PT PERTAMINA (PERSERO)

REFINERY UNIT II DUMAI

Hydrocracker Complex (HCC)

HCU - HANS

Presented for OJT BPST 23

November , 2012
Agenda

Topic
▪ HCC Introduction
▪ HCU
▪ Brief of Hydro cracking
▪ Reactor
R t Section
S ti

▪ Fractionation Section
▪ Hydrogen
y g Plant

▪ Amine Gas Treating & LPG Recovery

▪ Nitrogen Plant
▪ Amine Gas Treating & LPG Recovery

| 1
HC COMPLEX IN CONFIGURATION

*) Based on Configuration After Revamp HCU 2007

|
HYDROCRACKER COMPLEX

1 2

3
4
5

| 3
Agenda

Topic
▪ HCC Introduction
▪ HCU
▪ Brief of Hydrocracking
▪ Hydrocracker
H d k RU II

▪ LBO Integration
▪ Hydrogen
y g Plant

▪ Amine Gas Treating & LPG Recovery

▪ Nitrogen Plant
▪ Amine Gas Treating & LPG Recovery

| 4
HydroCraking Concept

FEEDSTOCK PRODUCT
HEAVY & DIRTY CLEAN & LIGHT

High MW Hydrocarbons Low MW Hydrocarbon

High Sulfur Low Sulfur `
High Nitrogen Low Nitrogen
High Oxygen Low Oxygen
High Unsaturated
Saturated Hydrocarbons
Catalytic Iso-parrafin
` Process Naphthens

HIGH YIELD
Hydrogenation
High yields
Cracking
C4+ ~ 115 vol%
vol%̀`
C5+ ~ 110 vol%

| 5
HydroProcessing Parameters

psig bar g
3000 207

HydroCracking
y g
2000 138
psig
ssure

Black
Prere,

1000 70 Distillate Oil

Pressu

Hydro- HDT
treating

500 Naphtha
Hydrotreating

0
Severity
(Lower LHSV)
(Higher Temperature)

|
Hydrocracking Chemistry

• Hydrotreating reactions to remove

contaminants
t i t
• Hydrocracking reactions promoted by elevated
temperature and pressure
• Direct C-C bond breaking to form lower
molecular weight paraffins
• Large consumer of hydrogen
• Coking
• Contaminant poisoning

|
Hydrocracking Reaction Mechanisms

H + H H H
R c c
R c H H
c + H R c
c H H
H 3. Diffusion to
H H R
acid sites

4. Crack H H H
R c R 5. Hydrogenation

c c H H
H H H
ACID SITE 2. Olefin METAL SITE
formation
1.
Dehydrogenation

H
H

Hydrocracking Science and Technology; Julius Scherzer, A.J. Gruia. \ Organic Chemistry 5th addition TW Graham Solomons.

|
Hydrocracking Unit – Desired Reactions

• Treating to remove contaminants

• Adding hydrogen to unsaturated
hydrocarbons
• Cracking to obtain desired boiling
range products

Treating Cracking
S lf
Sulfur
Nitrogen To desired
endpoint
Olefins
O
Oxygen To desired
Metals product
slate

|
Reasons for Hydrotreating

• Cracking catalyst will • Saturation of Olefins and

work more effectively Aromatics
* Organic
Og nitrogen
g *Aromatics
Aromatics must be
severely affects hydrogenated prior to
hydrocracking catalyst cracking
• Product stability
• Treating catalyst is less
expensive • Requires lower
temperature rise in
cracking beds
* Hydrotreating reactions
are highly exothermic

|
Agenda

Topic
▪ HCC Introduction
▪ HCU
▪ Brief of Hydrocracking
▪ Hydrocracker
H d k RU II

▪ LBO Integration
▪ Hydrogen
y g Plant

▪ Amine Gas Treating & LPG Recovery

▪ Nitrogen Plant
▪ Amine Gas Treating & LPG Recovery

| 11
Hydrocracker Unibon (HCU) RU II
* DESIGN * Typical
yp Operating
p g Condition & Yield
UNIT 211/211 Operating Condition

