Iocl Section 1 Process Specfication

INDIAN OIL CORPORATION LIMITED
NAPHTHA CRACKER PROJECT
800,000 TPA ETHYLENE PLANT
PANIPAT, INDIA
BASIC ENGINEERING PACKAGE
NAPHTHA CRACKER UNIT
SECTION 1 PROCESS SPECIFICATIONS
IOCL Section 1 – Process Specification.doc

February, 2005

PANIPAT, INDIA
PROCESS SPECIFICATION
for
LUMMUS PROJECT 12605

REVISION 1
ISSUE DATE FEBRUARY 28, 2005
BY RPT
IOCL Section 1 – Process Specification.doc Page 1

February, 2005

PANIPAT, INDIA
PROCESS SPECIFICATION
INDEX
ARTICLE I PLANT ELEMENT
1.0 WHAT CONSTITUTES THE PLANT

2.0 GENERAL DESCRIPTION OF THE NAPHTHA CRACKER UNIT
2.1 ISBL Facilities
2.2 ISBL Supporting Facilities
2.3 Capacity and Mode of Operation
2.4 Process Description
ARTICLE II PLANT SPECIFICATIONS
1.0 BASIS FOR PROCESS DESIGN

1.1 Plant Function and Capacity
1.2 Feedstock Properties
1.3 Product Specifications
1.4 Utility Specification
1.5 Site Location and Climatic Conditions
1.6 Battery Limit Conditions
1.7 Environmental Specifications
2.0 BASIS FOR PROCESS PERFORMANCE

2.1 General
2.2 Overall Material Balance
2.3 Once-Through Cracking Yields
2.4 Utility Consumption
2.5 Specific Energy Consumption
2.6 Catalyst and Chemical Consumption
2.7 Pyrolysis Heater Performance
2.8 Assumed Efficiencies
2.9 Heat Leak Factors

February, 2005
ARTICLE I – PLANT ELEMENTS
1.0 WHAT CONSTITUTES THE PLANT
The naphtha cracker project for Indian Oil Corporation Ltd. located in Panipat,
India consists of ISBL Process units and supporting facility designed to produce
polymer grade ethylene, polymer grade propylene, 1,3 Butadiene, benzene,
C7-C8 cut, partially hydrogenated C9+ stream and pyrolysis fuel oil.
The plant consists of the following process units:
• Naphtha Cracker Unit (NCU)

NCU uses naphtha as feedstock to produce polymer grade ethylene,
polymer grade propylene, raw C4 mix, raw pyrolysis gasoline and
pyrolysis fuel oil. Ethane, propane, hydrogenated C4s, C5s and C6 are
recycled to extinction. Recycles from polymer plants, ethylene BOG
from atmospheric storage and the FCC streams are the additional
feeds to the NCU recovery unit.
• Butadiene Extraction Unit (BEU)

BDEU recovers 1,3 Butadiene from the raw mixed C4s stream
produced in the NCU. BD raffinate is sent to the C4 hydrogenation unit.
• C4 Hydrogenation Unit
C4 hydro is designed to fully hydrogenate the BD raffinate in normal
operation. Hydrogenated C4s are recycled to the NCU cracking
heaters.
In alternate operation, when BEU is not operating, C4 hydrogenation

unit will process raw C4 mix. Butadiene and a portion of the butenes
are hydrogenated in this mode of operation.
• Pyrolysis Gasoline Hydrogenation Unit (PGHU)

PGHU processes raw pyrolysis gasoline from naphtha cracker in a
two-stage hydrotreating unit to produce a C6-C8 heart cut that is sent to
the Benzene Extraction Unit for benzene recovery, a fully
hydrogenated C5 cut that is recycled to the cracking heaters and a
partially hydrogenated C9+ product.
• Benzene Extraction Unit (BZEU)

BEU recovers benzene from the C6-C8 heart cut. Non-aromatic C6
stream is recycled to the NCU cracking heaters and C7-C8 cut is sent
as product to storage.
Block diagram of the process units is presented in Figure 1.1.

February, 2005
This Basic Engineering Package (BEP) for Naphtha Cracker Unit includes total
C4 hydrogenation and pyrolysis gasoline hydrogenation units. BEP for Butadiene
Extraction Unit and Benzene Extraction Unit are provided as separate
documents.

February, 2005
2.0 GENERAL DESCRIPTION OF THE NAPHTHA CRACKER UNIT
The naphtha cracker is designed to produce polymer grade ethylene and

polymer grade propylene by thermal cracking of naphtha and hydrogenated
C4/C5/C6 recycle streams from C4 hydrogenation, pyrolysis gasoline
hydrogenation and benzene extraction units respectively. Ethane and propane
are recycled to extinction. .
Recycles from LLDPE (swing plant), HDPE and PP plants, ethylene boil-off gas
(BOG), and FCC feeds are the additional feeds to the naphtha cracker recovery
unit.
The naphtha cracker unit is designed to produce the following by-products:
• Hydrogen
• Methane offgas
• Raw mixed C4
• C4 LPG (provision to draw part of hydrogenated C4 to LPG pool)
• Hydrogenated C6-C8
• Partially hydrogenated C9+ product
• Pyrolysis fuel oil (combined PGO + PFO)
2.1 ISBL Facilities
The ISBL facilities of the naphtha cracker unit consists of the following
processing areas:
• Cracking Heaters Feed System

• Pyrolysis Module
• Charge Gas Oil Quenching
• Gasoline Fractionation, Pyrolysis Gas Oil and Pyrolysis Fuel Oil
Stripping
• Charge Gas Water Quenching
• Process Water Stripping and Dilution Steam Generation
• Charge Gas Compression, Gasoline Stripping, Condensate Stripping
and Condensate Stripper Bottoms Drying
• Acid Gas Removal via Caustic Wash
• Spent Caustic Pretreatment via Gasoline Wash
• Charge Gas Drying and Dryer Regeneration Facilities
• Cracked Gas Chilling
• Demethanization and Methane Refrigeration
• Methanation and Hydrogen Purification
• Deethanization, Acetylene Hydrogenation, C2 Green Oil Removal and
Ethylene Drying
• Ethylene Fractionation

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• Ethylene Product System

• Depropanization and Debutanization
• MAPD Hydrogenation and Propylene Fractionation
• FCC C3s Treatment
• C4 Hydrogenation
• Pyrolysis Gasoline Hydrogenation (1st and 2nd stage)
• Propylene and Ethylene Refrigeration
2.2 ISBL Supporting Facilities
The supporting facilities include the following systems inside the battery
limit:
• Fuel gas system including LPG vaporizing facility and the fuel gas mix
drum, distribution and controls
• Chemical storage facilities, considered necessary for smooth operation
of the plant. Specifically these shall be limited to the day tanks of
caustic, DMDS, wash oil and methanol. Chemical injection facilities are
included
• Spent caustic pre-treatment
• Boiler feed water (1)
• Steam generation from the TLEs (1)
• Condensate collection, treatment, polishing and deaeration (1)
• Flare load summary, including ISBL knock-out drums, vaporizer and
liquid pumping (1)
• Plant air and instrument air (2)
• Nitrogen (2)
• Cooling water (2)
• Electrical (2)
Notes:
(1) Process design of these facilities is included in FEED package.
(2) The BEP does not include process design of these supporting
facilities, but does include user summaries defining the requirements
for supporting facilities.
2.3 Capacity and Mode of Operation
Base Capacity
The plant shall be designed to produce 800,000 TPA of polymer grade

ethylene, 504,834 TPA of polymer grade propylene in 8,000 operating
hours a year when cracking design naphtha and ethane, propane and
hydrogenated C4/C5/C6 streams. The production rates are net without
processing polymer plants recycles, ethylene BOG and the FCC feeds.

February, 2005
Case 1
This case includes recycles from LLDPE and PP planets and ethylene
BOG from atmospheric storage. The plant shall produce 830,632 TPA of
polymer grade ethylene, 584,352 TPA of polymer grade propylene in
8,000 operating hours a year when cracking design naphtha at flow rate
(293,201 kg/h) corresponding to base ethylene and propylene capacity
and processing LLDPE (swing plant) and PP recycles and ethylene BOG
vapors. FCC feeds are not processed in this case. Ethane, propane and
hydrogenated C4/C5/C6 are recycled to cracking heaters as in the base
case.
Case 2
This case includes two FCC streams as additional feed namely,
1) Treated FCC dry gas C2s and

2) Raw FCC C3s.
The plant shall produce 857,408 TPA of polymer grade ethylene, 666,544
TPA of polymer grade propylene in 8,000 operating hours a year when
cracking design naphtha at flow rate (293,201 kg/h) corresponding to base
ethylene and propylene capacity and processing recycle streams from
LLDPE and PP plants, ethylene BOG and FCC feeds. Ethane, propane
and hydrogenated C4/C5/C6 are recycled to cracking heaters.
The capacity and mode of operation is summarized below:
Design Case Feeds Ethylene Propylene Remarks

Capacity, Capacity,
TPA TPA
Base Case • Naphtha 800,000 504,834 --

• Hydrogenated
C4/C5/C6
recycle
•
Case 1 • Naphtha 830,632 584,352 Detailed Material
Balance Case
• Hydrogenated
C4/C5/C6
• LLDPE
recycle
• PP recycles
• Ethylene
BOG

February, 2005
Design Case Feeds Ethylene Propylene Remarks

Capacity, Capacity,
TPA TPA
Case 2 • Naphtha 857,408 666,544 Detailed Material

Balance Case
• Hydrogenated
C4/C5/C6
recycle
• LLDPE
recycle
• PP plant
recycles
• Ethylene
BOG
• FCC feeds
2.3.1 Turndown
The plant shall be designed for turndown to 70% of the design capacity.
Desired 50% minimum turndown will be achieved by over refluxing/reboiling the

towers and recycling.
2.3.2 Future Capacity
The plant shall be expandable to 1,000,000 TPA, preinvested for those

equipment which are necessary and those that cannot be modified in 30 days
mechanical shutdown of the plant.
Only critical piping will be designed for 1,000,000 TPA, all other piping will be
designed for 800,000 TPA.
2.4 Process Description
This section describes the process flow scheme selected for this project and as
shown on the Process Flow Diagrams.
Cracking Heaters Feed System
Naphtha feed is received from storage tanks outside battery limits at pressure
and ambient temperature. The naphtha is filtered and mixed with hydrogenated
C4, C5 and C6 recycle streams and then preheated against quench water to 60°C
prior to being sent to the SRT VI liquid cracking heaters. Sulfur injection (DMDS)
is provided into the naphtha/C4/C5/C6 feed upstream of the preheater. DMDS
injection in liquid feed is done only when sulfur content in naphtha feed is low.

February, 2005
Recycle ethane, after vaporization against charge gas and reheat in the cold box
is mixed with vaporized propane recycle. The combined ethane/propane stream
is superheated with quench water to 60°C before being sent to the recycle
cracking heater. DMDS injection into the ethane/propane recycle is provided
downstream of the superheater.
Raw C4 mix or BD raffinate is co-cracked with naphtha/ C4/C5/C6 during 1

regeneration of C4 hydro reactor catalyst
Pyrolysis Module
Six SRT VI and one SRT III type cracking heaters are provided. Five SRT VI
heaters are normally in service cracking liquid feedstock (naphtha/C4/C5/C6). One
SRT VI heater is available as a spare to provide operating continuity during
decoke operations.
The SRT III heater is in operation cracking ethane/propane recycle. When

recycle heater is being decoked, ethane/propane recycle is cracked in one of the
two liquid cracking heaters (11-H-0200/11-H-0300).
All the SRT VI and SRT III heaters operate using fuel gas only. The primary fuel
gas is methane rich offgas produced in the naphtha cracker unit. Make-up/ back-
up fuel is C3/C4 LPG supplied from adjacent refinery or RLNG vapor. As the
primary fuel gas is not sufficient to fully meet the heater firing demand, the small
shortfall is met by make-up LPG fuel. Combustion air for all the heaters is 100%
ambient air. Each heater is equipped with an ID fan for directing the flue gas to
the heater stack. All heaters are designed for steam/air decoking of the radiant
coil with the decoking effluent being sent directly to the heater firebox for
combustion.
For the SRT VI liquid heaters, the liquid feedstock is flow controlled to six sets of
radiant coils per liquid cracking heater. The liquid feed is first heated in the feed
preheat section of the heater, with the liquid feed being partially vaporized prior
to steam injection. The dilution steam injection is added to each coil on flow ratio
control. Dilution steam is first superheated in the dilution steam superheat section
of the heater which is located below the lower feed preheat section prior to
injection into the partially vaporized feed. The total mix is further heated in the
heater’s mixed preheat section before entering the radiant coils.
For ethane/propane recycle processing when 11-H-0100 is out of service, the

preheated ethane/propane vapor feed is flow controlled to the six sets of radiant
coils using an alternate feed control valve set and the dilution steam is added to
each coil on flow ratio control. The total feed enters at the inlet of the upper
mixed feed preheat section.

February, 2005
The crossover pipe from each convection section coil feeds a single radiant coil
manifold at the top of the radiant section. Each radiant coil consists of a 20-4
inlet-outlet pass configuration (i.e., five 4-1s). The flow from one radiant coil inlet
manifold is distributed to 20 inlet tubes of the first pass using critical flow venturis.
The flow is combined to the 4 tubes of the outlet pass. The 4 outlet radiant tubes
enter the primary TLE inlet head (bathtub type). There are six TLEs per heater.
The effluent from the liquid cracking heaters primary TLEs are combined in two
transfer lines.
For the SRT III gas cracking heater, ethane/propane feed is first heated in the
feed preheat section and then mixed with dilution steam on flow ratio control prior
to entering the secondary TLE (shell-side) where the preheated mix feed is
further preheated against heater effluent. The mixture is then split on flow control
to the six preheat coils, where it is further heated in the convection section before
entering the radiant section. The crossover pipe for each convection coil feeds a
single radiant inlet manifold at the inlet to the radiant section.
The recycle heater radiant coil is a six-pass design employing 4-2-1-1-1-1 inlet-
outlet pass configuration. Four (4) parallel tubes, which split from the radiant coil
inlet manifold comprise the first pass. These tubes join in pairs via a wye piece to
two (2) parallel tubes, which are the second pass of the coil. The two second-
pass tubes are joined via another wye piece to the third pass. A single tube is
used for the third, fourth, fifth and sixth passes.
The effluent from the ethane recycle heater radiant coils is combined in pairs and
sent to primary TLEs, three per cracking heater. The effluent from the primary
TLEs are further combined and sent to a single secondary TLE which cools the
effluent to 255°C. The heat exchanged in the secondary TLE is used to preheat
the mixed hydrocarbon feed after partial heating of the hydrocarbon in the
convection section and after injection of dilution steam.
For the SRT III gas cracking heaters and the SRT VI liquid cracking heaters, the
heater firing is controlled to maintain the average COT of all the coils and the
flow to each coil is adjusted to maintain a constant delta between the coil COT
and the average COT.
The primary TLEs generate steam at 128.5 kg/cm²g via a thermosyphon system
connected to a common steam drum for each heater. The boiler feed water to
the steam drum is preheated in the convection section of the cracking heater.
The steam generated is superheated to about 525°C in a superheater coil
integrated with the convection section of the heater. To control the superheater
outlet temperature, the coil design allows for phosphate free boiler feed water
injection to the partially superheated steam. After the BFW injection, the steam
is returned to the convection section for final superheating to the desired
temperature.

