RESIDUE FLUID CATALYTIC

CRACKER

TECHNICAL ENGLISH IMPROVEMENT PROGRAM

TABLE OF CONTENT

Section 1 - General Description

Section 2 - Process Flow Description

Section 3 - Fire & Gas Systems

Section 3 - Equipments

Section 6 - Quality Control

Section 9 - HSE

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Figure 1
UNIT 15
Figure 1

UNIT 15
General: Purpose of unit
To convert various reduced crudes to lower boiling, high value
products, primarily C3rC4 ,LPG, Gasoline and Light Cycle Oil (LCO)

 How?
Vapour phase chemical reactions with specialized FCC cracking
catalyst
Heat for the cracking process is supplied by the hot regenerated
catalyst
Regenerated catalyst vaporizes the finely atomized oil feed and
sets the stage for the cracking process
Vaporization and cracking reactions occur in the reactor riser in
about 2 sec.
By-products: fuel gas, slurry oil and coke

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General: Purpose of unit
Fractionation section:
 Fractionates the vapour product from the reaction
section into clarified oil, LCO and heavy naphta

Gas Recovery Section

Process the fractionator overhead liquid streams to
produce light gasoline, amine treated fuel gas and
amine treated LPG

Max Gasoline Operation: heavy naphta is combined

with the light gasoline
Max Distillate Operation: heavy naphta combined with
LCO products
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General: Duty of unit
 RFCC is designed for 2 atmospheric residues from Bach Ho and
Bach Ho/Dubai crudes RFCC is designed for 2 atmospheric
residues from Bach Ho and Bach Ho/Dubai crudes mixtures

 Design Capacity:
3,256,000 tones per annum of Bach Ho 370+°C CDU
residue, equivalent to 69,700 BPSD (with 8 000 hours of
RFCC operation per year)

 The RFCC is also designed to process both the Bach Ho and sour
crude mix residues in2 modes of operation:
Maximize RFCC Naphtha (Max Gasoline)
Maximize LCO (Max Distillate)

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General: Duty of unit
The RFCC is designed to process 100% hot feed direct
from the CDU and is capable of processing up to 100%
cold feed from storage.

RFCC Gas Plant can also process the following

streams:
CDU Stabilizer Off-gas
CDU LPG rich stream

The RFCC shall also treat the off-gas stream from the
NHT

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General: Duty of unit
The RFCC is designed to process 100% hot feed direct
from the CDU and is capable of processing up to 100%
cold feed from storage.

RFCC Gas Plant can also process the following

streams:
CDU Stabilizer Off-gas
CDU LPG rich stream

The RFCC shall also treat the off-gas stream from the
NHT

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 PROCESS FLOW DESCRIPTION

Figure 2
 TPC-DQR-002-TRM-OPS-015 – SECT. 1
Rev : A Date: 26 Mar. 2008

11
 TPC-DQR-002-TRM-OPS-015 – SECT. 1
Rev : A Date: 26 Mar. 2008
North East View

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 TPC-DQR-002-TRM-OPS-015 – SECT. 1
Rev : A Date: 26 Mar. 2008
North West View

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 TPC-DQR-002-TRM-OPS-015 – SECT. 1
Rev : A Date: 26 Mar. 2008
South East View

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 TPC-DQR-002-TRM-OPS-015 – SECT. 1
Rev : A Date: 26 Mar. 2008
South West View

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General: Description of RFCC
Converts various residues from CDU to lower boiling,
high value products:
 Naphta sent to NTU (unit 17)
 Light Cycle Oil sent to LCO HDT (unit 24) and
intermediate storage
 LPG sent to LTU (unit 16)

By products of the RFCC:

 Fuel gas, slurry oil and coke are generated in the
reactor-riser
Resulting Decanted Cycle Oil will be incorporated
in the Fuel Oil Blend

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General: Description of RFCC
The majority of the RFCC reaction section equipment
handles catalyst / vapour product separation and
removal of the coke from the catalyst
 Small portion of the equipment is dedicated to
cracking reaction

RFCC is also provided with:

 Fractionation Section to distillate the vapour product
from the reaction section
 Gas recovery Section to process the overhead of the
Fractionation Section