▪ Licensor : UOP Deskripsi Design

Pasca
Revamping
d M3/jam
Feed,
F /j 185 209
▪ EPC : Technidas Reunidas, H2/HC, Nm3/M3
Spain ƒ Fresh Feed 1300 1300
ƒ Recycle Feed 1200 1200
▪ Two Identical Train Tekanan, Kg/cm2
ƒ V8
V-8 176
ƒ
▪ Type : ƒ
V-9
V-10
28
7.8
- 2 Stage ƒ V-12 13
- Debutanizer first ƒ V-14 0.6
ƒ V-20
V 20 2.0
▪ Capacity ƒ V-22 3.5
Design : 27,9 MB/D Conv. Temperatur, oC
92 % ƒ Peak Temp V-1 Bed 1 < 454 < 454
ƒ Peak Temp V-1 Bed 2 < 454 < 454
ƒ Peak Tempp V-2 < 454 < 454
Revamp (2007) : 31
R 31.5
5 MB/D ƒ Peak Temp V-3 < 427 < 427
Conv. 85.7 ƒ ∆T V-1#1, V-1#2 , V-2 < 28 < 28
ƒ ∆T V-3 < 14 < 21
▪ Feed ƒ Outlet H-2 340
HVGO & HCGO ƒ Outlet H-3 370
Injeksi wash water, % vol on 3-8
3-8
feed

| 12
PFD HCU 211/212

| 13
Typical Yield
* Typical Yield
100% C
Capacity
it 113% CCapacity
it
No Yield , UOP Chevron New Catalyst
% Volume DHC-8 Catalyst Configuration
1 C3-C4
C3 C ((LPG)
G) 2.60
60 0.46
0 6 5 3
5.13
2 Light Naptha 4.60 7.69 10.47
3 Heavy Naptha 9.80 20.74 13.69
4 Light Kerosene 9.50 12.05 8.81
5 Heavy Kerosene 15 10
15.10 17 68
17.68 14 60
14.60
6 Diesel 63.70 42.82 44.92
7 UCO (bottom) 4.30 10.28 14.30
Total 109.60 111.72 111.92

* Product Specification
Smoke Flash
Distilasi (oC) Pour Point
Product API Point Point
IBP EP (mm) (oC) (oC)
L. Naptha 73 52 91 - - -
H. Naptha 59.5 95 134 - - -
L. Kerosene 57 149 177 27 - -
H. Kerosene 42.5 177 310 - 63 14
Diesel Oil 38 310 371 - 57 7

Go to backup
| 14
CONFIGURASI KATALIS

Fresh Feed Recycle Feed

CT-50
CT-30 CSM 1/4
TK-711
TK-551
UOP
HC-215 LT

CSM 1/8
CSM 1/4
CSM 3/4 UOP
DHC-8
CSM 1/4

UOP
HC-215 LT

CSM 1/8 CSM 1/8 CSM 1/8

CSM 1/4 CSM 1/4 CSM 1/4
CSM 3/4 CSM 3/
CS 3/4 CSM 3/
CS 3/4

211/212 V-1 211/212 V-2 211/212 V-3

Menagement HPNA

|
HPNA MANAGEMENT

A.
A Hot Flash Separation (pemisahan) 1
B. HPNA Adsorption (penyerapan HPNA) 2
C. Indirect Recycle (feed dikembalikan secara tidak langsung)
D. Split Shell Fractionator

LVGO

Distillate

HC
VGO
VT Rx
HPS F

HS

Pitch
HPNA
Indirect Adsorption
p
System Split Shell
Recycle
Fractionator

Menagement HPNA

|
Hot Flash Separation (pemisahan)

Fungsi hot separator untuk memisahkan antara liquid

R
Reactor
t (PNA) dan gas. Kemudian gas dilewatkan E-4 dan
Hot Separator liquid dialirkan ke seksi fraksinasi. Dengan demikian
Light Ends fluida yang lewat ke E-4 diharapkan bebas PNA.
CFE to Product
Condenser

HPNA-Rich Liquid
to Fractionation

Hot separator (V-101) berfungsi

untuk memisahkan fase liquid
dan vapor outlet reactor.

