002 0.0 0.0 16.0 13.5 13.5 13.5 0.5

1.000 1.000 0.998 0.997 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 0.180

LIQUID STREAM NAMEMASS FLOW (kg/h)

OPERATING TEMPERATURE (°C)OPERATING PRESSURE (kg/cm2 g)

VAPOUR FRACTION (mol. fr.)GAS STREAM NAMEMASS FLOW (kg/h)


VAPOUR FRACTION (mol. fr.)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60

NOTE 1)

NOTE 2)NO

NC

NOTE 3)

PROCESS AIR45-54°C7.0 kg/cm² g

NOTE 5)

NOTE 4)

603-V-503

603-P-503A/B 603-AC-501LV

CONTROL SECTION

TV

FV

FUEL GAS40°C

1.8 kg/cm² g

MP-STEAM275°C

13.5 kg/cm² g

WASTE WATER50°C

2.0 kg/cm² gFV

PFD-1151WASH WATER SUPPLY

TO 603-E-502

PFD-1151MAKE UP WATER

FROM 603-P-511A/B

PFD-1151WASH WATER RETURN

FROM 603-E-502

BATT

ERY

LIMIT

BATT

ERY

LIMIT

603-E-505603-E-503 603-E-504

PFD-1151OFF GAS

FROM 603-V-501

PFD-1151LP-STEAM

FROM DISTRIBUTION

BATT

ERY

LIMIT

TV

TO VENTS

PCV

603-FD-501A/B

TV

FV

603-IN-501

ATM

ATM

NLL

FV

603-V-502

603-E-506

TV

603-SK-501

603-V-504

PV

603-U-501INCINERATOR &HEAT RECOVERYPACKAGE UNIT

BATT

ERY

LIMIT

BFW100°C

22.0 kg/cm² g

603-P-512A/B

HV

ATM

20wt% NaOH 45°C

15 kg/cm² g603-T-511

PCV

24

35

36

38

13

37

41 42

40

17

23

18 19

20

22

21

48

52

25

51

49

50

39

43 44 45 46

47

ATM

RAW WATER40°C

4.0 kg/cm² g

26

BATT

ERY

LIMIT

ATM

PLOT DATE:CAD-FILE:

DWG-No.:

PROJECT CODE:

SCALE:

DRAWN

CHECKED

APPROVED

TITLE:

DATE NAMEA-1050 Vienna

Hamburgerstraße 9

Tel.:+43(5) 05899-0

Fax:+43(5) 05899-99

[email protected]

T18-603-PFD-1152-3_HEAT RECOVERY.DWG 06.06.2013

T18-

22.02.2013 FILZ

22.02.2013

22.02.2013

BATIK

KRACHER

PFD-1152603 - BITUROX UNITPROCESS FLOW DIAGRAM

OFF GAS SECTION

PREPAREDISSUE DESCRIPTION DATE CHECKED APPROVED

INDIAN OILCORPORATION LIMITED

Barauni Refinery

53 27

28

ATM

NC

CONTROL SECTION

603-V-505

TO VENTS

xx

BATIKFIRST ISSUE 22.02.2013 KRACHER FILZREV 0

NUHSBAUMERFIRST ISSUE - REVISION 04.04.2013 KRACHER FILZREV 1

NUHSBAUMERFIRST COMPLETE ISSUE 19.04.2013 KRACHER FILZREV 2

NUHSBAUMERFINAL ISSUE OF BDEP 26.07.2013 KRACHER FILZREV 3

603-X-502

603-X-503

603-X-504

DESIGN

GRA

DE V

G30

17992.4 17992.4 17992.4 947.0 18939.4 23086.6 4336.6 18750.0 18750.0 1064.7 700.0 50.3 314.4 91.9 801.1 801.1 42.8 60992.7 60992.7 10000.0 10000.0 1000.0 60000.0 2126.6 44.3 2082.3 462.7 525.2

90.0 203.8 216.3 90.0 210.0 250.0 250.0 250.0 150.0 40.0 40.0 40.0 40.0 145.0 145.0 80.0 45.0 63.8 50.0 50.1 52.8 50.0 50.5 100.0 100.0 100.0 40.0 60.08.0 4.0 3.0 5.0 3.0 23.0 23.0 18.0 15.0 11.0 11.0 11.0 11.0 0.4 6.4 5.0 2.0 9.5 8.5 8.5 4.0 2.0 3.0 22.0 22.0 22.0 4.0 0.0

