DETAILED PROCESS DESCRIPTION

GAS CONCENTRATION UNIT: The Gas concentration unit is designed to recover C3/C4 LPG and to produce a stabilized Naphtha feed to the Naphtha Hydrotreating unit. Gases from various process units are compressed in compressor section and routed through an absorption section to maximize the recovery of LPG. Off gas fr om the absorption section will be sent to fuel gas treater. Unstabilized Naphtha from various process units is routed through the distillation section to separate unstabilized Naphtha and LPG. The recovered LPG and Stabilized Naphtha are sent to LPG merox unit and Naphtha Hydrotreating Unit, respectively. The removal of lighter ends from the liquid by distillation process is called stabilization. Enough of the light ends are removed to make a stabilized liquid i.e. the liquid with low enough vapor pressure to permit its storage in ordinary tanks without vapor loss. OPERATION OF GAS CONCENTRATION UNIT: The operation of Gas Concentration Process Unit comprises of the following sections: 1. Compressor Section
a) High Pressure Separator b) Two Stage Centrifugal Compressor

2. Absorption Section a) Primary Absorber b) Sponge Absorber 3. Distillation Section a) Stripper Section b) Debutanizer Section

DETAILED PROCESS DESCRIPTION 1) Compressor Section:

The feed source to the compressor section of the Gas Concentration Unit consists of: Gas from Crude Distillation Unit (CDU) Gas from fractionator receiver at visbreaking unit. Gas from flash fractionator receiver at the Diesel MAX unit. Gas from stripper receiver at the Diesel MAX unit. Gas from stripper at Naphtha Hydrotreating Unit. Un-stabilized Naphtha from Crude Distillation Unit (CDU) Un-stabilized Naphtha from diesel max Product Fractionator Un-stabilized Naphtha from fractionator at visbreaking unit. Un-stabilized Naphtha from Flash Fractionator at Diesel MAX unit

All incoming gas streams flow into a two stage centrifugal compressor via the compressor suction cooler and the compressor suction drum. Mists separated and accumulated in the compressor suction drum is manually drained out and sent to the Crude Distillation Unit (CDU). Gas streams is pressurized to 3.7 to 8.2 kg/cm 2 in the first stage and then it enters the second stage of compressor via inter-stage cooler and compressor inter-stage suction drum and compressed to 17.1 kg/cm2(g). This pressurized gas mixes with the Stripper overhead vapor, the incoming liquid streams, and Primary Absorber bottoms. The combined stream is cooled in the high pressure cooler and sent to the high pressure r e c ei v e r. Li qui d se pa r at ed and ac c u m ul at ed i n t h e compressor inter-stage suction drum is pumped to the high pressure separator feed stream.

High Pressure Receiver:

High pressure inlet streams are as follows: Compressed gas from compressor. Un-stabilized Naphtha from Diesel Max Unit Un-stabilized Naphtha from fractionator at visbreaking unit. Unstabilized Naphtha from Crude Distillation Unit.
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DETAILED PROCESS DESCRIPTION

Stripper overhead vapor. Primary absorber bottom liquid.

These all streams enter the high pressure receiver where water is drained out. Overhead gases from the high pressure separator are sent to the absorption section and liquid stream is pumped to t he st ri pper .

2) Absorption Section:
Primary Absorber: The first column in the absorption process is the primary absorber. Primary absorber contains bubble cap trays. In the primary absorber stabilized naphtha from debutanizer bottom is used as lean oil. The C3/C4 rich gas stream from the high pressure receiver enters the column below the bottom tray. The absorption process is exothermic and to improve C3 and higher ends recovery, liquid from one or more of the middle trays is pumped through an intercooler and returned to tray above. The intercooler reflux is returned to the column at approximately the same temperature as the stabilized naphtha entering the top of the column. The primary absorber rich oil from the bottom of the column returns to the high pressure receiver, where most of the light material recovered is pumped with the heavier material to the stripper for further processing. Sponge Absorber: The second column in this section is sponge absorber. This column is smaller in size and filled with packing that allows intimate contact between liquid and gas streams. The overhead of the primary absorber is directed to the bottom of sponge absorber, while circulating diesel from crude unit used as lean oil enters top of the column. The rich diesel at bottom of the column is returned to crude unit. Gases leaving the sponge absorber are sent to Amine treating Unit. The process principle of the sponge absorber is the same as the primary absorber, in that the overhead gas from the primary absorber is intimately contacted with the heavier liquid to recover the C3/C4 material that was not absorbed in the primary absorber. The main differences between the primary and the sponge absorber are
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DETAILED PROCESS DESCRIPTION