Hot Flash Separation

|
Hot Flash Separation (pemisahan)

Hot Flash Separation

|
HPNA Adsorption

CBA ((carbon Bed Adsorber)) berfungsi

g
untuk menyerap HPNA yang terkandung
dalam recycle feed. Sehingga recylce
sudah tidak mengandung HPNA. Dengan
demikian
de a dea
deaktivasi
as rate
a e katalis
a a s dapa
dapat
diperlambat.

HCU 211/212 memiliki CBA (carbon

Bed Adsorber) 2 unit per train
(103/104) yang dioperasikan secara
seri (leag/lag).

|
Agenda

Topic
▪ HCC Introduction
▪ HCU
▪ Brief of Hydrocracking
▪ Hydrocracker
H d k RU II

▪ LBO Integration
▪ Hydrogen
y g Plant

▪ Amine Gas Treating & LPG Recovery

▪ Nitrogen Plant
▪ Amine Gas Treating & LPG Recovery

| 20
HCU REVAMP CONCEPT
ORIGINAL DESIGN REVAMP DESIGN *

HCU 211/212 (DESIGN) HCU 211/212

Capacity 55,600 B/D Capacity 63,000 B/D

Yield Base Yield Base
UCO 9,000 B/D | Conversion 85.7%
HVU 110 (DESIGN) HVU 110 (REVAMP 2007)
Capacity 92,600 B/D Capacity 106,000 B/D

LBO PLANT

C
Capacity
it 11 700 B/D (D
11,700 (Design)
i )
Product
Lube Base Gr III

LUBE UCO HVGO

9,000 B/D 9,000 B/D 54.0 MB/D
PATRA SK HCU Revamp HVU Revamp
| 21
Benefit Of HCU Revamp – LBO Complex

Main Factors
▪ Generate Margin – UCO Selling
Profit ▪ Profit to Pertamina via PT PatraSK as JVC

▪ Increase Reliability by equipment improvement

Reliability

▪ Lower Conversion – Higher

g Life Time

Catalyst
Lifetime

| 22
HCU – LBO INTEGRATION

18,900
Unit : B/D
31,500
Naphtha

FX
2nd
1st
Rx Diesel
Rx
Fuel Gas

23,400

10 900
10,900 12 500
12,500

31,500 18,900 VDU CDW

25,000 9,000
b/d 9,000 b/d
FX b/d
1st 2nd
Rx Rx

23 400
23,400 Lube
12,500
10,900

8,000 8,000
16,000

| 23
Agenda

Topic
▪ HCC Introduction
▪ HCU
▪ Brief of Hydrocracking
▪ Hydrocracker
H d k RU II

▪ LBO Integration
▪ Hydrogen
y g Plant

▪ Amine Gas Treating & LPG Recovery

▪ Nitrogen Plant
▪ Amine Gas Treating & LPG Recovery

| 24
Hydrogen Plant Integration

| 25
HYDROGEN PLANT CONFIGURATION
Feed Satuan Desain
Feed Gas nm3/jam 13419
Produk nm3/jam 43914
DP Reformer Kg/cm2 2.53
(2)
S/CReformer
Ratio mol/mol Min 4.26 (3) HTSC
((Top
p Eq.
fired,168
K2CO3 tube)) % wt 27
Tube Reactor
Purity –Endothermic
H2 % > 97
CO+CO2 ppm < 30
CH4 + H2O →CO + 3 H ∆H298 oC = + 49.3
kcal/gmol (4) LTSC
CO + H2O → CO2 + H2 ∆H298 oC = - 9.80 kcal/gm g

(5) Benfield System

(1) Hot Desulfurizer
(V-6A/B Series)

(6) Methanator

26 |
BASIC KNOWLEDGE

Page 27 |
Page 28 |
CATALYST Characteristic

Page 29 |
Why Catalyst Need to be Activated ?