0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

1321.8 200.0 2411.2 2461.5 2369.6 250.0 2619.6 51.1 4471.0 4471.0 1169.8 3301.2 7141.7 7141.7 7141.7 7141.7 7141.7 6498.9 2019.8 2019.8 2019.8 2064.2 62.5

60.0 180.0 180.0 145.0 145.0 180.0 148.4 40.0 20.0 80.0 80.0 80.0 850.0 465.9 413.2 309.7 280.0 63.8 203.5 197.5 300.0 275.0 111.47.5 3.5 2.0 0.1 0.1 3.5 0.0 1.8 0.0 0.060 0.010 0.010 0.010 0.007 0.005 0.002 0.0 0.0 16.0 13.5 13.5 13.5 0.5

1.000 1.000 0.998 0.997 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 0.180

LIQUID STREAM NAMEMASS FLOW (kg/h)


VAPOUR FRACTION (mol. fr.)GAS STREAM NAMEMASS FLOW (kg/h)


VAPOUR FRACTION (mol. fr.)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60

1

0Rev.

Rev.

BITUROX PROJECT

Projekt Nr.

project code T18

Dokument Nr.

Document No.

T18-603-

UTS-LV002

Seite

page1 of 4

Kunde

client

IOCL, Barauni

Refinery

Anlage


Kunden Nr.

client code

Utility and Chemical Summary

Final Issue of BDEP 26.07.13/Kracher 26.07.13/Foltyn 26.07.13/Filz

First Complete Issue 19.04.13/Kracher 19.04.13/Foltyn 19.04.13/FilzBeschreibung

description


prepared, date/name


checked, date/name


approved, date/name

PROJECT No:T18

CLIENT IOCL

PROJECT: 603 - BITUROX UNIT

LOCATION: BARAUNI REFINERY, INDIA

Doc No.: T18-603-UTS-LV002

Rev. :

Date: 26.07.13

T P

°C kg/cm2 g UNIT min. norm. max.

Feed t/h 18.0

1 LP-Steam in 150/180/320 3.0 /3.5/5.0 t/h 0.91 1.00 0.0506 t/t 1.5

2 LP Condensate out 90/100-120/165 2.5 /3.0/ 4.5 t/h 0.37 0.41 0.0206 t/t

3 MP-Steam Export out 250/275/330 13.5 t/h 1.70 1.87 0.0944 t/t 2.3

4 MP-Steam (consumed) ISBL / in 250/275/330 9.0/10.0/12.0 t/h 0.30 0.33 0.0167 t/t 0.5

5 MP-Steam (generated) ISBL 250/275/330 13.5 t/h 2.00 2.20 0.1111 t/t 2.3

6 MP-Condensate out 150-180 8.5/9.5/11.5 t/h 0.30 0.33 0.0167 t/t

7 Demineralized Water in 15 / 40 / 45 4.0 /4.0/ 6.0 m3/h 2.10 3.00 0.1167 m3/t 5.0

8 MP Boiled Feed Water in 100 22 m3/h 2.00 2.20 0.1111 m3/t 2.4

9 Cooling Water Supply in - / 33 / 35 3.8 /4.0/ 4.5 m3/h 0.00 0.00 0.0000 m3/t

10 Cooling Water Return out - / 42 / 45 2.0 /2.0/ 2.5 m3/h 0.00 0.00 0.0000 m3/t

11 Raw Water in 15 / 40 / 45 4 m3/h 0.50 0.00 0.0278 m3/t 1.0

12 Service Water in 15 / 40 / 45 4 m3/h 0.00 0.00 0.0000 m3/t 5.0

13 Process Air ISBL / in 2) 45 - 60 7.0-7.5 Nm3/h 1000.00 1200.00 55.5556 Nm3/t

14 Plant Air in 15 / 40 / 45 4.0 /6.5/ 7.0 Nm3/h 0.00 0.00 0.0000 Nm3/t 2000.0

15 Instrument Air in 15 / 40 / 45 4.0 /6.5/ 7.0 Nm3/h 15.00 18.00 0.8333 Nm3/t 36.0

16 Nitrogen in 15 / 40 / 45 4.0 /5.5/ 6.5 Nm3/h 0.00 0.00 0.0000 Nm3/t 1000.0

17 Fuel Gas in 15 / 40 / 45 1.0 / 1.8/ 2.5 Nm3/h 50.00 62.50 2.7778 Nm3/t 200.0

18 NaOH 20 wt% (Fresh Caustic Soda) in 45 15 t/h 0.05 0.06 0.0028 t/t

19 Flushing Oil Supply in 40 7 m3/h 0.00 0.00 0.0000 m3/t 20

20 Flushing Oil Return out 40-150 7 m3/h 0.00 0.00 0.0000 m3/t 20

Voltage

(V)

