INTRODUCTION OF DUNG QUAT REFINERY

DUNG QUAT REFINERY

Site

12 km in the East of No 1 national

road
7 km from Chu Lai Airport, 100km
from Da Nang
38 km from Quang Ngai Town
The Site is bounded by Dung Quat
Bay to the North and Viet Thanh
Bay to the South

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

DUNG QUAT REFINERY

Capacity:

6.5 million tons crude oil/annum (148,000

BPSD)

Feedstock:

Sweet case: Bach Ho Crude Oil

Sour Case: Mix Bach Ho + Dubai (5.5/1)

Capital investment $3.0 billion.

DUNG QUAT REFINERY

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

DUNG QUAT REFINERY

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

DUNG QUAT REFINERY

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

DUNG QUAT REFINERY

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

Crude Distillation Unit (CDU)

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

DUNG QUAT REFINERY

EPC Package 2: Crude Tankage

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

DUNG QUAT REFINERY

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

27 tanks with total working capacity: 397,000 m3 to store and

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

DUNG QUAT REFINERY

EPC Package 4: single point Mooring

(SPM)
Import Crude Oil from Tanker
The SPM Unit comprises of

Single Point Mooring Buoy

Interconnecting hoses
PLEM
submarine pipeline

The SPM buoy is located approximately 3.2km off-shore in

Viet Thanh bay.

DUNG QUAT REFINERY

EPC Package 5A: Beak water

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

DUNG QUAT REFINERY

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

DUNG QUAT REFINERY

EPC Package 7: Administration

Building
Operation Supports
Consists of:

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

DUNG QUAT REFINERY

Products Balance, tons/year
BMD
Propylene
108,333
LPG
286,000
Gasoline A92 (unlead) 1,407,667
Gasoline A83 (unlead) 534,667
Kerosene/Jet A1
282,333
Auto Diesel
2,084,333
Industrial Diesel
1,327,000
FO
115,667
Product Total
6,146,000
Lost and consumed
354,000
Total
6,500,000

BMG
157,000
343,667
1,952,333
718,000
219,667
2,115,667
430,000
177,000
6,113,000
386,667
6,500,000

MMD
111,000
276,333
1,534,333
407,667
219,667
2,225,333
252,000
1,131,667
6,158,000
342,000
6,500,000

MMG
147,666
307,000
2,081,667
515,667
219,667
2,321,000
30,000
466,000
6,088,667
441,333
6,500,000

DUNG QUAT REFINERY

PROCESS UNITS

DUNG QUAT REFINERY

RFCC
Gas Plant

LTU

LPG

PRU

LPG
LPG

LN

NHT

HN

Treated HN

CCR

Mix C4
C3

Reformate

Propylene
LPG
Mogas 92/83

Treated RFCC
Naphtha

SPM

Kerosene

CDU

Crude
Tankage

Note

Splitter

Note

Stabiliser

LPG + FG

Jet A1

KTU

Kerosene

LGO
HGO
RFCC Naphtha

Residue

NTU

LCO

RFCC
DCO

Note : Stabiliser and Naphtha Splitter are parts of CDU

Auto/Ind. Diesel
FO

Crude Distillation Unit (CDU)

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

Desalter
Fired Heater
Main Fractionators & associated Strippers
Stabilizers and Splitters

Crude Distillation Unit (CDU)

Product Streams:

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

To RFCC Gas Plant

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

Naphtha Hydrotreating Unit

(NHT)

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

protect CCR catalyst by Hydrotreating

Naphtha Hydrotreating Unit

(NHT)
A single fixed bed catalyst reactor

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

Continuous Catalytic Reformer

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

Continuous Catalytic Reformer

(CCR)
Systems:

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

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

Kerosene Treating Unit

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

Kerosene Treating Unit

(KTU)
System:

NAPFINING: Naphthenic acid extraction

MERICAT II: Mercaptan oxidation
AQUAFINING: Water washing

Remove Na+

Salt Dryer: Remove trace of free water and dry

kerosene below saturation
Clay Filter: Remove remaining solids, moistures, soaps,
emulsions and surfactant

Kerosene Treating Unit

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

Residue Fluid Catalytic Cracker

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

Residue Fluid Catalytic Cracker

(RFCC)
Operation mode:

Max Gasoline
Max Distillate

System:

Reactor and 2-stage catalyst regenerator

Main Fractionator
Gas Recovery Section (Gas Plant)

RFCC Gas Plant

Process the following streams:

CDU Stabilizer Off-gas

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

Duty:

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

Residue Fluid Catalytic Cracker

(RFCC)
Product streams:

Unsaturated off-gas: To Refinery Fuel gas

Mix C3/C4:
To LTU
Naphtha:
To NTU
Light Cycle Oil (LCO):
To Diesel Blending
Decant Oil (DCO):
To Fuel Oil Blending

Other streams:

Sour water:
Rich amine:

To SWS
To ARU

LPG Treating Unit (LTU)

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

LPG Treating Unit (LTU)

Treating reagents: NaOH 200 Be

Catalyst:
MEA 50%wt
Treated LPG: To PRU/Storage
Spent caustic: To CNU

RFCC Naphtha Treating Unit

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

RFCC Naphtha Treating Unit

(NTU)
Catalyst:
Cobalt Phthalocyanine
Treating reagents: NaOH 200 Be

Treated naphtha: To Mogas Blending

Spent caustic: To CNU

Sour Water Stripper (SWS)

