DOCUMENT TITLE: Process description

HEAVY NAPHTHA HYDROTREATER

UNIT (NHT2)
UNIT 72
25 000 BPSD

PROCESS DATA BOOK

 CONTENTS

INTRODUCTION......................................................................................................... 1
1. PROCESS SPECIFICATIONS SECTION ....................................................... 5
1.1 Basis of design ................................................................................................... 5
1.1.1 Duty of unit .................................................................................................... 5
1.1.2 Feeds specifications ....................................................................................... 6
1.1.3 Products specifications................................................................................... 9
1.1.4 Battery limit conditions................................................................................ 13
1.1.5 Utilities conditions and site information ...................................................... 14
1.1.6 Operating conditions .................................................................................... 32
1.1.7 Equipment Design Basis: Service Life ........................................................ 34
1.2 Unit description................................................................................................ 35
1.2.1 Fundamental reactions ................................................................................. 35
1.2.2 Process flow description .............................................................................. 37
1.3 Material balances ............................................................................................. 39
1.3.1 Component properties .................................................................................. 40
1.3.2 Molar Material Balances .............................................................................. 42
1.3.3 Weight Material Balances .......................................................................... 163
1.4 Physical and thermal properties of main process streams ............................. 284
1.4.1 Start Of Run (SOR) .................................................................................... 285
1.4.2 End Of Run (EOR)..................................................................................... 308
1.4.3 Catalyst in-situ regeneration ...................................................................... 309
1.5 Specifications of catalysts and chemicals ...................................................... 423
1.5.1 Catalyst ...................................................................................................... 434
1.5.2 Absorbent ................................................................................................... 435
1.5.3 Inert balls ................................................................................................... 436
1.5.4 ACT 068/108/139 ...................................................................................... 437
1.5.5 Chemicals ................................................................................................... 438
1.6 Utilities........................................................................................................... 441
1.6.1 Normal operation ....................................................................................... 441
1.6.2 Intermittent consumption ........................................................................... 443
1.7 Waste effluents .............................................................................................. 445
1.7.1 Flue gas from heaters ................................................................................. 445
 1.7.2 Sour Water to Sour Water Stripper ............................................................ 445
1.7.3 Waste effluents during in-situ catalyst regeneration .................................. 446
1.8 Qualified and recommended equipment, suppliers and sellers ..................... 447
1.8.1 Definition of qualified and recommended list ........................................... 447
1.8.2 List of qualified and recommended sellers for equipment and supplies .... 448
1.9 Documents to be transmitted to Axens for comments or informationError! Bookmark not d
1.10 Materials of construction ................................. Error! Bookmark not defined.
1.10.1 IN-45 .............................................................Error! Bookmark not defined.
1.10.2 IN-43 .............................................................Error! Bookmark not defined.
1.10.3 IN-42.1 ..........................................................Error! Bookmark not defined.
2. EQUIPMENT PROCESS SPECIFICATIONS SECTIONERROR! BOOKMARK NOT DE
2.1 Equipment list .................................................. Error! Bookmark not defined.
2.2 Vessels ............................................................. Error! Bookmark not defined.
2.2.1 Drums ............................................................Error! Bookmark not defined.
2.2.2 Columns ........................................................Error! Bookmark not defined.
2.2.3 Reactors.........................................................Error! Bookmark not defined.
2.3 Heat exchange equipment ................................ Error! Bookmark not defined.
2.3.1 Heat exchangers ............................................Error! Bookmark not defined.
2.3.2 Air coolers .....................................................Error! Bookmark not defined.
2.3.3 Heaters ..........................................................Error! Bookmark not defined.
2.4 Rotating machines............................................ Error! Bookmark not defined.
2.4.1 Pumps ............................................................Error! Bookmark not defined.
2.4.2 Compressors ..................................................Error! Bookmark not defined.
2.5 Miscellaneous equipment ................................ Error! Bookmark not defined.
2.5.1 Mixer .............................................................Error! Bookmark not defined.
2.5.2 Ejector ...........................................................Error! Bookmark not defined.
3. PIPING PROCESS SPECIFICATIONS SECTIONERROR! BOOKMARK NOT DEFINED
3.1 General notes ................................................... Error! Bookmark not defined.
3.1.1 Recommendations .........................................Error! Bookmark not defined.
3.1.2 Process piping classes ...................................Error! Bookmark not defined.
3.1.3 Piping identification system ..........................Error! Bookmark not defined.
3.2 Piping process specifications ........................... Error! Bookmark not defined.
4. INSTRUMENTATION PROCESS SPECIFICATION SECTIONERROR! BOOKMARK N
4.1 Instruments....................................................... Error! Bookmark not defined.
 4.1.1 Flow ..............................................................Error! Bookmark not defined.
4.1.2 Level .............................................................Error! Bookmark not defined.
4.1.3 Pressure .........................................................Error! Bookmark not defined.
4.1.4 Temperature ..................................................Error! Bookmark not defined.
4.1.5 Miscellaneous ...............................................Error! Bookmark not defined.
4.2 Valves .............................................................. Error! Bookmark not defined.
4.2.1 Control ..........................................................Error! Bookmark not defined.
4.2.2 On/Off ...........................................................Error! Bookmark not defined.
4.3 Pressure safety valves ...................................... Error! Bookmark not defined.
4.4 Alarms .............................................................. Error! Bookmark not defined.
4.5 Analysis point .................................................. Error! Bookmark not defined.
4.6 Analyzers ......................................................... Error! Bookmark not defined.
4.7 Hand switch ..................................................... Error! Bookmark not defined.
4.8 Shutdown logic and sequence logic ................. Error! Bookmark not defined.
4.9 Special loops description ................................. Error! Bookmark not defined.
5. DIAGRAMS SECTION...................... ERROR! BOOKMARK NOT DEFINED.
5.1 Process flow diagrams ..................................... Error! Bookmark not defined.
5.2 Material and mechanical diagrams (MMD) .... Error! Bookmark not defined.
5.3 Piping and instrumentation diagrams .............. Error! Bookmark not defined.
 INTRODUCTION