Frequency

(Hz) UNIT min. norm. max. Power Installed

21 El. Power in 415 50 kW 694.4 764.0 38.6 kWh/t 1051

UTILITY AND CHEMICAL SUMMARY

603 - BITUROX UNIT

1 - Final Issue of BDEP

DESCRIPTION

Consumption ContinuouslyB.L. Conditions

No.

Consumption

discontinuously

1)

Battery Limit Conditions & Total Consumption

1) During Start up, Shut down,…

2) in: alternativ supply of process air from the refinery

in/out Consumption per ton

feed

Consumption per ton feed

Pörner Ingenieurgesellschaft A-1050 Vienna Hamburgerstraße 9 Tel.: 0043-1-58 990-0

2 of 4

PROJECT No: T18

CLIENT IOCL




Rev. : 1 - Final Issue of BDEP

Date: 26.07.13

EQUIPMENTRev

No.

kg/h kg/h kg/h kg/h kg/h kg/h kg/h m3/h m3/h Nm3/h Nm3/h Nm3/h Nm3/h kg/h kW kW kW

603-AC-501 Wash Water Cooler 3 0 22.0 66.0 56.1

603-AG-501 Biturox Agitator 1 0 90.0 90.0 72.0

603-E-501A/B/C Feed/Product Heat Exchanger 3 0 0.0 0.0

603-E-502 Slop Oil Cooler 1 0 0.0 0.0

603-E-503 MP-Steam Generator I 1 0 0.0 0.0

603-E-504 MP-Steam Superheater 1 0 0.0 0.0

603-E-505 MP-Steam Generator II 1 0 0.0 0.0

603-E-506 Combustion/Quench Air Preheater 1 0 0.0 0.0

603-EE-507 Feed Heater 1 0 300.0 300.0 300.0

603-FD-501A/B Combustion/Quench Air Blower 1 1 22.0 44.0 18.7

603-IN-501 Incinerator 1 0 250.0 50.0 10.0 10.0 10.0

603-KA-511A/B Process Air Compressor 1 1 1000.0 150.0 300.0 135.0

603-P-501A/B Product Pump 1 1 50.0 45.0 90.0 36.0

603-P-502A/B Slop Oil Pump 1 1 100.0 60.0 5.0 10.0 4.0

603-P-503A/B Wash Water Circulation Pump 1 1 45.0 90.0 36.0

603-P-511A/B Process Water Pump 1 1 18.5 37.0 14.8

603-P-512A/B NaOH Dosing Pump 1 1 10.0 10.0 2.20 4.4 1.8

0.0 0.0

0.0 0.0

0.0 0.0

0.0 0.0

0.0 0.0

0.0 0.0

0.0 0.0

0.0 0.0

0.0 0.0

0.0 0.0

TOTAL (NORMAL OPERATION) 410.0 70.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 1000.0 0.0 0.0 50.0 0.0 1041.4 684.4

NOTES: 1) Estimated Values (to be verified during detail engineering)


CONSUMPTION

NitrogenBFW

sta

nd

by Process

Air

Raw

Water

Demin.

Water

Cooling

WaterLP Steam

El. Power

total 1)

El. Power in

operation 1)REMARKS

Fuel

Gas

Instrumen

t

AirDESCRIPTION

in o

pe

ratio

n

LP CondMP-

SteamMP-Cond

NaOH

20%

El. Power

per Eq. 1)

MP-

Steam

Generated

Pörner Ingenieurgesellschaft A-1050 Vienna Hamburgerstraße 9 Tel.: 0043-1-58 990-0

3 of 4

PROJECT No: T18

CLIENT IOCL





Date: 26.07.13

EQUIPMENT

Rev

No.

kg/h kg/h kg/h kg/h kg/h kg/h kg/h m3/h m3/h Nm3/h Nm3/h Nm3/h Nm3/h kg/h kW kW kW

FROM PREVIOUS SHEET 410.0 70.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 1000.0 0.0 0.0 50.0 0.0 1041.4 684.4

