Presentation on theme: "IMPROVEMENT OF LUBE OIL UNITS IN DAURA REFINERY BY COOPERATION BETWEEN PRDC & MRC WITH IMPA – ENGINEERING Prepared by Senior chief engineer SALAH MAHDI."— Presentation transcript:
IMPROVEMENT OF LUBE OIL UNITS IN DAURA REFINERY BY COOPERATION BETWEEN PRDC & MRC WITH IMPA – ENGINEERING Prepared by Senior chief engineer SALAH MAHDI ALI
النفط الخام Crude Oil 100,000 BPSD النفط الاسود الى الطاقة Fuel Oil For Power House النفط الاسود ( الخام المختزل ) الى الدهون Reduced Crude To Lube Plants وحدة هدرجة النفثا HDS Naphtha 18,000 BPSD وحدة تحسين البنزين رقم ( 2 ) Catalytic Reforming 10,000 BPSD وحدة تحسين البنزين رقم ( 1 ) Power Former 5,000 BPSD وحدة هدرجة النفط الابيض Kerosene HDS 13,000 BPSD وقود الطائرات Jet Fuel Blending النفط الاسود / المتبقي Heavy Fuel Oil / Residual زيت الغاز الخفيف Light Gas Oil Kirkukeكركوك API 35 o /36 o Basrah بصرة API 29 o /30 o Naft Khana نفط خانة API 42 o API 32 o وحدة استخلاص الغاز السائل LPG Unit 220 Ton/D وحدات التقطير الجوي Atmospheric Distillation Units زيت الغاز الثقيل Heavy Gas Oil شبكة غاز الوقود Fuel Gas Net بروبان الى وحدات الدهون Propane To Lube Plants النفط الاسود Heavy Fuel Oil وقود الديزل Diesel Fuel زيت الغاز الخفيف Gas Oil وقود الطائرات Jet Fuel النفط الابيض Kerosene بنزين السيارات Gasoline الغاز السائل LPG الشعلة Flare هيئة الزيوت الخفيفة Light oils corporation
هيئة الدهون Lube Oil corporation هيئة الدهون Lube Oil corporation دهون نهائية مختلفة الانواع Different Types Of Finished Lube Oils وحدة التقطير الفراغي Vacuum Distillation Unit وحدة ازالة الاسفلت PDA Unit وحدة الاستخلاص بالفرفرال Furfural Extraction Unit وحدة ازالة الشمع بالمذيب Solvent Dewaxing Unit وحدات هدرجة الدهن والشمع Oil & Wax Hydrofinshing Units زيت الغاز الفراغي V. G. O. 40 B.O. 60 B.O. 150 B.O. الشمع الصلب H. W. مادة الاكستراكت Extract الاسفلت الممزوج Blend Asphalt متبقي التقطير الفراغي V. R. الشمع الرخو S. W. 1 S. S. 3 S. S. D. A. O. الاسفلت الاساس Base Asphalt 40 Raff. 60 Raff. 150 Raff. 40 W.F.O. 60 W.F.O. 150 W.F.O. H. W. الخام المختزل R. C. الاسفلت المؤكسد Blown Asphalt 2 S. S. 2 S. S. (Fuel Oil System منظومة الوقود السائل) وحدة الاسفلت المؤكسد Blown Asphalt Unit مزج الاسفلت Asphalt Blending V. R. بروبان C 3 هواءAir مذيبSolvent فرفرال Furfural هيدروجين H 2 وحدات المزج Blending Units المضافات Additives
Object Deasphalting Unit No. 2 at Daura Refinery. The unit was designed &constructed by Snamprojetti,Italian company;&it was running from Purpose of the work Increasing of the plant capacity on feed. Brief of the technical proposal IMPA Engineering Co. suggests two variants of modernization. Variant No. 1 is aimed at increasing capacity by 10 – 15 %. Variant No. 2 is aimed at maximizing capacity by 30%.
Preliminary unit analysis Preliminary analysis of existing propane deasphalting unit : 1. Productivity of the unit decreased compared to design values due to inefficient work of furnace and heat exchangers. 2. The rotary disc contactors do not work and it affect the extraction process which will not achieve the design conditions. 3. Efficiency of some pumps is reduced due to their mechanical deficiency. 4. Ineffective scheme of solvent recovery in evaporators 02-Т2, 02- Т4.
The original flow diagram of the propane de-asphalting unit with faulty elements
Extractor 02-T1 analysis The extraction process on propane deasphalting unit was affected due to the improper function of rotary disk contactors which leads to the following: – low efficiency of the extractor because of poor mass transfer of phases. – reduction of plant capacity due to coke deposition on the rotary disk contactors. Therefore the main task is to upgrade the extractor by using RN-IMPA regular packing as a mass-transfer devices in the extractor. This packing has been specially designed for the process of propane de asphalting as used in Russia.