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 SECTION 2

BASIC OF PROCESS
General
Crude distillation unit consists principally of:
Distillation section
Separate products from the crude oil
Crude oil preheat and heat section
Raise the T° of the crude oil up to the necessary
condition for distillation
Desalter section
Remove salts in crude oil prior to heating
Stabilizer section
To refine naphta downstream distillation
Vacuum system
To maintain the LGO & HGO driers under vacuum

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 Doc No : TPC-DQR-002 – SECTION 1

3D View of Unit 11 – South West Rev : A Date: 31 Sept 2007

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 Doc No : TPC-DQR-002 – SECTION 1
Rev : A Date: 31 Sept 2007

3D View of Unit 11 – South East

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 Doc No : TPC-DQR-002 – SECTION 1

3D View of Unit 11 – Columns & Heater Rev : A Date: 31 Sept 2007

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Basic of Design: Feed Characteristics
 Atmospheric Residue Properties
Property Crude (Sour) Blend 100% (Sweet) Bach Ho ASTM Test Method
Cut Range, TPB (°C) 370+ 370+
Vol (%) on Crude 46.6 47.3
50.1
Wt (%) on Crude 50.0

API Gravity 2695 28.9

Specific Gravity at 15/4°C 0.893 0.882

Nitrogen (wt ppm) 1800 1300

Sulphur (wt%) 0.55 0.05 D-1266

Conradson Carbon (wt%) 2.66 1.57 D- 189

Vanadium (wt ppm) 10.5 0 D- 2787

Nickel (wt ppm) 5 1

Sodium (wt ppm) 1.6 1.6 D- 2788

Viscosity at 50°C (cSt) 43.4 43.4 D- 445

Viscosity at 100°C (cSt) 8.8 9

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Basic of Design: Feed Characteristics
 Atmospheric Residue Properties (Cont)
Property Crude (Sour) Blend 100% (Sweet) Bach Ho ASTM Test Method
Pour Point (°C) 50 52 D-97
Asphaltenes (wt%) 2.0 1.0 D- 128
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Wax Content (wt%) N/A

Hydrogen (wt%) 12.7 12.84 D-1018

Neutralization No. (mg D-3242

0.05 0.05
KOH/gm)
Characterization “K” 12.58 12.78
Factor
ASTM Distillation (°C) D-1160 at 760 mmHg
IBP 263 262
10% 379 379
30% 435 437
50% 475 480
Vol% above 550°C 32.4 32.5

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Basic of Design: Feed Characteristics
 CDU stabilizer off gas
Fed from the CDU Stabilizer, directly to the suction of the wet-gas compressor in the
RFCC Gas Plant

Property Crude (Sour) Blend (1) 100% (Sweet) Bach Ho

Flowrate (kg/hr) 50 52
Composition
C1 (mol%) - 0.7

C2 (mol%) 6.3 4.8

C3 (mol%) 37.0 22.7

iC4 (mol%) 14.3 16.0

nC4 (mol%) 40.6 53.5

iC5 (mol%) 339.0 291.0

H2O (mol%) 1.4 1.9
Total (mol%) 100.0 100.0
Molecular Weight 50.6 52.6

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Basic of Design: Feed Characteristics
 NHT Stripper off gas

Fed directly to the suction of the wet-gas compressor in the RFCC Gas Plant

Component Content
H2O (kg mol/h) 0.13

H2S (kg mol/h) 0.32

NH3 (kg mol/h) Trace

H2 (kg mol/h) 13.17
C1 (kg mol/h) 1.69

C2 (kg mol/h) 1.37

iC4 (kg mol/h) 0.06

nC4 (kg mol/h) 0.40

iC5 (mol%) 0.10

C6+ (kg mol/h) 0.63

Total (kg mol/h) 18.84

Total (kg/h) 243

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Basic of Design: Feed Characteristics
 CDU LPG Rich Stream

Fed directly to the stripper in the RFCC Gas Plant

Property Crude (Sour) Blend (1) 100% (Sweet) Bach Ho
Flowrate (kg/hr) 6206 2071

Specific Gravity at 15°C 0.565 0.572

Composition
Ethylene (mol%) - -

Ethane (mol%) 1.2 0.8

Propene (mol%) - -
Propane (mol%) 19.3 10.7

Butene (mol%) - -

iC4 (mol%) 16.5 16.1

nC4 (mol%) 61.7 71.0
iC5+ (mol%) 1.3 1.4
Total (mol%) 100.0 100.0
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Basic of Design: Feed Characteristics
Slops feed to RFCC