The purpose of the Naphtha Hydrotreater unit is to produce a clean desulfurized Naphtha cut
able to be processed in the Octanizing Reaction section unit after removal of all impurities
which are currently poisons for the catalysts (sulfur and nitrogen).
The design capacity of the Heavy Naphtha Hydrotreater Unit is 25 000 BPSD with a
turndown ratio of 60%.
 1. PROCESS SPECIFICATIONS SECTION

1.1 Basis of design

1.1.1 Duty of unit

The purpose of the Naphtha Hydrotreater unit is to produce a clean desulfurized Naphtha cut
able to be processed in the Octanizing Reaction section unit after removal of all impurities
which are currently poisons for the catalysts (sulfur and nitrogen).
The design feed capacity of this unit is 25 000 BPSD.
The design of equipments has been checked for 2 cases:
- Start Of Run (SOR)
- End Of Run (EOR)
with the possibility to process feed at a lower temperature (20° C instead of 40° C) and to use
hydrogen make-up from PSA Unit (instead of Octanizing Unit).
1.1.2 Feeds specifications
1.1.2.1 Heavy naphtha feed
TABLE I
FEEDSTOCK PROPERTIES

Origin Heavy SR naphtha

MW kg/kmol 111.45

Specific gravity 0.750 @15 deg. C / 15 deg. C

ASTM D-86 deg. C

I.B.P. 104.8

5% 107.6

10% 109.6

30% 115.1

50% 126.5

70% 138.6

90% 155.4

95% 160.2

F.B.P 166.3

MAV ou Diol % -

Impurities

Sulfur Wt ppm 1600

Nitrogen Wt ppm 2

Pb Wt ppb -

As Wt ppb -

Si Wt ppm -

Others Wt ppm -
1.1.2.2 Make-up hydrogen
The normal hydrogen make-up is from the Octanizing Unit (Unit 72). It has the following
composition:

TABLE II
HYDROGEN MAKE-UP PROPERTIES

Composition vol % = mol %

H2 91.0
C1 2.6
C2 2.8
C3 1.6
iC4 0.5
nC4 0.5
C5+ 1.0

Impurities vol ppm

CO + CO2 < 30
HCl <1
In case of Octanizing Unit shut-down, hydrogen make-up is supplied by Hydrogen Unit, with
the following composition.
TABLE III
BACK-UP HYDROGEN MAKE-UP PROPERTIES

Composition vol % = mol %

N2 0.2
H2 99.5 min
C1 0.3

Impurities vol ppm

CO + CO2 50 max
1.1.3 Products specifications

The main product is the:

- Hydrotreated Heavy Naphtha from the stripper bottom feeding the Octanizer unit
(OCT).

In addition there are two secondary purge gas streams:

- The first one comes from stripper reflux drum V72006 which contains mainly light
ends from the feed, hydrogen make-up. It is routed to the amine treatment unit.
- The other one is a small purge gas from the separator drum V72003. It is routed to the
amine treatment unit. This stream is effectively zero under ideal conditions.

1.1.3.1 Hydrotreated Heavy Naphtha

TABLE IV
HYDROTREATED HEAVY NAPHTHA PROPERTIES

Flow rate unit : wt % Heavy Hydrotreated

Naphtha to Octanizer Unit

NH3 0
H2S 0

H2 0
METHANE 0

ETHANE 0
PROPANE 0

NBUTANE 0
IBUTANE 0

NPENTANE 0
IPENTANE 0

22-DMButane 0
23-DMButane 0

2-MethylPentane 0
3-MethylPentane 0

NHEXANE 0.03
CycloPentane 0

MethylCycloPent 0.07
CycloHexane 0.56

BENZENE 0.05
HEPTANE 8.47

2-MethylHexane 2.83
Flow rate unit : wt % Heavy Hydrotreated
Naphtha to Octanizer Unit
3-MethylHexane 3.58
3-EthylPentane 0.02

22-DMPentane 0.03
24-DMPentane 0.10

223-TriMeButane 0.01
33-DMPentane 0.10

23-DMPentane 1.11
11-DMCycloPent 0.47

1cis3-DMCycloP 1.43
1tran3-DMCycloP 1.69

1tran2-DMCycloP 2.57
1cis2-DMCycloP 0.23

EthylCycloPent 0.02
MethylCycloHex 5.18

TOLUENE 4.67

OCTANE 7.63

3-MethylHeptane 8.36

11-DMCycloHex 0.11

23-DMHexane 3.18

ECH 0.82

1Methyl1EthylCC5 4.14

1tran3DMCC6 2.39

PRCP 0.25

MXYLENE 5.86

NONANE 6.33

3-MethylOctane 12.82

ButylCC5 1.34

1tran35TMCC6 2.41

124TMBENZENE 6.68

DECANE 2.43

3-MethylNonane 0.92

sec-ButylCC6 0.98

4-Ethyl-OrthoXyl 0.12

H2O 0

Total kmol/h 1 115.66

Total kg/h 124 352

Sp. Gr 0.7502
Maximum expected contaminant levels in hydrotreated naphtha:

Component Hydrotreated Naphtha

Sulphur <0.5 wt ppm
Nitrogen (organic) <0.1 wt ppm

1.1.3.2 Off gas to amine treatment unit

Flow rate unit : wt % Off gas to amine treatment

NH3 0
H2S 35.73

H2 4.70
METHANE 8.32

ETHANE 12.48
PROPANE 11.81

NBUTANE 5.61
IBUTANE 5.61

NPENTANE 2.68
IPENTANE 2.68

22-DMButane 0
23-DMButane 0.01

2-MethylPentane 0.10
3-MethylPentane 0.17

NHEXANE 0.73
CycloPentane 0

MethylCycloPent 0.55
CycloHexane 1.03

BENZENE 2.34
HEPTANE 0.77

2-MethylHexane 1.21
3-MethylHexane 0.94

3-EthylPentane 0
22-DMPentane 0.14

24-DMPentane 0.37
223-TriMeButane 0.02

33-DMPentane 0.07
23-DMPentane 0.37
Flow rate unit : wt % Off gas to amine treatment
11-DMCycloPent 0.17

1cis3-DMCycloP 0.30
1tran3-DMCycloP 0.29

1tran2-DMCycloP 0.43
1cis2-DMCycloP 0.01

EthylCycloPent 0
MethylCycloHex 0.14

TOLUENE 0.20

OCTANE 0.01

3-MethylHeptane 0.02

11-DMCycloHex 0

23-DMHexane 0.01

ECH 0

1Methyl1EthylCC5 0

1tran3DMCC6 0

PRCP 0

MXYLENE 0

NONANE 0

3-MethylOctane 0

ButylCC5 0

1tran35TMCC6 0

124TMBENZENE 0

DECANE 0

3-MethylNonane 0

sec-ButylCC6 0

4-Ethyl-OrthoXyl 0

H2O 0

Total kmol/h 593

Total kg/h 29.43

1.1.4 Battery limit conditions

Battery limit conditions for feeds and products are shown on next table.

