Sohar Report2
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Ahmed Ibrahim Ahmed EissaSohar Report2
Uploaded by
Ahmed Ibrahim Ahmed EissaOrpic, Sultanate of Oman Environmental Impact Assessment Report
CB&I, Netherlands Petrochemical Plant, Sohar
Document No.: G-S000-5240-003
Environmental Impact Assessment Report
Petrochemical Plant (Sohar)
June 2015
Project No: HMR/3817
Issue and Revision
HMR FEED/Company
Rev. Document Description Issue Date
Prepared Checked Approved Approved
G-S000-5240- EIA Report for Noelia Benzal
003 Issued for 1st March Martinez/
C Petrochemical Radheshyam Radheshyam Stuart
FEED 2015
Plant, Sohar Fahd Sharaf
G-S000-5240- EIA Report for Final Draft Noelia Benzal
003 22nd Jan Martinez/
B Petrochemical for client Radheshyam Radheshyam Stuart
2015
Plant, Sohar review Fahd Sharaf
G-S000-5240- EIA Report for Initial draft Noelia Benzal
003 8th Dec Martinez/
A Petrochemical issued for Radheshyam Radheshyam Stuart
2014
Plant, Sohar client review Fahd Sharaf
This document has been prepared for the above titled project and it should not be relied upon or used
for any other project without the prior written authority of HMR Environmental Engineering
Consultants. HMR Environmental Engineering Consultants accepts no responsibility or liability for this
document to any party other than the client for whom it was commissioned.
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Table of Contents
1 INTRODUCTION ........................................................................................................................... 1-1
1.1 Background ............................................................................................................................ 1-1
1.2 Objectives of the EIA Report ................................................................................................. 1-3
1.3 EIA Study Methodology ........................................................................................................ 1-3
1.3.1 Overview..................................................................................................................... 1-3
1.3.2 MECA’s Comments on Scoping.................................................................................. 1-4
1.3.3 Document Review ....................................................................................................... 1-4
1.3.4 Environmental Data Gathering.................................................................................. 1-5
1.3.5 Impact Assessment...................................................................................................... 1-5
1.3.6 Development of EMP.................................................................................................. 1-5
1.3.7 Structure of the EIA report ......................................................................................... 1-5
2 ENVIRONMENTAL REGULATORY FRAMEWORK................................................................ 2-1
2.1 Environmental Legislations in Oman..................................................................................... 2-1
2.2 Applicable Environmental Permits......................................................................................... 2-4
2.3 Regional and International Conventions and Protocols ......................................................... 2-4
2.4 International Guidelines and Best Practices ........................................................................... 2-5
2.5 Integrated Pollution Prevention and Control Directive .......................................................... 2-6
2.6 Seveso-II Directive................................................................................................................. 2-6
3 PROJECT DESCRIPTION.............................................................................................................. 3-1
3.1 Overview ................................................................................................................................ 3-1
3.2 Process Description ................................................................................................................ 3-1
3.3 Refinery Dry Gas Treatment Unit .......................................................................................... 3-3
3.4 NGL Treating and Fractionation Unit (NGLT)...................................................................... 3-3
3.5 Steam Cracker Unit ................................................................................................................ 3-4
3.6 Methyl Tertiary Butyl Ether (MTBE) Unit ............................................................................ 3-9
3.7 Butene-1 Recovery Unit ....................................................................................................... 3-10
3.8 Polyethylene Unit ................................................................................................................. 3-13
3.9 Polypropylene Unit............................................................................................................... 3-17
3.9.1 Pre-contacting and Pre-polymerization ................................................................... 3-17
3.9.2 Liquid Monomer Polymerization.............................................................................. 3-18
3.9.3 Gas Phase Copolymerization ................................................................................... 3-18
3.9.4 Polymer Drying ........................................................................................................ 3-19
3.9.5 Extrusion .................................................................................................................. 3-19
3.9.6 Pellets homogenization............................................................................................. 3-19
3.10 Pygas Hydrotreater Unit (PGHYD).................................................................................. 3-21
3.10.1 First Stage Reaction Section .................................................................................... 3-21
3.10.2 First Stage Distillation Section ................................................................................ 3-22
3.10.3 Second Stage Reaction Section................................................................................. 3-22
3.10.4 Second Stage Distillation Section............................................................................. 3-23
3.11 Utilities ............................................................................................................................. 3-25
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3.11.1 Power Plant.............................................................................................................. 3-25
3.11.2 Flare System ............................................................................................................. 3-26
3.11.3 Incinerators .............................................................................................................. 3-28
3.11.4 Drainage System....................................................................................................... 3-30
3.11.5 Potable and Service Water System ........................................................................... 3-33
3.11.6 Seawater Desalination System ................................................................................. 3-34
3.11.7 Fuel Gas and Natural Gas System ........................................................................... 3-34
3.11.8 Cooling Water System .............................................................................................. 3-36
3.11.9 Nitrogen Requirements............................................................................................. 3-36
3.11.10 Steam System ........................................................................................................ 3-36
3.11.11 Instrument and Plant Air ...................................................................................... 3-37
3.11.12 Overall Utilities Consumption.............................................................................. 3-39
3.12 Wastewater Collection, Treatment and Disposal ............................................................. 3-39
3.12.1 Last Line of Defense (LLOD) ................................................................................... 3-40
3.12.2 Benzene / MTBE Contaminated Wastewater Pre-treatment .................................... 3-42
3.12.3 Wastewater Primary Treatment ............................................................................... 3-43
3.12.4 Wastewater Secondary Treatment............................................................................ 3-44
3.12.5 Wastewater Tertiary Treatment................................................................................ 3-45
3.12.6 Spent Caustic Oxidation Unit................................................................................... 3-45
3.13 Project Construction Method............................................................................................ 3-46
3.13.1 Utilities during Construction Phase......................................................................... 3-47
3.13.2 Sourcing of Construction Materials ......................................................................... 3-48
3.13.3 Accommodation Facilities for Construction Workers .............................................. 3-48
3.13.4 Traffic Management Plan during Construction ....................................................... 3-49
3.14 Project Management......................................................................................................... 3-50
3.15 Project Schedule ............................................................................................................... 3-50
4 ENVIRONMENTAL BASELINE .................................................................................................. 4-1
4.1 Overview ................................................................................................................................ 4-1
4.2 Project Location ..................................................................................................................... 4-1
4.3 Topography and Landscape.................................................................................................... 4-4
4.4 Climate and Meteorology ....................................................................................................... 4-4
4.5 Ambient Air Quality............................................................................................................... 4-5
4.5.1 Ambient Dust .............................................................................................................. 4-7
4.5.2 Ambient Noise............................................................................................................. 4-9
4.6 Geology ................................................................................................................................ 4-11
4.7 Soil ....................................................................................................................................... 4-11
4.7.1 Soil Quality............................................................................................................... 4-12
4.8 Hydrology and Surface Drainage ......................................................................................... 4-14
4.9 Hydrogeology and Groundwater .......................................................................................... 4-14
4.9.1 Groundwater Resources ........................................................................................... 4-14
4.9.2 Groundwater Quality ............................................................................................... 4-15
4.10 Terrestrial Ecology ........................................................................................................... 4-16
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4.11 Marine Environment......................................................................................................... 4-16
4.12 Social Environment .......................................................................................................... 4-17
4.12.1 Connectivity.............................................................................................................. 4-17
5 ENVIRONMENTAL RELEASES .................................................................................................. 5-1
5.1 Releases during Construction Phase....................................................................................... 5-2
5.1.1 Air Emissions.............................................................................................................. 5-2
5.1.2 Liquid Effluents .......................................................................................................... 5-4
5.1.3 Solid Waste ................................................................................................................. 5-6
5.1.4 Noise........................................................................................................................... 5-8
5.1.5 Accidental Releases .................................................................................................... 5-8
5.2 Releases during Operation Phase ........................................................................................... 5-9
5.2.1 Air Emissions.............................................................................................................. 5-9
5.2.2 Wastewater ............................................................................................................... 5-14
5.2.3 Solid Waste ............................................................................................................... 5-17
5.2.4 Noise......................................................................................................................... 5-18
5.2.5 Accidental Releases .................................................................................................. 5-19
6 ANALYSIS OF ALTERNATIVES................................................................................................. 6-1
6.1 Need for the Project................................................................................................................ 6-1
6.2 Project Location ..................................................................................................................... 6-2
6.3 Sourcing of Utilities ............................................................................................................... 6-3
6.3.1 Sourcing of Power ...................................................................................................... 6-3
6.3.2 Sourcing of Water....................................................................................................... 6-5
6.3.3 Cooling Water System ................................................................................................ 6-6
6.3.4 Fuel for GT................................................................................................................. 6-7
6.4 Air Pollution Control Systems ............................................................................................... 6-7
6.4.1 CO2 Emission Control ................................................................................................ 6-7
6.4.2 CO and HC Emission Control.................................................................................... 6-8
6.4.3 NOx Emission Control ................................................................................................ 6-8
6.5 Sourcing of Fuels and Utilities during Construction Phase.................................................... 6-9
6.5.1 Power.......................................................................................................................... 6-9
6.5.2 Water .......................................................................................................................... 6-9
6.5.3 Fuels ......................................................................................................................... 6-10
6.5.4 Sourcing of Construction Materials ......................................................................... 6-10
6.5.5 Siting of Labour Camps............................................................................................ 6-10
6.6 BAT for Polymer Area ......................................................................................................... 6-11
6.6.1 Polymer BREF.......................................................................................................... 6-11
6.6.2 BAT Polyethylene .................................................................................................... 6-12
6.6.3 BAT LLDPE.............................................................................................................. 6-12
6.7 Steam Cracker Unit .............................................................................................................. 6-13
6.7.1 Large Combustion Plant .......................................................................................... 6-13
6.7.2 BAT for Large Volume Organic Chemicals ............................................................. 6-15
6.7.3 BAT for Incinerators ................................................................................................ 6-16
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6.7.4 BAT to Control Odour Emissions............................................................................. 6-17
6.7.5 Control of Emissions from Storage Tanks................................................................ 6-18
7 CLIMATE AFFAIRS ...................................................................................................................... 7-1
7.1 Contact Details ....................................................................................................................... 7-1
7.2 Integration of Climate Affairs Issues to the EIA.................................................................... 7-1
7.2.1 Type of ODS ............................................................................................................... 7-1
7.2.2 Equipment Containing ODS ....................................................................................... 7-1
7.2.3 ODS Alternative ......................................................................................................... 7-1
7.2.4 Plan for Use of ODS Alternative ................................................................................ 7-2
7.2.5 Adherence with Ministerial Decision 107/2013 ......................................................... 7-2
7.3 Greenhouse Gas (GHG) Emissions from Energy Sources – Combustion of fuel from the
Project .............................................................................................................................................. 7-2
7.3.1 Stationary Combustion Sources ................................................................................. 7-2
7.3.2 Mobile Combustion Sources....................................................................................... 7-3
7.3.3 Fugitive Emissions from Oil and Natural Gas System ............................................... 7-5
7.3.4 Land Use and Land Change Use or others ................................................................ 7-5
7.3.5 Summary of GHG Emission Calculations .................................................................. 7-5
7.3.6 GHG Emissions from Industrial Process of the Proposed Plant/Industry ................. 7-5
7.3.7 GHG Emissions from Solvent use in the Proposed Plant/Industry ............................ 7-6
7.3.8 GHG Emissions from Solid Waste generating from Plant/Industry premises............ 7-6
7.3.9 GHG Emissions from Wastewater Treatment in the Plant/Industry premises ........... 7-7
7.3.10 Reporting Total Amount of GHG Emission................................................................ 7-7
7.4 Climate Change Risk and Impact Assessment ....................................................................... 7-8
7.5 Identifying Alternatives and Mitigation Measures................................................................. 7-9
7.6 Climate Affairs Risk Reduction Plan (CARRP) .................................................................. 7-10
7.6.1 Storm, Flooding Events and Sea Level Rise ............................................................. 7-10
7.6.2 Global Warming, Increase in Temperature and Sea Level Rise .............................. 7-10
7.6.3 Landslide .................................................................................................................. 7-10
7.6.4 Tsunamis................................................................................................................... 7-10
7.6.5 Seismic Intensity ....................................................................................................... 7-11
8 ENVIRONMENTAL IMPACT ASSESMENT ............................................................................ 8-15
8.1 Methodology ........................................................................................................................ 8-15
8.2 Potential Hazards and Impacts by Activity .......................................................................... 8-17
8.3 Assessment of Impacts during Construction Phase.............................................................. 8-19
8.3.1 Natural Resources .................................................................................................... 8-20
8.3.2 Topography and Landscape ..................................................................................... 8-21
8.3.3 Ambient Air Quality.................................................................................................. 8-21
8.3.4 Ambient and Workplace Noise ................................................................................. 8-22
8.3.5 Terrestrial Ecology................................................................................................... 8-22
8.3.6 Soil and Groundwater .............................................................................................. 8-23
8.3.7 Impact on Local Economy ........................................................................................ 8-23
8.3.8 Impact on Land use and Local Communities ........................................................... 8-24
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8.3.9 Archaeology and Heritage ....................................................................................... 8-24
8.3.10 Summary of Impacts ................................................................................................. 8-24
8.4 Assessment of Impact during Operation Phase .................................................................... 8-25
8.4.1 Natural Resources .................................................................................................... 8-25
8.4.2 Topography and Landscape ..................................................................................... 8-26
8.4.3 Ambient Air Quality.................................................................................................. 8-26
8.4.4 Ambient and Workplace Noise ................................................................................. 8-29
8.4.5 Terrestrial Ecology................................................................................................... 8-29
8.4.6 Soil and Groundwater .............................................................................................. 8-29
8.4.7 Impact on Local Economy ........................................................................................ 8-30
8.4.8 Land Use and Local Communities ........................................................................... 8-31
8.4.9 Summary of Impacts ................................................................................................. 8-31
9 CONCLUSION................................................................................................................................ 9-1
APPENDIX A SEU/MECA FEEDBACK ON SCOPING REPORT.................................................A-1
APPENDIX B OMANI ENVIRONMENTAL LAWS AND REGULATIONS ................................B-1
APPENDIX C SOIL ANALYSIS REPORT ......................................................................................C-1
APPENDIX D GROUNDWATER ANALYSIS RESULTS..............................................................D-1
APPENDIX E ECOLOGICAL SETTINGS OF THE SITE AND ITS VICINITY ........................... E-1
APPENDIX F SOCIO-ECONOMIC SETTINGS OF PIA ................................................................ F-6
APPENDIX G DUST EMISSION FROM VEHICLES ON SITE .....................................................G-1
APPENDIX H EMISSIONS DUE TO PROJECT TRAFFIC ON SITE ............................................H-1
APPENDIX I DEFINITION OF IMPACT ASSESSMENT TERMS ............................................... I-1
APPENDIX J IMPACT ASSESSMENT MATRIX...........................................................................J-1
APPENDIX K GLC ISOPLETHS ......................................................................................................K-1
List of Tables
Table 1-1: Project Focal Point................................................................................................................ 1-2
Table 1-2: MECA/SEU’s Feedback on Scoping Report ........................................................................ 1-4
Table 2-1: Applicable Environmental Laws and Regulations................................................................ 2-2
Table 2-2: Permit Responsibility Matrix................................................................................................ 2-4
Table 2-3: International Conventions and Protocols .............................................................................. 2-5
Table 3-1: Main Wet Flare Connections .............................................................................................. 3-27
Table 3-2: Equipment’s connected to Flaring System ......................................................................... 3-28
Table 3-3: Type of Pressurized Sewer System and Stream Disposal/Treatment ................................. 3-32
Table 3-4: Utilities Consumption – Normal and Maximum Flow Rate ............................................... 3-39
Table 3-5: Sourcing of Construction Material...................................................................................... 3-48
Table 3-6: Tentative Project Schedule ................................................................................................. 3-50
Table 4-1: Coordinates of the Project Site ............................................................................................. 4-1
Table 4-2: Meteorological Conditions at Sohar 2011-2013 ................................................................... 4-4
Table 4-3: CAAQMS Monitoring Methods for Parameters................................................................... 4-6
Table 4-4: CAAQMS Monitoring Location Co-ordinates ..................................................................... 4-6
Table 4-5: AAQMS Results (Units in g/m3 unless otherwise specified) ............................................ 4-7
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Table 4-6: Ambient Dust Levels – Location Coordinates and Measured Values .................................. 4-9
Table 4-7: Maximum 24-hr avg. Dust Levels at the Site ....................................................................... 4-9
Table 4-8: Ambient Noise Level .......................................................................................................... 4-10
Table 4-9: Soil Sampling Location ...................................................................................................... 4-12
Table 4-10: Results of Laboratory Analysis of Soil Samples .............................................................. 4-12
Table 4-11: Groundwater Analysis Result ........................................................................................... 4-15
Table 5-1: Air Emissions during Construction Phase ............................................................................ 5-2
Table 5-2: DG Emissions from Construction Phase............................................................................... 5-3
Table 5-3: Dust Emissions from Vehicle on Unpaved area within Site after water spraying ................ 5-4
Table 5-4: Gaseous Emission from Vehicle Travelling at Site .............................................................. 5-4
Table 5-5: Wastewater Stream during Construction Phase .................................................................... 5-5
Table 5-6: Waste Generation during Construction Phase ...................................................................... 5-7
Table 5-7: Typical Noise Level.............................................................................................................. 5-8
Table 5-8: Emission Rate of Pollutants from Stacks............................................................................ 5-10
Table 5-9: Storage Tank Details and Expected Emissions................................................................... 5-13
Table 5-10: Wastewater Generated during Operation Phase................................................................ 5-15
Table 5-11: Solid Waste Generation during Operation Phase.............................................................. 5-17
Table 5-12: Noise Generation During Operational Phase .................................................................... 5-18
Table 7-1: GHG Emission from DG Set ................................................................................................ 7-3
Table 7-2: Detailed GHG Emission Calculation from Stationary Combustion Sources........................ 7-3
Table 7-3: GHG Emissions from Mobile Combustion........................................................................... 7-4
Table 7-4: Detailed GHG Emission Calculation for Mobile Combustion Sources................................ 7-4
Table 7-5: GHG Emission from Industrial Process................................................................................ 7-5
Table 7-6: Detailed GHG Emission Calculation from Industrial Process Combustion ......................... 7-6
Table 7-7: Total GHG Emissions (TPA)................................................................................................ 7-8
Table 7-8: Climate Change Matrix......................................................................................................... 7-9
Table 8-1: Potential Impacts from Construction Phase ........................................................................ 8-17
Table 8-2: Potential Impacts from Operation Phase............................................................................. 8-18
Table 8-3: Summary of Impacts during the Construction Phase.......................................................... 8-25
Table 8-4: Model Set Up ...................................................................................................................... 8-26
Table 8-5: Air Emissions from Operation Phase.................................................................................. 8-27
Table 8-6: Predicted GLC Values ........................................................................................................ 8-28
Table 8-7: Summary of Impacts during the Operation Phase .............................................................. 8-31
List of Figures
Figure 3-1: Overall Plot Plan of the Petrochemical Plant ...................................................................... 3-2
Figure 3-2: RDG Unit – Flow Diagram ................................................................................................. 3-3
Figure 3-3: NGL Treating and Fractionation Unit ................................................................................. 3-4
Figure 3-4: SCU Flow Diagram ............................................................................................................. 3-5
Figure 3-5: Flow Diagram –NGL Treatment and SCU.......................................................................... 3-7
Figure 3-6: Plot Plan of Steam Cracker Unit.......................................................................................... 3-8
Figure 3-7: MTBE and BUT-1 Unit Plot Plan ..................................................................................... 3-12
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Figure 3-8: Plot Plan - PE Plant .......................................................................................................... 3-16
Figure 3-9: Plant Layout – Polypropylene Unit ................................................................................... 3-20
Figure 3-10: Plot Plan for PGHYD Unit .............................................................................................. 3-24
Figure 3-11: Power Plant GTCC Configuration................................................................................... 3-25
Figure 4-1: Project Site Location ........................................................................................................... 4-2
Figure 4-2: Boundary Co-ordinates – Petrochemical Plant.................................................................... 4-3
Figure 4-3: Noise Monitoring Location ................................................................................................. 4-8
Figure 4-4: Road Connectivity In Vicinity of Petrochemical Plant ..................................................... 4-18
Figure 6-1: Road Connections between SIPA and other Destinations ................................................... 6-3
Figure 7-1: Landslide Hazard Distribution Map .................................................................................. 7-12
Figure 7-2: Earthquake Frequency for Middle East ............................................................................. 7-13
Figure 7-3: Seismicity Map for Middle East (1990-2012) ................................................................... 7-13
Figure 7-4: Peak Ground Acceleration................................................................................................. 7-14
Figure 8-1: Impact Assessment Matrix for Planned Aspects ............................................................... 8-16
Figure 8-2: Impact Assessment Matrix for Unplanned Aspects........................................................... 8-16
List of Attachment
Map 1: Overall Site Layout .......................................................................................................................A
Map 2: Site Layout for Steam Cracker Unit.............................................................................................. B
Map 3: Site Layout for PE/PP Plot............................................................................................................ C
Map 4: Overall Industrial Cluster in Sohar Area and Proposed plot Location..........................................D
Map 5: Plot 10 and Plot 18 Site location within SIPA .............................................................................. E
Map 6: Villages with 5 km Study Area from the Plots ..............................................................................F
List of Attachment
Attachment 1: Process Description – NGLT, RDG, SCU.........................................................................H
Attachment 2: Chemical Reaction Kinetics for Steam Cracker Unit ........................................................ I
Attachment 3: Steam Cracker Heat and Material Balance ......................................................................... J
Attachment 4: Process Description of Butene-1 .......................................................................................K
Attachment 5: Process Description Pygas Hydrotreater Unit ................................................................... L
Attachment 6: Process description for Flares........................................................................................... M
Attachment 7: Process Description for Incinerators..................................................................................N
Attachment 8: Process Description – Potable & Service Water Unit........................................................O
Attachment 9: Process description for Seawater Desalination System ......................................................P
Attachment 10: Process description for Fuel Gas and Natural Gas System..............................................Q
Attachment 11: Process description for Cooling Water System ............................................................... R
Attachment 12: Process Description for Nitrogen System.........................................................................S
Attachment 13: Process Description Steam System.................................................................................. T
Attachment 14: Process description for Instrument and Plant Air system ................................................U
Attachment 15: Process Description WWTP ............................................................................................ V
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Attachment 16: Process description and BAT for Spent Caustic Selection Process ................................ W
Attachment 17: Tie-ins and Interconnecting lines.....................................................................................X
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Abbreviations and Acronyms
°C Degree Centigrade
ALARP As Low As Reasonably Practicable
AOC Accidently Oil Contaminated
Amsl Above mean sea level
BAT Best Available Technique
BFW Boiler Feed Water
BLEVE Boiling Liquid Expanding Vapor Explosion
BRC Beyond Regulatory Control
BRCT Binary Refrigerant Compressor Turbine
BTEX Benzene Toluene
BUT Butene Recovery Unit
CAAQMS Continuous Ambient Air Quality Monitoring System
Capex Capital Expenditure
CB&I Chicago Bridge and Iron Co
CD Catalytic Distilation
CH4 Methane
CO Carbon Monoxide
CO2 Carbon dioxide
dB (A) Decibel (A-weighted)
DG Diesel Generator
DGCA Directorate General of Climate Affairs
DGEA Directorate General of Environmental Affairs
DGF Dissolved Gas Floatation
DIB Di-isobutylene
DM Demineralised
DMDS Di Methyl Di Sulphide
DME Dimethyl ether
DMS Di Methyl Sulphide
EIA Environmental Impact Assessment
EIL Engineers India Limited
EHS Environment, Health and Safety
EPC Engineering Procurement Construction
ER Environmental Review
FCS Fahud Compression Station
FEED Front End Engineering Design
FFB First Flush Basin
FG Fuel Gas
FID Flame Ionisation Detector
G gram
GHG Greenhouse Gases
GLC Ground level concentration
GPR Gas Phase Reactor
GT Gas Turbine
GTCC Gas Turbine Combined Cycle
Ha hectares
HDPE High density polyethylene
H2 S Hydrogen Sulfide
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HFC Hydrofluorocarbons
HMR HMR Environmental Engineering Consultants
HP NG High pressure natural gas
HRSG Heat Recovery Steam Generator
HSEMS Health Safety and Environmental Management System
IAM Impact Assessment Matrix
IG Inert Gas
IPCC Intergovernmental Panel on Climate Change
IPPC Integrated Pollution Prevention and Control
ISBL Inside Battery Limit
ISLM Integrating and Logging Sound Level Meter
IUCN International Union for the Conservation of Nature and Natural Resources
Km kilometer
kTA Kilo tones per annum
LDC Less developed countries
LLOD Last Line of Defense
LLDPE Linear low density polyethylene
LP Low Pressure
LPIC Liwa Plastic Industries Complex
m3 Cubic meter
m3/h Cubic meter per hour
MAF Mina Al Fahal
MECA Ministry of Environment and Climate Affairs
MED Muti effect distillation
MISC Majis Industrial Services Company
MRMWR Ministry of Regional Municipalities and Water Resources
Mg milligram
MSBE Methyl Secondary Butyl Ether
MTBE Methyl tertiary butyl ether
NG Natural gas
NGL Natural gas liquids
NGLE Natural gas liquid extraction
NGLT NGL Treating & Fractionation Unit
NOL No Objection Letter
O3 Ozone
OCB Oil Contaminated Basin
ODS Ozone Depleting Substances
OETC Oman Electricity Transmission Company
OPP Oman Polypropylene
Opex Operational Expenditure
ORPC Oman Refineries and Petrochemicals Company
Orpic Oman Oil Refineries and Petroleum Industries Company
OSBL Outside Battery Limit
OWS Oily Water Sewer
PEP Preliminary Environmental Permit
PGHYD Pygas hydrotreater unit
PM Particulate Matter
PM10 Particular Matter less than 10 micron
PMC Project Management Consultancy
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POB Peak overflow basin
POP Persistent Organic Pollutant
PPE Personal Protection Equipment
PRCT Propylene Refrigerant Compressor Turbine
RD Royal Decree
RDG Refinery Dry Gas
RFCC Residue Fluid Catalytic Cracker
ROP Royal Oman Police
SCU Steam Cracker Unit
SCWU Secondary Cooling Water Unit
SEU Sohar Environmental Unit
SF6 Sulfur hexafluoride
SHS Super High Pressure Steam
SHU/SLC4HY Selective C4 Hydrogenation Unit
SIPA Sohar Industrial Port Area
SO2 Sulfur dioxide
SRIP Sohar Refinery Improvement Project
STP Sewage Treatment Plant
TBA Tertiary Butyl Alcohol
TEAL Triethyl Aluminium
TLE Transfer Line Exchangers
TNMHC Total Non-methane hydrocarbon
TPA Tonnes per annum
TPH Tonnes per hour
UFCCC United Nations Framework Convention on Climate Change
UHC Unburned Hydrocarbon
USEPA United States Environmental Protection Agency
WWCT Wastewater Collection Tank
WWTU Wastewater Treatment Unit
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Executive Summary
Background
Oman Oil Refineries and Petroleum Industries Company (Orpic) is planning to set up a project Liwa
Plastic Industries Complex (LPIC) which will include a nominal 863,000 t/y ethylene cracking plant,
high density polyethylene (HDPE) plant, linear low density polyethylene (LLDPE) plant, new
polypropylene plant, methyl tertiary butyl ether (MTBE) plant, Butene-1 plant and associated utilities
and offsite facilities.
The LPIC Petrochemical Complex will be integrated with the Sohar Refinery, Aromatics Plant and
Polypropylene Plant. One of the feed-stocks is Natural Gas Liquids (NGL) i.e. C2+, which is
extracted from natural gas at Fahud, about 250 km southwest of Muscat, and transported to the Sohar
via pipeline. The NGL extraction plant and the pipeline will also be part of LPIC.
The proposed Petrochemical Complex is categorized under Group 1, ‘Industrial Projects’ sub
categorized as ‘Chemical and Petrochemical Project’, requiring to conduct an Environmental Impact
Assessment (EIA), accordingly CB&I has commissioned HMR to undertake an EIA study for the
Petrochemical Complex in Sohar.
The EIA scoping report for the project was submitted to MECA on 18th December 2014.
Subsequently, SEU/MECA provided their comments on the scoping report on 11th January 2015
(Appendix A) which are addressed in this EIA. Suggestions and comments provided by MECA on
EIA scoping report has been addressed in this EIA report.
Project Overview
The process units included in the Petrochemical Complex are:
Refinery Dry Gas Treating Unit (RDG Unit);
NGL Treating and Fractionation Unit;
Steam Cracker Unit (SCU);
Selective C4 Hydrogenation Unit;
MTBE Unit;
Butene-1 Recovery Unit;
Pygas Hydrotreater Unit (PGHYD);
HDPE Unit;
LLDPE Unit; and
PP Unit.
The utilities included in the Petrochemical Complex are:
150 MW
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Flaring System
Incinerators (2 incinerators)
Drainage systems
Potable and services water system
Seawater desalination system
Fuel Gas and Natural Gas System
Cooling Water System
Steam systems
Wastewater Collection, Treatment and Disposal
In addition to the above, the buildings such as the Main Control Room, Satellite Instrument Houses,
Substations, Main Substation and Analyser Houses will also be constructed in the petrochemical
complex.
Petrochemical Location
The project site for the Petrochemical Complex will be spread on two plots and located adjacent to
SRIP in Sohar Industrial Port Area (SIPA) which is a dedicated industrial area. The Petrochemical
Complex will be integrated with the Sohar Refinery, Aromatics Complex and Polypropylene Plant.
SIPA is spread over an area of 132km2 and located on Al Batinah coast about 20km north of Sohar
and 220km from Muscat.
Manpower for Construction and Operation Phases
The average labour requirement during project construction is estimated to be about around 1,000
with the peak requirement of about 2,500 workers. Portacabins will be erected on-site for
accommodating the project office and to provide the on-site catering and sanitation facilities for the
project staff. The project staff will either be accommodated in a labour camp set-up at nearby location
or rented accommodation facilities in Sohar. This will be decided by the EPC Contractor who will be
selected following the finalization of the project FEED.
During the operation phase of the Petrochemical Complex, 500 personnel will be working in the
Petrochemical Complex. The Petrochemical Complex will be operated in three shifts. The employees
will be accommodated in rented apartments/accommodations available in Sohar.
Environmental Baseline
The project site is located within the SIPA, which has been developed as a dedicated industrial area.
The project site has not been occupied since the establishment of the SIPA. The site was an
agricultural land, and was also used for livestock rearing and bee-farming. Earlier presence and
activities of humans are evident from the various crumbles shelters, grave and wells within the project
site.
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In order to develop environmental baseline status primary information collected through various site
visits and surveys, secondary information collated from various published documents were used.
Information on topography and landscape, climate and meteorology, geology, hydrology,
hydrogeology, and social environment are collected from published data and from concerned
authorities.
Ambient air quality at 3 locations for 45 days was measured using the Continuous Ambient Air
Quality Monitoring Station (CAAQMS). Some meteorological parameters were also measure by the
CAAQMS. The ambient air quality was found to be compliant with the Omani (Provisional) Ambient
Air Quality Standards and USEPA National Ambient Air Quality Standards, except PM10. This high
concentration of PM10 is contributed to heavy construction going in the area and is also contributed by
natural winds.
Dust and noise were also measured at different locations using hand held measuring devices. Dust
levels along the eastern, central and southern boundaries of the project site were higher than the
corresponding standards; and this may due to the construction works on plots located towards the
northwest of the project site. Ambient noise levels within the project site were well within the limit of
70 dB(A) for industrial area prescribed in MD 79/94.
No marine survey was conducted as the project does not discharge any waste directly into the marine
environment.
Soil and groundwater samples were also collected from the site and analysed. The soil quality was
found to be compliant with the limits given in USEPA’s Site Notification Standards for Industrial
Soils. The groundwater quality was found compliant with the Omani Drinking Water Standards,
except for sodium, nickel, chromium, Iron and magnesium. It can be noted from the above results that
the levels of sodium and magnesium in the groundwater sample is significantly above the limits
applicable for drinking water. Iron, chromium and nickel levels are also marginally above the
standard limits. However, the hydrocarbon and VOC levels are below the detection limits.
Overall the environmental condition of the project site is good. Further the terrestrial ecological
survey of the project site revealed that the birds observed in the site are mainly composed of highly
resilient species that can easily adapt to human induced habitat modifications. No reptiles or mammals
were recorded, which could be due to the fact that the site has already been subjected to habitat
alteration in the past. The tree species at the site serve as foraging, roosting and nesting sites for the
birds recorded in the area. None of the plant species recorded in the site are listed in the 2011 Red List
of the International Union for Conservation of Nature and Natural Resources.
Environmental Releases
The primary air emissions during the construction phase of the Project will be from the construction
machinery, diesel generators, construction vehicles, earthworks and fuel storage. The emissions will
include pollutants like NOX, SO2, CO, unburnt hydrocarbons, and PM10. Air emissions during the
operation phase will be mainly from the 14 stationary point sources of the Petrochemical Complex.
These sources will emit pollutants like NOX, SO2, CO, unburnt hydrocarbons, and PM10. The other
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emission sources will be the storage tanks which will release fugitive emissions of hydrocarbons, and
the mobile sources like vehicles, trucks, etc.
The major wastewater streams that can be expected during the construction phase will be machinery,
vehicle and floor washings, hydrotest water, chemical cleaning solutions, sewage wastewater from
site and accommodation camps, and surface run-off. During the operation phase, the Petrochemical
Complex is expected to release process wastewater (sampling point effluents, sour water, boiler
blowdowns and condensates, spent caustic, laboratory effluent , Benzene/MTBE containing
wastewater, decoking quench water, spent caustic, various process drainages and floor washings) and
seawater effluents (brine rejects and cooling water), bottom sediments and water from storage tanks,
sewage wastewater, firefighting water and water and firefighting foam mixture/water-foam emulsion
and surface run-off.
Solid wastes during the construction phase will be typical wastes like excavated soil, office wastes,
construction waste, food wastes, metal and plastic scraps, waste paints and chemicals, radioactive
wastes, waste batteries, empty drums, sludge, etc. During the operation phase of the Petrochemical
Complex more hazardous wastes are expected than the non-hazardous wastes. These wastes will
include spent oily sludge from the storage tank, DGF skimming, Benzene/MTBE WWCT, Coke from
cracking ethylene unit, polyethylene and polypropylene powder catalysts, spent filter media
(flammable) and oil absorbents and solvents, disposable filters, etc.
Noise during both phases will be from moving and rotating equipment. The main noise sources during
construction phase will be the diesel generators, and construction machineries and vehicles. During
the operation phase the noise sources will be gas turbines, boilers, pumps, blowers and compressors,
and flares.
Accidental releases of hazardous gases and liquids are possible from the storage tanks, especially
pressurized storage tanks. The potential for accidental releases is higher during the operation phase
than the construction phase, as there will be a higher number of tanks. During the construction phase
the storage facilities to be used will be diesel storage tanks and gas cylinders.
Environmental Impacts
The assessment of potential impacts has been carried out utilizing qualitative (Impact Assessment
Matrix) as well as quantitative (mathematical modeling) methods. In the qualitative method, impacts
are rated as ‘low’, ‘medium’ or ‘high’ depending on the severity of the impact and the duration /
likelihood of the impact. The impacts ratings for the project construction and operation phases are
presented in Table ES-1 and Table ES-2, respectively.
Table ES-1: Summary of the Construction Phase Environmental Impact Ratings
Issue Severity Duration Likelihood Impact Rating
Consumption of construction materials Minor Medium Term - Low
Impact on Natural Resources Minor Medium Term - Low
Impacts on topography and landscape Slight Long Term - Low
Ambient Air Quality Minor Medium Term - Low
Ambient Noise Minor Medium Term - Low
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Issue Severity Duration Likelihood Impact Rating
Workplace noise Moderate Medium Term - Medium
Impact on terrestrial ecology Slight Very Long Term - Low
Impacts on soil and groundwater from
Moderate Short Term - Low
normal waste management
Impact on soil and groundwater due to
Moderate - Unlikely Low
accidental releases
Local purchase of goods Positive Medium Term - +
Hiring of local people Positive Medium Term - +
Stress on infrastructure Slight Medium Term - Low
Impact on land use Slight Long Term - Low
Impact on settlements from construction
Slight Medium Term - Low
associated activities
Impact on settlements from accidental
Moderate - Unlikely Low
releases / abnormal operation
Traffic congestion / accidents Moderate - Likely Medium
Accidental Damage to sensitive sites Major - Very Unlikely Low
Table ES-2: Summary of Operation Phase Environmental Impact Ratings
Issue Severity Duration Likelihood Impact Rating
Stress on power supply Slight Long Term - Low
Stress on fuel supply-demand Slight Long Term - Low
Stress on water supply-demand Moderate Long Term - Medium
Impact on topography and landscape Slight Long Term - Low
Air Quality Moderate Long term - Medium
Greenhouse gas emission Moderate Long-term - Medium
Gaseous Pollutants Moderate Long-term - Medium
Damage to flora and fauna Slight Long Term - Low
Loss of habitat Slight Long Term - Low
Accidental damage to ecology and
Moderate - Very Unlikely Low
wildlife
Impact on soil and groundwater from
normal wastewater and waste Moderate Long Term - Medium
management
Impact on soil and groundwater from
improper handling and disposal of waste Moderate - Unlikely Low
and wastewater
Impact from loss of employment during
transition from construction to operation Slight Long Term - Low
phase
Impact on economy through generation of
business and operation phase employment Positive Long Term - ++
opportunities
Impact on land use Slight Long Term - Low
Impact on health and safety of
Major - Very Unlikely Low
settlements from accidental releases
Environmental Management Plan
An Environmental Management Plan (EMP) has been planned for the construction phase and
operational activities of the Petrochemical Complex so as to reduce and maintain the environmental
impacts below the As Low As Reasonably Practicable (ALARP) levels. A suitable environmental
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audit and monitoring program has been recommended, as a part of EMP, for the construction as well
as operation phases of the project in order to mitigate anticipated impacts and to ensure compliance
with Omani regulations.
Conclusions
Through the effective implementation of the proposed EMP, and careful design, engineering,
planning, construction and operation considerations, the associated impacts will be minimized.
Consequently, these impacts are not expected to cause any significant, long term and irreversible
change on the environment and the local community. It is concluded that the impacts from the
Petrochemical Complex acceptable from an environmental and social standpoint within the context of
the local and internationally comparable environmental standards including EHS guidelines.
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1 INTRODUCTION
1.1 Background
Oman Oil Refineries and Petroleum Industries Company (Orpic) is created the integration of three
companies - Oman Refineries and Petrochemicals Company LLC (ORPC), Aromatics Oman LLC
(AOL) and Oman Polypropylene (OPP). Orpic currently operates two oil refineries (Muscat and
Sohar) an Aromatics Plant and a Polypropylene Plant. The Sohar Refinery, Aromatics Plant and the
Polypropylene Plant are located at the Sohar Industrial Port Area (SIPA). Sohar Refinery includes a
115,000 barrels per stream day (BPSD) crude distillation unit, an 80,000 BPSD residue fluid catalytic
crac king unit (RFCC) that operates in a maximum olefins mode, an indirect alkylation unit, a TAME
process unit and various hydro processing and treating units. The Aromatics Plant processes naphtha
and produces 820,000 tons per year (t/y) of Paraxylene and 200,000 t/y of Benzene. The
Polypropylene Plant processes the propylene produced in the RFCC unit and can produce 350,000 t/y
of polypropylene.
Orpic is currently executing a major project for improvement of the existing refinery, which is
referred to as the Sohar Refinery Improvement Project (SRIP). The project involves the installation of
a new crude distillation unit, vacuum distillation unit, hydrocracking unit, delayed coking unit,
isomerization unit, hydrogen plant and Sulphur recovery facilities. SRIP project is currently in the
detailed engineering phase and is expected to be fully operational by the end of 2016.
The Liwa Plastic Industries Complex (LPIC) will be Orpic’s latest expansion, and will include a
nominal 863,000 t/y ethylene cracking plant, high density polyethylene (HDPE) plant, linear low
density polyethylene (LLDPE) plant, new polypropylene plant, methyl tertiary butyl ether (MTBE)
plant, Butene-1 plant and associated utilities and offsite facilities. The LPIC petrochemical plant will
be integrated with the Sohar Refinery, Aromatics Plant and Polypropylene Plant. One of the feed-
stocks is Natural Gas Liquids (NGL) i.e. C2+, which is extracted from natural gas at Fahud, about 250
km southwest of Muscat, and transported to the Sohar refinery by pipeline. The NGL extraction plant
and the pipeline will also be part of LPIC. Other feed-stocks are mixed Liquefied Petroleum Gas
(LPG) produced in the refinery and aromatics complex, dry gas produced in the RFCC unit and new
delayed coking unit that is included in the SRIP, and condensate (light naphtha) imported from Oman
LNG by marine tanker. Some of the materials produced in the petrochemical complex, including
hydrogen, MTBE, pyrolysis fuel oil and hydro-treated pyrolysis gasoline will be returned to the Sohar
Refinery, Aromatics Plant and existing Polypropylene Plant.
This report focuses on one of the three components of LPIC project i.e. Petrochemical Plant located
in SIPA. The LPIC has the following components:
An NGL extraction plant in Fahud;
300 km NGL pipeline between Fahud and SIPA;
An 863,000 t/y Steam Cracker Unit (SCU);
HDPE Plant;
LLDPE Plant;
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MTBE Plant;
Polypropylene Plant; and
Pygas Hydrotreater Unit (PGHYD)
Orpic, through a competitive bidding process, awarded the Project Management Consultancy (PMC)
contract to Engineers India Limited, New Delhi (EIL) and the Front End Engineering Design (FEED)
contract to Chicago Bridge and Iron Co (CB&I), The Hague, Netherlands. Benefiting from parallel
supply of gas from Fahud and naphtha from the Sohar Refinery, Orpic and CB&I have selected a
mixed steam cracker to produce ethylene, propylene, by-products and derivatives. With a capacity of
863,000 t/y ethylene, this mixed cracker will produce:
300,000 t/y of HDPE;
500,000 t/y of LLDPE;
300,000 t/y of polypropylene;
87,000 t/y of MTBE;
45,000 t/y of Butene-1; and
Pygas products (hydrogenated Pygas is recycled to SCU)
As per the categorization of projects by Ministry of Environment and Climate Affairs (MECA), the
proposed Petrochemical Plant is categorized under Group 1, ‘Industrial Projects’ sub categorized as
‘Chemical and Petrochemical Project’, requiring to conduct an Environmental Impact Assessment
(EIA) study entailing detailed evaluation of the potential environmental impacts, identification of
appropriate control measures to mitigate significant impacts and a detailed management plan to obtain
the Preliminary Environmental Permit (PEP) to commence the project construction.
Accordingly, CB&I has commissioned HMR Environmental Engineering Consultants (HMR) for
undertaking the EIA study for the proposed Petrochemical Plant in Sohar. This EIA study is carried
out during the FEED phase of the proposed Petrochemical Plant. As mentioned earlier, the NGL
extraction plant in Fahud and the pipeline between the NGL plant and the Petrochemical Plant in
SIPA are not within the scope of the present EIA.
The focal points of the project proponent and the consultants (FEED and EIA) and their contact
details are provided in Table 1-1.
Table 1-1: Project Focal Point
Organisation Contact Person Contact Details
Email: fahd.sharaf@orpic.com
Orpic Fahd Sharaf
Phone: +968 98239881
Email: nbenzalmartinez@cbi.com
CB&I Noelia Benzal Martinez
Phone: +31 612065399
Email: radheshyam@hmrenv.com
HMR Consultants Radheshyam Parmar
Phone: +968 24618833
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1.2 Objectives of the EIA Report
The overall objective of the EIA study is to identify and evaluate the environmental impacts from the
proposed petrochemical complex and to develop an appropriate Environmental Management Plan
(EMP) for the mitigation of the potential adverse impacts and ensure compliance with applicable
Omani environmental regulations to obtain the PEP for the project from Sohar Environmental Unit
(SEU)/MECA. The EIA study addresses the construction and operation phases of the project. The
decommissioning will be after the plant life (expected to be about 30 years) and accordingly, no
specific information on the same is available at present. Further, the impacts during the
decommissioning are expected to be similar to that of the construction phase and therefore, are not
discussed in detail.
The scope of work for this EIA was developed in line with the requirements of the Guidelines on
Environmental Impact Assessment issued by MECA and the Guidance Note on Requirements for EIA
issued by SEU1. Accordingly, the present EIA report has the following objectives:
Environmental review of the Petrochemical Plant for characterization and quantification of
wastes generated greenhouse gas (GHG) emissions, ozone depleting substances (ODS) used
and energy requirements during the project construction and operation;
Environmental analysis of alternatives for the processes, technologies and approaches
associated with the project development ;
Desktop reviews and field studies for describing the current status of the environment at
project site;
Identification and assessment of potential environmental and social impacts from the project
primarily during construction and operation and determination of significant impacts;
Development of a suitable EMP, including mitigation measures and monitoring programs;
and
Preparation of the EIA and EMP report for review by Director General of Environmental
Affairs (DGEA)/Director General of Climate Affairs (DGCA) - MECA and SEU.
1.3 EIA Study Methodology
1.3.1 Overview
The EIA study for the Project commenced in September 2014 and continued till February 2014. As
mentioned in Section 1.2, the overall EIA methodology was based on MECA’s and SEU’s guidance
notes.
1
REP-386-13–DJ Version July 2013
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1.3.2 MECA’s Comments on Scoping
As per the guidelines of SEU/MECA, prior to undertaking an EIA study, it is required to submit an
EIA scoping report summarizing the scope of the project, various environmental releases and
potential impacts from the project and the EIA methodology for review by MECA/SEU. Accordingly,
the EIA scoping report for the project was submitted to MECA on 18th December 2014. Subsequently,
SEU/MECA provided their comments on the scoping report on 11th January 2015 (Appendix A)
which are addressed in this EIA.
The main issues raised by MECA on the scoping report are summarized in Table 1-2 along with the
indication of the sections of the EIA where, each of the issues or concerns has been addressed.
Table 1-2: MECA/SEU’s Feedback on Scoping Report
# MECA’s Comments Addressed In
The scoping has not detailed the MTBE and Butene units that mentioned
Chapter 3 of this EIA
1 in the document. It is required to elaborate further in the description of the
report
process and the products line of each unit and their impacts.
It is required to include a clear waste management plan for all wastes Addressed in
2 streams and the overall project risk assessment and the project Environmental
environmental management system. Management plan
The company has to consider the nearby community that is not yet
Addressed in Chapter 6
3 transferred and what are the steps that will be taking to reduce the adverse
and 7 of EIA report
impact of the project.
4 NGLE and Pipeline parts shall be included in the EIA Study Noted
The company shall not import huge quantities of chemicals until ensure
5 Noted
their suitability in the process
The company shall consider in the EIA a separate section about the Noted, Chapter 7 of this
6
climate affairs report is Climate Affairs
In case the company will use piping networks for receiving or discharging
Detailed in Chapter 3 of
7 directly to the sea the cooling water or the desalination unit the piping
this EIA report
size, discharge temperature and the dilution process shall be mentioned
1.3.3 Document Review
The technical documents, process description, plant layout, process flow diagrams etc., for the
Petrochemical Plant and secondary information and previous studies in the Sohar area were reviewed
to gather relevant information on the facility. Various environmental releases from the Project and the
chemicals, fuels, etc., used and their storage and handling methods were studied in order to identify
potential environmental aspects. In addition, the rationale for the selection of all environmentally
critical processes and Best Available Techniques (BAT) for project construction and operation were
reviewed. Consultations were held with Orpic/CB&I through the entire study for better understanding
of the Project and the environmental management philosophy.
Environmental baseline information from previous studies in the area was reviewed to plan
acquisition of primary data through field studies, considering the interaction of the project
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components with various environmental elements. Field studies mainly focused on potential areas of
significance with regard to the environmental and social impacts of the project development.
1.3.4 Environmental Data Gathering
Environmental data gathering includes primary data collection from field studies and review of
secondary data from previous study reports. Environmental baseline information on topography,
meteorology, geology, hydrogeology, socio-cultural aspects, socio-economics, etc. were sourced from
several government departments, non-governmental institutions and recently conducted EIA studies
for this region. A number of environmental studies for various projects in the SIPA were conducted
by HMR viz., Sohar Aromatics Complex and OPP (which are part of Orpic), Sohar-I Independent
Power and Water Project, Sohar-II Independent Power Project, Sohar Iron Ore Pellet Plant, Oman
Formaldehyde Chemical Plant, Sohar Refinery Expansion Project, OMPET PET/PTA Plant etc.. Field
investigations for ambient air, noise, dust, ecology were carried out to augment and validate the
available baseline data. The results of these surveys reflect the present environmental conditions of
the project site.
1.3.5 Impact Assessment
Based on the above, the potential environmental and social impacts of the Project during the
construction and operation phases are identified using checklists and matrices. Various assessment
techniques, both qualitative and quantitative, are used to determine the magnitude of these impacts.
The significance of each impact is determined based on the nature, duration and severity of the impact
taking into consideration the current environmental quality. The details are presented in Chapter 8.
1.3.6 Development of EMP
As per the requirement of SEU the EMP is presented as a separate document based on detailed
assessment of the impacts presented in the EIA. The EMP was developed to reduce and mitigate all
significant adverse environmental impacts to acceptable levels. The EMP addresses construction and
operation phases of the Project separately addressing the various applicable environmental
components viz. ambient air quality, ambient noise, terrestrial ecology, soil and groundwater quality
etc. For the decommissioning phase (including site restoration), which is envisaged to be after ~ 30
years of plant operation, a generic consideration is provided due to lack of detailed information. Also,
the impacts during the decommissioning phase are considered to be similar to that of the construction
phase. Environmental monitoring systems are identified and monitoring programmes are developed
based on review of feasible alternatives. An environmental management organization is also proposed
for effective implementation of the management plan.
1.3.7 Structure of the EIA report
This EIA report includes 9 chapters as presented below. A technical summary of the report is
presented ahead of the main report. All other pertinent information that is not included in the main
sections is presented in appendices.
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Chapter 1 : Introduction
Presents the background and objective of the EIA report with the methodology.
Also provides a summary of SEU/MECA’s comments on the EIA scoping report.
Chapter 2 : Regulatory Framework
Presents the applicable environmental legislative and institutional requirements;
Chapter 3 : Project Description
Describes the various process units, utilities, project facilities and activities of the
PC Plant. Further, the construction methodology and resources required during
construction phase are described in this chapter.
Chapter 4 : Environmental Baseline
Provides description of the existing environmental settings at the project site.
Chapter 5 : Environmental Releases
Discusses the environmental releases from the PC Plant during construction and
operation phases. The handling, treatment and disposal philosophies proposed for
the releases are also presented in this chapter.
Chapter 6 : Climate Affairs
Identifies the type of ODS used in the project and presents an estimate of the
GHG emissions from the project construction and operation. Further, the chapter
assesses the influence of the project on climate change, and conversely, the
vulnerability of the plant to climate change;
Chapter 7 : Analysis of Alternatives
Analyzes the alternatives for the critical technology and processes, utilities,
project site etc. from environmental standpoint. Also, the BAT as per Integrated
Pollution Prevention and Control (IPPC) directives will also be considered.
Chapter 8 : Environmental Impact Assessment
Identifies and discusses potential impacts on the environment due to the PC Plant
primarily during construction and operation.
Chapter 9 : Conclusion
Presents the conclusions of the EIA study for the PC Plant
An EMP, including the recommendations for environmental mitigation and monitoring, based on the
impact identification and assessment are detailed in a separate document as per SEU’s requirement.
Moreover Rapid Risk Assessment (RRA) for the PC has been prepared and will be submitted as
separate document to SEU.
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2 ENVIRONMENTAL REGULATORY FRAMEWORK
The laws and regulations, including those on environmental protection and pollution control, in the
Sultanate of Oman are issued as Royal Decrees (RDs) and Ministerial Decisions (MDs). Any
industrial development in the Sultanate is bound to comply with the applicable Omani environmental
laws and regulations. Government policies and environmental standards specified in the RDs and
MDs regulate various industrial activities that can impact the environment and influence climate
change. It is within the scope of this EIA to highlight such laws and regulations and detail their
significance with regard to the PC Plant.
For areas where Omani regulations are not available, applicable international regulations such as
those contained in the environmental standards provided by the European Union (EU) and the United
States Environmental Protection Agency (USEPA) will be used to ensure that the technology,
equipment and operations selected for the project are capable of meeting national and international
environmental requirements. In addition, the Project will follow the requirements of international
engineering standards and codes as per contractual agreement with the technology providers and the
EPC contractor. The following sections detail the various national and international environmental
regulations and standards that are applicable to the present project.
In addition to various RDs and MDs, SEU has issued guidelines for management of materials and
wastes, industrial safety and EIA study for the industries within SIPA, which are also referred to.
Furthermore, this EIA study has considered the requirements of the IPPC Directive as well as the
Seveso-II Directive to assess the BAT for the various units of the proposed plant in order to reduce
and control environmental pollution, and to highlight measures for safety of the Petrochemical Plant
from major accidents / incidents during the operation phase.
2.1 Environmental Legislations in Oman
The Omani laws on environmental protection, control and management are covered under two basic
laws, viz., the “Law for the Conservation of the Environment and the Prevention of Pollution”
promulgated in November 2001 as RD 114/2001 (superseding RD 10/82 and its amendments) and the
“Law on Protection of Potable Water Sources from Pollution” promulgated as RD 115/2001. These
laws provide the framework for all other laws and regulations concerning environmental conservation
and water resources protection.
The responsibility for the implementation of these laws rests with MECA, which issues regulations,
standards and guidelines through MDs. Within MECA, the authority responsible for environmental
permitting, inspection and control in the Sultanate of Oman is DGEA) whereas, DGCA is the
authority to assess the potential aspects of the Project with regards to climate change. Further, since
the Project is located within SIPA, it needs to adhere to the guidance notes issued by SEU (an integral
part of MECA) which ensures that the organizations works in compliance with the Omani regulations
and in addition, encourages to adopt the Beyond Regulatory Control (BRC) mechanism through
implementation of BAT.
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The Omani environmental laws and regulations and SEU’s guidance notes applicable to the proposed
project, are listed in Table 2-1.
Table 2-1: Applicable Environmental Laws and Regulations
Reference No. Description Applicability to Project Activity
Environmental Law
Protection and conservation of cultural or
RD 6/80 Law of Protection of the National Heritage
heritage sites in the project area
Use of hazardous chemicals during construction
RD 46/95 Law on handling and use of chemicals
and operation phases
Law approving the Ratification by
Guiding law for the protection of ozone layer
Sultanate of Oman to Vienna Convention
RD 73/1998 and control and management of Ozone
for the Protection of Ozone Layer and
Depleting Substances (ODS)
Montreal Protocol concerning ODS
Issuing the Law of Water Resources Guiding law on sustainable use of water
RD 29/2000
Conservation resource
Law for Conservation of the Environment Guiding law on pollution prevention and natural
RD 114/2001
and Prevention of Pollution resource conservation
Law on Protection of Sources of Potable Guiding law on preventing pollution of ground
RD 115/2001
Water from Pollution water resources
Law on Nature Reserves and Wildlife Guiding law on protecting wildlife and habitat
RD 6/2003
Conservation in the vicinity of the project site
Environmental Regulations
MD 20/90 Regulations on Coastal Setbacks Regulations on protection of Coastal areas
Regulations for noise pollution in public
MD 79/94 Public noise control
environment
Regulations for noise pollution in the
MD 80/94 Workplace noise control
working environment
Issuing the regulation for registration of Chemicals management during construction and
MD 248/97 hazardous chemical substances and the operation phases and registration of chemicals
relevant permits used
Regulations for Septic Tanks, Soak away Regulates construction of holding tanks, septic
MD 421/98
Pits and Holding Tanks tanks and soak away pits
Regulation on protection of trees within the
MD 169/2000 Regulations on cutting of trees
project influence area
Regulations for Water abstraction from Construction of bore well to abstract water for
MD 264/2000
bore wells commercial project purposes
Issuance of the regulations for packaging
Hazardous chemicals management during
and binding conditions/stipulations and
MD 317/2001 construction and operational phases of the
putting information and labels on the
project
hazardous chemical substances
Issuing regulations for organizing
Regulates the procedure for obtaining
MD 187/2001 obtaining environmental approvals and
environmental permits
final environmental permit
Prohibits discharge of untreated wastewater to
Regulations for wastewater re use and
MD 55/2002 the environment and regulates wastewater
discharge
treatment
Regulations for the management of Handling, storage and disposal of hazardous
MD 18/93
hazardous wastes wastes generated from the project activities
Regulations for the management of the Handling, storage and disposal of non-
MD 17/93
solid non-hazardous wastes hazardous wastes from the project activities
Amending some provisions of MD
MD 71/2002 Organize license and municipal fees
177/2001
Prohibition of killing, hunting, or
MD 101/2002 Regulation on protection of wildlife
capturing of wild animals and birds
MD 281/2003 Regulations for control and management Management of radioactive substances
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Reference No. Description Applicability to Project Activity
of radioactive substances
Amending some provisions of MD Regulates the procedure for obtaining
MD 68/2004
187/2001 environmental permits
Regulations on controlling Air Pollutants Regulates installation and operation of
MD 118/2004
emanating from Stationary Sources stationary combustion sources
Discharge of uncontaminated storm water, fire
Regulation for the discharge of liquid
MD 159/2005 water run-off, treated wastewater into common
effluents into the marine environment
seawater outfall channel
Regulations for the control and
MD 107/2013 Prohibits the use of ODS
management of ODS
Regulations for Occupational Health and
MD 286/2008 Occupational health and safety of employees
Industrial Safety Precautions
Regulations for Organization of Handling
MD 25/2009 Chemical management during project activities
and Use of Chemicals
Regulation for Management of Climate Regulation for obtaining climate affairs license
MD 18/2012
Affairs from DGCA for discharge of GHG emissions
Omani standard for drinking water (Issued
OS 8/2012 by the Directorate General of Potable groundwater quality standards
Specifications and Measures, MoCI)
Regulation issued by Ministry of housing
MD 25/2013 Project activities in SIPA, Liwa
on relocation of people in Liwa
Omani
(Provisional)
Provisional Omani standards for ambient
Ambient Air Ambient air quality in the project area
air quality
Quality Standards
(OAAQS)
Guidelines on estimation and reporting of
greenhouse gases (GHG) and ozone
Estimation, reporting and control of GHG,
depleting substances (ODS) from project
energy consumption, etc., during the proposed
construction and operation phases, the
plants construction and operation phases,
Climate Affairs information to be provided towards
mitigation measures for reducing the project’s
Guidelines evaluation of the influence of project
influence of climate change and minimising
activities on climate change, impacts of
vulnerability of the project to consequences of
climate change on projects and the climate
climate change
change adaptation and mitigation
measures implemented by projects
SEU Guidance Note
REP-123-10-DJ Details the waste management at Sohar
Waste management
October 2010 Industrial Port and Sohar Free Zone
Procedures of disposing non-hazardous, non-
REP-114-10-DJ Non-hazardous industrial Waste Storage at
dusty and non-recyclable industrial waste at
November 2010 Sohar
Sohar Site (at Sohar Municipality landfill).
Procedures of storing hazardous waste at Al
REP-083-10-DJ
Hazardous waste storage at Liwa Batinah Temporary Hazardous Waste Facility
April 2010
(Liwa Site).
REP-115-10-DJ Guidance note on import, export, using,
Chemical Substances
January 2011 handling and storage at SIPA and SFZ
REP-159-11-RMO Guidance note for industrial safety for the
Industrial Safety
February 2011 Sohar Industrial Port and Sohar Free Zone
RFP-147-11-DJ, Details the requirements for EIA, ER, IPPC and
Requirements for EIA
January 2011 Seveso II
Guidance note for industries for on-site storage
RFP-230-12-MJ,
Onsite Storage of Industrial Waste industrial waste when there is no off-site
Jan 2012
solution
REP-225-11-DJ Note for efficient water management system at
Water management
April 2012 SIPA and SFZ
REP-211-11-DJ
Flaring Guidance Note on regulation of flaring
September 2011
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Reference No. Description Applicability to Project Activity
Reporting procedure for planned & unplanned,
REP-331-13-WP Incident Reporting to SEU not-normal operational conditions (incidents,
accidents and near incidents) to SEU.
SEU has compiled the Omani environmental laws and regulations into a single document and issued it
under the title “Advanced Regulatory Wiki Application: Omani Environmental Regulations
International References Documents” (ARWA). Brief descriptions of some of the environmental laws
and regulations applicable to the proposed plant are presented in Appendix B. The clauses and
standards presented are based on information provided in ARWA, second edition, issued in July 2013.
2.2 Applicable Environmental Permits
The proposed project will potentially require permits as mentioned in Table 2-2, as applicable for
construction or operation phase.
Table 2-2: Permit Responsibility Matrix
Permits Responsibility
Preliminary Environmental Permit from MECA/SEU Orpic
Final environmental permit from MECA/SEU EPC Contractor/ Orpic
Permit for storage, handling, transportation and disposal of hazardous
EPC Contractor/ Orpic
wastes during construction and operation from MECA and ROP
Permit for storage, handling and transportation of chemicals and fuel used at
EPC Contractor/ Orpic
site during construction and operation from MECA and ROP
Permit for operating stationary combustion sources from Air Pollution
EPC Contractor/ Orpic
Department, MECA
Permit for disposal of hydro-test water from MECA EPC Contractor
Permit for installing onsite sewage treatment plant (STP) and
reuse/discharge of treated wastewater or Approval for discharging sewage to EPC Contractor/ Orpic
municipal STP, as applicable, from MECA and concerned authorities
Permit for import, transportation, usage and storage of radioactive material
and explosives, if required (mainly during construction phase) from MECA EPC contractor
and ROP
Permit for use of industrial / laboratory gas cylinders from MECA EPC Contractor
Temporary approval for setting up of labor camp & offices, if required, from
EPC Contractor
Liwa Municipality and/or SIPC
NOL from SEU for storage of hazardous wastes at Liwa site EPC Contractor/ Orpic
NOL from SEU for storage of non-hazardous wastes at Sohar waste
EPC Contractor/ Orpic
collection site or for any other solution proposed by Orpic
2.3 Regional and International Conventions and Protocols
Several RDs concerning conventions and protocols to which Oman has acceded have been issued so
that these are taken into account during development of new projects in the country. RDs which
potentially apply to Petrochemical Plant are listed below:
RD 90/91 – Sanctioning the Accession of the Sultanate of Oman to the Marine Environment Protection
Protocol;
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RD 57/94 – Sanctioning the Accession of the Sultanate of Oman to two Protocols on Environment
Protection;
RD 119/94 – Sanctioning the Accession of the Sultanate of Oman to Basel Convention on the Control of
the Trans-boundary Movement of Hazardous Wastes and their disposal, the United Nations Framework
Convention on Climate Change and Convention on Biological Diversity;
RD 73/98 – Sanctioning the Accession of the Sultanate of Oman to the Vienna Convention for the
Protection of the Ozone Layer and the Montreal Protocol on Substances that Deplete the Ozone Layer;
RD 24/2002 – Sanctioning the Protocol on the Trans-boundary Movement of Hazardous Wastes and
Other Wastes and their Disposal;
RD 106/2004 – Sanctioning Montreal and Beijing Amendments to Montreal Protocol on Substances that
deplete the Ozone Layer; and
RD 107/2004 – Sanctioning Kyoto Protocol to the United Nations Framework Convention on Climate
Change.
RD 117/2004 – Sanctioning Stockholm Convention on Persistent Organic Pollutants (POP)
2.4 International Guidelines and Best Practices
To minimize the environmental impacts as practicably possible, for areas where Omani environmental
regulations/standards do not cover, applicable international guidelines, namely those contained in the
Environmental Health and Safety (EHS) Guidelines of the International Finance Corporation (IFC)
will be applied to the technology (equipment) and methods of operation selected for the Project
(together constituting the “techniques” used) when appropriate. In addition to the above, this EIA
study, where relevant, will take into account as ‘Best Practice’ environmental standards and
guidelines developed internationally by World Health Organization, USEPA and European Union.
Conventions and protocols relevant to proposed Petrochemical Plant is presented in Table 2-3.
Table 2-3: International Conventions and Protocols
# Convention Description
To reduce the movements of hazardous waste between
Basel convention on the control of
nations and specifically to prevent transfer of hazardous
1 transboundary movements of hazardous
waste from developed to less developed countries
wastes and their disposal
(LDCs).
Concerned with controlling and stabilizing greenhouse
United Nations framework convention on gas concentrations in the atmosphere at a level that would
2
climate change prevent dangerous anthropogenic interference with the
climate system
Concerned with conservation of biological diversity,
3 Convention on biological diversity Sustainable use of its components and fair and equitable
sharing of benefits arising from genetic resources
Vienna convention on the protection of the Acts as a framework for the international efforts to protect
4
ozone layer, 1985 the ozone layer
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# Convention Description
Is a protocol to the Vienna Convention for the Protection
of the Ozone Layer is an international treaty designed to
Montreal protocol on substances that
5 protect the ozone layer by phasing out the production of
deplete the ozone layer, 1987.
numerous substances believed to be responsible for ozone
depletion.
An international agreement on the reduction of
United Nations Framework Convention on
greenhouse gas emissions and on mechanisms aimed at
6 Climate Change (UFCCC) (1992),
cutting the costs of reducing emissions, in order to
including Kyoto Protocol (2005)
address possible changes in the climate
It is a multilateral treaty to promote shared responsibilities
in relation to importation of hazardous chemicals. The
Convention on the prior informed consent
convention promotes open exchange of information and
7 procedure for certain hazardous chemicals
calls on exporters of hazardous chemicals to use proper
and pesticides in international trade
labeling, include directions on safe handling, and inform
purchasers of any known restrictions or bans
2.5 Integrated Pollution Prevention and Control Directive
In principle, the Directive 2008/1/EC (IPPC Directive) is about minimizing pollution from various
industrial sources throughout the European Union (EU). Industrial facilities/projects which are
required to comply with the directive are covered in Annex I of the IPPC Directive. About 50,000
installations are covered by the IPPC Directive in the EU including the energy industries (includes oil
and gas refineries), production and processing of metals, the mineral industry, the chemical industry,
certain waste management activities and intensive farming.
As discussed earlier, this expansion project falls under IPPC Annex 1 industries and therefore is
needed to comply with the requirements of the directives. A summary of the applicable requirements
for the proposed project is listed below:
Use appropriate pollution-prevention measures, namely the BAT (which produce the least
waste, use less hazardous substances, energy recovery, enable the recovery and recycling of
substances generated, etc.);
Avert all large-scale pollution (reduction of NOx, SO2 and VOC emissions, control of liquid
effluent discharge quantities);
Prevent, recycle or dispose-off waste in the least polluting way possible;
Exercise energy usage efficiently;
Accident prevention and damage limitation; and
Return sites to their original state when the activity is completed.
2.6 Seveso-II Directive
The Seveso-II Directive aims at the prevention of major-accident hazards involving dangerous
substances. Secondly, as accidents do continue to occur, the directive aims at the limitation of the
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consequences of such accidents not only for people (safety and health aspects) but also for the
environment (environmental aspect). Both aims should be followed with a view to ensuring high
levels of protection throughout the community in a consistent and effective manner and shall form the
basis for Orpic to develop a comprehensive Health Safety and Environmental Management System
(HSEMS) for proposed petrochemical Plant at Sohar.
The Seveso-II Directive deals solely with the presence of dangerous substances in establishments. It
covers both, industrial activities as well as the storage of dangerous chemicals. The directive follows a
two tier approach viz. lower threshold quantities and higher threshold quantities and can be viewed as
inherently providing proportionate controls in practice, where larger quantities mean more controls.
Establishments that hold larger quantities of dangerous substance (above the higher threshold
quantities) contained in the directive will be covered by all the requirements contained within the
directive. Based on review of the presently available information, the petrochemical Plant will be
classified as a ‘Seveso-II’ project due to processing and storage of flammable substances such as
NGLs, LPG, Propylene, Naphtha, fuel oil, gasoline and others in excess of quantities given in Annex
1 of Seveso-II Directive (the assessment of the storage capacities against the thresholds given in
Seveso-II Directive will be included in the EIA).
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3 PROJECT DESCRIPTION
3.1 Overview
This chapter describes the process units and associated facilities to be provided as part of the
proposed PC Plant. The proposed PC Plant will be located adjacent (site coordinates are provided in
Chapter 4) to SRIP that will include a 863 kTPA ethylene cracking plant, HDPE Plant, LLDPE Plant,
PP Plant, MTBE Plant, butene-1 Plant and associated utilities and offsite facilities. The main feed-
stock for the petrochemical Plant is NGL (Natural Gas Liquids, C2+) which will be extracted from
natural gas. Extraction will be done in the proposed natural gas liquid extraction (NGLE) Plant near
the existing Fahud Compressor Station (FCS), located near Fahud about 300km south of the new
complex at Sohar. NGL product will be transported to the Petrochemical Plant via a new pipeline.
The NGLE Plant and the NGL pipeline are part of the LPIC. NGL will be transported to the
Petrochemical Plant in the pipeline in a liquid phase.
The Petrochemical Plant is scheduled for completion in 2018, which will enable Orpic to produce
polypropylene (in addition to the existing polypropylene plant) and, for the first time, polyethylene,
the plastic most in demand globally, which will boost Oman’s export earnings. At the same time and
with the production of one million tonnes of plastics, the country’s downstream plastics industry will
have the opportunity to grow, with the promise of more downstream industries, increased
employment, and overall additional in-country value. The overall plot plan is shown in Figure 3-1.
For detailed information and for layout clarity please refer to Map 1, Map 2 and Map 3 also
printed in A1 size.
3.2 Process Description
The process units included in the proposed complex are:
Refinery Dry Gas Treating Unit (RDG Unit);
NGL Treating and Fractionation Unit;
Steam Cracker Unit (SCU);
Selective C4 Hydrogenation Unit;
MTBE Unit;
Butene-1 Recovery Unit;
Pygas Hydrotreater Unit (PGHYD);
HDPE Unit;
LLDPE Unit; and
PP Unit
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PE/PP Steam
Plot_Plot 10
Cracker
Plot_Plot 10
Figure 3-1: Overall Plot Plan of the Petrochemical Plant
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3.3 Refinery Dry Gas Treatment Unit
Refinery dry gas treatment unit (RDG Unit) will treat refinery dry gas stream with an amine and caustic
solution in the absorber to remove CO2 and H2S present in the stream. The rich amine and spent caustic
stream is then sent to a stripper for regeneration. The treated feed liquid will be dried and then passed
through the RDG recovery section to fractionator towers where propane (C3H8), butanes (C4H10) and
other higher hydrocarbon condensates will be removed and recovered into separate streams. The
processed stream, primarily containing ethane, will be sent to the ethylene cracker to produce ethylene.
A flow diagram for the RDG treatment and recovery section is provided in Figure 3-2. Overall Process
description is provided in Attachment 1.
Figure 3-2: RDG Unit – Flow Diagram
3.4 NGL Treating and Fractionation Unit (NGLT)
The process starts with the fractionator plant; the ethane rich NGL feed stream received via pipeline
from Fahud NGLE facility will be treated with an amine solution in the absorber to remove CO2 and H2S
present in the stream. The rich amine stream is then sent to a stripper for regeneration and the lean amine
is re-circulated back to the absorber. The treated feed liquid will be dried using molecular sieves and
then passed through fractionator towers where propane, butanes and other higher hydrocarbon
condensates will be removed and recovered into separate streams. The processed stream, primarily
containing ethane, will be sent to the ethylene cracker to produce ethylene. Refer to Figure 3-3 for flow
diagram of NGL treating and fractionation unit. Overall Process description is provided in Attachment
1.
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Figure 3-3: NGL Treating and Fractionation Unit
3.5 Steam Cracker Unit
Steam cracking is a petrochemical process in which suitable hydrocarbons are heated to very high
temperatures, in the presence of steam, to split the molecules into olefins of lower molecular weight such
as unsaturated hydrocarbons: ethylene, propylene, butadiene etc. The feed-stock is heated to the point
that the energy transfer from heat is enough to ‘crack’ the molecule into two or more smaller molecules.
Typically, the reaction temperature is very high, at around 850°C. The cracking is done during a short
residence time and under high temperature followed by sudden quench. This is followed by product
fractionation and other processes for separating recoverable products. The flow diagram of the SCU is
shown in Figure 3-4. The process scheme for the NGL and SCU is shown in Figure 3-5 and the overall
plot plan is given in Figure 3-6. Overall Process description is provided in Attachment 1. Overall
chemical reactions and chemical kinetics are provided in Attachment 1.
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Figure 3-4: SCU Flow Diagram
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Separated ethane and ethane recycled from the RDG unit and NGL will be sent to the cracking furnaces
to produce ethylene by pyrolysis. Ethane feed along with unconverted reactants will be first preheated in
the furnace convection section and humidified with dilution steam to reduce coke formation and enhance
the conversion of ethane to ethylene. A small amount of dimethyl disulphide will also be added to the
feed stream to reduce carbon monoxide and coke formation during cracking in the radiant section of the
furnace.
Cracked gas will not only contain ethylene but also ethane, acetylene, methane, hydrogen, heavier
hydrocarbons and pyrolysis gasoline (called “pygas”). Hydrogen and methane fractions are separated
and used as a fuel gas in the furnaces. Any additional fuel gas required will be supplied from the natural
gas header.
The gas mixture coming out of cracking furnaces will first be cooled in transfer line exchangers and then
further cooled in a quench tower. Cracked gas from quench tower overheads is compressed in three
stages. The discharge vapour from each stage is cooled with water. The compressed cracked gas is
forwarded to the Caustic Wash System for removal of CO2 and H2S.
The cold section starts with the de-ethanizer, followed by the de-methanizer and C2 splitter. While de-
ethanizer system separates ethane and lighter components from the propylene and heavier components,
de-methanizer removes methane and hydrogen from the C2 mixture. The C2 splitter separates the feed
into ethylene as an overhead product and ethane in the bottoms. The unconverted ethane will be recycled
to the cracking furnaces as feed. Ethylene vapour will be compressed and condensed using propylene
refrigerant. Ethylene produced from the ethylene cracker will be polymerized in polyethylene plants to
manufacture both LLDPE and HDPE pellets.
Since polymerization of ethylene is highly exothermic, a large amount of heat will be generated. As
temperature of polymerization will be higher than the melting point of polyethylene, growing
polyethylene molecules will stay in solution as one phase. The product stream containing polyethylene
will be fed from the reactor system to the devolatilization section of the process. The devolatilization
section will separate the polyethylene/solvent solution. The polyethylene stream will enter the next
vessel at a high vacuum to flash most of the remaining solvent from polyethylene. The solvent that will
be recovered in the devolatilization section will be condensed, purified, and recycled back to the reactor.
The pellets will be air conveyed to the packaging section of the plant where finished product will be
packaged into either bags or bulk containers.
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Figure 3-5: Flow Diagram –NGL Treatment and SCU
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Figure 3-6: Plot Plan of Steam Cracker Unit
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3.6 Methyl Tertiary Butyl Ether (MTBE) Unit
Methyl Tertiary Butyl Ether (MTBE) is formed by the catalytic reaction of isobutylene with methanol.
MTBE is used as additive to gasoline to raise the Octane number, which helps prevent the engine
knocking. MTBE is also used as organic solvent in some of the plants in unit processes. The proposed
MTBE unit will utilize a Catalytic Distillation (CD) Reaction Column which combines reaction and
fractionation in a single unit operation which allows high conversion of isobutylene (exceeding fixed
bed equilibrium limitations) to be achieved. The reaction conditions range from 37 to 95°C at 5 to 10
Barg and the process utilizes an acidic ion exchange resin catalyst in the fixed bed reactor and
proprietary catalyst modules in the CD Reaction Column.
All by-products formed in the MTBE reaction and remaining with the MTBE product are gasoline
compatible components and include tertiary butyl alcohol (TBA), methyl secondary butyl ether
(MSBE) and di-isobutylene (DIB). Dimethyl ether (DME) is formed in the MTBE synthesis and
removed with the C4 raffinate in MTBE/C4 fractionation.
The following represents the chemistry of the main reaction and side reactions:
Main Reaction
Side Reaction
Mixed C4 feed-stock from the upstream Selective C4 Hydrogenation unit is first water-washed where
water soluble impurities such as nitriles are removed. The washed C4 stream is collected in the mixed
C4 Feed Surge Drum with a coalescer to remove any residual free water. From here, it is transported
to the MTBE reaction system. The combined mixed C4 feed from the mixed C4 feed surge drum is
mixed with a fresh and recycled methanol stream and preheated if feed temperature is lower than
40°C. Low Low Pressure (LLP) steam supplies the necessary heat to the feed preheater. The
preheated mixed C4 feed is then sent to the primary reactor. Flow diagram is given in Figure 3-7.
The etherification reaction is exothermic and dilution of the inlet stream limits the temperature rise
across the reactor, and prevents vaporization at the reactor outlet. The temperature of the primary
reactor is thus controlled thus extending the catalyst life and avoiding fouling. The cooled recycle
effluent provides the necessary dilution requirement at the inlet.
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The rest of the effluent is cooled via the Secondary Reactor Feed Cooler and then fed to the secondary
reactor. The primary and secondary reactors operate in series. The secondary reactor effluent is
preheated via the CD Reaction Column Bottoms/Feed exchanger and then fed to the CD Reaction
Column where the MTBE conversion is further increased and the product MTBE is separated from
the unreacted C4. The CD Reaction Column with Catalytic Distillation is operated in exactly the same
way as a conventional distillation column, with an external reboiler (using LP steam) and an overhead
condenser.
Above the feedpoint are catalyst beds containing etherification catalyst structures. Methanol, although
a high boiling component in this system, forms a minimum-boiling azeotrope with the C4s. This
azeotrope carries the methanol into the catalyst structures where the reaction proceeds. The MTBE
product is removed from the reaction zone by distillation. MTBE leaves the CD Reaction Column as
the bottom product together with a small amount of reaction by-products. Excess methanol distills
overhead with the unreacted C4s and is routed to the Methanol Recovery Section. Feed components
heavier than C4s will appear with the MTBE as the bottom product.
The C4 distillate stream is washed in the Methanol Extraction Column with a countercurrent stream of
water to extract the methanol. The methanol/water mixture from the bottom of the Methanol
Extraction Column is sent to the Methanol Recovery Column and the recovered methanol is blended
with fresh methanol and sent to the MTBE reaction section. The overhead stream from the Methanol
Extraction Column is the C4 raffinate 2 which is sent to the B-1 Recovery Unit for the recovery of
butene-1.
3.7 Butene-1 Recovery Unit
Butene-1 is used as a copolymer (in polyethylene alkylate gasoline, polybutenes, butadiene), as
intermediates for C4 and C5 (aldehydes, alcohols) and other derivatives, and is also used in the
production of maleic anhydride by catalytic oxidation.
Recovery of butene-1 from the raffinate stream entails only physical separation by distillation. C4
Raffinate-2 is sent to the first of the two Heavies Columns to separate the higher boiling Butene-2 and
n-Butane product from the rest of the raffinate. Heavies Column #1 works in tandem with Heavies
Column #2 (i.e. together the two columns function as one larger column).
Heavies Column #1 operates at a slightly lower pressure than Heavies Column #2 and does not
require reboiling because the combined enthalpy of the feeds (i.e. Raffinate 2 from MTBE effluent
and the overhead vapor from Heavies Column #2) is sufficient to provide the required tray traffic. The
bottoms stream from the Heavies Column #1 is pumped to Heavies Column #2 as reflux. Heavies
Column #2 is reboiled with LLP steam.
The overhead vapor from Heavies Column #1 is condensed and accumulated in the Reflux Drum. The
condensate is pumped and a portion is returned as reflux to the B-1 Heavies Column #1 as reflux
while the rest is sent to B-1 Lights column for final recovery of the butene-1 and isobutane products.
The bottoms stream from Heavies Column #2 is sent to the battery limits as the Butene-2/n-Butane
product. In a similar manner to the Heavies columns, the B-1 Lights Column #1 works in tandem with
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Lights Column #2 (i.e. together the two columns function as one larger column). Lights Column #1
operates at a slightly lower pressure than Lights Column #2. The bottoms stream from the Lights
Column #1 is pumped to Lights Column #2 as reflux. Lights Column #2 is also reboiled with LLP
steam. The overhead vapor from Lights Column #1 is condensed and accumulated in the Reflux
Drum. The condensate is pumped and a portion is returned as reflux to the B-1 Lights Column #1
while the rest is sent to battery limits as the isobutane product. Finally, the Lights Column #2 Bottoms
stream is pumped and sent to battery limits as the highly purified butene-1 product.
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Figure 3-7: MTBE and BUT-1 Unit Plot Plan
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3.8 Polyethylene Unit
The Polyethylene unit is designed to process 874,000 t/y of polymer grade ethylene with design on-
stream factor of 8000 h/year. The LLDPE Unit to process approximately 546,000t/y and the HDPE
Unit to process approximately 328,000t/y of polymer grade ethylene feed. The feed-stocks to the
Polyethylene (PE) Units are polymer grade ethylene, hexene-1, butene-1 and hydrogen from SCU or
from storage.
The ethylene supply is preheated in the ethylene interchanger with ethylene from the ethylene CO
removal vessel and then through the preheater where it is heated to 90°C before entering the ethylene
deoxo vessel. The deoxo vessel contains a fixed bed of free copper catalyst, which removes oxygen
from the ethylene stream by oxidation of the catalyst to copper oxides. The ethylene then passes
through the CO removal vessel which contains a fixed bed of copper oxides supported on zinc oxide,
which removes carbon monoxide from the ethylene stream by chemisorption. Refer to Figure 3-8 for
the plot plan of the PE unit.
Ethylene is then cooled before passing through the ethylene dryer which contain activated alumina
(Selexsorb CD and Selexorb COS), to remove water, methanol, other polar impurities and trace
amounts of carbon dioxide from the ethylene stream by physical adsorption and chemisorption.
3.8.1.1 PE Polymer Reaction Unit
Resin is produced by polymerization of reactants in a fluidized bed reactor. An externally cooled
cycle of reactant gas fluidizes the reactor bed and removes the exothermic heat of reaction. Catalyst
and purified reactants (ethylene, 1-butene or hexene, and hydrogen) are fed continuously to the
reactor. Product flows intermittently from the reactor through two product discharge systems which
operate in a sequentially alternating mode.
During the product discharge cycle, some of the entrained reaction gas is transferred to the other
discharge system. This temporarily stored reaction gas is indirectly returned to the reactor during the
next discharge cycle, thereby minimizing the reactor gas released from the reaction system. Various
modifiers are also added to the reactor to obtain specific characteristic of the final product.
The reaction system consists of a reactor, a cycle gas cooler and cycle gas compressor. The gaseous
reactants (a mixture of ethylene, butene or hexene, and hydrogen) and inerts are continuously cycled
by the cycle gas compressor through a fluidized bed of resin containing small quantities of catalyst.
The heat of polymerization is transferred to the cycle gas and removed in the external cycle gas
cooler. A perforated distributor plate supports the bed of granular resin and distributes gas flow into
the bottom of the bed.
The granular polyethylene resin is charged into the reactor to provide a reaction bed before start up.
The reactor expanded section serves to disengage resin fines.
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3.8.1.2 Kill System
The polymerization reaction can be stopped or slowed down by the kill system. The kill system
consists of cylinder bottles containing Modifier C and a system of distribution piping and air operated
valves designed to inject the Modifier C into the cycle gas piping when the kill system logic is
actuated. The kill system logic provides several options as follows:
Type 1 Kill: Automatically or manually actuated with continued cycle gas circulation.
Type 2 Kill: Automatically actuated with no cycle gas flow and a small reactor blowdown.
Type 3 Kill: Automatically or manually actuated with reduced cycle gas circulation and small
reactor blow down.
Auto Mini-Kill: Manually actuated from the control room for small reduction in reactor rate.
Mini-Kill: Manually actuated in the field for small reduction in reactor rate.
3.8.1.3 Product Discharge Unit
Each reactor has two, two-stage product discharge systems (PDS). Both discharge systems operate in
a "cross-tied, alternating sequence" mode. However, each system may be operated by itself while
maintenance is being done on the other. Each PDS consists of product chambers (PC) and product
blow tanks (PBT). Granular resin and reaction gas are discharged intermittently to the PC from the
reactor. The resin and gas separate in the PC and gas is vented to the top of the reactor as it is
displaced by additional resin. The resin flows by gravity to the PBT, from which it is high pressure
conveyed (dense phase) to the product purge bin.
3.8.1.4 Pelleting System
Granular resin and solid and liquid additives are fed through mixer feed hopper and vent filter into the
continuous mixer where they are melted and mixed. The molten polymer discharges through the melt
screen unit and the die plate of an underwater pelletizer. The pellet/water slurry from the Underwater
Pelletizer is fed to the agglomerate remover for separation of any agglomerates or clumps of pellets,
and then to the centrifugal pellet dryer. Dried pellets are fed to the pellet screener. Dried pellets flow
through the pellet screener where both over- and undersized material are separated from the main
pellet stream. The pellet streams are then delivered to product conveying system.
3.8.1.5 Pellet Conveying, Blending and Storage
The pneumatic product handling and storage system is subdivided into:
Pellet blending and storage,
Dedicated conveying systems.
Finished pellets from the pelleting unit will be fed by gravity into the surge hopper. The surge hopper
rotary feeder feeds the pellets to a dilute phase conveying system which conveys the pellets to one of
the ten blending bins. Only one bin can be filled at a time.
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Batch blending may be required to balance additive/resin properties variations as per
operation/customers need. For this type of product homogenization a blender system is necessary.
Only one bin can be blended at a time.
While in circulation mode the pellets are fed by gravity from the blender to the dedicated conveying
system to the top of the same blending bin. Transfer between different bins can be applied, e.g. to
upgrade off-spec material. The blenders are designed and equipped with appropriate internals in a way
that material being discharged at the blender outlet is a representative mixture of the entire bin
content. Once the blending is finished the product is sent to the bagging facility. Since the bagging
silo has the same size as the blending bin one complete homogenized batch can be transferred to one
bagging silo. The pneumatic system will have a discharge air filtration system to remove dust.
The blending bin rotary feeders are located under each blending bin to discharge the pellets from the
blending bins. Pellets flow by gravity from the rotary feeders to the pellet blending/transfer systems.
For pellet transfer to bagging area the conveying air is generated by a dedicated blower and an after
cooler cools the conveying air prior to the pellet pickup point. Pellets from each blending bin can be
transferred to bagging silos or bulk loading silo according the selected diverter valve position.
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Figure 3-8: Plot Plan - PE Plant
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3.9 Polypropylene Unit
The Polypropylene (PP) Unit will be designed to process 300kTA of polymer grade propylene. The
feed-stock to the PP unit is polymer grade propylene, polymer grade ethylene (via the Polyethylene
Units) and hydrogen from the SCU. The PP unit will produce the following products:
Homopolymer;
Random Copolymer; and
Impact Copolymer.
The PP unit consists of the following units as discussed in subsequent sections and as shown in
Figure 3-9.
3.9.1 Pre-contacting and Pre-polymerization
3.9.1.1 Pre-contacting
The catalyst system consists of three components - Titanium catalyst supported on MgCl2 (solid),
Triethyl aluminum (TEAL) (liquid) and Donor (liquid). The three components are fed separately to a
pre-contacting pot, where they are contacted and then fed to the reaction system. Catalyst, donor, and
TEAL are fed through metering pumps to the pre-contacting pot which is a constantly stirred vessel
with chilled water circulating in the jacket to maintain the temperature at 10C. The Donor and TEAL
supply lines are joined into a common line and cooled by using chilled water, in order to achieve a
better temperature control. The catalyst mud enters the pre-contacting pot through a separate dip tube.
The feed streams enter the pot from the top through dip tubes. The pot is operated full of liquid to
prevent gas pockets; the overflow feeds the pre-polymerization reactor. Catalyst mixture leaving the
pre-contacting pot is injected into a stream of cold propylene, which feeds the pre-polymerization
reactor.
Propylene is filtered to retain particles bigger than 10µm. Propylene is cooled down to 10°C and
mixed with catalyst mixture. The slurry is fed to a pre-polymerization reactor where reaction takes
place at low kinetics. Propylene is polymerized under controlled conditions of temperature (20°C),
pressure and residence time (at least 10-15 minutes) in the pre-polymer reactor. A very small amount
of propylene also polymerize through the flush line between the pre-contacting pot and the pre-
polymer reactor. The aim of pre-polymerization is to slowly form a shell of polymer around the
catalyst particles which is acting as a protection in the subsequent polymerization stage.
3.9.1.2 Pre-polymerization
The pre-polymerization reaction is carried out in a small loop reactor at 20 °C and 34-45 Barg. The
reactor is operated with cooled liquid propylene with about 200-300 g of propylene polymerized for
each gram of catalyst fed. The purpose of the pre-poly reactor is to slowly encapsulate, or form a shell
of polypropylene around the catalyst particle. This shell protects the catalyst when it enters the loop
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reactor. If the catalyst is directly fed to the loop without encapsulation the catalyst particles would not
be strong enough, resulting in excessive production of fines. The pre-contacting pot, pre-polymerizer,
and loop reactor are operated continuously, in series.
3.9.2 Liquid Monomer Polymerization
The main polymerization reaction including homopolymer, random copolymer, random terpolymer
and butene random production takes place in the loop reactor, as pre-polymerization stage. For
homopolymers and Random Copolymers the reaction temperature is about 70-73°C at a pressure of
34 – 45 Barg.
Reduced reaction temperature (60°C) is required during terpolymer (propylene + ethylene + butene
polymer) production to cope with the increased reactivity of the system and the lower melting point of
polymer. Liquid propylene (and propane) is used as the carrier fluid. The loop reactor has a circulating
pump, which continuously recirculates the contents of the loop and which is critical for maintaining
uniform temperature and pressure through the reactor. The pressure of the prepoly reactor and loop
reactor is controlled by the reactor surge drum. The pressurization drum is equipped with a steam
heated propylene vaporizer.
3.9.3 Gas Phase Copolymerization
In this phase the rubbery ethylene-propylene phase is added to the homopolymer matrix (coming from
bulk polymerization inside the loop reactor) to produce a high-impact heterophasic copolymer. The
polymerization step for the production of the rubbery phase takes place in a vertical cylindrical
fluidized bed reactor (Gas Phase Reactor –GPR), fed with homopolymer matrix. Polymer that enters
into the reactor falls downward and is contacted with an upward flowing gas stream. This monomer
stream is pumped through the slotted conical tray located at the bottom of the GPR. When the gas
passes through the polymer, three physical effects take place:
The polymer is fluidized.
Monomers contact the catalyst within the polymer granules and polymerize.
The temperature of the upward flowing gas increases, while removing heat of reaction.
Ethylene and propylene (and hydrogen for molecular weight control) are fed at constant flow rate and
in suitable ratios to meet the required properties of the copolymer products. Normal operating
conditions of gas phase reactor are 14 bar(g) and 75-80°C with an average bed density of 300-350
kg/m³
The copolymer produced is discharged from the reactor bottom for degassing. The reactive polymer
granules must be kept in constant motion to reduce the risk of plugging the reactor which is caused by
polymer fusion. To prevent such problems at the GPR bottom, continual rapid movement of the
polymer away from the bottom outlet is assured with a “fast loop” which is a loop pipe that takes the
majority of the GPR bottom discharge and allows it to flow by means of a pneumatic transport from
the bottom of the GPR near the top, dumping its content back into the reactor. Slurry discharged from
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the reactor consists of about 53% wt polymer and 47% wt liquid propylene + propane mix. The slurry
from the reactor is discharged to the flash pipe at the temperature up to 90°C for homopolymer run.
3.9.4 Polymer Drying
Polymer leaving the steamer contains about 2.5% wt of condensed water and this is removed in a fluid
bed dryer operated in a closed-loop nitrogen circulation system. Nitrogen is used in vessels and
process line to prevent explosive atmosphere, as well as polymer degradation.
PP polymer, discharged from the dryer is sent to the intermediate silos by nitrogen pneumatic haulage.
The silos are equipped with bag type filter and operate under nitrogen atmosphere. The solid
additives, coming from unloading stations are discharged into the screw feeder while the other
additive is discharged directly into the extruder hopper. A liquid peroxide metering station is provided
for special polymer grades production. The surge drum and the metering pumps are used to feed the
liquid peroxide into the extruder feed hopper. The equipment and lines in peroxide service are
maintained at temperature less than 40 C. For safety reasons the peroxide station will be located in a
separate room with explosion proof walls.
3.9.5 Extrusion
Additives and polymer mixture from the suction system are fed to the extruder through the feeding
hopper. Nitrogen is also fed to this hopper to prevent oxygen entering the extruder itself. Liquid
additives like organic peroxide and Atmer 163 are injected directly into the extruder hopper. PP
polymer powder and additives are homogenized, extruded and granulated by an under-water pelletizer
in the extruder. Granulation occurs in an underwater pelletizer. In the extruder, the melted polymer is
pushed against a die plate and cut into pellets by a set of rotating knives as soon as it emerges as
strands from the die plate.
Pellets are then transported by a water stream. Pellets and water stream leaving the underwater
pelletizer are conveyed to the dryer, via a separator. Water is separated from the pellets by gravity and
by centrifugal force. The pellets take a spiral path from the bottom to the top of the dryer. Final drying
is accomplished by the flow of dry air through the pellets. Dried pellets are conveyed by gravity to the
vibrating screen which separates fines and coarse from pellets. Coarse and fines are sent to off-size
pellets recovery package, while the on-spec pellets are discharged in the pneumatic transport hopper.
Finished PP pellets from the extrusion unit are collected by means of a pneumatic haulage in blender
silos.
3.9.6 Pellets homogenization
Pelletized product from the extrusion and pelletizing unit is conveyed to the homogenization silos by
a pneumatic transport in air. Pelletized product homogenization is carried out in homogenization silos
of 800m3 capacity each. Recirculation of pellets is provided by means of an open-circuit air pneumatic
conveyor. Conveying and ventilation air is vented to the atmosphere through the vents on top of silos.
Vents at the silos will be equipped with bag filters for venting the air
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Figure 3-9: Plant Layout – Polypropylene Unit
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3.10 Pygas Hydrotreater Unit (PGHYD)
The pygas hydro-treating unit, processes raw pyrolysis gasoline from the SCU, in a two- stage hydro-
treating unit to produce a C6-C7 heart cut, which will be sent to the existing Sohar Aromatics Plant, a
fully hydrogenated C5 cut that will be recycled to the cracking heaters of the SCU, a partially
hydrogenated C8-C9 cut that will be sent to the gasoline pool of the existing Sohar Refinery and
partially hydrogenated C10+ cut that will be combined with the pyrolysis fuel oil from the SCU and
sent to Sohar Refinery.
Raw pyrolysis gasoline originating from the debutanizer column in the SCU or from atmospheric
storage tank and hydrogen originating from the Pressure Swing Adsorption (PSA) of the SCU will be
the main feed-stock for the pygas hydro-treating unit. The pygas hydro-treating Unit will produce
Hydrogenated C5, C6-C7 Cut, C8-C9 Cut and C10+. The various units and process description are
presented in the following sections. Overall process description for Pygas Hydrotreater Unit id
provided in Attachment 5.
3.10.1 First Stage Reaction Section
The pyrolysis gasoline feed is pumped to the first stage reaction section under cascaded level-flow
control, and filtered in the feed filters in order to remove scale particles. The feed is first mixed with
make-up hydrogen from PSA. Combined feed is then mixed with the liquid diluent, recycled back
from the hot separator drum. The dilution lowers the feed reactivity and thus allows a smooth control
of temperature elevation.
The reactions (diolefins and alkenyl aromatics hydrogenation) occur in mixed phase (mainly liquid) in
a fixed bed type down flow reactor. As the catalyst activity decreases during the catalyst cycle, the
feed temperature of 1st Stage 1st Reactor increase from 60°C to 120°C. 1st Stage 1st Reactor effluent is
mixed with the quench stream coming from Hot Separator in a static mixer and routed to 1st Stage 2nd
Reactor. Second reactor inlet temperature will be such that the overall temperature rise in 1st Stage
reactor is maintained below 60°C. The reactors effluent is flashed into the Hot Separator Drum. Part
of the liquid from this is recycled through the 1st stage recycle pump and the remaining is sent under
cascaded level-flow control to stabilizer.
1st Stage Reactors are also designed to stand in-situ activation and regeneration of the catalyst. Due to
the use of nickel-based catalyst, an additional passivation step is performed to prevent high
hydrogenation rates of the feed with potential loss of aromatics and unbearable exotherm in 1st Stage
reactors. The active compound during passivation shall be Di Methyl Sulfide (DMS) which will be
injected in the closed loop from the DMS injection package.
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3.10.2 First Stage Distillation Section
3.10.2.1 Stabilizer
The Stabilizer has 30 trays and the feed enters the column at tray 18. The Stabilizer first stabilize the
first stage reactors product by removing the hydrogen and the light components and fractionate the C5
product as side-draw from the C6+ cut which is removed as the bottom product. The light gasoline cut
recovered as overhead product is routed to 2nd Stage Feed Surge Drum under flow control cascaded.
The C6+ cut leaving the tower bottoms feeds the Rerun Tower under flow control cascaded by the
level in the Stabilizer bottom.
3.10.2.2 Rerun Tower
The rerun tower has 24 trays and the feed enters the column at tray 14. The rerun tower purpose is to
fractionate the C6-C10 overhead cut from the C10+ cut (Heavy Cut) which is removed as the bottoms
product. The overhead vapor of the tower is partially condensed in the Rerun Tower Air Cooler and
the Rerun Tower Condenser and collected in the Rerun Tower Reflux Drum. Vapor phase from reflux
drum is sent to the rerun tower vacuum package. A part of the liquid is sent back as column reflux to
the top of the tower and the remaining liquid is sent to the 2nd stage feed surge drum. The heavy cut
leaving the tower bottom is pumped in the heavy cut pumps, cooled down in heavy cut air cooler and
sent to the PFO tank, under flow control cascaded by tower level controller.
3.10.3 Second Stage Reaction Section
The second stage reaction section feed is a blend of C5 cut from 1st stage stabilizer overhead and C6-
C10 cut from rerun tower overhead. It is charged to the 2nd stage feed surge drum. The feed is
pumped to the 2nd stage reaction section by 2nd stage feed pumps, under cascaded level flow control.
The feed is mixed with the recycle gas stream and a liquid diluent stream from 2nd stage separator
drum in order to dampen the reactor feed reactivity.
The hydrocarbons and hydrogen mixture is preheated in the 2nd stage feed/effluent exchangers against
2nd stage hydrogenation reactor effluent. The reactor feed is then heated to the required reactor inlet
temperature in the 2nd stage feed heater. The reactor is divided into three beds. In the upper two beds
of the reactor, mainly olefins hydrogenation occurs and in the lower bed (loaded with a different
catalyst) mainly desulphurization occurs. The combination of two catalysts enables to keep the loss of
aromatics low.
The effluent from the 2nd stage hydrogenation reactor is cooled and sent to 2nd stage separator drum.
The liquid hydrocarbon from this is split into two streams: one is sent to the 2nd stage stabilizer feed /
deheptanizer bottom exchanger and the other is pumped and recycled either directly to 2nd Stage
Reactor (quench streams), or to reactor feed preheat train (diluent stream). 2nd Stage reactor catalyst
activation is different from 1st stage reactors. Catalyst needs to be sulfided prior to being used.
Sulfiding will be performed by circulating hydrogen mixed with H2S inside the reactor in closed loop
through the normal operation lines. H2S will be generated in-situ by injecting Di Methyl Di Sulfide
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(DMDS) from DMDS Injection Package at 2nd Stage reactor inlet, which will decompose in H2S at the
sulfiding step conditions.
3.10.4 Second Stage Distillation Section
3.10.4.1 Stabilizer
Second Stage effluent is preheated in the 2nd Stage Stabilizer Feed / Deheptanizer Bottom Exchanger
and fed into the 2nd Stage Stabilizer. 2nd Stage Stabilizer has 30 trays and the feed enters the column at
tray 25. The Stabilizer stabilizes the second stage reactor liquid product by removing the H2S and the
light hydrocarbons dissolved in the column feed.
3.10.4.2 Depentanizer
The depentanizer has 55 trays and the feed enters the column at tray 26. The depentanizer recover a
C5 cut at overhead (Hydrogenated C5 cut). The overhead vapor of the tower is condensed in the
depentanizer condenser and collected in reflux drum. A part of this is routed back to the column as a
reflux while the remaining is sent to storage after being cooled down in the hydrogenated C5 trim
cooler.
3.10.4.3 Deheptanizer
The Deheptanizer has 43 trays and the feed enters the column at tray 26. The purpose of Deheptanizer
is to recover a C6-C7 cut at overhead and a C8-C10 cut in the bottoms. These streams will be routed
to Sohar Refinery
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Figure 3-10: Plot Plan for PGHYD Unit
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3.11 Utilities
The various utilities required during operation phase of the Petrochemical Plant are described in
subsequent sections of this chapter.
3.11.1 Power Plant
The total power required for the operation of the entire petrochemical Plant is estimated to be 150
MW. The power will be sourced from a captive power plant provided within the plant. Options
considered for the most reliable and economic power plant configuration by Orpic are:
Independent Gas Turbine Combined Cycle (GTCC) unit; and
Integration of Power Plant with the Steam System of the Olefins Complex.
Integration options with the steam system of the Olefins complex are found to be unreliable with
respect to the occurrence of trips, resulting in unacceptable production losses at the Olefins complex,
even with a reliable connection to the external power grid for back-up power. In addition, investment
cost will be increased due to the use of super high pressure (121 barg) steam as generated in the
Olefins complex.
Orpic after careful consideration of various options has proposed the use of two GTCC units including
connection with Oman Electricity Transmission Company (OETC) grid for back-up power as shown
in Figure 3-11.
Figure 3-11: Power Plant GTCC Configuration
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The proposed configuration is without any steam integration, because the steam integration:
Increases capex due to more expensive equipment.
Increases opex, notably due to more natural gas consumption and lower thermal efficiency.
Reduces reliability resulting in significant Olefins complex production losses.
Reduces operability due to more complexity and to many mutual influences between the
power plant and the Olefins complex.
Each unit has a gas turbine with a steam generator. Natural gas is used to drive the gas turbine, and the
hot exhaust is sent to the Heat Recovery Steam Generator (HRSG) possibly via an intermediate stack
with damper. The steam turbine expands the superheated steam to wet vacuum. The steam turbine
drives an independent generator.
Both units are fully independent and hence the reliability is high. Also it is possible to shut down one
unit for inspection and maintenance, while the other unit remains in full operation together with the
connection to the OETC grid. The reliability of power supply is increased by connecting to the
external power grid. The steam system of each unit is fully independent from the other unit. Further,
both units are also fully independent of the steam system of the Olefins complex.
3.11.2 Flare System
For the proposed Plant operation phase the flare system is expected to receive reliefs from all the
plants. The flare system will be designed to safely collect and dispose reliefs from the plant. Separate
collection headers will receive different discharge from the plant. Knock-out (KO) drums will be
provided for each process unit to separate liquid before the gasses are sent to the flare. Overall
process description for flares is provided in Attachment 6. The flare system consists of:
One Main Wet Flare;
One Main Cold Flare;
One Spare Storage Cold Flare;
One Spare Storage Wet Flare; and
Two LP Cryogenic Flares ( A and B).
3.11.2.1 Main Wet Flare
The wet flare system will handle wet vapor relief loads from safety valves and vent gases which are
above 0°C at atmospheric pressure or, when the relieved flow contains significant amounts of water
vapor. It shall consist of a branched header discharging into the wet flare KO drum which is located
near the flare stack.
Any liquid accumulated will be routed to the quench tower drain drum. Only during shutdown of the
SCU; the pumped liquid is routed to the wastewater collection tank (WWCT). The vapors flow
through the wet flare seal drum to the stack. Service water flows continuously through an orifice into
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the seal drum to ensure adequate water seal level. The continuous overflow is sent to the Oily Water
Sewer (OWS). The function of the seal drum is to prevent ingress of air into flare header. Ingress of
air is not allowed into the flare header as it can result in an explosive mixture in the header.
The inlet to the flare stack and the flare sub-headers will be purged with fuel gas to ensure a positive
flow from the flare system to the flare stack. Fuel gas is used as pilot gas and purge gas. Natural gas is
used as back-up for fuel gas. Medium Pressure (MP) steam is routed to the flare tip to ensure
smokeless flaring at low relief loads. The main equipment connected to this system is presented in
Table 3-1.
Table 3-1: Main Wet Flare Connections
# Main Unit Sub Units
RDG Amine / Wash Water Tower
1 Refinery Dry Gas Treating Unit
RDG Caustic / Water Wash Tower
2 NGL Treating and Fractionation Unit NGL Amine / Wash Water Tower
Quench Tower
Steam Cracker Unit Charge Gas Compressor 1st Suction Drum
3
Charge Gas Compressor 3rd Suction Drum
Debutanizer Reflux Drum
SHU 1st Stage Feed Drum
Selective C4 Hydrogenation Unit
4 SHU 1st Stage Separation Drum
(SHU)
SHU 2nd Stage Separation Drum
Methanol Extraction Column
Methanol Recovery Column
5 MTBE Unit and Butene-1 Unit
B-1 Heavies Column no. 1 & 2
B-1 Lights Column no. 1 & 2
DPG 1st Stage Feed Surge Drum
DPG 1st Stage Flash Drum
6 Pyrolysis Gasoline Hydrogenation Unit DPG Stabilizer
DPG Tailing Tower
Depentanizer
Mixed C4, Butene-1, Butene-2 and Isobutane,
7 Pressurized storage
Hydrogenated C4 and Hydrogenated C5
3.11.2.2 Spare Storage Wet Flare
In case the main wet flare is taken out of operation, all wet storage area vents and relief will be routed
to spare storage wet flare. From the main wet flare header the reliefs will be routed to the spare
storage wet flare KO Drum which is located near the flare stack. Any liquid accumulated will be
pumped to the liquid outlet line to be routed then to the quench tower drain drum. The main
equipment connected to this are pressurized storage for mixed C4, butene-1, butene-2 and Iso-butane,
Hydrogenated C4, and Hydrogenated C5.
3.11.2.3 Main Cold Flare
Dry/cold reliefs from the petrochemical Plant process units will be collected in dry/cold primary
knock KO drums located at each process unit. Any liquid accumulated in the these KO drums will be
either vaporized in the assigned drum vaporizer using low pressure steam or pumped back to the
process unit.
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The vapor streams from these KO drums will be directed to a common header and routed to the Flare
KO drum. Any liquid ethylene and propylene, accumulated will be vaporized by the main cold flare
vaporizer using low pressure steam. The main equipment connected to this flaring system is provided
in Table 3-2.
Table 3-2: Equipment’s connected to Flaring System
# Main Unit Sub Units
RDG Demethanizer , Deethanizer Reflux Drum,
Depropylenizer Reflux Drum
1 Refinery Dry Gas Treating Unit
NGL Treating and Fractionation Unit
NGL Deethanizer Reflux Drum
HP Depropanizer Reflux Drum
LP Depropanizer Reflux Drum
Demethanizer overheads
Deethanizer Reflux Drum
Ethylene Fractionator Reflux Drum
Propylene Fractionator No. 1 and 2 Reflux Drum
2 Steam Cracker Unit Debutanizer Reflux Drum
Propylene Refrigeration System Stage Suction Drum
Binary Refrigeration System Stage Suction Drum
Pressurized storage sphere for NGL C2+.
Pressurized storage spheres for Ethylene and Propylene.
High pressure equipment and piping of Cryogenic Ethylene
and Propylene Storage
3.11.2.4 Spare Storage Cold Flare
In case the main cold flare is taken out of operation, all storage area dry/cold vents are routed to spare
storage set flare. The cold reliefs from the pressurized storage are directed from the common cold
header to the spare storage cold flare KO Drum. Any liquid accumulated will be vaporized by the
spare storage cold flare vaporizer using low pressure steam. The capacity will be set to vaporize the
accumulated liquid in two hours. The cold flare sub-headers will be purged with fuel gas to ensure a
positive flow from to the flare stack. The main equipment connected to this header is:
Pressurized storage for NGL C2+;
High pressure equipment and piping of cryogenic ethylene and propylene storage; and
Pressurized storage spheres for Ethylene and Propylene.
3.11.3 Incinerators
The waste streams produced in the petrochemical Plant will be incinerated using three different type
of incinerator system as follows:
Vent gases with toxic components or odour will be routed to the Vent Gas Incinerator;
Waste Incinerator for liquid streams; and
Waste Incinerator for solid waste.
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The possibility to combine the liquid waste and solid waste incinerator will be considered during the
detailed designing stage. Overall process description for Incinerator is provided in Attachment 7.
3.11.3.1 Vent Gas Incinerator
The vent gases of the following storage tanks will be routed to the vent gas incinerator as these
contain nitrogen with toxic components. The following storages will be connected to vent gas
incinerator:
Raw pyrolysis gasoline storage tank;
Quench water storage tank;
C6 – C7 Cut storage tank;
C8 – C10 Cut storage tank;
Spent caustic storage tank;
Spent caustic oxidation effluent tank; and
OLNG condensate storage tank.
The vapor flows from the storage tanks are the result of pumping in and thermal out breathing during
the day. Blowers will be installed to transfer the vent gases from the storage tanks to the incinerator.
The second stream to be processed originates from the WWTU. Vapors formed during the thermal out
breathing and pumping in will be routed to the incinerator via a blower. This line is usually active and
can contain hydrocarbons in traces.
Benzene / MTBE contaminated wastewater collection tank;
Wastewater collection tank;
Skimmed oil vessel; and
Oily sludge storage tank.
The third stream will be incinerated is the spent air stream from the spent caustic oxidation unit. This
air stream has a continuous flow rate and contains traces of hydrocarbons.
The fourth stream will be processed is the vent gas from the PGHYD, when it is not routed to the
cracking heaters, containing hydrocarbons. During shut down of the SCU, the PGHYD waste gas flow
(stream 4) and the Spent Oxidation Unit waste gas flow (stream 3) is zero, whereas the vapor flow
from other sources (streams 1 and 2) continues. The vent gas incinerator is specially designed for high
hydrocarbon conversion efficiency.
Flame arrestors will be provided to prevent fire in case of back flow from the incinerators into the
vent gas line. In case the vent gas incinerator is not available and during the start-up of the blowers,
the vent gases are routed to the atmosphere at safe location via vent gas stack, which will only be for
shorter duration of time. The flue gas is routed via a stack to the atmosphere. The incinerator is fired
by means of fuel gas with natural gas as back-up.
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3.11.3.2 Liquid Waste Incinerator
The waste liquid streams from the process and utilities units will be collected in waste liquid hold-up
drum, all streams are considered intermittent. The fluids will be transported by tank car or drums and
contents mixed by pumping before it is routed to the liquid incineration unit. The following liquid
waste streams will be handled in this unit:
Skimmed oil from spent oxidation effluent tank;
Skimmed oil from wastewater treatment;
Maintenance waste oils;
Liquid waste from polymer plants containing up to 15 – 20% Alkyls; and
Hydrocarbon/water mixtures from drain vessels by tank car.
3.11.3.3 Solid Waste Incinerator
The solid waste will be transported by means of trucks and is dumped in a waste feed hopper part of
the solid waste incineration. A feeder charges the solids into the combustion chamber. The solids will
be converted into flue gas and solid effluent. This effluent shall be transported to a landfill. The fly
ash shall be removed from the flue gas and shall be stored in silos. The incinerator will handle the
following streams:
Cokes from cracking ethylene unit;
Polyethylene and polypropylene powder;
Dewatering sludge from wastewater treatment unit; and
Spent actived carbon from filters.
3.11.3.4 Cryogenic Low Pressure Flare A/B
Reliefs from the cryogenic ethylene and propylene storage tanks will be routed to the cryogenic low
pressure flare A/B which consists of flare tip, flare ignition system and molecular seal.
One system will be in operation and one in stand-by mode. MP steam will be routed to the flare tip to
ensure smokeless flaring at low relief load. Fuel gas will be used as pilot gas and purge gas and
natural gas as back-up for fuel gas. The cryogenic flare sub-headers will be purged with fuel gas to
ensure a positive flow from to the flare stack.
3.11.4 Drainage System
The drainage system for the proposed plant can be divided into following two systems
Open (non-pressurized) draining system; and
Closed (pressurized) draining systems.
Draining system shall comprise of piping, valves, drain funnels, catch (inlet) basins, manholes and
open drain channels, combined with fire and sand traps based on the type of drainage.
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3.11.4.1 Open (non-pressurized) systems
Non pressurized systems operate under gravity. Equipment drainage and/ or surface water run-off,
with the exception of the storage tank areas, is collected upon discharge. In the storage tank area, the
area within the dikes is drained either preceding the next rain shower or during a period of rainfall, all
depending on the rainfall intensity, after verification of the water composition. The area shall also be
drained when a tank farm is subject to firefighting, cooling and extinguishing.
Thus the surface water from the area subject to fire fighting and possible contamination, as well as the
tank and roof drainage can be contained in the catchment area, while the other catchment areas can be
drained via the normally closed isolation valve. Volatile, combustible, toxic, viscous materials or hot
materials that may be drained during shutdown should be kept out of the atmospheric sewers, as such
materials might polymerize or react when they contact with air. The curbed area shall have a sump
where any spillage can be collected and neutralized and afterward removed by vacuum truck or routed
to clean water sewer. To collect flushing medium and surface run off in the PC, the following open
(non-pressurized) systems are proposed:
Accidently Oil Contaminated Water Sewer (AOC)
AOC collects surface water run-off from areas where contamination sources may be present during
equipment drainage in ISBL/OSBL areas. AOC is water which may be hydrocarbon contaminated.
AOC water will be routed to Last Line of Defense (LLOD). Main flows contributing to the system
are:
Rain, wash or firewater falling onto the hard paved areas where hydrocarbon spillage and
leakages are anticipated.
Drainage from equipment containing water, which may be accidentally contaminated (i.e.
pumps containing water).
The surface water run-off from the paved area of the MTBE area, where hydrocarbon leakage may
occur, shall be checked for contamination before routing to AOC sewer system. In case of high
hydrocarbon contamination surface run-off shall be collected by vacuum truck and transferred to
Benzene/ MTBE contaminated WW collection tank.
Oily Water Sewer (OWS – Continuous oil contaminated)
OWS is all continuously oil contaminated wastewater from rotary equipment base plate in ISBL/
OSBL areas. OWS will be sent to WWTU in order to separate the water and the oil. Main flows
contributing to the system are:
Contaminated water and/or flushing effluent from equipment via open funnels;
Wash water via building drains in contaminated service;
Base plate drainage of skid mounted equipment, like pumps; and
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Surface water from concrete paved areas subject to constant contamination and dike areas, if
contaminated. Gasoline and MTBE drains, which need to be routed to the respective drain
systems.
Clean Water Sewer
This system collects surface water run-off from areas where contamination sources or leakages/spills
are not present, including fire and rainwater coming from:
Roads and building roofs;
LPG and hydrogen storage areas via a sealed sump, sand trap and atmospheric sewer;
Storage tank area via normally closed isolation valve (when clean);
Unpaved / Undeveloped areas; and
This is clean water and will be discharged to common outfall after treating in water clarifier.
Sanitary sewer
Domestic wastewater from buildings will be routed by gravity to the domestic effluent lift station,
where solid and liquid waste will be transferred by pump to OSBL (MISC) for further treatment. Main
flows contributing to the sanitary sewer are toilets, urinals, kitchen sinks, showers (not safety shower)
and the likes in buildings.
3.11.4.2 Pressurized system
To collect drain from equipment, piping or instruments in case of equipment maintenance or
shutdown the following drainage systems and treatment/disposal are envisaged in the PC Plant.
Table 3-3: Type of Pressurized Sewer System and Stream Disposal/Treatment
Sewer Type Type of Streams Routed to/Disposal
Collected hydrocarbon routed to
Equipment /piping containing Gasoline fractionators. Light
Hydrocarbon Drain System
hydrocarbon within ISBL/OSBL hydrocarbons are drained directly from
equipment to the flare system
Equipment/piping containing Collected amine pumped to the amine
Amine Drain System
amine within ISBL/OSBL. regenerator
Un-neutralized or undiluted spent
Spent caustic/caustic routed to the spent
Spent Caustic Drain System caustic waste from equipment and
caustic oxidation unit
piping
Drainage from areas, where
Content pumped back to MTBE unit if
contamination source are present,
MTBE Drain System MTBE is present otherwise send to
including equipment draining in
WWTU
ISBL/OSBL
Drainage of C6/C9/PGO/PFO
areas, where contamination source Treated in quench tower though quench
Benzene Drain System
are present, including equipment drain vessel
draining in ISBL/OSBL
Drainage of chemical dosing/
Stream is neutralized locally and routed
catalyst and/or sulfuric acid
Chemical Drain System to clean surface water sewer network or
spillage from equipment and
WWTU
piping from ISBL/OSBL areas
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Sewer Type Type of Streams Routed to/Disposal
Hot oil drainage from areas
Stream routed to effluent treatment unit
Hot Oil Drain including equipment and piping
to separate the oil and water
draining in OSBL/ISBL
Drainage of methanol from Stream pumped back to unit when
Methanol Drain System equipment and piping within methanol is present otherwise send to
ISBL/OSBL WWTU
Drainage of Quench Oil from
Quench Oil Drain System equipment/piping containing hot Content pumped to quench tower
oil within ISBL/OSBL areas
Drainage of Quench water from
Quench Water Drain System Content pumped to quench tower
equipment draining is ISBL/OSBL
Each system, except for the casing drain drums, shall discharge into respective below ground drip and
drain vessel as secondary containment in case of leakage, which will be located in a concrete pit. The
drain headers shall be directly connected to the drip and drain vessel to ensure that complete draining
is achieved. All concrete pits shall be provided with a drain pipe to the surface which is connected to
an installed ejector to allow emptying the rainwater from pit.
All drip and drain vessels are provided with nitrogen/fuel gas purge connection and shall have an open
connection to the flare in order to release vapors. Drain vessels are provided with a pump to transfer
the contents back into the process/treatment units
3.11.5 Potable and Service Water System
3.11.5.1 Service Water
Desalinated water from desalination unit will be stored in tanks and used as service water after
chemical injection. Desalinated water is routed to the Demineralized (DM) water unit, potable water
tank, utilities stations, buildings and irrigation. The major user out of all is the DM water unit. Before
distributing to the service water end users (other units) several chemicals like 30% Calcium Chloride,
15% Sodium Carbonate and a blended corrosion inhibitor are injected to prevent corrosion in service
water. The service water is distributed to NGLT, RDG, SCU, Selective C4 Hydrogenation Unit
(SLC4HY), MTBE, Butene Recovery Unit (BUT) and PGHYD. Overall process description for
service water and potable water system is provided in Attachment 8.
3.11.5.2 Potable Water System
A part of the service water will be fed into the potable water system and stored in the tank after salt
addition via salt solution unit and chlorination via hypochlorite injection unit. The potable water tank
is an atmospheric spherical tank, sized for a residence time of 24 hours based on normal flow rate and
installed at a sufficient elevation for distribution by gravity. Potable water shall be used for safety
showers, eye washer, etc
3.11.5.3 Fire Water
Fire water will be made up from desalination water and will be stored in the Fire Water Storage Tanks
for distribution. The fire water distribution network will be a closed loop to ensure multi-directional
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flow in the system. Isolation valves shall be provided in the network. The fire water pumps and
distribution system shall be designed for a minimum residual pressure of 7 bar (g).
3.11.6 Seawater Desalination System
Seawater desalination system is to generate desalinated water from sea water by Multi Effect
Distillation (MED). Desalinated water is fed to other water systems which will produce demineralized
water, service water and potable water. Overall process description on Seawater Desalination System
is provided in Attachment 9.
3.11.6.1 Desalination Package (MED)
Desalination system will be based on MED technology which consist of two identical trains (one
operating, one on stand-by) in which Low Low Pressure Steam (LSS) is used to evaporate sea water
in multi effects. Seawater is provided by means of sea water pumps and filtered to remove undesirable
particles before feeding into the desalination process. Sea water flows through tube bundles in MED
the condenser as cooling media. Condensed water from all effects is collected in the last chamber
called condenser where non-condensable gases are removed by means of an ejector and desalinated
water is pumped as product to tanks. Total sea water return and brine reject will be discharged in one
common header to the sea water outfall. It is to be noted that the seawater intake and outfall system
are not part of the Petrochemical Plant scope.
3.11.6.2 Demineralized Water Unit (EDI)
Part of the stored desalinated water will be pumped from the desalinated water tanks to the DM water
unit to produce DM water. The DM water package shall consist of two Electro De-Ionization (EDI)
trains (one operating, one on stand-by) to remove undesirable salts and components by conventional
ion exchange from the feed desalinated water. Demineralized water shall be produced with the
required specification. The concentrated waste stream (reject water) will be recycled back to the
desalination unit.
3.11.7 Fuel Gas and Natural Gas System
The fuel gas (FG) and natural gas (NG) system for the Petrochemical Plant will be a common
distribution system inside the plant. The fuel gas distribution system will receive vapors from the SCU
and provide fuel gas for the units. Considering the fact that the amount of fuel gas production from
SCU Unit will not be sufficient for the operation of the PC plant units, a need for additional natural
gas supplied from the existing NG intake station is also envisaged.
The collected gas will be routed to a fuel gas drum operating at 4.5 bar (g). From there the fuel gas is
distributed to the various units. In case the SCU is short in fuel gas, high pressure natural gas at 31 bar
(g) will be routed to the Cracking Heaters. The SCU shall have its own independent fuel gas drum and
pressure let down system. Overall process description for Fuel Gas and Natural Gas System is
provided in Attachment 10.
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3.11.7.1 FG Collection
Off gases produced in the new process units will be collected in one common header from the SCU.
The following streams will be the main off gas producers:
Regeneration Off gas from RDG treating unit; and
Fuel gas from PSA Unit in Steam Cracker Unit.
The split fuel gas serves the cracking units and the FG system. The fuel gas stream containing mainly
methane, minorities of heavier hydrocarbons and some inerts at about 4.5 bar(g) is mixed with the
natural gas stream from Sohar Refinery. The Static Mixer assures the continuous mixing of both
gases. The fuel gas will be further directed to the LP fuel gas drum which provides liquid droplet
separation, if present any.
3.11.7.2 HP NG Intake and Distribution
NG is used to compensate FG requirements in the Petrochemical Plant. A tie-in point downstream of
the existing gas intake station will be made to supply high pressure (HP) NG from the supply system
of Sohar Refinery for the PC Plant. The HP NG will be heated up in natural gas receiving heater prior
to the pressure reduction to avoid hydrate and liquid droplets and mist formation. The heated HP NG
will be routed the SCU only during the operation case in which the internal production is lower than
required for the main cracker heaters. The remaining heated up HP NG flows through a dedicated
pressure control valve to the FG distribution system. The NG intake will be clean and no filters are
required.
3.11.7.3 FG distribution
Pressure of the Fuel Gas System is regulated by the pressure controller located on the outlet of Fuel
Gas Mixing Drum, adjusting the intake of NG to the drum. The mixture of FG and NG is distributed
to all process and utility consumers in the Petrochemical Plant:
Pilot burners at flare tip;
Purge gas for flare sub-headers;
Auxiliary Steam Boilers, pilot and burners;
Vent Gas Incineration, pilot and burners;
Liquid Gas Incinerator, pilot and burners;
Solid Gas Incinerator, pilot and burners;
Blanketing gas for drain vessels; and
2nd stage hydrogenation heater in Pygas hydrogenation unit.
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3.11.8 Cooling Water System
The Secondary Cooling Water Unit (SCW) will be a closed pump around system. The SCW supplies
cooling water to all process units of petrochemical Plant except PE and PP Plant, utilities systems and
storage. The cooling water returned from the users will be cooled down against sea water in five plate
heat exchangers. In case of inspection or maintenance, the SCW system can be drained into pits from
where it is pumped. After inspection or maintenance the content can be pumped back into the system.
In this way loss of water will be minimized. In case of tube rupture the vapors will be released to the
flare via the vent line. The SCW storage tank will be provided with a blanketing system to prevent
ingress of air, which affects the water quality. Overall Process description for Cooling Water System
is provided in Attachment 11.
3.11.9 Nitrogen Requirements
For operation of the proposed petrochemical Plant, requirement of inert gas (Nitrogen) is envisaged.
Nitrogen will be continuously used for tank and vessel blanketing and for purging. Nitrogen will also
be used as part of regeneration media for the PGHYD unit reactors. Nitrogen will not be produced
within the plant, but will be sourced from a third party. The Nitrogen stream will be supplied from
Outside Boundary Limits (OSBL), from Sohar Refinery network. It is routed to the process users as
well as to Storage Area, Utility Area, Off-sites and to utilities stations from where it is used for
purging and maintenance purposes. For peak demands (above design flow), a connection from
temporary nitrogen supply will be made available. Normal operating pressure for Nitrogen will be 7
bar(g). Overall Process description for Nitrogen System is provided in Attachment 12.
3.11.10 Steam System
3.11.10.1 Auxiliary Boilers
Auxiliary steam system includes two utility boilers each of 250 t/hr steam generation capacity. Both
boilers will be normally in operation at reduced capacity. Fuel gas is used for firing of the boilers and
pilot burners. Auxiliary steam boiler unit receives super high pressure boiler feed water and produces
Super High Pressure Steam (SHS) at 121.3 bar(g) and 522 °C. Steam generated is sent to SHS header.
Overall Process description for Steam System is provided in Attachment 13. Following are the
various type of steam that will be used during operation of various process units within PC Plant:
Super High Pressure Steam - Super High Pressure Steam (SHS) is produced by SCU cracking
heaters and by Auxiliary Steam Boiler unit at 121.3 bar(g) and 522 °C and sent to the SHS
header. SHS is mainly used to drive charge gas compressor turbine and propylene refrigerant
compressor turbine (PRCT). Furthermore, SHS is intermittently used by the DPG First Stage
Reactor for regeneration and by DPG Second Stage Feed Heater.
High Pressure Steam - High Pressure Steam (HS) is produced by extraction from CGCT and
PRCT. HS is mainly used to drive some steam turbines in the process and utility units HS steam
is also used intermittently by Regeneration Gas Heater, RDG Oxygen Converter Feed Heater and
for the regeneration system of SCU, SHU and RDG unit reactors. Furthermore there is
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continuous HS supply to the PE and PP Unit. HS header normal operating conditions are 42.3
bar(g) and 385 °C.
Medium Pressure Steam - The Medium Pressure Steam (MS) header is fed by the extraction from
PRCT, exhaust from Hydrogen Compressor Turbine, outlet of DPG 2nd stage reactor feed heater
in the PGHYD Unit, flash steam from blowdown and flash drums. MS is used for heating,
stripping and other use in process units and for driving PW stripper feed pump, gasoline
fractionator reflux pump, PW stripper bottoms pump, demin water pump turbine, LNG C2+
transfer pump turbine, for dilution steam, and smokeless flaring.
Low Pressure Steam - The Low Pressure Steam (LS) header is fed by steam extraction from the
Binary Refrigerant Compressor Turbine (BRCT). LS is used for the column reboiler in the
PGHYD unit, regeneration of DPG first stage reactor and regeneration system of SCU, SHU and
RDG unit reactors. LS header normal operating conditions are 10.6 bar(g) and 220 °C.
Low Low Pressure Steam - The LLS is used for heating, stripping and other use in process units,
for heating in utility and storage units, for smothering steam, steam tracing and in de-aerator unit.
Excess LLS is condensed in excess LP steam condenser to avoid too high pressure in the LLS
header. LLS header normal operating conditions are 3.5 bar(g) and 180 °C.
3.11.10.2 Boiler Feed Water (BFW) System
BFW will be produced in the deaerator which has two sections, a degassing section and a storage
section (which provides the liquid hold up). Deaeration is achieved in the degassing section of a
deaerator by breaking the water into as many small droplets as possible, and surrounding these
droplets with an atmosphere of steam. This releases the dissolved gases, which will be carried with the
excess steam to atmosphere. The deaerated water then falls to the storage section of the vessel.
Demineralized water mainly recovered condensate, is pumped and heated up in a series of Heat
Exchangers prior to entering the deaerator. Demineralized water is required for producing BFW,
making up water losses caused by steam stripping, blowdown and etc.
Water is heated up to saturation temperature in the deaerator by direct spraying of LLS to the
degassing section. In order to meet BFW quality specification, amine solution (neutralizing amine)
and oxygen scavenger are added to BFW. Amine solution is injected to BFW downstream of the
deaerator and oxygen scavenger is injected into the storage section of the deaerator. Upstream of the
amine injection point there is a BFW take-off line to the MTBE unit. The BFW to MTBE unit will be
cooled by the BFW cooler.
3.11.11 Instrument and Plant Air
Compressed air will be used for three purposes in the proposed plant - serving as instrument air,
serving as plant air which can be also used as a utility stream for maintenance or purging purposes of
the units and as decoking air.
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Instrument air will be used for pneumatic-operated instrumentation such as control valves, on/off
valves, for purging / cooling of essential instruments such as burner flame scanners and for pilot
burner flame front generation of the flare(s). Plant air will be used for maintenance activities, as purge
and as tool air for industrial users. Plant Air will be also used as a peak demand for catalyst
regeneration (one day per year). Decoking air is used for steam/air decoking of Cracking Heaters and
TLE heat exchangers. Overall Process description for Instrument and Plant Air system is provided
in Attachment 14. The Air facilities can be divided in two sections:
Instrument and Plant Air System; and
Decoking Air System.
3.11.11.1 Instrument and Plant Air Generation
The compressed air system consists of the compressed air and the air dryer unit. The Compressed Air
unit mainly consists of the air compressors and the cooler. Air from ambient will be drawn in via Air
Inlet Filters. The compressed air is cooled by air finned coolers. Because the continuous air demand is
relatively low compared to peak air demand and in order to obtain sufficient controllability of the
compressor system, (2+1) equally sized compressors of 50% capacity required are installed in
parallel.
The continuously operating compressors will be steam turbine driven machine, the stand-by
compressor is electrical motor driven to increase the reliability of the system. The design capacity of
the air dryer unit is10,200Nm³/h of supply dried air to instrument air header and that of compressors
will be 6,600Nm³/h. Normal operating pressure of instrument air and plant air is 7 bar(g).
3.11.11.2 Other intermittent regeneration processes
Plant air will be also needed for regenerations of catalyst beds of the following units. All the processes
are on intermittent basis and lasting no longer than 48 hours and are not likely to be performed at the
same time.
MAPD Hydrogenation Reactor regenerations requires about 600kg/hr at max flow;
SLC4HY 1st stage and 2nd stage Reactor Regeneration requires about 1400kg/hr and 600kg/hr
at max flow, respectively;
Oxygen Converter Regeneration requires about 2500kg/hr at max flow; and
PGHYD 1st Reactor & 2nd reactor regeneration requires about 650kg/hr and 5950kg/hr at max
flow respectively
3.11.11.3 Decoking Air Generation
The decoking air is produced by the air compressors. During normal operation, scheduled decoking
will be for one furnace at the time. Because the decoking air is required on intermittent basis, both the
compressors will be motor-driven to avoid so called “blow-off”. Both compressors will be provided
with variable speed. The compressed air is routed to the Cracking Heater. The pressure in the header
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is controlled by venting to the atmosphere, and the decoking air is controlled by flow to the cracking
heaters.
3.11.12 Overall Utilities Consumption
From the various sections above the overall utilities consumption for the proposed petrochemical
complex is as given in Table 3-4.
Table 3-4: Utilities Consumption – Normal and Maximum Flow Rate
Flow Rate
# Unit Description Unit
Normal Maximum
1 Secondary Cooling Water tph 73,500 88,200
2 Deminerized Water kg/h 125,000 185,000
3 Potable Water kg/h 5,000 30,000
4 Service Water kg/h 50,000 110,000
5 SHP Steam kg/h 657,600 686,700
6 HP Steam kg/h 407,700 413,400
7 MP Steam kg/h 183,500 213,800
8 LLP Steam kg/h 251,400 264,000
9 Boiler Feed Water kg/h 701,200 730,200
10 Natural Gas kg/h 54,800 79,400
11 Instrument Air kg/h 7,000 14,200
12 Plant Air kg/h 4,650 6,850
13 Decoke Air kg/h 28,400 41,000
14 Nitrogen kg/h 8,050 23,354
3.12 Wastewater Collection, Treatment and Disposal
An adequate wastewater collection system plays an essential role in effective wastewater reduction
and treatment. Wastewater collection system routes the effluent streams to their appropriate treatment
device and prevents mixing of contaminated and non-contaminated wastewater.
For the proposed petrochemical Plant the wastewater collection system has been designed taking into
consideration the following criteria:
All liquid waste streams coming from process, utility and storage areas that could be
contaminated with hydrocarbon are collected and treated before disposal;
Process effluent streams are segregated from surface water run-offs;
Non-contaminated (clean) surface water run-off shall be kept separate from polluted or
potentially polluted run-offs;
Whereever applicable process effluents shall be segregated according to their contamination
load;
High benzene / MTBE contaminated wastewater shall be kept separate from low or non-
benzene / MTBE contaminated effluent streams; and
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All chemical effluents shall be neutralized inside the process unit’s battery limit and not to be
sent to sewer system.
The wastewater treatment unit (WWTU) for the proposed plant will consist of physical, chemical, and
biological treatment units as described below:
Last Line Of Defense (LLOD);
Oily Water Sewer (OWS)
Accidently Oil Contaminated Sewer (AOC)
Clean Water (ND) Sewer System
Domestic Sewer System
Chemical Sewer System
Benzene / MTBE contaminated wastewater pre-treatment;
Wastewater primary treatment;
Wastewater secondary (biological) treatment;
Wastewater tertiary treatment;
Clean surface water run-off treatment; and
Chemical storage, preparation and dosing.
3.12.1 Last Line of Defense (LLOD)
Equipment oily drains, pump base plates, hydrocarbon sampling points and surface water run-off
typically rain, fire and wash water from the paved areas, where hydrocarbon pollution may occur, are
collected upon discharge by proper sewer system and routed by gravity to the below grade Last Line
Of Defense (LLOD) basins. The LLOD will consist of influent Bar Screen, Oil Contaminated Basin
(OCB), First Flush Basin (FFB), Peak Overflow Basin (POB) and relevant pumps. The POB together
with the FFB are designed to catch the total firewater run-off resulting from the largest possible fire
scenario.
The inlet compartments of OCB and FOB are equipped with Oil Skimmer and Sludge Scraper. The
collected sludge will be sent to Oily Sludge Collection Tank. Taking into account the above
considerations, the following effluent collection system is designed for various waste streams:
3.12.1.1 Oily Water Sewer (OWS)
Equipment oily drains pump base plates, hydrocarbon sampling points and surface water run-off from
the paved area where hydrocarbon leakage expected to have occurred shall be collected by oily water
sewer system and routed by gravity to OCB. The collected oily water is then transferred to the
wastewater collection tank for appropriate treatment. The inlet compartment of OCB is equipped with
floating type oil skimmer. The skimmed oil is sent to Skimmed Oil Vessel.
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The quality of surface water run-off from the paved area where benzene / MTBE spillage may occur
shall be checked before routing to sewer system. In case of high benzene / MTBE contamination,
surface water run-off shall be collected by vacuum truck and sent to benzene / MTBE contaminated
wastewater pretreatment unit.
3.12.1.2 Accidently Oil Contaminated Sewer (AOC)
The AOC sewer system collects equipment drains and surface water run-off which is polluted neither
by benzene / MTBE nor by high concentration of other hydrocarbons and routes the collected effluent
to FFB through AOC water screen. The purpose of screening is to remove large objects such as rags,
plastics, paper, metals, and the likes and protect downstream equipment from damage or clogging.
The inlet compartment of FFB is equipped with a portable floating type oil skimmer to collect
skimmed oil if any. The skimmed oil is sent to Skimmed Oil Vessel. FFB is designed to hold rain
water run-off from potentially hydrocarbon polluted area during first 30 minutes of rain. After this
period, FFB is filled and the surface water run-off overflows to POB. It is expected that the
contamination level of surface water run-off collected in POB is diluted to such an extent that can
bypass biological treatment and be treated only by Induced Air Floatation (IAF) unit. If the quality of
collected run-off in POB is far from outfall water specification (high BOD / high COD), the collected
run-off shall be treated along with first flush water collected in FFB in biological treatment unit. In
addition, the POB is used as surge basin in case of cooling water oil contamination.
During normal plant operation, it is expected that good housekeeping keeps surface water run-off
collected in FFB clean enough (low BOD / low COD) to be treated only by an IAF unit for removing
any residual oil or suspended solids. The treated surface run-off will be sent to the treated effluent
tank for final check and settled sludge will be pumped directly to Sludge dewatering unit. However, if
the quality of collected water in FFB is off-spec due to high BOD / high COD, the water will be sent
to wastewater collection tank for further treatment in the WWTU.
3.12.1.3 Clean Water Sewer System
This system is a clean water sewer, collecting surface water run-off from non-contaminated areas
where source of hydrocarbon leakage/spillage does not exist. The collected run-off will be routed by
gravity to the Non-Contaminated Surface Run-Off Clarifier where suspended solids will be separated
and settled. The clarified run-off is then sent to treated effluent tank and the collected sludge will be
transferred to sludge dewatering unit.
3.12.1.4 Domestic Sewer System
This collects domestic wastewater from toilets, kitchen facilities, sinks, showers and the like from
buildings and shelters. Domestic effluent from kitchen facilities shall be equipped with grease traps.
Domestic effluents are routed by a sloped gravity underground pipe system into the centralized
Domestic Lift Station where the solid and liquid wastes will be transferred by pump to Majis
Industrial Services Company (MISC) for further treatment.
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3.12.1.5 Chemical Sewer System
Demineralized water spent regenerants, condensate polishing spent regenerants and spent chemical
shall be kept separate from surface water run-offs. To meet outfall water specification, the spent
chemicals shall be neutralized first. The neutralized spent chemical will be sent to the cooling water
outfall without further treatment.
3.12.2 Benzene / MTBE Contaminated Wastewater Pre-treatment
The benzene / MTBE contaminated wastewater pre-treatment will treat wastewater contaminated with
benzene or MTBE and include the following wastewater streams;
Pygas Hydro-treating unit ejectors condensate effluent;
SCU dilution steam drum blow down;
SCU stripped process water;
Quench water in case of SCU shutdown;
Butene-1/MTBE unit spent wash water;
First flush surface water run-off collected in LLOD, in case contaminated with
benzene/MTBE; and
Surface water run-off from paved area where source of benzene / MTBE leakage/spillage is
envisaged.
The benzene/MTBE contaminated wastewater pre-treatment unit consists of the following sections:
Benzene / MTBE Contaminated Wastewater Collection Tank (WWCT); and
Wastewater Steam Stripper
The WWCT collects all the wastewater streams before treatment in the wastewater steam stripper.
Since the wastewater contains benzene and/or MTBE, the tank is provided with a nitrogen blanket and
connected to the vent gas incinerator. The tank is equipped with a tangential inlet and oil skimming
facilities to remove the separated free oil. From the tank, wastewater is pumped at a controlled flow to
the wastewater steam stripper. If necessary, the pH is adjusted by means of caustic or sulfuric acid
dosing upstream the steam stripper.
The collected wastewater is preheated in Steam Stripper Feed/Effluent Heat Exchanger and fed to the
top of the steam stripper. At the bottom of this column, LP steam is supplied which strips the
hydrocarbons out of the influent. Vapors at the top of the column are condensed and collected in the
overhead reflux drum. In this vessel, the condensed liquid will separate to a water layer and a thin oil
layer, which flows over the installed weir into the hydrocarbons compartment. The water in the vessel
is pumped as reflux to the column. The recovered hydrocarbons are routed to the Skimmed Oil
Vessel. Vapors are vented to the wet flare system.
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Nitrogen will be used in order to maintain sufficient pressure in the overhead system of the column to
allow venting to the flare. Some nitrogen is required in case insufficient hydrocarbons (non-
condensable) are present in the wastewater feed stream.
The steam stripped effluent collected from the bottom of the column is pumped to the collection tank
after heat recovery in Feed/Effluent Heat Exchanger and cooling down in Stripped WW Trim Cooler
to below 40°C using cooling water. In case of high benzene and/or MTBE contamination of the steam
stripped effluent, it is manually routed back to the WWCT. If the stripped effluent is on-spec
according to benzene/MTBE contamination level but off-spec due to high TOC, the stripped
wastewater shall be sent to WWCT and to be treated by Dissolved Gas Floatation (DGF) Unit.
3.12.3 Wastewater Primary Treatment
The wastewater primary treatment will treat oil contaminated waste by means of DGF unit. The
wastewater primary treatment consists of the following operation units:
Wastewater WWCT;
DGF; and
Skimmed Oil Vessel
The WWCT is used to store the process wastewater awaiting the DGF treatment. The tank is equipped
with tangential inlet and skimming facilities to remove any separated free oil. From the tank, the
wastewater is pumped to DGF. Wastewater pH is adjusted by means of caustic or sulphuric acid
dosing upstream DGF unit. The DGF package should be sized such that to provide sufficient
operating flexibility to allow effluent quality to be maintained in acceptable range by considering the
expected variations in the influent characteristics.
Wastewater passes sequentially through coagulation, flocculation and floatation compartments of the
DGF unit. Cationic polymer solution is dosed into the influent upstream of the DGF unit to enhance
removal of free/emulsified oil and suspended solids. The system forces nitrogen gas into effluent by
means of hydraulic eductors. The nitrogen bubbles will adhere to the oil particles and form flocs and
help these particles to float to the water surface of each flotation compartment.
The floating scum layer is removed by means of a surface skimmer mechanism and sent to the
Skimmed Oil Vessel. The treated wastewater will overflow via the effluent weir into the DGF clear
well compartment and is pumped to the equalization tank. The Skimmed Oil Vessel collects the
following streams:
Skimmed oil from LLOD basins;
Skimmed oil from the Wastewater Collection Tank (WWCT);
Skimmed oil from Oily Sludge Storage Tank;
Skimmed oil from the Benzene/MTBE Contaminated WWCT;
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Skimmed oil from the steam stripper overhead reflux drum; and
DGF skimming
The collected skimmed oil will be sent to the Liquid Incinerator.
3.12.4 Wastewater Secondary Treatment
The wastewater secondary (biological) treatment consists of:
Equalization Tank;
Bio-treater; and
Sludge Treatment and Dewatering
The wastewater equalization tank receives the wastewater streams to be treated in the biological
treatment unit. The following streams are routed to the equalization tank:
DGF effluent from the wastewater primary treatment
TLE hydro-jetting / decoking quench water effluent
Stream drum and TLE intermittent blow down
Stripped effluent from Wastewater Steam Stripper
Equalization tank has a buffering and homogenization function for the feed stream to the Bio-treater,
thus minimizing fluctuations in flow rate and composition. In the Bio-treater, BOD and COD are
reduced by activated sludge using dissolved oxygen. Bio-treater will receive feed streams from
Contact Tank where the equalized wastewater will be mixed with the recycled activated sludge and
nutrients (urea and H3PO4).
After pH adjustment, the mixed stream is routed to the Aeration Tank where required amount of air is
supplied. Aerated stream will be routed to clarifier on gravity flow via degassing tank. In the clarifier,
the settled activated sludge is separated from the clean water. Part of the activated sludge is recycled
to the contact tank and the excess activated sludge is sent to the sludge digester followed by sludge
thickener. The clarified water is routed to the tertiary treatment to meet the outfall water specification.
Thickened excess bio-sludge from sludge thickener is sent to sludge dewatering unit where polymer
solution is added for conditioning of the sludge. Dewatered bio-sludge is collected in a mobile bio-
sludge cake container, which is trucked out for disposal by incineration. The decanted water from
Sludge Dewatering unit is recycled to the WWCT.
Oily sludge will be kept separate from bio-sludge. The oily sludge from LLOD basins, WWCT and
wastewater DGF will be sent to oily sludge storage tank where it will be pumped to sludge dewatering
unit. The dewatered oily sludge is collected in a mobile oily sludge container for incineration. The
reject stream will be sent to WWCT for further processing.
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3.12.5 Wastewater Tertiary Treatment
The wastewater tertiary treatment consists of:
Disinfection Unit;
Continuous Sand Filter;
Activated Carbon Filter; and
Treated Effluent Tank.
In order to meet discharge water specification, chlorine gas will be used for chlorination of clarified
water in Chlorination compartment of Chlorination/De-chlorination basin followed by SO2 injection
for de-chlorination in de-chlorination compartment. For removal of remaining suspended solids, the
de-chlorinated water is routed to the continuous sand filter. The unit consists of two continuously
regenerated sand filters, each designed for 70% of total capacity. The continuous backwash stream
from the sand filters is recycled to WWCT.
The clean effluent from sand filters will flow on gravity into the filtrate basin, where the treated
effluent quality is continuously monitored by means of a flow, turbidity, temperature, TDS and pH
measurement. It is expected that sand filter clear water can meet the outfall water quality. However, in
case of hydrocarbon contamination, the effluent can be sent to activated carbon filters for final
polishing. The treated wastewater will be sent to the treated effluent tank. Additional information
related to WWTP is provided in Attachment 15.
3.12.6 Spent Caustic Oxidation Unit
Spent caustic wastes contain high COD, TDS, sulfides, mercaptides, free caustic, polymeric organic
compounds and other aromatics. The high COD due to high sulfide content and high pH are
detrimental to the downstream oily water and biological treatment (high sulfide concentration will
poison the micro-organisms) systems. Therefore spent caustic streams shall be separately collected,
gasoline washed, treated in a Wet Air Oxidation (WAO) process and neutralized before sending for
further treatment to wastewater treatment.
In WAO process, air is brought into close contact with an aqueous solution and dispersion of organic
material at an elevated temperature and pressure is performed. During oxidation, the organic
compounds convert to CO2 plus water or organic acids and the sulfides to thiosulfates or sulfates.
Oxidation of sulfides to thiosulfates and sulfates happens according to the following exothermic
reactions:
Na2S + O2 + ½ H2O ½ Na2S2O3 + NaOH + Heat
½ Na2S2O3 + O2 + NaOH Na2SO4 + ½ H2O + Heat
The oxidized Spent caustic is neutralized with concentrated Sulfuric Acid. The neutralization
reactions are given below:
NaOH + ½ H2SO4 ½ Na2SO4 + H2O
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Na2CO3 + H2SO4 CO2 (g) + H2O (l) + Na2SO4 (aq)
Spent caustic waste stream from the Caustic/Water Wash Tower combined with spent caustic from the
caustic/water wash tower of the RDG is routed to spent caustic coalescer followed by spent gasoline
coalescer as a pretreatment step. Wash gasoline from quench water settler is added to spent caustic in
order to remove entrained oils and some dissolved organic compounds. The coalescer effluent is sent
to spent gasoline coalescer where the spent caustic and spent gasoline is separated. Then spent caustic
is sent to spent caustic storage tank from where it is pumped to the oxidation unit.
The spent caustic oxidation unit will be designed to treat the spent caustic stream in a WAO process.
The oxidized spent caustic is neutralized to a pH in the range of 7 to 9 with concentrated sulfuric acid.
The net neutralized spent caustic is sent to the SCO effluent tank where after homogenization, it will
be sent to WWTU. Additional information on Spent Caustic system is provided in Attachment 16.
3.13 Project Construction Method
The construction period of the proposed plant is expected to be about 20 months, including the
mobilization period. The activities during the construction phase will involve site preparation, site
leveling, and soil excavation, construction of foundations, building steel structures and assembling
and installing plant equipment.
Minimum quantities of soil are expected to be excavated during the plant construction as the site is
within the SIPA and is already leveled. Excavation of soil will be required for laying foundations for
various structures and plant equipment, pipelines and buildings. The excavated soil will be stored near
the excavation areas or in a dedicated storage area and will be used for backfilling, wherever possible.
The top soil layer that will contain roots, etc., will be transported outside the site to the Sohar waste
collection site for dumping, upon consent from the SEU. It must be noted that a soil investigation has
been carried out as part of the SEU requirement and PC project. During the piling for the foundation
dewatering will have to be carried out which needs to be in line with the MECA wastewater discharge
requirements.
Significant concrete work will be involved for the construction of plant and equipment foundations
and buildings. Further dewatering operations may be utilized to provide a dry work area. Asphalting
work will be required for the facility internal roads. Different concrete mixes may be used for
different requirements. Aggregate sources will be investigated by the contractor in order to ensure
adequate quality of aggregates. The aggregates and water required will be obtained from approved
sources so as to negate any significant adverse impact/stress on the environment. The EPC contractor
will consider the possibility of obtaining ready mix concrete and bitumen as opposed to engaging
concrete mixers and bitumen mixers onsite so as to minimise air emissions and other wastes.
The equipment to be used for the construction works will include excavators, shovels, dumpers,
tippers, vibrators, compactors, mobile cranes, water tankers, trailers and Diesel Generators (DGs).
Most of the equipment will be operated during the day time hours only. The types of materials
required for the construction work are described in the following section.
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Mechanical and electrical works will be typical of any industrial plant construction. Use of any
radioactive materials will be limited to NDT of plant equipment, pipelines and storage tanks using
sealed radioactive sources. Subcontractors with approvals from MECA and other concerned
authorities will be used for the NDT. Required permits will be obtained from MECA and other
concerned authorities for storage and handling of radioactive materials, as required.
3.13.1 Utilities during Construction Phase
3.13.1.1 Power
Power for the construction phase of the facility is expected to be sourced from existing grid or
alternatively will be met through portable DG units. Since the project is in its initial stages details on
the specifics such as number of DG sets required during project construction, their approximate
capacities etc. are not know at present. However it is expected that a DG sets of 450 kVA will be
needed for the power requirements during the construction phase.
3.13.1.2 Water
The potable water requirements during the construction phase are expected to be met by supplies from
approved local contractors through tanker supplies. Assuming a per capita potable water consumption
of approximately 240L/day the total freshwater requirements for the construction site and
accommodation facilities are estimated to be approximately 240m3/d2. In addition the water
requirement during the construction phase is expected to be 100m3/day. Some of the requirements at
construction site such as dust suppression will be met through utilizing treated wastewater. The total
water requirement during the construction phase is estimated to be approximately 340m3/day
3.13.1.3 Fuel
Diesel oil will be used as fuel for the DG units, various construction equipment, heavy vehicles and
some of the passenger vehicles used during construction. Diesel oil will be sourced from local
suppliers and stored onsite in dedicated storage tank with all regulatory requirements and approvals
from MECA and ROP.
It is expected that a maximum of about 20,000 L/month (8,000 L/month for the DG sets and 12,000
L/month for equipment and vehicles) of diesel fuel will be required during the construction period and
the fuel storage tank will be sized accordingly. Diesel would be stored in above ground tanks resting
on concrete foundations inside an adequate containment area. Diesel would be dispensed via a fuel
pump. The whole filling station would be fenced with restricted access. Fire- fighting equipment and
warning signs will be available at all times. Gasoline for light vehicles will be sourced from local
retail suppliers. Oils for DG units and equipment will be obtained from approved suppliers. They will
be stored in appropriate storage spaces provided at the site. Permits for storage and use will be
obtained from MECA, as appropriate.
2
Assuming an average workforce of 1000 people for construction phase.