Page 30 |
Page 31 |
REFORMER OVERVIEW

| 32
REFORMER OPERATING PROFILE & CATALYST
Date Design 16 Juni 2010
Catalyst age,
age months
Production rate, Nm3/h 43,522 44,057
Reported:
Feed gas, Nm3/h 13,409 12,777
Steam rate, kg/h 41,041 36,064
p
Exit temperature, oC 835.0 795.0
Exit pressure, kg/cm2 17.37 17.12
Inlet S/G ratio 3.81 3.31
Inlet S/C ratio 4.28 4.32
DP measured, kg/cm2 2.53 1.07
CH4 leakage, %v 2.21 3.74
ATE oC
ATE, C 03
0.3 13 4
13.4

Loaded
Jenis Proporsi Volume,
Posisi Density Shape
Katalis (% V) m3
(kg/m3)
Top Layer G-91 LDP 60 % 7.312 880 10 holes, ring
Bottom Layer C-11-9-02 40 % 10,968 1280 Ring

Page 33 |
Agenda

Topic
▪ HCC Introduction
▪ HCU
▪ Brief of Hydrocracking
▪ Hydrocracker
H d k RU II

▪ LBO Integration
▪ Hydrogen
y g Plant

▪ Amine Gas Treating & LPG Recovery

▪ Nitrogen Plant
▪ Amine Gas Treating & LPG Recovery

| 34
OBJECTIVE’s
Treating &
Reco er
Recovery ƒ Memproses off gas dari unit-unit proses dengan menghilangkan
Gas racun/impuritis yang bersifat korosif (H2S) untuk dijadikan feed
Recovery Hydrogen Plant dan Fuel Gas

▪ Memproses LPG dari unit-unit proses agar sesuai spesifikasi yang

LPG
dipersyaratkan
Recovery

▪ Melakukan treating H2S & Oksigenat melalui proses Amine (MEA)

Treating absorption - desorption

Hydrogen Plant ▪ Memenuhi

M hi spesifikasi
ifik i yang diperlukan
di l k sebagai
b i feed
f d H2 Pl
Plantt
Feed Preparation – Sulfur / H2S Content
– Pressure

| 35
BLOCK DIAGRAM

| 36
AMINE TREATING
Flow Process

• Feed gas dari unit proses bergabung dengan gas dari separator 410 V-3 masuk ke KO drum
410 V-1 (pemisahan air dan Gas)
• Gas dialirkan ke kompresor 410 C-1 dan masuk ke finfan cooler 410 E-13 dan didinginkan di
Absorption trim cooler 410 E-1 bergabung dengan MP gas dari HC Unibon
Section • Uap yang telah terpisah di 410 V
V-3
3 masuk ke off gas amine Absorber bagian bawah 410 VV-5
5
• Lean amine masuk dari bagian atas absorber
• MEA mengalir kebawah berlawanan arah dengan proses gas dimana H2S diabsorb dan
produk keluar pada bagian top absorber (Treated Gas)

• LPG dari unit proses masuk ke LPG amine absorber 410 V-6 untuk menghilangkan H2S
• Absorben menggunakan MEA dengan proses counter current
• LPG yang dihasilkan memiliki konsentrasi Butane dan propane minimum 97.5%
• Lean amine disirkulasikan dengan menggunakan 410 P-1 A/B
LPG recovery • LPG dari absorber 410 V-6 dipisahkan pada setler 410 V-18 selanjutnya bergabung dengan
section LPG ex PL II masuk ke LPG caustic wash 410 V-11 (menghilangkan entrainment H2S)
• LPG di masukkan ke sand filter 410 V-12
V 12 (menghilangkan entrainment caustic)
• LPG diproses di Deethanizer 410 V-13, ethane dikembalikan ke 410 V-3 dan LPG produk
dialirkan ke TK
• RichAmine ex 410 V-5&V-6 mengalir ke Rich amine flash drum 410 V-7 (memisahkan HC
yang terikut ke Rich amine)
• Lean
L amine
i masukk ke k flash
fl h drum
d b i atas
bagian t dengan
d proses counter
t currentt dengan
d Ri h
Rich
amine, Gas yang terpisah dialirkan ke FG
SWOT • Rich amine dari V-7 dipanaskan dan alirkan ke amine stripper 410 V-8 untuk memisahkan
Gas H2S
• Vapor dari top kolom dimasukkan ke stripper 410 V-9 dan selanjutnya gas dibuang ke flare
system.
• Lean amine disirkulasikan dengan menggunakan 410 P-1 A/B melalui filter 410 F-1 A/B

| 37
Seksi Amine Gas Absorsi

|
Seksi Amine Regenerasi

|
Agenda

Topic
▪ HCC Introduction
▪ HCU
▪ Brief of Hydrocracking
▪ Hydrocracker
H d k RU II