February, 2005
The effluent from the liquid feed heaters is oil quenched in two quench fittings.
The effluent from the recycle heater is not oil quenched, but is cooled via the
secondary TLE. After the secondary TLE, the recycle heater is split with a portion
sent to the quench tower and the remainder going to the midsection of the
pyrolysis feed oil stripper where it is utilized as stripping vapor to maintain and
control the viscosity of the circulating quench oil.
Gasoline Fractionation and Charge Gas Quenching
In the Gasoline Fractionator, the cracked effluent gases are further cooled,
pyrolysis fuel oil (PFO) is separated as a bottoms product, a side stream product-
pyrolysis gas oil (PGO) is withdrawn from the Fractionator, gasoline and lighter
materials are taken as an overhead vapor. Heat removed by circulating quench
oil from the tower bottom is recovered via dilution steam generation and process
water preheat going to the dilution steam drum. The tower is refluxed with
gasoline condensed in the Quench Tower.
The bottom pyrolysis fuel oil from the Gasoline Fractionator is sent to the
Pyrolysis Fuel Oil Stripper. This tower has two stripping sections, the top section
where most of the components boiling between 280°C and 370°C are stripped
out using part of the ethane recycle heater effluent and the bottom section where
PFO from the top section of the Pyrolysis Fuel Oil Stripper is steam stabilized to
achieve a fuel oil product of acceptable flash point. Pyrolysis fuel oil product is
mixed with heavy C9+ cut from the return tower of the Pyrolysis Gasoline
Hydrogenation unit and is cooled to 90°C prior to being sent to OSBL storage. A
side stream product withdrawn from the Fractionator is sent to the PGO Stripper
where it is steam stabilized using superheated LP steam injection from the steam
system. A portion of the stabilized PGO is filtered and used as purge oil for
instruments, the rest is blended with fuel oil and cooled before being sent to
OSBL storage.
The TLE effluent quenching and pyrolysis fuel oil stripping is accomplished in
such a fashion as to reduce the viscosity of the circulating quench oil stream.
The composition of the quench oil is changed by increasing the concentration of
relatively lighter components. This is accomplished by stripping the quench oil
entering the Pyrolysis Fuel Oil Stripper with part of the recycle heater effluent. A
relatively high percentage of components boiling between 280°C and 370°C are
stripped out. As a result, these components do not readily leave the system with
the stripped pyrolysis fuel oil and, therefore, concentrate in the circulating quench
oil. The concentration of this mid-boiling range material will maintain quench oil
viscosity to within the desired limits.
Filtering of the quench oil leaving the gasoline fractionator, the gasoline
fractionator bottoms pump discharge and the PFO stripper feed and product are
provided to prevent the buildup of coke fines and allow continuity of operation
between plant turnarounds. The level of filtering varies from using strainers at the

February, 2005
gasoline fractionator bottoms and cartridge filters on the quench oil pump
discharge, cartridge/basket type for PFO stripper feed and basket type on the
PFO stripper product suction filters.
Overhead vapor from the Gasoline Fractionator is cooled and partially

condensed by direct countercurrent contact with recirculating water in the
Quench Tower. The hot recirculating water from the Quench Tower supplies low
level heat to various process users, namely the Naphtha Feed Preheater,
Recycle Ethane/Propane Preheater, Charge Gas Heater, Deethanizer Reboiler,
MAPD Converter Feed Preheater, Propylene Fractionator Reboilers and Recycle
Propane Vaporizer. Quench water is also used to cool the PGO/PFO product to
90°C in the PGO/PFO Product Cooler.
The quench water is cooled further by cooling water. The overhead vapor from
the Quench Tower is sent to the Charge Gas Compressor. The gasoline
condensed in the Quench Tower is separated from the condensed dilution steam
in the Quench Water Settler. A part of the condensed hydrocarbons is returned
as reflux to the Gasoline Fractionator. The net gasoline is sent to the Gasoline
Stripper.
Process Water Stripping and Dilution Steam Generation
The dilution steam condensed in the quench tower is sent to the process water
stripper, where it is stripped with live dilution steam and LP steam to the bottom
of the tower, to remove acid gases and volatile hydrocarbons. The vapor leaving
the process water stripper is sent to the quench tower.
The process water from the PW Stripper is preheated by quench oil prior to
entering the dilution steam drum where it is then vaporized against circulating
quench oil and medium pressure steam in the dilution steam generators. The
steam generated is superheated against medium pressure steam before reuse
as dilution steam in the cracking heaters, stripping steam to the process water
stripper and as purge steam to the heaters.
Provisions for dilute caustic injection to dilution steam drum feed, process water
stripper feed and quench tower bottoms are provided for pH control.
To prevent a build-up of non-volatiles, a blowdown stream from the dilution

steam drum is drawn, cooled to 40°C against cooling water and sent to OSBL
waste treatment facility.
Charge Gas Compression, Gasoline and Condensate Stripping
The quench tower overhead vapors are compressed from 0.47 to 38.67 kc/cm2g
in a five-stage centrifugal compressor with interstage cooling to about 40°C.
Recycle streams from downstream swing PE plant, HDPE plant and PP plant

February, 2005
and off spec ethylene vapors from HP ethylene storage as well as internal
recycle streams of the naphtha cracker are also reprocessed in the Charge Gas
Compressor system. The charge gas compressor design shall incorporate dry
mechanical seals.
Between the third and fourth stages, the charge gas is treated by caustic wash to
remove acid gases generated in the cracking heaters. Spent caustic from the
caustic/water wash tower is washed with gasoline and sent to OSBL spent
caustic treatment facility.
The condensate from the third stage discharge drum is recycled to the third stage
suction drum; the condensate from the third stage suction drum is recycled back
to the second stage suction drum where hydrocarbon and water separation takes
place. Water condensed in the second stage suction drum is recycled to the first
stage suction drum and then pumped to the quench tower. Hydrocarbon
condensed in the second stage suction drum is sent to the gasoline stripper
which operates just above the 1st stage suction drum pressure. In this tower, the
hydrocarbon liquid is stripped of butane and light material by vapor generated
from the steam heated reboilers. A portion of the bottom liquid is used as wash
gasoline in the spent caustic pretreatment section. The net bottoms is combined
with the debutanizer bottoms, cooled and sent to the Pyrolysis Gasoline
Hydrogenation unit or OSBL storage. The overhead vapor is recycled back to the
quench tower. Provisions are available to send a portion of the bottom liquid to
the bottom of the quench tower to maintain adequate hydrocarbon inventory for
the gasoline fractionator reflux.
The 5th stage discharge, after water cooling is sent to the 5th stage discharge
drum. The vapor is cooled further by reheating lower deethanizer feed and then
by two levels of propylene refrigerant to 15.6°C. The partially condensed
liquid/vapor mixture flows to the dryer feed drum.
Hydrocarbon and water is separated in the dryer feed drum. The hydrocarbon is
pumped to the 5th stage discharge drum, and the water is sent to the 5th stage
suction drum. Condensed hydrocarbon and water from the 5th stage discharge
drum is sent to the 5th stage suction drum, where hydrocarbon and water
separation takes place. Water from the 5th stage suction drum is sent to the 4th
stage suction drum. Hydrocarbon from the 5th stage suction drum is sent to the
condensate stripper.
The condensate stripper operates just above the 4th stage suction drum
pressure. In the condensate stripper, the hydrocarbon is stripped of ethane and
lighter materials by the vapor generated by a steam heated reboiler. The
overhead vapor is recycled to the fourth stage suction drum. Water and
hydrocarbon condensed in the fourth stage suction drum is recycled to the
quench tower. The stripper bottoms is cooled against cooling water and sent to
the condensate stripper bottoms filter/coalescer. The purpose of the

February, 2005
coalescer/filter package is to remove free water from the stripper bottoms before
being sent to the dryers. Condensate stripper bottoms, after passing through the
coalescer is dried in a liquid-phase two-dryer molecular sieve drying system. One
dryer is operating while the other is being regenerated in a cyclic operation. The
dried stripper bottoms is sent to the depropanizer. Any water collected in the
condensate stripper is withdrawn from an intermediate tray and recycled back to
the 3rd stage suction drum.
The Charge Gas Compressor fouling is controlled by injecting wash oil into the
suction of each compressor stage. Common boiler feed water and wash oil
injection nozzles are provided for all wheels as an option for the future. The
source of wash oil can be light cycle oil or partially hydrogenated C9+ stream
from the Pyrolysis Gasoline Hydrogenation unit.
Acid Gas Removal
The 3rd stage discharge drum vapor is preheated to 45°C against quench water
prior to entering the caustic/water wash tower. In the caustic/water wash tower
the acid gases (H2S and CO2) are removed from the charge gas stream by
contacting with caustic solution. 50% caustic is received from OSBL which is
diluted to 20% before use in the caustic tower. The tower has two caustic
circulating sections in addition to the water wash section. The water wash section
has bubble cap trays while the two caustic circulating sections have valve trays.
After scrubbing in the two caustic sections, the charge gas essentially free of H2S
and CO2 is water washed using blowdown from the steam system in the top
water wash section to prevent caustic carryover into the downstream equipment.
The majority of the spent wash water is used to dilute the make-up caustic to the
upper caustic circulation. The net excess spent wash water is sent to OSBL
spent caustic treatment. The charge gas from the overhead of the caustic/water
wash tower is returned to the 4th stage suction of the charge gas compressor.
The spent caustic blowdown is sent to the spent caustic pretreatment section for
removal of free oils via gasoline wash prior to being sent to final OSBL spent
caustic treatment.
Any polymeric oil (yellow or red oil) which may accumulate in the tower bottom is
recombined with spent caustic stream and sent to the spent caustic/gasoline
wash system. The polymeric oil leaves with the spent gasoline from the spent
gasoline coalescer and is sent to the quench tower.
Spent Caustic Pre-treatment
The spent caustic solution from the caustic/water wash tower cannot be
discharged to the environment without further treatment. The spent caustic
solution contains sodium carbonate, sodium sulfide and a small percentage of
free (not reacted) sodium hydroxide. In addition, the solution may contain
dispersed hydrocarbons. The dispersed hydrocarbons in the spent caustic may

February, 2005
cause considerable fouling in the downstream OSBL treating unit and are
therefore removed with a gasoline wash.
Spent caustic from the caustic tower is mixed with wash gasoline from the
gasoline stripper in the feed line to the spent caustic coalescer. The spent
caustic/wash gasoline mixture is first degassed in the coalescer and then is
passed through a packed coalescing pad where the oil/caustic separation takes
place. The spent gasoline is then mixed with wash water drawn from the dilution
steam generator feed pump in the dilution steam system in the feed line prior to
entering the spent gasoline coalescer where the gasoline/water mixture is
passed through a packed bed for removal of entrained spent caustic. After
separation, the spent gasoline is returned to the quench tower. The spent
gasoline requires water washing to reduce the quantity of entrained caustic which
can cause a pH problem in the quench tower. The gasoline washed spent caustic
from the spent caustic coalescer is sent to OSBL for further treatment.
Charge Gas Drying
The charge gas at 15.5°C from the dryer feed drum is dried in a two bed
molecular sieve drying system. One bed is on stream while the other bed is
being regenerated in a cyclic operation. Methane offgas from the recovery
section is heated by high pressure steam and used to regenerate the desiccant.
The regeneration gas is cooled and sent to the regeneration gas K.O. drum for
removal of water prior to entering the fuel gas system. Any condensed water
from the regeneration gas K.O. drum is returned to the quench tower.
Charge Gas Chilling
The dry charge gas is progressively chilled against the process (deethanizer
feed, ethylene fractionator side reboiler, ethane recycle, demethanizer bottom
and side reboilers) and propylene and ethylene refrigeration to –72°C. The
condensate is separated in the demethanizer feed separator No. 1 and fed to the
demethanizer as two streams (demethanizer feed No. 1 and 2), after heat
exchange against itself.
The charge gas from the demethanizer feed Separator No. 1 is chilled against off
gases and coldest level of ethylene refrigerant to –97.9°C. The condensate is
separated in separator No. 2 and sent to the demethanizer as feed No. 3.
The charge gas from demethanizer feed separator No. 2 is further chilled in the
cold box to –131°C by heat exchange with hydrogen and methane offgas and by
evaporation of liquid methane. The condensate is separated in demethanizer
feed separator No. 3 and sent to the demethanizer as feed No. 4. The coldest
feed to the demethanizer is obtained from this drum and the residual gas is
hydrogen of approximately 75 mol% purity.