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3.13.2 Sourcing of Construction Materials
Table 3-5: Sourcing of Construction Material provides the list of other construction materials and
chemicals required for the project with supply source and mode of transport.
Table 3-5: Sourcing of Construction Material
Typical Construction Material Supply Source Storage Facility
Fill Materials and Aggregates Local Quarries by tippers On-site in lay down area
Cement Local Suppliers No storage envisaged
Metal and Wood Local and external Suppliers On-site in a designated area
Paints and other surface coating Local and external Suppliers In temporary stock containers
materials by trucks on site
Compressed Gases Local Suppliers On-site in a designated area
Diesel Oil Local Suppliers by tankers Storage tank above ground
Lube Oil and Greases Local Suppliers In drums on-site
Chemicals Local and external Suppliers In drums on-site
Will be provided by the
Enclosed facility at site for
Equipment spares, mechanical and construction contractor
sensitive equipment, others in lay
electrical tolls and spares sourced from local and
down areas
external suppliers
3.13.3 Accommodation Facilities for Construction Workers
The average number of people expected to be onsite during project construction is about 1,000 with
the peak requirement of about 2,500 people. Most of the workers will be sub-contractors staff who
will be engaged by the EPC contractor for executing the various civil, mechanical and electrical
works.
Porta-cabins will be erected on-site for accommodating the project office and to provide the on-site
catering and sanitation facilities for the project staff. The EPC contractor staff will most likely be
lodged in rented accommodation facilities near the project site. With regards to the sub-contractor
staff, it is likely that the local Omani staff will have their own local accommodation facilities. For the
accommodation of the non-local Omani staff and the non- Omani staff, the sub-contractors will either
utilize the existing labour camps or construct new labour camps.
The EPC contractor will select the location for the labour camp and organize to establish it. Since
selection of the EPC contractor for the project is to be done after completion of the FEED, the
location and number of construction camps is not known at present. However, following will have to
be considered while deciding to set-up labour camps:
Utilize an existing labour camp in the area, as feasible;
For any new labour camps, select the locations which will fully comply with local town
planning requirements;
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Avoid areas of high environmental sensitivity;
Provide all the basic facilities such as power supply, water supply, sanitation, security and
general hygiene; and
Implement the environment, health and safety management plan set out in this report.
The accommodation facility for the crew shall have the following facilities at a minimum-
All camp facilities shall be constructed to provide protection against pests and adverse weather
conditions;
Water for drinking, cooking, washing and toilets shall be provided from approved sources. A
minimum water supply of 250 l/person shall be provided;
If water is trucked in, the tanker truck shall be licensed in accordance with ROP requirements;
Water supplied to camps shall comply with the chemical and bacteriological limits specified in
Omani Standard 8/2012. Bacteriological limits in water storage tanks shall be checked
monthly and the tanks shall be cleaned annually;
Air conditioning should be by means of windows or split units and should include cooling and
heating system;
Sufficient natural and artificial light shall be provided in all rooms;
Toilet and washing facilities shall be provided in, or adjacent to, living quarters, work place
and recreation areas;
Adequate drainage from all sanitary facilities must be maintained to maintain hygiene
standards;
Sewage effluent and domestic waste shall be managed/transported and disposed in accordance
with MECA specification; and
General cleanliness and good housekeeping of camps and surroundings shall be maintained as
the primary method of pest control.
3.13.4 Traffic Management Plan during Construction
During the construction phase, the traffic management plan (TMP) is formulated to define the
transport management for the employees and equipment to and from the project site. This plan and its
procedure would define the standards which specify applicable traffic rules in the project area for the
developer and its contractors for movement of machinery, material and workers during the
construction activities. TMP aims to avoid any stress on the local community infrastructure caused
from sharing local resources with the project workers in the labour camps. Expectedly, the existing
local roads will be used as access for project site, labour camp and ware house (as applicable). It is
likely that there could be disturbance to movement of local community and livestock. Therefore, to
manage the likely disruption of local traffic the following aspects need to be considered prior to
formulating a TMP:
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• Identification of main route/s for community movement or road users;
• Identify locations for intervention to mitigate interface;
• Establish inter-agency linkages to facilitate implementation of this plan; and
• Suggest viable options for addressing concerns related to traffic associated with construction
activities.
Orpic is responsible for the implementation of this plan. Orpic will guide the construction contractor
to ensure that this procedure is brought to the attention of all employees at site and the content of this
plan is implemented as required and appropriate. The application of this plan will be verified at
appropriate intervals to avoid any health and safety concerns; and the contractor will ensure that the
workers and subcontractors over whom they have direct control comply with this procedure and that
subcontractors are managed accordingly. The preparation of the detailed TMP will be carried out
considering the site specific requirements in consultation with Royal Oman Police. The local
community may be involved to formulate the TMP with due considerations of the local traffic
concerns and safety of livestock.
3.14 Project Management
The organization owning and operating the plant will be Orpic. All the investment required for the
project will be made by Orpic. As mentioned earlier, EIL is the PMC for the project and the FEED
contractor for the project is CB&I.
Upon completion of FEED, the Engineering, Procurement and Construction (EPC) contractor for the
project will be selected through a competitive bidding process. The selected EPC contractor will
undertake the detailed engineering, construction and commissioning of the plant facilities. The EPC
contractor will typically engage subcontractors for various construction activities, some of whom are
expected to be local (Omani) companies.
Orpic acknowledges its obligation of maximizing where ever possible the use of Omani Goods and
Services in full support of the aspiration of the Government of Sultanate of Oman to maximize the
involvement of Omani nationals and Omani companies in the execution of its contracts. As part of its
active support, Orpic encourages its contractors and vendors, wherever possible, to utilize Omani
goods and Omani services in performance of the work on behalf of it.
3.15 Project Schedule
The tentative schedule is as presented in Table 3-6. It is to be noted that the schedule will be updated
all through the Project phases to accommodate project strategy, resources availability, constraints and
opportunities.
Table 3-6: Tentative Project Schedule
Project Component Schedule
Project FEED Completion Q2 2015
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EPC Tendering and Award Q2 2015
Commencement of Detailed Engineering and
Q2 2016
Project Construction
Plant Commissioning Q2 2018
Commercial Operation Q3 2018
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4 ENVIRONMENTAL BASELINE
4.1 Overview
The following sections present a description of the environmental settings of the proposed PC site and
its surroundings. A comprehensive environmental baseline study through primary surveys, monitoring
and secondary data collection was conducted during the EIA study. The proposed project is located
within SIPA and during the master-planning of the SIPA development a comprehensive
environmental baseline study has been conducted. Further HMR has carried out environmental
baseline studies for various industries within the SIPA. Consequently a large amount of data is
available with regard to the physical, biological and social environment in the area. This information
was reviewed to extract relevant secondary information on the proposed PC Plant site. In addition
primary information on the project site has been collected through site surveys and baseline
monitoring conducted during November/December 2014. These surveys were planned based on the
available information and were conducted with the intention of data validation and augmentation, as
required.
4.2 Project Location
The project site for the Petrochemical Plant will be spread on two plots and located adjacent to SRIP
in SIPA which is a dedicated industrial area. The Petrochemical Plant will be integrated with the
refinery, aromatics complex and polypropylene Plant. SIPA is spread on an area of 132km2 and
located on Al Batinah coast about 20km north of Sohar and 220km from Muscat.
A part of the PP is located on the southern boundary of the SIPA while the other is located on the
south eastern end. Plot 1 of the PP will have interphase with the aromatics complex on eastern side
and polypropylene facility on the northern side. Plot 2 is located on the southeast side of the SRIP
plant. The site location is shown in Figure 4-1. The UTM coordinates of plant boundary are
summarized in Table 4-1 and is shown in Figure 4-2. Additional informative maps are provided as
Map 1 through Map 6.
Table 4-1: Coordinates of the Project Site
Ref Easting Northing Ref Easting Northing
Plot 1 Plot 2
1 459659.0 2708173.00 1 461709.0 2704680.0
2 459390 2708601.0 2 462547.0 2705184.0
3 459387.0 2708644.0 3 462108.0 2705878.0
4 459979.0 2709013.0 4 461963.0 2705790.0
5 460286.00 2708500.00 5 461734.0 2705625.0
6 460147.0 2708412.0 6 461646.0 2705761.0
7 460040.0 2708580.0 7 461399.0 2705608.0
8 459850.0 2708465.0 8 461318.0 2705726.
9 459926.0 2708337.0 9 461113.0 2705594.0
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Figure 4-1: Project Site Location
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Plot-18
Plot-10
Figure 4-2: Boundary Co-ordinates – Petrochemical Plant
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4.3 Topography and Landscape
Topographically, the Batinah Region is a gentle slope of low-relief, interspersed by scattered hills
standing out through the alluvial cover in the piedmont zone. The most striking feature of the Batinah
is the narrow continuous strip of cultivation and settlements along the coastline and the Muscat-Sohar
highway.
The plant site elevation is about 0-1 m above mean sea level (amsl) for Plot 1 and 4-9 m above mean
sea level (amsl) for plot 2. The site is not fully leveled and is sparsely vegetated. As mentioned in the
previous section, SIPA, prior to development, was a flat farmland and was similar to other
undeveloped areas along the Al Batinah coast.
SIPA area is situated within a coastal area featuring coastal dunes and belts of scrub starting
approximately 300m inland. Aeolian sand dunes extend 0.5km from the shoreline and reach up to 3m
in height. Further from the shoreline, featureless ‘Sabkah’ with sparse vegetation is seen up to 1.5km.
Dense natural vegetation dominated by Acacia is seen along the wadi plains and in the agricultural
areas associated with the settlements at the outer limits of SIPA.
4.4 Climate and Meteorology
The climate of Oman is typically tropical hyper-arid. Winter period in Oman extends from late
November to April. Occasional cold fronts can cause widespread cloud and, consequently heavy
rainfalls occur on the major mountains. Fog is rare but is known to occur.
Batinah is characterized by a high variability and diversity in watershed characteristics. Two distinct
seasons are prevailing namely, winter (November to April), and summer (May to October), affected
by various meteorological mechanisms. During the period from January to March and November to
December, the controlling features of rainfall occurrence over the area are mainly due to the middle
latitude low pressure systems moving from west to east with thunderstorm activities. During the
months of May and October rainfall activities over the area is mainly due to cyclonic storms and
depressions. During September, the area gets rain partly due to monsoon and partly due to cyclones
and depressions. During the months of June, July and August, the monsoon season, the local climate
is more or less continuously raining. The meteorological/climate data for the project area is sourced
from the meteorological station located at Majis. The station is operated and maintained by
Department of Meteorology. A summary of the meteorological data for Sohar area CY 2011 through
2013 is presented in Table 4-2.
Table 4-2: Meteorological Conditions at Sohar 2011-2013
Temperature °C Relative Wind
Wind Avg. Rainfall
Month Humidity Direction
Speed m/s mm
Avg Max Min % (degree)
Jan-11 19.3 25.8 14.1 65 3.1 200 0
Feb-11 20.6 29.6 14.2 54 3.7 190 0
Mar-11 24.2 32.6 17.1 43 3.4 190 0
Apr-11 28.3 33.4 22.8 46 3.3 172 0.1
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Temperature °C Relative Wind
Wind Avg. Rainfall
Month Humidity Direction
Speed m/s mm
Avg Max Min % (degree)
May-11 33.8 42.1 25.1 34 3.7 182 0
Jun-11 36.6 44.4 31.1 36 3.8 179 0
Jul-11 35.8 42.5 31.2 42 3.8 160 0
Aug-11 35.9 42.0 30.2 42 4.2 162 0
Sep-11 33.7 38.2 29.4 43 3.6 180 0.01
Oct-11 28.6 34.0 22.5 54 3.2 181 0
Nov-11 23.7 28.6 19.2 64 3.1 196 0
Dec-11 18.6 24.5 13.5 60 3.1 186 0
Jan-12 18.5 27.6 11.6 59 3.3 197 0
Feb-12 18.9 29.0 12.0 55 3.7 179 0
Mar-12 23.0 33.1 15.5 49 3.7 175 0
Apr-12 28.1 33.5 22.4 41 3.3 188 0.01
May-12 34.2 40.9 27.9 37 3.8 177 0
Jun-12 35.6 42.6 32.1 36 3.9 174 0
Jul-12 37.4 45.6 33.2 41 4.1 161 0
Aug-12 35.4 40.9 31.0 48 3.9 158 0.04
Sep-12 34.0 38.4 29.2 44 3.7 168 0
Oct-12 28.8 33.6 24.1 51 2.9` 185 0
Nov-12 24.7 29.1 18.5 62 3.1 194 0.01
Dec-12 20.1 28.5 11.9 61 3.0 199 0.01
Jan-13 19.0 24.6 12.4 57 3.2 198 0
Feb-13 20.2 25.4 15.5 56 3.4 190 0
Mar-13 24.0 29.2 18.9 52 3.2 192 0.05
Apr-13 28.2 36.5 20.8 46 3.7 191 0.05
May-13 31.7 37.1 26.1 39 3.6 176 0.01
Jun-13 34.3 42.1 29.4 39 3.5 165 0
Jul-13 36.1 43.5 32.6 43 3.9 158 0
Aug-13 34.9 40.2 31.8 45 4.1 157 0.02
Sep-13 32.7 38.0 28.4 46 3.8 174 0
Oct-13 29.1 36.6 24.2 54 3.4 190 0
Nov-13 23.7 30.1 19.0 65 3.1 188 0.12
Dec-13 19.6 25.5 11.2 56 3.5 193 0
From the above table it is seen that the mean ambient temperature in the region around Majis follows
a similar trend during CY 2011 through 2013, varying between 18 and 36 ºC. The temperature peaks
during the summer months of June and July; while the ambient temperature dips during the months of
December and January. The maximum and minimum recorded ambient temperature at Sohar during
2011 through 2013 are 45.6ºC (July 2012) and 11.2 ºC (December 2013).
4.5 Ambient Air Quality
The ambient air quality in SIPA has been affected due to the construction and operation of various
industries in SIPA, the movement of vehicles and operation of various construction equipment. In
addition, the quality of ambient air will also be affected from the vehicle traffic on the Muscat-Sohar
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highway. Several environmental studies have been conducted by HMR from 2000 through to 2014 in
the industrial area, which included monitoring of the ambient air quality. The monitoring was largely
carried out by deploying passive diffusion tubes for a period of 3 to 4 weeks to measure the ground
level concentrations (GLCs) of various primary pollutants. However in recent years Continuous
Ambient Air Quality Monitoring Station (CAAQMS) has been preferred by the regulators for ambient
air quality monitoring. As part of the baseline survey for a project in SIPA in 2011, a CAAQMS was
installed at the project site at four locations. From these studies it has been observed that the GLCs of
NOx ranges from 3.7 to 26.8μg/m3, the GLCs of SO2 ranges from 4.4 to 12.3μg/m3, and the GLCs of
O3 range from 66 to 83μg/m3.
As part of the baseline study for PC Plant a CAAQMS was installed at three locations within the
project site. The locations were selected based on the wind direction and the ease of accessibility for
the trucks carrying the CAAQMS and the DG for the power supply. The DG was positioned at about
100 m downwind from the CAAQMS to prevent capturing of the DG emissions by the CAAQMS.
The monitoring methods for each parameter in the CAAQMS are presented in Table 4-3. The UTM
Coordinates of the locations and duration of monitoring at the locations are presented in Table 4-4.
Prior to commencement of monitoring, the analyzers were calibrated using zero air and subsequently
subjected to span calibration using the calibration gases from the cylinders housed within the
CAAQMS container.
Table 4-3: CAAQMS Monitoring Methods for Parameters
S. No Parameter Monitoring Method
1 CO Non-Dispersive Infrared (IR) Photometer
2 Nitric Oxide (NO) Gas-Phase Chemiluminescence Detection
3 NO2 Gas-Phase Chemiluminescence Detection
4 Oxides of Nitrogen (NOX) Gas-Phase Chemiluminescence Detection
5 O3 Non-Dispersive Ultraviolet (UV) Photometer
6 H2 S UV Fluorescence Spectrometer
7 SO2 UV Fluorescence Spectrometer
Methane (CH4) and Total Non-
8 Flame Ionization Detector (FID)
Methane HCs (TNMHC)
9 PM10 -Ray Attenuation
Table 4-4: CAAQMS Monitoring Location Co-ordinates
Duration (days) UTM Co-ordinates
Location
Northing Easting
CAAQMS 1 15 2709294 459799
CAAQMS 2 15 2705639 460019
CAAQMS 3 15 2704621 462224
At the end of the monitoring campaign, the ambient air quality monitoring data was downloaded and
the 1-hr, 3-hr, 8-hr and 24-hr averages were calculated, as applicable. The maximum of the calculated
averages were compared to the OAAQS and USEPA NAAQS limits. These are presented in Table
4-5.
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Table 4-5: AAQMS Results (Units in g/m3 unless otherwise specified)
Max Observed USEPA NAAQS OAAQS WHO standard
Pollutant
1-hr 3-hr 8-hr 24-hr 1-hr 3-hr 8-hr 24-hr 3-hr 8-hr 24-hr 8-hr 24-hr
CAAQMS-1
CO 332 - 303 - 40,000 - 10,000 - - 6,000 - - -
NO - - - - - - - - - -
- - -
NO2 35 - 16 188 - - - 112 - -
NOX - - - - - - - - - -
- 0.12 - 0.075 -
O3 50 - - 120 - 100 -
ppm ppm
0.5 0.14 -
SO2 - - 7 - - - 125 - 20
ppm ppm
H2 S - - - - - - - - - 40 - -
CH4 - - - - - - - - - -
TNMHC - - - - - - - - 40 - -
PM10 - - - 126 - - - 150 - - 125 - 50
CAAQMS-2
CO 103 - 712 - 40,000 - 10,000 - - 6,000 - - -
NO - - - - - - - - - -
NO2 22.88 - - 17.45 188 - - - - - 112 - -
NOX - - - - - - - - - -
- 0.12 - 0.075 -
O3 156 - - 120 - 100 -
ppm ppm
0.5 0.14 -
SO2 - - 7.43 - - - 125 - 20
ppm ppm
H2 S - - - - - - - - - 40 - -
CH4 - - - - - - - - - -
TNMHC - - - - - - - - 40 - -
PM10 - - - 127 - - - 150 - 125 - 50
CAAQMS-3
CO 110 - 885 - 40,000 - 10,000 - - 6,000 - - -
NO - - - - - - - - - -
NO2 20 - - 14.81 188 - - - - - 112 - -
NOX - - - - - - - - - -
- 0.12 - 0.075 -
O3 145 - - 120 - 100 -
ppm ppm
0.5 0.14 -
SO2 - - 6.07 - - - 125 - 20
ppm ppm
H2 S - - - - - - - - - 40 - -
CH4 - - - - - - - - - -
TNMHC - - - - - - - - 40 - -
PM10 - - - 150 - - - 150 - 125 - 50
4.5.1 Ambient Dust
In addition to the above parameters, the ambient dust levels were also measured as part of the baseline
studies. The dust levels were measured in terms of PM10, using a direct reading dust meter, the
Personnel Data RAM (pDR) 1000-AN. The instrument is a handheld dust monitor and draws air
passively through sensor, which works on the relationship between particulate concentration and
attenuation of light transmittance. It covers a measurement range of 0.001mg/m3 to 400mg/m3.
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The ambient dust levels were measured at various locations within the project site on 4th December
2014, for 15 -20 min at each location. The UTM Coordinates of these locations and the dust levels
measured are presented in Table 4-6 and indicated on Google Earth imagery in Figure 4-3. The
measured dust levels were compared with corresponding limits for PM10 in OAAQS (125μg/m3) and
USEPA NAAQS (150μg/m3).
Figure 4-3: Noise Monitoring Location
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Table 4-6: Ambient Dust Levels – Location Coordinates and Measured Values
UTM Co-ordinates
Location PM10(μg/m3)
Northing Easting
Plot 1
FL-1 459387 2708600 13
FL-2 459651 2708174 15
FL-3 460060 2708369 13
FL-4 459683 2708762 18
FL-5 460282 2708507 16
FL-6 459972 2709011 45
Plot 2
FL-1 461107 2705614 121
FL-2 462546 2705205 88
FL-3 461707 2704688 15
FL-4 462213 2705352 51
On comparison of the measured dust levels with the OAAQS and USEPA NAAQS, it is observed that
the dust levels measured at all locations within Plot 1 and Plot 2 are well below the OAAQS and
USEPA NAAQS limits. In addition, ambient dust levels were also measured by the CAAQMS at the
three monitoring locations. The maximum 24-hr averages for the three locations are compared with
the limits prescribed by OAAQS and USEPA NAAQS in Table 4-7.
Table 4-7: Maximum 24-hr avg. Dust Levels at the Site
Location PM10 (μg/m3) OAAQS USEPA NAAQS
CAAQMS-1 126
CAAQMS-2 127 125(μg/m3) 150(μg/m3)
CAAQMS-3 150
From the above table it is seen that the dust levels measured by the CAAQMS for all 3 locations are
within the USEPA NAAQS limits while there are slight exceedances when compared with the
OAAQS.
4.5.2 Ambient Noise
Ambient noise levels were also measured at the same locations where measurements of dust levels
were conducted. Noise level measurements were conducted using Integrating and Logging Sound
Level Meter (ISLM), Quest SoundPro which is capable of measuring equivalent continuous noise
levels (Leq). Noise levels were measured for 15mins at each location- during day, evening and night
times as defined in Article (6) of MD 79/1994.
Workdays (daytime) - A : after 7am and up to 6pm
Workdays (evenings) - B : after 6pm and up to 11pm
Holidays and nights - C : after 11pm and up to 7am
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Weather conditions were normal and there was no excess wind during the measurements. Wind
speeds were measured using a hand-held anemometer simultaneously with noise measurements to
ensure that the wind speeds were less, as high wind speeds would lead to errors in the measured noise
levels. The ambient noise levels during daytime, evening and night are presented in Table 4-8.
Table 4-8: Ambient Noise Level
UTM co-ordinates Noise
# Omani Standard3
Easting Northing Leq Lmin Lmax
PLOT 1
Daytime (7:00am to 6:00pm)
FL1 459387 2708600 59.9 52.2 81.9
FL2 459651 2708174 56.7 46.8 69.1
FL3 460060 2708369 67.2 65.5 70.1
70
FL4 459683 2708762 55.8 50.2 75.8
FL5 460282 2708507 65.3 63.0 75.5
FL6 459972 2709011 55.9 49.9 73.7
Evening Time (6:00pm to 11:00pm)
FL1 459387 2708600 55.4 50.6 61.24
FL2 459651 2708174 55.2 52.2 63.35
FL3 460060 2708369 54.67 50.8 62.3
70
FL4 459683 2708762 53.91 50.31 60.47
FL5 460282 2708507 54.11 51.20 61.05
FL6 459972 2709011 53.21 50.45 61.2
Night Time (11:00 pm to 7:00 am)
FL1 459387 2708600 52.34 49.23 60.45
FL2 459651 2708174 51.12 49.63 62.05
FL3 460060 2708369 52.76 51.29 60.63
70
FL4 459683 2708762 51.26 50.33 59.08
FL5 460282 2708507 50.19 48.16 61.45
FL6 459972 2709011 50.14 49.63 61.05
PLOT 2
Daytime (7:00am to 6:00pm), Plot 2
FL-1 461107 2705614 57.2 46.7 70.2
FL-2 462546 2705205 62.6 46.6 78.3
70
FL-3 461707 2704688 54.9 47.1 76.1
FL-4 462213 2705352 58.1 47.3 71.2
Evening Time (6:00pm to 11:00pm), Plot2
FL-1 461107 2705614 57.22 52.28 64.70
FL-2 462546 2705205 57.37 53.35 67.19
70
FL-3 461707 2704688 56.92 51.17 56.13
FL-4 462213 2705352 53.44 51.34 56.28
Night Time (11:00 pm to 7:00 am), Plot 2
FL-1 461107 2705614 55.22 51.28 62.70 70
3
Ambient noise standards issued under MD 79/94 from industrial sources applicable to the proposed plant (Industrial and Commercial) as
the project lies within a dedicated industrial area
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UTM co-ordinates Noise
# Omani Standard3
Easting Northing Leq Lmin Lmax
FL-2 462546 2705205 54.37 50.35 65.19
FL-3 461707 2704688 53.92 51.17 56.13
FL-4 462213 2705352 51.44 52.34 56.28
Villages
Daytime (7:00am to 6:00pm)
Ghadfan 460019 2705639 48.5 47.6 51.6
55
Khuwariya 462224 2704621 50.2 48.8 53.4
Evening Time (6:00pm to 11:00pm)
Ghadfan 460019 2705639 50.6 49.3 52.2
55
Khuwariya 462224 2704621 49.9 48.2 52.7
Night Time (11:00 pm to 7:00 am)
Ghadfan 460019 2705639 48.9 46.1 50.6
55
Khuwariya 462224 2704621 49.9 47.9 52.1
From the table it is observed that the measured during all the three instances (Daytime, Evening and
Night time) are well beyond the applicable Omani standard. The daytime noise level could be
attributed to the various industrial activities in the area.
4.6 Geology
Sohar area forms a part of the Batinah plain, which comprises of piedmont and coastal zones where
late tertiary-quaternary alluvial deposits dominate. The piedmont zone comprises of the slightly
elevated Batinah plain that extends between the coastal plain and the foothills of the western Al-Hajar
Mountains. The un-cemented alluvial wadi sediments in the recent wadi channels typically consist of
boulders, gravels and silty sands of variable composition. The piedmont areas are composed primarily
of ancient gravel terraces, incised by active wadi channels and subsequently covered with recent
alluvium. These alluvium deposits vary in thickness from a few meters to tens of meters.
The coastal zone comprises of extensive sand and gravel plain extending between the piedmont zone
and the gulf of Oman. The coastal zone is extremely flat and is covered by finer sediments (sand and
silt). Immediately adjacent to the coast, aeolian sands of recent to sub-recent age predominate.
However, intermingled deposits of clay and silt are common. A thin veneer of beach sand stretches
along the foreshore.
4.7 Soil
The surface soil in SIPA has been modified as part of the development of the industrial estate as the
area has been levelled and elevated to sufficient height.
The soils along the Batinah coast in Sohar are regarded as moderately to highly suitable for
agriculture. With depth, the soils tend to exhibit higher percentage of organic matter. According to the
Ministry of Agriculture and Fisheries, the land in Sohar is classified as S1, which means that land has
either no significant limitation or moderately significant limitation for sustained irrigated agriculture.
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The Sohar area is known for its agricultural produce, which include dates, citrus fruits and vegetables.
Generally the agricultural zone does not extend to the coastline because of saline water intrusion.
Within the sand and gravel plains, the soil cover is extremely thin and low in organic matter.
4.7.1 Soil Quality
Per SIPC requirement, it is mandatory for all the companies establishing in the industrial area to
conduct and submit a zero soil survey report prior to establishing the plant. Orpic has carried out soil
sampling and analysis as part of the zero survey report. For the PC plant site two composite soil
samples were collected from the site during the baseline survey.
The grab samples were collected from about 30cm depth and then mixed to form the composite
samples. The composite samples were collected in different wide-mouth glass jars and submitted at
Haya Laboratories in Muscat for analyses. The coordinates and the results of the analysis are
presented below in Table 4-9 and
Table 4-10 respectively. In the absence of Omani standards for soil quality, the analysis result is
compared with USEPA Site Notification Standards for Industrial Soil. A copy of the analysis report is
attached as Appendix C.
Table 4-9: Soil Sampling Location
UTM Coordinates (m)
Sample ID Remark
Northing Easting
LS1 2708552 459669 Collected by HMR on 4th December 2014
LS2 2705213 461833 Collected by HMR on 4th December 2014
Table 4-10: Results of Laboratory Analysis of Soil Samples
Parameter Unit LS1 LS2 USEPA4
Physico-Chemical Analysis
Chloride mg/kg 25400 620 -
Nitrate mg/kg 49.6 2.2 1,600,000
Total Kjeldahl Nitrogen mg/kg 400 210 -
Acid Volatile Sulphides mg/kg < 10 < 10 -
Fluoride mg/kg <1 2 -
Amonnia mg/kg < 10 < 10 -
Nitrite mg/kg 0.3 < 0.1 100,000
Total Nitrogen mg/kg 450 210 -
Sulphide mg/kg -
Total Cyanide mg/kg -
Moisture contect (dried at 103ْ c) % 2 0.9 -
4
USEPA Site Notification Standards for Industrial Soil (12th September 2008)
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Parameter Unit LS1 LS2 USEPA4
PH Value PH Unit 8.7 8.6 -
Reactive Phisphorus mg/kg 0.1 < 0.1 -
Sulphate mg/kg 8210 2370 -
Elemental Analysis
Arsenic mg/kg 2 8 1.6
Barium mg/kg 36 8 190000
Boron mg/kg <1 <1 200000
Cadmium mg/kg < 0.2 < 0.2 810
Chromium mg/kg 108 172 1,400
Cobalt mg/kg 37 36 300
Copper mg/kg 38 12 41,000
Iron mg/kg 36900 30200 720,000
Lead mg/kg 3 3 800
Magnesium mg/kg 88500 99400 -
Manganese mg/kg 588 400 23,000
Mercury mg/kg < 0.2 < 0.2 28
Nikel mg/kg 498 628 69,000
Vanadium mg/kg 47 19 7,200
Zinc mg/kg 44 27 310,000
Organic Analysis
Benzene mg/kg < 0.1 < 0.1 5.6
C10 - C14 Fraction mg/kg < 50 < 50 -
C15 - C28 Fraction mg/kg < 100 < 100 -
C29 - C36 Fraction mg/kg < 100 < 100 -
C6 - C9 Fraction mg/kg <2 <2 -
Ethylbenzene mg/kg < 0.2 < 0.2 29
Xylene mg/kg < 0.2 < 0.4 2,600
Toluene mg/kg 0.7 < 0.2 46,000
On comparison of the parameters in the soil samples from the project site with the corresponding
standard limits prescribed in the USEPA Site Notification Standards, it is seen that the parameter
levels are below the specified limits. The soil at the site is neither acidic not alkaline, high chloride
level at LS1 might be an effect of seawater intrusion. There is no evidence of any Hydrocarbon (HC)
contamination of the soil samples. The appreciable levels of magnesium and iron could be due to the
presence of minerals such as chromite in the region.
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4.8 Hydrology and Surface Drainage
Two major wadis, Wadi Suq and Wadi Fizh / Bani Gharbi originating from the southwest slopes of
the Western Al-Hajar Mountains make up the wadi system in the SIPA region. These wadis along
with numerous braided channels drain large areas and carry large volumes of water during rainfall
events. However, since the establishment of the SIPA, a peripheral storm water drainage has been
constructed which is designed to collect and convey the storm water flow from these wadi systems
away from the developments within the SIPA. During rainfall events, this storm water drain empties
the flow into the sea on the north-eastern and south-eastern sides of SIPA.
The natural surface drainage extends from the western Al Hajar Mountains towards the sea providing
variable infiltration throughout the region. Typically, alluvial deposits found in wadi channels will
allow surface water to quickly dissipate.
4.9 Hydrogeology and Groundwater
The Batinah region has a coastal aquifer system, which provides most of the current water demands of
the region for agricultural and urban development’s along the coast. The current system of water
supply is provided by the abstraction of groundwater through the use of hand-dug wells and pumps.
Over the years the groundwater salinity in the region has increased, which has been attributed to the
continuous abstraction of the groundwater and the proximity of the wells to the coast.
4.9.1 Groundwater Resources
The general groundwater flow in the region is towards Gulf of Oman. The information on
groundwater level and quality, well yield, and the aquifers itself have been obtained from the Ministry
of Regional Municipalities and Water Resources (MRMWR) for the monitoring and production wells.
As per records received from MRMWR, there are 55,322 NWI wells within Al Batinah Coastal Area
of which 21,899 wells are used to support agriculture and irrigation and the remaining are mainly used
for municipal and domestic / potable purposes. The groundwater gradient is steady throughout the
proposed development.
The agriculture practice in the Batinah area is limited to a narrow strip along the coast of Al Batinah
region which is less than 5km where the groundwater occurs in shallow condition. The national well
inventory has confirmed that the current level of abstraction on the coastal plain exceeds the natural
recharge to the groundwater in the area. Groundwater levels in the Batinah area are the principal
source of information about the hydrologic stresses acting on aquifers and in turn how these stresses
affect ground-water recharge, storage, and discharge. The groundwater level data for 85 wells
obtained from the MRMWR monitoring division department indicate that the average depth to
groundwater in the Al Batinah Region varies from 5m bgl at nearshore areas and upto 60m bgl near
the foothills.
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4.9.2 Groundwater Quality
Groundwater samples were not collected from the PC Plant as there was no groundwater well was
available. As a part of baseline studies groundwater sampling and analysis as part of the Zero Survey
for the nearest proposed facility (OMPET) was carried out by HMR and same has been used for the
baseline purpose. Report and the results of the analysis are presented in Appendix D. Samples were
collected from bore hole 23 at a depth of 4.1m bgl and analyzed for chemical parameters, petroleum
hydrocarbons and VOCs. A summary of the result is presented in Table 4-11.
Table 4-11: Groundwater Analysis Result
Parameter Unit OS 8/2012 Groundwater Sample BH23
Aluminium 0.2 10.9
Arsenic 0.01 <0.004
Calcium - 663
Cadmium 0.003 <0.003
Chromium 0.05 0.36
Copper 2.00 0.02
Iron 1.00 41.8
Lead 0.01 <0.01
Magnesium 150 1594
Mercury 0.001 <0.001
Nickel 0.02 1.58
Potassium mg/L - 537
Zinc 3.00 0.26
Vanadium - <0.03
Sodium 400 12,810
Silver - <0.01
Manganese 0.4 0.68
Cobalt - 0.10
Selenium 0.01 <0.003
Antimony 0.02 <0.02
Petroleum Hydrocarbons
<0.01
C8-C40
VOC including BTEX <0.01
It can be noted from the above results that the levels of Sodium and Magnesium in the groundwater
sample is significantly above the limits applicable for drinking water. Iron, chromium and Nickel
levels are also marginally above the standard limits. However, the hydrocarbon and VOC levels are
below the detection limits.
The results show that the groundwater in the area is highly saline and hard. The presence of
Chromium and Magnesium could be attributed to the leaching of these metals from local geological
formations. The high salinity could be attributed to saline water intrusion at the coastal area.
However, it is to be noted that the groundwater in the project area will neither be used for drinking
water nor for project requirements.
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4.10 Terrestrial Ecology
The Batinah region in the Sultanate of Oman harbours several types of natural ecosystems from
mangrove forests to natural woodlands, shrub lands and dune ecosystems that provide habitats to at
least 335 species of birds, 16 species of mammals and at least 38 species of reptiles and amphibians.
From various primary and secondary information, it is revealed that there are about 374 species of
terrestrial vertebrates in the Al Batinah Coastal area including 320 species of birds (68 breeding
resident), 18 mammal (15 are native), 33 reptiles and 2 amphibians. The terrestrial plant community
comprises more than 83 species of which at least three species are geographically restricted to the
Arabian Peninsula. It also serves as temporary habitat to hundreds of migratory birds. In addition, the
coastal region is known for its khawrs, mangroves and wadi stretches which have significant
vegetation cover. Because of the high conservation values, many of these areas are proposed as
National Nature Reserves (NNR), National Scenic Reserves (NSR) and National Resource Reserves
(NRR) areas by the International Union for the Conservation of Nature and Natural Resources
(IUCN) 1986.
As part of baseline studies for the proposed plant in SIPA, a rapid flora and fauna assessment was
conducted in September 2014 at the project site to verify and update findings from previous
ecological studies conducted in the area. The detailed ecological assessment is included in Appendix
E.
From the survey it is observed that the project site is a degraded and altered ecosystem as indicated by
the composition and current status of vegetation. Most of the area is covered by salt bush thickets and
a large number of thickets have dried up or desiccated. About 75% of the vegetation is represented by
dry and desiccated Suaeda and Salsola bushes. The proposed site does not have any plant species or
communities that are rare or threatened or endangered in Oman and the Arabian Peninsula. All
species found at the site are of common occurrence across the country and none have restricted
distribution.
Further the project site does not harbor any reptile or mammal fauna of great ecological or
conservation significance. The geckos and birds that were observed at the site during the study are
common species, which have wide ranging distribution across the country. Various ecological impacts
due to the proposed project will include loss of vegetation and loss of habitat for existing floral and
faunal assemblage. However these would not be significant since the site does not have any unique or
endemic flora or fauna.
4.11 Marine Environment
A brief of marine environment of the area from secondary sources (HMR archives) is presented in this
section. The intertidal region surrounding the outfall location is dominated by two distinct habitats,
viz., wide exposed rocky embankment (observed along both sides of the outfall) and tidally exposed
sandy bottom. The protected sea wall with large boulders supports a diverse and noticeable
assemblage of invertebrates. Typical fauna in intertidal region along the rocky embankment include
barnacles, few rock oysters (Saccostrea sp), several gastropods like Lunella sp., Nerita sp and few
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rock crabs (Grapsus sp.). The density and distribution of various species was observed to be very low
among the boulders close to the mouth area of the outfall. Relatively very small rocky embankment
and wide sandy intertidal area was exposed during the low tide in the outfall region. No sensitive
biota was identified in these tidal regions. Large amount of dead bivalves like Callista erycina, Tivela
ponderosa, Phaphia undulate, Anadara sp., Cardites bicolour and gastropods shells Murex sp,
Cypraea sp, Strombus sp., Bulla amppulla, Oliva sp were observed at the nearshore region of the
outfall.
The subtidal environment in the common intake region of SIPA comprised very cohesive, fine
sediment, covered with an algal mat. The sediment was observed to be fine, rich in organic matter and
rapidly hypoxic below the algal mat which may be primarily due to the existing breakwater that
typically promotes stagnant waters when compared to coastal areas where sediments tend to
accumulate rapidly. The maximum depth was recorded at 6m, with visibility about 1m due to the
murky water at the bottom. Relatively high populations of polychaetes were observed. A few
gastropods-Bulla ampulla were found foraging in the sediment. Few pelagic fishes like sardines were
observed in the area.
The proposed petrochemical Plant does not have any direct interaction with the marine environment.
There is no seawater intake envisaged for the project and only treated water that complies with MD
159/2005 is discharged into the common outfall canal. Accordingly, no dedicated seawater intake or
outfall facilities are expected to be provided for the Project. Since the Project has only indirect
impacts on near-shore through various service providers, no marine ecological survey was undertaken
as part of the EIA for the Project.
4.12 Social Environment
The project site is located within SIPA, an area designated for industrial development. However, the
current socio-economic condition near the project influence area (about 5km radius from both the
polymer area and the steam cracker unit) has been established based on published documents and
previous studies conducted in the area. A detailed social baseline assessment is presented in Appendix
F. A brief of the socio-economic setting of the area is presented below.
The project site falls under the North Al Batinah Governorate, which lies between Khatmat Malahah
in the North and Al Musanaah in the South and confined between the Al Hajar Mountains to the West
and the Gulf of Oman to the East. It is located within SIPA, which comes under the Wilayat Liwa and
characterized under industrial land use. There are 10 villages lying within a 5km radius of the project
sites as presented Appendix F.
4.12.1 Connectivity
The Muscat - Batinah highway serves as the main linkage for the project influence area. Running
parallel to the main highway is the service road, which seizes the local traffic spills, reduces pressure
on the main highway and facilitates movement between villages. However, connectivity at village
level is by means of internal or primary roads which traverse and connect each village.
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A coastal highway is also being constructed between SIPA and the existing Batinah highway (Figure
4-4) which would increase connectivity between SIPA and other regions of Batinah and Muscat
Governorates. Other major transport infrastructure development including the rail link (which would
connect the United Arab Emirates (UAE) and Gulf Cooperation Council (GCC) countries eventually),
in the Batinah region.
Figure 4-4: Road Connectivity In Vicinity of Petrochemical Plant
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5 ENVIRONMENTAL RELEASES
The project interaction with the environment during the construction and operation phase will be
primarily by way of consumption of resources, release of various waste streams and accidental
releases/spills of hazardous materials. In the following sections, potential releases to the environment
during construction and operation phases of the project are presented. The environmental releases will
be identified and quantified using empirical equations and mathematical models, such as AP-42
emissions factors, AERMOD, TANKS etc. It must be noted that the quantification of various wastes
from the proposed plant will be limited by the availability of engineering data on the activities. Where
sufficient data are not available, suitable assumptions are made based on the previous experience and
engineering rules of thumb.
Releases during the decommissioning phase are expected to be similar to that of construction phase
but for a shorter duration, and hence are not discussed separately. The waste streams are classified
based on their physical and chemical nature, as below:
Air emissions;
Stationary point source emissions;
Area and fugitive source emissions; and
Mobile source emissions.
Wastewater;
Process / industrial wastewater;
Sanitary wastewater (sewage); and
Surface runoffs and liquid hazardous wastes
Solid wastes;
Non-hazardous industrial solid wastes;
Domestic wastes including kitchen wastes; and
Hazardous wastes - Solid hazardous wastes
Noise; and
Accidental Releases
Gaseous Releases into the atmosphere; and
Liquid spills and leaks on land.
The construction and operation phases of the Project are discussed with regard to waste generation,
handling, storage, treatment and disposal. The waste management plan including the
recommendations for environmental mitigation and monitoring is included in the EMP, which is
presented as a separate document, as per SEU requirements.
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5.1 Releases during Construction Phase
The releases during construction phase will depend upon the type of construction activities,
construction methods, equipment, chemicals / materials used, source / amount of utilities and duration
of site work. It is to be noted that the construction activities will be restricted to the area allocated for
the proposed project in SIPA and existing accommodation camps of contracting companies within
Sohar/Liwa area will be potentially used for the workers during the construction period.
The environmental releases during the construction phase will include emissions from the DG units,
emissions from construction equipment and vehicle, movement of transport vehicles, dust generation
from earthworks, sewage generated at site and camp, waste chemicals generated at site, maintenance
wastes, and metal, wooden and plastic scraps, etc. These releases are discussed in the following
sections.
5.1.1 Air Emissions
5.1.1.1 Sources
Major sources of air emissions during the construction phase include land clearing activities,
excavation, DG units used at site for power generation, construction equipment, vehicles and the fuel
storage tanks. Pollutants released from these sources include NOx, SO2, CO, unburned HC (UHC),
PM and VOCs. The air emissions sources and the nature of air emissions due to the various
construction activities are presented below in Table 5-1.
Table 5-1: Air Emissions during Construction Phase
# Source Name Source Type Nature and Quantity Air Pollutants
Construction Stationary point NOX; SO2; CO;
1 Products of fuel combustion
machinery sources UHC, PM
Products of fuel combustion; NOX; SO2; CO;
2 Transport vehicles Mobile sources
suspended dust UHC, PM
NOX; SO2; CO;
3 Diesel generators Stationary point source Products of fuel combustion
UHC
Non-methane
Area sources - fugitive Vapours generated due to
4 Fuel storage tanks hydrocarbons
emissions evaporation under storage;
(NMHC)
Soil excavation, land
5 Area sources Suspended Dust PM10
clearing, etc.
5.1.1.2 Air Emissions Quantities and Characteristics
As described in the table, the main source of air emissions during the construction phase is the
combustion of diesel, which will be used in the construction machinery, DG units and vehicles. CO2,
will be the major product of this combustion along with CO, UHC, NOx, SO2, and PM10. CO and
UHC are a result of partial combustion of diesel, as no engines are 100% efficient. NOx occurs as a
result of the thermal oxidation of nitrogen present in the air as well as diesel. About 90 to 95 % of the
sulphur in the diesel will be oxidized to SO2, while the rest may get further oxidized to SO3, which
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may subsequently be converted into sulphate. PM10 is formed due to the ash content in the fuel as well
as any particles, such as soot, etc. during combustion.
Due to the complexity and variety of construction activities, quantification of the pollutants that will
be emitted during various construction activities is difficult at present. However, based on theoretical
assumptions and using USEPA AP-42 emissions factors, air emissions from stationary and mobile
sources are calculated. The expected emissions from the DG units are given in Table 5-2 below. A
summary of the assumptions made during the calculations are as given below:
One DG with a rating of 450 kVA would be working for a period of 8 to 10 hours/day during the
entire construction period; and
The exhaust gas flow rate and temperature and stack dimensions for the above DG sets are taken
from specifications for Caterpillar DG sets5.
6
Table 5-2: DG Emissions from Construction Phase
# Pollutant Emission Factor Unit lb/hr lb/hr g/s
1 NOx 0.024 lb/Hp-hr 14.48 8.64 1.09
2 PM 0.0007 lb/Hp-hr 0.42 0.25 0.032
3 SOx 0.004045 lb/Hp-hr 2.44 1.46 0.184
4 CO 5.50E-03 lb/Hp-hr 3.32 1.98 0.250
5 NMHC 1.32E-03 lb/Hp-hr 0.80 0.48 0.060
5.1.1.3 Dust and Other Emissions due to Project Traffic
As per the recent US EPA guidelines (April 2006), the particulate matter estimation (using
conventional AP-42 vehicular emission factors) does not fully account the emissions of dust. It has to
be estimated separately using AP-42 emission factors when the vehicles move on paved/unpaved road
within the project site.
Particulate emissions occur whenever vehicles travel over a paved surface such as a road or parking
lot. Particulate emissions from paved roads are due to direct emissions from vehicles in the form of
exhaust, brake wear and tire wear emissions and re-suspension of loose material on the road surface.
Re-suspended particulate emissions from unpaved roads originate from, and result in the depletion of,
the loose material present on the surface (i.e., the surface loading). In turn, that surface loading is
continuously replenished by other sources. Since the project is within a developed industrial area
movement of traffic over unpaved road is minimum and will be restricted to areas within the project
site.
Dust emissions (PM2.5, PM10 and Total Suspended Particular Matter) were calculated as per the
USEPA AP-42 emission factors. The average dust generation at project site due to project related
traffic during 10 hour per day working scenario is given in Table 5-3 and the detailed calculation is
given in Appendix G.
5
http://www.cat.com/cda/files/319291/7/C27+680+ekw+Prime+T2_EMCP4.pdf
6
http://www.epa.gov/ttnchie1/ap42/ch03/final/c03s04.pdf
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Table 5-3: Dust Emissions from Vehicle on Unpaved area within Site after water spraying
# Pollutant Units Concentrations
1 PM2.5 kg/d7 6.5
2 PM10 kg/d 64.8
3 TSPM kg/d 191.2
For other pollutants, the vehicular emissions at project site are estimated using AP-428 emission
factors, (Appendix H) and the results are presented in Table 5-4.
Table 5-4: Gaseous Emission from Vehicle Travelling at Site
# Pollutant Units Concentrations
1 Unburnt HC g/d 130
2 Carbon Monoxide (CO) g/d 643
3 Oxides of Nitrogen (NOx) g/d 403
It is to be noted that the above releases are very negligible and short term in nature and will be present
only for limited periods when the associated activities, as discussed above, are performed.
5.1.1.4 Pollution Control System
The engines and road vehicles will be maintained in accordance with the manufacturer’s
specifications and the emissions will be limited by ensuring equipment usage only when necessary.
Engines for construction machinery and vehicles will be of standard design and the engine emissions
will be released into the atmosphere through standard exhaust pipes. The emission rates of pollutants
will be controlled through proper engine tune-up. Similarly, the DG sets used will also be of standard
design. The dust risings will depend on the nature of the surface and the weather conditions. Water
sprinkling will be done to reduce dust emission. Excavated soil and rocks will be primarily used for
backfilling within the project site. Excess soil will be transported to nearest municipal dump site
(Sohar). Stockpiling for an extended period of time is not envisioned during the construction period.
5.1.2 Liquid Effluents
The approximate daily water requirement for the proposed project during construction phase is
detailed in Section 3.13.1.2. The major sources of wastewater likely to be generated during
construction will include domestic wastewater /sewage from construction offices and sanitary
facilities located on-site and off-site, spent hydro test water, construction machinery washings, various
construction works, surface run offs due to rainfall events etc.
5.1.2.1 Quantity and Characteristics
The washings may contain some SS, O&G, and traces of chemicals and organic compounds; while
waste oil, oil sludge and chemical cleaning solutions etc. are hazardous liquid wastes. The sewage
generated from the domestic use of water on-site and off-site will contain both suspended solids and
dissolved solids (TDS), with relatively high biochemical and chemical oxygen demand (BOD / COD).
7
Dust Concentration is kg/d after water spraying on roads
8
http://www.epa.gov/oms/models/ap42/ap42-h7.pdf
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The liquid effluent sources, their nature and typical characteristics for the construction phase are
summarized below in Table 5-5. With respect to the characteristics of the effluents, it is difficult to
determine the chemical composition of the various effluent streams. Therefore, first order
approximations for the characteristics (before any treatment) are presented in the same table.
Table 5-5: Wastewater Stream during Construction Phase
Nature of Expected
Wastewater Source of Generation Expected Quantity
Wastewater Composition
Kitchen, toilets and Continuous SS<250 mg/L
Sewage – On-
wash rooms located Contains SS, O&G< 100 mg/L
site and Off- ~220m3/d9
onsite; construction O&G, BOD and BOD< 200 mg/L
site
camps located off-site COD COD< 500 mg/L
Virtually free of
Spent Hydro Hydro testing of pipes
One occurrence any NA
test Water and process vessels
contaminants;
Periodic water-washing
Intermittent;
Machinery of construction SS < 100 mg/L;
May contain grit, Cannot be estimated
washings machinery, vehicles and O&G < 100mg/L
SS and O&G
floors
Chemicals, e.g.,
Chemical
Washing of machineries acids, alkalis,
cleaning COD < 400 mg/L Cannot be estimated
with cleaning solutions detergents,
solutions
solvents, etc.
Rarely
Drainage of rain water Free of pollutants
No pollutants
Surface runoff over area within the unless accidentally Depends on Rainfall
expected unless
project site contaminated
contaminated
The following measures will be implemented for the segregation, treatment and disposal of the above
wastewater streams.
Washings: Construction equipment and vehicles will be periodically water-washed to remove any
accumulated dirt. No detergents will be used. Washing will be carried out in a designated area at site
and the wash water will be collected in a sedimentation tank. The clarified effluent will be sent to the
municipal STP for treatment and disposal. Alternatively, the contractors may wash their machinery
and vehicles in their established garages located off-site.
Hydrotest Water: Hydrotesting will be carried out for identifying and eliminating any leakages /
opening in the process vessels, pipeline framework and the plumbing and chemical additives such as
corrosion inhibitor, oxygen scavenger, etc. may be added to the hydrotest water to prevent internal
corrosion. However, biodegradable additives with low toxicity will be used. Consequently, the spent
hydrotest water may contain traces of oil, SS and chemicals. The used hydrotest water will be
collected and reused for multiple tests, as far as practicable. Further, the hydrotesting procedure will
be planned such that the test water is allowed to remain inside the vessel or pipeline for minimal time;
thus reducing the requirement of using additives in the hydrotest water.
The spent hydrotest water from the final test will be collected in a tank or a lined evaporation pond
and checked for compliance with Standard A-2 prescribed in RD 115/2001. If the water complies with
9
Assuming an average manpower of 1000 and per capita waste generation of 220L//day
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the standard then it will be used for land discharge activities on obtaining requisite approvals from
MECA; else it will be let to dry out in a lined evaporation pond. After the water has evaporated , the
lining will be folded and sent for disposal to Orpic’s Hazardous waste facility. The hydrotest water
disposal plan will need to be submitted to MECA well ahead of the activity to obtain the requisite
approvals
Sewage: Sewage generated from the various on-site toilets, kitchens and wash rooms located in the
project site will be collected through underground pipes into a holding tank. From the holding tank,
the sewage will be routed to the STP operated by Majis Industrial Services (Majis).
In addition to on-site sewage, off-site sewage will also be generated from labour camps where the
sub-contractor staff involved with the project construction will be accommodated. Sewage generated
in each labour camp will be transferred to the municipal STP.
Surface run-off: Storm water, unless contaminated, will be allowed to flow out from the construction
area. All areas where hazardous materials and wastes are stored will be appropriately bunded to avoid
surface run-offs to prevent accidental contamination. Normally, runoffs from hazardous substance /
waste storage area will be collected within the secondary containment that will be provided around the
area. This potentially contaminated run-off will be routed to a collection sump from where it will be
pumped out for transport to the municipal WWTP.
5.1.3 Solid Waste
During the construction phase, the project activities will generate both non-hazardous and hazardous
solid wastes. Solid wastes are generated from construction debris, excavated soil, packaging material,
scrap metal, equipment maintenance work, etc. The possibility of recycling of materials such as scrap
metal, wooden and paper packaging materials, metal and plastic drums etc., will be assessed and will
be recycled to the extent possible. Since size and details of construction, waste generation rates,
material usage, etc., are not known and given the complexity of construction activities, such quantities
are difficult to estimate at this point in time. These quantities of the construction waste generated will
be updated precisely during EPC phase of the project.
Solid and liquid hazardous wastes include spent oils, wastes from on-site fabrication such as surface
blasting materials, paints, etc., , containers of paints/solvents/oils, used batteries, contaminated soil
from oil spills, hazardous waste spillage, etc. Most of these cannot be recycled and will need to be
stored / disposed to a licensed off site location.
Contaminated soils generated due to accidental spillage/leakage of oils, liquid chemicals, solvents and
paints will be stored in bunded areas and on impervious flooring to prevent leaching of hazardous
materials and contamination of land and water. Unused paints, chemicals and miscellaneous materials
such as batteries will be considered for returning to supplier, recycling or reuse either onsite or offsite.
Contaminated containers/packaging material such as oil drums, paint drums and chemical packaging
materials will be sent to authorized recyclers. Such quantities cannot be estimated, however,
experienced contractors typically include provisions (as per the MSDS and waste characteristics) for
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safe handling and storage of such wastes. The details on the type, handling, storage and disposal of
solid waste are presented in Table 5-6.
Table 5-6: Waste Generation during Construction Phase
Description of Release and Proposed Control, Treatment and Disposal
Nature of Release
Source Methods
Non-Hazardous Solid Wastes
Reused for backfilling to the extent possible /
Excavated soil - Excavation disposed of in municipal dump sites or other
Continuous during excavation
for foundations, roads and area in coordination with MECA/ SEU and
activities – Normally
other infrastructure Municipality;
uncontaminated
development If contaminated - collected and stored in
dedicated bunded storage areas.
Domestic waste, wastes from
project offices and kitchen Intermittent – Non-recyclable, Collected in waste skips and disposed of to the
wastes from dining facilities, biodegradable waste. Sohar waste disposal site.
etc.
Miscellaneous construction Intermittent – recyclable, non- Stockpiled and disposed to the Sohar waste
waste biodegradable. disposal site.
Metal scrap and empty metal
drums of non-hazardous Intermittent – recyclable, non-
Stockpiled and sold to scrap dealers.
materials - Metal work and biodegradable.
packaging materials
Stockpiled and sold to local waste paper
Paper and wood scrap - Intermittent – recyclable,
dealers to the extent possible and rest disposed
packaging materials biodegradable.
to waste disposal sites.
Empty plastic containers of Stockpiled and sold to recyclers/dealers to the
Intermittent – recyclable, non-
non-hazardous materials - extent possible/ disposed of to waste disposal
biodegradable.
packaging materials site.
Hazardous Waste
Stored in a secluded area on-site in storage
Isotopes for Non- Destructive
facilities as per design specified in MD
Radioactive Waste Test (NDT) for pipelines,
281/2003. Access to be restricted to personnel
flanges, pressure vessels, etc.
with valid permit.
Containers of hazardous Intermittent – Empty containers Will be either decontaminated for disposal as
materials (oil drums, paint contaminated with non-hazardous waste or stored on site in a
drums, chemical drums etc.) hydrocarbons and chemicals covered area and disposed at Liwa site
Contaminated soils due to
Stored on site in segregated, bunded and lined
accidental spills and leaks of Intermittent - Contaminated
area until treated
oils and liquid chemicals etc
Stored in segregated, bunded, lined and
Unused and off-spec
enclosed area; and
chemicals, paints, coatings Intermittent – Waste chemicals
Sent back to the supplier if feasible / disposed
etc.
in accordance with MECA.
Segregated and protected storage at site with
Waste oil and oil sludge - proper secondary containment to control
Fuel oil storage and Intermittent – oil and sludge spillage;
maintenance workshops Waste oil sold to local approved oil refining
units for recycling
Miscellaneous wastes such as Stored on site in segregated, roofed, bunded
spent batteries, used/soiled Intermittent – hazardous waste. and lined area within Orpic premises onsite
cotton wastes etc. industrial waste temporary storage facility
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5.1.4 Noise
The main sources of noise and vibration on site during the construction period will be construction
machineries such as bull-dozers, excavators, compactors, which generate significantly high noise
level. In addition, DGs used for power supply also produce high noise level. The vehicles used for the
transport of materials and men to the site will also generate significant noise along the route. Table
5-7 below presents the typical noise levels expected from various construction machinery and
activities along with the duration of operations.
Table 5-7: Typical Noise Level
# Source of Noise Duration of Operation Noise Level at 1m from Source dB(A)]
1 Excavator, shovels, dumpers etc. Day time only 70-80
2 Compactors Day time only 80-90
3 Motors and compressors Day time only 80-85
4 DG units 24 hours 75-85
5 Trucks Day time only 75-80
It is difficult to quantify noise emissions during construction activities as the type and numbers of
potential noise sources are not available at present. However noise level will be maintained in
compliance with MD 79/94 (Regulations for Noise Pollution in Public Environment) and MD 80/94
(Regulations for Noise Pollution in Work Environment). If the workers are likely to be exposed to
continuous noise level exceeding 85dB(A), they will be provided with appropriate personal protective
equipment (PPEs) such as ear plugs and ear muffs, as required by MD 80/94. Machineries will be
provided with suitable noise dampening agents like mufflers, enclosures, etc. to minimise noise at
source. High noise generating activities will be carried out in the day time to the extent possible.
5.1.5 Accidental Releases
The potential accidental releases include gaseous releases into atmosphere and liquid spills and
leaks on land. Accidental releases at the construction site mainly results from spills during routine
handling, loading/unloading, transportation and use of fuel/chemicals etc. There is also potential for
spill of fuel, lube oil, waste oil and other chemicals such as solvents, adhesives etc., at the site. Liquid
spills and leaks into the sea are not expected since the plant has no direct interface with the sea.
Accidental release of hazardous gases into the atmosphere is possible from compressed gas cylinders
used for welding work. Quantities of accidental releases are difficult to estimate as inventories and
storage details of chemicals were not available at the time of preparation of this report.
The clean-up of accidental spills generates contaminated soils, rags, etc. Contractors typically provide
adequate spill containment systems, remediation plans and maintain proper practices of storage and
handling of materials, which minimizes accidents. The hazardous materials will be stored in
segregated, enclosed and protected areas in such a way as to store materials, which are flammables,
corrosives, toxic, etc., separately, as per guidance in the MSDS. Such materials will be stored in
enclosed and roofed storage areas to the extent feasible in order to prevent from rains and runoffs
from storage areas.
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5.2 Releases during Operation Phase
The assessment of environmental releases during operation phase of the Project addresses various
waste streams generated due to the operation of the various units of the PC Plant and associated
utilities. The facility is still at the design stage and hence detailed information on the waste streams
cannot be quantified during the course of this study.
5.2.1 Air Emissions
5.2.1.1 Sources
The significant sources of air emissions – stationary as well as area – during the PC plant operation
phase are various process units, heaters, incinerators, flare system, power plant, emergency DG, tanks,
pipe fittings, storage tank farm etc,. The emissions from the stationary point sources can be either
continuous or intermittent. It may be noted that during the operation phase of the PC, the stationary
point sources will be the primary contributors to air emissions. The area sources will be less
significant when compared to the stationary point sources, while the mobile sources will be
insignificant.
Air emissions from the stacks attached to combustion systems, which include gas turbines, furnaces,
boilers and flares, are the products of combustion of the fuels and off-gases. While the main products
of combustion are carbon dioxide and water vapour, the emissions will also consist of a number of air
pollutants including NOX, SO2, CO, un-burnt HC and PM10. Among these, NOX, CO and to a lesser
extent HC are expected to be significant. SO2 and PM10 are not expected to be significant since mainly
gaseous fuels with negligible sulphur content are used.
Air emissions from stacks attached to incinerators will also consist of NOX, SO2, CO, un-burnt HC
and PM10. Pollutants such as HCl, HF and dioxins, which are normally associated with incinerators,
will not be released since no halogenated substances are incinerated in any of the incinerators.
As explained in Chapter 3, the proposed PC will have five types of flare systems within the plant viz.
main wet flare, one main cold flare, one spare storage cold flare, one spare storage wet flare and two
cryogenic flares ( A and B) for flaring of different type of vents from different process units. The
vent gases from the raw pyrolysis gasoline, quench water, C6-C7 cut storage tank, wastewater
collection tank spent caustic and effluent tank, benzene contaminated collection tank and waste gas
from SCO unit, DGF unit will be routed to a thermal incinerator as these contain nitrogen with toxic
components, hydrocarbons etc.
5.2.1.2 Quantities
Emissions from the incinerator, GTs, steam boilers and the flare will be products of combustion of FG
(treated off-gas) and NG. While the main product of combustion will be CO2 and water vapour,
several air pollutants including NOX, SO2, CO, UHC and PM10 will also be emitted. Table 5-8 gives
the details of stacks in the process plant and utilities and emission rates of the pollutants in the stacks
considered for the air dispersion modeling. It should be noted that emission scenarios under plant
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upset conditions are not considered for assessment of impacts on air quality. Such scenarios exist only
under emergency situations.
Table 5-8: Emission Rate of Pollutants from Stacks
Flow NOx SOx CO UHC PM10
# Sources rate 3 3 3 3 3
(m3/hr) (g/s) mg/m (g/s) mg/m (g/s) mg/m (g/s) mg/m (g/s) mg/m
SCU
1 Heater 26.4 3.28 124.2 0.1 3.8 0.2 7.6 0.25 9.5 1.25 47.3
Stack 1
SCU
2 Heater 26.4 2.68 101.5 0.1 3.8 0.2 7.6 0.25 9.5 1.25 47.3
Stack 2
SCU
3 Heater 26.4 3.55 134.5 0.1 3.8 0.2 7.6 0.25 9.5 1.25 47.3
Stack 3
SCU
4 Heater 26.4 3.55 134.5 0.1 3.8 0.2 7.6 0.25 9.5 1.25 47.3
Stack 4
SCU
5 Heater 26.4 3.55 134.5 0.1 3.8 0.2 7.6 0.25 9.5 1.25 47.3
Stack 5
SCU
6 Heater 34 4.37 128.5 0.1 2.9 0.2 5.9 0.25 7.4 1.25 36.8
Stack 6
SCA
7 Incinerator 0.9 0.08 88.9 0.02 22.2 0.03 33.3 0.01 11.1 0.05 55.6
1
SCA
8 Incinerator 0.9 0.08 88.9 0.02 22.2 0.03 33.3 0.01 11.1 0.05 55.6
2
SCA
Power
9 118.4 11 92.9 2.6 22.0 3.7 31.3 0.7 5.9 7.3 61.7
Generator
1st Stack
SCA
Power
10 118.4 11 92.9 2.6 22.0 3.7 31.3 0.7 5.9 7.3 61.7
Generator
2nd Stack
SCA High
Pressure
11 34 0.07 2.1 0.02 0.6 0.4 11.8 0.15 4.4 1.25 36.8
Flare
Stack
SCA Low
Pressure
12 34 0.07 2.1 0.02 0.6 0.4 11.8 0.15 4.4 1.25 36.8
Flare
Stack
13 Pygas 20 0.07 3.5 0.02 1.0 0.04 2.0 0.25 12.5 1.25 62.5
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Flow NOx SOx CO UHC PM10
# Sources rate 3 3 3 3 3
(m3/hr) (g/s) mg/m (g/s) mg/m (g/s) mg/m (g/s) mg/m (g/s) mg/m
Unit 2nd
Stage
Reactor
Feed
Heater
14 Boiler 1 26.4 3.76 142.4 0.1 3.8 0.2 7.6 0.25 9.5 1.25 47.3
15 Boiler 2 26.4 3.76 142.4 0.1 3.8 0.2 7.6 0.25 9.5 1.25 47.3
16 Boiler 3 26.4 3.76 142.4 0.1 3.8 0.2 7.6 0.25 9.5 1.25 47.3
It must be noted that each of the sources mentioned in the above table will have a dedicated stack, i.e.,
will have 14 continuously emitting stacks. Besides point sources, the PC Plant will also have area
emission sources, such as the process area, oil, fuel, chemical storage tanks etc.
Special Case for Cracking Furnace
NOx emission from the cracking furnaces of the LPP petrochemical complex will have to meet the
requirements of Oman regulation MD/118(2004), i.e. emission limit from boilers and heaters of 150
mg NOx/Nm3.
Two cracking furnace types are used in the LPP project:
Ethane cracking furnaces F20001, F20002
Flexible cracking furnaces F20003, F20004, F20005, F20006
The cracking furnaces will be capable of operating within an overall 150 mg/Nm3 limit.
For normal cracking modes and normal fuel gas composition, the NOx emission is guaranteed to be
150 mg/Nm3, corrected to 3% O2 and dry basis. This operating mode normally is about 95% of the
furnace operation time, the remaining 5% is required for Decoke mode, TLE Polishing, and Hot
Steam Standby (HSS) mode. The latter mode is to enable sufficient time for furnace switch over.
By nature of the operating mode, NOx actual absolute emission rate will decrease during the Decoke,
TLE Polishing and HSS modes while the NOx concentration corrected to 3% oxygen will increase for
these off-line modes.
NOx emission values from the different furnace types have been evaluated for all operating modes
and are summarized per furnace type, as well as for all furnaces in operation for an average one year
cycle. Scenarios have been developed both for the normal fuel gas composition range as well as for a
fuel gas with hydrogen content up to 50 mol%.
A typical furnace operating cycle consists of the following operating modes:
Cracking Operation
Decoke Operation
TLE Polishing (short or long)
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High Steam Standby (HSS) mode; basically an idle mode, including period for
switchover from operation to decoke mode and thereafter back to operation mode.
With a normal furnace run length of 60 days for the cracking mode, the typical overall cycle time is
63-70 days, depending on the number of days the furnace is kept in HSS mode. Examples are given in
this document are based on a total 3 days HSS period, unless indicated otherwise. Total cycle length
for these cases will be 65 days. A typical operation cycle for a cracking furnace is illustrated in below
figure.
For the NOx emission three indicators are shown. The “expected NOx” value is the NOx
concentration at the stack, on a dry basis. The second curve shows the NOx concentration as corrected
to 3% oxygen content to provide a uniform basis.
All these figures are based on dry flue gas; actual measured values will be lower due to presence of
moisture. The off-line operating modes have a high amount of excess air, therefore measured NOx
emission corrected to 3% O2 is high as well.
The third trend is the NOx mass flow. Note that where the NOx concentration increases outside the
normal cracking operation, the mass flow of NOx decreases in these off-line operating modes. The
normal cracking mode of operation thus has the highest NOx emission rate.
The average NOx emission for one full furnace cycle as illustrated above is summarized for both
furnace types as below:
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NOx emission one cycle one cycle
Etha ne Fl ex
furna ce furna ce
Average mass flow, kg/h 11.65 12.45
Average exected at stack, mg/Nm3 at stack 113 113
Average emission, mg/Nm3 at 3% O2 124 124
Although during the off-line modes the NOx concentration peaks above the 150 mg/Nm3, the
average concentration for the full (65 days) furnace cycle is well below the 150 mg/Nm3. On a
monthly basis, every other month (i.e. a month that includes the normal decoke/polishing/HSS
sequence peak values) the furnace average NOx emission (at 3%O2) may tip on the 150 mg/Nm3
limit, but the month thereafter the average will be as low as for normal cracking operation mode.
Storage Tanks
The storage tanks will have vents to facilitate release of the VOCs collected within the tank into the
atmosphere. The VOC emissions that are expected from the tank farms, product storage area and
loading areas are presented in Table 5-9. The estimations have been made by using US EPA’s
TANKS 4.0 software tool for estimating emissions from organic liquids in storage tanks.
Table 5-9: Storage Tank Details and Expected Emissions
Total
No. of Dimensions Working
# Source Tank Type Emissions
Tanks m Volume m3
t/y
Feed Storage
1 Methanol 2 Floating roof 17.5 x 12 2,589 14.67
2 Raw Pyrolysis 2 Fixed/Cone roof 17.5 x 17 3,848 58.06
Gasoline
3 Pyrolysis Fuel Oil 2 Fixed/Cone roof 15.0 x 11 1,767 14.52
Shell/Fixed/Cone
4 MTBE 2 15.0 x 12 1,908 59.85
roof
5 C6 – C7 Cut 2 Fixed/Cone roof 20.0 x 14 4,084 51.79
Product Storage
6 C8 – C10 Cut 2 Fixed/Cone roof 12.5 x 11 1,203 1.56
7 Lean Amine 1 Fixed 10.0 x 7.5 510 7.81
8 Diesel Fuel 2 Fixed 3.0 x 4 20 0.0030
The expected total VOC emissions from the storage tanks are 208.2 t/y. However it is to be noted that
the tanks will be connected either to the flare or the incinerator thus minimizing environmental
impacts from tank emissions.
Transport vehicles for people and material will constitute mobile emission sources. However,
emission contribution from these sources will be negligible in comparison to the other continuous and
fugitive emission sources. Furthermore, the emissions from the mobile sources are difficult to be
quantified or estimated at the present stage of the project.
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5.2.1.3 Control Measures
In order to minimize the air emissions, a number of state-of-the-art technologies will be integrated
into the process. The various pollution control measures that will be incorporated are described below:
Detailed control measures are explained in Chapter 6 – BAT Analysis.
Heaters and Incinerator - The heaters and incinerator will employ the low-NOX burners in order to
minimize the release of NOX into the atmosphere.
Gas Turbine and Steam Boilers - Since NG will be used as fuel, NOX is the major concern with
respect to gas turbines. The fuel will have very low Sulphur content (5ppm), considering this fact SO2
emission will be negligible and is not of concern. High temperature will result in high NOx
concentrations and therefore it is expected to be temperature controlled combustion. However,
sufficient excess air will be maintained which will minimize the CO and UHC concentrations.
Further, fuel will be gas, which will further reduce the chances of UHC emissions. The UHC emission
will not be significant due to the use of gaseous fuel and the nature of combustion and the associated
controls. None of the emissions are expected to exceed the limits prescribed in MD 118/2004. NOX
emissions will be controlled by the use of Dry Low NOx (DLN) combustion system.
Flares - In order to minimize pollution from the flare, it is proposed that the flare will be designed to
ensure that the smoke opacity will not be higher than Ringlemann 1. The flare will have continuous
pilot flame to prevent any cold venting, and will combust more than 99.8 % of HCs. In order to
reduce thermal NOX, the fuel-air ratio will be optimized and will be steam assisted.
Spent caustic wastes containing high COD, TDS, sulfides, mercaptides, free caustic, polymeric
organic compounds and other aromatics will be oxidized to convert organic compounds to CO2 and
sulphates.
Area Sources -The storage tanks for feedstock, product and intermediates will be provided with
nitrogen blanketing and floating roof. Further the vent gas from the storage tanks will be routed
to the vent gas incinerator.
5.2.2 Wastewater
The liquid wastewater sources in the project during normal operation may be classified into groups as
below:
Process water from various utilities in the complex – continuous and contaminated;
Containment water - wastewater from spills, general plant services, GT and other utility
washings, floor washings, fire events, rainwater run-off through process and utility areas, etc.)
– Intermittent release, quantity and quality will vary;
Storm water run-off (segregated from run-off through process and utility areas) – Intermittent
release, quantity and quality will vary;
Sewage;
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The exact quantities and characteristics of wastewater that would generate during operation phase are
not known at this stage. Approximate quantities and the characteristics of the continuously flowing
streams are presented below in Table 5-10.
Table 5-10: Wastewater Generated during Operation Phase
Description of Release and Nature of Control, Treatment &Monitoring
#
Source Release/Quantities Methods
Benzene/MTBE contaminated
wastewater including
PGHYD condensate effluent, Collected and treated in Wastewater steam
SCU blow down, stripper where benzene content is reduced
SCU process water, to 1 ppmw;
Quench water during SCU Caustic or sulphuric acid dosing done in
shutdown, Surface water Intermittent – case pH control is required;
1 contaminated with Contaminated with Steam stripped effluent routed to WWCT
benzene/MTBE, benzene/MTBE after heat recovery in heat exchanger and
First flush surface water run- cooled in cooler to below 40°C using
off collected in LLOD, in case cooling water;
contaminated with From WWCT the collected wastewater is
benzene/MTBE, sent for further treatment by DGF
Butene-1/MTBE unit spent
wash water
DGF effluent, TLE
hydrojetting/decoking quench
Continuous – Collected in wastewater equalization tank;
2 water effluent, TLE blow down,
Contaminated Treated by biological treatment
stripped effluent from
wastewater steam stripper
Collected in spent caustic coalescer where
gasoline is added to remove entrained oils
Spent caustic waste from and dissolved organic compounds;
Continous – COD,
caustic/water wash tower, Un- Routed and treated in Wet air oxidation
TDS, sulphides,
3 neutralized or undiluted spent unit for neutralising and converting the
mercaptides, organic
caustic waste from equipment organic compounds to CO2 plus water or
compounds etc
and piping organic acids and the sulfides to
thiosulfates or sulfates;
Further routed to WWTU
DM water spent regenerants, Routed for neutralisation;
4 condensate polishing spent Intermittent Neutralised spent chemicals sent to
regenerants, spent chemicals disposal without further treatment
Equipment oily drains, pump
base plates, hydrocarbon
sampling points and surface Intermittent – Collected by oily water sewer system and
5
water run-off from the paved contaminated routed to WWTU
area where hydrocarbon leakage
is expected
Collected and route to first flush basin
Equipment drains and surface
through AOC water screen.
water run-off which is polluted
Intermittent – Skimmed oil is collected and sent to
6 neither by benzene / MTBE nor
contaminated skimmed oil vessel
by high concentration of other
hydrocarbons Effluent collected in FFB allowed to flow
to POB and treated in IAF unit.
Liquid wastes from various Intermittent – Routed to neutralisation tank and then to
7
laboratories Contaminated WWTU for further treatment
Collected hydrocarbon routed to Gasoline
Equipment /piping containing Intermittent – fractionators.
8
hydrocarbon within ISBL/OSBL. Contaminated Light hydrocarbons are drained directly
from equipment to the flare system.
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Description of Release and Nature of Control, Treatment &Monitoring
#
Source Release/Quantities Methods
Equipment/piping containing Intermittent – Collected amine pumped to the amine
9
amine within ISBL/OSBL. Contaminated regenerator.
Drainage from areas, where
Content pumped back to MTBE unit if
contamination source are present, Intermittent –
10 MTBE is present
including equipment draining in Contaminated
Otherwise sent to WWTU
ISBL/OSBL
Drainage of C6/C9/PGO/PFO
areas, where contamination
Intermittent – Treated in quench tower though quench
11 source are present, including
Contaminated drain vessel
equipment draining in
ISBL/OSBL
Drainage of chemical dosing/
Stream is neutralized locally and routed to
catalyst and/or sulfuric acid Intermittent –
12 clean surface water sewer network or
spillage from equipment and Contaminated
WWTU
piping from ISBL/OSBL areas
Hot oil drainage from areas
Intermittent – Stream routed to effluent treatment unit to
13 including equipment and piping
Contaminated separate the oil and water
draining in OSBL/ISBL
Drainage of methanol from Stream pumped back to unit when
Intermittent –
14 equipment and piping within methanol is present
Contaminated
ISBL/OSBL Otherwise send to WWTU
Drainage of Quench Oil from
Intermittent –
15 equipment/piping containing hot Content pumped to quench tower
Contaminated
oil within ISBL/OSBL areas
Skimmed oil from spent
16
oxidation effluent tank
Skimmed oil from wastewater Fluids will be collected and transported by
17 tank car or drums
treatment
Routed to the liquid incineration unit and
18 Maintenance waste oils Intermittent – incinerated
Contaminated Alkyl waste from PP will be 10%, and this
Liquid waste from polymer waste will be neutralized with Atmer in
19 plants containing up to 15 – 20% neutralization unit and then send to the
Alkyls incineration.
Hydrocarbon/water mixtures
20
from drain vessels by tank car.
Storm water and surface water Routed by gravity to clarifier for removal
Unique occurrence
run-off from uncontaminated of suspended solids;
21 Rain water, typically
areas including fire fighting Clarified run off transported to treated
not contaminated
water effluent tank
Collected effluent routed through screening
unit to first flush basin;
The collected water routed to POB after a
Potentially contaminated residence period of 30 days and if found
Intermittent –
22 equipment drains and surface uncontaminated and then treated by IAF in
contaminated
run-offs IAF unit;
The collected water from POB routed for
further treatment in biological treatment
unit if found contaminated.
Wastewater generated during
Due to high acid and solid content,
unit washes, periodic equipment
wastewater is sent to the surge tank for
flushing, wastewater discharged
23 Intermittent temporary holding and processed slowly
abnormally from the unit,
after mixing with the normal wastewater in
drainage during start-up and
the equalization basin
shutdown.
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Description of Release and Nature of Control, Treatment &Monitoring
#
Source Release/Quantities Methods
Domestic effluent from kitchen equipped
Plant sewage - toilets, urinals, Continuous
with grease traps;
kitchen facilities, sinks, showers Wastewater with bio-
24 Routed by gravity to centralised lift station
and the like from buildings and degradable organics
and routed to MISC for treatment and
shelters and suspended solids
disposal
The various process stream generated in the PC Plant will be collected in respective sewer system and
routed to the WWTU as discussed in Section 3.11.3 and Section 3.12.
5.2.3 Solid Waste
The waste generation in the PC plant during normal operation will not be significant in terms of
quantities. However, it is envisaged that the wastes generated during the operation phase would
largely be hazardous wastes. The nature and disposal methods for the various waste generated in the
plant are summarized below in Table 5-11. Additional information related to quantities of waste
generation during operation phase will be confirmed at time of EPC phase EIA update. It is worth
noting that Landfill of beah will be ready by 2018 and common incinerator will be in operation by
2020. Orpic is planning to send the respective waste to the beah facility.
Table 5-11: Solid Waste Generation during Operation Phase
Waste Type Sources of Generation Method of On-site Storage and Final Disposal
Non-Hazardous Waste
Domestic waste, office Onsite non-industrial Collected in waste skips and disposed to the nearest
waste and general waste activities approved landfill site
Non burnable/ non Collected and disposed to the nearest approved
From gas phase PE plant
recyclable waste landfill site
General non-hazardous From Utilities/ Power Collected and disposed to the nearest approved
wastes plants landfill site
Wood Stockpiled and sold to local approved dealers
Metal scrap From plant and workshop Stockpiled and sold to local approved dealers
From solution and gas
phase PE plant
Scrap polymer Sold as low grade polymer
From slurry Polypropylene
and gas phase PE plants
Spent bag filters From silos
Collected and disposed to the approved landfill site
Hazardous Waste
Skimmed oil from
LLOD basin, WWCT,
Intermittent – Hazardous Collected and routed to liquid incinerator unit for
Oily sludge storage tank,
liquid incineration
DGF skimming,
Benzene/MTBE WWCT
Collected in mobile oily sludge container
Dewatered oily sludge WWTU
Incinerated
Sludge generated from Collected and to be sent to be’ah facility
Crystallizer
caustic treatment
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Waste Type Sources of Generation Method of On-site Storage and Final Disposal
Miscellaneous solid Intermittent~ •
wastes from all process Hazardous due to Disposed off by incineration in solid waste
plants and utilities hydrocarbons and other incinerator
organic matter
Waste oils and oily
Stored in segregated in bunded areas, waste oil sent
sludge, waste chemicals,
Intermittent to authorized waste oil recyclers
solvents, waste paints,
Hydrocarbon and other Waste solvents and chemicals, if feasible, will be
used cotton waste, etc.
chemicals sent back to the suppliers or disposed of in
from plants and
maintenance workshops accordance with MSDS
Cokes from cracking
SCU Plant
ethylene unit;
Polyethylene and
PE plant,
polypropylene powder;
Collected and transported by truck to solid waste
Dewatering sludge from
incinerator, except Polypropylene and polyethylene
wastewater treatment WWTU
powder will be sold as low polymer grade and do
unit; and
not send to the incinerator for incineration.
Spent activated carbon
from filters.
Cokes from cracking
PE plant
ethylene unit;
Spent filter media
Ethylene and polyethylene
(flammable) and oil Routed to waste incinerator
plants
absorbents
Intermittent - From Sludge collected pumped to sludge dewatering unit;
Sludge from WWTP
dewatering operation Dewatered sludge disposed of by incineration
Disposed at nearby landfill site stored as hazardous
Waste catalysts (non-
PE plant waste. Alternatively, could be sold to catalyst
flammable)
recyclers
Will be stored in enclosed and dedicated storage
Acetylene hydrogenation
Spent catalysts areas at site
catalysts in ethylene plant
Returned to manufacturer / reclaimer
Containers of hazardous Either decontaminated for disposal as non-
Metal and plastic containers
materials (oil drums, hazardous waste or stored on site in a covered area
of hazardous consumables
chemical drums etc.) and disposed at be’ah facility
5.2.4 Noise
The major noise generation sources during the operational phase will be gas turbines, steam
generators, flares, incinerators, WWTU etc. The typical noise levels expected from these sources are
presented in Table 5-12.
Table 5-12: Noise Generation During Operational Phase
Noise Level (in dB(A)) at 1m
Noise Source Duration of Operation
from Source
Gas turbine-generators Continuous 85 (maximum)
Steam Boilers Continuous 85 (maximum)
Compressors Continuous 90 (maximum)
Generator air coolers Continuous 85 (maximum)
Pumps Continuous 80 (maximum)
Flare – Normal Condition Continuous 90 (maximum)
Flare – Upset Condition Discontinuous and rare 115 (maximum)
Since the equipment and machineries will be of latest technology, it is expected that all the high noise
producing equipment will have inherent noise controls. Moreover, for machineries like GTs, steam
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generators and compressors, mufflers, acoustic enclosure and other suitable acoustic treatments will
be employed. All the high noise areas will be identified and workers engaged in those areas will be
provided with either earplug or ear muff, depending on the requirement. Furthermore, Orpic has
planned Green Belt with appropriate mix of trees and shrubs along its site fence line to ensure
additional noise attenuation. Detailed noise mitigation measures and controls including monitoring
requirements have been included in the EMP presented separately.
5.2.5 Accidental Releases
During the operation phase, the potential accidental releases include gaseous releases into
atmosphere, and liquid spills and leaks on land. The potential for accidental release of hazardous
gases into the atmosphere is significant due to the handling of NG, which will be used as fuel
within the plant. The potential for accidental release of hazardous liquids on land exists for the
storage drums and tanks of various feed stock, fuel and liquid chemicals.
The storage facilities will be designed to reduce the possibilities of any leakages or failure of the
facilities. Suitable material of constructions will be selected for building the storage tanks and drums.
Furthermore, the storage facilities will be provided with preventive measures such as secondary
containment, firefighting systems, etc. to prevent accidents due to any leakages from the storage
facilities.
Considering the above, the probability of failures / leakages of the storage tanks will be low. The risk
management for accidental release on hazardous substances will be developed based on a quantitative
risk assessment study that will be conducted as part of the project FEED.
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6 ANALYSIS OF ALTERNATIVES
The development, design and construction of PC plant in project site involve several major
management and technical decisions, some of which will have significant influence on the
environmental impacts from the project. In this section, the environmentally critical decisions are
identified and the justification for their selection is discussed. For the development and design of the
project, the following aspects are identified to be environmentally significant:
No project alternative
Selection of project site;
Selection of process and technology;
Sourcing of Utilities such as power and water;
Power and steam sourcing and power plant technology;
Water sourcing and water treatment technology;
Cooling water system;
Feedstock and fuel sourcing;
Air pollution control systems;
Wastewater treatment and disposal system;
Hazardous waste treatment and disposal system; and
Analysis of BAT.
For the construction phase of the project, the following aspects are identified to be environmentally
significant:
Sourcing of utilities;
Sourcing of fuels;
Sourcing of construction materials.
These aspects are discussed in the following sections.
6.1 Need for the Project
The Project will be Orpic’s latest expansion, which when complete will produce a nominal 863,000
t/y ethylene cracking plant, HDPE plant, LLDPE, PP plant, MTBE plant, Butene-1 plant and
associated utility and offsite facilities. Polyethylene is an important polymer used as starting material
in the manufacture of a wide range of plastic products for industrial and domestic use. The consumer
demand for both high density and low-density polyethylene is rapidly growing worldwide, and
particularly in the Asian countries.
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This Project is part of the Sultanate program to reduce its reliance on the export of crude oil and
natural gas in developing its downstream industry to retain more added value in the country. Further
this project brings to Oman, state-of-the-art petrochemical technology, world-wide operational
expertise and marketing know-how. The construction phase is expected to last for about 24 months.
The operational life span of the project will be 30 years. The Project is also expected to facilitate the
significant development of downstream industries in Oman that convert polyethylene to a range of
industrial and consumer products. This could potentially create further employment opportunities for
local populations.
In the event of no project alternative, the project site will continue to be a plot reserved for future
development by SIPA. Although the no project option will avoid any adverse impacts associated with
the construction and operation of the project, this option will not allow for the potential industrial and
economic prospects of the area. The project will initiate both short and long term employment and
business opportunities along with development in the area. The project contractors and sub-
contractors are expected to have approximately 1000 - 2000 people involved in construction. The
project once in regular operation, is expected to employ over 250-300 persons.
6.2 Project Location
The (PC) will be integrated within the Sohar Refinery, Aromatics Plant and Polypropylene Plant. The
site selected for the Project is thus close to the existing refinery. Further the following factors were
also taken into consideration whilst selecting the site for the PC;
The site is an approved industrial site, free of any settlements, free of any surface or sub-
surface structures, not used for any agricultural or fisheries activity and free of surface or sub-
surface contamination.
The project site is predominantly plain and levelled thus reducing the cost for site preparation.
The site lies at the southeast corner of SIPA, adjacent to Sohar Refinery site and close to the
port and SIA’s common seawater intake and outfall system.
The various utilities required for the development of the plant like power, water, natural gas,
etc are available within the SIPA.
Proximity to the port minimises the costs and environmental impacts associated with import
of materials and export of products.
Proximity to the refinery permits direct pipeline transport of refinery off-gases for use as
auxiliary fuel;
Sohar is an industrial town and as such the need for skilled workers can be easily met from
the available work force in Sohar and other similar units in and around the Arab countries to
some extent.
The industrial area is placed strategically close to proposed Al Batinah Express Way and Al
Batinah Railway, which will ensure great connectivity of the site in future. Further it is
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sufficiently connected with the existing Al Batinah High Way, which is traversing through the
southern side of the industrial area as shown below ;
Figure 6-1: Road Connections between SIPA and other Destinations
Therefore, no alternate sites were needed to be considered.
6.3 Sourcing of Utilities
6.3.1 Sourcing of Power
As discussed in the previous chapter the total power requirement for the proposed PC is 150MW. In
order to meet these requirements, the following five alternatives were considered based on overall
reliability (of the total Olefins complex), flexibility of power production, power price, natural gas
price and the (potential) loss of production of the Olefins complex due to insufficient power.
1. Two (2) independent Gas Turbine Combined Cycle (GTCC) units, each with gas turbine and
steam turbine including grid connection for back-up power.
2. An integrated unit, with two (2) gas turbines and single steam turbine.
3. Integrated unit, with import of SHP steam from the auxiliary boilers to produce more power.
4. Integrated unit, with import of SHP steam from the auxiliary boiler to produce more power
via two (2) steam turbines to improve reliability.
5. Integrated unit, with import of SHP steam from the auxiliary boilers and export of extraction
steam back to the Olefins complex steam system.
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6.3.1.1 Two Independent GTCC Including Grid Connection for Back-Up Power
Each unit will have a gas turbine with generator. Natural gas is used to drive the gas turbine and the
hot exhaust is sent to the HRSG (heat recovery steam generator). The steam system shall be of
standard design including a condensing steam turbine. The steam turbine expands the superheated
steam to wet vacuum. The steam turbine drives an independent generator.
Because both the units are fully independent, the reliability is the highest in this option. Also it is
possible to stop 1 unit for inspection and maintenance, while the other unit remains in full operation
together with the connection to the OETC grid. This configuration tends to be the most flexible with a
reliable connection to the grid.
6.3.1.2 Two Gas Turbines and Single Steam Turbine with Grid Connection
An alternative option is two (2) gas turbines sharing a single HRSG. A single steam turbine and a
single vacuum condenser is present with a grid connection for back-up power. This configuration is
called the 1 * (2+1) option, which contains 3 machines and 3 generators.
The gas turbines are less reliable and less available than the steam turbine and hence the numbers of
the gas turbines are doubled in this option. The reliability, availability and flexibility are less than the
previous option, but due to partial economy of scale, the equipment costs are lower. However, the
probability of trip of the Olefins complex, due to trip of the single steam turbine and consequently of
the gas turbines, is higher in this option.
Intermediate Stack
An alternative sub-option is with 2 gas turbines, a single HRSG and a single steam turbine and
including a grid connection. This option is without intermediate trip stack. As a result, in case of trip
of the HRSG or steam turbine, the total plant will trip, because the gas turbines also have to be
tripped. In case of presence of an intermediate trip stack, the hot exhaust of the gas turbines can be
sent to atmosphere instead of to the HRSG. As a result the gas turbines can remain in operation at
maximum 107MW. Thus the power only reduces from 150MW to 107MW and the remainder can be
imported via the grid connection, being 43MW. This is less than the anticipated 75MW as in the
previous case. However, a state-of-the-art combined cycle unit has a very reliable steam and
condensate system, including a very reliable steam turbine. This steam system is much more reliable
than the gas turbine which indicates that standard state-of-the-art combined cycle units hardly increase
their reliability with a trip stack.
6.3.1.3 Steam Integrated Power Plant – Single Steam Turbine
This integration option makes use of the spare capacity of the SHP steam of the auxiliary boilers of
the Olefins complex with a connection to the external power grid for back-up. Two (2) gas turbines
are present fired by natural gas to maximize reliability. The hot exhaust flows to the HRSG via an
intermediate trip stack. In the HRSG steam is produced with the same quality as the excess SHP from
the auxiliary boilers. This SHP steam is expanded to vacuum conditions and does not need a reheat (in
the HRSG). This steam turbine is more expensive than the 1 * (2+1) configuration, because much
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larger capacity steam turbine generator system is required. The main advantage of this configuration
is that more power can be generated.
6.3.1.4 Steam Integrated Power Plant – Two Steam Turbine
Two parallel steam turbines, each with its own air cooled vacuum condenser, are more reliable than a
single steam turbine with single vacuum condenser. The total steam turbine capacity is116 MW. Thus
each of the two (2) steam turbines has a capacity of 58MW. In case of tripping of one such steam
turbine, the power plant output could still be 2 * 54 + 58 = 166MW, which is more than the target
capacity of 150MW. Thus tripping of one such steam turbine trip will not trip the Olefins complex. In
case an auxiliary boiler trips, the connection to the external power grid can be used as back-up.
6.3.1.5 Double Sided Integration Option
Above described steam integration option is based on import of SHP steam to produce electric power.
It is also possible to import SHP steam and export the extraction steam(s) back to the Olefins
complex. The possible extraction levels are HP, MP and LP. However, exporting HP is the most
effective, because this superheated HP steam could be used for driving even more steam turbines at
the Olefins complex. Evidently the smaller the steam turbine and the lower the pressure and the
superheat, the lower the efficiency will be.
Integration options with the steam system of the Olefins complex are found to be unreliable with
respect to the occurrence of trips, resulting in unacceptable production losses at the Olefins complex,
even with a reliable connection to the external power grid for back-up power. In addition, investment
cost will be increased due to the use of super high pressure (121 barg) steam as generated in the
Olefins complex. After comparison of various options above taking into account capital expenditure
(capex), efficiency, reliability and availability, Orpic is proposing the use of two independent GTCC
with grid connection for back-up as the most optimum configuration
6.3.2 Sourcing of Water
The freshwater requirement in Sohar Site is 5,000kg/h under normal operation and service water
requirement is 50,000kg/h. Considering that local groundwater resources are very limited, the
freshwater requirements have to be met through desalination of seawater.
Two alternatives for sourcing desalinated water are available. One is to import from an off-site facility
and the other is to construct an exclusive on-site facility. It is not feasible to source desalinated water
from any existing or under-construction desalination plants. Moreover, in view of fluctuating water
demand and operational flexibility, it is determined that construction of an on-site desalination plant is
the only feasible option.
Membrane separation and evaporation are the only two processes that are suitable for commercial
scale desalination of seawater. In the membrane separation process, a semi-permeable synthetic
membrane is used to filter out the salt ion from the seawater to produce fresh water. The membrane
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separation processes for desalination of seawater include reverse osmosis (RO) and electro dialysis.
Generally, electro-dialysis is not suitable for large desalination plants.
In the evaporation process, thermal energy is supplied to evaporate water from brine. Both processes
result in the generation of concentrated seawater (brine reject) as a waste stream. The evaporation
processes for desalination of seawater include multiple-effect distillation (MED), multi-stage flash
evaporation (MSF) and vapour compression (VC).
With reference to environmental aspects, both processes generate concentrated brine as reject water,
which needs to be disposed back into the sea. In membrane processes, the reject stream will be at
ambient temperature while in thermal processes the brine will be heated. In terms of fuel consumption
(direct and indirect) per unit produced water, membrane processes (which use electrical energy)
consume more compared to thermal processes, thus resulting in more emissions
For the proposed project MED technology is determined to be the best option based on capital and
operating costs. MED technology will consist of two identical trains (one operating, one on stand-by)
in which Low Low Pressure Steam (LSS) is used to evaporate sea water in multi effects. Sea water is
filtered to remove undesirable particles before feeding into the desalination process. Sea water flows
through tube bundles in MED the condenser as cooling media. Condensed water from all effects is
collected in the last chamber called condenser where non-condensable gases are removed by means of
an ejector and desalinated water is pumped as product to tanks.
6.3.3 Cooling Water System
A number of process and auxiliary equipment require cooling. They include process condensers,
process coolers, and refrigeration systems. The various alternatives available for cooling include the
following:
Air cooling;
Re-circulating water cooling;
Once through seawater cooling; and
Closed cycle cooling with once through seawater cooling.
In air-cooling systems, atmospheric air is passed over the external heat transfer surface to remove the
heat. When direct environmental effects are considered, air-cooling is the best alternative of the three.
However, cooling systems based on air-cooling generally require very large heat transfer area and is
hence unsuitable in many cases.
In re-circulating water cooling systems, freshwater is circulated through a heat exchanger, the warm
outlet water is cooled in cooling towers and then recycled along with required make up water. Make
up water is required to compensate for water loss due to evaporation in cooling towers and cooling
tower blow down. Re-circulating cooling water systems require relatively low heat transfer surface,
but have environmental consequences due to freshwater consumption, use of chemicals (anti-scaling
and anti-corrosion) effluent treatment and disposal.
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In once through seawater cooling systems, seawater is passed through a heat exchanger and the warm
outlet water is discharged into the sea. There is no make-up water requirement. The outlet seawater
will be typically at about 10C warmer relative to the receiving water body. This has potential for
marine environmental impacts, especially thermal pollution, and requires careful design of marine
outfall.
The proposed plant utilise a cooling water unit which will be a closed pump around system. The
cooling water returned from the various users will be cooled down against sea water in five plate heat
exchangers. The closed cycle cooling water system will be maintained with minimal water losses.
6.3.4 Fuel for GT
A diverse range of solid, liquid and gaseous fuels can be used for power generation. From a viewpoint
of pollution prevention and abatement, liquid and gaseous fuels are better than solid fuels. The two
fuel alternatives available for the project are natural gas and light distillate oils. Between these two,
natural gas is environmentally more superior due to negligible sulphur content and low carbon
content. While low sulphur content results in low SO2 (acid gas) emissions, low carbon content results
in low CO2 (greenhouse gas) emissions. Further, natural gas is abundantly available in Oman, as
discussed in the preceding section.
Therefore, natural gas is selected as the primary fuel for the project. As a backup fuel, diesel oil with
<1.0% sulphur is considered. A tie-in point downstream of the existing gas intake station will be made
to supply HP NG from Sohar Refinery for the PC plant. The HP NG will be heated up in Natural Gas
Receiving Heater prior to the pressure reduction to avoid hydrate and liquid droplets and mist
formation. Diesel oil for back up fuel will be sourced from Sohar Refinery.
6.4 Air Pollution Control Systems
The major sources of air emissions present in PC plant are the power plant gas turbines, steam
generators, flares, incinerators etc. These sources release a number of pollutants into the atmosphere.
However, based on the expected mass rates of emissions, only CO2, NOx, CO and un-burnt HC are
considered to be of significant environmental concern. PM10 and SO2 are not considered significant
due to the use of virtually sulphur free natural gas as the fuel.
6.4.1 CO2 Emission Control
CO2 emissions are of environmental concern due to their global warming potential. At the project site,
CO2 will be generated from the combustion of fuel gas in the gas turbines, steam generators, furnaces
and flares. Only the mass emission rate of CO2 is of any relevance. Emission concentrations are not of
concern since ground level concentration of CO2 is virtually unaffected due to atmospheric dilution.
Currently, the best practice in the world for minimization of CO2 generation is through source
reduction, which includes
(i) Selection of fuel that contains less carbon content per unit energy content; and
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(ii) Improving energy conversion efficiency.
These two principles for CO2 reduction are applied in the design of combustion systems used in PC
Plant. These are highlighted below:
Use of natural gas as the primary fuel, which has the lowest CO2 emission factor among all
fossil fuels.
Use of high efficiency furnaces to minimize fuel gas consumption.
Recovery of off-gases containing hydrocarbons for reuse as fuel gas.
Use of energy efficient gas turbine technology for power generation.
6.4.2 CO and HC Emission Control
CO and un-burnt HC result from incomplete combustion of the fuel. Since incomplete combustion
leads to high-energy consumption and thus high operating costs, all modern combustion systems are
designed to achieve very high thermal efficiency. While high combustion temperature and high air-
fuel ratio yield low CO and un-burnt HC generation, such conditions have a negative effect on NOx
generation and overall energy recovery. Therefore, through optimal mixing of fuel and combustion
air and controlling the combustion temperature, CO and un-burnt HC emissions are minimized while
ensuring NOx emissions and overall thermal efficiency are not compromised. For flares, steam
injection is considered, as explained in Chapter 3 and using of smokeless flare, will further reduces
CO and UHC emissions.
6.4.3 NOx Emission Control
Among all the air pollutants, NOx emissions are considered to be of concern in the combustion
systems. PM10 and SO2 emissions are not of concerns due to the use natural gas as the fuel, which is
virtually sulphur free.
Low NOx combustion systems will be used for NOx emission control. As discussed in the preceding
section, care should be taken such that NOx reduction is not achieved at the expense of higher CO and
unburnt HC emissions. The following alternatives are available for low NOx emissions:
Water injection systems;
Steam injection systems; and
Dry low NOx (DLN) combustion systems.
All the above systems work on the similar principle of reducing the flame temperature to minimise
thermal NOx. Water or steam injected into the combustion system quenches the flame temperature.
While these designs are relatively less expensive compared to DLN design, they require significant
quantities of highly purified water. Considering that there are no natural sources of fresh water at the
project site, DLN burners are selected for all the major combustion systems, viz., gas turbines, steam
generators and furnaces.
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Emissions control using DLN burners relies on multiple combustion staging to optimise fuel-air
ratios. This is achieved through premixing fuel and air in various combinations, depending on the
desirable operating temperature. The emission control system regulates the division of the fuel among
the multiple combustion stages according to a schedule that is determined by a calculated value of the
combustion reference temperature. The control system also monitors the actual combustion system
operation to ensure compliance with the required schedule.
6.5 Sourcing of Fuels and Utilities during Construction Phase
The construction activities typically will involve site preparation, leveling, excavation, laying
foundations, building concrete structures, assembling and installing plant equipment, etc. The
construction materials used in project construction include aggregates, sand, cement, steel, wood,
surface-coating materials etc. All such materials can be sourced from local market. Since the project is
within an approved industrial area, the supply and transport of materials can be done through existing
vendors and transporters. Major plant equipment and components, which are to be sourced from
suppliers outside Oman, will be imported through sea and the existing port in Sohar will be potentially
used for the purpose thus avoiding the need for long distance road transportation of heavy plant
equipment. However, equipment / components, which are supplied from vendors in Oman, will have
to be transported on road to the proposed plant
The major utilities required during the construction phase of the project are power, non-potable water
and drinking water.
6.5.1 Power
The alternatives that may be considered are import from the local grid or the use of on-site diesel
generators. The first option is better from environmental considerations. Therefore, it is proposed,
when feasible, to source required power from the local grid, which has sufficient generating capacity
to meet the required construction demand. It is however recognised that during the initial stages of
project construction and until power import arrangements are made, on-site power generation may be
needed. Also due to construction activities it may not be practical to run power lines in certain
construction areas. This may continue throughout the project. During these periods, appropriate diesel
generators will be installed at site.
6.5.2 Water
The estimated peak non-potable water demand during construction phase will be 340m3/d, which
includes both construction water and non-potable water at site. Non-potable water at site can be
sourced from local groundwater wells or generated at site using a packaged RO plant. Groundwater
available near the project site has relatively high TDS and is not suitable for potable use but is still
suitable for agriculture. The current total demand of groundwater for agriculture is considered to be in
excess of local groundwater availability. Moreover, groundwater extraction has been rising steadily in
recent times to supply non-potable water for a number of ongoing construction projects in Sohar.
Therefore, the long-term sustainability of the local supply wells is not established. It is therefore
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proposed that either the EPC contractor will install a packaged RO plant at site or procure water by
tanker (depending on operational feasibility) to meet all non-potable water requirements associated
with the project construction.
In addition non-potable is required in labour camps. Labour camps will be located outside the project
site, either in Sohar or Liwa municipal areas. Depending on the exact location of each labour camp,
non-potable water may be sourced from municipal water supply lines or from the RO plant installed
by the contractors or by water tankers (depending on operational feasibility).
For drinking water at project site, it is proposed to use bottled mineral water. This option is considered
to be better in all respects in comparison to the other alternative of treating RO water or municipal
water to meet drinking water standards. For labour camps, either bottled water or treated municipal
water will be used.
6.5.3 Fuels
The fuels used during construction phase are diesel oil and petrol. Heavy construction equipment and
heavy transport vehicles are diesel oil fired, while light vehicles are petrol fired. The fuels will be
sourced from local fuel oil suppliers like Shell, Oman Oil and Al Maha.
The option of using dispensing tankers will be more suitable option for the Project. Such tankers can
be supplied and maintained by the central facilities of the contracting companies. This avoids the need
for onsite fuel storage and related safety protection systems. As the Project is in SIPA which is well
connected by road, the option of using tankers is the most suitable option. However, this will depend
upon the quantity of fuel required during the construction and will be finalised by the EPC contractor
based on the site requirements and logistics.
6.5.4 Sourcing of Construction Materials
The construction materials used in project construction include aggregates, sand, cement, steel, wood,
surface coating materials etc. All materials that are available locally or within the country will be
procured from local market unless they do not meet the quality requirements. All other materials will
be sourced from internally suppliers either directly or through their local agents.
6.5.5 Siting of Labour Camps
A number of contractors and subcontractors will be engaged in the project construction. The
construction staff accommodated in labour camps would be up to 1000 persons during the peak
construction period. A sizeable percentage of the total construction staff is expected to be local Omani
staff, who will have their own accommodation in Sohar or nearby areas. Non-local staff will be
accommodated in labour camps. It is the responsibility of the contractors and sub-contractors to set up
and operate labour camps for their staff. It is expected that they will either utilise the existing labour
camps or construct new labour camps.
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At this stage, it is not known how many new labour camps will be constructed and where, since the
sub-contractors are not yet identified. The EPC contractor will require the selected sub-contractors to
include the following criteria, while selecting sites for constructing new labour camps:
Compliance with local town planning restrictions;
Low environmental sensitivity;
Proximity to the site to minimise transport of workers to site and back;
Availability of access roads to site;
Avoidance of agricultural or highly vegetated sites; and
Availability of sustainable water sources.
6.6 BAT for Polymer Area
6.6.1 Polymer BREF
Reduce fugitive emissions by advanced equipment design including:
Use of valves with bellow or double packing seals or equally efficient equipment, Design considerations for
the equipment's are carried out as double packing seals.
Bellow valves are especially recommended for highly toxic services, Polymer plants (PP/PE) do not have
highly toxic chemicals requiring use of bellow valves, It’s may be considered in hot oil system where
temperature reach 250Deg C and pressure of 6 bar, for personnel protection.
Minimization of the number of flanges (connectors), Considered during design special care shall be given
to TEAL handling area.
Effective gaskets , this has been considered as a part of design.
Closed sampling systems wherever possible, Considered during design, close sampling system for
hydrocarbon and powder are foreseen and on line Hydrocarbon Analyzers whereas continuous monitoring
is requested for process or safety requirements.
Drainage of contaminated effluents in closed systems, Accidental Oil Contamination system and storm
water from process area are closed systems.
Collection of vents and Suitable disposal method, Considered during design: all hydrocarbon vents and
drains are connected to the flare system.
Establish and maintain an equipment monitoring and maintenance (M&M) and/or leak detection and repair
(LDAR) program based on a component and service database in combination with the fugitive loss
assessment and measurement , As per Orpic’s management policy the LDAR programs will be implemented
once the facility is under operation.
Reduce dust emissions with a combination of the following techniques
Use of cyclones and/or filters in the air exhausts of de-dusting units. The use of fabric filter systems is
more effective, especially for fine dust. In Polymer plants (PP/PE) all vessels handling polymer
powders are equipped with cyclone or bag filters (Polypropylene fabric) to avoid dust emission.
Vacuum cleaning system for dust cleaning is foreseen in the additives and extrusion area.
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Minimize plant start-ups and stops to avoid peak emissions and reduce overall consumption (e.g. energy,
monomers per ton of product); this has been considered as a part of design.
Secure the reactor contents in case of emergency stops (e.g. by using containment systems) In case of
emergency all the reactor vents are routed to the flare system.
Prevent water pollution by appropriate piping design and materials and facilitate inspection and repair of
effluent water collection systems, As per drainage philosophy separate drainage system will be provided
and will be inspected as per requirement.
Use separate effluent collection systems for: As per drainage philosophy separate drainage system will be
provided for
Contaminated process effluent water system.
Oily water system.
Storm water system.
Treating purge flows coming from blending silos vents with the following technique: activated carbon filter
for adsorptions at all silos vents, if required.
Use flaring systems to treat discontinuous emissions from the reactor system. Flaring of discontinuous
emissions from reactors is only BAT if these emissions cannot be recycled back into the process or used as
fuel: During plants upsets, equipment trips or utility failures the Reactor will be vented to the flare system,
no recycle is possible due to the presence of solids in the streams. During normal operation any venting
from process will be recycled back in to the process.
Re-use the potential waste from a polymer plant; Continuous wastes like extrusions discards, plant sweep
from polymer plant will be sold and reprocessed to external companies.
Treat waste water efficiently. Waste water treatment can be carried out in a central plant or in a plant
dedicated to a special activity. Depending on the waste water quality, additional dedicated pretreatment is
required. Process water will be routed to Central WWTP, hence such requirements should eventually be
imposed to the WWTP located in Plot 18 and included in SCU,U&O scope.
6.6.2 BAT Polyethylene
Recover monomers from reciprocating compressors in PE process recycling them back to the process;
Already part of current process design.
Operate the reactor at the highest possible polymer concentration. By increasing the concentration of the
polymer in the reactor, the overall energy efficiency of the production process is optimized , Unipol and
Spheripol technologies selected are the most efficient currently available on the market for licensing.
Use closed-loop cooling systems. this has been considered as a part of design.
6.6.3 BAT LLDPE
Condensation of the solvent (isopentane); Project is currently considering membrane technology option,
this is implemented in few units with conflicting results to operability; required overdesign of the
compressor will be eventually made for future implementation and flaring reduction.
Solvent selection - Low boiling solvents and suspension agents can be removed more easily and with less
consumption of energy from the product leading to a reduction of VOC emissions from the storage; Iso-
pentane is Low Boiling solvent and has been considered in design, no alternatives are currently available
Avoid oxygen intrusion into the Extruder feeding section; this has been considered as a part of design.
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Treatment of purge nitrogen from Product Purge Bins. The purged N2 will be Flared at the rate of 1,400
kg/hr with HC content of less then 2%, see above for the considerations currently ongoing to recover
Nitrogen and Hydrocarbons using membranes
6.7 Steam Cracker Unit
6.7.1 Large Combustion Plant
The PC plant has natural gas fired boilers, incinerators; GT’s and flares in the facility. The BAT that
is to be considered for the PC plant is as follows:
NOx emissions from furnaces to be reduced through use of low NOx burners this has been
considered as a part of design;
Use of control systems (hardware and software) for the core process and pollution control
equipment to ensure stable operations, high yields and good environmental performance under all
operational modes this has been considered as a part of design;
Implementation of a waste management system that includes ongoing waste minimization to
identify and implement techniques that reduce emissions and raw material consumption;
Approved vendor procedures will be used in all phases of the project and will have consignment
memos for the transfer and receipt of the any type of waste generated at the facility;
Minimise energy use and maximize energy recovery Combined Cycle; As a part of design waste
heat recovery has been considered from all GT’s;
Implement Leak Detection and Repair (LDAR) program for detection, monitoring and
minimization of leaks on pipes and equipment, fugitive emissions As per Orpic’s management
policy the LDAR programs will be implemented once the facility is under operation;
Repair pipe and equipment leaks in stages, carrying out immediate minor repairs (unless this is
impossible) on points leaking above some lower threshold and, if leaking above some higher
threshold, implement timely intensive repair. As per Orpic’s management policy the LDAR
programs will be implemented once the facility is under operation.
Minimize process water contamination with raw material, product or wastes by the use of –
Drum storage on concrete hard-standing that drains to a holding sump, this has been
considered as a part of design and same will be reflected in standard Operating
Procedures (SOP) Drain drums provided in tankage and ISBL areas however
FEED design to include the required provisions in datasheet/technical
specifications);
Providing spill clean-up material at strategic points around the installation and a
spill contingency plans, this has been considered as a part of design and same will
be reflected in standard Operating Procedures (SOP);
Increase the thermal efficiency of the plant to reduce greenhouse gases, in particular releases of
CO2 at the project FEED stage considering waste heat recovery thermal efficiency has been
improved by implementing this system;
Providing external floating roof with secondary seals (except for highly dangerous substances) for
storage tanks; Not Applicable
Providing fixed roof tanks with internal floating covers and rim seals (for more volatile liquids)
and with inert gas blanket (e.g. when needed for safety reasons); Noted
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Providing instrumentation and procedures to prevent overfilling and constructing impermeable
secondary containment with a bund capacity of 110 % of the largest tank; this has been
considered as a part of design additionally inlet streams shall be cutoff based on high level
interlocks;
Recovery of VOCs (by condensation, absorption or adsorption) before recycling or destruction by
combustion in an energy raising unit; Not Applicable
Minimise process water contamination with raw material, product or wastes by the use of –
Plant equipment and effluent collection systems made from corrosion resistant materials to
prevent leaks into wastewater, As per drainage philosophy wastewater will be temporary
stored in the concrete lined pit before sending for treatment and/or disposal. Acid gases will
be directed via separate riser to main flare tip, to minimize the corrosion problems in main
flare header and stack closed blowdown systems designed to control potential hydrocarbon
leaks to water system with recovery systems
Drum storage on concrete hard-standing that drains to a holding sump, this has been
considered as a part of design and same will be reflected in standard Operating Procedures
(SOP); Drain drums provided in tankage and ISBL areas however FEED design to include
the required provisions in datasheet/technical specifications;
Providing spill clean-up material at strategic points around the installation and a spill
contingency plans, consider in design during FEED phase of the project and will be
implemented during EPC stage and operation of the plant; Loss prevention philosophy to be
quoted with applicable standards;
Providing containment areas for fire-fighting water, consider in design during FEED phase
of the project and will be implemented during EPC stage and operation of the plant;
Constructing effluent collection systems (pipes and pumps) either placed above ground or
placed in ducts accessible for inspection and repair, or leak-free sewers (e.g. welded HDPE,
GRP), as per Drainage Philosophy this BAT has been already covered under design and
will be implemented
Maximizing wastewater re-use by the use of following:
Identifying options for the wastewater re-use commensurate with the wastewater quality; It
has clearly mentioned in drainage philosophy that the treated wastewater will be sent to
MISC for further use as irrigation or it is based on the MISC to be considered for final usage
Providing storage tanks for wastewater to balance periods of generation and demand; is part
of MISC
Increase the thermal efficiency of the plant to reduce greenhouse gases, in particular releases of
CO2; Pressure points and Boilers are Standardized and Optimized, Steam network will be
optimized no extra steam produced during operation, Steam assisted flaring etc.
Catalytic oxidation treatment of off gases to reduce VOC emissions; Not Applicable
All solid waste to be re-used or recycled to the extent possible; For dedusting off-gases from
combustion plants, BAT is the use of an electrostatic precipitator (ESP) or a fabric filter (FF),
where a fabric filter normally achieves emission levels below 5 mg/Nm3; Clean fuels shall be
utilized forSteam boilers,furnaces and power plant hence reduced potential for solids.Furnace technology
selected has provision for coke burning inside the furnace
BAT for the minimisation of CO emissions is complete combustion, which can be achieved with
good furnace design, the use of high performance monitoring and process control techniques, and
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maintenance of the combustion system; Considered in Design and will be implemented during
Operation phase
Surface run-off from the plant to be collected separately and re-used only after a sedimentation
step or chemical treatment. NA as Per Drainage Philosophy
6.7.2 BAT for Large Volume Organic Chemicals
Some of the techniques that are to be considered for the PC plant as per BAT requirement are as
follows:
NOx emissions from furnaces to be reduced through equipment revisions such as low NOx
burners consider in design during FEED phase of the project and will be implemented during
EPC stage and operation of the plant;
Use of control systems (hardware and software) for the core process and pollution control
equipment to ensure stable operations, high yields and good environmental performance under all
operational modes; consider in design during FEED phase of the project and will be implemented
during EPC stage and operation of the plant additional studies will be carried out for area
monitoring;
Implementation of a waste management system that includes ongoing waste minimization to
identify and implement techniques that reduce emissions and raw material consumption; As per
operation philosophy pre-treatment of feed to remove H2S, less SO2 feed-stock,minimum caustic
as per optimization will be calculated and used;
Minimise energy use and maximize energy recovery optimised furnace design WHR, from flue
gas; Reuse heat from furnace effluent to heat process stream and generate steam, Pressure levels
and refrigerant usage will be minimum as the SCU is optimized, generation of HP steam for
Steam Turbines will be carried from waste heat of the heaters;
Implement LDAR program for detection and minimization of leaks on pipes and equipment; As
per Orpic’s management policy the LDAR programs will be implemented once the facility is
under operation;
Repair pipe and equipment leaks in stages, carrying out immediate minor repairs (unless this is
impossible) on points leaking above some lower threshold and, if leaking above some higher
threshold, implement timely intensive repair. As per Orpic’s management policy the LDAR
programs will be implemented once the facility is under operation;
Providing external floating roof with secondary seals (except for highly dangerous substances) for
storage tanks; Not Applicable;
Providing fixed roof tanks with internal floating covers and rim seals (for more volatile liquids)
and with inert gas blanket (e.g. when needed for safety reasons); Has been considered in design
and is also covered in tankage philosophy;
Providing instrumentation and procedures to prevent overfilling and constructing impermeable
secondary containment with a bund capacity of 110 % of the largest tank; Tankage has
considered the bund capacities in the design;
Recovery of VOCs (by condensation, absorption or adsorption) before recycling or destruction by
combustion in an energy raising unit; Boil off gas recovery system and reuse;
Minimise process water contamination with raw material, product or wastes by the use of:
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Plant equipment and effluent collection systems made from corrosion resistant materials to
prevent leaks into wastewater. As per drainage philosophy wastewater will be temporary
stored in the concrete lined pit before sending for treatment and/or disposal Plant equipment
and effluent collection systems made from corrosion resistant materials to prevent leaks into
wastewater, As per drainage philosophy wastewater will be temporary stored in the concrete
lined pit before sending for treatment and/or disposal.
Drum storage on concrete hard-standing that drains to a holding sump, consider in design
during FEED phase of the Project and will be implemented during EPC stage and operation
of the plant;
Providing spill clean-up material at strategic points around the installation and a spill
contingency plans, consider in design during FEED phase of the Project and will be
implemented during EPC stage and operation of the plant;
Providing containment areas for fire-fighting water, consider in design during FEED phase of
the Project and will be implemented during EPC stage and operation of the plant;
Maximizing wastewater re-use by the use of following:
• Identifying options for the wastewater re-use commensurate with the wastewater quality; It
has clearly mentioned in drainage philosophy that the treated wastewater will be sent to
MISC for further use as irrigation or it is based on the MISC to be considered for final usage;
and
• Providing storage tanks for wastewater to balance periods of generation and demand; is part
of MISC
6.7.3 BAT for Incinerators
There are two types of incinerator in the proposed plant for the vent gas, (liquid waste and solid waste
incineration). BAT considered for incinerators in the proposed plant are:
The maintenance of the site in a generally tidy and clean state; Has been considered in SOP and
maintenance philosophy’
Maintain all equipment in good working order, and carry out maintenance inspections and
preventative maintenance; Has been considered in SOP and maintenance philosophy’
Establish and maintain quality controls over the waste input, according to the types of waste that
is received at the installation; Quality check will be performed at both the ends for at disposal end
and receiving end;
The wastes shall be stored according to a risk assessment of their properties, such that the risk of
potentially polluting released is minimised. Waste shall be stored in areas that have sealed and
resistant surfaces, with controlled and separated drainage; Dedicated storage facilities for liquid
and solid waste has been considered in the design;
Minimise the release of odour (and other potential fugitive releases) from bulk waste storage areas
and waste pretreatment areas by enclosing the waste storage areas and limiting the size of the
entrances to the waste storage areas and maintaining the storage under a slight negative pressure;
Design incorporated the utilization of the closed system, Vent gases from storage tanks will be
sent to vent gas incineration for compete combustion;
Make provision for the control of odour (and other potential fugitive releases) when the
incinerator is not available (e.g. during maintenance) by avoiding waste storage overload, and/or
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extracting the relevant atmosphere via an alternative odour control system, Backup for vent gas is
going to LP flare, and has been considered in design;
Developing a plan for the prevention, detection and control of fire hazards at the installation, in
particular for waste storage and pre-treatment areas, furnace loading areas, electrical control
systems etc; Active fire protection and fire and gas detection is planned and will be installed;
Use automatic fire detection and warning systems, and a manual or automatic fire intervention
and control system as required according to the risk assessment carried out; Active fire protection
and fire and gas detection is planned and will be installed;
Use of combustion control philosophy, and key combustion criteria and a combustion control
system to monitor and maintain these criteria within appropriate boundary conditions, in order to
maintain effective combustion performance; Controlled and monitored combustion within the
incinerator is part of package and will be optimised based on the material to be incinerated; and
Optimisation and control of combustion conditions by a combination of control of air (oxygen)
supply, distribution and temperature, including gas and oxidant mixing, the control of combustion
temperature level and distribution, and control of raw gas residence time; Controlled and
monitored and optimum residence time has been considered for the incinerator package.
6.7.4 BAT to Control Odour Emissions
Different potential sources of odours are generally released from the following process units:
Fugitive emissions from leaking process components (e.g. valves, pump seals, flanges);
Wastewater Treatment Facilities; Odour management plan will be prepared
Bulk Storage Tanks, All bulk storage tanks will be connected to VOC incinerator, or to
recovery system wherever possible.
It is recognized that odour abatement is linked to VOC abatement. Leaking of relief valves, safety
valves, bypass valves, and control valves can lead to fugitive emissions from the plant. BAT
considered for odour emissions in the proposed plant are:
Use a Leak Detection and Repair (LDAR) programme for the control of fugitive releases; As
per Orpic’s management policy the LDAR programs will be implemented once the facility is
under operation;
Use alternative proven types of low-release valves where gate valves are not essential, e.g.
quarter turn and sleeved plug valves, both of which have two independent seals; This point of
BAT has been covered in details for valve specification and piping in piping specification
document and will be implemented;
Minimise the number of flanged connections on pipelines and use high specification jointing
materials; use canned pumps or double seals on conventional pumps; piping of compressor
seals and vents: This point of BAT has been covered in details for valve specification and
piping in piping specification document and will be implemented, which is aligned with
piping specification ;
Use end caps or plugs on open ended lines and closed loop flush on liquid sampling points; It
is covered in sampling SOP and based on the type of chemicals to be sampled same will be
followed;
Identify and, where possible quantify, significant fugitive emissions to air from all the
specific relevant sources, estimating the proportion of total emissions that are attributable to
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fugitive releases for each substance. Where there are opportunities for reductions, the Permit
may require the updated inventory of fugitive emissions to be submitted. Same has been
calculated using the Tanks Model and estimated fugitive loss as TPA; and
Leak Detection and Repair (LDAR) compromises the detection and reparation of flare pipe
shutoff valves. A portable instrument is used to detect VOC leaks during regularly scheduled
inspections. Leaks are then repaired immediately or scheduled for reparation as quickly as
possible. An LDAR contains the following elements: As per Orpic’s management policy the
LDAR programs will be implemented once the facility is under operation.
6.7.5 Control of Emissions from Storage Tanks
This BREF provided BAT for storage of liquids related to tank design, inspection and maintenance,
location and layout, tank colour, emissions minimisation, VOC monitoring, and dedicated systems.
Listed below are BATs considered for storage tanks in the proposed plant:
Inspect vapor pressure of the stored material; Considered and detailed in tank design philosophy;
Bund all stored chemicals, with separate bunding for incompatibles; Considered and detailed in
tank design philosophy;
Apply emission reduction measures during tank cleaning; Considered and detailed in tank design
philosophy;
Apply concepts of good housekeeping and environmental management; Considered and detailed
in tank design philosophy;
Minimize number of tanks and volume by a suitable combination of: application of inline
blending, integration of processing units, co-operation with partners in industry; Considered and
detailed in tank design philosophy;
Enhance vapor balancing and back venting during loading/unloading processes; Considered and
detailed in tank design philosophy;
Apply vapor recovery (not applicable to non-volatile products) on tanks, vehicles, ships etc. in
stationary use and during loading/unloading; Considered and detailed in tank design philosophy
and Boil off gas and volume displacement gas/vapour recovery systems for marine and stationary
source has been considered in the design;
Reduce (risk of) soil contamination by the implementation of an inspection and maintenance
programme that could include implementing good housekeeping measures, double-bottom tanks,
impervious liners, good housekeeping practices (draining, sampling, tank bottoms); SOP and
maintenance philosophy has been consider in design and will be implemented at EPC and
Operation phase;
Install self-sealing hose connections or implement line draining procedures; SOP and
maintenance philosophy has been consider in design and will be implemented at EPC and
Operation phase. Moreover drainage philosophy will also be followed for process drains which is
closed loop;
Install barriers and/or interlock systems to prevent damage to equipment from the accidental
movement or driving away of vehicles (road or rail tank cars) during loading operations;
Considered and detailed in tank design philosophy;
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Implement procedures to ensure that arms are not operated until inserted fully into the container
to avoid splashing where top loading arms are used; SOP and maintenance philosophy has been
consider in design and will be implemented at EPC and operation phase;
Apply instrumentation or procedures to prevent overfilling; Considered and detailed in tank
design philosophy; and
Install level alarms independent of normal tank gauging system. Considered and detailed in tank
design philosophy and fire and gas detection and control system will be installed.
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7 CLIMATE AFFAIRS
This chapter presents the GHG emissions from the proposed construction and operational activities of
the petrochemical plant and discusses the impact on the climate due to the proposed project. A
forecast of the quantities of GHG emissions using the emission factors from the Intergovernmental
Panel on Climate Change (IPCC) Guideline, and data from the design documents is presented in this
chapter. This chapter has been prepared and structured as per the guidelines from the DGCA at
MECA.
7.1 Contact Details
Organization and contact details for issues related to climate affairs are provided below.
Organization : Oman Oil Refineries and Petrochemical Industries Co.
Address : P.O.Box 282, P.C. 322, Falaj Al Qabail, Sohar
Name of the Contact Person : Mr. Fahd Sharaf
Telephone Number : (+968) 2210 - 6340
7.2 Integration of Climate Affairs Issues to the EIA
7.2.1 Type of ODS
The device likely to contain ODS during project activities are the room air conditioners used in the
site offices and living quarters. Currently, it is expected that up to 25 units of window air conditioners
will be installed in the site offices during construction activities and about 50 units during the
operation phase. R-410A, a blend of hydrofluorocarbons (HFCs) that does not contribute to depletion
of the ozone layer, is the refrigerant used in air conditioners because of its relatively low ozone
depletion potential. The window air conditioners will be sourced, serviced and maintained by
authorized suppliers and service centres in Oman. The suppliers and service centres are expected to
comply with the requirements of MD 107/2013.
7.2.2 Equipment Containing ODS
Controlled substances listed in MD 107/2013 or equipment, appliances and products containing such
substances will not be used during any stage of project activities.
7.2.3 ODS Alternative
Except for the HFC that will be used as refrigerant there will be no other ODS used during either the
construction or operation phase of the project. Orpic shall ensure that EPC contractor identifies and
implement non-ozone depleting refrigerants during the project activities. In case required, all options
will be considered to use ODS substances alternatives.
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7.2.4 Plan for Use of ODS Alternative
As mentioned above, Orpic/EPC contractor, as feasible, will identify suitable non-ODS alternatives, if
any that can be used in the project. Regular maintenance of the air conditioning units will be carried
out, which will help to avoid leaks of refrigerants. Recapture and re-use of refrigerants will be
employed for all equipment undergoing maintenance or being disposed. No equipment containing
ODS will be released from the field without confirming recovery of refrigerants.
7.2.5 Adherence with Ministerial Decision 107/2013
As mentioned earlier, the air conditioning units will be procured from and serviced and maintained by
authorized suppliers and service centers in Oman, which are expected to comply with the
requirements of MD 107/2013. The maintenance of the equipment and handling of the refrigerants
will be carried out only by authorized personnel. The air conditioning units will be maintained
appropriately which will help to minimize leaks of refrigerants. Controlled substances listed in MD
107/2013 or equipment, appliances and products containing such substances will not be used during
any stage of project activities.
7.3 Greenhouse Gas (GHG) Emissions from Energy Sources –
Combustion of fuel from the Project
The GHG emissions during the project construction activity are fuel combustion, predominantly
diesel, in vehicles, construction machinery and DG sets. The sources of GHG emissions include both
mobile and stationary point sources. The mobile sources of GHG emission will be the vehicles for
passenger and material transport, earth moving etc. The point sources of GHG emissions are the DG
units.
Estimates of GHG during the project activity from the sources mentioned above are derived using
emission factors provided in the IPCC 2006 guidelines for National Greenhouse Gas Inventories,
Volume 2. The guidelines provide emission factors for GHG emissions from both stationary
combustion sources and mobile sources. It is to be noted that the mobile sources referred in the IPCC
guidelines cover off road transportation sources including vehicles and mobile machinery used for
construction and maintenance. An estimate of 20,000L/month of diesel fuel (8,000L/month for the
DG sets and 12,000L/month for equipment and vehicles) is expected to be used during the
construction period.
7.3.1 Stationary Combustion Sources
7.3.1.1 Construction Phase
It is expected that a diesel generator of 450 kVA rating will be used to meet power requirements
during the construction period. The construction period is expected to take about 20 months. As
mentioned above it is estimated that approximately 8,000L/m of diesel will be required during the
construction phase for operation of the DG set.
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The type and quantities of the GHG emissions during the construction stage of the project are
presented in
Table 7-1. The detailed GHG emission calculations for stationary combustion sources are given in
Table 7-2.
Table 7-1: GHG Emission from DG Set
Greenhouse Gas Emission (TPA)
Year
CO2 CH4 N2 O
201610 192.734 0.008 0.002
2017 235.564 0.010 0.002
Total 428.298 0.018 0.004
Table 7-2: Detailed GHG Emission Calculation from Stationary Combustion Sources
GHG Emissions from Stationary Point Sources (DGs) Remarks
DG Capacity 450 kVA
8,000 l/m
Diesel requirement
8.0 m³/m
0.86 kg/l
Density of Diesel
6,880 kg/m
LHV of Diesel 42,000 kJ/kg
288,960,000 kJ/m
Energy input
0.289 TJ/m
Stationary Combustion (IPCC Table 2-2)11 Stationary Combustion
CO2 emission factor 74100 kg/TJ IPCC Table 2-2
21,414.900 kg/m (IPCC Guidelines for
CO2 emitted from vehicle movement 21.415 tpm National Greenhouse Gas
256.979 tpa Inventories, 2006)
CH4 emission factor 3 kg/TJ
0.867 kg/m
CH4 emitted from vehicle movement 0.000867 tpm
0.010 tpa
N2O emission factor 0.6 kg/TJ
0.173 kg/m
N2O emitted from vehicle movement 0.000173 tpm
0.002 tpa
7.3.1.2 Operation Phase
During the operation phase the main stationary sources of GHG (i.e., CO2, CH4 and N2O) emissions
will be the various furnaces, the incinerators, the GTs, the steam boilers and the flares. The GHG
emission during operation phase is detailed in Section 7.3.6.
7.3.2 Mobile Combustion Sources
Mobile sources produce direct GHG like CO2, CH4 and N2O from the combustion of mostly diesel
and gasoline road transport vehicles. ,. Greenhouse gas emissions from mobile combustion are
estimated by major transport activity, i.e., road and off-road transportation. The road transportation
10
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category includes all the light and heavy-duty vehicles which operate on liquid or gaseous fuels. The
off-road category includes vehicles and mobile machinery used within the plant (including
construction and maintenance).
7.3.2.1 Construction Phase
The GHG emissions from mobile combustion sources (vehicles, machineries and construction
equipment) during construction phase are presented in Table 7-3.
Table 7-3: GHG Emissions from Mobile Combustion
Greenhouse Gas Emission (TPA)
Year
CO2 CH4 N2 O
201612 288.768 0.016 0.111
2017 352.938 0.020 0.136
Total 641.706 0.036 0.247
Table 7-4: Detailed GHG Emission Calculation for Mobile Combustion Sources
GHG Emissions from Mobile Sources Remarks
12,000 L/m
Diesel requirement
12 m³/m
Density of Diesel 0.86 kg/lit
Diesel consumption 10,320 Kg/m
LHV of Diesel 42000 KJ/kg
Energy input 433,440,000 KJ/ m
0.433 TJ/ m
Mobile Combustion (IPCC Table-3.3.1) Mobile Combustion IPCC
CO2 emission factor 74100 kg/TJ Table 3.3.113
32,085.300 kg/ m (IPCC Guidelines for National
CO2 emitted from vehicle movement 32.085 tp m Greenhouse Gas Inventories,
385.024 tpa 2006)
CH4 emission factor 4.15 kg/TJ
1.797 kg/ m
CH4 emitted from vehicle movement 0.0018 tp m
0.022 tpa
N2O emission factor 28.6 kg/TJ
12.384 kg/ m
N2O emitted from vehicle movement 0.0124 tp m
0.149 Tpa
7.3.2.2 Operation Phase
The mobile combustion sources during the operation phase of the project will be the trucks and other
vehicles used for transporting raw materials/products, shuttling the workers / staff between facility
and accommodation facilities, cars, private vehicles used by employees etc. Since information such as
the number of vehicles and diesel consumption rate of each vehicle, distances travelled by the
vehicles etc., are not available at the time of preparation of the report; the GHG emission for mobile
source during the operation phase is not estimated.
12
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7.3.3 Fugitive Emissions from Oil and Natural Gas System
The PC plant is likely to have diesel storage and dispensing facilities during the construction phase,
and diesel storage and supply facilities during the operation phase. During the operation phase, the
plant will also have natural gas system, including power plant.
Fugitive emissions from oil and natural gas systems are often difficult to quantify accurately. This is
largely due to the diversity of the industry, the large number and variety of potential emission sources,
the wide variations in emission-control levels and the limited availability of emission-source data. The
exact quantities of fugitive emissions cannot be estimated at this stage. The emission from the oil and
natural gas system will be calculated and reported during the EPC phase.
7.3.4 Land Use and Land Change Use or others
Not Applicable
7.3.5 Summary of GHG Emission Calculations
Type of Methodology according to Quantity of Total Emissions
Emission Factor
Activity IPCC fuel (tpa)
Stationary Default Emission Factors For
Combustion Stationary Combustion, Table 2- CO2 –74100 kg/TJ CO2 –256.98
Sources- 2 (IPCC Guidelines for National CH4 – 3 kg/TJ 8,000L/m CH4 –0.010
Construction Greenhouse Gas Inventories, N2O –0.6 kg/TJ N2O –0.002
Phase 2006)
Off -Road transportation
Mobile Mobile Combustion IPCC Table CO2 –74100 kg/TJ CO2 –385.02
Combustion 3.3.1 (IPCC Guidelines for CH4 – 4.15 kg/TJ 12,000 L/m CH4 –0.022
National Greenhouse Gas N2O – 28.6 kg/TJ N2O –0.149
Inventories, 2006)
Others - - - -
7.3.6 GHG Emissions from Industrial Process of the Proposed Plant/Industry
As mentioned earlier the potential sources of GHG emission during the operation phase include
emissions from flares, boilers, GT, incinerators etc. The aforementioned sources are continuous. In
addition, the plant will have DG that will be used during emergencies and hence will be an
intermittent source. The expected frequencies and periods of operation of this DG is not known at
present. It is envisaged that DG will be used for a very short period during emergencies and hence the
GHG emission is expected to be negligible. The plant will use FG and NG as fuel. The FG will be
mixed with NG and used as fuel for the various units in the plant. The power plant etc., will be run on
natural gas. The emergency DG will use diesel as fuel. The total hourly consumption of natural gas is
54,800kg/h during the operation phase of the proposed plant. Assuming that commercial operation
commence in Q3 2018, the GHG emission from combustion of natural gas is detailed in Table 7-6.
Table 7-5: GHG Emission from Industrial Process
GHG's (TPA)
Year
CH4 CO2 N2 O
2018 11.127 624,197.772 1.113
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Table 7-6: Detailed GHG Emission Calculation from Industrial Process Combustion
Details Units Value Remarks
kg/h 54,800
Fuel gas Consumption
kg/day 1,315,200
LHV of Fuel gas MJ/kg 47
Energy Input TJ/day 61.814
Emission Factor
CO2 kg/TJ 56,100 Stationary Combustion IPCC Table
CH4 kg/TJ 1 2.214
N2 O kg/TJ 0.1 (IPCC Guidelines for National
Emission Rate Greenhouse Gas Inventories, 2006)
kg/day 3,467,765.400
CO2
tpa 1,248,395.540
kg/day 61.814
CH4
tpa 22.253
kg/day 6.181
N2 O
tpa 2.225
7.3.7 GHG Emissions from Solvent use in the Proposed Plant/Industry
The exact quantity of solvents used in the plant and GHG emission from the same will be calculated
and reported during later stages of the Project.
7.3.8 GHG Emissions from Solid Waste generating from Plant/Industry
premises
The recyclable hazardous and non-hazardous waste generated at plant will be collected and stored
according to MD 18/93 and MD 17/93. As detailed in Section 3.10.3 the waste streams produced in
the petrochemical plant will be incinerated using three different type of incinerator system as follows:
Vent gases with toxic components or smelly fumes will be routed to the Vent Gas Incinerator;
and
Liquid streams and solid waste will be incinerated in Liquid/Solid Waste Incinerator.
Incineration of waste is sources of greenhouse gas emissions, like other types of combustion. Relevant
gases emitted include CO2, CH4 and nitrous oxide N2O. Normally, emissions of CO2 from waste
incineration are more significant than CH4 and N2O emissions.
7.3.8.1 CO2 Emission
Solid Waste
CO2 emission from solid waste incineration is calculated as follows:
Where Swi – Total amount of solid waste incinerated – 20.045 Gg/y
dmi – dry matter content in waste – 100%
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CFi – fraction of carbon in dry matter – 50 (default value for industrial waste)
FCFi – fraction of fossil carbon in total carbon – 90 (default value for industrial waste)
OFi - Oxidation Factor – 100 (default value for industrial waste)
i.e. Total CO2 emission is 33.074 Gg/y (33,074.25 tpa) from solid waste incineration
7.3.8.2 CH4 Emission15
CH4 Emissions = IWi X EFi x10E-6
IWi= amount of waste incinerated = 20.045Gg/y
EFi = aggregate CH4 emission factor kg CH4/GG waste = 6kg/Gg waste
Total CH4 emission is 0.0012Gg/y or 1.2tpa from solid waste incineration
7.3.8.3 NO2 Emission
IWi – amount of solid waste incinerated in Gg/y -20.045
EFi –NO2 emission factor, kg NO2/Gg of waste – 41g NO2/t waste ~0.000041 kg/Gg waste
NO2 = 20.045 Gg/y x 0.000041 kg/Gg waste = 0.00082 Gg/y
Total NO2 emission is 0.822 tpa from solid waste incineration
7.3.9 GHG Emissions from Wastewater Treatment in the Plant/Industry
premises
During the operational phase the plant will generate process effluents the total quantity of which is not
available at the present stage. As explained in Chapter 3 the wastewater streams will be treated
using appropriate treatment methods in the WWTP within the plant site. WWTP are significant
sources of emissions. These emissions could include the GHGs, such as CH4 and N2O. However,
information such as organic load, sludge generation rate, protein consumption rate, etc. cannot be
estimated at the present stage of the Project. Such data will be available either during detailed design
stage or during the operation phase of the project. Therefore, emissions of CH4 and N2O from
wastewater treatment cannot be estimated at present in this study.
7.3.10 Reporting Total Amount of GHG Emission
The GHG emission for the project is mainly during the construction period. The GHG emission
during the operation phase is mainly from the use of natural gas in flare, boilers, incinerators and the
wastewater treatment. Since no detailed information on the WWTP is available at the time of
15
For estimation of methane from incineration semicontineous incineration with stoken technology is assumed
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preparation of the report, the GHG emission from the same is not reported in this study. The total
GHG emission expected from the proposed facility are presented in Table 7-7 below.
Table 7-7: Total GHG Emissions (TPA)
Year CH4 CO2 N2 O SF6 HFC PFC
2016 0.024 481.502 0.113 Nil Nil Nil
2017 0.029 588.502 0.138 Nil Nil Nil
2018 11.727 640,734.902 1.524 Nil Nil Nil
2019-2034 586.325 32,036,744.750 76.175
Total 598.106 32,678,549.656 77.950 Nil Nil Nil
Annual Mean 22.152 1,210,316.654 2.887 Nil Nil Nil
From the above table it is seen that total CO2 emissions from the PC project would be about
32,678,550 t. In terms of global warming potential, the sum of GHG emissions during the project life
cycle would be 32,716,731t of CO216 equivalent
Currently, there is no ceiling limit set for CO2 emissions (mass) rates in Oman. According to the UN
Statistic Division and the Carbon Dioxide Information Analysis Centre (CDIAC) estimates, the
emissions in Oman were about 57,202 thousand tons per annum (tpa) during 2010, i.e. about 156,718
tpd.
In comparison with the estimates, the total CO2 emission from proposed activity is approximately
1,210,317TPA or 3,316TPD which would account for approximately 2%, of the total estimated
quantity of CO2 released each day in Oman.
7.4 Climate Change Risk and Impact Assessment
The release of GHGs into the atmosphere results in global warming which in turn could potentially
result in raise in sea levels. Further, the wind and wave patterns could be affected resulting in climate
and weather changes. Oman in recent years has experienced increasing frequency of rain events.
Additionally, the cyclones that originated in the Arabian Sea were earlier estimated to hit Oman’s
mainland once in ten years. However, Cyclone Gonu (2007) and Cyclone Phet (2010) were
experienced in a span of three years. However, these tropical cyclones have had minimal effect on the
coasts of Sohar.
The proposed PC plant will also contribute to GHG emissions. Cumulative impacts on climate change
will be resultant of other industrial activities in SIPA. In addition, road and sea traffic at the existing
and proposed infrastructure would contribute to GHG emissions and climate impacts. It is expected
that as part of the environmental permitting and reporting procedure in Oman, individual industries
will be monitoring and reporting such information to MECA and therefore, are not included here.
It is possible that an increase in the frequency of severe storm and flooding events could result under
climate change. The overall vulnerability of the project to climate change is low. However, it is not
possible to predict such events or estimate chances of occurrence due to lack of appropriate data. The
PC project has taken into account extreme events such as floods, cyclones, storms and rains.
16
http://www.epa.gov/cleanenergy/energy-resources/calculator.html
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Any disruptions that occur as a result of shutdowns caused by weather events will be short term in
nature. An overall change in climate will not affect the operation of the facilities. From the above
discussion, Climate Affairs Risks Matrix is given in Table 7-8 below.
Table 7-8: Climate Change Matrix
Climate Impacts due
Frequency/ degree of
Type of Risks to identified Risk Magnitude
Vulnerability
Vulnerability
Natural Disasters such as cyclone,
earthquake, high waves, landslides 1 1 1
and dust storms
Sea Level Rise 1 1 1
Temperature Increase 1 1 1
Heavy Rains 1 1 1
Flash Flooding 1 1 1
7.5 Identifying Alternatives and Mitigation Measures
New process technologies have been considered in the
design to maximise the energy efficiency and further to
Identify the new technologies and measures minimise the energy consumption. The detailed energy
to minimize the energy consumption and audit will be conducted during operational phase.
1
improve the energy efficiency for all stages The construction vehicles and equipment are sources
of the project. that will be used for short term. Orpic is intending to
use the best performing equipment in regards to GHG
emissions to the maximum extent possible and feasible.
Identify the potential usage of renewable
energy for all the stages of the project and At present the project is in FEED stage, during the
explain the future visions of how to operation phase of the project, Orpic will
2
incorporate them into the project activities identify/examine the feasible sources of the renewable
and how to eliminate the barriers, if exits, energy usage.
which prevents such action.
As explained above, the plant is under FEED stage.
During the subsequent detailed design, possibility of
using renewable energy such as solar powered lighting
Further should explore the benefits of CDM for the external lightings will be explored. Such plan
3
under Kyoto Protocol. and details will be communicated to MECA upon
finalization.
The plant currently does not involve opportunities for
carbon capture, reduction or sequestration.
It is proposed to develop greenbelt at the periphery of
the project site. This greenbelt development will prove
Describe plantations green covers trees etc.,
to be a sink for greenhouse gas emissions from the
which suits to local environment and
4 process.
conditions in order to increase the area of
It is to be noted that at present project is under FEED
GHG sinks.
stage, dedicated land for green belt development will
be allocated at the final design stage.
Determine the % of GHG sinks (green cover) As mentioned above this will be finalized at the final
5
compare to the total area of the project. design stage
It is to be noted that at present project is under FEED
stage, dedicated land for green belt development will
Attach the landscaping plan/design of be allocated at the final design stage.
6
proposed plantation/ green cover.
Landscaping plan yet to be finalized and same will be
communicated with MECA at the final Design stage
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7.6 Climate Affairs Risk Reduction Plan (CARRP)
Orpic has taken appropriate care during the project design stage to counter the impacts of natural
disasters and other anticipated vulnerabilities on the project infrastructure. Summary of the procedures
and tools to adapt and mitigate the impacts of climate change for the project in case of floods or
hurricanes, Sea level rise, Dust Storms, Earthquakes, Tsunami and Increase in temperature are shown
in following section below:
7.6.1 Storm, Flooding Events and Sea Level Rise
Oman receives very scanty rainfall and thus flooding does not occur in the region. Oman is generally
classified as a desert region with arid climate; hence an event of drought will not be relevant. The
project is located in a dedicated industrial area, which is designed to be protected from flooding (as
explained in Chapter 4, SIPA is provided with a peripheral drainage channel to safely discharge storm
water). The proposed PC plant will further have a perimeter drainage channel designed to collect the
storm water and discharge to the common channel.
7.6.2 Global Warming, Increase in Temperature and Sea Level Rise
The release of GHGs into the atmosphere is expected to contribute to the global warming, which in
turn could potentially result in a rise in sea levels. Long-term sea level rise is an on-going process
throughout the world. Historic rates are generally estimated to be in the range of 3.2 mm/year (or 0.16
m over 50 years). The rate of sea level rise is believed to be increasing, and while climate change
scenarios are not precise, the above increase is expected to range from approximately 0.5 to 3.0 mm
per year over the next 50 years (IPCC, 2007).
The proposed PC plant is located within a dedicated industrial area, which is expected to have taken
into account the above aspects.
7.6.3 Landslide
According to World Health Organisation atlas (Figure 7-1) landslide hazard index for complete
Oman is between low and very low. Hence, the likelihood of the PC project being affected by
landslide is very unlikely.
7.6.4 Tsunamis
The greatest tsunami threat facing the Omani coastline is expected to be from the Makran subduction
zone in the Gulf of Oman and the Northern Arabian Sea. However, within the Arabian Gulf it is rather
unlikely for large tsunamis to form. Given that the coast is shallow, not prone to landslides, and is
without volcanoes, the likelihood for tsunamis is relatively small. None of the historical or more
recent submarine or coastal earthquakes has generated tsunamis of any significance in the Gulf, with
the exception of the 1008 AD event, which is not conclusive (as it may have been the result of storm
surge).
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7.6.5 Seismic Intensity
The United States Geological Service (USGS) maintains a database of seismic events and publishes
these in the form of maps and charts. The USGS has not established any seismic stations in Oman but
regional data are available that indicate the potential frequency and magnitude of seismic events. To
this end, seismic activity is monitored by a global network of sensitive seismometers and strain
gauges. The recorded data are processed to provide peak particle acceleration. The resulting ‘hazard’
maps are used to determine the risk of damage to buildings or property and contribute to building
code limits and actuary table development. While such tables have not been developed for the Middle
East, available data indicate low to very low levels of seismic activity within Oman, largely due to its
location away from major tectonic boundaries.
Figure 7-2 and Figure 7-3 present the seismic areas for the Middle East Region indicated by the
number of earthquakes (all depths) per year and seismic events for the period 1990 to 2006
respectively. While there is a low occurrence of earthquakes within faults in the Northern Oman Hajar
Mountains, this activity would not seem to rest of Oman. This is supported by the fact that no
earthquakes have occurred within Oman from 1990 - 2006. Any activity has been limited to major
tectonic boundaries.
Predicted magnitude of seismic events presented as peak ground acceleration for the Middle East
region has been calculated by the USGS based on a worldwide network of seismic stations (Figure
7-4). Peak ground acceleration is a measure of ground motions as a result of seismic or other
activities. Global Earthquake Hazard Distribution-Peak ground acceleration is a 2.5 minute grid of
global earthquake hazards developed using Global Seismic Hazard Program (GSHAP) data that
incorporate expert opinion in predicting localities where there exists a 10 %chance of exceeding a
peak ground acceleration (pga) of 2m/s/y/s meters per second per second (approximately one-fifth of
surface gravitational acceleration) in a 50 year time span. This data set is the results of collaboration
among the Columbia University Center for Hazards and Risk Research (CHRR) and Columbia
University Center International Earth Science Information Network (CIESIN). As per the above data
set, peak ground acceleration for the concession area is predicted to be in the range of 2.4m/s2 with a
10% probability of exceeding in 50 years.
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Figure 7-1: Landslide Hazard Distribution Map
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Figure 7-2: Earthquake Frequency for Middle East Figure 7-3: Seismicity Map for Middle East (1990-2012)
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Figure 7-4: Peak Ground Acceleration
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8 ENVIRONMENTAL IMPACT ASSESMENT
This section identifies and assesses potential impacts on the environment from the construction and
operation activities of the proposed petrochemical plant. Identification and assessment of
environmental impacts in general is carried out in accordance with guidelines and requirements of
MECA/SEU. The impacts are identified and assessed considering the environmental releases from the
PC plant (as discussed in Chapter 5) and the environmental setting of the project site and its
surroundings (as presented in Chapter 4). Further, the impacts associated with the project
decommissioning (at the end of the project lifecycle of approximately 30 years) are not discussed
separately for want of specific information at present. Also, owing to the similarities in the
decommissioning and construction activities, the impacts during the decommissioning phase are
considered to be similar to that of the construction phase.
It must be noted that the impacts discussed in this chapter are residual impacts, i.e., the potential
environmental impacts due to the environment releases from project activities containing inherent
design control and safety measures. In other words, the impacts assessed in this chapter will be for
releases with such measures in place. The mitigation and control measures are suggested in a separate
EMP report as per the SEU’s requirement.
8.1 Methodology
The identification and assessment of environmental impacts is based on the guidelines provided in
ISO 14001 series of standards and includes the following steps:
Identification of major activities during the construction and operation phases of the project
based on the discussions on project details provided in Chapter 3;
Identification of potential environmental aspects from the project activities (identified in the
above step) based on discussions in Chapters 3 and 5;
Identification of potential impacts from the project considering the environmental aspects
identified above and various environmental elements / sensitivities (receptors) which are likely to
be impacted due to the project based on discussions presented in Chapter 4; and
Assessment of environmental impacts considering the severity of impact and the duration or
likelihood of its occurrence.
Based on the above, as the first step, each major activities of the project during the construction and
operation phases are identified. The associated environmental aspects are identified based on the
project description and various releases into the environment. The resulting impacts are identified by
combining the above information with the environmental elements / sensitivities.
Whenever interactions exist between the identified aspects and sensitivities, they are further analysed
to determine the potential impacts from the project. Impacts may be classified as beneficial/adverse,
direct/indirect, reversible/irreversible or short/long term. The assessment of potential impacts is
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carried out utilizing both qualitative and quantitative assessment techniques. In qualitative assessment
the impacts are rated as ‘negligible’, ‘low’, ‘medium’ or ‘high’.
For impacts arising from planned / expected aspects, this rating is based on two parameters, i.e.,
severity of impact and duration of its occurrence. Severity of any impact will depend on the nature
and size of the activity/aspect and the environmental/social sensitivity. An impact assessment matrix,
as presented in Figure 8-1, is used for combining the two assessment criteria.
Very
Duration Momentary Short Term Medium Term Long Term
Long Term
Severity 1 week < 1 year 1 – 10 years 10 – 50 years
> 50 years
Positive Effect + ++ +++
Slight Effect Negligible
Minor Effect Low Impact
Moderate Effect Medium Impact
Major Effect High Impact
Massive Effect
Figure 8-1: Impact Assessment Matrix for Planned Aspects
For impacts resulting from unplanned and accidental aspects/ activities, the assessment is based on
consideration of the impact severity and the likelihood of it is occurrence. While the impact severity
depends on the nature and size of the activity aspects and the environmental sensitivity, the likelihood
depends upon the nature of the activity/aspect and the control measures in place. An impact
assessment matrix, as presented in Figure 8-2, is used for combining the two assessment criteria, i.e.,
the severity of impact and the likelihood of its occurrence.
Duration Very
Unlikely Likely Very Likely Certain
Severity Unlikely
Slight Effect
Minor Effect Low Impact
Moderate Effect Medium Impact
Major Effect High Impact
Massive
Figure 8-2: Impact Assessment Matrix for Unplanned Aspects
In assessing the impacts, it is to be noted that the project activities, related environmental aspects and
associated impacts are presented together to facilitate subsequent rating. The ratings are primarily
based on qualitative assessment of the situation and its interaction with the environmental elements.