Pressure Temperature
Stream Origin or Destination
(bar g) (deg. C)
Incoming

Straight Run Heavy Splitter Section 9.2 40

Naphtha Storage 7.1 20

Octanizing Unit 24.1 40

Hydrogen Make-up
Hydrogen Unit 20.0 40
Washing Water MP Boiler Feed Water 27.0 130
Caustic Soda Unit 74 10.0 47
Outgoing
Stabilized Treated Octanizer Unit 8.1 101
Heavy Naphtha Storage 7.0 40

Stripper Purge Gas Amine Treatment Unit 7.0 44

Sour water Sour Water Stripper 3.5 45

Caustic Neutralization
Spent Caustic Soda 6.8 43
Unit
1.1.5 Utilities conditions and site information

1.1.5.1 Utilities conditions

1.1.5.1.1 Steam

HIGH PRESS. MEDIUM PRESS. LOW PRESS.

DESCRIPTION
STEAM STEAM STEAM

SYSTEM / FLUID HS MS LS
IDENTIFICATION
GENERATION
Press. min. bar(g) 42.5 20 4.2
(1) norm. bar(g) 43.1 21.4 4.5
max. bar(g) 44.9 21.8 4.8
des. bar(g) 47.24 22.4 5.2
Temp. min. deg C 365 280 210 (10)
norm. deg C 371 285 220
max. deg C 385 290 230
400
(2) des. deg C 382 265
385
(3) des. deg C 382 265
385
(4) des. deg C 380 265
 HIGH PRESS. MEDIUM LOW PRESS.
DESCRIPTION PRESS.
STEAM STEAM STEAM

SYSTEM / FLUID IDENTIFICATION HS MS LS

DISTRIBUTION (AT UNIT BATTERY LIMIT)

Press. min. bar(g) 41 19 3.2

norm. bar(g) 42.1 20.4 4.1

max. bar(g) 44.9 21.8 4.8

des. bar(g) 47.24 22.4 5.2

Temp. min. deg C (6)340 / 355(5) 265 200 (11)

norm. deg C (6)345 / 360(5) 275 210

max. deg C (6)360 / 380(5) 285 220

(2) des. deg C 400 382 265

(3) des. deg C 385 382 265

(4) des. deg C 385 380 (8) 265

NOTES
1) Steam generation within Process Units Battery Limits shall be referred at the
normal conditions of temperature and pressure.
2) Design data for piping.
3) Design data for vessel and exchangers.
4) Design data for steam turbines.
5) Operating temperature for utility area users.
6) Operating temperature for process area users.
7) Not used.
8) Design temperature for 20 bar (g) steam to flare stack.
9) The low pressure steam produced in Sulfur Recovery Unit and Asphalt Blowing
Unit shall be connected to the main LP steam header prior to branching to the
Users' area.
10) Temperature of LS steam from steam turbine drivers shall never be lower than
165 deg C.
11) For process design of exchangers, tank heaters and tracing etc, minimum
temperature of 200 deg C shall be used.
Effective minimum temperature can be as low as 155 deg C depending on
steam turbine driver's efficiency.
1.1.5.1.2 Condensates
Cold Condensate from Steam Turbine Surface Condensers
System/Fluid Identification CC
Polishing unit
Destination before the
deaerators
Grade Level destination
press.
( 1 ) bar (g) 4.5
Grade Level battery Limit
press.
min. bar (g) 6.5
( 2 ) norm. bar (g) 6.7 ( 3 )
des. bar (g) 7.5 ( 3 )
Grade Level battery Limit
temp.
norm. deg C 55
des. deg C 75
Condensate Collecting System
System/Fluid Identification MC LC

Destination (4) (5)

Grade Level destination press.
( 1 ) bar (g) 4.1 0.8
Grade Level battery Limit
press.
min. bar (g) 5.5
( 2 ) norm. bar (g) 7.5 1.4 ( 3 )
max. bar (g) 10 2.0 ( 3 )
des. bar (g) 22.4 5.2
Grade Level battery Limit
temp.
min. deg C 162
norm. deg C 173 127
max. deg C 184 134
des. deg C 221 160

NOTES
1) In the Utility Area.
2) At Process Units Battery Limits.
3) To be confirmed later.
4) Condensate recovery vessel connected to the LP steam network.
5) Condensate recovery vessels shall be designed so that no steam shall be vented to the
atmosphere in the Refinery.
1.1.5.1.3 Water
Water for Cooling Services, Drinking and Fire Users
Sea Machin.
Cooling Cooling Potable
DESCRIPTION Water Water (2) Plant Water Water (3) Fire Water
System/Fluid Identification SW CW UW DW FW
Desal. Desal. Desal.
Source Sea
Water Water Water (4)
Supply temperature
norm. degC 35 (8) 40 Amb. 39 max Amb.
min. degC 20
des. degC 65 70 70 60 70

Supply pressure at B.L.

at grade min. bar (g) 3.8 4.5 4.5 2 9
norm. bar (g) 4 5 5 5 11.5
des. bar (g) 7 7.5 8.5 7 14

Return pressure at B.L.

at grade norm. bar (g) 1.5 2 - - -
des. bar (g) 7 7.5 - - -

Return temperature
norm. degC 45 (5) 50 - - -
des. degC 75 80 - - -

Fouling factor deg

0.0004 (6) 0.0002 0.0001 0.0002 -
Cm2h/kcal
TDS ppm 47000
Chloride wt.ppm (1)
PH 8.3

Specific gravity at 20 deg C 1.032 0.998 0.998 0.998 0.998

 NOTES
1- Free chlorine according to WHO.
2- The minimum pressure of the machinery cooling water at the outlet of the machinery
cooling water / sea cooling water shall be higher than the normal pressure of the sea cooling
water circuit.
3- The minimum pressure of the potable water of the potable water / sea cooling water cooler
shall be higher than the normal pressure of the sea cooling water circuit.
4- Sea water may be used in emergency as an alternate source for fire water.
5- The maximum outlet temperature of each individual cooler shall not exceed 46 ◌ْ deg C.
6- For plate exchanger type a fouling factor of 0.0006 ◌ْ deg Cm2h/kcal shall be used.
7- Not used.
8- The supply temperature for the Desalination Unit Design is 32 ◌ْ deg C
Demineralised Water, Boiler Feed Water & Desalinated Water

Demin. Boiler Feed Water Desal.