603-R-501 Biturox Reactor 1 0 200.0 1500.0 0.0 0.0

603-SK-501 Stack 1 0 0.0 0.0

603-T-511 NaOH Storage Tank 1 0 50.0 50.0 0.0 0.0

603-V-501 Knock Out Drum 1 0 50.0 50.0 100.0 0.0 0.0

603-V-502 MP-Steam Drum 1 0 2000.0 2000.0 0.0 0.0

603-V-503 Scrubber 1 0 500.0 50.0 0.0 0.0

603-V-504 Blow Down Cooler 1 0 0.5 0.0 0.0

603-V-505 Fuel Gas Knock Out Drum 1 0 0.0 0.0

603-V-511 Process Water Receiver 1 0 0.0 0.0

603-V-512 Process Air Receiver 1 0 0.0 0.0

603-X-501 Blow Down Pit 1 0 50.0 50.0 0.0 0.0

0.0 0.0

0.0 0.0

0.0 0.0

0.0 0.0

0.0 0.0

1 0 15.0 0.0 0.0

1 0 300.0 300.0 0.0 0.0

1 0 150.0 150.0 0.0 0.0

1 0 10.0 10.0 10.0

TOTAL (NORMAL OPERATION) 910.0 370.0 300.0 300.0 2000.0 2) 2100.0 2000.0 0.0 0.5 1000.0 15.0 0.0 50.0 50.0 1051.4 694.4

NOTES: 1) Estimated Values (to be verified during detail engineering)

2) ISBL

DESCRIPTION

El. Power

in

operation

1)

NaOH

20%

Raw

Water

Lighting, Control room,...

sta

nd b

y

Process

AirLP Steam

Control Valves, Open/Close Valves,…

Heat tracing by MP Steam

Heat tracing by LP-Steam

LP CondCooling

Water

MP-

SteamMP-Cond

El. Power

per Eq. 1)

El. Power

total 1)


CONSUMPTION (Continue page)

in o

pera

tio

n Fuel

GasREMARKS

MP-

Steam

Generate

d

Demin.

Water

Instrumen

t

Air

NitrogenBFW

Pörner Ingenieurgesellschaft A-1050 Vienna Hamburgerstraße 9 Tel.: 0043-1-58 990-0 Fax.: 0043-1-58 990-99

4 of 4

2

1

0Rev.

Rev.

BITUROX PROJECT

Projekt Nr.

project code T18

Dokument Nr.

Document No.

T18-603-

EQL-LV003

Seite

page1 of 7

26.07.13/Foltyn 26.07.13/Filz

Kunde


Anlage


Kunden Nr.

client code

05.04.13/Kracher 05.04.13/Foltyn 05.04.13/Filz

Equipment List

Final Issue of BDEP 26.07.13/Kracher

Beschreibung

description


prepared, date/name


checked, date/name


approved, date/name

19.04.13/Kracher 19.04.13/Foltyn 19.04.13/Filz

First Issue


PROJECT No: T18

CLIENT IOCL



Doc No.: T18-603-EQL-LV003


Date: 26.07.2013

CAPACITY EST. WEIGHT

ID (mm) TL-TL (mm) (kg/cm2 g) (°C) (m3) (kg)

603-R-501 Biturox Reactor 1 V PFD-1151 2800 130006.0 /

FV @ 250°C350

86

(39 NET)

Guiding Cylinder:

ID = 1980 mmCS 2

603-V-501 Knock Out Drum 1 V PFD-1151 1400 60002.0 /

FV @ 180°C350 9.9

Deflector Plate

DemisterCS 2

603-V-502 MP-Steam Drum 1 H PFD-1152 min.1200 HOLD18.0 /

FV @ 210°C250 HOLD CS

603-V-503 Scrubber 1 V PFD-1152600/1400

2)

6300

3)0.49 330 HOLD SS 2

603-V-504 Blow Down Cooler 1 H PFD-1152 min. 750 HOLD 0.49 130 HOLD CS

603-V-505 Fuel Gas Knock Out Drum 1 V PFD-1152 600 1800 7.0 75 HOLD CS

603-V-511 Process Water Receiver 1 V PFD-1151 1400 3500 0.49 150 5.9 CS

603-V-512 Process Air Receiver 1 V PFD-1151 1600 5000 10,0 150 11.1 CS

EQUIPMENT LIST

REACTORS / VESSELS / DRUMS

Rev.TAG DESCRIPTION Qty H or V PFD MOC

Package Unit 603-U-501


1) Design conditions for steam

out: 0.5 kg/cm2 g / FV and

190°C.