February, 2005
The hydrogen rich stream is further upgraded to 95+ mol% purity in a two stage
expansion system. Here, hydrogen purification takes place in an adiabatic heat
exchange system in which the refrigeration required is derived from expansion of
liquefied methane (Joule-Thompson Expansion). In the first Joule-Thompson
Expansion, the 75 mol% purity stream is chilled to -143 °C, condensing a portion
of the contained methane and essentially all of the C2s. Refrigeration is provided
by expanding the condensed liquid to demethanizer overhead pressure. After
reheating, the methane rich stream is blended with the demethanizer overhead,
reheated further and sent to the dryer regeneration/fuel gas system as HP
methane. In the second Joule-Thompson Expansion, the overhead vapor which
is now about 83.5 mol% purity hydrogen is further chilled to -165 °C. The
refrigeration for this step is provided by expanding the condensed liquid to fuel
gas system pressure. Liquid is expanded, vaporized, reheated and sent to the
fuel gas system as LP methane.
The second JT expansion yields approximately 95.7 mol% hydrogen. This

hydrogen is reheated in the chilling train and sent to the methanator to meet the
carbon monoxide specification.
Demethanizer
The condensed liquids from the charge gas chilling train along with the vent gas
from ethylene fractionation and propylene fractionation, and light gas recycle
from PP plant are sent to the appropriate feed locations of the demethanizer.
This tower is operated at a pressure just high enough to permit using the
overhead methane product for dryer regeneration and still be at fuel gas
pressure. Provision for reprocessing off spec ethylene is also provided in the
demethanizer. Based on selected technology, there will be no recycle from PP
plant to the demethanizer as shown on the process flow diagram.
The demethanizer reboiling is carried out with charge gas in both the bottom and
side reboilers. The bottoms product is reheated against ethylene and propylene
refrigerant in the cold box, after which it is split into two streams. One stream is
sent directly as liquid to the deethanizer as the top feed. The other stream is
sent to the deethanizer as the second feed, but after further preheat against
charge gas in dryer effluent chiller and 5th stage discharge drum overhead vapor
in dryer feed cooler. Reflux to the tower is provided by an open-loop methane
refrigeration system which utilizes a motor driven centrifugal compressor. The
methane refrigeration is condensed by the lowest level ethylene refrigeration.
The system provides liquid methane as reflux to the tower as well as vapor/liquid
methane refrigeration for the chilling of the coldest demethanizer feed.
The overhead of the demethanizer is split into two streams, one stream is mixed
with reflux drum liquid and sent to the cold box as high pressure (HP) methane
refrigerant. The other stream is heated and compressed. The compressor
discharge is cooled against cooling water, chilled by demethanizer overhead

February, 2005
vapor and ethylene refrigerant and then it is sent to the reflux drum. The vapor
from the reflux drum is mixed with part of the demethanizer overhead going to
the cold box as HP methane. Part of the liquid from the reflux drum is sent to the
demethanizer as reflux. The remainder reflux drum liquid is mixed with
demethanizer overhead as discussed above and sent to cold box as methane
refrigerant.
A small portion of the methane refrigerant compressor discharge is sent to OSBL

as ballast gas for downstream MEG plant.
Methanation and Hydrogen Drying
The methanation section takes raw hydrogen (95 + mol% hydrogen) generated in
the hydrogen methane separator No. 2 and prepares it for use in the downstream
hydrogenation process. This involves two primary processing steps:
- Methanation is the conversion of the carbon monoxide (CO) in the

hydrogen to methane (CH4) and water. CO is a catalyst poison in the
downstream hydrogenation reactions.
- Drying of the hydrogen is required for the hydrogenation reactors as water

is a poison to these catalysts.
The hydrogen stream from the cold box is first heat interchanged with effluent
from the methanator and then further heated using high pressure steam to the
reaction temperature of 288°C. This temperature is required to initiate the
reaction. The conversion of the CO is an exothermic reaction, therefore, the
methanator temperature should be monitored closely as runaway reactions can
result.
Reactor effluent is used to heat the feed and is then cooled against cooling
water. The hydrogen stream is further cooled to about 18.6°C by propylene
refrigerant. Condensed water is separated in the hydrogen dryer K.O. drum. The
hydrogen leaving the drum goes to the hydrogen dryers. Two hydrogen dryers
are provided to accommodate the periodic regeneration required. The dry
hydrogen is used in the acetylene, MAPD, C4 hydrogenation and pyrolysis
gasoline hydrogenation reactors. Excess hydrogen is sent as product to the
OSBL refinery hydrogen header. In addition, any shortage of hydrogen will be
supplied from the OSBL refinery header via the hydrogen booster compressor
package.
Deethanization, Acetylene Hydrogenation and Ethylene Fractionation
The demethanizer bottoms product, which is split into two streams as described
in the demethanizer section, feeds the deethanizer. The deethanizer reflux is
supplied by condensing overhead vapors with –27.0°C propylene refrigerant. The

February, 2005
column is reboiled with quench water. A spare reboiler using LP steam is

provided to insure continuity of operation.
Deethanizer also processes FCC dry gas C2s and FCC C3 streams received
from adjacent refinery. Both these streams require treatment before being sent to
the deethanizer as follows:
- The FCC dry gas C2 stream contains significant impurities like H2S, CO,
H2, CO2, N2, oxygen, acetylene which must be removed. The FCC dry gas
treatment facility will be provided OSBL to produce a stream suitable for
addition to the ethylene plant for hydrocarbon recovery. Provision for
supplying C3 wash stream from NCU to the OSBL FCC dry gas treatment
facility is kept in the design. The C3 wash stream is drawn from MAPD
converter recycle cooler outlet.
- FCC C3 stream is saturated with water and contains impurities like CO2,
COS, Mercaptans, H2S, amines, arsine, phosphine, and halogens. which
must be removed prior to processing in the deethanizer. The treatment
facility for this stream is provided in NCU. The treatment facility is
discussed in later sections.
Treated FCC dry gas C2s feed is combined with the 2nd feed to the deethanizer.
The treated FCC C3s feed is sent to the deethanizer as the third feed.
Acetylene is removed from the net deethanizer overhead product by selective

hydrogenation to ethylene and ethane in a two bed acetylene converter with
intercooling. The acetylene converter uses a silver promoted palladium catalyst
which greatly reduces the need for CO as a catalyst moderator and the
production of C2 green oil. A spare converter with spare intercooler is provided so
that the catalyst can be regenerated (with a mixture of superheated steam and
air) without interrupting the continuity of operation. Hot hydrogen/nitrogen from
the MAPD reduction heater is used for catalyst reduction at initial start-up and
after each catalyst regeneration. Provisions have been kept (a bypass flow
controller line around the methanator) to allow for CO addition, if needed. Plants
typically operate between 5-9 months at selectivity levels above 50% minimum
acetylene to ethylene.
The net deethanizer overhead is preheated against the converter effluent, mixed
with the required hydrogen and further heated by low pressure steam, and
passed over the first catalyst bed. The temperature rise is proportional to the
percentage of hydrogen added to the feed. A safety monitor is provided to shut
off the hydrogen in the event that the reactor temperature becomes excessive.
The effluent from the first catalyst bed is mixed with more hydrogen, cooled by
cooling water, and then passed over the second catalyst bed for further
acetylene conversion. The effluent from the second bed, containing less than 1

February, 2005
ppm of acetylene relative to ethylene, is cooled by cooling water and by heat

exchange with the converter feed.
During hydrogenation, a small portion of the acetylene is converted to a polymer

called green oil. This material interferes with the proper drying of the ethylene
fractionator feed which is essential to avoid icing problems. This green oil is
removed by contacting the converter effluent with a slip stream of
ethylene/ethane stream taken as a side draw from the ethylene fractionator. This
ethylene/ethane stream is mixed with the converter effluent in a static mixer prior
to entering the C2 green oil K.O. drum. The C2 green oil K.O. drum bottoms
liquid, containing the green oil, is recycled back to the deethanizer. The
contained green oil leaves with the deethanizer bottoms to the depropanizers
and ends up in the raw pyrolysis gasoline. The overhead vapor from the C2
green oil K.O. drum passes to the ethylene fractionator via the ethylene dryer.
The ethylene dryer consists of a single molecular sieve bed. The desiccant is
regenerated using hot methane offgas from the dryer regeneration system.
The ethylene fractionator has one bottom reboiler and two side reboilers
permitting the maximum cold recuperation from this tower. One side reboiler is
used to chill charge gas and the other is used to condense ethylene refrigeration
compressor discharge. The main reboiler supply heat to the tower by
condensing –6.7°C propylene refrigerant vapor. The reflux for the tower is
condensed with –40.3°C propylene refrigerant. A pasteurization section on top of
the ethylene fractionator is used to remove the residual methane and hydrogen
from the ethylene product. Vent gas from the reflux drum is recycled back to the
demethanizer after passing through the vent condenser which uses –63°C
ethylene refrigerant to minimize the vent recycle rate.
The ethylene product is withdrawn as a side draw from the tower and sent to the
ethylene product surge drum along with excess ethylene liquid from the ethylene
refrigerant accumulator corresponding to ethylene boil-off gas. Liquid ethylene
product drawn from the tower is also used as makeup for the ethylene
refrigeration system. From the surge drum, the ethylene product is handled as
follows:
- One stream is chilled against –63°C, -75.0°C and –101.0°C ethylene

refrigeration in succession to –98°C and delivered to low pressure OSBL
cryogenic storage. In normal operation, 1200 kg/h of ethylene consistent
with ethylene boil-off gas rate is sent to low pressure cryogenic storage in
normal operation. Provision is kept to send up to 30,000 kg/h ethylene to
this storage.
- The second steam is pumped, heated, vaporized and superheated against

liquid propylene and delivered as MP ethylene vapor product at 28.0
kg/cm2g and 30°C.

February, 2005
- The third stream is pumped, heated, vaporized and superheated against

liquid propylene and delivered as HP ethylene vapor product at 52.0
kg/cm2g and 30°C.
In normal operation, liquid ethylene up to 10 t/h (10%) is recycled from

atmospheric storage to keep storage pumping system active.
Ethane is withdrawn from the ethylene fractionator bottom, vaporized against

charge gas and after further reheating against propylene refrigerant in the cold
box and is sent to the recycle cracking heaters or to the fuel gas system in the
event cracking heaters are unavailable.
Provisions are made for polymerization inhibitor injection into the condensate
stripper, reboilers, condensate stripper bottoms, C2 green oil bottoms feed to
deethanizer, deethanizer reboilers, depropanizer feed from deethanizer and
depropanizer reboilers.
Depropanization
The purpose of the depropanizer is to make a sharp separation between C3

components and the C4 and heavier components in the deethanizer bottoms and
condensate stripper bottoms.
Deethanizer bottoms, condensate stripper bottoms and a C3 green oil recycle

stream from the propane recycle drum are the feed to the depropanizer. The
tower overhead is condensed against -6.0°C propylene refrigerant. Part of the
distillate is used as reflux and net product and is pumped to the MAPD converter
system. The tower is reboiled by low pressure steam. The bottom product
containing C4s and heavier material is sent to the debutanizer.
MAPD Hydrogenation
In this section methyl acetylene (MA) and propadiene (PD) contained in the
depropanizer overhead are removed by selective hydrogenation to propylene
and propane in a single-bed reactor.
The net overhead stream from the depropanizer is pumped to the MAPD
converter. The MAPD reactor utilizes the Süd-Chemie G-68HX hydrogenation
catalyst. This catalyst achieves a selectivity to propylene of about 50% for an
outlet MAPD concentration of 200 mol. ppm (30% selectivity used for design).
The MAPD converter system consists of two reactors; one operating, and one
spare. As a result, the reactor can be regenerated while the plant is on-stream.
The C3 feed stream is mixed with recycle liquid from the MAPD Converter
Effluent Separator and the hydrogen from the methanator section and passed
through the converter. The MAPD hydrogenation is an exothermic reaction and

February, 2005
the heat of reaction is removed by vaporizing a portion of the feed with only a
moderate temperature rise. The fresh feed is diluted with liquid recycle to limit
vaporization, improve the overall selectivity and minimize green oil formation.
Liquid leaving the reactor flows to the MAPD Converter Effluent Separator.
Vapor leaving the reactor is cooled in a water-cooled vent condenser. Liquid
from the vent condenser is returned to the separator drum. Vapor leaving the
vent condenser is returned to charge gas compressor to recover H2, CH4 and C3
hydrocarbons. Liquid recycle leaving the drum is pumped, cooled and returned
to the reactor inlet for diluting the fresh feed. Converter feed heater is provided
for achieving end of run feed temperature during reduced catalyst activity. The
net C3 product from the separator drum is combined with C3 recycle from PP
plant and sent to the Propylene Fractionator No 2. Based on selected
technology, there will be no recycle from the PP plant to the propylene
fractionator.
During hydrogenation, a small amount of the MAPD is converted to a polymer

called C3 green oil. Contained green oil in the reactor effluent gets recycled from
the propane recycle drum to the depropanizer which eventually ends up in the
gasoline product.
Propylene Fractionator
The propylene fractionator uses a two-tower system to separate the feed into a
distillate product of polymer grade propylene and a bottom product containing
primarily propane. The tower operates at a pressure which permits total
condensation of propylene fractionator No. 2 overhead against cooling water.
Reboiler heat to the towers is supplied by circulating quench water.
The polymer grade propylene product is withdrawn as a sidedraw from tower no.
2. The product is pumped, cooled to 38°C and delivered to OSBL downstream
plants. Provision for diverting off spec propylene to OSBL HP storage is also
kept. A portion of the sidedraw product can be chilled at fractionator pressure
against -27°C and -40.3°C propylene refrigerant and -63°C ethylene refrigerant
in succession and delivered to low pressure OSBL cryogenic storage at -45oC.
The propane-rich bottoms product is withdrawn as bottoms product from

propylene fractionator No. 1 and sent to the propane recycle drum which is
equipped with a thermosyphon reboiler using quench water as the heating
medium. The recycle propane is vaporized and mixed with ethane recycle and
sent to the recycle cracking heater. A small liquid stream is withdrawn from the
propane recycle drum (to remove the green oil formed in the MAPD converter)
and returned to the depropanizer.
A pasteurization section on top of the propylene fractionator is used to remove

the residual methane and hydrogen from the propylene product. Vapor from the

February, 2005
reflux drum is cooled in the vent condenser against 15.6°C propylene refrigerant
to minimize propylene carryover. Vent gas from the vent condenser is recycled
to the demethanizer.
Debutanizer
The bottoms product from the Depropanizer flows to the debutanizer where the
raw C4s product is separated. The debutanizer operates at a pressure which
permits total condensation of the overhead vapor against cooling water. The
bottoms reboil heat is provided by low pressure steam. The debutanizer net
overhead product, consisting of mixed C4s, is pumped to the butadiene extraction
unit, C4 hydrogenation unit, or to OSBL storage for further processing.
The bottoms product is pumped and combined with gasoline from the gasoline
stripper to make up the total raw pyrolysis gasoline product. After cooling against
cooling water, the gasoline product is sent to pyrolysis gasoline hydrogenation
unit. Pyrolysis gasoline should always flow directly from debutanizer to pyrolysis
gasoline hydrogenation unit. Routing to intermediate storage provided between
the NCU and PGH units should be done during PGH catalyst regeneration only.
FCC C3s Treatment
The FCC C3 stream is passed through the dryer/treater and arsine treater and
filter before being sent to the deethanizer. The dryer/treater is regenerable,
whereas the arsine treater is non-regenerable. Two dryer/treaters are provided,
one dryer/treater on-stream while the other is being regenerated in a cyclic
operation.
A compound bed of three types of adsorbents is used in the regenerable

dryer/treater to remove water, CO2, COS, H2S, amines, halogens and
mercaptans. The bottom bed removes water and halogens, the middle bed
removes water and the top bed removes the remaining impurities.
The arsine treater contains a single bed of copper oxide/aluminum oxide based
adsorbent. The treater removes arsine and phosphine from the FCC C3 stream.
The treated stream is passed through a filter for removing any carried over
adsorbent particles before being sent to the deethanizer as third feed.
C4 Hydrogenation
C4 hydrogenation unit is designed to operate in two modes; 1) total

hydrogenation of the BD raffinate in normal operation, and 2) partially
hydrogenate the raw mixed C4 (butadiene saturation only) when butadiene
extraction unit is not in operation.