DESCRIPTION
Water L.P. M.P. H.P Water

System/Fluid Identification MW BW TW
Source Mixed bed Deaerator
Supply pressure at B.L.
at grade min. bar (g) 6.5 6.5
norm. bar (g) 7.5 11 27 59.4 7.5
des. bar (g) 10.2 17 37 78 10.2

Temperature norm. deg C 40 130 40

min. deg C 45 130 45
des. deg C 70 165 70
Fouling factor deg
0.0001 0.0002 0.0001
Cm2h/kcal
TDS mg/kg - - 10 max.
PH 7 ± 0.5 9
O2 mg/kg max - 0.005
Co2 mg/kg Not detect. Not detectable
Sio2 mg/kg max. 0.01 0.01
Cu mg/kg max. 0.003 0.003
Fe mg/kg max. 0.02 0.02
Conductivity micro
0.2 0.2
S/cm max.
Oil content mg/kg max. 0.5 0.5
Total hardness Not detect. Not detectable
Sea Water Analysis Results

Average
Date Sample Taken 19/01/1989 20/01/1989 22/01/1989 Results
PH 7.9 7.9 7.9 7.9
Conductivity at 25 deg C
(ms/cm) 50.4 50.5 50.3 50.4

Alkalinity ( P & M ) 138 137 137 137.3

Hardness
Ca 1100 1100 1100 1100
Mg 5450 5750 5750 5650

Total Dissolved solids

110 deg C 40710 40930 41300 40980
180 deg C 37450 37650 38000 37700

Chloride 21300 21300 21830 21477

Sulfate 2931 2946 2930 2936

Sodium 11200 11200 11500 11300

Iron 1.5 1.5 1.5 1.5

Copper < 0.01 < 0.01 < 0.01 < 0.01

Bromide 115 20 8 47.7

Turbidity < 10 < 10 < 10 < 10

Oily matter 2 4 4 3.3

Organic matter content < 5 < 5 < 5 < 5

H2S
(Hydrogen Sulphide) < 0.0005 < 0.0005 < 0.0005 < 0.0005

NH4 (Ammonia) < 0.1 < 0.1 < 0.1 < 0.1
All results in Milligrams/Liter
1.1.5.1.4 Air

Instrument Air Plant Air

System/Fluid Identification IA PA
Quality Oil free Oil free
Supply Temperature
norm. deg C 45 45
des. deg C 75 75

Supply Pressure
min. bar (g) 4.5 6
norm. bar (g) 7 7
max. bar (g) 8 8
des. bar (g) 10.25 10.25

Dew point at 8 bar(g) max

-20 -20
deg C
1.1.5.1.5 Nitrogen gas

System/Fluid Identification IG
Air Fractionation
Source
(Cryogenic Type)
Supply Temperature
norm. deg C 5 – 45
des. deg C 75

Supply Pressure at Process Units B. L.

min. bar (g) 6
norm. bar (g) 7
max. bar (g) 8.5
des. bar (g) 12.5

Nitrogen composition:
Nitrogen % 99.9 min.
Oxygen ppm 20.0 max.
Carbon dioxide ppm 10.0 max.
Carbon monoxide ppm 10.0 max.
Hydrocarbons ppm 5.00 max.
Water ppm 20.0 max.

Dew point at 8 bar (g) deg C -40

Axens specifications:
(1) For Catalyst Regeneration, maximum O2 content shall be 0.3 vol%.
1.1.5.1.6 Fuel

Fuel Oil

USERS Process Fired Heaters Auxiliary Boilers

System/Fluid Identification FO FO

VB tar 180 deg C+ cut VB tar 180 deg C+ cut

Type
back with kerosene back with kerosene
Specific gravity 15/4 deg C 1.02 - 1.06 1.02 - 1.06
Supply temperature
min. deg C 200 200
norm. deg C 210 210
max. deg C 230 230
des. deg C 260 260
Supply header pressure
min. bar (g) 9 12
norm. bar (g) 10 13
max. bar (g) 10.5 13.5
des. bar (g) 12.5 15.5
Return header pressure
min. bar (g)
norm. bar (g) 2 2
max. bar (g) 3 3
des. bar (g) 12.5 15.5
Lower heating value kj/kg 39300 39300
Viscosity at 100 deg C cSt 3150 3150
at 200 deg C cSt 35 35
Sulphur wt. % 4.15 4.15
Vanadium/Nickel wt.ppm 605/210 605/210
Flash Point deg C 85 85
Ash wt. % 0.16 0.16
Con.Carbon Res. wt. % 32 32
Iron wt.ppm 60 60
Nitrogen wt. % 1.05 1.05
Salt content (as NaCl) wt.ppm 25 25
Diesel Oil for Gas Turbine Generators

System/Fluid Identification DO Atm.Gasoil

Specific gravity 15/15 deg C 0.82 - 0.86 0.86

Supply Temperature Ambient 45

norm. deg C 70 75
des. deg C

Header Pressure
min. bar (g) 3.5
norm. bar (g) 4.5
max. bar (g) 6
des. bar (g) 10.5

Viscosity at 38 deg C cSt 2 + 5.5 4.7

Net heating value kcal/kg 10230

Sulphur wt. % 1.0 max. 1.14

Pour point deg C - 4.0 max. -8

Flash point deg C 54.0 min. 93 min.

