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PARCO-Mid Country Refinery

STUDY REPORT ON A-200 LIMITATIONS

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Prepared By:

Mirza Humayun Arshad/M. Usman Saeed


GC/VB Units

Reviewed By:

Abdul Nasir Khan


C.E. Process Section-II

Approved By:

Amar Abbas
Manager Process

Date of Issue:

June 4, 2016

Distribution:
CC:

GM Refinery
Manager TSD

Gas Concentration Unit

PARCO-Mid Country Refinery


STUDY REPORT ON A-200 LIMITATIONS

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Objective:
The objective of this report is to study limitations of GASCON at higher refinery load and local
crude processing.

Introduction:
Gas Concentration unit has capacity to process unstabilized naphtha flow of 146m 3/hr (100%
AL, Case-I) and 178m3/hr (70/30% UZ/MU, Case-II). The unit is designed to process Off-gases
and Unstabilized Naphtha received from various process units (CDU, VBU, D-Max & NHT).
Gases received are compressed at 411-C1 and routed to ATU after absorption at absorption
section (Primary Absorber & Sponge Absorber) for maximum recovery of C3/C4 (LPG).
Unstabilized Naphtha coming from process units is process to separate LPG & stabilized
naphtha. LPG is routed to A-500 & Stabilized Naphtha is R/D to NHT & stabilized naphtha
tankage.
Liquid hydrocarbon from 411-V3 (High Pressure Receiver) is routed to 411-V6 (Stripper) where
H2S & lighter components are stripped out. Stripper (411-V6) feed enters the column above the
top tray. Stripping action is facilitated through re-boilers (411-E8/E9) at the bottom of the
column. Heat is supplied from the debutanizer bottoms and MP steam. Stripper bottoms stream
is fed to the Tray 10 of debutanizer (411-V7). Heat is supplied via Debutanizer reboiler (411E11). The heating oil to the reboiler is the circulating diesel from the Crude Distillation Unit.

Limitations at Debutanizer Reboiler (411-E11):


Now a days GCU is being operated more than 100 % of its design capacity due to lighter crude
charge. It has been observed that 411-V6 stripper tray # 26 temperature and debutanizer (411V7) bottom temperature decreases at higher load of GCU. This affects the operating parameters
of Stripper (411-V6) and Debutanizer bottom (411-V7), resulting in lower IBP of Stabilized
Naphtha i.e. ~430C & C4 contents in Stabilized Naphtha also increases i.e. > 3% (Design: <1%).
Further, in case of high load GCU operation, decreasing trend of Stripper temperature Tray 26 in
Stripper (411-V6) often cause LPG off spec.
Debutanizer Reboiler (411-E11) heat duty limitations is affecting the required reboiling heat to
Stripper (411-V6) via Stripper Reboiler Exchanger (411-E8) and Stripper Reboiler (411-E9)
which ultimately effects GCU high load operation.
Debutanizer Reboiler (411-E11), Stripper Reboiler Exchanger (411-E8) and Stripper Reboiler
(411-E9) heat duties has been calculated on the basis of available data below:
Debutanizer Reboiler (411-E11):

PARCO-Mid Country Refinery


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STUDY REPORT ON A-200 LIMITATIONS


Description

Design

Current
480

309171
0.664
0.667

320160
0.664
0.667

100TI072

263

260

411TI089

224
39.000

236
24.500

7.846

5.1028

Design

Current

143056

143056

0.793

0.793

0.523

0.523

411TI087

186

167

411TI244

Tag No.
411FIC090
411FIC090

Mass Flow (Diesel) m3/hr


Mass Flow (Diesel) kg/hr
Specific Heat (cp @ 2630C)
Specific Gravity (@ 2630C)
Tube Side (Diesel) Inlet Temp (0C)
0

Tube Side (Diesel) outlet Temp ( C)


Hot Fluid Diff. Temperature
Heat Duty (Q=mcp D.T) X 106

Debutanizer Reboiler (411-E8)


Description

Tag No.

Mass Flow (Naphtha) kg/hr


0

Specific Heat (cp @ 142 C)


0

Specific Gravity (@ 142 C)


0

t1=Tube Side Inlet Temp ( C)


0

t2=Tube Side outlet Temp ( C)

149

143

37.00

24.00

3.778

2.723

Cold Fluid Diff. Temperature ( C)


Heat Duty (Q=mcp D.T) X 10

Debutanizer Reboiler (411-E9)


Description
Mass Flow Vapor (Naphtha) kg/hr
Mass Flow Liquid (Naphtha) kg/hr
Specific Heat (cp @ 1420C)

Tag No.

Shell Side (Naphtha) In Temp. (0C)


0

Shell Side (Naphtha)out Temp ( C)


Entahlpy @ 1420C
Cold Fluid Diff. Temperature (0C)
Heat Duty, Q X 10

411TI071

Design
33681
241192
0.689

Current
33681

142

133

164
22.66

147.6
22.66

22.00

14.60

4.930

3.528

241192
0.689

Conclusion:
On basis of above tabulated data, Debutanizer Reboiler (411-E11) heat duty has been reduced
due to suspected fouling of its tubes. The heat duty of Stripper Reboiler Exchanger (411-E8)
and Stripper Reboiler (411-E9) is affected due to their internal fouling in addition to effected
Debutanizer Reboiler (411-E11) fouling.
Recommendations:
Cleaning of Debutanizer Reboiler (411-E11), Stripper Reboiler Exchanger (411-E8) and Stripper
Reboiler (411-E9) is to be carried out in any available shut down opportunity.