February, 2005
Raffinate from BD plant or raw mixed C4 from debutanizer or OSBL storage flows
to the feed surge drum. In the feed surge drum, any entrained water, if present,
is separated. The feed is then pumped to reactor pressure and mixed with liquid
recycle stream prior to entering the reactor.
A single reactor is provided. When end of run conditions are reached, catalyst is
regenerated in-situ using a conventional steam and air procedure. Expected
regeneration cycle varies from approximately 1 year when processing raw C4s to
over 2 years when processing BD raffinate.
Provision is made to inject CO rich hydrogen to control the activity of the catalyst
during partially hydrogenation of raw C4s.
The recycle liquid from the HP flash drum is heated against liquid effluent from
the reactor prior to mixing with the feed. This recycle liquid is required to limit
vaporization and temperature rise across the reactor. The reactor inlet
temperature is controlled by adjusting the split of recycle through the
feed/effluent exchanger. At start-of-run, the tube side of the feed/effluent
exchanger is completely bypassed. A feed preheater using LP steam is provided
for start-up only.
When processing BD raffinate, the entire hydrogen flows to the top bed on flow
control (reset by pressure control). When processing raw C4s, the major part of
the hydrogen is added to the top bed on flow control and the remainder is
injected to the lower bed on pressure control. The mixed phase feed passes
downward through the catalyst beds where butadiene and butenes are
hydrogenated. The exothermic heat of reaction causes a temperature rise and
partial vaporization in the reactor. Liquid effluent from the reactor is cooled in a
feed/effluent exchanger. After combining with the vapor effluent from the reactor,
the mixture is partially condensed against the cooling water. Effluent from the
condenser passes to the HP flash drum where liquid recycle is separated and
returned to be mixed with fresh feed to the reactor. HP flash drum vapors are
chilled against 3°C propylene refrigerant in a vent condenser. Liquid from the
vent condenser flows back to the flash drum and non-condensables are recycled
to the charge gas compressor 3rd stage discharge drum for recovery. The net
liquid product is withdrawn from the HP flash drum and sent to the C4 stabilizer.
In the C4 stabilizer, dissolved hydrogen and methane are stripped from the C4
product. The stabilizer overhead is partially condensed against cooling water
and reboiled using LP steam. The C4 product is withdrawn from the C4 stabilizer
bottom, cooled in a water-cooled exchanger and recycled to cracking heater or
pumped to OSBL LPG storage. The vent gases containing unreacted hydrogen
and methane and equilibrium C4s are chilled against 3°C propylene refrigerant in
a vent condenser. Liquid from the vent condenser flows back to the reflux drum
and offgases are recycled to the charge gas compressor 3rd stage discharge
drum along with offgases from HP flash drum.

February, 2005
Pyrolysis Gasoline Hydrogenation
The raw pyrolysis gasoline from the debutanizer and gasoline stripper, after
cooling and filtering, is sent to feed surge drum where entrained water, if any, is
separated and drained. Normally, the feed does not contain entrained water.
DPG First Stage
The pyrolysis gasoline is pumped from the surge drum to the first stage reactor.
The fresh liquid feed is mixed with recycle liquid from the bottom of the reactor
before entering the top bed of the reactor. Catalyst activity decreases with time,
requiring raising of the reactor inlet temperature. The reactor inlet temperature is
set by controlling the split of recycle flow through the recycle air cooler. The
quantity of recycle is controlled to limit the exothermic temperature rise across
the reactor. A MP steam exchanger is provided for startup.
The hydrogen enters the top of the first stage reactor under pressure control and
travels down through the catalyst bed in intimate contact with the total liquid feed.
The principal hydrogenation reactions occurring are the conversion of diolefins to
olefins and styrene to ethylbenzene. Less than 10% of the diolefins and olefins
are converted to paraffins.
The reactions take place in the liquid phase. The exothermic temperature rise
across the reactor is controlled by adjusting the flow of recycle liquid.
Reactor temperature is raised as required to maintain product quality. The inlet

temperature of the reactor may vary from about 60°C at start of run to 133°C at
end of run. When the upper limit of operating temperature or reactor pressure
drop is reached or product quality can no longer be maintained, the catalyst is
regenerated in-situ using a conventional steam and air procedure.
The DPG1 reactor consists of one reactor. As a result, when reactor is

regenerated, the raw pyrolysis gasoline feed from the debutanizer section is sent
to OSBL storage. The storage capacity should be adequate for the regeneration
period. Net liquid effluent is cooled against cooling water and is pumped to the
first stage HP flash drum where hydrogen-rich gas is separated from the liquid
product. Hydrogen-rich gas from the flash drum is sent to the second stage.
Stabilizer
The liquid from the flash drum is sent to the Stabilizer. In the Stabilizer, the light
ends are separated from the treated gasoline. The tower is reboiled using MP
steam and the overhead is condensed against cooling water. The vent gas from
the reflux drum is sent to the charge gas compression section. The tower
bottoms flow to the Tailing Tower.

February, 2005
Tailing Tower
The Tailing Tower separates the treated gasoline from the stabilizer bottoms into
a C5-C8 cut overhead product and a C9+ bottoms product. The tower is reboiled
using MP steam and the overhead is condensed against air cooling. Tower
pressure is controlled by varying the pitch of the air coolers or by nitrogen
injection. The C9+ bottoms product is sent to the rerun tower and the C5-C8 cut is
sent to the DPG second-stage reactor.
Rerun Tower
The purpose of the rerun tower is to remove any heavy ends (200°C) material
from the C9+ stream. Gums present in the first stage DPG product end up with
the heaviest cut. As a result, the gums are concentrated in the 200°C plus stream
exiting the tailing tower bottom.
C9 plus stream from the tailing tower feeds the rerun tower. The rerun tower is
reboiled using MP steam and the tower overhead is condensed with cooling
water. The tower is operated under vacuum to minimize fouling in the tower
bottom. The reboiler circuit operates in forced circulation mode for zero
vaporization to minimize fouling. Non-condensable offgases (i.e., air leakage) are
boosted using an ejector with MP steam as the motive fluid to a pressure high
enough to send offgas to the heater firebox.
The heavy cut concentrated with gums is separated in the tower bottoms and is
mixed with pyrolysis fuel oil, cooled and sent to OSBL storage.
DPG Second Stage
The C5-C8 cut from the DPG first stage is the feed to the DPG second stage.
First stage treated C5-C8 heart cut is mixed with hydrogen-rich recycle gas and
recycle liquid. The two-phase mixture is completely vaporized and heated by
heat exchange against the second stage reactor effluent to the required reactor
inlet temperature. A super high-pressure steam exchanger is provide for start-
up.
In the second stage reactor, the olefins present in the feed are hydrogenated,
and the sulfur compounds are converted to hydrocarbons and H2S over the
catalyst. The reaction takes place in the vapor phase. The reactions are
exothermic resulting in a temperature rise across the reactor which is moderated
by recycle liquid. Catalyst activity decreases with time, requiring raising of the
reactor inlet temperature. The inlet temperature of the reactor may vary from
220°C at start of run to about 250°C at end of run. When the upper limit of the
operating temperature range is attained, the catalyst is regenerated in-situ, using

February, 2005
the conventional steam/air procedure. The reactor effluent preheats the reactor
feed before finally being cooled and partially condensed against cooling water.
The cooled vapor/liquid mixture is then separated in the high-pressure flash

drum. The major portion of the vapor leaving this drum is mixed with the
remainder of the make-up hydrogen required in the second stage and sent to the
recycle gas compressor suction drum. Vapor from this drum is compressed in
the recycle gas compressor and mixed with recycle liquid and first stage treated
C5-C8 cut. A small net vent flow from the high-pressure flash drum is sent to the
charge gas compression section. A portion of the liquid product (recycle liquid) is
pumped from the high-pressure flash drum to be mixed with reactor feed. The net
liquid product is sent to a low-pressure flash drum. The liquid from the low-
pressure flash drum is sent as feed to the Depentanizer Tower.
Depentanizer
In the depentanizer, the C5 stream is separated from the C6 plus stream. The
tower is reboiled using MP steam and the overhead is partially condensed in the
air cooler and trim condenser against cooling water. The vent gas from the reflux
drum plus the vapor from the low pressure flash drum are sent to the charge gas
compression section. The tower bottoms is sent to battery limits as the C6-C8
Heart Cut. The C5 product is recycled to the cracking heaters to be co-cracked
with the naphtha feedstock.
Propylene Refrigeration
The propylene refrigeration system is a closed, four stage system utilizing a

steam turbine driven centrifugal compressor. The system provides refrigeration
at four levels: -40.3°C, -27°C, -6.0°C and 15.6°C. Cooling water is used to
condense the compressor discharge vapors.
Refrigeration is recuperated against offgas reheating, ethane recycle heating,

deethanizer feed heating, ethylene fractionator reboiling and ethylene product
vaporizing and superheating in the chilling train.
The propylene refrigeration system is provided with suction drums at each stage
to provide surge volume for the various system users and to minimize liquid
entrainment into the compressor at each stage as well as an accumulator at the
compressor discharge to provide a liquid seal to ensure refrigerant condensing at
the compressor discharge.
The propylene compressor design incorporated dry mechanical seals. The

system is also designed to provide refrigeration for two BD plant users; namely
C4 acetylene condenser and butadiene product cooler.

February, 2005
Ethylene Refrigeration
The ethylene refrigeration is a closed, three stage system utilizing a steam

turbine driven centrifugal compressor. The system provides three levels of
refrigeration, i.e., -101.0°C, -75.0°C and –63°C. The compressor discharge
vapors are cooled first against cooling water and then partially desuperheated
against 15.6°C propylene refrigerant. The discharge is further desuperheated
condensed in the ethylene fractionator side reboiler. A back-up condenser
against –27°C propylene refrigerant is provided for start-up.
Refrigeration is recuperated by subcooling liquid ethylene refrigerant from the

accumulator against offgases, deethanizer feed in the chilling train.
The ethylene refrigerant system is provided with suction drums at each stage to
provide surge volume for the various system users and to minimize liquid
entrainment into the compressor at each stage as well as an accumulator at the
compressor discharge to provide a liquid seal to ensure refrigerant condensing at
the compressor discharge.
The ethylene compressor design incorporated dry mechanical seals which

prevents any compressor seal oil from entering the system and freezing. This
eliminates the need for an oil mist eliminator in the compressor discharge.
BOG vapors from the OSBL low temperature atmospheric ethylene storage is
reprocessed in the NCU via the ethylene refrigeration compressor. BOG vapors
flow to the first stage of the ethylene refrigeration compressor and get condensed
in the compressor discharge condenser. This liquid from the ethylene refrigerant
accumulator is sent to the ethylene product surge drum and then chilled in
ethylene product rundown chillers before being sent to OSBL cryogenic ethylene
storage.
Fuel Gas System
Primary fuel gas is a mixture of HP methane offgas from dryer regeneration

system and LP methane offgas from chilling train. Makeup/backup fuel is C3/C4
LPG supplied from the adjacent refinery. Provision to use revaporated liquefied
natural gas (RLNG) as makeup/backup fuel in the future is also provided.
In normal operation, primary fuel gas is not sufficient to fully meet the heater
firing demand. The shortfall is met by makeup LPG fuel.
Primary fuel gas is received in fuel gas mix drum. Ethane recycle vapor, BD unit
offgas and excess hydrogen can also be received in this drum. Any heavy liquid
condensed in the drum is drained to wet flare knockout drum. RLNG vapor will be
received in the mix drum under pressure control.

February, 2005
Low NOx burners require fuel gas to be free of rust particles and liquid droplets.
Therefore, fuel gas from mix drum passes through filter/coalescer before being
sent to the heaters.
C3/C4 LPG is received in the fuel gas vaporizer drum under level control. It is
vaporized with LP steam. The LPG vapor is superheated and sent to the fuel gas
mix drum under pressure control during normal, start-up and upset conditions.

February, 2005
ARTICLE II – PLANT SPECIFICATION
1.0 BASIS FOR PROCESS DESIGN
1.1 Plant Function and Capacity
Plant Function
The naphtha cracker unit is designed to produce polymer grade ethylene and
polymer grade propylene by thermal cracking of naphtha and hydrogenated
C4/C5/C6 recycle streams from C4 hydrogenation, pyrolysis gasoline
hydrogenation and benzene extraction units respectively. Ethane and propane
are recycled and cracked to extinction.
Recycles from polymer plants, ethylene BOG and the FCC streams are the
additional feeds to the Naphtha Cracker Recovery unit.
In addition to ethylene and propylene, the plant will produce the following
by-products:
Naphtha Cracker products

• Hydrogen
• Methane offgas
• Raw mixed C4s (1)
• C4 LPG (provision to draw part of hydrogenated C4 to LPG pool)
• Hydrogenated C6-C8 (2)
• Partially hydrogenated C9+
• Pyrolysis Fuel Oil (combined PGO + PFO)
Notes:
(1) Raw mixed C4s is sent to Butadiene Extraction unit for butadiene
recovery. BD raffinate is sent to the C4 hydro unit.
(2) Hydrogenated C6-C8 is sent to Benzene Extraction unit for benzene
recovery. Non-aromatic C6 stream is recycled to the NCU cracking
heaters and C7-C8 cut is sent as product to OSBL storage.
Considering all process units, overall product pattern is as follows:
• Hydrogen
• Methane offgas
• Polymer Grade Ethylene
• Polymer Grade Propylene
• Butadiene
• Benzene
• Hydrogenated C7-C8 cut

February, 2005
• Partially hydrogenated C9+ cut

• Pyrolysis fuel oil (combined PGO + PFO)
Plant Capacity
The plant is designed to produce 800,000 TPA of polymer grade ethylene and
504,834 TPA of polymer grade propylene in 8,000 operating hours a year. The
production rates are net without processing polymer plant recycles, ethylene
BOG and the FCC feeds.
The plant capacity with recycles from polymer plants, ethylene boil-off gas and
FCC feeds is as follows:
Case Ethylene Capacity, Propylene

TPA Capacity, TPA
1 (without FCC feeds) 830,632 584,352
2 (with FCC feeds) 857,408 666,544
1.2 Feedstock Properties
1.2.1 Design Naphtha
Density at 15.5°C, kg/m3 702.03

ASTM D-86 Distillation (vol%) °C
1% 51
5% 60
10% 62
30% 74
50% 97
70% 114
90% 147
95% 151
98% 178
EP 182
PONA (wt%)
N-Paraffins * 34.1
I-Paraffins 34.1
Naphthenes 21.7
Aromatic 10.1
* assumed 50/50 iso/normal paraffin split

February, 2005
1.2.2 Check Naphtha
Density at 15.5°C, kg/m3 700.00

ASTM D-86 Distillation (vol%)
1% 45
5% 60
10% 65
30% 79
50% 100
70% 117
90% 138
98% 146
EP 155
PONA (wt%)
N-Paraffins * 36.5
I-Paraffins 36.5
Naphthenes 19.0
Aromatic 8.0
* assumed 50/50 iso/normal paraffin split
Contaminants in design and check naphtha are as follows:
Contaminants Unit Value

Sulfur wt. ppm 500 max.
Total Chloride wt. ppm 3 max.
Lead wt. ppb 5 max.
Arsenic wt. ppb 1 max.
Mercury wt. ppb 1 max.
Note: Plant design will be based on design naphtha. However, plant is capable
of processing check naphtha with production rates same as with design
naphtha.
1.2.3 Recycle Streams from Polymer Plants
Naphtha cracker is designed to process recycle streams from polymer plants.