Ash wt.% 0.01 max. -

Carbon residue (on 10% bottoms) 0.1 max -

Water and Sediment vol.% 0.05 max. 900 wt.ppm

Cetane Index 50 min. 56

Fuel Gas

System/Fluid
FG FG
Identification
Refinery Fuel
NATURAL GAS
Gas
Refin.B.L. H2 Plant Gas turb. Blank.
Nat.gas +
Source External Pipeline
ref.gas
Supply Temperature
norm. deg C Ambient 40
des. deg C 70 70

Header Pressure
min. bar (g) 30 29.4 17.5 - 3
norm. bar (g) 18 7 3.5
max. bar (g) 41.4 41 20 8 4
des. bar (g) 45 45 22 10 5.5

Net Heat. Value

kcal/kg 9875 9875 9875 9875 9875-10965
Viscosity at 40 deg C
cP 0.012 0.012 0.012 0.012 0.011-0.013
MW 18.8 16 - 30
Hydrogen sulfide ppm 60 max. 100 max.
Gas Composition
NATURAL GAS

Component Composition (vol %)

H2S 60 ppm wt max

N2 10.03 max
CO2 0.66 max
CH4 85.03
C2H6 1.70
C3H8 0.90
n-C4 0.44
i-C4 0.24
n-C5 0.12
i-C5 0.14
C6 + 0.74

Total 100.00
The pressure of natural gas at Refinery Battery Limit shall be in the range 30 to 41.4 bar (g).

REFINERY FUEL GAS ( 1 )

Component Composition (vol.%)

H2O 1
N2 4.93
CO 0.25
H2 23.79
C1 23.49
C2= 7.48
C2 23.61
C3= 2.93
C3 6.53
C4 = 0.26
iC4 1.1
nC4 1.8
C5= 0.16
iC5 1.49
nC5 0.74
C6+ 0.44

Total 100
Hydrogen Sulphide 100 wt. ppm max.

NOTES
( 1 ) Amine treated LP Off-Gas.

1.1.5.1.7 Flare header

 Pressure – bar g

Normal Design
Knock Out Drum Condition
0.34 3.5

1.1.5.2 Site information

 Temperature

Average maximum temperature (hottest

month) 42 deg C
Extreme highest temperature 47 deg C
Average minimum temperature (coldest
month) 8 deg C
Extreme lowest temperature 2 deg C
Average ambient temperature (process design) 42 deg C
Minimum temperature (metallurgical design) 2 deg C
Frost line (below surface) 85m
Winterizing temperature 2 deg C
 Barometric pressure

Highest absolute barometric pressure 1010 mbar

Annual average barometric pressure (process design) 1010 mbar
 Humidity of air (relative humidity %)

Relative humidity in warmest month 65-75%

Relative humidity in coldest month 70-80%
Design relative humidity in Summer 75%
Design relative humidity in Winter 80%
Average relative humidity of year 50-72%
 Water Temperature at sea surface

Max Water Temperature 35 deg C

Average Water Temperature 27 deg C
Min. Water Temperature 16 deg C
 Wind Velocity
Average wind velocity (process design) 44.4 m/s
Wind Velocity in Summer 13.5 m/s
Wind Velocity in Winter 19.3 m/s
Design Wind Speed for structure 44.4 m/s
Average maximum wind velocity for 10 minutes 44.4 m/s
(10 m above ground level)

For wind load for static calculations, design wind pressure shall be taken as to the following,
subject to UBC factor adjustment:

Height Zone (Meter) Pressure on flat surface

Mpa kg/cm² g
less than 10 9.8×10-4 (100)
10-20 11.8×10-4 (120)
20-30 13.0×10-4 (133)
30 and above 14.7×10-4 (150)
 Extreme Wind Conditions

Extreme Wind Speed for 10 minutes duration (return period 100 years)
:

Direction Wind Speed (m/s)

N 11
NE 19
E 13
SE 20
S 21
SW 16
W 14
NW 13

Annual regime of wind is :

Direction Annual Distribution

S 30%
SW 15%
SE 13%
 Information for insulation design

Mechanical design minimum ambient temperature

2 deg C
For non-insulated equipment/piping
Design maximum temperature for personnel protection 60 deg C
Design minimum ambient temperature for
2 deg C
Insulation / tracing
Maximum allowable furnace skin temperature
60 deg C
At ambient temperature of 24 deg C
Wind velocity 10 m/s
1.1.6 Operating conditions

1.1.6.1 Reactor V72002

In order to maintain the expected performance, the hydrotreating reactor is designed to

operate under specific conditions. SOR (Start of Run) and EOR (End of Run) are two design
cases related to catalyst activity and ageing.
SOR EOR
Reactor inlet pressure (bar g) 23.1 23.1
Reactor inlet temperature ( deg. C) 295 325
Outlet Hydrogen partial pressure (bar abs) 9.15 mini 9.15 mini

The space velocity (LHSV) is the volume of HC liquid feed at 15 deg. C in m3/hr divided by
the volume of catalyst.
Space velocity = 4 h-1

1.1.6.2 Feed surge drum V72001

SOR EOR
Pressure bar g 2.0 2.0
Temperature, deg. C 40 40

1.1.6.3 Separator drum V72003

SOR EOR
Pressure bar g 17.0 17.0
Temperature, deg. C 45.0 45.0

1.1.6.4 Compressor KO drum V72004

SOR EOR
Pressure bar g 16.9 16.9
Temperature, deg. C 45.0 45.0

1.1.6.5 Stripper V72005

 SOR / EOR
Number of trays 35
Feed temperature deg. C 190.7
Top temperature deg. C 171.8
Bottom temperature deg. C 235.7
Feed pressure bar g 10.8
Top pressure bar g 10.7
Bottom pressure bar g 11.2
Reflux drum temperature deg. C 45.0
Reflux drum pressure bar g 10.0
Reflux/feed ratio (wt/wt) 0.28
1.1.7 Equipment Design Basis: Service Life

1.1.7.1 Equipment Design Life

The following design life has been applied to the design of the unit:

- Reactors / Heavy wall vessels or exchangers 20 years

(including non removable internals and catalyst bed support beams if
any ):
- Reactor removable internals: ............................................................. 20 years
- Columns, other vessels: .................................................................... 20 years
- Other heat exchangers: ...................................................................... 20 years
- Stainless steel, high alloy and non ferrous material heat 20 years
exchanger tube bundles: .....................................................................
- Carbon steel / low alloyed steel heat exchanger tube bundles: ........ 20 years
- Furnace tubes: ................................................................................... 20 years
- Piping: ............................................................................................... 10 years

1.1.7.2 Corrosion allowance

Carbon steel (including Low Alloy <5%Cr steels)

Whichever is greater:
- Corrosion allowance calculated for 20 years of service for equipment and 10 years of
service for piping.
- Corrosion allowance of 1.0mm for piping and 3.0mm for equipment
High Alloy or Stainless Steel:
Corrosion allowance calculated for 20 years of service for equipment and 10 years of service
for piping.
1.2 Unit description
Refer to the unit process flow diagrams when reading the following descriptions.