DESIGN COND. 1)REMARKS

DIMENSIONS

1) Design conditions for steam

out: 0.5 kg/cm2 g / FV and

190°C.


2) jet pipe/vessel

3) total height of vessel

INTERNALS

Pörner Ingenieurgesellschaft A-1050 Vienna Hamburgerstraße 9 Tel.: 0043 5 05 899-0 Fax.: 0043 5 05 899-99

Page 2 of 7

PROJECT No: T18

CLIENT IOCL





Date: 26.07.2013

DUTY Shell ID TUBES MTD U AREA WEIGHT

Medium (kg/cm2 g) (°C) MOC Medium (kg/cm2 g) (°C) MOC (MM kcal/h) (mm) (°C) (kcal/m2.h.K) (m2) (kg)

603-AC-501 Wash Water Air Cooler 1 PFD-1152 Air Cooler air --- --- ---wash

water12 150 SS 0.868 --- 2

603-E-

501A/B/C

Feed/Product Heat

Exchanger3 PFD-1151

Shell and Tube

AES

vacuum

residue33 300 CS product 30 300 CS 1.022 1190

Nu. = 908; Lenght = 6096 mm

OD = 25.4 mm; Thk. = 2.769 mm

Pitch = 31.75 mm; Layout = 90

44.4 19.83 x

441.72

603-E-502 Slop Oil Cooler 1 PFD-1151Shell and Tube

BES

wash

water12 150 SS slop oil 11 175 SS 0.028 360

Nu. = 56; Lenght = 2438 mm

OD = 25.4 mm; Thk. = 2.108 mm

Pitch = 31.75 mm; Layout = 90

55.6 62.0 10.9 2

603-E-503 MP-Steam Generator I 1 PFD-1152Heating Coils in

Flue Gas Channelflue gas

BFW /

steam

18.5 /

FV @ 211°C350 CS 1.148

603-E-504 MP-Steam Superheater 1 PFD-1152Heating Coils in


MP-

Steam17.0 380 CS 0.150

603-E-505 MP-Steam Generator II 1 PFD-1152Heating Coils in


BFW /

steam

18.5 /

FV @ 211°C350 CS 0.288

603-E-506Combustion/Quench Air

Preheater1 PFD-1152

Heating Register in

Flue Gas Channelflue gas air -0.1 - 0.5 330 CS 0.0875

603-EE-507 Feed Heater 1 PFD-1151 Electrical Heatervacuum

residue33 300 CS --- --- --- --- 0.257 HOLD ---

EQUIPMENT LIST

HEAT EXCHANGERS

Rev.REMARKS

Also used as start up heater;

El. Power: 300 kW



TAG DESCRIPTION Qty PFD TYPE OF HE

El. Power: 3 x 22 kW

3 shells in series


SHELL DESIGN COND. TUBE DESIGN COND.



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PROJECT No: T18

CLIENT IOCL





Date:

TEMP DENSITY PRESS. HEAD DP CAPACITY MOTOR POWER

(°C) (kg/m3) (m) (kg/cm2) (m3/h) (kW)

603-P-501A/B Product Pump 2 PFD-1151 Rotary 180-270 850-950 --- 20.0 26 45

603-P-502A/B Slop Oil Pump 2 PFD-1151 Rotary max.145 750-850 --- 6.0 1 5

603-P-503A/BWash Water Circulation

Pump2 PFD-1152 Centrifugal 60-65 985 90 9.36 80 45 2

603-P-511A/B Process Water Pump 2 PFD-1151 Centrifugal 15-45 1000 110 11.0 5 18.5

603-P-512A/B NaOH Dosing Pump 2 PFD-1152Membrane

Positive Displ. 30-45

1214-

120516.6 2.0 0.01-0.06 2.2 2

Rev.REMARKSTYPE OF PUMPPFD MOC

EQUIPMENT LIST

26.07.2013

PUMPS

TAG DESCRIPTION Qty

- External PSV set pressure = 27.0 kg/cm2 g


- Stop and Go operation between two switch points

LSH and LSL

- Equiped with frequency controller



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PROJECT No: T18

CLIENT IOCL





Date: 26.07.2013

DP CAPACITY (each) MOTOR POWER

(kg/cm2) (Nm3/h) (kW)

603-FD-501A/BCombustion/Quench Air

Blower2 1 PFD-1152 HOLD 0.06 5000 22

603-KA-511A/B Process Air Compressor 2 HOLD PFD-1152 HOLD 7.5 1380 150

EQUIPMENT LIST

BLOWER & COMPRESSOR


- Max. Air Rate required = 1250 Nm3/h

- Stand-by Capacity = 100%

NO. OF

STAGESRev.