Flow rates and composition of these streams are presented in this section.
As polymer plants licensor selection was not completed at the design basis
meeting stage, preliminary information of the potential licensors was given as the
basis for material balances. Therefore, for each recycle, data is given for two
cases:

February, 2005
i) Flow rate and composition used in material balances,

ii) Flow rate and composition based on selected licensors.
Ethylene Purge Stream from LLDPE/HDPE (Swing Plant)
Based on selected licenser
Ethylene 93-95 wt%

Ethane 2-3 wt%
Hydrogen 0.5 wt% max
Nitrogen 0.5 wt% max
Methane 1.0 wt% max
Acetylene 120 wt ppm max
CO 15-30 wt ppm max
CO2 0.25 wt% max
Propylene 0.06 wt% max
Butene-1 3.0 wt% max
Butene-2 0.1 wt% max
Flow rate, kg/h Normal 2000-2800
Max 3800
Lummus Material Balance Basis
Composition, wt%
Hydrogen 1.5
Ethylene 25.0
Ethane 7.0
Propane 65.5
Flow rate, kg/h 1,750
Phase Vapor
Recycle from PP Plant
wt%
Propylene 70 - 80
Propane 17.5 - 20
Butene-1 0 - 13
Hydrogen 0 - 0.05
Ethylene 0 - 3.5
Ethane 0 – 0.1
Flow rate, kg/h 1800 - 2400
(Traces of CO, CO2,, methanol and iso-propanol are present)

February, 2005
Two recycle streams from PP plant are considered in material balances.
(i) C3 Recycle
Component kg/h
Ethylene 1
Ethane 0
Propylene 8,397
Propane 452
Total 8,850
Phase Liquid
(ii) Light Gas Recycle
Component kg/h
Nitrogen 7
Hydrogen 8
Methane 3
Ethylene 1,244
Ethane 18
Propylene 1,244
Propane 63
Total 2,587
Phase Vapor
HDPE Plant Recycle

Energy rich stream (low N2 concentration)
wt%
H2 0 – 5.0
N2 1 – 7.5
C2s 60 – 90
C4s 0 – 0.5
C6 5.0 - 20
Flow rate, kg/h Normal: 270
Peak: 650
Note: The stream is water saturated at about 45°C and 4.08 kg/cm2g

February, 2005
Recycle HDPE was not envisioned at design basis meeting stage, therefore, it is
not considered in the material balances.
1.2.4 Ethylene Boil Offgas from Atmospheric Storage
Flow Rate 1200 kg/h (estimated)

Composition Same as of ethylene product
1.2.5 FCC Feeds
The plant processes two FCC streams received from adjacent refinery.
• Treated FCC dry gas C2s

• Raw FCC C3s
Flow rates and composition of FCC feeds are as follows:
(i) Treated FCC Dry Gas C2s
Treated FCC Dry Gross Feed including

Gas C2s C3 Wash Stream
Component kg/h
Ethylene 1,449.50 1,449.50
Hydrogen 0.18
Methane 1.52
Ethane 634.40 634.61
MAPD 0.25
Propylene 144.00 1,942.46
Propane 44.10 229.95
1-butene 41.00 41.58
Butadiene 0.03
N-butane 55.80 55.80
C5s 116.12 116.12
C6s 0.92
Total 2,484.92 4,472.92

February, 2005
(ii) Raw FCC C3s
Component kg/h
Methane 0.90
Ethylene 11.71
Ethane 123.35
Propylene 9,688.03
Propane 2,588.31
Total 12,412.30
Contaminants
CO 0.1 vol ppm max
CO2 5 wt ppm max.
O2 2 vol ppm max.
COS 5 wt ppm ma.
H2S 1.0 wt ppm max
Mercaptan Normally nil
In upset condition:
4 times per month for 8-10 hrs,
mercaptan level can reach 50 wt ppm
Arsine 100 wt ppb max.
Phosphine 100 wt ppb max.
Mercury Nil
Amine 3-4 vol ppm max.
Fluoride 1 wt ppm max.
Chloride 1 wt ppm max.
Water Saturated at 43°C (no free water)
1.2.6 Hydrogen Import from Adjacent Refinery
Purity PSA quality, 99.5 mol% hydrogen

February, 2005
1.3 Product Specifications
1.3.1 Polymer Grade Ethylene
Component Specification Unit Test Method

Ethylene 99.95 mol% min. ASTM D2505
Methane + Ethane 500 mol ppm max. ASTM D2505
Ethane 300 mol ppm max. ASTM D2505
Acetylene 1 wt. ppm max. ASTM D2505
Propylene 10 wt. ppm max. ASTM D2505
Hydrogen 2 mol ppm max. ASTM D2504
Carbon Monoxide 0.03 mol ppm max. ASTM D2504
Oxygen 1 mol ppm max. O2 meter
Carbon Dioxide 5 ** mol ppm max. ASTM D2505
Water 1 Mol ppm max. Dew Point Meter
Ammonia 1 mol ppm max. Colorimetric Method
Phosphine 0.03 mol ppm max.
Sulfur as H2S 1 mol ppm max. GC
Oxygenated solvents* 1 wt. ppm max. GC
* Methanol, ethanol, propanol, acetone, acetaldehyde

** Expected CO2 in ethylene product is 3 mol ppm
1.3.2 Polymer Grade Propylene

Propylene 99.5 wt% min. 100-impurities
Propane 0.4 wt% max. ASTM D2163
Methylacetylene 2 wt. ppm max. ASTM D2712
Propadiene 3 wt. ppm max. ASTM D2712
Methane 200 vol ppm max. ASTM D2712
Ethane 300 vol ppm max. ASTM D2712
Ethylene 10 wt. ppm max. ASTM D2712
Acetylene 1 wt. ppm max. ASTM D2712
1,3-Butadiene* 3 wt. ppm max. ASTM D2712
Total C4s 10 wt. ppm max. ASMT D2712
C5 & heavier 10 wt. ppm max. ASTM D2712
Hydrogen 1 wt. ppm max. ASTM D2504
Carbon monoxide 0.03 wt. ppm max. ASTM D2504
Oxygen 1 wt. ppm max. O2 meter
COS 20 wt. ppb max. GC
Carbon dioxide 1 wt. ppm max. ASTM D2505
Water 2 wt. ppm max. Dew Point Meter
Ammonia 0.2 wt. ppm max. Colorimetric Method
Total sulfur as H2S 0.5 wt. ppm max. ASTM D3246
Arsine 20 wt. ppb max. UOP 834/UOP 387
Phosphine 0.03 wt. ppm max.
Methanol 5 wt. ppm max. GC

February, 2005

Oxygenated solvents** 10 wt. ppm max. GC
* 1,3 Butadiene expected to be nil

** Methanol, ethanol, propanol, acetone, acetaldehyde
1.3.3 H2 Product
Component
Hydrogen 95.68 mol%
Methane 4.32 mol%
Carbon monoxide 1 mol ppm
CO2 + Nitrogen Traces
Chloride content 1 vol ppm
1.3.4 Methane Rich Offgas (expected)
Component, mol% Case 2

Hydrogen 14.32
Methane 84.85
Total C2s 0.41
Carbon monoxide 0.42
100.00
1.3.5 Raw Mixed C4
C3s and lighter 0.3 wt% max.

C5s and heavier 0.3 wt% max.
Expected Composition, wt% Case 2

MAPD 0.13
Propylene 0.06
Propane 0.02
1,3 Butadiene 28.80
1,2 Butadiene 0.17
Vinyl Acetylenes 0.29
Ethyl Acetylenes 0.10
1-butene 11.58
Cis-2-butene 3.26
Trans-2-butene 3.99
Isobutene 24.44
n-butane 12.66
iso-butane 14.20
C5s 0.30
Total 100.00

February, 2005
Impurities, wt ppm
Water Nil
Total sulfur 10 wt ppm max.
1.3.6 Butadiene Product
Sr. No. Property Specification Unit Test Method

1. 1-3 Butadiene 99.6 min. wt% GC Technique
2. 1-2 Butadiene 20 max. wt ppm GC Technique
3. Propadiene 5 max. wt ppm GC Technique
4. Total Acetylene 20 max. wt ppm GC Technique
5. Carbonyls as 10 max. wt ppm GC Technique
Acetaldyhyde
6. Sulfur Note 1 wt ppm ASTM D5453
7. NMP/Solvent 5 max. wt ppm GC Technique
8 Butadiene Dimer 50 max. wt ppm GC Technique
9. Butane + Butene 0.4 max. wt% GC Technique
10. Methyl Acetylene 5 max. wt ppm GC Technique
11. TBC content Note 2 wt ppm ASTM D1157
Notes:
1. This specification depends upon the sulfur content (mercaptan) of the
mixed C4 stream. The source of the Mercaptans in C4 product is the
unreacted mercaptans contained in the naphtha feedstock. Since feed
concentrations are not available and the kinetics are not precisely
known, it is difficult to predict the sulfur content of the mixed C4 stream.
Typical sulfur specification for butadiene product is 10 wt ppm.
2. TBC is injected into the butadiene product to inhibit polymer formation

during storage. Typical TBC dosage in butadiene product is 50-75 wt
ppm.
1.3.7 Raw Pyrolysis Gasoline
C4 and lighter 0.5 wt%

End Point (ASTM) 204°C

C4s 0.31
C5 Saturates 8.76
C5 Olefins 3.08
C5 Diolefins 10.53
C6 Saturates 6.34
C6 Olefins 4.33
C6 Diolefins 4.77
Benzene 16.37

February, 2005
C7 Saturates 1.65
C7 Olefins 1.81
C7 Diolefins 1.87
Toluene 15.50
C8Saturates 0.75
C8 Olefins 0.52
C8 Diolefins 0.52
Ethylbenzene 1.89
Xylenes 6.71
Styrene 2.52
C9 – 204°C 11.77
Total 100.00
Sulfur, wt ppm 130
1.3.8 Hydrotreated C6-C8 Heart Cut to Benzene Extraction Unit
C5s 1.0 wt% max.

C9-204°C 1.0 wt% max.

Cyclopentane 1.00
C6 Paraffins 10.45
Methyl cyclopentane 9.98
Cyclohexane 2.80
Benzene 24.56
C7 Paraffins 4.92
1,1 dimethyl cyclo C5 0.17
cis 1,3-dimethyl cyclo C5 0.37
trans 1,3-dimethyl cyclo C5 0.30
Methyl cyclohexane 1.13
Ethyl cyclopentane 0.64
Toluene 23.34
C8 Paraffins 1.50
Total dimethyl cyclohexane 0.30
Ethyl cyclohexane 0.03
n-propyl cyclopentane 0.09
Isopropyl cyclopentane 0.06
Total trimethyl cyclopentane 0.52
Ethylbenzene 6.67
Xylenes 9.81
C9 plus 0.69
Total 100.00

February, 2005
Bromine Index, mg/100g 300 (max)

Water No free water
Total Sulfur, wt ppm 0.2 (max)
1.3.9 Benzene Product
Property Specification Unit Test Method

Solidification Point 5.4 °C min. ASTM D852
Benzene Purity 99.9 wt% min. ASTM D4492
Total Sulfur 0.5 wt ppm max. ASTM D4045
Thiophene 0.5 wt ppm max. ASTM D1685
Toluene 100 wt ppm max. ASTM D4492
Toluene + MCH 150 wt ppm max. ASTM D5713
Xylene 10 wt ppm max. ASTM D4492
Non-Aromatics 400 wt ppm max. ASTM D2360
Acid Wash Color 1 wt ppm max. ASTM D848
Acidity Nil ASTM D847
Copper Strip Pass 1a or 1b ASTM D849
Corrosion
Bromine Index 10 mg Br/100 gm ASTM D1492
max.
Appearance Clear Visual
sediment free
Color 10 Alpha max. ASTM D1209
Relative Density 0.882-0.886 At 15.56/15.56 C ASTM D4052
Distillation Range <1 incl. 80.1 At 760 mm Hg. °C ASTM D-850
Total Chloride, as Cl 1 wt ppm max. ASTM D5194
H2S/SO2 Nil wt ppm max. ASTM D853
Nitrogen-organic 1 wt ppm max. ASTM D4629
bound
Water 200 wt ppm max. ASTM D1364
Solvent 1 wt ppm max. ASTM D-
3961
Dioxane 1 wt ppm max. UOP 921
Method

February, 2005
1.3.10 C7-C8 Product

Cyclohexane 0.02
Benzene 0.06
C7 Paraffins 7.38
1,1 dimethyl cyclo C5 0.05
Methyl cyclohexane 2.22
Ethyl cyclopentane 1.29
Toluene 46.79
C8 Paraffins 3.32
Total dimethyl cyclohexane 0.66
Ethyl cyclohexane 0.07
n-propyl cyclopentane 0.20
Isopropyl cyclopentane 0.13
Total trimethyl cyclopentane 1.15
Ethylbenzene 13.30
Xylenes 19.79
C9 plus 2.03
Total 100.00
Related Specs
Bromine Index, mg/100g 10 (max)
Total Sulfur, wt ppm 0.2 (max)
Estimated RON 100
Estimated MON 94
Density 844 kg/m3 at 15.5°C
Benzene Content 0.054 to max 0.9 vol%
Aromatics 82 wt%
Olefins 60 wt ppm max

February, 2005
1.3.11 C9+ Product
Estimated composition for Case 2.
Temp., °C
IBP 158
10 vol% 170
50 vol% 175
90 vol% 185
EP 195
Total Sulfur <150 wt ppm

Aromatics 80 wt%
Existent Gum <5 mg/100 ml
Related Specs
Estimated RON 103
Estimated MON 94
Density 898 kg/m3
Benzene Content Nil (2 ppb)
Olefins 20 wt%
Note: Inhibited with antioxident
Estimated Component Breakdown wt%

Cumene 1.65
n-Propyl Benzene 1.65
1-Methyl-3-Ethyl-Benzene 12.62
1,3,5-Trimethyl Benzene 3.30
Meta Methyl Styrene 2.48
C10 Paraffins/Naphthenes 0.47
Dicyclopentadiene (DCPD) 1.30
Indan 8.61
Indene 6.37
1,2-Diethyl Benzene 2.12
1-Methyl 2-Propyl Benzene 1.06
1,3 Diethyl Benzene 1.65
1,3 Dimethyl 5-Ethyl Benzene 2.24
Cymenes 0.47
1-Methyl 4-n-Propyl Benzene 0.35
Dihydro-DCPD 12.64
Tetrahydro-DCPD 5.37

February, 2005

3,5 Dimethyl Styrene 0.35
Methyl-Indenes 3.20
Naphthalene 0.05
C10 Aromatics 2.91
Total 100.00
1.3.12 Pyrolysis Fuel Oil (PGO + PFO Mixed Stream)
Sr. Property Specification Unit Test Method

No.
1. Acidity Nil mg ASTM D1093
KOH/gm
2. Ash 0.1 max. % mass
3. Density @ 15°C To report Gm/cm3 ASTM D287
or ASTM
D4052
4. Flash Point 70 min. °C ASTM E502
5. Pour Point Summer: +15 °C ASTM D97
max.
Winter: +21 max.
6. Viscosity at 90°C 35 cP ASTM D445
7. Water Content 1 max. % vol
8. Sediment 0.25% max. % mass
Expected BMCI for pyrolysis fuel oil is 110-130.
Note: PGO stream is essentially a 204-288°C cut with flash point of 81°C
minimum.
1.3.13 Hydrogenated C4 Product for LPG Pool
(i) Raffinate Case

Propane 0.17
Isobutane 52.37
Normal Butane 44.09
Isobutylene 1.90
1-Butene 0.05
t-2-Butene 0.65
c-2-Butene 0.40
Butadiene Nil
Pentanes 0.37

February, 2005
Specification
Olefins 5.0 wt% max
(ii) Raw C4 Mix Hydrogenation (Butadiene Unit not operating)

Propane 0.05
Propylene 0.13
Isobutane 18.91
Isobutylene 19.22
Normal Butane 22.58
1-Butene 2.61
t-2-Butene 24.57
c-2-Butene 11.62
1,3-Butadiene 0.01
Pentanes 0.06
Pentenes 0.24
Specification
Butadiene 0.1 wt% max
1.4 Utility Specification
Utility specifications are provided on the following pages. With the

exception of steam and fuel gas, which are generated ISBL, all other
utilities are imported from the central utility center.
1.4.1 Steam
The following table summarizes the steam header conditions and steam
conditions for the equipment design.