1.2.1 Fundamental reactions

The purpose of this Heavy Naphtha Hydrotreatment unit is to protect the Octanizer Section
catalyst by eliminating or reducing to an acceptable level the impurities of the light naphtha.
Impurities, which are considered detrimental to the catalyst activity, are mainly sulfur and
nitrogen. The treating process is achieved by passing the naphtha over a fixed bimetallic
catalyst bed in an adiabatic reactor in the presence of hydrogen.
There are principally two fundamental reactions occurring:
• hydrorefining,
• hydrogenation.

1.2.1.1 Hydrorefining

1.2.1.1.1 Desulfurization
Sulfides, desulfides and mercaptans react readily to produce the corresponding saturated or
aromatic compound releasing H2S.

RSR’ + 2 H2 RH + R’H + H2S

RSSR’ + 3 H2 RH + R’H + 2 H2S
RSH + H2 RH + H2S

Sulfur combined in an aromatic structure like thiophen is more difficult to react. The aromatic
ring must open first before saturation of the aliphatic compound. It occurs with the release of
H2S.

e.g. + 4H2 C
4
H
10
+ H 2S

S
1.2.1.1.2 Denitrification
This reaction occurs at a lower rate than desulfurization, here nitrogen is released to form
ammonia.

R - NH2 + H2 R - H + NH3

1.2.1.2 Hydrogenation

This refers to the saturation of the olefins and diolefins if present in the feed (when processing
cracked naphthas). The reaction occurs readily in the top portion of the catalytic bed releasing
exothermic heat and consuming hydrogen.
C7H14 + H2 C7H16

C8H14 + 2H2 C8H18

Minimal hydrogenation of aromatics occurs, estimated at less than one percent. This is a
consequence of the high selectivity of the AXENS bimetallic catalyst.

1.2.1.3 Elimination of arsenic and other metals

Arsenic and other metals when present are typically in organo-metallic form. After
hydrogenation in the hydrotreater reactor, the hydrogenated form reacts with the hydrotreater
catalyst forming a bimetallic compound. As a result arsenic and the other metals are
physically adsorbed by the catalyst creating a gradient on the catalyst bed.
During the operation cycle, the equilibrium level of the contaminants will progressively move
down the bed. It is good operating practice to analyze and replace this top portion of the
catalyst bed as necessary to prevent contaminant breakthrough into the Aromizing feed.
1.2.2 Process flow description

1.2.2.1 Normal operation

1.2.2.1.1 Reaction section

The naphtha feed enters the unit at battery limits conditions and is stored in surge drum
V72001; then the liquid is pumped under flow control by NHT feed pump P72001 A,B to the
reaction circuit. The heavy naphtha is mixed with recycle hydrogen from the recycle
compressor C72001 A,B.
This two phase mixture is then preheated in the reactor feed/effluent exchangers E72001 A to
F, and further heated to the required reactor inlet temperature in the fired heater H72001.
The reactor inlet temperature is controlled by regulating fuel flow rate to burners; this
temperature varies from 295 deg. C to 325 deg. C depending on the position in the cycle. The
reactor volume is filled with HR-506. The HR-506 is a Cobalt Molybdenum catalyst
developed by AXENS to selectively hydrotreat the naphtha feed.
In the reactor hydrogenation reactions occur, and since there are few components to
hydrogenate, the reactor effluent temperature is almost at the same temperature as the inlet (5
deg. C increase between inlet and outlet for both SOR and EOR cases).
After heat exchange in E72001 A to F the reactor effluent is cooled down to 45 deg. C in the
reactor effluent air cooler A72001 and in reactor effluent trim cooler E72002. Upstream the
air condenser, water can be injected to dissolve any chloride, sulphide and ammonium salts
which precipitate at low temperatures. The three phases mixture separates in separator drum
V72003.
The overhead gas is routed through the recycle compressor KO drum V72004 to the suction
of recycle gas compressor C72001 A,B. A small purge (NNF) can be removed by flow
control and is sent to amine treatment prior to flare. This stream is used to control the
hydrogen concentration in the recycle gas. Hydrogen make-up from Octanizer unit is injected
before C72001 A,B recycle compressor KO drum to maintain reaction section pressure.
The separated water containing the dissolved salts, H2S and NH3 is routed under level control
in the boot to the sour water stripper unit.
The separated hydrocarbon liquid is routed under flow control with level reset to the stripping
section.
1.2.2.1.2 Stripper section
The separator liquid is preheated in the stripper feed/bottom exchangers E72003 A,B,C to
enter the stripper column V72005 on tray # 24. The Stripper V72005 (35 trays) separates light
components and hydrogen sulphide from heavy hydrotreated naphtha to meet the light ends
and total sulphur specifications.
This column is reboiled using fired heater H72002. Column overhead is partially condensed
in stripper overhead air condenser A72002 and stripper overhead trim condenser E72004 to
collect in V72006, the stripper reflux drum. A corrosion inhibitor solution is injected
upstream of the air condenser to protect the equipment downstream of the condensation point.
The overhead vapor from V72006 is routed to amine treatment. V72006 liquid is pumped by
P72002 A,B under flow control with level reset to V72005 as reflux.
The stripper bottom goes through the stripper feed/bottom exchanger E72003 A,B,C. The
treated heavy naphtha is then sent to Octanizer Unit under level control or to storage after
cooling in air cooler A72003 and trim coolers E72005 and E72006.