El. Power is related to Compressor and

air cooler.

REMARKSSPECIFICATIONS

- Operating Temperature = 80°C

- Design Temperature = 100°C

TAG DESCRIPTION Qty PFD TYPE


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PROJECT No: T18

CLIENT IOCL





Date:

(kg/cm2 g) (°C)

603-AG-501 Biturox Agitator 1 PFD-11513-Impeller

with 6-Blades

6.0 /

FV @ 250°C350 SS

603-IN-501 Incinerator 1 PFD-1152

Horizontal

combustion

chamber

with lining

0.011000 (lining)

250 (steel)CS

603-SK-501 Stack 1 PFD-1152Vertical Doubble

Pipe Stack0.005 330

CS (outer pipe)

SS (inner pipe)

603-X-501 Blow Down Pit 1 PFD-1151Concrete pit with

flat metal coveratm. 300 Cover: CS

EQUIPMENT LIST

MISCELLANEOUS

- Impeller Diameter = 780 mm

- Agitator Rotation Speed = 172 rmp

- Motor Power = 90 kW

Rev.PFD MOCType of Equipment SPECIFICATIONS Remarks

26.07.2013

TAG DESCRIPTION Qty


DESIGN COND.

Combustion Chamber:

- ID = 1350 mm; Lenght = 7500 mm

- Combustion Temperature = 850°C

- Retention time = 1.5 sec

- Burner Design Duty = 1.72 MM kcal/h


1) acc. to TEG1-1031-001 calculated

stack height is 10 m. But the minimum

stack height shall be 60m.

- Concrete pit, bottom with slope and

with flat metal cover

- LP-Steam Heating Coil

- Flue Gas Velocity < 20 m/s

- ID = > 400 mm

- Height = 60 m 1)

- Lenght = 3500 mm

- Width = 2400 mm

- Height = 1500 mm

- Capacity = 12.6 m3


Page 6 of 7

PROJECT No: T18

CLIENT IOCL





Date: 26.07.2013

EST. WEIGHT

ID (mm) HEIGHT (mm) (kg/cm2 g) (°C) (kg)

603-T-511 NaOH Storage Tank 1 PFD-1152Flat Bottom &

Conical Fixed Roof2200 4300 17 (14 NET) atm. 150 SS

- Storage Capacity: 2 weeks

- External Heating Coils (LP-Steam)

Rev.TAG DESCRIPTION Qty PFD TYPE CAPACITY (m3)

DIMENSIONSMOC

DESIGN COND.REMARKS

EQUIPMENT LIST

TANKS


Page 7 of 7

BITUROX PROJECT

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Pörner Ingenieurges.m.b.H. / T18-603-EFS-CV008-1_Efluent Summary.doc

Efluent Summary

(Waste Stream Specification)

Flue gas from 603-SK-501

Slop Oil from 603-V-501

Waste Water from 603-V-503

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Pörner Ingenieurges.m.b.H./ FILE: T18-603-EFS-CV008-1_Efluent Summary.doc

Table of content

1 GENERAL ..................................................................................................................................... 3

2 OFF GAS TREATMENT................................................................................................................ 3

3 SLOP OIL ...................................................................................................................................... 4

4 WASTE WATER ........................................................................................................................... 5

5 FLUE GAS ..................................................................................................................................... 6

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1 GENERAL

The source of the waste streams in the Biturox® Unit is the off gas from the Biturox

® process.

The off gas is coming out of the reactor 603-R-501 at a temperature of 180°C and consists mainly

of nitrogen and water (see Fig. 1).

The pollutants formed in the Biturox® Process have inorganic and organic character:

Sulfurous gases (SO2, SO3, H2S) and

Oxides of carbon (CO and CO2)

Organic pollutants consist of the hydrocarbons stripped out of the liquid product during the blowing process.

The representative analysis of the off gas out of the reactor 603-R-501 is shown in Fig. 1.