The impacts, which are rated as low are considered to be acceptable or within “As Low As
Reasonably Practicable (ALARP)” levels. Control measures for further mitigation of these impacts
may not be viable. Impacts that are rated as medium and high (significant impacts) will be managed
through mitigation measures and implementation of the environmental and social management plan to
reduce the residual risks / impacts to ALARP levels. Definition of terms used in the matrix is
presented in Appendix I.
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8.2 Potential Hazards and Impacts by Activity
Impact identification has been carried out using a detailed activity-receptor matrix as presented in
Appendix J. A blank cell indicates no or negligible interaction. A bullet ‘•’ placed in the cell indicates
potentially significant interaction. A summary of the potential impacts of the construction and
operation activities is presented in Table 8-1 and Table 8-2.
Table 8-1: Potential Impacts from Construction Phase
# Significant Sources of Impact Potential Environmental Impacts
Land take
Land take for installation of facilities; Loss of terrestrial habitat;
1 construction office/lay down areas for storage Conflict with current land use;
of construction materials and wastes etc. Visual impacts
Construction works (Direct actions and effects)
Stress on traffic along the route of travel of men,
materials and equipment;
Mobilization of construction equipment and Safety risk to road users;
2
people. Influx of large number of people into the project
area; and
Health risk to local people.
Loss of terrestrial habitat
Damage to vegetation
Damage to archaeological resources
Changes to landscape
Damage to existing surface drainage channels
Site preparation comprising removal of
and impacts of flooding
3 vegetation, levelling, grading and fencing at the
Access restrictions to current users
project and labour camp sites
Nuisance due to increased activity and traffic
Stress on road traffic due to movement of men
and materials to and from the site
Safety risk to people using nearby roads and
areas.
Adverse impact on aesthetics of the site;
Damage to vegetation;
Damage to habitats;
Changes to landscape
Construction work (excavation, foundation
4 Damage to existing surface drainage channels &
work and concrete & asphalting work)
impacts of flooding
Health and safety for workers & community;
Nuisance to surrounding Community;
Generation of employment and economic benefit.
Resource use
Off-site impacts from quarrying for rocks,
aggregates, soil.
Utilization of mineral resources (For
5 Off-site impacts on borrow pits (for soil if the
construction materials)
excavated soil from the site is found insufficient
or unsuitable for use)
Depletion of non-renewable resources;
Utilisation of fuels (For DG sets, construction
6 Loss of fuel due to inappropriate storage and
vehicles and equipment)
handling
Utilization of water resources (For construction
7 Stress on water supply resources offsite
water and domestic / potable water)
Generation of employment for local workers;
Utilization of human resources (Employment of
8 Public safety and health risks;
immigrant / expatriate workers for construction)
Social conflicts due to workforce influx.
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# Significant Sources of Impact Potential Environmental Impacts
Stress on local infrastructure facilities;
Utilization of local infrastructure facilities
Stress on traffic;
9 (Accommodation, roads, local transport, power
Public safety and health risks;
supply, water supply, sanitation, hospitals etc.)
Local life style and cultural conflicts
Releases to environment
Release of air pollutants (Dust from
Degradation of local air quality
10 construction activities and road traffic; gaseous
Nuisance and health risks for local communities.
emissions from fuel run engines)
Increase in ambient noise levels;
Generation of high level noise (From
11 Disturbance to local communities, workers;
construction equipment and vehicles)
Health risk to workers.
Wastewater management (Discharge of
Onsite/Offsite soil contamination;
equipment washings, hydrotest water, domestic
12 Onsite/Offsite groundwater pollution;
wastewater, dewatering effluents, accidental
Health risk to workers and local people
spillage of hazardous liquid/materials etc.)
Soil contamination onsite/offsite;
Groundwater pollution;
Health risk for community;
Management of solid wastes (Storage, handling, Housekeeping issue (restriction on movement
transport and disposal of non-hazardous due improper waste collection and storage,
13
construction and domestic wastes and disposal potential blockage of access to assembly point
of hazardous wastes from construction site) due storage at undesignated area, tripping or
slipping hazards, etc.);
Health risk to workers and local people; and
Stress on landfill for the area.
Onsite/Offsite soil and groundwater
contamination;
Fire, explosion and health risk to workers and
Handling, storage and transport of hazardous
14 local people;
substances (Fuel oils, hazardous chemicals etc.)
Risk from electrical failures and falling objects to
workers; and
Public health risk from accidental spillage
Functional aspects
Traffic congestion;
15 Transport of materials and workers to site Public safety;
Accidental damage to community properties
Offsite land and groundwater contamination due
Accidental spillages of fuels, chemicals,
16 to spillages
solvents, etc., during transportation
Fire and safety risk to public
Table 8-2: Potential Impacts from Operation Phase
# Significant Sources of Impact Potential Environmental Impacts
Resources use
Depletion of resources
Utilization of mineral resources during operation Degradation of ambient air quality due to
1
phase (NG, diesel) consumption (combustion) of NG and fossil
fuels
Stress on groundwater resources due to
Utilization of water resources (For potable water at
2 additional user for water;
site)
Potential depletion of non-renewable resources
Generation of employment for local workers;
Public health risks from large scale use of
Utilization of human resources (Employment of
3 immigrant workers;
immigrant / expatriate workers in the facility)
Stress on local healthcare infrastructure; and
Social conflicts due to workforce influx.
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# Significant Sources of Impact Potential Environmental Impacts
Stress on local infrastructure facilities;
Utilization of local infrastructure facilities
Traffic congestion;
4 (Accommodation, roads, local transport, power
Public safety and health risks; and
supply, water supply, sanitation, hospitals etc.)
Local life style and cultural conflicts.
Releases to environment
Degradation of ambient air quality;
Release of air pollutants from various emission
Disturbance to flora and fauna.
5 sources at the plant (GTs, heaters, boilers,
Health risk and nuisance to employees and
incinerators, process vents etc.)
community
Increase in ambient noise levels;
Generation of noise from process units/equipment
6 Human health impacts; and
and transport vehicles
Disturbance to fauna.
Onsite and offsite groundwater pollution;
Industrial and domestic wastewater management Land contamination;
7
(accidental spillage of hazardous liquids etc.) Human health impacts; and
Impacts on flora and fauna.
Onsite and offsite soil and groundwater
contamination
Nuisance due to foul odour
Housekeeping issue (restriction on movement
Non-hazardous (industrial and domestic) and
due improper waste collection and storage,
8 hazardous waste management (improper transport
potential blockage of access to assembly point
and disposal of the wastes)
due storage at undesignated area, tripping or
slipping hazards, etc.)
Health risk to employees, contractors and local
people
Onsite/Offsite land contamination;
Storage, Management and Disposal of non-
Onsite/Offsite groundwater pollution; and
9 hazardous wastes
Public health risk from hazardous waste
transport and disposal.
Functional aspects
Traffic congestion, road closures;
Public safety risk;
Transport of raw materials/finished products; Noise nuisance;
10
Transport of workers to the site. Degradation of air quality;
Disturbance to flora and fauna; and
Damage to archaeological, cultural sites.
Land contamination;
Handling, storage and transport of non-hazardous Groundwater contamination;
11
materials including waste. Public health risk from material transport ; and
Disturbance to flora and fauna.
Land contamination;
Handling, storage and transport of hazardous Groundwater contamination;
12 substances (Fuel oils, flammable gases, hazardous Public health risk from hazardous material
feedstock, chemicals etc.) transport; and
Disturbance to flora and fauna.
8.3 Assessment of Impacts during Construction Phase
This section presents the evaluation of a potential environmental impacts identified in Table 8-1. For
a potential impact, there can be more than one source. Therefore, the net impact on each receiving
environmental element due to the various environmental aspects is presented in the following
sections. It is to be noted that the entire construction activity, from contractor mobilisation to de-
mobilisation, will be completed within 20 months.
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8.3.1 Natural Resources
The activities that may have potential impacts on natural resources during the construction phase are
consumption of materials such as wood, metal, cement, rocks, aggregates, etc., consumption of fuel
and electrical power for construction equipment, transport vehicles and in labour camps; and
consumption of groundwater for construction and domestic use.
The rocks and aggregates that will be used in the civil works will be procured from local quarries.
Quarries not having the required environmental permit as per MD 200/2000 will not be used. Any
fresh/virgin soil required would be procured from local borrow pits, which are approved by the
municipality. These resources are abundantly available, locally, and hence no adverse impacts are
expected. However, some off-site impacts on air quality due to dust generation and public safety and
health due to quarrying activities are expected. These impacts are further discussed in the related
sections.
Diesel oil will be used as fuel for construction machinery and DG sets. It is expected that the local
suppliers of refined petroleum products can adequately supply the required quantities of fuel, without
adversely affecting the local demand-supply balance. The power requirement during the construction
phase is expected to be sourced from the DG sets. Alternatively sourcing power from existing grid
will also be investigated.
The water required for the construction phase will be sourced from local groundwater wells or from
authorized tanker suppliers. If water is sourced from groundwater wells, the wells will be selected
taking into account the existing use and the capacity / yield of the wells in order to minimise impacts
on existing users. Groundwater extracted from the wells located near the project site is mostly used
for agriculture. No current data is available on groundwater extraction, aquifer recharge and variations
in groundwater table. However, it is known that some of the coastal wells are affected by saline
intrusion apparently due to over-exploitation. Therefore, some adverse impacts on the existing users
(farmers) may be expected if groundwater required for the project is extracted from low yielding
wells. It is however envisaged that the water requirement during the construction phase will be
sourced through approved tankers.
Appropriate storage and handling facilities will be established for water and fuel in order to minimise
losses due to leaks and spillages. Further, the consumption of resources will be optimized, minimizing
wastage. The foodstuff and other materials required for the labour camps will be sourced from local
suppliers. The usage / consumption of such materials will be optimized and wastage minimized.
The construction workforce is expected to be accommodated in established camps in Liwa, Sohar or
Majan. These accommodation facilities will have established water and power supplies. No additional
resource consumption is envisaged in this regard. Based on the above, the impacts to natural resources
are rated as below:
Impact Severity Duration Likelihood Impact Rating
Consumption of construction
Minor Medium - Low
materials
Impact on Natural Resources Minor Medium - Low
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8.3.2 Topography and Landscape
The activities that can have impacts on the topography and landscape include the leveling and grading
of the site, excavation for foundations, etc. As mentioned in Chapter 4, the project site is generally flat
and therefore, will not require significant cutting and filling thereby minimizing the changes to
topography and landscape of the site. The leveling activities will be restricted to the designated plot
boundaries. Further, the cutting and leveling activities within the site will be controlled as required for
the installation of plant and equipment, which will further minimise the landscape changes. Upon
clearing and levelling of the site, the site will be flat and compacted, with no vegetation and this
change in the landscape will be permanent after construction of the proposed plant.
Drainage channels will be provided around the site in order to route the flow in order to avoid
flooding. . It will be ensured that surface flow from areas where hazardous materials and wastes will
be stored will not mix with the uncontaminated surface run-off. As the proposed site is within the
SIPA, aesthetic impacts due to the project construction will be negligible. Based on the above
discussions, the impacts on topography and landscape are rated as below.
Impact Severity Duration Likelihood Impact rating
Impacts on topography & landscape Slight Long Term - Low
8.3.3 Ambient Air Quality
The aspects that may have potential impacts on ambient air quality during construction phase of the
project are as below:
Generation of dust due to site preparation, earthwork, excavation, and movement of vehicles;
Release of SO2, NOx, VOCs and PM from diesel engines of construction machineries,
vehicles and DG units used for power generation;
Welding / metal works, surface cleaning and painting. These activities will release fumes and
VOCs; and
Fugitive emissions from storage of fuels, lube oils and other chemicals releasing VOCs
The dust generation during site preparation activities could be significant onsite. Estimates of dust
generation during excavation are not available. However, such activities lend themselves to a
considerable amount of onsite dust generation which can potentially affect the workforce.
With respect to exhaust emissions from earthmoving equipment and other engines and generator sets
on site, these have been discussed in Section 7.3. The total emission of CO2 and NOx for the whole of
the construction activity is estimated to be about 1,070t and 0.251t respectively.
Material like asbestos etc are also prohibited in industrial application in Oman. Though it is difficult
at this stage to quantify the impacts on air quality, it is reasonable to consider that impacts will be
limited to the nearby environment considering the nature of construction activities and will be for a
period of not more than 20 months. Human receptors are not located within the site boundary. The
control measures to be implemented in order to minimise the adverse impacts on air quality are
discussed in the EMP report. Accordingly, the impacts on ambient air quality are rated as follows:
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Impact Severity Duration Likelihood Impact Rating
Ambient Air Quality Minor Medium Term - Low
8.3.4 Ambient and Workplace Noise
The heavy equipment used for the construction work, fabrication activities, earthwork such as grading
and excavation, and the vehicles used for transportation of men and materials to site will have an
adverse impact on the noise levels in the workplace as well as ambient. Due to the nature and
complexity of industrial construction activities and in the absence of specific information on the type,
number, location and duration of operation of major noise sources at the construction site (this will be
planned by the contractor), it is difficult to quantify impacts on noise levels during construction. It is
likely that at certain locations close to the noise sources within the work site, the noise levels will be
in excess of 85dB(A) requiring the personnel on-site to wear ear protection devices.
With regard to the ambient noise levels, since noise is attenuated by distance (typically noise levels
drop by about 40 dB (A) at 100m distance from the source), the activities on-site are unlikely to affect
the ambient noise levels significantly. However, during night times when the ambient noise levels are
low, the level of perception to noise may be more acute. Noise from transport vehicles will be only
transient for a given location and can be considered as a nuisance during night time through the route
which it passes. Mitigation measures to be implemented in order to minimise impacts on noise levels
are described in the EMP report. Accordingly, the impacts on noise levels are rated as below.
Impact Severity Duration Likelihood Impact Rating
Ambient Noise Minor Medium Term - Low
Workplace noise Moderate Medium Term - Medium
8.3.5 Terrestrial Ecology
The ecology setting at the proposed site is described in Chapter 4 and Appendix E. The impacts on
ecology will be largely due to activities like site clearing and leveling during the construction phase.
All vegetation’s within the site are likely to be cleared. Further, disturbance to ecology in the area will
also result from increase in noise during construction activities and vehicle movements.
It can be noted from the findings of the rapid ecological survey conducted for the Project, that there
are no species within or around the site that are classified as rare, threatened, endangered or of
significant conservation value. All the terrestrial vertebrates identified/recorded during the survey are
common, highly mobile and resilient species which will likely move to neighboring undisturbed
habitats.
The natural landscape in SIPA is heavily altered due to industrial developments since its inception in
2002. The habitat loss and mortality of flora due to land preparation activities cannot be avoided as
the project site is situated in a parcel of land specifically dedicated for industrial development.
Further the inevitable impact on flora can be minimized by the establishment of green belt using
native plant species in the periphery of proposed plant. In addition, whenever applicable the century
old stands of Ghaf Tree (P. cineraria) should be incorporated in the landscape design within the
footprint of the Project. Accordingly the impacts on terrestrial ecology are rated below.
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Impact Severity Duration Likelihood Impact Rating
Impacts on flora & fauna Slight Effect Very Long Term - Low
8.3.6 Soil and Groundwater
The activities that can have potential impacts on soil and groundwater during the construction are
collection, handling, storage and disposal of wastewaters, contaminated run-offs, non-hazardous and
hazardous wastes and storage and handling of hazardous substances such as fuel, lube oil, chemicals,
radioactive substances (if any), etc.
The waste and wastewater streams associated with project construction activities are characterized
and quantified in Chapter 5 along with the handling and disposal method for each stream. Improper
collection, handling, storage and disposal or accidental releases of wastewaters, non-hazardous and
hazardous wastes and hazardous substances can lead to contamination of soil and/or groundwater. The
improper handling may be due to absence or lack of proper facilities and methods for handling the
materials and wastes. Adequate provisions will be made for the management of these waste streams in
an environmental friendly manner. The severity of impacts on soil and groundwater is expected to be
‘low’ since environmental impacts will be contained within the project site and construction camps.
Accordingly, the impacts on soil and groundwater are rated as below.
Impact Severity Duration Likelihood Impact Rating
Impacts on soil & groundwater from
Moderate Short Term - Low
normal waste management
Impact on soil & groundwater due to
Moderate - Unlikely Low
accidental releases
8.3.7 Impact on Local Economy
As mentioned above, the project site is located within a designated industrial area and most of the
infrastructure facility are already developed and will be provided by SIPC. The construction activities
will require significant number of local skilled and unskilled workers. The involvement of local
community for employment will be carried through the Wali of Sohar or Liwa and the respective
village Sheikhs. People from nearby settlements, are likely to be benefited through employment as
part of the construction activities as the construction activities will require a number of skilled and
unskilled workers. This however, could be only for a limited period of time during the construction
phase. However, positive impact on the local livelihood during the construction phase through
creating new job opportunity is envisaged.
In addition, local suppliers will also be benefited as they will be contracted for the supply of water,
foodstuff etc. Considering the above, beneficial impacts are envisaged from the project on the local
employment and economy. Therefore, it can be concluded that the project will set positive impact on
local livelihood option.
Noise and road congestion from vehicle movement is likely to create some nuisance along the road
network. However, the construction activities will be restricted to SIPA and daytime thereby limiting
the nuisance during night when the perception to noise is the highest. Infrastructure such as access
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roads, water, electricity, mosque, healthcare services, recreation facilities, sanitation, and waste
services may be shared with the local community.
Issue Severity Duration Likelihood Impact rating
Local purchase of goods Positive Medium Term - +
Hiring of local people Positive Medium Term - +
Stress on infrastructure Slight Medium Term - Low
8.3.8 Impact on Land use and Local Communities
As mentioned in Chapter 4, the project site is a vacant land within the dedicated SIPA. It is envisaged
that there will be insignificant or no land use conflicts with local communities during construction or
operation phase. However, the community may be impacted by movement of heavy machinery and
traffic during the construction phase.
Impacts to local communities during the construction phase are also likely from health and safety risk
from waste management activities, transportation / movement of heavy equipment and vehicles,
earthwork such as excavation, dust and gaseous emissions, noise and influx of large number
construction workers to the area. Further, nuisance from increased activities and traffic, stress on road
traffic, groundwater use, etc., are likely to have impacts on local communities in the area. Based on
the above the impact rating is presented below.
Impact Severity Duration Likelihood Impact Rating
Impact on land use Slight Long Term - Low
Impact on settlements from
Slight Medium Term - Low
construction associated activities
Impact on settlements from accidental
Moderate - Unlikely Low
releases
Traffic congestion / accidents Moderate - Likely Medium
8.3.9 Archaeology and Heritage
No sites or objects of archaeological importance are expected to occur within the project site, being a
dedicated industrial area. However, if any such objects are encountered during the construction, such
area will be immediately cordoned off and Orpic or its contractors will inform MHC accordingly to
obtain further advice from the Ministry.
Issue Severity Duration Likelihood Impact rating
Accidental Damage to sensitive sites Major - Very Unlikely Low
8.3.10 Summary of Impacts
A summary of the net impacts during the construction phase and their significance is presented in
Table 8-3. It is noted that there are no impacts that are rated as high which would have required
alternatives to be developed for activities leading to such impacts. Proposals for mitigating the
impacts rated as ‘Medium’ are described in a separate EMP report. Although the impacts that are
rated as ‘Low’ are considered As Low as Reasonably Practicable, some management plans in line
with good practice and Orpic’s institutional policies have also been listed in the EMP.
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Table 8-3: Summary of Impacts during the Construction Phase
Issue Severity Duration Likelihood Impact Rating
Consumption of construction materials Minor Medium Term - Low
Impact on Natural Resources Minor Medium Term - Low
Impacts on topography and landscape Slight Long Term - Low
Ambient Air Quality Minor Medium Term - Low
Ambient Noise Minor Medium Term - Low
Workplace noise Moderate Medium Term - Medium
Impact on terrestrial ecology Slight Very Long Term - Low
Impacts on soil and groundwater from
Moderate Short Term - Low
normal waste management
Impact on soil and groundwater due to
Moderate - Unlikely Low
accidental releases
Local purchase of goods Positive Medium Term - +
Hiring of local people Positive Medium Term - +
Stress on infrastructure Slight Medium Term - Low
Impact on land use Slight Long Term - Low
Impact on settlements from construction
Slight Medium Term - Low
associated activities
Impact on settlements from accidental
Moderate - Unlikely Low
releases / abnormal operation
Traffic congestion / accidents Moderate - Likely Medium
Accidental Damage to sensitive sites Major - Very Unlikely Low
8.4 Assessment of Impact during Operation Phase
The evaluation of potential environmental impacts during the operational phase of the petrochemical
complex and as identified in Table 8-2 are described in subsequent sections.
8.4.1 Natural Resources
The natural resources that will be directly consumed during the PC plant operation phase are NG,
diesel and petrol. The NG for the plant will be used for power generation and for complementing the
FG requirement for the plant. Other aspects that may have potential impacts (direct or indirect) on
depletion of natural resources in the area are the consumption of electrical power (for emergency
operations or during maintenance of the power plant units) and consumption of water for domestic use
and process units. Once constructed, industries are acknowledged to be significant users of natural
resources particularly energy and water.
The power requirement for the plant will be sourced from the power plant that will be provided in the
facility. The power plant will be run on natural gas. Petrol and diesel will be used as fuels for vehicles
and emergency power generation. Estimates of number of vehicles and run time of emergency DG
sets are not available and hence the fuel consumption cannot be evaluated at this stage. Local
suppliers of refined petroleum products can supply such quantities without causing imbalance on local
demand-supply. In light of the fact that the present project will contribute to the industrial and
economic development of the region which is in line with the overall development plans of the
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country and weighing the benefits of such development with the consumption of the above resources,
the impacts can be considered to be low.
Issue Severity Duration Likelihood Impact rating
Stress on power supply Slight Long Term - Low
Stress on fuel supply-demand Slight Long Term - Low
Stress on water supply-demand Moderate Long Term - Medium
8.4.2 Topography and Landscape
The alteration to the topography and landscape will be primarily during the construction phase of the
Project and impacts during the operational phase will be minimal. Accordingly the impacts on
topography and landscape are rated as below.
Impact Severity Duration Likelihood Impact Rating
Impact on Topography & Landscape Slight Long Term - Low
8.4.3 Ambient Air Quality
The main air emissions generating sources from the petrochemical plant will be flares, boilers, gas
turbine, incinerators etc. The impact from the stationary sources has been quantified and assessed
using USEPA approved model; AERMOD, ISC AERMOD software of Lakes Environmental has
been used for the dispersion modelling of the pollutants. This software is widely used for air
dispersion modelling. This model is capable of simulating maximum Ground Level Concentration
(GLC) for pollutant, such as NOx, CO, SO2, PM and UHC.
Dispersion modelling using AERMOD requires hourly meteorological data and for the Project this
has been sourced from Lakes Environmental (MM5 pre-processed data for CY 2009 to 2013, 5 years).
The model set-up is presented in Table 8-4.
Table 8-4: Model Set Up
Model used AERMOD
Topography for dispersion Rural, Flat terrain
Averaging time 3hours, 8 hours, 24 hours
Source type Point source
Source group All
Building downwash option No buildings taller than proposed stack in the facility
Boundary limits 20 km x 20 km
Co-ordinate system Cartesian
Grid Uniform 150X150 m
Receptor height 0 (at ground level)
Anemometer height 14 m
Surface meteorological data MM5 ready processed data from Lakes Environmental (CY 2009 – CY 2013)
Upper air data Upper air estimator using AERMET processor
Elevation of the site 10 m amsl
The continuous point sources and pollutant emission rates are given in Table 8-5. The AERMOD has
been run for normal operation scenario of all the emission sources (emitting combustion products).
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Table 8-5: Air Emissions from Operation Phase
Stack UTM Co-ordinates Stack Details (m) Temp Flow rate NOx SOx CO UHC PM10
Sources
ID Easting Northing Height Diameter K (m3/hr) (g/s) mg/m3 (g/s) mg/m3 (g/s) mg/m3 (g/s) mg/m3 (g/s) mg/m3
1 SCU Heater Stack 1 461955 2705120 40 2.5 450 26.4 3.28 124.2 0.1 3.8 0.2 7.6 0.25 9.5 1.25 47.3
2 SCU Heater Stack 2 461963 2705106 40 2.5 450 26.4 2.68 101.5 0.1 3.8 0.2 7.6 0.25 9.5 1.25 47.3
3 SCU Heater Stack 3 461970 2705093 40 2.5 450 26.4 3.55 134.5 0.1 3.8 0.2 7.6 0.25 9.5 1.25 47.3
4 SCU Heater Stack 4 461977 2705078 40 2.5 450 26.4 3.55 134.5 0.1 3.8 0.2 7.6 0.25 9.5 1.25 47.3
5 SCU Heater Stack 5 461986 2705061 40 2.5 450 26.4 3.55 134.5 0.1 3.8 0.2 7.6 0.25 9.5 1.25 47.3
6 SCU Heater Stack 6 461955 2705046 40 2.5 450 34 4.37 128.5 0.1 2.9 0.2 5.9 0.25 7.4 1.25 36.8
7 SCA Incinerator 1 461498 2705598 20 0.3 443 0.9 0.08 88.9 0.02 22.2 0.03 33.3 0.01 11.1 0.05 55.6
8 SCA Incinerator 2 462363 2705196 20 0.3 443 0.9 0.08 88.9 0.02 22.2 0.03 33.3 0.01 11.1 0.05 55.6
9 SCA Power Generator 1st Stack 462201 2705202 60 1.5 318 118.4 11 92.9 2.6 22.0 3.7 31.3 0.7 5.9 7.3 61.7
10 SCA Power Generator 2nd Stack 462127 2705161 60 1.5 318 118.4 11 92.9 2.6 22.0 3.7 31.3 0.7 5.9 7.3 61.7
11 SCA High Pressure Flare Stack 461961 2705643 170 1.5 443 34 0.07 2.1 0.02 0.6 0.4 11.8 0.15 4.4 1.25 36.8
12 SCA Low Pressure Flare Stack 461581 2705653 60 1.5 443 34 0.07 2.1 0.02 0.6 0.4 11.8 0.15 4.4 1.25 36.8
Pygas Unit 2nd Stage Reactor Feed
13 461785 2705191 10 0.5 443 20 0.07 3.5 0.02 1.0 0.04 2.0 0.25 12.5 1.25 62.5
Heater
14 Boiler 1 461832 2705202 40 2.5 450 26.4 3.76 142.4 0.1 3.8 0.2 7.6 0.25 9.5 1.25 47.3
15 Boiler 2 461846 2705180 40 2.5 450 26.4 3.76 142.4 0.1 3.8 0.2 7.6 0.25 9.5 1.25 47.3
16 Boiler 3 461859 2705159 40 2.5 450 26.4 3.76 142.4 0.1 3.8 0.2 7.6 0.25 9.5 1.25 47.3
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The estimated maximum GLCs for each pollutant and corresponding distances for the modeled
pollutants are presented in Table 8-6. The GLC isopleths for maximum averages of pollutants are
presented in Appendix K. The contours are presented covering the nearby areas as well as a larger
area up to 20 km distance from the project site.
Table 8-6: Predicted GLC Values
Location of Resultant
Distance to Direction
Max. GLC max. GLC Concentration17
Pollutants max. GLC to max.
(µg/m3) (UTM
(m) GLC*
Coordinates)
Normal E 461322
17.95 671 W
Operation N 2705428
CO
8-hr avg. 6,000
Std. Lt.** (OAAQS); - -
E 461322
NOX Normal 47.8 667 SW
N 2705428
24-hr Operation
avg. 112
Std. Lt. - -
(OAAQS)
E 463133
SO2 Normal 3.88 732 S
N 2704602
24-hr Operation
avg. 125
Std. Lt. - -
(OAAQS)
E 462063
Normal 19.6 665 W
PM10 N 2705718
Operation
24-hr
avg. 125
Std. Lt. (OAAQS); - - -
E 461322
UHC Normal 8.92 675 W
N 2705428
3 hr Operation
avg. 160
Std. Lt. - - -
(OAAQS)
Note: All distances are measured from High Pressure Flare Stack
Further the emissions from storage tanks, which are fugitive in nature, have been quantified using
USEPA’s TANKS 4.0 software model as discussed in Chapter 5. The inputs for the TANKS 4.0
model were taken from the data provided by CB&I. Fugitive emissions from pipelines and fittings are
insignificant compared to the point source emissions. It is seen that the estimated annual fugitive
emissions from the tanks are low. CB&I will provide appropriate measures in the design of the tanks
for minimizing the fugitive emissions from the storage tanks.
17
“Guidelines for air quality dispersion modelling in British Columbia”, Page no 82, for cumulative impacts. (http://www.env.gov.bc.ca/air)
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From the above table it can be seen that the predicted GLC’s of all the pollutants due to the plant
operation are within the OAAQS during the normal operation condition. Based on the above the
impact on ambient air quality can be rated as below
Issue Severity Duration Likelihood Impact rating
Air Quality Moderate Long term - Medium
Greenhouse gas emission Moderate Long-term - Medium
Gaseous Pollutants Moderate Long-term - Medium
8.4.4 Ambient and Workplace Noise
The proposed plant will include a number of noise sources, which will have potential adverse impacts
on the workplace and ambient noise levels. Equipment such as pumps, blowers, compressors, gas
turbine, flare, WWTU, boilers etc will be continuous sources of noise. The equipment will be
designed and provided with noise attenuation accessories to ensure that the noise levels at 1 m from
the sources are below 85 dB(A). Nevertheless, areas where the noise levels are above 85 dB(A)
appropriate sign boards will be installed; and any personnel working in such areas will have to wear
proper PPE. Further, in planning the layout of the proposed plant measures will be incorporated in the
design to ensure that the noise level at the plant boundary is well within 70 dB(A) as per MD 79/94.
In order to determine the impacts of the various noise sources in the facility, a noise modeling using
SoundPLAN software will be conducted during the EPC stage of the project, based on the final
selection of equipment and lay out, the source noise levels and noise attenuation measures adopted.
8.4.5 Terrestrial Ecology
The vegetation present in the site will be completely removed during the construction phase. No
species within or around the site that are classified as rare, threatened, endangered or of significant
conservation value. All of the species encountered at the study area are common and none are listed as
threatened species in the IUCN 2011 Red list of threatened animals (IUCN 2011). Hence the impacts
on flora and fauna during the operation phase will be negligible. Although unlikely, the possibility of
accidental kills of fauna or damage to flora may occur during the movement of operation and
maintenance crew.
Issue Severity Duration Likelihood Impact rating
Damage to flora and fauna Slight Long Term - Low
Loss of habitat Slight Long Term - Low
Accidental damage to ecology & wildlife Moderate - Very Unlikely Low
8.4.6 Soil and Groundwater
The activities that can have potential impacts on soil and groundwater during the operation phase of
the project are as below:
Collection, handling, storage and disposal of wastewaters / aqueous effluents generated from
the processes, and contaminated run-offs;
Storage and handling of hazardous substances such as skimmed oil from LLOD basin,
WWCT, Oily sludge storage tank, DGF skimming, Benzene/MTBE WWCT, dewatered oily
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sludge, waste oils and oily sludge, waste chemicals, solvents, waste paints, used cotton waste,
etc. from plants and maintenance workshops, polyethylene and polypropylene powder;
Containers of hazardous materials (oil drums, chemical drums etc.), spent filter medium,
sludge from WWTU, fuel, chemicals, etc.;
Storage and handling of hazardous wastes received at the facility; and
Storm water drainage from the plant.
Collection, handling, storage, transportation and disposal or accidental releases of wastewaters, non-
hazardous and hazardous wastes and hazardous substances can lead to contamination of soil and/or
groundwater, if proper facilities and methods for handling are not established.
The domestic sewage generated from toilets, washrooms and kitchen will be connected via pipeline to
the holding tanks and routed to the sewage network operated by MISC in SIPA for treatment in their
STP. The surface run-off water from the process and storage area which may be contaminated will be
routed to a sump from where it will be directed to the WWTU. All effluents (except cooling water,
brine rejectsand boiler blow down) will be segregated and routed to the WWTU for treatment to
marine discharge standards (as per MD 159/2005). There will be no underground storage tanks at the
facility and the material loading and unloading areas will be designed with proper enclosures and
secondary containment on paved surfaces.
The proposed practices on storage and handling of hazardous materials discharge of liquid effluents
and disposal of hazardous wastes are detailed in the EMP and these will ensure to minimise the
resulting impacts. Accordingly, the impacts on soil and groundwater are rated as below.
Impact Severity Duration Likelihood Impact Rating
Impact on soil & groundwater from normal
Moderate Long Term - Medium
wastewater & waste management
Impact on soil and groundwater from
improper handling & disposal of waste & Moderate - Unlikely Low
wastewater
8.4.7 Impact on Local Economy
The overall manpower requirement during the operation phase of the project is estimated to be 500,
working in three shifts, which is significantly low when compared to the construction phase. Hence,
upon completion of the facility construction and commencement of operation, most people employed
during the construction may be discontinued for the operation phase, which is likely to cause stress.
Orpic will explore the possibility of recruitment of local workers having pertinent education skills.
In addition, the local businesses such as fabricators, maintenance service providers, foodstuff
suppliers, transporters, etc., are likely to have business opportunities associated with the operation of
the plant. Based on the above, the impacts are rated as below:
Issue Severity Duration Likelihood Impact rating
Impact from loss of employment
during transition from construction to Slight Long Term - Low
operation phase
Impact on economy through generation Positive Long Term - ++
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Issue Severity Duration Likelihood Impact rating
of business and operation phase
employment opportunities
8.4.8 Land Use and Local Communities
There will no land-use conflict during the operation phase as the Project is being developed in a
designated industrial area.
The impacts on local communities during the operation phase will be related to health and safety risk
from waste management activities, transportation of hazardous wastes and materials, gaseous
emissions the emissions sources, noise and influx of expatriate operation staff to the area. Further,
nuisance from increased activities and traffic, stress on roads, etc., are likely to have impacts on local
communities and the livestock farms in the area.
The storage, treatment and disposal of hazardous wastes are likely to pose health risk to employees
and the community. Accidental releases of hazardous wastes from storage areas may pose soil and
groundwater contamination, which in turn may pose health risks. Accordingly the impact is rated
below:
Impact Severity Duration Likelihood Impact Rating
Impact on land use Slight Long Term - Low
Impact on health and safety of Very
Major - Low
settlements from accidental releases Unlikely
8.4.9 Summary of Impacts
A summary of the net impacts during the operation phase and their significance is presented in Table
8-7. It is noted that there are no impacts that are rated as high which would have required alternatives
to be developed for activities leading to such impacts. Proposals for mitigating the impacts rated as
‘Medium’ are described in a separate EMP report. Although the impacts that are rated as ‘Low’ are
considered As Low as Reasonably Practicable, some management plans in line with good practice and
Orpic’s institutional policies have also been listed in the EMP.
Table 8-7: Summary of Impacts during the Operation Phase
Issue Severity Duration Likelihood Impact Rating
Stress on power supply Slight Long Term - Low
Stress on fuel supply-demand Slight Long Term - Low
Stress on water supply-demand Moderate Long Term - Medium
Impact on topography and landscape Slight Long Term - Low
Air Quality Moderate Long term - Medium
Greenhouse gas emission Moderate Long-term - Medium
Gaseous Pollutants Moderate Long-term - Medium
Damage to flora and fauna Slight Long Term - Low
Loss of habitat Slight Long Term - Low
Accidental damage to ecology and
Moderate - Very Unlikely Low
wildlife
Impact on soil and groundwater from
normal wastewater and waste Moderate Long Term - Medium
management
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Issue Severity Duration Likelihood Impact Rating
Impact on soil and groundwater from
improper handling and disposal of waste Moderate - Unlikely Low
and wastewater
Impact from loss of employment during
transition from construction to operation Slight Long Term - Low
phase
Impact on economy through generation of
business and operation phase employment Positive Long Term - ++
opportunities
Impact on land use Slight Long Term - Low
Impact on health and safety of
Major - Very Unlikely Low
settlements from accidental releases
“The environmental impact assessment process adopted for the Project assesses and evaluates each
impact after application of the proposed controls and mitigation measures applied. These controls
and mitigation measures have been documented in the BAT analysis and associated environmental
management plans (EMP). As such the impacts presented in this Section and as summarized in the
Impact Summary Tables are the residual impact”.
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9 CONCLUSION
The EIA study for the petrochemical project concludes that the project will not cause any
significant deterioration of the environmental quality and will in fact generate revenues,
employment and invigorate the economy.
As mentioned in various sections of this report, the project will implement appropriate control and
mitigation measures to minimise the environmental impacts and to ensure compliance with applicable
Omani and International Environmental Regulations and requirements of World Bank Equator
Principles. Through effective implementation of the Environmental and Social Management Plan
(EMP) and careful design, engineering, planning, construction and operation considerations the
associated residual impacts will be minimized. Consequently, these impacts are not expected to cause
any significant, long term and irreversible change on the environment and the local community.
Activity specific management plans shall be developed following the award of tenders to contractors
developing various features of the project. Emphasis on rigorous environmental monitoring of various
aspects as presented in the EMP report needs to be reinforced at the highest level within Orpic so that
distinct trends in adverse impacts can be promptly identified for suitable mitigation in consultation
with experts at SEU/MECA.
From the BAT analysis it is concluded that FEED has considered all applicable BAT criteria for the
proposed Petrochemical Plant.
The proposed project will significantly contribute to the on-going industrial development in Oman
and to the economic growth of the country and pioneer industrial development. It is expected to
provide employment opportunities for Omani people both during construction and operation phases of
the project.
Therefore, the proposed project is considered to be acceptable from an environmental and social
standpoint within the context of local and internationally comparable environmental standards.
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Appendix A SEU/MECA Feedback on Scoping Report
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Appendix B Omani Environmental Laws and Regulations
1) Environmental Protection and Prevention of Pollution (RD 114/2001)
RD 114/2001 provides the framework for environmental protection and prevention of pollution in
Oman. Applicable requirements of the above RD are listed below:
Article 7 - It is not allowed to use Oman environment for the disposal of environmental
pollutants in quantities and types that may adversely affect its intactness and its natural
resources or nature conservation areas and the historical and cultural heritage of the Sultanate.
No pollutants shall be disposed of in the natural ecosystems unless in accordance with the
regulations and conditions issued by a decision from the Minister;
Article 9 - No establishment of any source or area of work shall be started before obtaining an
environmental permit confirming its environmental soundness. The permit shall be issued upon
an application to the Ministry. The Minister shall issue a decision specifying procedures
conditions and rules regulating issue, term and renewal of such permit;
Article 10 - The owner shall take the necessary measures and adopt the state-of-the-art
techniques, approved by the, to minimize generation of waste at the source and to use clean
production techniques to prevent pollution of the environment. The owner undertakes to submit
a contingency plan for approval by the Ministry which shall be reviewed periodically;
Article 11 - No owner shall, by omission or commission, increase the level of environmental
pollution in ecosystems or in nature conservation areas, above the pollution standards and
discharge specifications from the Minister;
Article 19 and 22 restrict dumping / disposal of hazardous and non-hazardous wastes into the
environment without any permit; and
Article 41 - Whoever causes environmental damage shall undertake to remove it at his own
expense and shall reinstate the environmental status in addition to payment of necessary
compensation. In the event of failure of the violator to remove reasons of the violation within
the specified period, the Ministry shall have the right to arrange for removal of the same at the
expense of the violator.
2) Environmental Permitting (MD 187/2001)
MD 187/2001 and its amendments through MD 68/2004 specify the requirements and procedural
process for applying and obtaining an environmental approval/permit prior to commencing any
development activities. The relevant articles promulgated under this regulation in regard to the
proposed project are:
Article 3 – The owner shall apply to MECA on the form approved by the Ministry and in
addition enclose an environmental impact study prepared by a consulting office approved by
the Sultanate, if required by the Ministry;
Article 4 - The Ministry official shall as a preliminary step toward issuance of the
environmental approval, inspect the proposed sites to determine the environmental conditions
that must be fulfilled;
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Article 5 – The owner of the establishment shall be bound to implement the required conditions
and shall inform the Ministry of the same after ensuring that all the conditions are implemented
prior to issuance of environmental approval or environmental permit; and
Article 7 – The owner, if the nature of their activities so require as evaluated by the Ministry,
shall be bound to conduct an Environmental Audit by specialized companies approved by the
Sultanate according to the requirements of ISO 14000 series of EMS.
Article 8 – Without prejudice to penalties stipulated by the mentioned law on Conservation of
the Environment and Prevention of Pollution, the Ministry may close down the establishment if
it practiced its activity without environmental approval or final environmental permit or after
their expiry dates.
3) Protection of Potable Water Sources from Pollution (RD 115/2001)
RD 115/2001 provides the framework for protection of potable water sources from pollution. Listed
below are applicable Articles from this RD:
Article 8 - Non-household effluent shall not be discharged in sewage networks unless it is
treated in order to be in conformity with the specifications stated in appendix no. (3) of this
law. No sewage water or any other water pollutants shall be discharged in rainwater drainage
networks;
Article 9 - Solid non-hazardous waste shall only be disposed of in sanitary landfills licensed by
the Ministry. No solid non-hazardous waste shall be mixed with any category of hazardous
waste at any stage;
Article 13 - Every person who pollutes water shall be bound to remove such pollution at his
own expense and pay compensation for the damage. The Ministry shall have the right, in the
event of the failure of the violator to remove the violation within the specified period, to
arrange for removal of the violation at the expense of the violator;
Article 16 - No hazardous substances or waste or other water pollutants shall be discharged in
aflaj and their channels, surface watercourses, wadis or places of underground water recharge;
and
The RD further specifies conditions for treatment discharge and re-use of wastewater.
4) Regulation on Air Pollutants from Stationary Sources
Omani standards for maximum permissible emission concentrations from stationary sources are
issued under MD 118/2004. Applicable limits for emissions from stationary point sources in the
present project are provided in the table. The key provisions of this regulation as they apply to the
proposed project are presented below:
Article (2): Emission controls have to be provided to all emission sources from the plant in
order to prevent noxious or offensive emissions;
Article (3): Monitoring of emissions from stationary sources have to be conducted and reported
to the Ministry. The Ministry has the right to request to improve the monitoring method and
equipment used in such monitoring;
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Article (4): Necessary action shall be taken by the operator of the facility to eliminate any
harmful effects to public health and nuisance or emission of noxious odours arising from the
work area;
Article (6): The owner shall submit an application to obtain an environmental permit and shall
not commission or operate the plant unless the height of the chimney serving the plant has been
approved by the Ministry that it is sufficient enough to prevent the smoke, grit, dust and toxic
gases from becoming prejudicial to health or nuisance. The minimum stack heights from
ground level shall be as follows:
Power Plants
Plants generated by natural gas 26m
Plants generated by natural gas 35m
Boilers
Boilers generated by natural gas 15m
Boilers generated by natural gas 20m
Incinerators
Medical, municipal and industrial waste 15-20m
For other categories, the chimney height shall be calculated as "2.5 multiplied by the height of
the highest building (in meters) in the concerned establishment complex".
Article (7) – The permit to operate shall be issued for a period of three years, renewable for a
same period within one month from the date of expiry;
Article (10): Any change of ownership or production process of the facility shall be
communicated to DGEA; and
Article (11): Failure to comply with any provisions of this regulation will result in penalties and
the Ministry may close down the establishment if there is prejudice harm to the public health or
environmental damage.
Emission Standards as per MD 118/2004
Pollutant Maximum Permissible limits
General
Grit and dust Dark smoke products of combustion shall not emit smoke
0.050 g/m3
as dark as or darker than shade1 on the Ringlemann scale (20 % opacity)
Flaring
Nitrogen dioxide 0.150 g/m3
Particulates 0.100 g/m3
Unburned Hydrocarbons 0.010 g/m3
Carbon monoxide 0.050 g/m3
Carbon dioxide 5.000 g/m3
Sulphur dioxide 0.035 g/m3
Petrochemical Works
Particulates from catalytic crackers 0.100 g/m3
Sulphur recovery units maximum efficiency 99.9%
Organic compounds from fume recovery units 0.035 g/m3
Hydrogen sulphide 5ppm v/v
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Pollutant Maximum Permissible limits
Power Plant (Natural Gas)
Nitrogen dioxide 0.150 g/m3
Particulates 0.050 g/m3
Unburned Hydrocarbons 0.010 g/m3
Carbon dioxide 5.000 g/m3
Power Plant (Diesel Gas)
Nitrogen dioxide 0.150 g/m3
Particulates 0.100 g/m3
Unburned Hydrocarbons 0.010 g/m3
Carbon monoxide 0.050 g/m3
Sulphur dioxide 0.035 g/m3
Combustion sources - Natural gas fired (Industrial boilers, furnaces, industrial ovens)
Nitrogen dioxide 0.150 g/m3
Particulates 0.050 g/m3
Unburned Hydrocarbons 0.010 g/m3
Carbon dioxide 5.000 g/m3
Combustion sources - Diesel oil fired (Industrial boilers, furnaces, industrial ovens)
Carbon monoxide 0.050 g/m3
Sulphur dioxide 0.035 g/m3
Nitrogen dioxide 0.150 g/m3
Particulates 0.100 g/m3
Unburned Hydrocarbons matters 0.010 g/m3
Incineration Works
Hydrogen chloride 0.050 g/m3
Hydrogen fluoride 0.010 g/m3
Oxides of nitrogen, calculated as nitrogen dioxide 0.200 g/m3
Phosphorous compounds, calculated as phosphorus pentoxide 0.050 g/m3
Hydrogen sulphide 5ppm v/v
Dioxin 0.500 ng/m3
Total Particulates 0.050 g/m3
5) Regulation for Wastewater and Sewage Storage
Omani regulation issued under MD 421/98 specifies the regulations for septic tanks, soak away pits
and holding tanks in order to protect the land and water resources from pollution, and to achieve
proper health standards. The relevant articles in the regulations are listed below:
Article (3) - Septic Tanks shall only be allowed in institutions and accommodations which
discharge solely domestic wastewater from population equivalents not greater than 150. Any
larger institutions must be served by sewage treatment plants subject to the “Regulations for
Wastewater Re-use and Discharge” of Ministerial Decision Number 145/93;
Article (4) - Septic Tanks may only be installed with the prior approval and consent of the
concerned Municipality;
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Article (5) – Septic Tank capacity must be calculated according to the procedures set out in
Annex A and designed according to the criteria given in Annex B of the regulations issued in
MD 421/98;
Article (7) – Septic Tanks must be constructed in such manner and using appropriate materials,
as to ensure that they remain watertight at all times; and
Article (10) – Septic Tanks and Soak away pits must comply with the conditions stipulated in
Article (10) of the regulation MD 421/98.
6) Ambient Air Quality
Presently, there are no Omani standards for ambient air quality. Therefore, MECA recommends the
use of USEPA's National Ambient Air Quality (NAAQ) standards. The NAAQ standards are
presented below.
USEPA National Air Quality Standards
Pollutant Averaging Period Maximum Permissible Limit
Particulates (PM10) 24-hour average 150 µg/m3
24-hour average 35 µg/m3
Particulates (PM2.5)
Annual arithmetic mean 15 µg/m3
3-hour average 0.5 ppm (1300 µg/m3)
Sulphur dioxide (SO2) 24-hour average 0.14 ppm
Annual arithmetic mean 0.03 ppm
Annual arithmetic mean 0.053 ppm (100 µg/m3)
Nitrogen dioxide (NO2)
1-hour average 0.100 ppm
1-hour average 35 ppm (40 mg/m3)
Carbon monoxide (CO)
8-hour average 9 ppm (10 mg/m3)
1-hour average 0.12 ppm
Ozone (O3)
8-hour average 0.075 ppm
Rolling 3-month average 0.15 µg/m3
Lead (Pb)
Quarterly average 1.5 µg/m3
MECA however is currently in the process of developing Omani Ambient Air Quality (OAAQ)
Standards. Although the standards have not yet been promulgated, the provisional standards are
provided as presented in Table.
Ambient Air Quality Standards
Parameters Averaging Period Standard Limits (µg/m3)
NO2 24-hour average 112
SO2 24-hour average 125
CO 8-hour average 6000
H2 S 24-hour average 40
O3 8-hour average 120
HCNM 3-hour average 160
PM10 24-hour average 125
There are no Omani standards for work place air quality. Therefore, United States Occupational
Safety and Health Administration (OSHA) 8-hr limit can be used. The maximum permissible limit
specified by OSHA for respirable particulate matter (PM10) within the workplace is 5,000μg/m3.
7) Noise (MD 79/94 & MD 80/94)
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The regulations for noise control are applicable to workplace noise levels and ambient noise levels.
The ambient noise standards are issued under MD 79/94 and the limits for ambient noise levels from
industrial sources applicable to the proposed plant (Industrial and Commercial) is summarized in
Table.
Ambient Noise Standard applicable to PC plant
Maximum Permissible Noise Level [as Leq in dB (A)]
Type of District
A18 B19 C20
Industrial and commercial 70 70 70
8) Noise Pollution Control in Working Environment
MD 80/94 specifies the regulations for noise pollution control in working environment. These
regulations state that no employee shall be exposed to noise levels exceeding 85 dB (A). If the
workplace noise level exceeds 85 dB (A), suitable ear protection devices shall be provided. The
attenuation of such protection devices shall reduce the noise level to 80 dB (A) or lower.
9) Hazardous Waste (MD 18/93)
MD 18/93 specifies the Omani regulations on hazardous waste management. Hazardous waste is
defined as “any liquid or solid waste, which because of its quantity, physical, chemical or infectious
characteristics can result in hazards to human health or the environment when improperly handled,
stored, transported, treated or disposed-off”.
10) Non-hazardous Waste (MD 17/93)
MD 17/93 specifies the Omani regulations for non-hazardous solid waste management.
11) Handling and Use of Chemicals (RD 46/95)
RD 46/95 provides the framework for the handling and use of chemicals. Relevant articles of this RD
are listed below:
Article 2 states persons involved in manufacture, import, export, transport, handling, storage,
and use of chemicals must satisfy requirements of this RD;
Article 8 states that transport and storage of hazardous chemicals require permits from the
Director General of Civil Defence – Royal Oman Police (ROP);
Article 9 states import, export, transport, or handling of any hazardous chemicals requires
packing in special containers;
Article 11 requires the user of any hazardous chemical to dispose at his expenses empty
container and hazardous wastes, under supervision of the Ministry, per requirements of MD in
force; and
18
Workdays –Daytime: After 7 am up to 6 pm
19
Workdays – Evenings: After 6 pm up to 11 pm
20
Holidays and Night time – After 11 pm up to 7 am
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Article 12 requires training and provision of personal protective equipment to staff. It further
requires maintaining records of staff handling hazardous chemicals, quantities, and handling
process.
12) Registration of Chemical Substances and Relevant Permits (MD 248/97)
MD 248/97 provides regulations for the control and management of chemical substances. The
relevant articles promulgated under this regulation are presented below:
Article (2) – Any natural or juridical person who intends to deal with any hazardous chemical
by manufacture, import, export, transport, storage, handling, use or disposal shall apply to the
Ministry, by filling the designated form, obtain the environmental permit after paying the
necessary fees;
Article (4) – Any person dealing with hazardous chemicals shall maintain a valid
environmental permit and chemical safety data as per Annex (2), and shall keep copy of the
permit and the data in a safe place far from where the chemical is kept or transported;
Article (5) – The dealer shall abide to carry out all conditions, follow all procedures specified in
the chemical safety data or any other conditions or procedures required in the environmental
permit or in the Law.
Article (6) – Staff designated by decision of the Minister shall have the powers to examine any
chemical transaction, activity, or conduct necessary tests and investigations to enforce the
provisions of these regulations.
Article (7) – Offenders of the provisions of these regulations shall be liable to penalties stated
in the Law
13) Management of Radioactive Substances (MD 281/2003)
MD 249/97, amended by MD 281/2003, specifies regulations for the control and management of
radioactive materials. The relevant articles promulgated under this regulation with regard to the
proposed project are listed below:
Article (2) – Any organization intending to import, transport, store or use radioactive materials
or equipment containing radioactive material must apply to the Ministry for a permit;
Article (3) – The organization shall, after Ministry’s approval , provide qualified personnel to
monitor and control radioactive material and ensure that the provisions of this regulation are
complied with;
Article (22) – Permanent storage of radioactive materials shall be permitted only at locations
approved by the Ministry. The organization using these locations should have written
procedures of operations, security facilities, dose rate limitations, notices and labels as per the
specified design model;
Article (23) – The storage locations must fulfil the following:
A. Should be away from populated areas;
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B. All radioactive materials shall be adequately shielded, labelled and kept in locked and
secure places to protect them from theft, damage or use by unauthorized persons;
C. Special procedures shall be established for control of the storage facilities keys;
D. Clearly label “Radioactive Materials” both in Arabic and English on each store containing
radioactive materials as per instructions of the Ministry; and
E. The dose rate outside the storage facility shall not exceed 2.5μSv/h.
14) SEU Guidance Notes
Waste Management
The basic approach towards SIPA Waste Management prescribed in this Guidance Note is as follows:
Polluter Pays principle;
Priority order: reduction, recycling, energizing, controlled disposal;
All generated / transported industrial waste has to be registered by SEU [by Permit or No-
Objection Letter (NOL)];
On-site storage of hazardous wastes is allowed (under Permit or NOL) when off-site solutions
are not available; and
When off-site solutions are available, on-site storage of hazardous wastes is allowed (under
Permit or NOL) for limited time and quantities.
Summary of additional guideline requirements are as follows:
Facilities that generate, transport, recycle, treat, store or dispose of wastes are required to notify
SEU of their waste quantities;
The waste generator is expected to categorize the waste based on best practices for sampling
and analysis. SEU has distinguished four basic categories, viz., household, non-hazardous and
hazardous wastes and construction excavation material / wastes. For the hazardous waste
identification the Basel Convention and the EPA tables are to be used;
Hazardous wastes that are exported from Oman have to follow the ‘Basel route’. The Basel
desk is located in MECA Muscat office; however SEU will be the gateway for application.
Construction and excavation wastes / materials can be categorized as non-hazardous if a
‘statement of non-contamination’ is submitted with the NOL. This statement might be based on
laboratory result or a plausible explanation and should be verifiable by SEU;
SEU identifies the SIPA companies possessing PEP who are generating wastes as responsible
parties for the generated waste. Service providers, subcontractors and transporters can only
formally interact with SEU when they work on behalf of the SIPA company. SIPA companies
will remain responsible as Generators for the waste stored in Liwa and for waste that is
disposed illegally by subcontractors / transporters; and
The transporters of hazardous wastes, hired by the project company, need to possess basic
licenses from MECA, ROP, etc. to be registered. SEU will issue an NOL to transport
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consignments to the hazardous waste site at Liwa (Liwa site) if the framework licenses are
present.
Non-Hazardous Industrial Waste Storage at Sohar
This Guidance Note identifies for the waste generator a non-hazardous waste site inside the Sohar
Municipal solid waste facility (that will be called the Sohar waste collection site).
While the Sohar waste collection site is open both during daytime from 7 am to 1 pm and evening
time from 3 pm to 6 pm, SEU allows access only during the daytime. Several areas in the site are
reserved for SIPA companies. The waste generator / transporter must not damage the trees on the site.
Only bagged or properly packed material is only allowed to be dumped at the site. A gate fee of RO
2/- has to be paid. A summary of the guidelines prescribed in this Guidance Notes are listed below:
The type and quantities of the non-hazardous wastes generated within SIPA has to be tracked
for their type and quantities;
The waste generator will have to obtain NOL for every type of non-hazardous waste if the
generator wants to use the Sohar waste collection site or proposes another solution. The NOL
will be valid for a maximum of one year and is not transferrable; and
Every truckload of a consignment must be accompanied by a manifest document, issued by the
generator (which will be based on SEU provided blueprint). The generator will be held
accountable for any non-conformity and if the consignment or part of it is not covered by the
NOL, the waste has to be taken back to the generator on its cost.
The Guidance Note further provides templates for the NOL for Disposal of Non-Hazardous Industrial
Waste and for the Manifest for Non-Hazardous Industrial Waste.
Hazardous Waste Storage at Liwa
Summary of the guideline prescribed in this Guidance Note are listed below:
The waste generator will have to apply for and obtain a Consignment Note (CN) for every
waste type from SEU if the generator wants to use Liwa site. The CN will be valid for a
maximum one year and is not transferrable; SEU accepts only MECA registered transporter
companies that have a permit that is explicitly specific for the consignment under
consideration;
SEU accepts only results from certified laboratories. A parameter passes when the measured
value is within the range of acceptance with a ± 10 % range extension due to measurement
inaccuracies. Results outside the extended acceptance range will be assessed by the SEU on a
case by case basis. Test result reports must include test method, detection limit and accuracy;
Samples that are taken from a consignment need to be representative of that consignment and
are the responsibility of the generator; and
Every truckload of a consignment must be accompanied by a manifest document, a copy of the
CN and weighing document. The generator will be held accountable for any non-conformance
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and if the consignment or part of it is not covered by the CN, the waste has to be taken back to
the generator on its costs.
The Guidance Note provides templates for the CN and manifest for registering the transportation of
hazardous industrial waste.
Import, Export, Using, Handling and Storage of Chemicals at SIPA
This Guidance Note categorizes the chemicals substances as non-hazardous, hazardous and extremely
hazardous. Summary of the guidelines prescribed in this Guidance Note is listed below:
A chemical permit has to be obtained from MECA for each chemical to be used. Applications
for chemical permit by a SIPA company are to be submitted to the SEU;
In some cases, SEU will include conditions in addition to those already in the chemical permits
issued by MECA. This will be mostly in the case of extremely hazardous substances;
The Guidance Note further provides a comprehensive guideline on chemical storage best practices
during construction and operation and for the storage facilities and equipment.
Industrial Safety at SIPA
This Guidance Note lays down the requirements of the Seveso-II Directive to be considered for
analysis of the safety aspects of the industrial project within SIPA. Seveso-II Directive covers all
necessary elements for the prevention of a major accident in an industry. Two kinds of so called
Seveso companies are identified, viz., lower tier / tier 1 and higher tier / tier 2. The difference between
the two tiers is based on the amount of dangerous substances. The tier 2 companies must provide a
safety report to demonstrate that the company controls the chance of a major accident and its potential
consequences.
The Guidance Note also provides Seveso classification for industries in SIPA. SEU has defined two
phases in order to implement the Seveso-II Directive in SIPA. The initial phase will involve the
following:
Development of Major Accident Prevention Policy (MAPP). MAPP will include a definition of
the companies’ own acceptable level of risks and tables for likelihood and severity, including a
risk matrix. MAPP is to be reviewed annually and updated;
Development of a Safety Management System (SMS) to implement the MAPP. SEU suggests
the NTA 8620 as a useful tool for the SMS. This document presented in the Guidance Note and
is also available with SEU. SEU will email a copy of this tool upon request;
Conducting Hazard Identification and Risk Assessment (HIRA) study. Based on the HIRA
study a Maximum Credible Accident (MCA) scenario can be identified;
Development of an Emergency Response Plan (ERP). The ERP will be based on the MCA
scenario. SEU suggests through the Guidance Note that the ERP must be practiced at least
twice a year and one of the exercises to be carried out in coordination with SIPC. Every
exercise must be based on a realistic scenario and must be evaluated; and
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Preparation of a list of hazardous substances used in the company (HSL). The up-to-date HSL
must be present at the company to ensure the emergency services have direct access to at least
the current information within an installation of the hazardous substance (list of information to
be displayed or documented is provided in the Guidance Note).
The following phase must result in:
Preparation of a Safety Report (SR) (if so required); and
Preparation of an Incident Investigation Report.
Requirements for EIA, ER, IPPC and Seveso-II
This Guidance Note prescribes requirements related to the EIA study for companies planning new
development or modification in existing facilities within the SIPA. Further, guidelines on
Environmental Review (ER) and requirements of IPPC and Seveso-II are also provided.
SEU will assess the requirements for the PEP when a company establishes a new industrial activity or
will implement major change in its facilities. This process has the following phases:
Initial Assessment resulting in an No Objection Letter (NOL) for proposed activity in the
proposed site;
Screening to verify the need for the EIA and categorize the company as per the IPPC and
Seveso-II Directives;
Scoping, identifying the topics that need to be studied in the EIA (the Terms of Reference for
the EIA) and identifying requirements for IPPC and Seveso-II;
Reviewing, assessment of the EIA study and identification of lack of information;
Permitting, setting the conditions for the PEP.
EIA Criteria
The guidelines indicates that all petrochemical and metal sector activities in the SIPA requires an EIA
study as the impact on environment is considered to be significant and industrial safety issues are
involved. It also specifies the need for EIA scoping report. Further an EMP is required to be provided
as a separate document and not as a chapter of the EIA report.
IPPC Criteria
The Guidance Note makes a note that not all companies within SIPA will be IPPC company, i.e., not
all SIPA companies will come under the purview of IPPC. The criteria for IPPC companies are
provided in EU’s IPPC Directive (Directive 2008/1/EC). The directives are provided in Annex I of
Directive 2008/1/EC (refer Section 2.4).
Seveso-II Criteria
The Guidance Note briefly explains the classification of Seveso-II companies, viz., Tier 1 and Tier 2
companies, depending on the amount of particular substances a company has (stores or uses) on site.
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In the Tier 2 category, the companies are required to provide a safety report (SR) that describes the
SMS and the MAPP.
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Appendix C Soil Analysis Report
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Appendix D Groundwater Analysis Results
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Appendix E Ecological Settings of the Site and its Vicinity
The proposed project area is located in SIPA which is designated for industrial development.
Therefore, large part of this area is altered and impacted due to industrial development and other
activities. The proposed project location and its vicinity is highly altered and is covered with
halophytes (plants that can tolerate saline soil conditions) indicating saline soil conditions. The
vegetation is dominated by two main species viz. Suaeda vermiculata and Salsola imbricata of
Chenopodiaceae (Salt Bush) family. These bushes are 2m wide, 1 m high thickets within the site.
Regional Settings
As mentioned the proposed project is located in SIPA near Sohar Port, which is one of the important
commercial ports of North Batinah region in Oman. Al Batinah region is important agriculture area in
Oman known for khwars and mangrove forests of national importance. Most of the khwars and
mangrove forest areas are declared or proposed as National Nature Reserves or National Resource
Reserves. The most prominent of them are the mangroves of Khawr Shinas and Khawr Harmul. The
mangrove forests in the region, characterized by homogenous stand of Avicennia marina, are known to
harbor a population of White-collared Kingfisher (Halcyon chloris kalbaensis) (HMR 2010,
Unpublished report). Apart from mangrove forests, other important habitats found here include large
woodlands of Acacia tortilis and Prosopis cineraria, which also is a home to great diversity of birds
and mammals. The Indian bark gecko (Hemidactylus leschenaultii) was recently reported for the first
time in Arabia and appears to be restricted to mature Acacia tortilis woodlands along Al Batinah coast
(Gardner, 1992).
Local Settings
The proposed site is located within Sohar Industrial Port Area, where natural landscapes and habitats
have undergone transformation due to developmental activities and industrialization. Most of the
habitats are altered and heavily impacted due to industrial development. There are few pockets outside
the port area which support woodlands and open scrub vegetation. The woodlands typically shows
presence of consisting of Acacia tortilis, Ziziphus spina-christi and Prosopis cineraria.
Observations and ecology of the proposed site
Objectives and Methods
The ecological assessment was carried out at the proposed site and its vicinity during November 2014.
The assessment was undertaken to fulfil following objectives,
To document and enlist flora and fauna
To identify sensitive sites and habitats if any
To assess the impact of flora, fauna and associated habitats within study area
Information was gathered by walking through transects covering entire site. Systematic efforts were
made for documentation of flora and fauna present within the site. Wherever possible various floral
and faunal elements were photo-documented.
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Field guides such as Common Birds in Oman, Wild Plants of Oman were used for confirming
identification of the species of birds and plants. Secondary sources of literature were used to
complement findings of the field based assessment.
Terrestrial Flora
During the study 16 species of plants (including trees, shrubs, herbs and grasses), which belong to 11
families were observed within the site and its immediate vicinity. It includes 2 Chenopodiaceae
members’ viz. Suaeda vermiculata and Salsola imbricata which dominate the vegetation. These two
species constitute approximately 80 to 90% vegetation found in the site.
The only tree species present at the site can be either Acacia tortilis or Prosopis juliflora; it could not
be identified since it was completely desiccated. Other species are shrubs or sub-shrubs. A sedge
Cyperus conglomeratus and two Poaceae members (Grass Family) includes Cymbopogon sp. and
Cenchrus sp. Other associate species include Lotus garcinii, Cyperus conglomeratus, Indigofera sp.
However their number is much lower than that of Chenopods. Fagonia indica were also observed
occasionally amongst bushes of Indigofera sp. and Lotus garcinii.
Thickets of Saltbush at the site Luxuriant growth of Chenopods within site
Suaeda vermiculata flowers Salsola imbricata flowers
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Indigofera sp. Fagonia indica flower
Some parts of the site such as the northern and southern corners appear to have retained some natural /
original vegetation which consists of Aerva javanica, D. glaucum, Heliotropium bacciferum and
Acacia sp. The northern corner has number of D. glaucum bushes. During the study all D. glaucum
plants were in bloom and number of bees was observed on the small yellow flowers.
Deptarygium glaucum bush and close-up of the flowers
The site has an embankment on western and southern side. The slopes of the embankment on the
western side also support non-halophytic vegetation. This includes propagules of Acacia or Prosopis
juliflora, Aerva javanica, Cleome austroarabica, tufts of Cymbopogon sp. etc.
A detail list of various species observed during the study is given in a table below with comments
about their abundance and IUCN status.
List of plants observed during study
Taxonomy Remarks IUCN Status*
Amaranthaceae
Aerva javanica Occassional Not Assessed
Aizoaceae
Dried and decicated habit like
Aizoon canariense Not Assessed
Aizoon
Boraginaceae
Heliotropium bacciferum Rare Not Assessed
Chenopodaceae
Salsola imbricata Abundant Not Assessed
Sueaeda vermiculata Abundant Not Assessed
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Taxonomy Remarks IUCN Status*
Cleomaceae
Cleome austroarabica Rare Not Assessed
Dipterygium glaucum Restricted to one corner occasional Not Assessed
Cyperaceae
Cyperus conglomeratus Occasional
Fabaceae
Indigofera sp. Common
Lotus garcinii Common Not Assessed
Mimosaceae
Acacia tortilis Rare Not assessed
Prosopis juliflora Rare Not Assessed
Nyctaginaceae
Boerhavia elegans Rare Not Assessed
Poaceae
Cenchrus sp. Rare
Cymbopogon sp. Occasional
Zygophyllaceae
Fagonia indica Rare Not Assessed
*Source: The IUCN Red List of Threatened Species. Version 2014.2 <www.iucnredlist.org>. Downloaded on 19
October 2014
Terrestrial Fauna
Suaeda and Salsola species provide main vegetation cover for the fauna found at the site. A number of
burrows and indirect evidences of animals were observed during the study. Many of these burrows
were present under large thickets of the salt bushes.
A few Pristrus geckos and 2 or 3 individuals of Lacertid Acanthodactylus were observed during the
study. Apart from direct sightings of reptiles, a number of burrows of various sizes were observed
within the site. It is quite possible that burrows (like the one shown below) are being used by species
of rodents. However there were no other evidences to confirm the species. Apart from these animals
feral dogs may be using this area.
Burrow observed at the site Little Green Bee Eater
Other fauna includes birds – these are mostly common birds found in this part of the country and are
limited to 5 to 6 species. These include Laughing Dove, Collared Dove, Little Green Bee Eater, House
Sparrow, Rock Dove and Yellow Vented Bulbuls were observed in and around the site. The site does
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not support any fauna i.e. mammal or bird or reptile which is of high conservation importance
nationally and globally.
Discussions and Conclusion
The site is a degraded and altered ecosystem as is indicated by vegetation composition and present
status of the vegetation. Most of the area is covered by salt bush thickets and a large number of
thickets have dried up or desiccated. About 75% vegetation is represented by dry and desiccated
Suaeda and Salsola bushes. The proposed site does not have any plant species or communities that are
rare or threatened or endangered in Oman or within Arabian Peninsula. All species found at the site
are of common occurrence across the country and none has restricted distribution. Some of the species
found are also considered as weeds.
Some parts of the site appear like waste land owing to presence of refuse and debris. The site does not
harbour any reptile or mammal fauna of great ecological or conservation significance. The geckos and
birds that were observed at site during the study are common species, which has wide range of
distribution across the country.
Various ecological impacts due to proposed project will include loss of vegetation and loss of habitat
for existing floral and faunal assemblage. However this will not be significant since site does not have
any unique or endemic flora or fauna.
In general there are no ecological sensitivities at the site that will be lost whilst implementation of the
proposed project. Loss of vegetation can be compensated by planting native tree species during
landscaping work. Measures such as creation of vegetation screen using native vegetation can be
considered during landscaping work. This will add to biodiversity of the area.
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References
1. Eriksen H., & Eriksen J., 2005; Common Birds in Oman – an identification guide, Al Royal
Publishing
2. Ghazanfar S. A., 1998; Status of Flora and Plant Conservation in the Sultanate of Oman,
Biological Conservation 85 (1998) 287-295
3. Gardner A. S. 1992; Geographic distribution of Hemidactylus leschenaultii. Herpetological
Review 23:123 in Fund, W. (2014). Gulf of Oman desert and semi-desert. Retrieved from
4. http://www.eoearth.org/view/article/153201
5. HMR Environmental Engineering Consultants 2010; Environmental Impact Assessment of
Sohar II Power Plant Al Batinah Power Co., S.A.O.C.
6. Pickering H. & Patzelt A., 2008; Field Guide to the Wild Plants of Oman, Kew Publishing,
Royal Botanical Garden, Kew Winbow C., 2008; The Native Plants of Oman: An
Introduction, Environmental Society of Oman
Appendix F Socio-Economic Settings of PIA
Profile of Project Influence Area
The project site falls under the North Al Batinah Governorate, which lies between Khatmat Malahah
in the north and Al Musanaah in the south and is confined between the Al Hajar Mountains in the
west and the Oman Sea in the east. It is located within the Sohar Industrial Port Area (SIPA), which is
part of the Wilayat of Liwa and is characterized by the industrial land use.
There are 10 villages lying within 5 km radius of the Project Influence Area (PIA) as presented in
Table below and depicted in the figure. Out of these 10 villages, 7 come under the Wilayat of Liwa
and 3 are part of Wilayat of Sohar. Analysis of all aspects of the socio-economic profile was carried
out at the micro level entailing these individual villages as well as the PIA as a whole.
Villages within PIA
Approximate
# Village Wilayat Direction from Plant
Distance from Plant
1 Harmul 4 N
2 Al Mukhaylif 3.5 NW
3 Uqdat Al Mawani 3 NW
4 Wadi Al Qasab Liwa 2.0 NW
5 Al Hadd 1.1 SW
6 Al Ghuzayyil 1 SW
7 Ghadfan 2.5 S
8 Al Khuwayriah 2.0 E
9 Majees Sohar NE
10 Amq SE
Source: HMR Archives and Google Earth
There are also various industries in the contiguity of the plant as presented in Table below.
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List of Major Industries Adjacent to Project Site
# Industry Distance & Direction from Proposed Plant
1 Jindal Steel Plot 1 - 1.5 km (North West)
2 Vale Plot 1 - 1.0 km (West)
3 Proposed PIA Plant Plot 1 - 0.1 km (1km– North West)
4 Oman Polypropylene Plot 1 - 0.7 km (Adjacent - North)
Sohar International Urea and
5 Plot 1 - 1.5 km (North-East)
Chemical Industries
6 Aromatics Oman Plot 1 - Adjacent (East)
7 Orpic Plot 2 - 2.0 km (West)
8 Oman Methanol Company Plot 2 - 2.0 km (North-West)
9 Sohar Aluminum Power Plant Plot 2 - 2.0 km (North)
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PIA – An Overview
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List of Major Industries Adjacent to thr Proposed Plant
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Land Utilization Pattern
The land use in the PIA exhibits agricultural plots, plantations, open and built up areas including
settlements and SIPA alongside a vast fishing ground along the Al Batinah coastline. In addition, there are
limited pastures for animal rearing and areas where fertile soil is utilized for cultivation of vegetables and
plantations.
Agriculture is one of the major sources of employment for people in this area especially cultivation of
date palm, vegetables and citrus fruits. Dug wells are still the main source of irrigation even though most
of these wells and groundwater supplies have been contaminated by salt-water intrusion. As a result, a
considerable number of date palm plantations adjacent to the SIPA have been abandoned due to increased
salinisation. Treated or desalinated water is also used to irrigate some of the agricultural lands in the
vicinity of SIPA.
Some of the local population rears animals like goats mostly for domestic consumption. Although there
are areas within the villages that supports grazing (natural vegetation in the form of shrubs and small
trees), animal fodder is usually purchased from the local market and livestock are fed in temporary sheds
(either in homes or farms).
Fishing is a significant part of the economy as fish is an essential part of the daily diet of the community.
There are number of fishing areas rich in important marine species in the vicinity of the project area.
Some of the chief species found here include Kingfish, mackerels and sardine. Majees and Harmul are
considered as fishing settlements.
Land Ownership
As per the RD 80/2002, approximately 2000 hectares of area was declared as Sohar Industrial Port Area.
Therefore there are no traditional rights over the project site. However, the community has traditional
rights for grazing and fishing.
Settlement Pattern
Most of the settlements are positioned in such a way that they have an easy access to the highway for
connectivity, and simultaneously they are also in the vicinity of marine sources. Majees is situated along
the coast and exhibits fishing village characteristics. Except for Al Khuwayriah, which is isolated from the
rest of the villages, there is no physical demarcation of the boundaries for the villages located along the
main highway. Housings units are placed along the internal roads in such a manner that the units are
located in proximity to each other.
Demographic Profile
The demographic profile of local population is analysed based on parameters including population
numbers and its composition.
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Population Distribution
Based on the 2003 Census Al Batinah region is considered as the largest populated region in Sultanate’s
with 27.92% of the total population. As per the census 2003 the total population of Al Batinah region was
653,505. However, in 2010 census the population increased to 772,590 and hence accounts only 27.86%
of the Sultanate’s population after the Muscat Region. During 2003-2010 the population growth rate of Al
Batinah region is 18.22% while the average annual growth rate is recorded as 2.60%.
Out of the twelve Wilayats Sohar acts as a Regional center and is the most populated Wilayat with
18.12% of Region’s total population (Census 2010). However, Liwa, the adjacent Wilayat of Sohar which
conceives the major industrial development of the country (including the project site) has total population
of 34,001 and is considered amongst the sparsely populated Wilayats of the Region. It constitutes less
than 5% of the Region’s population.
Population Distribution of Liwa and Sohar
Population Decennial
Region / Wilayat / No. of Population
Land Area
Town Households Male Female Total Growth
(2003 – 2010)
Batinah Region 12,500 km2 106,465 434,032 338,558 772,590 18.22%
2
Wilayat of Liwa 728 km 4,190 19,999 14,002 34,001 31.91%
Wilayat of Sohar 1728 km² 20,886 85,346 54,660 140,006 34.20%
Demographic aspects of the study area are assessed based on the population figures reported in the 2010
census. The population (M = Male; F = Female; T= Total), the total number of families and the average
family size of the identified settlements within the study area is presented in table below
Human Settlements within 5km Radius from PC
Omani Population Non-Omani Population Total Population Total
Avg
Number
House
Village of House
M F T M F T M F T Hold
Holds /
Size
Family
Ghadfan 1885 1955 3840 3064 420 3484 4949 2375 7324 1037 7.1
Liwa 1926 1881 3807 1264 268 1532 3190 2149 5339 1170 4.5
Harmul 1026 1013 2039 45 36 81 1071 1049 2120 248 8.5
Al Mukhaylif 761 800 1561 192 69 261 953 869 1822 264 7
Wadi Al Qasab 334 326 660 1001 19 1020 1335 345 1680 116 14.5
Uqdat Al Mawani 557 547 1104 383 39 422 940 586 1526 238 6.4
Al Hadd 433 390 823 39 24 63 472 414 886 156 5.9
Al Ghzayyal 961 955 1916 74 46 120 1035 1001 2036 317 5.4
AlKhuwairiya &
3432 37391 40823 14843 5032 19875 18275 42423 60698 - -
Majees
Total 11315 45258 56573 20905 5953 26858 32220 51211 83431 - -
The average family size in the settlements within the study area is around 7 persons / family which lower
than the family size of Wilayat Liwa and Sohar. Since the age wise population information for each
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settlements as well as for Region and Wilayat for census 2010 are not available from any of the published
government reports / documents, the regional level and Wilayat level census (2003) information is used to
appraise the age structure of the study area. Reportedly, the Region had almost 38% of its population in
the age group of 0-14 during 2003. The age group of 15-64 years constitutes 59% of the regional
population whilst the ratio of elderly above the age group of 65 years is relatively less (3%).
Social Infrastructure
Housing
Salient features of residential development in PIA are:
Along the existing Batinah Highway and around the Sohar Port area, large numbers of multi-
storeyed buildings with both commercial and residential use have been constructed in recent
years. Within the study area, new / modern villas have come up. Overall, there is a good mix of
old / traditional housing units and new/modern buildings. Ministry of Housing has planned two
locations for future residential development apart from a large planned residential area near the
existing Batinah Highway, just north of the SFZ.
In terms of number of rooms, villas are the largest units, followed by Arabic houses. Apartments
and rural houses are small with 3-4 rooms on an average.
In terms of household occupancy, villas accommodate larger households, followed by Arabic
houses. Apartments and rural houses accommodate 4-5 members on an average.
About 87% of the houses in the Liwa are occupied on ownership basis. This indicates a smaller
share of working / migrant population occupying about 13% houses on rental basis. It is about
60% on ownership basis and 40% houses on rental basis in Sohar Wilayat. However, the scenario
may change with significant industrialization and development of Port Sohar. This is also evident
from the construction of many apartment buildings in the area adjacent to the highway.
As per the existing land-use plan for Al Batinah Region, residential land-use in Wilayat Liwa is
about 368 ha and gross residential population density is 84 persons per ha and in Wilayat Sohar it
is about 1105 ha and gross residential population density is 114 persons per ha. However the
concentration is much higher in the settlements located eastern side of the plot within the study
area.
Health
Ministry of Health (MoH) is the main provider of health services; however there are private hospitals and
clinic to provide health services. MoH provides five categories of health services. Sohar hospital is the
nearest regional hospital to the study area and providing the primary and secondary health care for entire
North Al Batinah Governorate. In terms of coverage, Liwa Wilayat has two health centres. However there
are no in-patient facilities available for the entire Wilayat. Available primary health facilities for 10,000
population in the Wilayat is 0.6 which is relatively equal with the national average.
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People of the study area have to depend on the health facilities of Sohar for treating critical illness. Health
institutions of Sohar have a provision of almost 28 hospital beds per 10,000 populations, which is above
the global average (27). However, considering that Sohar hospital caters to the region, the availability of
beds is rather limited. Table presents the health facilities in Sohar and Liwa Wilayat.
Health Facilities in Liwa/Sohar Wilayat
Total Hospitals
Year of Facilities Beds for
# Hospital Population No of for 10,000
establishment available 10,000
beds population
1 Liwa Health Center 1984 L, R
29,606 Nil 0.6 0
2 Nabr Health Centre 2007 R, L
Sohar Hospital
3 1973 363 D, R, L
Regional Hospital
4 Wadi Hibi local Hospital 1993 18 D, R, L
5 Wadi Ahin Health Center 1993 0 L
124,643 0.4 28.5
Sohar Extended Health
6 1997 0 R, L
Center
7 Al Multaqa Health Centre 2004 0 R, L
8 Al Uwaynat Health Centre 2007 0 R, L
L-Laboratory, R-Radiological Procedure: Source: Annual Health Report
Private hospitals play a significant role in the health care system. Private hospitals are licensed hospitals
by MoH under the direct supervision of respective regional directorates. Nearest private hospitals is at
Falaj al Qabail. However, private clinics are providing primary health care services.
Education
The fundamental principle of Oman education policy is to achieve equity between its citizens and
expatriates in general education and the provision of a free general education up to grade twelve for all
citizens and Arabic speaking expatriates and to set laws and regulations regarding work in government
and private education institutions.
In Liwa Wilayat, total number of schools available for 10,000 population is 4.2 which is greater than the
national average of 3.7. In Sohar Wilayat, total number of schools available for 10000 population is 3.5
which is lower than the national average. The total enrolment rate of the wilayat is 80% which is lower
than the national and regional average. In the entire wilayat 41 schools are available of which 23% of
schools are providing the first cycle of basic education, 28% of the schools are providing second cycle of
basic education,5% of schools are providing post basic education. 13% of the schools are providing
complete general education and 38% of schools provide mix grade education.
Activities
Camel Racing - This sport has sustained itself and grown since HM The Sultan instituted a number of
measures to encourage it. It has a strong following in the Batinah Region, including Wilayat Liwa. It is
now a spectator sport enjoyed by a large section of the community including expatriates as well as foreign
tourists. However it requires an active local group of camel breeders to sustain it and improve local results
in competitions, which include local camels racing in big events in the UAE. Thus any reduction in
available grazing will reduce the opportunity for local breeders to succeed in the sport.
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Places for Rural Recreation. The foothills of Jebel Shaykh have areas of dense pre-Islamic grave clusters
from the Hafeet and Wadi Suq periods, giving a historical dimension to valuable natural landscapes. This
was identified as an important recreational resource in the original Sohar Industrial Master Plan (SIAMP),
although the proposed ‘Green Belt’ areas were shown only with indicative colouring and not included
within the Plan boundaries. This example was chosen to publicly launch a Green Belt Policy for Oman in
the Ministry magazine ‘Man and the Environment’. However, no further action has since been taken to
identify, designate and implement green belt areas. Destruction of the scenic values of such cultural
landscapes leads to a loss of amenity for the inhabitants of the
Northern Batinah Region, especially those in Liwa including expatriate employees. Despite the lack of
formal facilities for local tourists in the region’s countryside, Omanis enjoy taking their families on
outings in the countryside on Thursdays or Fridays.. Much opportunity has already been lost, so it is
doubly important to retain what remains for the general standard of living and amenity of the locals.
Physical Infrastructure
Water Supply
The general groundwater flow in the region is towards the Oman Sea. The groundwater gradient is steady
throughout the Al Batinah Coastal Area. Using the most recent statistics, the World Bank reported that in
year 2000, about 82% of the population of Oman had access to treated water. The ground water is often
the only source of fresh water in this region. Extensive ground water withdrawal along the coastal strip,
mainly for irrigating crops in excess of natural replenishment results in a progressive lowering of the
water table and thus a sustainable water supply is endangered or even impossible.
In the Al Batinah Coastal Area, the water table in coastal aquifer currently declines by a rate 0.5m to 2.0
meters per year. This over-exploitation leads to intrusion of sea water in coastal areas resulting in
increasing salinity of ground water aquifer. Thus not only ground water, but also the quality of ground
water is highly endangered. Despite high evapo-transportation rate, there is still opportunity for
groundwater recharge since rainfall occurs in storms on very few rain days and because the infiltration
capacity of coarse alluvium and fissured rock is high. Oman is also keen to restore the depleted ground
water and therefore have already constructed number of recharge dams in the Al Batinah area. MoWR is
also planning to construct more check dams for recharging, so that the stored ground water is used in case
of emergency through construction of emergency water supply network and storage reservoirs.
Sultanate of Oman had opened up and privatized the power and water sector in 1999. This was considered
part of Omani economic reforms that have taken place since the third and fourth five years plans
instigated by the Government. Due to this initiative power generation plants and desalination plants have
been constructed on Build Own and Operate (BOO) basis. As per the agreements, power and bulk water is
produced at private owned power and desalination plants and is sold in bulk quantities to the respective
authorities based on the fixed tariff rates decided by a regulatory authority.
Sohar Power and Desalination Plant (Sohar – I) was the second plant commissioned. It came to operation
in the year 2007. It is also owned by the private sector. The Project has been constructed on the basis of
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BOO agreement. This plant supplies drinking water to Shinas, Liwa, Sohar, Saham, Al Khabourah and
Suwayaq Wilayats of North Al Batinah Governorate. It has four Multi Stage Flash (MSF) desalination
units installed each with a capacity of 37,500 cubic meters per day. Water from the desalination plant is
transmitted to Project Area through transmission mains. The maintenance of the, pump house and
reservoirs is a responsibility of the Public Authority for Electricity and Water (PAEW). The transmission
lines are distributing the water from Sohar and Barka Integrated Water and Power Plant (IWPP) reservoir
to different service reservoirs in planning area. Water from the various desalination plants is transmitted to
residential and commercial areas through transmission mains. The maintenance of the, pump house and
reservoirs are the responsibility of the PAEW. The transmission lines are distributing the water from
Sohar IWPP reservoir to different service reservoirs.
Details of Transmission mains to North Al-Batinah
Transmission Length of the transmission
Wilayat’s covered Connected with
line line in the Project Area (Km)
DN700 &1200 STEEL,
Buraimi line 29.78 Sohar, Liwa (part)
DN 700 MS
DN 600 DI, DN 600, 700
Shinas line 48.6 Liwa (part),Shinas
&1200 DI
Liwa(part),Sohar,Saham, DN 1200 MS, DN 1000
Suwayq line 134.9 Al Khabourah, As MS PIPE, DN 900 MS
Suwayq PIPE
Power Supply
The power sector of Oman has undergone significant structural changes to promote and infuse private
capital. The residential sector is the largest consumer category, which consumes more than half of the
total production. Reportedly, total number of registered electricity customer in Oman was 597,323 in
2008. Major supplier of power in the study area is Sohar Power and Desalination Plant Phase -1. This is a
gas based power generating and desalination project with capacity of 585 MW power generations. Oman
Electricity Transmission Company (OETC) is responsible for transmitting the power from generation
plant to distribution lines. In Oman total power supply system is divided into three division i.e. Main
Interconnected System (MIS), Salalah system and Rural Areas system. MIS has 220kV and 132 kV
capacity lines in the Northern Region of Oman and its service area is approximately 130,000 km2. The
PIA is located under the areas of MIS and serves around 500,000 consumers. The Grid consists of about
686 km of 220 kV circuits, 2,838 km of 132 kV circuits and 38 Grid stations.
Sultanate of Oman provides a considerable subsidy to the electricity sector. Residential customers enjoys
the maximum benefits since it accounts for the largest share with respect to all other customers. To
encourage comprehensive development in the Sultanate of Oman, the government also provides subsidy
to all other customers such as commercial, industrial, agricultural, fisheries, tourism and hotels. The
commercial tariff of 20 baiza per KW/H without maximum consumption limit applies to Showrooms and
Commercial shops and cold stores foodstuff sale, Stores, bakeries, Fabrics and readymade garments sale
shops – pharmacy and fuel filling stations.
Industrial tariff is mandatory for the industrial unit to satisfy the following conditions in order to benefit
from the industrial tariff:
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Approval from the Ministry of Commerce and Industry
Installation of Power factor Improvement devices
Specifications of power consumption equipment are needed to submit to Authority of Electricity
Regulations and compliance with its instructions in this regard.
Solid Waste Management
Municipalities are responsible for collection and management of all municipal solid wastes in the Wilayat.
The wastes are collected by Municipality in dedicated collection trucks and transfer to the waste
dumpsites within the Wilayat. The dumpsites are also managed and maintained by the local municipality.
However, the Oman Environmental Services Holding Company (OESHCO) is formed by a Royal Decree
in August 2009, to take over the waste management responsibilities from the municipalities and ensure
proper management of all solid wastes in the Sultanate. Disposal of non-hazardous industrial solid wastes
is responsibility of respective industries and this is usually be channelized through the licensed contractors
of municipalities.
Presently there is no scientific or engineered way of disposal of the hazardous solid wastes and is
currently being stored within the generating facilities. However, for the SIPA, a centralized hazardous
waste storage yard has been constructed in Liwa and is currently being utilized by the industries.
Furthermore, OESHCO is in the process of developing plans for safe and scientific methods of treatment
and disposal. Based on available information, the main hazardous waste management facility will come in
Adam Wilayat with transfer stations located throughout the country at appropriate locations.
Wastewater Management
Wastewater management system in the Al Batinah Region is predominantly treating residential
wastewater (domestic wastewater). Domestic wastewater management broadly includes the following:
Wastewater collection and storage;
Transportation to treatment facilities; and
Treatment and disposal of wastewater.
Method of transportation of wastewater in the study area is mainly through tankers and the collected waste
is transported to the Sewage Treatment Plants (STP). The treatment of wastewater in the STPs is based on
the conventional method of aeration and trucks to the various waste dumpsites for disposal carry the
sludge from the STPs away. Currently there are no common effluent treatment plants in the Sultanate that
receives industrial wastewater; however, Majis Industrial Services Company SAOG (MISC) has taken up
the responsibility to collect treated industrial wastewater, which is meeting the standards recommended in
RD 115/2001, from the individual industries within SIPA. MISC is currently evaluating various options of
applications of the treated industrial wastewater to conserve the water and use it most appropriately. Other
industries outside these industrial areas, the most prominent being the Aluminum Smelter and the
independent water and power plants in Barka, have installed their own dedicated treatment plants within
the facilities.
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Appendix G Dust Emission from Vehicles on site
Air Emissions
Dust Emission fromTrucks traveling at the site (Unpaved Roads)
Number of trucks = 10 truck per day
Truck travel at the site = 10 km/truck
For emission estimation, truck emissions/day froma total of: 100 km/day
The PM/dust emissions will be calculated based on unpaved road using equation (1a) contained in USEPA
AP-42 emission factor document entitled "Unpaved Roads - Miscellaneous Sources" contained in Chapter 13.2.2
The following equation applies to vehicles traveling on unpaved surfaces at non-publicly accessible roads.
E = (K) x (s/12)^a x (W/3)^b
Parameter PM2.5 PM10 TSPM
K (lb/VMT) 0.15 1.5 4.9
a 0.9 0.9 0.7
b 0.45 0.45 0.45
K = lbs/VMT, where VMT = vehicular mile traveled;
a =empirical factor;
b = empirical factor;
s = %, silt content; and 20
W= tons, mean vehicular weight 40
PM2.5E (lb/VMT) = 0.76
PM10 E (lb/VMT) = 7.62
TSPME (lb/VMT) = 22.48
Therefore, for 100 kmper day traveled by trucks at the project site, the dust suspension may be
estimated as follows:
PM2.5 47.6 lbs per day
21.6 kg per day, uncontroled
6.5 kg per days, after water spraying of the roads
PM10 476.3 lbs per day
216.1 kg per day, uncontroled
64.8 kg per days, after water spraying of the roads
TSPM 1404.7 lbs per day
637.4 kg per day, uncontroled
191.2 kg per days, after water spraying of the roads
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Appendix H Emissions due to Project Traffic on Site
Air Emissions
Mobile Sources
From Appendix H: Highway Mobile Source Emission Factor Tables from USEPA AP-42 Volume -II for heavy duty
diesel powered vehicles, the following equation may be used:
BER (g/mile) = ZML (zero mile level, g/mile) + {(DR-g/ml/10kmiles) X M(cumulative mileage/10k miles)}
For the following assumptions, the vehicular emission is as follows:
Assume the vehicle is approximately 10-year old, I.e., 2000/01-make and has ~ 100,000 miles.
ZML = 2.1 g/mile for HC, 9.52 g/mile for CO, 6.49 g/mile for NOx;
DR = 0 g/mile/10k mile for HC, 0.08 g/mile/10k mile for CO, 0 g/mile/10k mile for NOx; and
M= 2.1 for HC, 10.32 for CO, 6.49 for NOx
HC = 2.1 g/mile ? 1.3 g/km
CO = 10.346 g/mile ? 6.4 g/km
NOx = 6.49 g/mile ? 4.0 g/km
For a total of 100 kmper day, the following emissions may be estimated per day
HC = 130 g/day
CO = 643 g/day
NOx = 403 g/day
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Appendix I Definition of Impact Assessment Terms
Category Definition
Certain Will occur under normal operating conditions.
Very likely Very likely to occur under normal operational conditions.
Likely Likely to occur at some time under normal operating conditions.
Unlikely to but may occur at some time under normal operating
Unlikely
conditions.
Very unlikely to occur under normal operating conditions but may occur in
Very unlikely
exceptional circumstances.
Severity Definition
Persistent severe environmental damage or severe nuisance extending over
Massive a large area;
Constant, high exceedance of statutory or prescribed limits (representing a
threat to ecosystem in both the long and short term);
In terms of commercial or recreational use or nature conservancy, a major
economic loss for the company.
Severe environmental damage;
Extended exceedance of statutory or prescribed limits;
Major
The company is required to take extensive measures to restore the
contaminated environment to its original state.
Release of quantifiable discharges of known toxicity;
Moderate Instances exceedance of statutory or prescribed limit;
Causing localized nuisance both on and of site;
Staining;
Minor No permanent effects to the environment;
Single exceedance of statutory or prescribed criterion;
Single complaint.
Slight Local environmental damage
Within the fence and within systems
Negligible financial consequences
Some beneficial improvement to human health.
Modest Some benefits to individual livelihoods (e.g. additional employment
Benefit opportunities).
Limited improvements to community facilities/utilities (e.g. no discernible
improvement).
Some impact on the wider economy (e.g. limited local procurement).
Significant Major beneficial improvement to human health.
Benefit Large scale benefits to individual livelihoods (e.g. large scale employment).
Major improvements to community facilities/utilities.
Notable impact on the wider economy (e.g. extensive use of local supplies).
The resultant impact (consequence) is defined as the multiplication of severity and duration or
likelihood. Accordingly, from the assessment matrix, the resultant impacts are classified as low,
medium, and high. These terms are explained as follows:
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Low impacts are considered to be acceptable or within ALARP levels. Further control measures are
not required to mitigate these impacts.
Medium impacts are those requiring control measures; management plans need to be implemented so
as to mitigate the impacts to ALARP levels.
High Impacts are those requiring additional studies for such impacts, alternative activities with lower
impacts or alternative locations with lower environmental sensitivities or compensatory measures
need to be considered during the detailed design stage of the project.
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Appendix J Impact Assessment Matrix
Construction
Receptors
Hydrology and Groundwater
Topography and Landscape
Community Infrastructure
Public and Worker Safety
Archaeology and Culture
Geology and Soil Quality
Liability and Reputation
Climate and Air Quality
Population in Vicinity
Marine Environment
Activity
Ecology and Wildlife
Noise and Vibration
Natural Resources
Procurement of construction material
Water Abstraction for construction
Installation of temporary camps
Pipeline/Equipment cleaning and hydro-testing
On-site generation of power using DG set
Construction Activity
Operation of construction equipment, vehicles
Supply, storage and use of fuels
Disposal of sewage and wastewaters
Disposal of solid wastes
Accidental release of flammable, materials from on-
site tankage
Disposal of hazardous waste
Storage and transport of radioactive substances
Storage and transport of construction materials,
chemicals and hazardous substances such as fuels,
flammable gases, hazardous chemicals etc.
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Operation
Receptors
Hydrology and Groundwater
Topography and Landscape
Community Infrastructure
Public and Worker Safety
Archaeology and Culture
Geology and Soil Quality
Liability and Reputation
Climate and Air Quality
Population in Vicinity
Marine Environment
Ecology and Wildlife
Noise and Vibration
Activity
Natural Resources
Water
Operation and Maintenance Phase
Disposal of sewage and wastewaters
Disposal of solid wastes
Operation of utilities like WWTU, emergency DG
sets etc
Furnace, incinerator, flare operation
Accidental release of flammable, materials from
on-site tankage
Disposal of hazardous waste
Storage and transport of chemicals and hazardous
substances such as fuels, flammable gases,
hazardous chemicals etc.
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Appendix K GLC Isopleths
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Map 1: Overall Site Layout
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Map 2: Site Layout for Steam Cracker Unit
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Map 3: Site Layout for PE/PP Plot
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Map 4: Overall Industrial Cluster in Sohar Area and Proposed plot Location
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Map 5: Plot 10 and Plot 18 Site location within SIPA
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Map 6: Villages with 5 km Study Area from the Plots
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Attachment 1: Process Description – NGLT, RDG, SCU
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Liwa Plastics Project
CB&I ORPIC
Document Title: Process Description – NGLT 1100, RDG 1200, SCU 2000 –
2600 and SLC4HY 2800
Document No: S-S100-5223-002
CB&I Contract No: 189709
Issued for FEED 0 13-Mar-2015 JRAJEN SNAN/VK SRD
Revision Descriptions Rev Date Originator Checker Approver
Page 1 of 41
"THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY (CB&I). IT MAY CONTAIN INFORMATION
DESCRIBING TECHNOLOGY OWNED BY CB&I AND DEEMED TO BE COMMERCIALLY SENSITIVE. IT IS TO BE USED ONLY IN
CONNECTION WITH WORK PERFORMED BY CB&I. REPRODUCTION IN WHOLE OR IN PART FOR ANY PURPOSE OTHER THAN
WORK PERFORMED BY CB&I IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN PERMISSION OF CB&I. IT IS TO BE SAFEGUARDED
AGAINST BOTH DELIBERATE AND INADVERTENT DISCLOSURE TO ANY THIRD PARTY."
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description – NGLT 1100, RDG 1200, SCU 2000 - 2600 S-S100-5223-002 0
and SLC4HY 2800
INPUTS / REFERENCE DOCUMENTS
Document Number Title Status
PDP Section 1B – Process Description Rev 1
S-S000-5222-001 Project Basis of Design – LPP Facilities
S-S100-5223-101 SCU – Process Design Basis
S-S110-5223-001 ARU – Process Design Basis
S-S100-5223-101 to Process Flow Diagrams S100- to S280
S-S280-5223-103
REVISION NOTES AND HOLDS
Revision Description of Changes & Holds
HOLDS Description of Holds Rev Date
Page 2 of 41
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description – NGLT 1100, RDG 1200, SCU 2000 - 2600 S-S100-5223-002 0
and SLC4HY 2800
Table of Contents
Contents Page
1.0 INTRODUCTION..................................................................................................................................5
2.0 DEFINITIONS ......................................................................................................................................6
3.0 SCU DESIGN CASES..........................................................................................................................6
4.0 NATURAL GAS LIQUID (NGL) TREATING AND FRACTIONATION UNIT..........................................7
4.1 NGL Deethanizer ......................................................................................................................7
4.2 Acid Gas Removal ....................................................................................................................8
4.3 Regeneration ............................................................................................................................8
5.0 REFINERY DRY GAS (RDG) TREATING UNIT ...................................................................................9
5.1 Refinery Dry Gas Compression ...............................................................................................9
5.2 RDG Amine/Water Wash Column ..........................................................................................10
5.3 RDG Caustic Treatment and Oxygen Converter ...................................................................10
5.4 Mixed LPG Drying ..................................................................................................................12
5.5 Refining Dry Gas Chilling & RDG Demethanizer...................................................................13
5.6 RDG Deethanizer ....................................................................................................................13
5.7 RDG Depropylenizer...............................................................................................................14
6.0 AMINE REGENERATION UNIT .........................................................................................................14
6.1 Amine Feed.............................................................................................................................15
6.2 Amine Regeneration...............................................................................................................15
6.3 Amine Preparation, Drain and Storage..................................................................................16
6.4 Amine Reclaiming ..................................................................................................................16
6.5 Acid Gas Treatment ...............................................................................................................16
7.0 STEAM CRACKER UNIT...................................................................................................................16
7.1 Furnace Feed System ............................................................................................................17
7.2 Cracking Heaters....................................................................................................................18
7.3 Gasoline Fractionator ............................................................................................................20
7.4 Quench Tower ........................................................................................................................22
7.5 Process Water Stripping and Dilution Steam Generation ....................................................23
7.6 Charge Gas Compression (Stages 1-2) .................................................................................24
7.7 Acid Gas Removal ..................................................................................................................25
7.8 Charge Gas Compression (Stage 3) ......................................................................................25
7.9 Spent Caustic Pretreatment...................................................................................................26
7.10 Charge Gas and Liquid Condensate Drying .........................................................................27
7.11 Regeneration System.............................................................................................................27
7.12 Depropanization and Acetylene Hydrogenation ...................................................................28
7.13 Charge Gas Chilling ...............................................................................................................30
7.14 Demethanization ....................................................................................................................31
7.15 Deethanization........................................................................................................................31
7.16 Ethylene Fractionation...........................................................................................................32
7.17 MAPD Conversion ..................................................................................................................33
7.18 Propylene Fractionation.........................................................................................................33
7.19 Propylene Product System ....................................................................................................34
7.20 Debutanization .......................................................................................................................35
7.21 Propylene Refrigeration System............................................................................................36
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Liwa Plastics Project
Document Title: Document No. Rev:
Process Description – NGLT 1100, RDG 1200, SCU 2000 - 2600 S-S100-5223-002 0
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7.22 Binary Refrigeration System..................................................................................................36
8.0 SELECTIVE C4 HYDROGENATION UNIT (SHU) ..............................................................................36
st
8.1 SHU 1 Stage Reactor............................................................................................................37
nd
8.2 SHU 2 Stage Reactor ...........................................................................................................38
rd
8.3 SHU 3 Stage Reactor ...........................................................................................................39
9.0 DRAIN SYSTEM ................................................................................................................................39
9.1 Hydrocarbon Drain Drum.......................................................................................................39
9.2 Amine Drain Drum..................................................................................................................40
9.3 Caustic Drain Drum ................................................................................................................40
9.4 Quench Oil Drain Drum..........................................................................................................40
9.5 Quench Water Drain Drum.....................................................................................................40
10.0 UNIT FLARE KO DRUMS..................................................................................................................40
10.1 Wet Flare KO Drum ................................................................................................................40
10.2 Sour Gas Flare KO Drum .......................................................................................................41
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Liwa Plastics Project
Document Title: Document No. Rev:
Process Description – NGLT 1100, RDG 1200, SCU 2000 - 2600 S-S100-5223-002 0
and SLC4HY 2800
1.0 INTRODUCTION
Oman Oil Refineries and Petrochemicals Industries Company (ORPIC) currently operates an oil refinery,
aromatics plant (AP) and polypropylene (PP) plant at its complex located within the Port of Sohar Oman.
The refinery includes 115,000 barrels per stream day (BPSD) Crude Unit, an 80,000 BPSD Residue Fluid
Catalytic Cracking (RFCC) unit that operates in a maximum olefins mode, an indirect Alkylation Unit, a
TAME Unit and various hydroprocessing and treating units. The AP processes naphtha and produces
820,000 tonnes per year of Paraxylene and 200,000 tonnes per year of Benzene. The PP plant processes
the propylene produced in the RFCC unit and can produce 350,000 tonnes per year of polypropylene.
ORPIC is currently executing a major project to improve the Sohar Refinery, which is referred to as the
Sohar Refinery Improvement Project (SRIP). The project involves the installation of a new Crude Unit,
Vacuum Unit, Hydrocracking Unit, Delayed Coking Unit, Isomerization Unit, Hydrogen Plant and Sulphur
Recovery Facilities. The project is currently in the detailed engineering phase and is expected to be fully
operational by the end of 2016.
In addition to SRIP, ORPIC is planning the installation of a new Petrochemical Complex to be called Liwa
Plastics Project (LPP) adjacent to SRIP that will include a Steam Cracker Unit (SCU) designed to produce
867 kilo tons per annum (KTA) of polymer grade ethylene and 300 KTA of polymer grade propylene,
Refinery Dry Gas Unit, NGL Treating and Fractionation Unit, Selective C4 Hydrogenation Unit, MTBE Unit,
Butene-1 Recovery Unit, Pygas Hydrotreating Unit, High Density Polyethylene (HDPE) Plant, Linear Low
Density Polyethylene Plant (LLDPE), new Polypropylene Plant (PP), and associated utility and offsite
facilities. The new petrochemical plant will be integrated with the Sohar Refinery, Sohar AP and Sohar PP
plant.
ORPIC is also planning the installation of a new NGL Extraction plant located in Fahud, Central Oman. The
NGL (C2+) extracted from the natural gas will be transported to the petrochemical complex by pipeline and
used as feedstock to LPP. The new NGL Extraction plant will have independent utility and offsite facilities.
Additional feedstock to LPP are mixed LPG (produced in the Sohar Refinery and Sohar AP), refinery dry
gas produced in the RFCC unit and new Delayed Coking unit (included in SRIP), light naphtha condensate
from OLNG by marine tanker.
Some of the materials produced in the LPP petrochemical complex, including hydrogen, MTBE, pyrolysis
fuel oil and products from Pygas Hydrotreating unit will be returned to the refinery, existing aromatics plant
and polypropylene plant.
The Liwa Plastics Project is strategically located in the Sohar Industrial Port next to the SRIP.
This provides excellent opportunities to:
Synergize with the Refinery by upgrading the lower value Refinery products (LPG) and byproducts
(Refinery Dry Gas) to the higher value plastics while upgrading the Steam Cracker products
(Hydrogenated Mixed C4 to MTBE) and byproducts (Raw Pyrolysis Gasoline, Pyrolysis Fuel Oil) in the
Refinery to gasoline and provide valuable hydrogen.
Synergize with the Aromatics Plant by recovering aromatics from the Steam Cracker byproduct (Raw
Pyrolysis Gasoline).
Convert the lower value NGLs from OLNG to the higher value plastics.
Convert the lower value NGLs recovered from Natural Gas in Central Oman (Fahud) to the higher
value plastics.
Give a major boost to plastics production in Oman and provide excellent job opportunities to the local
Omani population.
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Liwa Plastics Project
Document Title: Document No. Rev:
Process Description – NGLT 1100, RDG 1200, SCU 2000 - 2600 S-S100-5223-002 0
and SLC4HY 2800
This document covers the process description for the Steam Cracker Units (1000-2600 and 2800) of the
new Liwa Plastics Project in Oman.
2.0 DEFINITIONS
The following terms and abbreviations have been used in this document:
Term Definition
ARU Amine Regeneration Unit
DCU Delayed Coker Unit
DGA Diglycol Amine
LLP Steam Low Low Pressure Steam
LPG Liquefied Petroleum Gas
LPP Liwa Plastic Project
NGLT NGL Treatment
ORPIC Oman Refineries and Petrochemical Company
OSBL Outside Battery Limit
PFD Process Flow Diagram
RDG Refinery Dry Gas Treating Unit
RFCC Residue Fluid Catalytic Cracking
SCU Steam Cracker Unit
SHU Selective Hydrogenation Unit
3.0 SCU DESIGN CASES
There are three cases considered for the process design below:
Case 1: Normal feeds and external recycles as defined in Section 7.1 below.
Case 2: Refinery Dry Gas and Refinery LPG not available, the NGL C2+ is increased 10% and
increase LPG to make minimum 75,000 kg/h ethylene and same propylene as case 1.
Case 3: Low severity case for maximizing propylene.
Case 1 operation will be discussed in this Process Description document.
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Liwa Plastics Project
Document Title: Document No. Rev:
Process Description – NGLT 1100, RDG 1200, SCU 2000 - 2600 S-S100-5223-002 0
and SLC4HY 2800
4.0 NATURAL GAS LIQUID (NGL) TREATING AND FRACTIONATION UNIT
The Natural Gas Liquid (NGL) Treating and Fractionation Unit is designed to process a C2+ stream from
the NGL Extraction Plant located in Fahud, Central Oman. The NGL unit cleans up the C2+ stream and
produces C2 and C3+ products that are each sent to the Steam Cracking Unit (SCU) as cracker feed.
4.1 NGL Deethanizer
NGL C2+ from OSBL enters the NGL Treating and Fractionation Unit at 50°C and 54 bar(g) and is sent to
the NGL Deethanizer Feed Heater, E-11001A/B/C via flow control valve. A provision is made for NGL Boil
Off Gas (BOG) to enter this stream downstream of the valve. The combined stream enters the feed heater
at 26°C where the stream is heated to 45°C by controlling the amount of 48°C propylene refrigerant sent to
E-11001A/B/C. The heated feed then enters the NGL Deethanizer, C-11001, on Tray #14.
The NGL Deethanizer, C-11001, is comprised of 25 valve trays and the primary purpose of this tower is to
separate C2 and lighter components from C3 and heavier components which ultimately become feeds to
two separate cracking furnaces in the SCU.
The top of the NGL Deethanizer operates at a pressure of 20.8 bar(g) which partially condenses overhead
vapor by -10°C propylene refrigerant in the NGL Deethanizer Condenser, E-11003. The tower overhead
pressure is set by a pressure controller (PC) in the gross overhead line, which resets the setpoint of the
flow controller on the feed to the tower. The two-phase stream leaving E-11003 enters the NGL
Deethanizer Reflux Drum, V-11002, where an overhead vapor stream, containing ethane and lighter
components, is sent to the NGL Amine/Water Wash Tower, C-11002, for acid gas removal. Prior to
entering C-11002, the stream is sent to the NGL Amine/Water Wash Column Feed Heater, E-11005 where
the stream is heated to 40°C by controlling the amount of 48°C propylene refrigerant sent to E-11005. Net
liquid from V-11002 is pumped by the Deethanizer Reflux Pumps, P-11001A/B, as reflux to the NGL
Deethanizer, C-11001, on flow control. The level in V-11002 is controlled by throttling the amount of
propylene refrigerant sent to the NGL Deethanizer Condenser, E-11003.
Tower reboiler duty is provided by Low Low Pressure Steam (LLS) in the NGL Deethanizer Reboiler, E-
11002. A temperature controller on Tray #10 sets the temperature by resetting the setpoint of the flow
controller on the LLS feeding the reboiler. The NGL Deethanizer bottoms product, which contains C3 and
heavier components, is cooled to 45°C by cooling water in the NGL Deethanizer Bottoms Cooler, E-11006.
The cooled C3+ stream is sent on flow control, reset by level controller in the tower bottoms sump, through
the NGL COS Treaters, V-11001A/B, for removal of COS and some mercaptans. The stream continues
through the NGL COS Treater Filters, S-11001A/B and is then let down to the desired pressure in a
pressure control valve, and enters the C3+ Feed Preheater, E-20002, located in the SCU furnace feed
system. Downstream of E-20002 is the C3+ Feed Vaporizer Drum, V-20012, on which there is a high level
override level controller to reset the setpoint on the NGL Deethanizer bottoms when high level is reached in
the drum.
An on-line analyzer is provided with probes in two locations which detect the top and bottom specification
of the NGL Deethanizer. One probe detects the amount of C3s found in the C2 and lighter overhead vapor
being fed to the amine wash section. The other probe detects the amount of C2s found in the C3+ feeding
the NGL COS Treaters.
One NGL COS Treater is in operation and operates at a pressure of 11.3 bar(g) while the second treater is
being regenerated or on standby. On-line analyzers are provided to detect the amounts of COS and
mercaptans entering and leaving the treaters. The treaters are designed to run for 48 hours before
requiring regeneration. The process of switching from one treater to the next is a “semi-automated” timed
cycle operation. Prior to switching treaters, it is important to fill the NGL Gas Treater Drain Drum, V-11004,
Page 7 of 41
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description – NGLT 1100, RDG 1200, SCU 2000 - 2600 S-S100-5223-002 0
and SLC4HY 2800
with some of the C3+ product effluent from the treater in operation. Once V-11004 is filled, the liquid is
sent to the standby treater. Then, the online treater is placed in parallel with the standby treater and then
taken offline. The newly off-line treater is drained to the NGL Gas Treater Drain Drum, V-11004, after which
it can undergo regeneration.
Regeneration of the NGL COS Treaters is a two stage approach. In the first stage, hot C3+ vapor from the
C3+ Stripping System is used to strip and recover any C3+ liquid trapped in the pores of the adsorbent.
This stripping step is important because there is a large amount of liquid entrained in the adsorbent pores
even after draining; approximately 20-30% by volume. This material would end up in the fuel gas system
which would alter the molecular weight of the feed stock and result in lost feedstock. Furthermore, when
the pressure is dropped to a level so that the regeneration can enter from the fuel gas system, a
considerable drop in temperature will occur from the flashing of the entrained liquid, also called auto-
refrigeration. At the end of this first stripping stage the resulting temperature in the bed will be 95°C. The
second stage of regeneration is carried out by circulating hot methane-rich regeneration gas from the
treater regeneration system at 290-300°C to drive out the impurities adsorbed in the treater bed. After the
bed has reached the required temperature of 270-290°C, the bed is cooled with unheated regeneration
gas. The spent regeneration gas is returned to the fuel gas system.
4.2 Acid Gas Removal
In amine treatment, acid gases are removed via absorption into a lean amine solution, and regeneration of
the rich amine solution is possible via stripping (OSBL). Amine treatment is used to remove bulk of the
acid gases and caustic treatment is required to bring down the acid gas levels to trace levels. For this
project, Diglycolamine (DGA) will be diluted with water to 30 wt.% and used as the circulating lean amine
solution. Lean amine is available from the Amine Regeneration Unit (ARU) at a pressure of 25 bar(g) and
42°C and is shared among the NGL and RDG units.
The NGL Amine/Water Wash Column, C-11002, runs at a pressure of 19.8 bar(g) and temperature of 42°C
in the overhead. The column is comprised of two sections. The top portion contains 3 bubble cap trays
and serves as a water wash section to avoid amine entrainment in the overhead product. Wash water for
the NGL Amine/Water Wash Column, C-11002, comes from the Continuous Blowdown Cooler, E-20014,
located in the SCU. Waste water from the water section (bubble cap trays) is totally drawn off below the
th
14 tray and is sent to Neutralization (OSBL). The bottom portion is comprised of 13 valve trays and two
packed beds (including a pump-around loop for heat removal) and serves as the amine wash section.
Lean amine, 30 wt.% DGA, is fed to the top of the amine wash section above the valve trays on flow
control. As the vapor continues up the tower the acid compounds (H2S and CO2) will absorb into the lean
amine solution. The bottom of the tower will have a higher temperature, due to the heat of absorption. The
overhead of the NGL Amine/Water Wash Column will contain less than 100 mol ppm CO2 and trace levels
of H2S, and is then sent to the Ethane Feed Preheater, E-20001, in the SCU furnace feed system. Any oils
that form in the absorption process can be skimmed off the liquid level in the sump of C-11002 and sent to
NGL Amine Oil Degassing Drum, V-11006. Overhead vapor from V-11016 is sent to Wet Flare, while any
liquid is sent to the Amine Drain system.
Rich amine, leaving the bottom of C-11002 is sent to the OSBL Amine Regeneration Unit (ARU) on flow
control reset by the level controller on C-11002 at a pressure of 8.0 bar(g) and 63°C.
4.3 Regeneration
As discussed in Section 4.1, regeneration of the NGL COS Treaters, V-11001A/B, is carried out using a
two stage approach. The first stage is the C3+ stripping step which improves feedstock recovery, and
stabilizes the return composition of the fuel gas. A treater is first drained, and then warmed with hot C3+
Page 8 of 41
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description – NGLT 1100, RDG 1200, SCU 2000 - 2600 S-S100-5223-002 0
and SLC4HY 2800
compounds to drive out all the remaining liquid trapped in the pores of the adsorbent and between the
adsorbent particles. The hot C3+ compounds are provided by the C3+ Stripping System which is a
recirculating system.
In the recirculating C3+ stripping system, C3+ liquid is stored in the C3+ Stripping Holdup Drum, V-11007
at a pressure of 9.5 bar(g). The liquids leaving the holdup drum are pumped on flow control by the C3+
Stripping Pumps, P-11004A/B, and vaporized/superheated in the C3+ Stripping Vaporizer, E-11011. The
temperature of the superheated C3+ stripping stream is controlled by throttling the amount of Low Low
Pressure Steam (LLS) flowing to E-11011. The super-heated C3+ stripping vapor is directed to the NGL
COS Treaters, V-11001A/B, for stripping and/or to the C3+ Stripping Condenser, E-11012, via a pressure
differential control valve. C3+ stripping vapor from the treaters (which contains recovered material) is also
condensed in E-11012 prior to entering the C3+ Stripping Holdup Drum. The initial charge of C3+ in this
system is from the NGL COS Treater effluent. Any C3+ compounds recovered during this stripping step
will build up over time in this recirculating system; they are pumped on flow control by P-11004A/B to the
NGL Gas Treater Drain Drum, V-11004.
The second stage involves passing hot methane-rich regeneration gas from the Regeneration Gas Electric
Heater, E-11009, through the treaters at a temperature of 290-300°C. A temperature of 270-290°C is
required in the treater bed to drive out adsorbed impurities. In order to reach this regeneration
temperature, regeneration gas from the SCU fuel system is heated to 290-300°C in the Regeneration Gas
Electric Heater, E-11009. This regeneration heater also provides hot regeneration gas at 290-300°C for
the RDG Dryer/Treater, V-12006A/B.
5.0 REFINERY DRY GAS (RDG) TREATING UNIT
A combined stream of refinery dry gas (RDG) from the Sohar Refinery RFCC and DCU is routed to the
RDG Treating Unit. A Mixed LPG produced in the refinery and aromatics complex is also fed to the RDG
Treating Unit and used as wash liquid. The RDG Treating Unit provides the following products:
RDG Fuel Gas which is sent to the SCU fuel gas system
C2 stream which contains ethylene and ethane that is suitable for recovery in the Steam Cracker Unit
(SCU) Ethylene Fractionator
C3+ stream that is fed to the SCU Cracking Heaters
Polymer grade propylene product
5.1 Refinery Dry Gas Compression
The refinery dry gas feed is available from the battery limits at 40°C and 4 bar(g) and must be compressed
in a two stage compressor to meet the required pressure for treatment and separation of the products. The
refinery dry gas feed is comprised primarily of C1-C4 hydrocarbons but also contains significant impurities
including: hydrogen sulfide, oxygen, carbon dioxide, nitrogen oxides, and various metals. The levels of
these contaminants must be significantly reduced before processing in the recovery section of the Refinery
Dry Gas Treating Unit.
The refinery dry gas feed enters the RDG Compressor 1st Stage Suction Drum, V-12001, on flow control.
An online analyzer on the main feed detects the composition of the refinery dry gas feed including levels of
st
acid gas (CO2 and H2S). The overhead vapor from this drum enters the 1 Stage of the RDG Feed
Compressor, K-12001. A steam turbine utilizes High Pressure steam (HS) drives K-12001. The
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Process Description – NGLT 1100, RDG 1200, SCU 2000 - 2600 S-S100-5223-002 0
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st
compressed hydrocarbon continues to the RDG Compressor 1 Stage Aftercooler, E-12001, where it is
cooled to 48°C against cooling water. The suction pressure of the RDG Feed compressor is controlled via
two pressure controllers located on V-12001. Primary pressure control is accomplished by throttling High
Pressure steam (HS) to the RDG Feed Compressor Turbine. Secondary pressure control is accomplished
by controlling the amount of refinery dry gas vented to the Fuel Gas system or Wet Flare.
The effluent of E-12001, continues to the RDG Compressor 2nd Stage Suction Drum, V-12002. The
nd
overhead vapor from this drum enters the 2 Stage of the RDG Feed Compressor, K-12001. The
nd
compressed hydrocarbon continues to the RDG Compressor 2 Stage Aftercooler, E-12002 where it is
nd
cooled to 48°C against cooling water before it enters the RDG Compressor 2 Stage Discharge Drum, V-
12003. The 48°C temperature on the outlet of E-12002 is controlled by bypassing some of the flow feeding
the exchanger. Flow through both stages of the compressor is measured upstream of the cooler, and
nd
controls the minimum flow recycle from RDG 2 Stage Discharge Drum overhead to the inlet of the RDG
st
Compressor 1 Stage Suction Drum.
Provisions have been made to allow for any hydrocarbon liquid or water that knocks out in the suction and
discharge drums to be combined and sent to the Quench Water Settler, V-21002, in the SCU.
5.2 RDG Amine/Water Wash Column
The compressed refinery dry gas from V-12003 is sent to the RDG Amine/Water Wash Column, C-12001,
for bulk removal of CO2 and H2S from the feed gas. The top of C-12001 runs at a pressure of 11.7 bar(g)
and a temperature of 48°C.
The RDG Amine/Water Wash Column, C-12001 is comprised of two sections. The top portion contains 3
bubble cap trays and serves as a water wash section to prevent amine entrainment in the overhead
product. Wash water for the RDG Amine/Water Wash Column, C-12001, comes from the Continuous
Blowdown Cooler, E-20014, located in the SCU. Waste water from the water section (bubble cap trays) is
totally drawn off below tray #1 and is sent to Neutralization (OSBL). The bottom portion is comprised of
two packed beds and serves as the amine wash section.
Lean amine, 30 wt.% DGA, is fed to the top of the amine wash section above the two packed beds on flow
control. As the vapor continues up the tower the acid compounds (H2S and CO2) will absorb into the lean
amine solution. The bottom of the tower will have a higher temperature, due to the heat of absorption. The
overhead of the NGL Amine/Water Wash Column will contain less than 100 ppm (m) CO2 and trace levels
of H2S.
Any oils that form in the absorption process can be skimmed off the liquid level in the sump of C-12001 and
sent to RDG Amine Oil Degassing Drum, V-12016. Overhead vapor from V-12016 is sent to Wet Flare,
while any liquid is sent to the Amine Drain system.
5.3 RDG Caustic Treatment and Oxygen Converter
A caustic wash removes acid gases (H2S and CO2) by reaction and a non-regenerable waste caustic
stream is created. While the amine treatment is used to remove the bulk amount of the acid gases, the
caustic treatment brings down acid gases down to trace level.
The RDG Caustic/Water Wash Column, C-12002, operates similarly to the SCU Caustic/Water Wash
Column, C-22001, except the one in the Refinery Dry Gas unit functions as two separate caustic/water
sections. The overhead from the RDG Amine/Water Wash Column, C-12001, is sent to the lower section
of the RDG Caustic/Water Wash Tower, C-12002. The refinery dry gas is washed in the lower packed
section with weak level caustic to remove CO2 and H2S. The treated gas is then washed with water in 3
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Process Description – NGLT 1100, RDG 1200, SCU 2000 - 2600 S-S100-5223-002 0
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bubble cap trays to prevent caustic carryover. Wash water for the RDG Amine/Water Wash Column, C-
12002, comes from the Continuous Blowdown Cooler, E-20014, located in the SCU. Waste water from the
st
lower water section (bubble cap trays) is totally drawn off below the 1 tray and is sent to Waste Water
Treatment (OSBL). The refinery dry gas vapor is then totally drawn off and sent to the RDG Oxygen
Converter Feed/Effluent Exchanger, E-12004. On-line analyzers are provided to detect the amounts of
CO2 and H2S entering and leaving this section of C-12002.
The refinery dry gas is heated in the RDG Oxygen Converter Feed/Effluent Exchanger, E-12004, and by
High Pressure Steam (HS) in the RDG Oxygen Converter Feed Heater, E-12005. The hot refinery dry gas
(221°C at SOR, 240°C at EOR) is passed through the RDG Oxygen Converter, R-12001A/B. The catalyst
selectivity is moderated by injecting Dimethyl Disulfide (DMDS) upstream of E-12005, which is eventually
removed in the upper portion of the RDG Caustic/Water Wash Column, C-12002.
The catalyst in the oxygen convertor is a Nickel-sulfide catalyst (Sud-Chemie OleMax 101) and is selective
only in a certain range of temperature. Due to aging of the catalyst, the operating conditions require
gradually increasing temperature with time to maintain conversion. However, as the temperature increases,
the selectivity decreases, and DMDS injection is required to maintain optimum performance.
The Oxygen Converter catalyst primarily removes oxygen, acetylene, and NOx by reaction to other
species. Oxygen is converted to water and NOx is converted to ammonia and water. The Oxygen
Converter also hydrogenates acetylene to ethane and ethylene. In addition, for any C3 or C4 acetylenes
are present, the methylacetylene and the propadiene are partially converted to propylene, and about half of
the butadienes are converted primarily to butenes. Volatile metals such as arsine, phosphine, and mercury
are absorbed onto the oxygen converter catalyst and reduced to less than 5 ppb in the effluent. The
scheme provides a spare reactor bed for in situ regeneration of the catalyst. The Oxygen Converter has
the following expected performance:
Effluent Acetylene < 1 ppmv
Effluent Oxygen < 1 ppmv
Effluent NOx < 10 ppbv
On-line analyzers are provided to detect the amounts of C2H2, C2H4, CO, O2, and NOX, entering and
leaving the O2 Converter.
A temperature rise is seen across the reactor (14°C at SOR, 20°C at EOR) and the hot oxygen-free
refinery dry gas effluent passes through the RDG Oxygen Converter Feed/Effluent Exchanger, E-12004,
and is then cooled against cooling water to 45°C in the RDG Oxygen Converter Effluent Cooler, E-12006,
before entering the upper caustic/water wash unit of C-12002.
The oxygen free refinery dry gas is washed with strong level caustic in a packed section. This section
ensures near complete removal of CO2 and H2S. The acid free RDG vapor flows to a water wash section
comprised of three bubble cap trays. Wash water for the RDG Amine/Water Wash Column, C-12002,
comes from the Continuous Blowdown Cooler, E-20014, located in the SCU. Waste water from the lower
st
water section (bubble cap trays) is totally drawn off below the 1 tray and is sent to Waste Water Treatment
(OSBL).
Strong caustic solution from the upper section of the RDG Caustic/Water Wash Tower is added to the
lower section caustic circulation to maintain the appropriate concentration of caustic solution. A net flow of
caustic from the bottom of this tower is sent to the SCU Spent Caustic Treatment.
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Process Description – NGLT 1100, RDG 1200, SCU 2000 - 2600 S-S100-5223-002 0
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Despite low diolefin concentration, polymeric oil (yellow oil) may form to some extent in the RDG
Caustic/Water Wash Tower. Provisions are made for this oil to be decanted from the tower bottom and
sent, along with the spent caustic for treatment in the SCU.
The overhead of the upper section of the RDG Caustic/Water Wash Tower, C-12002, is chilled against 9°C
propylene refrigerant in the RDG Dryer/Treater Feed Chiller, E-12003. The outlet temperature of E-12003
is controlled to 12°C by throttling the amount of propylene refrigerant sent to the exchanger. The chilled
effluent is sent to RDG Dryer/Treater Feed Gas KO Drum, V-12005, where condensed water and/or
hydrocarbon is knocked out sent to Waste Water Treatment. The overhead from V-12005 proceeds to the
RDG Dryer/Treater V-12006A/B.
The refinery dry gas passes through V-12006A/B for drying and removal of trace impurities such as water,
NH3, COS, CO2, CS2, acetonitrile, aldehydes, and amines to less than 1 ppm (w). After treatment, the
treated refinery dry gas is sent through the RDG Dryer/Treater Effluent Filter, S-12001A/B, and then to the
RDG Cold Box Exchanger No. 1, ME-12000-E01.
One RDG Dryer/Treater is in operation and operates at a pressure of 9.5 bar(g) while the second treater is
being regenerated or on standby. On-line analyzers are provided to detect the amounts of H2O, CO2, H2S,
NOx, and NH3 entering and leaving the treaters. A third probe is placed in the bottom portion of the
adsorbent bed to detect breakthrough of impurities. The treaters are designed to run for 48 hours before
requiring regeneration. The process of switching from one treater to the next is a timed cycle operation.
Regeneration of the RDG Dryer/Treater is accomplished by circulating hot methane-rich regeneration gas
from the Regeneration Electric Heater, E-11009, at 290-300°C and heating the bed to 270-290°C in order
to drive out impurities adsorbed in the treater bed. The spent regeneration gas is returned to the fuel gas
system. After the bed has reached the required temperature, the bed is cooled with unheated regeneration
gas.
5.4 Mixed LPG Drying
A Mixed LPG produced in the refinery and aromatics complex enters the RDG unit with B.L. condition as
14 bar(g) and 38°C. Then Mixed LPG is routed to Mixed LPG Holdup Drum V-12018 at 13.1 bar(g) and
38°C. The Mixed LPG is then pumped via Mixed LPG Feed Pumps P-12009 A/B to pass it through the LPG
Dryer, V-12012A/B, for removal of moisture. The concentration of water is reduced to less than 1 ppm.
On-line analyzers are provided to detect the amounts of H2O entering and leaving the dryer. A third probe
is placed in the top portion of the dryer to detect breakthrough of impurities. The dried LPG stream passes
through another on-line analyzer for detection of C2H4, C2H6, C3H6, C3H8, BD, C4s, and C5+ and then
through the LPG Dryer Effluent Filter, S-12002A/B.
One LPG Dryer is in operation and operates at a pressure of 12.8 bar(g) while the second dryer is being
regenerated or on standby. The dryers are designed to run for 48 hours before requiring regeneration.
The process of switching from one dryer to the next is a “semi-automatic” timed cycle operation. Since the
Mixed LPG is coming OSBL storage, the feed flow rate is on flow control. When regeneration is required,
the flow rate will be increased and the extra capacity will be used to fill the standby dryer. Likewise, when
regeneration is complete, the LPG Dryer Drain Drum Pumps, P-12008A/B, will pump the liquid out of the
dryer and back into the main process feed. During this step, the main feed flow rate will be decreased by
the amount of feed that is supplemented from the pump.
Regeneration of the LPG Dryer is accomplished by heating the bed with 232°C gas in order to drive out
moisture. The spent regeneration gas is returned to the fuel gas system. After the bed has reached the
required temperature, the bed is cooled with unheated regeneration gas.
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Process Description – NGLT 1100, RDG 1200, SCU 2000 - 2600 S-S100-5223-002 0
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Provisions are made to re-route the Mixed LPG to the SCU furnace feed system during Case 2 operation
or also as safe startup fluid to the Selective Hydrogenation Unit (SHU) when required.
5.5 Refining Dry Gas Chilling & RDG Demethanizer
The treated refinery dry gas and LPG enter the RDG Cold Box Exchanger No.1, ME-12000-E01, at 12°C
and 38°C respectively. In the cold box, these streams are progressively chilled to -37°C by 4 levels of
propylene refrigeration; the refrigeration levels range from 9°C to -40°C. The refinery dry gas and LPG
proceed to the RDG Cold Box Exchanger No.2, ME-12000-E02, in which they are both chilled to -90°C by
binary refrigerant at -98.4°C. The treated refinery dry gas enters the RDG Demethanizer, C-12003, above
two sections of packing. The LPG temperature is controlled to -90°C by controlling the amount of binary
refrigerant flows to ME-12000-E02. It is then mixed with reflux from the RDG Demethanizer Reflux Pumps,
P-12003A/B, and used as wash liquid in the RDG Demethanizer, C-12003.
In the RDG Demethanizer, C-12003, fractionation is based on the absorption principle whereby the
ethylene and heavier components are absorbed by the LPG wash liquid. The tower is comprised of four
packed beds and the fractionation occurs on the basis of the absorption principle whereby the C2’s
contained in the refinery dry gas are absorbed by the C3 plus LPG Wash Liquid.
The top of C-12003 operates at a pressure of 8.2 bar(g) and the gross overhead is partially condensed by
binary refrigerant in the RDG Demethanizer Condenser, ME-12000-E03, which is also part of the RDG cold
box package. The condenser effluent is sent to the RDG Demethanizer Reflux Drum, V-12007, where any
liquid that condenses is pumped by the RDG Demethanizer Reflux Pumps, P-12003A/B, as reflux to C-
12003 on flow control reset by the level controller on V-12007. The overhead from V-12007, called RDG
Fuel Gas, is comprised primarily of methane and lighter compounds and the temperature of this stream is
set to -93.4°C by controlling the amount of binary refrigeration sent to the RDG Demethanizer Condenser,
ME-12000-E03. The RDG Fuel Gas is then progressively heated in the RDG Cold Box Exchanger No. 2,
ME-12000-E02, to -40°C and further heated in the RDG Cold Box Exchanger No. 1, ME-12000-E01 where
the temperature is set to 35°C by controlling the amount of propylene refrigerant sent to ME-12000-E01.
Once it is heated, the RDG Fuel Gas is sent to the SCU fuel gas system. The pressure in the RDG
Demethanizer is accomplished by controlling the amount of this stream being sent to the SCU fuel gas
system.
The RDG Demethanizer Reboiler, E-12007, supplies heat to the tower by subcooling 48°C propylene
refrigerant. The temperature in the RDG Demethanizer is controlled by the amount of propylene refrigerant
sent to E-12007. The LPG wash liquid along with C2 & heavier components from refinery dry gas is
pumped from the bottom of the RDG Demethanizer, C-12003, to the RDG Deethanizer, C-12004, on flow
control reset by the level controller in the RDG Demethanizer bottom sump. An on-line analyzer on this
stream detects the amount of methane that is found in this stream.
5.6 RDG Deethanizer
The RDG Demethanizer, C-12003, bottoms enter the RDG Deethanizer, C-12004 on the Tray #43. The
RDG Deethanizer is comprised of 63 valve trays and the primary purpose of this tower is to recover ethane
and ethylene components from a stream of C2 and heavier components.
The top of the RDG Deethanizer operates at a pressure of 16.4 bar(g) and the gross overhead vapor from
this tower is totally condensed in the RDG Deethanizer Condenser, E-12009 by -27°C propylene
refrigerant. The tower overhead pressure is set by a split-range pressure controller (PC) in the gross
overhead line. Primary pressure control is accomplished by controlling the amount of -27°C propylene
refrigerant sent to E-12009. Secondary pressure control is accomplished by controlling the vent (normally
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Process Description – NGLT 1100, RDG 1200, SCU 2000 - 2600 S-S100-5223-002 0
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closed) to the Cold Flare from the RDG Deethanizer Reflux Drum, V-12008. The condensed stream
leaving E-12009 enters the V-12008. Total liquid from V-12008 is pumped by the RDG Deethanizer Reflux
Pumps, P-12005A/B, and a portion is sent as reflux to C-12004 on flow control. The remaining overhead
liquid product is sent to the SCU Ethylene Fractionator, C-24002, on flow control reset by the level
controller in V-12008.
Tower reboiler duty is provided by Low Low Pressure Steam (LLS) in the RDG Deethanizer Reboiler, E-
12008. A temperature controller on Tray #33 sets the temperature by resetting the setpoint of the flow
controller on the LLS feeding the reboiler. The RDG Deethanizer bottoms product, which contains C3 and
heavier components, is sent to the RDG Depropylenizer, C-12005, on flow control reset by the level
controller in C-12004 bottom sump.
An on-line analyzer is provided with probes in two locations which detect the top and bottom specification
of the RDG Deethanizer with measurements made for C1, C2, and C3 components. If any methane or
other non-condensable component makes its way to this tower, it will accumulate in the RDG Deethanizer
Reflux Drum, V-12008. If any non-condensables accumulate in V-12008, a hand control (HC) provides the
ability to send this material back to the cold box for reprocessing.
5.7 RDG Depropylenizer
The RDG Deethanizer, C-12004, bottoms enter the RDG Depropylenizer, C-12005, on the Tray #46. The
RDG Depropylenizer is comprised of 135 valve trays and the primary purpose of this tower is to recover
polymer grade propylene a stream of C3 and heavier components.
The top of the RDG Depropylenizer operates at a pressure of 7.6 bar(g) and gross overhead vapor from
this tower is totally condensed in the RDG Depropylenizer Condenser, E-12011, by 9°C propylene
refrigerant. The tower overhead pressure is set by pressure controller (PC) in the gross overhead line.
Primary pressure control is accomplished by controlling the amount of 9°C propylene refrigerant sent to E-
12011. The condensed stream leaving E-12011 enters the RDG Depropylenizer Reflux Drum, V-12010.
Total liquid from V-12010 is pumped by the RDG Depropylenizer Reflux Pumps, P-12006A/B, and a portion
is sent as reflux to C-12005 on flow control. An on-line analyzer is provided to detect product quality. The
remaining overhead liquid product is sent to the RDG Propylene Product Heater, E-12012, on flow control
reset by the level controller on V-12010. The temperature of this stream is heated to 40°C by controlling
the amount of propylene refrigerant sent to E-12012. The heated RDG propylene product is sent to
intermediate storage spheres OSBL.
Tower reboiler duty is provided by Quench Water (QW) from the SCU in the RDG Depropylenizer Reboiler,
E-12010A/B. A continuous analyzer controller on Tray #34 controls the propylene content on that tray and
resets the setpoint of the flow controller on the QW feeding the reboiler. The RDG Depropylenizer bottoms
product, which contains C3 and heavier components, is sent on flow control reset by the level controller in
the C-12005 bottom sump to the C3+ Feed Vaporizer Drum, V-20012, located in the SCU furnace feed
system. An on-line analyzer is provided to detect the amount of propylene contained in this stream. There
is a high level override to reset the setpoint on the tower bottoms flow controller when high level is reached
in V-20012. A normally closed line is available to send material back to the RDG cold box on flow control.
This provides product flexibility if the tower bottoms requires reprocessing. Furthermore, this also provides
an option to build up an internal wash liquid for the RDG Demethanizer, C-12003, in the event that there is
no mixed LPG available.
6.0 AMINE REGENERATION UNIT
Amine regeneration unit is required to treat rich amine from amine absorbers, in NGLT (C-11002) and RDG
(C-12001) respectively. The treatment involves removal of absorbed CO2 and H2S from the rich amine,
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reclamation, filtration and circulation of lean amine back to the absorbers. The major consumer of lean
amine from ARU is the NGLT amine absorber (C-11002) which is about 95% of the circulation rate. NGLT
and RDG feeds are rich in CO2 and H2S; however the CO2 content in NGLT feed is bound to increase in
few years after the plant startup (two fold increase expected). Due to an increase in CO2 content of NGLT
feed, ARU is designed for a 45 wt. % solution of DGA (Diglycol Amine) in water to handle the high CO2
feed (Case-II). However, the unit is also capable of operating at a DGA (Diglycol Amine) concentration of
30 wt. % which will be the initial conditions of operations to handle the normal CO2 feed (Case-I). The unit
is designed to finally deliver a lean amine product specification of max. 0.045 mol CO2/mol amine (CO2 is
the major component present and absorbed from both NGLT and RDG feeds and H2S loading in both
cases are negligible). The design capacity of the unit is 422.5 T/h of rich amine.
The diglycol amine absorbs CO2 and H2S from NGLT and RDG feeds based on the following reactions:
2RNH2 + H2S (RNH3)2S
(RNH3)2S + H2S 2(RNH3)HS
2RNH2 + CO2 RNHCOONH3R
RNH2 + H2O + CO2 RNH3HCO3 where R = OH-CH2-CH2-O-CH2-CH2-
6.1 Amine Feed
Rich Amine solution from NGLT Amine Wash Column (C-11002) and RDG Amine Wash Column (C-
12001) is routed to the Rich Amine Flash Drum (V-11054). Liquid hydrocarbons are separated and
overflow to hydrocarbon compartment in the flash drum and are then disposed to hydrocarbon
compartment of Amine Drain Drum (V-11053). Lighter hydrocarbons (vent gas) flashed off in the Rich
Amine Flash Drum are routed to the Quench Tower (C-21003) in SCU. Flashed rich amine is fed to the
Amine Regenerator (C-11051) via the Lean/Rich Amine Exchanger (E-11052 A/B/C/D) where it is
preheated on the tube side against the lean amine product from the regenerator bottom on the shell side.
The flow rate of the feed to the regenerator is maintained based on the amine level in the flash drum.
6.2 Amine Regeneration
The CO2 and H2S are stripped out from the DGA solution in the Amine Regenerator (C-11051). The heat to
the regenerator is delivered by the kettle type Amine Regenerator Reboiler (E-11051). The reboiler heating
medium is desuperheated low low pressure steam. The steam desuperheater is implemented on the LLP
steam line in order to keep the tube skin temperature on the lean amine side in the reboiler below 180°C to
prevent degradation of amine.
Vapor from the overhead of the regenerator is cooled and partially condensed in the Amine Regenerator
Condenser (E-11054). Variable speed control of motor of the air cooled condenser is provided to control
the temperature downstream of the condenser such that most of the water vapors are condensed. This
partially condensed stream is separated into Acid gas and Water in the Amine Regenerator Reflux drum
(V-11052). Acid gas (mainly CO2) from the reflux drum is sent to the Acid Gas Treatment Package (ME-
11052) for H2S removal in order to meet the environmental specifications. The regenerator overhead
pressure is maintained by a control valve on the acid gas line from the Amine Regenerator Reflux Drum (V-
11052) and in order to prevent undesirable relief in case of a higher pressure an additional protective
pressure control valve on the acid flare line reduces the pressure when required. Additionally, there is also
a column overpressure protection interlock which shuts down steam to the reboiler.
The condensed water is refluxed to the top of the Amine Regenerator (C-11051) by the Amine Regenerator
Reflux Pumps (P-11052 A/B). Make-up water from SCU blowdown (E-20014) is added to the reflux drum to
compensate for water losses with the acid gas and also to maintain the required DGA concentration.
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Lean amine from the bottom of the regenerator is pumped by the Lean Amine Pumps (P-11051 A/B) to
NGL Amine Wash Column (C-11002) and RDG Amine Wash Column (C-12001) after cooling and filtering.
Lean amine is cooled against the amine regenerator feed in the Lean/Rich Amine Exchangers (E-11052
A/B/C/D) and further cooled by Lean Amine Air Cooler (E-11056) with temperature control on the fans and
finally a Lean Amine Cooler (E-11053 A/B) with cooling water on the tube side to 42°C. FeS corrosion
particles and degraded products, hydrocarbons, carbon fines from activated carbon bed and other
contaminants in the lean amine are removed in the Amine Pre-Filter (S-11051), the Amine Carbon Filter
(V-11051) and the Amine Post Filter (S-11052) – all operated in series. 20% slipstream of the lean amine
flow is filtered; the rest is routed via a bypass line to the amine wash columns.
6.3 Amine Preparation, Drain and Storage
Preparation and storage of DGA solution will be performed in the Amine Tank (T-11051). Fresh DGA is
unloaded to the tank from truck. Cold condensate is used to produce the DGA solution of desired
concentration (30 or 45 wt. % based on NGL feed CO2 levels). The tank is equipped with a nitrogen
blanketing system to avoid oxygen ingress. Amine tank capacity is designed to accumulate the amine
inventory when the unit is taken out of service. As prepared DGA solution is pumped from the tank by the
amine make-up pump (P-11055) through the Amine Make-up Filter (S-11053) to upstream of the Lean/Rich
Amine Exchanger (E-11052 A/B/C/D) for reprocessing.
Hydrocarbon drains are collected from the hydrocarbon compartment of rich amine flash drum (V-11054) in
the Amine Drain Drum (V-11053) hydrocarbon compartment. Hydrocarbons are then pumped by the
Hydrocarbon Drain Pump (P-11054) to the incinerator.
6.4 Amine Reclaiming
Due to the degrading nature of DGA with time, a reclaiming operation is essential depending on the amine
loss in the system. A 5 % slip stream of the lean amine flow from Lean Amine Cooler (E-11053 A/B)
downstream is diverted to the Amine Reclaimer Package (ME-11053). This operation is periodic and is
carried out based on sampling and the amount of heat stable salts build up in the circulating amine. The
package ensures that the heat stable salts are removed and maximum possible amine is recovered. The
heat stable salts are neutralized and disposed to the Amine Drain Drum (V-11053).
6.5 Acid Gas Treatment
The acid gas from the regenerator reflux drum is sent to an Acid Gas Treatment Package (ME-11052) for
removal of H2S before being vented to the atmosphere. H2S is removed from the acid gas by treatment in
ZnO packed beds, which reduce outlet H2S content of gas to required environmental specifications. After
treatment the gas composed majorly of CO2 is vented to the atmosphere.
7.0 STEAM CRACKER UNIT
The Steam Cracker Unit (SCU) is designed to produce the following products and by-products:
Polymer Grade Ethylene
Polymer Grade Propylene
Hydrogen Product
Fuel Gas
Mixed C4 Product
C5+ Pyrolysis Gasoline
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Pyrolysis Fuel Oil
Capacity and Mode of Operation
The Plant is designed based on 8000 operating hours per year.
7.1 Furnace Feed System
The following fresh feeds are processed in the SCU cracking heaters:
The feed to the Ethane Feed Preheater, E-20001, is a combination of the following streams:
Ethane from the NGL Treating and Fractionation Unit
Ethane recycle from the Ethylene Fractionator, C-24002
A temperature controller sets the temperature of this combined stream to 60°C by controlling the amount of
low low pressure steam (LLS) sent to E-20001. A pressure controller on this combined stream sets the
pressure by controlling the amount of ethane is brought in from the NGL unit. In a high pressure scenario,
a pressure controller on this combined stream will open a normally closed vent to the Wet Flare. A
provision is provided for a fresh propane/LPG stream (normally no flow) from OSBL to be vaporized in the
Propane Feed Vaporizer, E-20020, and to be combined with main ethane feed, upstream of E-20001.
The feed to the C3+ Feed Preheater, E-20002, is a combination of the following streams:
Propane recycle from the Propylene Fractionator, C-24003/4
Treated C3+ from the RDG unit (during Case 1&3 operation)
Mixed LPG from OSBL (during Case 2 operation)
Isobutane/n-butane Recycle from the OSBL Butene-1 Unit
C3+ from the NGL Treating and Fractionation Unit
A temperature controller sets the temperature of this combined stream to 58°C by controlling the amount of
quench water (QW) sent to E-20002. The preheated C3+ stream is sent to the C3+ Feed Vaporizer Drum,
V-20012, where it is vaporized by low low pressure steam (LLS) in the C3+ Feed Vaporizer, E-20018A/B/C.
The vaporized C3+ from V-20012 are superheated in the C3+ Feed Superheater, E-20019, where a
temperature controller sets this temperature to 80°C by controlling the amount of LLS sent to E-20019. A
pressure controlled on this superheated stream sets the pressure by controlling the amount of LLS sent to
the C3+ Feed Vaporizer, E-20018A/B/C. In a high pressure scenario, a pressure controller on this
combined stream will open a normally closed vent to the Wet Flare. When the level gets too high in the
C3+ Feed Vaporizer Drum, V-20012, a high level override provides the ability to reset flow controllers on
each of the feeds to the drum.
The feed to the Liquid Feed Surge Drum, V-20011, is a combination of the following streams:
Light Naphtha Condensate from OLNG (tanker)
C5s from Pyrolysis Gasoline Hydrogenation (PGH) Unit
Each stream is sent to V-20011 on flow control reset by the level controller in the drum. Liquid feed is
pumped from V-20011 on pressure control through the Liquid Feed Filters, S-20000A/B and is preheated in
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the Liquid Feed Preheater, E-20003. A temperature controller sets the temperature of this stream to 60°C
by controlling the amount of low low pressure steam (LLS) sent to E-20003.
7.2 Cracking Heaters
The following feeds are cracked at different once-thru conversion/severity and steam to oil ratio (S/O) as
summarized in the following table. Severity is defined as Propylene to Ethylene (P/E) in the heater effluent.
Feed S/O Severity / Conversion
Ethane 0.3 63% C2 CONV
C3+ 0.4 92.8% NC4 CONV
C5 / OLNG 0.5 0.62 P/E
Ethane/Propane Co-Crack (up to 50/50 w/w) 0.3 63% C2 CONV
Ethane/C3+ Co-Crack(up to 50/50 w/w) 0.4 92.8% NC4 CONV
A total of six SRT-VI cracking heaters provide the cracking capacity of the plant; five heaters will be in
operation along with one spare to allow for decoking or maintenance. The heaters are grouped into two
“Ethane” Heaters (F-20001 and F-20002) and four “Flexible” Heaters (F-20003 thru F-20004).
The heaters are designed and piped to crack different feeds, thus providing feedstock flexibility for easy
operation. The table below summarizes the feed flexibility for the two heater types.
Heater Configuration
F-20006
Heater UID F-20001 F-20002 F-20003 F-20004 F-20005
C2 C2
C2/C3 co-cracking C2/C3 co-cracking
Feed Flexibility C3+ C3+
C2/C3+ co-cracking
C5/OLNG /C3+ split cracking
# of Radiant Coils 8 8 6 6 6 6
# of Primary TLEs 8 8 6 6 6 6
# of Secondary TLEs 1 1 0 0 0 0
Two of the cracking heaters, F-20001 and F-20002, are designed to crack ethane normally. For flexibility,
these heaters are also designed to crack C3+ or cocrack ethane and propane (EP). EP can have up to
50%wt propane in the ethane/propane mix. These heaters have 8 radiant coils and 8 Primary Transfer Line
Exchangers (TLE) per heater, E-20004A-H and E-20005A-H. The TLE’s are connected to one common
steam drum for each heater. Secondary Transfer Line Exchanger (STLE), E-20011 and E-20012, are
provided for additional heat recovery for ethane and EP cracked gas from the PTLE. Mixed feed
(hydrocarbon and dilution steam) is preheated in the shell side of the STLE. A bypass is provided for the
mixed feed around the STLE to limit the tube side STLE outlet temperatures to minimize condensation of
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heavy components in the cracked gas which could foul the STLE. For EP co cracking, the STLE should be
partially bypassed to no less than 230 °C in the STLE outlet. For C3+ cracking, the STLE should be totally
bypassed. For ethane cracking, no bypass is required.
The remaining four cracking heaters, F-20003 thru F-20006, are “flexible” heaters for all feeds. These
heaters have 6 radiant coils and 6 Primary TLEs, E-20006A-F thru E-20009A-F. The TLE’s are connected
to one common steam drum for each heater. These cracking heaters do not have Secondary TLEs.
Cracking heaters F-20004 and F-20006 crack C3+ feed at 0.40 S/O and split crack C5/OLNG at 0.5 S/O.
All four “flexible” heaters are designed for split cracking: four of the coils will crack C3+ feed while the
remaining two coils will crack C5/OLNG.
All heaters are twin radiant cell design with a common convection section, stack, and steam drum. The
flue gas is exhausted to the atmosphere with one stack and ID fan per heater.
The table below shows some of the many feed allocations that can occur during operation.
Typical Heater Arrangement During Operation for Various Cases
Heater UID F-20001 F-20002 F-20003 F-20004 F-20005 F-20006
Normal Case 1-3 Ethane Ethane Spare C3+ C3+ / C5 C3+
QO Case C3+ Ethane Ethane C3+ C3+ / C5 HSS
H1 Case HSS Ethane Ethane C3+ C3+ / C5 C3+
In the QO Oil case shown above the cracking heaters are processing different feeds than normal operation.
F-20001 switches from processing ethane to C3+ feed, F-20003 is now in operation cracking ethane, and
the F-20006 heater is on High Steam Standby (HSS).
The radiant coil outlet pressure (COP) is designed for 0.562 bar(g) (22.85 psia). The cracking heaters are
designed for 100% fuel gas fired based on fuel gas produced in the SCU at 10% excess air during normal
feed cracking mode.
For each cracking heater, the feed is preheated in the feed preheat coil in the convection section and then
combined with dilution steam. Ethane feed to the Flexible Heaters F-20003 thru 20006 requires bypass of
the Upper Feed Preheat Coils and part of the Lower Feed Preheat Coils due to the lower feed preheat
requirement of ethane compared to the need to vaporize the liquid C5/OLNG feed. The feed is then
heated in the mixed feed preheat coil to the crossover temperature and then distributed equally to the inlet
tubes of each radiant coil by critical flow venturis. The cracked furnace effluent from each coil is cooled in
a Transfer Line Exchanger.
The ethane cracking effluent from the Primary TLE for F-20001 and F-20002 are further cooled in the
Secondary TLE to maximize heat recovery. Preheated ethane feed from the LFP is mixed with dilution
steam before entering the shell side of the secondary TLE where it is preheated by the ethane cracking
effluent. The mixed feed is sent back to the convection section to further preheat to the crossover
temperature in the Mix Preheat section.