1.2.2.2 Catalyst in-situ regeneration operation

The Heavy Naphtha Hydrotreatment unit is equipped with catalyst in-situ regeneration
facilities that involve:
- ammonia ,
- injection lines,
- a caustic soda solution injection,
- Lines, valves and spool piece by-passing totally feed/effluent exchangers E72001
A,B,C,D,E,F
- a caustic mixer MX72001 that should be installed inside the reaction loop section,
upstream of V72003,
- an air injection line upstream compressor KO drum V72004.
The catalyst of the reactor should be regenerated at the end of the normal cycle of the unit,
when catalyst activity becomes too low.
The reaction section is hydrocarbon free and put under nitrogen atmosphere. Then feed surge
drum, feed pumps, stripper and sour water line to sour water stripper are isolated from the
reaction section. The regeneration procedure includes:
a. Commissioning of ammonia injection lines and caustic soda injection lines to the circuit.
b. A first coke combustion with 345 deg. C reactor inlet temperature and 0.5% vol. oxygen
in the reactor inlet gas.
c. A second coke combustion with 1.0% vol. oxygen in the reactor inlet gas.
d. A finishing phase with 1.0% vol. oxygen and 425 deg. C reactor inlet temperature.
(These conditions are kept during 8 hours).
e. The shut-off of ammonia injection caustic scrubbing.
f. Cooling down of the reactor temperature using the recycle gas circulation to prepare
the unit for the new start-up.
All these steps and procedures will be detailed in the Operating Instructions.
1.3 Material balances
1.3.1 Component properties
1.3.1.1 Start Of Run (SOR) / End Of Run (EOR)
1.3.1.2 Catalyst in-situ regeneration
1.3.2 Molar Material Balances
1.3.2.1 Start Of Run (SOR)
1.3.2.2 End Of Run (EOR)
1.3.2.3 Catalyst in-situ regeneration
1.3.3 Weight Material Balances
1.3.3.1 Start Of Run (SOR)
1.3.3.2 End Of Run (EOR)
1.3.3.3 Catalyst in-situ regeneration
1.4 Physical and thermal properties of main process streams
1.4.1 Start Of Run (SOR)
1.4.2 End Of Run (EOR)
1.4.3 Catalyst in-situ regeneration
1.5 Specifications of catalysts and chemicals
1.5.1 Catalyst
1.5.2 Absorbent

Not applicable
1.5.3 Inert balls
1.5.4 ACT 068/108/139
1.5.5 Chemicals
 1.5.5.1 Corrosion inhibitor

The corrosion inhibitor is injected in the stripper overhead, diluted at 10% with stripper reflux
at the rate of 10 wt ppm of pure product compared to the total column overheads.
 1.5.5.2 Sulfiding agent

The sulfiding agent is injected at the NHT feed pumps suction, P72001 A,B for fresh or
regenerated NHT catalyst sulfiding.
1.6 Utilities
The utility summary (72-GM-E-205998) is included in paragraph 1.6 of document 72-GA-E-
205091.

1.6.1 Normal operation

Utilities consumptions in normal operation are summarized in the following tables:

ELECTRICITY:

PUMPS

Electricity (kW)

P72001 A,B (1 running + 1 spare) Feed Pumps 231

P72002 A,B (1 running + 1 spare) Stripper Reflux Pumps 16

P72003 A,B (1 running + 1 spare) Stripper Reboiler Pumps 112

P72004 Sulfiding Agent Injection Pumps <1

P72006 A,B (1 running + 1 spare) Corrosion Inhibitor Injection Pumps <1

Sub-total Pumps (kW) 361

COMPRESSORS

Electricity (kW)

C72001 A,B Recycle Gas Compressors 535

Sub-total Compressors (kW) 535

AIR COOLERS

Electricity (kW)

A72001 Reactor Effluent Air Cooler 120

A72002 Stripper Air Cooler 60

A72003 Stabilized hydrotreated Naphtha Air Cooler 60

Sub-total Air coolers (kW) 240

TOTAL ELECTRICITY (KW) 1136

SEA WATER :

Flow (T/h)

E72002 Reactor Effluent Trim Condenser 95.2

E72004 Stripper Trim Condenser 25.9

E72005 First Stabilized hydrotreated Naphtha trim cooler 50.9

E72006 Second Stabilized hydrotreated Naphtha trim cooler 158.7

Total Sea water (T/h) 330.7

FUEL GAS :

Maximum duty Fired duty

Process side (MW) (MW)(1)(2)

H72001 Reactor Feed Heater 5.43 6.4

H72002 Stripper Reboiler 9.85 11.6

Total 15.3 18
(1) The overall heater efficiency is assumed to be 85% (to be confirmed by Detail
Engineering Contractor)
(2) Based on these duties, the fuel gas consumption will be calculated by the Heater
Manufacturer during EPC phase.
1.6.2 Intermittent consumption

1.6.2.1 Washing water

Flow (T/h)

Total Washing water consumption (T/h) 6.25

 Normal operation: Frequency: 3 or 4 hours once a week

 Regeneration operation: During 10 days (once per 3 years minimum).

1.6.2.2 Electricity

During catalyst sulfiding operation (after regeneration or loading), sulfiding agent injection
pump P-72004 is used.
Estimated consumption: <1 kW

1.6.2.3 Start-up requirement

Assume V is the estimated volume of reaction section (V=162 m3) (to be checked by detailed
engineering contractor). Here below are listed the total absolute requirements for the unit.

 Start-up Nitrogen (Nm3/h)

Nitrogen gas will be necessary at start-up and shut-down periods in order to free the unit of
any oxygen or hydrocarbons.

Unit pressurization 8V
Catalyst drying 15V
Unit purge 3V
Total 26 V
Regeneration 17 V

 Start-up plant air (Nm3/h)

Air pressurization and tightness tests 6V
Regeneration air: 408 kg/h for approximately 240 hr.

 Start-up Hydrogen (Nm3/h)

Unit pressurization 20 V
Make-up 10 V
Total 30 V

 Low pressure steam

Engineering to estimate the required steam consumption for:
o The steam out of vessels,
o The reaction section oxygen purging (using the start-up ejector).
1.7 Waste effluents
The effluent summary (72-GM-E-206072) is included in paragraph 1.7 of document 72-GA-
E-205091.
Figures given hereafter are estimated characteristics.