OFF GAS FROM REACTOR

N2 Vol.% 30 – 40

H2O Vol.% 55 – 65

O2 Vol.% 1 – 2

CO Vol.% 0.03 – 0.05

CO2 Vol.% 0.5 – 1.5

C1-C4 Vol.% < 0.20

C5+ (average C16) Vol.% < 0.8

H2S vppm 200 – 500

SO2 vppm 10 – 50

Fig. 1

2 OFF GAS TREATMENT

Because of the waste components in the off gas comming from the reactor 603-R-501 the treatment line consisting of the foolowing steps is designed:

Cooling of the off gas to 145°C to recover a part of the hydrocarbons by means of injection water

Separation of the condensed liquid part – slop oil - in the knock out drum 603-V-501

Combustion of the off gas in the incinerator 603-IN-501 at 850°C to burn the waste components (H2S, R-SH, hydrocarbons and CO) to SO2, CO2 and H2O.

Heat recovery to utilize the heat of the flue gas (from 850°C to 280°C) that is used for generation of MP steam in 603-E-503 to 603-E-505 and combustion air preheating in 603-E-506.

Washing of the flue gas in the scrubber 603-V-503 to remove SO2/SO3 by means of caustic soda at 60-70°C.

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After scrubbing the flue gas is led via Stack 603-SK-501 to the atmosphere with a temperature of 60-70°C.

Based on the described off gas treatment following waste streams arise out of the Biturox® Unit:

FLUE GAS

WASTE WATER

SLOP OIL (defined as by-product)

The estimated characteristic of the slop oil, waste water and the flue gas is shown in Fig. 2- Fig. 4.

The prognosis is based on the following:

Mass and Heat Balance for production of the design grade VG30 (norm case) and the alternative grades VG10, VG20 and VG40 considered in the range (see the Mass & Heat Balances in the documents T18-603-HMB-CV002 to CV005).

Laboratory measurements of SO2 and H2S in the off gas during the pilot tests carried out for Biturox projects.

Concentrations of NOx, C-org, CO and TSP (solids) in the flue gas are based on the requirements for incinerator.

3 SLOP OIL

Fig. 2 shows the estimated slop oil stream arizing from the Biturox® Unit. The produced slop oil

consists of the recovered hydrocarbons stripped from the Biturox® reactor. It can be used in the

refinery as fuel or can be added to a similar oily type of feed or intermediate product streams for further processing or treatment.

ESTIMATED SLOP OIL

Stream Source 603-V-501

Balance point in PFD 14 (continuously separated) 16 (disc. pumped to B.L.)

Type of stream

Liquid hydrocarbons condensed from reactor off gas

Temperature °C max. 80

OPERATING CASE NORM 1)

RANGE

Molecular weight average kg/kmol 315 300 - 350

Mass Density kg/m3 840 (@ 80°C) 820-860

Kin. Viscosity @ 80°C cSt 6 (@ 80°C) 5-10

Water content mass % 0 max. 2

Flash Point (acc. ASTM D93) °C 120

Slop oil amount (continuous) kg/h 90 10 - 150

Fig. 2

1) Related to the design product VG30

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4 WASTE WATER

Fig. 3 shows an estimated waste water from the Biturox® Unit.

ESTIMATED SPENT CAUSTIC

Waste Source Scrubber 603-V-503

Stream number in the process flow diagram 22

Type of waste Spent caustic

Temperature °C 50

OPERATING CASE NORM 1)

RANGE

Volume Flow 2)

m3/h 1 0.5-1.5

pH --- 8 7.5 - 9

Absorbed SO2 as Sulfur kg/h 3.7 max. 4.6

Na2SO4 kg/h 16 max. 20

Salt concentration 3)

mass % 1.6 max. 2.0

Fig. 3

1) Related to the design product VG30 2) Adjusted by fresh water addition 3) Related to specified flow of waste water

The waste water has to be led to the further treatment step – neutralization.

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5 FLUE GAS

Fig. 4 bellow shows estimated gaseous emissions from the Bitumen Unit calculated for production of road bitumen using Biturox

® Process.