Steam is generated in the TLE and superheated in the USSH and LSSH. There is a desuperheater for
temperature control: one at the outlet of the USSH. The desuperheater is required for temperature control
and to prevent the steam going below the saturation point after BFW injection.
DMDS is injected into the dilution steam header at the inlet to each furnace.
Burners for the heaters shall be hearth burners on the floor plus wall burners. Each of the two radiant cells
of a heater has separate firing controls.
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Jackshaft is provided to adjust the hearth burner air dampers from the DCS and safety interlock systems
for automatic preset shutdown conditions to protect the convection section.
One ID fan will be provided for each cracking heater with Variable Frequency Drive (VFD) for draft control.
Flue gas exhausts from two radiant cells are combined to a common convection section and single stack.
The heater effluent from the TLE is directed to the main transfer line via the Transfer Line Valve (TLV).
When a heater is in decoke mode, the TLV is closed and the decoke valve is open to the decoke piping.
The Transfer Line Valve is part of a 3-valve system which also includes the TLV on the main transfer line
and the small and large Decoke Valves (DV). The Small Decoke Valve is mechanically linked to the TLV to
make sure the heater effluent will not be blocked and cause overpressure. The objectives of the transfer
line valve and decoke valve system are:
a) To provide heater isolation during decoking
b) To prevent reverse flow during valve switching
c) To prevent overpressure of the individual heater during valve switching
The heater’s cracked effluent outlet piping that connects to the main transfer line must be positively
isolated during the decoking operation to prevent leakage of air into the hydrocarbon-carrying main transfer
line during the burn-off phase of the decoking cycle. Likewise, positive isolation is necessary when
maintenance is being performed on the heater (i.e., mechanical cleaning of TLE's), to ensure against a
backflow of hydrocarbon gas into the heater piping or decoke system.
To achieve the objectives described above a 3-valve mechanical link transfer line valve system will be
used.
Regardless of feedstock type, the heater effluent from the cracking heater TLEs is fed to two main transfer
lines. Each main transfer line receives effluent from three heaters (one Ethane Heater and two Flexible
Heaters) and is sent to the Common Quench Fittings, M-21001A/B. Quench oil is used in the quench
fittings to quench the heater effluent before entering the gasoline fractionator, C-21001.
The heaters are designed for steam/air decoking of the radiant coils and TLE. The TLE decoking procedure
is an extension of the radiant decoke. Normally, the decoking procedure is terminated after the radiant coil
is decoked. When TLE decoking is required, the procedure is extended and additional steps are used to
clean the TLE. Decoke effluent is directed to the firebox where the coke particles are combusted.
7.3 Gasoline Fractionator
The hot effluent from the cracking heaters is combined in the main transfer lines, quenched in the quench
fittings, and sent to the Gasoline Fractionator system where they are further cooled to stop the pyrolysis
reactions. A circulating quench oil loop within the Gasoline Fractionator, C-21001, cools the heater effluent
via direct contact in the Quench Fittings, M-21001A,B and the cooled effluent enters the bottom of C-
21001. The temperature of the cooled effluent from the quench fittings is set to 180°C by controlling the
amount of quench oil sent to M-21001A,B.
The following streams are withdrawn form C-21001:
Gasoline and lighter materials as overhead vapor to Quench Tower, C-21003
Pyrolysis Gas Oil (PGO) as side stream sent to the PFO Stripper, C-21002
Pyrolysis Fuel Oil (PFO) as bottoms product sent to the PFO Stripper, C-21002
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Quench Oil recirculated back to C-21001 as a heat recovery loop
The Gasoline Fractionator is comprised of two sections. The top section contains IMTP packing and 8
valve trays serve to separate out the gasoline and lighter ends from the heavier hydrocarbons in the heater
effluent. The bottom section contains grid packing and serves as the heat removal zone for the Quench Oil
Loop.
The total bottoms stream of the Gasoline Fractionator, at 170°C is filtered in the Quench Oil Strainers, S-
21001A/B/C/D, and pumped by the Quench Oil Circulation Pumps, P-21001A/B/C/D, through Quench Oil
Coke Removal Package, ME-21000. In this package, the quench oil quality is improved for use in the
process water and dilution steam system as well as the quench fittings. The improved quench oil is split
into two streams. A small purge stream (3% of total quench oil flow) from ME-21000 is sent back to the
Gasoline Fractionator bottoms. The net bottoms product is sent on flow control to the Pyrolysis Fuel Oil
Stripper, C-21002 via the PFO Stripper Feed Filters, S-21002A/B. The remaining quench oil is passed
through the following equipment for heat removal:
E-21003A/B Quench Oil/Process Water Exchanger
E-21002A/B Process Water Stripper Reboiler
The quench oil loop is split again, with a portion sent to the Common Quench Fittings, M-21001A,B. The
remaining quench oil is sent on flow control to the Quench Oil Cooler, E-21001A/B. In this exchanger, the
quench oil vaporizes LP condensate into Very Low Pressure Steam (VLS) used in the Steam and
Condensate system. The temperature of the quench oil is set to 130°C by controlling the amount of LP
condensate sent to E-21001A/B. A blowdown stream from E-21001A/B (3% of VLS generated) is sent to
the Steam and Condensate system. An on-line analyzer to measure the viscosity of the quench oil is
provided.
The Gasoline Fractionator is refluxed with gasoline condensed in the Quench Tower sent on flow control.
Provision is made to inject Flux Oil from storage into the C-21001 sump, if it is required for purpose of
inventory/makeup and, if required, viscosity adjustment.
A side stream product of Pyrolysis Gas Oil (PGO) is withdrawn from the fractionator and sent to the
Gasoline Fractionator Side Draw Drum, V-21001 on flow control reset by the level controller in V-21001.
PGO from V-21001 is pumped by the Gasoline Fractionator Sidedraw Pumps, P-21002A/B where a part of
the PGO is used as purge oil for instrument flushing prior to returning to the Gasoline Fractionator. The
remainder of the PGO is sent to the Pyrolysis Fuel Oil Stripper, C-21002, bottom section on flow control
reset by the level controller in the bottoms sump of C-21002. Dilution steam is sent to the bottoms of C-
21002 on flow control and serves to control the Pyrolysis Fuel Oil product flash point. The Gasoline
Fractionator net bottoms, PFO, is sent to the upper portion of the Pyrolysis Fuel Oil Stripper, C-21002,
where it is stabilized using Medium Pressure Steam (MS) sent on flow control to achieve a fuel oil product
of acceptable flash point greater than 82°C. The overhead of C-21002 containing vaporized light material
is sent to the bottoms of the Gasoline Fractionator. The bottoms of C-21002, PFO product is pumped by
the Pyrolysis Fuel Oil Pumps, P-21003A/B through the PFO Stripper Bottoms Filters, S-21003A/B, and
then to the PFO Product Cooler, E-21004A/B where it is cooled by Quench Water prior to ending up in
OSBL storage. The temperature of the PFO product is cooled to 90°C by controlling the amount of Quench
Water sent to E-21004A/B.
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7.4 Quench Tower
Overhead vapor from the Gasoline Fractionator, C-21001, is sent to the Quench Tower, C-21003, where it
is cooled and partially condensed by direct counter-current contact with recirculating water, called quench
water (QW). The recirculating quench water is sent from the tower bottoms to supply low level heat at 76°C
to various process users. Provision for amine injection to the recirculating quench water is provided for pH
control.
The circulating quench water is pumped by the Quench Water Circulation Pumps, P-21004A/B/C, and
cooled in the following exchangers (unless noted otherwise):
st
1 Level: High Temperature Quench Water
E-24011 Propylene Fractionator No. 1 Reboiler
E-24002 Deethanizer Reboiler
E-21004A/B PFO Product Cooler (QW heated)
st nd
A bypass is provided for unused 1 level quench water to enter the 2 temperature level through a
st
differential pressure control valve. The quench water is collected from the 1 level exchangers and
undergoes further cooling in the following exchangers:
nd
2 Level: Medium Temperature Quench Water
E-12010 RDG Depropylenizer Reboiler
E-22003 Caustic Charge Gas Feed Heater
A bypass is provided for unused 2nd level quench water to enter the 3rd temperature level through a
nd
differential pressure control valve. The quench water is collected from the 2 level exchangers and
undergoes further cooling in the following exchangers:
rd
3 Level: Low Temperature Quench Water
E-20002 C3+ Feed Preheater
rd
A bypass is provided for unused 3 level quench water through a differential pressure control valve. The
cooled quench water is collected and undergoes further cooling in the Quench Water Cooler No. 2, E-
21005A/B/C, by cooling water. The effluent from E-21005A/B/C is split and a portion is returned to above
the bottom packed bed in the Quench Tower, C-21003, on flow control which is reset by the Quench Tower
bottom temperature controller to maintain a bottoms temperature of 76°C. The temperature of this
midpoint return stream is controlled to 53°C by throttling the amount of quench water that bypasses E-
21005A/B/C. The remaining quench, sent on flow control, is cooled in the Quench Water Cooler No. 1, E-
21006A/B, by cooling water, before re-entering the top of the Quench Tower. The temperature of this
stream is controlled to 40°C by throttling the amount of quench water that bypasses E-21006A/B.
The overhead vapor from the Quench Tower is sent to the charge gas compression section. In a high
pressure scenario, the pressure of this stream is controlled by regulating the amount of vapor sent to Wet
Flare. In a low pressure scenario, the pressure of this stream is controlled by regulating the amount of fuel
gas mixed with this overhead vapor stream.
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The condensed gasoline and dilution steam (as process water) is separated from the recirculating quench
water in the Quench Tower bottoms and sent to Quench Water Settler, V-21002. Here, the gasoline is
separated from process water. The condensed hydrocarbon is pumped by the Gasoline Fractionator Reflux
Pumps, P-21006A/B and returned as reflux to the Gasoline Fractionator, or used as wash gasoline for
spent caustic treatment. Any excess gasoline is mixed with the bottoms stream from the Debutanizer, and
sent to OSBL as Raw Pyrolysis Gasoline.
The process water from the Quench Water Settler, V-21002, is pumped by the Process Water Stripper
Feed Pump, P-21005A/B, through the Process Water Coalescer Package, ME-21006, where suspended
solids and emulsified oil are removed from process water. The process water is then sent to the Process
Water Stripping section.
7.5 Process Water Stripping and Dilution Steam Generation
Process Water is sent on flow control from the Process Water Coalescer Package, ME-21006, is heated by
hot blowdown from the Dilution Steam Drum, V-21003, in the Process Water Stripper Feed Heater, E-
21008 and enters the Process Water on the top tray of the Process Water Stripper, C-21004. A level
controller in the bottoms sump of C-21004 resets the flow control on the process water feed.
The Process Water Stripper is comprised of 12 valve trays and operates at a pressure of 0.40 bar(g) and
temperature of 108°C in the top. The Process Water Stripper Reboiler, E-21002A/B, generates the
stripping steam necessary to remove acid gases and volatile hydrocarbons from the process water. Live
dilution steam injection is provided to the bottom of the process water stripper to supplement steam
generation in the reboiler, if required. The heating medium of E-21002A/B is the recirculating hot quench
oil from the Gasoline Fractionator, C-21001. The overhead vapor from C-21004 is sent back to the Quench
Tower, C-21003, and flow control is accomplished by throttling the amount of Quench Oil bypassing the
Process Water Stripper Reboiler, E-21002A/B. The bottoms of C-21004 is stripped process water and is
pumped by the Process Water Stripper Bottoms Pumps, P-21007A/B, to the Dilution Steam Drum, V-
21003, on flow control reset by the level in the bottom sump of V-21003. Prior to entering V-21003, a
portion of the process water stripper bottoms stream, used as wash water, is sent to the Spent Gasoline/
Wash Water Mixer, M-22003. The rest of the C-21004 bottoms stream is preheated by hot quench oil in
the Quench Oil/Process Water Exchanger, E-21003A/B. Makeup boiler feed water, if required, is added to
the process water before it enters the dilution steam drum. Make up is normally not expected.
The Dilution Steam Drum, V-21003, contains three valve trays in addition to a demister in order to minimize
the possibility of entrainment of residual caustic into the dilution steam. The process water is vaporized at
177°C by Medium Pressure Steam (MS) in the Dilution Steam Drum MS Steam Reboiler, E-21009A/B/C/D.
The dilution steam is superheated against MS in the Dilution Steam Superheater, E-21010, and primary
pressure control is accomplished by controlling the amount of MS sent to E-21010. If necessary,
secondary pressure control involves the injection of live MS into the header to maintain pressure.
Provisions for amine injection to the dilution steam drum feed and process water stripper feed are provided
for pH control.
The steam generated in V-21003 is sent to the cracking heaters as dilution steam and purge steam for
instruments and valves. Dilution steam is also sent to the PFO Stripper, C-21002.
To prevent a build-up of non-volatiles, a blowdown stream from the dilution steam drum is cooled in the
Process Water Stripper Feed Heater, E-21008, and further cooled to 50°C by cooling water in the Dilution
Steam Blowdown Cooler, E-21011. The cooled blowdown is sent to the OSBL waste treatment facility on
flow control reset by the interface level controller in V-21002. An on-line analyzer is provided to measure
the pH this cooled blowdown.
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7.6 Charge Gas Compression (Stages 1-2)
st
The Quench Tower overhead vapors are sent to the Charge Gas Compressor 1 Stage Suction drum, V-
22001. Any hydrocarbon and water liquids knocked out in this drum are pumped to the quench tower by
st
the CGC 1 Stage Suction Drum Pumps, P-22001A/B, on flow control reset by the level controller in V-
st
22001. The overhead vapor from this drum enters the 1 stage of the Charge Gas Compressor, K-22001.
A steam turbine utilizing Super High Pressure Steam (SHS) drives K-22001. Boiler Feed Water (BFW) is
injected into the compressor to help maintain temperature below 100°C and consequently reduce fouling.
Wash Oil Injection is provided individually at all three compression stages to wash the rotors as required.
st
The compressed hydrocarbon stream continues to the Charge Gas Compressor 1 Stage Aftercooler, E-
22001A/B, where it is cooled to 40°C by cooling water. Continuous vents from the Selective Hydrogenation
Unit (SHU), Pyrolysis Gasoline Hydrogenation (PGH) Unit, and Polypropylene (PP) plant, as well as other
normally closed vents from other parts of the SCU and the Polyethylene (PE) plant are combined with the
nd
cooled charge gas and sent to the Charge Gas Compressor 2 Stage Suction Drum, V-22002.
nd
Any hydrocarbons condensed in the Charge Gas Compressor 2 Stage Suction Drum, V-22002, are sent
to the Quench Water Settler, V-21002 by the level controller in V-22002. Any water that is knocked out in
st
V-22002, is sent to the Charge Gas Compressor 1 Stage Suction Drum, V-22001, by the interface level
nd
controller on V-22002. The overhead vapor from this drum enters the 2 stage of the Charge Gas
Compressor, K-22001.
nd
The compressed hydrocarbon stream continues to the Charge Gas Compressor 2 Stage Aftercooler, E-
22002A/B, where it is cooled to 40°C by cooling water. A continuous vent from the Propylene Fractionator
Vent Condenser, E-24010, along with normally closed offspec ethylene and propylene BOG vapors are
nd
combined with the cooled charge gas and sent to the Charge Gas Compressor 2 Stage Discharge Drum,
V-22003.
nd
Any hydrocarbons and water components that are knocked out in the Charge Gas Compressor 2 Stage
Discharge Drum, V-22003, are sent back to Charge Gas Compressor 2nd Stage Suction Drum, V-22002, on
the level control from V-22003. The vapor from V-22003 is heated to 45°C by Quench Water in the Caustic
Charge Gas Feed Heater, E-22003, and sent to the Caustic/Water Wash Tower, C-22001. This preheat
prevents hydrocarbon condensation which contributes to "yellow oil" formation. However, the temperature
should not be increased above this value since high temperatures can lead to precipitation of salts resulting
in plugging.
The basic control scheme of the Charge Gas Compressor (Stages 1-2) takes the following actions:
st
A pressure controller on the 1 Stage Suction Drum, V-22001, overhead controls the suction pressure
by throttling (SHS) sent to the turbine.
In cases when the pressure gets too high in V-22001, pressure is controlled by venting hydrocarbons
to Wet Flare.
nd
Flow through the first three stages is measured at the 2 stage discharge, upstream of the cooler, and
nd
controls the minimum flow recycle from the Charge Gas Compressor 2 Stage Discharge Drum
st
overhead to the inlet of the Charge Gas Compressor 1 Stage Suction Drum.
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and SLC4HY 2800
7.7 Acid Gas Removal
The heated charge gas from E-22003 is fed to the bottom of the lower packed bed in the Caustic/Water
Wash Tower, C-22001, where acid gases (H2S and CO2) are removed by weak caustic pumped in from the
Weak Caustic Circulation Pump, P-22002. Acid gases are reacted with caustic to form sodium sulfide and
sodium carbonate salts. The cleaner charge gas continues through to the bottom of the upper packed bed
in C-22001 where acid gases are removed by medium level caustic pumped to the top of the bed by the
Middle Caustic Circulation Pumps, P-22003A/B. The charge gas then proceeds to the third section of acid
gas removal, 15 valve trays, where strong caustic solution is pumped in from the Strong Caustic Circulation
Pumps, P-22004A/B. In this section the required CO2 spec in the Ethylene Product is met. Before the
acid-free charge gas leaves the Caustic/Water Wash Tower, wash water is introduced to the top of three
bubble cap trays to ensure no caustic is carried over into downstream equipment. Wash water for the
Caustic/Water Wash Tower, C-22001, comes from the Continuous Blowdown Cooler, E-20014. Waste
th
water from the water section is totally drawn off below the 16 tray and is sent to Spent Caustic Wash
Gasoline Mixer, M-22002.
Any significant breakthrough of H2S or CO2 can jeopardize downstream operations or final product
specifications. 20% Caustic is fed from OSBL to the suction line of P-22004A/B to make up any caustic
that leaves the bottoms (spent caustic) of C-22001.
7.8 Charge Gas Compression (Stage 3)
After acid gas removal in the Caustic/Water Wash Tower, the charge gas is cooled by 9°C propylene
rd
refrigeration in the Caustic Tower Effluent Cooler, E-22005, and sent to the Charge Gas Compressor 3
Stage Suction Drum, V-22004. In this drum the condensed hydrocarbon and water phases are separated.
The hydrocarbon is split into two streams. One stream is recycled on flow control (with a low level override
from level controller in V-22004) to the Quench Tower, C-21003, to maintain gasoline inventory. The other
rd
stream is pumped by the CGC 3 Stage Suction Drum Pumps, P-22006A/B, to the Liquid Condensate
Coalescer Package, ME-22002, on flow control reset by level controller in V-22004. An interface level
controller sends Water from V-22004 to the Quench Tower, C-21003. The overhead vapor from this drum
rd
enters the 3 stage of the Charge Gas Compressor, K-22001.
rd
The compressed hydrocarbon stream continues to the Charge Gas Compressor 3 Stage Aftercooler No.
1, E-22006, where it is cooled to 40°C by cooling water. The charge gas undergoes further cooling to 12°C
rd
in the Charge Gas Compressor 3 Stage Aftercooler No. 2, E-22007, by 9°C propylene refrigerant and is
rd
sent to the Charge Gas Compressor 3 Stage Discharge Drum, V-22005. In this drum the condensed
rd
hydrocarbon and water phases are separated. The hydrocarbon stream is pumped by the CGC 3 Stage
Discharge Drum Pumps, P-22007A/B to the Liquid Condensate Coalescer Package, ME-22002, on flow
control reset by level controller in V-22005. An interface level controller sends Water from V-22005 to the
Quench Tower, C-21003. The overhead vapor from is sent to the Charge Gas Dryers.
The basic control scheme of the Charge Gas Compressor (Stage 3) takes the following actions:
A temperature controller on the 3rd Stage Suction Drum, V-22004, overhead sets the temperature to
15°C by throttling the amount of 9°C propylene refrigerant to E-22005.
In cases when the pressure gets too high in V-22004, pressure is controlled by venting hydrocarbons
to Wet Flare.
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and SLC4HY 2800
rd
In cases when the pressure gets too high on the 3 stage discharge, pressure is controlled by venting
hydrocarbons to Wet Flare.
rd
Flow through the third stage is measured at the 3 stage discharge, upstream of the cooler, and
rd
controls the minimum flow recycle from the Charge Gas Compressor 3 Stage Discharge Drum
nd
overhead to the inlet of the Charge Gas Compressor 2 Stage Suction Drum.
7.9 Spent Caustic Pretreatment
The spent caustic solution and yellow oil from the SCU and RDG Caustic/Water Wash Towers (C-22001
and C-12002) cannot be discharged to the environment without further treatment. The spent caustic
solution contains sodium carbonate, sodium sulfide, and a small percentage of free, unreacted, sodium
hydroxide. In addition, the solution may contain dispersed hydrocarbons. The dispersed hydrocarbons
may cause considerable fouling in the OSBL Wet Air Oxidation Unit (WAO) and are therefore removed with
a gasoline wash.
Spent caustic leaves the bottom of the SCU and RDG Caustic/Water Wash Towers, along with a cooled
wash gasoline stream is sent to the Spent Caustic Wash Gasoline Mixer, M-22002, and then processed in
the Spent Caustic Coalescer, V-22008. Wash gasoline is pumped from the Quench Water Settler on flow
ratio control, maintaining a consistent ratio to the spent caustic flow. Prior to entering V-22008, it is cooled
by cooling water in the Spent Caustic Wash Gasoline Cooler, E-22008. The gasoline wash recovers
hydrocarbon from the spent caustic stream. In the Spent Caustic Coalescer the combined stream is first
degassed, then passed through a packed coalescing pad and into the settling compartment where the
gasoline/caustic separation takes place. The spent caustic is routed to the OSBL WAO unit on flow control
reset by the level controller on V-22008, where it undergoes further treatment. The Wet Air Oxidation unit
converts the sodium sulfides to sodium sulfates and thiosulfates.
The spent gasoline from V-22008, requires further water washing to reduce the quantity of entrained
caustic which can lead to a pH problem. The gasoline is sent on flow control reset by the level controller
on V-22008 to the Spent Gasoline/Wash Water Mixer, M-22003, where it is contacted with wash water prior
to entering the Spent Gasoline Coalescer, V-22009. Wash water is pumped from the Process Water
Stripper bottoms on flow ratio control, maintaining a consistent ratio to the wash gasoline flow from V-
22008. In the Spent Gasoline Coalescer the combined stream is passed through a packed coalescing pad
and into the settling compartment where the gasoline/water separation takes place. The spent wash water
is sent on flow control reset by the level controller on V-22009 to the OSBL WAO. The spent gasoline is
returned to the Quench Tower.
The pressure in the Spent Caustic Coalescer, V-22008, is controlled by split range pressure controllers
located in the overhead vent to the Wet Flare. In a high pressure scenario, the overhead stream is vented
to the Wet Flare. In a low pressure scenario, Nitrogen is brought into the overhead line. The pressure is
set to a sufficient level in the Spent Caustic Coalescer to send spent caustic to the OSBL WAO unit and
Spent Gasoline to the Spent Gasoline Coalescer Drum without the use of pumps.
Similarly, the pressure in the Spent Gasoline Coalescer, V-22009, is controlled by split range pressure
controllers located in the overhead vent to the Wet Flare. In a high pressure scenario, the overhead
stream is vented to the Wet Flare. In a low pressure scenario, Nitrogen is brought into the overhead line.
The pressure is set to a sufficient level in the Spent Gasoline Coalescer to send spent wash water to the
OSBL WAO unit and Spent Gasoline to the Quench Tower without the use of pumps.
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and SLC4HY 2800
7.10 Charge Gas and Liquid Condensate Drying
The charge gas passes through the Charge Gas Dryers, V-22010A/B, for moisture removal. After drying,
the charge gas is sent through the Charge Gas Dryer Outlet Filters, S-22002A/B, and then to the HP
Depropanizer, C-22002. The removal of water from the charge gas is necessary to prevent the formation
of ice and hydrates in the HP Depropanizer.
One Charge Gas Dryer is in operation and operates at a pressure of 24.4 bar(g) while the second dryer is
being regenerated or on standby. Each dryer contains two desiccant bed sections. A moisture analyzer is
provided below the first (main) bed to indicate the arrival of the wet gas “front”. The second bed (guard)
prevents break-through moisture from leaving the dryer. Any indication of the wet gas “front” reaching the
analyzer probes indicates exhaustion and the dryers should be switched immediately. The dryers are
designed to run for 48 hours before requiring regeneration. The process of switching from one dryer to the
next is a timed cycle operation. Regeneration is carried out by circulating hot methane-rich regeneration
gas from the regeneration system at 232°C to drive out moisture adsorbed in the dryer bed. After the bed
has reached the required temperature, the bed is cooled with unheated regeneration gas. The spent
regeneration gas is returned to the fuel gas system.
Liquid condensate is pumped from V-22004 and V-22005 to the Liquid Condensate Coalescer Package,
ME-22002, where the separated hydrocarbon proceeds to the Liquid Condensate Dryers, V-22007A/B, for
moisture removal. Any free water in the feed stream is removed from the bottom boot of ME-22002-V01 on
interface level control and sent to the Quench Tower, C-21003. After drying, the liquid condensate flows
through the Liquid Condensate Dryer Outlet Filter, S-22001A/B, and then sent directly to the HP
Depropanizer, C-22002.
One Liquid Condensate Dryers is in operation and operates at a pressure of 26.2 bar(g) while the second
dryer is being regenerated or on standby. Each dryer contains one dessicant bed. A moisture analyzer is
provided towards the end of the bed to indicate arrival of the wed gas “front”. Any indication of the wet gas
“front” reaching the analyzer probe indicates exhaustion and the dryer should be switched immediately.
The dryers are designed to run for 72 hours before requiring regeneration. The process of switiching from
one dryer to the next is timed cycle operation. The regeneration procedure is similar to that of the Charge
Gas Dryers mentioned above. An on-line analyzer on the effluent from the Liquid Condensate Dryers
measures any water that may break through. A separate on-line analyzer provides a composition of the
charge gas, as well as detecting any acid gases (CO2 and H2S).
7.11 Regeneration System
Dryers and treaters in the complex operate on the principle of Temperature Swing Adsorption (TSA), in
which water and/or impurities adsorb into a packed bed at one temperature, and are released from the bed
at higher temperature during regeneration. The size of the beds determines how long each adsorption
cycle is, before the beds become saturated and require regeneration.
Fuel gas from the RDG as well as methane rich offgas from the SCU fuel gas system is combined and
used as regeneration gas in the complex. It is split into two cooling and heating regeneration headers.
The cooling regeneration gas is at a temperature of 40°C. The heating regeneration gas is preheated by
the Regeneration Feed/Effluent Exchanger, E-22009, and then against High Pressure Steam (HS) in the
Regen Gas Heater, E-22011. The temperature of the heating regeneration gas is controlled to 240°C by
throttling the amount of HS sent to E-22011. Some of this heating regeneration gas is sent to the
Regeneration Gas Electric Heater, E-11009, in the NGL unit. A mixture of heating and cooling
regeneration gas is sent to the dryers and treaters on flow control.
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and SLC4HY 2800
The regeneration procedure consists of several steps including gradual heating by regeneration gas,
holding at this temperature until all water is driven from the molecular sieve, and finally cooling the beds
before returning to service. Flow control on the combined regeneration gas is established by controlling
the heating regeneration gas sent to the dryer or treater. Temperature control on the combined
regeneration gas is established by resetting the set point on the flow controller of the cooling regeneration
gas.
The spent regeneration gas from the users is cooled in the Regeneration Feed/Effluent Exchanger, E-
22009, and cooled to 45°C in the Regeneration Gas Cooler, E-22010, by cooling water. The cooled
regeneration gas continues to the Regeneration Gas K.O. Drum, V-22011, for removal of water prior to re-
entering the fuel gas system. Any condensed water from the regeneration gas K.O. drum is returned to the
Quench Water Tower, C-21003, on level control.
The reactors in the complex require different types of gases during their regeneration cycles. A Reactor
Reduction Gas Heater, E-22031, heats a Nitrogen (N2) stream along with Hydrogen (H2) when required.
The temperature is controlled by throttling the amount of Medium Pressure Steam (MS) sent to E-22031.
There are also provisions for Plant Air, Super High Pressure Steam (SHS), and Low Low Pressure Steam
(LLS) to be sent to reactors during regeneration oxidation steps.
7.12 Depropanization and Acetylene Hydrogenation
The purpose of the depropanizer system is to achieve a C4's content in the net overhead consistent with
the allowable specifications of the final C3 product streams. The bottoms composition is adjusted to
maintain the bottoms temperature such that fouling tendencies in the trays and the reboiler are minimized.
The Depropanizer System employs a two tower system, with each tower operating at a different pressure.
By utilizing two distillation towers, refrigeration demand and fouling is minimized, when compared with
single-tower systems.
The charge gas from the Charge Gas Dryers and the condensed hydrocarbon liquid from the Liquid
Condensate Dryer are fed to tray #15 and #19 respectively of the High Pressure (HP) Depropanizer, C-
22002. The gross overhead from the High Pressure Depropanizer, C-22002, at 23.5 bar(g) is heated by
Acetylene Converter reactor effluent in the Acetylene Converter Feed/Effluent Exchanger No. 1 and No. 2,
E-22012A/B and E-22013A/B. The temperature of the reactor feed after the second feed/effluent
exchanger is set to 53°C by controlling the amount that bypasses E-22013A/B. An on-line analyzer detects
the amount of C4’s in this stream, which indicates tower separation performance. A separate analyzer
detects any carbon monoxide found in the stream, which is a temporary poison to the Acetylene Converter
catalyst that reduces activity.
The reactor feed is heated to 66°C at SOR (116°C at EOR) in the Acetylene Converter Heater, E-22014, by
throttling the amount of Medium Pressure Steam (MS) sent to E-22014. The front end Acetylene Converter
system selectively hydrogenates acetylene to ethylene and ethane. Some methyl-acetylene/ propadiene
(MAPD) are hydrogenated to propylene and propane. An on-line analyzer on this stream measures the
amount of acetylene, ethane, and MAPD in the reactor feed.
The Acetylene Converter, R-22001A/B/C, contains 3 beds operating in series with intercoolers after each
staged cooled by cooling water. Temperature controllers downstream of each intercooler set the
temperature of the cooled effluent feeding the next bed, by controlling the amount bypassing each
intercooler. Reactor regeneration is performed ex-situ. The reactor vessels are configured to be put in any
order to allow single vessel catalyst replacement if required. The reactor effluent, 74°C at SOR (125°C at
EOR) is cooled by in the Acetylene Converter Aftercooler, E-22017, by cooling water. An on-line analyzer
on this stream measures the amount of acetylene, ethane, and MAPD in the reactor effluent. The reactor
effluent then is further cooled in the Acetylene Converter Feed/Effluent Exchanger No. 2, E-22013A/B, after
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and SLC4HY 2800
which it is sent to the molecular sieve Acetylene Converter Dryer, V-22014A/B, for moisture removal. The
dryer effluent flows through the Acetylene Converter Dryer Outlet Filter, S-22004A/B, and is further cooled
in Acetylene Converter Feed/Effluent Exchanger No. 1 and then sent to the HP Depropanizer Condenser,
E-22018. The hydrocarbons are partially condensed at -21°C by -27°C propylene refrigerant and then
enters the HP Depropanizer Reflux Drum, V-22012. The level controller on V-22012 controls the amount
of propylene refrigerant sent to E-22018. The liquid from V-22012 is pumped by the HP Depropanizer
Reflux Pumps, P-22010A/B, on flow control as reflux to C-22002.
The condensed liquid from the reflux drum provides some of the reflux to the HP Depropanizer. The net
overhead from the HP Depropanizer, which contains the C3 and lighter components of the charge gas, is
then fed to the chilling train. The pressure of the reflux drum is controlled by a pressure controller that
regulates the amount of net overhead vapor is sent to the Demethanizer Feed Chiller, E-23001. A second
pressure controller will vent material to the Cold Flare in high pressure scenarios.
Tower reboiler duty is provided by Desuperheated Low Low Pressure Steam (DS LLS) in the HP
Depropanizer Reboiler, E-22020A/B. Only one of the reboilers is in operation; a spare is provided since
fouling is an issue in this system and periodic cleaning is required. A temperature controller on the
downcomer of Tray #10 maintains a bottoms temperature to 82°C by resetting the setpoint of the flow
controller on the DS LLS feeding the reboiler. The HP Depropanizer bottoms is cooled by cooling water in
the HP Depropanizer Bottoms Cooler, E-22021, and then fed to the LP Depropanizer, C-22003 flow control
reset by the level controller on C-22002 bottoms sump. An on-line analyzer provides a measurement of
C2’s in the bottoms stream which is an indication of tower separation performance. Polymerization
inhibitor from the Polymerization Inhibitor Injection System, ME-22000, is injected into the HP Depropanizer
feed and Reboiler inlet streams.
The bottoms product of the HP Depropanizer enters on tray #33 of the LP Depropanizer which operates at
a top pressure of 6.2 bar(g). The gross overhead of the LP Depropanizer is fully condensed by -27°C
refrigerant in the LP Depropanizer Condenser, E-22002. The tower overhead pressure is set by a split-
range pressure controller (PC) in the gross overhead line. Primary pressure control is accomplished by
controlling the amount of -27°C propylene refrigerant sent to E-22022. Secondary pressure control is
accomplished by controlling the vent (normally closed) to the Cold Flare from the LP Depropanizer Reflux
Drum, V-22015. The condensed stream leaving E-22022 enters V-22015. Total liquid from V-22015 is
pumped by the LP Depropanizer Reflux Pumps, P-22011A/B, and a portion is sent as reflux to the C-22003
on flow control. The remaining overhead liquid product is sent to the HP Depropanizer, C-22002, on flow
control reset by the level controller in V-22015.
Tower reboiler duty is provided by Desuperheated Low Low Pressure Steam (DS LLS) in the LP
Depropanizer Reboiler, E-22023A/B. Only one of the reboilers is in operation; a spare is provided since
fouling is an issue in this system and periodic cleaning is required. A temperature controller in the
downcomer of Tray #14 maintains a bottoms temperature of 75°C resetting the setpoint of the flow
controller on the DS LLS feeding the reboiler. The LP Depropanizer bottoms product, which contains C4
and heavier components, is pumped by the LP Derpopanizer Bottoms Pumps, P-22012A/B, to the
Debutanizer, C-24005, on flow control reset by the level controller in C-22003 bottom sump. On-line
analyzers detect the amount of C4’s in the overhead product stream as well as the C3’s in bottoms product
stream, which indicate tower separation performance. Polymerization inhibitor from the Polymerization
Inhibitor Injection System, ME-22000, is injected into the LP Depropanizer feed and Reboiler inlet streams.
A normally closed vent stream from V-22015, controlled by hand controller (HC), is provided to rout
st
material back to the Charge Gas Compressor 1 Stage Suction Drum, V-22001, for reprocessing.
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7.13 Charge Gas Chilling
The charge gas from the HP Depropanizer overhead is progressively chilled against -40°C propylene
refrigerant in the Demethanizer Feed Chiller, E-23001, and then in the Demethanizer Reboiler, E-23002
before it is finally chilled in the Offgas Exchanger No. 3, ME-23000-03. The temperature of the charge gas
is set to -80°C by controlling the amount of Binary Refrigerant (BR) sent to ME-23000-E03 and the stream
is flashed in the Demethanizer Feed Separator No.1, V-23001. The condensate is separated in V-23001
and fed to the Demethanizer, C-23001, as the “Bottom Feed” on flow control reset by the level controller in
V-23001.
The overhead vapor from the Demethanizer Feed Separator No. 1 is further chilled against offgases and
binary refrigerant in the Offgas Exchanger No. 2, ME-23000-E02. The temperature of the charge gas is set
to -110°C by controlling the amount of binary refrigerant sent to ME-23000-02 and the stream is flashed in
the Demethanizer Feed Separator No. 2, V-23002. The condensate from the Demethanizer Feed
Separator No. 2, V-23002, is sent to the Demethanizer as the “Middle Feed” on flow control reset by the
level controller in V-23002.
The overhead vapor from the Demethanizer Feed Separator No. 2 is further chilled against offgases and
binary refrigerant in the Offgas Exchanger No. 1, ME-23000-01, and is mixed with methane wash liquid in
the Demethanizer Feed/Methane Wash Mixer, M-23001, and is flashed in the Demethanizer Feed
Separator No. 3, V-23003. The condensate from the Demethanizer Feed Separator No. 3, V-23003, is
sent to the Demethanizer as the “Top Feed” on flow control reset by the level controller in V-23003.
The overhead vapor from the Demethanizer Feed Separator No. 3, called hydrogen rich offgas, is reheated
by charge gas in the cold box system and compressed in the Hydrogen Compressor, K-23001, before
being sent to the Hydrogen Pressure Swing Adsorption (PSA) Unit, ME-23001, for hydrogen purification.
The pressure of V-23003 is controlled by two pressure controllers. Primary pressure control is
accomplished by resetting the speed controller on K-23001. In a high pressure scenario, the speed
controller for K-23001 may reach its limit and secondary pressure control is accomplished by sending the
hydrogen rich offgas to the fuel gas system.
The Hydrogen Compressor is comprised of two stages and the discharge from each stage is cooled to
45°C by cooling water in the Hydrogen Compressor Intercooler and Aftercooler, E-23003 and E-23004
respectively. The pressure of the stream is increased to 32.9 bar(g) which is sufficient for the purified
hydrogen (>99.9 mol.%) from the PSA Unit to be sent to the following locations:
R-280011/21/31, Selective Hydrogenation Reactors
R-24001A/B, MAPD Converter
E-22031, Reactor Reduction Gas Heater
A portion is sent out as High Pressure (HP) Hydrogen product to OSBL at 45°C and 31.4 bar(g) while the
remaining high purity H2 from the PSA is exported on flow control as hydrogen product to OSBL at 45°C
and 21.0 bar(g).
Offgas from the PSA Unit is combined with returned regeneration gas and is sent directly to the Fuel Gas
system. A portion of this fuel gas is sent to the Fuel Gas Knock-Out Drum, V-23005, where any liquids are
removed on level control and sent back to the Quench Tower, C-21003. The pressure of V-23005 is
controlled to 4.5 bar(g) by two pressure controllers in the overhead line. In a high pressure scenario, fuel
gas is vented to the Wet Flare. In a low pressure scenario, supplemental fuel gas is brought into V-23005
from OSBL. The overhead of V-23005 undergoes further processing in the Fuel Gas Filter/Coalescer, S-
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23001A/B, where condensate is removed and sent back to the Quench Tower. The processed fuel gas is
consumed by the Cracking Heaters, F-20001-6, any excess is sent to OSBL. On-line analyzers detect the
composition of this fuel gas stream, to control the firing rate in the cracking heater burners.
7.14 Demethanization
The Demethanizer, C-23001, tower is comprised of four packed bed sections and its primary purpose is to
separate methane and lighter components from the remaining charge gas. The tower operates at a top
pressure of 7.1 bar(g), just high enough to permit overhead methane product to get into the fuel gas
system. By minimizing the operating pressure, the separation efficiency is increased which reduces both
reflux requirements and energy consumption.
There are three primary condensed liquid feeds (top/middle/bottom) to the Demethanizer, C-23001, which
come from feed separator drums in the chill train. Demethanizer gross overhead vapor at -130°C is
partially condensed with binary refrigerant in the Demethanizer Condenser, ME-23000-E07, and sent to the
Demethanizer Reflux Drum, V-23004. The overhead of V-23004 is sent back to the cold box where it is
heated before being sent to the regeneration system; any fuel gas not used for regeneration proceeds to
the PSA unit for hydrogen recovery. A control valve controls the flow of this stream through the control box
which sets the pressure in the Demethanizer tower. The liquid from V-23004 is pumped by the
Demethanizer Reflux Pumps, P-23001A/B. A portion is sent on flow control as reflux to the top bed of the
Demethanizer, while the remaining liquid is used as methane wash liquid in the Demethanizer Feed
Separator No. 3 in the charge gas chilling train to reduce ethylene loss. The level in V-23004 is controlled
by throttling the amount of binary refrigerant sent to the Demethanizer Condenser, ME-23000-E07.
Tower reboiler duty is provided by heat interchange with hot charge gas from the HP Depropanizer Reflux
Drum, V-22012, in the Demethanizer Reboiler, E-23002. A temperature controller sets the temeperature
profile in the tower by bypassing a portion of the charge gas around E-23002. The bottoms product is
pumped by the Demethanizer Bottoms Pumps, P-23002A/B, and split into two streams before being heated
in the cold box and eventually entering the Deethanizer, C-24001. One stream is sent directly as liquid
from the cold box to the Deethanizer as the “Upper Feed”. The other stream is vaporized in the cold box
and sent to the Deethanizer as the “Lower Feed”. A level controller resets the flow controller on the “Lower
Feed” upstream of the cold box. The “Upper Feed” flow controller is set on ratio control relative to the
“Lower Feed”. An on-line analyzer in the tower bottoms detects for methane, an indication of tower
separation performance.
Provisions are made to reprocess vents from ethylene fractionation or the binary refrigeration system.
7.15 Deethanization
The Demethanizer bottoms product, which is split into two streams as described in the Demethanizer
section, feeds the Deethanizer, C-24001. The Deethanizer is comprised of 70 valve trays and its primary
purpose is to create a C2 stream sent to the Ethylene Fractionator and a C3 stream sent to the Propylene
Fractionators.
The top of the Deethanizer operates at a pressure of 18.4 bar(g) and gross overhead vapor is partially
condensed against -27°C propylene refrigerant in the Deethanizer Condenser, E-24001. The two phase
stream leaving E-24001 enters the Deethanizer Reflux Drum, V-24001 where an overhead vapor stream,
containing ethane and ethylene, is sent to the Ethylene Fractionator, C-24002 on flow control. The tower
overhead pressure is set by a pressure controller in the gross overhead line resetting the flow controller on
the C2s sent to the Ethylene Fractionator. In a high pressure scenario, a second pressure controller will
open a normally closed vent on V-24001 to the Cold Flare. Total liquid from V-24001 is pumped by the
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Deethanizer Reflux Pumps, P-24001A/B, and sent as reflux to the C-24001 on flow control. The level in V-
24001 is controlled by throttling the amount of propylene refrigerant sent to the Deethanizer Condenser, E-
24001.
Tower reboiler duty is provided by Quench Water (QW) in the Deethanizer Reboiler, E-24002. A
temperature controller on Tray #18 sets the temperature by resetting the setpoint of the flow controller on
the QW feeding the reboiler. The Deethanizer LLS Steam Reboiler, E-24016, is provided for use as a
startup/spare reboiler. The Deethanizer bottoms product, which contains C3 and heavier components, is
pumped by the Deethanizer Bottoms Pumps, P-24002A/B, to the MAPD Trim Reactor Feed Cooler, E-
24008, on flow control reset by the level controller in C-24001 bottom sump.
On-line analyzers are provided in the net overhead vapor product and bottoms product to measure their
compositions, and tower separation performance.
7.16 Ethylene Fractionation
The Ethylene Fractionator, C-24002, is comprised of 139 valve trays and its primary purpose is to produce
99.9 mol.% ethylene overhead product, as well as high purity ethane bottoms product which is recycled to
the cracking heater feed system. There are two feeds to this tower:
Net overhead vapor product from the Deethanizer Reflux Drum, V-24001, fed to Tray #41
Treated C2 stream from the RDG Deethanizer Reflux Pumps, P-12005A/B, fed to Tray #28
The top of the Ethylene Fractionator operates at a pressure of 16.3 bar(g) and gross overhead vapor is
totally condensed against -40°C propylene refrigerant in the Ethylene Fractionator Condenser, E-24003
before it enters the Ethylene Fractionator Reflux Drum, V-24002. The tower overhead pressure is set by a
pressure controller in the gross overhead line which controls the amount of propylene refrigerant sent to E-
24003. In a high pressure scenario, a second pressure controller will open a normally closed vent on V-
24002 to the Cold Flare. If any non-condensables accumulate in V-24002, a hand control (HC) provides
the ability to send this material back to the Demethanizer, C-23001, for reprocessing. The liquid from V-
24002, ethylene product, is pumped by the Ethylene Fractionator Reflux Pumps, P-24003A/B, and sent as
reflux to C-24002 on flow control. A portion of this ethylene product is sent on flow ratio control to the
OSBL storage spheres, maintaining a constant ratio to the reflux flow. This prevents exporting offspec
Ethylene Product. The level controller in V-24002 resets the reflux flow and, therefore, the product draw-off
rate.
Onspec HP Ethylene from OSBL storage is pumped to the Offgas Exchanger No. 6, ME-23000-E06, in the
cold box to heat the stream, before it is vaporized in the kettle side of the Ethylene Product Vaporizer, E-
23005, by 9°C propylene refrigerant. The vaporized ethylene from E-23005 undergoes more heating in
ME-23000-E06, and is sent as HP Ethylene Product Vapor to OSBL at 45°C and 37 bar(g). The pressure
of this stream is set by controlling the amount of liquid ethylene feeding E-23005. A level controller in E-
23005, sends a high level override to control the feed if the level gets too high.
A continuous ethylene rundown stream of 5,000 kg/hr is withdrawn on from the Ethylene Fractionator
Reflux Drum, V-24002, and is chilled by binary refrigerant in the Ethylene Rundown Chiller, ME-24000. A
temperature controller on the outlet of ME-24000 sets the temperature of the ethylene rundown to -101°C.
The ethylene rundown (in liquid phase) is sent to OSBL LP Storage on flow control. A level controller in
OSBL LP Storage, sends a high level override to control the flow if the level gets too high. Higher levels of
rundown can be achieved during SCU turn down.
Tower reboiler duty is provided by two reboilers which permits the maximum cold recuperation from this
tower. In the kettle type Ethylene Fractionator Side Reboiler, E-24006, a liquid stream withdrawn from Tray
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#21 on flow control is vaporized by -10°C propylene refrigerant. A level controller in E-24006, sends a high
level override to control the sidedraw if the level gets too high. In the Ethylene Fractionator Reboiler, E-
24007, a portion of the bottom sump is vaporized by 9°C propylene frefrigerant. An analyzer controller
detects the ethylene content in the downcomer of Tray #17 and resets the flow controller on the propylene
refrigerant sent to E-24007.
The Ethylene Fractionator bottoms product, ethane recycle, is sent to the cold box on flow control reset by
the level controller on the tower bottom sump. In the cold box, the ethane recycle is heated and vaporized
in the Offgas Exchangers No. 5 and 6, ME-23000-E05/E06 before is recycled back to the feed heater
system.
On-line analyzers are provided on the overhead and bottoms product to ensure product specifications are
met.
7.17 MAPD Conversion
The Deethanizer bottoms is blended with an MAPD Converter recycle stream, and is cooled in the MAPD
Trim Reactor Feed Cooler, E-24008, by cooling water. The effluent from E-24008 is sent on flow control to
MAPD Converter, R-24001A/B. Hydrogen from the PSA is blended with cooled effluent from E-24008, on
flow ratio control relative to the Deethanizer bottoms flow rate. A temperature controller sets this combined
stream temperature to 38°C by controlling the amount of the Deethanizer bottoms stream bypasses, E-
24008, prior to entering the MAPD Converter, R-24001A/B.
The MAPD Converter, R-24001A/B, operates at a pressure of 23.7 bar(g) and is a trickle flow (downflow)
single trim reactor system which reduces the MAPD content in the effluent stream to less than 300 ppm.
The amount of hydrogen injected is just slightly above the amount required to saturate the MAPD so there
is not any need for a separator on the outlet. There is a distributor inside of the reactor to ensure that the
hydrogen is properly mixed. As the liquid reacts with H2 in the reactor a noticeable temperature rise of
15°C will occur, which leads to vaporization. A vapor product is removed from the bottom of R-24001A/B
on back pressure control and is sent to the Propylene Fractionator No. 1, C-24003. Maintaining back
pressure ensures the liquid in the R-24001A/B bottom sump has enough pressure to be sent to the C-
24003 on level control. A portion of the bottom liquid product from R-24001A/B is recycled back to the feed
by the MAPD Recycle Pumps, P-24004A/B which helps control temperature rise, and henceforth,
controlling the vaporization that occurs in the reactor.
On-line analyzers detect the MAPD, propylene, and propane on the feed and product sides of the MAPD
Converter. If too much hydrogen is added, the reactor may become less selective, so it is important to
closely monitor this during operation.
7.18 Propylene Fractionation
The following two towers work together as essentially one propylene fractionator:
C-24003: Propylene Fractionator No. 1 (127 trays)
C-24004: Propylene Fractionator No. 2 (99 Trays)
The feed to this system is effluent from the MAPD Converter which enters Tray #6 of Propylene
Fractionator No.1. The primary purpose of this upper tower is to produce 99.5 mol.% propylene product,
while the lower tower produces a high purity propane bottoms product which is recycled to the cracking
heater feed system.
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The top of Propylene Fractionator No. 1, operates at a pressure of 20.2 bar(g) and gross overhead vapor is
totally condensed against cooling water in the Propylene Fractionator Condenser, E-24009A/B/C/D, before
it enters the Propylene Fractionator Reflux Drum, V-24003. The tower overhead pressure is set by a “hot
vapor bypass”, where a portion of the gross overhead bypasses the condenser and is fed directly to the
reflux drum. Depending on the amount of material that bypasses the condenser, the operating pressure of
the reflux drum will change. By changing the pressure difference between the condenser and the reflux
drum, the liquid level in the condenser will expose or submerge more condenser tubes. A second pressure
controller in the gross overhead line which controls the amount of cooling water sent to the condenser. In a
high pressure scenario, a hand control can open a vent on V-24003 to the Cold Flare. A continuous vent
from V-24003 is cooled in the Propylene Fractionator Vent Condenser, E-24010, by cooling water where
any liquid that condenses is sent back to V-24003. Any non-condensables are sent on flow control to the
nd
Charge Gas Compressor 2 Stage Discharge Drum, V-22003. In a low pressure scenario, the pressure
controller on the gross overhead vapor line will cut back on the amount of vented to V-22003.
The liquid from V-24003, is pumped by the Propylene Fractionator No. 1 Reflux Pumps, P-24005A/B, and
sent as reflux to the top of C-24003 on flow control reset by the level controller on V-24003. A
pasteurization section is provided at the top of Propylene Fractionator No.1 to strip residual hydrogen
added in the MAPD Converter from the propylene. The propylene product (99.5% purity) is withdrawn as a
side draw from C-24003 Tray #115, and is pumped by the Propylene Product Pumps, P-24007A/B, and
sent to the Propylene Treater Feed Cooler, E-24017. A flow ratio controller controls this product side-draw,
maintaining a constant ratio to the reflux flow. This prevents the draw-off of off-spec Propylene Product.
Tower reboiler duty for C-24003 is provided by quench water sent to the Propylene Fractionator No. 1
Reboiler, E-24011A/B. The bottoms product of C-24003 is pumped by the Propylene Fractionator No. 2
Reflux Pump, P-24006A/B, on flow control reset by the level controller in the tower bottom sump as reflux
to the top of Propylene Fractionator No. 2, C-24004.
The top of Propylene Fractionator No.2, C-24004, operates at a pressure of 21.3 bar(g) and the overhead
vapor is sent to the bottom of Propylene Fractionator No. 1, C-24003. Tower reboiler duty for the C-24004
is provided by Very Low Pressure Steam (VLS) sent to the Propylene Fractionator No. 2 Reboiler, E-
24012A/B. An on-line analyzer detects the propylene content in the downcomer of Tray #35 and resets the
flow controller on the VLS feeding the reboiler. The tower bottoms product, primarily propane, is sent on
flow control reset by the level controller in the bottom sump to the C3+ Feed Preheater, E-20002, and then
the C3+ Feed Vaporizer Drum, V-20012, in the furnace feed system. A high level override from the level
controller on V-20012, can control the bottoms product rate if level gets too high.
On-line analyzers are provided on the overhead and bottoms product to ensure product specifications are
met.
7.19 Propylene Product System
Propylene product from P-24007A/B is cooled by cooling water in the Propylene Treater Feed Cooler, E-
24017, and mixed with propylene product from the RDG Depropylenizer before entering the PG Propylene
Treaters, V-24006A/B. In the Propylene Treaters, the polymer grade propylene product is treated for
reduction of COS to trace levels (<30 ppbw). The treated polymer grade propylene contunes through the
Propylene Product Filters, S-24001A/B and then is split into two streams. The first is a propylene rundown
stream of 2,000 kg/hr which is chilled by propylene refrigerant in the Propylene Rundown Chiller, ME-
24001. A temperature controller on the outlet of ME-24001 sets the temperature of the propylene rundown
to -37°C. The propylene rundown (in liquid phase) is sent to OSBL LP Storage on flow control at 4.0
bar(g). A level controller in OSBL LP Storage, sends a high level override to control the flow if the level
gets too high. Higher levels of rundown can be achieved during SCU turn down. The second stream
continues to OSBL HP Liquid Propylene Storage at 22.5 bar(g). Polymer grade propylene is pumped from
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HP storage to product conditions at 49°C and 29 bar(g). A provision is made for offspec propylene product
to be reprocessed in the Deethanizer, C-24001.
One PG Propylene Treater is in operation and operates at a pressure of 25.0 bar(g) while the second
treater is being regenerated or on standby. On-line analyzers are provided to detect the amounts of COS
entering and leaving the treaters. The treaters are designed to run for 48 hours before requiring
regeneration. The process of switching from one treater to the next is a timed cycle operation.
Regeneration of the PG Propylene Treaters is carried out by circulating hot methane-rich regeneration gas
from the Treater Regeneration Gas Electric Heater, E-24018, at 290-300°C to drive out the impurities
adsorbed in the treater bed. After the bed has reached the required temperature of 270-290°C, the bed is
cooled with unheated regeneration gas. The spent regeneration gas is returned to the fuel gas system.
7.20 Debutanization
The LP Depropanizer bottoms stream containing C4 and heavier material enters the Debutanizer, C-
24005, on Tray #17. Polymerization Inhibitor from the Polymerization Inhibitor Package, ME-22000, is
injected into the main feed to the Debutanizer to limit fouling in the tower. The Debutanizer is comprised of
43 valve trays and the primary purpose of this tower is to separate a mixed C4 product sent to the
Selective Hydrogenation Unit (SHU) from a C5+ raw pyrolysis gasoline product sent to the Pyrolysis
Gasoline Hydrogenation (PGH) unit OSBL.
The top of the Debutanizer operates at a pressure of 5.3 bar(g) and the gross overhead vapor from this
tower is totally condensed in the Debutanizer Condenser, E-24013, by cooling water before it enters the
Debutanizer Reflux Drum, V-24004. The tower overhead pressure is set by a “hot vapor bypass”, where a
portion of the gross overhead bypasses the condenser and is fed directly to the reflux drum. Depending on
the amount of material that bypasses the condenser, the operating pressure of the reflux drum will change.
By changing the pressure difference between the condenser and the reflux drum, the liquid level in the
condenser will expose or submerge more condenser tubes. In a high pressure scenario, a second
pressure controller in the gross overhead vapor line can open a vent on V-24004 to the Wet Flare. If any
non-condensables accumulate in V-24004, a hand control (HC) provides the ability to send this material
back to the Quench Tower, C-21003, for reprocessing. Total liquid from V-24004 is pumped by the
Debutanizer Reflux Pumps, P-24008A/B, and a portion is sent as reflux to the C-24005 on flow control.
st
The remaining overhead liquid product is sent to the SHU 1 Stage Feed Drum, V-28011, on flow control
reset by the level controller in V-24004, at 48°C and 7.0 bar(g). A provision is made to send this mixed C4
product to storage if the downstream SHU is down; the ability to inject TBC into this stream (to limit
polymerization) is provided from the TBC Inhibitor Injection System, ME-24002.
Tower reboiler duty is provided by Low Low Pressure Steam (LLS) in the Debutanizer Reboiler, E-
24014A/B. A temperature controller on Tray #3 sets the temperature by resetting the setpoint of the flow
controller on the LLS feeding the reboiler. The bottoms temperature of 130°C should be closely monitored
and controlled to limit fouling. The Debutanizer bottoms product, which is raw pyrolysis gasoline, is sent to
the OSBL PGH unit, on flow control reset by the level controller in C-24005 bottom sump. Prior to exiting
the SCU, the raw pyrolysis gasoline is combined with gasoline from the Quench Water Settler, V-21002,
and cooled in the Pyrolysis Gasoline Cooler, E-24015, by cooling water and leaves battery limits at 45°C
and 4.2 bar(g). A provision is made to send this product to storage if the downstream PGH unit is down.
Gasoline Polymerization Inhibitor from the Gasoline Polymerization Inhibitor Package, ME-21001, is
injected into the raw pyrolysis gasoline product. Also before sending the raw pyrolysis gasoline to the PGH
unit it will always pass through the Raw Pyrolysis Gasoline Coalescer Package ME-24003 to ensure that
there is no free water carry over towards the downstream PGH Unit.
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An on-line analyzer is provided to detect the top specification of the Debutanizer with measurements made
for C3 and C5 components. A second on-line analyzer detects C4 components that end up in the raw
pyrolysis gasoline product.
7.21 Propylene Refrigeration System
The Propylene Refrigeration system is a closed loop four stage system, which utilizes a steam turbine
driven centrifugal compressor. The system provides refrigeration at four levels: -40°C, -27°C, -10°C and
9°C.
The compressor discharge vapor is desuperheated and condensed by cooling water. The liquid propylene
refrigerant is subcooled against cold streams in the RDG, NGL, and SCU areas before being used at each
level. During normal operation, propylene vapor extracted from the compressor 2nd stage discharge is
condensed against the ethylene fractionator side reboiler.
Major propylene refrigeration users in the SCU are the ethylene fractionator condenser, the binary
refrigerant condenser and the HP and LP depropanizer condensers. Other users are the charge gas area
and demethanizer feed chilling.
The propylene refrigeration system also provides cooling to the RDG and NGL units.
7.22 Binary Refrigeration System
The binary refrigeration system is a two-component, constant composition mixed refrigeration system
composed of about 37 mol % methane and 63 mol % ethylene. It is a closed, three stage system utilizing
a steam turbine driven centrifugal compressor and dry mechanical seals. The system provides four levels
of refrigeration to the ethylene unit users from -40°C to -134°C. It supersedes the ethylene and methane
refrigeration systems of older plants.
The binary refrigerant (BR) compressor discharge vapors are cooled first against cooling water partially
condensed against three levels of propylene refrigerant and finally condensed against itself in the cold box.
The condensed BR is sub-cooled against demethanizer bottoms and further sub-cooled against highest
level BR. A portion of the sub-cooled BR stream is then let down to a lower pressure and fully vaporized by
the process users on each level. The remaining BR stream flows to the next lowest level where it is again
further sub-cooled and partially let down. Since the system has a constant composition, it is not subject to
the fluctuations in refrigeration temperature that can be the case with other mixed refrigeration systems.
Makeup ethylene liquid is provided from HP ethylene storage while liquid methane is provided from the
demethanizer reflux drum. In addition, ethylene vapor is provided from the LP ethylene product header
while makeup methane vapor is provided from the demethanizer reflux drum.
The binary refrigeration system also provides cooling to the RDG unit.
8.0 SELECTIVE C4 HYDROGENATION UNIT (SHU)
The mixed C4 feed from the SCU is processed in a three-stage Selective C4 Hydrogenation Unit (SHU) to
convert 1, 3-Butadiene (BD) to normal butenes with a high ratio of Butene-1 (B1) to Butene-2 (B2). In
summary, there are three stages of hydrogenation shown below:
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BD Concentration (wt)
Inlet Outlet
st
1 Stage SHU 29% 1.5 %
nd
2 Stage SHU 1.5% 300 ppm
3rd Stage SHU 300 ppm 10 ppm
st
8.1 SHU 1 Stage Reactor
st
A mixed C4 product from the Debutanizer, C-24005, is fed into the SHU 1 Stage Feed Drum, V-28011,
st
prior to being fed to the 1 Stage SHU Reactor. The total fresh C4 stream is then pumped by the SHU First
Stage Feed Pumps, P-28011A/B, to the SHU 1st Stage Reactor, R-28011A/B, where it is mixed with the
hydrogenated recycle before entry. The flow rate of the fresh C4 stream is controlled by the liquid level
controller on V-28011 which resets a flow controller. The recycle stream is fed on flow control. The recycle
stream reduces the butadiene concentration to 4 wt.% and thereby limits the temperature rise across the
reactor. The recycle stream temperature provides for temperature control of the SHU reactor inlet. The
conversion of butadiene achieved in the reactor is determined by catalyst activity, reactor temperature and
st
equilibrium. Hydrogen from the PSA unit is fed to the 1 Stage SHU reactor on ratio flow control to the
fresh C4 feed stream. The reactor has a distributor to ensure even distribution across the catalyst bed.
There are three types of chemical reactions which occur in the SHU; selective hydrogenation of butadiene
and acetylenes into n-butenes, hydro-isomerization of n-butenes between butene-1 and 2-butene, and
olefin saturation. Olefin saturation, however, is minimized due to the high reactivity of butadiene in relation
to the olefins.
Selective hydrogenation is an exothermic process and therefore causes a temperature rise across the
reactor. The heat of reaction is absorbed by the C4 stream as it passes downward through the catalyst bed.
st
The reaction product is then flashed in the SHU 1 Stage Separator Drum, V-28012. In the Separator
Drum, hydrogen, other light gases, and any C4’s vaporized by the heat of reaction are separated. The
st
flashed vapor is sent to the shell side of the SHU 1 Stage Vent Condenser, E-28011, which utilizes
cooling water to condense C4’s which flow by gravity back to V-28012. The off-gas from the cooler is sent
nd
on pressure control to the Charge Gas Compressor 2 Stage Suction Drum, V-22002. The pressure
st
controller on the off-gas is the control point for the 1 Stage SHU Reactor system pressure. If the
hydrogen does not contain sufficient inerts or is reacting to completion, a small amount can be directed to
the Separator Drum to assist in pressure control.
st
The liquid leaving the Separator Drum is pumped by the SHU 1 Stage Recycle/Product Pumps,
nd st
P-28012A/B, to either the 2 Stage SHU or as recycle to the SHU 1st Stage Reactor. The SHU 1 stage
st
effluent is cooled with cooling water in the SHU 1 Stage Recycle/Product Cooler, E-28013. The
st
temperature of the SHU 1 Stage effluent for either location is maintained by separate bypass temperature
st st
controllers. The SHU 1 stage effluent is recycled back to the feed on flow control. The SHU 1 stage
nd
effluent feeding the SHU 2 Stage is fed on flow control reset by level on the Separator Drum.
A gradual loss of catalyst activity will occur as the active sites on the catalyst become blocked by coke.
Regeneration of the catalyst is required when catalyst activity has dropped to the point when the reactor
st
outlet temperature exceeds the 1 Stage Reactor EOR conditions, when high reactor pressure drop
occurs, or with significant loss of selectivity. Regeneration requires the catalyst bed to be taken offline,
drained and purged of hydrocarbons, and heated with hot nitrogen followed by superheated steam. Air is
fed on flow control in the superheated steam to decoke the catalyst bed. A final nitrogen purge, which
contains a controlled amount of hydrogen, activates the catalyst bed by reduction. Regeneration of the
SHU catalyst is typically required after one year of operation.
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st
The C4 recycle-to-fresh feed ratio in the SHU 1 Stage System is kept constant from SOR to EOR at 10 to
1 on a weight basis.
During startup, a safe fluid (low olefin content) is circulated to bring the system up to the required operating
st st
temperature. The SHU 1 Stage Startup Heater, E-28012, located between the SHU 1 Stage Separator
st
Drum and the SHU 1 Stage Recycle/Product Cooler provides the required heat. The temperature of the
safe fluid is set by a temperature controller, which controls the amount of Saturated LLS sent to E-28012.
Once normal production rates are established, this heater is bypassed.
nd
8.2 SHU 2 Stage Reactor
nd st
The SHU 2 Stage Reactor, R-28021A/B, has a configuration very similar to that of the SHU 1 Stage
nd
Reactor, R-28011A/B. The major difference between the two is that the 2 Stage Reactor’s feed has a
much lower concentration of butadiene and therefore the exothermic temperature rise across the catalyst
nd
bed is smaller. The 2 Stage SHU Reactor reduces the concentration of butadiene in the feed from
approximately 1.5 wt% to below 300 ppmw.
nd st
The SHU 2 Stage Reactor feed is the SHU 1 Stage Reactor effluent mixed with hydrogen from the PSA
nd
unit and SHU 2 stage recycle. Hydrogen is added to the mixed feed stream using a flow ratio controller.
st
This flow ratio controller receives a signal from a flow indicator on the SHU 1 stage effluent stream. The
nd st
SHU 2 Stage effluent recycle stream is added on flow control to the SHU 1 Stage Effluent before the
hydrogen addition. The recycle stream is used to dilute the butadiene concentration at the reactor inlet to
about 0.5 wt.% and thereby limit the exothermic temperature rise. To provide the desired operating
nd
temperature for the reaction, the SHU 2 Stage Feed Heater, E-28021, can heat the reactor feed using
Saturated Low Low pressure steam (Sat LLS) if required. A temperature controller on the 2nd stage feed
resets the flow controller on Saturated LLS fed to E-28021. Control of the inlet temperature and hydrogen
ratio controls the butadiene conversion.
The exothermic heat of reaction heats the C4 stream as it passes downward through the catalyst bed. Like
st
the 1 Stage Reactor, there is a reactor distributor present to ensure even distribution across the catalyst
nd
bed. The reaction product is flashed in the SHU 2 Stage Separator Drum, V-28022. The vapor from the
Separator Drum, which contains some unreacted hydrogen, inerts, and any C4’s vaporized by the heat of
nd
reaction, is sent to the SHU 2 Stage Vent Condenser, E-28022, which uses cooling water in the tube
side. The off-gas from the cooler is sent on pressure control the Charge Gas Compressor 2nd Stage
Suction Drum, V-22002. The pressure controller on the off-gas is the control point for the SHU 2nd Stage
Reactor system pressure. If the hydrogen does not contain sufficient inerts or is reacting to completion, a
small amount can be directed to the Separator Drum to assist in pressure control.
nd
The liquid from the separator drum is then pumped by the SHU 2 Stage Recycle/Product Pumps P-
rd nd
28022A/B, either as product to 3 Stage SHU or as recycle back to the SHU 2 Stage Reactor, R-
28021A/B. Each effluent stream’s temperature is independently controlled using temperature bypass
nd
control around the SHU 2 Stage Recycle/Product Cooler, E-28023, which operates on cooling water in
the tube side. The SHU 2 stage effluent is recycled back to the feed on flow control. The SHU 2nd stage
nd
rd
effluent feeding the SHU 3 Stage is sent on flow control reset by level on the Separator Drum.
st
Just as in the SHU 1 Stage Reactor, a gradual loss of catalyst activity will occur as the active sites on the
nd
catalyst in the 2 Stage Reactor become blocked by coke. Regeneration of the catalyst is required when
nd
catalyst activity has dropped to the point when the reactor outlet temperature exceeds the 2 Stage
Reactor EOR conditions, when high reactor pressure drop occurs, or with significant loss of selectivity.
Regeneration requires the catalyst bed to be taken off line, drained, purged of hydrocarbons, heated with
hot nitrogen, and then with superheated steam. Air is fed on flow control into the steam to decoke the
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catalyst bed. A final nitrogen purge, which contains a controlled amount of hydrogen, activates the catalyst
bed by reduction. Regeneration of the SHU catalyst is typically required after one year of operation.
nd
The C4 recycle-to-fresh feed ratio in the SHU 2 Stage System is kept constant from SOR to EOR at 2 to
1 on a weight basis.
During startup, a safe fluid (low olefin content) is circulated to bring the system up to the required operating
temperature as is done in the SHU 1st Stage. Unlike the SHU 1st Stage, there is no startup heater. The
nd
heat input (if required) is provided by the SHU 2 Stage Feed Heater, E-28021.
rd
8.3 SHU 3 Stage Reactor
rd
The SHU 3 Stage Reactor, R-28031, has a configuration that differs from the previous two stages of
hydrogenation. The major difference is that there is no recycle of reactor effluent to mix with the feed. The
rd
3 Stage SHU Reactor reduces the concentration of butadiene in the feed from approximately 300 ppmw
to below 10 ppmw.
rd nd
The SHU 3 Stage Reactor feed is the SHU 2 Stage Reactor effluent mixed with hydrogen from the PSA
unit. Hydrogen is added to the mixed feed stream using a flow ratio controller. This flow ratio controller
nd
receives a signal from a flow indicator on the SHU 2 stage effluent stream. To provide the desired
rd
operating temperature for the reaction, the SHU 3 Stage Feed Heater, E-28031, can heat the reactor feed
rd
using Saturated Low Low pressure steam (Sat LLS) if required. A temperature controller on the 3 stage
feed resets the flow controller on Saturated LLS fed to E-28031. Control of the inlet temperature and
hydrogen ratio controls the butadiene conversion.
The exothermic heat of reaction heats the C4 stream as it passes downward through the catalyst bed. Like
the first two SHU stages, there is a reactor distributor present to ensure even distribution across the
rd
catalyst bed. The reaction product is cooled by cooling water in the SHU 3 Stage Effluent Cooler, E-
rd
28032A/B. Pressure control is accomplished in the system by controlling the amount of SHU 3 Stage
product leaves the system.
Just as the first two SHU stages, a gradual loss of catalyst activity will occur as the active sites on the
rd rd
catalyst in the 3 Stage Reactor become blocked by coke. Since no spare reactor is provided for the 3
Stage SHU, the ability to bypass this reactor is provided if regeneration is required. Regeneration of the
catalyst is required when catalyst activity has dropped to the point when the reactor outlet temperature
rd
exceeds the 3 Stage Reactor EOR conditions, when high reactor pressure drop occurs, or with significant
loss of selectivity. Regeneration requires the catalyst bed to be taken off line, drained, purged of
hydrocarbons, heated with hot nitrogen, and then with superheated steam. Air is fed on flow control into
the steam to decoke the catalyst bed. A final nitrogen purge, which contains a controlled amount of
hydrogen, activates the catalyst bed by reduction. Regeneration of the SHU catalyst is typically required
after one year of operation.
During startup, a safe fluid (low olefin content) is brought in to soak the catalyst.
9.0 DRAIN SYSTEM
Drain drums and pumps are common for both hot section and cold section of Steam Cracker Unit (SCU).
Drain system includes the following:
9.1 Hydrocarbon Drain Drum
Two Hydrocarbon Drain Drums, V-10001 and V-10002 are dedicated for SCU. The drums handle the
draining of equipment and piping containing hydrocarbon within SCU. In addition, V-10001 also receives
Page 39 of 41
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description – NGLT 1100, RDG 1200, SCU 2000 - 2600 S-S100-5223-002 0
and SLC4HY 2800
hydrocarbon from OSBL Hydrocarbon Drain Drum (V-83015). Hydrocarbon Drain Pumps (P-10001A and
P-10002A) pump the collected hydrocarbon to Quench Tower (C-21003). The drums are floating on the
flare header and equipped with LLP Steam heating coil to maintain the temperature inside the vessel and
prevent hydrocarbon getting viscous. The drums are swept with fuel gas to prevent concentration of toxic
gas. Hydrocarbon which is drained to the drums may contain benzene more than 5%.
9.2 Amine Drain Drum
One dedicated Amine Drain Drum (V-11053) is located in Amine Regeneration Unit (ARU). This drum
handles the draining equipment and piping containing amine solution in SCU. Amine Drain Pump (P-
11053) pumps the collected amine solution to Amine Regenerator Column (C-11051) via Lean/Rich Amine
Exchangers (E-11052A/B). The drum is swept with fuel gas to prevent concentration of toxic gas.
9.3 Caustic Drain Drum
Caustic Drain Drum (V-10005) handles spent caustic and fresh caustic from equipment and piping. Caustic
Drain Pump (P-10005A/B) pumps the collected caustic solution to Spent Caustic Oxidation Unit (SCOU).
The drum is swept with fuel gas to prevent concentration of toxic gas.
9.4 Quench Oil Drain Drum
Quench Oil Drain Drum (V-21006) handles the draining of quench oil from equipment and piping containing
hot oil within SCU. Quench Oil Drain Pump (P-21011A/B) pumps the collected quench oil back to Gasoline
Fractionator (C-21001). Steam coil is installed in the drum to maintain the temperature of the collected
quench oil. The drum is connected to Quench Oil Drain Drum Seal Pot (V-21007) and installed with
nitrogen blanketing.
9.5 Quench Water Drain Drum
Quench Water Drain Drum (V-10003) handles the draining of quench water from equipment and piping in
SCU. The drum also receives sour water from Pygass Unit and effluent from Flare Unit. Quench Water
Drain Pump (P-10003A) pumps the collected quench water back to Quench Tower (C-21003) or to Sour
Water Stripper Unit (SWS) in SOHAR refinery. The drum is swept with fuel gas to prevent concentration of
toxic gas.
10.0 UNIT FLARE KO DRUMS
Wet Flare KO Drum (V-10006) and Sour Gas Flare KO Drum (V-10008) are installed in SCU as unit flare
KO drums to handle the relief load before routing the load to the main flare KO drums. The function of unit
flare KO drum is to provide residence time for liquid discharge and to limit liquid carryover to the flare
header and main flare KO drum.
10.1 Wet Flare KO Drum
Wet Flare KO Drum (V-10006) handles wet, warm vapor relief loads from safety valves that are above 0°C
at atmpospheric pressure or, if the relieved flow contains significant amounts of water vapor. The vapor is
routed to the Main Wet Flare KO Drum (V-89001). Any liquid accumulated in the drum is pumped to
Quench Tower (C-21003) via Wet Flare KO Drum Pump (P-10006A/B). The drum is designed with split-
entry configuration to reduce drum diameter for large flow rates.
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Document Title: Document No. Rev:
Process Description – NGLT 1100, RDG 1200, SCU 2000 - 2600 S-S100-5223-002 0
and SLC4HY 2800
10.2 Sour Gas Flare KO Drum
Sour Gas Flare KO Drum (V-10008) handles wet, warm vapor relief loads from safety valves containing
H2S and CO2. The drum is mainly dedicated for Amine Regeneration Unit (ARU). In addition, a number of
relief loads from Refinery Dry Gas Unit (RDG) are also routed to this drum. The vapor is routed to the Acid
Wet Flare KO Drum (V-89008) in the main flare unit. Sour Flare KO Drum Pump (P-10008A/B) pumps any
liquid accumulated in the drum to Quench Water Drain Drum (V-10003), which eventually sends the water
to Quench Tower (C-21003). The drum is also designed with split-entry configuration.
Page 41 of 41
Petrochemical Plant Sohar Environmental Impact Assessment Report
Orpic and CB&I HMR #3817
Attachment 2: Chemical Reaction Kinetics for Steam Cracker Unit
G-S000-5240-003 HMR Consultants
June 2015 I
Lummus Petrochemicals
Client ORPIC 188081 ORPIC SOM SECTION 3 0
Project Liwa Plastics Project Project No Document Rev.
3.0 OPERATING VARIABLES & CONTROL
3.1 General Description
The following section highlights the important considerations involved in the
design and operation of the equipment and systems that Lummus Petrochemical
has specified for the cracking heaters.
Six (6) SRT VI cracking heaters are installed. Five heaters are normally in
operation and one heater is spare for decoke or maintenance. There are two
Ethane Heaters and four Flexible Heaters. Each heater consists of two radiant
cells, a common convection section, a steam drum, an induced draft (ID) fan, a
SHP steam vent silencer, two desuperheaters, a main transfer line valve, one
large decoke valve, and one small decoke valve. There are 8 radiant coils and 8
primary transfer line exchangers (TLE) for each Ethane Heater. There is one
secondary TLE per heater following the primary TLEs. There are 6 radiant coils
and 6 primary TLE’s for each Flexible Heater. There is no secondary TLE in the
Flexible Heater.
Each heater has two radiant cells with a common convection section in the
middle. There is one ID Fan and stack on top of the convection section. There
is one Steam Drum per heater.
Refer to Section 2 for information and description on the heater design, and the
BEP for the Basis of Design.
The Flexible Heaters are designed to crack all feeds, thus providing full
feedstock flexibility for easy operation. All heaters are twin radiant cell design
with common convection section, stack, and stream drum. The Ethane Heaters
are designed to optimize the cracking of ethane feed. Secondary TLE is
provided for the Ethane Heaters to maximize energy recovery. Flexibility is
provided for the Ethane Heaters to cocrack ethane and propane feed by partially
bypassing the secondary TLE. Additional flexibility is provided for the Ethane
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Heaters to crack C3+ feed by complete bypass of the Secondary TLE to
minimize fouling. The Ethane Heaters are not designed to process the liquid
C5/OLNG feed. The Flexible Heaters are capable of cracking mixed
ethane/C3+ feed. Ethane/Propane and Ethane/C3+ feed cocracking is based on
up to either 50% propane or C3+ feed with ethane.
The liquid C5/OLNG feed is cracked in 2 coils of one Flexible Heater at a
propylene/ethylene ratio of 0.62 w/w and a steam to oil (S/O) ratio of 0.5.
C3+ feed is normally cracked in two heaters plus 4 coils of a Flexible Heater at
0.4 S/O ratio and about 92.8% n-butane conversion.
Fresh Ethane feed and recycle ethane and propane are cracked in two Ethane
Heaters at 0.3 S/O ratio and 63% ethane conversion.
Feed Cracking Severity or S/O
Conversion
C5/OLNG 0.62 P/E 0.5
C3+ 92.8%nC4 Conversion 0.4
C2/C3+ Co crack 92.8%nC4 Conversion 0.4
(upto 50/50 w/w)
Ethane/Propane Co crack 63% C2 Conversion 0.3
(upto 50/50 w/w)
3.1.1 Convection Section
The convection section of the Ethane Heaters F-20001 and F-20002 contains
the following coil services (in order from top to bottom):
Upper Feed Preheat (UFP) coil,
Boiler Feed Water Preheat (BFWP) coil,
Lower Feed Preheat (LFP) coil,
Upper SHP Steam Superheat (USSH) coil,
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Lower SHP Steam Superheat (LSSH) coil
Lower Mixed Preheat (LMP) coil.
The convection section of the Flexible Cracking Heaters F-20003 through F-
20006 contains the following coil services (in order from top to bottom):
Upper Feed Preheat (UFP) coil,
Boiler Feed Water Preheat (BFWP) coil,
Lower Feed Preheat coil(LFP)
Upper Mixed Preheat (UMP) coil,
Upper SHP Steam Superheat (USSH) coil,
Middle SHP Steam Superheat (MSSH) coil
Lower Steam Superheat (LSSH) coil
Lower Mixed Preheat (LMP) coil.
The convection section is arranged in banks of horizontal tubes and is in the
middle of two radiant cells and is offset from the radiant section.
For the Flexible Heaters, the upper feed preheat (UFP) coil is used to preheat
and vaporize the liquid C5/OLNG feed and preheat the C3+ feeds Light gas
feeds such as ethane to the Flexible Heaters requirebypassing of the Upper
Feed Preheat Coils and part of the Lower Feed Preheat Coils due to low feed
preheat duty requirement of the ethane compared to the duty needed to vaporize
the liquid C5/OLNG feed. Refer to the Heater Datasheets for the specific usage
of the UFP coil for various feeds.
For each Flexible Cracking Heater, the hydrocarbon feed on flow control to the 6
individual coil passes is first heated in the Upper and Lower Feed Preheat
coils(except for the light gas feed like ethane bypassing the UFP as mentioned
previously) of the heater convection section. Dilution Steam is mixed with the
preheated feed from the Lower Feed Preheat Coil. The mixed hydrocarbon and
dilution steam feed is returned to the Upper Mix Preheat (UMP) Coil of the
convection section. The total mixture of hydrocarbon and steam is heated to the
crossover temperature in the Mixed Preheat Coils before entering the Radiant
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Coils via external crossover piping. The crossover piping from each convection
section coil feeds a single radiant coil inlet manifold at the top of the radiant
section. From the cross over manifold critical flow venturis are provided to
distribute the flow equally to the inlet tubes of the radiant coil. DMDS is injected
into the dilution steam header at the inlet to each heater before mixing with the
preheated hydrocarbon feed as required.
The Ethane Cracking Heaters have a total of 8 radiant coils per heater, four in
each cell and has one Secondary TLE per heater. The effluents from all primary
TLEs are combined and sent to the secondary exchanger.
Excess heat in the flue gas after heating the hydrocarbon and dilution steamg is
recovered in the convection section by preheating the boiler feed water in the
BFWP coil and also by superheating the SHP steam in the USSH and LSSH
coils. There is a Desuperheater for temperature control: one at the outlet of the
USSH before reentering the LSSH. The Desuperheater is required for
temperature control of the SHP steam, which otherwise may exceed the SHP
steam outlet temperature specification and to prevent the steam going below the
saturation point after BFW injection.
Each heater discharges flue gas into an individual stack. A motor-driven induced
draft fan is located in each stack. Draft in the heater is adjusted via a pressure
controller that manipulates the variable frequency drive (VFD) to control the
speed of the fan.
Thermocouples are provided at various locations in the convection section of
each heater to measure flue gas temperatures. These are approximate
measurements since the reading of the thermocouple can be impacted by
radiation affects. The temperature readings should be noted during normal and
decoking operations while the heater is new. Changes in operation that result in
flue gas temperatures which are higher than the design or significantly different
from the run averaged values, can result in damage to the tube supports and
convection tubes, and should be investigated.
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Client ORPIC 188081 ORPIC SOM SECTION 3 0
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3.1.2 Radiant Section
There are 8 radiant coils, 8 primary TLE’s and one secondary TLE in one Ethane
Heater and 6 radiant coils and six primary TLE’s in one Flexible Heater.
There are two radiant cells per heater. Each Ethane Heater radiant cell has 4
radiant coils. Each Flexible Heater radiant cell has 3 radiant coils.
Each radiant coil is composed of four two-pass 8-1 units. This 8-1 coil
arrangement is the same for both Ethane and Flexible Heaters. This results in a
radiant coil with a total of 32 tubes in the inlet pass and 4 tubes in the outlet pass.
The flow to one 32-4 radiant coil is controlled by one (HC) feed control valve and
one dilution steam control valve. The four outlet radiant tubes are combined and
fed to the Primary Transfer Line Exchanger (TLE). There is one TLE per radiant
coil.
The flow from one radiant coil inlet manifold (cross over) is equally distributed to
the multiple inlet tubes of the first pass of the radiant coils using critical flow
venturis.
The first pass inlet tubes are connected to the second pass outlet tubes via
contoured manifold. The manifold is placed in a trough in the radiant box. With
temperature (thermal expansion) and creep the coil freely moves. Free
movement of the coil is important to minimize bending and bowing of the coils.
This is discussed elsewhere.
Figure 3.1.2 – Radiant Coil Configuration
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3.1.3 Burners
The heaters are hearth fired supplemented with wall burners. The proportion of
the total firing for the wall/hearth burners is 25%/75%, respectively. The hearth
and wall burners are arranged symmetrically on both sides of the radiant coils.
All burners are capable of firing methane offgas (plant fuel gas) for normal
operation, natural gas as backup/startup fuel gas, as well as high ethane and
hydrogen as specified in the project design data.
It is expected that the same fuel gas composition will be sent simultaneously to
all heaters at all times, because the fuel gas is fed from a common fuel gas drum.
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The fuel gas flow is compensated by a continuous calorimeter measurement
(Wobbe meter) to maintain a constant firing rate for a given heater.
Coil outlet temperature (COT) is controlled via duty control cascaded to the
hearth fuel gas flow which will vary automatically to maintain the required total
fired duty for the feedrate loading and COT setpoints. The wall burners are base
loaded, therefore the hearth firing varies only the remainder of the required fired
duty.
Individual firing control is provided for each of the two radiant cells of a heater.
The COT control for the coils controls the firing of the corresponding radiant cell.
Large deviations between the firing rates between the two radiant cells should be
minimized.
3.1.4 Critical Flow Venturis
Multiple small diameter tubes are utilized in the first pass of the radiant coils of
each heater. Each first pass tube has a critical flow venturi at the inlet. The
venturis insure equal flow distribution to the inlet pass tubes fed by each
crossover pipe and each radiant inlet manifold.
The first pass pressure drop (excluding the venturi) is designed to be relatively
low for good selectivity to olefins. However, this makes the flow distribution very
sensitive to differences in flow resistance among the inlet tubes. As a result,
coke may be deposited unevenly among the tubes during the run cycle and
result in pressure drop differences and flow maldistribution which, in turn, can
cause further premature coking and reduced run length. Therefore, the two-pass
coil design uses a critical flow venturi at the inlet of each first pass tube to
counteract this effect and thus maintain even flow distribution at all times during
the run cycle.
The venturi is designed so that the throat velocity remains sonic (choked) from
Start-of-Run (SOR) to End-of-Run (EOR) for all anticipated operating conditions.
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Thus, the flow to each tube is accurately and uniformly controlled by the choked
throat. This design concept results in the pressure upstream of the venturi
remaining essentially constant from SOR to EOR for any given operating
condition. These are specially designed venturis machined with high precision
tools. For the 8 coil Ethane Heaters, the venturi throat diameter is 14.0 mm with
a tolerance of +0.0 / -0.1 mm. For the 6 coil Flexible Heaters, the venture throat
diameter is 15.2 mm with a tolerance of +0.0 / -0.1 mm.
For each 8-1 radiant coil grouping, there is a single pressure differential indicator
(PDI) to monitor the venturi pressure drop across one of the eight venturis.
Coupled with the pressure measured upstream of the radiant inlet manifold
(“crossover pressure”), it is possible to calculate and trend the PDI to upstream
PI ratio as an effective method to monitor whether or not the venturis are choked.
The gage pressure data from the PI should be converted to absolute unit in the
PDI to PI ratio. Unchoking of a venturi (PDI/PI abs. < 0.1) in any of the
groupings is one of the criteria for terminating the heater run cycle. Only one
PDI per grouping is necessary, since the inlet pass tubes experience similar coke
buildup under normal operation. Thus the PDI measurement across a single
venturi in each 8-1 grouping is, in theory, identical to other venturis connected to
the same bottom manifold.
The S/HC ratio should be increased if necessary to keep the venturi choked.
3.1.5 Primary Transfer Line Exchangers
The purpose of the Primary Transfer Line Exchanger (PTLE) is to cool the heater
effluent as rapidly as possible, which minimizes undesirable polymerization and
other tar forming reactions, and to recover energy by generating steam at super
high pressure level.
Effluent from one 32-4 radiant coil outlet is sent to one primary transfer line
exchanger. Each SRT VI Ethane Cracking Heater has eight (8) TLE’s, one for
each radiant coil. Each Flexible Cracking heater has six (6) TLE,s, one for each
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radiant coil. Temperature indicators and high temperature alarms are provided at
the outlet of each PTLE to monitor exchanger performance and to guard against
overheating that might cause damage to the PTLE and downstream transfer line.
The Primary TLE's are vertical exchangers of a special design. The hot cracked
gas enters the tube side via an internally lined inlet cone at the bottom of the
exchanger and flows upward. Super high pressure boiler feed water enters the
shell side via a distribution system at the bottom. The steam/water mixture flows
upward, co-current with the process gas. The steam generation circuit in the
riser and downcomer piping between the steam drum and Primary TLE’s is
designed to circulate water for partial vaporization (about 10% of the circulated
flow) by thermosyphon action, using static head from the steam drum located
above the TLE's as the driving force.
3.1.6 Secondary Transfer Line Exchangers
The purpose of the Secondary Transfer Line Exchanger (STLE) is to recover
additional heat from the Ethane Heater cracked gas effluents (tube side) by
preheating the mixed hydrocarbon/dilution steam (mixed feed) to the heaters
(shell side).
Each Ethane Heater has one Secondary TLE. The Secondary TLE is a vertical
heat exchanger that cools the cracked gas effluent (from the Primary TLE’s) on
the tube side and heats the mixed feed on the shell side. The effluents from the
eight Primary TLE’s of one heater are combined and sent to a Secondary TLE.
A bypass is provided for the mixed feed (shell side) around the STLE to limit the
tube side STLE outlet temperatures to minimize the condensation of heavy
components in the cracked gas which could foul the STLE. For EP co cracking,
the STLE should be partially bypassed to no less than 230 °C in the STLE outlet.
ORPIC SOM – SECTION 3.DOC Page 9 of 60
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For C3+ cracking, the STLE should be totally bypassed. For ethane cracking,
no bypass is required. The tarry material present in C9+ components condense
causing this problem. Therefore with higher fuel oil yield, bypassing the
secondary TLE outlet temperature also increases. The above values are only
suggested values for the design feed at the design conditions. When the fouling
is more severe than normal, increase the bypass flow rate.
3.1.7 Transfer Line Valve and Decoke Valves
The flow from the TLE section of each heater can follow two flow paths:
During normal cracking operation, the combined cracked gas effluent
from the TLE’s is sent through the Main Transfer Line Valve (TLV) and
then to the downstream recovery section via the main transfer line.
During steam/air decoking, the combined effluent from the TLE’s is
routed through the decoke valves (motor-operated Large Decoke
Valve and non-MOV Small Decoke Valve) into the decoke effluent
piping to the firebox.
During High Steam Standby, the effluent from the TLE’s can take
either flow path described above.
The motor operated Main TLV and the decoke valves (Large and Small DV) are
interlocked to prevent the accidental release of cracked gas heater effluent to the
atmosphere via the decoking line, or alternatively, the introduction of decoking
steam and air to the downstream recovery section. The Small Decoke Valve
(SDV) is operated via a mechanical link with the Main TLV. Using the SDV
permits its maintaining upstream pressure during switching to be sufficiently high
to prevent reverse flow from the main transfer line into the decoke piping system,
yet avoid overpressure of the main transfer line.
The mechanical linkage between Main TLV and SDV is designed by the valve
vendor such that closing the Main TLV will create adequate backpressure to
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prevent backflow of cracked gases from the main transfer line into the decoke
line. The switching must be done at High Steam Standby (HSS) flow rate. The
SDV, in fact, is sized to have choked flow based on the HSS flowrate. Therefore,
even if the Main TLV and SDV are simultaneously fully open, backflow of
hydrocarbon effluent from the main transfer line into the decoking system cannot
occur against the normal backpressure expected in the transfer line (downstream
of the Main TLV).
The Large Decoke Valve (LDV), in conjunction with the SDV, isolates the heater
from the decoke piping system during cracking operation, and provides the basis
for the main decoke line size to minimize erosion of this piping. The LDV is
interlocked and cannot be opened (in preparation for decoking after feed-out)
unless the Main TLV is fully closed, and conversely, the Main TLV cannot be
opened (in preparation for feed-in after decoking) unless the LDV is fully closed.
Operators should become completely familiar with the 3-valve interlock operation
and sequential movement of these valves before starting the heater. Refer to
the interlock summary table in the BEP.
A flat bottom eccentric reducer is provided upstream of the LDV (downstream of
the full-size takeoff tee from the main transfer line) to insure that coke particles
will be blown through the decoke piping into the decoke system, rather than
accumulate in front of the LDV. The decoke line slopes from the LDV towards
the low point in the decoke piping to the decoke system to minimize
accumulation of steam condensate.
Periodic steam purging through the two drain connections shown on the P&ID
during the High Steam Standby, Decoke or Shutdown modes of operation is
recommended to minimize the accumulation of material upstream of the both the
Main TLV and the LDV.
There are also continuous steam purges through the Main TLV, LDV and SDV.
Refer to Section 4 for detailed discussions on these steam purges.
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3.1.8 Quench Fittings
The cracked effluents from all heaters are collected and sent to gasoline
fractionator by a common transferline. Quench Fittings are installed in the
common transferline where the combined stream is cooled to the desired
temperature with quench oil.
The new plant shall have two main transfer lines to collect and direct the cracked
gas effluent from the outlet of the TLE’s for the six (6) Cracking Heaters (F-
20001 thru F-20006) to the Gasoline Fractionator. Each one of the two transfer
lines collects the cracked gas from three (3) Heaters and directs the flow to one
of two Quench Fittings M-21001A/B. Quench oil is sprayed into the gas causing
the cooling. The quench oil flow rate is controlled based on outlet temperature.
Too low outlet temperature will require high flow rate of quench oil. Too small
flow rate may produce high mixed temperature. At high temperatures, quench oil
itself can generate coke or tarry matter. Therefore optimum quenching is
recommended (+/- 5 °C of design outlet temperature).
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3.2 Process Variables and Operation
3.2.1 Introduction
A number of operating variables may be changed or optimized within the heater
design constraints such as firing rate, convection tube material limitation, and
radiant tube metal temperature. In addition other operating constraints such as
heater run length, coil pressure drop, Charge Gas Compressor suction pressure,
downstream equipment limitations and product demand also affect the
optimization.
The heaters operate under the following allocations for the design operating
case (Case 1) to achieve the required plant capacity:
KTA Ethylene per
Total P/E Heater Feed KG/H per
# Heater #Coils or %CONV (8000 hrs) Heater
C5/OLNG 0.33 2 0.62 42 19,089
C3+ 0.67 4 92.8% nC4 91 39,439
C3+ 2 12 92.8% nC4 126 54,575
Ethane 2 16 63% C2 211 50,880
Spare 1 12
Total 6 40
Refer to the Heater Performance Data Sheets in PDP for a more complete
summary of the detailed parameters.
.
3.2.2 Operating Variables and Controls
The main operating variables and controls for the cracking heater are:
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Operating Variable Control
Hydrocarbon Throughput Summation of individual pass
flows;
Total flow to each heater;
Flow control set by operator.
Conversion / Severity of Coil outlet temperature (COT) control via
Cracking adjustment to heater firing.
Coil-to Coil COT Differential COT control by individual
Difference pass flow rate adjustment.
Hydrocarbon Partial Dilution steam to HC feed ratio
Pressure (S/HC);
Coil Outlet Pressure (COP) by means
of Charge Gas Compressor suction
pressure control.
Coke Formation/Radiant Heater loading, severity, S/HC;
Tube Metal Temperature Burner firing pattern;
Sulfur injection.
Heat Input (Fuel Fired) Fuel flow (adjusted for Wobbe index)
Heater Draft ID Fan VFD Control
Excess Combustion Air Position of hearth burner dampers
(by common jack shaft);
Draft
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3.2.3 Feed Rate
The total feed rate to the cracking heaters is set by the operator based on plant
production requirements, with feed allocation not to exceed the design rate of
any heater.
Operating the heater at higher than design ethylene production rates can result
in short run lengths and/or exceeding design temperatures in the convection
section. In extreme cases, it can damage the heater.
3.2.4 Dilution Steam
Dilution steam is added to the hydrocarbon feed to control the partial pressure of
the reacting hydrocarbons. A lower hydrocarbon partial pressure results in a
higher yield of desirable products such as ethylene. Higher dilution steam rates
also reduce the radiant coil coking rate and the TLE fouling rate. Reducing
dilution steam will have the opposite effect. For each feed type there is a
minimum steam-to-oil ratio. Below this value is not recommended.
The dilution steam rate is usually expressed as a ratio of steam to hydrocarbon
(S/HC).
Operation at higher or lower than design S/HC is possible with the consequences
as noted above as well as impacts on equipment loading and energy
consumption.
The dilution steam rate also impacts the operation of the critical flow venturis on
the heaters. The limitations on venturi operation and heater turndown should be
considered before adjusting S/HC to lower than design values. The S/HC should
be increased as needed to keep the venturi choked (PDI/PI absolute ratio larger
than 0.1).
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Experience has shown that the optimum amount of dilution steam is dependent
upon the feedstock properties and cracking severity. The design quantity of
dilution steam selected for the heaters is shown below as weight ratios of the
feedstock rate.
Design Dilution Steam Quantity
Feedstock S/HC Ratio, kg/kg
C5/OLNG 0.5
C3+ or C2/C3+ 0.4
Ethane or C2C3 0.3
3.2.5 Sulfur Injection
Experience has shown that the injection of small amounts of sulfur into
feedstocks that are essentially sulfur-free will reduce the concentration of CO
and CO2 in the cracked effluent. Sulfur addition has also been shown to reduce
coking in some cases and carburization of the radiant coils.
The nickel and nickel oxides on the surface of the radiant coil promote a carbon
reaction with steam to produce CO and CO2. The catalytic action is greatest at
start of run with a clean tube. Generally dimethyl disulfide (DMDS) or dimethyl
sulfide(DMS) is used as sulfiding agent for gaseous feeds. All sulfur molecules r
crack to H2S in the pyrolysis coil. Sulfur reacts with coil metal and metal oxides
to form a protective coating. It inhibits the catalytic action of the nickel.
Even hydrocarbon feeds that contain sulfur may require addition sulfur (DMDS or
DMS) to passivate the metal. Amount of sulfur addition varies with feedstock, but
each feed must have a minimum amount. The lowest effective dose can be
found by experimentation. Start with a high sulfur injection rate at feed-in and
decrease the rate until the CO does not change significantly any more.
Experience dictates that this minimum amount is between 50 and 100 ppmw of
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contained sulfur. Figure 3.2.5 depicts the typical relationship between CO
production and sulfur concentration.
Figure 3.2.5
Relationship between CO production and sulfur concentration
The normal injection rate is 50 -100 ppm by weight of sulfur for feedstocks that
are very low in sulfur (C3,C4, light naphtha, condensate liquids) or are essentially
sulfur-free (C2, C3 or C2/C3 mixed gases). For feeds that already contain sulfur,
the injected amount of sulfur should supplement the feed sulfur content such that
about 50-100 ppm is always maintained.
Avoid injected sulfur rates of 200 ppmw and higher as these levels can lead to
sulfur attack and damage to the radiant coils.
The normal concentration of CO and CO2 in the heater effluent is about 0.07
and 0.02 wt%, respectively. Higher effluent levels of CO and CO2 indicate that
the sulfur concentration is insufficient and DMDS rate should be increased. A
calibrated analyzer should be used to verify the small amounts of CO and CO2.
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Some clients practice pre-sulfiding, which is the injection of 200 ppm sulfur
during HSS operation for up to 4 hours prior to feed-in. In these special cases,
pre-sulfiding can help suppress CO formation and possibly extend run length.
For this project front end acetylene converters are used. Therefore, CO to the
converters has to be limited. Hence, presulfiding must be done before oil-in.
The sulfur compound injected into the feed is typically dimethyl-disulfide (DMDS)
of which 68 wt% sulfur. Refer to Section 4 for more discussions on the DMDS
Injection System.
DMDS to the heater should be shut when there is no feed to heater unless
heater is being presulfided. Shutting the supply of DMDS to the decoking heater
should include shutting the manual valve(s) to make sure DMDS is not in contact
with the decoke air or dilution steam. The sulfur when mixed with decoke
air/dilution steam could be a corrosion problem for the radiant coils and
downstream decoke piping. Sulfur should not be discharged to the decoke
system to avoid acid gas emissions.
3.2.6 Conversion/Severity
In general, higher coil outlet temperature means higher conversion (or severity).
Conversion and severity are measured in various ways. Conversion or severity
measures how severely a feedstock is cracked.
Conversion is used as the measure of cracking for feedstocks composed of light
pure compounds such as ethane, propane, or butane. The conversion is
measured by the disappearance of the principle component being cracked. The
difference in weight between the amount of the principle component in the feed
and in the effluent is used to calculate the conversion.
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The heaters are designed for a conversion of 63% ethane when cracking ethane
feed. For the C3+ Mix, the heaters are designed for 92.8% n-butane conversion.
Operating at higher conversion is possible but this will decrease the run length.
Operation at lower conversion will increase the recycle flows. In commercial units
even for pure components conversion is difficult to measure. Therefore, often
severity as defined by the ratio of two effluent components is used. The famous
one is propylene to ethylene ratio.
When the feedstock is a complex mixture of heavier compounds such as
C5/OLNG, the conversion is measured indirectly using a severity indicator. While
several measures are possible, Lummus uses propylene to ethylene weight ratio
(P/E). For ethane cracking alone P/E ratio is not a good measure since the
amount of propylene yield in ethane cracking is very small. Instead of propylene
to ethylene ratio, one can use ethylene/ethane ratio to monitor the conversion.
For the ratio, methane, ethylene, propylene and ethane components are used.
Since these are light gases, almost all of them are present in the vapor phase
only. Therefore gas chromatographs, which are routinely used as on-line
analyzers measure the total concentration. Hence the ratios are reliable. When
heavier components like butene or butane are used, they will be present in vapor
and liquid phases when the sample is cooled for analysis. So analyzing the
vapor phase only will cause significant error. For control and measuring the
severity P/E is the preferred one. For ethane rich mixture cracking alone
ethylene/ethane ratio should be used.
When an OLNG feedstock is cracked harder (more severely, or higher severity),
the ethylene yield will increase and the propylene yield will decrease resulting in
a lower P/E value. The coking rate will become more rapid as severity increases
(lower P/E). At some point the coking rate will become too rapid resulting in
unacceptably short heater run lengths.
As severity is decreased (higher P/E), the ethylene yield will decrease and the
propylene yield will increase until the point of maximum propylene yield is
reached (typically near a P/E of 0.65-0.70 for OLNG). After this point both
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propylene and ethylene will both decrease. Operation at a severity below the
maximum propylene yield is typically not cost-effective for plant economics.
The following table shows the impact of increasing COT/severity/conversion on
all yields:
Component Naphtha or Ethane Propane
C5/OLNG
Hydrogen Increase Increase Increase
Methane Increase Increase Increase
Acetylene Increase Increase Increase
Ethylene Increase Increase Increase
Ethane Increase & then Decrease Increase & then
decrease Decrease
MA + PD Increase Increase Increase
Propylene Increase then Increase Decrease
decrease
Propane Decrease Increase Decrease
Total C4 Increase & Increase & Increase &
Decrease decrease decrease
Butadiene Increase and Increase Increase & then
then decrease decrease
Pyrolysis Decrease Increase Increase
Gasoline
Fuel Oil Increase Increase Increase
Conversion and severity are calculated using information from the heater effluent
analyzer. A typical analyzer (GC) will report only C3 and lighter components in
mole percent. The reported values are then converted to weight percent or P/E
weight ratio.
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Severity/conversion is influenced by:
Coil outlet temperature (COT)
Coil outlet pressure (COP)
Steam to hydrocarbon ratio (S/O)
Feed rate
Severity and conversion are controlled by changing the heater COT which has
the most significant impact. Increasing COT will increase conversion/severity,
and vice-versa.
The COT required for a given conversion or severity is influenced by the
operating conditions of the heater (COP, S/HC, etc.) and the feedstock
composition. Note that the COT measurement will be subject to certain factors
and errors that cannot be predicted by a simulation model of the radiant coil
performance. Therefore the COT required to achieve design severity or
conversion may be different from the value provided in the heater data sheets.
The severity or conversion should be assessed based on the analyzer readings
and the COT should be adjusted as required. The analyzer and sample system
should therefore be ready and calibrated for start up and maintained regularly.
In general COTs shown in the datasheets are 10 to 20oC hotter than the actual
value for the given severity. Therefore, always start at 20 to 25oC below the
target COT. After analyzing the effluents and confirming the severity only, the
COT can be increased. Also during this soft start-up, the heater has to be
physically inspected for any mechanical problems like bowing and burner
performance. At low temperatures malfunction of the equipment can be
corrected easily and the damage to the heater is minimum.
3.2.7 Selectivity
As discussed above, severity and conversion are a measure of how severely or
deeply a feedstock is cracked. Selectivity is a measure of the quality of cracking.
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At constant severity/conversion cracking, higher selectivity will yield more
desirable products such as ethylene, propylene, and butadiene. At the same
time the production of methane, fuel oil and aromatics are reduced.
Selectivity is a function of hydrocarbon partial pressure (HCPP) and residence
time (RT) in the radiant coil. As HCPP and RT increase the selectivity decreases,
and vice-versa.
Changes in RT and HCPP affect all types of cracking feeds but the effect on
yield for heavier feedstocks, such as OLNG, is much greater than the lighter
feeds such as ethane and propane.
The order of magnitude of RT is largely a function of the radiant coil design but is
relatively affected by:
Feed rate – as feed rate increases the RT decreases
S/HC – as S/HC increases the RT decreases
COP – as COP decreases the RT decreases
In practice, these changes are relatively small and have only a small impact on
selectivity once the coil type is finalized.
The selectivity is a much stronger function of HCPP, which is influenced by:
Feed rate – as feed rate increases the HCPP increases due to higher
pressure drop
S/HC – as S/HC increases the HCPP decreases
COP – as COP decreases the HCPP decreases
The S/HC can be varied to change selectivity. Increasing the S/HC increases
selectivity and the production of desirable products but also consumes more
energy and increases the loading on the heaters, gasoline fractionator, and
quench tower. Decreasing S/HC has the reverse impact and it increases the
coking rate.
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The S/HC can therefore be optimized based on economic factors and in
consideration of equipment constraints. Plants typically do not operate at lower
S/HC values while only a few have justified using a higher S/HC.
Decreasing COP results in a lower HCPP and improved yields. However, the
charge gas compressor (CGC) suction pressure must be reduced in order to
decrease COP, resulting in increased energy consumption and a higher loading
on the compressor. COP can therefore also be optimized based on economic
factors and in consideration of equipment constraints.
COP can be affected significantly by fouling of the radiant coils and TLEs. The
Lummus radiant coils and TLEs are designed to minimize pressure drop
increase over the cracking cycle, thus maintaining close to SOR yields
throughout the run cycle. However, upsets and coke spalling events can result in
increased COP. For example, coke that spalls from the radiant coil can partially
block TLE tubes and increase the COP.
3.2.8 Convection Section Heat Recovery
Only 40 to 45% of the heat released by the fuel in a cracking heater is absorbed
in the radiant section. This value is defined as the radiant efficiency. The
remaining heat in the flue gas is recovered in the convection section or lost to the
surroundings (as heat loss).
The purpose of the convection section is to:
Maximize heat recovery from the flue gases exiting the radiant section
Preheat the feed to the desired crossover temperature (XOT)
The overall thermal efficiency is a measure of the percent of fired duty (heat
input), which is recovered as useful heat. Usable heat is the sum of the heat
required to preheat the feed, BFW, SHP steam (superheat), dilution steam, plus
the heat absorbed by the radiant coils, which provide the heat of reaction for the
cracking products. By difference, the unrecovered or unused heat is the sum of
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the heat lost to atmosphere by the flue gas through the heater stack plus the
heat lost to the atmosphere through the casing and convection module (heat
leak).
The convection section is designed to maximize heat recovery. The simplest way
to monitor heater efficiency is by measuring the stack temperature.
Approximately an increase in stack temperature of 18°C indicates a loss of about
1 percentage point in efficiency. Note that increases in stack temperature can
result from other causes.
Heat loss through the casing walls is minimized by maintaining the insulation in
the radiant and convection sections.
The heat lost from the stack can be affected by:
Excess air
Heater loading
Feed inlet and/or BFW preheat temperature
Fouling of the inside or outside of the convection section tubes
Increasing the excess air results in additional flue gas flow and an increased load
on the convection section. As a result, the stack temperature and heat loss will
increase. Small increases in excess air will not result in significant changes in
efficiency in a modern high efficiency heater. Aggressive control of excess air
(low excess air) therefore does not typically yield large benefits. Operating below
10% excess air is discouraged as this can result in poor flame quality for some
burners and the heater damage from localized afterburning.
Increasing the heater feed rate will result in a decrease in efficiency, but the
impact will be small for up to about a 10% change in rate.
Increased feed inlet or BFW inlet temperature will reduce efficiency by reducing
the available temperature driving force for heat transfer (‘LMTD” or log-mean
temperature differential). The impact is minor compared to other factors cited.
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The largest impact on heater efficiency results from fouling. Fouling on the
inside of the convection tubes is generally not significant, unless the feed has
high boiling components. Fouling on the outside of the tubes results from debris
depositing between the fins on the tubes. The material that deposits is believed
to be largely from the atmosphere and brought in with combustion air via the
burners. Refractory dust, dust from decoking and oxidized material from the
radiant coil can also contribute to outside fouling.
There are several methods of cleaning the outside surface of the convection
tubes. All methods work better if the fouling is not allowed to stay in place for a
long time. After several years the material gets baked onto the fins and is much
more difficult or impossible to remove. Lummus should be consulted about the
best method for cleaning the convection section.
Convection section efficiency can also be affected by damage to the tube fins
caused by overheating. Damage can occur if the heater is operated:
At higher than design feed rates and or severities
With very high or low excess air
Fouled or poorly adjusted burners
Some overheating (short duration) can also occur during crash shutdowns.
Consistent overheating of the convection section will oxidize tube fins and
reduce efficiency. Overheating can also damage tube supports and bow tubes
greatly reducing their life span.
Thermocouples are provided at various locations in the convection section to
measure flue gas temperatures. These are approximate measurements since
the reading of the thermocouple can be impacted by radiation affects. The
temperature readings should be noted during normal operation and typical
decoking operation while the heater is new. Changes in operation that result in
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significantly higher temperatures can result in heater damage and should be
investigated.
The heater crossover temperature (XOT) is the temperature of the mixed
preheat stream exiting the convection section and entering the radiant section.
The optimum XOT is a temperature close to the temperature at which the
feedstock starts cracking (“incipient cracking”), but where the conversion is
insufficient to cause coking in the convection section and crossover piping.
For the design feeds typical maximum cross over temperatures are 660C for
C5/OLNG, 680°C for C3+ and 750oC for ethane. These maximum XOT’s are
recommended to prevent coking in the convection tubes. The mechanical
design temperature limit for the crossover piping is 760C. Exercise caution while
decoking since high cross over temperatures are noticed during decoking.
In operation, the XOT will be a function of the feed rate, S/HC,
severity/conversion, excess air, and the fuel gas composition.
Excess air has the most significant impact. Increasing the excess air will result in
a higher XOT, since more flue gas will be generated as a result of increased
firing in the radiant section.
Increasing the feed rate will also generate more firing, but since more feed is
preheated in the convection section, the result is that XOT is relatively insensitive
to feed rate.
Changes in fuel gas composition that result in a lower fuel heating value will
increase the XOT. For example, a change in the normal fuel gas composition
from 55% to 35% hydrogen (balance methane) results in a predicted XOT
increase of about 4-6°C.
The heater design philosophy precludes the need for XOT to be explicitly
controlled; rather it is set by designing for optimum heating surface utilizing the
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relative heat absorbed duties of the various process streams. Crossover
temperatures that are far outside the normal range can be indicative of excess
air maladjustment, convection section fouling (tube side and/or flue gas side) or
burner problems. These should be addressed on a high priority to resolve the
differences.
Air can leak into the convection section wherever there are penetrations as such
where BFW enters the preheat coil, where the crossovers exit the convection
section, etc. The cold air that leaks into the heater will reduce the temperature of
the flue gases and increase the mass of flue gas to be processed in the
convection section. Air leakage therefore reduces heater efficiency and
overloads the ID fan. Care should be taken to maintain the seals at all potential
leak points. Comparing the oxygen concentration at the bridge wall (arch) to that
at the stack exit can provide a quantitative measure of leakage in the convection
section. Ideally the stack oxygen concentration should be no more than 0.5%
greater than the bridge wall concentration (make sure that both measurements
are on the same basis, i.e., wet or dry). It is recommended to control the heater
based on excess oxygen measured around bridge wall since the leakage is
minimum. Additional air ingressed in the convection section is not seen at the
burners. This will avoid low excess ( below stoichiometric) oxygen at the burners.
3.2.9 Effluent Cooling and Quenching
3.2.9.1 Primary Transfer Line Exchanger (PTLE)
The PTLE rapidly quenches the heater effluent exiting the radiant coil so that the
undesirable secondary reactions are minimized and the selectivity to olefins is
maximized. The important operating parameters of the TLE are discussed below.
a) PTLE Tube-side Heat Transfer / Outlet Temperature
Heat transfer in the PTLE is a function of the amount of fouling that occurs
during the run cycle. Maximum heat transfer occurs at start-of-run (SOR) when
the radiant and TLE tubes have just been cleaned.
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The expected SOR temperature at the PTLE outlet is about 360 - 370C for the
Ethane Heaters cracking ethane normally. When the Ethane Heater is cracking
C3+ (non-normal operation), the PTLE outlet is about 390 - 400C. The
expected SOR temperature at the PTLE outlet is about 350 - 360C for the
Flexible Heaters.
As the run progresses, fouling in the tubes occurs and reduces the heat transfer
and also increases pressure drop. It is very unlikely that the maximum primary
TLE outlet temperature is reached during normal operation. This temperature
will depend on the feedstock and cracking conditions.
The maximum PTLE outlet temperature limit for the Ethane Heaters is 454C
and for Flexible Heaters is 525C. This mechanical design limit must not be
exceeded because it is the basis for material selection of the PTLE and
downstream transfer line. Temperature indicators are provided at the outlet of
the PTLE’s with high temperature alarms. If the mechanical design temperature
is reached, the run should be terminated, and the heater and PTLE should be
decoked.
The heater PTLEs should be cleaned using the TLE online air-polishing step
after the radiant coil decoke is completed. If the air-polishing procedure fails to
return the SOR PTLE temperature to within 10°C of design, the PTLE should be
mechanically cleaned.
As the run cycle progresses, fouling inside the PTLE tubes occurs due to the
condensation high molecular weight components and this reduces the heat
transfer. The fouling for C3+ feed cracking may not be as severe as the
C5/OLNG case. Ethane and propane crackings also result in deposits of coke
on the hot PTLE inlet tubesheet, but much less inside the tubes. If not removed
by decoking or mechanical cleaning, these deposits on the tubesheet can result
in partially or fully blocked TLE tubes, resulting in decreased heat transfer and
increased pressure drop in the exchanger. The rate of fouling can vary
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depending on the composition of the gas feed and heater operating conditions
over the cycle.
b) PTLE Steam (water) Side
Maintaining boiler feed water quality to specifications is absolutely essential to
the proper performance and mechanical integrity of the PTLE and to the entire
steam system. SHP Water quality requirements are tabulated in the
PTLE/Steam Drum Process Specifications. Any values outside the minimum
specifications should be reviewed by the PTLE/Steam Drum vendor prior to long
term operation.
The PTLE vendor’s requirements for water quality should be strictly adhered to.
Refer to PTLE Specification.
It is important to maintain water inventory on the steam/water side of the primary
TLE to prevent overheating of the tubes during all modes of operation. The
steam drum and PTLE should be inventoried prior to firing off the heater. Even a
small flow of hot air in a dry TLE during start-up could damage the exchanger.
When decoking the heater, circulation on the steam/water side of the PTLE will
be maintained because the steam drum is operated at design pressure level.
During decoking, steam will continue to be generated at the SHP level and be
superheated in the convection coils, but to a lesser quantity than normal cracking
operation.
c) PTLE Channel Blowdown
Inlet channel steam-side blowdown connections may be provided on the
exchanger. Refer to the specific vendor’s operating manual regarding the
frequency and duration of their use. Some vendors do not recommend any
blowdown of the PTLE at normal operating conditions, while other vendors
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recommend regular (up to once per shift) blowdown to clear the deposition of
solids( water side) on inlet tubesheet. Usually the duration of PTLE blowdown is
very short, lasting less than 15 seconds.
3.2.9.2 Quench Fittings
Quench Fitting
For the Quench Fittings, quench oil from the bottom of the gasoline fractionator
is used to quench the cracked effluent before being routed to the gasoline
fractionator. This quench fitting uses a special arrangement of multiple full-cone
spray nozzles that cool the effluent uniformly within a short distance without
fouling the nozzle and without fouling the downstream transfer line.
Refer to Section 4.4.1 for details of the Quench Fitting, including design,
operation, turndown, temperature control and high temperature interlock
associated with this fitting.
3.2.10 Burners
The operator should refer to burner test flux profiles measured by the vendor.
These tests simulate the particular combination of hearth and wall burner
designs selected for the heaters.
The hearth burner tip design, burner position (orientation) and cleanliness have a
major impact on the heat flux profile in the radiant section.
The hearth burner is a flat-flame (fan-shaped) design which is required due to
the close proximity of the radiant tubes to the wall. The freestanding flame is
directed upwards and towards the radiant section wall to heat the refractory,
which in turn radiates heat to the radiant coil. The hearth flame should never be
directed towards the radiant tubes.
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The hearth burners consist of two stages of fuel release. The fuel is released
from primary tips and secondary tips, which are necessary to achieve low NOx
emissions. NOx formation is inhibited by producing a “cooler” flame, which for
staged burners is a result of entraining flue gas from the firebox and delaying
combustion of a certain amount of the fuel released. This “secondary“ fuel is
burned at a slightly higher elevation just above the corresponding primary burner
tips of the same burner, which cools the flame. As a consequence, a low NOX
staged burner profile will exhibit lower flux near the bottom of the heater
compared to higher elevations. For the burner design selected, hearth burner
flames result in lower heat flux near the bottom and top of the firebox and higher
flux in the middle.
Low NOx staged burners are sensitive to plugging and air supply and therefore
require particular attention and monitoring by the operator.
The hearth burner tip is typically characterized by a patterned array of small
openings (holes and/or slots). The openings and orientation of the burner tip
relative to the coils and the refractory walls are unique design parameters that
are necessary to obtain proper flux distribution, flame height and low NOx.
These tip holes should not be drilled out, enlarged, plugged, or otherwise
modified, as the flame pattern and NOx emissions will change. Special attention
should be given to ensuring the tips are oriented properly during installation or
replacement.
The small openings at the tip mean a greater tendency for fouling due to pipe
scale in the fuel gas piping or contamination of the fuel gas by heavier polymer
forming components. Fouled burners will be evident by visual inspection through
the heater peep doors and will cause poor flux profile and uneven and
incomplete combustion. Malfunctioning burners must be cleaned as soon as
possible. The burner tip is kept cool as long as a good flow of air and fuel is
maintained. A completely plugged floor burner tip will be badly damaged or
destroyed by the heat release from neighboring burners in a very short time.
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Each hearth burner is equipped with a combination of primary and staged burner
tips. Selected staged burner tips are piped up to the secondary fuel header to
allow fuel to these burner tips to be shut during partial trips, high steam standby
and decoking operation. Typically at least one (actual number to be confirmed
with burner vendor) staged burner tip per burner is piped with the fuel supplied to
the primary burner tips, because the primary burner tip capacity is not large
enough to handle the firing duty required during partial trip, high steam standby
and decoking heater operation. Each hearth burner is provided with a manual
shutoff valve for the primary tips (plus one secondary tip, to be confirmed by
burner vendor), the secondary tips, and the pilot gas.
The wall burners help improve the heat flux of the upper portion of the firebox.
The wall burners are used in combination with the hearth burners to optimize the
radiant heat flux profile from floor to arch and thus insure good operation.
Burner Maintenance
Individual burners can be removed one at a time, cleaned and replaced without
shutting down the heater. A cleaned burner should be reinserted and secured to
the correct position and alignment. Always burner vendor instructions have to be
followed. Refer to Section 6 for burner lighting procedures.
Partial Trip
The heater design provides for a partial heater trip mode to low firing on High
Steam Standby. The partial trip capability minimizes the frequency of heater
shutdown incidents, thus preventing thermal shock to many critical heater
components (tubes, refractory, and supports). Hearth burner firing is reduced to
about 25-40% of design by tripping the staged fuel tips connected to the
secondary fuel gas header (refer to Section 3.2.3.4).
3.2.11 Draft
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The cracking heaters are designed to operate at a slight negative draft of as little
as 2.5 mm of draft (minus 2.5 mm of water gauge pressure measured at the arch
location at the top of the radiant section just before the transition to the
convection section). Higher draft will increase air leakage and reduce heater
efficiency but this will not be significant in a well-sealed heater. Too low a draft
setting, however, can create positive pressure in the radiant section which is a
hazardous condition. Outward leakage of hot flue gas can damage the heater
casing, and can cause injury to personnel particularly when peep doors are
opened.
Operating with a minimum draft setting of 5 mm at the arch is generally
recommended, as it will make the burner flame more stable especially under
windy conditions. Higher draft settings of 8 to 12 mm (usually high excess air)
may be used to extend a run cycle for a few days to avoid immediately shutting
down the heater for decoking at EOR TMT by improving the burner firing for a
better heat flux profile which can result in longer run length. The hearth burner
air dampers will need to be closed more to keep the excess air/O2 at the same
level with the higher draft. Close monitoring of TMT (daily) and visual inspection
for hot spots are required. When TMT reaches EOR TMT, the heater has to be
shutdown and decoked.
A pressure controller measures the firebox pressure at the arch (at the radiant-
to-convection section transition) and adjusts the induced draft fan speed to
maintain the draft setpoint.
3.2.12 Excess Combustion Air
The hearth burners are the raw gas type, meaning that combustion air is pulled
into the burner corresponding to the draft and air damper setting.
The wall burners self inspirate the primary air with the fuel gas. They are
designed so that air flow self-adjusts to changes in fuel flow and draft. The
primary air doors for all of the wall burners should be initially adjusted individually
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with the secondary air doors closed. If insufficient air is available with the
primary air door(s) full open, the secondary air door(s) can be opened. The
adjustment of the air is done by observing the flame while adjusting the air doors
to give non-luminous flame with the minimum air to the burner at normal firing
conditions
Excess air is that amount of combustion air above the theoretical stoichiometric
quantity to ensure complete combustion of a given fuel. Excess air is typically
10% minimum for gas firing.
While it is often desirable to operate at the lowest excess air possible, excess air
significantly below 10% can lead to an unsafe condition. For lower than 10%
excess air operating target, more operator attention is required to keep
satisfactory individual burner performance. It is extremely important that all
burners receive adequate combustion air. If air to any single burner falls below
that required for complete combustion, the unburned fuel will find the necessary
oxygen for combustion at random points in the heater, possibly far from the
burner. This after-burning is a major cause of poor heat flux profiles, local hot
spots and high TMT’s. Though each burner is manufactured to tight tolerance, in
the heater setting identical performance can’t be expected. Therefore, to avoid
substoichiometric combustion in any burner, Lummus recommends 10%
minimum excess at the arch level.
The excess air is monitored by use of a flue gas oxygen analyzer. With a proper
draft control established at the arch, the flue gas should contain about 1.7 vol%
oxygen (wet basis) or 2.1 vol% oxygen (dry basis) corresponding to 10% excess
air when firing the (most) design fuel gas. When the analyzer is not located at
the arch level, suitable correction has to be applied for equivalent arch value.
Often more than one excess oxygen values are analyzed. The average value will
be used for control. The deviations from the average can be used to judge
burner performance in those corresponding locations.
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Each hearth burner is provided with an air damper. Hearth burner air dampers
on each side of the heater are linked to a common jackshaft mechanism. Each
radiant cell of a heater has two jackshafts; one on each side running the length
of the radiant cell. Rotation of the jackshaft via a pneumatically-controlled
actuator by a manual HC (one for each jackshaft) from the operator console
simultaneously sets the opening of all connected hearth air dampers. Typically
the two jackshafts on both sides of a heater are set identically. The position of
the jackshaft is calibrated to the individual damper positions during heater
commissioning to compensate for damper-to-damper linkage differences, and to
verify the proper settings for a given heater capacity. The jackshaft system is
primarily used to automatically close the dampers upon partial trip to High Steam
Standby conditions, thus minimizing the combustion air and preventing
overheating of the convection section. The jackshaft system is also used to
manually reduce air flow to a preset position during decoking and High Steam
Standby, or to increase air flow for a high firing (rated capacity) condition. It is
not recommended, however, to automatically control excess air to the burners
using the jackshaft.
It is not possible to vary the position of an individual damper different from the
jackshaft setting. Each damper cannot be disconnected from the jackshaft.
3.2.13 Coke Formation
Coke is an unavoidable cracking reaction byproduct that gradually collects on the
inner tube surfaces of the reaction coils. As coke accumulates, the increased
resistance of the coke layer to heat transfer results in increased Tube Metal
Temperatures (TMT). Once the TMT limit is reached, the heater must then be
taken off-line and decoked.
Decoking refers to the process of removing the coke buildup via combustion by a
mixture of steam and air as it flows through the tubes (radiant coil and TLE).
Radiant coil coking is a function of:
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Feedstock type and quality
Cracking conditions
Burner performance
Radiant coil maintenance
Stability of operation
Feedstock type and quality
Coking rate is a function of feedstock type. Ethane and lighter feedstocks will
have different coking rates than OLNG.
The quality of the feedstock is also important. Feedstocks of all types sometimes
contain impurities that can impact coking rates. Coking rates can be increased
by impurities such as:
Chlorides
Fluorides
Hydrofluoric and other acids
Iron oxides
Potassium
Metals (e.g., vanadium)
Sodium
High boiling compounds (coke precursors)
All of these and potentially other compounds can accelerate coking substantially
if present in sufficient quantity. Sodium has been found to be the most significant
coking accelerator.
A minimum sulfur content of 50 to 100 ppmw in the feed is generally acceptable
and is required to avoid accelerated coking. If sulfur levels are lower than 50
ppmw, sulfur must be added to the feed.
Cracking Conditions
Coking rate can be varied by changing cracking conditions. Higher coking rate is
caused by:
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Increase in severity/conversion
Increase in coil outlet pressure
Decrease in S/HC ratio
Increase in feed rate
Burner Performance
Burner performance is critical to minimize coking rate and maximizing run length.
Burners must be installed correctly, maintained properly, and operated
consistently and, most times, uniformly. They must be cleaned properly so that
all tips are working properly.
Depending on the fuel type used and impurities contained in the fuel, burners
can foul over time. Fouling results in plugged fuel ports and distorted flame
patterns. The distortion of the flame pattern can result in poor flux profiles and
hot spots on the radiant tubes. Hot spots will accelerate coking and potentially
damage tubes.
Excess air supply is also critical in maintaining proper burner performance.
Operation at too low excess air rates (below 10%) can result in some burners
operating below stoichiometric air requirements. This results in unburned fuel
drifting away from the localized burner combustion zone. This unburned fuel can
potentially ignite near the tubes causing hot spots.
Radiant Coil Maintenance
Radiant coil condition can have a dramatic impact on coking rate. Anything that
damages the radiant coil surface can accelerate coking rates. The primary
causes of radiant coil surface damage are:
Feedstock impurities:
Feedstocks with impurities, especially those listed above, should be
avoided.
Overheating:
Coils should never be overheated above their respective design
temperatures (refer to heater data sheet 2a) particularly exceeding
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1150°C. The firebox temperature should never be increased by more
than 100°C per hour, which can cause tube metal temperatures to
increase too rapidly. The coil outlet temperature (COT) should not be
changed rapidly and should never exceed 900°C.
Rapid changes in temperature:
Crash shutdowns should be avoided by providing reliable feed and utility
supplies.
Tube aging, distortion, and welding:
The heater coil hanging system should be installed correctly, set up
correctly and maintained to avoiding bowing and other tube distortions.
Large tube distortions can result in increased metal temperatures and hot
spots. Poor field welds (and surface preparation) can also result in local
areas which are susceptible to higher coking rates.
Dilution steam quality has to be monitored carefully. Sodium carry over
will result in coil damage. Damaged coil reduces the heater run length
significantly. Often coil replacement may be the only solution to restore
the run length. Such carry overs have been reported after plant start-ups
and upset conditions. Especially end heaters are vulnerable.
Stability of operation
Changes in operating conditions should be minimized. Changes in feed rate,
severity, and other conditions tend to accelerate coking resulting in shorter run
lengths. The difference in run length between heaters operated at constant feed
rate compared to those where feed rates are changed every few days is often
dramatic. Rapid changes have significantly worse impacts on run length.
Changes in operating conditions will result in changes in tube metal
temperatures. Reductions in the temperature of the tubes result in contractions,
where coke deposited on the inside of the tubes can break off as the tubes
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contract. This phenomenon is known as spalling. Spalled coke can partially block
the radiant tubes or TLE tubes, causing an increase in pressure drop. A rapid
increase in pressure drop is, in fact, an excellent indication that spalling has
occurred. Spalling is more significant in ethane cracking, especially at high
conversion, because the coke is harder. OLNG coke is softer and tends to break
up and pass through the radiant coil and TLE. For this and other reasons cited
above, rapid changes in operation during a run should be avoided.
3.2.14 Decoking
Periodically, the heater must be taken out of service to remove coke from the
radiant tubes and polymerization/condensation products from the TLE’s.
Decoking of the radiant coils and primary TLE’s is accomplished by a special
on-line procedure. The decoking procedure is based on the Lummus Decoking
Technology, which uses both steam/air cleaning and then an air polishing step
at the end.
Decoking is performed after the heater is lined out in the High Steam Standby
mode of operation by withdrawing the hydrocarbon feed and isolating the heater
from the downstream plant transfer line. Decoking air, along with the decoking
steam, is fed into the heater to a controlled outlet temperature (approximately
850-870°C) to "burn off" the coke.
The decoking procedure is designed to clean the radiant coils in a carefully
controlled manner. Burning of the coke forms carbon oxides (i.e., CO and CO2).
The steam/air decoking reaction is exothermic and hot spots can develop along
the radiant coil tube walls. Care must be taken during decoking to limit the
radiant coil TMTs to avoid damaging the tubes. The maximum outlet TMT during
the decoking procedure should be limited to 1025°C-1050°C. This allows for
localized burning in other parts of the coil which may not be noticed, such that
the TMT does not exceed the design value of 1125°C.
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The decoking effluent is sent through the TLE's and to the firebox. Any coke
particles in the effluent will be burned in the firebox.
The recommended flow rates of steam and air for decoking of each heater type
are described in the decoking procedure in Section 8.
The heater run length should be terminated and the heater decoked if any of the
following conditions occur:
The average of the maximum radiant tube metal temperature (TMT) for
the outlet tubes exceeds 1115 °C, corrected for reflectivity using the chart
provided in this supervisory operating manual or using a pyrometer
designed to measured emissivity and make corrections to the measured
TMT.
The outlet temperature of any heater TLE exceeds 454°C for Ethane
Heaters and 525°C for the Flexible Heaters.
When the venturi pressure drop decreases to less than 10% of the venturi
upstream pressure (in absolute units).
When a heater is shutdown or tripped under emergencies after 5 days of
operation (cracking).
The heater should never be operated more than 60 days of cracking
hydrocarbons. Longer operation can result in heavy coking of radiant coils and
/or TLEs and can result in difficulty in decoking. When the radiant coil is heavily
coked it may be necessary to increase the duration of the decoking procedure,
as discussed in Section 8. Often subsequent run lengths after a long run length
are short.
The maximum allowable crossover temperature during decoke operation should
not exceed the design limit of the radiant inlet manifold and crossover piping
(760°C).
The TLE’s will need to be mechanically cleaned if:
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a. A rapid pressure drop increase occurs across the TLE that does
not return to normal with TLE polishing. This is usually due to coke
spalling which blocks some tubes;
b. When a TLE outlet temperature does not return to within 10 to
20°C of the theoretical clean SOR outlet temperature after heater
decoking;
c. When a TLE cannot be successfully cleaned by the decoking
procedure, i.e., the TLE pressure drop at feed-in is more than 0.03
to 0.04 bar above its theoretical SOR pressure drop.
Extreme caution should be exercised during decoking to firebox. The dilution
steam quality must be absolutely free of hydrocarbons. Make sure the dilution
steam generators are working properly. Any hydrocarbon carryover with dilution
steam has melted the furnace. If dilution steam is suspected of contamination of
hydrocarbons, use MP steam in place of dilution steam. During cracking, oil
contaminated dilution steam is acceptable since it will be cracked with feed.
However, during decoking it adds to the fuel (without the knowledge of the
operator) and the control system may not detect this.
3.2.15 Heater Kinetics
Basics
The cracking of feed to yield ethylene and byproducts results from the
summation of numerous endothermic reactions. Hundreds of free radical and
molecular reactions occur even when cracking relatively simple gas feeds.
A free radical reaction involves one or more neutral species that has an unpaired
electron. An example free radical reaction is:
H C2 H 4 C2 H 5
where hydrogen radical combines with ethylene molecule to form ethyl radical.
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Molecular reactions of the type shown below also occur:
C2 H 6 C2 H 4 H 2
C3 H 8 C3 H 6 H 2
In the radiant coil thousands of reactions take place. The overall reaction is
endothermic (consuming heat). For illustration purpose only some simplified
reactions are shown.
Conversion
Some typical reactions involved in ethane cracking are given below ( as an
example):
C 2 H 6 2 CH 3
CH 3 C 2 H 6 CH 4 C 2 H 5
H C 2 H 6 H 2 C 2 H 5
Each of these reactions consumes ethane. Ethane conversion increases as the
rate of these reactions increase. Typical rate equations and constants for these
reactions are given below:
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r1 k1 C2 H 6 k1 4.0 x1016 exp
87,500
RT
16,500
r2 k 2 C2 H 6 CH 3 k 2 3.8 x1011 exp
RT
9,700
r3 k3 C2 H 6 H k3 1.0 x1011 exp
RT
Where
C 2 H 6 = ethane concentration in moles per volume
k = rate constant
r = reaction rate
R = gas constant
T = temperature, °K
all in appropriate units
The table below shows the rates for these three reactions at three different
temperatures:
Rate @ 700 °C @ 800 °C @ 900 °C Ratio of
Constan k at 900 °C
t to
k at 700 °C
k1 8.78 x 10-4 5.97 x 10-2 1.97 2200
7 8 8
k2 7.46 x 10 1.65 x 10 3.20 x 10 4.3
k3 6.62 x 108 1.06 x 109 1.56 x 109 2.4
As the temperature increases, the reaction rates increase indicating that ethane
conversion increases with temperature. In addition, the reaction rate for k1
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increases much more rapidly than others. Reaction 1 is called as initiation
reaction. Operation at high coil outlet temperatures will favor reaction 1, thus
changing the conversion and thus the yields.
Selectivity
Selectivity is the measure of desirable products made in cracking. High
selectivity cracking results in more desirable products such:
Ethylene
Propylene
Butadiene
Lower selectivity results in higher yields of less desirable products such as:
Methane
Fuel Oil
Aromatics
The changes in yield noted above result from the competition between primary
and secondary reactions. Primary reactions form ethylene and other desirable
products. Secondary reactions destroy these products and form fuels and
aromatics. The reactions below are typical primary and secondary reactions that
occur in ethane cracking:
(1) C2 H 5 C2 H 4 H
(2) C2 H 4 CH 3 C3 H 7
Equation 1 shows a typical primary reaction that creates ethylene. Equation 2
destroys ethylene and is therefore a secondary reaction.
The rate equations for these reactions are shown below:
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r1 k1 C2 H 5
r2 k C H CH
2 2 4
3
Considering just these two reactions, the following equation gives the net
formation of ethylene:
dFC 2 H 4
dv
r1 r2 k1 C2 H 5 k2 C2 H 4 CH 3
In the gas phase in a cracking heater, the concentration of a component is given
by:
Fx
Concentration pt
Ft RT
Where :
F moles of component x
Ft total moles FHC FDS
FHC moles of hydrocarbon
FDS moles of dilution steam
R Gas constant
T Temperature
Pt Total pressure
Therefore for a differential reactor volume (dv):
dFC2 H 4 k1 FC H k 2 FC2 H 4 FCH
2 5
pt 3
pt2
dv Ft RT Ft RT 2
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It can be seen from this equation that ethylene production will decrease as
pressure increases. Therefore increases in coil outlet pressure (COP) as the
result of increased TLE fouling and or charge gas compressor suction pressure
increases will reduce selectivity.
Any decrease in dilution steam ratio will favor increases in secondary reactions
and result in poorer selectivity.
Increases in coil pressure drop as the coil cokes will also decrease selectivity.
Coils designed with larger tubes and lower pressure drop are therefore favored.
The rate constants of the two equations analyzed above are given by:
40,000
k1 3.2 x1013 exp
RT
7,900
k 2 2.0 x108 exp
RT
Using these equations, we can calculate the rates of the two reactions at various
temperatures.
Rate @ 700 °C @ 800 °C @ 900 °C
Constant
k1 3.3 x 104 2.28 x 105 1.13 x 106
k2 3.36 x 106 4.91 x 106 6.75 x 106
k1/k2 0.00985 0.046 0.167
The primary reaction rate increases more rapidly as temperature increases.
Higher temperature thus favors increased selectivity. A shorter residence time
coil that operates at a higher COT will therefore produce a more selective yield.
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The above reactions are used to simply illustrate the effect of pressure,
temperature (and/ or residence time) on conversion (a measure of severity) and
selectivity for ethane cracking. The same concept applies to all feeds, but the
mechanism is more complex than that discussed here.
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3.3 Control System Description
The basic heater controls are:
Feed Throughput control
Steam to hydrocarbon ratio control of individual coils
Average COT control
Heater Firing control
COT Balancing – Differential Temperature Controller
Heater draft control
Excess air control
Steam drum level control
SHP Steam temperature control
The following sections provide basic descriptions of the heater controls.
It is important to make sure the different heater control loops are properly tuned
and to note the differences of tuning requirements between the different
operating modes such as normal run operation and High Steam Standby/Decoke
conditions.
3.3.1 Feed Throughput Control
The total throughput controller manipulates the associated individual feed flow
controller’s setpoints to regulate the total feed flow to the heater. In normal
operation, the total feed throughput controller works in conjunction with the
individual coil temperature balancing differential COT controllers to manipulate
the setpoints of the corresponding coil individual feed controllers. This scheme
allows for total feed throughput control as well as individual coil flow trimming so
that all coils operate with the same COT.
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The (HC) feed streams to each heater have separate gas and liquid flow control
and measurements. The individual liquid and gas feed flow measurements are
density compensated based on the measured density of the feed. The feed total
throughput is calculated by summing together the setpoints of the individual feed
controller. The feed selector switch and associated control logic are used to
select the feed and associated flow control to each heater. During split cracking
mode for the Flexible Heaters, Coil 3 feed flow is directly controlled by Coil 3
COT. Coils 1 and 2 will have OLNG feed in Cell “A”. Coil 3 in Cell A and all 3
coils (4, 5 & 6) of Cell “B” will be on C3+ feed. Since the firing in Cell “A” is
dictated by OLNG, C3+ flow rate will be adjusted in Coil 3 to keep the same COT
as coils 4 to 6. During other operation modes, the Coil 3 flow is controlled by the
Cell “A” throughput controller. Therefore the average flow rate in Coil 4 to 6 in
Cell B may be different from Coil 3 flow rate for C3+ feed. COT for the OLNG
feed should be established initially and periodically based on offline sampling
analysis from the TLE effluent of the two coils to meet the required cracking
severity (P/E ratio). The operating COT should be slightly lower (~5 C) than the
true COT measured by effluent sampling to allow for potential fluctuation of the
feedstock quality to prevent overcrack.
3.3.2 Steam to hydrocarbon ratio control of individual coils
Dilution steam is mixed with the preheated feed using ratio control. Each coil is
provided with a ratio block that sets the setpoint of the dilution steam flow
controller equal to a ratio to the setpoint of each operating individual coil feed
flow controller. A manual loader (HIC) and high signal selector is furnished to
prevent the ratio controller from reducing the dilution flow setpoint to less than a
preset minimum during heater standby operation and heater trips. Automatic
logic is present in the DCS to determine operating feed (gas or liquid) based on
the position of the heater feed selector switch position.
3.3.3 Average COT Control
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The COT controller manipulates the heater hearth burner firing rate to regulate
the heater average coil outlet temperature. The process variable for the COT
controller is the average of "good" individual COT measurements ("bad"
thermocouple measurements are ignored).
For the 4 radiant coil groups per coil, there are 4 outlets. Each pair of outlets
from the 4 radiant coil groups is combined with wye fittings into 2 outlets and 2
COT measurements. The 2 COT measurements are averaged representing the
averaged COT for each coil. Each of the COT measurement is provided with
duplex thermocouples with upscale burnout alarms. A hand switch is furnished
in the DCS that allows the operator to select which of the two temperature
measurements from the duplex thermocouple will be utilized in the COT control
strategy. Although the system is configured to continue to operate if the COT
reading of one or more coils is bad, it is recommended to immediately determine
the cause of the failed reading(s), or replace the thermocouple(s). The individual
coil’s COT is used in the coil balancing strategy before being averaged together
with other coil temperatures in a radiant cell to calculate the overall average coil
outlet temperature for the corresponding radiant cell. The two radiant cells of a
heater have separate COT balancing control for each cell.
The COT/firing controller tuning constant which is needed for stable control will
be different during decoking and HSS compared to normal cracking operation,
due to differences in the heat absorbed of hydrocarbon cracking vs. HSS/decoke
operations. Controller tuning constants may need to be changed when switching
to different heater operating modes.
3.3.4 Heater Firing Control
The burners are designed to burn design process gas or startup/backup fuels
using ambient air for combustion. Process upsets or the sudden switch to/from
backup fuel can result in large swings in fuel gas composition. Fuel gas heating
value compensation is furnished with heater firing controls to minimize COT and
combustion excess air fluctuations during fuel composition swings. Rather than
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regulating heater firing based on fuel gas flow rate, the controls are designed to
regulate heater firing based on measured heat energy released from the burners.
The objective of the heater firing controls is to maintain the desired average COT
corresponding to the desired process performance (i.e., conversion or severity).
Each heater has two radiant cells with independent firing control for the
corresponding cell. Therefore, the description below for a “heater” is also
applicable for firing to one radiant cell.
All heaters are equipped with gas fired hearth and wall burners.
The hearth burner firing rate is varied to control the COT for each radiant cell.
The flow of fuel to the hearth burners is controlled by the heat rate controller QC
which receives set points from the average coil outlet temperature controller (TIC)
of each radiant cell. The wall burner firing rates are base-loaded, thus there is an
additional feedback signal to the heat rate controller which compensates for the
partial heat input to the wall burners. Combined with compensation for fuel gas
composition via a continuous calorimeter measurement, the result is that a
constant firing rate (heat energy release from the burners) to the heater radiant
cell is maintained.
The actual total heat energy release to the heaters is calculated by multiplying
the fuel gas heating value by the fuel gas flow which has been corrected for
temperature and pressure fluctuations. The fuel gas heating value is measured
by the Wobbe meter, located in the main gas header upstream of all the heaters.
The Wobbe index may be entered manually via the controller (HS) should the
Wobbe meter be out of service. If the Wobbe index is input by the operator, the
associated auto/manual station must be placed in manual mode.
Pressure controllers have been furnished for hearth burner firing controls for use
during heater start-up and decoke, when the fuel flow rates are less than the
minimum turn down limitations of fuel flow meter. Additionally, these pressure
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controllers are designed to provide low pressure override protection during
normal operation and to prevent automatic controls from lowering the fuel
pressure below the burner low pressure trip setpoint.
Specifically, the burner fuel gas control valve is controlled by the resulting signal
from its respective QC via a high signal selector (QY) which selects the higher of
the two signals from the QC and the burner PC. This insures that the minimum
stable fuel gas pressure to the burners is always maintained.
The heaters should always be operated with the Wobbe meter as an active part
of the control system. During times when it is necessary for the operator to take
direct control of the heater firing, this should be done by breaking the TIC to QIC
cascade and putting a set point into the QIC. Should the fuel composition
change, the control system will attempt to maintain the heat input specified by
the operator.
The operator should be fully trained in the principles and specifics of this firing
control system. The operator should be aware of the circumstances that may
lead up to and result in a shift to backup fuel, as well as the consequence of
shifting to back up fuel and the actions that may be required. For large molecular
weight changes, the operator may be required to assist the control system even
if the Wobbe Meter is in service.
When the Wobbe meter is out of service or should it become necessary to
operate the fuel to the heater on either pressure or flow control only, the operator
should diligently monitor the firing, being alert for rapid increases in COTs, XOTs,
or flue gas temperatures. When the Wobbe meter is out of service the operator
should have access to alternate measurements (i.e. flow indication) that indicate
that backup fuel has begun to flow into the system.
Cautionary Note
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At times, the operator may feel it would be easier to maintain fuel flow to the
heaters on direct fuel gas pressure control, and bypass the heat input (Wobbe
index) compensation control.
Extreme care must be exercised when operating heater controls without the
heating value compensation factor in service. A sudden increase in the fuel
heating value, and/or molecular weight, as could be experienced during a
process upset could cause heater overfiring and/or substoichiometric combustion
resulting in damage to the heater. For the same reason, the hearth burners
should never be operated under pressure (PC) control; they should always be
operated on heat rate (QC) control.
The secondary fuel header for each heater is furnished with a control valve that
may be manually shut (HC) by the operator during very low firing operation (High
Steam Standby and decoking) to allow all hearth burners to remain
commissioned on primary tips only, without risk of tripping due to low burner
pressure. During a partial trip, this secondary fuel header valve is automatically
shut.
There is an interlock to shut the secondary fuel when the arch temperature is
below 700 °C. The wall burners will be shut when there is insufficient hearth wall
burner fuel pressure.
3.3.5 COT Balancing – Differential Temperature Controller
Each coil is provided with a differential temperature controller (TDC) that is
designed to adjust coil flows to insure that all coils operate at the same coil outlet
temperature (in some cases within tolerance). This is accomplished by adding a
small positive or negative bias to the total feed throughput controller output
before the signal is sent as a setpoint to each individual feed flow controller. In
principle the tolerance in COT can be as low as +/-0.1oC and the typical value is
+/- 1oC. However, as mentioned above flow rate is varied to maintain the COT.
Large differences (more than +/- 5% from the average) should be avoided.
ORPIC SOM – SECTION 3.DOC Page 53 of 60
Lummus Petrochemicals
Client ORPIC 188081 ORPIC SOM SECTION 3 0
Project Liwa Plastics Project Project No Document Rev.
Under such circumstances the tolerance can be higher than 1oC in that cracking
cycle. Burner malfunction and severe coking in one coil are probable causes for
large deviations. The operator should try correct these problems as soon as
possible.
3.3.6 Heater Draft Control
A draft pressure controller, located at the heater arch, controls heater draft by
adjusting the ID fan speed.
3.3.7 Excess Air Control
Combustion air to the burners is regulated differently for the hearth and wall
burners. The combination of draft control and manipulation of these airflow
openings provide the means for manually controlling excess air.
For the hearth burners, the air dampers are connected together and manipulated
by pneumatically actuated jackshafts (refer to Section 3.2.2.12). The mechanical
linkage at each damper is calibrated at heater commissioning to permit virtually
identical air flow to all burners connected to the same jackshaft. Individual
damper control is not possible because the linkage cannot be disconnected from
the jackshaft once installed, and there would be no means of holding the
disconnected damper in a fixed position.
Each wall burner is provided with a rotating shaft that changes the airflow
opening when dialed to a specific position (called primary air). The wall burner
flame must be observed from the peep door above to insure the flame pattern is
acceptable. Typically a low to middle setting of the airflow opening will provide
sufficient excess combustion air, with all the burners set at approximately the
same opening. When more than one row of wall burners is installed, these
opening will vary from row to row. Adjacent wall burners in the same row have
the same level of opening. Since they are self- inspirating the wall burners are
not sensitive to draft (primary air). Wall burners are also provided with secondary
ORPIC SOM – SECTION 3.DOC Page 54 of 60
Lummus Petrochemicals
Client ORPIC 188081 ORPIC SOM SECTION 3 0
Project Liwa Plastics Project Project No Document Rev.
air door. These doors will be used when primary air is alone insufficient for good
combustion. Secondary air is sensitive to draft. When the burners are selected,
usually secondary doors will be closed for design conditions. Recommendations
from the burner vendor have to be followed for the recommended settings. They
affect the heat flux pattern and the NOx. During decoking most wall burners will
be shut off except the selected few. The lighted wall burner pattern is usually
obtained with experience gained in decoking.
3.3.8 Steam Drum Level Control
BFW flow to the Super High Pressure (SHP) Steam Drum is controlled by a
three- element control strategy. The setpoint of the BFW flow controller is
manipulated based on summing the measured temperature and pressure
compensated flow of steam production and the (density compensated) output of
the drum level controller.
The strategy is designed to immediately adjust the setpoint of the BFW controller
proportionally to any variation in measured steam production. Once the strategy
is properly tuned, a one unit change in measured steam flow should cause the
BFW setpoint to be adjusted to cause approximately (minus desuperheater BFW
fraction) an equal change in BFW flow rate. The level controller should then be
required to make minor adjustments to the BFW valve's position to insure that
the steam level is maintained at a set value.
The heater is equipped with a BFW preheat coil. The BFW control valve is
furnished with a minimum stop to insure there is flow in the preheat coil at all
times.
The drum level measurement is pressure compensated to account for variations
in condensate/steam density.
A manual calibrated blowdown valve is utilized to vary the continuous blow-down
flowrate. A high level controller opens an automatic blow-down control valve in
ORPIC SOM – SECTION 3.DOC Page 55 of 60
Lummus Petrochemicals
Client ORPIC 188081 ORPIC SOM SECTION 3 0
Project Liwa Plastics Project Project No Document Rev.
the event the drum level exceeds the controller's setpoint. The high level
controller may be required during upset conditions and during startup when BFW
demand is less than the minimum stop position of the BFW control valve.
Refer to the primary TLE vendor operating manual for heat up rate and other
related information.
3.3.9 SHP Steam Temperature Control
Super high pressure steam generated by the primary TLE's is superheated in the
convection section of each heater. Each heater has one desuperheater installed
between the Upper SSH and Lower SSH coils to control the steam superheater
outlet temperature. The flow of phosphate-free BFW to the desuperheater is
adjusted to control the superheater outlet temperature.
A high temperature interlock will shutdown the heater in the event the steam
superheater outlet temperature approaches the piping design temperature to
avoid damage to the convection section coil and downstream piping.
3.3.10 Interlock and Trips
To help guard against mal-operation of the heaters, a safety interlock system
has been installed. This system will automatically take preventative measures
and/or lock out certain operations, depending on conditions. Heater interlock
summaries for are provided in the PDP package. Operating personnel should
become totally familiar with this system prior to its use.
ORPIC SOM – SECTION 3.DOC Page 56 of 60
Lummus Petrochemicals
Client ORPIC 188081 ORPIC SOM SECTION 3 0
Project Liwa Plastics Project Project No Document Rev.
3.4 Heater Turndown
The heaters can operate down to about 70% of design hydrocarbon rate. This is
considered minimum turndown (TD) for feedrate at design cracking severity or
conversion. Dilution steam to the heater may be increased to maintain choked
venturi conditions and to keep coking rates low. Burner firing is reduced
uniformly with all burners operating.
The heater can operate on High Steam Standby (dilution steam only) and
decoking (steam plus air mixture), which are considered minimum turndown
conditions for firing. The burner fuel pressure should be closely monitored to
stay above the minimum fuel pressure trip setting for extreme turndown
conditions.
The heater flowrate may be reduced for long-term operation to the minimum
turndown S/HC conditions shown in Table 3.4.1, based on the limitation of
maintaining choked flow through the critical flow venturis in the radiant section
inlet pass tubes. These minimum S/HC are estimates and should be increased
as needed to keep the venturi choked. The venturi pressure ratio (PDI/PI)
should be closely monitored. Refer to previous section on critical flow venturis for
additional information on the venturis. The limitation for choked flow through the
venturis assumes that the coil outlet pressure (COP) upstream of the transfer
line exchanger at SOR conditions does not exceed 0.54 BarG. For a higher
operating SOR COP, the turndown requirements for dilution steam may change
if experience indicates that run length tends to be limited by unchoking venturis
instead of radiant TMT.
The required minimum S/HC at intermediate feedrate percentage not specified in
the table may be interpolated linearly from those shown, then rounding up the
nearest hundredth S/HC. Design hydrocarbon rates are referenced from the
heater data sheets.
ORPIC SOM – SECTION 3.DOC Page 57 of 60
Lummus Petrochemicals
Client ORPIC 188081 ORPIC SOM SECTION 3 0
Project Liwa Plastics Project Project No Document Rev.
