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ASSOCIATED UNIT
OPaL ,Dahej
Prepared By : Mr.Y.A.SASTRY ,AGM
: Mr.UDAY KRISHNA
Dy.MANAGER(M)
Naphtha or
Ethane 1 C3/C4 Feed *)
1 Feed BFW
BFW 2
11 C2/C3 Feed *)
2
Convection Section 3
Convection Section 3 Dilution
4 Steam
10
4 Dilution
10
Steam 5
Quenchoil
5 11
6/7 VHP
6/7 Steam
VHP 8
Steam
8
Cracked Gas
Radiant Section
to Primary Oil
Fractionator
Radiant Section Cracked Gas
to Primary Oil
Fractionator
9 *) Only for furnaces flexible
for all feedstocks (ethane,
C3/C4 and naphtha)
9 07-F01 and 08-F01
Section Description
1 Feed Preheater
2 BFW Economiser
Section Description 3 High Temp. Convection 1A (HTC-1A)
4 Dilution Steam Superheater
1 Feed Preheater 1
5 High Temp. Convection 1B (HTC-1B)
2 BFW Economiser 1
6/7 VHP Steam Superheater (incl. BFW Injection)
3 Feed Preheater 2 8 High Temp. Convection 2 (HTC-2)
4 BFW Economiser 2 9 Radiant Coils (PyroCrack 1-1)
5 High Temp. Convection 1 (HTC-1) 10 LQE (Linear Quench Exchanger)
6/7 VHP Steam Superheater (incl. BFW Injection) 11 Quench Fitting
8 High Temp. Convection 2 (HTC-2)
9 Radiant Coils (PyroCrack 1-1)
10 LQE (Linear Quench Exchanger) LEPC 1, DAHEJ PETROCHEMICAL
11 SQE (Secondary Quench Exchanger) PROJECT-6987
Process description
Feed Preheating
Ethane Recycle and Feed - preheated up to 60 °C
ethane is used as a fuel by Ethane Start-up Evaporator 25-E16 for start-up operation
Propane and Butane feedstock - preheated up to 60 °C
Naphtha (LAN+ARN) – preheated up to 80 °C
Furnace
Feed + Process steam cracked gas & decoking gas, VHP steam
01-F01 to 03-F01 (gas cracker) - Secondary Quench Exchangers 01-E02 to 03-E02
04-F01 to 08-F01 (liquid cracker) - direct oil injection into the transfer line w/o SQE
Caustic scrubbing
the sour gases carbon dioxide (CO2) and hydrogen sulphide (H2S) are removed
from the cracked gas by washing the cracked gas with caustic. They are
converted to their respective salts.
2 NaOH + CO2 → Na2CO3 + H2O
2 NaOH + H2S → Na2S + 2 H2O
(< 1 vol ppm) of H2S and CO2 is performed in the lower and the middle
section of the caustic scrubber.
Caustic concentration of approx. 3 % in the upper cycle is adjusted by the water
flow received from the top water wash section.
The back wash water trays on top of the column are charged with BFW to
prevent any entrainment of caustic to the cracked gas compressor.
LEPC 1, DAHEJ PETROCHEMICAL
PROJECT-6987
Spent caustic oxidation
stripped with methane at low pressure to remove light hydrocarbons and
benzene
caustic is mixed with steam and air in a caustic/air/steam mixer.
sulphide and hydrogen sulphide are oxidized to thiosulphate and then to sulphate:
2Na 2 S 1.5O 2 2H 2 O Na 2 S 2 O 3 2NaOH
(100 % conversion )
2NaHS 2O 2 Na 2 S 2 O 3 H 2 O
(100 % conversion )
Na 2 S 2 O 3 2NaOH 2O 2 2Na 2 SO 4 H 2 O
(50 - 70 % conversion depending on residence time)
Excess air separated in the neutralisation drum and vent gas from the caustic
tank are sent to the sour gas flare
Effluent suitable for Biological Treatment to be sent to OSBL (pH 7.0 by
sulphuric acid)
Sulphide content in oxidized effluent is less than 10 mg/l.
COD is reduced to 4,000 – 6,000 mg/l.
C2H6 CH4
H2 Inerts
C2- to
Hydrogenation
C3H6 26 bar
C3H6
+10°C
-38 °C
C3H6
-16 °C
- 38°C
-10 °C C2H4
- 55°C
-24 °C
Water
LP
Steam
86 °C
C3+ to
Depropanizer
C2- from
Deethanizer
Methanol
- 36 °C 65 °C
Startup
Heater
°C
Methanol
80 Vapor Pressure
73 °C
70
60
Product compression
CW CW CW
Ethylene
Product (vap)
LP
C2 Feed C2H4
HP MP
C2H4 C2H4
LP
C3H6
Ethane
Recycle
Ethylene
Product (liq)
PSA Plant
Pure hydrogen is delivered to
- C3-Hydrogenation (PU 52)
- Gasoline Hydrogenation I and II (PU 61 and 64)
- Regeneration of reactors
- Export to BL
C3 Hydrog. (52-R01)
C3 (27 bar, 16 oC) C3= (propylene) C3= Liquid to B.L.
Deethanizer
bottom C3 Splitter (55-T01)
(26 bar, 89 oC) C3 Stripper (54-T01) (18 bar, 43 oC)
(14 bar, 31 oC) C3
C3+
C3- Propane recycle to furnaces
Butadiene
Depropanizer (51-T01) C4 Extraction 1,3-Butadiene to B.L.
(8.6 bar, 15 oC) (58-Y01)
C5 C5 recycle to furnaces
C6 Bz. Ext.
Debutanizer (57-T01) Gasol. Hydrog.I (67-Y01) Benzene to B.L.
(5.6 bar, 68 oC) (61-R01A/S ~ 30
bar 86 oC)
C5+ Pyrolysis Gasoline to B.L.
C7-C8
C7+
C6/C7 Separation (62-T01) Deoctanizer (63-T01)
(1.7 bar, 80 oC) (1.9 bar, 144 oC)
Instrumentation Work
• Three Remote Instrument Buildings (RIB) were constructed at site.
• RIBs are equipped with system/marshalling/power cabinets, UPS systems, MMS and F&G
system
• Honeywell’s DCS System with C300 controllers with Field bus Interface Modules (FIM) and
Process Manager I/O Processers are implemented, to permit centralized operation of plant.
I/O Modules segregated as follows :
o RIB 1 - Furnace(1~8) & Quench Area
o RIB 2 - Compressor & Cold Area
o RIB 3 - BdEU, BzEU & PGHU Area
• ESD and F&G, SIL3 complied and TUV certified. Interfaced with DCS system supplied by
Honeywell.
Analyzer System, CCTV, MMS are other main highlights