ESTIMATED GASEOUS EMISSIONS

CHARACTERISTIC UNIT VALUE

Emission Point --- Stack 603-SK-501

Balance point in PFD --- 48

Type --- Flue Gas

OPERATING CASE: --- NORM 1)

RANGE

Temperature °C 63.8 60-70

Flue Gas Flow:

Mass Flow kg/h 6500 < 7000

Norm. Volume Flow Nm3/h 5460

Norm. Volume Flow DRY Nm3/h 3650

Act. Volume Flow m3/h 6720

Flue Gas Composition: range

N2 Vol.% 65.1 60 - 70

O2 Vol.% 6.9 6 – 10

H2O Vol.% 23.5 19 – 25 5)

CO2 Vol.% 4.5 4.2 – 4.7

Total Vol.% 100.0

SO2 2)

vppm 20 < 25

kg/h 0.31 < 0.39

mg/Nm3 57 < 70

Molecular Weight kg/kmol 26.7

Mass Density kg/m3 0.97

Estimated Pollution 1)

3) 4)

Pollutants vppm mg/Nm3 kg/h

SO2 max. 32.6 93.2 0.31

NOx (as NO2) max. 100 3)

205 0.69

CO max. 35 3)

43.7 0.15

C-org. (as C3H8) max. 18.7 10 3)

0.03

TSP (solids) max. - 20 3)

0.07

H2S max. 1 3)

1.5 0.005

Fig. 4

1) Related to the design product VG30 2) The values for SO2 has been calculated considering 96% absorption efficiency for flue gas desulphurisation in the scrubber

up stream the stack. 3) The values for NOx, CO, C-org., TSP and H2S introduce the required limits for incinerator vendor for the flue gas from the

stack. 4) The concentration values for the pollutants (vppm and mg/Nm

3) are referred to 6 Vol. % O2 and dry conditions.

5) Saturated concentration at actual temperature

1

0Rev.

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First Complete Issue 19.04.13/Enz 19.04.13/Foltyn 19.04.13/FilzBeschreibung

description


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Final Issue of BDEP 26.07.13/Enz 26.07.13/Foltyn 26.07.13/Filz

Electrical Data

Kunde


Anlage


Kunden Nr.

client code

BITUROX PROJECT

Projekt Nr.

project code T18

Dokument Nr.

Document No.

T18-603-

ELD-LN001

Seite

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PROJECT No:T18

CLIENT IOCL



Doc No.: T18-603-ELD-LN001


Date: 26.07.2013

No. Description Equip. Number P & ID P/[kW] 1) Un/ [V] In/[A] cos phi f/[Hz] [rpm] IP class EEx- Class Starter type Rev.

1 Wash Water Cooler 603-AC-501 PID-1164 3 x 22 415 50 IP55 EEx e IIC T3 direct starter 1

2 Biturox Agitator 603-AG-501 PID-1155 90 415 50 IP55 EEx e IIC T3 direct starter 1

3 Feed Heater 603-EE-507 PID-1154 300 415 50 IP55 EEx e IIC T3 direct starter

4 Combustion/Quench Air Blower 603-FD-501A PID-1162 22 415 50 IP55 EEx e IIC T5 fuse

5 Combustion/Quench Air Blower 603-FD-501B PID-1162 22 415 50 IP55 EEx e IIC T5 fuse

6 Process Air Compressor 603-KA-511A PID-1159 150 415 50 IP55 EEx e IIC T3 fuse

7 Process Air Compressor 603-KA-511B PID-1159 150 415 50 IP55 EEx e IIC T3 fuse

8 Product Pump 603-P-501A PID-1158 45 415 50 IP55 EEx e IIC T3 direct starter

9 Product Pump 603-P-501B PID-1158 45 415 50 IP55 EEx e IIC T3 direct starter

10 Slop Oil Pump 603-P-502A PID-1161 5 415 50 IP55 EEx e IIC T3 direct starter

11 Slop Oil Pump 603-P-502B PID-1161 5 415 50 IP55 EEx e IIC T3 direct starter

12 Wash Water Circulation Pump 603-P-503A PID-1164 45 415 50 IP55 EEx e IIC T3 direct starter

13 Wash Water Circulation Pump 603-P-503B PID-1164 45 415 50 IP55 EEx e IIC T3 direct starter

14 Process Water Pump 603-P-511A PID-1160 18.5 415 50 IP55 EEx e IIC T3 direct starter

15 Process Water Pump 603-P-511A PID-1160 18.5 415 50 IP55 EEx e IIC T3 direct starter

16 NaOH Dosing Pump 603-P-512A PID-1165 2.2 415 50 IP55 EEx e IIC T3 frequency drive

17 NaOH Dosing Pump 603-P-512B PID-1165 2.2 415 50 IP55 EEx e IIC T3 frequency drive

18

19

20

21

22

23

24

25

ELECTRICAL DATA603 - BITUROX UNIT

1) Estimated values; to be verified during detail engineering by vendor


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