February, 2005
Table 1.4.1.1
Steam Header Conditions and Steam Conditions for Equipment Design
Steam Conditions for Equipment
Header Specification
Conditions At
for At Turbine At Heat
Steam Header Equipment Turbine Extraction Exchanger Mechanical
Generation Conditions Design (1) Inlet (2) Inlet Design
Min Normal Max
Super High Pressure
(SHP)
Pressure, kg//cm2g 122.5 122.0 120 119
Temperature, °C 525 520 515 515
High Pressure (HP)

Pressure, kg//cm2g 40.0 42.0 44.0 40.0 39.0 41.0 38.0 50/FV
Temperature, °C 380 390 400 380 375 375 427
Medium Pressure (MP)

Pressure, kg//cm2g 15.1 16.3 17.7 15.1 14.1 15.6 13.6 20.4/FV
Temperature, °C 270 285 310 270 265 265 350
Low Pressure (LP)

Pressure, kg//cm2g 3.6 4.0 4.5 3.6 4.1 2.7 6.5/FV
Temperature, °C 195 200 225 195 190 288
Low Pressure
Desuperheated (LPS)
Pressure, kg//cm2g 2.7 6.5/FV
Temperature, °C 148.2 288

February, 2005
Notes:
1. Minimum steam header conditions are used for design of
equipment (exchangers and turbines) with suitable pressure drops
in lines to the users.
2. Turbine extraction pressure is consistent with minimum header
conditions given for equipment design.
3. Steam condensing pressure at turbine exhaust shall be considered
as 0.12 kg/cm2a.
4. Import steam from OSBL auxiliary boilers will be available at SHP
level. SHP steam import is required for the following cases:
− For start-up
− During turndown operation
− To purge the cracking heater coils during emergency
1.4.2 Cooling Water
Normal Design
2
Supply Pressure, kg/cm g 5.0 10.0
Supply Temperature, °C 33.0 max. 65
Return Pressure, kg/cm2g 2.2
Return Temperature, °C 45 max.
Note:
1. Design fouling factor for cooling water: 0.0004 h-m2-°C/kcal
2. Cleanliness factor for surface condenser: 0.80
1.4.3 Instrument Air
• Quality oil and dust free

• Dew point -40°C at atmospheric pressure
• Conditions
Normal Mechanical Design
2
Pressure, kg/cm g 7.0 10.0
6.5 (min)
Temperature, °C 40 65
1.4.4 Plant Air
• Quality oil and dust free

• Conditions
2
Pressure, kg/cm g 6.0 (min) 10.0
Temperature, °C 40 65

February, 2005
1.4.5 Nitrogen
• Quality
Parameter Unit Specification
Purity vol% (min) 99.99
Oxygen vol ppm 3.0
Carbon dioxide vol ppm 3.0
Carbon monoxide vol ppm Traces
Oil Nil
Dew Point °C at (-) 100°C
atmospheric
pressure
• Conditions
2
Pressure, kg/cm g 6.0 10.5
Temperature, °C 40 65.0
1.4.6 DM Water (makeup)
Quality suitable for SHP steam generation.
Parameter Units Specification

pH @ 25°C 6-8
Conductivity Micro mho/cm 0.2 max.
Silica (as SiO2) ppb wt 20 max.
Iron (as Fe) ppb wt 10 max.
Total copper (as Cu) ppb wt 3 max.
Total dissolved solids ppb wt 100 max.
Oily matter ppb wt 200 max.
Chlorides ppb wt 10 max.
Total CO2 ppb wt None detectable
Total hardness ppb wt None detectable
Bacteria (coliform) None
Turbidity NTU None
Color Colorless
Conditions at Deaerator
Normal
Pressure, kg/cm2g 0.75
Temperature, °C 115.6

February, 2005
1.4.7 Electricity
Power for electric drives and lighting shall be:
1. 6600V ± 6%, 3 phase, 50 Hz ± 3% resistance grounded for drives

of 160 kW.
2. 415V ± 10%, 3 phase, 50 Hz ± 3% for drives up to 160 kW, neutral
is solidly earthed.
3. For instruments and lighting the voltage shall be 240V ± 6%, 50 Hz
± 3%, single phase AC grounded.
4. UPS system shall be 110V AC.
1.4.8 Fuel Gas
Heaters operate using fuel gas only. The primary supply of fuel gas is
methane rich offgas produced in the naphtha cracker unit. During normal
operation, methane rich offgas produced in NCU is not sufficient to meet
the heaters firing demands. During start-up or when there is a deficit, fuel
gas will be supplied by vaporizing makeup/backup fuel. Provision to use
RLNG as makeup/backup fuel will be kept in the design.
(a) Primary fuel gas to heaters
Component, mol% Case 1 Case 2

Hydrogen 14.20 14.32
Methane 84.95 84.85
Total C2s 0.42 0.41
Carbon monoxide 0.43 0.42
100.00 100.00
(b) Makeup/backup fuel
LPG from refinery and/or RLNG vapors will be makeup/backup fuel

with the following composition:
Composition:
(i) LPG
Composition, wt%
Ethane 1.11
Propane 40.00
Butanes 58.55
C5+ 0.34
Water <5 wt. ppm

February, 2005
Note: Hydrogenated C4 product from C4 Hydrogenation unit

may also be used as makeup/back-up fuel.
(ii) RLNG Vapor
Component Specification Range, mol %

Min. Methane Max. Methane
Methane 84.50 98.77
Ethane 9.00 0.69
Propane 3.00 0.03
Butane 2.00 0
Pentane and Heavier 0.25 0
Nitrogen 1.25 0.51
100.00 100.00
Other specifications:
Cross heating value of gas = approximately 8,900 - 9.900
kcal/SCM
Total non hydrocarbons = 2.0 mol% (max)
Total sulfur including H2S = 10 wt ppm max
Expected H2S = 4 vol ppm max
Carbon dioxide = 0
Water content = 112 kg/MM SCM max.
Gas shall be reasonably free from dust (max size 5 microns), gum
forming constituents and other deleterious solid and/or liquid matter
which will cause damage to or interfere with the operation of
transport facilities.

February, 2005
1.5 Site Location and Climatic Conditions
The naphtha cracker and associated units will be located at Panipat, in the
state of Haryana, India.
1.5.1 Meteorological Data
Sl# Parameter Minimum Normal/ Maximum/

Average Design
(A) METEOROLOGICAL DATA
1 Elevation above mean sea level, m 238 m
2 Barametric pressure, mbar 967.3 978.675 988.4
3 Ambient temperature, °C tmin = (-) 0.7 tnor = tmax = 46.6
4 Relative humidity, % @ tmin 88 @ tnor 95 @ tmax
5 Rainfall data: (a) for 1-hour period 72 mm
(b) for 24-hour period 218 mm
6 Wind data
(a) Wind velocity at a height of 30m 168 km/h
(b) Wind velocity at a height of 10m 152 km/h
(c) Wind direction:
i) Morning SE to NW
ii) Evening NW to SE
(B) DATA FOR EQUIPMENT DESIGN
1 Design dry bulb temperature, °C 39
2 Design wet bulb temperature, °C 27.5
3 Low ambient temperature for MDMT, °C (-) 0.7
4 Design air temperature for air cooled exchangers, °C 45
5 Preferred process temperatures break point for air cooled 65
exchangers where followed by water cooling, °C
6 Preferred process temperatures break point for air cooled 55
exchangers where not followed by water cooling, °C
7 Coincident temperature and relative humidity for Air Blower/Air (a) 40°C
Compressor design. (b) 80%*
* Maximum relative humidity is 95% and normal is 88%.
1.5.2 Earthquake
Seismic load shall be calculated by Indian Codes and Standards. Panipat

lies in the seismic zone IV as per IS1893 (to be confirmed).
1.5.3 Special Consideration
Provision for winterization is not required.

February, 2005
1.6 Battery Limit Conditions
Pressure Temperature, Phase

kg/cm2g °C
Feedstocks
Naphtha 12.0 min Amb. (5 min) Liquid
Hydrogenated C4 Recycle from C4 12.0 43 Liquid
Hydrogenation Unit
Hydrogenated C5 Recycle from 12.0 43 Liquid
PGHU
C6 Recycle from Benzene Extraction 12.0 40 Liquid
Unit
Downstream Plant Recycle

C3 Recycle from PP (Note 5) 20.6 Liquid
Light Gas Recycle from PP (Note 5) 8.0 40 Vapor
Purge Gas from LLDPE/HDPE (swing 1.8 40 Vapor
plant)
Ethylene Boil-off gas 1.5 -20.0 Vapor
Recycle from PP plant (based on 2.0 – 3.0 10 – 15 Vapor
selected technology)
Recycle from HDPE (Note 6) Vapor
Other Streams
FCC Dry Gas Hydrocarbons 24.5 -20 Liquid
Raw FCC C3s 27.0 43.5
Offspec Ethylene 14.0 -34.5 Mixed
phase
Off-spec. Propylene 27.5 45 Liquid
Products
Hydrogen Export 26.0 18.6 Vapor
Hydrogen Import from Refinery 31.0 40 Vapor
Methane Offgas 3.5 (1) 38-40 Vapor
HP Ethylene to downstream plant (2) 52.0 30 Vapor
MP Ethylene to downstream plant (2) 35.0 30 Vapor
(Revised to
28.0)
Ethylene Product to LP storage (3) 1.95 -98.0 Liquid
Polymer Grade Propylene 28.0 38 Liquid
Propylene to Atmospheric Storage (4) 4.0 -45 Liquid
Raw Mix C4s to storage 6.0 41.4 Liquid
Hydrogenated C4 to LPG pool 20.0 43.0 Liquid
Raw Mix C4 from storage to C4 Hydro 7.0 41.0

February, 2005
Pressure Temperature, Phase

kg/cm2g °C
Raw Pyrolysis Gasoline to 4.0 40 Liquid
storage/PGHU
C6-C8 Heart Cut to storage 4.5 40 Liquid
C6-C8 Heart Cut to BEU 5.0 89 Liquid
C9+ Product to storage 4.0 43 Liquid
Benzene Product 4.0 40 Liquid
C7-C8 Cut to storage 4.0 40 Liquid
Fuel Oil 5.0 90 Liquid
Miscellaneous
Relief to flare 0.1 normal Vapor
1.5 max.
1.7 build-up
at PSV inlet
Pretreated Spent Caustic (gasoline 2.5 74 Liquid
wash) to OSBL
50% Caustic from OSBL 4.5 40
Dilution Steam Drum Blowdown to 3.2 40 Liquid
OSBL
Fuel Gas Export 3.2 37.0 Vapor
Methane Ballast Gas 35.0 41.0 Vapor
Offspec Ethylene Vapor from HP 10.5 5 Vapor
Storage
Liquid Ethylene Recycle from 18.0 -72.0 Liquid
atmospheric storage
Liquid Propylene Recycle from 24.5 -35.0 Liquid
atmospheric storage
RLNG Fuel Ambient Vapor
Notes:
1. At fuel gas knock out drum.
2. Ethylene is produced and delivered as vapor product to downstream
plants at two pressure levels.
Ethylene Vapor
Product Flow Rate kg/h
User BL Pressure, kg/cm2g Case 1 Case 2
- HDPE and PP Plant 52.0 40,650 40,650
- Swing Polyethylene 35.0 Balance Balance
and MEG Plants
In addition 1,200 kg/h of ethylene product, equivalent to boil-off gas, is

sent as liquid ethylene to low pressure storage.