1.7.1 Flue gas from heaters

Flue gas effluent compositions and flowrates from Reactor Heater H72001 and Stripper
Reboiler Heater H72002 have to be given by heater manufacturers.

1.7.2 Sour Water to Sour Water Stripper

In normal operation, sour water from drums V72003 and V72006 is routed to Sour Water
Stripper.
Maximum ammonium salts concentration: 4 wt%.
Stream composition:
Flowrate (kg/h)
H2O 6250
H2S 36.2
NH3 17
Total 6303.2
1.7.3 Waste effluents during in-situ catalyst regeneration

1.7.3.1 Spent caustic to treatment

Estimated composition of spent caustic is as follows:

Component Composition wt %
N2 -
CO2 -
H2O 94.9
NaOH 1.6
(NH4)2SO4 -
Na2CO3 2.4
Na2SO3 1.1
Total Flowrate (kg/h) 4 698

1.7.3.2 Purge gas

Estimated composition and flowrate of the purge gas are as follows.

Component Composition mol. %

N2 93.4
CO2 4.3
H2O 1.2
Ar 1.1
Total 100.0
Flowrate kg/h 337
1.8 Qualified and recommended equipment, suppliers and sellers
1.8.1 Definition of qualified and recommended list

"List of Qualified Equipment and supplies. The list included hereafter, specifies all
Qualified Equipment and supplies. The process design of all Qualified Equipment and
Supplies is included in the process book. Such process design by Licensor does not alter
Licensee's sole responsibility to perform the detailed engineering, procurement, expediting,
inspection installation, start-up and acceptance of the Qualified Equipment and Supplies. For
the avoidance of doubt, Qualified Equipment and Supplies contribute to Licensor assessment
in its determination of guaranteed performances (if any)."
"List of Qualified Sellers. The list included hereafter, specifies for each Qualified
Equipment and Supply, the names of the Qualified Sellers.
As specified in the license agreement, failure by Licensee to select, for any Qualified
Equipment or Supply, its seller from among the listed Qualified Sellers results in cancellation
of Axens' performance guarantee for the relevant process unit.
For the avoidance of doubt, Qualified Equipment and supplies have been developed
concurrently with the development of the licensed process. Axens maintains an all-year
relationship with all such Qualified Sellers and qualifies them for the manufacture of the
Qualified Equipment and Supplies in view of their ability to deliver the expected
performance."
"List of Recommended Equipment and Supplies. The list included hereafter, specifies all
Recommended Equipment and Supplies. The process design of all Recommended Equipment
and Supplies is included in the process book. Such process design by Licensor does not alter
Licensee's sole responsibility to perform the detailed engineering, procurement, expediting,
inspection, installation, start-up and acceptance of the Recommended Equipment and
Supplies.
Subject to the above and based on its review of past and current experience, Licensor believes
that the Recommended Equipment and Supplies, as long as they are manufactured by
Recommended Sellers in accordance with Licensor's process requirements and Sellers
customary quality standards, should perform, including during start-up and subsequent
operations, in accordance with the quality requirements customary to the oil, gas and
petrochemical industry."
"List of Recommended Sellers. The list included hereafter, specifies for each Recommended
Equipment and Supply, the names of the Recommended Sellers.
Axens maintains a relationship with all such Recommended Sellers and qualifies them for the
manufacture of the Recommended Equipment and Supplies in view of their ability to
contribute to the expected performance."
1.8.2 List of qualified and recommended sellers for equipment and supplies

1.8.2.1 List of qualified sellers

1.8.2.1.1 CATALYST (HR-506)

AXENS
89, bd Franklin Roosevelt – BP 50802
92508 Rueil-Malmaison Cedex
France
Phone: 33 (0) 1 47 14 21 00
Fax : 33 (0) 1 47 14 25 00
e-mail/web site : www.axens.net

1.8.2.1.2 ABSORBENT (D-1275)

AXENS
89, bd Franklin Roosevelt – BP 50802
92508 Rueil-Malmaison Cedex
France
Phone: 33 (0) 1 47 14 21 00
Fax : 33 (0) 1 47 14 25 00
e-mail/web site : www.axens.net

1.8.2.1.3 GRADING MATERIALS (ACT, Inert balls)

AXENS
89, bd Franklin Roosevelt – BP 50802
92508 Rueil-Malmaison Cedex
France
Phone: 33 (0) 1 47 14 21 00
Fax : 33 (0) 1 47 14 25 00
e-mail/web site : www.axens.net
1.8.2.2 List of recommended sellers

1.8.2.2.1 Reactor internals made with profile wire screens

JOHNSON FILTRATION SYSTEMS

Zone Industrielle
86530 Availles en Châtellerault
France
Phone : 33 (0) 5 49 02 16 00
Fax : 33 (0) 5 49 02 16 16
e-mail/web site : www.johnsonscreens.com

EUROSLOT
Z.A. Les Priédons Sud
86140 Scorbé-Clairvaux
France
Phone : 33 (0) 5 49 93 93 93
Fax : 33 (0) 5 49 93 86 71
e-mail/web site : www.euroslot-screens.com

JOHNSON SCREENS (Australia)

88 Brickyard Road
Geebung QLD 4034
Australia
Phone : 61 (7) 3867 5555
Fax : 61 (7) 3265 2768
e-mail/web site : www.johnsonscreens.com

NAGAOKA INTERNATIONAL CORPORATION

6-1 Nagisa-cho,
Izumiotsu-city - Osaka
Japan
Phone : 81 725 21 5750
Fax : 81 725 21 2266
e-mail/web site : www.nagaokajapan.co.jp
1.8.2.2.2 Corrosion inhibitor
CHIMEC S.P.A.
Via Delle Ande, 19
00 144 Roma
Italy
Phone: 06 918251
Fax : 06 5918943
e-mail/web site : www.chimec.it

1.8.2.2.3 Sulfiding agent

ARKEMA
4-8 cours Michelet, Cedex 42
92091 Paris La Défense 10
France
Phone: 33 (0) 1 49 00 80 80
Fax : 33 (0) 1 49 00 83 98
e-mail/web site : www.arkemagroup.com