Table 3.4.1 - Radiant Coil Venturi Turndown Operation
Hydrocarbon (HC) rates shown are per heater (Based on DESIGN CASE)
At SOR conditions (clean coil, clean TLE)
FLEXIBLE HEATERS (6 COILS/HEATER)
MIN. S/HC TO CHOKE
NORMAL OPERATION @ 100% FLOW VENTURI (a, b)
Design @80% @70%
VENTURI Total HC S/HC ratio Number of TURNDOW TURNDOW
Feed ID, MM (b) Flow, kg/hr (wt/wt) coils N N
C3+ 15.2 57776 0.40 6 0.48 0.54
C3+ SC 15.2 41540 0.40 4 0.40 0.40
C5OLNG
SC 15.2 18960 0.50 2 0.58 0.64
C2 SWING 15.2 51081 0.30 6 0.39 0.46
ETHANE HEATERS (8 COILS/HEATER)
MIN. S/HC TO CHOKE
NORMAL OPERATION @ 100% FLOW VENTURI (a, b)
Design @80% @70%
VENTURI Total HC S/HC ratio Number of TURNDOW TURNDOW
Feed ID, MM (b) Flow, kg/hr (wt/wt) coils N N
C2 14.0 50880 0.30 8 0.41 0.50
C3+ 14.0 54574 0.40 8 0.50 0.57
EP COCRK 14.0 50879 0.30 8 0.41 0.49
Notes:
(a) Minimum S/HC required to maintain choked flow through venturi.
(b) SC = split crack operation.
ORPIC SOM – SECTION 3.DOC Page 58 of 60
Lummus Petrochemicals
Client ORPIC 188081 ORPIC SOM SECTION 3 0
Project Liwa Plastics Project Project No Document Rev.
3.5 Firing Pattern and Balanced Heat Flux
Proper heater operation means the ability to control conversion, maintain high
heater efficiency, meet environmental emissions standards, extend heater run
length, avoid upsets and prolong the mechanical life of the heater components.
These goals can only be achieved by diligent attention by the operator to
establish and monitor proper burner operations. The radiant coil arrangement,
the firebox geometry and the selected burner characteristics and locations
provide the capability to obtain a properly balanced heat flux in the radiant
firebox. Heat flux in cracking heater applications is defined as the amount of
heat from the firebox that is transferred through the radiant tube wall to the
unreacted feed and reaction products per unit of tube surface.
A theoretically balanced and uniform heat flux condition would be one where the
total amount of radiant heat absorbed is equally divided to each coil and equally
along the circumference and length of each tube.
As low temperature difference as possible between the top and bottom of the
outlet tube should be maintained. A poor heat flux distribution will be observed
with uneven TMT profiles vertically on the tube(s).
Firebox conditions that lead to poor heat flux profiles include:
Uneven Fuel Usually a sign of improperly adjusted or
Distribution: fouled burners
Low Overall Excess Causing after-burning in upper levels of the
Air: firebox and flue gas patterns that result in
dead zones in the fire box.
Poor Air Distribution: Leading to combustion deficiencies at
individual burners.
Poor Firing Balance Firing the hearth burners non-uniformly
Among Hearth results in varying heat flux at different parts
ORPIC SOM – SECTION 3.DOC Page 59 of 60
Lummus Petrochemicals
Client ORPIC 188081 ORPIC SOM SECTION 3 0
Project Liwa Plastics Project Project No Document Rev.
Burners: of the coils and thus higher TMT and
shorter run length to achieve the same
conversion.
In order to ensure uniformity of temperature, pyrometer surveys of tube metal
temperature (TMT) are essential. Deviations from a smooth curve are an
indication of irregular firing or local coke buildup.
Tube metal temperatures are determined by taking readings using a pyrometer
that can be either an infrared, optical, or laser/micrometer device. The
pyrometer measures the heat flux (intensity) emanating from the tube that is
correlated to temperature. See "Pyrometer Surveys" in Section 8.1 for
information on how and at what frequency such readings should be taken.
ORPIC SOM – SECTION 3.DOC Page 60 of 60
Petrochemical Plant Sohar Environmental Impact Assessment Report
Orpic and CB&I HMR #3817
Attachment 3: Steam Cracker Heat and Material Balance
G-S000-5240-003 HMR Consultants
June 2015 J
Liwa Plastics Project
CB&I ORPIC
Document Title: Material and Heat Balance - NGTL 1100, RDG 1200, SCU
2000-2600 and SLC4HY 2800
Document No: S-S100-5223-101
CB&I Contract No: 189709
Issued for FEED 0 12-Mar-2015 FSUMAR SNAN/VK SRD
Revision Descriptions Rev Date Originator Checker Approver
Page 1 of 3
"THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY (CB&I). IT MAY CONTAIN INFORMATION
DESCRIBING TECHNOLOGY OWNED BY CB&I AND DEEMED TO BE COMMERCIALLY SENSITIVE. IT IS TO BE USED ONLY IN
CONNECTION WITH WORK PERFORMED BY CB&I. REPRODUCTION IN WHOLE OR IN PART FOR ANY PURPOSE OTHER THAN
WORK PERFORMED BY CB&I IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN PERMISSION OF CB&I. IT IS TO BE SAFEGUARDED
AGAINST BOTH DELIBERATE AND INADVERTENT DISCLOSURE TO ANY THIRD PARTY."
Liwa Plastics Project
Document Title: Document No. Rev:
Material and Heat Balance – NGTL 1100, RDG 1200, SCU 2000- S-S100-5230-201 0
2600 and SLC4HY 2800
INPUTS / REFERENCE DOCUMENTS
Document Number Title Status
S-S000-5222-001 Project Basis of Design – LPP Facilities
S-S100-5223-101 SCU – Process Design Basis
PDP Section 2 and Section 3 Rev 1
REVISION NOTES AND HOLDS
Revision Description of Changes & Holds
HOLDS Description of Holds Rev Date
1
2
3
4
Page 2 of 3
Liwa Plastics Project
Document Title: Document No. Rev:
Material and Heat Balance – NGTL 1100, RDG 1200, SCU 2000- S-S100-5230-201 0
2600 and SLC4HY 2800
SUMMARY
Refer Licensor’s Heat and Material Balance (PDP Revision1) Section 3 for NGLT 1100, RDG 1200, SCU 2000-
2600 and SLC4HY 2800’s Heat and Material Balance for LIWA Plastics Project. Refer to Material and Heat
Balance – ARU-1100 (doc. no S-S110-5223-101) for Amine Regeneration Unit.
Cases are defined as below.
SECTION 3A - OVERALL MATERIAL BALANCES
Material Balances are provided for the following design cases:
Case 1: Normal feeds and external recycles.
Case 2: Refinery Dry Gas and Refinery LPG not available, the NGL C2+ is increased 10% and increase LPG to
make minimum 75,000kg/h ethylene and same propylene as Case 1.
Case 3: Low severity case for maximizing propylene.
SECTION 3B - DETAILED MATERIAL BALANCES
Detailed Material Balances are provided for the following design cases:
Case 1: Normal feeds and external recycles.
Case 2: Refinery Dry Gas and Refinery LPG not available, the NGL C2+ is increased 10% and increase LPG to
make minimum 75,000kg/h ethylene and same propylene as Case 1.
Case 3: Low severity case for maximizing propylene.
SECTION 3C - SUPPLEMENTARY MATERIAL BALANCES
Supplementary Material Balances are provided for the following cases:
RDG End of Run: Oxygen Converter
SCU End of Run: Acetylene Converter, MAPD Converter
SHU End of Run: 1st Stage SHU, 2nd Stage SHU, 3rd Stage SHU
QO and H1:
QO case provided is Case 1 operation with the TLEs operating at average run temperatures and 1 secondary TLE
bypassed. H1 case provided is Case 1 operation with 1 heater on HHS.
Alternate High CO2:
It is anticipated that the CO2 content in NGL feed will increase over time. To compensate, the DGA concentration in
the lean amine sent to the NGL and RDG Amine/Water Wash Columns can be increased from 30% to 45 wt%.
Page 3 of 3
Liwa Plastics Project
CB&I ORPIC
Document Title: Heat and Material Balance - ARU
Document No: S-S110-5223-101
CB&I Contract No: 189709
Issued for FEED 0 13-Mar-2015 JRAJEN VINOD.KUMAR SRD
Revision Descriptions Rev Date Originator Checker Approver
"THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY (CBI). IT MAY CONTAIN PROPRIETARY
INFORMATION (CBI BACKGROUND & FOREGROUND INFORMATION) OWNED BY CBI AND DEEMED TO BE COMMERCIALLY
SENSITIVE. IT IS TO BE USED ONLY IN CONNECTION WITH WORK PERFORMED BY CBI. REPRODUCTION IN WHOLE OR IN
PART FOR ANY PURPOSE OTHER THAN WORK PERFORMED BY CBI IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN
PERMISSION OF CBI. IT IS TO BE SAFEGUARDED AGAINST BOTH DELIBERATE AND INADVERTENT DISCLOSURE TO ANY
THIRD PARTY."
Page 1 of 4
Liwa Plastics Project
Heat and Material Balance
ARU
Notes:
1) Material Balance Case I: 30 wt% DGA
- 8.6 wt.% CO2, 40 ppmwt H2S in NGL feed + 1.95 wt.% CO2, 1100 ppmwt H2S in RDG feed
2) Material Balance Case II: 45 wt% DGA
- 16.8 wt.% CO2, 60 ppmwt H2S in NGL feed + 1.95 wt.% CO2, 1100 ppmwt H2S in RDG feed
3) Quantity and composition of waste by Reclaimer Package (ME-11053) Vendor.
4) Stream detailed composition by Acid Gas Package (ME-11052) Vendor.
5) Stream flow rate and composition to be confirmed and finalised based on Reclaimer Package (ME-11053) Vendor information by
EPC contractor.
Holds:
Document Title: Heat and Material Balance - ARU
Document No.: S-S110-5223-101
Rev.: 0 Page 2 of 4
Liwa Plastics Project
Heat and Material Balance
ARU
Case I
Stream Number 1162 1163 1171 1172 1173 1174 1175 1176 1177 1178 1179 1180 1181 1182 1183 1184 1185 1151 1187 20651188 1189 1190 1191
Note 4 Note 5 Note 5 Note 3
Stream Name R.Amine Vent Gas R.Amine R.Amine R.Amine Ov Vapor Ov Vapor Acid Gas Acid Gas Reflux Bottom Vap Ret L.Amine L.Amine L.Amine L.Amine L.Amine L.Amine LLS H2O Mkup CO2 L.Amine L.Amine Waste
From C-11002 V-11054 V-11054 E-11052 FCV C-11051 E-11054 V-11052 PCV V-11052 C-11051 E-11051 C-11051 E-11052 E-11056 E-11053 E-11053 Filters DS-11051 E-20014 ME-11052 E-11053 ME-11053 ME-11053
To V-11054 C-21003 E-11052 FCV C-11051 E-11054 V-11052 PCV ME-11052 C-11051 E-11051 C-11051 E-11052 E-11056 E-11053 Filters Filters C-11002 E-11051 V-11052 To ATM ME-11053 P-11051 WWT-Ref
Phase Mixed Vapor Liquid Mixed Mixed Vapor Mixed Vapor Vapor Liquid Liquid Vapor Liquid Liquid Liquid Liquid Liquid Liquid Vapor Liquid Vapor Liquid Liquid Liquid
Component (wt%)
Water 66.63 1.88 66.65 66.65 66.65 20.39 20.39 3.25 3.25 99.84 71.83 94.18 69.44 69.44 69.44 69.44 69.44 69.44 100.00 100.00 0.00 69.44 69.44 69.44
Carbon Dioxide 4.46 0.56 4.46 4.46 4.46 78.85 78.85 95.83 95.83 0.16 1.01 5.23 0.56 0.56 0.56 0.56 0.56 0.56 0.00 0.00 100.00 0.56 0.56 0.56
Hydrogen Sulfide 0.02 0.01 0.02 0.02 0.02 0.32 0.32 0.38 0.38 0.00 0.01 0.03 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Methane 0.00 1.58 0.00 0.00 0.00 0.01 0.01 0.01 0.01 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Ethylene 0.00 0.99 0.00 0.00 0.00 0.01 0.01 0.01 0.01 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Ethane 0.06 91.49 0.02 0.02 0.02 0.41 0.41 0.50 0.50 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Propane 0.00 2.90 0.00 0.00 0.00 0.01 0.01 0.01 0.01 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
DGA 28.84 0.00 28.85 28.85 28.85 0.00 0.00 0.00 0.00 0.00 27.16 0.55 30.00 30.00 30.00 30.00 30.00 30.00 0.00 0.00 0.00 30.00 30.00 30.00
Total Units
Mass Flow kg/h 304447 116 304331 304331 304331 15126 15126 12440 12440 3496 323967 31291 292676 292676 292676 292676 29268 292676 32566 810 11921 14634 14634
Molar Flow kg mol/h 12411 3.9 12407 12407 12407 446 446 297 297 194 13828 1675 12153 12153 12153 12153 1215 12153 1809 45 607.2 607.2
Molecular Weight kg/kg mol 24.5 29.5 24.5 24.5 24.5 33.9 33.9 41.9 41.9 18.0 23.4 18.7 24.1 24.1 24.1 24.1 24.1 24.1 18.0 18.0 24.1 24.1
Temperature °C 63 63 63 99 99 98 58 57 57 57 131 132 132 97 59 42 42 42 148 45 42 42
Pressure bar (g) 8 6 6 5.25 1.7 1.5 1.4 1.3 1.2 1.5 1.7 1.7 1.7 29.45 28.75 28.05 28.05 25 3.5 1.5 28.05 3.5
Liquid Weight Fraction % 99.97 0 100 99.99 99.95 0 17.71 0 0 100 100 0 100 100 100 100 100.0 100 0 100 100 100
Specific Enthalpy kcal/kg -2887.6 -698.3 -2888.4 -2856.0 -2856.0 -2322.4 -2432.8 -2148.2 -2148.2 -3754.8 -2913.2 -3090.9 -2837.9 -2870.5 -2905.3 -2920.4 -2920.4 -2920.4 -3153.7 -3769.3 -2920.4 -2920.4
Critical Temperature °C 367.2 38.9 367.3 367.3 367.3 163.1 163.1 57.3 57.3 374.0 373.9 366.6 374.9 374.9 374.9 374.9 374.9 374.9 374.2 374.2 374.9 374.9
Critical Pressure bar (g) 165.3 49.9 165.3 165.3 165.3 116.2 116.2 80.4 80.4 220.0 172.2 214.3 167.7 167.7 167.7 167.7 167.7 167.7 220.167 220.167 167.7 167.7
Stream Enthalpy MMkcal/h -879.11 -0.08 -879.03 -869.16 -869.16 -35.13 -36.80 -26.72 -26.72 -13.13 -943.78 -96.72 -830.58 -840.12 -850.30 -854.72 -85.47 -854.72 -102.70 -3.05 -42.74 -42.74
Vapor
Mass Flow kg/h 96 116 37 140 15126 12447 12440 12440 31291 32566 11921
Actual Volumetric Flow m3/h 9.7 15.1 6.1 53.5 5428.7 3361.3 3490.9 3649.0 20420.6 13647.0
Molecular Weight kg/kg mol 29.5 29.5 29.7 29.5 33.9 41.9 41.9 41.9 18.7 18.0
Density kg/m3 9.99 7.67 6.15 2.61 2.79 3.70 3.56 3.41 1.53 2.39
Viscosity cP 0.011 0.011 0.013 0.014 0.017 0.016 0.016 0.016 0.014 0.014
Liquid
Mass Flow kg/h 304351 304331 304294 304192 2679.18 3496.43 323967 292676 292676 292676 292676 29267.6 292676 810 14634 14634
Volumetric Flow m3/h 297.3 297.3 305.3 305.2 2.7 3.6 340.1 307.8 297.4 289.1 286.3 28.6 286.4 0.8 14.3 14.3
Molecular Weight kg/kg mol 24.5 24.5 24.5 24.5 18.0 18.0 23.4 24.1 24.1 24.1 24.1 24.1 24.1 18.0 24.1 24.1
Density kg/m3 1023.82 1023.81 996.66 996.67 984.01 984.57 952.46 950.87 984.21 1012.28 1022.17 1022.17 1022.08 989.49 1022.17 1022.17
Viscosity cP 0.97 0.97 0.53 0.54 0.49 0.50 0.34 0.36 0.56 1.07 1.56 1.56 1.56 0.61 1.56 1.56
Surface Tension mN/m 60.77 60.77 54.69 54.71 66.28 66.51 50.24 49.87 56.31 62.79 65.53 65.53 65.52 68.86 65.53 65.53
Thermal Conducitivity kcal/(h.m.°C) 0.382 0.382 0.386 0.387 0.554 0.553 0.418 0.406 0.408 0.402 0.397 0.397 0.397 0.543 0.397 0.397
Document Title: Heat and Material Balance - ARU
Document No.: S-S110-5223-101
Rev.: 0 Page 3 of 4
Liwa Plastics Project
Heat and Material Balance
ARU
Case II
Stream Number 1162 1163 1171 1172 1173 1174 1175 1176 1177 1178 1179 1180 1181 1182 1183 1184 1185 1151 1187 20651188 1189 1190 1191
Note 4 Note 5 Note 5 Note 3
Stream Name R.Amine Vent Gas R.Amine R.Amine R.Amine Ov Vapor Ov Vapor Acid Gas Acid Gas Reflux Bottom Vap Ret L.Amine L.Amine L.Amine L.Amine L.Amine L.Amine LLS H2O Mkup CO2 L.Amine L.Amine Waste
From C-11002 V-11054 V-11054 E-11052 FCV C-11051 E-11054 V-11052 PCV V-11052 C-11051 E-11051 C-11051 E-11052 E-11056 E-11053 E-11053 Filters DS-11051 E-20014 ME-11052 E-11053 ME-11053 ME-11053
To V-11054 C-21003 E-11052 FCV C-11051 E-11054 V-11052 PCV ME-11052 C-11051 E-11051 C-11051 E-11052 E-11056 E-11053 Filters Filters C-11002 E-11051 V-11052 To ATM ME-11053 P-11051 WWT-Ref
Phase Mixed Vapor Liquid Mixed Mixed Vapor Mixed Vapor Vapor Liquid Liquid Vapor Liquid Liquid Liquid Liquid Liquid Liquid Vapor Liquid Vapor Liquid Liquid Liquid
Component (wt%)
Water 50.79 3.68 50.81 50.81 50.81 18.83 18.83 3.26 3.26 99.84 58.87 93.49 54.24 54.24 54.24 54.24 54.24 54.24 100.00 100.00 0.00 54.24 54.24 54.24
Carbon Dioxide 6.91 3.90 6.91 6.91 6.91 80.69 80.69 96.17 96.17 0.16 1.30 5.40 0.75 0.75 0.75 0.75 0.75 0.75 0.00 0.00 100.00 0.75 0.75 0.75
Hydrogen Sulfide 0.01 0.02 0.01 0.01 0.01 0.18 0.18 0.22 0.22 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Methane 0.00 1.04 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Ethylene 0.00 0.51 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Ethane 0.06 87.18 0.02 0.02 0.02 0.28 0.28 0.33 0.33 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Propane 0.00 3.34 0.00 0.00 0.00 0.01 0.01 0.02 0.02 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
DGA 42.22 0.00 42.24 42.24 42.24 0.00 0.00 0.00 0.00 0.00 39.83 1.10 45.01 45.01 45.01 45.01 45.01 45.01 0.00 0.00 0.00 45.01 45.01 45.01
Total Units
Mass Flow kg/h 384000 181 383819 383819 383819 29524 29524 24763 24763 5966 408398 48170 360227 360227 360227 360227 36023 360227 49856 1205 23814 18011 18011
Molar Flow kg mol/h 12981 6.1 12975 12975 12975 854 854 590 590 331 15014 2564 12450 12450 12450 12450 1245 12450 2767 67 623.2 623.2
Molecular Weight kg/kg mol 29.6 29.7 29.6 29.6 29.6 34.6 34.6 41.9 41.9 18.0 27.2 18.8 28.9 28.9 28.9 28.9 28.9 28.9 18.0 18.0 28.9 28.9
Temperature °C 80 80 80 99 99 97 58 57 57 57 132 135 135 116 59 42 42 42 148 45 42 42
Pressure bar (g) 8 6 6 5.25 1.7 1.5 1.4 1.3 1.2 1.5 1.7 1.7 1.7 29.45 28.75 28.05 28.05 25 3.5 1.5 28.05 3.5
Liquid Weight Fraction % 99.96 0 100 99.99 99.94 0 16.10 0 0 100 100 0 100 100 100 100 100 100 0 100 100 100
Specific Enthalpy kcal/kg -2469.0 -789.9 -2469.8 -2453.9 -2453.9 -2311.4 -2412.0 -2154.6 -2154.6 -3754.7 -2556.4 -3075.9 -2416.9 -2432.7 -2481.5 -2495.5 -2495.5 -2495.5 -3153.7 -3769.3 -2495.5 -2495.5
Critical Temperature °C 361.1 51.6 361.2 361.2 361.2 155.1 155.1 57.3 57.3 374.0 374.1 366.4 375.7 375.7 375.7 375.7 375.7 375.7 374.2 374.2 375.7 375.7
Critical Pressure bar (g) 138.8 52.7 138.8 138.8 138.8 113.3 113.3 80.5 80.5 220.0 149.8 213.2 141.5 141.5 141.5 141.5 141.5 141.5 220.2 220.2 141.5 141.5
Stream Enthalpy MMkcal/h -948.10 -0.14 -947.96 -941.87 -941.87 -68.24 -71.21 -53.35 -53.35 -22.40 -1044.04 -148.17 -870.64 -876.34 -893.91 -898.96 -89.90 -898.96 -157.23 -4.54 44.95 44.95
Vapor
Mass Flow kg/h 151 181 42 230 29524 24771 24763 24763 48170 49856 23814
Actual Volumetric Flow m3/h 15.8 29.7 6.6 83.7 10356 6680 6943 7258 31426 20893
Molecular Weight kg/kg mol 29.8 29.7 30.6 31.1 34.6 41.9 41.9 41.9 18.8 18
Density kg/m3 9.51 7.31 6.32 2.75 2.85 3.71 3.57 3.41 1.53 2.39
Viscosity cP 0.011 0.012 0.013 0.015 0.017 0.017 0.016 0.016 0.014 0.014
Liquid
Mass Flow kg/h 383849 383819 383777 383589 4752 5966 408398 360227 360227 360227 360227 36023 360227 1205 18011 18011
Volumetric Flow m3/h 367.8 367.8 373.2 373.0 4.8 6.1 425.9 376.8 369.0 351.3 347.5 34.8 347.5 1.2 17.4 17.4
Molecular Weight kg/kg mol 29.6 29.6 29.6 29.6 18.0 18.0 27.2 28.9 28.9 28.9 28.9 28.9 28.9 18.0 28.9 28.9
Density kg/m3 1043.64 1043.64 1028.27 1028.29 984.02 984.52 958.82 955.92 976.19 1025.38 1036.60 1036.60 1036.49 989.49 1036.60 1036.60
Viscosity cP 1.21 1.21 0.86 0.87 0.49 0.50 0.45 0.50 0.64 1.81 2.79 2.79 2.79 0.61 2.79 2.79
Surface Tension mN/m 54.69 54.69 51.71 51.74 66.28 66.49 48.51 47.77 51.11 60.36 62.81 62.81 62.80 68.86 62.81 62.81
Thermal Conducitivity kcal/(h.m.°C) 0.363 0.312 0.312 0.312 0.553 0.553 0.352 0.331 0.335 0.337 0.336 0.336 0.336 0.542 0.336 0.336
Document Title: Heat and Material Balance - ARU
Document No.: S-S110-5223-101
Rev.: 0 Page 4 of 4
Liwa Plastics Project
CB&I ORPIC
Heat and Material Balances - MTBE 6000 & Butene-1 6100
Document Title:
Unit
Document No: S-S600-5223-101
CB&I Contract No: 189709
Issued for FEED 0 18-Mar-2015 AMAH EBRAKEL JL
Revision Descriptions Rev Date Originator Checker Approver
"THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY (CBI). IT MAY CONTAIN PROPRIETARY INFORMATION
(CBI BACKGROUND & FOREGROUND INFORMATION) OWNED BY CBI AND DEEMED TO BE COMMERCIALLY SENSITIVE. IT IS TO BE
USED ONLY IN CONNECTION WITH WORK PERFORMED BY CBI. REPRODUCTION IN WHOLE OR IN PART FOR ANY PURPOSE OTHER
THAN WORK PERFORMED BY CBI IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN PERMISSION OF CBI. IT IS TO BE SAFEGUARDED
AGAINST BOTH DELIBERATE AND INADVERTENT DISCLOSURE TO ANY THIRD PARTY."
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 1
Stream 6001 6003 6004 6005
0 0 0
Stream Description MIXED WATER WASH WASTE WATER TOTAL WASTE
HYDROGENATED COLUMN TO WATER TO
C4S FROM OSBL BOTTOMS WASTE WATER WASTE WATER
PLANT OSBL PLANT OSBL
0 0 0 0
Stream Phase LIQUID LIQUID LIQUID LIQUID
0 0 0 0
Component (wt%) 0 0 0 0
Water 0.00 100.00 100.00 100.00
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.01 0.00 0.00 0.00
Propylene 0.01 0.00 0.00 0.00
Propane 0.08 0.00 0.00 0.00
Propadiene 0.03 0.00 0.00 0.00
Isobutane 13.92 0.00 0.00 0.00
Isobutene 30.58 0.00 0.00 0.00
1-Butene 23.41 0.00 0.00 0.00
Butadiene 0.00 0.00 0.00 0.00
n-Butane 14.34 0.00 0.00 0.00
2-Butene 17.25 0.00 0.00 0.00
C5's 0.37 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 0.00 0.00 0.00 0.00
TBA 0.00 0.00 0.00 0.00
DME 0.00 0.00 0.00 0.00
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 22376 6706 6706 6709
Molar Flow Rate kg mol/hr 394.9 372.3 372.3 372.4
Molecular Weight 56.7 18.0 18.0 18.0
Temperature °C 41 40 40 40
Stream Pressure bar (g) 11.0 9.0 3.0 3.0
Stream Enthalpy MMkcal/h 0.504 0.271 0.271 0.271
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 147 374 374 374
Critical Pressure bar (a) 38.6 220.2 220.2 220.2
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 22376 6706 6706 6709
Actual Volumetric Flow m³/h 39.7 6.8 6.8 6.8
Actual Density kg/m³ 564 992 990 990
Standard Specific Gravity 0.60 1.00 1.00 1.00
Dynamic Viscosity cP 0.15 0.65 0.65 0.65
Kinematic Viscosity cSt 0.26 0.65 0.65 0.65
Specific Enthalpy kcal/kg 22.5 40.3 40.3 40.3
Surface Tension mN/m 10.1 69.5 69.5 69.5
Specific Heat Capacity kcal/(kg°C) 0.58 1.00 1.00 1.00
Thermal Conductivity kcal/(h·m·°C) 0.086 0.542 0.542 0.542
Project No: 189709 Rev .0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 1
Stream 6006 6007 6008 6009
0 0 0 0
Stream Description WATER WASH FEED TO C4 FEED C4 FEED
COLUMN C4 FEED PUMP PUMP
OVERHEAD SURGE DRUM SUCTION DISCHARGE
0 0 0 0
Stream Phase LIQUID LIQUID LIQUID LIQUID
0 0 0 0
Component (wt%) 0 0 0 0
Water 0.03 0.03 0.03 0.03
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.01 0.01 0.01 0.01
Propylene 0.01 0.01 0.01 0.01
Propane 0.08 0.08 0.08 0.08
Propadiene 0.03 0.03 0.03 0.03
Isobutane 13.92 13.92 13.92 13.92
Isobutene 30.57 30.57 30.57 30.57
1-Butene 23.40 23.40 23.40 23.40
Butadiene 0.00 0.00 0.00 0.00
n-Butane 14.34 14.34 14.34 14.34
2-Butene 17.25 17.25 17.25 17.25
C5's 0.37 0.37 0.37 0.37
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 0.00 0.00 0.00 0.00
TBA 0.00 0.00 0.00 0.00
DME 0.00 0.00 0.00 0.00
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 22383 22383 22383 22383
Molar Flow Rate kg mol/hr 395.2 395.2 395.2 395.2
Molecular Weight 56.6 56.6 56.6 56.6
Temperature °C 40 40 40 42
Stream Pressure bar (g) 7.0 5.0 5.0 17.5
Stream Enthalpy MMkcal/h 0.502 0.502 0.502 0.520
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 148 148 148 148
Critical Pressure bar (a) 38.8 38.8 38.8 38.8
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 22383 22383 22383 22383
Actual Volumetric Flow m³/h 39.7 39.7 39.7 39.8
Actual Density kg/m³ 564 564 564 562
Standard Specific Gravity 0.60 0.60 0.60 0.60
Dynamic Viscosity cP 0.15 0.15 0.15 0.15
Kinematic Viscosity cSt 0.26 0.26 0.26 0.26
Specific Enthalpy kcal/kg 22.4 22.4 22.4 23.2
Surface Tension mN/m 10.1 10.1 10.1 10.0
Specific Heat Capacity kcal/(kg°C) 0.58 0.58 0.58 0.58
Thermal Conductivity kcal/(h·m·°C) 0.086 0.086 0.086 0.085
Project No: 189709 Rev .0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 1
Stream 6010 6011 6012 6013
0 0 0 0
Stream Description C4 FEED MIXED DEMINERALIZED DEMINERALIZED
PUMP C4s & MeOH WATER FROM WATER FEED
DISCHARGE OSBL TO WATER TO WATER
DOWNSTRM FV WASH COLUMN WASH COLUMN
0 0 0 0
Stream Phase LIQUID LIQUID LIQUID LIQUID
0 0 0 0
Component (wt%) 0 0 0 0
Water 0.03 0.04 100.00 100.00
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.01 0.01 0.00 0.00
Propylene 0.01 0.01 0.00 0.00
Propane 0.08 0.07 0.00 0.00
Propadiene 0.03 0.02 0.00 0.00
Isobutane 13.92 11.68 0.00 0.00
Isobutene 30.57 25.65 0.00 0.00
1-Butene 23.40 19.64 0.00 0.00
Butadiene 0.00 0.00 0.00 0.00
n-Butane 14.34 12.03 0.00 0.00
2-Butene 17.25 14.47 0.00 0.00
C5's 0.37 0.31 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 0.00 16.07 0.00 0.00
TBA 0.00 0.00 0.00 0.00
DME 0.00 0.00 0.00 0.00
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 22383 26673 6713 6713
Molar Flow Rate kg mol/hr 395.2 529.2 372.6 372.6
Molecular Weight 56.6 50.4 18.0 18.0
Temperature °C 42 43 40 40
Stream Pressure bar (g) 16.0 16.0 12.0 7.5
Stream Enthalpy MMkcal/h 0.520 0.650 0.268 0.268
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 148 171 374
Critical Pressure bar (a) 38.8 49.3 220.2
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 22383 26673 6713 6713
Actual Volumetric Flow m³/h 39.8 45.5 6.8 6.8
Actual Density kg/m³ 562 586 990 990
Standard Specific Gravity 0.60 0.62 1.00 1.00
Dynamic Viscosity cP 0.15 0.20 0.65 0.65
Kinematic Viscosity cSt 0.26 0.34 0.66 0.66
Specific Enthalpy kcal/kg 23.2 24.4 40.0 40.0
Surface Tension mN/m 10.0 12.6 69.6 69.6
Specific Heat Capacity kcal/(kg°C) 0.58 0.59 1.00 1.00
Thermal Conductivity kcal/(h·m·°C) 0.085 0.090 0.541 0.541
Project No: 189709 Rev .0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 1
Stream 6014 6015 6016 6017
0 0 0 0
Stream Description REACTOR PRIMARY PRIMARY SECONDARY
FEED REACTOR REACTOR REACTOR
PREHEATER FEED EFFLUENT FEED
OUTLET COOLER
INLET
0 0 0 0
Stream Phase LIQUID LIQUID LIQUID LIQUID
0 0 0 0
Component (wt%) 0 0 0 0
Water 0.04 0.04 0.04 0.04
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.01 0.01 0.01 0.01
Propylene 0.01 0.01 0.01 0.01
Propane 0.07 0.07 0.07 0.07
Propadiene 0.02 0.02 0.02 0.02
Isobutane 11.68 11.68 11.68 11.68
Isobutene 25.65 15.68 5.71 5.71
1-Butene 19.64 19.62 19.59 19.59
Butadiene 0.00 0.00 0.00 0.00
n-Butane 12.03 12.03 12.03 12.03
2-Butene 14.47 14.47 14.47 14.47
C5's 0.31 0.31 0.31 0.31
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.06 0.12 0.12
Methanol 16.07 10.38 4.68 4.68
TBA 0.00 0.05 0.10 0.10
DME 0.00 0.03 0.06 0.06
MTBE 0.00 15.52 31.04 31.04
MSBE 0.00 0.04 0.07 0.07
Mass Flow Rate kg/h 26673 53345 53345 26673
Molar Flow Rate kg mol/hr 529.2 963.6 868.9 434.4
Molecular Weight 50.4 55.4 61.4 61.4
Temperature °C 43 42 71 71
Stream Pressure bar (g) 15.3 14.2 13.5 13.5
Stream Enthalpy MMkcal/h 0.650 1.235 2.112 1.056
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 171 172 173 173
Critical Pressure bar (a) 49.3 45.7 41.3 41.3
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 26673 53345 53345 26673
Actual Volumetric Flow m³/h 45.5 89.1 93.5 46.7
Actual Density kg/m³ 586 599 571 571
Standard Specific Gravity 0.62 0.63 0.64 0.64
Dynamic Viscosity cP 0.20 0.19 0.15 0.15
Kinematic Viscosity cSt 0.34 0.32 0.26 0.26
Specific Enthalpy kcal/kg 24.4 23.2 39.6 39.6
Surface Tension mN/m 12.6 12.7 9.5 9.5
Specific Heat Capacity kcal/(kg°C) 0.59 0.58 0.61 0.61
Thermal Conductivity kcal/(h·m·°C) 0.090 0.092 0.084 0.084
Project No: 189709 Rev .0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 1
Stream 6018 6019 6020 6021
0 0 0 0
Stream Description SECONDARY SECONDARY SECONDARY INLET TO
REACTOR REACTOR REACTOR PRIMARY
FEED FEED EFFLUENT REACTOR
COOLER EFFLUENT
OUTLET COOLER
0 0 0 0
Stream Phase LIQUID LIQUID LIQUID LIQUID
0 0 0 0
Component (wt%) 0 0 0 0
Water 0.04 0.04 0.04 0.04
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.01 0.01 0.01 0.01
Propylene 0.01 0.01 0.01 0.01
Propane 0.07 0.07 0.07 0.07
Propadiene 0.02 0.02 0.02 0.02
Isobutane 11.68 11.68 11.68 11.68
Isobutene 5.71 5.71 2.57 5.71
1-Butene 19.59 19.59 19.57 19.59
Butadiene 0.00 0.00 0.00 0.00
n-Butane 12.03 12.03 12.03 12.03
2-Butene 14.47 14.47 14.47 14.47
C5's 0.31 0.31 0.31 0.31
C6's 0.00 0.00 0.00 0.00
DIB 0.12 0.12 0.12 0.12
Methanol 4.68 4.68 2.88 4.68
TBA 0.10 0.10 0.10 0.10
DME 0.06 0.06 0.06 0.06
MTBE 31.04 31.04 35.97 31.04
MSBE 0.07 0.07 0.10 0.07
Mass Flow Rate kg/h 26673 26673 26673 26673
Molar Flow Rate kg mol/hr 434.4 434.4 419.4 434.4
Molecular Weight 61.4 61.4 63.6 61.4
Temperature °C 40 40 49 71
Stream Pressure bar (g) 12.9 10.6 9.9 13.5
Stream Enthalpy MMkcal/h 0.577 0.577 0.716 1.056
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 173 173 174 173
Critical Pressure bar (a) 41.3 41.3 39.7 41.3
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 26673 26673 26673 26673
Actual Volumetric Flow m³/h 43.5 43.5 44.2 46.7
Actual Density kg/m³ 613 613 604 571
Standard Specific Gravity 0.64 0.64 0.65 0.64
Dynamic Viscosity cP 0.19 0.19 0.17 0.15
Kinematic Viscosity cSt 0.31 0.31 0.29 0.26
Specific Enthalpy kcal/kg 21.6 21.6 26.8 39.6
Surface Tension mN/m 12.8 12.8 11.8 9.5
Specific Heat Capacity kcal/(kg°C) 0.57 0.57 0.57 0.61
Thermal Conductivity kcal/(h·m·°C) 0.093 0.093 0.090 0.084
Project No: 189709 Rev .0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 1
Stream 6022 6023 6024 6025
0 0 0 0
Stream Description PRIMARY PRIMARY PRIMARY CD REACTION
REACTOR REACTOR REACTOR COLUMN
RECYCLE RECYCLE RECYCLE FEED
PUMP PUMP
SUCTION DISCHARGE
0 0 0 0
Stream Phase LIQUID LIQUID LIQUID LIQUID
0 0 0 0
Component (wt%) 0 0 0 0
Water 0.04 0.04 0.04 0.04
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.01 0.01 0.01 0.01
Propylene 0.01 0.01 0.01 0.01
Propane 0.07 0.07 0.07 0.07
Propadiene 0.02 0.02 0.02 0.02
Isobutane 11.68 11.68 11.68 11.68
Isobutene 5.71 5.71 5.71 2.57
1-Butene 19.59 19.59 19.59 19.57
Butadiene 0.00 0.00 0.00 0.00
n-Butane 12.03 12.03 12.03 12.03
2-Butene 14.47 14.47 14.47 14.47
C5's 0.31 0.31 0.31 0.31
C6's 0.00 0.00 0.00 0.00
DIB 0.12 0.12 0.12 0.12
Methanol 4.68 4.68 4.68 2.88
TBA 0.10 0.10 0.10 0.10
DME 0.06 0.06 0.06 0.06
MTBE 31.04 31.04 31.04 35.97
MSBE 0.07 0.07 0.07 0.10
Mass Flow Rate kg/h 26673 26673 26673 26673
Molar Flow Rate kg mol/hr 434.4 434.4 434.4 419.4
Molecular Weight 61.4 61.4 61.4 63.6
Temperature °C 40 41 41 70
Stream Pressure bar (g) 12.8 17.8 15.3 6.8
Stream Enthalpy MMkcal/h 0.577 0.585 0.585 1.037
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 173 173 173 174
Critical Pressure bar (a) 41.3 41.3 41.3 39.7
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 26673 26673 26673 26673
Actual Volumetric Flow m³/h 43.5 43.6 43.6 46.3
Actual Density kg/m³ 613 612 612 576
Standard Specific Gravity 0.64 0.64 0.64 0.65
Dynamic Viscosity cP 0.19 0.19 0.19 0.15
Kinematic Viscosity cSt 0.31 0.31 0.31 0.26
Specific Enthalpy kcal/kg 21.6 21.9 21.9 38.9
Surface Tension mN/m 12.8 12.8 12.8 9.5
Specific Heat Capacity kcal/(kg°C) 0.57 0.57 0.57 0.61
Thermal Conductivity kcal/(h·m·°C) 0.093 0.093 0.093 0.085
Project No: 189709 Rev .0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 1
Stream 6026 6027 6028 6029
0 0 0 0
Stream Description CD REACTION MTBE MTBE MTBE
COLUMN PRODUCT PRODUCT PRODUCT
BOTTOMS COOLER COOLER TO OSBL
INLET OUTLET
0 0 0 0
Stream Phase LIQUID LIQUID LIQUID LIQUID
0 0 0 0
Component (wt%) 0 0 0 0
Water 0.00 0.00 0.00 0.00
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.00 0.00 0.00 0.00
Propylene 0.00 0.00 0.00 0.00
Propane 0.00 0.00 0.00 0.00
Propadiene 0.00 0.00 0.00 0.00
Isobutane 0.00 0.00 0.00 0.00
Isobutene 0.00 0.00 0.00 0.00
1-Butene 0.00 0.00 0.00 0.00
Butadiene 0.00 0.00 0.00 0.00
n-Butane 0.02 0.02 0.02 0.02
2-Butene 0.07 0.07 0.07 0.07
C5's 0.76 0.76 0.76 0.76
C6's 0.00 0.00 0.00 0.00
DIB 0.29 0.29 0.29 0.29
Methanol 0.10 0.10 0.10 0.10
TBA 0.26 0.26 0.26 0.26
DME 0.00 0.00 0.00 0.00
MTBE 98.05 98.05 98.05 98.05
MSBE 0.43 0.43 0.43 0.43
Mass Flow Rate kg/h 10867 10867 10867 10867
Molar Flow Rate kg mol/hr 123.8 123.8 123.8 123.8
Molecular Weight 87.8 87.8 87.8 87.8
Temperature °C 135 85 45 45
Stream Pressure bar (g) 7.0 6.7 6.4 4.5
Stream Enthalpy MMkcal/h 0.808 0.487 0.246 0.246
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 224 224 224 224
Critical Pressure bar (a) 33.5 33.5 33.5 33.5
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 10867 10867 10867 10867
Actual Volumetric Flow m³/h 18.2 16.3 15.3 15.3
Actual Density kg/m³ 598 666 713 713
Standard Specific Gravity 0.74 0.74 0.74 0.74
Dynamic Viscosity cP 0.13 0.19 0.27 0.27
Kinematic Viscosity cSt 0.22 0.29 0.38 0.38
Specific Enthalpy kcal/kg 74.4 44.8 22.7 22.7
Surface Tension mN/m 7.1 12.3 16.9 16.9
Specific Heat Capacity kcal/(kg°C) 0.62 0.57 0.53 0.53
Thermal Conductivity kcal/(h·m·°C) 0.101 0.101 0.104 0.104
Project No: 189709 Rev .0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 1
Stream 6030 6031 6032 6033
0 0 0 0
Stream Description CD REACTION CD REACTION FEED TO CD REACTION
COLUMN COLUMN CD REACTION COLUMN
OVERHEAD CONDENSER COLUMN REFLUX PUMP
OUTLET OVERHEAD SUCTION
DRUM
0 0 0 0
Stream Phase VAPOR LIQUID LIQUID LIQUID
0 0 0 0
Component (wt%) 0 0 0 0
Water 0.09 0.09 0.09 0.09
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.01 0.01 0.01 0.01
Propylene 0.01 0.01 0.01 0.01
Propane 0.11 0.11 0.11 0.11
Propadiene 0.04 0.04 0.04 0.04
Isobutane 19.35 19.35 19.35 19.35
Isobutene 0.04 0.04 0.04 0.04
1-Butene 32.41 32.41 32.41 32.41
Butadiene 0.00 0.00 0.00 0.00
n-Butane 19.92 19.92 19.92 19.92
2-Butene 23.87 23.87 23.87 23.87
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 3.99 3.99 3.99 3.99
TBA 0.00 0.00 0.00 0.00
DME 0.16 0.16 0.16 0.16
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 37028 37028 37028 37028
Molar Flow Rate kg mol/hr 672.9 672.9 672.9 672.9
Molecular Weight 55.0 55.0 55.0 55.0
Temperature °C 59 50 50 50
Stream Pressure bar (g) 6.3 6.0 5.9 5.9
Stream Enthalpy MMkcal/h 4.424 1.046 1.046 1.046
Weight Fraction Liquid 0.0 1.0 1.0 1.0
Critical Temperature °C 155 155 155 155
Critical Pressure bar (a) 41.8 41.8 41.8 41.8
Vapor
Mass Flow rate kg/h 37028
Actual Volumetric Flow m³/h 2167
Molecular Weight 55.0
Actual Density kg/m³ 17.1
Viscosity cP 0.009
Specific Enthalpy kcal/kg 119.49
Specific Heat Capacity kcal/(kg°C) 0.45
Thermal Conductivity kcal/(h·m·°C) 0.016
Liquid
Mass Flow Rate kg/h 37028 37028 37028
Actual Volumetric Flow m³/h 66.7 66.7 66.7
Actual Density kg/m³ 555 555 555
Standard Specific Gravity 0.00 0.60 0.60 0.60
Dynamic Viscosity cP 0.14 0.14 0.14
Kinematic Viscosity cSt 0.26 0.26 0.26
Specific Enthalpy kcal/kg 28.3 28.3 28.3
Surface Tension mN/m 10.0 10.0 10.0
Specific Heat Capacity kcal/(kg°C) 0.60 0.60 0.60
Thermal Conductivity kcal/(h·m·°C) 0.084 0.084 0.084
Project No: 189709 Rev .0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 1
Stream 6034 6035 6036 6037
0 0 0 0
Stream Description CD REACTION CD REACTION CD REACTION MEOH EXT.
COLUMN COLUMN COLUMN COLUMN
REFLUX PUMP REFLUX REFLUX AT FEED
DISCHARGE COLUMN FEED COOLER
INLET
0 0 0 0
Stream Phase LIQUID LIQUID LIQUID LIQUID
0 0 0 0
Component (wt%) 0 0 0 0
Water 0.09 0.09 0.09 0.09
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.01 0.01 0.01 0.01
Propylene 0.01 0.01 0.01 0.01
Propane 0.11 0.11 0.11 0.11
Propadiene 0.04 0.04 0.04 0.04
Isobutane 19.35 19.35 19.35 19.35
Isobutene 0.04 0.04 0.04 0.04
1-Butene 32.41 32.41 32.41 32.41
Butadiene 0.00 0.00 0.00 0.00
n-Butane 19.92 19.92 19.92 19.92
2-Butene 23.87 23.87 23.87 23.87
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 3.99 3.99 3.99 3.99
TBA 0.00 0.00 0.00 0.00
DME 0.16 0.16 0.16 0.16
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 37028 20929 20929 16099
Molar Flow Rate kg mol/hr 672.9 380.3 380.3 292.5
Molecular Weight 55.0 55.0 55.0 55.0
Temperature °C 51 51 51 51
Stream Pressure bar (g) 13.6 13.6 6.6 13.6
Stream Enthalpy MMkcal/h 1.065 0.602 0.602 0.463
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 155 155 155 155
Critical Pressure bar (a) 41.8 41.8 41.8 41.8
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 37028 20929 20929 16099
Actual Volumetric Flow m³/h 66.8 37.8 37.8 29.1
Actual Density kg/m³ 554 554 554 554
Standard Specific Gravity 0.60 0.60 0.60 0.60
Dynamic Viscosity cP 0.14 0.14 0.14 0.14
Kinematic Viscosity cSt 0.26 0.26 0.26 0.26
Specific Enthalpy kcal/kg 28.8 28.8 28.8 28.8
Surface Tension mN/m 9.9 9.9 9.9 9.9
Specific Heat Capacity kcal/(kg°C) 0.60 0.60 0.60 0.60
Thermal Conductivity kcal/(h·m·°C) 0.084 0.084 0.084 0.084
Project No: 189709 Rev .0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 1
Stream 6038 6039 6040 6041
0 0 0 0
Stream Description C4 DISTILLATE METHANOL METHANOL METHANOL
TO METHANOL EXTRACTION REC. COL. RECOVERY
EXTRACTION COLUMN FEED/BTMS COLUMN
COLUMN BOTTOMS EXCHANGER FEED
INLET
0 0 0 0
Stream Phase LIQUID LIQUID LIQUID LIQUID
0 0 0 0
Component (wt%) 0 0 0 0
Water 0.09 80.00 80.00 80.00
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.01 0.00 0.00 0.00
Propylene 0.01 0.00 0.00 0.00
Propane 0.11 0.00 0.00 0.00
Propadiene 0.04 0.00 0.00 0.00
Isobutane 19.35 0.00 0.00 0.00
Isobutene 0.04 0.00 0.00 0.00
1-Butene 32.41 0.00 0.00 0.00
Butadiene 0.00 0.00 0.00 0.00
n-Butane 19.92 0.00 0.00 0.00
2-Butene 23.87 0.00 0.00 0.00
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 3.99 20.00 20.00 20.00
TBA 0.00 0.00 0.00 0.00
DME 0.16 0.00 0.00 0.00
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 16099 3213 3213 3213
Molar Flow Rate kg mol/hr 292.5 162.8 162.8 162.8
Molecular Weight 55.0 19.7 19.7 19.7
Temperature °C 40 40 40 75
Stream Pressure bar (g) 12.2 12.2 1.3 0.9
Stream Enthalpy MMkcal/h 0.360 0.118 0.118 0.223
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 155 358 358 358
Critical Pressure bar (a) 41.8 202.9 202.9 202.9
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 16099 3213 3213 3213
Actual Volumetric Flow m³/h 28.3 3.4 3.4 3.5
Actual Density kg/m³ 569 938 938 915
Standard Specific Gravity 0.60 0.95 0.95 0.95
Dynamic Viscosity cP 0.16 0.62 0.62 0.37
Kinematic Viscosity cSt 0.27 0.66 0.66 0.40
Specific Enthalpy kcal/kg 22.4 36.8 36.8 69.4
Surface Tension mN/m 11.1 63.6 63.6 58.2
Specific Heat Capacity kcal/(kg°C) 0.59 0.92 0.92 0.94
Thermal Conductivity kcal/(h·m·°C) 0.088 0.320 0.320 0.315
Project No: 189709 Rev .0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 1
Stream 6042 6043 6044 6045
0 0 0
Stream Description METHANOL C4s TO METHANOL METHANOL
EXTRACTION B-1 RECOVERY RECOVERY
COLUMN HEAVIES COLUMN COLUMN
OVERHEAD COLUMN BOTTOMS BOTTOMS PUMP
DISCHARGE
0 0 0
Stream Phase LIQUID LIQUID LIQUID LIQUID
0 0 0
Component (wt%) 0 0 0
Water 0.03 0.03 100.00 100.00
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.01 0.01 0.00 0.00
Propylene 0.01 0.01 0.00 0.00
Propane 0.11 0.11 0.00 0.00
Propadiene 0.04 0.04 0.00 0.00
Isobutane 20.17 20.17 0.00 0.00
Isobutene 0.04 0.04 0.00 0.00
1-Butene 33.78 33.78 0.00 0.00
Butadiene 0.00 0.00 0.00 0.00
n-Butane 20.76 20.76 0.00 0.00
2-Butene 24.87 24.87 0.00 0.00
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 0.00 0.00 0.00 0.00
TBA 0.00 0.00 0.00 0.00
DME 0.17 0.17 0.00 0.00
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 15447 15447 2562 2562
Molar Flow Rate kg mol/hr 272.0 272.0 142.2 142.2
Molecular Weight 56.8 56.8 18.0 18.0
Temperature °C 40 40 126 126
Stream Pressure bar (g) 10.5 7.4 1.4 16.0
Stream Enthalpy MMkcal/h 0.344 0.344 0.324 0.325
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 148 -125 374 374
Critical Pressure bar (a) 38.6 39.5 220.2 220.2
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 15447 15447 2562 2562
Actual Volumetric Flow m³/h 27.5 27.4 2.7 2.7
Actual Density kg/m³ 562 563 939 939
Standard Specific Gravity 0.59 0.59 1.00 1.00
Dynamic Viscosity cP 0.14 0.14 0.22 0.22
Kinematic Viscosity cSt 0.25 0.25 0.23 0.23
Specific Enthalpy kcal/kg 22.3 22.3 126.6 126.7
Surface Tension mN/m 10.3 10.5 54.0 54.0
Specific Heat Capacity kcal/(kg°C) 0.58 0.58 1.02 1.02
Thermal Conductivity kcal/(h·m·°C) 0.086 0.086 0.592 0.591
Project No: 189709 Rev .0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 1
Stream 6046 6047 6048 6049
0 0 0 0
Stream Description RECYCLE RECYCLE RECYCLE METHANOL
WATER WATER WATER TO RECOVERY
COOLER COOLER METHANOL COLUMN
INLET OUTLET EXTRACTION OVERHEAD
COLUMN
0 0 0 0
Stream Phase LIQUID LIQUID LIQUID VAPOR
0 0 0 0
Component (wt%) 0 0 0 0
Water 100.00 100.00 100.00 0.05
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.00 0.00 0.00 0.00
Propylene 0.00 0.00 0.00 0.00
Propane 0.00 0.00 0.00 0.00
Propadiene 0.00 0.00 0.00 0.00
Isobutane 0.00 0.00 0.00 0.00
Isobutene 0.00 0.00 0.00 0.00
1-Butene 0.00 0.00 0.00 0.00
Butadiene 0.00 0.00 0.00 0.00
n-Butane 0.00 0.00 0.00 0.00
2-Butene 0.00 0.00 0.00 0.00
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 0.00 0.00 0.00 99.95
TBA 0.00 0.00 0.00 0.00
DME 0.00 0.00 0.00 0.00
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 2562 2562 2562 1929
Molar Flow Rate kg mol/hr 142.2 142.2 142.2 60.2
Molecular Weight 18.0 18.0 18.0 32.0
Temperature °C 86 40 40 78
Stream Pressure bar (g) 15.7 15.3 10.6 0.7
Stream Enthalpy MMkcal/h 0.220 0.102 0.102 0.603
Weight Fraction Liquid 1.0 1.0 1.0 0.0
Critical Temperature °C 374 374 374 240
Critical Pressure bar (a) 220.2 220.2 220.2 80.1
Vapor
Mass Flow rate kg/h 1929
Actual Volumetric Flow m³/h 1000
Molecular Weight 32.0
Actual Density kg/m³ 1.9
Viscosity cP 0.012
Specific Enthalpy kcal/kg 312.51
Specific Heat Capacity kcal/(kg°C) 0.37
Thermal Conductivity kcal/(h·m·°C) 0.018
Liquid
Mass Flow Rate kg/h 2562 2562 2562
Actual Volumetric Flow m³/h 2.6 2.6 2.6
Actual Density kg/m³ 967 990 990
Standard Specific Gravity 1.00 1.00 1.00 0.00
Dynamic Viscosity cP 0.33 0.65 0.65
Kinematic Viscosity cSt 0.34 0.66 0.66
Specific Enthalpy kcal/kg 85.8 40.0 40.0
Surface Tension mN/m 62.0 69.6 69.6
Specific Heat Capacity kcal/(kg°C) 1.00 1.00 1.00
Thermal Conductivity kcal/(h·m·°C) 0.577 0.541 0.541
Project No: 189709 Rev .0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 1
Stream 6050 6051 6052 6053
0 0 0 0
Stream Description METHANOL METHANOL METHANOL METHANOL
RECOVERY RECOVERY RECOVERY RECOVERY
COLUMN COLUMN COLUMN COLUMN
CONDENSER OVHD DRUM REFLUX PUMP REFLUX PUMP
OUTLET INLET SUCTION DISCHARGE
0 0 0 0
Stream Phase LIQUID LIQUID LIQUID LIQUID
0 0 0 0
Component (wt%) 0 0 0 0
Water 0.05 0.05 0.08 0.08
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.00 0.00 0.00 0.00
Propylene 0.00 0.00 0.00 0.00
Propane 0.00 0.00 0.00 0.00
Propadiene 0.00 0.00 0.00 0.00
Isobutane 0.00 0.00 0.00 0.00
Isobutene 0.00 0.00 0.00 0.00
1-Butene 0.00 0.00 0.00 0.00
Butadiene 0.00 0.00 0.00 0.00
n-Butane 0.00 0.00 0.00 0.00
2-Butene 0.00 0.00 0.00 0.00
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 99.95 99.95 99.92 99.92
TBA 0.00 0.00 0.00 0.00
DME 0.00 0.00 0.00 0.00
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 1929 1929 5868 5868
Molar Flow Rate kg mol/hr 60.2 60.2 183.3 183.3
Molecular Weight 32.0 32.0 32.0 32.0
Temperature °C 66 66 49 50
Stream Pressure bar (g) 0.5 0.4 0.4 19.2
Stream Enthalpy MMkcal/h 0.078 0.078 0.173 0.178
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 240 240 240 240
Critical Pressure bar (a) 80.1 80.1 80.2 80.2
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 1929 1929 5868 5868
Actual Volumetric Flow m³/h 2.6 2.6 7.7 7.7
Actual Density kg/m³ 749 749 766 765
Standard Specific Gravity 0.80 0.80 0.80 0.80
Dynamic Viscosity cP 0.34 0.34 0.41 0.40
Kinematic Viscosity cSt 0.46 0.46 0.53 0.52
Specific Enthalpy kcal/kg 40.6 40.6 29.4 30.3
Surface Tension mN/m 18.8 18.8 20.3 20.2
Specific Heat Capacity kcal/(kg°C) 0.68 0.68 0.64 0.65
Thermal Conductivity kcal/(h·m·°C) 0.162 0.162 0.166 0.166
Project No: 189709 Rev .0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 1
Stream 6054 6055 6056 6057
0 0 0 0
Stream Description METHANOL METHANOL METHANOL RECYCLE
RECOVERY RECOVERY TO MTBE METHANOL
COLUMN COLUMN REACTION TO C4s
REFLUX REFLUX AT SECTION STREAM
COLUMN FEED
0 0 0 0
Stream Phase LIQUID LIQUID LIQUID LIQUID
0 0 0 0
Component (wt%) 0 0 0 0
Water 0.08 0.08 0.08 0.08
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.00 0.00 0.00 0.00
Propylene 0.00 0.00 0.00 0.00
Propane 0.00 0.00 0.00 0.00
Propadiene 0.00 0.00 0.00 0.00
Isobutane 0.00 0.00 0.00 0.00
Isobutene 0.00 0.00 0.00 0.00
1-Butene 0.00 0.00 0.00 0.00
Butadiene 0.00 0.00 0.00 0.00
n-Butane 0.00 0.00 0.00 0.00
2-Butene 0.00 0.00 0.00 0.00
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 99.92 99.92 99.92 99.92
TBA 0.00 0.00 0.00 0.00
DME 0.00 0.00 0.00 0.00
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 1286 1286 4582 4290
Molar Flow Rate kg mol/hr 40.2 40.2 143.1 134.0
Molecular Weight 32.0 32.0 32.0 32.0
Temperature °C 50 50 50 50
Stream Pressure bar (g) 19.2 0.7 19.2 19.2
Stream Enthalpy MMkcal/h 0.039 0.039 0.139 0.130
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 240 240 240 240
Critical Pressure bar (a) 80.2 80.2 80.2 80.2
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 1286 1286 4582 4290
Actual Volumetric Flow m³/h 1.7 1.7 6.0 5.6
Actual Density kg/m³ 765 765 765 765
Standard Specific Gravity 0.80 0.80 0.80 0.80
Dynamic Viscosity cP 0.40 0.40 0.40 0.40
Kinematic Viscosity cSt 0.52 0.52 0.52 0.52
Specific Enthalpy kcal/kg 30.3 30.3 30.3 30.3
Surface Tension mN/m 20.2 20.2 20.2 20.2
Specific Heat Capacity kcal/(kg°C) 0.65 0.65 0.65 0.65
Thermal Conductivity kcal/(h·m·°C) 0.166 0.166 0.166 0.166
Project No: 189709 Rev .0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 1
Stream 6058 6059 6060 6061
0 0 0
Stream Description RECYCLE METHANOL METHANOL METHANOL
METHANOL INJECTION TO INJECTION TO INJECTION TO
TO C4s CD REACTION CD REACTION CD REACTION
STREAM COLUMN COLUMN COLUMN
0 0 0
Stream Phase LIQUID LIQUID LIQUID LIQUID
0 0 0 0
Component (wt%) 0 0 0 0
Water 0.08 0.08 0.08 0.08
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.00 0.00 0.00 0.00
Propylene 0.00 0.00 0.00 0.00
Propane 0.00 0.00 0.00 0.00
Propadiene 0.00 0.00 0.00 0.00
Isobutane 0.00 0.00 0.00 0.00
Isobutene 0.00 0.00 0.00 0.00
1-Butene 0.00 0.00 0.00 0.00
Butadiene 0.00 0.00 0.00 0.00
n-Butane 0.00 0.00 0.00 0.00
2-Butene 0.00 0.00 0.00 0.00
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 99.92 99.92 99.92 99.92
TBA 0.00 0.00 0.00 0.00
DME 0.00 0.00 0.00 0.00
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 4290 294 15 279
Molar Flow Rate kg mol/hr 134.0 9.2 0.5 8.7
Molecular Weight 32.0 32.0 32.0 32.0
Temperature °C 50 50 50 50
Stream Pressure bar (g) 16.0 19.2 6.6 6.6
Stream Enthalpy MMkcal/h 0.130 0.009 0.000 0.008
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 240 240 240 240
Critical Pressure bar (a) 80.2 80.2 80.2 80.2
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 4290 294 15 279
Actual Volumetric Flow m³/h 5.6 0.4 0.0 0.4
Actual Density kg/m³ 765 765 765 765
Standard Specific Gravity 0.80 0.80 0.80 0.80
Dynamic Viscosity cP 0.40 0.40 0.40 0.40
Kinematic Viscosity cSt 0.52 0.52 0.52 0.52
Specific Enthalpy kcal/kg 30.3 30.3 30.3 30.3
Surface Tension mN/m 20.2 20.2 20.2 20.2
Specific Heat Capacity kcal/(kg°C) 0.65 0.65 0.65 0.65
Thermal Conductivity kcal/(h·m·°C) 0.166 0.166 0.166 0.166
Project No: 189709 Rev .0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 1
Stream 6062 6063 6064 6065
0 0 0
Stream Description FRESH FILTERED FILTERED CD REACTION
METHANOL FRESH FRESH COLUMN
FROM METHANOL METHANOL REBOILER
STORAGE AT INLET
OSBL
0 0 0 0
Stream Phase LIQUID LIQUID LIQUID LIQUID
0 0 0 0
Component (wt%) 0 0 0 0
Water 0.10 0.10 0.10 0.00
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.00 0.00 0.00 0.00
Propylene 0.00 0.00 0.00 0.00
Propane 0.00 0.00 0.00 0.00
Propadiene 0.00 0.00 0.00 0.00
Isobutane 0.00 0.00 0.00 0.00
Isobutene 0.00 0.00 0.00 0.00
1-Butene 0.00 0.00 0.00 0.00
Butadiene 0.00 0.00 0.00 0.00
n-Butane 0.00 0.00 0.00 0.02
2-Butene 0.00 0.00 0.00 0.07
C5's 0.00 0.00 0.00 0.76
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.29
Methanol 99.90 99.90 99.90 0.10
TBA 0.00 0.00 0.00 0.26
DME 0.00 0.00 0.00 0.00
MTBE 0.00 0.00 0.00 98.05
MSBE 0.00 0.00 0.00 0.43
Mass Flow Rate kg/h 3939 3939 3939 191943
Molar Flow Rate kg mol/hr 123.0 123.0 123.0 2185.8
Molecular Weight 32.0 32.0 32.0 87.8
Temperature °C 40 40 40 135
Stream Pressure bar (g) 3.0 2.8 0.4 7.0
Stream Enthalpy MMkcal/h 0.094 0.094 0.094 14.271
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 240 240 240 224
Critical Pressure bar (a) 80.2 80.2 80.2 33.5
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 3939 3939 3939 191943
Actual Volumetric Flow m³/h 5.1 5.1 5.1 321.2
Actual Density kg/m³ 775 775 775 598
Standard Specific Gravity 0.80 0.80 0.80 0.74
Dynamic Viscosity cP 0.40 0.40 0.40 0.13
Kinematic Viscosity cSt 0.58 0.58 0.58 0.22
Specific Enthalpy kcal/kg 24.0 24.0 24.0 74.4
Surface Tension mN/m 21.1 21.1 21.1 7.1
Specific Heat Capacity kcal/(kg°C) 0.63 0.63 0.63 0.62
Thermal Conductivity kcal/(h·m·°C) 0.166 0.166 0.166 0.101
Project No: 189709 Rev .0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 1
Stream 6066 6067 6068 6099
0 0 0
Stream Description CD REACTION METHANOL METHANOL C4 DISTILLATE
COLUMN RECOVERY RECOVERY TO METHANOL
REBOILER COLUMN COLUMN EXTRACTION
OUTLET REBOILER REBOILER COLUMN
INLET OUTLET
0 0 0 0
Stream Phase MIXED LIQUID MIXED LIQUID
0 0 0 0
Component (wt%) 0 0 0 0
Water 0.00 99.99 99.99 0.09
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.00 0.00 0.00 0.01
Propylene 0.00 0.00 0.00 0.01
Propane 0.00 0.00 0.00 0.11
Propadiene 0.00 0.00 0.00 0.04
Isobutane 0.00 0.00 0.00 19.35
Isobutene 0.00 0.00 0.00 0.04
1-Butene 0.00 0.00 0.00 32.41
Butadiene 0.00 0.00 0.00 0.00
n-Butane 0.02 0.00 0.00 19.92
2-Butene 0.07 0.00 0.00 23.87
C5's 0.76 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.29 0.00 0.00 0.00
Methanol 0.10 0.01 0.01 3.99
TBA 0.26 0.00 0.00 0.00
DME 0.00 0.00 0.00 0.16
MTBE 98.05 0.00 0.00 0.00
MSBE 0.43 0.00 0.00 0.00
Mass Flow Rate kg/h 191943 4239 4239 16099
Molar Flow Rate kg mol/hr 2185.8 235.3 235.3 292.5
Molecular Weight 87.8 18.0 18.0 55.0
Temperature °C 135 126 125 40
Stream Pressure bar (g) 6.9 1.4 1.3 13.2
Stream Enthalpy MMkcal/h 17.752 0.536 1.202 0.360
Weight Fraction Liquid 0.7 1.0 0.7 1.0
Critical Temperature °C 224 374 374 155
Critical Pressure bar (a) 33.5 220.2 220.2 41.8
Vapor
Mass Flow rate kg/h 57401 1278
Actual Volumetric Flow m³/h 2322.0 987.0
Molecular Weight 87.5 18.0
Actual Density kg/m³ 24.7 1.3
Viscosity cP 0.010 0.013
Specific Enthalpy kcal/kg 135.26 649.19
Specific Heat Capacity kcal/(kg°C) 0.50 0.46
Thermal Conductivity kcal/(h·m·°C) 0.021 0.023
Liquid
Mass Flow Rate kg/h 134542 4239 2961 16099
Actual Volumetric Flow m³/h 225.0 4.5 3.2 28.3
Actual Density kg/m³ 598 939 939 569
Standard Specific Gravity 0.75 1.00 1.00 0.60
Dynamic Viscosity cP 0.13 0.22 0.22 0.16
Kinematic Viscosity cSt 0.22 0.23 0.23 0.27
Specific Enthalpy kcal/kg 74.2 126.3 125.6 22.4
Surface Tension mN/m 7.2 54.1 54.2 11.1
Specific Heat Capacity kcal/(kg°C) 0.62 1.02 1.02 0.59
Thermal Conductivity kcal/(h·m·°C) 0.101 0.591 0.591 0.088
Project No: 189709 Rev .0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 1
Stream 0
Stream Description
Stream Phase 0
0
Component (wt%) 0
Water 0.00
Hydrogen 0.00
Methane 0.00
Propylene 0.00
Propane 0.00
Propadiene 0.00
Isobutane 0.00
Isobutene 0.00
1-Butene 0.00
Butadiene 0.00
n-Butane 0.00
2-Butene 0.00
C5's 0.00
C6's 0.00
DIB 0.00
Methanol 0.00
TBA 0.00
DME 0.00
MTBE 0.00
MSBE 0.00
0.00
0.00
Mass Flow Rate kg/h 0
Molar Flow Rate kg mol/hr 0.0
Molecular Weight 0.0
Temperature °C 0.0
Stream Pressure bar (g) 0.0
Stream Enthalpy MMkcal/h 0.000
Weight Fraction Liquid 0.00
Critical Temperature °C 0.0
Critical Pressure bar (a) 0.0
0
Vapor 0.0
Mass Flow rate kg/h 0
Actual Volumetric Flow m³/h 0
Molecular Weight 0.00
Actual Density kg/m³ 0.00
Viscosity cP 0.0000
Specific Enthalpy kcal/kg 0.0
Specific Heat Capacity kcal/(kg°C) 0.000
Thermal Conductivity kcal/(h·m·°C) 0.0000
0.000
Liquid 0.0
Mass Flow Rate kg/h 0
Actual Volumetric Flow m³/h 0.0
Actual Density kg/m³ 0.0
Standard Specific Gravity 0.000
Dynamic Viscosity cP 0.000
Kinematic Viscosity cSt
Specific Enthalpy kcal/kg 0.0
Surface Tension mN/m 0.0
Specific Heat Capacity kcal/(kg°C) 0.000
Thermal Conductivity kcal/(h·m·°C) 0.000
Project No: 189709 Rev .0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 1
Stream 6101 6102 6103 6104
Stream Description B-1 HEAVIES B-1 HEAVIES B-1 HEAVIES B-1 HEAVIES
COLUMN #1 COLUMN COLUMN #2 COLUMN #2
BOTTOMS TRANSFER FEED OVERHEAD
PUMP DISCH.
Stream Phase LIQUID LIQUID LIQUID VAPOR
Component (wt%)
Water 0.00 0.00 0.00 0.00
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.00 0.00 0.00 0.00
Propylene 0.00 0.00 0.00 0.00
Propane 0.01 0.01 0.01 0.02
Propadiene 0.01 0.01 0.01 0.01
Isobutane 11.73 11.73 11.73 13.46
Isobutene 0.05 0.05 0.05 0.05
1-Butene 57.02 57.02 57.02 57.31
Butadiene 0.00 0.00 0.00 0.00
n-Butane 19.18 19.18 19.18 17.91
2-Butene 11.97 11.97 11.97 11.18
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 0.00 0.00 0.00 0.00
TBA 0.00 0.00 0.00 0.00
DME 0.02 0.02 0.02 0.04
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 115886 115886 115886 124137
Molar Flow Rate kg mol/hr 2043.5 2043.5 2043.5 2189.2
Molecular Weight 56.7 56.7 56.7 56.7
Temperature °C 65 65 65 65
Stream Pressure bar (g) 7.3 11.1 7.3 7.3
Stream Enthalpy MMkcal/h 4.275 4.306 4.279 13.860
Weight Fraction Liquid 1.0 1.0 1.0 0.0
Critical Temperature °C 148 148 148 147
Critical Pressure bar (a) 39.6 39.6 39.6 39.6
Vapor
Mass Flow rate kg/h 124137
Actual Volumetric Flow m³/h 6218
Molecular Weight 56.7
Actual Density kg/m³ 20.0
Viscosity cP 0.009
Specific Enthalpy kcal/kg 111.65
Specific Heat Capacity kcal/(kg°C) 0.48
Thermal Conductivity kcal/(h·m·°C) 0.017
Liquid
Mass Flow Rate kg/h 115886 115886 115886
Actual Volumetric Flow m³/h 219.5 219.2 219.5
Actual Density kg/m³ 528 529 528
Standard Specific Gravity 0.59 0.59 0.59 0.00
Dynamic Viscosity cP 0.11 0.11 0.11
Kinematic Viscosity cSt 0.22 0.21 0.22
Specific Enthalpy kcal/kg 36.9 37.2 36.9
Surface Tension mN/m 7.6 7.5 7.5
Specific Heat Capacity kcal/(kg°C) 0.61 0.61 0.61
Thermal Conductivity kcal/(h·m·°C) 0.080 0.079 0.080
Project No: 189709 Rev. 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 1
Stream 6105 6106 6107 6108
Stream Description B-1 HEAVIES B-1 HEAVIES B-1 HEAVIES WASTEWATER
COLUMN #1 COLUMN COLUMN TO OSBL
OVERHEAD CONDENSER OVERHEAD
OUTLET DRUM INLET
Stream Phase VAPOR LIQUID LIQUID
Component (wt%)
Water 0.06 0.06 0.06
Hydrogen 0.00 0.00 0.00
Methane 0.03 0.03 0.03
Propylene 0.02 0.02 0.02
Propane 0.21 0.21 0.21
Propadiene 0.08 0.08 0.08
Isobutane 37.76 37.76 37.76
Isobutene 0.07 0.07 0.07
1-Butene 61.34 61.34 61.34
Butadiene 0.00 0.00 0.00
n-Butane 0.10 0.10 0.10
2-Butene 0.02 0.02 0.02
C5's 0.00 0.00 0.00
C6's 0.00 0.00 0.00
DIB 0.00 0.00 0.00
Methanol 0.00 0.00 0.00
TBA 0.00 0.00 0.00
DME 0.31 0.31 0.31
MTBE 0.00 0.00 0.00
MSBE 0.00 0.00 0.00
Mass Flow Rate kg/h 113249 113249 113249
Molar Flow Rate kg mol/hr 1999.7 1999.7 1999.7
Molecular Weight 56.6 56.6 56.6
Temperature °C 57 46 46
Stream Pressure bar (g) 6.6 6.3 6.2
Stream Enthalpy MMkcal/h 12.277 2.914 2.914
Weight Fraction Liquid 0.0 1.0 1.0
Critical Temperature °C 142 142 142
Critical Pressure bar (a) 39.4 39.4 39.4
Vapor
Mass Flow rate kg/h 113249
Actual Volumetric Flow m³/h 6121
Molecular Weight 56.6
Actual Density kg/m³ 18.5
Viscosity cP 0.009
Specific Enthalpy kcal/kg 108.40
Specific Heat Capacity kcal/(kg°C) 0.44
Thermal Conductivity kcal/(h·m·°C) 0.016
Liquid
Mass Flow Rate kg/h 113249 113249
Actual Volumetric Flow m³/h 207.8 207.8
Actual Density kg/m³ 545 545
Standard Specific Gravity 0.00 0.59 0.59
Dynamic Viscosity cP 0.13 0.13
Kinematic Viscosity cSt 0.23 0.23
Specific Enthalpy kcal/kg 25.7 25.7
Surface Tension mN/m 9.1 9.1
Specific Heat Capacity kcal/(kg°C) 0.59 0.59
Thermal Conductivity kcal/(h·m·°C) 0.082 0.082
Project No: 189709 Rev. 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 1
Stream 6109 6110 6111 6112
Stream Description WASTEWATER B-1 HEAVIES B-1 HEAVIES B-1 HEAVIES
TO OSBL COLUMN COLUMN COLUMN
REFLUX PUMP REFLUX PUMP REFLUX
SUCTION DISCHARGE
Stream Phase LIQUID LIQUID LIQUID
Component (wt%)
Water 0.06 0.06 0.06
Hydrogen 0.00 0.00 0.00
Methane 0.03 0.03 0.03
Propylene 0.02 0.02 0.02
Propane 0.21 0.21 0.21
Propadiene 0.08 0.08 0.08
Isobutane 37.76 37.76 37.76
Isobutene 0.07 0.07 0.07
1-Butene 61.34 61.34 61.34
Butadiene 0.00 0.00 0.00
n-Butane 0.10 0.10 0.10
2-Butene 0.02 0.02 0.02
C5's 0.00 0.00 0.00
C6's 0.00 0.00 0.00
DIB 0.00 0.00 0.00
Methanol 0.00 0.00 0.00
TBA 0.00 0.00 0.00
DME 0.31 0.31 0.31
MTBE 0.00 0.00 0.00
MSBE 0.00 0.00 0.00
Mass Flow Rate kg/h 113249 113249 104998
Molar Flow Rate kg mol/hr 1999.7 1999.7 1854.0
Molecular Weight 56.6 56.6 56.6
Temperature °C 46 46 46
Stream Pressure bar (g) 6.2 10.0 10.0
Stream Enthalpy MMkcal/h 2.914 2.943 2.728
Weight Fraction Liquid 1.0 1.0 1.0
Critical Temperature °C 142 142 142
Critical Pressure bar (a) 39.4 39.4 39.4
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 113249 113249 104998
Actual Volumetric Flow m³/h 207.8 207.6 192.5
Actual Density kg/m³ 545 546 546
Standard Specific Gravity 0.59 0.59 0.59
Dynamic Viscosity cP 0.13 0.13 0.13
Kinematic Viscosity cSt 0.23 0.23 0.23
Specific Enthalpy kcal/kg 25.7 26.0 26.0
Surface Tension mN/m 9.1 9.0 9.0
Specific Heat Capacity kcal/(kg°C) 0.59 0.59 0.59
Thermal Conductivity kcal/(h·m·°C) 0.082 0.082 0.082
Project No: 189709 Rev. 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 1
Stream 6113 6114 6115 6116
Stream Description B-1 HEAVIES B-1 HEAVIES B-1 HEAVIES B-1 HEAVIES
COLUMN COLUMN COLUMN COLUMN #2
REFLUX AT OVERHEAD TO OVERHEAD TO BOTTOMS
COLUMN FEED B-1 LIGHTS B-1 LIGHTS
COLUMN COLUMN
Stream Phase LIQUID LIQUID LIQUID LIQUID
Component (wt%)
Water 0.06 0.06 0.06 0.00
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.03 0.03 0.03 0.00
Propylene 0.02 0.02 0.02 0.00
Propane 0.21 0.21 0.21 0.00
Propadiene 0.08 0.08 0.08 0.00
Isobutane 37.76 37.76 37.76 0.00
Isobutene 0.07 0.07 0.07 0.00
1-Butene 61.34 61.34 61.34 2.18
Butadiene 0.00 0.00 0.00 0.00
n-Butane 0.10 0.10 0.10 44.45
2-Butene 0.02 0.02 0.02 53.37
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 0.00 0.00 0.00 0.00
TBA 0.00 0.00 0.00 0.00
DME 0.31 0.31 0.31 0.00
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 104998 8251 8251 7196
Molar Flow Rate kg mol/hr 1854.0 145.7 145.7 126.3
Molecular Weight 56.6 56.6 56.6 57.0
Temperature °C 46 46 46 74
Stream Pressure bar (g) 6.6 10.0 8.4 8.0
Stream Enthalpy MMkcal/h 2.728 0.214 0.214 0.314
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 142 142 -131 155
Critical Pressure bar (a) 39.4 39.4 39.0 40.0
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 104998 8251 8251 7196
Actual Volumetric Flow m³/h 192.8 15.1 15.1 13.7
Actual Density kg/m³ 545 546 545 526
Standard Specific Gravity 0.59 0.59 0.60
Dynamic Viscosity cP 0.13 0.13 0.13 0.12
Kinematic Viscosity cSt 0.23 0.23 0.23 0.23
Specific Enthalpy kcal/kg 26.0 26.0 26.0 43.6
Surface Tension mN/m 9.0 9.0 9.0 7.4
Specific Heat Capacity kcal/(kg°C) 0.59 0.59 0.59 0.65
Thermal Conductivity kcal/(h·m·°C) 0.082 0.082 0.082 0.078
Project No: 189709 Rev. 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 1
Stream 6117 6118 6119 6120
Stream Description B-1 HEAVIES BUTENE-2 BUTENE-2 B-1 LIGHTS
COLUMN #2 PRODUCT PRODUCT COLUMN #1
BOTTOMS COOLER TO OSBL BOTTOMS
PUMP OUTLET
DISCHARGE
Stream Phase LIQUID LIQUID LIQUID LIQUID
Component (wt%)
Water 0.00 0.00 0.00 0.00
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.00 0.00 0.00 0.00
Propylene 0.00 0.00 0.00 0.00
Propane 0.00 0.00 0.00 0.00
Propadiene 0.00 0.00 0.00 0.00
Isobutane 0.00 0.00 0.00 31.37
Isobutene 0.00 0.00 0.00 0.11
1-Butene 2.18 2.18 2.18 68.46
Butadiene 0.00 0.00 0.00 0.00
n-Butane 44.45 44.45 44.45 0.04
2-Butene 53.37 53.37 53.37 0.01
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 0.00 0.00 0.00 0.00
TBA 0.00 0.00 0.00 0.00
DME 0.00 0.00 0.00 0.00
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 7196 7196 7196 126123
Molar Flow Rate kg mol/hr 126.3 126.3 126.3 2223.4
Molecular Weight 57.0 57.0 57.0 56.7
Temperature °C 75 45 45 68
Stream Pressure bar (g) 9.2 8.5 7.0 8.6
Stream Enthalpy MMkcal/h 0.315 0.182 0.182 4.892
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 155 155 155 143
Critical Pressure bar (a) 40.0 40.0 40.0 39.2
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 7196 7196 7196 126123
Actual Volumetric Flow m³/h 13.7 12.7 12.7 244.7
Actual Density kg/m³ 526 568 568 516
Standard Specific Gravity 0.60 0.60 0.60 0.59
Dynamic Viscosity cP 0.12 0.15 0.15 0.11
Kinematic Viscosity cSt 0.23 0.26 0.26 0.21
Specific Enthalpy kcal/kg 43.7 25.3 25.3 38.8
Surface Tension mN/m 7.4 10.7 10.7 6.7
Specific Heat Capacity kcal/(kg°C) 0.65 0.60 0.60 0.62
Thermal Conductivity kcal/(h·m·°C) 0.078 0.087 0.087 0.076
Project No: 189709 Rev. 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 1
Stream 6121 6122 6123 6124
Stream Description B-1 LIGHTS B-1 LIGHTS B-1 LIGHTS B-1 LIGHTS
COLUMN COLUMN #2 COLUMN #2 COLUMN #1
TRANSFER FEED OVERHEAD OVERHEAD
PUMP DISCH.
Stream Phase LIQUID LIQUID VAPOR VAPOR
Component (wt%)
Water 0.00 0.00 0.00 0.04
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.00 0.00 0.00 0.06
Propylene 0.00 0.00 0.00 0.05
Propane 0.00 0.00 0.00 0.51
Propadiene 0.00 0.00 0.00 0.18
Isobutane 31.37 31.37 32.62 90.95
Isobutene 0.11 0.11 0.11 0.03
1-Butene 68.46 68.46 67.22 7.40
Butadiene 0.00 0.00 0.00 0.00
n-Butane 0.04 0.04 0.03 0.00
2-Butene 0.01 0.01 0.01 0.00
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 0.00 0.00 0.00 0.01
TBA 0.00 0.00 0.00 0.00
DME 0.00 0.00 0.00 0.75
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 126123 126123 121296 108492
Molar Flow Rate kg mol/hr 2223.4 2223.4 2137.4 1886.9
Molecular Weight 56.7 56.7 56.7 57.5
Temperature °C 68 68 68 60
Stream Pressure bar (g) 12.4 8.6 8.6 7.9
Stream Enthalpy MMkcal/h 4.926 4.896 13.372 11.491
Weight Fraction Liquid 1.0 1.0 0.0 0.0
Critical Temperature °C 143 143 143 135
Critical Pressure bar (a) 39.2 39.2 39.2 37.3
Vapor
Mass Flow rate kg/h 121296 108492
Actual Volumetric Flow m³/h 5176 4831
Molecular Weight 56.7 57.5
Actual Density kg/m³ 23.4 22.5
Viscosity cP 0.010 0.009
Specific Enthalpy kcal/kg 110.25 105.91
Specific Heat Capacity kcal/(kg°C) 0.49 0.48
Thermal Conductivity kcal/(h·m·°C) 0.017 0.017
Liquid
Mass Flow Rate kg/h 126123 126123
Actual Volumetric Flow m³/h 244.3 244.7
Actual Density kg/m³ 516 515
Standard Specific Gravity 0.59 0.59 0.00 0.00
Dynamic Viscosity cP 0.11 0.11
Kinematic Viscosity cSt 0.21 0.21
Specific Enthalpy kcal/kg 39.1 38.8
Surface Tension mN/m 6.6 6.6
Specific Heat Capacity kcal/(kg°C) 0.62 0.62
Thermal Conductivity kcal/(h·m·°C) 0.076 0.076
Project No: 189709 Rev. 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 1
Stream 6125 6126 6127 6128
Stream Description B-1 LIGHTS B-1 LIGHTS WASTEWATER WASTEWATER
COLUMN COLUMN TO OSBL TO OSBL
CONDENSER REFLUX
OUTLET DRUM INLET
Stream Phase LIQUID LIQUID WATER WATER
Component (wt%)
Water 0.04 0.04 100.00 100.00
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.06 0.06 0.00 0.00
Propylene 0.05 0.05 0.00 0.00
Propane 0.51 0.51 0.00 0.00
Propadiene 0.18 0.18 0.00 0.00
Isobutane 90.95 90.95 0.00 0.00
Isobutene 0.03 0.03 0.00 0.00
1-Butene 7.40 7.40 0.00 0.00
Butadiene 0.00 0.00 0.00 0.00
n-Butane 0.00 0.00 0.00 0.00
2-Butene 0.00 0.00 0.00 0.00
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 0.01 0.01 0.00 0.00
TBA 0.00 0.00 0.00 0.00
DME 0.75 0.75 0.00 0.00
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 108492 108492 2 2
Molar Flow Rate kg mol/hr 1886.9 1886.9 0.1 0.1
Molecular Weight 57.5 57.5 18.0 18.0
Temperature °C 46 46 46 46
Stream Pressure bar (g) 7.6 7.5 7.5 3.0
Stream Enthalpy MMkcal/h 2.888 2.888 0.000 0.000
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 135 135 374 374
Critical Pressure bar (a) 37.3 37.3 221.2 221.2
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 108492 108492 2 2
Actual Volumetric Flow m³/h 206.4 206.4 0.0 0.0
Actual Density kg/m³ 526 526 990 990
Standard Specific Gravity 0.57 0.57 1.00 1.00
Dynamic Viscosity cP 0.14 0.14 0.58 0.58
Kinematic Viscosity cSt 0.26 0.26 0.59 0.59
Specific Enthalpy kcal/kg 26.6 26.6 46.1 46.1
Surface Tension mN/m 7.9 7.9 70.0 70.0
Specific Heat Capacity kcal/(kg°C) 0.62 0.62 1.00 1.00
Thermal Conductivity kcal/(h·m·°C) 0.076 0.076 0.547 0.547
Project No: 189709 Rev. 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 1
Stream 6129 6130 6131 6132
Stream Description B-1 LIGHTS B-1 LIGHTS B-1 LIGHTS B-1 LIGHTS
COLUMN COLUMN COLUMN COLUMN
REFLUX PUMP REFLUX PUMP REFLUX REFLUX AT
SUCTION DISCHARGE COLUMN FEED
Stream Phase LIQUID LIQUID LIQUID LIQUID
Component (wt%)
Water 0.04 0.04 0.04 0.04
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.06 0.06 0.06 0.06
Propylene 0.05 0.05 0.05 0.05
Propane 0.51 0.51 0.51 0.51
Propadiene 0.18 0.18 0.18 0.18
Isobutane 90.96 90.96 90.96 90.96
Isobutene 0.03 0.03 0.03 0.03
1-Butene 7.40 7.40 7.40 7.40
Butadiene 0.00 0.00 0.00 0.00
n-Butane 0.00 0.00 0.00 0.00
2-Butene 0.00 0.00 0.00 0.00
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 0.01 0.01 0.01 0.01
TBA 0.00 0.00 0.00 0.00
DME 0.75 0.75 0.75 0.75
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 108489 108489 105069 105069
Molar Flow Rate kg mol/hr 1886.8 1886.8 1827.3 1827.3
Molecular Weight 57.5 57.5 57.5 57.5
Temperature °C 46 47 47 47
Stream Pressure bar (g) 7.5 15.0 15.0 7.9
Stream Enthalpy MMkcal/h 2.888 2.944 2.852 2.852
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 135 135 135 135
Critical Pressure bar (a) 37.3 37.3 37.3 37.3
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 108489 108489 105069 105069
Actual Volumetric Flow m³/h 206.4 206.0 199.5 200.3
Actual Density kg/m³ 526 527 527 525
Standard Specific Gravity 0.57 0.57 0.57 0.57
Dynamic Viscosity cP 0.14 0.13 0.13 0.13
Kinematic Viscosity cSt 0.26 0.26 0.26 0.26
Specific Enthalpy kcal/kg 26.6 27.1 27.1 27.1
Surface Tension mN/m 7.9 7.8 7.8 7.8
Specific Heat Capacity kcal/(kg°C) 0.62 0.62 0.62 0.62
Thermal Conductivity kcal/(h·m·°C) 0.076 0.076 0.076 0.076
Project No: 189709 Rev. 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 1
Stream 6133 6135 6136 6137
Stream Description ISOBUTANE ISOBUTANE B-1 LIGHTS B-1 LIGHTS
PRODUCT PRODUCT COLUMN #2 COLUMN
TO OSBL BOTTOMS BOTTOMS
PUMP DISCH.
Stream Phase LIQUID LIQUID LIQUID LIQUID
Component (wt%)
Water 0.04 0.04 0.00 0.00
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.06 0.06 0.00 0.00
Propylene 0.05 0.05 0.00 0.00
Propane 0.51 0.51 0.00 0.00
Propadiene 0.18 0.18 0.00 0.00
Isobutane 90.96 90.96 0.09 0.09
Isobutene 0.03 0.03 0.10 0.10
1-Butene 7.40 7.40 99.60 99.60
Butadiene 0.00 0.00 0.00 0.00
n-Butane 0.00 0.00 0.17 0.17
2-Butene 0.00 0.00 0.03 0.03
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 0.01 0.01 0.00 0.00
TBA 0.00 0.00 0.00 0.00
DME 0.75 0.75 0.00 0.00
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 3420 3420 4827 4827
Molar Flow Rate kg mol/hr 59.5 59.5 86.0 86.0
Molecular Weight 57.5 57.5 56.1 56.1
Temperature °C 47 47 73 73
Stream Pressure bar (g) 15.0 13.0 9.3 9.7
Stream Enthalpy MMkcal/h 0.093 0.093 0.198 0.198
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 135 135 147 147
Critical Pressure bar (a) 37.3 37.3 40.4 40.4
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 3420 3420 4827 4827
Actual Volumetric Flow m³/h 6.5 6.5 9.3 9.3
Actual Density kg/m³ 527 527 519 519
Standard Specific Gravity 0.57 0.57 0.60 0.60
Dynamic Viscosity cP 0.13 0.14 0.10 0.10
Kinematic Viscosity cSt 0.26 0.26 0.20 0.20
Specific Enthalpy kcal/kg 27.1 27.1 41.1 41.1
Surface Tension mN/m 7.8 7.8 6.6 6.6
Specific Heat Capacity kcal/(kg°C) 0.62 0.62 0.60 0.60
Thermal Conductivity kcal/(h·m·°C) 0.076 0.076 0.079 0.079
Project No: 189709 Rev. 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 1
Stream 6138 6139 6140 6141
Stream Description BUTENE-1 BUTENE-1 B-1 HEAVIES B-1 HEAVIES
PRODUCT PRODUCT COLUMN COLUMN
COOLER TO OSBL REBOILER REBOILER
OUTLET INLET OUTLET
Stream Phase LIQUID LIQUID LIQUID MIXED
Component (wt%)
Water 0.00 0.00 0.00 0.00
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.00 0.00 0.00 0.00
Propylene 0.00 0.00 0.00 0.00
Propane 0.00 0.00 0.00 0.00
Propadiene 0.00 0.00 0.00 0.00
Isobutane 0.09 0.09 0.00 0.00
Isobutene 0.10 0.10 0.00 0.00
1-Butene 99.60 99.60 2.26 2.26
Butadiene 0.00 0.00 0.00 0.00
n-Butane 0.17 0.17 44.70 44.70
2-Butene 0.03 0.03 53.03 53.03
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 0.00 0.00 0.00 0.00
TBA 0.00 0.00 0.00 0.00
DME 0.00 0.00 0.00 0.00
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 4827 4827 426058 426058
Molar Flow Rate kg mol/hr 86.0 86.0 7475.9 7475.9
Molecular Weight 56.1 56.1 57.0 57.0
Temperature °C 45 45 74 74
Stream Pressure bar (g) 9.0 8.0 8.0 8.0
Stream Enthalpy MMkcal/h 0.119 0.119 18.582 28.139
Weight Fraction Liquid 1.0 1.0 1.0 0.7
Critical Temperature °C 147 147 155 155
Critical Pressure bar (a) 40.4 40.4 40.0 40.0
Vapor
Mass Flow rate kg/h 127844
Actual Volumetric Flow m³/h 5969
Molecular Weight 57.0
Actual Density kg/m³ 21.4
Viscosity cP 0.009
Specific Enthalpy kcal/kg 118.33
Specific Heat Capacity kcal/(kg°C) 0.50
Thermal Conductivity kcal/(h·m·°C) 0.018
Liquid
Mass Flow Rate kg/h 4827 4827 426058 298214
Actual Volumetric Flow m³/h 8.6 8.6 809.7 566.6
Actual Density kg/m³ 561 561 526 526
Standard Specific Gravity 0.60 0.60 0.60 0.60
Dynamic Viscosity cP 0.12 0.12 0.12 0.12
Kinematic Viscosity cSt 0.22 0.22 0.23 0.23
Specific Enthalpy kcal/kg 24.6 24.6 43.6 43.6
Surface Tension mN/m 9.9 9.9 7.4 7.4
Specific Heat Capacity kcal/(kg°C) 0.57 0.57 0.65 0.65
Thermal Conductivity kcal/(h·m·°C) 0.088 0.088 0.078 0.078
Project No: 189709 Rev. 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 1
Stream 6142 6143
Stream Description B-1 LIGHTS B-1 LIGHTS
COLUMN COLUMN
REBOILER REBOILER
INLET OUTLET
Stream Phase LIQUID MIXED
Component (wt%)
Water 0.00 0.00
Hydrogen 0.00 0.00
Methane 0.00 0.00
Propylene 0.00 0.00
Propane 0.00 0.00
Propadiene 0.00 0.00
Isobutane 0.09 0.09
Isobutene 0.11 0.11
1-Butene 99.60 99.60
Butadiene 0.00 0.00
n-Butane 0.17 0.17
2-Butene 0.03 0.03
C5's 0.00 0.00
C6's 0.00 0.00
DIB 0.00 0.00
Methanol 0.00 0.00
TBA 0.00 0.00
DME 0.00 0.00
MTBE 0.00 0.00
MSBE 0.00 0.00
Mass Flow Rate kg/h 398289 398289
Molar Flow Rate kg mol/hr 7098.0 7098.0
Molecular Weight 56.1 56.1
Temperature °C 73 73
Stream Pressure bar (g) 9.3 9.3
Stream Enthalpy MMkcal/h 16.354 25.032
Weight Fraction Liquid 1.0 0.7
Critical Temperature °C 147 147
Critical Pressure bar (a) 40.4 40.4
Vapor
Mass Flow rate kg/h 119487
Actual Volumetric Flow m³/h 4853
Molecular Weight 56.1
Actual Density kg/m³ 24.6
Viscosity cP 0.010
Specific Enthalpy kcal/kg 113.67
Specific Heat Capacity kcal/(kg°C) 0.49
Thermal Conductivity kcal/(h·m·°C) 0.017
Liquid
Mass Flow Rate kg/h 398289 278802
Actual Volumetric Flow m³/h 767.8 537.5
Actual Density kg/m³ 519 519
Standard Specific Gravity 0.60 0.60
Dynamic Viscosity cP 0.10 0.10
Kinematic Viscosity cSt 0.20 0.20
Specific Enthalpy kcal/kg 41.1 41.1
Surface Tension mN/m 6.6 6.6
Specific Heat Capacity kcal/(kg°C) 0.60 0.60
Thermal Conductivity kcal/(h·m·°C) 0.079 0.079
Project No: 189709 Rev. 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 2
Stream 6001 6003 6004 6005
0 0 0
Stream Description MIXED WATER WASH WASTE WATER TOTAL WASTE
HYDROGENATED COLUMN TO WATER TO
C4S FROM OSBL BOTTOMS WASTE WATER WASTE WATER
PLANT OSBL PLANT OSBL
0 0 0 0
Stream Phase LIQUID LIQUID LIQUID LIQUID
0 0 0 0
Component (wt%) 0 0 0 0
Water 0.00 100.00 100.00 100
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.01 0.00 0.00 0.00
Propylene 0.01 0.00 0.00 0.00
Propane 0.08 0.00 0.00 0.00
Propadiene 0.03 0.00 0.00 0.00
Isobutane 18.96 0.00 0.00 0.00
Isobutene 29.08 0.00 0.00 0.00
1-Butene 18.67 0.00 0.00 0.00
Butadiene 0.00 0.00 0.00 0.00
n-Butane 18.79 0.00 0.00 0.00
2-Butene 14.00 0.00 0.00 0.00
C5's 0.37 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 0.00 0.00 0.00 0.00
TBA 0.00 0.00 0.00 0.00
DME 0.00 0.00 0.00 0.00
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 25719 7708 7708 7712
Molar Flow Rate kg mol/hr 452.3 427.9 427.9 428.1
Molecular Weight 56.9 18.0 18.0 18.0
Temperature °C 41 40 40 40
Stream Pressure bar (g) 11.0 9.0 3.0 3.0
Stream Enthalpy MMkcal/h 0.582 0.311 0.311 0.311
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 147 374 374 374
Critical Pressure bar (a) 38.3 220.2 220.2 220.2
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 25719 7708 7708 7712
Actual Volumetric Flow m³/h 45.9 7.8 7.8 7.8
Actual Density kg/m³ 560 992 990 990
Standard Specific Gravity 0.59 1.00 1.00 1.00
Dynamic Viscosity cP 0.15 0.65 0.65 0.65
Kinematic Viscosity cSt 0.26 0.65 0.65 0.65
Specific Enthalpy kcal/kg 22.6 40.3 40.3 40.3
Surface Tension mN/m 9.9 69.5 69.5 69.5
Specific Heat Capacity kcal/(kg°C) 0.58 1.00 1.00 1.00
Thermal Conductivity kcal/(h·m·°C) 0.085 0.542 0.542 0.542
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 2
Stream 6006 6007 6008 6009
0 0 0 0
Stream Description WATER WASH FEED TO C4 FEED C4 FEED
COLUMN C4 FEED PUMP PUMP
OVERHEAD SURGE DRUM SUCTION DISCHARGE
0 0 0 0
Stream Phase LIQUID LIQUID LIQUID LIQUID
0 0 0 0
Component (wt%) 0 0 0 0
Water 0.03 0.03 0.03 0.03
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.01 0.01 0.01 0.01
Propylene 0.01 0.01 0.01 0.01
Propane 0.08 0.08 0.08 0.08
Propadiene 0.03 0.03 0.03 0.03
Isobutane 18.96 18.96 18.96 18.96
Isobutene 29.08 29.08 29.08 29.08
1-Butene 18.66 18.66 18.66 18.66
Butadiene 0.00 0.00 0.00 0.00
n-Butane 18.79 18.79 18.79 18.79
2-Butene 14.00 14.00 14.00 14.00
C5's 0.37 0.37 0.37 0.37
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 0.00 0.00 0.00 0.00
TBA 0.00 0.00 0.00 0.00
DME 0.00 0.00 0.00 0.00
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 25727 25727 25727 25727
Molar Flow Rate kg mol/hr 452.8 452.8 452.8 452.8
Molecular Weight 56.8 56.8 56.8 56.8
Temperature °C 40 40 40 42
Stream Pressure bar (g) 7.0 5.0 5.0 17.5
Stream Enthalpy MMkcal/h 0.579 0.579 0.579 0.601
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 147 147 147 147
Critical Pressure bar (a) 38.4 38.4 38.4 38.4
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 25727 25727 25727 25727
Actual Volumetric Flow m³/h 45.8 45.9 45.9 46.0
Actual Density kg/m³ 561 561 561 559
Standard Specific Gravity 0.59 0.59 0.59 0.59
Dynamic Viscosity cP 0.15 0.15 0.15 0.15
Kinematic Viscosity cSt 0.26 0.26 0.26 0.26
Specific Enthalpy kcal/kg 22.5 22.5 22.5 23.3
Surface Tension mN/m 10.0 10.0 10.0 9.8
Specific Heat Capacity kcal/(kg°C) 0.58 0.58 0.58 0.59
Thermal Conductivity kcal/(h·m·°C) 0.085 0.085 0.085 0.084
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 2
Stream 6010 6011 6012 6013
0 0 0 0
Stream Description C4 FEED MIXED DEMINERALIZED DEMINERALIZED
PUMP C4s & MeOH WATER FROM WATER FEED
DISCHARGE OSBL TO WATER TO WATER
DOWNSTRM FV WASH COLUMN WASH COLUMN
0 0 0 0
Stream Phase LIQUID LIQUID LIQUID LIQUID
0 0 0 0
Component (wt%) 0 0 0 0
Water 0.03 0.04 100.00 100.00
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.01 0.01 0.00 0.00
Propylene 0.01 0.01 0.00 0.00
Propane 0.08 0.07 0.00 0.00
Propadiene 0.03 0.02 0.00 0.00
Isobutane 18.96 16.00 0.00 0.00
Isobutene 29.08 24.53 0.00 0.00
1-Butene 18.66 15.74 0.00 0.00
Butadiene 0.00 0.00 0.00 0.00
n-Butane 18.79 15.85 0.00 0.00
2-Butene 14.00 11.81 0.00 0.00
C5's 0.37 0.31 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 0.00 15.62 0.00 0.00
TBA 0.00 0.00 0.00 0.00
DME 0.00 0.00 0.00 0.00
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 25727 30493 7716 7716
Molar Flow Rate kg mol/hr 452.8 601.6 428.3 428.3
Molecular Weight 56.8 50.7 18.0 18.0
Temperature °C 42 43 40 40
Stream Pressure bar (g) 16.0 16.0 12.0 7.5
Stream Enthalpy MMkcal/h 0.601 0.745 0.308 0.308
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 147 170 374 374
Critical Pressure bar (a) 38.4 48.8 220.2 220.2
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 25727 30493 7716 7716
Actual Volumetric Flow m³/h 46.0 52.4 7.8 7.8
Actual Density kg/m³ 559 582 990 990
Standard Specific Gravity 0.59 0.62 1.00 1.00
Dynamic Viscosity cP 0.15 0.20 0.65 0.65
Kinematic Viscosity cSt 0.26 0.34 0.66 0.66
Specific Enthalpy kcal/kg 23.3 24.4 40.0 40.0
Surface Tension mN/m 9.8 12.4 69.6 69.6
Specific Heat Capacity kcal/(kg°C) 0.59 0.60 1.00 1.00
Thermal Conductivity kcal/(h·m·°C) 0.084 0.089 0.541 0.541
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 2
Stream 6014 6015 6016 6017
0 0 0 0
Stream Description REACTOR PRIMARY PRIMARY SECONDARY
FEED REACTOR REACTOR REACTOR
PREHEATER FEED EFFLUENT FEED
OUTLET COOLER
INLET
0 0 0 0
Stream Phase LIQUID LIQUID LIQUID LIQUID
0 0 0 0
Component (wt%) 0 0 0 0
Water 0.04 0.04 0.04 0.04
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.01 0.01 0.01 0.01
Propylene 0.01 0.01 0.01 0.01
Propane 0.07 0.07 0.07 0.07
Propadiene 0.02 0.02 0.02 0.02
Isobutane 16.00 16.00 16.00 16.00
Isobutene 24.53 14.99 5.46 5.46
1-Butene 15.74 15.72 15.71 15.71
Butadiene 0.00 0.00 0.00 0.00
n-Butane 15.85 15.85 15.85 15.85
2-Butene 11.81 11.81 11.81 11.81
C5's 0.31 0.31 0.31 0.31
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.06 0.11 0.11
Methanol 15.62 10.17 4.72 4.72
TBA 0.00 0.05 0.09 0.09
DME 0.00 0.03 0.06 0.06
MTBE 0.00 14.84 29.68 29.68
MSBE 0.00 0.03 0.06 0.06
Mass Flow Rate kg/h 30493 60986 60986 30493
Molar Flow Rate kg mol/hr 601.6 1099.6 996.0 498.0
Molecular Weight 50.7 55.5 61.2 61.2
Temperature °C 43 42 69 69
Stream Pressure bar (g) 15.3 14.2 13.5 13.5
Stream Enthalpy MMkcal/h 0.745 1.418 2.377 1.188
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 170 171 172 172
Critical Pressure bar (a) 48.8 45.3 41.1 41.1
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 30493 60986 60986 30493
Actual Volumetric Flow m³/h 52.4 102.6 107.4 53.7
Actual Density kg/m³ 582 595 568 568
Standard Specific Gravity 0.62 0.63 0.64 0.64
Dynamic Viscosity cP 0.20 0.19 0.15 0.15
Kinematic Viscosity cSt 0.34 0.32 0.26 0.26
Specific Enthalpy kcal/kg 24.4 23.3 39.0 39.0
Surface Tension mN/m 12.4 12.5 9.5 9.5
Specific Heat Capacity kcal/(kg°C) 0.60 0.58 0.62 0.62
Thermal Conductivity kcal/(h·m·°C) 0.089 0.091 0.083 0.083
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 2
Stream 6018 6019 6020 6021
0 0 0 0
Stream Description SECONDARY SECONDARY SECONDARY INLET TO
REACTOR REACTOR REACTOR PRIMARY
FEED FEED EFFLUENT REACTOR
COOLER EFFLUENT
OUTLET COOLER
0 0 0 0
Stream Phase LIQUID LIQUID LIQUID LIQUID
0 0 0 0
Component (wt%) 0 0 0 0
Water 0.04 0.04 0.04 0.04
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.01 0.01 0.01 0.01
Propylene 0.01 0.01 0.01 0.01
Propane 0.07 0.07 0.07 0.07
Propadiene 0.02 0.02 0.02 0.02
Isobutane 16.00 16.00 16.00 16.00
Isobutene 5.46 5.46 2.46 5.46
1-Butene 15.71 15.71 15.69 15.71
Butadiene 0.00 0.00 0.00 0.00
n-Butane 15.85 15.85 15.85 15.85
2-Butene 11.81 11.81 11.81 11.81
C5's 0.31 0.31 0.31 0.31
C6's 0.00 0.00 0.00 0.00
DIB 0.11 0.11 0.11 0.11
Methanol 4.72 4.72 3.00 4.72
TBA 0.09 0.09 0.09 0.09
DME 0.06 0.06 0.06 0.06
MTBE 29.68 29.68 34.40 29.68
MSBE 0.06 0.06 0.08 0.06
Mass Flow Rate kg/h 30493 30493 30493 30493
Molar Flow Rate kg mol/hr 498.0 498.0 481.6 498.0
Molecular Weight 61.2 61.2 63.3 61.2
Temperature °C 40 40 49 69
Stream Pressure bar (g) 12.9 10.6 9.9 13.5
Stream Enthalpy MMkcal/h 0.664 0.664 0.815 1.188
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 172 172 172 172
Critical Pressure bar (a) 41.1 41.1 39.6 41.1
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 30493 30493 30493 30493
Actual Volumetric Flow m³/h 50.2 50.2 50.9 53.7
Actual Density kg/m³ 608 608 600 568
Standard Specific Gravity 0.64 0.64 0.64 0.64
Dynamic Viscosity cP 0.19 0.19 0.17 0.15
Kinematic Viscosity cSt 0.31 0.31 0.29 0.26
Specific Enthalpy kcal/kg 21.8 21.8 26.7 39.0
Surface Tension mN/m 12.6 12.6 11.6 9.5
Specific Heat Capacity kcal/(kg°C) 0.57 0.57 0.58 0.62
Thermal Conductivity kcal/(h·m·°C) 0.092 0.092 0.089 0.083
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 2
Stream 6022 6023 6024 6025
0 0 0 0
Stream Description PRIMARY PRIMARY PRIMARY CD REACTION
REACTOR REACTOR REACTOR COLUMN
RECYCLE RECYCLE RECYCLE FEED
PUMP PUMP
SUCTION DISCHARGE
0 0 0 0
Stream Phase LIQUID LIQUID LIQUID LIQUID
0 0 0 0
Component (wt%) 0 0 0 0
Water 0.04 0.04 0.04 0.04
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.01 0.01 0.01 0.01
Propylene 0.01 0.01 0.01 0.01
Propane 0.07 0.07 0.07 0.07
Propadiene 0.02 0.02 0.02 0.02
Isobutane 16.00 16.00 16.00 16.00
Isobutene 5.46 5.46 5.46 2.46
1-Butene 15.71 15.71 15.71 15.69
Butadiene 0.00 0.00 0.00 0.00
n-Butane 15.85 15.85 15.85 15.85
2-Butene 11.81 11.81 11.81 11.81
C5's 0.31 0.31 0.31 0.31
C6's 0.00 0.00 0.00 0.00
DIB 0.11 0.11 0.11 0.11
Methanol 4.72 4.72 4.72 3.00
TBA 0.09 0.09 0.09 0.09
DME 0.06 0.06 0.06 0.06
MTBE 29.68 29.68 29.68 34.40
MSBE 0.06 0.06 0.06 0.08
Mass Flow Rate kg/h 30493 30493 30493 30493
Molar Flow Rate kg mol/hr 498.0 498.0 498.0 481.6
Molecular Weight 61.2 61.2 61.2 63.3
Temperature °C 40 41 41 70
Stream Pressure bar (g) 12.8 17.8 15.3 6.8
Stream Enthalpy MMkcal/h 0.664 0.673 0.673 1.194
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 172 172 172 172
Critical Pressure bar (a) 41.1 41.1 41.1 39.6
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 30493 30493 30493 30493
Actual Volumetric Flow m³/h 50.2 50.2 50.2 53.5
Actual Density kg/m³ 608 607 607 570
Standard Specific Gravity 0.64 0.64 0.64 0.64
Dynamic Viscosity cP 0.19 0.19 0.19 0.15
Kinematic Viscosity cSt 0.31 0.31 0.31 0.26
Specific Enthalpy kcal/kg 21.8 22.1 22.1 39.2
Surface Tension mN/m 12.6 12.6 12.6 9.3
Specific Heat Capacity kcal/(kg°C) 0.57 0.57 0.57 0.61
Thermal Conductivity kcal/(h·m·°C) 0.092 0.092 0.092 0.083
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 2
Stream 6026 6027 6028 6029
0 0 0 0
Stream Description CD REACTION MTBE MTBE MTBE
COLUMN PRODUCT PRODUCT PRODUCT
BOTTOMS COOLER COOLER TO OSBL
INLET OUTLET
0 0 0 0
Stream Phase LIQUID LIQUID LIQUID LIQUID
0 0 0 0
Component (wt%) 0 0 0 0
Water 0.00 0.00 0.00 0.00
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.00 0.00 0.00 0.00
Propylene 0.00 0.00 0.00 0.00
Propane 0.00 0.00 0.00 0.00
Propadiene 0.00 0.00 0.00 0.00
Isobutane 0.00 0.00 0.00 0.00
Isobutene 0.00 0.00 0.00 0.00
1-Butene 0.00 0.00 0.00 0.00
Butadiene 0.00 0.00 0.00 0.00
n-Butane 0.03 0.03 0.03 0.03
2-Butene 0.07 0.07 0.07 0.07
C5's 0.80 0.80 0.80 0.80
C6's 0.00 0.00 0.00 0.00
DIB 0.29 0.29 0.29 0.29
Methanol 0.10 0.10 0.10 0.10
TBA 0.26 0.26 0.26 0.26
DME 0.00 0.00 0.00 0.00
MTBE 98.09 98.09 98.09 98.09
MSBE 0.36 0.36 0.36 0.36
Mass Flow Rate kg/h 11877 11877 11877 11877
Molar Flow Rate kg mol/hr 135.3 135.3 135.3 135.3
Molecular Weight 87.8 87.8 87.8 87.8
Temperature °C 135 81 45 45
Stream Pressure bar (g) 7.0 6.7 6.4 4.5
Stream Enthalpy MMkcal/h 0.883 0.504 0.269 0.269
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 224 224 224 224
Critical Pressure bar (a) 33.5 33.5 33.5 33.5
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 11877 11877 11877 11877
Actual Volumetric Flow m³/h 19.9 17.7 16.7 16.7
Actual Density kg/m³ 598 671 713 713
Standard Specific Gravity 0.74 0.74 0.74 0.74
Dynamic Viscosity cP 0.13 0.20 0.27 0.27
Kinematic Viscosity cSt 0.22 0.29 0.38 0.38
Specific Enthalpy kcal/kg 74.3 42.4 22.7 22.7
Surface Tension mN/m 7.1 12.8 16.9 16.9
Specific Heat Capacity kcal/(kg°C) 0.62 0.57 0.53 0.53
Thermal Conductivity kcal/(h·m·°C) 0.101 0.101 0.104 0.104
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 2
Stream 6030 6031 6032 6033
0 0 0 0
Stream Description CD REACTION CD REACTION FEED TO CD REACTION
COLUMN COLUMN CD REACTION COLUMN
OVERHEAD CONDENSER COLUMN REFLUX PUMP
OUTLET OVERHEAD SUCTION
DRUM
0 0 0 0
Stream Phase VAPOR LIQUID LIQUID LIQUID
0 0 0 0
Component (wt%) 0 0 0 0
Water 0.09 0.09 0.09 0.09
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.01 0.01 0.01 0.01
Propylene 0.01 0.01 0.01 0.01
Propane 0.11 0.11 0.11 0.11
Propadiene 0.04 0.04 0.04 0.04
Isobutane 25.78 25.78 25.78 25.78
Isobutene 0.04 0.04 0.04 0.04
1-Butene 25.28 25.28 25.28 25.28
Butadiene 0.00 0.00 0.00 0.00
n-Butane 25.54 25.54 25.54 25.54
2-Butene 18.94 18.94 18.94 18.94
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 4.00 4.00 4.00 4.00
TBA 0.00 0.00 0.00 0.00
DME 0.16 0.16 0.16 0.16
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 43506 43506 43506 43506
Molar Flow Rate kg mol/hr 787.3 787.3 787.3 787.3
Molecular Weight 55.3 55.3 55.3 55.3
Temperature °C 59 50 50 50
Stream Pressure bar (g) 6.3 6.0 5.9 5.9
Stream Enthalpy MMkcal/h 5.168 1.229 1.229 1.229
Weight Fraction Liquid 0.0 1.0 1.0 1.0
Critical Temperature °C 154 154 154 154
Critical Pressure bar (a) 41.4 41.4 41.4 41.4
Vapor
Mass Flow rate kg/h 43506
Actual Volumetric Flow m³/h 2528
Molecular Weight 55.3
Actual Density kg/m³ 17.2
Viscosity cP 0.009
Specific Enthalpy kcal/kg 118.78
Specific Heat Capacity kcal/(kg°C) 0.45
Thermal Conductivity kcal/(h·m·°C) 0.016
Liquid
Mass Flow Rate kg/h 43506 43506 43506
Actual Volumetric Flow m³/h 78.9 78.9 78.9
Actual Density kg/m³ 552 552 552
Standard Specific Gravity 0.00 0.60 0.60 0.60
Dynamic Viscosity cP 0.14 0.14 0.14
Kinematic Viscosity cSt 0.26 0.26 0.26
Specific Enthalpy kcal/kg 28.3 28.3 28.3
Surface Tension mN/m 9.8 9.8 9.8
Specific Heat Capacity kcal/(kg°C) 0.61 0.61 0.61
Thermal Conductivity kcal/(h·m·°C) 0.084 0.084 0.084
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 2
Stream 6034 6035 6036 6037
0 0 0 0
Stream Description CD REACTION CD REACTION CD REACTION MEOH EXT.
COLUMN COLUMN COLUMN COLUMN
REFLUX PUMP REFLUX REFLUX AT FEED
DISCHARGE COLUMN FEED COOLER
INLET
0 0 0 0
Stream Phase LIQUID LIQUID LIQUID LIQUID
0 0 0 0
Component (wt%) 0 0 0 0
Water 0.09 0.09 0.09 0.09
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.01 0.01 0.01 0.01
Propylene 0.01 0.01 0.01 0.01
Propane 0.11 0.11 0.11 0.11
Propadiene 0.04 0.04 0.04 0.04
Isobutane 25.78 25.78 25.78 25.78
Isobutene 0.04 0.04 0.04 0.04
1-Butene 25.28 25.28 25.28 25.28
Butadiene 0.00 0.00 0.00 0.00
n-Butane 25.54 25.54 25.54 25.54
2-Butene 18.94 18.94 18.94 18.94
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 4.00 4.00 4.00 4.00
TBA 0.00 0.00 0.00 0.00
DME 0.16 0.16 0.16 0.16
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 43506 24590 24590 18916
Molar Flow Rate kg mol/hr 787.3 445.0 445.0 342.3
Molecular Weight 55.3 55.3 55.3 55.3
Temperature °C 50 50 50 50
Stream Pressure bar (g) 13.6 13.6 6.6 13.6
Stream Enthalpy MMkcal/h 1.251 0.707 0.707 0.544
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 154 154 154 154
Critical Pressure bar (a) 41.4 41.4 41.4 41.4
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 43506 24590 24590 18916
Actual Volumetric Flow m³/h 79.0 44.7 44.7 34.4
Actual Density kg/m³ 550 550 550 550
Standard Specific Gravity 0.60 0.60 0.60 0.60
Dynamic Viscosity cP 0.14 0.14 0.14 0.14
Kinematic Viscosity cSt 0.26 0.26 0.26 0.26
Specific Enthalpy kcal/kg 28.8 28.8 28.8 28.8
Surface Tension mN/m 9.7 9.7 9.7 9.7
Specific Heat Capacity kcal/(kg°C) 0.61 0.61 0.61 0.61
Thermal Conductivity kcal/(h·m·°C) 0.083 0.083 0.083 0.083
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 2
Stream 6038 6039 6040 6041
0 0 0 0
Stream Description C4 DISTILLATE METHANOL METHANOL METHANOL
TO METHANOL EXTRACTION REC. COL. RECOVERY
EXTRACTION COLUMN FEED/BTMS COLUMN
COLUMN BOTTOMS EXCHANGER FEED
INLET
0 0 0 0
Stream Phase LIQUID LIQUID LIQUID LIQUID
0 0 0 0
Component (wt%) 0 0 0 0
Water 0.09 80.00 80.00 80.00
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.01 0.00 0.00 0.00
Propylene 0.01 0.00 0.00 0.00
Propane 0.11 0.00 0.00 0.00
Propadiene 0.04 0.00 0.00 0.00
Isobutane 25.78 0.00 0.00 0.00
Isobutene 0.04 0.00 0.00 0.00
1-Butene 25.28 0.00 0.00 0.00
Butadiene 0.00 0.00 0.00 0.00
n-Butane 25.54 0.00 0.00 0.00
2-Butene 18.94 0.00 0.00 0.00
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 4.00 20.00 20.00 20.00
TBA 0.00 0.00 0.00 0.00
DME 0.16 0.00 0.00 0.00
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 18916 3784 3784 3784
Molar Flow Rate kg mol/hr 342.3 191.7 191.7 191.7
Molecular Weight 55.3 19.7 19.7 19.7
Temperature °C 40 40 40 75
Stream Pressure bar (g) 12.2 12.2 1.3 0.9
Stream Enthalpy MMkcal/h 0.426 0.139 0.139 0.262
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 154 358 358 358
Critical Pressure bar (a) 41.4 202.9 202.9 202.9
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 18916 3784 3784 3784
Actual Volumetric Flow m³/h 33.5 4.0 4.0 4.1
Actual Density kg/m³ 565 938 938 915
Standard Specific Gravity 0.60 0.95 0.95 0.95
Dynamic Viscosity cP 0.16 0.62 0.62 0.37
Kinematic Viscosity cSt 0.28 0.66 0.66 0.40
Specific Enthalpy kcal/kg 22.5 36.8 36.8 69.4
Surface Tension mN/m 10.9 63.6 63.6 58.2
Specific Heat Capacity kcal/(kg°C) 0.59 0.92 0.92 0.94
Thermal Conductivity kcal/(h·m·°C) 0.087 0.320 0.320 0.315
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 2
Stream 6042 6043 6044 6045
0 0 0
Stream Description METHANOL C4s TO METHANOL METHANOL
EXTRACTION B-1 RECOVERY RECOVERY
COLUMN HEAVIES COLUMN COLUMN
OVERHEAD COLUMN BOTTOMS BOTTOMS PUMP
DISCHARGE
0 0 0
Stream Phase LIQUID LIQUID LIQUID LIQUID
0 0 0
Component (wt%) 0 0 0
Water 0.03 0.03 100.00 100.00
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.01 0.01 0.00 0.00
Propylene 0.01 0.01 0.00 0.00
Propane 0.11 0.11 0.00 0.00
Propadiene 0.04 0.04 0.00 0.00
Isobutane 26.87 26.87 0.00 0.00
Isobutene 0.04 0.04 0.00 0.00
1-Butene 26.35 26.35 0.00 0.00
Butadiene 0.00 0.00 0.00 0.00
n-Butane 26.62 26.62 0.00 0.00
2-Butene 19.75 19.75 0.00 0.00
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 0.00 0.00 0.00 0.00
TBA 0.00 0.00 0.00 0.00
DME 0.17 0.17 0.00 0.00
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 18148 18148 3016 3016
Molar Flow Rate kg mol/hr 318.1 318.1 167.4 167.4
Molecular Weight 57.1 57.1 18.0 18.0
Temperature °C 40 40 126 126
Stream Pressure bar (g) 10.5 7.3 1.4 16.0
Stream Enthalpy MMkcal/h 0.407 0.407 0.382 0.382
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 147 -126 374 374
Critical Pressure bar (a) 38.2 39.0 220.2 220.2
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 18148 18148 3016 3016
Actual Volumetric Flow m³/h 32.5 32.5 3.2 3.2
Actual Density kg/m³ 558 559 939 939
Standard Specific Gravity 0.59 1.00 1.00
Dynamic Viscosity cP 0.14 0.14 0.22 0.22
Kinematic Viscosity cSt 0.25 0.25 0.23 0.23
Specific Enthalpy kcal/kg 22.4 22.4 126.6 126.7
Surface Tension mN/m 10.0 10.2 54.0 54.0
Specific Heat Capacity kcal/(kg°C) 0.59 0.59 1.02 1.02
Thermal Conductivity kcal/(h·m·°C) 0.085 0.085 0.592 0.591
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 2
Stream 6046 6047 6048 6049
0 0 0 0
Stream Description RECYCLE RECYCLE RECYCLE METHANOL
WATER WATER WATER TO RECOVERY
COOLER COOLER METHANOL COLUMN
INLET OUTLET EXTRACTION OVERHEAD
COLUMN
0 0 0 0
Stream Phase LIQUID LIQUID LIQUID VAPOR
0 0 0 0
Component (wt%) 0 0 0 0
Water 100.00 100.00 100.00 0.05
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.00 0.00 0.00 0.00
Propylene 0.00 0.00 0.00 0.00
Propane 0.00 0.00 0.00 0.00
Propadiene 0.00 0.00 0.00 0.00
Isobutane 0.00 0.00 0.00 0.00
Isobutene 0.00 0.00 0.00 0.00
1-Butene 0.00 0.00 0.00 0.00
Butadiene 0.00 0.00 0.00 0.00
n-Butane 0.00 0.00 0.00 0.00
2-Butene 0.00 0.00 0.00 0.00
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 0.00 0.00 0.00 99.95
TBA 0.00 0.00 0.00 0.00
DME 0.00 0.00 0.00 0.00
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 3016 3016 3016 2271
Molar Flow Rate kg mol/hr 167.4 167.4 167.4 70.9
Molecular Weight 18.0 18.0 18.0 32.0
Temperature °C 86 40 40 78
Stream Pressure bar (g) 15.7 15.3 10.6 0.7
Stream Enthalpy MMkcal/h 0.259 0.121 0.121 0.710
Weight Fraction Liquid 1.0 1.0 1.0 0.0
Critical Temperature °C 374 374 374 240
Critical Pressure bar (a) 220.2 220.2 220.2 80.1
Vapor
Mass Flow rate kg/h 2271
Actual Volumetric Flow m³/h 1178
Molecular Weight 32.0
Actual Density kg/m³ 1.9
Viscosity cP 0.012
Specific Enthalpy kcal/kg 312.51
Specific Heat Capacity kcal/(kg°C) 0.37
Thermal Conductivity kcal/(h·m·°C) 0.018
Liquid
Mass Flow Rate kg/h 3016 3016 3016
Actual Volumetric Flow m³/h 3.1 3.0 3.0
Actual Density kg/m³ 967 990 990
Standard Specific Gravity 1.00 1.00 1.00 0.00
Dynamic Viscosity cP 0.33 0.65 0.65
Kinematic Viscosity cSt 0.34 0.66 0.66
Specific Enthalpy kcal/kg 85.8 40.0 40.0
Surface Tension mN/m 62.0 69.6 69.6
Specific Heat Capacity kcal/(kg°C) 1.00 1.00 1.00
Thermal Conductivity kcal/(h·m·°C) 0.577 0.541 0.541
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 2
Stream 6050 6051 6052 6053
0 0 0 0
Stream Description METHANOL METHANOL METHANOL METHANOL
RECOVERY RECOVERY RECOVERY RECOVERY
COLUMN COLUMN COLUMN COLUMN
CONDENSER OVHD DRUM REFLUX PUMP REFLUX PUMP
OUTLET INLET SUCTION DISCHARGE
0 0 0 0
Stream Phase LIQUID LIQUID LIQUID LIQUID
0 0 0 0
Component (wt%) 0 0 0 0
Water 0.05 0.05 0.08 0.08
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.00 0.00 0.00 0.00
Propylene 0.00 0.00 0.00 0.00
Propane 0.00 0.00 0.00 0.00
Propadiene 0.00 0.00 0.00 0.00
Isobutane 0.00 0.00 0.00 0.00
Isobutene 0.00 0.00 0.00 0.00
1-Butene 0.00 0.00 0.00 0.00
Butadiene 0.00 0.00 0.00 0.00
n-Butane 0.00 0.00 0.00 0.00
2-Butene 0.00 0.00 0.00 0.00
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 99.95 99.95 99.92 99.92
TBA 0.00 0.00 0.00 0.00
DME 0.00 0.00 0.00 0.00
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 2271 2271 6580 6580
Molar Flow Rate kg mol/hr 70.9 70.9 205.5 205.5
Molecular Weight 32.0 32.0 32.0 32.0
Temperature °C 64 64 49 50
Stream Pressure bar (g) 0.5 0.4 0.4 19.2
Stream Enthalpy MMkcal/h 0.090 0.090 0.194 0.200
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 240 240 240 240
Critical Pressure bar (a) 80.1 80.1 80.2 80.2
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 2271 2271 6580 6580
Actual Volumetric Flow m³/h 3.0 3.0 8.6 8.6
Actual Density kg/m³ 750 750 766 765
Standard Specific Gravity 0.80 0.80 0.80 0.80
Dynamic Viscosity cP 0.35 0.35 0.41 0.40
Kinematic Viscosity cSt 0.46 0.46 0.53 0.52
Specific Enthalpy kcal/kg 39.8 39.8 29.4 30.3
Surface Tension mN/m 18.9 18.9 20.3 20.2
Specific Heat Capacity kcal/(kg°C) 0.67 0.67 0.64 0.65
Thermal Conductivity kcal/(h·m·°C) 0.162 0.162 0.166 0.166
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 2
Stream 6054 6055 6056 6057
0 0 0 0
Stream Description METHANOL METHANOL METHANOL RECYCLE
RECOVERY RECOVERY TO MTBE METHANOL
COLUMN COLUMN REACTION TO C4s
REFLUX REFLUX AT SECTION STREAM
COLUMN FEED
0 0 0 0
Stream Phase LIQUID LIQUID LIQUID LIQUID
0 0 0 0
Component (wt%) 0 0 0 0
Water 0.08 0.08 0.08 0.08
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.00 0.00 0.00 0.00
Propylene 0.00 0.00 0.00 0.00
Propane 0.00 0.00 0.00 0.00
Propadiene 0.00 0.00 0.00 0.00
Isobutane 0.00 0.00 0.00 0.00
Isobutene 0.00 0.00 0.00 0.00
1-Butene 0.00 0.00 0.00 0.00
Butadiene 0.00 0.00 0.00 0.00
n-Butane 0.00 0.00 0.00 0.00
2-Butene 0.00 0.00 0.00 0.00
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 99.92 99.92 99.92 99.92
TBA 0.00 0.00 0.00 0.00
DME 0.00 0.00 0.00 0.00
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 1514 1514 5066 4766
Molar Flow Rate kg mol/hr 47.3 47.3 158.2 148.8
Molecular Weight 32.0 32.0 32.0 32.0
Temperature °C 50 50 50 50
Stream Pressure bar (g) 19.2 0.7 19.2 19.2
Stream Enthalpy MMkcal/h 0.046 0.046 0.154 0.145
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 240 240 240 240
Critical Pressure bar (a) 80.2 80.2 80.2 80.2
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 1514 1514 5066 4766
Actual Volumetric Flow m³/h 2.0 2.0 6.6 6.2
Actual Density kg/m³ 765 765 765 765
Standard Specific Gravity 0.80 0.80 0.80 0.80
Dynamic Viscosity cP 0.40 0.40 0.40 0.40
Kinematic Viscosity cSt 0.52 0.52 0.52 0.52
Specific Enthalpy kcal/kg 30.3 30.3 30.3 30.3
Surface Tension mN/m 20.2 20.2 20.2 20.2
Specific Heat Capacity kcal/(kg°C) 0.65 0.65 0.65 0.65
Thermal Conductivity kcal/(h·m·°C) 0.166 0.166 0.166 0.166
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 2
Stream 6058 6059 6060 6061
0 0 0
Stream Description RECYCLE METHANOL METHANOL METHANOL
METHANOL INJECTION TO INJECTION TO INJECTION TO
TO C4s CD REACTION CD REACTION CD REACTION
STREAM COLUMN COLUMN COLUMN
0 0 0
Stream Phase LIQUID LIQUID LIQUID LIQUID
0 0 0 0
Component (wt%) 0 0 0 0
Water 0.08 0.08 0.08 0.08
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.00 0.00 0.00 0.00
Propylene 0.00 0.00 0.00 0.00
Propane 0.00 0.00 0.00 0.00
Propadiene 0.00 0.00 0.00 0.00
Isobutane 0.00 0.00 0.00 0.00
Isobutene 0.00 0.00 0.00 0.00
1-Butene 0.00 0.00 0.00 0.00
Butadiene 0.00 0.00 0.00 0.00
n-Butane 0.00 0.00 0.00 0.00
2-Butene 0.00 0.00 0.00 0.00
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 99.92 99.92 99.92 99.92
TBA 0.00 0.00 0.00 0.00
DME 0.00 0.00 0.00 0.00
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 4766 300 15 285
Molar Flow Rate kg mol/hr 148.8 9.4 0.5 8.9
Molecular Weight 32.0 32.0 32.0 32.0
Temperature °C 50 50 50 50
Stream Pressure bar (g) 16.0 19.2 6.6 6.6
Stream Enthalpy MMkcal/h 0.145 0.009 0.000 0.009
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 240 240 240 240
Critical Pressure bar (a) 80.2 80.2 80.2 80.2
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 4766 300 15 285
Actual Volumetric Flow m³/h 6.2 0.4 0.0 0.4
Actual Density kg/m³ 765 765 765 765
Standard Specific Gravity 0.80 0.80 0.80 0.80
Dynamic Viscosity cP 0.40 0.40 0.40 0.40
Kinematic Viscosity cSt 0.52 0.52 0.52 0.52
Specific Enthalpy kcal/kg 30.3 30.3 30.3 30.3
Surface Tension mN/m 20.2 20.2 20.2 20.2
Specific Heat Capacity kcal/(kg°C) 0.65 0.65 0.65 0.65
Thermal Conductivity kcal/(h·m·°C) 0.166 0.166 0.166 0.166
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 2
Stream 6062 6063 6064 6065
0 0 0
Stream Description FRESH FILTERED FILTERED CD REACTION
METHANOL FRESH FRESH COLUMN
FROM METHANOL METHANOL REBOILER
STORAGE AT INLET
OSBL
0 0 0 0
Stream Phase LIQUID LIQUID LIQUID LIQUID
0 0 0 0
Component (wt%) 0 0 0 0
Water 0.10 0.10 0.10 0.00
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.00 0.00 0.00 0.00
Propylene 0.00 0.00 0.00 0.00
Propane 0.00 0.00 0.00 0.00
Propadiene 0.00 0.00 0.00 0.00
Isobutane 0.00 0.00 0.00 0.00
Isobutene 0.00 0.00 0.00 0.00
1-Butene 0.00 0.00 0.00 0.00
Butadiene 0.00 0.00 0.00 0.00
n-Butane 0.00 0.00 0.00 0.03
2-Butene 0.00 0.00 0.00 0.07
C5's 0.00 0.00 0.00 0.80
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.29
Methanol 99.90 99.90 99.90 0.10
TBA 0.00 0.00 0.00 0.26
DME 0.00 0.00 0.00 0.00
MTBE 0.00 0.00 0.00 98.09
MSBE 0.00 0.00 0.00 0.36
Mass Flow Rate kg/h 4309 4309 4309 222076
Molar Flow Rate kg mol/hr 134.6 134.6 134.6 2529.3
Molecular Weight 32.0 32.0 32.0 87.8
Temperature °C 40 40 40 135
Stream Pressure bar (g) 3.0 2.8 0.4 7.0
Stream Enthalpy MMkcal/h 0.103 0.103 0.103 16.508
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 240 240 240 224
Critical Pressure bar (a) 80.2 80.2 80.2 33.5
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 4309 4309 4309 222076
Actual Volumetric Flow m³/h 5.6 5.6 5.6 371.6
Actual Density kg/m³ 775 775 775 598
Standard Specific Gravity 0.80 0.80 0.80 0.74
Dynamic Viscosity cP 0.40 0.40 0.40 0.13
Kinematic Viscosity cSt 0.58 0.58 0.58 0.22
Specific Enthalpy kcal/kg 24.0 24.0 24.0 74.3
Surface Tension mN/m 21.1 21.1 21.1 7.1
Specific Heat Capacity kcal/(kg°C) 0.63 0.63 0.63 0.62
Thermal Conductivity kcal/(h·m·°C) 0.166 0.166 0.166 0.101
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 2
Stream 6066 6067 6068 6099
0 0 0
Stream Description CD REACTION METHANOL METHANOL C4 DISTILLATE
COLUMN RECOVERY RECOVERY TO METHANOL
REBOILER COLUMN COLUMN EXTRACTION
OUTLET REBOILER REBOILER COLUMN
INLET OUTLET
0 0 0 0
Stream Phase MIXED LIQUID MIXED LIQUID
0 0 0 0
Component (wt%) 0 0 0 0
Water 0.00 99.99 99.99 0.09
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.00 0.00 0.00 0.01
Propylene 0.00 0.00 0.00 0.01
Propane 0.00 0.00 0.00 0.11
Propadiene 0.00 0.00 0.00 0.04
Isobutane 0.00 0.00 0.00 25.78
Isobutene 0.00 0.00 0.00 0.04
1-Butene 0.00 0.00 0.00 25.28
Butadiene 0.00 0.00 0.00 0.00
n-Butane 0.03 0.00 0.00 25.54
2-Butene 0.07 0.00 0.00 18.94
C5's 0.80 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.29 0.00 0.00 0.00
Methanol 0.10 0.01 0.01 4.00
TBA 0.26 0.00 0.00 0.00
DME 0.00 0.00 0.00 0.16
MTBE 98.09 0.00 0.00 0.00
MSBE 0.36 0.00 0.00 0.00
Mass Flow Rate kg/h 222076 4992 4992 18916
Molar Flow Rate kg mol/hr 2529.3 277.1 277.1 342.3
Molecular Weight 87.8 18.0 18.0 55.3
Temperature °C 135 126 125 40
Stream Pressure bar (g) 6.9 1.4 1.3 13.2
Stream Enthalpy MMkcal/h 20.536 0.631 1.415 0.426
Weight Fraction Liquid 0.7 1.0 0.7 1.0
Critical Temperature °C 224 374 374 154
Critical Pressure bar (a) 33.5 220.2 220.2 41.4
Vapor
Mass Flow rate kg/h 66406 1505
Actual Volumetric Flow m³/h 2687.0 1162.0
Molecular Weight 87.5 18.0
Actual Density kg/m³ 24.7 1.3
Viscosity cP 0.010 0.013
Specific Enthalpy kcal/kg 135.26 649.19
Specific Heat Capacity kcal/(kg°C) 0.50 0.46
Thermal Conductivity kcal/(h·m·°C) 0.021 0.023
Liquid
Mass Flow Rate kg/h 155670 4992 3487 18916
Actual Volumetric Flow m³/h 260.3 5.3 3.7 33.5
Actual Density kg/m³ 598 939 939 565
Standard Specific Gravity 0.74 1.00 1.00 0.60
Dynamic Viscosity cP 0.13 0.22 0.22 0.16
Kinematic Viscosity cSt 0.22 0.23 0.23 0.28
Specific Enthalpy kcal/kg 74.2 126.3 125.6 22.5
Surface Tension mN/m 7.2 54.1 54.2 10.9
Specific Heat Capacity kcal/(kg°C) 0.62 1.02 1.02 0.59
Thermal Conductivity kcal/(h·m·°C) 0.101 0.591 0.591 0.087
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 2
Stream 0
Stream Description
Stream Phase 0
0
Component (wt%) 0
Water 0.00
Hydrogen 0.00
Methane 0.00
Propylene 0.00
Propane 0.00
Propadiene 0.00
Isobutane 0.00
Isobutene 0.00
1-Butene 0.00
Butadiene 0.00
n-Butane 0.00
2-Butene 0.00
C5's 0.00
C6's 0.00
DIB 0.00
Methanol 0.00
TBA 0.00
DME 0.00
MTBE 0.00
MSBE 0.00
0.00
0.00
Mass Flow Rate kg/h 0
Molar Flow Rate kg mol/hr 0.0
Molecular Weight 0.0
Temperature °C 0.0
Stream Pressure bar (g) 0.0
Stream Enthalpy MMkcal/h 0.000
Weight Fraction Liquid 0.00
Critical Temperature °C 0.0
Critical Pressure bar (a) 0.0
Vapor 0.0
Mass Flow rate kg/h 0
Actual Volumetric Flow m³/h 0
Molecular Weight 0.00
Actual Density kg/m³ 0.00
Viscosity cP 0.0000
Specific Enthalpy kcal/kg 0.0
Specific Heat Capacity kcal/(kg°C) 0.000
Thermal Conductivity kcal/(h·m·°C) 0.0000
0.000
Liquid 0.0
Mass Flow Rate kg/h 0
Actual Volumetric Flow m³/h 0.0
Actual Density kg/m³ 0.0
Standard Specific Gravity 0.000
Dynamic Viscosity cP 0.000
Kinematic Viscosity cSt
Specific Enthalpy kcal/kg 0.0
Surface Tension mN/m 0.0
Specific Heat Capacity kcal/(kg°C) 0.000
Thermal Conductivity kcal/(h·m·°C) 0.000
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 2
Stream 6101 6102 6103 6104
Stream Description B-1 HEAVIES B-1 HEAVIES B-1 HEAVIES B-1 HEAVIES
COLUMN #1 COLUMN COLUMN #2 COLUMN #2
BOTTOMS TRANSFER FEED OVERHEAD
PUMP DISCH.
Stream Phase LIQUID LIQUID LIQUID VAPOR
Component (wt%)
Water 0.00 0.00 0.00 0.00
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.00 0.00 0.00 0.00
Propylene 0.00 0.00 0.00 0.00
Propane 0.01 0.01 0.01 0.03
Propadiene 0.01 0.01 0.01 0.01
Isobutane 17.22 17.22 17.22 19.69
Isobutene 0.05 0.05 0.05 0.06
1-Butene 43.30 43.30 43.30 43.67
Butadiene 0.00 0.00 0.00 0.00
n-Butane 25.34 25.34 25.34 23.49
2-Butene 14.04 14.04 14.04 13.01
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 0.00 0.00 0.00 0.00
TBA 0.00 0.00 0.00 0.00
DME 0.02 0.02 0.02 0.05
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 121306 121306 121306 130908
Molar Flow Rate kg mol/hr 2130.4 2130.4 2130.4 2299.1
Molecular Weight 56.9 56.9 56.9 56.9
Temperature °C 64 65 64 65
Stream Pressure bar (g) 7.2 11.0 7.2 7.2
Stream Enthalpy MMkcal/h 4.490 4.523 4.494 14.586
Weight Fraction Liquid 1.0 1.0 1.0 0.0
Critical Temperature °C 147 147 147 147
Critical Pressure bar (a) 39.3 39.3 39.3 39.2
Vapor
Mass Flow rate kg/h 130908
Actual Volumetric Flow m³/h 6606
Molecular Weight 56.9
Actual Density kg/m³ 19.8
Viscosity cP 0.009
Specific Enthalpy kcal/kg 111.42
Specific Heat Capacity kcal/(kg°C) 0.49
Thermal Conductivity kcal/(h·m·°C) 0.017
Liquid
Mass Flow Rate kg/h 121306 121306 121306
Actual Volumetric Flow m³/h 230.5 230.2 230.5
Actual Density kg/m³ 526 527 526
Standard Specific Gravity 0.59 0.59 0.59 0.00
Dynamic Viscosity cP 0.12 0.11 0.12
Kinematic Viscosity cSt 0.22 0.22 0.22
Specific Enthalpy kcal/kg 37.0 37.3 37.0
Surface Tension mN/m 7.5 7.5 7.5
Specific Heat Capacity kcal/(kg°C) 0.62 0.62 0.62
Thermal Conductivity kcal/(h·m·°C) 0.079 0.079 0.079
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 2
Stream 6105 6106 6107 6108
Stream Description B-1 HEAVIES B-1 HEAVIES B-1 HEAVIES WASTEWATER
COLUMN #1 COLUMN COLUMN TO OSBL
OVERHEAD CONDENSER OVERHEAD
OUTLET DRUM INLET
Stream Phase VAPOR LIQUID LIQUID
Component (wt%)
Water 0.05 0.05 0.05
Hydrogen 0.00 0.00 0.00
Methane 0.02 0.02 0.02
Propylene 0.02 0.02 0.02
Propane 0.21 0.21 0.21
Propadiene 0.08 0.08 0.08
Isobutane 50.79 50.79 50.79
Isobutene 0.08 0.08 0.08
1-Butene 48.31 48.31 48.31
Butadiene 0.00 0.00 0.00
n-Butane 0.09 0.09 0.09
2-Butene 0.03 0.03 0.03
C5's 0.00 0.00 0.00
C6's 0.00 0.00 0.00
DIB 0.00 0.00 0.00
Methanol 0.00 0.00 0.00
TBA 0.00 0.00 0.00
DME 0.32 0.32 0.32
MTBE 0.00 0.00 0.00
MSBE 0.00 0.00 0.00
Mass Flow Rate kg/h 121284 121284 121284
Molar Flow Rate kg mol/hr 2131.4 2131.4 2131.4
Molecular Weight 56.9 56.9 56.9
Temperature °C 56 46 46
Stream Pressure bar (g) 6.5 6.2 6.1
Stream Enthalpy MMkcal/h 13.002 3.157 3.157
Weight Fraction Liquid 0.0 1.0 1.0
Critical Temperature °C 141 141 141
Critical Pressure bar (a) 38.8 38.8 38.8
Vapor
Mass Flow rate kg/h 121284
Actual Volumetric Flow m³/h 6585
Molecular Weight 56.9
Actual Density kg/m³ 18.4
Viscosity cP 0.008
Specific Enthalpy kcal/kg 107.20
Specific Heat Capacity kcal/(kg°C) 0.45
Thermal Conductivity kcal/(h·m·°C) 0.016
Liquid
Mass Flow Rate kg/h 121284 121284
Actual Volumetric Flow m³/h 224.5 224.5
Actual Density kg/m³ 540 540
Standard Specific Gravity 0.00 0.58 0.58
Dynamic Viscosity cP 0.13 0.13
Kinematic Viscosity cSt 0.24 0.24
Specific Enthalpy kcal/kg 26.0 26.0
Surface Tension mN/m 8.8 8.8
Specific Heat Capacity kcal/(kg°C) 0.60 0.60
Thermal Conductivity kcal/(h·m·°C) 0.081 0.081
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 2
Stream 6109 6110 6111 6112
Stream Description WASTEWATER B-1 HEAVIES B-1 HEAVIES B-1 HEAVIES
TO OSBL COLUMN COLUMN COLUMN
REFLUX PUMP REFLUX PUMP REFLUX
SUCTION DISCHARGE
Stream Phase LIQUID LIQUID LIQUID
Component (wt%)
Water 0.05 0.05 0.05
Hydrogen 0.00 0.00 0.00
Methane 0.02 0.02 0.02
Propylene 0.02 0.02 0.02
Propane 0.21 0.21 0.21
Propadiene 0.08 0.08 0.08
Isobutane 50.79 50.79 50.79
Isobutene 0.08 0.08 0.08
1-Butene 48.31 48.31 48.31
Butadiene 0.00 0.00 0.00
n-Butane 0.09 0.09 0.09
2-Butene 0.03 0.03 0.03
C5's 0.00 0.00 0.00
C6's 0.00 0.00 0.00
DIB 0.00 0.00 0.00
Methanol 0.00 0.00 0.00
TBA 0.00 0.00 0.00
DME 0.32 0.32 0.32
MTBE 0.00 0.00 0.00
MSBE 0.00 0.00 0.00
Mass Flow Rate kg/h 121284 121284 111682
Molar Flow Rate kg mol/hr 2131.4 2131.4 1962.7
Molecular Weight 56.9 56.9 56.9
Temperature °C 46 47 47
Stream Pressure bar (g) 6.1 10.0 10.0
Stream Enthalpy MMkcal/h 3.157 3.189 2.937
Weight Fraction Liquid 1.0 1.0 1.0
Critical Temperature °C 141 141 141
Critical Pressure bar (a) 38.8 38.8 38.8
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 121284 121284 111682
Actual Volumetric Flow m³/h 224.5 224.3 206.6
Actual Density kg/m³ 540 541 541
Standard Specific Gravity 0.58 0.58 0.58
Dynamic Viscosity cP 0.13 0.13 0.13
Kinematic Viscosity cSt 0.24 0.24 0.24
Specific Enthalpy kcal/kg 26.0 26.3 26.3
Surface Tension mN/m 8.8 8.7 8.7
Specific Heat Capacity kcal/(kg°C) 0.60 0.60 0.60
Thermal Conductivity kcal/(h·m·°C) 0.081 0.081 0.081
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 2
Stream 6113 6114 6115 6116
Stream Description B-1 HEAVIES B-1 HEAVIES B-1 HEAVIES B-1 HEAVIES
COLUMN COLUMN COLUMN COLUMN #2
REFLUX AT OVERHEAD TO OVERHEAD TO BOTTOMS
COLUMN FEED B-1 LIGHTS B-1 LIGHTS
COLUMN COLUMN
Stream Phase LIQUID LIQUID LIQUID LIQUID
Component (wt%)
Water 0.05 0.05 0.05 0.00
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.02 0.02 0.02 0.00
Propylene 0.02 0.02 0.02 0.00
Propane 0.21 0.21 0.21 0.00
Propadiene 0.08 0.08 0.08 0.00
Isobutane 50.79 50.79 50.79 0.00
Isobutene 0.08 0.08 0.08 0.00
1-Butene 48.31 48.31 48.31 1.68
Butadiene 0.00 0.00 0.00 0.00
n-Butane 0.09 0.09 0.09 56.42
2-Butene 0.03 0.03 0.03 41.89
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 0.00 0.00 0.00 0.00
TBA 0.00 0.00 0.00 0.00
DME 0.32 0.32 0.32 0.00
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 111682 9601 9601 8546
Molar Flow Rate kg mol/hr 1962.7 168.7 168.7 149.3
Molecular Weight 56.9 56.9 56.9 57.2
Temperature °C 47 47 47 74
Stream Pressure bar (g) 6.5 10.0 7.8 7.9
Stream Enthalpy MMkcal/h 2.937 0.252 0.252 0.371
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 141 141 -133 155
Critical Pressure bar (a) 38.8 38.8 38.5 39.6
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 111682 9601 9601 8546
Actual Volumetric Flow m³/h 207.0 17.8 17.8 16.3
Actual Density kg/m³ 540 541 540 523
Standard Specific Gravity 0.58 0.58 0.60
Dynamic Viscosity cP 0.13 0.13 0.13 0.12
Kinematic Viscosity cSt 0.24 0.24 0.24 0.22
Specific Enthalpy kcal/kg 26.3 26.3 26.3 43.5
Surface Tension mN/m 8.7 8.7 8.7 7.3
Specific Heat Capacity kcal/(kg°C) 0.60 0.60 0.60 0.65
Thermal Conductivity kcal/(h·m·°C) 0.081 0.081 0.081 0.078
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 2
Stream 6117 6118 6119 6120
Stream Description B-1 HEAVIES BUTENE-2 BUTENE-2 B-1 LIGHTS
COLUMN #2 PRODUCT PRODUCT COLUMN #1
BOTTOMS COOLER TO OSBL BOTTOMS
PUMP OUTLET
DISCHARGE
Stream Phase LIQUID LIQUID LIQUID LIQUID
Component (wt%)
Water 0.00 0.00 0.00 0.00
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.00 0.00 0.00 0.00
Propylene 0.00 0.00 0.00 0.00
Propane 0.00 0.00 0.00 0.00
Propadiene 0.00 0.00 0.00 0.00
Isobutane 0.00 0.00 0.00 31.54
Isobutene 0.00 0.00 0.00 0.18
1-Butene 1.68 1.68 1.68 68.24
Butadiene 0.00 0.00 0.00 0.00
n-Butane 56.42 56.42 56.42 0.02
2-Butene 41.89 41.89 41.89 0.01
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 0.00 0.00 0.00 0.00
TBA 0.00 0.00 0.00 0.00
DME 0.00 0.00 0.00 0.00
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 8546 8546 8546 239688
Molar Flow Rate kg mol/hr 149.3 149.3 149.3 4225.2
Molecular Weight 57.2 57.2 57.2 56.7
Temperature °C 74 45 45 65
Stream Pressure bar (g) 9.1 7.6 6.9 8.0
Stream Enthalpy MMkcal/h 0.372 0.218 0.218 8.872
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 155 155 155 143
Critical Pressure bar (a) 39.6 39.6 39.6 39.2
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 8546 8546 8546 239688
Actual Volumetric Flow m³/h 16.3 15.2 15.2 461.0
Actual Density kg/m³ 524 564 564 520
Standard Specific Gravity 0.60 0.60 0.60 0.59
Dynamic Viscosity cP 0.12 0.14 0.14 0.11
Kinematic Viscosity cSt 0.22 0.25 0.25 0.21
Specific Enthalpy kcal/kg 43.5 25.5 25.5 37.0
Surface Tension mN/m 7.3 10.5 10.5 7.0
Specific Heat Capacity kcal/(kg°C) 0.65 0.60 0.60 0.61
Thermal Conductivity kcal/(h·m·°C) 0.078 0.087 0.087 0.077
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 2
Stream 6121 6122 6123 6124
Stream Description B-1 LIGHTS B-1 LIGHTS B-1 LIGHTS B-1 LIGHTS
COLUMN COLUMN #2 COLUMN #2 COLUMN #1
TRANSFER FEED OVERHEAD OVERHEAD
PUMP DISCH.