Regular packing for extraction processes Field of application Realization of mass-exchange process in ‘liquid-liquid’ systems for extraction refining and separation of hydrocarbons. Examples of application extraction columns of lube-oil selective treatment units; extractors of aromatic hydrocarbons separation sections of catalytic reforming units; extractors for after treatment of diesel fuel. Results improvement of product quality; increase in target product yield; reduction of ‘solvent-feed’ ratio; reduction of power consumption. Features of the packing film mode of flow; the film is double-sided; turbulent mode of flow; redistribution of liquid; higher efficiency.
Note: The actual capacity now is about 70% of the design about 9 m3/h due to limitations of heater & exchanger. Therefore the 1 st increment is from actual to design(30%) 2 nd increment is from design to 130% Design Case 1 Case2
Description of technical proposal for variant № 2-A Purpose – maximum increase in capacity (preliminary 30 %). Technical proposal: 1) Replacement of internal devices of extractor 02-T1: – using RN-IMPA tower packing; – replacement of heaters at the top of the column. 2)Modernization of fired heater with replacement of furnace coil 02-Н1. 3)Replacement of faulty pumps 02-P1, 02-P2, 02-P3,02-P4 which would allow a capacity increase of 30%. 4)Replacement of faulty heat exchangers or tube bundles. 5) Replacement of the internal devices of columns 02-T3 and 02-T5. 6) Optimization of the process and process parameters of the unit: – changing the operating mode of the column 02-Т1; – installation of a new heat exchanger 02-E6 / 1 AB on the propane cooling and condensation line in series with 02-E6 AB; – installation of an additional heat exchanger in front of the fired heater on asphalt flow. 7) Use of an additional second stage flash tower 02-T2 / 1 for de asphalted oil: – installation of heat exchanger 02-E4/1 on the line of de asphalted oil from 02-T2 to 02-T2/1; – to supply propane from 02-T4 under the liquid level in the new evaporator 02-T2/1.
Rosneft, LLC “Novokuybishevsk lube-oil and additives plant” 1. Deasphalting unit # 36/3 Year of modernization: Deasphalting unit # 36/4 The modernization purpose – increase in feed capacity. Description: single unit’s feed capacity 900 tons per day, 40 m3/h feed vacuum residua solvent liquid propane products deasphalted oil, asphalt Scope of work: base project; design of the new extractors; Results: increase in feed capacity on 30 %; increase in deasphalted oil yield by 3 – 5 % reduction of “solvent-feed” ratio by 20 % the tower packing works without repair of 5 years.
Flow diagram modernized plant for the variant № 2-А
Description of technical proposal for variant № 2-B/С Purpose – maximum increase in capacity (preliminary 30 %). Technical proposal: 1) Replacement of internal devices of extractor 02-T1: – using RN-IMPA tower packing; – replacement of heaters at the top of the column. 2)Modernization of fired heater with replacement of furnace coil 02-Н1. 3)Replacement of faulty pumps 02-P1, 02-P2, 02-P3,02-P4 which would allow a capacity increase of 30%. 4)Replacement of faulty heat exchangers or tube bundles. 5) Replacement of the internal devices of columns 02-T3 and 02-T5. 6) Optimization of the process and process parameters of the unit: – changing the operating mode of the column 02-Т1; – installation of a new heat exchanger 02-E6 / 1 AB on the propane cooling and condensation line in series with 02-E6 AB; – installation of an additional heat exchanger in front of the fired heater on asphalt flow. 7) For variant 2-В: installation the evaporator 02-Е4/1on the line of mixture DAO with propane from 02-Т1to 02-Е3. For variant 2-С: installation two evaporators 02-E4/1 and 02-E4/2 on the line of mixture DAO with propane from 02-Т1 to 02-T2 and use the column 02-T2 as separator. To supply propane from 02-T4 with the propane from evaporators 02-E4/1 and 02-E4/2 to 02-T2.
Flow diagram modernized plant for the variant № 2-В
Flow diagram modernized plant for the variant № 2-С
Subjects under discussion 1- All materials, mechanical design and manufacturing should be standardized according to international codes which are used in Iraqi refineries ( MRC ). 2 - Due to the high sulfur content in Propane ( there is no any sweetening unit in MRC for LPG ) and to avoid the corrosion problem in the existing equipment and the new installed equipment discussion was carried out to install new sweetening unit. 3- Ensuring that the increase in capacity should not affect the existing specifications or it will improve to any positive limits. 4- Due to increasing in capacity,the utilities such as : electricity, steam, C.W, F.G, solvents will be increased, it is necessary to fix the difference to prepare the demands and the total consumption / ton product should be less than the original rate as IMPA committed.
Recommendations on process control -The process of de asphalting is carried out using liquid propane at pressures up to 40 atm. and refers to the high-class explosion and fire facilities. -For control of units of this class, it is advisable to replace the current automated system to modern one. -This will also improve the accuracy of received information and the quality of technological parameters control.