February, 2005
Subsequently, flow rates and BL pressures for ethylene product have

been revised as follows:
BL Pressure, kg/cm2g Flow Rate, kg/h

HP Ethylene 52.0 Normal: 46,000
Max.: 52,000
MP Ethylene 28.0 Balance
(Case 2: 59,976)
Revised flow rates and pressure will be used for specification of product
pumps and exchangers only. Material balances will not be revised to
reflect this change.
3. Up to 240,000 TPA (30,000 kg/h) ethylene may be delivered to

atmospheric storage at these conditions. The flow rate is 30% of the base
ethylene capacity of 800,000 TPA.
4. Up to 151,450 TPA (18,930 kg/h) propylene may be delivered to

atmospheric storage at these conditions. The flow rate is 30% of the base
capacity of 504,834 TPA.
5. Based on selected technology, these steams do not exist.
6. Connected to charge gas compressor first stage suction.
7. All pressures are at grade unless otherwise noted.
1.7 Environmental Specifications
This section describes the atmospheric emissions, liquid effluents and solids that
will be generated by the naphtha cracker unit. The quantity and characteristics
for these environmental streams are summarized in Section 6.3.
1.7.1 Atmospheric Emissions
The following gaseous emissions will be produced by the Naphtha Cracker Plant:
• Cracking Heater Flue Gas during Normal Operation

• Gas emissions during High Steam Standby/Decoking
• Acetylene Converter Regeneration Offgas
• MAPD Converter Regeneration Offgas
• C4 Hydrogenation Reactor Regeneration Offgas
• First Stage DPG Reactor Regeneration Offgas
• Second Stage DPG Reactor Regeneration Offgas

February, 2005
1.7.2 Liquid Effluents
The following aqueous effluent streams will be produced by the Naphtha Cracker
plant:
• Dilution Steam Drum Blowdown

• Spent Wash Water from the Caustic Water Wash Tower and
Pretreated (Gasoline Wash) Spent Caustic
• Continuous Blowdown from the SHP Steam Drums
• Intermittent Blowdown from the SHP Steam Drums and Transfer Line
Exchangers
• TLE Hydrojetting Water
• Polymeric Oil from the Caustic Water Wash Tower 1
• Slop Oils
• Rerun Tower Ejector Condensate
1.7.3 Solids
Periodically, the desiccants, absorbents, catalyst, as well as various filter media

must be changed.
In addition, the following sources of material will be produced by the plant:
• Coke from TLE Hydrojetting

• Coke from Quench Oil Pump Suction and Discharge Filters
• Coke from Pyrolysis Fuel Oil Stripper Feed and Product Suction Filters
1.7.4 Flue Gas Specification
Gaseous emissions will be in the following stipulations.
Particular Matter 150 mg/Nm3 max

CO 500 ppm vol max
NOx 50 ppmv at 3% O2 (dry) in emissions
SOx To be reported
1.7.5 Noise Level
Maximum noise level generated by any equipment shall be less than 85 dB(A) at
a distance of 1 meter.
1.7.6 Tolerance Limit
Tolerance limit for effluent discharged into inland surface water – refer to Table
1.7.6.1.

February, 2005
Table 1.7.6.1
Tolerance limits for effluent to be discharged into inland surface water (most
stringent between general effluent standards for discharge of environmental
pollutants (Part – A) and MINAS).
SR Characteristics Unit Requirements (Tolerance

No. Limits)
1 Color and Odor See Note 1
2 Suspended solids Mg/lit max. 100 (20 ppm for MINAS)
3 Particle size for suspended Shall pass 850 micron IS
solids sieve
4 pH value 5.5 to 9.0 (6.0 to 8.5 for
MINAS)
5 Temperature Deg C max. Shall not exceed 5 deg C
above the receiving water
temp.
6 Oil and Grease Mg/lit max. 10
7 Total residual chloride Mg/lit max. 1
8 Ammoniacal Nitrogen (as N) Mg/lit max. 50
9 Total Kjeldahl Nitrogen (as N) Mg/lit max. 100
10 Free Ammonia (as NH3) Mg/lit max. 5
11 Biochemical oxygen demand Mg/lit max. 30 (15 ppm as per MINAS)
(5 days at 20 deg C)
12 Chemical oxygen demand Mg/lit max. 250
13 Arsenic Mg/lit max. 0.2
14 Mercury (as Hg) Mg/lit max. 0.01
15 Lead (as Pb) Mg/lit max. 0.1
16 Cadmium (as Cd) Mg/lit max. 2
17 Hexacalent chromium (as Mg/lit max. 0.1
Cr+6)
18 Total chromium (as Cr) Mg/lit max. 2
19 Copper (as Cu) Mg/lit max. 3
20 Zinc (as Zn) Mg/lit max. 5
21 Selenium (as Se) Mg/lit max. 0.05
22 Nickel (as Ni) Mg/lit max. 3
23 Cyanide (as CN) Mg/lit max. 0.2
24 Chloride (as Cl) Mg/lit max. 1000
25 Fluoride Mg/lit max. 2
26 Dissolved phosphate (as P) Mg/lit max. 5
27 Sulfide (as S) Mg/lit max. 2 (as per MINAS 0.5 ppm
max)
28 Pesticides Absent
29 Phenolic compounds (as Mg/lit max. 1
C6H5OH)
30 Radioactive material
(a) Alpha emitters Micro curie/ml max. 1 x 10-7
(b) Beta emitters Micro curie/ml max. 1 x 10-6
Note 1: All efforts should be made to remove color and unpleasant odor as far as
practicable.

February, 2005
2.0 BASIS FOR PROCESS PERFORMANCE
2.1 General
The Naphtha Cracker Plant design shall be flexible to accommodate normally

anticipated fouling of equipment and catalyst deactivation. The stated process
performance is based on all equipment in the clean condition, with compressors
operating at or near the efficiencies stated in section 2.8. The exception to this is
the transferline exchangers which operate on relatively short cycles and are
assumed to be operating in the average fouled condition.
Hydrogenation reactors are assumed operating with average selectivities as

below:
Converter: Acetylene
Selectivity to Ethylene: 50%
Converter: MAPD 30%

Selectivity to Propylene:
2.2 0verall Material Balance
When cracking the design feedstocks having the specifications given in Section
1.0, the Plant shall be designed to produce the following terminal material
balances for the design cases. Balances are based on 8000 operation hours per
year.

February, 2005
Table 2.2.1
Material Balance
(includes Naphtha Cracker Unit, C4 Hydrogenation Unit and Pyrolysis
Gasoline Hydrogenation Unit)
Case 1 Case 2
Feed, kg/h
Naphtha 293,201 293,201
BD Raffinate to C4 Hydro 42,608 42,867
C6 Raffinate from GTC 14,306 14,319
Treated FCC C3s 12,412
Treated FCC Dry Gas 2,485 (1)
BOG from ethylene storage 1,200 1,200
C3 recycle from PP plant 8,850 8,850
Light gas from PP plant 2,587 2,587
Purge gas from PE plant 1,750 1,750
BD unit offgas 101 101
Net steam reacted 655 662
Total 365,258 380,434
Products, kg/h
Hydrogen 506 584
Methane Offgas 50,220 51,083
Polymer Grade Ethylene 103,829 107,176
Polymer Grade Propylene 73,044 83,318
Raw C4s 59,847 60,256
C6-C8 cut 59,650 59,795
C9+ cut 7,627 7,591
Pyrolysis Fuel Oil 10,432 10,629
Water from Methanator 123 124
Acid Gases 424 428
Total 365,702 380,984
Material Balance Deviation, kg/h 444 550
Recycles, kg/h
Ethane 21,407 22,797
Propane 5,471 8,314
C5s 19,560 19,782
Note:
(1) The flow rate excludes 1,988 kg of C3 wash stream.

February, 2005
Table 2.2.2
Material Balance
(including Naphtha Cracker, C4 Hydrogenation Unit, Pyrolysis Gasoline
Hydrogenation, Butadiene and Benzene Units)
Case 1 Case 2
Feed, kg/h
Naphtha 293,201 293,201
Raw FCC C3s -- 12,412
Treated FCC Dry Gas -- 2,485 (2)
BOG from ethylene storage 1,200 1,200
C3 recycle from PP plant 8,850 8,850
Light gas from PP plant 2,580 2,587
Purge gas from PE plant 1,750 1,750
Net steam reacted 655 662
Total 308,236 323,147
Products, kg/h
Hydrogen 506 584
Methane Offgas 50,220 51,083
Polymer Grade Ethylene 103,829 107,176
Polymer Grade Propylene 73,044 83,318
Butadiene 17,020 17,163
Benzene (1) 14,491 14,589
C7-C8 cut (1) 29,422 29,456
C9+ cut 7,627 7,591
Pyrolysis Fuel Oil 10,432 10,629
Water from Methanator 123 124
Acid Gases 424 428
Waste HC Stream from
Butadiene Unit 122 127
Total 307,260 322,268
Material Balance Deviation, kg/h 976 879
Recycles, kg/h
Ethane 21,407 22,797
Propane 5,471 8,314
C4s 42,919 43,177
C5s 19,560 19,782
C6s 14,306 14,319
Note:
(1) Products from Benzene Extraction Unit are adjusted based on final
feed rate and composition of treated C6-C8 stream from PGHU
shown in Table 2.2.1.
(2) The flow rate excludes 1,988 kg of C3 wash stream.

February, 2005
(3) Case 1 material balance for Butadiene and Benzene Extraction

units is based on terminal balance using Case 2 material balance
information.
2.3 Once-Through Cracking Yields
The once-through cracking yields for all feedstocks plus ethane and propane
recycle are presented in tabular form in this section. Please note that these
yields are based upon a cracking selectivity level determined by an SRT radiant
coil, a coil outlet pressure of 1.76 kg/cm2a and a steam-to-hydrocarbon ratio of
0.50 for Naphtha/C4/C5/C6 and 0.3 for ethane and propane recycle.
IOCL Naphtha Cracker - Once-Thru Yields
Recycle Recycle
Ethane Propane
Naphtha C4 Recy C5 Recy C6 Recy Naphtha/ Stream Stream
Feedstock (1) (1) (1) (1) C4/C5/C6 (2) (2)
Yields, wt%
Hydrogen 0.75 0.90 0.76 0.80 0.77 3.85 1.48

Methane 12.20 12.75 14.62 15.69 12.53 4.42 25.24
Acetylene 0.39 0.22 0.26 0.59 0.37 0.42 0.55
Ethylene 25.10 14.12 18.63 30.21 23.66 52.04 36.87
Ethane 3.69 1.84 2.71 3.42 3.41 34.65 3.99
Propadiene 0.52 0.90 1.07 1.21 0.62 0.06 0.48
Propylene 15.92 20.59 18.97 17.56 16.69 1.15 12.33
Propane 0.37 0.28 0.50 0.41 0.37 0.17 5.63
Butadienes 5.07 1.23 4.21 5.79 4.60 1.31 4.11
Butenes 5.54 13.43 15.14 6.55 7.02 0.19 0.82
Butanes 0.67 30.91 0.09 0.11 4.14 0.23 0.07
C5's 4.97 1.04 19.99 1.37 5.20 0.30 1.66
C6-C8 NA 6.40 0.50 0.86 6.85 5.43 0.38 0.31
Benzene 4.63 0.61 0.64 2.77 3.87 0.57 3.12
Toluene 4.62 0.28 0.48 0.89 3.74 0.11 0.67
Xylenes + EB 2.61 0.05 0.06 0.20 2.08 0.01 0.10
Styrene 0.73 0.08 0.09 0.16 0.60 0.00 0.52
C9-200oC 2.69 0.09 0.74 1.19 2.23 0.04 1.12
PGO/PFO 3.13 0.18 0.18 4.23 2.67 0.10 0.93
Total 100.00 100.00 100.00 100.00 100.00 100.00 100.00
Notes:
(1) Naphtha and hydrogenated C4, C5 and C6 are co-cracked in SRT-VI

heaters. This yield data is for the Naphtha, C4, C5 and C6 part of the
blend.

February, 2005
(2) Recycle ethane and propane are co-cracked. Ethane conversion is

65% and corresponding propane conversion is 94.23%. Once
through yield data is given for recycle streams.

February, 2005
2.4 Utility Consumption
Utility consumptions for Case 1 and 2 are provided in Section 3 of the Basic
Engineering Package. The basis for the balances are indicated in each utility
section. The utility consumptions are summarized in Table 2.4.1 below. The
consumption includes all the process units (Naphtha Cracker, C4 Hydro,
Pyrolysis Gasoline Hydrogenation, Butadiene and Benzene units) and the ISBL
steam/condensate system including deaerater/BFW pumps.
Table 2.4.1
Utility Consumption
Utility Unit Normal Hourly Quantity

Case 1 Case 2
Fuel gas MMKcal 629.7 638.6

Steam (SHP) T 0 0
Steam (HP) T (-) 9.20 (-) 8.9
Steam (MP) T 0 0
Steam (LP) T 7.1 9.2
Electric Power kW 15,317 15,754
Cooling Water m3 44,487 46,590
Note:
1. (-) means export
2.5 Specific Energy Consumption
The specific energy consumption is a useful measure to evaluate the overall

efficiency of a process. When making this comparison, it is extremely important
to understand the basis of the specific energy calculation. In general, two
techniques are utilized in the industry.
The first approach evaluates steam as equivalent SHP steam since useful work
may be derived between the various steam levels. When using this approach the
fuel equivalent values are assigned as follows:
(1) For SHP steam, the fuel equivalent value is calculated by taking the
enthalpy difference between the blend of turbine and LP
condensates feeding the deaerater at 100°C and the SHP steam
level of 120.0 kg/cm2g and 520°C. SHP steam is raised in the
cracking heater at 93.5% efficiency. The resulting value is 761
kcal/kg.

February, 2005
(2) For HP steam import or export the fuel equivalent value is set by
calculating the additional SHP steam that must be produced and let
down in the various compressor turbines to produce a fixed quantity
of HP steam. This ratio is 0.736 kg of SHP steam per kg of HP
steam. Hence, the fuel equivalent value is 560 kcal/kg. In a similar
fashion the fuel equivalent value of MP steam is 419 kcal/kg and LP
steam is 302 kcal/kg.
(3) For electricity the fuel equivalent value is 2.46 MMkcal per MW of
electric power based on a 35% power plant efficiency.
The second approach is to value the export steam at its enthalpy value. This
approach will result in the reporting of lower specific energy consumptions. Using
this technique the following fuel equivalent values may be assigned:
kcal/kg
2
SHP Steam 122.0 kg/cm g & 520°C 812.4
HP Steam 40.0 kg/cm2g & 380°C 756.0
MP Steam 15.1 kg/cm2g & 270°C 708.5
LP Steam 3.6 kg/cm2g & 195°C 679.9
Values have been calculated both ways to show the relative impact. The values
are presented in the Table 2.5.1.
The basis for the specific energy calculation is the normal operating fuel gas,
steam, and electric power at 800,000 TPA plant capacity for all ISBL process
units (Naphtha Cracker, C4 Hydro, PGHU, BEU and BZEU) and deaerater and
BFW pumps. .

February, 2005
Table 2.5.1
Specific Energy Consumption
Normal Operation
Approach 1 Approach 2
Case 1 Case 2 Case 1 Case 2
Fuel Fired
Cracking Heaters, MM Kcal/h 629.7 638.6 629.7 638.6
HP Steam Export
T/h 9.20 8.90 9.20 8.90
MM Kcal/h 5.15 4.98 6.96 6.73
LP Steam Import
T/h 7.1 9.2 7.1 9.2
MM Kcal/h 2.14 2.78 4.83 6.26
Electrical
kW 15,317 15,754 15,317 15,754
MM Kcal/h 37.68 38.75 37.68 38.75
Specific Energy
MM Kcal/h 664.37 675.15 665.25 676.88
kcal/kg of ethylene 6,398 6,299 6,407 6,316
kcal/kg of ethylene + propylene 3,756 3,544 3,761 3,553
2.6 Catalyst and Chemical Consumption
The Catalyst and Chemical Consumptions for Case 2 at normal operation of the
plant at the 800,000 TPA Plant capacity are summarized below.
2.6.1 Desiccant/Adsorbents
• Charge Gas Dryers
Volume Basis: 24 hour cycle + 6 hour guard bed.