Stream Phase LIQUID LIQUID VAPOR VAPOR
Component (wt%)
Water 0.00 0.00 0.00 0.04
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.00 0.00 0.00 0.04
Propylene 0.00 0.00 0.00 0.04
Propane 0.00 0.00 0.00 0.39
Propadiene 0.00 0.00 0.00 0.14
Isobutane 31.54 31.54 32.13 94.24
Isobutene 0.18 0.18 0.19 0.04
1-Butene 68.24 68.24 67.65 4.48
Butadiene 0.00 0.00 0.00 0.00
n-Butane 0.02 0.02 0.02 0.00
2-Butene 0.01 0.01 0.01 0.00
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 0.00 0.00 0.00 0.01
TBA 0.00 0.00 0.00 0.00
DME 0.00 0.00 0.00 0.59
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 239688 239688 235264 217529
Molar Flow Rate kg mol/hr 4225.2 4225.2 4146.4 3771.8
Molecular Weight 56.7 56.7 56.7 57.7
Temperature °C 65 65 65 57
Stream Pressure bar (g) 11.8 8.0 8.0 7.3
Stream Enthalpy MMkcal/h 8.936 8.879 25.759 22.794
Weight Fraction Liquid 1.0 1.0 0.0 0.0
Critical Temperature °C 143 143 143 135
Critical Pressure bar (a) 39.2 39.2 39.2 37.1
Vapor
Mass Flow rate kg/h 235264 217529
Actual Volumetric Flow m³/h 10728 10361
Molecular Weight 56.7 57.7
Actual Density kg/m³ 21.9 21.0
Viscosity cP 0.009 0.008
Specific Enthalpy kcal/kg 109.49 104.79
Specific Heat Capacity kcal/(kg°C) 0.49 0.47
Thermal Conductivity kcal/(h·m·°C) 0.017 0.017
Liquid
Mass Flow Rate kg/h 239688 239688
Actual Volumetric Flow m³/h 460.4 461.1
Actual Density kg/m³ 521 520
Standard Specific Gravity 0.59 0.59 0.00 0.00
Dynamic Viscosity cP 0.11 0.11
Kinematic Viscosity cSt 0.21 0.21
Specific Enthalpy kcal/kg 37.3 37.0
Surface Tension mN/m 6.9 7.0
Specific Heat Capacity kcal/(kg°C) 0.62 0.62
Thermal Conductivity kcal/(h·m·°C) 0.077 0.077
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 2
Stream 6125 6126 6127 6128
Stream Description B-1 LIGHTS B-1 LIGHTS WASTEWATER WASTEWATER
COLUMN COLUMN TO OSBL TO OSBL
CONDENSER REFLUX
OUTLET DRUM INLET
Stream Phase LIQUID LIQUID WATER WATER
Component (wt%)
Water 0.04 0.04 100.00 100.00
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.04 0.04 0.00 0.00
Propylene 0.04 0.04 0.00 0.00
Propane 0.39 0.39 0.00 0.00
Propadiene 0.14 0.14 0.00 0.00
Isobutane 94.24 94.24 0.00 0.00
Isobutene 0.04 0.04 0.00 0.00
1-Butene 4.48 4.48 0.00 0.00
Butadiene 0.00 0.00 0.00 0.00
n-Butane 0.00 0.00 0.00 0.00
2-Butene 0.00 0.00 0.00 0.00
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 0.01 0.01 0.00 0.00
TBA 0.00 0.00 0.00 0.00
DME 0.59 0.59 0.00 0.00
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 217529 217529 4 4
Molar Flow Rate kg mol/hr 3771.8 3771.8 0.2 0.2
Molecular Weight 57.7 57.7 18.0 18.0
Temperature °C 46 46 46 46
Stream Pressure bar (g) 7.0 6.9 6.9 3.0
Stream Enthalpy MMkcal/h 5.795 5.795 0.000 0.000
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 135 135 374 374
Critical Pressure bar (a) 37.1 37.1 221.2 221.2
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 217529 217529 4 4
Actual Volumetric Flow m³/h 414.6 414.6 0.0 0.0
Actual Density kg/m³ 525 525 990 990
Standard Specific Gravity 0.57 0.57 1.00 1.00
Dynamic Viscosity cP 0.14 0.14 0.58 0.58
Kinematic Viscosity cSt 0.26 0.26 0.59 0.59
Specific Enthalpy kcal/kg 26.6 26.6 46.0 46.0
Surface Tension mN/m 7.8 7.8 70.0 70.0
Specific Heat Capacity kcal/(kg°C) 0.62 0.62 1.00 1.00
Thermal Conductivity kcal/(h·m·°C) 0.076 0.076 0.547 0.547
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 2
Stream 6129 6130 6131 6132
Stream Description B-1 LIGHTS B-1 LIGHTS B-1 LIGHTS B-1 LIGHTS
COLUMN COLUMN COLUMN COLUMN
REFLUX PUMP REFLUX PUMP REFLUX REFLUX AT
SUCTION DISCHARGE COLUMN FEED
Stream Phase LIQUID LIQUID LIQUID LIQUID
Component (wt%)
Water 0.04 0.04 0.04 0.04
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.04 0.04 0.04 0.04
Propylene 0.04 0.04 0.04 0.04
Propane 0.39 0.39 0.39 0.39
Propadiene 0.14 0.14 0.14 0.14
Isobutane 94.24 94.24 94.24 94.24
Isobutene 0.04 0.04 0.04 0.04
1-Butene 4.48 4.48 4.48 4.48
Butadiene 0.00 0.00 0.00 0.00
n-Butane 0.00 0.00 0.00 0.00
2-Butene 0.00 0.00 0.00 0.00
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 0.01 0.01 0.01 0.01
TBA 0.00 0.00 0.00 0.00
DME 0.59 0.59 0.59 0.59
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 217525 217525 212351 212351
Molar Flow Rate kg mol/hr 3771.6 3771.6 3681.9 3681.9
Molecular Weight 57.7 57.7 57.7 57.7
Temperature °C 46 47 47 47
Stream Pressure bar (g) 6.9 15.0 15.0 7.3
Stream Enthalpy MMkcal/h 5.795 5.919 5.778 5.778
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 135 135 135 135
Critical Pressure bar (a) 37.1 37.1 37.1 37.1
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 217525 217525 212351 212351
Actual Volumetric Flow m³/h 414.6 413.6 403.8 405.7
Actual Density kg/m³ 525 526 526 523
Standard Specific Gravity 0.57 0.57 0.57 0.57
Dynamic Viscosity cP 0.14 0.14 0.14 0.14
Kinematic Viscosity cSt 0.26 0.26 0.26 0.26
Specific Enthalpy kcal/kg 26.6 27.2 27.2 27.2
Surface Tension mN/m 7.8 7.7 7.7 7.7
Specific Heat Capacity kcal/(kg°C) 0.62 0.62 0.62 0.62
Thermal Conductivity kcal/(h·m·°C) 0.076 0.076 0.076 0.076
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 2
Stream 6133 6135 6136 6137
Stream Description ISOBUTANE ISOBUTANE B-1 LIGHTS B-1 LIGHTS
PRODUCT PRODUCT COLUMN #2 COLUMN
TO OSBL BOTTOMS BOTTOMS
PUMP DISCH.
Stream Phase LIQUID LIQUID LIQUID LIQUID
Component (wt%)
Water 0.04 0.04 0.00 0.00
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.04 0.04 0.00 0.00
Propylene 0.04 0.04 0.00 0.00
Propane 0.39 0.39 0.00 0.00
Propadiene 0.14 0.14 0.00 0.00
Isobutane 94.24 94.24 0.01 0.01
Isobutene 0.04 0.04 0.12 0.12
1-Butene 4.48 4.48 99.60 99.60
Butadiene 0.00 0.00 0.00 0.00
n-Butane 0.00 0.00 0.19 0.19
2-Butene 0.00 0.00 0.07 0.07
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 0.01 0.01 0.00 0.00
TBA 0.00 0.00 0.00 0.00
DME 0.59 0.59 0.00 0.00
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 5174 5174 4424 4424
Molar Flow Rate kg mol/hr 89.7 89.7 78.8 78.8
Molecular Weight 57.7 57.7 56.1 56.1
Temperature °C 47 47 71 71
Stream Pressure bar (g) 15.0 13.0 8.7 9.1
Stream Enthalpy MMkcal/h 0.141 0.141 0.175 0.175
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 135 135 147 147
Critical Pressure bar (a) 37.1 37.1 40.4 40.4
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 5174 5174 4424 4424
Actual Volumetric Flow m³/h 9.8 9.8 8.5 8.5
Actual Density kg/m³ 526 526 523 523
Standard Specific Gravity 0.57 0.57 0.60 0.60
Dynamic Viscosity cP 0.14 0.14 0.10 0.10
Kinematic Viscosity cSt 0.26 0.26 0.20 0.20
Specific Enthalpy kcal/kg 27.2 27.1 39.5 39.5
Surface Tension mN/m 7.7 7.7 6.9 6.9
Specific Heat Capacity kcal/(kg°C) 0.62 0.62 0.59 0.59
Thermal Conductivity kcal/(h·m·°C) 0.076 0.076 0.080 0.080
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 2
Stream 6138 6139 6140 6141
Stream Description BUTENE-1 BUTENE-1 B-1 HEAVIES B-1 HEAVIES
PRODUCT PRODUCT COLUMN COLUMN
COOLER TO OSBL REBOILER REBOILER
OUTLET INLET OUTLET
Stream Phase LIQUID LIQUID LIQUID MIXED
Component (wt%)
Water 0.00 0.00 0.00 0.00
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.00 0.00 0.00 0.00
Propylene 0.00 0.00 0.00 0.00
Propane 0.00 0.00 0.00 0.00
Propadiene 0.00 0.00 0.00 0.00
Isobutane 0.01 0.01 0.00 0.00
Isobutene 0.12 0.12 0.00 0.00
1-Butene 99.60 99.60 1.75 1.75
Butadiene 0.00 0.00 0.00 0.00
n-Butane 0.19 0.19 56.54 56.54
2-Butene 0.07 0.07 41.71 41.71
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 0.00 0.00 0.00 0.00
TBA 0.00 0.00 0.00 0.00
DME 0.00 0.00 0.00 0.00
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 4424 4424 450601 450601
Molar Flow Rate kg mol/hr 78.8 78.8 7873.5 7873.5
Molecular Weight 56.1 56.1 57.2 57.2
Temperature °C 45 45 74 74
Stream Pressure bar (g) 8.7 8.0 7.9 7.9
Stream Enthalpy MMkcal/h 0.109 0.109 19.573 29.632
Weight Fraction Liquid 1.0 1.0 1.0 0.7
Critical Temperature °C 147 147 155 155
Critical Pressure bar (a) 40.4 40.4 39.6 39.6
Vapor
Mass Flow rate kg/h 135193
Actual Volumetric Flow m³/h 6346
Molecular Weight 57.2
Actual Density kg/m³ 21.3
Viscosity cP 0.009
Specific Enthalpy kcal/kg 117.81
Specific Heat Capacity kcal/(kg°C) 0.51
Thermal Conductivity kcal/(h·m·°C) 0.018
Liquid
Mass Flow Rate kg/h 4424 4424 450601 315408
Actual Volumetric Flow m³/h 7.9 7.9 861.1 602.7
Actual Density kg/m³ 561 561 523 523
Standard Specific Gravity 0.60 0.60 0.60 0.60
Dynamic Viscosity cP 0.12 0.12 0.12 0.12
Kinematic Viscosity cSt 0.22 0.22 0.22 0.22
Specific Enthalpy kcal/kg 24.6 24.6 43.4 43.5
Surface Tension mN/m 9.9 9.9 7.3 7.3
Specific Heat Capacity kcal/(kg°C) 0.57 0.57 0.65 0.65
Thermal Conductivity kcal/(h·m·°C) 0.088 0.088 0.078 0.078
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 2
Stream 6142 6143
Stream Description B-1 LIGHTS B-1 LIGHTS
COLUMN COLUMN
REBOILER REBOILER
INLET OUTLET
Stream Phase LIQUID MIXED
Component (wt%)
Water 0.00 0.00
Hydrogen 0.00 0.00
Methane 0.00 0.00
Propylene 0.00 0.00
Propane 0.00 0.00
Propadiene 0.00 0.00
Isobutane 0.02 0.02
Isobutene 0.12 0.12
1-Butene 99.61 99.61
Butadiene 0.00 0.00
n-Butane 0.18 0.18
2-Butene 0.07 0.07
C5's 0.00 0.00
C6's 0.00 0.00
DIB 0.00 0.00
Methanol 0.00 0.00
TBA 0.00 0.00
DME 0.00 0.00
MTBE 0.00 0.00
MSBE 0.00 0.00
Mass Flow Rate kg/h 773340 773340
Molar Flow Rate kg mol/hr 13782.2 13782.2
Molecular Weight 56.1 56.1
Temperature °C 71 71
Stream Pressure bar (g) 8.7 8.7
Stream Enthalpy MMkcal/h 30.504 47.564
Weight Fraction Liquid 1.0 0.7
Critical Temperature °C 147 147
Critical Pressure bar (a) 40.4 40.4
Vapor
Mass Flow rate kg/h 232001
Actual Volumetric Flow m³/h 10023
Molecular Weight 56.1
Actual Density kg/m³ 23.1
Viscosity cP 0.010
Specific Enthalpy kcal/kg 112.96
Specific Heat Capacity kcal/(kg°C) 0.48
Thermal Conductivity kcal/(h·m·°C) 0.017
Liquid
Mass Flow Rate kg/h 773340 541339
Actual Volumetric Flow m³/h 1478.6 1035.1
Actual Density kg/m³ 523 523
Standard Specific Gravity 0.60 0.60
Dynamic Viscosity cP 0.10 0.10
Kinematic Viscosity cSt 0.20 0.20
Specific Enthalpy kcal/kg 39.4 39.5
Surface Tension mN/m 6.9 6.9
Specific Heat Capacity kcal/(kg°C) 0.59 0.59
Thermal Conductivity kcal/(h·m·°C) 0.080 0.080
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 3
Stream 6001 6003 6004 6005
0 0 0
Stream Description MIXED WATER WASH WASTE WATER TOTAL WASTE
HYDROGENATED COLUMN TO WATER TO
C4S FROM OSBL BOTTOMS WASTE WATER WASTE WATER
PLANT OSBL PLANT OSBL
0 0 0 0
Stream Phase LIQUID LIQUID LIQUID LIQUID
0 0 0 0
Component (wt%) 0 0 0 0
Water 0.00 100.00 100.00 100.00
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.01 0.00 0.00 0.00
Propylene 0.01 0.00 0.00 0.00
Propane 0.08 0.00 0.00 0.00
Propadiene 0.03 0.00 0.00 0.00
Isobutane 19.08 0.00 0.00 0.00
Isobutene 29.15 0.00 0.00 0.00
1-Butene 18.48 0.00 0.00 0.00
Butadiene 0.00 0.00 0.00 0.00
n-Butane 18.93 0.00 0.00 0.00
2-Butene 13.86 0.00 0.00 0.00
C5's 0.37 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 0.00 0.00 0.00 0.00
TBA 0.00 0.00 0.00 0.00
DME 0.00 0.00 0.00 0.00
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 26103 7823 7823 7827
Molar Flow Rate kg mol/hr 459.0 434.3 434.3 434.5
Molecular Weight 56.9 18.0 18.0 18.0
Temperature °C 41 40 40 40
Stream Pressure bar (g) 11.0 9.0 3.0 3.0
Stream Enthalpy MMkcal/h 0.591 0.316 0.316 0.316
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 147 374 374 374
Critical Pressure bar (a) 38.3 220.2 220.2 220.2
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 26103 7823 7823 7827
Actual Volumetric Flow m³/h 46.6 7.9 7.9 7.9
Actual Density kg/m³ 560 992 990 990
Standard Specific Gravity 0.59 1.00 1.00 1.00
Dynamic Viscosity cP 0.15 0.65 0.65 0.65
Kinematic Viscosity cSt 0.26 0.65 0.65 0.65
Specific Enthalpy kcal/kg 22.6 40.3 40.3 40.3
Surface Tension mN/m 9.9 69.5 69.5 69.5
Specific Heat Capacity kcal/(kg°C) 0.58 1.00 1.00 1.00
Thermal Conductivity kcal/(h·m·°C) 0.085 0.542 0.542 0.542
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 3
Stream 6006 6007 6008 6009
0 0 0 0
Stream Description WATER WASH FEED TO C4 FEED C4 FEED
COLUMN C4 FEED PUMP PUMP
OVERHEAD SURGE DRUM SUCTION DISCHARGE
0 0 0 0
Stream Phase LIQUID LIQUID LIQUID LIQUID
0 0 0 0
Component (wt%) 0 0 0 0
Water 0.03 0.03 0.03 0.03
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.01 0.01 0.01 0.01
Propylene 0.01 0.01 0.01 0.01
Propane 0.08 0.08 0.08 0.08
Propadiene 0.03 0.03 0.03 0.03
Isobutane 19.08 19.08 19.08 19.08
Isobutene 29.14 29.14 29.14 29.14
1-Butene 18.48 18.48 18.48 18.48
Butadiene 0.00 0.00 0.00 0.00
n-Butane 18.93 18.93 18.93 18.93
2-Butene 13.86 13.86 13.86 13.86
C5's 0.37 0.37 0.37 0.37
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 0.00 0.00 0.00 0.00
TBA 0.00 0.00 0.00 0.00
DME 0.00 0.00 0.00 0.00
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 26111 26111 26111 26111
Molar Flow Rate kg mol/hr 459.5 459.5 459.5 459.5
Molecular Weight 56.8 56.8 56.8 56.8
Temperature °C 40 40 40 42
Stream Pressure bar (g) 7.0 5.0 5.0 17.5
Stream Enthalpy MMkcal/h 0.588 0.588 0.588 0.610
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 147 147 147 147
Critical Pressure bar (a) 38.4 38.4 38.4 38.4
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 26111 26111 26111 26111
Actual Volumetric Flow m³/h 46.5 46.6 46.6 46.7
Actual Density kg/m³ 561 561 561 559
Standard Specific Gravity 0.59 0.59 0.59 0.59
Dynamic Viscosity cP 0.15 0.15 0.15 0.15
Kinematic Viscosity cSt 0.26 0.26 0.26 0.26
Specific Enthalpy kcal/kg 22.5 22.5 22.5 23.3
Surface Tension mN/m 10.0 10.0 10.0 9.8
Specific Heat Capacity kcal/(kg°C) 0.58 0.58 0.58 0.59
Thermal Conductivity kcal/(h·m·°C) 0.085 0.085 0.085 0.084
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 3
Stream 6010 6011 6012 6013
0 0 0 0
Stream Description C4 FEED MIXED DEMINERALIZED DEMINERALIZED
PUMP C4s & MeOH WATER FROM WATER FEED
DISCHARGE OSBL TO WATER TO WATER
DOWNSTRM FV WASH COLUMN WASH COLUMN
0 0 0 0
Stream Phase LIQUID LIQUID LIQUID LIQUID
0 0 0 0
Component (wt%) 0 0 0 0
Water 0.03 0.04 100.00 100.00
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.01 0.01 0.00 0.00
Propylene 0.01 0.01 0.00 0.00
Propane 0.08 0.07 0.00 0.00
Propadiene 0.03 0.02 0.00 0.00
Isobutane 19.08 16.09 0.00 0.00
Isobutene 29.14 24.58 0.00 0.00
1-Butene 18.48 15.58 0.00 0.00
Butadiene 0.00 0.00 0.00 0.00
n-Butane 18.93 15.97 0.00 0.00
2-Butene 13.86 11.69 0.00 0.00
C5's 0.37 0.31 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 0.00 15.64 0.00 0.00
TBA 0.00 0.00 0.00 0.00
DME 0.00 0.00 0.00 0.00
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 26111 30955 7831 7831
Molar Flow Rate kg mol/hr 459.5 610.8 434.7 434.7
Molecular Weight 56.8 50.7 18.0 18.0
Temperature °C 42 43 40 40
Stream Pressure bar (g) 16.0 16.0 12.0 7.5
Stream Enthalpy MMkcal/h 0.610 0.757 0.313 0.313
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 147 170 374 374
Critical Pressure bar (a) 38.4 48.8 220.2 220.2
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 26111 30955 7831 7831
Actual Volumetric Flow m³/h 46.7 53.2 7.9 7.9
Actual Density kg/m³ 559 582 990 990
Standard Specific Gravity 0.59 0.62 1.00 1.00
Dynamic Viscosity cP 0.15 0.20 0.65 0.65
Kinematic Viscosity cSt 0.26 0.34 0.66 0.66
Specific Enthalpy kcal/kg 23.3 24.4 40.0 40.0
Surface Tension mN/m 9.8 12.4 69.6 69.6
Specific Heat Capacity kcal/(kg°C) 0.59 0.60 1.00 1.00
Thermal Conductivity kcal/(h·m·°C) 0.084 0.089 0.541 0.541
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 3
Stream 6014 6015 6016 6017
0 0 0 0
Stream Description REACTOR PRIMARY PRIMARY SECONDARY
FEED REACTOR REACTOR REACTOR
PREHEATER FEED EFFLUENT FEED
OUTLET COOLER
INLET
0 0 0 0
Stream Phase LIQUID LIQUID LIQUID LIQUID
0 0 0 0
Component (wt%) 0 0 0 0
Water 0.04 0.04 0.04 0.04
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.01 0.01 0.01 0.01
Propylene 0.01 0.01 0.01 0.01
Propane 0.07 0.07 0.07 0.07
Propadiene 0.02 0.02 0.02 0.02
Isobutane 16.09 16.09 16.09 16.09
Isobutene 24.58 15.03 5.47 5.47
1-Butene 15.58 15.57 15.55 15.55
Butadiene 0.00 0.00 0.00 0.00
n-Butane 15.97 15.97 15.97 15.97
2-Butene 11.69 11.69 11.69 11.69
C5's 0.31 0.31 0.31 0.31
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.06 0.11 0.11
Methanol 15.64 10.18 4.72 4.72
TBA 0.00 0.05 0.09 0.09
DME 0.00 0.03 0.06 0.06
MTBE 0.00 14.87 29.74 29.74
MSBE 0.00 0.03 0.06 0.06
Mass Flow Rate kg/h 30955 61911 61911 30955
Molar Flow Rate kg mol/hr 610.8 1116.2 1010.8 505.4
Molecular Weight 50.7 55.5 61.2 61.2
Temperature °C 43 42 69 69
Stream Pressure bar (g) 15.3 14.2 13.5 13.5
Stream Enthalpy MMkcal/h 0.757 1.440 2.415 1.207
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 170 171 172 172
Critical Pressure bar (a) 48.8 45.3 41.1 41.1
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 30955 61911 61911 30955
Actual Volumetric Flow m³/h 53.2 104.1 109.0 54.5
Actual Density kg/m³ 582 595 568 568
Standard Specific Gravity 0.62 0.63 0.64 0.64
Dynamic Viscosity cP 0.20 0.19 0.15 0.15
Kinematic Viscosity cSt 0.34 0.32 0.26 0.26
Specific Enthalpy kcal/kg 24.4 23.3 39.0 39.0
Surface Tension mN/m 12.4 12.5 9.5 9.5
Specific Heat Capacity kcal/(kg°C) 0.60 0.58 0.62 0.62
Thermal Conductivity kcal/(h·m·°C) 0.089 0.091 0.083 0.083
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 3
Stream 6018 6019 6020 6021
0 0 0 0
Stream Description SECONDARY SECONDARY SECONDARY INLET TO
REACTOR REACTOR REACTOR PRIMARY
FEED FEED EFFLUENT REACTOR
COOLER EFFLUENT
OUTLET COOLER
0 0 0 0
Stream Phase LIQUID LIQUID LIQUID LIQUID
0 0 0 0
Component (wt%) 0 0 0 0
Water 0.04 0.04 0.04 0.04
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.01 0.01 0.01 0.01
Propylene 0.01 0.01 0.01 0.01
Propane 0.07 0.07 0.07 0.07
Propadiene 0.02 0.02 0.02 0.02
Isobutane 16.09 16.09 16.09 16.09
Isobutene 5.47 5.47 2.46 5.47
1-Butene 15.55 15.55 15.53 15.55
Butadiene 0.00 0.00 0.00 0.00
n-Butane 15.97 15.97 15.97 15.97
2-Butene 11.69 11.69 11.69 11.69
C5's 0.31 0.31 0.31 0.31
C6's 0.00 0.00 0.00 0.00
DIB 0.11 0.11 0.11 0.11
Methanol 4.72 4.72 2.99 4.72
TBA 0.09 0.09 0.09 0.09
DME 0.06 0.06 0.06 0.06
MTBE 29.74 29.74 34.47 29.74
MSBE 0.06 0.06 0.08 0.06
Mass Flow Rate kg/h 30955 30955 30955 30955
Molar Flow Rate kg mol/hr 505.4 505.4 488.7 505.4
Molecular Weight 61.2 61.2 63.3 61.2
Temperature °C 40 40 49 69
Stream Pressure bar (g) 12.9 10.6 9.9 13.5
Stream Enthalpy MMkcal/h 0.674 0.674 0.828 1.207
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 172 172 172 172
Critical Pressure bar (a) 41.1 41.1 39.6 41.1
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 30955 30955 30955 30955
Actual Volumetric Flow m³/h 50.9 50.9 51.6 54.5
Actual Density kg/m³ 608 608 600 568
Standard Specific Gravity 0.64 0.64 0.64 0.64
Dynamic Viscosity cP 0.19 0.19 0.17 0.15
Kinematic Viscosity cSt 0.31 0.31 0.29 0.26
Specific Enthalpy kcal/kg 21.8 21.8 26.7 39.0
Surface Tension mN/m 12.6 12.6 11.6 9.5
Specific Heat Capacity kcal/(kg°C) 0.57 0.57 0.58 0.62
Thermal Conductivity kcal/(h·m·°C) 0.092 0.092 0.089 0.083
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 3
Stream 6022 6023 6024 6025
0 0 0 0
Stream Description PRIMARY PRIMARY PRIMARY CD REACTION
REACTOR REACTOR REACTOR COLUMN
RECYCLE RECYCLE RECYCLE FEED
PUMP PUMP
SUCTION DISCHARGE
0 0 0 0
Stream Phase LIQUID LIQUID LIQUID LIQUID
0 0 0 0
Component (wt%) 0 0 0 0
Water 0.04 0.04 0.04 0.04
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.01 0.01 0.01 0.01
Propylene 0.01 0.01 0.01 0.01
Propane 0.07 0.07 0.07 0.07
Propadiene 0.02 0.02 0.02 0.02
Isobutane 16.09 16.09 16.09 16.09
Isobutene 5.47 5.47 5.47 2.46
1-Butene 15.55 15.55 15.55 15.53
Butadiene 0.00 0.00 0.00 0.00
n-Butane 15.97 15.97 15.97 15.97
2-Butene 11.69 11.69 11.69 11.69
C5's 0.31 0.31 0.31 0.31
C6's 0.00 0.00 0.00 0.00
DIB 0.11 0.11 0.11 0.11
Methanol 4.72 4.72 4.72 2.99
TBA 0.09 0.09 0.09 0.09
DME 0.06 0.06 0.06 0.06
MTBE 29.74 29.74 29.74 34.47
MSBE 0.06 0.06 0.06 0.08
Mass Flow Rate kg/h 30955 30955 30955 30955
Molar Flow Rate kg mol/hr 505.4 505.4 505.4 488.7
Molecular Weight 61.2 61.2 61.2 63.3
Temperature °C 40 41 41 70
Stream Pressure bar (g) 12.8 17.8 15.3 6.8
Stream Enthalpy MMkcal/h 0.674 0.683 0.683 1.212
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 172 172 172 172
Critical Pressure bar (a) 41.1 41.1 41.1 39.6
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 30955 30955 30955 30955
Actual Volumetric Flow m³/h 50.9 51.0 51.0 54.3
Actual Density kg/m³ 608 607 607 570
Standard Specific Gravity 0.64 0.64 0.64 0.64
Dynamic Viscosity cP 0.19 0.19 0.19 0.15
Kinematic Viscosity cSt 0.31 0.31 0.31 0.26
Specific Enthalpy kcal/kg 21.8 22.1 22.1 39.2
Surface Tension mN/m 12.6 12.6 12.6 9.3
Specific Heat Capacity kcal/(kg°C) 0.57 0.57 0.57 0.61
Thermal Conductivity kcal/(h·m·°C) 0.092 0.092 0.092 0.083
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 3
Stream 6026 6027 6028 6029
0 0 0 0
Stream Description CD REACTION MTBE MTBE MTBE
COLUMN PRODUCT PRODUCT PRODUCT
BOTTOMS COOLER COOLER TO OSBL
INLET OUTLET
0 0 0 0
Stream Phase LIQUID LIQUID LIQUID LIQUID
0 0 0 0
Component (wt%) 0 0 0 0
Water 0.00 0.00 0.00 0.00
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.00 0.00 0.00 0.00
Propylene 0.00 0.00 0.00 0.00
Propane 0.00 0.00 0.00 0.00
Propadiene 0.00 0.00 0.00 0.00
Isobutane 0.00 0.00 0.00 0.00
Isobutene 0.00 0.00 0.00 0.00
1-Butene 0.00 0.00 0.00 0.00
Butadiene 0.00 0.00 0.00 0.00
n-Butane 0.03 0.03 0.03 0.03
2-Butene 0.07 0.07 0.07 0.07
C5's 0.80 0.80 0.80 0.80
C6's 0.00 0.00 0.00 0.00
DIB 0.29 0.29 0.29 0.29
Methanol 0.10 0.10 0.10 0.10
TBA 0.26 0.26 0.26 0.26
DME 0.00 0.00 0.00 0.00
MTBE 98.09 98.09 98.09 98.09
MSBE 0.36 0.36 0.36 0.36
Mass Flow Rate kg/h 12082 12082 12082 12082
Molar Flow Rate kg mol/hr 137.6 137.6 137.6 137.6
Molecular Weight 87.8 87.8 87.8 87.8
Temperature °C 135 81 45 45
Stream Pressure bar (g) 7.0 6.7 6.4 4.5
Stream Enthalpy MMkcal/h 0.898 0.514 0.274 0.274
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 224 224 224 224
Critical Pressure bar (a) 33.5 33.5 33.5 33.5
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 12082 12082 12082 12082
Actual Volumetric Flow m³/h 20.2 18.0 17.0 17.0
Actual Density kg/m³ 598 670 713 713
Standard Specific Gravity 0.74 0.74 0.74 0.74
Dynamic Viscosity cP 0.13 0.20 0.27 0.27
Kinematic Viscosity cSt 0.22 0.29 0.38 0.38
Specific Enthalpy kcal/kg 74.3 42.5 22.7 22.7
Surface Tension mN/m 7.1 12.8 16.9 16.9
Specific Heat Capacity kcal/(kg°C) 0.62 0.57 0.53 0.53
Thermal Conductivity kcal/(h·m·°C) 0.101 0.101 0.104 0.104
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 3
Stream 6030 6031 6032 6033
0 0 0 0
Stream Description CD REACTION CD REACTION FEED TO CD REACTION
COLUMN COLUMN CD REACTION COLUMN
OVERHEAD CONDENSER COLUMN REFLUX PUMP
OUTLET OVERHEAD SUCTION
DRUM
0 0 0 0
Stream Phase VAPOR LIQUID LIQUID LIQUID
0 0 0 0
Component (wt%) 0 0 0 0
Water 0.09 0.09 0.09 0.09
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.01 0.01 0.01 0.01
Propylene 0.01 0.01 0.01 0.01
Propane 0.11 0.11 0.11 0.11
Propadiene 0.04 0.04 0.04 0.04
Isobutane 25.97 25.97 25.97 25.97
Isobutene 0.04 0.04 0.04 0.04
1-Butene 25.05 25.05 25.05 25.05
Butadiene 0.00 0.00 0.00 0.00
n-Butane 25.75 25.75 25.75 25.75
2-Butene 18.78 18.78 18.78 18.78
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 4.00 4.00 4.00 4.00
TBA 0.00 0.00 0.00 0.00
DME 0.16 0.16 0.16 0.16
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 44111 44111 44111 44111
Molar Flow Rate kg mol/hr 798.1 798.1 798.1 798.1
Molecular Weight 55.3 55.3 55.3 55.3
Temperature °C 59 50 50 50
Stream Pressure bar (g) 6.3 6.0 5.9 5.9
Stream Enthalpy MMkcal/h 5.238 1.246 1.246 1.246
Weight Fraction Liquid 0.0 1.0 1.0 1.0
Critical Temperature °C 154 154 154 154
Critical Pressure bar (a) 41.4 41.4 41.4 41.4
Vapor
Mass Flow rate kg/h 44111
Actual Volumetric Flow m³/h 2563
Molecular Weight 55.3
Actual Density kg/m³ 17.2
Viscosity cP 0.009
Specific Enthalpy kcal/kg 118.76
Specific Heat Capacity kcal/(kg°C) 0.45
Thermal Conductivity kcal/(h·m·°C) 0.016
Liquid
Mass Flow Rate kg/h 44111 44111 44111
Actual Volumetric Flow m³/h 80.0 80.0 80.0
Actual Density kg/m³ 552 552 552
Standard Specific Gravity 0.00 0.60 0.60 0.60
Dynamic Viscosity cP 0.14 0.14 0.14
Kinematic Viscosity cSt 0.26 0.26 0.26
Specific Enthalpy kcal/kg 28.3 28.3 28.3
Surface Tension mN/m 9.8 9.8 9.8
Specific Heat Capacity kcal/(kg°C) 0.61 0.61 0.61
Thermal Conductivity kcal/(h·m·°C) 0.083 0.083 0.083
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 3
Stream 6034 6035 6036 6037
0 0 0 0
Stream Description CD REACTION CD REACTION CD REACTION MEOH EXT.
COLUMN COLUMN COLUMN COLUMN
REFLUX PUMP REFLUX REFLUX AT FEED
DISCHARGE COLUMN FEED COOLER
INLET
0 0 0 0
Stream Phase LIQUID LIQUID LIQUID LIQUID
0 0 0 0
Component (wt%) 0 0 0 0
Water 0.09 0.09 0.09 0.09
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.01 0.01 0.01 0.01
Propylene 0.01 0.01 0.01 0.01
Propane 0.11 0.11 0.11 0.11
Propadiene 0.04 0.04 0.04 0.04
Isobutane 25.97 25.97 25.97 25.97
Isobutene 0.04 0.04 0.04 0.04
1-Butene 25.05 25.05 25.05 25.05
Butadiene 0.00 0.00 0.00 0.00
n-Butane 25.75 25.75 25.75 25.75
2-Butene 18.78 18.78 18.78 18.78
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 4.00 4.00 4.00 4.00
TBA 0.00 0.00 0.00 0.00
DME 0.16 0.16 0.16 0.16
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 44111 24933 24933 19179
Molar Flow Rate kg mol/hr 798.1 451.1 451.1 347.0
Molecular Weight 55.3 55.3 55.3 55.3
Temperature °C 50 50 50 50
Stream Pressure bar (g) 13.6 13.6 6.6 13.6
Stream Enthalpy MMkcal/h 1.269 0.717 0.717 0.552
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 154 154 154 154
Critical Pressure bar (a) 41.4 41.4 41.4 41.4
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 44111 24933 24933 19179
Actual Volumetric Flow m³/h 80.1 45.3 45.3 34.8
Actual Density kg/m³ 550 550 550 550
Standard Specific Gravity 0.60 0.60 0.60 0.60
Dynamic Viscosity cP 0.14 0.14 0.14 0.14
Kinematic Viscosity cSt 0.26 0.26 0.26 0.26
Specific Enthalpy kcal/kg 28.8 28.8 28.8 28.8
Surface Tension mN/m 9.7 9.7 9.7 9.7
Specific Heat Capacity kcal/(kg°C) 0.61 0.61 0.61 0.61
Thermal Conductivity kcal/(h·m·°C) 0.083 0.083 0.083 0.083
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 3
Stream 6038 6039 6040 6041
0 0 0 0
Stream Description C4 DISTILLATE METHANOL METHANOL METHANOL
TO METHANOL EXTRACTION REC. COL. RECOVERY
EXTRACTION COLUMN FEED/BTMS COLUMN
COLUMN BOTTOMS EXCHANGER FEED
INLET
0 0 0 0
Stream Phase LIQUID LIQUID LIQUID LIQUID
0 0 0 0
Component (wt%) 0 0 0 0
Water 0.09 80.00 80.00 80.00
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.01 0.00 0.00 0.00
Propylene 0.01 0.00 0.00 0.00
Propane 0.11 0.00 0.00 0.00
Propadiene 0.04 0.00 0.00 0.00
Isobutane 25.97 0.00 0.00 0.00
Isobutene 0.04 0.00 0.00 0.00
1-Butene 25.05 0.00 0.00 0.00
Butadiene 0.00 0.00 0.00 0.00
n-Butane 25.75 0.00 0.00 0.00
2-Butene 18.78 0.00 0.00 0.00
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 4.00 20.00 20.00 20.00
TBA 0.00 0.00 0.00 0.00
DME 0.16 0.00 0.00 0.00
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 19179 3834 3834 3834
Molar Flow Rate kg mol/hr 347.0 194.2 194.2 194.2
Molecular Weight 55.3 19.7 19.7 19.7
Temperature °C 40 40 40 75
Stream Pressure bar (g) 12.2 12.2 1.3 0.9
Stream Enthalpy MMkcal/h 0.432 0.141 0.141 0.266
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 154 358 358 358
Critical Pressure bar (a) 41.4 202.9 202.9 202.9
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 19179 3834 3834 3834
Actual Volumetric Flow m³/h 34.0 4.1 4.1 4.2
Actual Density kg/m³ 564 938 938 915
Standard Specific Gravity 0.60 0.95 0.95 0.95
Dynamic Viscosity cP 0.16 0.62 0.62 0.37
Kinematic Viscosity cSt 0.28 0.66 0.66 0.40
Specific Enthalpy kcal/kg 22.5 36.8 36.8 69.4
Surface Tension mN/m 10.9 63.6 63.6 58.2
Specific Heat Capacity kcal/(kg°C) 0.59 0.92 0.92 0.94
Thermal Conductivity kcal/(h·m·°C) 0.087 0.320 0.320 0.315
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 3
Stream 6042 6043 6044 6045
0 0 0
Stream Description METHANOL C4s TO METHANOL METHANOL
EXTRACTION B-1 RECOVERY RECOVERY
COLUMN HEAVIES COLUMN COLUMN
OVERHEAD COLUMN BOTTOMS BOTTOMS PUMP
DISCHARGE
0 0 0
Stream Phase LIQUID LIQUID LIQUID LIQUID
0 0 0
Component (wt%) 0 0 0
Water 0.03 0.03 100.00 100.00
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.01 0.01 0.00 0.00
Propylene 0.01 0.01 0.00 0.00
Propane 0.11 0.11 0.00 0.00
Propadiene 0.04 0.04 0.00 0.00
Isobutane 27.07 27.07 0.00 0.00
Isobutene 0.04 0.04 0.00 0.00
1-Butene 26.11 26.11 0.00 0.00
Butadiene 0.00 0.00 0.00 0.00
n-Butane 26.84 26.84 0.00 0.00
2-Butene 19.57 19.57 0.00 0.00
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 0.00 0.00 0.00 0.00
TBA 0.00 0.00 0.00 0.00
DME 0.17 0.17 0.00 0.00
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 18401 18401 3056 3056
Molar Flow Rate kg mol/hr 322.5 322.5 169.6 169.6
Molecular Weight 57.1 57.1 18.0 18.0
Temperature °C 40 40 126 126
Stream Pressure bar (g) 10.5 7.4 1.4 16.0
Stream Enthalpy MMkcal/h 0.413 0.413 0.387 0.387
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 147 -126 374 374
Critical Pressure bar (a) 38.2 39.0 220.2 220.2
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 18401 18401 3056 3056
Actual Volumetric Flow m³/h 33.0 32.9 3.3 3.3
Actual Density kg/m³ 558 559 939 939
Standard Specific Gravity 0.59 0.59 1.00 1.00
Dynamic Viscosity cP 0.14 0.14 0.22 0.22
Kinematic Viscosity cSt 0.25 0.25 0.23 0.23
Specific Enthalpy kcal/kg 22.4 22.4 126.6 126.7
Surface Tension mN/m 10.0 10.2 54.0 54.0
Specific Heat Capacity kcal/(kg°C) 0.59 0.59 1.02 1.02
Thermal Conductivity kcal/(h·m·°C) 0.085 0.085 0.592 0.591
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 3
Stream 6046 6047 6048 6049
0 0 0 0
Stream Description RECYCLE RECYCLE RECYCLE METHANOL
WATER WATER WATER TO RECOVERY
COOLER COOLER METHANOL COLUMN
INLET OUTLET EXTRACTION OVERHEAD
COLUMN
0 0 0 0
Stream Phase LIQUID LIQUID LIQUID VAPOR
0 0 0 0
Component (wt%) 0 0 0 0
Water 100.00 100.00 100.00 0.05
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.00 0.00 0.00 0.00
Propylene 0.00 0.00 0.00 0.00
Propane 0.00 0.00 0.00 0.00
Propadiene 0.00 0.00 0.00 0.00
Isobutane 0.00 0.00 0.00 0.00
Isobutene 0.00 0.00 0.00 0.00
1-Butene 0.00 0.00 0.00 0.00
Butadiene 0.00 0.00 0.00 0.00
n-Butane 0.00 0.00 0.00 0.00
2-Butene 0.00 0.00 0.00 0.00
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 0.00 0.00 0.00 99.95
TBA 0.00 0.00 0.00 0.00
DME 0.00 0.00 0.00 0.00
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 3056 3056 3056 2301
Molar Flow Rate kg mol/hr 169.6 169.6 169.6 71.8
Molecular Weight 18.0 18.0 18.0 32.0
Temperature °C 86 40 40 78
Stream Pressure bar (g) 15.7 15.3 10.6 0.7
Stream Enthalpy MMkcal/h 0.262 0.122 0.122 0.719
Weight Fraction Liquid 1.0 1.0 1.0 0.0
Critical Temperature °C 374 374 374 240
Critical Pressure bar (a) 220.2 220.2 220.2 80.1
Vapor
Mass Flow rate kg/h 2301
Actual Volumetric Flow m³/h 1193
Molecular Weight 32.0
Actual Density kg/m³ 1.9
Viscosity cP 0.012
Specific Enthalpy kcal/kg 312.51
Specific Heat Capacity kcal/(kg°C) 0.37
Thermal Conductivity kcal/(h·m·°C) 0.018
Liquid
Mass Flow Rate kg/h 3056 3056 3056
Actual Volumetric Flow m³/h 3.2 3.1 3.1
Actual Density kg/m³ 967 990 990
Standard Specific Gravity 1.00 1.00 1.00 0.00
Dynamic Viscosity cP 0.33 0.65 0.65
Kinematic Viscosity cSt 0.34 0.66 0.66
Specific Enthalpy kcal/kg 85.8 40.0 40.0
Surface Tension mN/m 62.0 69.6 69.6
Specific Heat Capacity kcal/(kg°C) 1.00 1.00 1.00
Thermal Conductivity kcal/(h·m·°C) 0.577 0.541 0.541
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 3
Stream 6050 6051 6052 6053
0 0 0 0
Stream Description METHANOL METHANOL METHANOL METHANOL
RECOVERY RECOVERY RECOVERY RECOVERY
COLUMN COLUMN COLUMN COLUMN
CONDENSER OVHD DRUM REFLUX PUMP REFLUX PUMP
OUTLET INLET SUCTION DISCHARGE
0 0 0 0
Stream Phase LIQUID LIQUID LIQUID LIQUID
0 0 0 0
Component (wt%) 0 0 0 0
Water 0.05 0.05 0.08 0.08
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.00 0.00 0.00 0.00
Propylene 0.00 0.00 0.00 0.00
Propane 0.00 0.00 0.00 0.00
Propadiene 0.00 0.00 0.00 0.00
Isobutane 0.00 0.00 0.00 0.00
Isobutene 0.00 0.00 0.00 0.00
1-Butene 0.00 0.00 0.00 0.00
Butadiene 0.00 0.00 0.00 0.00
n-Butane 0.00 0.00 0.00 0.00
2-Butene 0.00 0.00 0.00 0.00
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 99.95 99.95 99.92 99.92
TBA 0.00 0.00 0.00 0.00
DME 0.00 0.00 0.00 0.00
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 2301 2301 6684 6684
Molar Flow Rate kg mol/hr 71.8 71.8 208.7 208.7
Molecular Weight 32.0 32.0 32.0 32.0
Temperature °C 64 64 49 50
Stream Pressure bar (g) 0.5 0.4 0.4 19.2
Stream Enthalpy MMkcal/h 0.092 0.092 0.197 0.203
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 240 240 240 240
Critical Pressure bar (a) 80.1 80.1 80.2 80.2
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 2301 2301 6684 6684
Actual Volumetric Flow m³/h 3.1 3.1 8.7 8.7
Actual Density kg/m³ 750 750 766 765
Standard Specific Gravity 0.80 0.80 0.80 0.80
Dynamic Viscosity cP 0.35 0.35 0.41 0.40
Kinematic Viscosity cSt 0.46 0.46 0.53 0.52
Specific Enthalpy kcal/kg 39.9 39.9 29.4 30.3
Surface Tension mN/m 18.9 18.9 20.3 20.2
Specific Heat Capacity kcal/(kg°C) 0.67 0.67 0.64 0.65
Thermal Conductivity kcal/(h·m·°C) 0.162 0.162 0.166 0.166
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 3
Stream 6054 6055 6056 6057
0 0 0 0
Stream Description METHANOL METHANOL METHANOL RECYCLE
RECOVERY RECOVERY TO MTBE METHANOL
COLUMN COLUMN REACTION TO C4s
REFLUX REFLUX AT SECTION STREAM
COLUMN FEED
0 0 0 0
Stream Phase LIQUID LIQUID LIQUID LIQUID
0 0 0 0
Component (wt%) 0 0 0 0
Water 0.08 0.08 0.08 0.08
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.00 0.00 0.00 0.00
Propylene 0.00 0.00 0.00 0.00
Propane 0.00 0.00 0.00 0.00
Propadiene 0.00 0.00 0.00 0.00
Isobutane 0.00 0.00 0.00 0.00
Isobutene 0.00 0.00 0.00 0.00
1-Butene 0.00 0.00 0.00 0.00
Butadiene 0.00 0.00 0.00 0.00
n-Butane 0.00 0.00 0.00 0.00
2-Butene 0.00 0.00 0.00 0.00
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 99.92 99.92 99.92 99.92
TBA 0.00 0.00 0.00 0.00
DME 0.00 0.00 0.00 0.00
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 1534 1534 5150 4845
Molar Flow Rate kg mol/hr 47.9 47.9 160.8 151.3
Molecular Weight 32.0 32.0 32.0 32.0
Temperature °C 50 50 50 50
Stream Pressure bar (g) 19.2 0.7 19.2 19.2
Stream Enthalpy MMkcal/h 0.047 0.047 0.156 0.147
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 240 240 240 240
Critical Pressure bar (a) 80.2 80.2 80.2 80.2
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 1534 1534 5150 4845
Actual Volumetric Flow m³/h 2.0 2.0 6.7 6.3
Actual Density kg/m³ 765 765 765 765
Standard Specific Gravity 0.80 0.80 0.80 0.80
Dynamic Viscosity cP 0.40 0.40 0.40 0.40
Kinematic Viscosity cSt 0.52 0.52 0.52 0.52
Specific Enthalpy kcal/kg 30.3 30.3 30.3 30.3
Surface Tension mN/m 20.2 20.2 20.2 20.2
Specific Heat Capacity kcal/(kg°C) 0.65 0.65 0.65 0.65
Thermal Conductivity kcal/(h·m·°C) 0.166 0.166 0.166 0.166
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 3
Stream 6058 6059 6060 6061
0 0 0
Stream Description RECYCLE METHANOL METHANOL METHANOL
METHANOL INJECTION TO INJECTION TO INJECTION TO
TO C4s CD REACTION CD REACTION CD REACTION
STREAM COLUMN COLUMN COLUMN
0 0 0
Stream Phase LIQUID LIQUID LIQUID LIQUID
0 0 0 0
Component (wt%) 0 0 0 0
Water 0.08 0.08 0.08 0.08
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.00 0.00 0.00 0.00
Propylene 0.00 0.00 0.00 0.00
Propane 0.00 0.00 0.00 0.00
Propadiene 0.00 0.00 0.00 0.00
Isobutane 0.00 0.00 0.00 0.00
Isobutene 0.00 0.00 0.00 0.00
1-Butene 0.00 0.00 0.00 0.00
Butadiene 0.00 0.00 0.00 0.00
n-Butane 0.00 0.00 0.00 0.00
2-Butene 0.00 0.00 0.00 0.00
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 99.92 99.92 99.92 99.92
TBA 0.00 0.00 0.00 0.00
DME 0.00 0.00 0.00 0.00
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 4845 306 15 290
Molar Flow Rate kg mol/hr 151.3 9.5 0.5 9.1
Molecular Weight 32.0 32.0 32.0 32.0
Temperature °C 50 50 50 50
Stream Pressure bar (g) 16.0 19.2 6.6 6.6
Stream Enthalpy MMkcal/h 0.147 0.009 0.000 0.009
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 240 240 240 240
Critical Pressure bar (a) 80.2 80.2 80.2 80.2
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 4845 306 15 290
Actual Volumetric Flow m³/h 6.3 0.4 0.0 0.4
Actual Density kg/m³ 765 765 765 765
Standard Specific Gravity 0.80 0.80 0.80 0.80
Dynamic Viscosity cP 0.40 0.40 0.40 0.40
Kinematic Viscosity cSt 0.52 0.52 0.52 0.52
Specific Enthalpy kcal/kg 30.3 30.3 30.3 30.3
Surface Tension mN/m 20.2 20.2 20.2 20.2
Specific Heat Capacity kcal/(kg°C) 0.65 0.65 0.65 0.65
Thermal Conductivity kcal/(h·m·°C) 0.166 0.166 0.166 0.166
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 3
Stream 6062 6063 6064 6065
0 0 0
Stream Description FRESH FILTERED FILTERED CD REACTION
METHANOL FRESH FRESH COLUMN
FROM METHANOL METHANOL REBOILER
STORAGE AT INLET
OSBL
0 0 0 0
Stream Phase LIQUID LIQUID LIQUID LIQUID
0 0 0 0
Component (wt%) 0 0 0 0
Water 0.10 0.10 0.10 0.00
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.00 0.00 0.00 0.00
Propylene 0.00 0.00 0.00 0.00
Propane 0.00 0.00 0.00 0.00
Propadiene 0.00 0.00 0.00 0.00
Isobutane 0.00 0.00 0.00 0.00
Isobutene 0.00 0.00 0.00 0.00
1-Butene 0.00 0.00 0.00 0.00
Butadiene 0.00 0.00 0.00 0.00
n-Butane 0.00 0.00 0.00 0.03
2-Butene 0.00 0.00 0.00 0.07
C5's 0.00 0.00 0.00 0.80
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.29
Methanol 99.90 99.90 99.90 0.10
TBA 0.00 0.00 0.00 0.26
DME 0.00 0.00 0.00 0.00
MTBE 0.00 0.00 0.00 98.09
MSBE 0.00 0.00 0.00 0.36
Mass Flow Rate kg/h 4383 4383 4383 225143
Molar Flow Rate kg mol/hr 136.9 136.9 136.9 2564.2
Molecular Weight 32.0 32.0 32.0 87.8
Temperature °C 40 40 40 135
Stream Pressure bar (g) 3.0 2.8 0.4 7.0
Stream Enthalpy MMkcal/h 0.105 0.105 0.105 16.736
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 240 240 240 224
Critical Pressure bar (a) 80.2 80.2 80.2 33.5
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 4383 4383 4383 225143
Actual Volumetric Flow m³/h 5.7 5.7 5.7 376.7
Actual Density kg/m³ 775 775 775 598
Standard Specific Gravity 0.80 0.80 0.80 0.74
Dynamic Viscosity cP 0.40 0.40 0.40 0.13
Kinematic Viscosity cSt 0.58 0.58 0.58 0.22
Specific Enthalpy kcal/kg 24.0 24.0 24.0 74.3
Surface Tension mN/m 21.1 21.1 21.1 7.1
Specific Heat Capacity kcal/(kg°C) 0.63 0.63 0.63 0.62
Thermal Conductivity kcal/(h·m·°C) 0.166 0.166 0.166 0.101
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 3
Stream 6066 6067 6068 6099
0 0 0
Stream Description CD REACTION METHANOL METHANOL C4 DISTILLATE
COLUMN RECOVERY RECOVERY TO METHANOL
REBOILER COLUMN COLUMN EXTRACTION
OUTLET REBOILER REBOILER COLUMN
INLET OUTLET
0 0 0 0
Stream Phase MIXED LIQUID MIXED LIQUID
0 0 0 0
Component (wt%) 0 0 0 0
Water 0.00 99.99 99.99 0.09
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.00 0.00 0.00 0.01
Propylene 0.00 0.00 0.00 0.01
Propane 0.00 0.00 0.00 0.11
Propadiene 0.00 0.00 0.00 0.04
Isobutane 0.00 0.00 0.00 25.97
Isobutene 0.00 0.00 0.00 0.04
1-Butene 0.00 0.00 0.00 25.05
Butadiene 0.00 0.00 0.00 0.00
n-Butane 0.03 0.00 0.00 25.75
2-Butene 0.07 0.00 0.00 18.78
C5's 0.80 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.29 0.00 0.00 0.00
Methanol 0.10 0.01 0.01 4.00
TBA 0.26 0.00 0.00 0.00
DME 0.00 0.00 0.00 0.16
MTBE 98.09 0.00 0.00 0.00
MSBE 0.36 0.00 0.00 0.00
Mass Flow Rate kg/h 225143 5057 5057 19179
Molar Flow Rate kg mol/hr 2564.2 280.7 280.7 347.0
Molecular Weight 87.8 18.0 18.0 55.3
Temperature °C 135 126 125 40
Stream Pressure bar (g) 6.9 1.4 1.3 13.2
Stream Enthalpy MMkcal/h 20.820 0.639 1.434 0.432
Weight Fraction Liquid 0.7 1.0 0.7 1.0
Critical Temperature °C 224 374 374 154
Critical Pressure bar (a) 33.5 220.2 220.2 41.4
Vapor
Mass Flow rate kg/h 67324 1525
Actual Volumetric Flow m³/h 2724.0 1177.0
Molecular Weight 87.5 18.0
Actual Density kg/m³ 24.7 1.3
Viscosity cP 0.010 0.013
Specific Enthalpy kcal/kg 135.26 649.19
Specific Heat Capacity kcal/(kg°C) 0.50 0.46
Thermal Conductivity kcal/(h·m·°C) 0.021 0.023
Liquid
Mass Flow Rate kg/h 157819 5057 3532 19179
Actual Volumetric Flow m³/h 263.9 5.4 3.8 34.0
Actual Density kg/m³ 598 939 939 564
Standard Specific Gravity 0.74 1.00 1.00 0.60
Dynamic Viscosity cP 0.13 0.22 0.22 0.16
Kinematic Viscosity cSt 0.22 0.23 0.23 0.28
Specific Enthalpy kcal/kg 74.2 126.3 125.6 22.5
Surface Tension mN/m 7.2 54.1 54.2 10.9
Specific Heat Capacity kcal/(kg°C) 0.62 1.02 1.02 0.59
Thermal Conductivity kcal/(h·m·°C) 0.101 0.591 0.591 0.087
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 3
Stream 0
Stream Description
Stream Phase 0
0
Component (wt%) 0
Water 0.00
Hydrogen 0.00
Methane 0.00
Propylene 0.00
Propane 0.00
Propadiene 0.00
Isobutane 0.00
Isobutene 0.00
1-Butene 0.00
Butadiene 0.00
n-Butane 0.00
2-Butene 0.00
C5's 0.00
C6's 0.00
DIB 0.00
Methanol 0.00
TBA 0.00
DME 0.00
MTBE 0.00
MSBE 0.00
0.00
0.00
Mass Flow Rate kg/h 0
Molar Flow Rate kg mol/hr 0.0
Molecular Weight 0.0
Temperature °C 0.0
Stream Pressure bar (g) 0.0
Stream Enthalpy MMkcal/h 0.000
Weight Fraction Liquid 0.00
Critical Temperature °C 0.0
Critical Pressure bar (a) 0.0
0
Vapor 0.0
Mass Flow rate kg/h 0
Actual Volumetric Flow m³/h 0
Molecular Weight 0.00
Actual Density kg/m³ 0.00
Viscosity cP 0.0000
Specific Enthalpy kcal/kg 0.0
Specific Heat Capacity kcal/(kg°C) 0.000
Thermal Conductivity kcal/(h·m·°C) 0.0000
0.000
Liquid 0.0
Mass Flow Rate kg/h 0
Actual Volumetric Flow m³/h 0.0
Actual Density kg/m³ 0.0
Standard Specific Gravity 0.000
Dynamic Viscosity cP 0.000
Kinematic Viscosity cSt
Specific Enthalpy kcal/kg 0.0
Surface Tension mN/m 0.0
Specific Heat Capacity kcal/(kg°C) 0.000
Thermal Conductivity kcal/(h·m·°C) 0.000
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 3
Stream 6101 6102 6103 6104
Stream Description B-1 HEAVIES B-1 HEAVIES B-1 HEAVIES B-1 HEAVIES
COLUMN #1 COLUMN COLUMN #2 COLUMN #2
BOTTOMS TRANSFER FEED OVERHEAD
PUMP DISCH.
Stream Phase LIQUID LIQUID LIQUID VAPOR
Component (wt%)
Water 0.00 0.00 0.00 0.00
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.00 0.00 0.00 0.00
Propylene 0.00 0.00 0.00 0.00
Propane 0.01 0.01 0.01 0.03
Propadiene 0.01 0.01 0.01 0.01
Isobutane 17.36 17.36 17.36 19.83
Isobutene 0.05 0.05 0.05 0.05
1-Butene 43.08 43.08 43.08 43.43
Butadiene 0.00 0.00 0.00 0.00
n-Butane 25.40 25.40 25.40 23.56
2-Butene 14.06 14.06 14.06 13.04
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 0.00 0.00 0.00 0.00
TBA 0.00 0.00 0.00 0.00
DME 0.02 0.02 0.02 0.05
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 123871 123871 123871 133600
Molar Flow Rate kg mol/hr 2175.3 2175.3 2175.3 2346.2
Molecular Weight 56.9 56.9 56.9 56.9
Temperature °C 65 65 65 65
Stream Pressure bar (g) 7.3 11.1 7.3 7.3
Stream Enthalpy MMkcal/h 4.626 4.659 4.630 14.905
Weight Fraction Liquid 1.0 1.0 1.0 0.0
Critical Temperature °C 147 147 147 147
Critical Pressure bar (a) 39.3 39.3 39.3 39.2
Vapor
Mass Flow rate kg/h 133600
Actual Volumetric Flow m³/h 6659
Molecular Weight 56.9
Actual Density kg/m³ 20.1
Viscosity cP 0.009
Specific Enthalpy kcal/kg 111.57
Specific Heat Capacity kcal/(kg°C) 0.49
Thermal Conductivity kcal/(h·m·°C) 0.017
Liquid
Mass Flow Rate kg/h 123871 123871 123871
Actual Volumetric Flow m³/h 235.7 235.5 235.8
Actual Density kg/m³ 525 526 525
Standard Specific Gravity 0.59 0.59 0.59 0.00
Dynamic Viscosity cP 0.11 0.11 0.11
Kinematic Viscosity cSt 0.22 0.22 0.22
Specific Enthalpy kcal/kg 37.3 37.6 37.4
Surface Tension mN/m 7.5 7.4 7.5
Specific Heat Capacity kcal/(kg°C) 0.62 0.62 0.62
Thermal Conductivity kcal/(h·m·°C) 0.079 0.078 0.079
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 3
Stream 6105 6106 6107 6108
Stream Description B-1 HEAVIES B-1 HEAVIES B-1 HEAVIES WASTEWATER
COLUMN #1 COLUMN COLUMN TO OSBL
OVERHEAD CONDENSER OVERHEAD
OUTLET DRUM INLET
Stream Phase VAPOR LIQUID LIQUID
Component (wt%)
Water 0.05 0.05 0.05
Hydrogen 0.00 0.00 0.00
Methane 0.02 0.02 0.02
Propylene 0.02 0.02 0.02
Propane 0.21 0.21 0.21
Propadiene 0.07 0.07 0.07
Isobutane 51.20 51.20 51.20
Isobutene 0.08 0.08 0.08
1-Butene 47.91 47.91 47.91
Butadiene 0.00 0.00 0.00
n-Butane 0.09 0.09 0.09
2-Butene 0.03 0.03 0.03
C5's 0.00 0.00 0.00
C6's 0.00 0.00 0.00
DIB 0.00 0.00 0.00
Methanol 0.00 0.00 0.00
TBA 0.00 0.00 0.00
DME 0.32 0.32 0.32
MTBE 0.00 0.00 0.00
MSBE 0.00 0.00 0.00
Mass Flow Rate kg/h 123297 123297 123297
Molar Flow Rate kg mol/hr 2166.4 2166.4 2166.4
Molecular Weight 56.9 56.9 56.9
Temperature °C 56 46 46
Stream Pressure bar (g) 6.6 6.3 6.2
Stream Enthalpy MMkcal/h 13.234 3.208 3.208
Weight Fraction Liquid 0.0 1.0 1.0
Critical Temperature °C 141 141 141
Critical Pressure bar (a) 38.8 38.8 38.8
Vapor
Mass Flow rate kg/h 123297
Actual Volumetric Flow m³/h 6604
Molecular Weight 56.9
Actual Density kg/m³ 18.7
Viscosity cP 0.009
Specific Enthalpy kcal/kg 107.33
Specific Heat Capacity kcal/(kg°C) 0.45
Thermal Conductivity kcal/(h·m·°C) 0.016
Liquid
Mass Flow Rate kg/h 123297 123297
Actual Volumetric Flow m³/h 228.3 228.3
Actual Density kg/m³ 540 540
Standard Specific Gravity 0.00 0.58 0.58
Dynamic Viscosity cP 0.13 0.13
Kinematic Viscosity cSt 0.24 0.24
Specific Enthalpy kcal/kg 26.0 26.0
Surface Tension mN/m 8.8 8.8
Specific Heat Capacity kcal/(kg°C) 0.60 0.60
Thermal Conductivity kcal/(h·m·°C) 0.081 0.081
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 3
Stream 6109 6110 6111 6112
Stream Description WASTEWATER B-1 HEAVIES B-1 HEAVIES B-1 HEAVIES
TO OSBL COLUMN COLUMN COLUMN
REFLUX PUMP REFLUX PUMP REFLUX
SUCTION DISCHARGE
Stream Phase LIQUID LIQUID LIQUID
Component (wt%)
Water 0.05 0.05 0.05
Hydrogen 0.00 0.00 0.00
Methane 0.02 0.02 0.02
Propylene 0.02 0.02 0.02
Propane 0.21 0.21 0.21
Propadiene 0.07 0.07 0.07
Isobutane 51.20 51.20 51.20
Isobutene 0.08 0.08 0.08
1-Butene 47.91 47.91 47.91
Butadiene 0.00 0.00 0.00
n-Butane 0.09 0.09 0.09
2-Butene 0.03 0.03 0.03
C5's 0.00 0.00 0.00
C6's 0.00 0.00 0.00
DIB 0.00 0.00 0.00
Methanol 0.00 0.00 0.00
TBA 0.00 0.00 0.00
DME 0.32 0.32 0.32
MTBE 0.00 0.00 0.00
MSBE 0.00 0.00 0.00
Mass Flow Rate kg/h 123297 123297 113569
Molar Flow Rate kg mol/hr 2166.4 2166.4 1995.5
Molecular Weight 56.9 56.9 56.9
Temperature °C 46 47 47
Stream Pressure bar (g) 6.2 10.0 10.0
Stream Enthalpy MMkcal/h 3.208 3.240 2.985
Weight Fraction Liquid 1.0 1.0 1.0
Critical Temperature °C 141 141 141
Critical Pressure bar (a) 38.8 38.8 38.8
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 123297 123297 113569
Actual Volumetric Flow m³/h 228.3 228.1 210.1
Actual Density kg/m³ 540 541 541
Standard Specific Gravity 0.58 0.58 0.58
Dynamic Viscosity cP 0.13 0.13 0.13
Kinematic Viscosity cSt 0.24 0.24 0.24
Specific Enthalpy kcal/kg 26.0 26.3 26.3
Surface Tension mN/m 8.8 8.7 8.7
Specific Heat Capacity kcal/(kg°C) 0.60 0.60 0.60
Thermal Conductivity kcal/(h·m·°C) 0.081 0.081 0.081
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 3
Stream 6113 6114 6115 6116
Stream Description B-1 HEAVIES B-1 HEAVIES B-1 HEAVIES B-1 HEAVIES
COLUMN COLUMN COLUMN COLUMN #2
REFLUX AT OVERHEAD TO OVERHEAD TO BOTTOMS
COLUMN FEED B-1 LIGHTS B-1 LIGHTS
COLUMN COLUMN
Stream Phase LIQUID LIQUID LIQUID LIQUID
Component (wt%)
Water 0.05 0.05 0.05 0.00
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.02 0.02 0.02 0.00
Propylene 0.02 0.02 0.02 0.00
Propane 0.21 0.21 0.21 0.00
Propadiene 0.07 0.07 0.07 0.00
Isobutane 51.20 51.20 51.20 0.00
Isobutene 0.08 0.08 0.08 0.00
1-Butene 47.91 47.91 47.91 1.66
Butadiene 0.00 0.00 0.00 0.00
n-Butane 0.09 0.09 0.09 56.85
2-Butene 0.03 0.03 0.03 41.48
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 0.00 0.00 0.00 0.00
TBA 0.00 0.00 0.00 0.00
DME 0.32 0.32 0.32 0.00
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 113569 9728 9728 8672
Molar Flow Rate kg mol/hr 1995.5 170.9 170.9 151.5
Molecular Weight 56.9 56.9 56.9 57.2
Temperature °C 47 47 47 74
Stream Pressure bar (g) 6.6 10.0 8.0 8.0
Stream Enthalpy MMkcal/h 2.985 0.256 0.256 0.380
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 141 141 -133 155
Critical Pressure bar (a) 38.8 38.8 38.5 39.6
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 113569 9728 9728 8672
Actual Volumetric Flow m³/h 210.5 18.0 18.0 16.6
Actual Density kg/m³ 540 541 540 522
Standard Specific Gravity 0.58 0.58 0.60
Dynamic Viscosity cP 0.13 0.13 0.13 0.12
Kinematic Viscosity cSt 0.24 0.24 0.24 0.22
Specific Enthalpy kcal/kg 26.3 26.3 26.3 43.8
Surface Tension mN/m 8.7 8.7 8.7 7.2
Specific Heat Capacity kcal/(kg°C) 0.60 0.60 0.60 0.65
Thermal Conductivity kcal/(h·m·°C) 0.081 0.081 0.081 0.077
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 3
Stream 6117 6118 6119 6120
Stream Description B-1 HEAVIES BUTENE-2 BUTENE-2 B-1 LIGHTS
COLUMN #2 PRODUCT PRODUCT COLUMN #1
BOTTOMS COOLER TO OSBL BOTTOMS
PUMP OUTLET
DISCHARGE
Stream Phase LIQUID LIQUID LIQUID LIQUID
Component (wt%)
Water 0.00 0.00 0.00 0.00
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.00 0.00 0.00 0.00
Propylene 0.00 0.00 0.00 0.00
Propane 0.00 0.00 0.00 0.00
Propadiene 0.00 0.00 0.00 0.00
Isobutane 0.00 0.00 0.00 31.72
Isobutene 0.00 0.00 0.00 0.19
1-Butene 1.66 1.66 1.66 68.06
Butadiene 0.00 0.00 0.00 0.00
n-Butane 56.85 56.85 56.85 0.02
2-Butene 41.48 41.48 41.48 0.01
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 0.00 0.00 0.00 0.00
TBA 0.00 0.00 0.00 0.00
DME 0.00 0.00 0.00 0.00
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 8672 8672 8672 256782
Molar Flow Rate kg mol/hr 151.5 151.5 151.5 4526.3
Molecular Weight 57.2 57.2 57.2 56.7
Temperature °C 74 45 45 66
Stream Pressure bar (g) 9.2 7.7 7.0 8.2
Stream Enthalpy MMkcal/h 0.380 0.221 0.221 9.658
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 155 155 155 143
Critical Pressure bar (a) 39.6 39.6 39.6 39.2
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 8672 8672 8672 256782
Actual Volumetric Flow m³/h 16.6 15.4 15.4 495.4
Actual Density kg/m³ 523 563 563 518
Standard Specific Gravity 0.60 0.60 0.60 0.59
Dynamic Viscosity cP 0.12 0.14 0.14 0.11
Kinematic Viscosity cSt 0.22 0.25 0.25 0.21
Specific Enthalpy kcal/kg 43.9 25.5 25.5 37.6
Surface Tension mN/m 7.2 10.5 10.5 6.9
Specific Heat Capacity kcal/(kg°C) 0.65 0.60 0.60 0.62
Thermal Conductivity kcal/(h·m·°C) 0.077 0.087 0.087 0.077
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 3
Stream 6121 6122 6123 6124
Stream Description B-1 LIGHTS B-1 LIGHTS B-1 LIGHTS B-1 LIGHTS
COLUMN COLUMN #2 COLUMN #2 COLUMN #1
TRANSFER FEED OVERHEAD OVERHEAD
PUMP DISCH.
Stream Phase LIQUID LIQUID VAPOR VAPOR
Component (wt%)
Water 0.00 0.00 0.00 0.04
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.00 0.00 0.00 0.04
Propylene 0.00 0.00 0.00 0.04
Propane 0.00 0.00 0.00 0.38
Propadiene 0.00 0.00 0.00 0.14
Isobutane 31.72 31.72 32.28 94.32
Isobutene 0.19 0.19 0.19 0.04
1-Butene 68.06 68.06 67.50 4.42
Butadiene 0.00 0.00 0.00 0.00
n-Butane 0.02 0.02 0.02 0.00
2-Butene 0.01 0.01 0.01 0.00
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 0.00 0.00 0.00 0.01
TBA 0.00 0.00 0.00 0.00
DME 0.00 0.00 0.00 0.58
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 256782 256782 252336 232155
Molar Flow Rate kg mol/hr 4526.3 4526.3 4447.0 4025.2
Molecular Weight 56.7 56.7 56.7 57.7
Temperature °C 66 66 66 58
Stream Pressure bar (g) 12.0 8.2 8.2 7.5
Stream Enthalpy MMkcal/h 9.727 9.666 27.693 24.398
Weight Fraction Liquid 1.0 1.0 0.0 0.0
Critical Temperature °C 143 143 143 135
Critical Pressure bar (a) 39.2 39.2 39.2 37.1
Vapor
Mass Flow rate kg/h 252336 232155
Actual Volumetric Flow m³/h 11251 10791
Molecular Weight 56.7 57.7
Actual Density kg/m³ 22.4 21.5
Viscosity cP 0.009 0.008
Specific Enthalpy kcal/kg 109.75 105.09
Specific Heat Capacity kcal/(kg°C) 0.49 0.47
Thermal Conductivity kcal/(h·m·°C) 0.017 0.017
Liquid
Mass Flow Rate kg/h 256782 256782
Actual Volumetric Flow m³/h 494.7 495.5
Actual Density kg/m³ 519 518
Standard Specific Gravity 0.59 0.59 0.00 0.00
Dynamic Viscosity cP 0.11 0.11
Kinematic Viscosity cSt 0.21 0.21
Specific Enthalpy kcal/kg 37.9 37.6
Surface Tension mN/m 6.8 6.8
Specific Heat Capacity kcal/(kg°C) 0.62 0.62
Thermal Conductivity kcal/(h·m·°C) 0.077 0.077
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 3
Stream 6125 6126 6127 6128
Stream Description B-1 LIGHTS B-1 LIGHTS WASTEWATER WASTEWATER
COLUMN COLUMN TO OSBL TO OSBL
CONDENSER REFLUX
OUTLET DRUM INLET
Stream Phase LIQUID LIQUID WATER WATER
Component (wt%)
Water 0.04 0.04 100.00 100.00
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.04 0.04 0.00 0.00
Propylene 0.04 0.04 0.00 0.00
Propane 0.38 0.38 0.00 0.00
Propadiene 0.14 0.14 0.00 0.00
Isobutane 94.32 94.32 0.00 0.00
Isobutene 0.04 0.04 0.00 0.00
1-Butene 4.42 4.42 0.00 0.00
Butadiene 0.00 0.00 0.00 0.00
n-Butane 0.00 0.00 0.00 0.00
2-Butene 0.00 0.00 0.00 0.00
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 0.01 0.01 0.00 0.00
TBA 0.00 0.00 0.00 0.00
DME 0.58 0.58 0.00 0.00
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 232155 232155 4 4
Molar Flow Rate kg mol/hr 4025.2 4025.2 0.2 0.2
Molecular Weight 57.7 57.7 18.0 18.0
Temperature °C 47 47 47 47
Stream Pressure bar (g) 7.2 7.1 7.1 3.0
Stream Enthalpy MMkcal/h 6.248 6.248 0.000 0.000
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 135 135 374 374
Critical Pressure bar (a) 37.1 37.1 221.2 221.2
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 232155 232155 4 4
Actual Volumetric Flow m³/h 443.0 443.0 0.0 0.0
Actual Density kg/m³ 524 524 990 990
Standard Specific Gravity 0.57 0.57 1.00 1.00
Dynamic Viscosity cP 0.14 0.14 0.58 0.58
Kinematic Viscosity cSt 0.26 0.26 0.58 0.58
Specific Enthalpy kcal/kg 26.9 26.9 46.5 46.5
Surface Tension mN/m 7.8 7.8 70.0 70.0
Specific Heat Capacity kcal/(kg°C) 0.62 0.62 1.00 1.00
Thermal Conductivity kcal/(h·m·°C) 0.076 0.076 0.548 0.548
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 3
Stream 6129 6130 6131 6132
Stream Description B-1 LIGHTS B-1 LIGHTS B-1 LIGHTS B-1 LIGHTS
COLUMN COLUMN COLUMN COLUMN
REFLUX PUMP REFLUX PUMP REFLUX REFLUX AT
SUCTION DISCHARGE COLUMN FEED
Stream Phase LIQUID LIQUID LIQUID LIQUID
Component (wt%)
Water 0.04 0.04 0.04 0.04
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.04 0.04 0.04 0.04
Propylene 0.04 0.04 0.04 0.04
Propane 0.38 0.38 0.38 0.38
Propadiene 0.14 0.14 0.14 0.14
Isobutane 94.32 94.32 94.32 94.32
Isobutene 0.04 0.04 0.04 0.04
1-Butene 4.42 4.42 4.42 4.42
Butadiene 0.00 0.00 0.00 0.00
n-Butane 0.00 0.00 0.00 0.00
2-Butene 0.00 0.00 0.00 0.00
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 0.01 0.01 0.01 0.01
TBA 0.00 0.00 0.00 0.00
DME 0.58 0.58 0.58 0.58
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 232151 232151 226872 226872
Molar Flow Rate kg mol/hr 4025.0 4025.0 3933.4 3933.4
Molecular Weight 57.7 57.7 57.7 57.7
Temperature °C 47 47 47 47
Stream Pressure bar (g) 7.1 15.0 15.0 7.5
Stream Enthalpy MMkcal/h 6.248 6.376 6.231 6.168
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 135 135 135 135
Critical Pressure bar (a) 37.1 37.1 37.1 37.1
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 232151 232151 226872 226872
Actual Volumetric Flow m³/h 443.0 442.5 432.4 433.3
Actual Density kg/m³ 524 525 525 524
Standard Specific Gravity 0.57 0.57 0.57 0.57
Dynamic Viscosity cP 0.14 0.14 0.14 0.14
Kinematic Viscosity cSt 0.26 0.26 0.26 0.26
Specific Enthalpy kcal/kg 26.9 27.2 27.2 27.2
Surface Tension mN/m 7.8 7.7 7.7 7.7
Specific Heat Capacity kcal/(kg°C) 0.62 0.62 0.62 0.62
Thermal Conductivity kcal/(h·m·°C) 0.076 0.076 0.076 0.076
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 3
Stream 6133 6135 6136 6137
Stream Description ISOBUTANE ISOBUTANE B-1 LIGHTS B-1 LIGHTS
PRODUCT PRODUCT COLUMN #2 COLUMN
TO OSBL BOTTOMS BOTTOMS
PUMP DISCH.
Stream Phase LIQUID LIQUID LIQUID LIQUID
Component (wt%)
Water 0.04 0.04 0.00 0.00
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.04 0.04 0.00 0.00
Propylene 0.04 0.04 0.00 0.00
Propane 0.38 0.38 0.00 0.00
Propadiene 0.14 0.14 0.00 0.00
Isobutane 94.32 94.32 0.01 0.01
Isobutene 0.04 0.04 0.12 0.12
1-Butene 4.42 4.42 99.60 99.60
Butadiene 0.00 0.00 0.00 0.00
n-Butane 0.00 0.00 0.19 0.19
2-Butene 0.00 0.00 0.07 0.07
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 0.01 0.01 0.00 0.00
TBA 0.00 0.00 0.00 0.00
DME 0.58 0.58 0.00 0.00
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 5280 5280 4446 4446
Molar Flow Rate kg mol/hr 91.5 91.5 79.2 79.2
Molecular Weight 57.7 57.7 56.1 56.1
Temperature °C 47 47 72 72
Stream Pressure bar (g) 15.0 13.0 8.9 9.3
Stream Enthalpy MMkcal/h 0.145 0.145 0.178 0.178
Weight Fraction Liquid 1.0 1.0 1.0 1.0
Critical Temperature °C 135 135 147 147
Critical Pressure bar (a) 37.1 37.1 40.4 40.4
Vapor
Mass Flow rate kg/h
Actual Volumetric Flow m³/h
Molecular Weight
Actual Density kg/m³
Viscosity cP
Specific Enthalpy kcal/kg
Specific Heat Capacity kcal/(kg°C)
Thermal Conductivity kcal/(h·m·°C)
Liquid
Mass Flow Rate kg/h 5280 5280 4446 4446
Actual Volumetric Flow m³/h 10.1 10.1 8.5 8.5
Actual Density kg/m³ 525 525 522 522
Standard Specific Gravity 0.57 0.57 0.60 0.60
Dynamic Viscosity cP 0.14 0.14 0.10 0.10
Kinematic Viscosity cSt 0.26 0.26 0.20 0.20
Specific Enthalpy kcal/kg 27.2 27.2 40.0 40.0
Surface Tension mN/m 7.7 7.8 6.8 6.8
Specific Heat Capacity kcal/(kg°C) 0.62 0.62 0.60 0.60
Thermal Conductivity kcal/(h·m·°C) 0.076 0.076 0.080 0.080
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 3
Stream 6138 6139 6140 6141
Stream Description BUTENE-1 BUTENE-1 B-1 HEAVIES B-1 HEAVIES
PRODUCT PRODUCT COLUMN COLUMN
COOLER TO OSBL REBOILER REBOILER
OUTLET INLET OUTLET
Stream Phase LIQUID LIQUID LIQUID MIXED
Component (wt%)
Water 0.00 0.00 0.00 0.00
Hydrogen 0.00 0.00 0.00 0.00
Methane 0.00 0.00 0.00 0.00
Propylene 0.00 0.00 0.00 0.00
Propane 0.00 0.00 0.00 0.00
Propadiene 0.00 0.00 0.00 0.00
Isobutane 0.01 0.01 0.00 0.00
Isobutene 0.12 0.12 0.00 0.00
1-Butene 99.60 99.60 1.73 1.73
Butadiene 0.00 0.00 0.00 0.00
n-Butane 0.19 0.19 56.96 56.96
2-Butene 0.07 0.07 41.30 41.30
C5's 0.00 0.00 0.00 0.00
C6's 0.00 0.00 0.00 0.00
DIB 0.00 0.00 0.00 0.00
Methanol 0.00 0.00 0.00 0.00
TBA 0.00 0.00 0.00 0.00
DME 0.00 0.00 0.00 0.00
MTBE 0.00 0.00 0.00 0.00
MSBE 0.00 0.00 0.00 0.00
Mass Flow Rate kg/h 4446 4446 460140 460140
Molar Flow Rate kg mol/hr 79.2 79.2 8039.0 8039.0
Molecular Weight 56.1 56.1 57.2 57.2
Temperature °C 45 45 74 74
Stream Pressure bar (g) 8.7 8.0 8.0 8.0
Stream Enthalpy MMkcal/h 0.109 0.109 20.137 30.383
Weight Fraction Liquid 1.0 1.0 1.0 0.7
Critical Temperature °C 147 147 155 155
Critical Pressure bar (a) 40.4 40.4 39.6 39.6
Vapor
Mass Flow rate kg/h 138055
Actual Volumetric Flow m³/h 6405
Molecular Weight 57.2
Actual Density kg/m³ 21.6
Viscosity cP 0.009
Specific Enthalpy kcal/kg 117.95
Specific Heat Capacity kcal/(kg°C) 0.51
Thermal Conductivity kcal/(h·m·°C) 0.018
Liquid
Mass Flow Rate kg/h 4446 4446 460140 322085
Actual Volumetric Flow m³/h 7.9 7.9 880.8 616.5
Actual Density kg/m³ 561 561 522 522
Standard Specific Gravity 0.60 0.60 0.60 0.60
Dynamic Viscosity cP 0.12 0.12 0.12 0.12
Kinematic Viscosity cSt 0.22 0.22 0.22 0.22
Specific Enthalpy kcal/kg 24.6 24.6 43.8 43.8
Surface Tension mN/m 9.9 9.9 7.2 7.2
Specific Heat Capacity kcal/(kg°C) 0.57 0.57 0.65 0.65
Thermal Conductivity kcal/(h·m·°C) 0.088 0.088 0.077 0.077
Project No: 189709 Rev 0
Lummus Technology
Liwa Plastics Project
Heat and Material Balance
-----------------------------------------------------------------------------------------------------------------------------
Case: Case 3
Stream 6142 6143
Stream Description B-1 LIGHTS B-1 LIGHTS
COLUMN COLUMN
REBOILER REBOILER
INLET OUTLET
Stream Phase LIQUID MIXED
Component (wt%)
Water 0.00 0.00
Hydrogen 0.00 0.00
Methane 0.00 0.00
Propylene 0.00 0.00
Propane 0.00 0.00
Propadiene 0.00 0.00
Isobutane 0.02 0.02
Isobutene 0.12 0.12
1-Butene 99.61 99.61
Butadiene 0.00 0.00
n-Butane 0.18 0.18
2-Butene 0.07 0.07
C5's 0.00 0.00
C6's 0.00 0.00
DIB 0.00 0.00
Methanol 0.00 0.00
TBA 0.00 0.00
DME 0.00 0.00
MTBE 0.00 0.00
MSBE 0.00 0.00
Mass Flow Rate kg/h 829054 829054
Molar Flow Rate kg mol/hr 14775.2 14775.2
Molecular Weight 56.1 56.1
Temperature °C 72 72
Stream Pressure bar (g) 8.9 8.9
Stream Enthalpy MMkcal/h 33.156 51.369
Weight Fraction Liquid 1.0 0.7
Critical Temperature °C 147 147
Critical Pressure bar (a) 40.4 40.4
Vapor
Mass Flow rate kg/h 248715
Actual Volumetric Flow m³/h 10523
Molecular Weight 56.1
Actual Density kg/m³ 23.6
Viscosity cP 0.010
Specific Enthalpy kcal/kg 113.20
Specific Heat Capacity kcal/(kg°C) 0.48
Thermal Conductivity kcal/(h·m·°C) 0.017
Liquid
Mass Flow Rate kg/h 829054 580339
Actual Volumetric Flow m³/h 1589.5 1112.7
Actual Density kg/m³ 522 522
Standard Specific Gravity 0.60 0.60
Dynamic Viscosity cP 0.10 0.10
Kinematic Viscosity cSt 0.20 0.20
Specific Enthalpy kcal/kg 40.0 40.0
Surface Tension mN/m 6.8 6.8
Specific Heat Capacity kcal/(kg°C) 0.60 0.60
Thermal Conductivity kcal/(h·m·°C) 0.080 0.080
Project No: 189709 Rev 0
Liwa Plastics Project
CB&I ORPIC
Document Title: Material & Heat Balance - PGHYD 6200
Document No: S-S620-5223-121
CB&I Contract No: 189709
Issued for FEED 0 23-Feb-2015 WMORAIS EBRAKEL JL
Revision Descriptions Rev Date Originator Checker Approver
"THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY (CBI). IT MAY CONTAIN PROPRIETARY
INFORMATION (CBI BACKGROUND & FOREGROUND INFORMATION) OWNED BY CBI AND DEEMED TO BE
COMMERCIALLY SENSITIVE. IT IS TO BE USED ONLY IN CONNECTION WITH WORK PERFORMED BY CBI.
REPRODUCTION IN WHOLE OR IN PART FOR ANY PURPOSE OTHER THAN WORK PERFORMED BY CBI IS FORBIDDEN
EXCEPT BY EXPRESS WRITTEN PERMISSION OF CBI. IT IS TO BE SAFEGUARDED AGAINST BOTH DELIBERATE AND
Page 1 of 8
Liwa Plastics Project
Document Title
- This document contains the Material & Heat balance for the Catalyst Treatment Gas System.
Refer to Process Flow Diagrams: D-S620-5223-111
D-S620-5223-112
- For the Material & Heat balances for the licensed Process unit, please refer to the following Axens documents:
Component properties: S-S620-5223-101
Molar balances: S-S620-5223-102
S-S620-5223-103
S-S620-5223-104
S-S620-5223-105
S-S620-5223-106
S-S620-5223-107
Weight balances: S-S620-5223-108
S-S620-5223-109
S-S620-5223-110
S-S620-5223-111
S-S620-5223-112
S-S620-5223-113
Heat balances: S-S620-5223-114
S-S620-5223-115
S-S620-5223-116
S-S620-5223-117
S-S620-5223-118
Overall Unit Balance and Product Properties: S-S620-5223-119
Document Title: Material Heat Balance - Unit 6200
Document No.: S-S620-5223-121
Rev. 0 23FEB2015 Page 2 of 8
Liwa Plastics Project Document Title: Material Heat Balance - Unit 6200
Document No.: S-S620-5223-121
1st Stage Activation
Name H2 N2 PA MS 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215
MEDIUM
HYDROGEN PRESSURE H2 BEFORE N2 BEFORE PA BEFORE MS BEFORE ELECTRIC ELECTRIC 1ST STAGE 2ND STAGE 1ST STAGE 2ND STAGE MIXTURE MIXTURE
NITROGEN PLANT AIR TO KO TO SAFE
MAKE‐UP STEAM CONTROL CONTROL CONTROL CONTROL HEATER HEATER REACTOR REACTOR REACTOR REACTOR COOLER COOLER TO FLARE
FEED FEED DRUM LOCATION
FEED FEED FEED VALVE VALVE VALVE VALVE INLET OUTLET INLET INLET OUTLET OUTLET INLET OUTLET
FEED
Temperature (C) 45 10 45 10 19 410 410 410 410 300 300
Pressure (bara) 31.4 8.0 31.4 7.9 7.3 7.0 7.0 6.0 6.0 5.7 1.5
Weight rate (kg/h) 60 2340 60 2340 2400 2400 2400 2400 2400 2400 2400
Molar rate (kmol/h) 29.8 83.5 29.8 83.5 113.3 113.3 113.3 113.3 113.3 113.3 113.3
Volumetric rate (m3/h) 25.4 244.7 25.4 246.6 376.1 921.4 921.4 1074.7 1074.7 949.0 3601.2
Enthalpy (MMkcal/h) 0.00407 ‐0.0101 0.00407 ‐0.0101 ‐0.00631 0.311 0.311 0.311 0.311 0.220 0.220
Spec. Enthalpy (kcal/kg) 67.8 ‐4.3 67.8 ‐4.3 ‐2.6 129.4 129.4 129.4 129.4 91.6 91.6
Density (kg/m3) 2.366 9.564 2.366 9.489 6.382 2.605 2.605 2.233 2.233 2.529 0.666
Mol. Weight 2.02 28.01 2.02 28.01 21.18 21.18 21.18 21.18 21.18 21.18 21.18
Viscosity (cP) 0.0094 0.0177 0.0094 0.0177 0.0163 0.0313 0.0313 0.0313 0.0313 0.0269 0.0269
Thermal. Cond. (kcal/h.m.C) 0.160 0.022 0.160 0.022 0.038 0.072 0.072 0.072 0.072 0.064 0.064
Specific Heat (kcal/kg.C) 3.398 0.252 3.398 0.252 0.330 0.347 0.347 0.347 0.347 0.341 0.341
Cp/Cv 1.419 1.418 1.419 1.418 1.414 1.373 1.373 1.372 1.372 1.381 1.380
Z‐factor 1.011 0.995 1.011 0.995 0.999 1.002 1.002 1.002 1.002 1.002 1.000
1st Stage Reactivation
Name H2 N2 PA MS 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215
MEDIUM
HYDROGEN H2 BEFORE N2 BEFORE PA BEFORE MS BEFORE ELECTRIC ELECTRIC 1ST STAGE 2ND STAGE 1ST STAGE 2ND STAGE MIXTURE MIXTURE
NITROGEN PLANT AIR PRESSURE TO KO TO SAFE
MAKE‐UP CONTROL CONTROL CONTROL CONTROL HEATER HEATER REACTOR REACTOR REACTOR REACTOR COOLER COOLER TO FLARE
FEED FEED STEAM DRUM LOCATION
FEED VALVE VALVE VALVE VALVE INLET OUTLET INLET INLET OUTLET OUTLET INLET OUTLET
FEED
Temperature (C) 45 10 45 10 19 160 160 160 160 100 100
Pressure (bara) 31.4 8.0 31.4 7.9 7.3 7.0 7.0 6.0 6.0 5.7 1.5
Weight rate (kg/h) 60 2340 60 2340 2400 2400 2400 2400 2400 2400 2400
Molar rate (kmol/h) 29.8 83.5 29.8 83.5 113.3 113.3 113.3 113.3 113.3 113.3 113.3
Volumetric rate (m3/h) 25.4 244.7 25.4 246.6 376.1 584.0 584.0 681.1 681.1 617.3 2341.6
Enthalpy (MMkcal/h) 0.00407 ‐0.0101 0.00407 ‐0.0101 ‐0.00631 0.106 0.106 0.106 0.106 0.0584 0.0584
Spec. Enthalpy (kcal/kg) 67.8 ‐4.3 67.8 ‐4.3 ‐2.6 44.3 44.3 44.3 44.3 24.3 24.3
Density (kg/m3) 2.366 9.564 2.366 9.489 6.382 4.110 4.110 3.524 3.524 3.888 1.025
Mol. Weight 2.02 28.01 2.02 28.01 21.18 21.18 21.18 21.18 21.18 21.18 21.18
Viscosity (cP) 0.0094 0.0177 0.0094 0.0177 0.0163 0.0216 0.0216 0.0216 0.0216 0.0193 0.0193
Thermal. Cond. (kcal/h.m.C) 0.160 0.022 0.160 0.022 0.038 0.052 0.052 0.052 0.052 0.046 0.046
Specific Heat (kcal/kg.C) 3.398 0.252 3.398 0.252 0.330 0.335 0.335 0.335 0.335 0.332 0.331
Cp/Cv 1.419 1.418 1.419 1.418 1.414 1.395 1.395 1.394 1.394 1.401 1.398
Z‐factor 1.011 0.995 1.011 0.995 0.999 1.002 1.002 1.002 1.002 1.001 1.000
3 of 8
Rev. 0 23FEB2015
Liwa Plastics Project Document Title: Material Heat Balance - Unit 6200
Document No.: S-S620-5223-121
1st Stage Hot Hydrogen Stripping
H2 MAKE‐
UP FROM N2 FROM PA FROM MS FROM
Name B.L. B.L. B.L. B.L. 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215
MEDIUM
HYDROGEN H2 BEFORE N2 BEFORE PA BEFORE MS BEFORE ELECTRIC ELECTRIC 1ST STAGE 2ND STAGE 1ST STAGE 2ND STAGE MIXTURE MIXTURE
NITROGEN PLANT AIR PRESSURE TO KO TO SAFE
MAKE‐UP CONTROL CONTROL CONTROL CONTROL HEATER HEATER REACTOR REACTOR REACTOR REACTOR COOLER COOLER TO FLARE
FEED FEED STEAM DRUM LOCATION
FEED VALVE VALVE VALVE VALVE INLET OUTLET INLET INLET OUTLET OUTLET INLET OUTLET
FEED
Temperature (C) 45 10 45 10 19 410 410 410 410 300 300
Pressure (bara) 31.4 8.0 31.4 7.9 7.3 7.0 7.0 6.0 6.0 5.7 1.5
Weight rate (kg/h) 60 2340 60 2340 2400 2400 2400 2400 2400 2400 2400
Molar rate (kmol/h) 29.8 83.5 29.8 83.5 113.3 113.3 113.3 113.3 113.3 113.3 113.3
Volumetric rate (m3/h) 25.4 244.7 25.4 246.6 376.1 921.4 921.4 1074.7 1074.7 949.0 3601.2
Enthalpy (MMkcal/h) 0.00407 ‐0.0101 0.00407 ‐0.0101 ‐0.00631 0.311 0.3107 0.3107 0.3107 0.2199 0.2199
Spec. Enthalpy (kcal/kg) 67.8 ‐4.3 67.8 ‐4.3 ‐2.6 129.4 129.4 129.4 129.4 91.6 91.6
Density (kg/m3) 2.366 9.564 2.366 9.489 6.382 2.605 2.605 2.233 2.233 2.529 0.666
Mol. Weight 2.02 28.01 2.02 28.01 21.18 21.18 21.18 21.18 21.18 21.18 21.18
Viscosity (cP) 0.0094 0.0177 0.0094 0.0177 0.0163 0.0313 0.0313 0.0313 0.0313 0.0269 0.0269
Thermal. Cond. (kcal/h.m.C) 0.160 0.022 0.160 0.022 0.038 0.072 0.072 0.072 0.072 0.064 0.064
Specific Heat (kcal/kg.C) 3.398 0.252 3.398 0.252 0.330 0.347 0.347 0.347 0.347 0.341 0.341
Cp/Cv 1.419 1.418 1.419 1.418 1.414 1.373 1.373 1.372 1.372 1.381 1.380
Z‐factor 1.011 0.995 1.011 0.995 0.999 1.002 1.002 1.002 1.002 1.002 1.000
1st Stage Purge/Heating
Name H2 N2 PA MS 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215
MEDIUM
HYDROGEN H2 BEFORE N2 BEFORE PA BEFORE MS BEFORE ELECTRIC ELECTRIC 1ST STAGE 2ND STAGE 1ST STAGE 2ND STAGE MIXTURE MIXTURE
NITROGEN PLANT AIR PRESSURE TO KO TO SAFE
MAKE‐UP CONTROL CONTROL CONTROL CONTROL HEATER HEATER REACTOR REACTOR REACTOR REACTOR COOLER COOLER TO FLARE
FEED FEED STEAM DRUM LOCATION
FEED VALVE VALVE VALVE VALVE INLET OUTLET INLET INLET OUTLET OUTLET INLET OUTLET
FEED
Temperature (C) 10 10 10 200 200 200 200 150 150
Pressure (bara) 8.0 7.4 7.3 7.0 7.0 6.0 6.0 5.7 1.5
Weight rate (kg/h) 3100 3100 3100 3100 3100 3100 3100 3100 3100
Molar rate (kmol/h) 110.7 110.7 110.7 110.7 110.7 110.7 110.7 110.7 110.7
Volumetric rate (m3/h) 324.1 348.6 355.3 623.5 623.5 727.1 727.1 684.2 2595.0
Enthalpy (MMkcal/h) ‐0.0133 ‐0.0133 ‐0.0136 0.136 0.136 0.136 0.136 0.0967 0.0967
Spec. Enthalpy (kcal/kg) ‐4.3 ‐4.3 ‐4.4 44.0 44.0 44.0 44.0 31.2 31.2
Density (kg/m3) 9.564 8.892 8.727 4.973 4.973 4.264 4.264 4.531 1.195
Mol. Weight 28.01 28.01 28.00 28.00 28.00 28.00 28.00 28.00 28.00
Viscosity (cP) 0.0177 0.0177 0.0177 0.0256 0.0256 0.0256 0.0256 0.0236 0.0235
Thermal. Cond. (kcal/h.m.C) 0.022 0.022 0.022 0.032 0.032 0.032 0.032 0.029 0.029
Specific Heat (kcal/kg.C) 0.252 0.252 0.252 0.258 0.258 0.257 0.257 0.255 0.255
Cp/Cv 1.418 1.417 1.417 1.386 1.386 1.386 1.386 1.391 1.388
Z‐factor 0.995 0.996 0.996 1.002 1.002 1.002 1.002 1.001 1.000
4 of 8
Rev. 0 23FEB2015
Liwa Plastics Project Document Title: Material Heat Balance - Unit 6200
Document No.: S-S620-5223-121
1st Stage Preoxidation
Name H2 N2 PA MS 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215
MEDIUM
HYDROGEN H2 BEFORE N2 BEFORE PA BEFORE MS BEFORE ELECTRIC ELECTRIC 1ST STAGE 2ND STAGE 1ST STAGE 2ND STAGE MIXTURE MIXTURE
NITROGEN PLANT AIR PRESSURE TO KO TO SAFE
MAKE‐UP CONTROL CONTROL CONTROL CONTROL HEATER HEATER REACTOR REACTOR REACTOR REACTOR COOLER COOLER TO FLARE
FEED FEED STEAM DRUM LOCATION
FEED VALVE VALVE VALVE VALVE INLET OUTLET INLET INLET OUTLET OUTLET INLET OUTLET
FEED
Temperature (C) 10 280 10 280 264 264 264 263 263 210 204 204
Pressure (bara) 8.0 19.0 8.0 18.7 7.3 7.0 7.0 6.0 6.0 5.7 1.5 1.5
Weight rate (kg/h) 55 2400 55 2400 2455 2455 2455 2455 2455 2455 2455 2455
Molar rate (kmol/h) 1.9 133.2 1.9 133.2 135.2 135.2 135.2 135.2 135.2 135.2 135.2 135.2
Volumetric rate (m3/h) 5.6 304.6 5.6 308.8 807.2 844.0 844.0 985.6 985.6 930.0 3554.8 3556.7
Enthalpy (MMkcal/h) 0.00 ‐7.44 ‐0.000228 ‐7.44 ‐7.44 ‐7.44 ‐7.44 ‐7.44 ‐7.44 ‐7.50 ‐7.50 ‐7.50
Spec. Enthalpy (kcal/kg) ‐4.1 ‐3101.3 ‐4.1 ‐3101.3 ‐3031.7 ‐3031.3 ‐3031.3 ‐3031.3 ‐3031.3 ‐3056.3 ‐3056.3 ‐3056.3
Density (kg/m3) 9.903 7.879 9.903 7.771 3.042 2.909 2.909 2.491 2.491 2.640 0.691 0.690
Mol. Weight 28.95 18.02 28.95 18.02 18.16 18.16 18.16 18.16 18.16 18.16 18.16 18.16
Viscosity (cP) 0.0182 0.0193 0.0182 0.0193 0.0141 0.0141 0.0141 0.0140 0.0140 0.0125 0.0122 0.0122
Thermal. Cond. (kcal/h.m.C) 0.021 0.038 0.021 0.037 0.035 0.035 0.035 0.035 0.035 0.030 0.029 0.029
Specific Heat (kcal/kg.C) 0.240 0.510 0.240 0.509 0.481 0.480 0.480 0.479 0.479 0.473 0.464 0.464
Cp/Cv 1.428 1.373 1.428 1.372 1.330 1.329 1.329 1.325 1.325 1.338 1.318 1.318
Z‐factor 0.993 0.945 0.993 0.945 0.978 0.979 0.979 0.982 0.982 0.976 0.994 0.994
1st Stage Combustion
Name H2 N2 PA MS 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215
MEDIUM
HYDROGEN H2 BEFORE N2 BEFORE PA BEFORE MS BEFORE ELECTRIC ELECTRIC 1ST STAGE 2ND STAGE 1ST STAGE 2ND STAGE MIXTURE MIXTURE
NITROGEN PLANT AIR PRESSURE TO KO TO SAFE
MAKE‐UP CONTROL CONTROL CONTROL CONTROL HEATER HEATER REACTOR REACTOR REACTOR REACTOR COOLER COOLER TO FLARE
FEED FEED STEAM DRUM LOCATION
FEED VALVE VALVE VALVE VALVE INLET OUTLET INLET INLET OUTLET OUTLET INLET OUTLET
FEED
Temperature (C) 10 280 10 280 235 410 410 409 409 300 296 296
Pressure (bara) 8.0 19.0 8.0 18.7 7.3 7.0 7.0 6.0 6.0 5.7 1.5 1.5
Weight rate (kg/h) 650 2400 650 2400 3050 3050 3050 3050 3050 3050 3050 3050
Molar rate (kmol/h) 22.5 133.2 22.5 133.2 155.7 155.7 155.7 155.7 155.7 155.7 155.7 155.7
Volumetric rate (m3/h) 65.6 304.6 65.6 308.8 882.0 1254.1 1254.1 1463.4 1463.4 1287.5 4902.4 4907.5
Enthalpy (MMkcal/h) ‐0.00269 ‐7.44 ‐0.00269 ‐7.44 ‐7.45 ‐7.21 ‐7.21 ‐7.21 ‐7.21 ‐7.36 ‐7.36 ‐7.36
Spec. Enthalpy (kcal/kg) ‐4.1 ‐3101.3 ‐4.1 ‐3101.3 ‐2441.1 ‐2363.9 ‐2363.9 ‐2363.9 ‐2363.9 ‐2412.4 ‐2412.4 ‐2412.4
Density (kg/m3) 9.903 7.879 9.902 7.771 3.458 2.432 2.432 2.084 2.084 2.369 0.622 0.622
Mol. Weight 28.95 18.02 28.95 18.02 19.59 19.59 19.59 19.59 19.59 19.59 19.59 19.59
Viscosity (cP) 0.0182 0.0193 0.0182 0.0193 0.0147 0.0207 0.0207 0.0206 0.0206 0.0168 0.0166 0.0166
Thermal. Cond. (kcal/h.m.C) 0.021 0.038 0.021 0.037 0.032 0.047 0.047 0.047 0.047 0.038 0.037 0.037
Specific Heat (kcal/kg.C) 0.240 0.510 0.240 0.509 0.433 0.451 0.451 0.450 0.450 0.437 0.432 0.432
Cp/Cv 1.428 1.373 1.428 1.372 1.342 1.305 1.305 1.304 1.304 1.322 1.312 1.312
Z‐factor 0.993 0.945 0.993 0.945 0.979 0.993 0.993 0.994 0.994 0.989 0.997 0.997
5 of 8
Rev. 0 23FEB2015
Liwa Plastics Project Document Title: Material Heat Balance - Unit 6200
Document No.: S-S620-5223-121
1st Stage Polishing
Name H2 N2 PA MS 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215
MEDIUM
HYDROGEN H2 BEFORE N2 BEFORE PA BEFORE MS BEFORE ELECTRIC ELECTRIC 1ST STAGE 2ND STAGE 1ST STAGE 2ND STAGE MIXTURE MIXTURE
NITROGEN PLANT AIR PRESSURE TO KO TO SAFE
MAKE‐UP CONTROL CONTROL CONTROL CONTROL HEATER HEATER REACTOR REACTOR REACTOR REACTOR COOLER COOLER TO FLARE
FEED FEED STEAM DRUM LOCATION
FEED VALVE VALVE VALVE VALVE INLET OUTLET INLET INLET OUTLET OUTLET INLET OUTLET
FEED
Temperature (C) 10 280 10 280 235 480 480 480 480 300 296 296
Pressure (bara) 8.0 19.0 8.0 18.7 7.3 7.0 7.0 6.0 6.0 5.7 1.5 1.5
Weight rate (kg/h) 650 2400 650 2400 3050 3050 3050 3050 3050 3050 3050 3050
Molar rate (kmol/h) 22.5 133.2 22.5 133.2 155.7 155.7 155.7 155.7 155.7 155.7 155.7 155.7
Volumetric rate (m3/h) 65.6 304.6 65.6 308.8 882.0 1385.8 1385.8 1617.0 1617.0 1287.5 4902.4 4907.5
Enthalpy (MMkcal/h) ‐0.00269 ‐7.44 ‐0.00269 ‐7.44 ‐7.45 ‐7.11 ‐7.11 ‐7.11 ‐7.11 ‐7.36 ‐7.36 ‐7.36
Spec. Enthalpy (kcal/kg) ‐4.1 ‐3101.3 ‐4.1 ‐3101.3 ‐2441.1 ‐2332.0 ‐2332.0 ‐2332.0 ‐2332.0 ‐2412.4 ‐2412.4 ‐2412.4
Density (kg/m3) 9.903 7.879 9.902 7.771 3.458 2.201 2.201 1.886 1.886 2.369 0.622 0.622
Mol. Weight 28.95 18.02 28.95 18.02 19.59 19.59 19.59 19.59 19.59 19.59 19.59 19.59
Viscosity (cP) 0.0182 0.0193 0.0182 0.0193 0.0147 0.0232 0.0232 0.0231 0.0231 0.0168 0.0166 0.0166
Thermal. Cond. (kcal/h.m.C) 0.021 0.038 0.021 0.037 0.032 0.053 0.053 0.053 0.053 0.038 0.037 0.037
Specific Heat (kcal/kg.C) 0.240 0.510 0.240 0.509 0.433 0.460 0.460 0.459 0.459 0.437 0.432 0.432
Cp/Cv 1.428 1.373 1.428 1.372 1.342 1.294 1.294 1.293 1.293 1.322 1.312 1.312
Z‐factor 0.993 0.945 0.993 0.945 0.979 0.995 0.995 0.996 0.996 0.989 0.997 0.997
2nd Stage Purge/Heating
Name H2 N2 PA MS 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215
MEDIUM
HYDROGEN H2 BEFORE N2 BEFORE PA BEFORE MS BEFORE ELECTRIC ELECTRIC 1ST STAGE 2ND STAGE 1ST STAGE 2ND STAGE MIXTURE MIXTURE
NITROGEN PLANT AIR PRESSURE TO KO TO SAFE
MAKE‐UP CONTROL CONTROL CONTROL CONTROL HEATER HEATER REACTOR REACTOR REACTOR REACTOR COOLER COOLER TO FLARE
FEED FEED STEAM DRUM LOCATION
FEED VALVE VALVE VALVE VALVE INLET OUTLET INLET INLET OUTLET OUTLET INLET OUTLET
FEED
Temperature (C) 10 10 10 200 200 200 200 150 150
Pressure (bara) 8.0 7.4 7.3 7.0 7.0 6.0 6.0 5.7 1.5
Weight rate (kg/h) 3300 3300 3300 3300 3300 3300 3300 3300 3300
Molar rate (kmol/h) 117.8 117.8 117.9 117.9 117.9 117.9 117.9 117.9 117.9
Volumetric rate (m3/h) 345.0 374.9 378.2 663.7 663.7 773.9 773.9 728.3 2762.4
Enthalpy (MMkcal/h) ‐0.0142 ‐0.0142 ‐0.0145 0.145 0.145 0.145 0.145 0.103 0.103
Spec. Enthalpy (kcal/kg) ‐4.3 ‐4.3 ‐4.4 44.0 44.0 44.0 44.0 31.2 31.2
Density (kg/m3) 9.564 8.801 8.727 4.973 4.973 4.264 4.264 4.531 1.195
Mol. Weight 28.01 28.01 28.00 28.00 28.00 28.00 28.00 28.00 28.00
Viscosity (cP) 0.0177 0.0177 0.0177 0.0256 0.0256 0.0256 0.0256 0.0236 0.0235
Thermal. Cond. (kcal/h.m.C) 0.022 0.022 0.022 0.032 0.032 0.032 0.032 0.029 0.029
Specific Heat (kcal/kg.C) 0.252 0.252 0.252 0.258 0.258 0.257 0.257 0.255 0.255
Cp/Cv 1.418 1.417 1.417 1.386 1.386 1.386 1.386 1.391 1.388
Z‐factor 0.995 0.996 0.996 1.002 1.002 1.002 1.002 1.001 1.000
6 of 8
Rev. 0 23FEB2015
Liwa Plastics Project Document Title: Material Heat Balance - Unit 6200
Document No.: S-S620-5223-121
2nd Stage Steam Stripping
Name H2 N2 PA MS 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215
MEDIUM
HYDROGEN H2 BEFORE N2 BEFORE PA BEFORE MS BEFORE ELECTRIC ELECTRIC 1ST STAGE 2ND STAGE 1ST STAGE 2ND STAGE MIXTURE MIXTURE
NITROGEN PLANT AIR PRESSURE TO KO TO SAFE
MAKE‐UP CONTROL CONTROL CONTROL CONTROL HEATER HEATER REACTOR REACTOR REACTOR REACTOR COOLER COOLER TO FLARE
FEED FEED STEAM DRUM LOCATION
FEED VALVE VALVE VALVE VALVE INLET OUTLET INLET INLET OUTLET OUTLET INLET OUTLET
FEED
Temperature (C) 280 278 267 410 410 409 409 300 296 296
Pressure (bara) 19.0 17.4 7.3 7.0 7.0 6.0 6.0 5.7 1.5 1.5
Weight rate (kg/h) 6050 6050 6050 6050 6050 6050 6050 6050 6050 6050
Molar rate (kmol/h) 335.8 335.8 335.9 335.9 335.9 335.9 335.9 335.9 335.9 335.9
Volumetric rate (m3/h) 767.9 841.3 2008.2 2698.0 2698.0 3148.8 3148.8 2767.4 10549.3 10593.0
Enthalpy (MMkcal/h) ‐18.8 ‐18.8 ‐18.8 ‐18.3 ‐18.3 ‐18.3 ‐18.3 ‐18.7 ‐18.7 ‐18.7
Spec. Enthalpy (kcal/kg) ‐3101.3 ‐3101.3 ‐3101.1 ‐3030.1 ‐3030.1 ‐3030.1 ‐3030.1 ‐3084.1 ‐3084.1 ‐3084.1
Density (kg/m3) 7.879 7.191 3.013 2.243 2.243 1.921 1.921 2.186 0.574 0.571
Mol. Weight 18.02 18.02 18.01 18.01 18.01 18.01 18.01 18.01 18.01 18.01
Viscosity (cP) 0.0193 0.0192 0.0188 0.0248 0.0248 0.0248 0.0248 0.0202 0.0201 0.0201
Thermal. Cond. (kcal/h.m.C) 0.038 0.037 0.035 0.049 0.049 0.049 0.049 0.038 0.037 0.037
Specific Heat (kcal/kg.C) 0.510 0.506 0.487 0.504 0.504 0.503 0.503 0.488 0.481 0.481
Cp/Cv 1.373 1.367 1.329 1.298 1.298 1.296 1.296 1.316 1.304 1.304
Z‐factor 0.945 0.949 0.977 0.990 0.990 0.991 0.991 0.986 0.996 0.996
2nd Stage Combustion
Name H2 N2 PA MS 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215
MEDIUM
HYDROGEN H2 BEFORE N2 BEFORE PA BEFORE MS BEFORE ELECTRIC ELECTRIC 1ST STAGE 2ND STAGE 1ST STAGE 2ND STAGE MIXTURE MIXTURE
NITROGEN PLANT AIR PRESSURE TO KO TO SAFE
MAKE‐UP CONTROL CONTROL CONTROL CONTROL HEATER HEATER REACTOR REACTOR REACTOR REACTOR COOLER COOLER TO FLARE
FEED FEED STEAM DRUM LOCATION
FEED VALVE VALVE VALVE VALVE INLET OUTLET INLET INLET OUTLET OUTLET INLET OUTLET
FEED
Temperature (C) 10 280 10 278 235 410 410 409 409 300 296 296
Pressure (bara) 8.0 19.0 8.0 17.4 7.4 7.0 7.0 6.0 6.0 5.7 1.5 1.5
Weight rate (kg/h) 1650 6050 1650 6050 7700 7700 7700 7700 7700 7700 7700 7700
Molar rate (kmol/h) 57.0 335.8 57.0 335.8 392.9 392.9 392.9 392.9 392.9 392.9 392.9 392.9
Volumetric rate (m3/h) 166.6 767.9 166.7 841.3 2211.8 3164.0 3164.0 3692.1 3692.1 3248.2 12368.1 12440.6
Enthalpy (MMkcal/h) ‐0.00683 ‐18.8 ‐0.00683 ‐18.8 ‐18.8 ‐18.2 ‐18.2 ‐18.2 ‐18.2 ‐18.5 ‐18.5 ‐18.5
Spec. Enthalpy (kcal/kg) ‐4.1 ‐3101.3 ‐4.1 ‐3101.3 ‐2437.6 ‐2360.4 ‐2360.4 ‐2360.4 ‐2360.4 ‐2408.8 ‐2408.8 ‐2408.8
Density (kg/m3) 9.903 7.879 9.898 7.191 3.481 2.434 2.434 2.086 2.086 2.371 0.623 0.619
Mol. Weight 28.95 18.02 28.95 18.02 19.60 19.60 19.60 19.60 19.60 19.60 19.60 19.60
Viscosity (cP) 0.0182 0.0193 0.0182 0.0192 0.0147 0.0207 0.0207 0.0206 0.0206 0.0168 0.0166 0.0166
Thermal. Cond. (kcal/h.m.C) 0.021 0.038 0.021 0.037 0.032 0.047 0.047 0.047 0.047 0.038 0.037 0.037
Specific Heat (kcal/kg.C) 0.240 0.510 0.240 0.506 0.432 0.451 0.451 0.450 0.450 0.437 0.432 0.432
Cp/Cv 1.428 1.373 1.428 1.367 1.342 1.305 1.305 1.304 1.304 1.322 1.312 1.312
Z‐factor 0.993 0.945 0.993 0.949 0.979 0.993 0.993 0.994 0.994 0.989 0.997 0.997
7 of 8
Rev. 0 23FEB2015
Liwa Plastics Project Document Title: Material Heat Balance - Unit 6200
Document No.: S-S620-5223-121
2nd Stage Polishing
Name H2 N2 PA MS 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215
MEDIUM
HYDROGEN H2 BEFORE N2 BEFORE PA BEFORE MS BEFORE ELECTRIC ELECTRIC 1ST STAGE 2ND STAGE 1ST STAGE 2ND STAGE MIXTURE MIXTURE
NITROGEN PLANT AIR PRESSURE TO KO TO SAFE
MAKE‐UP CONTROL CONTROL CONTROL CONTROL HEATER HEATER REACTOR REACTOR REACTOR REACTOR COOLER COOLER TO FLARE
FEED FEED STEAM DRUM LOCATION
FEED VALVE VALVE VALVE VALVE INLET OUTLET INLET INLET OUTLET OUTLET INLET OUTLET
FEED
Temperature (C) 10 280 10 278 180 480 480 480 480 300 298 298
Pressure (bara) 8.0 19.0 8.0 17.4 7.4 7.0 7.0 6.0 6.0 5.7 1.5 1.5
Weight rate (kg/h) 5950 6050 5950 6050 12000 12000 12000 12000 12000 12000 12000 12000
Molar rate (kmol/h) 205.5 335.8 205.5 335.8 541.4 541.4 541.4 541.4 541.4 541.4 541.4 541.4
Volumetric rate (m3/h) 600.9 767.9 604.4 841.3 2711.7 4831.3 4831.3 5636.1 5636.1 4497.6 17100.5 17312.7
Enthalpy (MMkcal/h) ‐0.0246 ‐18.8 ‐0.0246 ‐18.8 ‐18.8 ‐17.4 ‐17.4 ‐17.4 ‐17.4 ‐18.3 ‐18.3 ‐18.3
Spec. Enthalpy (kcal/kg) ‐4.1 ‐3101.3 ‐4.1 ‐3101.3 ‐1565.6 ‐1453.6 ‐1453.6 ‐1453.6 ‐1453.6 ‐1521.5 ‐1521.5 ‐1521.5
Density (kg/m3) 9.903 7.879 9.844 7.191 4.425 2.484 2.484 2.129 2.129 2.668 0.702 0.693
Mol. Weight 28.95 18.02 28.95 18.02 22.16 22.16 22.16 22.16 22.16 22.16 22.16 22.16
Viscosity (cP) 0.0182 0.0193 0.0182 0.0192 0.0159 0.0276 0.0276 0.0276 0.0276 0.0206 0.0205 0.0205
Thermal. Cond. (kcal/h.m.C) 0.021 0.038 0.021 0.037 0.029 0.050 0.050 0.050 0.050 0.037 0.037 0.037
Specific Heat (kcal/kg.C) 0.240 0.510 0.240 0.506 0.362 0.388 0.388 0.387 0.387 0.370 0.367 0.367
Cp/Cv 1.428 1.373 1.428 1.367 1.363 1.309 1.309 1.308 1.308 1.335 1.327 1.327
Z‐factor 0.993 0.945 0.993 0.949 0.982 0.998 0.998 0.998 0.998 0.994 0.998 0.998
8 of 8
Rev. 0 23FEB2015
Petrochemical Plant Sohar Environmental Impact Assessment Report
Orpic and CB&I HMR #3817
Attachment 4: Process Description of Butene-1
G-S000-5240-003 HMR Consultants
June 2015 K
Liwa Plastics Project
CB&I ORPIC
Document Title: Process Description - MTBE & BUT-1 6000 & 6100
Document No: S-S600-5223-002
CB&I Contract No: 189709
Issued For FEED 0 24-Feb-2015 AMAH EBRAKEL JL
Revision Descriptions Rev Date Originator Checker Approver
Page 1 of 10
"THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY (CB&I). IT MAY CONTAIN INFORMATION
DESCRIBING TECHNOLOGY OWNED BY CB&I AND DEEMED TO BE COMMERCIALLY SENSITIVE. IT IS TO BE USED ONLY IN
CONNECTION WITH WORK PERFORMED BY CB&I. REPRODUCTION IN WHOLE OR IN PART FOR ANY PURPOSE OTHER THAN
WORK PERFORMED BY CB&I IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN PERMISSION OF CB&I. IT IS TO BE SAFEGUARDED
AGAINST BOTH DELIBERATE AND INADVERTENT DISCLOSURE TO ANY THIRD PARTY."
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description - MTBE & BUT-1 6000 & 6100 S-S600-5223-002 0
INPUTS / REFERENCE DOCUMENTS
Document Number Title Status
S-S000-5222-001 Project Basis of Design – LPP Facilities Rev. C, 19-Sep-2014
S-S600-5223-001 MTBE 6000 & BUT-1 6100 – Process Basis of Design Rev. 0, 23-Feb-2015
D-S600-5223-101 Process Flow Diagram – Water Wash Section Rev. 0, 20-Feb-2015
D-S600-5223-102 Process Flow Diagram – MTBE Reaction Section 1/2 Rev. 0, 20-Feb-2015
D-S600-5223-103 Process Flow Diagram – MTBE Reaction Section 2/2 Rev. 0, 20-Feb-2015
D-S600-5223-104 Process Flow Diagram – Methanol Recovery Section Rev. 0, 20-Feb-2015
D-S600-5223-105 Process Flow Diagram – Drain Drums Rev. 0, 20-Feb-2015
D-S610-5223-101 Process Flow Diagram – B-1 Heavies Column Rev. 0, 20-Feb-2015
D-S610-5223-102 Process Flow Diagram – B-1 Lights Column Rev. 0, 20-Feb-2015
REVISION NOTES AND HOLDS
Revision Description of Changes & Holds
HOLDS Description of Holds Rev Date
Page 2 of 10
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description - MTBE & BUT-1 6000 & 6100 S-S600-5223-002 0
Table of Contents
Contents Page
1.0 INTRODUCTION..................................................................................................................................4
2.0 PROCESS DESCRIPTION...................................................................................................................5
2.1 MTBE Unit (6000)......................................................................................................................5
2.2 B-1 Unit (6100) ..........................................................................................................................8
2.3 MTBE Unit Drain Drum Pit Z-60001 (6000 & 6100) ..................................................................9
2.4 MTBE Unit Rain Water Collection Pit Z-60002 (6000 & 6100) .................................................9
2.5 Flare Knock Out Drum V-60006 (6000 & 6100) ......................................................................10
Page 3 of 10
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description - MTBE & BUT-1 6000 & 6100 S-S600-5223-002 0
1.0 INTRODUCTION
Oman Oil Refineries and Petrochemicals Industries Company (ORPIC) is currently executing a major
project to improve their existing Sohar Refinery located in the Sultanate of Oman, which is referred to as
the Sohar Refinery Improvement Project (SRIP).
In addition to SRIP, ORPIC is planning the installation of a new petrochemical complex in Sohar, adjacent
to SRIP, which will be part of the Liwa Plastics Project (LPP).
The new petrochemical complex will include a Steam Cracker Unit (SCU) designed to produce polymer
grade ethylene and polymer grade propylene, Refinery Dry Gas (RDG) Unit, NGL Treating and
Fractionation Unit, Selective C4’s Hydrogenation Unit, MTBE Unit, Butene-1 Recovery Unit, Pygas
Hydrotreating Unit, High Density Polyethylene (HDPE) Plant, Linear Low Density Polyethylene Plant
(LLDPE), Polypropylene (PP) Plant and associated Utility, Offsite and Storage Facilities.
The petrochemical plant will be integrated with the existing Sohar Refinery, Sohar Aromatics Plant (AP)
and Sohar PP plant.
Page 4 of 10
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description - MTBE & BUT-1 6000 & 6100 S-S600-5223-002 0
2.0 PROCESS DESCRIPTION
This document describes the Process Flow Scheme of the MTBE and Butene-1 (B-1) Unit as shown on the
Process Flow Diagrams.
2.1 MTBE Unit (6000)
2.1.1 Feed Preparation
The hydrocarbon feed to the unit is supplied from the upstream Selective C4 Hydrogenation unit
(SLC4HY). The Hydrogenated C4 feed is washed with countercurrent stream of deaerated demineralized
water from OSBL to the Water Wash Column, C-60001. This extraction column is composed of 24 sieve
trays with a coalescer pad at its top section. The demineralized water quantity used for washing is typically
˚
30% of the feed rate of the hydrocarbons. The wash water temperature requirement is 40 C or lower. Any
temperature higher than 40˚C adversely impacts the efficiency of acetonitrile removal and increases the
hydrocarbon losses in the effluent water. The washing process removes catalyst poisons such as metal
ions, acetonitrile, some propionitrile and other basic nitrogen compounds. The process wastewater from
the bottom of C-60001 is then sent to a waste water unit at OSBL.
The washed mixed C4 stream is collected in the C4 Feed Surge Drum, V-60001, with a coalescer to
remove any residual free water. From this drum, it is then transported to the MTBE reaction system via C4
Feed Pumps, P-60001A/B. An analyzer is available at the outlet of this pump to determine the composition
of the mixed C4s, especially isobutylene, present in the feed. A calculator block determines the required
methanol flow to be fed to the Primary Reactors R-60001A/B and to the catalytic section of the CD
Reaction Column, C-60002.
2.1.2 MTBE Reaction
The combined C4s feed from the C4 Feed surge Drum, V-60001 is mixed with a fresh and recycled
methanol stream. A Reactor Feed Preheater, E-60001 is provided to reach the required inlet temperature
during the start-up (in case feed C4 feed temperature lower than 40°C). LLP steam supplies the necessary
heat to the feed preheater.
The feed is combined with the recycle stream of the Primary Reactor effluent via the Primary Reactor Feed
Mixer, M-60001, to ensure a homogeneous mixture. The mixture is then fed to Primary Reactors, R-
60001A/B. These reactors are fixed-bed down-flow adiabatic reactors. One Primary Reactor acts as a
spare of the other. Alternatively the spare reactor can be used as Secondary Reactor in case of catalyst
change-out of Secondary Reactor (R-60002), hereby providing the unit with additional flexibility.
The etherification reaction is exothermic. Therefore, there is an increase in temperature across the reactor.
Dilution of the inlet stream limits the temperature rise across the reactor, and prevents vaporization at the
reactor outlet. By doing this, the temperature of the Primary Reactor is controlled and it also serves to
extend the catalyst life and avoids fouling. The cooled recycle effluent provides the necessary dilution
requirement at the inlet.
Page 5 of 10
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description - MTBE & BUT-1 6000 & 6100 S-S600-5223-002 0
The pressure in this system is maintained by monitoring the pressure upstream of R-60001A/B and
controlling the feed rate to the Secondary Reactor, R-60002. Effluent cooling is provided by Primary
Reactor Effluent Cooler E-60002 and Secondary Reactor Feed Cooler E-60003, respectively.
R-60002 operates in Boiling Point mode. This reactor is a fixed-bed down-flow adiabatic reactor and further
converts the isobutylene to MTBE. There is a limited amount of vaporization that takes place inside this
reactor. A temperature control is provided at the inlet of this reactor to achieve the desired value. For
flexibility purposes, this reactor is identical to the Primary Reactor, and alternative line-up can be
accommodated, i.e. switch of Primary and Secondary Reactor.
The system pressure is controlled by the CD Reaction Column overhead which sets the boiling point of the
reactor contents and hence, the maximum temperature. Since the reacting liquid mixture is at its boiling
point, even the localized “site” temperature cannot exceed the boiling temperature.
Outlet baskets are installed inside each reactor bottom to prevent carryover of catalyst in the reactor
effluent streams.
Effluent from Secondary Reactor R-60002 is heated against the CD Reaction Column C-60002 bottoms
product via the CD Reaction Column Feed/ Bottoms Exchanger, E-60004. It is then fed to the CD Reaction
Column, C-60002, where the rest of the MTBE conversion takes place.
The CD Reaction Column C-60002, has forty-nine (49) valve trays and contains beds packed with Lummus
Technology proprietary catalyst called “CD Modules”. To maximize MTBE conversion in this column,
additional methanol is injected into these packed beds. The amount of methanol carried overhead in the
CD Reaction Column is limited by the azeotropic composition of 4.0-5.0 wt% methanol in non-reactive C4
hydrocarbons. Any excess methanol over this azeotropic limit will exit the CD Reaction Column bottoms
together with the MTBE product as an impurity. The expected overall conversion is greater than 99.9% to
have less than 450 wt.-ppm of Isobutylene in the C4 Raffinate to the B-1 Section.
An online infrared analyzer is provided in the CD Reaction Column C-60002, to monitor the methanol
concentration profile and to adjust the flows of the methanol injections to the packed beds.
The overhead vapor is condensed against cooling water in the CD Reaction Column Condenser, E-60005.
Distillate flows to the CD Reaction Column Overhead Drum, V-60002. A fraction of the distillate from the
drum is pumped via CD Reaction Column Reflux Pumps, P-60003A/B, back to the CD reaction Column as
reflux. Any non-condensables present in the stream are vented to the wet flare.
MP steam supplies the heat required to the CD Reaction Column C-60002 via the CD Reaction Column
Reboiler, E-60006. MP steam passes through the desuperheater DS-60001 where it is saturated by means
of boiler feed water (BFW). The BFW supply is on the temperature control downstream of the
desuperheater DS-60001 on saturated steam line to the reboiler E-60006. The steam supply is on flow
Page 6 of 10
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description - MTBE & BUT-1 6000 & 6100 S-S600-5223-002 0
control reset by the temperature controller in the column, cascaded with level controller of the condensate
pot V-60021. A condensate pot V-60021 collects the low pressure condensate from E-60006 and the
condensate is transferred via condensate header to the B.L. under flooding level control cascaded with MP
steam supply controller to the desuperheater DS-60001.
MTBE product from the bottom of the CD Reaction Column flows to the CD Reaction Column Feed/
Bottoms Exchanger, E-60004, where heat is removed by preheating the Secondary Reactor effluent
stream.
MTBE product from the CD Reaction Column bottoms is cooled by product cooler E-60007 and sent to
OSBL.
2.1.3 Methanol Recovery Section
C4 Distillate from the CD Reaction Column C-60002, is cooled via the Methanol Extraction Column Feed
Cooler, E-60012. It is then fed to the bottom of the Methanol Extraction Column, C-60003. Twenty-four (24)
sieve trays inside this column are provided for methanol removal and a coalescer pad on top for coalescing
residual free water that is escaped with methanol through entrainment. Methanol is extracted from the
hydrocarbons by countercurrent contact with water recycled from the Methanol Recovery Column, C-
60004.
The hydrocarbon effluent from the top of C-60003 is fed to the B-1 Unit on pressure control. The water and
methanol mixture leaving the bottom of the Extraction Column C-60003 is on flow control reset by the
interface level at its top section.
The Methanol Recovery Column, C-60004, utilizes fifty-five (55) valve trays to separate water and
methanol. Low Low pressure steam provides heat in the Methanol Recovery Column Reboiler, E-60010.
The steam supply is on flow or level condensate cascade control reset by temperature control of the top
section. Condensate pot V-60022 collects the low low pressure condensate from shell side outlet of the E-
60010. The condensate pot V-60022 is on flooding level control and transfers the condensate via
condensate header under level control cascaded low low pressure steam flow to the reboiler and
temperature controller of tray 32 of Methanol Recovery Column C-60004.
Water exits the bottom of this column for recycle to Methanol Extraction Column, C-60003, via the
Methanol Recovery Column Bottoms Pumps, P-60005A/B. The recycle water is cooled by the Methanol
Recovery Column Feed/Bottoms Exchanger, E-60008 and Recycle Water Cooler, E-60011 before entering
Methanol Extraction Column C-60003.
The Methanol Recovery Column overhead vapor is condensed against air in the Methanol Recovery
Column Condenser, E-60009. The overhead liquid from Methanol Recovery Column C-60004 and the
Fresh Methanol from OSBL are collected in the Methanol Recovery Column Overhead Drum, V-60003.
Fresh methanol from OSBL first passes through Methanol Feed Filters, S-60001A/B. The Methanol
Recovery Column Reflux Pump, P-60004A/B, transfers the methanol mixture to the column as reflux and
the rest to the MTBE Reaction Section.
Page 7 of 10
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description - MTBE & BUT-1 6000 & 6100 S-S600-5223-002 0
To limit fouling and impurity accumulation, the Methanol Recovery Column C-60004 bottom sump is
purged once every four (4) weeks. Water should be purged by the operator observing the level in the sump
of the Methanol Recovery Column C-60004 until a low level is reached. The purged water, containing less
than 25 ppmw methanol, is sent to the wastewater plant OSBL. The operator should then make-up the
water in the system using demineralized and deaerated water from the complex. This operation is carried
out using manual control by observing the liquid level in the sump of the Methanol Recovery Column C-
60004.
2.2 B-1 Unit (6100)
The C4 raffinate from the top of Methanol Extraction Column C-60003 is fed to the B-1 Heavies columns C-
61002, which is used to separate Raffinate from Butene-1 and other lower boiling C4s. Because the B-1
Heavies column would be too tall otherwise, it is split into two smaller columns, B-1 Heavies Column #1 (C-
61001) and B-1 Heavies Column #2 (C-61002), which correspond to the upper and lower section of the
column, respectively. The bottoms from column #1 is pumped to the top of column #2 using the B-1
Heavies Column Transfer Pump, P-61001A/B. The overhead vapor from column #2 is fed below the
bottom tray of column #1.
The Butene-2 product from Heavies column #2 to OSBL, is pumped using the B-1 Heavies Column
Bottoms Pump P-61003A/B and cooled using the Butene-2 Product Cooler.
LLP steam supplies the heat required to the B-1 Heavies Column #2 via the B-1 Heavies Column Reboiler,
E-61002. The steam supply is on flow control.
Condensate pot V-61021 collects the low low pressure condensate from shell side outlet of the B-1
Heavies Column Reboiler E-61002. The condensate pot V-61021 is on flooding level control and transfers
the condensate via condensate header under level control cascaded to low low pressure steam flow to the
reboiler E-61002.
The overhead from the B-1 Heavies Column #1 is cooled in B-1 Heavies Column Condenser, E-61001,
and collected in B-1 Heavies Column Overhead Drum, V-61001. A bypass around the trim condenser is
used to control the B-1 Heavies Column #1 pressure. The vapor that results from the reflux drum is vented
to wet flare. Both reflux and the overhead product to the B-1 Lights section are pumped via the B-1
Heavies Column Reflux Pump, P-61002A/B, to their respective destinations. Any accumulated water in V-
61001 will be sent to waste water plant on interface level control.
The B-1 Lights Column #2 separates the Butene-1 product from the isobutane product. Because the B-1
Lights column would be too tall otherwise, it is split into two smaller columns, B-1 Lights Column #1 (C-
61003) and B-1 Lights Column #2 (C-61004), which correspond to the upper and lower section of the
column, respectively. The bottoms from column #1 is pumped to the top of column #2 using the B-1 Lights
Column Transfer Pump, P-61004A/B. The overhead vapor from column #2 is fed below the bottom tray of
column #1.
The Butene-1 product from Lights column #2 to OSBL, is pumped using the B-1 Lights Column Bottoms
Pump P-61006A/B and cooled using the Butene-1 Product Cooler prior to sending it the B.L.
LLP steam supplies the heat required to the B-1 Lights Column #2 via the B-1 Lights Column Reboiler, E-
61005. The steam supply is on flow control.
Page 8 of 10
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description - MTBE & BUT-1 6000 & 6100 S-S600-5223-002 0
Condensate pot V-61022 collects the low low pressure condensate from shell side outlet of the B-1 Lights
Column Reboiler E-61005. The condensate pot V-61022 is on flooding level control and transfers the
condensate via condensate header under level control cascaded to low low pressure steam flow to the
reboiler E-61005
The overhead from the B-1 Lights Column #1 is cooled in B-1 Lights Column Condenser, E-61004, and
collected in B-1 Lights Column Overhead Drum, V-61002. A bypass around the trim condenser is used to
control the B-1 Lights Column #1 pressure. The vapor that results from the reflux drum is vented to wet
flare. Both reflux and the Isobutane product to OSBL are pumped via the B-1 Lights Column Reflux Pump,
P-61005A/B, to their respective destinations. Any accumulated water in V-61002 will be sent to waste
water plant on interface level control.
2.3 MTBE Unit Drain Drums Pit Z-60001 (6000 & 6100)
MTBE Unit Drain Drum Pit Z-60001 contains two drain drums i.e. Methanol Drains Drum V-60004 and
MTBE Drains Drum V-60005. Surface water, rain water, spills from the drain drums that are collected in the
pit are transferred to MTBE Unit Rain Water Collection Pit Z-60002 by means of air-driven Drain Drum Pit
Dewatering Pump P-60010 that is installed at grade.
2.3.1 Methanol Drains Drum (V-60004)
Methanol that is collected via underground methanol closed drain system, as well as from B.L., is routed to
Methanol Drains Drum V-60004. Methanol Drain Drums Pump P-60006 is a submerged pump in V-60004
that recycles the collected methanol under flow control, back to the Methanol Recovery Column
Feed/Bottoms Exchanger E-60008 for processing in Methanol Recovery Column C-60004. P-60006 will be
started or stopped manually upon receiving high or low level indication via radar type level indicator.
Methanol Drains Drum V-60004 is connected to flare and is provided with fuel gas and nitrogen supply
lines for purging and inerting for maintenance purposes.
2.3.2 MTBE Drains Drum (V-60005)
MTBE and other hydrocarbons from MTBE and BUT-1 Unit that are collected via underground MTBE
closed drain system, as well as, from B.L. are routed to MTBE Drains Drum V-60005. MTBE Unit Drain
Drum Pump P-60007 is a submerged pump in MTBE Unit Drains Drum V-60005 that recycles the collected
hydrocarbons including MTBE, back to the C4 Feed Surge Drum V-60001 for further processing. P-60007
will be started or stopped manually upon receiving high or low level indication via radar type level indicator.
MTBE Drains Drum V-60005 is connected to flare and is provided with fuel gas and nitrogen supply lines
for purging and inerting for maintenance purposes.
2.4 MTBE Unit Rain Water Collection Pit Z-60002 (6000 & 6100)
MTBE Unit Rain Water Collection Pit Z-60002 collects rainwater as well as oil/hydrocarbon contaminated
water from the MTBE Unit Drain Drums Pit Z-60001, which is transferred from Z-60001 to Z-60002 by
means of Drain Drum Pit Dewatering Pump P-60010. Water in the Z-60002 is collected through a sample
connection for analysis. On the basis of the results of the analysis, the water is pumped out by MTBE Unit
Rain Water Pump P-60008 to the oily water contaminated sewer or to the waste water treatment plant for
further treatment.
Page 9 of 10
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description - MTBE & BUT-1 6000 & 6100 S-S600-5223-002 0
2.5 Flare Knock Out Drum V-60006 (6000 & 6100)
All relief loads from relief valves and incidental operational loads from flare lines connected to equipment
(such as reactors) are collected via ISBL flare header to the MTBE Unit Flare Knock Out Drum V-60006.
Gaseous phase is routed via wet flare header to off-sites. The liquid hydrocarbon condensate is recycled
by MTBE Unit Flare K.O. Drum Pump P-60009 A/B to C4 Feed Surge Drum V-60001 for reprocessing.
This pump is started and stopped automatically, based on high / low level in V-60006.
Page 10 of 10
Petrochemical Plant Sohar Environmental Impact Assessment Report
Orpic and CB&I HMR #3817
Attachment 5: Process Description Pygas Hydrotreater Unit
G-S000-5240-003 HMR Consultants
June 2015 L
Liwa Plastics Project
CB&I ORPIC
Document Title: PGHYD 6200 – Process Description
Originally issued by Axens as S-S620-5223-031
Document No: S-S620-5223-002
CB&I Contract No: 189709
Issued for FEED 1 23-Feb-2015 EBRAKEL WMORAIS JL
Revision Descriptions Rev Date Originator Checker Approver
Page 1 of 13
"THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY (CB&I). IT MAY CONTAIN INFORMATION
DESCRIBING TECHNOLOGY OWNED BY CB&I AND DEEMED TO BE COMMERCIALLY SENSITIVE. IT IS TO BE USED ONLY IN
CONNECTION WITH WORK PERFORMED BY CB&I. REPRODUCTION IN WHOLE OR IN PART FOR ANY PURPOSE OTHER THAN
WORK PERFORMED BY CB&I IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN PERMISSION OF CB&I. IT IS TO BE SAFEGUARDED
AGAINST BOTH DELIBERATE AND INADVERTENT DISCLOSURE TO ANY THIRD PARTY."
UNIT DESCRIPTION
Job Number Unit Type Page
06146 6200 02UD 2/13
Client Oman Oil Refineries and Petroleum Ind. Co. SAOC Date By Check By Rev
Liwa Plastics Project - Sohar 04-11-14 CWE ASL 0
Unit Pygas Hydrotreating Unit 23-02-15 EBRAKEL PPETRO 1
CONTENT
1. FIRST STAGE REACTION SECTION .......................................................................... 3
2. FIRST STAGE DISTILLATION SECTION .................................................................... 5
2.1 Stabilizer.............................................................................................................................. 5
2.2 Rerun Tower........................................................................................................................ 5
3. SECOND STAGE REACTION SECTION ..................................................................... 7
4. SECOND STAGE DISTILLATION SECTION ............................................................... 9
4.1 2nd Stage Stabilizer.............................................................................................................. 9
4.2 Depentanizer ....................................................................................................................... 9
4.3 Deheptanizer ..................................................................................................................... 10
5. NON-LICENSED PROCESS SYSTEMS .................................................................... 11
5.1 Steam System of Pygas Unit Reboilers............................................................................. 11
5.2 Fuel Gas System............................................................................................................... 11
5.3 Pygas Catalyst Treatment Gas Preparation ...................................................................... 11
5.4 Drain systems.................................................................................................................... 12
5.5 Flare KO Drum .................................................................................................................. 13
ABRREVIATIONS
AOC Accidentally Oil Contaminated
FEED Front-End Engineering and Design
HPS High Pressure Steam
LPP Liwa Plastics Project
MPS Medium Pressure Steam
ORPIC Oman Oil Refineries and Petroleum Industries Company
Pygas Pyrolysis Gasoline
SCU Steam Cracker unit
WWTP Waste Water Treatment Plant
This document contains confidential proprietary information belonging to Axens
Rev.1 23/02/15 It shall not be disclosed to any third parties without Axens’ prior written consent.
PROCESS DESCRIPTION
Job Number Unit Type Page
06146 6200 02UD 3/13
Client Oman Oil Refineries and Petroleum Ind. Co. SAOC Date By Check By Rev
Liwa Plastics Project - Sohar 04-11-14 CWE ASL 0
Unit Pygas Hydrotreating Unit 23-02-15 EBRAKEL PPETRO 1
1. FIRST STAGE REACTION SECTION
The raw pyrolysis gasoline feed coming from battery limit is first routed to the Feed Surge Drum V-62001.
The Feed Surge Drum pressure is maintained by split range control on both hydrogen make-up and vent to
wet flare. The unit feed is pumped to the first stage reaction section by 1st Stage Feed Pumps P-62001A/B,
under cascaded level-flow control, and filtered in the Feed Filters S-62001A/B in order to remove scale
particles.
The feed is first mixed with make-up hydrogen from PSA. The make-up hydrogen is injected to the first
reaction section under flow ratio control compared to fresh feed.
Combined feed is then mixed with the liquid diluent, recycled back from the Hot Separator Drum V-62002.
The dilution lowers the feed reactivity and thus allows a smooth control of temperature elevation in the 1st
Stage Hydrogenation Reactors R-62001A/B and R-62002A/B and by extent a limitation of polymerization
reactions, thus leading to extended cycles.
The mixed streams are feeding the reactors after being heating through the 1st Stage Feed / Effluent
Exchanger E-62001.
The inlet temperature of the reactor is controlled by by-passing part of the 1st Stage Feed / Effluent
Exchanger E-62001 shell side as required. During start-up, the temperature is controlled by means of the
1st Stage Start-Up Heater E-62002. The start-up heater is used only during start-up or unit restart, and is
isolated from the process during normal operation.
Two trains of two reactors in series (two operating and two spare) are used to enable a continuous
operation: R-62001A in series with R-62002A, and R-62001B in series with R-62002B. The piping
arrangement and valves allow the flexibility to take one set of reactors off line for isolation and catalyst
treatment or change out, while the other set of reactors is in operation.
The reactions (diolefins and alkenyl aromatics hydrogenation) occur in mixed phase (mainly liquid) in a
fixed bed type downflow reactor.
As the catalyst activity decreases during the catalyst cycle, the feed temperature of 1st Stage Hydrogenation
1st Reactor (R-62001A/B) is increased from 60°C (Start-of-Run, SOR) to 120°C (End-of-Run, EOR).
1st Stage Hydrogenation 1st Reactor effluent is mixed with the quench stream coming from Hot Separator in
a static mixer M-62001A/B before being routed to 1st Stage Hydrogenation 2nd Reactor R-62002A/B.
Second reactor inlet temperature will be set in order to maintain the overall temperature rise in 1st Stage
reactors below 60°C.
The reactors effluent, partly cooled through E-62001 against the reactors feed, is flashed into the Hot
Separator Drum V-62002. Part of the liquid from V-62002 is recycled through the 1st Stage Recycle Pumps
P-62002A/B. The remaining is sent under cascaded level-flow control to Stabilizer C-62011.
This document contains confidential proprietary information belonging to Axens
Rev.1 23/02/15 It shall not be disclosed to any third parties without Axens’ prior written consent.
PROCESS DESCRIPTION
Job Number Unit Type Page
06146 6200 02UD 4/13
Client Oman Oil Refineries and Petroleum Ind. Co. SAOC Date By Check By Rev
Liwa Plastics Project - Sohar 04-11-14 CWE ASL 0
Unit Pygas Hydrotreating Unit 23-02-15 EBRAKEL PPETRO 1
Liquid from the recycle pump is cooled down in 1st Stage Recycle Air Cooler E-62004. Part of it is mixed
with the fresh feed, and the second part is further cooled down in 1st Stage Quench Trim Cooler E-62005
and mixed with 1st Stage Hydrogenation 1st Reactor effluent.
The vapor from Hot separator which contains light hydrocarbons shall be partially condensed in the 1st
Stage Condenser E-62003 and sent to the Cold Separator Drum V-62003. Vapor from V-62003 is sent to
the Second Stage reaction section as make-up hydrogen, under First Stage reaction section pressure
control (pressure control at 1st Stage Hydrogenation Reactors inlet). Liquid from Cold Separator is merged
with liquid from Hot Separator to feed 1st Stage Stabilizer C-62011 under level-flow cascaded control.
1st Stage reactors are also designed to stand in-situ activation and regeneration of the catalyst. Generation
of catalyst treatment gas and management of the catalyst treatment offgases are OSBL and outside Axens
scope of work.
Due to the use of nickel-based catalyst, an additional passivation step shall be performed to prevent high
hydrogenation rates of the feed with potential loss of aromatics and unbearable exotherm in 1st Stage
reactors. This operation will be executed with dedicated facilities (Passivation drum V-62004 and
Passivation pump P-62003) to allow a closed loop circulation of inert naphtha through the 1st Stage First
and Second reactors of the same train (either A or B). The active compound during passivation shall be Di
Methyl Sulfide which will be injected in the closed loop from the DMS injection package A-62001.
This document contains confidential proprietary information belonging to Axens
Rev.1 23/02/15 It shall not be disclosed to any third parties without Axens’ prior written consent.
PROCESS DESCRIPTION
Job Number Unit Type Page
06146 6200 02UD 5/13
Client Oman Oil Refineries and Petroleum Ind. Co. SAOC Date By Check By Rev
Liwa Plastics Project - Sohar 04-11-14 CWE ASL 0
Unit Pygas Hydrotreating Unit 23-02-15 EBRAKEL PPETRO 1
2. FIRST STAGE DISTILLATION SECTION
2.1 Stabilizer
The Stabilizer C-62011 has 30 trays and the feed enters the column at tray 18.
The Stabilizer first purpose is to stabilize the first stage reactors product by removing the hydrogen and the
light components. The second purpose is to fractionate the C5 product as side-draw from the C6+ cut which
is removed as the bottom product.
The overhead vapor of the tower is partially condensed in the 1st Stage Stabilizer Air Cooler and Condenser
(E-62011, E-62012) and collected in the 1st Stage Stabilizer Reflux Drum V-62011. Vapor phase from reflux
drum is routed to SCU under column overhead pressure control. A part of the liquid phase is sent back as
column reflux to the top of the tower through 1st Stage Stabilizer Reflux Pumps P-62011A/B on flow control.
The reflux drum is equipped with a boot to remove any potential free water. Water (if any) is sent to Waste
Water header under level control.
To prevent fouling in reboiler, MP steam shall be desuperheated down to 215°C maximum in DS-62011,
prior to being sent to 1st Stage Stabilizer Reboiler E-62013. In start-up mode, the steam flow control can be
cascaded by the temperature at reboiler outlet.
The light gasoline cut recovered as overhead product is routed to 2nd Stage Feed Surge Drum V-62031
under flow control cascaded by reflux drum level controller, and prevent overload of Rerun Tower overhead.
The C6+ cut leaving the tower bottoms feeds the Rerun Tower C-62012 under flow control cascaded by the
level in the Stabilizer bottom.
2.2 Rerun Tower
The Rerun Tower C-62012 has 24 trays and the feed enters the column at tray 14.
The Rerun Tower purpose is to fractionate the C6-C10 overhead cut from the C10+ cut (Heavy Cut) which
is removed as the bottoms product.
The overhead vapor of the tower is partially condensed in the Rerun Tower Air Cooler E-62014 and the
Rerun Tower Condenser E-62015 and collected in the Rerun Tower Reflux Drum V-62012. Vapor phase
from reflux drum is sent to the Rerun Tower Vacuum Package J-62011, which maintains the vacuum in
Rerun Tower. A nitrogen injection allows to control the column overhead pressure. Reflux drum liquid
inventory is pumped in Rerun Tower Reflux Pumps P-62012A/B. A part of the liquid is sent back as column
reflux to the top of the tower under flow control. The remaining liquid is sent to the 2nd Stage Feed Surge
Drum, under flow control cascaded by reflux drum level controller.
This document contains confidential proprietary information belonging to Axens
Rev.1 23/02/15 It shall not be disclosed to any third parties without Axens’ prior written consent.
PROCESS DESCRIPTION
Job Number Unit Type Page
06146 6200 02UD 6/13
Client Oman Oil Refineries and Petroleum Ind. Co. SAOC Date By Check By Rev
Liwa Plastics Project - Sohar 04-11-14 CWE ASL 0
Unit Pygas Hydrotreating Unit 23-02-15 EBRAKEL PPETRO 1
The reflux drum is equipped with a boot, which removes potential water. Water (if any) is sent to Waste
Water header.
Rerun Tower is reboiled by the Rerun Tower Reboilers E-62017A/B. To prevent fouling in reboiler, HP
steam shall be desuperheated down to 215°C maximum in DS-62012, prior to being sent to reboiler. In
start-up mode, the steam flow control can be cascaded by the temperature at reboiler outlet.
A spare Rerun Tower Reboiler shall be also installed to allow change-over to maintain continuous
operation.
The Heavy Cut leaving the tower bottom is pumped in the Heavy Cut Pumps P-62013A/B, cooled down in
Heavy Cut Air Cooler E-62016 and sent to the PFO tank, under flow control cascaded by tower level
controller.
This document contains confidential proprietary information belonging to Axens
Rev.1 23/02/15 It shall not be disclosed to any third parties without Axens’ prior written consent.
PROCESS DESCRIPTION
Job Number Unit Type Page
06146 6200 02UD 7/13
Client Oman Oil Refineries and Petroleum Ind. Co. SAOC Date By Check By Rev
Liwa Plastics Project - Sohar 04-11-14 CWE ASL 0
Unit Pygas Hydrotreating Unit 23-02-15 EBRAKEL PPETRO 1
3. SECOND STAGE REACTION SECTION
The Second Stage reaction section feed is a blend of C5 cut from 1st Stage Stabilizer overhead and C6-C10
cut from Rerun Tower overhead. It is charged to the 2nd Stage Feed Surge Drum V-62031. In case the
Second Stage is down (e.g. for maintenance purpose), the 2nd Stage feed flow will be routed to the raw
pyrolysis gasoline storage tank T-83014A/B.
The vessel pressure is maintained by split range control of hydrogen and venting to wet flare. The feed is
pumped to the 2nd Stage reaction section by 2nd Stage Feed Pumps P-62031A/B, under cascaded level flow
control. The feed is mixed with the recycle gas stream (composed of the recycled hydrogen coming from
the Recycle Compressor K-62031A/B, of the fresh make-up hydrogen and of the 1st Stage reaction section
purge gas), and a liquid diluent stream from 2nd Stage Separator drum in order to dampen the reactor feed
reactivity.
The hydrocarbons and hydrogen mixture is preheated in the 2nd Stage Feed/Effluent Exchangers E-
62031A/B/C (tube side) against 2nd Stage Hydrogenation Reactor effluent (shell side). At E-62031C outlet,
the feed stream is totally vaporized. The reactor feed is then heated to the required reactor inlet
temperature in the 2nd Stage Reactor Feed Heater F-62031.
The 2nd Stage Hydrogenation Reactor R-62031 operates in downflow mode in totally vaporized phase. The
reactor is divided into three beds. In the upper two beds of the reactor, mainly olefins hydrogenation occurs
and in the lower bed (loaded with a different catalyst) mainly desulphurization occurs. The combination of
two catalysts enables to keep the loss of aromatics low.
The temperature profile through the reactor is controlled by the injection of liquid quench in inter-bed areas.
This allows control of the middle and lower catalytic beds inlet temperatures. Quench material will come
from the 2nd Stage Recycle Pumps P-62032A/B at the 2nd Stage Separator Drum V-62032 liquid outlet.
The effluent from the 2nd Stage Hydrogenation Reactor is cooled in E-62031A/B/C shell side. Final cooling
is achieved by the 2nd Stage Reactor Effluent Air Cooler and Condenser (E-62032 and E-62033).