the internals of the column and the type of lean oil used. The sponge absorber has a packed section instead of trays for the intimate contact between the down flowing liquid and upward flowing gases. The sponge absorber does not have a reflux flow as the primary absorber has a demister blanket installed near the top of the column. The lean oil used in the sponge absorber is circulating diesel from the crude distillation unit. After passing down the column the diesel is collected in the bottom of the column where it is returned to the crude distillation unit as rich oil on level control at the bottom of the sponge absorber. The lean gas is sent to the amine treating unit and then to the refinery fuel gases system after passing through a pressure control valve maintaining a constant pressure on the entire absorption system.

3) Distillation Section:
Stripping Section: The liquid hydrocarbon stream from the high pressure receiver consists mostly of C 3 and higher hydrocarbons; however it also has smaller fractions like methane ethane etc., and is pumped to the stripper to strip off light ends (lighter than C3) plus the bulk of hydrogen sulfide. Stripper feed enters the column above the top tray. Feed to the stripper is heated using the debutanizer bottoms. The stripping action is provided by the reboiler present at the bottom of the column and heat is provided to rebolier by the debutanizer bottom stream and Medium Pressure Steam. The unstabilized naphtha flows downward through the column. The vapors stripped from the unstabilized naphtha leave the top of the stripper and pass through the high pressure cooler into the high pressure receiver. The stripper bottoms under level control on the bottom of the stripper are pressured to the debutanizer column. Debutanizer Section: The feed to the debutanizer is the stripper bottom stream which contains C 3, C4 and naphtha. The debutanizer feed enters the column in the top half of the column. Heat is supplied via reboiler using circulating diesel from crude unit as heating oil. The lighter components (C3 /C4 ) of the feed vaporize and are carried overhead where it is condensed and stored in debutanizer receiver and sent to LPG Merox Unit for further
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DETAILED PROCESS DESCRIPTION

processing. Some portion of the overhead product can be returned to the tower as reflux. The debutanizer bottoms leave the column and after passing through one of the stripper reboiler and the stripper feed preheater, the flow is divided into two flows. The first flow is directed on flow control to top of the primary absorber as lean oil or sent to the stabilized naphtha storage tank. The second flow is directed on level control from the bottom of the debutanizer to the Naphtha Hydrotreating Unit.

Feed and Products:

Feeds: The gas feed to the Gas Concentration Process Unit are as follows: Gas from Crude Distillation Unit (CDU) Gas from fractionator receiver at visbreaking unit. Gas from flash fractionator receiver at the Diesel MAX unit. Gas from stripper receiver at the Diesel MAX unit. Gas from stripper at Naphtha Hydrotreating Unit. ` Un-stabilized Naphtha from Crude Distillation Unit (CDU) Un-stabilized Naphtha from diesel max Product Fractionator Un-stabilized Naphtha from fractionator at visbreaking unit. Un-stabilized Naphtha from Flash Fractionator at Diesel MAX unit

Products: A mixed C3/C4 LPG Stream is recovered and sent to LPG Merox unit. Debutanizer naphtha is sent to Naphtha Hydrotreating Unit for further processing. Off gas from the absorber is routed to the fuel gas treater at the Amine treating Unit.