Type: UOP molecular sieve Type: 3A-EPG
compound bed (1/4” TRISIV + 1/16”
pellets)
Volume: 114.2 m3 per dryer, 228.4 m3 for two dryers
Weight: Approx. 142,885 kg for 2 dryers
Estimated Life: Projected 5 years

February, 2005
• Condensate Stripper Bottoms Dryers
Volume Basis: 48 hour cycle

Type: UOP Molecular Sieve Type: 3A-EPG
1/16” pellets
• Hydrogen Dryers
Volume Basis: 48 hour cycle + 6 hour below moisture

probe
1/16” pellets
• Ethylene Dryer
Volume Basis: 48 hour cycle

1/8” pellets
Volume: 15 m3 in single dryer
Weight: 9,660 kg for single dryer
Estimated Life: Project life 5 years
• FCC C3’s Dryers/Treaters
Volume Basis: 72 hour cycle for first two years of

operation
48 hour cycle for third year of
operation
24 hour cycle at end of five years
Type: UOP Adsorbent Type: D-201, 3A-EPG
AZ-300 compound bed
Volume: 41.8 m3 for one dryer/treater, 83.6 m3 for
two
Weight: 53,070 kgs for two dryer/treaters
(4626 kg of D-201; 24222 kg of type
3A-EPG; 24222 kg of Type AZ-300)
Estimated Life: Guaranteed 3 years, projected life 5
years with reduced cycle time

February, 2005
FCC C3’s Arsine Treater
Volume Basis: The absorbent quantity determined by

minimum contact time
Type: UOP Adsorbent Type: GB-238
Volume: 4.6 m3 in single treater
Weight: 3265 kg in single treater
Estimated Life: Projected 5 years, guaranteed 3 years
2.6.2 Catalyst
• Acetylene Hydrogenation
Volume Basis: To meet 1 mol ppm acetylene spec. in

Ethylene Product.
Type. Sud-Chemie Type: G-58C silver
promoted palladium catalyst
Cycle Length: 5-9 months between regeneration
Volume: 52.8 m3 per reactor, 105.6 m3 for two
reactors
Weight: 76,800 kg for two reactors
Estimated Life Typically 8-12 years, 5 years guaranteed
• Methanator
Type: Sud-Chemie Type C13-4-04 nickel

catalyst ¼” – 1/8” spheres.
Volume: 7.8 m3 in single reactor
Weight: 7,020 kg
Estimated Life: Guaranteed 5 years
• MAPD Hydrogenation
Volume Basis: To achieve less than 200 mol ppm

MAPD in reactor effluent
Type: Sud-Chemie Type: G-68HX
1.3 mm CDS Extrusions
No. Reactors Req'd. 2
Volume: 15.8 m3 per reactor, 31.6 m3 Total
Weight: 19,000 kg for two reactors
Expected Cycle Length: Over one year
Expected Catalyst Life: Expected over 5 years, guaranteed
3 years

February, 2005
• C4 Hydrogenation
Volume Basis: Partially hydrogenate mixed C4’s

butadiene saturation only) when BD unit
is not in operation. Butadiene spec. for
C4 product is 1,000 wt. ppm max.
Volume: Combination of Sud-Chemie G-68HX
selective hydrogenation palladium
catalyst and T-2464B olefin
saturation, palladium catalyst.
G-68HX: 13.7 m3, 1.6 mm CDS extrusion
T-2464B: 13.7 m3, 1.6 mm CDS extrusion
Weight G-68HX – 8,200 kg
T-2464B – 6,165 kg
Total = 14,385 kg
Estimated Cycle Time: 1 year between regeneration, (over 2
years for C4 raffinate case)
Estimated Life: 3 years guaranteed
• DPG - Stage I
Volume Basis: To meet C5-C8 Product Spec.

No. reactors req'd. 1
Type DPG-1 selective hydrogenation
palladium catalyst. The reactor
consist of two beds in a single vessel.
Volume: 24.6 m3 per bed, 49.2 m3 total
Weight 35,424 kg total
Estimated cycle time 1 year
Estimated Life: Expected 5 years, 3 years guaranteed

February, 2005
• DPG - Stage II
Volume Basis: To meet depentanizer product spec.

(C5 cut and C6-C8 Product Spec.)
Type - Sud-Chemie Type OPGH II, Ni-Mo
2,5 mm CDS olefin saturation catalyst
- Sud-Chemie Type OPGH II, CO-Mo
1.5 mm CDS hydrodesulphurization
catalyst
Volume: OPGH III 37.3 m3
OPGH II 40.4 m3
Weight OPGH III – 22,380 kg +
OPGH II - 24,240 kg
Total = 46,620 kg
Estimated cycle time 12 months after initial start-up
Estimated Life: Estimated life is over 5 years, guaranteed
3 years
2.6.3 Chemicals
Caustic Soda
Caustic/Water Wash
Tower Usage: 1000 kg/h as 100% NaOH
Concentration: 20 wt.%
Quality: Rayon grade
Methanol
Type: Commercial Grade 99.85% purity

Inventory: 20 m3
Consumption: Intermittent

February, 2005
Injection Sulfur
Type: DMDS – Technical Grade (68% by

weight sulfur)
Usage: 100 ppm by wt. sulfur injection in ethane/
propane recycle and naphtha/C4/C5/C6 feed
to heaters
Consumption: 75 kg/day
Note:
Above consumption is for ethane/propane recycle feed only. Naphtha/C4/C5/C6

feeds do not require sulfur injection as naphtha feed contains 500 ppm sulfur.
Chemical Injection Agents
(a) Corrosion Inhibitor for Dilution Steam System
Chemical Dosage Consumption
Caustic Soda 4 ppm (as 100% NaOH basis) 25 kgs (100% basis) per day
to process water/quench water
Note:
Normal injection point of caustic is to the dilution steam drum feed. Dilute
caustic soda of approximately 2 wt.% solution is injected.
(b) Polymerization Inhibitor
Type: Nalco Actrene EC3214A

Usage: 30-50 ppm by wt. dosage of neat process
Antifoulant Nalco Actrene EC3214A.
Injection Point Dosage Liter/h max. as 100%

ppmw Inhibitor
− Condensate Stripper Reboiler 30 3.29

− Condensate Stripper Bottoms 50 5.91
− Recycle from C2 Green Oil Drum or 30 3.10
Deethanizer Reboilers
− Depropanizer Feed from Deethanizer 50 5.91
− Bottoms
− Depropanizer Reboilers 30 3.55

February, 2005
(c) Mixed C4 Product Inhibitor
Type: Tertiary Butyl Catechol (TBC) at a

Concentratiaon of 10 wt.% in toluene
solution.
Usage: 50 wt. ppm TBC into mixed C4 product when
sent to storage.
Consumption:
Normal Nil
Max, 75 kg/day as 100% TBC
(d) DPG Antioxidant Injection
Type: Nalco Energy Services EC3199A, diluted to

50 vol. % antioxidant agent. Treated C6-C8
cut from the depentanizer or C7-C8 cut from
the benzene extraction unit can be used
as diluent.
Usage: - 75 wt. ppm (100% antioxidant) injection into
raw pyrolysis gasoline when set to storage
60 wt. ppm (100% antioxidant) injection into
- C9 plus product to storage.
Consumption: Pyrolysis Gasoline:
Normal: 0
Max: 7 kg/h as 100% antioxidant
C9 Plus Product: 11 kg/day as 100%
antioxidant
(e) Depentanizer Corrosion Inhibitor
Type: Nalco Energy Services EC1046A. The

inhibitor is diluted by a small slip-stream of
reflux from Depentanizer reflux pumps (11-P-
5506A/B) and atomized through a spray nozzle
into the overhead vapor just upstream of the
Depentanizer condenser.
Usage: 8-15 wt. ppm of 100% corrosion inhibitor
Consumption: 13 to 25 kg/day as 100% inhibitor
(f) DPG Presulfiding Agent
Type: DMDS – Technical Grade (68% by wt. sulfur)

Usage: As required for presulfiding DPG second stage
catalyst.
Consumption: 7990 kgs as DMDS

February, 2005
(g) Boiler Feed Water Chemical Treatment
Amine, phosphate and oxygen scavengers are injected in BFW for SHP
Steam Drum Water quality control. The type of chemical and consumption
levels will be provided in the FEED package.
(h) Chemicals for Condensate Treatment
Caustic soda and acid are required for regeneration of cation and mixed
bed polishers. Consumption rates will be provided in the FEED package.
• Compressor Wash Oil and Flux Oil
Source: Partially hydrogenated C9 plus from 1st Stage DPG

is used as wash oil in normal operation. Light cycle
oil is available as back-up wash oil from adjacent
refinery.
Flux oil is required during start-up. Imported wash

oil or flux oil properties are as follows:
Type: Light Cycle oil or equivalent

Boiling Range, oC 230 to 340
Sulfur Content, wt.%: 2.5 max.
Viscosity @100oC cP: 20 – 30 max.
SG @15.6 oC: 0.95
Consumption: 2.5 t/h (500 kg/h/stage)
• Purge Oil
Source: Filtered pyrolysis gas oil from gasoline fractionator

Usage: As required for instrument purging in quench oil
system.
Consumption: 12.0 t/h as PGO from gasoline fractionator
Note: Purge oil after instrument flush ends up in gasoline fractionator.

Therefore, there is no consumption.
• Propylene Refrigerant
Usage: As required for initial inventory/make-up in

propylene refrigeration system.
Type: 99.5 wt.% Propylene
Water Dew Point – 45oC
Inventory: As calculated during detailed engineering

February, 2005
• Ethylene Refrigerant
Usage: As required for initial inventory/make-up in ethylene

Refrigeration system.
Type: 99.5 mol.% Ethylene

Water Dew Point – 105oC
Inventory: As calculated during detailed engineering
2.7 Pyrolysis Heater Performance
Normally, there will be five operating liquid SRT IV cracking heaters and one SRT III
recycle cracking heater. The heater guaranteed run lengths is presented below.
Feedstock Run Length

Naphtha + Hydrogenated C4/C5/C6 60 days
Ethane/Propane Recycle 60 days
Note: The run length of the heater shall be terminated when the maximum tube
wall metal temperature exceeds 1125°C (corrected for tube reflectivity) or
the average tube wall temperature reaches 1115°C (corrected for tube
reflectivity).
2.8 Assumed Efficiencies
The balances provided in this section are based on the following major equipment
efficiencies:
· Charge Gas Compressor
1st Stage 0.866

2nd Stage 0.871
3rd Stage 0.867
4th Stage 0.866
5th Stage 0.869
Turbine Driver Extract./Cond. 0.77/0.75
· Propylene Refrigeration Compressor
1st Stage 0.849

2nd Stage 0.879
3rd Stage 0.847
4th Stage 0.871

February, 2005
Turbine Driver Extract./Cond. 0.77/0.75
· Ethylene Refrigeration Compressor
1st Stage 0.807

2nd Stage 0.783
3rd Stage 0.790
Turbine Driver Condensing 0.77
· Methane Refrigeration Compressor
1st Stage 0.807

2nd Stage 0.689
Motor 0.88
DPG Recycle Compressor 0.75

Motor 0.88
Pump Motor Turbine

EFF EFF EFF
Pump
BFW Pump 0.8 0.9 0.65
QO Pump 0.85 0.94 0.65
QW Pump 0.84 0.94 0.60
Pumps and motor efficiencies for other process pumps are provided in electrical
power consumption tabulations in Section 3, Tab D, of the Basic Engineering
Package.
2.9 Heat Leak Factors
The propylene and ethylene refrigeration loads are estimated based on the
following heat leak factors:
• For shell and tube or kettle exchangers:
Temperature Level, °C Heat Leak, %

13 0.0
6 0.2
-27 1.2
-40 1.6
-63 2.3
-75 2.7
-101 3.5
-120 4.4
-150 5.0

February, 2005

Iocl Section 1 Process Specfication

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Iocl Section 1 Process Specfication

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What is the plant designed to produce?

What is the plant designed to produce?

What are the main process units involved?

What are the main process units involved?

INDIAN OIL CORPORATION LIMITED

INDIAN OIL CORPORATION LIMITED

NAPHTHA CRACKER PROJECT

800,000 TPA ETHYLENE PLANT

BASIC ENGINEERING PACKAGE

NAPHTHA CRACKER UNIT

SECTION 1 PROCESS SPECIFICATIONS

IOCL Section 1 – Process Specification.doc

INDIAN OIL CORPORATION LIMITED

NAPHTHA CRACKER PROJECT

800,000 TPA ETHYLENE PLANT

NAPHTHA CRACKER UNIT

LUMMUS PROJECT 12605

IOCL Section 1 – Process Specification.doc Page 1

INDIAN OIL CORPORATION LIMITED

NAPHTHA CRACKER PROJECT

800,000 TPA ETHYLENE PLANT

NAPHTHA CRACKER UNIT

ARTICLE I PLANT ELEMENT

1.0 WHAT CONSTITUTES THE PLANT

ARTICLE II PLANT SPECIFICATIONS

1.0 BASIS FOR PROCESS DESIGN

2.0 BASIS FOR PROCESS PERFORMANCE

IOCL Section 1 – Process Specification.doc Page 2

ARTICLE I – PLANT ELEMENTS

1.0 WHAT CONSTITUTES THE PLANT

The plant consists of the following process units:

• Naphtha Cracker Unit (NCU)

• Butadiene Extraction Unit (BEU)

In alternate operation, when BEU is not operating, C4 hydrogenation

• Pyrolysis Gasoline Hydrogenation Unit (PGHU)

• Benzene Extraction Unit (BZEU)

Block diagram of the process units is presented in Figure 1.1.

IOCL Section 1 – Process Specification.doc Page 3

IOCL Section 1 – Process Specification.doc Page 4

2.0 GENERAL DESCRIPTION OF THE NAPHTHA CRACKER UNIT

The naphtha cracker is designed to produce polymer grade ethylene and

The naphtha cracker unit is designed to produce the following by-products:

2.1 ISBL Facilities

• Cracking Heaters Feed System

IOCL Section 1 – Process Specification.doc Page 5

• Ethylene Product System

2.2 ISBL Supporting Facilities

2.3 Capacity and Mode of Operation

The plant shall be designed to produce 800,000 TPA of polymer grade

IOCL Section 1 – Process Specification.doc Page 6

This case includes two FCC streams as additional feed namely,

1) Treated FCC dry gas C2s and

The capacity and mode of operation is summarized below:

Design Case Feeds Ethylene Propylene Remarks

Base Case • Naphtha 800,000 504,834 --

IOCL Section 1 – Process Specification.doc Page 7

Design Case Feeds Ethylene Propylene Remarks

Case 2 • Naphtha 857,408 666,544 Detailed Material