The 2nd Stage reactor effluent is sent to 2nd Stage Separator Drum V-62032. The liquid hydrocarbon from V-
62032 is split into two streams: one is sent to the 2nd Stage Stabilizer Feed / Deheptanizer Bottom
Exchanger E-62041 (Second Stage distillation section) under flow control cascaded by level controller; the
other is pumped by P-62032A/B and recycled either directly to 2nd Stage Reactor (quench streams), or to
reactor feed preheat train (diluent stream).
The vapor hydrocarbon flows to the Recycle Compressors K.O. Drum V-62033 to trap any liquid carry-over,
which will be routed to Sour Water Drain (Sohar SWS) header. Part of the vapor from 2nd Stage Separator
Drum can be purged under flow control to SCU, to maintain the hydrogen purity of the recycle gas (the
purge control will be overridden by the Second Stage pressure controller in case of high pressure in the
system). The remaining gas is then compressed and recycled in the Recycle Compressors K-62031A/B,
after being mixed with the 1st Stage reaction section purge gas which is hydrogen-rich.
This document contains confidential proprietary information belonging to Axens
Rev.1 23/02/15 It shall not be disclosed to any third parties without Axens’ prior written consent.
PROCESS DESCRIPTION
Job Number Unit Type Page
06146 6200 02UD 8/13
Client Oman Oil Refineries and Petroleum Ind. Co. SAOC Date By Check By Rev
Liwa Plastics Project - Sohar 04-11-14 CWE ASL 0
Unit Pygas Hydrotreating Unit 23-02-15 EBRAKEL PPETRO 1
The hydrogen consumption in Second Stage will be balanced by injecting pure make-up hydrogen from
PSA. The flow will be automatically adjusted to maintain the pressure in 2nd Stage Separator drum.
2nd Stage reactor is also designed to stand in-situ activation and regeneration of the catalyst. Generation of
catalyst treatment gas for regeneration and management of the catalyst treatment offgases are OSBL and
outside Axens scope of work.
2nd Stage reactor catalyst activation is different from 1st Stage reactors. Catalyst needs to be sulfided prior
to being used. Sulfiding will be performed by circulating hydrogen mixed with H2S inside the reactor in
closed loop through the normal operation lines. H2S will be generated in-situ by injecting Di Methyl Di
Sulfide (DMDS) from DMDS Injection Package A-62031 at 2nd Stage reactor inlet, which will decompose in
H2S at the sulfiding step conditions.
This document contains confidential proprietary information belonging to Axens
Rev.1 23/02/15 It shall not be disclosed to any third parties without Axens’ prior written consent.
PROCESS DESCRIPTION
Job Number Unit Type Page
06146 6200 02UD 9/13
Client Oman Oil Refineries and Petroleum Ind. Co. SAOC Date By Check By Rev
Liwa Plastics Project - Sohar 04-11-14 CWE ASL 0
Unit Pygas Hydrotreating Unit 23-02-15 EBRAKEL PPETRO 1
4. SECOND STAGE DISTILLATION SECTION
4.1 2nd Stage Stabilizer
Second Stage effluent is preheated in the 2nd Stage Stabilizer Feed / Deheptanizer Bottom Exchanger E-
62041 against the Deheptanizer C-62043 bottom product and then feeds the 2nd Stage Stabilizer C-62041.
2nd Stage Stabilizer has 30 trays and the feed enters the column at tray 25.
The Stabilizer stabilizes the second stage reactor liquid product by removing the H2S and the light
hydrocarbons dissolved in the column feed.
Due to the high H2S content, Corrosion Inhibitor is injected in the column overhead from the Corrosion
Inhibitor Injection Package A-62041.
The overhead vapor of the tower is partially condensed in the 2nd Stage Stabilizer Air Cooler E-62042 and
the 2nd Stage Stabilizer Condenser E-62043, then collected in 2nd Stage Stabilizer Reflux Drum V-62041.
Vapor phase is purged to SCU under column overhead pressure control. Liquid is sent back to the column
as column reflux (total reflux) under cascaded level flow control. Any free water present in the vessel will be
separated in the boot and routed to Sour Water Drain header.
Column is reboiled in the 2nd Stage Stabilizer Reboiler E-62044 with MP steam. Steam flowrate is actually
controlled by varying condensate level in reboiler (flooded-type exchanger).
The bottom product leaving the tower feeds the Depentanizer C-62042 under flow control cascaded by the
level in the Stabilizer bottom.
4.2 Depentanizer
The Depentanizer C-62042 has 55 trays and the feed enters the column at tray 26.
The Depentanizer purpose is to recover a C5 cut at overhead (Hydrogenated C5 cut).
The overhead vapor of the tower is totally condensed in the Depentanizer Condenser E-62046 and
collected in Depentanizer Reflux Drum V-62042. The liquid phase is pumped through the Depentanizer
Reflux/Product Pumps P-62042A/B, a part of it is routed back to the column as a reflux under flow control,
while the remaining is sent to storage under flow control cascaded by reflux drum controller, after being
cooled down in the Hydrogenated C5 Trim Cooler E-62047 to meet the refinery battery limit temperature
requirement.
The pressure in reflux drum will be controlled by engassing hot vapor from column overhead under
differential pressure control (PDC). The purpose of the PDV valve on the bypass line is to ensure a
constant differential pressure between the Depentanizer and the reflux drum. If the pressure in the
Depentanizer overhead decreases, then PIC will close the valve on the main line, increasing the pressure
This document contains confidential proprietary information belonging to Axens
Rev.1 23/02/15 It shall not be disclosed to any third parties without Axens’ prior written consent.
PROCESS DESCRIPTION
Job Number Unit Type Page
06146 6200 02UD 10/13
Client Oman Oil Refineries and Petroleum Ind. Co. SAOC Date By Check By Rev
Liwa Plastics Project - Sohar 04-11-14 CWE ASL 0
Unit Pygas Hydrotreating Unit 23-02-15 EBRAKEL PPETRO 1
drop in this valve. As the differential pressure between the Depentanizer overhead and the reflux drum is
kept constant by the PDC on the bypass, pressure drop in the air cooler decreases (flow in it decreases).
As the flow decreases and the same amount of vapor is still coming from the Depentanizer overhead, the
pressure tends to increase. When the pressure increases, the pressure control valve starts to open more
and more until equilibrium is reached in the system.
Column is reboiled in the Depentanizer Reboiler E-62048 with MP steam. Steam flowrate is actually
controlled by varying condensate level in reboiler (flooded-type exchanger).
The bottom product leaving the tower feeds the Deheptanizer under flow control cascaded by the level in
the Depentanizer bottom.
4.3 Deheptanizer
The Deheptanizer C-62043 has 43 trays and the feed enters the column at tray 26.
The Deheptanizer purpose is to recover a C6-C7 cut at overhead and a C8-C10 cut in the bottoms.
The overhead vapor of the tower is totally condensed in the Deheptanizer Condenser E-62049 and
collected in Deheptanizer Reflux Drum V-62043. The liquid phase is pumped the Deheptanizer
Reflux/Product Pumps P-62043A/B, a part of it is routed back to the column as a reflux under flow control,
while the remaining is sent to storage under flow control cascaded by reflux drum level controller, after
being cooled down in the C6-C7 Cut Air Cooler E-62050 and C6-C7 Cut Trim Cooler E-62051 to meet the
refinery battery limit temperature requirement.
The pressure in reflux drum will be controlled by engassing hot vapor from column overhead under
differential pressure control (PDC). The purpose of the PDV valve on the bypass line is to ensure a
constant differential pressure between the Deheptanizer and the reflux drum. If the pressure in the
Deheptanizer overhead decreases, then PIC will close the valve on the main line, increasing the pressure
drop in this valve. As the differential pressure between the Deheptanizer overhead and the reflux drum is
kept constant by the PDC on the bypass, pressure drop in the air cooler decreases (flow in it decreases).
As the flow decreases and the same amount of vapor is still coming from the Deheptanizer overhead, the
pressure tends to increase. When the pressure increases, the pressure control valve starts to open more
and more until equilibrium is reached in the system.
Column is reboiled in the Deheptanizer Reboiler E-62052 with HP steam. Steam flowrate is actually
controlled by varying condensate level in reboiler (flooded-type exchanger).
The bottom product leaving the tower is pumped and routed to storage under flow control cascaded by the
level in the Deheptanizer bottom, after being cooled down in 2nd Stage Stabilizer Feed/Deheptanizer Bottom
Exchanger E-62041 and C8-C10 Cut Trim Cooler E-62045.
This document contains confidential proprietary information belonging to Axens
Rev.1 23/02/15 It shall not be disclosed to any third parties without Axens’ prior written consent.
PROCESS DESCRIPTION
Job Number Unit Type Page
06146 6200 02UD 11/13
Client Oman Oil Refineries and Petroleum Ind. Co. SAOC Date By Check By Rev
Liwa Plastics Project - Sohar 23-02-15 EBRAKEL PPETRO 1
Unit Pygas Hydrotreating Unit
5. NON-LICENSED PROCESS SYSTEMS
5.1 Steam System of Pygas Unit Reboilers
The reboiler systems of the Pygas unit’s distillation columns are equipped with condensate pots for
easy condensate removal. The design of the five reboiler systems is as follows:
Column Reboiler Desuper- Steam Condensate Column temperature
heater level Pot control by
(HP BFW)
C-62011 E-62013 DS-62011 MPS V-62013 Steam flow control
C-62012 E-62017A/B DS-62012 HPS V-62014 Steam flow control
C-62041 E-62044 - MPS V-62044 Reboiler flooding
C-62042 E-62048 - MPS V-62045 Reboiler flooding
C-62043 E-62052 - HPS V-62046 Reboiler flooding
5.2 Fuel Gas System
Any liquid that is present in the fuel gas supply is knocked out in Fuel Gas KO Drum V-62034.
5.3 Pygas Catalyst Treatment Gas Preparation
The Pygas catalyst treatment gas preparation system is used for mixing and heating catalyst
treatment gas in the right quantities and temperature, before being sent to the off-line reactor(s)
which need catalyst treatment.
Hydrogen and nitrogen, or plant air and medium pressure steam are combined via a control valve
manifold and filtered in Catalyst treatment Gas Filter S-62060. The filtered gas is heated in Catalyst
Treatment Gas Electric Heater E-62060 before it is routed to First or Second Stage Hydrogenation
Reactors:
R-62001A / R-62002A, or
R-62001B / R-62002B, or
This document contains confidential proprietary information belonging to Axens
Rev.1 23/02/15 It shall not be disclosed to any third parties without Axens’ prior written consent.
PROCESS DESCRIPTION
Job Number Unit Type Page
06146 6200 02UD 12/13
Client Oman Oil Refineries and Petroleum Ind. Co. SAOC Date By Check By Rev
Liwa Plastics Project - Sohar 23-02-15 EBRAKEL PPETRO 1
Unit Pygas Hydrotreating Unit
R-62031.
The maximum operating temperature of the hydrogen and nitrogen mixture is 410°C and the
maximum operating temperature of the steam and air mixture is 480°C.
After catalyst treatment the off-gas mixture is cooled in Catalyst Treatment Off-Gas Air Cooler E-
62061. The maximum temperature downstream Catalyst Treatment Gas Cooler E-62061 is 300°C.
The pressure downstream E-62061 is maintained at 5 barg by pressure control valve PV-138.
Steam/Air mixtures are routed to safe location via Catalyst Treatment Gas KO Drum V-62060.
Hydrogen/Nitrogen mixtures are routed to flare.
Full details of catalyst treatment operations are given in the Utility Summary (doc. nr S-S620-5223-
521). The following is a summary of the required catalyst treatment steps:
- Catalyst Activation occurs with hydrogen and nitrogen at minimum 400°C for 15 hours.
- Passivation occurs with Dimethyl Sulfide and naphtha
- Reactivation occurs with nitrogen and hydrogen for 8 hours at 150°C minimum
- Hot hydrogen stripping is done at minimum 400°C for 12 hours.
- Pre-oxidation, combustion and polishing is done with steam & air mixture. During polishing the
temperature is 460°C maximum for 4 hours.
- Regeneration of R-62001 A/B occurs every 18 months and regeneration of R-620031 occurs
every 24 months. The estimated total time that the temperature is at 460°C is expected to be
200 hours during the design life time of 25 years.
5.4 Drain systems
Pygas Unit WW Drain Drum
The waste water from the Pygas unit is routed to Pygas Unit WW Drain Drum V-62052. This drum
contains water and potentially some hydrocarbons. No H2S is expected to be present in this waste
water, since sour drains are lined up to the existing Sohar sour water strippers, via V-10003 in the
SCU. The Drain drum is under nitrogen and fuel gas purge.
The collected Waste Water is pumped to WWTP via Pygas Unit WW Drain Drum Pump P-62052.
Pygas Unit Drain Drum
The hydrocarbon drains from the Pygas unit are routed to the Pygas Unit Drain Drum V-65020. The
drains contain hydrocarbons including Benzene, H2S and also water can be present. The drum is
under nitrogen and fuel gas purge. This drain system is a dedicated system for the Pygas unit.
The collected drains are pumped to the Quench Tower C-21003 in SCU via Pygas Unit Drain Drum
Pump P-62050.
Pygas Unit Drain Drums Pit
This document contains confidential proprietary information belonging to Axens
Rev.1 23/02/15 It shall not be disclosed to any third parties without Axens’ prior written consent.
PROCESS DESCRIPTION
Job Number Unit Type Page
06146 6200 02UD 13/13
Client Oman Oil Refineries and Petroleum Ind. Co. SAOC Date By Check By Rev
Liwa Plastics Project - Sohar 23-02-15 EBRAKEL PPETRO 1
Unit Pygas Hydrotreating Unit
Both drain drums are located in Pygas Unit Drain Drums Pit Z-60001. Any collected rainwater is
pumped out by air-driven Dewatering Pump P-62053 and sent to Rainwater Collection Pit Z-60002.
Pygas Unit Rainwater Collection Pit
Rainwater, which is collected from the paved area of the Pygas unit, is collected in Rainwater
Collection Pit Z-62002. If benzene levels are too high, the pit may be emptied by vacuum truck. If
found clean after sampling, surface, water may be discharged to the AOC system on gravity.
5.5 Flare KO Drum
Pygas unit safety valve releases are routed via ISBL wet flare header to Flare KO Drum V-62051 of
the Pygas unit. H2S can be present in the flare release gas. The flare gas is routed to the main wet
flare header of the complex.
The Flare KO Drum is under nitrogen and fuel gas purge.
Collected liquids are pumped to the Quench Tower C-21003 in SCU via Flare KO Drum Pump P-
62051A/B. It is sent to the SCU via a combined drain and flare liquids line.
This document contains confidential proprietary information belonging to Axens
Rev.1 23/02/15 It shall not be disclosed to any third parties without Axens’ prior written consent.
Petrochemical Plant Sohar Environmental Impact Assessment Report
Orpic and CB&I HMR #3817
Attachment 6: Process description for Flares
G-S000-5240-003 HMR Consultants
June 2015 M
Liwa Plastics Project
CB&I ORPIC
Document Title: Process Description – 8900 FLRU
Document No: S-S890-5223-002
CB&I Contract No: 189709
Issued for FEED 0 18-03-2015 AYV SNAZARI JL
Revision Descriptions Rev Date Originator Checker Approver
Page 1 of 11
"THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY (CB&I). IT MAY CONTAIN INFORMATION
DESCRIBING TECHNOLOGY OWNED BY CB&I AND DEEMED TO BE COMMERCIALLY SENSITIVE. IT IS TO BE USED ONLY IN
CONNECTION WITH WORK PERFORMED BY CB&I. REPRODUCTION IN WHOLE OR IN PART FOR ANY PURPOSE OTHER THAN
WORK PERFORMED BY CB&I IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN PERMISSION OF CB&I. IT IS TO BE SAFEGUARDED
AGAINST BOTH DELIBERATE AND INADVERTENT DISCLOSURE TO ANY THIRD PARTY."
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description – 8900 – FLRU S-S890-5223-002 0
INPUTS / REFERENCE DOCUMENTS
Document Number Title Status
S-S000-5222-001 Project Basis of Design - LPP Facilities
S-S000-5223-002 Process Design Basis for Utilities
D-S890-5223-101 Utility Process Flow Diagram Main Wet Flare - 8900
D-S890-5223-102 Utility Process Flow Diagram Cryogenic LP Flare - 8900
D-S890-5223-103 Utility Process Flow Diagram Spare Storage Wet Flare - 8900
REVISION NOTES AND HOLDS
Revision Description of Changes & Holds
HOLDS Description of Holds Rev Date
1 Holds are identified in the document and summarized here.
2
3
4
Page 2 of 11
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description – 8900 – FLRU S-S890-5223-002 0
Table of Contents
Contents Page
1.0 INTRODUCTION..................................................................................................................................5
2.0 FLARE SYSTEM .................................................................................................................................5
2.1 Main Wet Flare ME-89001.........................................................................................................5
2.2 Spare Storage Wet Flare ME-89003 .........................................................................................8
2.3 Acid Gas Flare ........................................................................................................................10
2.4 Cryogenic Low Pressure Flare ME-89002 A/B ......................................................................11
Page 3 of 11
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description – 8900 – FLRU S-S890-5223-002 0
ABBREVIATION
HP High Pressure
FG Fuel Gas
LPP Liwa Plastic Project
NG Natural Gas
SCU Steam Cracker Unit
Page 4 of 11
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description – 8900 – FLRU S-S890-5223-002 0
1.0 INTRODUCTION
For operation of the new Olefins Complex located at the Sohar refinery, The Sultanate of Oman, an
elevated flare system has been foreseen to receive reliefs from all the plants.
The new flare system is designed to safely collect and dispose reliefs from the plant. Separate collection
headers are receiving different discharges from the plant. Knock-out drums are foreseen for each process
unit to separate liquid before the gasses are sent to flare. Liquid Hydrocarbon and aqueous phases are
routed to appropriate destination for reprocessing.
2.0 FLARE SYSTEM
The Flare system consists of:
One Wet Flare (common for wet and cold/dry reliefs)
One Spare Storage Wet Flare (common for wet and cold/dry reliefs)
One Acid Gas Flare (part of stack to be common with wet flare)
Two LP Cryogenic Flares (A and B)
2.1 Main Wet Flare Stack Package ME-89001
The Wet Flare system handles wet vapor relief loads from safety valves and vent gases which are above
0°C at atmospheric pressure or, when the relieved flow contains significant amounts of water vapor. It
consists of a branched header discharging into the Wet Flare K.O. Drum V-89001 which is located near the
Flare Stack.
In addition to wet vapor reliefs, dry/cold reliefs from the Steam Cracker Unit, Refinery Dry Gas Treatment
Unit, NGL Treating and Fractionation Unit and Pressurized Storage for Ethylene, Propylene and NGLE C2+
will have a common Cold Flare K.O. drum (V-83012) handling vapor reliefs and (manual) liquid drain
scenarios. Any liquid in the drum will be vaporized in special type heat exchanger (Armstrong type or
equivalent) to avoid freezing of the heating fluid in such a system.
The Wet and Cold Flare headers will be combined before to route to main wet flare header/stack. In order
to combine the Wet Flare and Cold Flare into one flare header/stack, the cold flare vapors from the Cold
Flare KO drum (V-83012) is heated to a temperature well above the minimum allowable metal temperature
for Low Temperature Carbon Steel, i.e. above -45°C by means of superheater. After the temperature has
been raised the combine wet and cold reliefs header is routed to Wet Flare K.O. Drum V-89001.
Any liquid accumulated in the V-89001 is routed by the Flare Knock Out Drum Pump P-89001A/B to the
Quench Water Drain Drum V-10003. Only during shutdown of the SCU; the pumped liquid is routed to the
Waste Water Collection Tank T-85001. The pump is automatically started at high level and stopped at low
level. Both pumps are connected to the emergency power grid. The pump capacities are set to drain the
determining load of liquid hydrocarbons and water in two (2) hours.
The vapors flow through the Wet Flare Seal Drum (ME-89001-V-02) to the Wet Flare Stack (ME-89001-
SK-01). Service Water is supplied to Wet Flare Seal Drum to maintain the water seal level. In addition
Service Water flows continuously through an orifice (parallel to the level controller) into the seal drum to
ensure adequate water seal level. The continuous overflow is sent to the Oily Water Sewer (OWS). The
function of the seal drum is to prevent ingress of air into flare header. Ingress of air is not allowed into the
flare header as it can result in an explosive mixture in the header.
Page 5 of 11
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description – 8900 – FLRU S-S890-5223-002 0
The inlet to the flare stack and the flare sub-headers are purged with fuel gas to ensure a positive flow from
the flare system to the flare stack. Nitrogen is used as back-up for fuel gas purge.
Vapors from Wet Flare K.O. Drum V-89001 are routed to the Flare Package ME-89001 which mainly
consists of: Wet Flare Seal Drum (ME-89001-V-02), Flare Stack (ME-89001-SK-01), Flare Tip, Flare Fuel
Gas KO Drum (ME-89001-V-01), Flare Ignition System, Molecular Seal and required instrumentation for
control and safe guarding. For details reference is made to Main Wet Flare Package (ME-89001) package
specification.
The stack is equipped with a molecular dry seal as additional protection against air ingress. The relief
gases are ignited by the pilot flames and released to atmosphere. A flame generator is installed to ignite
the pilots. The flare tip pilot temperature switches-on automatically the ignition in case of loss of flame.
Remote ignition from control room is possible in case the automatic re-ignition does not work.
Fuel gas is used as pilot gas and purge gas. Natural gas is used as back-up for fuel gas.
MP steam is routed to the Flare Tip to ensure smokeless flaring at low relief loads and to protect flare
system against flame back. The MP steam flow is controlled by a control valve proportional to the relieved
gas flow rate. To optimize the steam consumption infrared sensors are installed to sense flare
characteristic of the flame and adjust the steam flow rate automatically.
The main equipment connected directly to wet flare header are:
Refinery Dry Gas Treating Unit
st
o RDG Compressor 1 Stage Suction Drum (V-12001)
o RDG Oxygen Converter (R-12001 A/B)
o RDG Amine / Water Wash Column (C-12001)
o RDG Depropylenizer (C-12005)
NGL Treating and Fractionation Unit
o NGL Amine / Water Wash Column (C-11002)
o C3+ Stripping Hold Up Drum (V-11007)
Steam Cracker Unit
o C3+ Feed Vaporizer (E-20018 A/B)
o Quench Tower (C-21003)
st
o Charge Gas Compressor 1 Stage Suction Drum(V-22001)
rd
o Charge Gas Compressor 3 Stage Suction Drum(V-22004)
o Hydrogen Compressor (K-23001)
o Fuel Gas KO Drum (V-23005)
o Acetylene Converters (R-22001 A/B/C)
o MAPD Converters (R-24001 A/B)
o Debutanizer Reflux Drum (V-24004)
o Propylene Fractionators (C-24003-04)
o Propylene Refrigeration Compressor (K-25001)
o Binary Refrigerant Compressor (K-26001)
Selective C4 Hydrogenation Unit
st
o SHU 1 Stage Feed Drum (V-28011)
st
o SHU 1 Stage Separator Drum (V-28012)
nd
o SHU 2 Stage Separator Drum (V-28022)
Page 6 of 11
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description – 8900 – FLRU S-S890-5223-002 0
MTBE Unit and Butene-1 Unit
o Water Wash Column (C-60001)
o C4 Feed Surge Drum (V-60001)
o Secondary Reactor (R-60002)
o CD Reaction Column (C-60002)
o CD Reaction Column OVHD Drum (V-60002)
o Methanol Extraction Column (C-60003)
o Methanol Recovery Column OVHD Drum (V-60003)
o Methanol Recovery Column (C-60004)
o Methanol Drain Drum (V-60004)
o B-1 Heavies Column #1 (C-61001)
o B-1 Heavies Column Overhead Drum (V-61001)
o B-1 Lights Column #1 (C-61003)
o B-1 Lights Column Reflux Drum (V-61002)
Pyrolysis Gasoline Hydrogenation Unit
ST
o 1 Stage Feed Surge Drum (V-62001)
o 1st Stage Hydrogenation 1st Reactor (R-62001A/B)
o Cold Separator Drum (V-62003)
o Passivation Drum (V-62004)
nd
o 2 Stage Separator Drum (V-62032)
o 2nd Stage Feed Surge Drum (V-62031)
o 2nd Stage Hydrogenation Reactor (R-62031)
o Recycle Compressors K.O. Drum (V-62033)
o Recycle Compressors (K-62031 A/B)
ST
o 1 Stage Stabilizer (C-62011)
nd
o 2 Stage Stabilizer (C-62041)
o Depentanizer (C-62042)
o Depentanizer Reflux Drum (V-62042)
o Rerun Tower (C-62012)
o Deheptanizer (C-62043)
o Deheptanizer Reflux Drum (V-62043)
Pressurized storage for Mixed C4, Butene-1, Butene-2 and Hydrogenated C4.
One Hydrocarbon Drain Drum V-89002 is available to drain the liquid from the Main Wet Flare System and
Spare Storage Wet Flare System. The contents are routed to the Quench Tower Drain Drum by the
Hydrocarbon Drain Pump P-89002. Only during shutdown of the SCU; the pumped liquid is routed to the
Waste Water Collection Tank.
The main equipment connected to wet flare header via cold/dry relief header are:
Refinery Dry Gas Treating Unit
o RDG Demethanizer Reflux Drum (V-12007)
o RDG Deethanizer Reflux Drum (V-12008)
o RDG Depropylenizer Reflux Drum (V-12010)
o NGL Treating and Fractionation Unit
o NGL Deethanizer Reflux Drum (V-11002)
Steam Cracker Unit
o HP Depropanizer Reflux Drum (V-22012)
Page 7 of 11
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description – 8900 – FLRU S-S890-5223-002 0
o LP Depropanizer Reflux Drum (V-22015)
o Demethanizer (C-23001)
o Deethanizer Reflux Drum (V-23004)
o Hydrogen Offgas (ME-23000-E06)
o Methane Offgas (ME-23000-E06)
o Recycle Ethane (ME-23000-E06)
o Ethylene Product (ME-23000-E06)
o Ethylene Fractionator Reflux Drum (V-24002)
o Propylene Fractionator No. 1 and 2 Reflux Drum (V-24003)
o Debutanizer Reflux Drum (V-24004)
st
o Propylene Refrigeration System 1 Stage Suction Drum (V-25001)
o Propylene Refrigeration System 2nd Stage Suction Drum (V-25002)
rd
o Propylene Refrigeration System 3 Stage Suction Drum (V-25003)
th
o Propylene Refrigeration System 4 Stage Suction Drum (V-25004)
st
o Binary Refrigeration System1 Stage Suction Drum (V-26001)
nd
o Binary Refrigeration System 2 Stage Suction Drum (V-26002)
rd
o Binary Refrigeration System 3 Stage Suction Drum (V-26003)
Pressurized storage sphere for NGL C2+.
Pressurized storage spheres for Ethylene and Propylene.
High pressure equipment and piping of Cryogenic Ethylene and Propylene Storage
For graphical representation of the Main Wet Flare System reference is made to the Utility Process Flow
Diagram D-S890-5223-101.
2.2 Spare Storage Wet Flare ME-89003
In case the Main Wet Flare ME-89001 is taken out of operation, all storage area vents and wet reliefs are
routed to Spare Storage Wet Flare ME-89003.
From the main combined wet and cold flare header the reliefs are routed to the Spare Storage Wet Flare
K.O. Drum V-89004 which is located near the Flare Stack.
Any liquid accumulated in the V-89004 is pumped by the Spare Storage Wet Flare Knock Out Drum Pump
P 89003A/B to the liquid outlet line from the V-89001 to be routed then to the Quench Water Drain Drum V-
10003. Only during shutdown of the SCU; the pumped liquid is routed to the Waste Water Collection Tank
T-85001. The pump is automatically started at high level and stopped at low level. Both pumps are
connected to the emergency power grid. The pump capacities are set to drain the determining load of liquid
hydrocarbons and water in two (2) hours.
The vapors flow through the Wet Flare Water Seal Drum (ME-89003-V-01) to the Wet Flare Stack ME-
89003-SK-01. Service Water is supplied to Wet Flare Water Seal Drum (ME-89003-V-01) to maintain the
water seal level. In addition Service Water flows continuously through an orifice (parallel to the level
controller) into the seal drum to ensure adequate water seal level. The continuous overflow is sent to the
Oily Water Sewer (OWS). The function of the seal drum is to prevent ingress of air into flare header.
Ingress of air is not allowed into the flare header as it can result in an explosive mixture in the header.
The inlet to the flare stack and the flare sub-headers are purged with fuel gas to ensure a positive flow from
the flare system to the flare stack. Nitrogen is used as back-up for fuel gas purge.
Vapors from Spare Storage Wet Flare K.O. Drum V-89004 are routed to the Flare Package ME-89003
which consists of: Wet Flare Water Seal Drum (ME-89003-V-01), Flare Stack (ME-89003-SK-01), Flare
Tip, Molecular Seal and required instrumentation for control and safe guarding. Ignition system and fuel
gas ko drum will be common with the main wet flare system. For details reference is made to Main Wet
Flare Package (ME-89003) package specification.
Page 8 of 11
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description – 8900 – FLRU S-S890-5223-002 0
The stack is equipped with a molecular dry seal as additional protection against air ingress. The relief
gases are ignited by the pilot flames and released to atmosphere. A flare generator is installed to ignite the
pilots. Fuel gas is used as pilot gas and purge gas. Natural gas is used as back-up for fuel gas. The flare
tip pilot temperature switches-on automatically the ignition in case of loss of flame. Remote ignition from
control room is possible in case the automatic re-ignition does not work.
MP steam is routed to the Flare Tip to ensure smokeless flaring at low relief loads and to protect flare
system against flame back. The MP steam flow is controlled by a control valve proportional to the relieved
gas flow rate. To optimize the steam consumption infrared sensors are installed to sense flare
characteristic of the flame and adjust the steam flow rate automatically.
The main equipment connected to this header is:
Pressurized storage for Mixed C4, Butene-1, Butene-2, Hydrogenated C4, Pressurized storage spheres
for NGL C2+, Ethylene and Propylene including high pressure equipment and piping in Cryogenic
Ethylene and Propylene Storage area.
For graphical representation of the Spare Storage Wet Flare System reference is made to the Utility
Process Flow Diagram D-S890-5223-103.
Page 9 of 11
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description – 8900 – FLRU S-S890-5223-002 0
2.3 Acid Gas Flare
The Acid Gas Flare system handles vapor relief loads from safety valves and vent gases with H2S content
higher than 1000 ppm. It consists of a branched header discharging into the Acid Gas Flare K.O. Drum V-
89008 which is located near the Main Wet Flare Stack (ME-89001-SK-01).
Any liquid accumulated in the V-89008 is routed by the Acid Gas Flare KO Drum Pump P-89008 A/B to the
SCU Sour Gas KO Drum (V-10008). The pump is automatically started at high level and stopped at low
level. Both pumps are connected to the emergency power grid. The pump capacities are set to drain the
determining load of liquid hydrocarbons and water in two (2) hours.
Vapors from Acid Gas Flare K.O. Drum V-89001 are routed to acid gas flare riser which is connected to the
combustion zone of Wet Flare Stack (ME-89001-SK-01) upstream of wet flare molecular seal. The inlet to
the flare stack and the flare sub-headers are purged with fuel gas to ensure a positive flow from the flare
system to the flare stack. Ingress of air is not allowed into the flare header as it can result in an explosive
mixture in the header. Nitrogen is used as back-up for fuel gas purge.
The Acid Gas Flare riser is equipped with a molecular dry seal as additional protection against air ingress.
The relief gases are ignited by the wet flare pilot flames and released to atmosphere.
Fuel gas is used as pilot gas and purge gas. Natural gas is used as back-up for fuel gas.
MP steam is routed to the Flare Tip to ensure smokeless flaring at low relief loads and to protect flare
system against flame back. The MP steam flow is controlled by a control valve proportional to the relieved
gas flow rate. To optimize the steam consumption infrared sensors are installed to sense flare
characteristic of the flame and adjust the steam flow rate automatically.
The main equipment connected directly to wet flare header are:
Amine Regenerator Reflux Drum (V-11052)
Amine Regenerator (C-11051)
RDG Mixed Feed from DCU & RFCC (B/L Interconnecting)
Amine Carbon Filter (V-11051)
Amine Regenerator Reboiler A/B (E-11051A/B)
RDG Amine / Water Wash Column (C-12001)
RDG Compressor First Stage Suction Drum (V-12001)
RDG Compressor Second Stage Suction Drum (V-12002)
RDG Compressor Second Stage (K-12001-2)
RDG Compressor Second Stage Discharge Drum (V-12003)
RDG Amine Oil Degassing Drum (V-12016)
One Sour Water Collection Drum V-89003 is available to drain the liquid from the Acid Gas Flare System.
The contents are routed to the Quench Water Drain Drum (V-10003) by the Sour Water Drain Drum Pump
P-89004.
Sour Water Drain Drum V-89003 is continuously purged with fuel gas and floating on acid gas flare header
pressure.
Page 10 of 11
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description – 8900 – FLRU S-S890-5223-002 0
2.4 Cryogenic Low Pressure Flare ME-89002 A/B
Reliefs from the Cryogenic Propane / LPG, Ethylene and Propylene Storage Tanks T-81008, T-83003 and
T-83004 respectively are collected in Cryogenic LP Flare KO Drum V-83013 and routed to the Cryogenic
Low Pressure Flare ME-89002 A/B which consists of: Flare Stack (ME-89002-SK-01A/B), Flare Tip, Flare
Ignition System, and Molecular Seal and Fuel Gas KO Drum (ME-89002-V-01): One system is in operation
and one is in stand-by.
MP steam is routed to the Flare Tip to ensure smokeless flaring at low relief load and to protect flare
system against flame back.
Fuel gas is used as pilot gas and purge gas. Natural gas is used as back-up for fuel gas.
The cryogenic flare sub-headers are purged with fuel gas to ensure a positive flow from to the flare stack.
The stack is equipped with a molecular seal as additional protection against air ingress. The relief gases
are ignited by the pilot flames and released to atmosphere. A flare generator is installed to ignite the pilots.
Fuel gas is used as pilot gas and purge gas. Natural gas is used as back-up for fuel gas. The flare tip pilot
temperature switches-on automatically the ignition in case of loss of flame. Remote ignition from control
room is possible in case the automatic re-ignition does not work.
For graphical representation of the Cryogenic LP Flare reference is made to the Utility Flow Diagram D-
S890-52233-102.
Page 11 of 11
Petrochemical Plant Sohar Environmental Impact Assessment Report
Orpic and CB&I HMR #3817
Attachment 7: Process Description for Incinerators
G-S000-5240-003 HMR Consultants
June 2015 N
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
NOTES
A A
B B
HOLDS:
C C
D D
E E
F F
G G
H H
J J
K K
REFERENCE DRAWINGS
Liwa Plastics Project
ORPIC PROJECT NO:
L 0 ISSUED FOR FEED KK SNAZARI JL 09-MAR-15 L
REV DESCRIPTION DRAWN CK'D APPD CLIENT DATE
D-S860-5223-101
UTILITY PROCESS FLOW DIAGRAM
WASTE INCINERATION UNIT
VENT GAS INCINERATOR
M UNIT NAME: UNIT NO: CB&I PROJECT NO:
M
SCALE: SHEET: DWG NO: D-S860-5223-101 A1 REV: 0
A1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
NOTES
A A
B B
C C
D D
E E
F F
G G
H H
J J
K K
REFERENCE DRAWINGS
Liwa Plastics Project
ORPIC PROJECT NO:
L 0 ISSUED FOR FEED KK SNAZARI JL 09-MAR-15 L
REV DESCRIPTION DRAWN CK'D APPD CLIENT DATE
D-S860-5223-102
UTILITY PROCESS FLOW DIAGRAM
WASTE INCINERATION UNIT
LIQUID AND SOLID WASTE INCINERATOR
M UNIT NAME: UNIT NO: CB&I PROJECT NO:
M
SCALE: SHEET: DWG NO: D-S860-5223-102 A1 REV: 0
A1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Liwa Plastics Project
CB&I ORPIC
Document Title: Process Description – WIU 8600
Document No: S-S860-5223-002
CB&I Contract No: 189709
Issued for FEED 0 18-03-2015 AVY SNAZARI JL
Revision Descriptions Rev Date Originator Checker Approver
Page 1 of 6
"THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY (CB&I). IT MAY CONTAIN INFORMATION
DESCRIBING TECHNOLOGY OWNED BY CB&I AND DEEMED TO BE COMMERCIALLY SENSITIVE. IT IS TO BE USED ONLY IN
CONNECTION WITH WORK PERFORMED BY CB&I. REPRODUCTION IN WHOLE OR IN PART FOR ANY PURPOSE OTHER THAN
WORK PERFORMED BY CB&I IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN PERMISSION OF CB&I. IT IS TO BE SAFEGUARDED
AGAINST BOTH DELIBERATE AND INADVERTENT DISCLOSURE TO ANY THIRD PARTY."
Liwa Plastics Project
Document Title: Document No. Rev
Process Description –WIU 8600 S-S860-5223-002 0
INPUTS / REFERENCE DOCUMENTS
Document Number Title Status
S-S000-5222-001 Project Basis of Design - LPP Facilities
S-S000-5223-003 Process Design Basis for Off-Site Facilities
D-S860-5223-101 Utility Process Flow Diagram - Vent Gas Incinerator
D-S860-5223-102 Utility Process Flow Diagram – Liquid Waste Incinerator
D-S860-5223-103 Utility Process Flow Diagram – Solid Waste Incinerator
REVISION NOTES AND HOLDS
Revision Description of Changes & Holds
HOLDS Description of Holds Rev Date
1
2
3
4
Page 2 of 6
Liwa Plastics Project
Document Title: Document No. Rev
Process Description –WIU 8600 S-S860-5223-002 0
Table of Contents
Contents Page
1.0 INTRODUCTION..................................................................................................................................5
2.0 VENT GAS INCINERATOR .................................................................................................................5
3.0 LIQUID AND SOILD WASTE INCINERATOR ......................................................................................6
Page 3 of 6
Liwa Plastics Project
Document Title: Document No. Rev
Process Description –WIU 8600 S-S860-5223-002 0
ABBREVIATIONS
LPP Liwa Plastics Project
SCU Steam Cracker Unit
PGHYD Pygas Hydrotreater Unit
Page 4 of 6
Liwa Plastics Project
Document Title: Document No. Rev
Process Description –WIU 8600 S-S860-5223-002 0
1.0 INTRODUCTION
Waste incineration unit consists of vent gas incinerator package and combined liquid and solid incinerator
package.
Vent gases with toxic components or smelly fumes are routed to the Vent Gas Incinerator.
One Waste Incinerator is foreseen to receive liquid and solids streams.
The possibility to combine these two incinerators shall be investigated by the vendor during EPC phase.
Reference for this process description is:
Utility Flow Diagram for Vent Gas incineration (Unit 8600) doc. no. D-S860-5223-101.
Utility Flow Diagram for Liquid-Solid Waste incineration (Unit 8600) doc. no. D-S860-5223-102.
2.0 VENT GAS INCINERATOR
The vent gases of the following storage tanks have to be routed to a Vent Gas Incinerator as these contain
nitrogen with toxic components or smelly fumes:
Raw Pyrolysis Gasoline Storage Tank
C6 – C7 Cut Storage Tank
The vapor flows from the storage tanks are the result of pumping in and thermal out breathing during the
day. Pyrolysis Gasoline Vent Gas Blowers (K-83005A/B) are installed to transfer the vent gases from the
storage tanks to the Vent Gas Incinerator package.
A second stream to be processed is originating from the Waste Water Treatment Unit. Vapors formed
during the thermal out breathing and pumping in are routed to the Vent Gas Incinerator via Vent Gas
Blower (K-85001 A/B). This line is usually active and can contain hydrocarbons in traces.
Benzene / MTBE Contaminated Waste Water Collection Tank
Waste Water Collection Tank
Skimmed Oil Vessel
Oily Sludge Storage Tank
Spent Caustic Storage Tank
Spent Caustic Oxidation Effluent Tank
The third stream to be processed is the spent air stream from the Spent Caustic Oxidation Unit. This air
stream has a continuous flow rate and contains traces of hydrocarbons.
The fourth stream to be processed is the vent gas from Rerun Tower Vacuum Package (J-62011) in Pygas
Hydrotreater Unit, when it is not routed to the Cracking Heaters, containing air with hydrocarbons.
During shut down of the SCU, the PGHYD waste gas flow and the Spent Oxidation Unit 8100 waste gas
flow becomes zero, whereas the vapor flow from other sources continues.
This package is an incinerator specially designed for high hydrocarbon conversion efficiency.
Flame Arrestors ME-86001-A01A/B and ME-86001-A02A/B (part of ME-86001) are required to prevent fire
in case of back flow from the incinerators into the vent gas line.
In case the Vent Gas Incinerator ME-86001-F-01 is not available and during the start-up of the blowers, the
vent gases are routed to the atmosphere at safe location via Vent Gas Stack (ME-86001-SK-01).
The flue gas is routed via a stack to the atmosphere. The incinerator is fired by means of fuel gas with
Natural Gas as back-up.
Page 5 of 6
Liwa Plastics Project
Document Title: Document No. Rev
Process Description –WIU 8600 S-S860-5223-002 0
3.0 LIQUID AND SOILD WASTE INCINERATOR
The liquid and solid waste streams from the process and utilities units are collected in Waste Liquid Hold-
up Drum V-86001.
V-86001 is provided with low pressure steam coils in order to keep the fluid at the right temperature to
allow pumping to the incinerator. The vessel is purged with nitrogen to remove any hydrocarbon vapors to
the Wet Flare.
All streams are considered intermittent. Part of the liquid streams is transported by tank car or drums and
partly by pipeline.
The solid waste is transported by means of trucks or by conveyor and is dumped in a Waste Feed Hopper
part of Waste Liquid Hold-up Drum V-86001. A feeder charges the solids into the drum.
The Waste Liquid Hold-up Drum V-86001 has a buffering and homogenization function for the feed stream
to the waste incinerator.
To prevent suspend solids settle down, the vessel content is continuously recirculating by P-86001A/B and
mixed by internal mixer(s) inside of V-86001.
Level controller on the Waste Liquid Hold-UP Drum V-86001 manipulates the Waste Liquid Feed Pump P-
86001A/B, in order to adjust the flow to the combined Solid and Liquid Waste Incinerator package.
One connection to the tank car is available in case that the incinerator package is not available.
This incinerator is fired with fuel gas with Natural Gas as back-up. The following main liquid and solid
waste streams will be handled:
Skimmed Oil from Skimmed Oil Pump P-85010 (Skimmed Oil Vessel V-85001 in WWTU)
Waste Liquid from ME-86001-P-01 (Vent Gas KO Drum part of Vent Gas Incinerator Package)
Dewatered Bio Sludge from ME-85007 (by conveyor from WWTU)
Dewatered Oily Sludge from ME-85007 (by conveyor from WWTU)
Liquid waste (in barrel or by truck) from polymer plants
Skimmed oil from Amine Unit hydrocarbon drain pump (P-11054)
Hydrocarbon/water mixtures from drain vessels by tank car
Hydrocarbon/water mixtures or Maintenance Waste Oils from drums
Tar from quench water system
The solids are converted into flue gas and solid effluent. This effluent has to be transported to a landfill.
The fly ash shall be removed from the flue gas and shall be stored in silos.
Page 6 of 6
Petrochemical Plant Sohar Environmental Impact Assessment Report
Orpic and CB&I HMR #3817
Attachment 8: Process Description – Potable & Service Water Unit
G-S000-5240-003 HMR Consultants
June 2015 O
Liwa Plastics Project
CB&I ORPIC
Document Title: Process Description – PSWU 7340
Document No: S-S734-5223-002
CB&I Contract No: 189709
Issued for FEED 0 12-Mar-2015 VNAPOLI SNAZARI JL
Revision Descriptions Rev Date Originator Checker Approver
Page 1 of 6
"THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY (CB&I). IT MAY CONTAIN INFORMATION
DESCRIBING TECHNOLOGY OWNED BY CB&I AND DEEMED TO BE COMMERCIALLY SENSITIVE. IT IS TO BE USED ONLY IN
CONNECTION WITH WORK PERFORMED BY CB&I. REPRODUCTION IN WHOLE OR IN PART FOR ANY PURPOSE OTHER THAN
WORK PERFORMED BY CB&I IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN PERMISSION OF CB&I. IT IS TO BE SAFEGUARDED
AGAINST BOTH DELIBERATE AND INADVERTENT DISCLOSURE TO ANY THIRD PARTY."
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description – SWDU 7340 S-S734-5223-002 0
INPUTS / REFERENCE DOCUMENTS
Document Number Title Status
S-S000-5222-001 Project Basis of Design - LPP Facilities
S-S000-5223-002 Process Design Basis for Utilities
D-S734-5223-101 Utility Process Flow Diagrams - 7340 - Potable and Service
Water System
D-S720-5223-101 Utility Process Flow Diagram - 7200 - Sea Water Intake
Station
REVISION NOTES AND HOLDS
Revision Description of Changes & Holds
HOLDS Description of Holds Rev Date
1 Holds are identified in the document and summarized here.
Page 2 of 6
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description – SWDU 7340 S-S734-5223-002 0
Table of Contents
Contents Page
1.0 INTRODUCTION ................................................................................................................................. 5
2.0 SERVICE WATER SYSTEM................................................................................................................ 5
3.0 SERVICE WATER DISTRIBUTION ..................................................................................................... 5
4.0 POTABLE WATER SYSTEM .............................................................................................................. 5
5.0 POTABLE WATER DISTRIBUTION.................................................................................................... 6
Page 3 of 6
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description – SWDU 7340 S-S734-5223-002 0
ABBREVIATIONS
BUT-1 Butene-1 Recovery Unit
LPP Liwa Plastics Project
MTBE Methyl Tertiary Butyl Ether
NGLT NGL Treating & Fractionation Unit
PE Polyethylene Unit
PP Polypropylene Unit
PGHYD Pyrolysis Gasoline Hydrotreater Unit
RDG Refinery Dry Gas Treating Unit
SCU Steam Cracker Unit
SLC4HY Selective C4 Hydrogenation Unit
Page 4 of 6
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description – SWDU 7340 S-S734-5223-002 0
1.0 INTRODUCTION
The objective of Potable and Service Water System is to generate Service Water and Potable Water from
Desalinated Water and distribute to the end users. Service water is to be sent to all process units for LPP
project including PE and PP plant however potable water is only for internal use (PP / PE plant potable
water is to be provided by OTHERS).
For the process description of this system, reference is made to the following Utility Process Flow
Diagrams (UFD’s):
D-S734-5223-101: Potable and Service Water System (Unit 7340)
2.0 SERVICE WATER SYSTEM
Desalinated water from Sea Water Desalination Package (MED) (ME-73201) is stored in Desalinated
Water Tank (T-73401A/B) and used as service water after chemical conditioning. Desalinated water from
T-73401A/B is sent to the utilities stations, buildings and for irrigation via the Service Water Pump (P-
73401A/B/C).
Since Desalinated water, due to nature is corrosive, before distributing to the service water end users
some chemicals like Salt Solution (via Salt Solution Package, ME-73402) and a Blended Corrosion
Inhibitor and Antiscalant (via PC-900 Injection Package, ME-73405) and Hypochlorite (via Hypochlorite
Injection Package, ME-73401) have to be injected to prevent corrosion in service water downstream
equipment and pipes.
3.0 SERVICE WATER DISTRIBUTION
The service water is distributed to the following end users.
Unit Name Unit Number Service
7000 – 7800
Utilities and Off-sites Service Water
8400 - 9100
Storage 8100 - 8300 Service Water
NGLT 1100 Service Water
RDG 1200 Service Water
SCU 2000 – 2600 Service Water
SLC4HY 2800 Service Water
MTBE 6000 Service Water
BUT-1 6100 Service Water
PGHYD 6200 Service Water
PE/PP - Service Water
Power Plant - Service Water
4.0 POTABLE WATER SYSTEM
A part of Desalinated water is fed into the Potable Water Tank (T-73402) after salt addition via Sodium
Carbonate Injection Package (ME-73404), Calcium Chloride Injection Package (ME-73403) and
Page 5 of 6
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description – SWDU 7340 S-S734-5223-002 0
chlorination via Hypochlorite Injection Package (ME-73401). The potable water tank is an atmospheric tank
and sized for a residence time of 3 days based on normal potable water demand.
The potable Water tank (T-73402) represents a break between the desalinated water and the potable
water distribution system.
The chemical solutions are injected into the desalinated water upstream of potable water tank by the
reciprocating pump. The chemical injection rate is controlled by pump stroke to meet WHO potable water
quality specification.
Concentration of residual chlorine in potable water shall be kept at 0.2 – 0.5 mg/l. The concentration of
Chlorine is analyzed at the tank inlet / outlet.
To prevent stagnant point, potable water shall be circulated.
The chemically conditioned potable water is to pass through UV Filter (S-73401) and needs to be chilled by
0
Chilling Package (ME-73406) to 25 C before sending to end users.
5.0 POTABLE WATER DISTRIBUTION
The Potable water is used for safety showers, eye washer, etc. and is distributed to the following end
users.
Unit Name Unit Number Service
7000 – 7800
Utilities and Off-sites Potable Water
8400 - 9100
Storage 8100 - 8300 Potable Water
NGLT 1100 Potable Water
RDG 1200 Potable Water
SCU 2000 – 2600 Potable Water
SLC4HY 2800 Potable Water
MTBE 6000 Potable Water
BUT-1 6100 Potable Water
PGHYD 6200 Potable Water
Page 6 of 6
Petrochemical Plant Sohar Environmental Impact Assessment Report
Orpic and CB&I HMR #3817
Attachment 9: Process description for Seawater Desalination System
G-S000-5240-003 HMR Consultants
June 2015 P
Liwa Plastics Project
CB&I ORPIC
Document Title: Process Description – SWDU 7320
Document No: S-S732-5223-002
CB&I Contract No: 189709
Issued for FEED 0 12-Mar-2015 VNAPOLI SNAZARI JL
Revision Descriptions Rev Date Originator Checker Approver
Page 1 of 5
"THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY (CB&I). IT MAY CONTAIN INFORMATION
DESCRIBING TECHNOLOGY OWNED BY CB&I AND DEEMED TO BE COMMERCIALLY SENSITIVE. IT IS TO BE USED ONLY IN
CONNECTION WITH WORK PERFORMED BY CB&I. REPRODUCTION IN WHOLE OR IN PART FOR ANY PURPOSE OTHER THAN
WORK PERFORMED BY CB&I IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN PERMISSION OF CB&I. IT IS TO BE SAFEGUARDED
AGAINST BOTH DELIBERATE AND INADVERTENT DISCLOSURE TO ANY THIRD PARTY."
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description – SWDU 7320 S-S732-5223-002 0
INPUTS / REFERENCE DOCUMENTS
Document Number Title Status
S-S000-5222-001 Project Basis of Design - LPP Facilities
S-S000-5223-002 Process Design Basis for Utilities
S-S720-5223-002 Process Description - SWIU 7200
D-S732-5223-101 Utility Process Flow Diagram - 7320 - Desalination and
Demin Water Package
D-S720-5223-101 Utility Process Flow Diagram - 7200 - Sea Water Intake
Station
D-S734-5223-101 Utility Process Flow Diagram - 7340 - Potable and Service
Water System
REVISION NOTES AND HOLDS
Revision Description of Changes & Holds
HOLDS Description of Holds Rev Date
1 Utilizing EDI reject stream as service water.
Page 2 of 5
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description – SWDU 7320 S-S732-5223-002 0
Table of Contents
Contents Page
1.0 INTRODUCTION..................................................................................................................................5
2.0 SEA WATER DESALINATION PACKAGE (MED) ...............................................................................5
3.0 DEMIN WATER PACKAGE (EDI)........................................................................................................5
4.0 DESALINATED WATER DISTRIBUTION ............................................................................................5
Page 3 of 5
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description – SWDU 7320 S-S732-5223-002 0
ABBREVIATIONS
EDI Electro De-Ionization
LPP Liwa Plastics Project
LLS Low Low Pressure Steam
MED Multi Effect Distillation
Page 4 of 5
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description – SWDU 7320 S-S732-5223-002 0
1.0 INTRODUCTION
The objective of Sea Water Desalination System is to generate Desalinated Water from sea water by a
proven technique which is called Multi Effect Distillation (MED). Desalinated Water is fed to other water
systems which will produce Demineralized Water, Service Water and Potable Water.
For the process description of this system, reference is made to the following Utility Process Flow
Diagrams (UFD’s):
D-S732-5223-101: Desalination and Demin Water Package (Unit 7320)
2.0 SEA WATER DESALINATION PACKAGE (MED)
The Sea Water Desalination Package (MED) (ME-73201) is based on Multi Effect Distillation technology
which produces Desalinated Water from sea water. It is consisting of three identical trains (two operating,
one on stand-by) in which Low Low Pressure Steam is used to evaporate sea water in multi effects.
Sea water is provided by means of Sea Water Pump (P-72001 A/B/C/D/E/F) and filtered to remove
undesirable particles before feeding into the desalination process. Part of sea water flows through tube
bundles of MED as cooling media. Preheated sea water is routed to evaporation effects. Remaining sea
water is mixed with hot brine and returned back to the sea. LLS Steam flows through a tube bundle in the
first effect to evaporate sea water in the effect chamber. The evaporated water from each effect is
condensed in the downstream effect through a tube bundle to evaporate saline water in the effect
chamber. Total condensed water from all effects is collected in the last chamber called condenser where
non-condensable gases are removed by means of an ejector. Desalinated Water is pumped as product to
Desalinated Water Tank (T-73401 A/B) and Potable Water Tank (T-73402).
Total sea water return and brine reject are discharged in one common header to the Sea Water Outfall
Channel (Z-72002).
The above described package set-up has to be confirmed during the EPC phase based on selected vendor
input.
3.0 DEMIN WATER PACKAGE (EDI)
Part of the stored Desalinated Water is pumped from the Desalinated Water Tank (T-73401 A/B) to the
Demin Water Package (ME-73202) to produce Demin Water.
The Demin Water package consists of two Electro De-Ionization (EDI) trains (one operating, one on stand-
by) to remove undesirable ions and components by ion exchange from the feed desalinated water. Demin
Water is produced with the required specification. The concentrated waste stream (reject water) is
discharged into the sea (HOLD 1) via a concrete Sea Water Outfall Channel (Z-72002). The produced
Demin Water is sent to the Demin Water Tank (T-74102 A/B), which are designated to Unit 7410.
4.0 DESALINATED WATER DISTRIBUTION
The Desalinated Water is used for producing Demin Water (as described above) and for producing Potable
and Service Water in Unit 7340. It is also used a back-up for make-up of Secondary Cooling Water
System.
Page 5 of 5
Petrochemical Plant Sohar Environmental Impact Assessment Report
Orpic and CB&I HMR #3817
Attachment 10: Process description for Fuel Gas and Natural Gas System
G-S000-5240-003 HMR Consultants
June 2015 Q
Liwa Plastics Project
CB&I ORPIC
Document Title: Process Description – 7500 FNGSU
Document No: S-S750-5223-002
CB&I Contract No: 189709
Issued for FEED 0 18-03-2015 AVY SNAZARI JL
Revision Descriptions Rev Date Originator Checker Approver
Page 1 of 6
"THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY (CB&I). IT MAY CONTAIN INFORMATION
DESCRIBING TECHNOLOGY OWNED BY CB&I AND DEEMED TO BE COMMERCIALLY SENSITIVE. IT IS TO BE USED ONLY IN
CONNECTION WITH WORK PERFORMED BY CB&I. REPRODUCTION IN WHOLE OR IN PART FOR ANY PURPOSE OTHER THAN
WORK PERFORMED BY CB&I IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN PERMISSION OF CB&I. IT IS TO BE SAFEGUARDED
AGAINST BOTH DELIBERATE AND INADVERTENT DISCLOSURE TO ANY THIRD PARTY."
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description – 7500 – FNGSU S-S750-5223-002 0
INPUTS / REFERENCE DOCUMENTS
Document Number Title Status
S-S000-5222-001 Project Basis of Design - LPP Facilities
S-S000-5223-002 Process Design Basis for Utilities
D-S750-5223-101 Utility Process Flow Diagram Fuel Gas System-7500
REVISION NOTES AND HOLDS
Revision Description of Changes & Holds
HOLDS Description of Holds Rev Date
1
2
3
4
Page 2 of 6
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description – 7500 – FNGSU S-S750-5223-002 0
Table of Contents
Contents Page
1.0 INTRODUCTION..................................................................................................................................5
2.0 FG COLLECTION ................................................................................................................................5
3.0 HP NG INTAKE AND DISTRIBUTION .................................................................................................5
4.0 FG DISTRIBUTION..............................................................................................................................6
Page 3 of 6
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description – 7500 – FNGSU S-S750-5223-002 0
ABBREVIATION
HP High Pressure
FG Fuel Gas
LP Low pressure
LPP Liwa Plastic Project
NG Natural Gas
SCU Steam Cracker Unit
Page 4 of 6
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description – 7500 – FNGSU S-S750-5223-002 0
1.0 INTRODUCTION
The Fuel Gas (FG) and Natural Gas (NG) system for the LPP project is a common distribution system
inside the LPP Complex including PP and PE units. The fuel gas distribution system receives off-gas from
the Steam Cracker Unit and provides fuel gas for the consumers. Due to the fact that the amount of fuel
gas production from SCU Unit is not sufficient for the operation of the LPP Units there is a need for
additional Natural Gas supplied from the existing NG intake station.
The produced off-gas will be routed to a Fuel Gas K.O. Drum (V-75001) operating at 4.0 bar (g) where fuel
gas is distributed to the consumers.
In case of fuel gas shortage, high pressure Natural Gas at 31 bar (g) is routed to the Cracking Heaters.
The SCU has its own independent fuel gas k.o drum and pressure let down system.
Reference for this process description is Utility Process Flow Diagram for Fuel Gas And Natural Gas
Supply Unit 7500, Doc. No. D-S750-5223-101.
2.0 FG COLLECTION
Off gases produced in the new process units are collected in one common header from the SCU. The
following streams are the main off gas producers:
Regeneration Offgas from Refinery Dry Gas Treating Unit.
Fuel gas from PSA Unit in Steam Cracker Unit.
The off gas stream is divided, one branch serves the Cracking Heaters and the rest is routed to the OSBL
fuel gas system.
The fuel gas stream containing mainly methane, minorities of heavier hydrocarbons and some inerts at
about 4.0 barg is mixed with the Natural Gas stream from Oman Gas Company (OGC). The Static Mixer
(M-75001) assures the continuous mixing of both gases. The fuel gas is further directed to the Fuel Gas
K.O. Drum (V-75001) which provides liquid droplet separation, if present.
3.0 HP NG INTAKE AND DISTRIBUTION
NG is used to compensate FG requirements in the LPP Complex. A tie-in point downstream of the existing
gas intake station is made to supply HP NG from Oman Gas Company (OGC) for the LPP Complex. It has
been assumed that the NG is clean and no filter is required.
Part of HP NG is sent to power plant and PP/PE plant. HP NG flows to PP/PE plant pass through a
dedicated pressure control valve reducing the pressure from 31 bar (g) to 4 bar (g).
The rest of HP NG is heated up in Natural Gas Receiving Heater (E-75001 A/B) prior to the pressure
reduction to avoid hydrate and liquid droplets and mist formation. E-75001 A is steam heater and will be
used during normal operation. E-75001 B is electric heater and is to be used during initial start-up when
steam is not available.
Part of the heated up HP NG is routed to SRIP and SCU. The SRIP demand is continuous and to
compensate the DCU off gas which is sent to RDG unit. The SCU demand is not continuous and limited to
the operation case in which the internal fuel gas production in SCU is lower than the main cracker heaters
demand. Additionally, one part of heated NG is used to back-up of flare unit and auxiliary steam boiler fuel
demand in case of lack of FG. The flare unit pressure reduction valve is located in the fuel gas area and
Page 5 of 6
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description – 7500 – FNGSU S-S750-5223-002 0
the pressure reduction valve for the auxiliary steam boilers is located in SCU area. The remaining heated
up HP NG flows through a dedicated pressure control valve to the FG distribution system.
4.0 FG DISTRIBUTION
Pressure of the Fuel Gas System is regulated by the pressure controller located on the outlet of Fuel Gas
Mixing Drum (V-75001), adjusting the intake of NG to the drum. The mixture of FG and NG from V-75001
is distributed to all process and utility consumers in the LPP Complex including PP and PE units. The main
consumers are listed below:
Pilot burners at flare tip.
Purge gas for flare sub-headers.
Auxiliary Steam Boilers, pilot and burners.
Vent Gas Incineration, pilot and burners.
Liquid- Solid Incinerator, pilot and burners.
Blanketing gas for drain vessels.
2nd stage hydrogenation heater in Pygas hydrogenation unit.
PE/PP unit
MTBE/BUT-1 unit
For continuous measurement and monitoring of the FG mixture composition and properties two analyzers
are provided downstream of V-75001 to measure the gas mixture Wobbe Index and FG composition by GC
analyzer.
Page 6 of 6
Petrochemical Plant Sohar Environmental Impact Assessment Report
Orpic and CB&I HMR #3817
Attachment 11: Process description for Cooling Water System
G-S000-5240-003 HMR Consultants
June 2015 R
Liwa Plastics Project
CB&I ORPIC
Document Title: Process Description - SCWU 7310
Document No: S-S731-5223-002
CB&I Contract No: 189709
Issued for FEED 0 12-Mar-2015 VNAPOLI SNAZARI JL
Revision Descriptions Rev Date Originator Checker Approver
Page 1 of 6
"THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY (CB&I). IT MAY CONTAIN INFORMATION
DESCRIBING TECHNOLOGY OWNED BY CB&I AND DEEMED TO BE COMMERCIALLY SENSITIVE. IT IS TO BE USED ONLY IN
CONNECTION WITH WORK PERFORMED BY CB&I. REPRODUCTION IN WHOLE OR IN PART FOR ANY PURPOSE OTHER THAN
WORK PERFORMED BY CB&I IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN PERMISSION OF CB&I. IT IS TO BE SAFEGUARDED
AGAINST BOTH DELIBERATE AND INADVERTENT DISCLOSURE TO ANY THIRD PARTY."
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description-SCWU 7310 S-S731-5223-002 0
INPUTS / REFERENCE DOCUMENTS
Document Number Title Status
S-S000-5222-001 Project Basis of Design - LPP Facilities
S-S000-5223-002 Process Design Basis for Utilities
S-S720-5223-002 Process Description - SWIU 7200
D-S720-5223-101 Utility Process Flow Diagram - 7200 - Sea Water Intake
Station
D-S731-5223-101 Utility Process Flow Diagram - 7310 - Secondary Cooling
Water Unit
D-S731-5223-102 Utility Process Flow Diagram - 7310 - Secondary Cooling
Water Storage Tank
D-S731-5223-103 Utility Process Flow Diagram - 7310 - Secondary Cooling
Water Chemical Dosing
REVISION NOTES AND HOLDS
Revision Description of Changes & Holds
HOLDS Description of Holds Rev Date
1 Number of plate and frame heat exchangers
2 Number of drain pits and pumps.
Page 2 of 6
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description-SCWU 7310 S-S731-5223-002 0
Table of Contents
Contents Page
1.0 INTRODUCTION..................................................................................................................................5
2.0 PROCESS DESCRIPTION...................................................................................................................5
Page 3 of 6
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description-SCWU 7310 S-S731-5223-002 0
ABBREVIATIONS
BUT-1 Butene-1 Recovery Unit
CW Cooling Water
MTBE Methyl Tertiary Butyl Ether
NGLE NGL Extraction Unit
NGLT NGL Treating & Fractionation Unit
ORPIC Oman Refineries and Petrochemical Company
PE Polyethylene Unit
PP Polypropylene Unit
PGHYD Pyrolysis Gasoline Hydrotreater Unit
RDG Refinery Dry Gas Treating Unit
SCC Steam Cracker Complex
SCU Steam Cracker Unit
SCW Secondary Cooling Water
SLC4HY Selective C4 Hydrogenation Unit
WWTP Waste Water Treatment Plant
Page 4 of 6
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description-SCWU 7310 S-S731-5223-002 0
1.0 INTRODUCTION
The Secondary Cooling Water Unit (SCWU) is a closed pump around system. The SCWU supplies cooling
water to all process units of LPP project except PE and PP plant, utilities systems and storage. The system
consists of an expansion drum, circulating pumps, plate and frame coolers, cooling water drain pit(s) and
drain pit pump(s), one storage tank and associated filling pump and chemical dosing package foreseen for
emptying and filling the system.
Reference for this process description is:
Utility Process Flow Diagram for Secondary Cooling Water for Olefins (Unit 7310), document no.
D-S731-5223-101 to D-S731-5223-103.
2.0 PROCESS DESCRIPTION
The Secondary Cooling Water System for Olefins Complex supplies Cooling Water for the following units:
U-1100 NGLT.
U-1200 RDG.
U-2000 to 2600 SCU.
U-2800 SLC4HY.
U-6000-6100 MTBE+BUT-1.
U-6200 PGHYD.
Utilities.
Storage.
Power Plant.
The SCW is supplied to the users via two supply headers at a temperature of 37°C, and returned at 46°C.
The SCW is routed to the users via the SCW Pump (P-73101 A/B/C/D/E) passing first through SCW Cooler
(E-73101) and is then returned to the pump suction.
Four pumps (two steam driven and two electrical driven) are normally running and one (electrical driven) is
on stand-by. All electrical driven pumps have dual power supply.
The cooling water flow is controlled by adjusting the throttle valve downstream each user.
A SCW Expansion Drum (V-73101) is provided in order to handle the expansion of the water in the system
during normal operation and after filling. In case the level in the expansion drum decreases below the
normal liquid level, Cold Condensate/demin water is fed into the V-73101. Desalinated Water can be also
used alternatively for make-up.
In case the level in the V-73101 increases, an ON/OFF valve will open to transfer liquid to the SCW
Storage Tank T-73101.
At regular time intervals a sample has to be taken from recirculating water. The quality of the water is
measured in the laboratory. Depending on the result required chemicals can be injected into the system via
ME-73101 (biocide) and ME-73102 (antiscalant/corrosion inhibitor) or can be added manually.
The SCW Expansion Drum (V-73101) is nitrogen blanketed for two purposes:
Preventing air ingress into the system.
Page 5 of 6
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description-SCWU 7310 S-S731-5223-002 0
Pressurizing the system as to maintain positive pressure all over the system.
The V-73101 will be located above the highest consumer to maintain the static pressure even in case of
loss of nitrogen.
The cooling water returned from the users is cooled down against sea water in plate and frame heat
exchangers (E-73101). In total, 28 plate and frame heat exchangers are expected, 27 in operation and one
is available for cleaning (HOLD 1).
In case of inspection or maintenance, the Secondary Cooling Water System can be drained into pits from
where it is pumped to the T-73101 (the number of pits and drain pumps will be defined based on the final
plant lay-out by detail engineering contractor). After inspection or maintenance the content can be pumped
back into the system via the Secondary Cooling Water Filling Pump, P-73103. In this way loss of water is
minimized.
In case of tube rupture the vapors are released to the flare via the vent line on the top of the V-73101.
In case of a small tube leakage in an exchanger, the cooling water system can be kept in operation and
hydrocarbons can be drained periodically by means of the skimming connection on the expansion vessel.
In case the leak is more severe or cannot be skimmed off easily, the contents of the closed loop cooling
water system can be routed to the SCW Storage Tank T-73101, and then routed to the Waste Water
Treatment unit. TOC analyzers are installed in return line from each area and in the common return line to
the circulation pumps, to monitor the hydrocarbons content in the system. Recirculating water conductivity
is monitored too.
The SCW Storage Tank T-73101 is provided with a blanketing system to prevent ingress of air, which
affects the water quality.
Page 6 of 6
Petrochemical Plant Sohar Environmental Impact Assessment Report
Orpic and CB&I HMR #3817
Attachment 12: Process Description for Nitrogen System
G-S000-5240-003 HMR Consultants
June 2015 S
Liwa Plastics Project
CB&I ORPIC
Document Title: Process Description – 7700 N2U
Document No: S-S770-5223-002
CB&I Contract No: 189709
Issued for FEED 0 18-03-2015 AVY SNAZARI JL
Revision Descriptions Rev Date Originator Checker Approver
Page 1 of 5
"THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY (CB&I). IT MAY CONTAIN INFORMATION
DESCRIBING TECHNOLOGY OWNED BY CB&I AND DEEMED TO BE COMMERCIALLY SENSITIVE. IT IS TO BE USED ONLY IN
CONNECTION WITH WORK PERFORMED BY CB&I. REPRODUCTION IN WHOLE OR IN PART FOR ANY PURPOSE OTHER THAN
WORK PERFORMED BY CB&I IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN PERMISSION OF CB&I. IT IS TO BE SAFEGUARDED
AGAINST BOTH DELIBERATE AND INADVERTENT DISCLOSURE TO ANY THIRD PARTY."
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description – 7700 – N2U S-S770-5223-002 0
INPUTS / REFERENCE DOCUMENTS
Document Number Title Status
S-S000-5222-001 Project Basis of Design - LPP Facilities
S-S000-5223-002 Process Design Basis for Utilities
D-S770-5223-101 Utility Process Flow Diagram Nitrogen Unit-7700
REVISION NOTES AND HOLDS
Revision Description of Changes & Holds
HOLDS Description of Holds Rev Date
1
2
3
4
Page 2 of 5
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description – 7700 – N2U S-S770-5223-002 0
Table of Contents
Contents Page
1.0 INTRODUCTION..................................................................................................................................5
2.0 PROCESS DESCRIPTION...................................................................................................................5
Page 3 of 5
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description – 7700 – N2U S-S770-5223-002 0
ABBREVIATION
LPP Liwa Plastic Project
Page 4 of 5
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description – 7700 – N2U S-S770-5223-002 0
1.0 INTRODUCTION
For operation of the new LPP of Olefins Complex, located in the Republic of Oman, inert gas (Nitrogen) is
required.
Nitrogen is continuously used for blanketing, purging, start-up, emergency shutdown, catalyst activation,
stripping and regeneration of reactors. Nitrogen is not produced inside the Complex, but it is supplied from
third party to the new Petrochemical Complex.
2.0 PROCESS DESCRIPTION
The Nitrogen stream will be supplied from OSBL by ALSIG, from Sohar Refinery network.
It is routed to the process users as well as to Storage Area, Utility Area, Off-sites and to utilities stations
from where it can be used for purging and maintenance purposes.
For peak demands (above design flow), a connection from temporary nitrogen supply is available.
Normal operating pressure for Nitrogen is 7 barg.
For graphical representation of the Nitrogen, Unit 7700, reference is made to the Utility Process Flow
Diagrams D-S770-5223-101.
Page 5 of 5
Petrochemical Plant Sohar Environmental Impact Assessment Report
Orpic and CB&I HMR #3817
Attachment 13: Process Description Steam System
G-S000-5240-003 HMR Consultants
June 2015 T
Liwa Plastics Project
CB&I ORPIC
Document Title: Process Description – STMBU 7400, CONDU 7410 /
BFWU 7420
Document No: S-S740-5223-002
CB&I Contract No: 189709
Issued for FEED 0 25-Mar-2015 EVDGR SNAZARI JL
Revision Descriptions Rev Date Originator Checker Approver
Page 1 of 17
"THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY (CB&I). IT MAY CONTAIN INFORMATION
DESCRIBING TECHNOLOGY OWNED BY CB&I AND DEEMED TO BE COMMERCIALLY SENSITIVE. IT IS TO BE USED ONLY IN
CONNECTION WITH WORK PERFORMED BY CB&I. REPRODUCTION IN WHOLE OR IN PART FOR ANY PURPOSE OTHER THAN
WORK PERFORMED BY CB&I IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN PERMISSION OF CB&I. IT IS TO BE
SAFEGUARDED AGAINST BOTH DELIBERATE AND INADVERTENT DISCLOSURE TO ANY THIRD PARTY."
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description- STMB/COND/BFW Unit 7400/7410/7420 S-S740-5223-002 0
INPUTS / REFERENCE DOCUMENTS
Document Number Title Status
S-S000-5222-001 Project Basis of Design – LPP Facilities
S-S000-5223-002 Process Design Basis for Utilities
D-S740-5223-101 Utility Process Flow Diagram - Steam Generation
D-S740-5223-102 Utility Process Flow Diagram - SHP Steam Distribution
D-S740-5223-103 Utility Process Flow Diagram - HP Steam Distribution
D-S740-5223-104 Utility Process Flow Diagram - MP Steam Distribution
D-S740-5223-105 Utility Process Flow Diagram - LP Steam Distribution Cancelled
D-S740-5223-106 Utility Process Flow Diagram - LLP Steam Distribution
D-S740-5223-107 Utility Process Flow Diagram - Letdown Stations, Sheet 1
D-S740-5223-108 Utility Process Flow Diagram - Letdown Stations, Sheet 2
D-S740-5223-109 Utility Process Flow Diagram - Blowdown Drums
D-S741-5223-101 Utility Process Flow Diagram HP/MP Condensate Collection
D-S741-5223-102 Utility Process Flow Diagram - LP Condensate Collection Cancelled
D-S741-5223-103 Utility Process Flow Diagram - LLP Condensate Collection
D-S741-5223-104 Utility Process Flow Diagram - Vacuum Condensate
Collection
D-S741-5223-105 Utility Process Flow Diagram - Condensate Collection and
Storage
D-S741-5223-106 Utility Process Flow Diagram - Condensate Treatment
D-S741-5223-107 Utility Process Flow Diagram - Sulfuric Acid and Caustic
Dosing
D-S741-5223-108 Utility Process Flow Diagram - Demin Water Collection and
Storage
D-S742-5223-101 Utility Process Flow Diagram - Deaerator
D-S742-5223-102 Utility Process Flow Diagram - BFW Chemical Injection
D-S742-5223-103 Utility Process Flow Diagram - BFW Pumps
REVISION NOTES AND HOLDS
Revision Description of Changes & Holds
HOLDS Description of Holds Rev Date
1
2
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Table of Contents
Contents Page
ABBREVIATIONS ............................................................................................................................................... 4
1.0 INTRODUCTION ....................................................................................................................................... 6
2.0 STEAM SYSTEM INCLUDING AUXILIARY BOILERS ........................................................................... 7
2.1 Auxiliary Boilers .................................................................................................................................. 7
2.2 Super High Pressure Steam ............................................................................................................... 7
2.3 High Pressure Steam .......................................................................................................................... 7
2.4 Medium Pressure Steam..................................................................................................................... 8
2.5 Low Low Pressure Steam ................................................................................................................... 9
2.6 Letdown Stations................................................................................................................................. 9
2.7 Blowdown from Auxiliary Boilers .................................................................................................... 11
3.0 STEAM CONDENSATE SYSTEM.......................................................................................................... 12
3.1 High Pressure Condensate/Medium Pressure Condensate/Low Low Pressure Condensate... 12
3.2 Condensate Collection and Storage................................................................................................ 13
3.3 Condensate Treatment ..................................................................................................................... 13
4.0 BOILER FEED WATER SYSTEM .......................................................................................................... 14
4.1 Deaerator............................................................................................................................................ 14
4.2 BFW Chemical Injection ................................................................................................................... 15
4.3 BFW Pumps ....................................................................................................................................... 16
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ABBREVIATIONS
AOC Accidentally Oil Contaminated
BB Intermittent Blowdown
BFW Boiler Feed Water
BRC Binary Refrigerant Compressor
BRCT Binary Refrigerant Compressor Turbine
CB Continuous Blowdown
CC Cold Condensate
CGC Charge Gas Compressor
CGCT Charge Gas Compressor Turbine
CW Cooling Water
DMW Demin Water
FDF Forced Draft Fan
HP BFW High Pressure Boiler Feed Water
HPC High Pressure Condensate
HS High Pressure Steam
LHC Low Pressure Hot Clean Condensate
LLC Low Low Pressure Condensate
LLOD Last Line Of Defence
LLS Low Low Pressure Steam
LNG C2+ Liquified Natural Gas, containing ethane and heavier
MP BFW Medium Pressure Boiler Feed Water
MHC Medium Pressure Hot Clean Condensate
MPS Medium Pressure Steam
MTBE Methyl Tertiary Butyl Ether (Unit)
OLNG Orpic Liquefied Natural Gas
ORPIC Orpic Refineries and Petrochemical Company
PE Polyethylene (Unit)
PGHYD Pyrolysis Gasoline Hydrotreater (Unit)
PP Polypropylene (Unit)
PRC Propylene Refrigerant Compressor
PRCT Propylene Refrigerant Compressor Turbine
PW Process Water
RDG Refinery Dry Gas Treating (Unit)
SCC Steam Cracker Complex
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SCU Steam Cracker Unit
SCW Secondary Cooling Water
SHP BFW Super High Pressure Boiler Feed Water
SHS Super High Pressure Steam
SLC4HY Selective C4 Hydrogenation Unit
TOC Total Organic Carbon
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1.0 INTRODUCTION
For the Liwa Plastics Project in Oman this document describes the process of the following units which
are part of utility systems:
Steam System including Auxiliary Boilers (Unit 7400)
Steam Condensate System (Unit 7410)
Boiler Feed Water System (Unit 7420)
For the graphical representation of the Steam System including Auxiliary Boilers (Unit 7400) reference
is made to the Utility Process Flow Diagrams D-S740-5223-101 to D-S740-5223-109.
For the graphical representation of the Steam Condensate System (Unit 7410) reference is made to the
Utility Process Flow Diagrams D-S741-5223-101 to D-S741-5223-108.
For the graphical representation of the Boiler Feed Water System (Unit 7420) reference is made to the
Utility Process Flow Diagrams D-S742-5223-101 to D-S742-5223-103.
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2.0 STEAM SYSTEM INCLUDING AUXILIARY BOILERS
2.1 Auxiliary Boilers
Auxiliary Steam Boiler Package (ME-74001) includes three (3) utility boilers each of 260 t/h steam
generation capacity. All three boilers are normally in operation at reduced capacity. Fuel gas is used for
firing of the boilers and pilot burners.
Each utility boiler has two (2) by 60 % FDF, one steam turbine driven and the other one electrical motor
driven. FDF turbines are back-pressure type with High Pressure Steam (HS) inlet from header and Low
Low Pressure Steam (LSS) exhaust to LSS header.
Auxiliary Steam Boiler Package (ME-74001) receives SHP BFW from Super High Pressure BFW Pump
(P-74201 A/B/C) and produces Super High Pressure Steam (SHS) at 121.3 barg and 522 °C. Steam
generated is sent to SHS header.
The signal from the pressure controller of the SHS header to the combustion control system of ME-
74001 is used to adjust steam production capacity.
Continuous and intermittent blowdown streams from ME-74001 are sent to Continuous Blowdown
Drum (V-74001) and Intermittent Blowdown Drum (V-74002), respectively. For more information
regarding blowdown streams see section 2.8.
In order to avoid scale formation, scale inhibitor is injected into the steam drums of ME-74001 by BFW
Chemical Injection Package (ME-74002).
2.2 Super High Pressure Steam
Super High Pressure Steam (SHS) is produced by Cracking Heaters (F-20001 through F-20006) of the
Steam Cracker Unit (SCU) and by Auxiliary Steam Boiler Package (ME-74001) at 121.3 barg and
522 °C and sent to the SHS header.
SHS is mainly used to drive Charge Gas Compressor Turbine (CGCT) (KT-22001) and Propylene
Refrigerant Compressor Turbine (PRCT) (KT-25001).
Furthermore, SHS is intermittently used for the regeneration system of SCU, SHU and RDG unit
reactors.
SHS pressure is controlled with a set of three (3) pressure controllers. In case the SHS header
pressure decreases, the Auxiliary Steam Boiler capacity is adjusted to produce more steam in order to
recover the pressure. In case the header pressure increases, the Auxiliary Steam Boiler capacity is
adjusted to produce less steam. If the header pressure continues to increase, SHS is letdown to HS via
SHP/HP Steam Desuperheater (DS-74001). If the pressure still continues to increase, SHS is vented to
atmosphere via the Super High Pressure Steam Vent Silencer (J-74001) prior to the pressure safety
valve(s) opening as a final protection of the steam system. Pressure safety valves located in the SHS
lines from Cracking Heaters and Auxiliary Steam Boilers are provided for this purpose.
A Fast Acting SHP/HP Steam Desuperheater (DS-74002) is installed in parallel to DS-74001 for quick
letdown of steam in case CGC/CGCT (K-22001/KT-22001) and/or PRC/PRCT (K-25001/KT-25001)
trips. During normal operation no steam letdown is required. However, a minimum continuous flow of
SHS is passed through DS-74001 and DS-74002 in order to keep the letdown with the desuperheater
hot and to avoid thermal shock in case large steam quantities are to be letdown and/or desuperheated.
2.3 High Pressure Steam
High Pressure Steam (HS) is produced by the following sources:
Extraction from PRCT (KT-25001).
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Letdown from DS-74001/DS-74002.
HS is mainly used to drive some steam turbines in the process units (KT-12001, KT-23001, KT-26001,
PT-21001A and PT-21004A) and some steam turbines in the utility units (PT-73101 A/B and Boiler
FDF Turbines).
HS steam is also used intermittently by Regeneration Gas Heater (E-22011), RDG Oxygen Converter
Feed Heater (E-12005).
Furthermore there is continuous HS supply to the PE and PP Unit.
HS header normal operating conditions are 42.3 barg and 385 °C. For HS header pressure control, see
section 2.6.1 of this document.
2.4 Medium Pressure Steam
The Medium Pressure Steam (MS) header is fed by the following sources:
Extraction from CGCT (KT-22001).
Exhaust from Hydrogen Compressor Turbine (KT-23001).
Letdown from DS-74003 and DS-74004.
Flash steam from blowdown and flash drums (V-20007, V-74001 and 74101).
MS is used for the following applications:
For heating, stripping and other use in process units.
Driving PW Stripper Feed Pump (P-21005A)
Driving Gasoline Fractionator Reflux Pump (P-21006A)
Driving Air Compressors (K-76001A/B)
Driving Hydrogen Lube Oil Pump
Driving CGC Lube Oil Pump
Driving CGC Hot Well Pump
Driving SHP BFW Pump (P-74201 A/B)
Driving PRC Lube Oil Pump
Driving PRC Hot Well Pump
Driving PW Stripper Bottoms Pump (P-21007A)
Driving LNG C2+ Transfer Pump (P-81001A)
Driving BRC Lube Oil Pump
Driving BRC Hot Well Oil Pump
Driving RDG Lube Oil Pump
Driving Demin Water Pump (P-74103 A)
Dilution steam back-up
Smokeless flaring
MS normal operating conditions are 21 barg and 320 °C. For MS header pressure control, see section
2.6.2 of this document.
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2.5 Low Low Pressure Steam
The Low Low Pressure Steam (LLS) header is fed by the following sources:
Exhaust from BRC Turbine (KT-26001)
Exhaust from Demin Water Pump Turbine (PT-74103A)
Exhaust from LNG C2+ Pump Turbine (PT-81001A)
Exhaust from Quench Oil Circulation Pump Turbine(PT-21001A)
Exhaust from Quench Water Circulation Pump Turbine (PT-21004A)
Exhaust from PW Stripper Feed Pump Turbine (PT-21005A)
Exhaust from Gasoline Fractionator Reflux Pump Turbine (PT-21006A)
Exhaust from PW Stripper Bottoms Pump Turbine (PT-21007A)
Exhaust from Refinery Dry Gas Feed Compressor Turbine (KT-12001)
Exhaust from Air Compressors Turbine (KT-76001A/B)
Exhaust from Lube Oil Pump Turbines of CGC, PRC, BRC, RDG and Hydrogen
Exhaust from Hot Well Pump Turbines of CGC, PRC, BRC
Exhaust of the Boiler FDF Turbines
Exhaust of the SHP BFW Pumps (P-74201A/B).
Letdown from MP/LP Steam Desuperheater (DS-74005 and DS-74009)
Flash steam from flash drum (V-74102).
LLS is used for the following applications:
For heating, stripping and other use in process units
For heating in utility and storage units
Steam tracing
Deaerator Packages (ME-74201 and ME-74203)
Excess LLS is condensed in Excess LP Steam Condenser (E-74001) to avoid too high pressure in the
LLS header.
LLS header normal operating conditions are 3.5 barg and 180 °C. For LLS header pressure control,
see section 2.6.3 of this document.
2.6 Letdown Stations
The following desuperheaters/letdown stations are installed to balance the steam system. The actual
number and the location of the desuperheaters will be defined based on plot area and steam piping
routing during Detail Engineering.
2.6.1 SHP/HP Steam Desuperheaters
HS header pressure is controlled with a set of five (5) pressure controllers. The pressure in HS header
is normally controlled by adjusting the extraction flow rate from PRCT (KT-25001).
In case the HS header pressure increases, first the HS extraction flow rate from KT-25001 is
decreased. If the header pressure continues to increase, HS is letdown to MS via HP/MP Steam
Desuperheater (DS-74003). If the pressure still continues to increase, HS is vented to atmosphere via
the HP Steam Vent Silencer for DS-74001 (J-74002) prior to pressure safety valve(s) opening as the
final protection of the steam header.
In case the HS header pressure decreases, first the HS extraction rate from K-25001 is increased. If
the header pressure continues to decrease, SHS is letdown to HS via DS-74001 to recover the
pressure. A high selector is provided to override the signal from the SHS header for this purpose.
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Trip of PRC/PRCT causes sudden decrease of the HS header pressure and consequently opening of
Fast Acting SHP/HP Steam Desuperheater (DS-74002). This results in quick pressure recovery of the
HS header by letting down the excess SHS caused by the turbine trip.
During normal operation no steam letdown is required. However, a minimum continuous flow of SHS is
passed through DS-74001 and DS-74002 in order to keep letdown/desuperheater hot and to avoid
thermal shock in case large steam quantities are to be letdown/desuperheated.
Temperature of the HS leaving the desuperheater is controlled by adjusting the flow rate of HP BFW to
the desuperheater.
2.6.2 HP/MP Steam Desuperheaters.
MS header pressure is controlled with a set of five (5) pressure controllers. The pressure in the MS
header is normally controlled by adjusting the extraction flow rate from CGCT (KT-22001).
In case the MS header pressure increases, the MS extraction flow rate from KT-22001 is decreased. If
the header pressure continues to increase then MS is letdown to LS via MP/LP Steam Desuperheater
(DS-74005). If the pressure continues to increase, MS is vented to atmosphere via the MP Steam Vent
Silencer for DS-74003 (J-74003) prior to the pressure safety valve(s) opening as the final protection of
the steam header.
In case the MS header pressure decreases, first the MS extraction flow rate from KT-22001 is
increased. If the header pressure continues to decrease, more HS is letdown to MS via DS-74004 to
recover the pressure. A high selector is provided to override the signal from the HS header for this
purpose.
Trip of any of the high power backpressure turbines or the corresponding pumps/compressors which
feed MS (e.g. KT-23001) causes sudden decrease of the header pressure and consequently opening
of Fast Acting HP/MP Steam Desuperheater (DS-74004). This results in pressure recovery of the MS
steam header by letting down the excess HS caused by the pump/compressor/turbine trip.
Trip of CGC/CGCT causes sudden decrease of the MS header pressure and consequently opening of
DS-74004 to recover the pressure. Opening of DS-74004 with constant HS demand results in a sudden
decrease of the HS header pressure and consequently opening of DS-74002. The mentioned
sequence results in pressure recovery in the MS header by letting down the excess SHS caused by trip
of CGC/CGCT.
During normal operation no steam letdown is required. However, a minimum continuous flow of HS is
passed through DS-74003 and DS-74004 in order to keep letdown/desuperheater hot and to avoid
thermal shock in case large steam quantities are to be letdown/desuperheated.
Temperature of the MS leaving the desuperheater is controlled by adjusting the flow rate of HP BFW to
the desuperheater.
2.6.3 MP/LLP Steam Desuperheater
The LLS header pressure is controlled with a set of five (5) pressure controllers. The pressure in the
LLS header is normally controlled by adjusting extraction flow rate from the BRCT (KT-26001).
In case the LLS header pressure increases, the LLS extraction flow rate from KT-26001 is decreased.
If the header pressure continues to increase then first LLS is routed to E-74001 for condensation. If the
pressure still continues to increase, LLS is vented to atmosphere via LLS Steam Vent Silencer for DS-
74005 (J-74004) prior to the pressure safety valve(s) opening as the final protection of the steam
header.
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In case the LLS header pressure decreases, first the LLS extraction flow rate from KT-26001 is
increased. If the header pressure continues to decrease, more MS is letdown to LLS via DS-74009 to
recover the pressure. A high selector is provided to override the signal from the LS header for this
purpose.
During normal operation no steam letdown is required. However, a minimum continuous flow of MS is
passed through DS-74005 and DS-74009 in order to keep letdown/desuperheater hot and to avoid
thermal shock in case large steam quantities are to be letdown/desuperheated.
Temperature of the LLS leaving the desuperheater is controlled by adjusting the flow rate of HP BFW
to the desuperheater.
2.7 Blowdown from Auxiliary Boilers
2.7.1 Continuous Blowdown Drum
Continuous Blowdown (CB) from Auxiliary Steam Boiler Package (ME-74001) is sent to Continuous
Blowdown Drum (V-74001) in which steam is flashed off to MS and blowdown condensate. V-74001 is
floating on MS header pressure.
The flashed off steam is sent to MS header. Blowdown condensate from V-74001 is sent to SCU SHP
Steam Continuous Blowdown Drum (V-20007) by means of Continuous Blowdown Pump (P-74001
A/B) on level control.
CB to V-74001 is provided for BFW quality control. The CB flow rate from ME-74001 is normally
controlled at about 2.0 % of the inlet BFW flow rate.
2.7.2 Intermittent Blowdown Drum
Intermittent Blowdown (BB) from ME-74001 is sent to Intermittent Blowdown Drum (V-74002).
In V-74002, blowdown is flashed off to LLS and blowdown condensate. V-74002 is floating on LLS
header pressure.
The flashed off steam is sent to LLS header. Blowdown liquid from V-74002 is cooled down by mixing
with service water prior to being sent to the clean drain system on level control.
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3.0 STEAM CONDENSATE SYSTEM
3.1 High Pressure Condensate/Medium Pressure Condensate/Low Low Pressure Condensate
Source of High Pressure Condensate (HPC) is the Steam Condensate which might be formed in SHS
header. Another source of HPC is the steam condensate which might be formed in the HS header or
condensate from the HS consumer heat exchangers which have process side operating pressures
lower than the steam side pressure. Therefore, no hydrocarbon or process fluid can leak into this type
of condensate.
HPC is sent to HP Condensate Flash Drum (V-74101) in which the condensate is flashed off to MS and
Medium Pressure Condensate (MHC). The HP Condensate Flash Drum is floating on the MS header
pressure. Flashed off steam is sent to the MS header. MHC flows to the MP Condensate Flash Drum
(V-74102) on level control.
MHC is the steam condensate which might be formed in the MS header or from MS consumer heat
exchangers with process side operating pressure mostly lower than the steam side pressure and
occasionally higher than the steam side pressure. Therefore, MHC is normally clean (not contaminated
with hydrocarbons). When contamination is detected, all the heat exchangers shall be inspected to find
source of the contamination.
MHC from process units is mixed with MHC from V-74101 and routed to MP Condensate Flash Drum
(V-74102). In V-74102, condensate is flashed off to LLS and Low Low Pressure Condensate (LLC). MP
Condensate Flash Drum is floating on LLS pressure. Flashed off steam is sent to LLS header.
Normally flash condensate from V-74102 is routed to LLP Condensate Flash Drum (V-74104) for
further recovery on level control. A TOC analyzer installed in the condensate line from V-74102 is used
for detection of hydrocarbon contamination and for control of the condensate routing via a selector
switch. The selector switch diverts the level control signal from V-74102 to either of the control valves
on the line to V-74104 or the line to the AOC Sewer System via the Contaminated Condensate Cooler
(E-74101) in case of condensate contamination.
Low Low Pressure Condensate (LLC) is the steam condensate which is formed in the LLS steam
header or condensate from LLS consumer heat exchangers with process side operating pressures
generally higher than the steam side pressure. Therefore, hydrocarbon contamination or process fluid
leaking into this type of condensate has to be considered.
LLC from the process units and the storage area, LLC from Excess LLP Steam Condenser (E-74001)
and condensate from MP Condensate Flash Drum (V-74102) are mixed and routed to LLP Condensate
Flash Drum (V-74104) where it is flashed off at near atmospheric pressure. Flashed condensate from
MP Condensate Flash Drum (V-74102) and LLC from DM Water/LLP Steam Exchanger (E-74107) are
not prone to be hydrocarbon contaminated.
A TOC Analyzer is installed in the condensate line to V-74104 and is used for detection of hydrocarbon
contamination and for control of the condensate routing via an automatic switch. The switch is used for
diverting of LLP Condensate to either V-74104 or the AOC Sewer System via Contaminated
Condensate Cooler E-74101.
A dedicated header for contaminated condensate from SCU unit has been foreseen to route
contaminated condensate to AOC Sewer system via E-74101.
Flashed steam in V-74104 is condensed in LLP Condensate Flash Drum Vent Condenser (E-74102)
for recovery and returned to V-74104. Cooling water (CW) is used as cooling medium in E-74102. Non-
condensable vapors from E-74102 are vented to atmosphere at safe location.
Flashed off condensate from V-74104 is pumped to Raw Condensate Collection Tank (T-74101) by
Clean Condensate Pump (P-74101A/B/C) on level control. Prior to sending condensate to T-74101, the
hot raw condensate is cooled against demin water in DM Water/Raw Condensate Exchanger (E-
74106).
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Clean Condensate Pumps are driven by electric motor which is fed by emergency power. During
normal operation, two pumps are in operation and the third one is standby.
Vacuum Condensate or Cold Condensate (CC) is the steam condensate from surface condensers for
the turbines of the CGC (KT-22001), PRC (KT-25001), BRC (KT-26001), and Secondary CW Pump (P-
73101A/B). It is directly pumped to the ion exchange mixed beds of Condensate Polishing Package
(ME-74001) by the condensate pumps provided at the outlet of each surface condenser.
CC can be contaminated if CW leaks in the surface condensers. Possible leakage of CW into CC is
indicated by detection from the conductivity analyzers installed in CC lines from each of the surface
condensers. In case of high conductivity detection the CC routing is automatically diverted to the
Desalinated Water Tank (T-73401A/B).
3.2 Condensate Collection and Storage
In order to maximize the energy recovery, hot raw condensate from LLP Condensate Flash Drum (V-
74104) heats up Demineralized Water in DM Water/Raw Condensate Exchanger (E-74106) before
entering to Raw Condensate Collection Tank (T-74101).
The tank is a fixed roof tank equipped with nitrogen blanketing system in order to avoid air ingress into
the condensate. A pressure controller is used to maintain the tank operating pressure within the
allowable range.
Raw Condensate from the tank is pumped by Raw Condensate Pump (P-74102A/B/C) and further
cooled in Raw Condensate/ Cooling Water Exchanger (E-74103) prior to being sent to Condensate
Polishing Package (ME-74101). Raw Condensate Pumps (P-74102A/B/C) are fed by emergency
power.
Upstream of ME-74101 at the discharge of E-74103 a TOC Analyzer is provided to monitor the raw
condensate contamination level continuously. Upon detection of contamination in the raw condensate
to ME-74101 the condensate can be diverted manually to LLOD via AOC Sewer System.
The raw condensate flow to ME-74101 is controlled with the flow controller located at the discharge of
P-74102A/B/C.
3.3 Condensate Treatment
Raw condensate collected in Raw Condensate Collection Tank (T-74101) is pumped to the
Condensate Polishing Package (ME-74101). The package consists of the following equipment (to be
confirmed with package vendor):
(2 + 1) x 50 % raw steam condensate pumps.
(2 + 1) x 50 % cartridge filters.
(5 + 1) x 20 % activated carbon filters.
(3 + 1) x 35 % mixed bed ion exchangers.
Condensate treatment consists of two sections; Condensate Filtration and Condensate Polishing.
The Condensate Filtration Section consists of cartridge filters and activated carbon filters. Raw
condensate is pumped to the cartridge filters followed by the activated carbon filters in order to remove
suspended solids, oil and hydrocarbons. To monitor oil removal efficiency and detect any hydrocarbon
breakthrough, a TOC analyzer is installed downstream of the activated carbon filters.
Activated carbon filters contain granular carbon with a high microscopic internal surface area (about
1000 m²/g). When hydrocarbon molecules or other chemicals enter the microscopic passages of
activated carbon, they become adsorbed by activated carbon due to formation of electrostatic forces.
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Due to accumulation of suspended solids and hydrocarbons, it is necessary to regenerate the activated
carbon filters by backwashing. Demineralized water used for backwashing is supplied by Backwash
Water Pump (P-74104A/B) which is located in the demin water unit plot area.
Filtered condensate will be sent to the Condensate Polishing section to meet demin water quality.
Deionization or demineralization of filtered condensate takes place in mixed bed resin ion exchangers.
This is essential to meet the quality requirements of BFW. Four (3+1) mixed beds are provided for this
purpose.
A mixed-bed is a demineralizer unit in which the cation and anion resin beads are mixed together. In
effect, it is equivalent to a number of two-step demineralizers in series. De-ionization or
Demineralization of condensate takes place in mixed beds by exchanging of positive charge ions of
condensate with hydrogen ions (H+) and negative charge ions with hydroxyl ions (OH-).
After all activated sites on resins are deactivated by absorbed anion and cations, mixed bed resins
shall be regenerated by washing with diluted sulfuric acid and caustic. The regeneration effluent will be
sent to Neutralization Basin (Z-74101) for neutralization.
External regeneration of mixed beds is the preferred method of regeneration because of the following
reasons:
To avoid accidental ingress of regenerant chemicals in the water and steam circuit.
To design the operating unit without internals, and with a low bed depth producing a relatively low
pressure drop, whilst the regeneration station is designed with narrower columns and a high bed
depth facilitating resin separation.
In external regeneration exhausted resin is transferred hydraulically from the operating unit to the
regeneration station and a fresh regenerated resin charge is transferred back immediately.
Treated condensate is routed to Demin Water Tank (T-74102A/B) to be used as Demineralized Water
(DMW).
Silica and carbonate content in the raw condensate dictate the quality of the polished condensate. In
order to monitor performance of the polishing section, a silica-analyzer, conductivity-analyzer and a pH-
analyzer are installed downstream of the mixed beds.
To compensate losses of BFW caused by steam stripping, blowdown and etc. an addition of demin
water is required.
Main portion of Demin Water is pumped by Demin Water Pump (P-74103A/B/C) through series of heat
exchangers (E-74106 and E-74107) prior to being sent to the Deaerator Package (ME-74201). The
demin water temperature at the outlet of E-74107 is controlled by adjusting the LLS flow rate to the
exchanger. A small portion of demin water is sent to Power Plant and to Storage area for caustic
dilution prior heating in E-74106 and E-74107.
The Polymer plant demin water demand is provided by DM Water Transfer pump (P-74107 A/B).
A portion of demin water or condensate is utilized for filter backwash and different steps of regeneration
of mixed bed ion exchangers by means of related pumps.
4.0 BOILER FEED WATER SYSTEM
4.1 Deaerator
Deaerator Package (ME-74201) consists of (1+1) x 50% deaerators which each deaerator has two
sections, a Degassing Section and a Storage Section (which provides the liquid hold up).
Deaerating is achieved in the Degassing Section of a deaerator by breaking the water into as many
small droplets as possible, and surrounding these droplets with an atmosphere of steam. This releases
the dissolved gases, which are carried with the excess steam to atmosphere. The deaerated water
then falls to the storage section of the vessel.
Page 14 of 17
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description- STMB/COND/BFW Unit 7400/7410/7420 S-S740-5223-002 0
Demineralized Water (DMW), mainly recovered condensate, is pumped by Demin Water Pump (P-
74103A/B) and heated up in a series of Heat Exchangers (E-74106, and E-74107) prior to entering the
deaerator. DMW is required for producing BFW, making up water losses caused by steam stripping,
blowdown and etc.
Water is heated up to saturation temperature in the deaerator by direct spraying of LLS to the
Degassing Section. The deaerator operates at a positive pressure of 0.4 barg, to produce water at
approximately 110°C.
In order to increase the efficiency of the deaerator and to minimize stripping LLS steam use, the inlet
temperature of DMW to the deaerator (outlet temperature of E-74107) is maintained at 104 °C which is
approximately 6° C colder than the water saturation temperature at deaerator pressure.
The level controller of the deaerator maintains normal liquid level of the vessel by adjusting the flow of
DMW. The deaerator pressure is controlled by regulating flow of LLS supply while maintaining a fixed
purge rate through a restriction orifice.
Downstream of the deaerator, a conductivity analyzer and dissolved oxygen analyzer are used in order
to measure the efficiency of the deaerator and to monitor the BFW quality. Residual oxygen content of
BFW leaving the deaerator shall be less than 20 ppb prior to chemical injection. Residual oxygen of the
treated BFW shall be less than 7 ppb.
In order to meet BFW quality specification, amine solution (neutralizing amine) and oxygen scavenger
are added to BFW. Amine solution is injected to BFW downstream of the deaerator and oxygen
scavenger is injected into the Storage Section of the deaerator.
Downstream of the amine solution injection point, a pH Analyzer is provided to monitor the
performance of the amine solution.
In order to ensure that the desired quality is achieved, regular sampling of BFW is required.
MTBE unit is required deaerated water with specific chemical conditions and temperature. To meet the
MTBE BFW demand, a dedicated BFW Transfer Deaerator Package (ME-74203) is to be installed.
Demin water is to be heated by DM water / LLP Steam Exchanger (E-74108) to 104 °C which is
approximately 6° C colder than the water saturation temperature at BFW Transfer Deaerator Package
(ME-74203) operating pressure.
The deaerated water is sent by BFW Transfer Pump (P-74204 A/B) to MTBE unit after cooling in BFW
Cooler (E-74201) against cooling water. Part of deaerated water is sent directly to MTBE unit without
cooling.
4.2 BFW Chemical Injection
In order to meet BFW quality specifications, chemicals are added to BFW at different locations. BFW
Chemical Injection Package (ME-74202) is provided for this purpose.
4.2.1 BFW Chemical Injection Package
The BFW Chemical Injection Package includes the following packages:
1. Amine Solution Injection Package
Amine solutions are high pH chemicals which neutralize carbonic acid formed in condensate (acid
attack). An amine solution cannot be used for protection against oxygen attack; however, it helps to
keep oxygen less reactive by maintaining an alkaline pH.
Amine solution is injected into the Storage Section of the deaerator by the Amine Solution Injection
Package
Page 15 of 17
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description- STMB/COND/BFW Unit 7400/7410/7420 S-S740-5223-002 0
The amine solution which is neutralizing amine shall be STEAMATE NA0880 (NALCO), GE or CH
1764D (CHIMEC) or equivalent. This has to be confirmed by chemicals supplier. The injection rate of
neutralizing amine shall be advised by chemicals supplier based on type of chemical selected.
2. Oxygen Scavenger Injection Package
Oxygen forms localized corrosion areas referred to as pits. Oxygen pits can rapidly drill through metal
surfaces, leading to metal fatigue and failure.
In order to avoid the mentioned problems, Oxygen Scavenger is injected into the Storage Section of
the deaerator by the Oxygen Scavenger Injection Package.
Oxygen Scavenger shall be CORTROL OS5300, GE or CH 4069 (CHIMEC) or equivalent. To be
confirmed by chemicals supplier. The injection rate of oxygen scavenger shall be advised by chemicals
supplier based on type of chemical selected.
3. Scale Inhibitor Injection Package
Scale is one of the most common deposit related problems in boilers. Scale is a buildup of solid
material from the reactions between the impurities in water and tube metal, on the water side of tube
surface. Scale acts as an insulation which reduces heat transfer coefficient and therefore causes
reduction in boiler efficiency and excessive fuel consumption. The other negative effects are
overheating of tubes and potential tube failure (equipment damage).
Scale inhibitor buffers the water to minimize pH fluctuation. It also precipitates calcium or magnesium
into a soft deposit rather than a hard scale. Additionally, it helps to promote the protective layer on
metal surfaces of boiler.
In order to avoid the mentioned problems, scale inhibitor is injected to the steam drums of Auxiliary
Steam Boiler Package (ME-74001) and into the SHS drums of the Cracking Heaters (F-20001 through
F-20006) by the Scale Inhibitor Package.
It is required to use phosphate-free BFW for the desuperheaters. Therefore, scale inhibitor (phosphate)
is injected directly into the steam drums of the Auxiliary Steam Boiler Package and the steam drums of
the Cracking Heaters.
Scale inhibitor shall be OPTISPERSE 2100/3100 (Phosphate type), GE or CH 3636 (CHIMEC) or
equivalent. To be confirmed by chemicals supplier. The injection rate of scale inhibitor shall be advised
by chemicals supplier based on type of chemical selected.
4.3 BFW Pumps
4.3.1 SHP BFW Pumps
Three (3) Super High Pressure BFW Pumps (P-74201A/B/C), two (2) driven by steam turbine and one
(1) driven by electric motor, are provided to send the treated BFW from the deaerator to SHP Steam
Drums (V-20001 through V-20006), SHP Steam Desuperheaters (DS-20001 through DS-20006),
Steam drums of Auxiliary Steam Boiler Package (ME-74001). Each Super High Pressure BFW Pump is
sized for 50 % of total SHP BFW demand.
Super High Pressure BFW Pump Turbines (PT-74201A/B) are back pressure type, utilizing MS which
is expanded to LLS across the turbine. The steam leaving the turbine is sent to the LLS header.
During normal operation, pumps P-74201A/B are in operation and P-74201C is on standby. During
start-up, it is necessary to use pumps P-74201C until the steam system is operational and steam is
produced.
Page 16 of 17
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description- STMB/COND/BFW Unit 7400/7410/7420 S-S740-5223-002 0
4.3.2 HP BFW Pumps
Two (2) High Pressure BFW Pumps (P-74202A/B), both driven by electric motor, are provided to send
the treated BFW from the deaerator to the following users:
Desuperheaters DS-74001 to DS-74005 and DS-74009
Desuperheaters in SCU, ARU and PYGAS Unit
Charge Gas Compressor K-22001 for injection
Each High Pressure BFW pump is sized for 100 % of total HP BFW demand and feb by emergency
power system.
During normal operation, pump P-74202A is in operation and P-74202B is on standby.
Page 17 of 17
Petrochemical Plant Sohar Environmental Impact Assessment Report
Orpic and CB&I HMR #3817
Attachment 14: Process description for Instrument and Plant Air system
G-S000-5240-003 HMR Consultants
June 2015 U
Liwa Plastics Project
CB&I ORPIC
Document Title: Process Description – 7600 IPAU
Document No: S-S760-5223-002
CB&I Contract No: 189709
Issued for FEED 0 18-03-2015 AVY SNAZARI JL
Revision Descriptions Rev Date Originator Checker Approver
Page 1 of 7
"THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY (CB&I). IT MAY CONTAIN INFORMATION
DESCRIBING TECHNOLOGY OWNED BY CB&I AND DEEMED TO BE COMMERCIALLY SENSITIVE. IT IS TO BE USED ONLY IN
CONNECTION WITH WORK PERFORMED BY CB&I. REPRODUCTION IN WHOLE OR IN PART FOR ANY PURPOSE OTHER THAN
WORK PERFORMED BY CB&I IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN PERMISSION OF CB&I. IT IS TO BE SAFEGUARDED
AGAINST BOTH DELIBERATE AND INADVERTENT DISCLOSURE TO ANY THIRD PARTY."
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description – 7600 – IPAU S-S760-5223-002 0
INPUTS / REFERENCE DOCUMENTS
Document Number Title Status
S-S000-5222-001 Project Basis of Design - LPP Facilities
S-S000-5223-002 Process Design Basis for Utilities
D-S760-5223-101 Utility Process Flow Diagram Instrument Air and Plant Air -
7600
REVISION NOTES AND HOLDS
Revision Description of Changes & Holds
HOLDS Description of Holds Rev Date
1
2
3
4
Page 2 of 7
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description – 7600 – IPAU S-S760-5223-002 0
Table of Contents
Contents Page
1.0 INTRODUCTION..................................................................................................................................5
2.0 PROCESS DESCRIPTION...................................................................................................................5
2.1 Instrument and Plant Air Generation.......................................................................................5
2.2 Other intermittent regeneration processes.............................................................................6
2.3 Decoking Air Generation..........................................................................................................7
Page 3 of 7
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description – 7600 – IPAU S-S760-5223-002 0
ABBREVIATION
PGHYD Pyrolysis Gasoline Hydrogenation Unit
SLC4HY Selective C4 Hydrogenation Unit
TLE Transfer Line Exchanger
Page 4 of 7
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description – 7600 – IPAU S-S760-5223-002 0
1.0 INTRODUCTION
For operation of the new LPP of Petrochemical Complex, located in Sohar refinery, the Sultanate of Oman,
compressed air is required.
Compressed Air is used for three main functions: serving as Instrument Air, serving as Plant Air which can
be also used as a utility stream for maintenance or purging purposes of the Units and as Decoking Air.
Instrument Air is used for pneumatic-operated instrumentation such as control valves, on/off valves, for
purging / cooling of essential instruments such as burner flame scanners and for pilot burner flame front
generation of the flare(s).
Plant air is used for maintenance activities, as purge and as tool air for industrial users. Plant Air is also
used as a peak demand for catalyst regeneration.
Decoking Air is used for steam/air decoking of Cracking Heaters and TLE heat exchangers.
2.0 PROCESS DESCRIPTION
The Compressed Air facilities can be divided in two sections:
Instrument and Plant Air System
Decoking Air System
For graphical representation of the Air, Unit 7600, reference is made to the Utility Process Flow Diagrams
D-S760-5223-101 and D-S760-5223-102.
2.1 Instrument and Plant Air Generation
The compressed air system consists of the Compressed Air Package ME-76001 and the Air Dryer
Package ME-76002.
The Compressed Air Package mainly consists of the air compressors (ME-76001-K01A/B/C) and the after
coolers (ME-76001-E01A/B/C). Air from ambient will be sucked in via Air Inlet Filters. The compressed air
is cooled by cooling water. Because the continuous air demand is relatively low compared to peak air
demand and in order to obtain sufficient controllability of the compressor system, (2 + 1) equally sized
compressors of 50% capacity required are installed in parallel.
In case more air is required the third standby compressor will be started by low pressure switch
downstream of Air KO Drum (V-76001). The continuously operating compressors will be steam turbine
driven machine, the stand-by compressor is electrical motor driven to increase the reliability of the system.
A load control system (supplied by compressor package vendor) manipulates stream driven compressors
based on compressed air pressure downstream of Air KO Drum (V-76001).
Peak air demand is based on the following consumptions:
Continuous instrument air and plant air consumption
Maximum plant air for catalyst regeneration
To meet the required dew point of-40°C at atmospheric pressure or -30°C at 7 barg pressure specification
for instrument air, the required amount of compressed air is routed to the Air Dryer package ME-76002. To
reduce the load of the air dryer package, the discharged air is cooled in the compressor after cooler
included in the Vendor package and condensed water is knocked out in the separator V-76001. The water
separator is installed downstream the aftercooler and is equipped with an automatic drain valve to remove
Page 5 of 7
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description – 7600 – IPAU S-S760-5223-002 0
the condensate. The water separator is designed so that the air at the outlet of the separator shall not be
more than 5 % over-saturated under any operating conditions. For start-up, a connection for portable air
compressor upstream Air KO Drum (V-76001) has been foreseen.
To reduce the dew point of the compressed air to -30°C at normal operating pressure for dedicated
Instrument air purpose, a heatless desiccant type Air Dryer package ME–76002 will be installed. The
package consists of two set Air Dryers (ME-76002-D01A/B/C/D), each set capable of 100 % air flow. The
desiccant is usually activated alumina or silica gel beds. To prevent rust settlement on the air dryer
desiccants (1 + 1) x 100 % air pre-filter are provided at inlet of the air dryer package.
The Air Dryers are twin vessel adsorption type and provided with depressurization silencer and valves at
the vessels inlets and outlets for automatic switching the vessels from drying to the regeneration stage and
vice versa. Automatic switching is based on air dew point metering/control on dried air header. The
moisture controller is only permitted to change over when the desiccant has adsorbed moisture to its
capacity. During regeneration, the vessel is depressurized slowly to prevent blowing out and/or
fragmentation of the desiccant and is slowly pressurized prior to adsorption.
It is assumed that 20 % of dried air is utilized for air dryer regeneration. After desiccant has been
regenerated the vessel is pressurized slowly before switchover. Slow venting and pressurizing reduce
noise and damage to desiccant bed. Also to prevent desiccant particles from entering the instrument air
supply piping, (1+1) x 100% after-filters are provided at outlet of Air Dryer package. The design capacity of
the Air Dryer Package is set based on dried air to be supplied to instrument air distribution.
The air will be dried in order to avoid condensation in the lines and subsequently corrosion, leading to rust
particles which can clog up instrument air lines and orifices. Filters up and downstream of the dryers
prevent subsequently clogging up of the dryers or desiccant particles in the dried air
Part of dried air is delivered to the Instrument Air Buffer Vessel V-76002 to serve as buffer volume in the
event of compressor failure and also as fluctuation damper for compressors loading and unloading. The
buffer vessel is sized for 20 min of hold-up to provide enough time for operators corrective action. From
there the air is sent via pressure control to instrument air distribution header. The plant air is taken out
upstream of Air Dryers Package (ME-76002) on pressure control. The plant air supply is closed if
Instrument Air pressure in the header becomes too low in order to assure sufficient pressure for instrument
air distribution.
Part of dried instrument air (when is required) is compressed to 40 barg by HP Air Compressor Package
(ME-76004) and stored in high pressure Second Instrument Air Buffer Vessel (V-76003) to serve auxiliary
steam boilers and cracker heaters in case of lack of instrument air. The buffer vessel is sized for 6 hours
hold-up to provide sufficient time for operators for safe shutdown of cracker heaters.
Normal operating pressure of instrument air and plant air is 7 barg.
2.2 Other intermittent regeneration processes
Plant air will be also needed for regenerations of catalyst beds of following units:
MAPD Hydrogenation Reactor
st
SLC4HY 1 stage Reactor
nd
SLC4HY 2 stage Reactor
nd
SLC4HY 2 stage Reactor
Oxygen Converter Regeneration
st
PGHYD 1 Reactor Regeneration
nd
PGHYD 2 Reactor Regeneration
Page 6 of 7
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description – 7600 – IPAU S-S760-5223-002 0
The detailed procedures of regeneration of catalyst beds including the required plant air demand is
provided by the relevant Licensors.
All the above processes are on intermittent basis and are not likely to be performed at the same time.
2.3 Decoking Air Generation
The decoking air is produced by the air compressors ME-76003-K01A/B. During normal operation,
scheduled decoking will be for one furnace at the time however the decoking air system is to be designed
to provide the possibility to decoke two furnaces at the same time. In this case the second compressor
needs to be in operation.
Furnace decoking process requires air quantities to range gradually from virtually zero up to a maximum to
avoid radiant coils overheating due to uncontrolled coke combustion reaction inside the coils. Detailed
procedure of decoking process and required ramp up of air flow together with diluting steam flow will be
provided by the Licensor.
The controllability of the compressor system is of crucial importance. Because the decoking air is required
on intermittent basis, the both compressors will be electric motor-driven and operates based on so called
blow-off and inlet throating.
The compressed air is routed to the Cracking Heater. The pressure in the header is controlled by venting to
the atmosphere, and the decoking air is controlled by flow control valve located at the cracking heaters.
Page 7 of 7
Petrochemical Plant Sohar Environmental Impact Assessment Report
Orpic and CB&I HMR #3817
Attachment 15: Process Description WWTP
G-S000-5240-003 HMR Consultants
June 2015 V
Liwa Plastics Project
CB&I ORPIC
Document Title: Process Description - WWTU 8500
Document No: S-S850-5223-002
CB&I Contract No: 189709
Issued for FEED 0 12-March-2015 KJADHAV SNAZARI JL
Revision Descriptions Rev Date Originator Checker Approver
Page 1 of 11
"THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY (CB&I). IT MAY CONTAIN INFORMATION
DESCRIBING TECHNOLOGY OWNED BY CB&I AND DEEMED TO BE COMMERCIALLY SENSITIVE. IT IS TO BE USED ONLY IN
CONNECTION WITH WORK PERFORMED BY CB&I. REPRODUCTION IN WHOLE OR IN PART FOR ANY PURPOSE OTHER THAN
WORK PERFORMED BY CB&I IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN PERMISSION OF CB&I. IT IS TO BE SAFEGUARDED
AGAINST BOTH DELIBERATE AND INADVERTENT DISCLOSURE TO ANY THIRD PARTY."
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description for Waste Water Treatment Unit S-S850-5223-002 0
INPUTS / REFERENCE DOCUMENTS
Document Number Title Status
S-S000-5222-001 Project Basis of Design – LPP Facilities
S-S000-5223-003 Process Design Basis for Off-Site Facilities
D-S850-5223-301 BFD Waste Water Treatment Unit
D-S850-5223-101 UFD WWTU – Last Line Of Defense (LLOD)
D-S850-5223-102 UFD WWTU – Waste Water Collection Tank
D-S850-5223-103 UFD WWTU – Dissolved Gas Floatation (DGF)
D-S850-5223-104 UFD WWTU – WW Equalization Tank
D-S850-5223-105 UFD WWTU – Secondary Treatment (Biotreater)
D-S850-5223-106 UFD WWTU – Secondary Treatment (Sludge Treatment)
D-S850-5223-107 UFD WWTU – Sludge Dewatering
D-S850-5223-108 UFD WWTU – Tertiary Treatment
D-S850-5223-109 UFD WWTU – Treated Effluent Tank
D-S850-5223-110 UFD WWTU – Induced Air Floatation (IAF)
D-S850-5223-111 UFD WWTU – Surface Run-Off Treatment
D-S850-5223-112 UFD WWTU – Benzene/MTBE Contaminated WW Collection Tank
D-S850-5223-113 UFD WWTU – Waste Water Steam Stripper
D-S850-5223-114 UFD WWTU – Skimmed Oil Vessel
D-S850-5223-115 UFD WWTU – Domestic Effluent Lift Station
D-S850-5223-116 UFD WWTU – Neutralization Basin
D-S850-5223-117 UFD WWTU – Nutrient Dosing
D-S850-5223-118 UFD WWTU – Polymer Solution Dosing
D-S850-5223-119 UFD WWTU – Caustic / Sulfuric Acid Dosing
D-S850-5223-120 UFD WWTU – Hypochlorite and SMBS Dosing
REVISION NOTES AND HOLDS
Revision Description of Changes & Holds
HOLDS Description of Holds Rev Date
1 Deleted
2 Deleted
3 Deleted
Page 2 of 11
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description for Waste Water Treatment Unit S-S850-5223-002 0
Table of Contents
Contents Page
1.0 INTRODUCTION..................................................................................................................................4
2.0 DEFINITIONS ......................................................................................................................................4
3.0 WASTE WATER TREATMENT UNIT...................................................................................................5
3.1 Waste Water Collection and Handling.....................................................................................5
3.2 Last Line of Defense (LLOD)....................................................................................................5
3.3 Benzene / MTBE Contaminated Waste Water Pre-treatment..................................................7
3.4 Waste Water Primary Treatment..............................................................................................8
3.5 Waste Water Secondary Treatment .........................................................................................9
3.6 Waste Water Tertiary Treatment ............................................................................................10
3.7 Chemical Storage, Preparation and Dosing..........................................................................10
Page 3 of 11
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description for Waste Water Treatment Unit S-S850-5223-002 0
1.0 INTRODUCTION
Oman Refineries and Petrochemicals Company (ORPIC) is planning the installation of a new
Petrochemical Complex to be called Liwa Plastics Project (LPP) adjacent to Sohar Refinery Improvement
Project (SRIP) that will include a Steam Cracker Unit (SCU) designed to produce 859 kilo tons per annum
(KTA) of polymer grade ethylene and 286 KTA of polymer grade propylene, Refinery Dry Gas Unit, NGL
Treating and Fractionation Unit, Selective C4 Hydrogenation Unit, MTBE Unit, Butene-1 Recovery Unit,
Pygas Hydrotreating Unit, High Density Polyethylene (HDPE) Plant, Linear Low Density Polyethylene Plant
(LLDPE), new Polypropylene Plant (PP), and associated utility and offsite facilities. The new petrochemical
plant will be integrated with the Sohar Refinery, Sohar Aromatics Plant (AP) and Sohar Polypropylene
Plant (PP) plant.
ORPIC is also planning the installation of a new NGL Extraction plant located in Fahud, Central Oman. The
NGL (C2+) extracted from the natural gas will be transported to the petrochemical complex by pipeline and
used as feedstock to LPP. The new NGL Extraction plant will have independent utility and offsite facilities.
Additional feedstock to LPP are mixed LPG (produced in the Sohar Refinery and Sohar AP), refinery dry
gas produced in the RFCC unit and new Delayed Coking unit (included in SRIP), light naphtha condensate
from OLNG by marine tanker.
This document covers the process description for the Waste Water Treatment Unit 8500 of the new Liwa
Plastics Project in Oman. This document needs to be updated based on package equipment vendor
information in the later stage of project.
2.0 DEFINITIONS
The following terms and abbreviations have been used in this document:
Term Definition
AOC Accidentally Oil Contaminated
BOD Biological Oxygen Demand
COD Chemical Oxygen Demand
DGF Dissolved Gas Floatation
FFB First Flush Basin
IAF Induced Air Floatation
LLOD Last Line Of Defense
OC Oil Contaminated
OCB Oil Contaminated Basin
POB Peak Overflow Basin
TOD Total Oxygen Demand
WW Waste Water
WWT Unit Waste Water Treatment Unit
Page 4 of 11
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description for Waste Water Treatment Unit S-S850-5223-002 0
3.0 WASTE WATER TREATMENT UNIT
The waste water treatment unit will consist of physical, chemical, and biological treatment units as
described below:
Last Line Of Defense (LLOD)
Benzene / MTBE contaminated waste water pre-treatment
Wastewater primary treatment
Wastewater secondary (biological) treatment
Wastewater tertiary treatment
Clean surface water run-off treatment
Chemical storage, preparation and dosing
For graphical representation of the Waste Water Treatment Unit 8500, reference is made to the Utility Flow
Diagrams D-S850-5223-101 to D-S850-5223-120.
3.1 Waste Water Collection and Handling
An adequate waste water collection system plays an essential role in effective waste water reduction and
treatment. Waste water collection system routes the effluent streams to their appropriate treatment device
and prevents mixing of contaminated and non-contaminated waste water.
To design an adequate waste water collection system, the following rules are considered:
All liquid waste streams coming from process, utility and storage areas that could be
contaminated with hydrocarbon are collected and treated before disposal into open water.
Process effluent streams are segregated from surface water run-offs.
Non-contaminated (clean) surface water run-off is to be kept separate from polluted or potentially
polluted run-offs.
Where ever applicable process effluents has been segregated according to its contamination
load.
High benzene / MTBE contaminated waste water shall be kept separate from low or non-
benzene / MTBE contaminated effluent streams.
All chemical effluent shall be neutralized inside the process unit’s battery limit and not to be sent
to sewer system.
3.2 Last Line of Defense (LLOD)
Equipment oily drains, pump base plates, hydrocarbon sampling points and surface water run-off typically
rain, fire and wash water from the paved areas, where hydrocarbon pollution may occur, are collected upon
discharge by proper sewer system and routed by gravity to the below grade Last Line Of Defense (LLOD)
basins.
The LLOD consists of influent Bar Screening Package (ME-85001 and ME-85002), Oil Contaminated Basin
(Z-85001), First Flush Basin (Z-85002), Peak Overflow Basin (Z-85003) and relevant pumps. The POB
together with the FFB are designed to catch the total firewater run-off result of the biggest fire scenario.
The inlet compartments of Z-85001 and Z-85002 are equipped with Oil Skimmer and Sludge Scraper (ME-
85003 and ME-85004). The collected sludge will be sent to Oily Sludge Collection Tank (T-85005) awaiting
dewatering process via LLOD Sludge Pumps (P-85003A/B/C/D).
By taking into account the above considerations, the following effluent collection systems are designed:
Page 5 of 11
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description for Waste Water Treatment Unit S-S850-5223-002 0
Oily Water Sewer (OWS)
Equipment oily drains, pump base plates, hydrocarbon sampling points and surface water run-off from the
paved area where hydrocarbon leakage expected to be occurred shall be collected by oily water sewer
system and routed by gravity to OCB (Z-85001). Then the collected oily water is send to Waste Water
Collection Tank via OC Water Pump (P-85001 A/B) for appropriate treatment. The OC Water Pump (P-
85001 A/B) will be fed by emergency power and protected against clogging by OC Water Screening
Package (ME-85001). The OC Water Pump (P-85001 A/B) is low speed non-emulsified pump. The inlet
compartment of OCB is equipped with portable floating type oil skimmer. The skimmed oil is sent to
Skimmed Oil Vessel (V-85001).
The quality of surface water run-off from the paved area where benzene / MTBE spillage may occur shall
be checked before routing to sewer system. In case of high benzene / MTBE contamination, surface water
run-off shall be collected and sent to benzene / MTBE contaminated waste water pre-treatment unit.
Accidently Oil Contaminated Sewer (AOC)
The AOC sewer system collects equipment drains and surface water run-off which is polluted neither by
benzene / MTBE nor by high concentration of other hydrocarbons and routes the collected effluent to FFB
through AOC Water Screening Package (ME-85002). The purpose of screening is to remove large objects
such as rags, plastics, paper, metals, dead animals, and the like and protect downstream equipment from
damage or clogging. The inlet compartment of FFB is equipped with a portable floating type oil skimmer to
collect skimmed oil if any. The skimmed oil is sent to Skimmed Oil Vessel (V-85001).
FFB is designed to hold rain water run-off from potentially hydrocarbon polluted area during first
35 minutes of rain. After this period, FFB is filled and the surface water run-off overflows to POB. It is
expected that the contamination level of surface water run-off collected in POB is diluted to such an extent
that can bypass biological treatment and be treated only by Induced Air Floatation (IAF) unit (ME-85009). If
the quality of collected run-off in POB is far from outfall water specification (high BOD / high COD), the
collected run-off shall be treated along with first flush water collected in FFB in biological treatment unit. In
addition, the POB is used as surge basin in case of cooling water oil contamination.
During normal plant operation, it is expected that good housekeeping keeps surface water run-off collected
in FFB clean enough (low BOD / low COD) to be treated only by an Induced Air Floatation (IAF) Unit (ME-
85009) for removing any residual oil or suspended solids. Then the treated surface run-off will be sent to
Treated Effluent Tank (T-85003) for the final check and settled sludge will be pumped directly to Sludge
Dewatering Package (ME-85007). However, if the quality of collected water in FFB is off-spec due to high
BOD / high COD, the water will be sent to Waste Water Collection Tank (T-85001) by means of FFB Water
Pump (P-85002 A/B) for further treatment in the WWT unit. If the Benzene contamination of the collected
surface water run-off exceeds 10 ppm, then the collected water has to be sent to Benzene / MTBE
Contaminated WW Collection Tank (T-85004) for further treatment.
Clean Water (ND) Sewer System
This system is a clean water sewer, collecting surface water run-off from non-contaminated areas where
source of hydrocarbon leakage/spillage is not exist. Due to the fact that the collected run-off is inherently
clean, it will be routed by gravity to the Sea Water Outfall Channel. If surface water run-off cannot meet the
clean water spec then the storm water is to be routed to Storm Water Clarifier (ME-85010) where
suspended solids and trace of hydrocarbons (if any) will be separated. The clarified storm water will be
sent to MISC (OSBL) along with the provision for sending it to Sea Water Return Channel and the collected
sludge will be transferred to Sludge Dewatering Package (ME-85007).
Domestic Sewer System
This system collects domestic waste water from toilets, urinals, kitchen facilities, sinks, showers and the
like from buildings and shelters. Domestic effluent from kitchen facilities shall be equipped with grease
traps. Domestic effluents are routed by a sloped gravity underground pipe system into the centralized
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Domestic Lift Station (ME-85011). Eight (8) number of Domestic Lift Pump Stations will be installed in
specific areas which shall transfer the solid and liquid wastes to OSBL (MISC) for further treatment.
Chemical Sewer System
Demin water spent regenerants, condensate polishing spent regenerants and spent chemical shall be kept
separate from surface water run-offs. To meet outfall water specification, the spent chemicals shall be
neutralized first. The neutralized spent chemical will be sent to the OSBL (Cooling Water Outfall) without
further treatment.
3.3 Benzene / MTBE Contaminated Waste Water Pre-treatment
The benzene / MTBE contaminated waste water pre-treatment will treat waste water contaminated with
benzene or MTBE. By utilizing steam stripping the benzene content is reduced to 1 ppmw. The following
waste water streams are pre-treated:
SCU dilution steam drum blowdown
SCU stripped process water
Quench water in case of SCU shutdown
MTBE unit spent wash water
First flush surface water run-off collected in LLOD, in case contaminated with benzene/MTBE
Surface water run-off from paved area where source of benzene / MTBE leakage/spillage is
exist, in case contaminated with benzene / MTBE
The benzene/MTBE contaminated waste water pre-treatment unit consists of the following main sections:
Benzene / MTBE Contaminated Waste Water Collection Tank
Waste Water Steam Stripper
The Benzene / MTBE Contaminated Waste Water Collection Tank (T-85004) is used to collect all the
waste water streams before treatment in the Waste Water Steam Stripper (C-85001). Since the waste
water contains benzene and/or MTBE, the tank is provided with a nitrogen blanket and connected to the
Tank Vent Gas Incinerator Package (ME-86001) through Vent Gas Blower (K-85001A/B). The tank is
equipped with a tangential inlet and oil skimming facilities to remove the separated free oil. From the tank,
waste water is pumped by means of the Benzene / MTBE Contaminated Waste Water Pump (P-
85007 A/B) at a controlled flow to the Waste Water Steam Stripper (C-85001). If necessary, the pH is
adjusted by means of caustic or sulfuric acid dosing upstream the steam stripper.
Benzene / MTBE contaminated waste water is preheated against the stripper effluent stream in Steam
Stripper Feed/Effluent Heat Exchanger (E-85001 A/B) and fed to the top of the Waste Water Steam
Stripper. At the bottom of this column, LP steam is supplied which strips the hydrocarbons out of the
influent. Vapors at the top of the column are condensed and collected in the Steam Stripper Overhead
Reflux Drum (V-85002). In this vessel, the condensed liquid will separate in a water layer and a thin oil
layer, which flows over the installed weir into the hydrocarbons compartment. The water in the vessel is
pumped by means of the Steam Stripper Reflux Pump (P-85008 A/B) on level control as reflux to the
column. The recovered hydrocarbons are routed to the Skimmed Oil Vessel (V-85001). Vapors are vented
to the wet flare system.
Nitrogen will be used in order to maintain sufficient pressure in the overhead system of the column to allow
venting to the flare. Some nitrogen is required in case insufficient hydrocarbons (non-condensable) are
present in the waste water feed stream. It is fed upstream of the Steam Stripper Overhead Condenser (E-
85003) to ensure proper condenser operation. In the event of a pressure loss in the system due to low
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Process Description for Waste Water Treatment Unit S-S850-5223-002 0
concentrations of hydrocarbons in the feed, the PC will open the valve in the nitrogen line to bring the
pressure up to the desired set point. When there is an overpressure due to an increase in the quantity of
non-condensable in the feed, the PC opens the valve on the vapor outlet to the wet flare. The pressure in
the overhead reflux drum is set at about 1 barg in order to ensure proper disposal of vents to the flare.
The steam stripped effluent collected from the bottom of the column is pumped by means of the Stripped
Waste Water Pump (P-85009 A/B) to the Waste Water Equalization Tank (T-85002) after heat recovery in
Feed/Effluent Heat Exchanger (E-85001 A/B) and cooling down in Stripped WW Trim Cooler (E-85002) to
below 40 °C using cooling water.
In case of high benzene and/or MTBE contamination of the steam stripped effluent, it is manually routed
back to the Benzene / MTBE Contaminated WW Collection Tank (T-85004). This is also done in case of
low-low temperature in the column. In the latter case, sufficient stripping of benzene/MTBE cannot be
ensured.
If the stripped effluent is on-spec according to benzene/MTBE contamination level but off-spec due to high
TOC, the stripped waste water shall be sent to Waste Water Collection Tank (T-85001) and to be treated
by Dissolved Gas Floatation Unit (ME-85005), Otherwise stripped waste water shall be sent to WW
Equalization Tank (T-85002).
3.4 Waste Water Primary Treatment
The waste water primary treatment will treat oil contaminated waste by means of Dissolved Gas Floatation
(DGF) unit. The waste water primary treatment consists of the following operation units:
Waste Water Collection Tank (T-85001)
DGF Package (ME-85005)
Skimmed Oil Vessel (V-85001)
The Waste Water Collection Tank (T-85001) is used to store the process waste water awaiting the DGF
treatment. The tank is equipped with tangential inlet and skimming facilities to remove any separated free
oil. From the tank, the waste water is pumped by the Waste Water Transfer Pump (P-85004 A/B) under
flow control to Dissolved Gas Floatation (DGF) package (ME-85005). Waste water pH is adjusted by
means of caustic or sulfuric acid dosing upstream DGF unit.
The DGF package should be sized such that to provide sufficient operating flexibility to allow effluent
quality to be maintained in acceptable range by considering the expected variations in the influent
characteristics. The operator should be able to adjust the following major operating variables:
pH
coagulant and flocculant type and dose
nitrogen pressure
recycle rate
Waste water enters on one end and passes sequentially through coagulation, flocculation and floatation
compartments of the DGF unit (ME-85005). Cationic polymer solution is dosed into the influent upstream of
the DGF unit to enhance the removal of free/emulsified oil and suspended solids. The system forces
nitrogen gas into effluent by means of hydraulic eductors. The nitrogen bubbles will adhere to the oil
particles and form flocs and help these particles to float to the water surface of each flotation compartment.
The floating scum layer is removed by means of a surface skimmer mechanism and sent to the Skimmed
Oil Vessel (V-85001) by WW DGF Skimming Pump. The treated waste water will overflow via the effluent
weir into the DGF clearwell compartment and is pumped by means of the DGF Clearwell Pump to the
Waste Water Equalization Tank (T-85002).
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The Skimmed Oil Vessel collects the following streams:
Skimmed oil from LLOD basins
Skimmed oil from the Waste Water Collection Tank
Skimmed oil from Oily Sludge Storage Tank
Skimmed oil from the Benzene/MTBE Contaminated Waste Water Collection Tank
Skimmed oil from the Steam Stripper Overhead Reflux Drum
DGF skimming
Skimmed oil from Spent Caustic Oxidation unit storage tanks
Inside the Skimmed Oil Vessel (V-85001), a special plate pack is installed to separate oil and water
efficiently. The separated oil is collected via a weir in the oil compartment of the vessel. The collected
skimmed oil will be sent to Liquid-Solid Incinerator Package (ME-86002) by Skimmed Oil Pump (P-85010).
Skimmed Oil Effluent will be transferred to WW Collection Tank(T-85001) by Skimmed Oil Effluent Pump
(P-85011).
3.5 Waste Water Secondary Treatment
The waste water secondary (biological) treatment consists of:
Equalization Tank
Biotreater
Sludge Treatment and Dewatering
The Waste Water Equalization Tank (T-85002) receives the waste water streams to be treated in the
Biological Treatment Package (ME-85006). The following streams are routed to the Waste Water
Equalization Tank:
DGF effluent from the waste water primary treatment
TLE Hydrojetting / decoking quench water effluent
Stripped effluent from Waste Water Steam Stripper
Crystallizer Distillate Effluent from ME-63002.
The Waste Water Equalization Tank has a buffering and homogenization function for the feed stream to
the Biotreater, thus minimizing fluctuations in flow rate and composition.
In the Biotreater, BOD and COD is reduced by activated sludge using dissolved oxygen. Biotreater will
receive feed streams from Contact Tank where the equalized WW will be mixed with the recycled activated
sludge and nutrients (urea and H3PO4).
After pH adjustment, the mixed stream is routed to the Aeration Tank where the required amount of air is
supplied by Air Compressor Package (ME-85017 to be supplied by WW Secondary Treatment Package
Vendor). Control of the required amount of air is done by means of a dissolved oxygen measurement.
Aerated stream will be routed to Clarifier on gravity flow via Degassing Tank. In the Clarifier, the settled
activated sludge is separated from the clean water. Part of the activated sludge is recycled to the Contact
Tank and the excess activated sludge is sent to the Sludge Digester followed by Sludge Thickener. The
clarified water is routed to the tertiary treatment to meet the outfall water specification.
Thickened excess bio-sludge from Sludge Thickener is sent to Sludge Dewatering Package (ME-85007)
where polymer solution is added for conditioning of the sludge. Dewatered bio-sludge is collected in a
mobile bio-sludge cake container, which is trucked out for disposal or sent to incineration. The decanted
water from Sludge Dewatering Package is recycled to the Waste Water Collection Tank (T-85001).
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Oily sludge will be kept separate from bio-sludge. The oily sludge from LLOD basins, Waste water
Collection Tank (T-85001), Skimming from IAF (ME-85009), Sludge from Polymer Plant and WW Dissolved
Gas Floatation (DGF) package (ME-85005) will be sent to Oily Sludge Collection Tank (T-85005) where it
will be pumped to Sludge Dewatering Package (ME-85007). The dewatered oily sludge is collected in a
mobile oily sludge container for incineration. The reject stream will be sent to Waste Water Secondary
Treatment (ME-85006) Package for further processing.
Air Compressor Package (ME-85017) and Critical Equipment in WW Secondary Treatment Package e.g.
Clarifier Scraper, Recirculating Pump etc. to be fed by Emergency Power Supply System.
3.6 Waste Water Tertiary Treatment
The waste water tertiary treatment consists of:
Disinfection Unit
Continuous Sand Filter
Activated Carbon Filter
Treated Effluent Tank
In order to meet discharge water specification, Sodium Hypochlorite solution is used for chlorination of
clarified water in Chlorination compartment of Chlorination/Dechlorination Basin followed by Sodium
Metabisulfite (SMBS) injection for De-chlorination in De-chlorination compartment.
For removal of remaining suspended solids, the dechlorinated water is routed to the Continuous Sand
Filter. The unit consists of two continuously regenerated sand filters, each designed for 70 % of total
capacity. The continuous backwash stream from the sand filters is recycled to WW Collection Tank (T-
85001). In case of high TOC in Chlorination Tank, the Chlorination Tank has to be drained into the Waste
Water Collection Tank (T-85001) via Backwash Effluent Basin.
The clean effluent from sand filters will flow on gravity into the Filtrate Basin, where the treated effluent
quality is continuously monitored by means of a flow, turbidity, temperature, TOD and pH measurement.
It is expected that sand filter clear water can meet the outfall water quality. However, in case of
hydrocarbon contamination, the effluent can be sent to Activated Carbon Filters for final polishing. The
treated waste water will be sent to the Treated Effluent Tank (T-85003).
3.7 Chemical Storage, Preparation and Dosing
Concentrated Sulfuric Acid Dosing Package (ME-85015)
Concentrated sulfuric acid (H2SO4) is used for pH control within waste water treatment unit. Concentrated
sulfuric acid is supplied from Sulfuric Acid Storage Tank to Sulfuric Acid Dosing Vessel. The dosing vessel
vent/breathing line is routed to hydraulically sealed neutralization pot, filled with Limestone.
Sulfuric Acid Dosing Vessel and Sulfuric Acid Dosing Pump are surrounded by a dike wall to isolate the
package from surrounding environment in case of any accidental leakages. The drainage is routed to
Neutralization Pit (Z-85005).
Caustic Soda Dosing Package (ME-85014)
Caustic soda (20 wt%) is used for pH control within wastewater treatment unit. Caustic soda (20 wt%) is
supplied from Caustic Storage Tank to Caustic Dosing Vessel. The dosing vessel vent/breathing line is
routed to hydraulically sealed neutralization pot.
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Caustic Dosing Vessel and Caustic Dosing Pump are surrounded by a dike wall to isolate the package
from surrounding environment in case of any accidental leakages. The drainage is routed to Neutralization
Pit (Z-85005).Nutrient (Urea and Phosphoric Acid) Preparation and Dosing Package (ME-85012)
Urea and phosphoric acid are used as nitrogen and phosphorous supplement for Aeration Tanks and
aerobic Sludge Digester.
Granular urea is dissolved in water with a concentration of about 10 wt% and stored in Urea Solution Tank.
Diluted urea is sent to the users by Urea Solution Dosing Pump.
Concentrated phosphoric acid is supplied in 1 m3 plastic containers. Concentrated phosphoric acid is
diluted with water to a concentration of about 10 wt% in Phosphoric Acid Dosing Vessel and is sent to the
users via Phosphoric Acid Dosing Pumps. The dosing packages are surrounded by a dike wall to isolate
the package from surrounding environment in case of any accidental leakages. The drainage is routed to
Neutralization Pit (Z-85005).
Hypochlorite and SMBS Dosing Package (ME-85016)
Sodium hypochlorite is used for treated wastewater disinfection and Sodium Metabisulfite (SMBS) is
utilized for dechlorination of treated wastewater in Chlorination/Dechlorination Basin.
Sodium hypochlorite and SMBS will be supplied by bag/container. All required components for preparation,
injection and control of hypochlorite and SMBS into treated waste water will be provided by package (ME-
85016) vendor. The drainage is routed to Neutralization Pit (Z-85005).
Polymer Preparation and Dosing Package (ME-85013)
Cationic polyelectrolyte is used as coagulant in the following equipment:
WW Dissolved Gas Floatation (DGF) Package (ME-85005)
Secondary Clarifier in Biotreater (ME-85006)
Sludge Dewatering Package (ME-85007)
Induced Air Floatation (IAF) Package (ME-85009)
Storm Water Clarifier (ME-85010)
Solid polyelectrolyte is dissolved in water and injected into influent streams by means of injection pumps.
All chemical dosing packages are surrounded by a dike wall to isolate the package from surrounding
environment in case of any accidental leakages. The drainage is routed to Neutralization Pit (Z-85005).
Chemical Neutralization
All chemical drains, Benzene/MTBE contaminated WW from drainage of P-85007A/B, P-85008A/B and P-
85009A/B are routed by gravity to Neutralization Pit (Z-85005) where either caustic or sulfuric acid will be
added to neutralize the content of basin. A pH measurement is installed for control of neutralization.
To facilitate neutralization process, Neutralization Pit Pump (P-85012 A/B) is utilized to circulate the basin
content. The neutralized chemical will be sent to Cooling Water Outfall channel along with manual
provision for routing it to WW Equalization Tank. Primary destination is Cooling Water Outfall Channel. Due
to high salt content in Neutralized chemical effluent, treated waste water may not meet outfall water spec in
case of routing it to Equalization Tank (T-85002).
The operators are to flush the chemical collection header with water after each drain or spillage.
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Liwa Plastics Project
CB&I ORPIC
Document Title: Process Description - WWTU 8500
Document No: S-S850-5223-002
CB&I Contract No: 189709
Issued for FEED 0 12-March-2015 KJADHAV SNAZARI JL
Revision Descriptions Rev Date Originator Checker Approver
Page 1 of 11
"THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY (CB&I). IT MAY CONTAIN INFORMATION
DESCRIBING TECHNOLOGY OWNED BY CB&I AND DEEMED TO BE COMMERCIALLY SENSITIVE. IT IS TO BE USED ONLY IN
CONNECTION WITH WORK PERFORMED BY CB&I. REPRODUCTION IN WHOLE OR IN PART FOR ANY PURPOSE OTHER THAN
WORK PERFORMED BY CB&I IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN PERMISSION OF CB&I. IT IS TO BE SAFEGUARDED
AGAINST BOTH DELIBERATE AND INADVERTENT DISCLOSURE TO ANY THIRD PARTY."
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description for Waste Water Treatment Unit S-S850-5223-002 0
INPUTS / REFERENCE DOCUMENTS
Document Number Title Status
S-S000-5222-001 Project Basis of Design – LPP Facilities
S-S000-5223-003 Process Design Basis for Off-Site Facilities
D-S850-5223-301 BFD Waste Water Treatment Unit
D-S850-5223-101 UFD WWTU – Last Line Of Defense (LLOD)
D-S850-5223-102 UFD WWTU – Waste Water Collection Tank
D-S850-5223-103 UFD WWTU – Dissolved Gas Floatation (DGF)
D-S850-5223-104 UFD WWTU – WW Equalization Tank
D-S850-5223-105 UFD WWTU – Secondary Treatment (Biotreater)
D-S850-5223-106 UFD WWTU – Secondary Treatment (Sludge Treatment)
D-S850-5223-107 UFD WWTU – Sludge Dewatering
D-S850-5223-108 UFD WWTU – Tertiary Treatment
D-S850-5223-109 UFD WWTU – Treated Effluent Tank
D-S850-5223-110 UFD WWTU – Induced Air Floatation (IAF)
D-S850-5223-111 UFD WWTU – Surface Run-Off Treatment
D-S850-5223-112 UFD WWTU – Benzene/MTBE Contaminated WW Collection Tank
D-S850-5223-113 UFD WWTU – Waste Water Steam Stripper
D-S850-5223-114 UFD WWTU – Skimmed Oil Vessel
D-S850-5223-115 UFD WWTU – Domestic Effluent Lift Station
D-S850-5223-116 UFD WWTU – Neutralization Basin
D-S850-5223-117 UFD WWTU – Nutrient Dosing
D-S850-5223-118 UFD WWTU – Polymer Solution Dosing
D-S850-5223-119 UFD WWTU – Caustic / Sulfuric Acid Dosing
D-S850-5223-120 UFD WWTU – Hypochlorite and SMBS Dosing
REVISION NOTES AND HOLDS
Revision Description of Changes & Holds
HOLDS Description of Holds Rev Date
1 Deleted
2 Deleted
3 Deleted
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Process Description for Waste Water Treatment Unit S-S850-5223-002 0
Table of Contents
Contents Page
1.0 INTRODUCTION..................................................................................................................................4
2.0 DEFINITIONS ......................................................................................................................................4
3.0 WASTE WATER TREATMENT UNIT...................................................................................................5
3.1 Waste Water Collection and Handling.....................................................................................5
3.2 Last Line of Defense (LLOD)....................................................................................................5
3.3 Benzene / MTBE Contaminated Waste Water Pre-treatment..................................................7
3.4 Waste Water Primary Treatment..............................................................................................8
3.5 Waste Water Secondary Treatment .........................................................................................9
3.6 Waste Water Tertiary Treatment ............................................................................................10
3.7 Chemical Storage, Preparation and Dosing..........................................................................10
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Process Description for Waste Water Treatment Unit S-S850-5223-002 0
1.0 INTRODUCTION
Oman Refineries and Petrochemicals Company (ORPIC) is planning the installation of a new
Petrochemical Complex to be called Liwa Plastics Project (LPP) adjacent to Sohar Refinery Improvement
Project (SRIP) that will include a Steam Cracker Unit (SCU) designed to produce 859 kilo tons per annum
(KTA) of polymer grade ethylene and 286 KTA of polymer grade propylene, Refinery Dry Gas Unit, NGL
Treating and Fractionation Unit, Selective C4 Hydrogenation Unit, MTBE Unit, Butene-1 Recovery Unit,
Pygas Hydrotreating Unit, High Density Polyethylene (HDPE) Plant, Linear Low Density Polyethylene Plant
(LLDPE), new Polypropylene Plant (PP), and associated utility and offsite facilities. The new petrochemical
plant will be integrated with the Sohar Refinery, Sohar Aromatics Plant (AP) and Sohar Polypropylene
Plant (PP) plant.
ORPIC is also planning the installation of a new NGL Extraction plant located in Fahud, Central Oman. The
NGL (C2+) extracted from the natural gas will be transported to the petrochemical complex by pipeline and
used as feedstock to LPP. The new NGL Extraction plant will have independent utility and offsite facilities.
Additional feedstock to LPP are mixed LPG (produced in the Sohar Refinery and Sohar AP), refinery dry
gas produced in the RFCC unit and new Delayed Coking unit (included in SRIP), light naphtha condensate
from OLNG by marine tanker.
This document covers the process description for the Waste Water Treatment Unit 8500 of the new Liwa
Plastics Project in Oman. This document needs to be updated based on package equipment vendor
information in the later stage of project.
2.0 DEFINITIONS
The following terms and abbreviations have been used in this document:
Term Definition
AOC Accidentally Oil Contaminated
BOD Biological Oxygen Demand
COD Chemical Oxygen Demand
DGF Dissolved Gas Floatation
FFB First Flush Basin
IAF Induced Air Floatation
LLOD Last Line Of Defense
OC Oil Contaminated
OCB Oil Contaminated Basin
POB Peak Overflow Basin
TOD Total Oxygen Demand
WW Waste Water
WWT Unit Waste Water Treatment Unit
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Process Description for Waste Water Treatment Unit S-S850-5223-002 0
3.0 WASTE WATER TREATMENT UNIT
The waste water treatment unit will consist of physical, chemical, and biological treatment units as
described below:
Last Line Of Defense (LLOD)
Benzene / MTBE contaminated waste water pre-treatment
Wastewater primary treatment
Wastewater secondary (biological) treatment
Wastewater tertiary treatment
Clean surface water run-off treatment
Chemical storage, preparation and dosing
For graphical representation of the Waste Water Treatment Unit 8500, reference is made to the Utility Flow
Diagrams D-S850-5223-101 to D-S850-5223-120.
3.1 Waste Water Collection and Handling
An adequate waste water collection system plays an essential role in effective waste water reduction and
treatment. Waste water collection system routes the effluent streams to their appropriate treatment device
and prevents mixing of contaminated and non-contaminated waste water.
To design an adequate waste water collection system, the following rules are considered:
All liquid waste streams coming from process, utility and storage areas that could be
contaminated with hydrocarbon are collected and treated before disposal into open water.
Process effluent streams are segregated from surface water run-offs.
Non-contaminated (clean) surface water run-off is to be kept separate from polluted or potentially
polluted run-offs.
Where ever applicable process effluents has been segregated according to its contamination
load.
High benzene / MTBE contaminated waste water shall be kept separate from low or non-
benzene / MTBE contaminated effluent streams.
All chemical effluent shall be neutralized inside the process unit’s battery limit and not to be sent
to sewer system.
3.2 Last Line of Defense (LLOD)
Equipment oily drains, pump base plates, hydrocarbon sampling points and surface water run-off typically
rain, fire and wash water from the paved areas, where hydrocarbon pollution may occur, are collected upon
discharge by proper sewer system and routed by gravity to the below grade Last Line Of Defense (LLOD)
basins.
The LLOD consists of influent Bar Screening Package (ME-85001 and ME-85002), Oil Contaminated Basin
(Z-85001), First Flush Basin (Z-85002), Peak Overflow Basin (Z-85003) and relevant pumps. The POB
together with the FFB are designed to catch the total firewater run-off result of the biggest fire scenario.
The inlet compartments of Z-85001 and Z-85002 are equipped with Oil Skimmer and Sludge Scraper (ME-
85003 and ME-85004). The collected sludge will be sent to Oily Sludge Collection Tank (T-85005) awaiting
dewatering process via LLOD Sludge Pumps (P-85003A/B/C/D).