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

Amine Regeneration Unit

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

Spent Caustic Neutralization Unit

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

FIBER-FILM Contactor

Spent Caustic Neutralisation Unit

(CNU)
Caustic Deep Neutralization:

Neutralize by sulphuric acid 96% and remove acid gases,

naphthenic, phenolic acids from the brine

Neutralization and Phenol Extraction:

Neutralize to pH=7 and extract phenol from acidic brine by

solvent (Kerosene)

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

H2SO4 96%, NaOH 50Be,

To ETP
To SRU
To Fuel Oil Blending

Propylene Recovery Unit

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

Propylene: To Propylene Tankage/PP

Plant
C3/C4:
To LPG Blending

Propylene Recovery Unit

(PRU)
System:

C3/C4 Splitter: Remove C4s from LPG

Propane/propylene splitting facility:

De-ethaniser: Release product lighter than propylene

Propane/Propylene splitting column

Propylene purification:

Carbonyl sulfide removal

Arsenic, phosphorous and antimony removal

Sulfur Recovery Unit (SRU)

Licensed unit
Capacity:

Sweet case:
Sour case:

3 tons/day
36 tons/day

Duty: Recover Sulfur in Refinery off-gas to

meet environment protection requirements
(SO2 concentration)
Product: Sulfur Powder

Polypropylene (PP) Plant

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

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

Service water to users at Refinery and PTF

Make-up supply to freshwater cooling system
Make-up supply to Refinery potable water system
Make-up supply to dematerialized water system
Make-up supply to Refinery fire water system

Steam and Condensate

Provides:

HP, MP, LP Steam to and subsequent distribution

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

Steam and Condensate

Comprise of:

Steam producing equipment

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

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

Cooling Water
Comprise of:

Cooling Water Circulation Pumps

Plate Heat Exchanger
Expansion Tank
Expansion Tank Oil Skimmer
Chemical Dosing Package

Sea Water Intake

Provides:

Seawater to Power Station for once-through cooling in

Vacuum Condensers
Seawater to seawater/freshwater exchanger for cooling
the closed loop cooling water system

Sea Water Intake

Consists of:

Seawater Intake box (located offshore)

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

Hypochlorite for seawater chlorination is generated

on site by electrolysis of seawater

Plant and Instrument Air

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

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

Nitrogen System
Provides:

Gaseous nitrogen to process users in normal operation

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

Nitrogen System
Comprises of:

Nitrogen Generation Package

Liquid Nitrogen Storage
Vaporisation Package

Method of generation:

Cryogenic Air Separation

Nitrogen purity: 96% volume

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

CDU charge heater

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

Fuel Gas
Other users:

Refinery Flare System

Product Tankage (Flare system, steam regenerators)

Comprises of:

Fuel Gas Mix Drums

Vaporiser Package

Vaporise LPG/Propylene for use at Startup,disposal of

LPG/Propylene off-spec., low FG pressure or emergency event

Fuel Gas collection/distribution pipework

Refinery Fuel Oil

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

2 Refinery Fuel Oil Storage Tanks

Fuel Oil Pumps
Fuel Oil Heater
Supply and return pipework

Refinery Fuel Oil

Source of Refinery Fuel Oil:

In normal operation: Decant Oil (DCO) from

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

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

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

500 Be (49.5 wt%)

200 Be (14.4 wt%)

Made up by dissolving solid caustic in demin. water

Made up by diluting 500 Be caustic in demin. water

50 Be (3.4 wt%)

Made up by diluting 500 Be caustic in demin. water

Power Generation &

Distribution
Provide:

Electrical Power to Refinery and all associated

facilities
Steam and condensate to Refinery

4 15 MW Steam Turbine TurboGenerators

Ability to import/export power from/to
EVN grid

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

1 Off-spec Propylene Sphere

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

1
2
1
2

Light Naphtha Tank

Mix C4s Spheres
HGO Tank
LCO Tanks

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

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

Flushing Oil
Unit number: 055
Provides:

Flushing Oil for process units and Offsite pipework

Contains catalyst fines

Pour point is higher than minimum daily ambient temp.

Flushing Oil for SPM loop

Consists of:

Facilities for flushing process units

Separated facilities for flushing SPM loop

Flushing Oil
Source of Flushing Oil:

For Process units and Offsite pipework:

LCO from LCO Intermediate Storage Tank

For SPM loop:

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

SPM loop is flushed immediately before and after

each transfer operation

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

Flare System
Consists of:

Refinery Flare System

Product Tank Farm Flare System

Each Flare System comprises of:

Main Flare Stack

Sour Gas Flare Riser (handle all discharges
containing H2S at levels higher than 10%
vol.)

Effluent Treatment Plant

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

Refinery ETP

Primary, secondary and tertiary treatment

facilities to remove oils, solids and organics

Product Tankage ETP

Primary treatment for removing oil and solids

Effluent Treatment Plant

(ETP)
Products stream:

Treated effluent: discharged to the sea

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

Fire Water System

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

Refinery and nearby facilities

Product Tank Farm, Truck Loading and Jetty
Topsides

Firewater was taken from the sea at Jetty