▪ LBO Integration
▪ Hydrogen
y g Plant

▪ Amine Gas Treating & LPG Recovery

▪ Nitrogen Plant
▪ Amine Gas Treating & LPG Recovery

| 40
NITROGEN

Concerns Remarks
Inert Gas for :
ƒ Storage tank blanketing
1 N2 Purposes ƒ Purging
ƒ Catalyst transfer – CCR, etc
ƒ DGS (Dry Gas Seal – Buffer Gas)
• Cryogenic liquefaction
2
Production • Distillation
• Pressure swing adsorption (PSA)
• Membrane separation

ƒ Udara mengandung 78.03% Nitrogen (N2)

3 ƒ Specific gravity N2 gas Æ 0.967
Characteristic
ƒ N2 boiling point -195.8°C at atmospheric pressure
(O2 b
boiling
ili point
i t -183oC
183 C att atmosferik
t f ik pressure))
ƒ Tidak berwarna, tidak berbau, dan tidak memiliki rasa

SOURCE: Team analysis | 41

NITROGEN CRYOGENIC RU II

Design Data

Capacity Product N2 : 500 Nm3/h (ref. cond. 0oC, 1013 mbar)

Nitrogen purity (+Noble gas) : min. 99.999 vol. %
O
Oxygen content
t t : max. 2.8
2 8 ppmv
Dewpoint : o
-40 C (at 1 atm.) or better
Product Quality :

K
Komponen U it
Units N2 Plant
Pl t (Existing)
(E i ti )
Nitrogen %vol (min) 99.9
Carbon Dioxide ppm (max) 20
Carbon Monoxide ppm ((max))
pp 20
Other Carbon
ppm (max) 2
Compound
Chlorine ppm (max) 5
Water ppm ((max))
pp 20
Hydrogen ppm (max) 5
Oxygen ppm (max) 2.8
Noble gases ppm (max) Remainder

| 42
NITROGEN Consumption

SOURCE: Team analysis | 43

SIMPLIFIED BLOCK DIAGRAM

|
Agenda

Topic
▪ HCC Introduction
▪ HCU
▪ Brief of Hydrocracking
▪ Hydrocracker
H d k RU II

▪ LBO Integration
▪ Hydrogen
y g Plant

▪ Amine Gas Treating & LPG Recovery

▪ Nitrogen Plant
▪ Fuel Gas System

| 45
FUEL GAS SYSTEM (920)

Concerns Remarks
Gathering & Stabilize Supply Of Fuel Gas for:
•Blowdown system DCU #140 (FI_394)
FGS •Excess g
gas dari MUGC HCU #211/212 ((FR_626))
1 Purposes •Release gas dari HP Separator HCU:V-8 #211/212 (FR_132)
•LPG make up dari tangki

Intake ggas ex unit dialirkan menujuj Fuel Gas Drum V-1 sebagai g
2 Operation
O ti pengatur pressure FG kyang akan dialirkan ke unit. Fuel gas yang
Principle dialirkan ke unit memiliki min pressure 3.5 kg/cm2. Jika total gas ex
unit yang dikirim ke FGS menurun, maka make up LPG dilakukan
untuk menjaga sistem tetap beroperasi normal (cascade antara
pressure V-1, opening control FC_25 dan FI_1700). LPG untuk
make up ini diambil dari tangki (T-32 atau T-33).
Pengoperasian FGS secara garis besar adalah sebagai berikut:

SOURCE: Team analysis | 46

DCS – Fuel Gas System (Unit 920)

| 47
*) GOE (Government of Entitlement) average bulan Okt-Nov-Des 2012 sebesar 133,81 MBCD.

PT PERTAMINA (PERSERO)
REFINERY UNIT II DUMAI

| 48
BACKUP

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