Provision is made to allow the re-running of

slops through the RFCC main fractionator:

Heavy slops: 5000 BPSD

Light slops: 5000 BPSD

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Basic of Design: Product Property
 Distillation Specifications

Product Property Max. Gasoline Max. Distillate

TBP cut points C5 - 205°C C5 - 165°C
Gasoline
TBP cut point 60 max
TBP cut point 205 – 360°C 165 – 390°C
LCO
Flash Point 65°C min.
Slurry TBP cut point 360+°C 390+°C
Flash Point 100°C min.

 Gas Recovery Targets

Component Value
C3 overall recovery 95% min.
C4 overall recovery 96% min.
C5+ content in LPG 0.7% wt max.
H2S content in LPG 25 ppm wt max.
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Basic of Design: Product Specifications
 Flue Gas Specifications
Downstream of the electrostatic precipitator and the DeSOx unit:

Component Value
NOx 1000 mg/Nm3 max
SOx 500 mg/Nm3 max
Catalyst fines 50m/Nm3 max
CO content 300 mg/Nm3 max

 DeSOx unit will be provided in the future

The unit will be initially operated with Bach Ho Crude only

 SO2 content produced smaller than 500 mg/Nm3

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Basic of Design: Product Specifications
 Fuel Gas Specifications
 H2S content: 50 wt ppm MAX

 Decant Oil Specification (after Slurry Separation)

 Catalyst content: 100 wt ppm MAX

Mixed MG Bach Ho MG Mixed MD Bach Ho MD

Specific Gravity 15/15 0.565 0.566 0.565 0.565
Mercaptans (wt ppm) 78 7.1 78 1.7
COS (wt ppm) 5.0 5.0 5.0 5.0
Total Sulphur (wt ppm) 3786 332 4260 383
Butadiene (wt ppm) 3012 1647 1358 1063

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Basic of Design: Product Specifications
Mixed MG Bach Ho MG Mixed MD Bach Ho MD
LPG
Specific Gravity 15/15 0.565 0.566 0.565 0.565
COS (wt ppm) 5.0 5.0 5.0 5.0
Total Sulphur (wt ppm) 3786 332 4260 383
Butadiene (wt ppm) 3012 1647 1358 1063

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Basic of Design: Estimated Product
Properties
Mixed MG Bach Ho MG Mixed MD Bach Ho MD
Gasoline (C5 – 165°C)
Sulphur (wt ppm) 230 10
RON clear 92.0 91.7
MON clear 79.5 79.2
True Vapour Pressure (g/cm2) 498 531
Reid Vapour Pressure (kPa) 48 51
Specific Gravity (15/15) 0.719 0.715
D-86
IBP 35 34
5 43 42
10 47 46
30 60 58
50 72 70
70 1 89
90 129 129
95 144 143
EBP 159 156
Olefins (wt %) 43 45
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Basic of Design: Estimated Product
Properties
Mixed MG Bach Ho MG Mixed MD Bach Ho MD
Gasoline (C5 – 205°C)
Sulphur (wt ppm) 340 10
RON clear 92.1 91.8
MON clear 79.9 79.6
True Vapour Pressure (g/cm2) 337 363
Reid Vapour Pressure (kPa) 32 34
Specific Gravity (15/15) 0.736 0.732
D-86
IBP 50 49
5 55 54
10 71 70
30 90
50 116
87
70 160 113
90 176 159
95 197 175
EBP 197
Olefins (wt %) 34 35
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Basic of Design: Estimated Product
Properties
Mixed MG Bach Ho MG Mixed MD Bach Ho MD
Light Cycle Oil (165 – 390°C)
Sulphur (wt ppm) 0.45 0.04
Cetane Number 33.9 38.4
Cloud Point (°C) -1.8 -0.9
Viscosity at 100°C (cSt) 1.02 1.02
Viscosity at 50°C (cSt) 2.05 2.04
Pour Point (°C) -17.3 -18.9
Flash Point (°C) 67 67
Specific Gravity (15/15) 0.881 0.864
D-86
IBP 189 189
5 203 204
10 212 212
30 239 239
50 263 264
70 291 292
90 333 334
95 349 350
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