DETAILED PROCESS DESCRIPTION

CHARACTERISTICS OF UNSTABILIZED NAPHTHA Property TBP Cut Point, C Gravity, API (Sp. Gr.) Sulphur Wt. % Nitrogen Wt. % Paraffin, Vol. % Olefin, Vol. % Napthenes, Vol. % Aromatics, Vol. % 100% Light Arabian Crude Oil 21-150 64.72 0.85 0.00 33.3 38.1 22.7 5.8

Feed composition incase of 70/30% Upper Zakhum/Murban Crude Mix:

Feed Gas From Stripper From Flash fractionator 3.05 1.91 102.68 From Fractionator From Stripper From Net gas comp.

H2O NH3 H2S H2 C1 =C2

1.54 20.01 41.94 12.9 -

1.32 3.81 2.47 17.2 0.78

0.93 TRACE 1.33 36.81 13.26 -

3.57 -

DETAILED PROCESS DESCRIPTION

C2 =C3 C3 =NiC4 =iC4 iC4 nC4 =C5 iC 5 nC5 CP 22DMB 23DMB 2MP 3MP nC6 MCP CH BZ Naphtha 39.27 28.28 3.95 6.7 1.97 1.6 0.89 0.26 0.41 0.07 0.59 45.88 45.55 3.33 19.92 3.31 0.35 2.85 0.14 0.1 0.4 0.15 2.49 0.65 0.15 2.35 10.29 2.9 7.7 2.54 0.99 2.59 0.57 0.31 0.55 2.55 7.48 2.28 0.3 20.64 5.74 2.11 0.01 0.02 0.02 0.14 0.07 0.11 0.01 TRACE 0.01 TRACE 2.56 21.82 3.93 13.01 4.11 5.84 0.16 8.07

DETAILED PROCESS DESCRIPTION

Kg-mole/h Flow Rate, kg/h 160.39 4514 235.26 7581 56.58 1946 91.29 2493 62.27 3575

DETAILED PROCESS DESCRIPTION

Feed Unstabilized Naphtha From Crude column H2O NH3 H2S H2 C1 =C2 C2 =C3 C3 =NiC4 =iC4 iC4 nC4 =C5 iC 5 nC5 CP 22DMB 23DMB 2MP 1.57 2.7 34.29 21.8 93.16 64.17 99.53 4.95 From Prod. fractionator 0.05 0.07 0.08 0.44 1.36 1.99 2.11 3.58 From Fractionator From Flash fractionator 0.2 0.23 2 3.89 12.39 2 16.18 6.7 0.65 6.75 0.51 0.44 2.02

0.46 0.01 0.31 0.04 0.77 0.61 1.84 1.64 0.56 1.94 1.24 0.56 1.25 -

DETAILED PROCESS DESCRIPTION

3MP nC6 MCP CH BZ Naphtha Kg-mole/h Flow Rate, kg/h 749.52 1071.7 104808 1.54 2.77 0.37 7.16 21.52 1923 27.9 39.1 3827 0.81 16.71 5.07 1.68 59.2 137.44 12195

Product composition is as follows:

Product LPG Stabilized naphtha Off gas

H2O NH3 H2S H2 C1 =C2 C2 =C3 C3 =NiC4 =iC4 iC4

TRACE 0.47 TRACE 0.27 3.1 122.04 4 0.42 31.95

0.02 TRACE TRACE 0.15 0.01 0.81

1.75 23.25 80.92 144.59 0.76 99.07 0.3 7.53 0.01 TRACE 0.08

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DETAILED PROCESS DESCRIPTION

nC4 =C5 iC 5 nC5 CP 22DMB 23DMB 2MP 3MP nC6 MCP CH BZ Naphtha Kg-mole/h Flow Rate, kg/h 145.1 0.19 2.04 0.32 TRACE TRACE TRACE 309.92 16259 15.23 10.98 69.12 110.65 5.44 0.02 0.54 6.86 1 20.7 8.76 1.81 0.45 839.39 1091.94 113570 0.69 0.01 0.15 0.06 TRACE TRACE TRACE TRACE TRACE TRACE TRACE TRACE 359.19 6715

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