By taking into account the above considerations, the following effluent collection systems are designed:
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Process Description for Waste Water Treatment Unit S-S850-5223-002 0
Oily Water Sewer (OWS)
Equipment oily drains, pump base plates, hydrocarbon sampling points and surface water run-off from the
paved area where hydrocarbon leakage expected to be occurred shall be collected by oily water sewer
system and routed by gravity to OCB (Z-85001). Then the collected oily water is send to Waste Water
Collection Tank via OC Water Pump (P-85001 A/B) for appropriate treatment. The OC Water Pump (P-
85001 A/B) will be fed by emergency power and protected against clogging by OC Water Screening
Package (ME-85001). The OC Water Pump (P-85001 A/B) is low speed non-emulsified pump. The inlet
compartment of OCB is equipped with portable floating type oil skimmer. The skimmed oil is sent to
Skimmed Oil Vessel (V-85001).
The quality of surface water run-off from the paved area where benzene / MTBE spillage may occur shall
be checked before routing to sewer system. In case of high benzene / MTBE contamination, surface water
run-off shall be collected and sent to benzene / MTBE contaminated waste water pre-treatment unit.
Accidently Oil Contaminated Sewer (AOC)
The AOC sewer system collects equipment drains and surface water run-off which is polluted neither by
benzene / MTBE nor by high concentration of other hydrocarbons and routes the collected effluent to FFB
through AOC Water Screening Package (ME-85002). The purpose of screening is to remove large objects
such as rags, plastics, paper, metals, dead animals, and the like and protect downstream equipment from
damage or clogging. The inlet compartment of FFB is equipped with a portable floating type oil skimmer to
collect skimmed oil if any. The skimmed oil is sent to Skimmed Oil Vessel (V-85001).
FFB is designed to hold rain water run-off from potentially hydrocarbon polluted area during first
35 minutes of rain. After this period, FFB is filled and the surface water run-off overflows to POB. It is
expected that the contamination level of surface water run-off collected in POB is diluted to such an extent
that can bypass biological treatment and be treated only by Induced Air Floatation (IAF) unit (ME-85009). If
the quality of collected run-off in POB is far from outfall water specification (high BOD / high COD), the
collected run-off shall be treated along with first flush water collected in FFB in biological treatment unit. In
addition, the POB is used as surge basin in case of cooling water oil contamination.
During normal plant operation, it is expected that good housekeeping keeps surface water run-off collected
in FFB clean enough (low BOD / low COD) to be treated only by an Induced Air Floatation (IAF) Unit (ME-
85009) for removing any residual oil or suspended solids. Then the treated surface run-off will be sent to
Treated Effluent Tank (T-85003) for the final check and settled sludge will be pumped directly to Sludge
Dewatering Package (ME-85007). However, if the quality of collected water in FFB is off-spec due to high
BOD / high COD, the water will be sent to Waste Water Collection Tank (T-85001) by means of FFB Water
Pump (P-85002 A/B) for further treatment in the WWT unit. If the Benzene contamination of the collected
surface water run-off exceeds 10 ppm, then the collected water has to be sent to Benzene / MTBE
Contaminated WW Collection Tank (T-85004) for further treatment.
Clean Water (ND) Sewer System
This system is a clean water sewer, collecting surface water run-off from non-contaminated areas where
source of hydrocarbon leakage/spillage is not exist. Due to the fact that the collected run-off is inherently
clean, it will be routed by gravity to the Sea Water Outfall Channel. If surface water run-off cannot meet the
clean water spec then the storm water is to be routed to Storm Water Clarifier (ME-85010) where
suspended solids and trace of hydrocarbons (if any) will be separated. The clarified storm water will be
sent to MISC (OSBL) along with the provision for sending it to Sea Water Return Channel and the collected
sludge will be transferred to Sludge Dewatering Package (ME-85007).
Domestic Sewer System
This system collects domestic waste water from toilets, urinals, kitchen facilities, sinks, showers and the
like from buildings and shelters. Domestic effluent from kitchen facilities shall be equipped with grease
traps. Domestic effluents are routed by a sloped gravity underground pipe system into the centralized
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Document Title: Document No. Rev:
Process Description for Waste Water Treatment Unit S-S850-5223-002 0
Domestic Lift Station (ME-85011). Eight (8) number of Domestic Lift Pump Stations will be installed in
specific areas which shall transfer the solid and liquid wastes to OSBL (MISC) for further treatment.
Chemical Sewer System
Demin water spent regenerants, condensate polishing spent regenerants and spent chemical shall be kept
separate from surface water run-offs. To meet outfall water specification, the spent chemicals shall be
neutralized first. The neutralized spent chemical will be sent to the OSBL (Cooling Water Outfall) without
further treatment.
3.3 Benzene / MTBE Contaminated Waste Water Pre-treatment
The benzene / MTBE contaminated waste water pre-treatment will treat waste water contaminated with
benzene or MTBE. By utilizing steam stripping the benzene content is reduced to 1 ppmw. The following
waste water streams are pre-treated:
SCU dilution steam drum blowdown
SCU stripped process water
Quench water in case of SCU shutdown
MTBE unit spent wash water
First flush surface water run-off collected in LLOD, in case contaminated with benzene/MTBE
Surface water run-off from paved area where source of benzene / MTBE leakage/spillage is
exist, in case contaminated with benzene / MTBE
The benzene/MTBE contaminated waste water pre-treatment unit consists of the following main sections:
Benzene / MTBE Contaminated Waste Water Collection Tank
Waste Water Steam Stripper
The Benzene / MTBE Contaminated Waste Water Collection Tank (T-85004) is used to collect all the
waste water streams before treatment in the Waste Water Steam Stripper (C-85001). Since the waste
water contains benzene and/or MTBE, the tank is provided with a nitrogen blanket and connected to the
Tank Vent Gas Incinerator Package (ME-86001) through Vent Gas Blower (K-85001A/B). The tank is
equipped with a tangential inlet and oil skimming facilities to remove the separated free oil. From the tank,
waste water is pumped by means of the Benzene / MTBE Contaminated Waste Water Pump (P-
85007 A/B) at a controlled flow to the Waste Water Steam Stripper (C-85001). If necessary, the pH is
adjusted by means of caustic or sulfuric acid dosing upstream the steam stripper.
Benzene / MTBE contaminated waste water is preheated against the stripper effluent stream in Steam
Stripper Feed/Effluent Heat Exchanger (E-85001 A/B) and fed to the top of the Waste Water Steam
Stripper. At the bottom of this column, LP steam is supplied which strips the hydrocarbons out of the
influent. Vapors at the top of the column are condensed and collected in the Steam Stripper Overhead
Reflux Drum (V-85002). In this vessel, the condensed liquid will separate in a water layer and a thin oil
layer, which flows over the installed weir into the hydrocarbons compartment. The water in the vessel is
pumped by means of the Steam Stripper Reflux Pump (P-85008 A/B) on level control as reflux to the
column. The recovered hydrocarbons are routed to the Skimmed Oil Vessel (V-85001). Vapors are vented
to the wet flare system.
Nitrogen will be used in order to maintain sufficient pressure in the overhead system of the column to allow
venting to the flare. Some nitrogen is required in case insufficient hydrocarbons (non-condensable) are
present in the waste water feed stream. It is fed upstream of the Steam Stripper Overhead Condenser (E-
85003) to ensure proper condenser operation. In the event of a pressure loss in the system due to low
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Document Title: Document No. Rev:
Process Description for Waste Water Treatment Unit S-S850-5223-002 0
concentrations of hydrocarbons in the feed, the PC will open the valve in the nitrogen line to bring the
pressure up to the desired set point. When there is an overpressure due to an increase in the quantity of
non-condensable in the feed, the PC opens the valve on the vapor outlet to the wet flare. The pressure in
the overhead reflux drum is set at about 1 barg in order to ensure proper disposal of vents to the flare.
The steam stripped effluent collected from the bottom of the column is pumped by means of the Stripped
Waste Water Pump (P-85009 A/B) to the Waste Water Equalization Tank (T-85002) after heat recovery in
Feed/Effluent Heat Exchanger (E-85001 A/B) and cooling down in Stripped WW Trim Cooler (E-85002) to
below 40 °C using cooling water.
In case of high benzene and/or MTBE contamination of the steam stripped effluent, it is manually routed
back to the Benzene / MTBE Contaminated WW Collection Tank (T-85004). This is also done in case of
low-low temperature in the column. In the latter case, sufficient stripping of benzene/MTBE cannot be
ensured.
If the stripped effluent is on-spec according to benzene/MTBE contamination level but off-spec due to high
TOC, the stripped waste water shall be sent to Waste Water Collection Tank (T-85001) and to be treated
by Dissolved Gas Floatation Unit (ME-85005), Otherwise stripped waste water shall be sent to WW
Equalization Tank (T-85002).
3.4 Waste Water Primary Treatment
The waste water primary treatment will treat oil contaminated waste by means of Dissolved Gas Floatation
(DGF) unit. The waste water primary treatment consists of the following operation units:
Waste Water Collection Tank (T-85001)
DGF Package (ME-85005)
Skimmed Oil Vessel (V-85001)
The Waste Water Collection Tank (T-85001) is used to store the process waste water awaiting the DGF
treatment. The tank is equipped with tangential inlet and skimming facilities to remove any separated free
oil. From the tank, the waste water is pumped by the Waste Water Transfer Pump (P-85004 A/B) under
flow control to Dissolved Gas Floatation (DGF) package (ME-85005). Waste water pH is adjusted by
means of caustic or sulfuric acid dosing upstream DGF unit.
The DGF package should be sized such that to provide sufficient operating flexibility to allow effluent
quality to be maintained in acceptable range by considering the expected variations in the influent
characteristics. The operator should be able to adjust the following major operating variables:
pH
coagulant and flocculant type and dose
nitrogen pressure
recycle rate
Waste water enters on one end and passes sequentially through coagulation, flocculation and floatation
compartments of the DGF unit (ME-85005). Cationic polymer solution is dosed into the influent upstream of
the DGF unit to enhance the removal of free/emulsified oil and suspended solids. The system forces
nitrogen gas into effluent by means of hydraulic eductors. The nitrogen bubbles will adhere to the oil
particles and form flocs and help these particles to float to the water surface of each flotation compartment.
The floating scum layer is removed by means of a surface skimmer mechanism and sent to the Skimmed
Oil Vessel (V-85001) by WW DGF Skimming Pump. The treated waste water will overflow via the effluent
weir into the DGF clearwell compartment and is pumped by means of the DGF Clearwell Pump to the
Waste Water Equalization Tank (T-85002).
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Document Title: Document No. Rev:
Process Description for Waste Water Treatment Unit S-S850-5223-002 0
The Skimmed Oil Vessel collects the following streams:
Skimmed oil from LLOD basins
Skimmed oil from the Waste Water Collection Tank
Skimmed oil from Oily Sludge Storage Tank
Skimmed oil from the Benzene/MTBE Contaminated Waste Water Collection Tank
Skimmed oil from the Steam Stripper Overhead Reflux Drum
DGF skimming
Skimmed oil from Spent Caustic Oxidation unit storage tanks
Inside the Skimmed Oil Vessel (V-85001), a special plate pack is installed to separate oil and water
efficiently. The separated oil is collected via a weir in the oil compartment of the vessel. The collected
skimmed oil will be sent to Liquid-Solid Incinerator Package (ME-86002) by Skimmed Oil Pump (P-85010).
Skimmed Oil Effluent will be transferred to WW Collection Tank(T-85001) by Skimmed Oil Effluent Pump
(P-85011).
3.5 Waste Water Secondary Treatment
The waste water secondary (biological) treatment consists of:
Equalization Tank
Biotreater
Sludge Treatment and Dewatering
The Waste Water Equalization Tank (T-85002) receives the waste water streams to be treated in the
Biological Treatment Package (ME-85006). The following streams are routed to the Waste Water
Equalization Tank:
DGF effluent from the waste water primary treatment
TLE Hydrojetting / decoking quench water effluent
Stripped effluent from Waste Water Steam Stripper
Crystallizer Distillate Effluent from ME-63002.
The Waste Water Equalization Tank has a buffering and homogenization function for the feed stream to
the Biotreater, thus minimizing fluctuations in flow rate and composition.
In the Biotreater, BOD and COD is reduced by activated sludge using dissolved oxygen. Biotreater will
receive feed streams from Contact Tank where the equalized WW will be mixed with the recycled activated
sludge and nutrients (urea and H3PO4).
After pH adjustment, the mixed stream is routed to the Aeration Tank where the required amount of air is
supplied by Air Compressor Package (ME-85017 to be supplied by WW Secondary Treatment Package
Vendor). Control of the required amount of air is done by means of a dissolved oxygen measurement.
Aerated stream will be routed to Clarifier on gravity flow via Degassing Tank. In the Clarifier, the settled
activated sludge is separated from the clean water. Part of the activated sludge is recycled to the Contact
Tank and the excess activated sludge is sent to the Sludge Digester followed by Sludge Thickener. The
clarified water is routed to the tertiary treatment to meet the outfall water specification.
Thickened excess bio-sludge from Sludge Thickener is sent to Sludge Dewatering Package (ME-85007)
where polymer solution is added for conditioning of the sludge. Dewatered bio-sludge is collected in a
mobile bio-sludge cake container, which is trucked out for disposal or sent to incineration. The decanted
water from Sludge Dewatering Package is recycled to the Waste Water Collection Tank (T-85001).
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Document Title: Document No. Rev:
Process Description for Waste Water Treatment Unit S-S850-5223-002 0
Oily sludge will be kept separate from bio-sludge. The oily sludge from LLOD basins, Waste water
Collection Tank (T-85001), Skimming from IAF (ME-85009), Sludge from Polymer Plant and WW Dissolved
Gas Floatation (DGF) package (ME-85005) will be sent to Oily Sludge Collection Tank (T-85005) where it
will be pumped to Sludge Dewatering Package (ME-85007). The dewatered oily sludge is collected in a
mobile oily sludge container for incineration. The reject stream will be sent to Waste Water Secondary
Treatment (ME-85006) Package for further processing.
Air Compressor Package (ME-85017) and Critical Equipment in WW Secondary Treatment Package e.g.
Clarifier Scraper, Recirculating Pump etc. to be fed by Emergency Power Supply System.
3.6 Waste Water Tertiary Treatment
The waste water tertiary treatment consists of:
Disinfection Unit
Continuous Sand Filter
Activated Carbon Filter
Treated Effluent Tank
In order to meet discharge water specification, Sodium Hypochlorite solution is used for chlorination of
clarified water in Chlorination compartment of Chlorination/Dechlorination Basin followed by Sodium
Metabisulfite (SMBS) injection for De-chlorination in De-chlorination compartment.
For removal of remaining suspended solids, the dechlorinated water is routed to the Continuous Sand
Filter. The unit consists of two continuously regenerated sand filters, each designed for 70 % of total
capacity. The continuous backwash stream from the sand filters is recycled to WW Collection Tank (T-
85001). In case of high TOC in Chlorination Tank, the Chlorination Tank has to be drained into the Waste
Water Collection Tank (T-85001) via Backwash Effluent Basin.
The clean effluent from sand filters will flow on gravity into the Filtrate Basin, where the treated effluent
quality is continuously monitored by means of a flow, turbidity, temperature, TOD and pH measurement.
It is expected that sand filter clear water can meet the outfall water quality. However, in case of
hydrocarbon contamination, the effluent can be sent to Activated Carbon Filters for final polishing. The
treated waste water will be sent to the Treated Effluent Tank (T-85003).
3.7 Chemical Storage, Preparation and Dosing
Concentrated Sulfuric Acid Dosing Package (ME-85015)
Concentrated sulfuric acid (H2SO4) is used for pH control within waste water treatment unit. Concentrated
sulfuric acid is supplied from Sulfuric Acid Storage Tank to Sulfuric Acid Dosing Vessel. The dosing vessel
vent/breathing line is routed to hydraulically sealed neutralization pot, filled with Limestone.
Sulfuric Acid Dosing Vessel and Sulfuric Acid Dosing Pump are surrounded by a dike wall to isolate the
package from surrounding environment in case of any accidental leakages. The drainage is routed to
Neutralization Pit (Z-85005).
Caustic Soda Dosing Package (ME-85014)
Caustic soda (20 wt%) is used for pH control within wastewater treatment unit. Caustic soda (20 wt%) is
supplied from Caustic Storage Tank to Caustic Dosing Vessel. The dosing vessel vent/breathing line is
routed to hydraulically sealed neutralization pot.
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Process Description for Waste Water Treatment Unit S-S850-5223-002 0
Caustic Dosing Vessel and Caustic Dosing Pump are surrounded by a dike wall to isolate the package
from surrounding environment in case of any accidental leakages. The drainage is routed to Neutralization
Pit (Z-85005).Nutrient (Urea and Phosphoric Acid) Preparation and Dosing Package (ME-85012)
Urea and phosphoric acid are used as nitrogen and phosphorous supplement for Aeration Tanks and
aerobic Sludge Digester.
Granular urea is dissolved in water with a concentration of about 10 wt% and stored in Urea Solution Tank.
Diluted urea is sent to the users by Urea Solution Dosing Pump.
Concentrated phosphoric acid is supplied in 1 m3 plastic containers. Concentrated phosphoric acid is
diluted with water to a concentration of about 10 wt% in Phosphoric Acid Dosing Vessel and is sent to the
users via Phosphoric Acid Dosing Pumps. The dosing packages are surrounded by a dike wall to isolate
the package from surrounding environment in case of any accidental leakages. The drainage is routed to
Neutralization Pit (Z-85005).
Hypochlorite and SMBS Dosing Package (ME-85016)
Sodium hypochlorite is used for treated wastewater disinfection and Sodium Metabisulfite (SMBS) is
utilized for dechlorination of treated wastewater in Chlorination/Dechlorination Basin.
Sodium hypochlorite and SMBS will be supplied by bag/container. All required components for preparation,
injection and control of hypochlorite and SMBS into treated waste water will be provided by package (ME-
85016) vendor. The drainage is routed to Neutralization Pit (Z-85005).
Polymer Preparation and Dosing Package (ME-85013)
Cationic polyelectrolyte is used as coagulant in the following equipment:
WW Dissolved Gas Floatation (DGF) Package (ME-85005)
Secondary Clarifier in Biotreater (ME-85006)
Sludge Dewatering Package (ME-85007)
Induced Air Floatation (IAF) Package (ME-85009)
Storm Water Clarifier (ME-85010)
Solid polyelectrolyte is dissolved in water and injected into influent streams by means of injection pumps.
All chemical dosing packages are surrounded by a dike wall to isolate the package from surrounding
environment in case of any accidental leakages. The drainage is routed to Neutralization Pit (Z-85005).
Chemical Neutralization
All chemical drains, Benzene/MTBE contaminated WW from drainage of P-85007A/B, P-85008A/B and P-
85009A/B are routed by gravity to Neutralization Pit (Z-85005) where either caustic or sulfuric acid will be
added to neutralize the content of basin. A pH measurement is installed for control of neutralization.
To facilitate neutralization process, Neutralization Pit Pump (P-85012 A/B) is utilized to circulate the basin
content. The neutralized chemical will be sent to Cooling Water Outfall channel along with manual
provision for routing it to WW Equalization Tank. Primary destination is Cooling Water Outfall Channel. Due
to high salt content in Neutralized chemical effluent, treated waste water may not meet outfall water spec in
case of routing it to Equalization Tank (T-85002).
The operators are to flush the chemical collection header with water after each drain or spillage.
Page 11 of 11
Liwa Plastics Project
CB&I ORPIC
Document Title: Operation and Control Philosophy – WWTU 8500
Document No: S-S850-5371-101
CB&I Contract No: 189709
Issued for FEED 0 16-Mar-2015 RKALKMAN SNAZARI JL
Revision Descriptions Rev Date Originator Checker Approver
Page 1 of 13
"THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY (CB&I). IT MAY CONTAIN INFORMATION
DESCRIBING TECHNOLOGY OWNED BY CB&I AND DEEMED TO BE COMMERCIALLY SENSITIVE. IT IS TO BE USED ONLY IN
CONNECTION WITH WORK PERFORMED BY CB&I. REPRODUCTION IN WHOLE OR IN PART FOR ANY PURPOSE OTHER THAN
WORK PERFORMED BY CB&I IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN PERMISSION OF CB&I. IT IS TO BE SAFEGUARDED
AGAINST BOTH DELIBERATE AND INADVERTENT DISCLOSURE TO ANY THIRD PARTY."
Liwa Plastics Project
Document Title: Document No. Rev:
Operation and Control Philosophy – WWTU 8500 S-S850-5371-101 0
INPUTS / REFERENCE DOCUMENTS
Document Number Title Status
S-S000-5223-003 Process Design Basis for Off-Sites Facilities
D-S850-5223-101..120 Utility Process Flow Diagram – Waste Water Treatment Unit
S-S850-5223-002 Process Description – WWTU 8500
S-G000-5220-011 General Process Control Functional Specification
REVISION NOTES AND HOLDS
Revision Description of Changes & Holds
HOLDS Description of Holds Rev Date
1 Deleted
2 Deleted
3 Deleted
4
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Document Title: Document No. Rev:
Operation and Control Philosophy – WWTU 8500 S-S850-5371-101 0
Table of Contents
Contents Page
1.0 INTRODUCTION..................................................................................................................................4
1.1 Purpose ....................................................................................................................................4
1.2 General .....................................................................................................................................4
2.0 REFERENCES.....................................................................................................................................4
3.0 DEFINITIONS ......................................................................................................................................4
4.0 OPERATIONAL CONTROL PHILOSPHY............................................................................................5
4.1 Liquid Waste Handling and Collection ....................................................................................5
4.2 Last Line Of Defense................................................................................................................5
4.3 Benzene / MTBE Contaminated Waste Water Pre-treatment..................................................7
4.4 Waste Water Primary Treatment..............................................................................................9
4.5 Waste Water Secondary Treatment .......................................................................................10
4.6 Waste Water Tertiary Treatment ............................................................................................11
4.7 Chemical Storage, Preparation and Dosing..........................................................................12
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Liwa Plastics Project
Document Title: Document No. Rev:
Operation and Control Philosophy – WWTU 8500 S-S850-5371-101 0
1.0 INTRODUCTION
1.1 Purpose
The purpose of this document is to present the operation and process control philosophy for the new
Waste Water Treatment Unit 8500, part of the off-sites facilities of the LPP.
1.2 General
Process control is a multi-disciplinary specialism where the process objectives, process constraints,
instrumentation functionality and operational experience should come together to maintain a safe, stable
and optimum operation.
All process control activities are related to the following two functionalities:
Operational control
Instrumented safeguarding
1.2.1 Operational control
Operational control involves all manual, continuous and automated actions to properly operate the process
and keep the process within its operating window. Operational control consists of regulatory control,
sequence control, manual manipulation and advanced process control.
1.2.2 Instrumented safeguarding
Instrumented safeguarding involves all unscheduled instrument actions which are designed to set the
process in a safe state if it moves out of its operating window and towards an unsafe situation.
Instrumented safeguarding comprises of the protection against personal injury, equipment and
environmental damage and production loss.
2.0 REFERENCES
The following documents are referenced herein and form part of the technical requirements.
This document shall be read in conjunction with the following documents:
S-S000-5223-003 Process Design Basis for Off-Sites Facilities
D-S850-5223-101 .. 120 Utility Process Flow Diagram - Waste Water Treatment Unit
S-S8500-5223-002 Process Description – WWTU 8500
S-G000-5220-011 General Process Control Functional Specification
3.0 DEFINITIONS
Term Definition
ASL Atmospheric Safe Location
AOC Accidentally Oil Contaminated
BOD Biological Oxygen Demand
BPCS Basic Process Control System
COD Chemical Oxygen Demand
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Document Title: Document No. Rev:
Operation and Control Philosophy – WWTU 8500 S-S850-5371-101 0
DGF Dissolved Gas Floatation
EPC Engineering Procurement and Construction
FFB First Flush Basin
IAF Induced Air Floatation
LLOD Last Line Of Defense
LPP Liwa Plastic Project
OC Oil Contaminated
OCB Oil Contaminated Basin
ORPIC Oman Oil Refineries and Petroleum Industries Company
PFD Process Flow Diagram
POB Peak Overflow Basin
SCU Steam Cracker Unit
SIS Safety Instrumented System
TOD Total Oxygen Demand
UFD Utility Flow Diagram
WW Waste Water
WWTU Waste Water Treatment Unit
4.0 OPERATIONAL CONTROL PHILOSPHY
4.1 Liquid Waste Handling and Collection
All liquid waste streams coming from process, utility and storage areas that could be contaminated with
hydrocarbon shall be collected and treated before disposal into open water. It is assumed that all chemical
effluent will be neutralized inside the process battery limits before sending to the off-site area.
The WWTU consists mainly of the following sections:
Last Line Of Defense
Benzene and MTBE contaminated waste water pre-treatment
Waste water primary treatment
Waste water secondary (biological) treatment
Waste water tertiary treatment
Chemical storage, preparation and dosing packages
Clean surface water run-off treatment
Depending on the type of pollution, the waste water stream is routed to the appropriate treatment.
4.2 Last Line Of Defense
Equipment oily drains, pump base plates, hydrocarbon sampling points and surface water run-off typically
rain, fire and wash water from the paved areas, where hydrocarbon pollution may occur, are collected upon
discharge by proper sewer system and routed by gravity to the below grade LLOD basins.
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Document Title: Document No. Rev:
Operation and Control Philosophy – WWTU 8500 S-S850-5371-101 0
The LLOD consists of influent Bar Screening Package ME-85001 and ME-85002, Oil Contaminated Basin
Z-85001, First Flush Basin Z-85002, Peak Overflow Basin Z-85003 and relevant pumps. The inlet
compartments of Z-85001 and Z-85002 are equipped with Oil Skimmer and Sludge Scraper ME-85003 and
ME-85004. The collected sludge will be transferred via LLOD Sludge Pumps P-85003A/B/C/D to Oily
Sludge Collection Tank T-85005 awaiting dewatering process.
Oily Water Sewer
Equipment oily drains, pump base plates, hydrocarbon sampling points and surface water run-off from the
paved area where hydrocarbon leakage expected to be occurred shall be collected by oily water sewer
system and routed by gravity to OCB Z-85001. Collected oily water is transferred to Waste Water
Collection Tank T-85001 via OC Water Pump P-85001A/B for appropriate treatment. Pump P-85001A/B
will be fed by emergency power and protected against clogging by OC Water Screening Package ME-
85001. The inlet compartment of OCB is equipped with a portable floating type oil skimmer to collect
skimmed oil. The skimmed oil is routed to Skimmed Oil Vessel V-85001.
The oily water level in Z-85001 is controlled by ON/OFF control via level transmitter located in Z-85001. In
case of the level in Z-85001 rises to a certain H level, pump P-85001A is automatically started by BPCS.
When the level still rises up to HH level limit, pump P-85001B is started by BPCS. When the level lowers to
a certain L level limit, pump P-85001A is automatically stopped by BPCS. When the level lowers to a
certain LL level limit pump P-85001B is automatically stopped by BPCS.
The quality of surface water run-off from the paved area where benzene / MTBE spillage may occur shall
be checked before routing to the sewer system. In case of high benzene / MTBE contamination, surface
water run-off shall be collected and sent to benzene / MTBE contaminated waste water pre-treatment unit.
Accidently Oil Contaminated Sewer
The AOC sewer system collects equipment drains and surface water run-off which is polluted neither by
benzene / MTBE nor by high concentration of other hydrocarbons and routes the collected effluent to FFB
Z-85002 through AOC Water Screening Package ME-85002, used to remove large objects for protecting
downstream equipment against damage or clogging. The inlet compartment of FFB is equipped with a
portable floating type oil skimmer to collect skimmed oil. The skimmed oil is transferred to Skimmed Oil
Vessel V-85001.
FFB is designed to hold rain water run-off from potentially hydrocarbon polluted area during first 35
minutes of rain fall. After this period FFB is filled and the surface water run-off overflows to POB. It is
expected that the contamination level of surface water run-off collected in POB is diluted to such an extent
that can bypass biological treatment and be treated only by IAF unit ME-85009. If the quality of collected
run-off in POB is far from outfall water specification (high BOD / high COD), the collected run-off shall be
treated along with first flush water collected in FFB in biological treatment unit. In addition, the POB is used
as surge basin in case of cooling water oil contamination. The WW in POB is routed to the Air Floatation
Package ME-85009 by using POB Water Pump P-85014A/B. Pump P-85014A/B is started manually by
operator and is protected by low level switch function located in POB Z-85003 via BPCS. Standby pump P-
85014A/B is available and can be used when required.
However, if the quality of collected water in FFB is off-spec due to high BOD / high COD, the water will be
sent to Waste Water Collection Tank T-85001 by means of FFB Water Pump P-85002A/B for further
treatment in the WWTU. Pump P-85002A/B is started manually by operator and is protected by low level
switch function located in FFB Z-85002 via the BPCS. Standby pump P-85002A/B is available and can be
used when required.
Sludge handling
LLOD Sludge from OCB Z-85001 screening package ME-85001, is routed to Oily Sludge Collection Tank
T-85005 by LLOD Sludge Pump P-85003A/B. The selected duty pump P-85003A/B via BPCS is
automatically started upon H level limit and automatically stopped upon L level limit. A standby pump is
available and can be used when required.
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Document Title: Document No. Rev:
Operation and Control Philosophy – WWTU 8500 S-S850-5371-101 0
LLOD Sludge from FFB Z-85002 screening package ME-85002, is routed to Oily Sludge Collection Tank T-
85005 by LLOD Sludge Pump P-85003C/D. The selected duty pump P-85003C/D via BPCS is
automatically started upon H level limit and automatically stopped upon L level limit. A standby pump is
available and can be used when required.
Clean Water Sewer System
This system is a clean water sewer, collecting surface water run-off from non-contaminated areas where
source of hydrocarbon leakage/spillage does not exist. Due to the collected run-off is inherently clean, it
will be routed by gravity to the Storm Water Channel Pump Pit Z-85006. Overflow from Storm Water
Channel Pump Pit is routed to outfall channel. Collected surface water run-off is routed to Storm Water
Clarifier ME-85010 by using Storm Water Pump P-85015A/B. P-85015A/B is manually started and
protected against running dry by low level trip in the BPCS on the pump pit. The flow to ME-85010 is set by
single flow controller which manipulates the flow control valve downstream the controller. In package ME-
85010 suspended solids and trace of hydrocarbons (if any) will be separated. The clarified storm water will
be sent to MISC along with the provision for sending it to sea water return channel, and the collected
sludge will be transferred to Sludge Dewatering Package ME-85007.
All controls and instrumented safeguarding of the Storm Water Channel and the Storm Water Clarifier ME-
85010 shall be housed within the BPCS and SIS. This will be further developed during EPC phase of the
LPP by Detail Engineering Contractor and vendor.
Domestic Sewer System
This system collects domestic waste water from toilets, urinals, kitchen facilities, sinks, showers and the
like from buildings and shelters. Domestic effluent from kitchen facilities shall be equipped with grease
traps. Domestic effluents are routed by a sloped gravity underground pipe system into the centralized
Domestic Lift Station ME-85011. Eight (8) Domestic Lift Pump stations will be installed in specific areas
which shall transfer the solid and liquid wastes routed to MISC (OSBL) for further treatment.
All controls and instrumented safeguarding of the Domestic Lift Station ME-85011 shall be housed within
the BPCS and SIS. This will be further developed during EPC phase of the LPP by vendor.
Chemical Sewer System
To meet outfall water specification, the spent chemicals shall be neutralized first.
The Chemical Effluent from the collection system is collected by the Neutralization Pit Z-85005, where the
chemical solution is neutralized. The chemical content of the Neutralization Pit is mixed by a Jet Mixer M-
85003. The chemical solution from Z-85005 is pumped through the Jet Mixer M-85003, by Neutralization
Pit Pump P-85012A/B. The pump is manual operated by the operator and a standby pump is available
when required. The pump is protected against running dry, by means of low low level trip, which stops the
pump via BPCS. 20wt% Caustic from Caustic Dosing Package ME-85014 and concentrated sulfuric acid
from Sulfuric Acid Dosing Package ME-85015 can be added in the discharge stream of P-85012A/B, to
neutralize the chemical mixture in the Neutralization Pit Z-85005.
The neutralized spent chemical can be normally transferred to the Cooling Water Outfall Channel when the
temperature is right without further treatment, by using the Neutralization Pit Pump P-85012A/B, along with
manual provision for routing it to the WW Equalization Tank. In normal operation the primary destination is
the Cooling Water Outfall Channel, however due to high salt content in the neutralized chemical effluent
the treated WW may not meet the outfall water specification. When Outfall WW specification is not met the
neutralized spent chemical will be routed to the WW Equalization Tank.
4.3 Benzene / MTBE Contaminated Waste Water Pre-treatment
The benzene / MTBE contaminated waste water pre-treatment will treat WW contaminated with benzene or
MTBE. By utilizing steam stripping the benzene content is reduced to 1 ppmw.
The Benzene / MTBE contaminated WW pre-treatment unit consists of the following main sections:
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Document Title: Document No. Rev:
Operation and Control Philosophy – WWTU 8500 S-S850-5371-101 0
Benzene / MTBE Contaminated Waste Water Collection Tank
Waste Water Steam Stripper
The Benzene / MTBE Contaminated Waste Water Collection Tank T-85004 is used to collect all the waste
water streams before treatment in the Waste Water Steam Stripper C-85001. Since the WW contains
benzene and/or MTBE, the tank is provided with nitrogen blanketing. It is advised to provide the Nitrogen
blanketing pressure control with a ‘dead band’ (gap control), in order to avoid waste of Nitrogen. When the
pressure lowers in the tank to a certain limit Nitrogen will be added, and when the pressure rises to a
certain limit vapors from the tank are vented to the Vent Gas Incinerator Unit via Vent Gas Blower K-
85001A/B.
The tank is equipped with a tangential inlet and oil skimming facilities to remove the separated free oil.
From the tank, waste water is pumped by means of the Benzene / MTBE Contaminated Waste Water
Pump P-85007A/B on flow control to the Waste Water Steam Stripper C-85001. The Contaminated WW
flow to C-85001 is maintained by master level controller located on the WW Collection Tank T-85004,
which adjusts the set point of the slave Contaminated WW flow controller. The flow controller manipulates
the flow control valve in the Contaminated WW line connected to the top of C-85001. If necessary, the pH
of the Contaminated WW is adjusted by means of caustic or sulfuric acid dosing upstream the Steam
Stripper Feed/Effluent Heat Exchanger E-85001A/B. It is advised to provide the pH control with a ‘dead
band’ (gap control), in order to avoid waste of chemicals and unstable pH value. When the pH value lowers
to a certain limit, sulfuric acid will be added via control valve. In case of the pH value rises to a certain limit,
caustic will be added via control valve.
Benzene / MTBE contaminated WW is preheated by the stripper effluent stream in Steam Stripper
Feed/Effluent Heat Exchanger E-85001 A/B and fed to the top of the Waste Water Steam Stripper C-
85001. At the bottom of this column, LLP steam is supplied which strips the hydrocarbons out of the
influent. The amount of LP steam is controlled by a steam control valve located in the LLP steam supply
line, which is manipulated by a flow controller located in the column overhead line. The flow controller
output is adjusted automatically by a Feed Forward signal from the influent flow controller. In case of more
or less influent is transferred to the column, the overhead flow controller is reacting automatically. Vapors
at the top of the column are condensed and collected in the Steam Stripper Overhead Reflux Drum V-
85002. In this vessel, the condensed liquid will separate in a water layer and a thin oil layer, which flows
over the installed weir into the hydrocarbons compartment. The water in the vessel is pumped by means of
the Steam Stripper Reflux Pump P-85008A/B on level control as reflux to the column. A single interface
level controller in V-85002 manipulates the pump stroke length of pump P-85008A/B, in order to maintain a
stable level. A standby pump is available when required. The recovered hydrocarbons are routed to the
Skimmed Oil Vessel V-85001 on intermittent basis, by level on/off control, which manipulates the on/off
valve in the recovered hydrocarbon outlet of V-85002 to the open position automatically when the level
rises to a certain H level limit. The valve is closed automatically when the level is lowered to a certain L
level limit. Vapors are vented to the wet flare system.
Nitrogen will be used in order to maintain sufficient pressure in the overhead system of the column to allow
venting to the flare. Some nitrogen is required in case insufficient hydrocarbons (non-condensable) are
present in the waste water feed stream. It is fed upstream of the Steam Stripper Overhead Condenser E-
85003 to ensure proper condenser operation. In the event of a pressure loss in the system due to low
concentrations of hydrocarbons in the feed, the pressure controller will open the valve in the nitrogen line
to bring the pressure up to the desired set point. When there is an overpressure due to an increase in the
quantity of non-condensable in the feed, the pressure controller opens the valve on the vapor outlet to the
wet flare. It is advised to provide the pressure control with a ‘dead band’ (gap control), in order to avoid
waste of Nitrogen. The pressure in the overhead reflux drum is set at about 1 barg in order to ensure
proper disposal of vents to the flare.
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Document Title: Document No. Rev:
Operation and Control Philosophy – WWTU 8500 S-S850-5371-101 0
The steam stripped effluent collected in the bottom of the column is pumped to the Waste Water
Equalization Tank T-85002 by means of the Stripped Waste Water Pump P-85009A/B under flow control,
after heat recovery in Feed/Effluent Heat Exchanger E-85001A/B. Downstream E-85001A/B the Stripped
WW is further cooled in Stripped WW Trim Cooler E-85002 to below 40°C using cooling water.
Downstream E-85002 the slave flow controller is located, which manipulates the flow control valve
downstream the flow controller in the same line. The slave flow controller set point is automatically
adjusted by master level controller, which is located at the bottom of the WW Steam Stripper C-85001 in
order to maintain a stable level. The Stripped WW Pump P-85009A/B is protected against too low flow by
minimum flow controller located in the pump discharge, which manipulates flow control valve in the pump
minimum flow bypass line routed back to the column bottom. The standby pump is started automatically
upon HH level limit in the stripper bottom and automatically stopped upon LL level limit, detected by BPCS
level transmitter.
In case of high benzene and/or MTBE contamination of the steam stripped effluent, it is manually routed by
BPCS operated 3-way valve back to the Benzene / MTBE Contaminated WW Collection Tank T-85004 for
recycle. This is also done in case of low-low temperature in the column. In the latter case, sufficient
stripping of benzene/MTBE cannot be ensured.
If the stripped effluent is on-spec according to benzene/MTBE contamination level but off-spec due to high
Total Oil Content, the stripped WW shall be manually routed by BPCS operated 3-way valve to Waste
Water Collection Tank T-85001 and to be treated by Dissolved Gas Floatation Unit ME-85005. During
normal operation the stripped WW shall be sent to WW Equalization Tank T-85002.
4.4 Waste Water Primary Treatment
The waste water primary treatment will treat oil contaminated waste by using the Dissolved Gas Floatation
unit. The waste water primary treatment consists of the following operation units:
Waste Water Collection Tank T-85001
DGF Package ME-85005
Skimmed Oil Vessel V-85001
The Waste Water Collection Tank T-85001 is used to store the process WW awaiting the DGF treatment.
The tank is equipped with tangential inlet and skimming facilities to remove any separated free oil. From
the tank, the waste water is transferred by the Waste Water Transfer Pump P-85004A/B under flow control
to the DGF package ME-85005. T-85001 is provided with nitrogen blanketing. It is advised to provide the
Nitrogen blanketing pressure control with a ‘dead band’ (gap control), in order to avoid waste of Nitrogen.
When the pressure lowers in the tank to a certain limit Nitrogen will be added, and when the pressure rises
to a certain limit vapors from the tank are vented to the Vent Gas Incinerator Unit via Vent Gas Blower K-
85001A/B. The Vent gas Blower is equipped with a pressure controller, which regulates the suction
pressure of the blower by manipulating the pressure control valve in the discharge of the blower. A low flow
bypass across the blower prevents the blower from damage, by using a flow controller in the blower
discharge, which manipulates the flow control valve in the blower bypass line.
The amount of WW to DGF package ME-85005 is flow controlled by a slave flow controller, which
manipulates the downstream flow control valve in the WW transfer line to DGF package ME-85005. The
slave flow controller set point is adjusted automatically by master level controller located on the WW
Collection Tank T-85001. A Feed Forward signal (flow value) from the flow controller is used for
anticipating on pH control by dosing of Caustic or Sulfuric Acid into the WW stream within package ME-
85005.
The DGF package ME-85005 should be developed to provide sufficient operating flexibility to allow effluent
quality to be maintained in acceptable range by considering the expected variations in the influent
characteristics. The operator should be able to adjust the following major operating variables:
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Document Title: Document No. Rev:
Operation and Control Philosophy – WWTU 8500 S-S850-5371-101 0
pH
coagulant and flocculant type and dose
nitrogen pressure
recycle rate
WW enters on one end and passes sequentially through coagulation, flocculation and floatation
compartments of the DGF package ME-85005. Poly electrolyte is dosed into the influent upstream of the
DGF unit to enhance the removal of free/emulsified oil and suspended solids. The system forces nitrogen
gas into effluent by means of hydraulic eductors. The nitrogen bubbles will adhere to the oil particles and
form flocs and help these particles to float to the water surface of each flotation compartment. The floating
scum layer is removed by means of a surface skimmer mechanism and sent to the Skimmed Oil Vessel V-
85001. The treated waste water will overflow via the effluent weir into the DGF clear well compartment and
is pumped by means of the DGF Clear well Pump to the Waste Water Equalization Tank T-85002.
All controls and instrumented safeguarding of the DGF package ME-85005 shall be housed within the
BPCS and SIS. This will be further developed during EPC phase of the LPP by vendor.
The Skimmed Oil Vessel V-85001 collects several oil streams from oil skimming facilities. Inside the vessel
a special plate pack is provided to separate the oil and water efficiently. The separated oil is collected via a
weir in the oil compartment of the vessel. This vessel is equipped with an interface level controller in the
oil/water compartment, which manipulates the variable speed drive of the Skimmed Oil Vessel Effluent
Pump P-85011, in order to maintain the interface level in the vessel. Pump P-85011 transfers Skimmed Oil
Vessel Effluent to WW Collection tank T-85001. On/off level control function in the oil compartment of the
vessel starts the Skimmed Oil Pump P-85010 automatically when a certain H level limit is reached, which
transfers skimmed oil to the Liquid Incinerator Package. When the level is lowered to a certain L level limit,
the pump is automatically stopped.
4.5 Waste Water Secondary Treatment
The waste water secondary (biological) treatment consists of:
Equalization Tank
Biotreater (part of package ME-85006)
Sludge Treatment and Dewatering (part of package ME-85007)
The Waste Water Equalization Tank T-85002 receives the waste water streams to be treated in the
Biological Treatment Package ME-85006. The Waste Water Equalization Tank has a buffering and
homogenization function for the feed stream to the Biotreater. T-85002 is equipped with compressed air
nozzles inside the tank, to allow pre-dissolving oxygen in the WW if required. The compressed air flow can
be set by single flow controller in the compressed air line towards the nozzles, which manipulates the flow
control valve in the same line. The compressed air is produced by a compressed air package ME-85017,
details to be provided by vendor in EPC phase of the LPP. The WW is transferred by Equalization Tank
Transfer Pump P-85005A/B under flow control to the Biotreater. The slave flow controller manipulates the
flow control valve in the discharge of the pump P-85005A/B. The master level controller on the Waste
Water Equalization Tank T-85002, adjusts the set point of the slave flow controller, in order to maintain a
stable level in the tank. A Feed Forward signal from the flow controller (flow value) is used on the PH
controller in the Biotreater, in order to have a stable and accurate pH level. A part of the discharge flow
from pump P-85005A/B is transferred to the Waste Water Equalization Tank Jet Mixer M-85001 for
continuous mixing of the WW in the tank. Pump P-85005A/B is protected against running dry by low level
trip in the tank. A standby pump is available when required.
In the Biotreater package ME-85006, BOD and COD is reduced by activated sludge using dissolved
oxygen. Biotreater will receive feed streams from Contact Tank where the equalized WW will be mixed with
the recycled activated sludge and nutrients (urea and phosphoric acid).
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Document Title: Document No. Rev:
Operation and Control Philosophy – WWTU 8500 S-S850-5371-101 0
After pH adjustment, the mixed stream is routed to the Aeration Tank where the required amount of air is
supplied by Air Compressor Package ME-85017. Control of the required amount of air is done by means of
a dissolved oxygen measurement. Aerated stream will be routed to Clarifier on gravity flow via Degassing
Tank. In the Clarifier, the settled activated sludge is separated from the clean water. Part of the activated
sludge is recycled to the Contact Tank and the excess activated sludge is sent to the Sludge Digester
followed by Sludge Thickener part of package ME-85006. The clarified water is routed to the tertiary
treatment to meet the outfall water specification.
All controls and instrumented safeguarding of the Compressed Air Package ME-85017 and Biotreater
package ME-85006, shall be housed within the BPCS and SIS. This will be further developed during EPC
phase of the LPP by vendor.
Thickened excess bio-sludge from Sludge Thickener is sent to Sludge Dewatering Package ME-85007
where polymer electrolyte solution is added for conditioning of the sludge. Dewatered bio-sludge is
collected in a mobile bio-sludge cake container, which is trucked out for disposal or incineration. The
decanted water from Sludge Dewatering Package ME-85007 is recycled to the Waste Water Collection
Tank T-85001.
Oily sludge will be kept separate from bio-sludge. The oily sludge from LLOD basins, Waste Water
Collection Tank T-85001, skimming from IAF Package ME-85009, sludge from polymer plant and WW
Dissolved Gas Floatation package ME-85005, will be routed to Oily Sludge Collection Tank T-85005 where
it will be pumped by Oily Sludge Pump P-85013A/B to Sludge Dewatering Package ME-85007. The
dewatered oily sludge is collected in a mobile oily sludge container for incineration. The reject stream will
be sent to Sludge Treatment Package ME-85006 for further processing. T-85005 is provided with Nitrogen
blanketing. It is advised to provide the Nitrogen blanketing pressure control with a ‘dead band’ (gap
control), in order to avoid waste of Nitrogen. When the pressure lowers in the tank to a certain limit
Nitrogen will be added, and when the pressure rises to a certain limit vapors from the tank are vented to
the Vent Gas Incinerator Unit via Vent Gas Blower K-85001A/B. The Oily Sludge Pump P-85013A/B is
protected against running dry by a low level trip on the tank via BPCS. A standby pump is available when
required.
All controls and instrumented safeguarding of the Sludge Dewatering Package ME-85007, shall be housed
within the BPCS and SIS. This will be further developed during EPC phase of the LPP by vendor.
4.6 Waste Water Tertiary Treatment
The waste water tertiary treatment consists of:
Disinfection Unit (part of package ME-85008)
Continuous Sand Filter (part of package ME-85008)
Activated Carbon Filter (part of package ME-85008)
Treated Effluent Tank
In order to meet outfall water specification, Sodium Hypochlorite solution is used for chlorination of clarified
water in Chlorination compartment of Chlorination/De-chlorination Basin followed by Sodium Metabisulfate
(SMBS) injection for de-chlorination in de-chlorination compartment.
For removal of remaining suspended solids, the de-chlorinated water is routed to the Continuous Sand
Filter. The unit consists of two continuously regenerated sand filters, each designed for 70 % of total
capacity. The continuous backwash stream from the sand filters is recycled to WW Collection Tank T-
85001. The clean effluent from sand filters will flow on gravity into the Filtrate Basin, where the treated
effluent quality is continuously monitored by means of a flow, turbidity, temperature, TOD and pH
measurement.
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Document Title: Document No. Rev:
Operation and Control Philosophy – WWTU 8500 S-S850-5371-101 0
It is expected that sand filter effluent (clear water) can meet the outfall water quality. However, in case of
hydrocarbon contamination or high BOD / COD, the effluent can be transferred by manual operation of a 3-
way valve via BPCS to the Activated Carbon Filters for final polishing.
All controls and instrumented safeguarding of the Waste Water Tertiary Treatment package ME-85008,
shall be housed within the BPCS and SIS. This will be further developed during EPC phase of the LPP by
vendor.
Finally the treated WW will be transferred to the Treated Effluent Tank T-85003, from where the treated
WW is transferred to MISC (OSBL) by using Treated Effluent Pump P-85006A/B under flow control. The
slave flow controller in the discharge of the pump manipulates the downstream located flow control valve.
The master level controller on T-85003 adjusts the set point of the slave flow controller automatically, in
order to maintain a stable level in the tank. A standby pump is available when required.
4.7 Chemical Storage, Preparation and Dosing
Sulfuric Acid Dosing Package ME-85015
Concentrated Sulfuric Acid (H2SO4) is used for pH control within the waste water treatment unit.
Concentrated Sulfuric Acid is supplied from Sulfuric Acid Storage Tank to Sulfuric Acid Dosing Vessel. The
dosing vessel vent/breathing line is routed to hydraulically sealed neutralization pot, filled with limestone.
The drainage is routed to the Neutralization Pit Z-85005.
All controls and instrumented safeguarding of the Sulfuric Acid Dosing package ME-85015, shall be
housed within the BPCS and SIS. This will be further developed during EPC phase of the LPP by vendor.
Caustic Soda Dosing Package ME-85014
Caustic Soda (20 wt%) is used for pH control within the wastewater treatment unit. Caustic Soda (20 wt%)
is supplied from Caustic Storage Tank to Caustic Dosing Vessel. The dosing vessel vent/breathing line is
routed to hydraulically sealed neutralization pot. The drainage is routed to the Neutralization Pit Z-85005.
All controls and instrumented safeguarding of the Caustic Soda Dosing package ME-85014, shall be
housed within the BPCS and SIS. This will be further developed during EPC phase of the LPP by vendor.
Nutrient (Urea and Phosphoric Acid) Preparation and Dosing Package ME-85012
Urea and phosphoric acid are used as nitrogen and phosphorous supplement for Aeration Tanks and
aerobic Sludge Digester.
Granular urea is dissolved in water with a concentration of about 10 wt% and stored in Urea Solution Tank.
Diluted urea is sent to the users by Urea Solution Dosing Pump.
Concentrated phosphoric acid is supplied in 1 m3 plastic containers. Concentrated phosphoric acid is
diluted with water to a concentration of about 10 wt% in Phosphoric Acid Dosing Vessel and is sent to the
users via Phosphoric Acid Dosing Pumps. The drainage of both tanks is routed to the Neutralization Pit Z-
85005.
All controls and instrumented safeguarding of the Nutrient Preparation and Dosing package ME-85012,
shall be housed within the BPCS and SIS. This will be further developed during EPC phase of the LPP by
vendor.
Hypochlorite and SMBS Dosing Package (ME-85016)
Sodium hypochlorite is used for treated wastewater disinfection and Sodium Metabisulfate (SMBS) is
utilized for dechlorination of treated wastewater in Chlorination/Dechlorination Basin.
Sodium hypochlorite and SMBS will be supplied by bag/container.
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Document Title: Document No. Rev:
Operation and Control Philosophy – WWTU 8500 S-S850-5371-101 0
All controls and instrumented safeguarding of the Hypochlorite and SMBS Dosing package ME-85016,
shall be housed within the BPCS and SIS. This will be further developed during EPC phase of the LPP by
vendor.
Polymer Preparation and Dosing Package ME-85013
Cationic polyelectrolyte is used as coagulant in the following equipment:
WW Dissolved Gas Floatation (DGF) Package ME-85005
Secondary Clarifier in Biotreater ME-85006
Sludge Dewatering Package ME-85007
Induced Air Floatation (IAF) Package ME-85009
Storm water clarifier ME-85010
Solid polyelectrolyte is dissolved in water and injected into influent streams by means of injection pumps.
The drainage is routed to the Neutralization Pit Z-85005.
All controls and instrumented safeguarding of the Polymer Preparation and Dosing package ME-85013,
shall be housed within the BPCS and SIS. This will be further developed during EPC phase of the LPP by
vendor.
Page 13 of 13
Liwa Plastics Project
CB&I ORPIC
Document Title: Guidelines for Operating Manual - Off Sites
Document No: S-S800-5230-001
CB&I Contract No: 189709
Issued for Feed 0 25-Mar-2015 KJADHAV SNAZARI JL
Revision Descriptions Rev Date Originator Checker Approver
Page 1 of 75
"THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY (CB&I). IT MAY CONTAIN INFORMATION
DESCRIBING TECHNOLOGY OWNED BY CB&I AND DEEMED TO BE COMMERCIALLY SENSITIVE. IT IS TO BE USED ONLY IN
CONNECTION WITH WORK PERFORMED BY CB&I. REPRODUCTION IN WHOLE OR IN PART FOR ANY PURPOSE OTHER THAN
WORK PERFORMED BY CB&I IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN PERMISSION OF CB&I. IT IS TO BE SAFEGUARDED
AGAINST BOTH DELIBERATE AND INADVERTENT DISCLOSURE TO ANY THIRD PARTY."
Liwa Plastics Project
Document Title: Document No. Rev:
Guidelines for Operating Manual - Off Sites S-S800-5230-001 0
INPUTS / REFERENCE DOCUMENTS
Document Number Title Status
S-S000-5222-001 Project Basis of Design – LPP Facilities
S-S000-5223-003 Process Design Basis for Off-Site Facilities
D-S850-5223-301 BFD Waste Water Treatment Unit
D-S850-5223-101 UFD WWTU – Last Line Of Defense (LLOD)
D-S850-5223-102 UFD WWTU – Waste Water Collection Tank
D-S850-5223-103 UFD WWTU – Dissolved Gas Floatation (DGF)
D-S850-5223-104 UFD WWTU – WW Equalization Tank
D-S850-5223-105 UFD WWTU – Secondary Treatment (Biotreater)
D-S850-5223-106 UFD WWTU – Secondary Treatment (Sludge Treatment)
D-S850-5223-107 UFD WWTU – Sludge Dewatering
D-S850-5223-108 UFD WWTU – Tertiary Treatment
D-S850-5223-109 UFD WWTU – Treated Effluent Tank
D-S850-5223-110 UFD WWTU – Induced Air Floatation (IAF)
D-S850-5223-111 UFD WWTU – Surface Run-Off Treatment
D-S850-5223-112 UFD WWTU – Benzene/MTBE Contaminated WW Collection Tank
D-S850-5223-113 UFD WWTU – Waste Water Steam Stripper
D-S850-5223-114 UFD WWTU – Skimmed Oil Vessel
D-S850-5223-115 UFD WWTU – Domestic Effluent Lift Station
D-S850-5223-116 UFD WWTU – Neutralization Basin
D-S850-5223-117 UFD WWTU – Nutrient Dosing
D-S850-5223-118 UFD WWTU – Polymer Solution Dosing
D-S850-5223-119 UFD WWTU – Caustic / Sulfuric Acid Dosing
D-S850-5223-120 UFD WWTU – Hypochlorite and SMBS Dosing
D-S850-5223-121 UFD WWTU – Mass Balance
D-S860-5223-101 UFD WI - Vent Gas Incineration
D-S860-5223-102 UFD WI – Liquid and Solid Waste Incinerator
D-S860-5223-104 UFD WI – Waste Incinerator Mass Balance
D-S890-5223-101 UFD FLR – Main Wet Flare
D-S890-5223-102 UFD FLR – Cryogenic LP Flare
D-S890-5223-103 UFD FLR – Spare Storage Wet Flare
D-S850-5225-101 P&ID WWTU – LLOD Basin
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Document Title: Document No. Rev:
Guidelines for Operating Manual - Off Sites S-S800-5230-001 0
D-S850-5225-102 P&ID WWTU – LLOD OC/FFB Transfer Pump
D-S850-5225-103 P&ID WWTU – LLOD Sludge Pumps
D-S850-5225-104 P&ID WWTU – POB Water Pumps
D-S850-5225-105 P&ID WWTU – Waste Water Collection Tank
D-S850-5225-106 P&ID WWTU – Waste Water Transfer Pump
D-S850-5225-107 P&ID WWTU – Vent Gas Blower
D-S850-5225-108 P&ID WWTU – Dissolved Gas Floatation Package
D-S850-5225-110 P&ID WWTU – Waste Water Equalization Tank
D-S850-5225-111 P&ID WWTU – Equalization Tank Transfer Pump
D-S850-5225-112 P&ID WWTU – Air Compressor Package
D-S850-5225-113 P&ID WWTU – Biological Treatment Biotreater Package
D-S850-5225-116 P&ID WWTU – Oily Sludge Collection Tank
D-S850-5225-117 P&ID WWTU – Oily Sludge Pump
D-S850-5225-118 P&ID WWTU – Sludge Dewatering Package
D-S850-5225-119 P&ID WWTU – Tertiary Treatment Package
D-S850-5225-120 P&ID WWTU – Treated Effluent Tank
D-S850-5225-121 P&ID WWTU – Treated Effluent Pump
D-S850-5225-123 P&ID WWTU – Induced Air Floatation (IAF) Package
D-S850-5225-124 P&ID WWTU – Non Contaminated Surface Run off Clarifier
D-S850-5225-126 P&ID WWTU – Benzene/MTBE Contaminated WW Collection Tank
D-S850-5225-127 P&ID WWTU – Benzene/MTBE Contaminated WW Pump and Mixer
D-S850-5225-129 P&ID WWTU – Steam Stripper Feed/Effluent Exchanger and Cooler
D-S850-5225-130 P&ID WWTU – Steam Stripper Column and pump
D-S850-5225-131 P&ID WWTU – Steam Stripper Column Overhead Condenser reflux
Drum and Pump
D-S850-5225-133 P&ID WWTU – Skimmed Oil Vessel
D-S850-5225-134 P&ID WWTU – Domestic Effluent Station Package
D-S850-5225-135 P&ID WWTU – Neutralization Basin
D-S850-5225-137 P&ID WWTU – Nutrient Preparation and Dosing Package
D-S850-5225-138 P&ID WWTU – Polymer Preparation and Dosing Package
D-S850-5225-139 P&ID WWTU – Caustic Dosing Package
D-S850-5225-140 P&ID WWTU – Concentrated Sulfuric Acid Dosing Package
D-S850-5225-142 P&ID WWTU – Hypochlorite and SMBS Dosing Package
Page 3 of 75
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Document Title: Document No. Rev:
Guidelines for Operating Manual - Off Sites S-S800-5230-001 0
D-S860-5225-101…104 P&ID WIU 8600
D-S890-5225-101…111 P&ID FLRU 8900
D-S850-5223-901….920 Material Selection Diagram WWTU 8500
D-S860-5223-901…902 Material Selection Diagram WIU 8600
D-S890-5223-901…903 Material Selection Diagram FLRU 8900
S-S800-5223-901 Material Selection Report – 8000 – Offsite Common
S-S850-5223-002 Process Description WWTU – 8500
S-S860-5223-002 Process Description - WIU 8600
S-S890-5223-002 Process Description - FLRU 8900
S-S850-5224-001 Process Equipment List – WWTU 8500
S-S860-5224-001 Process Equipment List - WIU 8600
S-S890-5224-001 Process Equipment List - FLRU 8900
S-S850-5371-101 Operation and Control Philosophy – WWTU 8500
S-S860-5371-101 Operation and Control Philosophy - WIU 8600
S-S890-5371-101 Operation and Control Philosophy - FLRU 8900
S-S850-5223-701 Flare Load Summary – WWTU 8500
S-S860-5223-701 Flare Load Summary – WI 8600
S-S890-5223-701 Flare Load Summary – FLRU 8900
S-S860-5370-102 Range Alarm Trip Setting List unit 8600 - WIU
S-S890-5370-102 Range Alarm Trip Setting List unit 8900 - FLRU
REVISION NOTES AND HOLDS
Revision Description of Changes & Holds
HOLDS Description of Holds Rev Date
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Table of Contents
Contents Page
1.0 INTRODUCTION ................................................................................................................................. 6
1.1 Plant Duty................................................................................................................................. 7
2.0 DEFINITIONS...................................................................................................................................... 8
3.0 DESIGN BASIS................................................................................................................................... 9
3.1 Equipment Summary ............................................................................................................... 9
3.2 Product................................................................................................................................... 12
3.3 Overall Material Balance........................................................................................................ 13
4.0 OPERATING VARIABLES AND CONTROL ..................................................................................... 21
4.1 Waste Water Treatment Unit (WWTU – 8500) ....................................................................... 21
4.2 Waste Incineration Unit (WIU – 8600).................................................................................... 29
4.3 Flare Unit (FLRU – 8900)........................................................................................................ 29
5.0 PREPARATION FOR INITIAL START-UP - PLANT CHECKOUT ..................................................... 32
5.1 P&ID Checks .......................................................................................................................... 32
5.2 Operability Checks ................................................................................................................ 32
5.3 Mechanical Checks................................................................................................................ 32
5.4 Instrument Checks ................................................................................................................ 32
5.5 Cleaning of Lines................................................................................................................... 33
6.0 NORMAL START-UP ........................................................................................................................ 38
7.0 NORMAL OPERATION ..................................................................................................................... 42
8.0 NORMAL SHUTDOWN ..................................................................................................................... 65
9.0 EMERGENCY SHUTDOWN .............................................................................................................. 67
10.0 SAFETY AND SAFEGUARDING ...................................................................................................... 70
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1.0 INTRODUCTION
Oman Oil Refineries and Petroleum Industries Company (ORPIC) is planning the installation of a new
Petrochemical Complex to be called Liwa Plastics Project (LPP) adjacent to Sohar Refinery Improvement
Project (SRIP) that will include a Steam Cracker Unit (SCU) designed to produce 859 kilo tons per annum
(KTA) of polymer grade ethylene and 286 KTA of polymer grade propylene, Refinery Dry Gas Unit, NGL
Treating and Fractionation Unit, Selective C4 Hydrogenation Unit, MTBE Unit, Butene-1 Recovery Unit,
Pygas Hydrotreating Unit, High Density Polyethylene (HDPE) Plant, Linear Low Density Polyethylene Plant
(LLDPE), new Polypropylene Plant (PP), and associated utility and offsite facilities. The new petrochemical
plant will be integrated with the Sohar Refinery, Sohar Aromatics Plant (AP) and Sohar Polypropylene
Plant (PP) plant.
ORPIC is also planning the installation of a new NGL Extraction plant located in Fahud, Central Oman. The
NGL (C2+) extracted from the natural gas will be transported to the petrochemical complex by pipeline and
used as feedstock to LPP. The new NGL Extraction plant will have independent utility and offsite facilities.
Additional feedstock to LPP are mixed LPG (produced in the Sohar Refinery and Sohar AP), refinery dry
gas produced in the RFCC unit and new Delayed Coking unit (included in SRIP), light naphtha condensate
from OLNG by marine tanker.
This document contains the Guidelines for Operating Manual of the Off-sites facilities for the following units
of the new Liwa Plastics Project in Oman.
Waste Water Treatment Unit – 8500
Waste Incineration Unit – 8600
Flare Unit – 8900
This manual describes mainly the LLOD section; Benzene/MTBE contaminated waste water steam
stripping section of the WWTU and equipment which are out of package vendor scope of design and
supply for all the three mentioned units. The manual for the entire Utility unit itself will be supplied by the
package vendors. Therefore this manual shall be used together with the vendor’s operating manual(s) as
the basis for the preparation of the detailed operating manuals per unit.
This operating manual is intended as a guide and reference for personnel involved in the operations of the
mentioned units. It provides basic information which should be with the reference documents and vendor
information, sufficient to prepare detailed procedures and instructions for the operations of the unit.
In this operating Manual, reference is made to the following documents:
Process Block Flow Diagram
Utility Process Flow Diagrams
Utility Piping & Instrument Diagrams
Process Equipment List
Relief Load Summary
Material Selection Diagrams & Report
Alarm and Trip Settings
This document is useful as a guide in operation and does not necessarily represent exact operating
conditions or guarantees.
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1.1 Plant Duty
The objectives of the Off-Sites facilities are:
Reduce the impact of water outfall to the environment.
Protection of public health.
Reduce discharge to Project standards effluents in a technologically and economically sound way.
Fulfilling the local environment requirements.
The waste effluents from multiple sources will be treated in the Off-Sites facilities to meet Project
specification.
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2.0 DEFINITIONS
The following terms and abbreviations have been used in this document:
Term Definition
AOC Accidentally Oil Contaminated
BOD Biological Oxygen Demand
COD Chemical Oxygen Demand
DGF Dissolved Gas Floatation
FFB First Flush Basin
IAF Induced Air Floatation
LLOD Last Line Of Defense
OC Oil Contaminated
OCB Oil Contaminated Basin
POB Peak Overflow Basin
TOD Total Oxygen Demand
TOC Total Organic Content
DO Dissolved Oxygen
TLE Transfer Line Exchanger
DCS Distributed Control System
TSS Total Suspended Solids
WW Waste Water
WWT Unit Waste Water Treatment Unit
OSBL Outside Battery Limit
ACF Activated Carbon Filter
DEC Detailed Engineering Contractor
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3.0 DESIGN BASIS
3.1 Equipment Summary
3.1.1 Waste Water Treatment Unit (WWTU – 8500)
All liquid waste streams coming from process, utility and storage areas that could be contaminated with
hydrocarbon shall be collected and treated before disposal into open water. All chemical effluent will be
neutralized inside the process battery limits before sending to off-site area.
The WWTU has been designed to process the following effluents:
TLE hydro jetting / decoking quench water
Wash water from NGL Amine / Water wash column
Wash water from Caustic / Water wash Tower
Oil contaminated surface water run-off (by vacuum truck)
Accidentally oil contaminated surface water run-off
Surface run-off water from Polymer Unit
Dilution steam drum effluent
Crystallizer Distillate Effluent from Spent Caustic Oxidation Unit
Hydrocarbon drains from Flare HC Drain Drum Pump
MTBE / Benzene contaminated water from MTBE and Pygas Unit
Contaminated Condensate from Steam Condensate Unit
Contaminated Cooling Water
Contaminated storm water from ISBL Areas
Contaminated Storm water from Storage Tank Dike Areas
Depending on the type of pollution, the waste water stream is routed to the appropriated treatment. As a
general rule, areas that could be contaminated with hydrocarbon shall be kept as small as possible. Also
continuously contaminated streams shall be kept separate from streams that are usually not contaminated
(Accidentally Contaminated) or not contaminated (Clean Drain).
The waste water treatment unit consists mainly of the following sections:
Last Line Of Defence (LLOD)
Benzene / MTBE contaminated waste water pre-treatment
Waste water primary treatment
Waste water secondary (biological) treatment
Waste water tertiary treatment
Clean Surface water run-off treatment
Domestic Effluent Collection and Treatment
Chemical storage, preparation and dosing
Last Line Of Defence (LLOD)
The LLOD mainly consists of influent Water Screening Package (ME-85001 & ME-85002), Oil Skimmer
and Sludge Scraper Package (ME-85003 & ME-85004), Oil Contaminated Basin (OCB), First Flush Basin
(FFB) and Peak Overflow Basin (POB) with relevant pumps. This section has been designed to collect
equipment drains and surface water run-off from potentially / continuously contaminated areas.
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Benzene / MTBE contaminated waste water pre-treatment
The Benzene/MTBE contaminated waste water pre-treatment will treat waste water contaminated with
Benzene/MTBE. By utilizing steam stripping the Benzene/MTBE content is reduced to 1 ppm wt.
Waste Water Primary Treatment
Depending on the type of pollution, effluent streams are routed to the appropriated sections in primary
treatment. The waste water primary treatment will treat oil contaminated waste streams and polluted
surface water run-off (e.g. rainwater) by means of Dissolved Gas Floatation (DGF) unit.
Waste Water Secondary (biological) Treatment
Subsequently, the pre-treated streams from Dissolved Gas Floatation (DGF) Unit are collected and mixed
with other waste water streams in Waste Water Equalization tank (T-85002). The homogenized stream is
sent to the biological treatment unit. In the Biotreater, BOD and COD is reduced by activated sludge using
dissolved oxygen.
Aerated stream will be routed to clarifier on gravity flow via Degassing Tank, where the settled activated
sludge is separated from the clean water. Part of the activated sludge is recycled to Biotreater and the
excess activated sludge is sent to the excess sludge dewatering package via sludge thickener. Thickened
excess sludge from sludge thickener is sent to sludge dewatering package. Dewatered sludge is collected
in a mobile sludge cake container, which is trucked out for disposal by land filling or incineration.
Waste Water Tertiary Treatment
In order to meet discharge water standard, Biotreater clarified effluent is routed to the Tertiary Treatment to
remove the remaining suspended solids and hydrocarbons. Sodium Hypochlorite and SMBS Solution are
used for Chlorination and De-chlorination of the waste water in Chlorination / De-chlorination Basin
respectively. The treated effluent will be sent to MISC (OSBL).
Domestic Effluent Collection and Treatment
This system collects domestic waste water from toilets, urinals, kitchen facilities, sinks, showers and the
like from buildings and shelters. Domestic effluents are routed by a sloped gravity underground pipe
system into the Domestic Lift Station, where the solid and liquid wastes will be transferred by pump to
MISC (OSBL) for further treatment.
Clean Surface Water run-off Treatment
This system is a clean water sewer, collecting surface water run-off from non-contaminated areas where
source of hydrocarbon leakage/spillage is not exist. Collected surface water run-off then routed to Storm
Water Clarifier (ME-85010) where suspended solids and trace of hydrocarbons (if any) will be separated.
The clarified storm water will be sent to MISC (OSBL) along with the provision for sending it to Sea water
return channel and the collected sludge will be transferred to Sludge Dewatering Package (ME-85007).
Chemical Storage, Preparation and Handling
This section consists of all necessary provisions for unloading, storing, preparation, transfer to consumers
and injection of the required chemicals in WWTU.
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3.1.2 Waste Incinerator Unit (WIU – 8600)
All waste streams produced in the LPP project have to be incinerated. Vent gases with toxic components or
smelly fumes are routed to the Vent Gas Incinerator. One Waste Incinerator is foreseen to receive liquid
and solids streams.
Vent gas Incinerator receives the vent gas from following:
Raw Pyrolysis Gasoline Storage Tank
C6 – C7 Cut Storage Tank
Benzene / MTBE Contaminated Waste Water Collection Tank
Waste Water Collection Tank
Skimmed Oil Vessel
Oily Sludge Storage Tank
Spent Caustic Storage Tank
Spent Caustic Oxidation Effluent Tank
Spent Caustic Oxidation Unit
Rerun Tower Vacuum Package (J-62011) from Pygas Hydrotreater Unit
The Liquid and Solid Waste incinerator is fired with fuel gas with Natural Gas as back-up. The following
liquid and solid waste streams will be handled:
Skimmed Oil from Skimmed Oil Pump P-85010 (Skimmed Oil Vessel V-85001 in WWTU)
Waste Liquid from ME-86001-P-01 (Vent Gas KO Drum part of Vent Gas Incinerator Package)
Dewatered Bio Sludge from ME-85007 (from conveyor in WWTU)
Dewatered Oily Sludge from ME-85007 (from conveyor in WWTU)
Liquid waste (in barrel) from polymer plants containing up to 15 – 20% Alkyls
Skimmed oil from Amine Unit hydrocarbon drain pump (P-11054)
Hydrocarbon/water mixtures from drain vessels by tank car
Hydrocarbon/water mixtures or Maintenance Waste Oils from drums
Tar from Quench Water System
3.1.3 Flare Unit (FLRU – 8900)
The Flare system consists of:
One Wet Flare (common for wet and cold/dry reliefs)
One Spare Storage Wet Flare (common for wet and cold/dry reliefs)
One Acid Gas Flare (pat of stack to be common with wet flare)
Two LP Cryogenic Flares (A and B)
The Wet Flare system (ME-89001) handles wet vapor relief loads from safety valves and vent gases which
are above 0°C at atmospheric pressure or, when the relieved flow contains significant amounts of water
vapor.
In case the Main Wet Flare ME-89001 is taken out of operation, all wet storage area vents and relief are
routed to Spare Storage Wet Flare ME-89003.
The Acid Gas Flare system handles vapor relief loads from safety valves and vent gases with H2S content
higher than 1000 ppm.
Reliefs from the Cryogenic Propane / LPG, Ethylene and Propylene Storage Tanks T-81008, T-83003 and
T-83004 respectively are routed to the Cryogenic Low Pressure Flare ME-89002 A/B which consists of:
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Flare Stack (ME-89002-SK-01A/B), Flare Tip, Flare Ignition System, and Molecular Seal and Fuel Gas KO
Drum (ME-89002-V-01): One system is in operation and one is in stand-by.
3.2 Product
3.2.1 Treated Waste Water
The quality of treated water should be based on value limits specified in MD 159/2005 "Discharge liquid
effluent in Marine Environment" and MD 145/1993 "Regulation for waste water re-uses and discharge" as
shown in the table in Project Basis of Design. The treated waste water will be sent to MISC (OSBL)
Specification Unit Max limit for quality according to
MD 159/2005
Temperature °C No more than 10 degrees centigrade over
the temperature of the surrounding
seawater
Oxygen biological demand mg/l 20.0
(5 days at 20 degree
centigrade)
Oxygen chemical demand mg/l 200.0
Suspended solid materials mg/l 30.0
Total dissolved solids mg/l
Electrical conductivity (micro micro s/cm
s/cm)
Sodium absorption ratio -
pH (within range) -
Aluminum mg/l 5.0
Arsenic mg/l 0.100
Barium mg/l 2.0
Beryllium mg/l 0.300
Boron mg/l 1.0
Cadmium mg/l 0.010
Chrome mg/l 0.050
Cobalt mg/l 0.050
Copper mg/l 0.200
Cyanide (total) mg/l 0.100
Fluoride mg/l 2.0
Iron mg/l 1.5
Lead mg/l 0.08
Lithium mg/l 0.070
Magnesium (as Mg) mg/l
Manganese (as Mn) mg/l
Mercury mg/l 0.001
Molybdenum mg/l 0.05
Nickel mg/l 0.100
Ammonia nitrogen (nitrogen mg/l 1.0
shaped)
Nitrate nitrogen (nitrate mg/l 15.0
shaped)
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Specification Unit Max limit for quality according to
MD 159/2005
Organic nitrogen (Kjeldahl) mg/l 5.0
Total nitrogen mg/l 15.0
Oil mg/l 10.0
Phenols (total) mg/l 0.002
Phosphor mg/l 2.0
Selenium mg/l 0.020
Silver mg/l 0.010
Sodium (as Na) mg/l
Sulfur mg/l 0.100
Total chlorine mg/l 0.4
Vanadium mg/l 0.100
Zinc mg/l 1.0
Number of colon feces mg/l 1000
bacillus (per liter)
Number of tapeworm eggs mg/l <1
(per liter)
Organic halogen mg/l <0.001
Pesticides and its byproducts mg/l <0.001
Organic silicon components mg/l <0.001
Organic copper components
Organic tin components mg/l 0.00002
3.3 Overall Material Balance
3.3.1 Influent to Waste Water Treatment Unit
The specification of the different influent streams is provided in the below table:
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TLE Hydro jetting & Crystallizer Distillate Surface water run-off
Specifications Unit Decoking Quench Water Effluent
Source TLEs Crystallizer Package Polymer Unit
Destination WW Equalization tank WW Collection Tank WW Collection Tank / IAF
Flow Condition Intermittent Intermittent Intermittent
Normal 110
3
Flow Rate Max m /hr 121
Design 5 10 121
Aluminum (Al+3) mg/l
Ammonium ion mg/l
Anionic Synthetic Surfactants mg/l
Acetonitrile mg/l
Benzene mg/l
BOD5 mg O2/l < 30 < 25
Vanadium mg/l
Suspended Solids mg/l < 50
DMF mg/l
Total Iron mg/l
Manganese mg/l
Copper mg/l
Methanol mg/l
Methyl Benzene (Toluene) mg/l
Petroleum Products (free oil & grease) mg/l
Nitrates (as NO3) mg/l
Nitrites (as NO2) mg/l
Non-Anionic Synthetic Surfactants mg/l
Styrene mg/l
Sulfates (as SO4) mg/l
Thiosulfate mg/l
Sulfides mg/l
Dry Residue mg/l
Titanium mg/l
Phenols mg/l
Formaldehyde mg/l
Phosphates mg/l
Chloride mg/l
Chromium (Cr+6) mg/l
Zinc (Zn+2) mg/l
Ethylene Benzene mg/l
pH - 7.0 – 8.0 7.0 – 8.0
COD mg O2/l < 50
o
Temperature C AMBIENT
NMP (N-Methylpyrrolidone) mg/l
Vinylcyclohexene mg/l
TBC (4-Tert-Butylpyrocatechol) mg/l
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Clean Surface water run- Oil Contaminated Surface Accidentally Oil
Specifications Unit off from Collection Water Contaminated Surface Water
Network Run-Off Run-Off
Source Paved Area Paved Area Paved Area
Destination Storm Water Clarifier LLOD LLOD
Flow Condition Intermittent Intermittent Intermittent (Note 3)
Normal 8767 (DID NOT FIND)
Flow Rate Max m3/hr
Design 110 110
Aluminum (Al+3) mg/l
Ammonium ion mg/l
Anionic Synthetic Surfactants mg/l
Acetonitrile mg/l
Benzene mg/l
BOD5 mg O2/l < 650 < 650
Vanadium mg/l
Suspended Solids mg/l < 100 < 100
DMF mg/l
Total Iron mg/l
Manganese mg/l
Copper mg/l
Methanol mg/l
Methyl Benzene (Toluene) mg/l
Petroleum Products (free oil & grease) mg/l < 1000
Nitrates (as NO3) mg/l
Nitrites (as NO2) mg/l
Non-Anionic Synthetic Surfactants mg/l
Styrene mg/l
Sulfates (as SO4) mg/l
Thiosulfate mg/l
Sulfides mg/l
Dry Residue mg/l
Titanium mg/l
Phenols mg/l
Formaldehyde mg/l
Phosphates mg/l
Chloride mg/l
Chromium (Cr+6) mg/l
+2
Zinc (Zn ) mg/l
Ethylene Benzene mg/l
pH - 6.0 – 8.0 6.0 – 8.0
COD mg O2/l <1000 < 1000
o
Temperature C
NMP (N-Methylpyrrolidone) mg/l
Vinylcyclohexene mg/l
TBC (4-Tert-Butylpyrocatechol) mg/l
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Oil Contaminated Hydrocarbon Drain from Dilution steam Drum Effluent
Specifications Unit Cooling water from P- Flare KO Drum
73103
Source P-73103 Flare Unit
WW Collection Tank / WW Collection Tank Benzene/MTBE Contaminated
Destination
POB WW Collection Tank
Flow Condition Continuous Continuous
NNF (Ref, S-S850-535A- 5 1.03
Normal
008 pg15)
Flow Rate m3/hr
Max 15
Design 250 (see ref above) HOLD 15 x 1.2
Aluminum (Al+3) mg/l
Ammonium ion mg/l
Anionic Synthetic Surfactants mg/l
Acetonitrile mg/l
Benzene mg/l
BOD5 mg O2/l < 300 100 - 300
Vanadium mg/l
Suspended Solids mg/l <5 < 10 <200
DMF mg/l
Total Iron mg/l
Manganese mg/l
Copper mg/l
Methanol mg/l
Methyl Benzene (Toluene) mg/l
Petroleum Products (free oil & grease) mg/l < 50 < 100 10 – 100
Nitrates (as NO3) mg/l
Nitrites (as NO2) mg/l
Non-Anionic Synthetic Surfactants mg/l
Styrene mg/l
Sulfates (as SO4) mg/l
Thiosulfate mg/l
Sulfides mg/l
Dry Residue mg/l
Titanium mg/l
Phenols mg/l 10 – 50
Formaldehyde mg/l
Phosphates mg/l
Chloride mg/l
Chromium (Cr+6) mg/l
+2
Zinc (Zn ) mg/l
Ethylene Benzene mg/l
pH - 6.0 – 8.0 8.5 – 10.0
COD mg O2/l < 600 200 - 500
o
Temperature C
NMP (N-Methylpyrrolidone) mg/l
Vinylcyclohexene mg/l
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TBC (4-Tert-Butylpyrocatechol) mg/l
Unit Wash water from NGL MTBE / Benzene Contaminated Condensate
Amine / Water Wash and contaminated water from from E-74101/E-74103
Specifications
Caustic / Water Wash MTBE / Pygas Unit
Tower
Source SCU MTBE/Pygas Unit E-74101 / E-74103
Destination WW Collection Tank T-85004 LLOD
Flow Condition Continuous / Intermittent Continuous Intermittent
Normal 21
Flow Rate Max m3/h
Design 6.7 / 0.6 34.7
Aluminum (Al+3) mg/l
Ammonium ion mg/l
Anionic Synthetic Surfactants mg/l
Acetonitrile mg/l
Benzene mg/l <1
BOD5 mg O2/l
Vanadium mg/l
Suspended Solids mg/l < 10
DMF mg/l
Total Iron mg/l
Manganese mg/l
Copper mg/l
Methanol mg/l
Methyl Benzene (Toluene) mg/l <1
Petroleum Products (free oil & grease) mg/l < 100
Nitrates (as NO3) mg/l
Nitrites (as NO2) mg/l
Non-Anionic Synthetic Surfactants mg/l
Styrene mg/l <1
Sulfates (as SO4) mg/l
Thiosulfate mg/l
Sulfides mg/l
Dry Residue mg/l
Titanium mg/l
Phenols mg/l < 50
Formaldehyde mg/l
Phosphates mg/l
Chloride mg/l
Chromium (Cr+6) mg/l
Zinc (Zn+2) mg/l
Ethylene Benzene mg/l
pH - 6.5 – 7.5
COD mg O2/l
o
Temperature C
NMP (N-Methylpyrrolidone) mg/l
Vinylcyclohexene mg/l
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TBC (4-Tert-Butylpyrocatechol) mg/l
Notes –
1. The indicated flow rates represent Waste Water Treatment Design Case. Operating Case flow rates
may differ from these figures.
2. Flow Specified in m3/day.
3. The provided figures are related to surface water run-off collected in Last Line of Defense basins in
case of “good housekeeping”. There is no guarantee on these figures as quality of surface water run-
off inherently depends on Orpic Unit operator’s attention on good housekeeping.
4. In case of higher concentration, the collected water has to be sent to Waste Water Stripper Unit.
5. FFB is designed to hold rain water run-off from potentially hydrocarbon polluted area during first 35
minutes of rain. After this period, FFB is filled and the surface water run-off overflows to POB.
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3.3.2 Domestic Effluent
The specification of the collected domestic effluents which will be sent to MISC (OSBL) is defined below:
Specifications Unit Domestic Effluent
Source Collection from Various sources in LPP Facilities
Destination MISC (OSBL)
Flow Condition Intermittent
Normal
Flow Rate Max m3/hr
Design
Aluminum (Al+3) mg/l
Ammonium ion (as N) mg/l
Anionic Synthetic Surfactants mg/l
Acetonitrile mg/l
Benzene mg/l
BOD5 mg O2/l 200 – 250
Vanadium mg/l
Suspended Solids mg/l < 750
DMF mg/l
Total Iron mg/l
Manganese mg/l
Copper mg/l
Methanol mg/l
Methyl Benzene (Toluene) mg/l
Petroleum Products (free oil & grease) mg/l 20 – 70
Nitrates (as NO3) mg/l
Nitrites (as NO2) mg/l
Non-Anionic Synthetic Surfactants mg/l < 30
Styrene mg/l
Sulfates (as SO4) mg/l
Thiosulfate mg/l
Sulfides mg/l
Dry Residue mg/l 500
Titanium mg/l
Phenols mg/l
Formaldehyde mg/l
Phosphates mg/l < 40
Chloride mg/l < 100
Chromium (Cr+6) mg/l
Zinc (Zn+2) mg/l
Ethylene Benzene mg/l
pH - 7–8
COD mg O2/l 300 – 400
o
Temperature C
NMP (N-Methylpyrrolidone) mg/l
Vinylcyclohexene mg/l
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Specifications Unit Domestic Effluent
TBC (4-Tert-Butylpyrocatechol) mg/l
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4.0 OPERATING VARIABLES AND CONTROL
4.1 Waste Water Treatment Unit (WWTU – 8500)
4.1.1 Normal Operating Conditions
For normal operating conditions, reference is made to the:
Process Description, Doc. S-S850-5223-002
Utility Process Flow Diagram, Doc. D-S850-5223-101 to D-S850-5223-120
4.1.2 Process Variables
This manual describes mainly process variables for the normal operation of Last Line Of Defense (LLOD)
section, Benzene / MTBE contaminated waste water steam stripping section and equipment out of
package vendor scope of design and supply. The normal operating variables for Wastewater Treatment
Packages will be defined by the package vendor.
4.1.2.1 First Flush Basin (FFB) Liquid Level Control
Accidentally Oil Contaminated (AOC) water run-off from the surface drainage of the whole plant in addition
to equipment drainage are collected via industrial sewer system and routed to First Flush Basin (Z-85002).
By getting level in FFB, level alarm high (850-LI-006A) informs operators to check the quality of collected
water. In case the water quality meets the clean water spec, operator starts FFB Water Pump (P-85002A
or B) to send the collected water to Induced Air Floatation Package (ME-85009) by-passing the Dissolved
Gas Floatation Package.
Sometimes test result of collected effluent may exceed the contaminants limit. In such cases, collected
effluent has to be sent to appropriate treatment section in waste water treatment unit subject to nature of
pollutant and contamination level. If hydrocarbon content (excluding benzene) of collected effluent exceeds
the limits (High BOD / High COD), the effluent has to be sent to Waste Water Collection Tank (T-85001) for
treatment.
If benzene contamination of the collected effluent exceeds the limit of 10 ppm, the collected effluent has to
be sent to Benzene / MTBE Contaminated Waste Water Collection Tank (T-85004) for further treatment by
operator action.
During normal plant operation, it is expected that good housekeeping keeps surface water run-off collected
in FFB clean enough (low BOD / low COD) to be treated only by a dedicated Induced Air Floatation (IAF)
Unit (ME-85009) for removing any residual oil or suspended solids.
The following analyzers continuously monitor the quality of incoming effluent to facilitate operator’s
decision making regarding the proper distention of collected effluent in FFB:
TOD analyzer
pH analyzer
Benzene analyzer (This Analyzer need to be provided with Audio / Visual Alarm at Field to alert
the operator of High Benzene contamination)
FFB Z-85002 is provided with high level alarm, High-High, Low and Low-Low (850-LI-006A). If the basin
continues to get level, Operator will manually start FFB Water Pump (P-85002A or B); upon high-high liquid
standby pump can be used if required.
In case of low level detection in the FFB (850-LI-034), the duty pump P-85002A or P-85002B will be
stopped automatically by BPCS.
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4.1.2.2 First Flush Basin (FFB) Sludge Interface Level Control
By getting sludge level in the inlet compartment of FFB and/or sand trap compartment, level alarm high
(850-LI-035A), opens the sludge isolating valve (850-XV-001) and start selected duty LLOD Sludge Pump
(P-85003C/D) automatically via BPCS.
Upon getting low level detection (850-LI-035A) in sand trap or inlet compartment of FFB, LLOD Sludge
Pumps (P-85003C/D) will be stopped automatically and suction isolating valves 850-XV-001 will be closed.
Sludge pumps are located in pits adjacent to inlet compartment. Pump pit is equipped with gas detectors
with an automatic alarm and emergency ventilation to avoid the gas pollution hazard.
4.1.2.3 Peak Overflow Basin (POB) Liquid Level Control
FFB is designed to hold rain water run-off from potentially hydrocarbon polluted area during first
35 minutes of rain. After this period, FFB is filled and the surface water run-off is overflowed to POB.
It is expected that the contamination level of surface water run-off collected in POB is diluted to such an extent
that can bypass biological treatment and be treated only by IAF unit ME-85009. If the quality of collected run-off
in POB is far from outfall water specification (high BOD / high COD), the collected run-off shall be treated along
with first flush water collected in FFB in biological treatment unit. In addition, the POB is used as surge basin in
case of cooling water oil contamination.
POB Pump (P-85014A/B) is started manually by operator to send the water to ME-85009. Upon getting low
level detection by 850-LI-033 low level alarm will stop POB Pump (P-85014A/B) automatically via BPCS.
4.1.2.4 Oil Contaminated Water Basin (OCB) Liquid Level Control
Water run-off from Continuously Oil Contaminated areas and oily equipment drains are collected and sent
to Oil Contaminated Water Basin (Z-85001). In addition, all tank overflow and surface water run-off from
waste water treatment area will be routed to OC basin via underground header.
When the basin continuous getting level and liquid level reaches the high switch setting of 850-LI-032, the
OC Water Pump (P-85001A) is started automatically by BPCS to empty the OCB content to Waste Water
Collection Tank (T-85001) for proper treatment.
If the basin continues to get level, in spite of OC Water Pump running, upon high high level detection by
850-LI-032 in the Oil Contaminated Water Basin, the stand-by pump P-85001B will be started automatically
by BPCS.
In case of low level detection (850-LI-032) in the Oil Contaminated Water Basin, the duty pump P-85002A
will be stopped automatically via BPCS.
Upon continuous low low level detection (850-LI-032) in the Oil Contaminated Water Basin, both pumps the
standby pump P-85002B will also be stopped automatically via BPCS.
4.1.2.5 Oil Contaminated Basin (OCB) Sludge Interface Level Control
By getting sludge level in the inlet compartment of OCB and/or sand trap compartment, level alarm high
(850-LI-031A), opens the sludge isolating valve (850-XV-003) and start selected duty LLOD Sludge Pump
(P-85003A/B) automatically via BPCS.
Upon getting low level detection (850-LI-031A) in sand trap or inlet compartment of OCB, LLOD Sludge
Pumps (P-85003A/B) will be stopped automatically and suction isolating valves 850-XV-003 will be closed.
Sludge pumps are located in pits adjacent to inlet compartment. Pump pit is equipped with gas detectors
with an automatic alarm and emergency ventilation to avoid the gas pollution hazard.
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4.1.2.6 Waste Water Collection Tank (T-85001) Normal Operating Variables
The Waste Water Collection Tank (T-85001) is used to store the process waste water awaiting the DGF
treatment. To reduce impact of VOC (Volatile Organic Carbon) on environment, the tank has been
blanketed with nitrogen and protected against over pressuring by PSV. In addition Waste Water Collection
Tank (T-85001) has been equipped with water sealed over flow line to be routed to LLOD basin via fixed
connection. Waste water collection Tank is provided with Safety Hatch to protect form overpressure during
fire case. The relief is routed to Atmosphere.
4.1.2.6.1 Waste Water Collection Tank (T-85001) Level Control
The Waste Water Collection Tank level will be controlled via liquid level controller (850-LC-009A) by
manipulating flow control valve (850-FV-005) on Waste Water Transfer Pump (P-85004A/B) discharge
line.
To protect Waste Water Transfer Pump (P-85004A/B) against running dry, by getting low-low liquid
level (850-LI-008) in the Waste Water Collection Tank, both pumps P-85004A/B will be stopped
automatically by BPCS. In order to avoid the closing of flow control valve 850-FV-005 more than
required, level indicator (850-LI-008) is provided with high-high alarm.
4.1.2.6.2 Waste Water Collection Tank (T-85001) Pressure Control
To prevent ingress of hazardous hydrocarbons (VOC) to the atmosphere, Waste Water Collection
Tank will be kept under nitrogen blanketing.
It is advised to provide the Nitrogen blanketing pressure control with a ‘dead band’ (gap control), in
order to avoid waste of Nitrogen. When the pressure lowers (850-PC-011) in the tank to a certain limit
Nitrogen will be added (Opens Pressure control valve 850-PV-011), and when the pressure rises to a
certain limit vapors from the tank are vented (by means of pressure control valve 850-PV-012) to the
Vent Gas Incinerator Unit via Vent Gas Blower K- 85001A/B.
4.1.2.7 Vent Gas Blower (K-85001A/B) Normal operating Variables
4.1.2.7.1 Vent gas Blower (K-85001A/B) Suction Pressure Control
The 850-PC-015 keeps the suction pressure of the Vent Gas Blowers (K-85001A/B) at a set point by
controlling the discharge control valve (850-PV-015). To prevent vacuum, Vent Gas Blower (K-
85001A/B) is continuously purged by nitrogen at constant rate. If the suction pressure increases, high
pressure alarm (850-PC-015) will inform operators and the controller will open 850-PV-015 in the
discharge line. If the suction pressure decreases, low pressure alarm (850-PC-015) will inform
operators and the controller will start closing the valve in the discharge line. In this case, the minimum
flow controller (850-FC-006) will start circulating part of discharge gas to the suction of the Vent Gas
Blower to maintain its suction pressure at set point.
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4.1.2.8 Waste Water Equalization Tank (T-85002) Normal Operating Variables
The Waste Water Equalization Tank (T-85002) receives the waste water streams to be treated in the
Waste water Secondary Treatment Package / Biotreater Package (ME-85006). To reduce chance of solid
particles sedimentation and prevent anaerobic condition, tank is continuously purged with air. To have a
homogenized flow to Biotreater, internal jet mixers are utilized. The Waste Water Equalization Tank (T-
85002) vent line has been equipped with flame arrestor and water sealed over flow line.
4.1.2.8.1 Waste Water Equalization Tank (T-85002) Level Control
The Waste Water Equalization Tank level will be controlled via liquid level controller (850-LC-010) by
manipulating flow control valve (850-FV-008) on Equalization Tank Transfer Pump (P-85005A/B)
discharge line.
To protect pumps against running dry, by getting low-low liquid level (850-LI-011) in the Waste Water
Equalization Tank, both pumps P-85005 A/B will be stopped automatically via BPCS.
4.1.2.8.2 Waste Water Equalization Tank (T-85002) Temperature Control
Waste Water Equalization Tank is equipped with temperature monitoring, recording and alarm high
(850-TI-001) and high temperature alarm (850-TI-002) at Equalization Tank Transfer pump (P-
85005A/B) discharge. This is done in order to avoid the upset condition in Waste water Secondary
Treatment (ME-85006) package. Temperature is to be maintained in the range of 15°-35°C. DEC to
investigate the requirement of Potential Chiller Installation.
4.1.2.9 Air Compressor (ME-85017) Normal operating Variables
4.1.2.9.1 Air Compressor (ME-85017) Flow Control
The flow control (850-FC-010) adjusts the air flow depending on the level measurement (850-LC-010)
in the WW Equalization Tank, by manipulating the flow control valve (850-FV-010) in the air line from
the Air Compressor (ME-85017).
4.1.2.10 Treated Effluent Tank (T-85003) Normal Operating Variables
The Treated Effluent Tank (T-85003) receives the treated effluent awaiting sending to MISC (OSBL) for
further treatment. The Treated Effluent Tank (T-85003) vent line has been equipped with flame arrestor.
Safety Hatch is provided to protect the tank from overpressure during fire scenario. Vent from safety hatch
is routed to atmosphere.
4.1.2.10.1 Treated Effluent Tank (T-85003) Level Control
The Treated Effluent Tank level will be controlled via liquid level controller (850-LC-014A) by
manipulating flow control valve (850-FV-012) on Treated Effluent Pump (P-85006A/B) discharge line.
To protect pumps against running dry, by getting low-low liquid level (850-LI-015) in the Waste Water
Equalization Tank, both pumps P-85006 A/B will be stopped automatically via BPCS.
4.1.2.11 Oily Sludge Collection Tank (T-85005) Normal Operating Variables
The oily sludge from LLOD basins, Waste water Collection Tank (T-85001), WW Dissolved Gas Floatation
(DGF) package (ME-85005), Skimming from IAF Package ME-85009 and Sludge from Polymer Plant will
be sent to Oily Sludge Storage Tank (T-85005) from where it will be pumped to Sludge Dewatering
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Package (ME-85007) by Oily Sludge Pump P-85013A/B. The tank has been blanketed with nitrogen and
protected against over pressuring by PSV. In addition Oily Sludge Collection Tank (T-85005) has been
equipped with water sealed over flow line to be routed to Bounded Area. Oily Sludge Collection Tank is
provided with Safety Hatch to protect from overpressure during fire case. The relief is routed to
Atmosphere.
4.1.2.11.1 Oily Sludge Collection Tank (T-85005) Level Control
The Oily Sludge Collection Tank (T-85005) is equipped with Level monitoring, recording and alarm
high & Low (850-LI-012A).
To protect Oily Sludge Pump (P-85013A/B) against running dry, by getting low-low liquid level (850-LI-
013) in the Oily Sludge Collection Tank, both pumps P-85013A/B will be stopped automatically by
BPCS.
4.1.2.11.2 Oily Sludge Collection Tank (T-85005) Pressure Control
Oily Sludge Collection Tank will be kept under nitrogen blanketing. It is advised to provide the Nitrogen
blanketing pressure control with a ‘dead band’ (gap control), in order to avoid waste of Nitrogen. When
the pressure lowers (850-PC-023) in the tank to a certain limit Nitrogen will be added (Opens Pressure
control valve 850-PV-024), and when the pressure rises to a certain limit vapors from the tank are
vented (by means of pressure control valve 850-PV-023) to the Vent Gas Incinerator Unit via Vent Gas
Blower K- 85001A/B.
4.1.2.12 Skimmed Oil Vessel (V-85001) Normal Operating Variables
The skimming vessel collects all skimmed hydrocarbons from different sources. The vessel is continuously
purged by nitrogen and floating on wet flare header pressure. The collected skimmed hydrocarbons will be
sent for incineration.
4.1.2.12.1 Skimmed Oil Vessel (V-85001) Level Control
By getting high level detection in the Skimming Vessel by 850-LI-026, the Skimmed Oil Pump P-85010
will be started automatically. In case of low level detection in the Skimming Vessel by 850-LI-026, the
Skimmed Oil Pump P-85010 will be stopped automatically.
This vessel is equipped with an interface level controller (850-LC-027) in the oil/water compartment,
which manipulates the variable speed drive of the Skimmed Oil Vessel Effluent Pump P-85011, in
order to maintain the interface level in the vessel.
4.1.2.12.2 Skimmed Oil Vessel (V-85001) Temperature Control
Skimmed Oil Vessel (V-85001) is equipped with Temperature monitoring, recording and alarm high &
Low (850-TI-007).
4.1.2.12.3 Skimmed Oil Vessel (V-85001) Pressure Control
Skimmed Oil Vessel (V-85001) is purged with Nitrogen and vent from the vessel is sent to Vent Gas
Incinerator via Vent Gas Blower K-85001A/B. In case of overpressure, the nitrogen line is provided with
PSV venting to Wet Flare. Valves on the vent line to K-85001A/B are interlocked and vented to
Atmosphere at safe Location.
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4.1.2.13 Neutralization Pit (Z-85005) Normal Operating Variables
The neutralization pit is designed to collect chemical spillage from chemical dosing area. Drains from
Benzene / MTBE Contaminated Waste water transfer pumps (P-85007A/B, P-85008A/B and P-85009A/B)
are also routed to Neutralization Pit. The operators are to flush the chemical collection header with water
after each drain or spillage. The neutralized chemical effluent will be sent to cooling water outfall channel
and a provision also to route it to Waste water Equalization Tank (T-85002).
4.1.2.13.1 Neutralization Pit (Z-85005) Level Control
In case of chemical spillage, the operators will wash the spillage by water. The diluted chemicals will
be routed by gravity into Neutralization Pit (Z-85005). By getting level in the Neutralization Pit, 850-LI-
028A level alarm high, informs the operators to start neutralization process.
By getting low-low level detection in the Neutralization Pit (Z-85005) by 850-LI-029, the duty pump (P-
85012A or P-85012B) will be stopped automatically via BPCS.
4.1.2.13.2 Neutralization Pit (Z-85005) pH Control
By getting level in the Neutralization Pit, 850-LI-028A level alarm high, informs the operators to start
neutralization process based on the below procedure:
Operator to check the position of vale to T-85002 or Cooling water outfall channel in closed
position and circulating valve on open position.
Operator to identify duty and standby pump, check suction and discharge valves are in open
position
Operator to start duty pump P-85012A (or P-85012B) and recirculate the content of Neutralization
Basin (Z-85005)
The pH analyzer indicates which chemical (caustic or sulfuric acid) is required for neutralization.
Operator to slightly open the valve on neutralizing chemical to gently adding the neutralizing
chemical into the Neutralization Basin (Z-85005). Operator to check the basin temperature to be
below 50 °C during neutralization process. In case of temperature exceeds 50 °C, operator to stop
adding neutralizing chemical and keep the pump on circulating mode.
pH analyzer indicates the end of neutralization process.
Operator to close isolating valve on neutralizing chemical
Operator to open valve to Cooling water outfall channel (Primary destination is cooling water outfall
channel. Due to high salt content in neutralized chemical effluent, treated waste water may not
meet outfall water spec, in case of routing to WW Equalization Tank) and close circulating valve
By getting low-low liquid level alarm running pump will be stopped automatically via BPCS.
Operator to check if running pump has been stopped
4.1.2.14 Benzene/MTBE Contaminated Waste Water Collection Tank (T-85004) Normal Operating Variables
The Benzene/MTBE Contaminated Waste Water Collection Tank (T-85004) is used to store the
benzene/MTBE contaminated waste water awaiting steam stripping treatment. To reduce impact of VOC
(Volatile Organic Carbon) on environment, the tank has been blanketed with nitrogen and protected against
over pressuring by PSV. Tank is provided with safety hatch, to protect against the overpressure during the
fire scenario. The vapor release is vented to atmosphere.
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4.1.2.14.1 Benzene/MTBE Contaminated Waste Water Collection Tank (T-85004) Level Control
The Benzene/MTBE Contaminated Waste Water Collection Tank level will be controlled via liquid level
controller (850-LC-017A) by manipulating flow control valve (850-FV-015) on the feed line to Steam
Stripper Column (C-85001).
To protect Benzene Contaminated WW Pump (P-85007A/B) against running dry, by getting low-low
liquid level (850-LI-018) in Benzene Contaminated Waste Water Collection Tank, both pumps P-
85007A/B will be stopped automatically via BPCS.
4.1.2.14.2 Benzene/MTBE Contaminated Waste Water Collection Tank (T-85004) Pressure Control
To prevent ingress of hazardous hydrocarbons (VOC) to the atmosphere, Benzene/MTBE
Contaminated Waste Water Collection Tank will be kept under nitrogen blanketing.
It is advised to provide the Nitrogen blanketing pressure control with a ‘dead band’ (gap control), in
order to avoid waste of Nitrogen. When the pressure lowers (850-PC-032) in the tank to a certain limit
Nitrogen will be added (Opens Pressure control valve 850-PV-033), and when the pressure rises to a
certain limit vapors from the tank are vented (by means of pressure control valve 850-PV-032) to the
Vent Gas Incinerator Unit via Vent Gas Blower K- 85001A/B.
4.1.2.14.3 Benzene/MTBE Contaminated WW pH Adjustment Mixer (M-85002) Normal Operating Variables
The pH of the Benzene/MTBE Contaminated WW is adjusted by means of caustic and sulfuric acid
dosing upstream of M-85002.
It is advised to provide the pH control with a ‘dead band’ (gap control), in order to avoid waste of
chemicals and unstable pH value. When the pH value lowers to a certain limit (850-AC-010), sulfuric
acid will be added via control valve (850-AV-011). In case of the pH value rises to a certain limit (850-
AC-010), 20% caustic will be added via control valve (850-AV-010).
4.1.2.15 WW Steam Stripper (C-85001) Normal Operating Variables
Steam stripper is utilized to strip-off the light hydrocarbons such as benzene. The stripped waste water,
after heat recovery, will be sent to either WW Collection Tank (T-85001) or WW Equalization Tank (T-
85002) subject to TOC level (850-AI-012). In case of high benzene contamination detected by (850-AI-013)
or low temperature (850-TI-006, 009, 010) in WW Steam Stripper (C-85001), the stripped WW is to be
returned to Benzene/MTBE Contaminated WW Collection Tank by means of three way valve 850-XV-007.
4.1.2.15.1 WW Steam Stripper (C-85001) Steam Flow Control
During normal operation, the feed to the waste water steam stripper is pre-heated by stripping column
effluent. The LP stripping steam flow rate is controlled by a ratio control between the feed (850-FC-
015) and the overhead vapor flow (850-FC-018) of WW Steam Stripper (C-85001).
4.1.2.15.2 WW Steam Stripper (C-85001) Pressure Control
The pressure in the column is controlled by the pressure controller (850-PC-xxx) in Steam Stripper
OVHD line. Upon high-high pressure detection in WW Steam Stripper (C-85001), feed to the stripper
(850-FV-015) and steam supply (850-FV-018) is stopped automatically. This will stop the
Benzene/MTBE Contaminated WW Pump P-85007A/B.
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4.1.2.15.3 WW Steam Stripper (C-85001) Level Control
The WW Steam Stripper (C-85001) level will be controlled via liquid level controller (850-LC-019) by
manipulating flow control valve (850-FV-017) on the stripper effluent line located downstream of
Stripped WW Trim Cooler (E-85002).
To protect Stripped WW Pump (P-85009A/B) against running dry, by getting low-low liquid level (850-
LI-020) in WW Steam Stripper (C-85001) bottom, both pumps P-85009A/B will be stopped
automatically.
4.1.2.15.4 Stripped WW Pump (P-85009A/B) minimum Flow Control
The flow control (850-FC-016) controls the minimum flow through the Stripped WW Pumps, by
manipulating flow control valve (850-FV-016) in the minimum flow return line to the WW Steam Stripper
(C-85001).
4.1.2.16 Steam Stripper OVHD Reflux Drum (V-85002) Normal Operating Variables
4.1.2.16.1 Steam Stripper OVHD Reflux Drum (V-85002) Pressure Control
Nitrogen is used in the stripper overhead to maintain sufficient pressure in the overhead system of the
column to allow venting to the flare. Some nitrogen is required in case insufficient hydrocarbons (non-
condensable) are present in the waste water feed stream. It is fed upstream of the Steam Stripper
Overhead Condenser E-85003 to ensure proper condenser operation. In the event of a pressure loss
(850-PC-044) in the system due to low concentrations of hydrocarbons in the feed, the pressure
controller (850-PC-044) will open the valve (850-PV-044) in the nitrogen line to bring the pressure up to
the desired set point. When there is an overpressure due to an increase in the quantity of non-
condensable in the feed, the pressure controller (850-PC-045) opens the valve (850-PV-045) on the
vapor outlet to the wet flare. It is advised to provide the pressure control with a ‘dead band’ (gap
control), in order to avoid waste of Nitrogen. The pressure in the overhead reflux drum is set at about
1 barg in order to ensure proper disposal of vents to the flare.
4.1.2.16.2 Steam Stripper OVHD Reflux Drum (V-85002) Level Control
The level control (850-LC-024) controls the Interface liquid level in the hydrocarbon water compartment
of Steam Stripper Overhead Reflux Drum by manipulating the discharge flow of the WW Steam
Stripper Reflux Pumps P-85008A/B by adjusting its stroke.
The ON/OFF level controller (850-LC-022) controls the skimmed oil liquid level in the skimmed oil
compartment of Steam Stripper Overhead Reflux Drum by opening or closing the on-off valve (850-XV-
008) regulating the skimmed oil flow to the Skimmed Oil Vessel (V-85001).
4.1.2.17 Stripped WW Filter (S-85001A/B) Normal Operating Variables
When the unit is in operation the Stripped WW Filter (S-85001A/B) steadily gets fouled. The pressure drop
over the filter (850-PDI-039) is an indication for the extent of fouling. The operator should check this
pressure drop regularly. If the pressure drop exceeds the maximum value of 70 kPa, manual cleaning of
the filter is required. Meanwhile operation can continue using the spare filter.
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4.2 Waste Incineration Unit (WIU – 8600)
4.2.1 Normal Operating Condition
For normal operating conditions, reference is made to the:
Process Description, Doc. S-S860-5223-002
Utility Process Flow Diagram, Doc. D-860-5223-101 to D-860-5223-102
4.2.2 Process Variables
Vendor Operating manual of Vent gas Incinerator (ME-86001) and Liquid & Solid Waste Incinerator
Package (ME-86002) to be referred for process variables and controls inside the package.
4.2.2.1 Waste Liquid Hold-up Drum (V-86001) Level Control
The waste liquid streams from the process and utility units are collected in Waste Liquid Hold-up Drum (V-
76001). All streams are considered intermittent. Part of the fluids are transported tank car or drums and
partly by pipeline.
A minimum level in the drum is maintained by a single level controller (860-LC-005) on the Waste Liquid
Hold-up Drum V-86001, which manipulates the Variable Speed Drive of the Waste Liquid Feed Pump P-
86001A/B, in order to reduce the out flow to the combined Solid and Liquid Incinerator Package.
4.2.2.2 Waste Liquid pump-around flow Control
The waste liquid streams in Waste Liquid Hold-up Drum (V-76001) are mixed by pumping around before
routing to Solid and Liquid waste Incinerator Package ME-86002. For pump around purpose a flow
controller (860-FC-002) is located in the pump around line, branched off from the Waste Liquid Feed Pump
P-86001A/B discharge and is routed back to the Waste Liquid Hold-up Drum V-86001, where it is
connected to a jet mixer inside the drum. The single flow controller (860-FC-002) manipulates downstream
flow control valve (860-FV-002) in the pump around line.
4.2.2.3 Waste Liquid Pressure Control
The Waste Liquid Feed to the combined Solid and Liquid Incinerator package ME-86002 is transferred by
the Waste Liquid Feed Pump P- 86001A/B under pressure control via single pressure controller (860-PC-
011), which manipulates the downstream pressure control valve (860-PV-011) in the Waste Liquid Feed
line.
4.3 Flare Unit (FLRU – 8900)
4.3.1 Normal Operating Condition
For normal operating conditions, reference is made to the:
Process Description, Doc. S-S890-5223-002
Utility Process Flow Diagram, Doc. D-890-5223-101 to D-890-5223-103
4.3.2 Process Variables
Vendor Operating manual of Main Wet Flare Package (ME-89001), Cryogenic LP Flare Package (ME-
89002A/B) and Spare Storage Wet Flare Package (ME-89003) to refer for process variable and control.
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4.3.2.1 Acid Wet Flare KO Drum (V-89008) Level Control
Any liquid accumulated in V-89008 is routed by the Acid Gas Flare KO Drum Pump P-89008 A/B to the
SCU Sour Gas Flare KO Drum V-10003. The pump is automatically started upon H level limit (850-LI-
002A) and stopped at L level (850-LI-002A) limit by the BPCS. Both pumps are connected to the
emergency power grid.
4.3.2.2 Main Wet Flare KO Drum (V-89001) Level Control
Any liquid accumulated in V-89001 is routed by the Flare Knock-out Drum Pump P-89001A/B to the
Quench Tower Drain Drum. Only during shutdown of the SCU; the pumped liquid is routed to the Waste
Water Collection Tank. The selected duty pump is automatically started upon a certain high level (850-LI-
005) limit and stopped at a certain low level limit by the BPCS. Upon high-high level limit the selected
standby pump is started automatically and stopped upon low-low level limit by the BPCS. Both pumps are
connected to the emergency power grid.
4.3.2.3 MP Steam to Main Wet Flare (ME-89001) Flow Control
MP steam is routed to the Flare Tip to ensure smokeless flaring at low relief loads. The MP steam is flow
controlled by a flow controller (890-FC-026A) which manipulates flow control valve (890-FV-003)
downstream the flow controller in the MP steam line. In order to react adequately on the relief vapor flow
fluctuations towards the flare stack, a ratio function (calculation) connected to a high selector will be
provided, in order to adjust the set point of the MP steam flow controller. A minimum steam flow will be set
by a hand controller (890-HC-001), which is connected to the same high selector, in order to ensure a
minimum amount of MP steam flow to the flare tip. To optimize the steam consumption infrared sensors
are installed to sense flare characteristic of the flame and adjust the MP steam flow controller set point
automatically. The MP steam flow is adjusted automatically by the total relief flow from Acid Gas Flare KO
drum V-89008 and Wet Gas Flare KO Drum V-89001 towards the flare stack.
4.3.2.4 Spare Storage Wet Flare KO Drum (V-89004) Level Control
In case the Main Wet Flare ME-89001 is taken out of operation, all wet storage area vents and relief are
routed to Spare Storage Wet Flare Package ME-89003. From the main combined wet and cold flare
header the reliefs are routed to the Spare Storage Wet Flare K.O. Drum V-89004 which is located near the
Flare Stack.
Any liquid accumulated in V-89004 is pumped by the Spare Storage Wet Flare Knock Out Drum Pump P
89003A/B to the liquid outlet line from the V-89001 to be routed to the Quench Tower Drain Drum. Only
during shutdown of the SCU; the pumped liquid is routed to the Waste Water Collection Tank. The selected
duty pump is automatically started upon a certain High level (890-LI-015) limit and stopped at a certain low
level limit by the BPCS. Upon high-high level limit the selected standby pump is automatically started and
stopped at a certain low-low level limit by the BPCS. Both pumps are connected to the emergency power
grid.
4.3.2.5 MP Steam to Spare Storage Wet Flare (ME-89003) Flow Control
MP steam is routed to the Flare Tip to ensure smokeless flaring at low relief loads. The MP steam is flow
controlled by a flow controller (890-FC-017A) which manipulates flow control valve (890-FV-017)
downstream the flow controller in the MP steam line. In order to react adequately on the relief vapor flow
fluctuations towards the flare stack, a ratio function (calculation) connected to a high selector will be
provided, in order to adjust the set point of the MP steam flow controller. A minimum steam flow will be set
by a hand controller (890-HC-023), which is connected to the same high selector, in order to ensure a
minimum amount of MP steam flow to the flare tip. To optimize the steam consumption infrared sensors
are installed to sense flare characteristic of the flame and adjust the MP steam flow controller set point
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automatically. The MP steam flow is adjusted automatically by the total relief flow from Acid Gas Flare KO
drum V-89008 and Wet Gas Flare KO Drum V-89001 towards the flare stack.
4.3.2.6 MP Steam to Cryogenic LP Flare Package (ME-89002A/B) Flow Control
MP steam is routed to the Flare Tip to ensure smokeless flaring at low relief loads. The MP steam is flow
controlled by a flow controller (890-FC-010A for ME-89002A and 890-FC-013A for ME-89002B) which
manipulates flow control valve (890-FV-010 for ME-89002A and 890-FV-013 for ME-89002B) downstream
the flow controller in the MP steam line. In order to react adequately on the relief vapor flow fluctuations
towards the flare stack, a ratio function (calculation) connected to a high selector will be provided, in order
to adjust the set point of the MP steam flow controller. A minimum steam flow will be set by a hand
controller (890-HC-007 for ME-89002A and 890-HC-011 for ME-89002B), which is connected to the same
high selector, in order to ensure a minimum amount of MP steam flow to the flare tip. To optimize the
steam consumption infrared sensors are installed to sense flare characteristic of the flame and adjust the
MP steam flow controller set point automatically. The MP steam flow is adjusted automatically by the total
relief flow from Acid Gas Flare KO drum V-89008 and Wet Gas Flare KO Drum V-89001 towards the flare
stack.
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5.0 PREPARATION FOR INITIAL START-UP - PLANT CHECKOUT
The following gives a general outline for the procedures of the various checks to be done on the unit prior
to initial start-up. The package vendors have to be consulted in this regard.
The procedures described below are carried out during the final stages of construction, under the
supervision of the operations supervisor responsible for the unit. Many of the checks may be made
simultaneously, depending on the degree of completion of each system of the unit
5.1 P&ID Checks
The plant is checked against the final edition of the Piping and Instrument Diagrams (P&ID’s) and
isometrics and any deviations are noted and reported. Corrective work can then be carried out, where
necessary. This check is intended primarily for piping and instrumentation.
5.2 Operability Checks
This check should be completed before the completion of construction work, in order to assure that the unit
is satisfactory from an operator point of view. It is performed, preferably, by personnel with start-up
experience and should include a study of all operations required to (pre)commission, start-up and
shutdown the unit and is intended to confirm that all necessary lines and equipment are available for these
operations. All valves should be easily accessible by operating personnel. Fire hoses should be available
at the intended points. Drains should be available at low points and there should be no pockets that are
difficult or impossible to drain. The sloping of lines should be correct.
5.3 Mechanical Checks
All equipment should be inspected to assure that it is ready for use. Some of the items to be checked
include but not limited to the following:
Vessel Internals: check for proper installation and levelness of trays, baffles, cleanliness, etc.
Pumps: properly supported pipe work, proper installation of cooling and seal-water piping,
proper installation of lubricating systems, proper strainers and filters.
Exchangers: piping free to expand as designed properly supported pipe work.
Columns: check for proper installation and levelness of trays, properly supported pipe work,
manholes boxed up, PSV's properly installed and interlocks installed in the proper way.
Piping: expansion, pipe supports, gaskets, hot water tracing, electric heat tracing and insulation,
direction of flow for globe valves, check valves, etc.
5.4 Instrument Checks
All control valves should have been checked for correct installation, sufficient air supply, access for
maintenance, visibility of gauges, indicators, etc. All loops should have been checked and signed off as
complete. All valves should have been greased and stroked. All instruments calibrated, checked against
performance requirements, located on right place (i.e. required length of immersion). Level alarm settings
and trips should be checked for the densities of the media used during start-up to prevent level misreading.
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5.5 Cleaning of Lines
Following construction completion, all unit process lines should be thoroughly cleaned of debris and scales.
Generally, it is convenient to achieve this by flushing the lines with water before the tightness tests; it may
be possible to combine the flushing effort with hydro testing. If desired, all pumps can also be run in at the
same time and used to circulate water for removing dirt and scales via the pump suction strainers and the
filters present.
Cleaning operation can also be carried out by air blowing but for large equipment and lines having a
diameter larger than 24" the cleaning is achieved manually.
5.5.1 Water Flushing
Water flushing concerns the following lines:
In general lines full of liquid during normal operation.
Mixed phase service up to 10” diameter. For greater diameters, the water velocity is in general
not sufficient to get a good cleaning efficiency.
Lines will be flushed clear before pumps will be run with water.
Note: It should be checked that the quality of the water for flushing (and hydro testing) is suitable for the
purpose. In particular stainless steel lines and equipment should not be flushed with water
containing chlorides.
Lines that cannot be properly flushed with water will be steam or air blown.
5.5.2 Air Blowing
The following lines are subject to air blowing:
Lines with gas in normal operation.
Mixed phase service, in general over 10” diameter, when water flushing is not sufficient for a
good cleaning efficiency.
See exceptions in paragraph 6.5.3
5.5.3 Hand Cleaning
Examples of lines that should be cleaned by hand:
Overhead lines of columns.
Lines with a diameter larger than 24”.
These lines must be carefully cleaned by hand before erection and carefully checked by the construction
team for cleanliness.
5.6 Cleaning and Servicing of Utilities Systems
Following construction, the various utilities such as steam, cooling water, air, etc., must be put into service.
Before commissioning, the various lines must be cleared of debris, dust and construction trash and tested
for leakage. The cleaning may be done by water and steam flushing or by air blowing techniques,
depending on the particular utility service. These techniques are generally described below for each utility
system.
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General Note: In each unit, all the utility systems must be in service at normal conditions before
beginning operations on process equipment.
5.6.1 Steam Lines
Once steam is available in the unit, the steam lines can be warmed up and blown free from debris. Before
putting steam into the system, all steam traps, control valves, turbines, instruments, vacuum ejector and
strainers should be removed or blinded off from the system. The steam headers should be slowly warmed
up, one header at a time, while expansion of the line is observed. Special attention should be given to pipe
support shoes. Condensate must be drained manually as it forms to prevent water hammering. The
headers should then be blown using a low-pressure, high-velocity sweep. A second steam blow can be
performed for better removal of scaling.
When the headers are warm, the drain and vent valves should be opened and blown vigorously for a few
moments before closing again. Each down-comer to heater, exchangers or service lines should be blown
in the same manner, but never more than one at the time. A temporary movable silencer may have to be
used to avoid exceeding noise level limitations during the steam blowing operation.
When blowdown of the steam system is completed, traps and other equipment that were removed prior to
the blowdown may be reconnected. After the steam has passed the steam test, it can then be placed into
service.
5.6.2 Condensate Lines
All lines should be flushed with raw water first and then with Condensate. After flushing, commission the
network normally.
Condensate lines may be cleaned in the same manner as steam lines. However, close observation of the
pressure on the condensate line is necessary since the working pressure and the temperature of the
condensate lines are generally lower than that of the steam headers.
5.6.3 Cooling Water Lines
The cooling water network should be cleaned with a high velocity flush of water after all equipment
(coolers, condensers, etc.) has been disconnected at the inlet and at the outlet.
When the system has been washed out successfully, connect equipment and pressurize the lines and
equipment to the normal operating pressure. The cooling water network is then ready for use.
Notes:
1. Normally equipment delivered from the factory is clean and it is not always necessary to
clean them. It is recommended to check if this equipment has to be cleaned.
2. During filling of equipment, do not forget:
To open all vents at high points in order to evacuate the air contained in the equipment and
piping.
To open the valves at battery limit slowly and steadily.
5.6.4 Air Systems
5.6.4.1 Instrument Air
Instrument air network shall be blown through completely from battery limit with a high airflow rate
in order to clean and dry all the lines.
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The main header is blown first with a high air rate. First the lines from the header to the instrument
air regulators should be disconnected and any other regulator removed from the lines. Each
individual airline should be blown and dried.
The instrument air system shall be tested pneumatically with dry air.
All joints and connections shall be checked for tightness with a soapy water solution. Header and
branch lines shall be blown through with a high flow rate of air. During all these tests, the
instruments that will be supplied with air shall be carefully isolated from the system.
At the end of blowing and drying, all regulators and instruments should be connected again and
the instrument air system is placed in service at the normal operating pressure.
The water dew point of the air should be low enough to avoid condensation (and freezing) of water
at the local atmospheric conditions.
5.6.4.2 Plant Air
Plant air system shall be blown through completely from battery limit with a high air flow rate in
order to clean all the lines. The main header is blown first while the lines from the header to the
users are disconnected at the inlet to the users. Next, the header is blown with a high airflow. After
the main header, each individual line should be blown. After cleaning and drying, the plant air
system should be placed in service at the normal operating pressure.
5.6.5 Nitrogen Lines
The nitrogen lines should be disconnected from the equipment and any regulator and pressure reducer
should be removed. The header should be blown first with plant air connected by hoses to the nitrogen
lines. It should be swept with a high flow rate through the vents to remove impurities. Then the lines should
be flushed with inert gas, nitrogen, at a low flow rate to remove air and dry the network. Check for oxygen
content before stopping inert gas sweeping; check for dew point. The oxygen content in the nitrogen lines
must be below 0.5%. Pressurize the system to the normal operating pressure and maintain the net in
service.
Note: Nitrogen is an asphyxiating gas and any activity regarding nitrogen should be considered for this
safety aspect.
5.6.6 Potable Water Lines
Potable water lines to eye wash facilities, safety showers, and drinking fountains should be flushed, and
then left running to remove and dilute any harmful substance. Analysis of the water should be made to be
sure the water is suitable for human consumption. After cleaning, the potable water network should be
placed in service.
5.6.7 Fire Water and Sprinkler Systems
After removing all nozzles, each fire hydrant and monitor should be flushed. All monitor nozzles should be
placed when flushing is completed. Before flushing sprinkler systems, all sprinkler heads should be
removed and the entire system flushed. When lines are clean, heads should be re-installed. Each head
must be inspected before installation to ensure that it is clean. After cleaning, the fire water system is
placed in service and maintained ready for service.
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5.6.8 Flare System
The flare system is blown by depressurization of vessels, either using air after the tightness test of the
vessel or using nitrogen during the inerting exercise on the vessels, or better, on both. After the blowing
operation, the flare system is inerted.
5.6.9 Drain Systems
Generally sewer systems are installed in order to catch equipment and instruments drains before
maintenance and/or inspection or during normal operation. The following sewer systems have been
provided:
Industrial Sewer System
Clean Sewer System
Domestic Sewer System
Chemical Drain Sewer System
These systems are the first to be prepared and put into service, ready to receive the various releases. They
are generally prepared as follows, in parallel with the fire water network:
Check peep holes and all drains.
All sewer lines should be flushed with raw water. After flushing, commission the network
normally.
Check if the destination unit (spent caustic incinerator or the existing facilities) is ready to accept
feed.
5.6.10 Electricity
The electric facilities should be checked and commissioned by the electrical specialists/vendors and other
parties that are involved in these facilities.
5.7 Unit Drying
5.7.1 Drying Main Equipment and Process Lines
The drying out of main equipment and piping can be carried out in the usual way with dry air. A procedure
should be provided during Detailed Engineering.
5.8 Tightness Tests
The unit being washed and dried, the tightness test can be undertaken. The unit should be isolated by
blinds from other units.
The WWT unit is subdivided in several sections, according to their operating pressures, and isolated by
blinds or block valves before performing the tightness tests. The defined sections are pressurized with
nitrogen (or air), at the maximum operating pressure where feasible. The flanges are sealed with a
masking tape in which a small hole is drilled. Leaks are detected using a soapy water solution or a ready-
made test fluid.
When the required pressure is reached, the pressurization is stopped and the loss of pressure checked
with an accurate manometer or better, with a pressure recorder.
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In the field, the leaks are spotted and eliminated.
The tightness tests with nitrogen (or air) are considered satisfactory when the decrease of pressure is not
higher than 0.05 bar/h during minimal 4-8 hours taking temperature changes into consideration during the
test period.
5.9 Air Purging / Inerting
The purging of air (specifically oxygen) can be done in several ways. Air can be replaced by nitrogen by
pressurizing with nitrogen and subsequently depressurizing. The air purging may also be carried out by
steam out of the equipment followed by pressurization with nitrogen. Special care shall be considered by
operators to select the right equipment for steam out due to equipment design temperature.
The oxygen content in the equipment contacted by hydrocarbons must be brought down below 1 % vol.
maximum.
Inerting with nitrogen is preferred for small sized units or when large amount of nitrogen is easily available.
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6.0 NORMAL START-UP
6.1 Introduction
In this section an outline is given for the normal start-up of the WWTU. It shall be reminded that the
package vendors have to be consulted for start-up operation.
6.2 General Safety and Operational Practices
General safety and operational practices used in preparation and start-up are listed below to avoid
repeating them in detail at each step during the start-up procedure.
All supporting auxiliary facilities for running of equipment, e.g. seal oil, lube oil and cooling water
pumps, must be started and tested before taking the main equipment into service.
While heating the lines and equipment in a new plant, frequent inspection of expansion loops
and hangers is necessary to make sure these facilities are properly placed and adequate. Make
sure that the lines and equipment are not subjected to heavy strains and vibration. Heating of
equipment and lines must be done slowly and carefully to prevent uneven expansion that may
cause leakage at flanges.
It is recommended that a detailed planning of the start-up (and shutdown) is made to coordinate
well between all parties involved and to minimize the start-up (shutdown) time. Detailed
procedures and operational checklists is a good practice.
6.3 Start-up Conditions
Before commencing start-up of the units, a number of conditions must be met to ensure a proper and safe
start-up. The most important conditions are:
Pre-commissioning is completed.
The unit is checked for correct positioning of spades, spectacle blinds, valves, relief valves and
swing elbows.
All safeguarding systems are commissioned, for example relief valves, valve interlock systems,
fire protection systems, remote operated valves, etc.
All safety equipment is installed and commissioned, for example eye wash facilities and safety
showers.
All fire equipment is installed.
All gas alarms and personal warning systems are commissioned, for example chlorine gas
detectors.
All required utilities and chemicals are available. Packing, filter elements, etc., are installed.
Electrical tracing and hot water tracing is activated when required.
Instruments have been checked for proper functioning and have been calibrated for the desired
range. The instruments themselves, except where stated specifically, are not yet in service
since at this stage of the operation, the instruments have to be isolated (e.g. vacuum test) or no
reading is available since operating conditions are outside the range of the instrument. Pressure
vacuum gauges should be available to monitor the pressure, during evacuation and pressure
testing.
A check has been made that the products of the units can be safely run down to the proper
storage tanks.
Relief valves are not lined-up to flares, if air is still present in the unit.
The unit is leak-tested with nitrogen to detect major leakage, prior to the tests mentioned at the
relevant sections.
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6.4 Pre Start-up
Pre start-up activities are meant to enable actual start-up of the unit. These activities consist of charging
utility systems and steaming out the units where ever applicable. The package vendors have to be
consulted in this regard.
6.4.1 Status
When the pre-commissioning and commissioning activities have been completed, the status of the units is
as follows:
All equipment and piping has been cleaned, tested and drained.
All equipment is at ambient conditions full of air.
All battery limit valves are closed and can be opened as required.
All instrumentation is commissioned and ready for use.
Seal-oil/water systems are commissioned and ready for use.
All motors are ready for operation.
All relief valves have been shop tested and reinstalled.
All vents, drains and sample points are closed.
The plant has been verified to have been built according to P&IDs.
6.4.2 Charge Utility Headers
The utility headers are supplied from the main utility headers at the battery limits of the unit. The headers
are commodity cleaned prior to the charging of the headers and the utilities are charged before the process
systems of the units are commissioned.
The charging of the headers can be started after:
All equipment has been tested and drained.
All the plant utility main headers are operational.
All equipment is at ambient conditions and full of air.
All instruments are commissioned and ready for use.
All relief valves have been recently shop tested and reinstalled.
After inerting, if required, the charging of the headers is done by gradually opening the battery limit valve.
The headers are pressurized and checked for leaks. The headers are blown or flushed through to displace
the air or inert medium. The vents and drains are closed and the header is pressured to plant header
pressure.
6.4.3 Steam-out
Prior to actual start-up, proper steam out has to take place in order to expel air or inerts and clean
equipment and lines. The procedure is general.
First operator has to check that selected equipment is designed for steam out condition
Using the steam out nozzle or utility connection nozzle in equipment, commence steaming out
the unit to displace air and warm up pipe work.
Check that pipe work and vessels are free to expand as designed and are not obstructed.
Drain condensate from all low point drains.
Continue steaming out, until clean white steam plumes are seen at the vents and oxygen
content in the equipment is below 1% vol.
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Close vents and drains and stop steam flows. Prevent vacuum due to cool down in equipment
which normally operates under atmospheric conditions or overpressure: maintain positive
pressure by introducing nitrogen.
6.5 Start-up
This section describes mainly LLOD and waste water stripper section. For normal start-up procedure
reference is made to package vendor instructions.
6.5.1 LLOD
The start-up procedures described below assumes that appropriate pre-startup preparation of the waste
water collection system has taken place. This includes the following:
All collection pits / sumps / basins / tanks are cleaned
All pumps are installed and tested for good operation
All analyzers are installed and calibrated
The Industrial sewer drainage piping are clean
The Waste Water Collection Tank (T-85001) is properly lined up and blanketed with nitrogen.
The vent gas line from the WW Collection Tank to the Vent Gas Incinerator package is open
and available.
Vent gas Blower K-85001A/B is ready for use, as the vent gas from the tank will be routed to
Vent gas Incinerator package through this Blower.
All controllers are in manual mode.
All utilities should be available at sufficient quantities.
The complete system has to be filled up with clean water.
Before the drainage of water from curbed, diked and bund wall areas, the content has to be
neutralized.
The start-up procedure of the waste water collection system is described below by focusing on the basic
sequence and type of activities that need to be done. Each step needs to be described in more detail in the
Operating Manual to be prepared by Detailed Design Contractor.
Before operation, the complete system has to be partially filled with (clean) water (walls have to
be wet); to prevent that oil is sticking to the wall.
The Oil Contaminated Water Basin (Z-85001) is designed that at high level, pumps will
automatically be switched on by a level switch.
Operator has to take samples from the water in the different compartments of the FFB (Z-
85002), and determine if it has to be treated, and what kind of treatment is required
(Benzene/MTBE containing or non-Benzene / MTBE). Based on the selected treatment, the
correct discharge valves downstream the FFB Water Pump (P-85002A/B) has to be opened and
closed. This procedure has to be executed each time the FFB (Z-85002) and POB (Z-85003)
are filled and has to be emptied.
6.5.2 Waste Water Steam Stripper
The start-up procedures described below assumes that appropriate pre-startup preparation of the Waste
Water Steam Stripper has taken place. This includes the following:
The Waste Water Steam Stripper and associated equipment are cleaned.
All pumps are installed and tested for good operation.
All utilities should be available at sufficient quantities.
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All safeguarding systems should be reset and activated.
Sulfuric acid and caustic dosing packages are available for use and properly lined up.
The Benzene/MTBE Contaminated Waste Water Collection Tank (T-85004) is properly lined up
and blanketed with nitrogen.
The level of Benzene/MTBE Contaminated Waste Water Collection Tank (T-85004) should be
between minimum level and 50% to allow recycling of the stripped WW until benzene
specification is met
Steam Stripper column pressure control (850-PC-044 and 850-PC-045) and flow ratio control
(850-FC-018) are in manual mode.
Level controls (Column: 850-LC-019 and 850-LC-020 and Steam Stripper Overhead Reflux
Drum: 850-LC-022 and 850-LC-024) are put in automatic mode.
All analyzers are calibrated and activated.
Sufficient cooling water must flow to the Steam Stripper OVHD Condenser (E-85003) and
Stripped WW Trim Cooler (E-85002)
Stripped waste water effluent to be lined up to Benzene/MTBE Contaminated WW Collection
Tank T-85004.
The following sequence has to be used during start-up:
Start feeding clean water to the Waste Water Steam Stripper System
Start Steam Stripper OVHD Condenser (E-85003)
Opening the nitrogen supply valve (850-PV-044, in manual mode) to increase the pressure in
the Waste Water Steam Stripper system.
Switch the pressure control (850-PC-044 and 850-PC-045) to automatic mode when the
pressure of the system reaches 1 bar-g.
Open slowly the steam supply valve (850-FV-018, in manual mode) to increase the temperature
in the Waste Water Steam Stripper system.
Switch the ratio flow control (850-FC-018) in automatic mode when the temperature reaches
131 °C.
Route the stripper column effluent to Benzene/MTBE Contaminated WW Collection Tank T-
85004.
When the Waste Water Steam Stripper System is running stable (no fluctuations in pressure
and temperature), the system can be fed with Benzene/MTBE containing wastewater.
Wait until operation is running smooth and stable.
Open the valves downstream E-85002 to WW Collection Tank (T-85001).
Close the valves downstream E-85002 to Benzene/MTBE Contaminated WW Collection Tank T-
85004
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7.0 NORMAL OPERATION
7.1 Normal Operating Parameters
This section describes normal operation requirements for LLOD section; Benzene/MTBE contaminated
waste water steam stripping section and equipment out of package vendor scope of design and supply.
Further information will be provided by waste water treatment package vendors.
For Normal operating settings for the main automatic controls reference is made to Range Alarm and Trip
Setting List of Individual Unit.
7.1.1 Waste Water Treatment Unit (WWTU - 8500)
The waste water treatment unit will consist of physical, chemical, and biological treatment units as
described below:
Last Line Of Defense (LLOD)
Benzene / MTBE contaminated waste water pre-treatment
Wastewater primary treatment
Wastewater secondary (biological) treatment
Wastewater tertiary treatment
Chemical storage, preparation and dosing
For graphical representation of the Waste Water Treatment Unit 8500, reference is made to the Utility Flow
Diagrams D-S850-5223-101 to D-S850-5223-120.
Waste Water Collection and Handling
An adequate waste water collection system plays an essential role in effective waste water reduction and
treatment. Waste water collection system routes the effluent streams to their appropriate treatment device
and prevents mixing of contaminated and non-contaminated waste water.
To design an adequate waste water collection system, the following rules are considered:
All liquid waste streams coming from process, utility and storage areas that could be
contaminated with hydrocarbon are collected and treated before disposal into open water.
Process effluent streams are segregated from surface water run-offs.
Non-contaminated (clean) surface water run-off is to be kept separate from polluted or potentially
polluted run-offs.
Where ever applicable process effluents has been segregated according to its contamination
load.
High benzene / MTBE contaminated waste water shall be kept separate from low or non-
benzene / MTBE contaminated effluent streams.
All chemical effluent shall be neutralized inside the process unit’s battery limit and not to be sent
to sewer system.
Last Line of Defense (LLOD)
Equipment oily drains, pump base plates, hydrocarbon sampling points and surface water run-off typically
rain, fire and wash water from the paved areas, where hydrocarbon pollution may occur, are collected upon
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discharge by proper sewer system and routed by gravity to the below grade Last Line Of Defense (LLOD)
basins.
The LLOD consists of influent Bar Screening Package (ME-85001 and ME-85002), Oil Contaminated Basin
(Z-85001), First Flush Basin (Z-85002), Peak Overflow Basin (Z-85003) and relevant pumps. The POB
together with the FFB are designed to catch the total firewater run-off result of the biggest fire scenario.
The inlet compartments of Z-85001 and Z-85002 are equipped with Oil Skimmer and Sludge Scraper (ME-
85003 and ME-85004). The collected sludge will be sent to Oily Sludge Collection Tank (T-85005) awaiting
dewatering process via LLOD Sludge Pumps (P-85003A/B/C/D).
By taking into account the above considerations, the following effluent collection systems are designed:
Oily Water Sewer (OWS)
Equipment oily drains, pump base plates, hydrocarbon sampling points and surface water run-off from the
paved area where hydrocarbon leakage expected to be occurred shall be collected by oily water sewer
system and routed by gravity to OCB (Z-85001). Then the collected oily water is send to Waste Water
Collection Tank via OC Water Pump (P-85001 A/B) for appropriate treatment. The OC Water Pump (P-
85001 A/B) will be fed by emergency power and protected against clogging by OC Water Screening
Package (ME-85001). The OC Water Pump (P-85001 A/B) is low speed non-emulsified pump. The inlet
compartment of OCB is equipped with portable floating type oil skimmer. The skimmed oil is sent to
Skimmed Oil Vessel (V-85001).
The quality of surface water run-off from the paved area where benzene / MTBE spillage may occur shall
be checked before routing to sewer system. In case of high benzene / MTBE contamination, surface water
run-off shall be collected and sent to benzene / MTBE contaminated waste water pre-treatment unit.
Accidently Oil Contaminated Sewer (AOC)
The AOC sewer system collects equipment drains and surface water run-off which is polluted neither by
benzene / MTBE nor by high concentration of other hydrocarbons and routes the collected effluent to FFB
through AOC Water Screening Package (ME-85002). The purpose of screening is to remove large objects
such as rags, plastics, paper, metals, dead animals, and the like and protect downstream equipment from
damage or clogging. The inlet compartment of FFB is equipped with a portable floating type oil skimmer to
collect skimmed oil if any. The skimmed oil is sent to Skimmed Oil Vessel (V-85001).
FFB is designed to hold rain water run-off from potentially hydrocarbon polluted area during first 35
minutes of rain. After this period, FFB is filled and the surface water run-off overflows to POB. It is
expected that the contamination level of surface water run-off collected in POB is diluted to such an extent
that can bypass biological treatment and be treated only by Induced Air Floatation (IAF) unit (ME-85009). If
the quality of collected run-off in POB is far from outfall water specification (high BOD / high COD), the
collected run-off shall be treated along with first flush water collected in FFB in biological treatment unit. In
addition, the POB is used as surge basin in case of cooling water oil contamination.
During normal plant operation, it is expected that good housekeeping keeps surface water run-off collected
in FFB clean enough (low BOD / low COD) to be treated only by an Induced Air Floatation (IAF) Unit (ME-
85009) for removing any residual oil or suspended solids. Then the treated surface run-off will be sent to
Treated Effluent Tank (T-85003) for the final check and settled sludge will be pumped directly to Sludge
Dewatering Package (ME-85007). However, if the quality of collected water in FFB is off-spec due to high
BOD / high COD, the water will be sent to Waste Water Collection Tank (T-85001) by means of FFB Water
Pump (P-85002 A/B) for further treatment in the WWT unit. If the benzene contamination of the collected
surface water run-off exceeds 10 ppm, then the collected water has to be sent to Benzene / MTBE
Contaminated waste water collection Tank (T-85004) by means of FFB Water Pump (P-85002A/B) for
further Treatment.
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Clean Water (ND) Sewer System
This system is a clean water sewer, collecting surface water run-off from non-contaminated areas where
source of hydrocarbon leakage/spillage is not exist. Collected surface water run-off from Storm water
channel pump pit (Z-85006) is pumped by Storm water pump (P-85015A/B) to Storm Water Clarifier (ME-
85010) where suspended solids and trace of hydrocarbons (if any) will be separated. The overflow from
Sea water Channel Pump Pit is routed to Sea Water Outfall Channel. The clarified storm water from ME-
85010 will be sent to MISC (OSBL) along with provision for routing it to Sea water return channel and the
collected sludge will be transferred to Sludge Dewatering Package (ME-85007).
Domestic Sewer System
This system collects domestic waste water from toilets, urinals, kitchen facilities, sinks, showers and the
like from buildings and shelters. Domestic effluent from kitchen facilities shall be equipped with grease
traps. Domestic effluents are routed by a sloped gravity underground pipe system into the centralized
Domestic Lift Station (ME-85011). Eight (8) numbers of Domestic lift pump stations will be installed in
specific areas which will transfer the solid and liquid wastes MISC (OSBL) for further treatment.
Chemical Sewer / Neutralization System
Demin water spent regenerants, condensate polishing spent regenerants, spent chemicals,
Benzene/MTBE contaminated WW from drainage of P-85007A/B, P-85008A/B, and P-85009A/B shall be
kept separate from surface water run-offs. To meet outfall water specification, the spent chemicals shall be
neutralized first.
The Chemical Effluent from the collection system is collected by the Neutralization Pit Z-85005, where
either Caustic or sulphuric acid will be added to neutralize the content of Pit. A pH measurement is
installed for control of neutralization. The chemical content of the Neutralization Pit is mixed by a Jet Mixer
M-85003. The chemical solution from Z-85005 is pumped through the Jet Mixer M-85003, by Neutralization
Pit Pump P-85012A/B.
The neutralized spent chemical will be sent to the Cooling Water Outfall channel (along with the provision
to send it to WW Equalization Tank T-85002), when the temperature is right without further treatment.
Primary destination is the cooling water outfall channel. Due to high salt content in neutralized chemical
effluent, treated waste water may not meet outfall water spec, in case of routing to WW Equalization Tank
(T-85002).
Benzene / MTBE Contaminated Waste Water Pre-treatment
The benzene / MTBE contaminated waste water pre-treatment will treat waste water contaminated with
benzene or MTBE. By utilizing steam stripping the benzene content is reduced to 1 ppmw. The following
waste water streams are pre-treated:
SCU dilution steam drum blowdown
SCU stripped process water
Quench water in case of SCU shutdown
Surface water run-off from Benzene Contaminated Area
Contaminated Condensate from SCU
First flush surface water run-off collected in LLOD, in case contaminated with benzene/MTBE
Surface water run-off from paved area where source of benzene / MTBE leakage/spillage is
exist, in case contaminated with benzene / MTBE
The benzene/MTBE contaminated waste water pre-treatment unit consists of the following main sections:
Benzene / MTBE Contaminated Waste Water Collection Tank
Waste Water Steam Stripper
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The Benzene / MTBE Contaminated Waste Water Collection Tank (T-85004) is used to collect all the
waste water streams before treatment in the Waste Water Steam Stripper (C-85001). Since the waste
water contains benzene and/or MTBE, the tank is provided with a nitrogen blanket and connected to the
Vent Gas Incinerator Package (ME-86001). The tank is equipped with a tangential inlet and oil skimming
facilities to remove the separated free oil. From the tank, waste water is pumped by means of the Benzene
/ MTBE Contaminated Waste Water Pump (P-85007 A/B) at a controlled flow to the Waste Water Steam
Stripper (C-85001). If necessary, the pH is adjusted by means of caustic or sulfuric acid dosing upstream
the steam stripper.
Benzene / MTBE contaminated waste water is preheated against the stripper effluent stream in Steam
Stripper Feed/Effluent Heat Exchanger (E-85001 A/B) and fed to the top of the Waste Water Steam
Stripper. At the bottom of this column, LP steam is supplied which strips the hydrocarbons out of the
influent. Vapors at the top of the column are condensed and collected in the Steam Stripper Overhead
Reflux Drum (V-85002). In this vessel, the condensed liquid will separate in a water layer and a thin oil
layer, which flows over the installed weir into the hydrocarbons compartment. The water in the vessel is
pumped by means of the Steam Stripper Reflux Pump (P-85008 A/B) on level control as reflux to the
column. The recovered hydrocarbons are routed to the Skimmed Oil Vessel (V-85001). Vapors are vented
to the wet flare system.
Nitrogen will be used in order to maintain sufficient pressure in the overhead system of the column to allow
venting to the flare. Some nitrogen is required in case insufficient hydrocarbons (non-condensable) are
present in the waste water feed stream. It is fed upstream of the Steam Stripper Overhead Condenser (E-
85003) to ensure proper condenser operation. In the event of a pressure loss in the system due to low
concentrations of hydrocarbons in the feed, the PC will open the valve in the nitrogen line to bring the
pressure up to the desired set point. When there is an overpressure due to an increase in the quantity of
non-condensable in the feed, the PC opens the valve on the vapor outlet to the wet flare. The pressure in
the overhead reflux drum is set at about 1 barg in order to ensure proper disposal of vents to the flare.
The steam stripped effluent collected from the bottom of the column is pumped by means of the Stripped
Waste Water Pump (P-85009 A/B) to the Waste Water Collection Tank (T-85001) after heat recovery in
Feed/Effluent Heat Exchanger (E-85001 A/B) and cooling down in Stripped WW Trim Cooler (E-85002) to
below 40 °C using cooling water.
In case of high benzene and/or MTBE contamination of the steam stripped effluent, it is manually routed
back to the Benzene / MTBE Contaminated WW Collection Tank (T-85004). This is also done in case of
low-low temperature in the column. In the latter case, sufficient stripping of benzene/MTBE cannot be
ensured.
If the stripped effluent is on-spec according to benzene/MTBE contamination level but off-spec due to high
TOC, the stripped waste water shall be sent to Waste Water Collection Tank (T-85001) and to be treated
by Dissolved Gas Floatation Unit (ME-85005); otherwise Stripped WW shall be sent to WW Equalization
Tank T-85002.
Waste Water Primary Treatment
The waste water primary treatment will treat oil contaminated waste by means of Dissolved Gas Flotation
(DGF) unit. The following waste water streams are pre-treated:
Oil Contaminated Cooling Water
Crystallizer Distillate Effluent from Spent Caustic Oxidation Unit
Wash water from NGL Amine/Water Wash Column
Hydrocarbon drains from Flare Hydrocarbon Drain Drum
Wash water from Caustic / Water Wash Tower
Surface water run-off from Polymer Plant
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The waste water primary treatment consists of the following operation units:
Waste Water Collection Tank (T-85001)
DGF Package (ME-85005)
Skimmed Oil Vessel (V-85001)
The Waste Water Collection Tank (T-85001) is used to store the process waste water awaiting the DGF
treatment. The tank is equipped with tangential inlet and skimming facilities to remove any separated free
oil. From the tank, the waste water is pumped by the Waste Water Transfer Pump (P-85004 A/B) under
flow control to Dissolved Gas Floatation (DGF) package (ME-85005). Waste water pH is adjusted by
means of caustic or sulfuric acid dosing upstream DGF unit.
The DGF package should be sized such that to provide sufficient operating flexibility to allow effluent
quality to be maintained in acceptable range by considering the expected variations in the influent
characteristics. The operator should be able to adjust the following major operating variables:
pH
coagulant and flocculant type and dose
nitrogen pressure
recycle rate
Waste water enters on one end and passes sequentially through coagulation, flocculation and floatation
compartments of the DGF unit (ME-85005). Cationic polymer solution is dosed into the influent upstream of
the DGF unit to enhance the removal of free/emulsified oil and suspended solids. The system forces
nitrogen gas into effluent by means of hydraulic eductors. The nitrogen bubbles will adhere to the oil
particles and form flocs and help these particles to float to the water surface of each flotation compartment.
The floating scum layer is removed by means of a surface skimmer mechanism and sent to the Skimmed
Oil Vessel (V-85001). The treated waste water will overflow via the effluent weir into the DGF clear well
compartment and is pumped by means of the DGF Clear well Pump to the Waste Water Equalization Tank
(T-85002).
The Skimmed Oil Vessel (V-85001) collects the following streams:
Skimmed oil from LLOD basins
Skimmed oil from the Waste Water Collection Tank (T-85001)
Skimmed oil from Oily Sludge Storage Tank (T-85005)
Skimmed oil from the Benzene/MTBE Contaminated Waste Water Collection Tank (T-85004)
Skimmed oil from the Steam Stripper Overhead Reflux Drum (V-85002)
DGF skimming (ME-85005)
Skimmed oil from Spent Caustic Oxidation unit storage tanks (T-63001/T-63002)
Inside the vessel, a special plate pack is installed to separate the oil and water efficiently. The separated oil
is collected via a weir in the oil compartment of the vessel. The collected skimmed oil will be sent to Liquid-
Solid Incinerator Package (ME-86002) by Skimmed Oil pump P-85010. Skimmed oil effluent will be
transferred to WW Collection Tank (T-85001) by Skimmed oil Effluent Pump P-85011.
Waste Water Secondary Treatment
The waste water secondary (biological) treatment consists of:
WW Equalization Tank (T-85002)
Biotreater (ME-85006)
Sludge Treatment and Dewatering (ME-85007)
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The Waste Water Equalization Tank (T-85002) receives the waste water streams to be treated in the
Biological Treatment Package (ME-85006). The following streams are routed to the Waste Water
Equalization Tank:
DGF effluent from the waste water primary treatment
TLE Hydrojetting / decoking quench water effluent
Stripped effluent from Waste Water Steam Stripper
The Waste Water Equalization Tank has a buffering and homogenization function for the feed stream to
the Biotreater, thus minimizing fluctuations in flow rate and composition.
In the Biotreater, BOD and COD is reduced by activated sludge using dissolved oxygen. Biotreater will
receive feed streams from Contact Tank where the equalized WW will be mixed with the recycled activated
sludge and nutrients (urea and H3PO4).
After pH adjustment, the mixed stream is routed to the Aeration Tank where the required amount of air is
supplied by Air Compressor Package. Control of the required amount of air is done by means of a
dissolved oxygen measurement. Aerated stream will be routed to Clarifier on gravity flow via Degassing
Tank. In the Clarifier, the settled activated sludge is separated from the clean water. Part of the activated
sludge is recycled to the Contact Tank and the excess activated sludge is sent to the Sludge Digester
followed by Sludge Thickener. The clarified water is routed to the tertiary treatment to meet the outfall
water specification.
Thickened excess bio-sludge from Sludge Thickener is sent to Sludge Dewatering Package (ME-85007)
where polymer solution is added for conditioning of the sludge. Dewatered bio-sludge is collected in a
mobile bio-sludge cake container, which is trucked out for disposal by incineration. The decanted water
from Sludge Dewatering Package is recycled to the Waste Water Secondary Treatment Package (ME-
85006).
Oily sludge will be kept separate from bio-sludge. The oily sludge from LLOD basins, Waste water
Collection Tank (T-85001), WW Dissolved Gas Floatation (DGF) package (ME-85005), Skimming from IAF
Package ME-85009 and Sludge from Polymer Plant will be sent to Oily Sludge Storage Tank (T-85005)
from where it will be pumped to Sludge Dewatering Package (ME-85007) by Oily Sludge Pump P-
85013A/B. The dewatered oily sludge is collected in a mobile oily sludge container for incineration. The
reject stream from Sludge Dewatering Package (ME-85007) will be sent to Waste Water Secondary
Treatment Package (ME-85006) for further processing.
Waste Water Tertiary Treatment
The waste water tertiary treatment consists of:
Disinfection Unit
Continuous Sand Filter
Activated Carbon Filter
Treated Effluent Tank (T-85003)
In order to meet discharge water specification, Sodium Hypochlorite solution is used for chlorination of
clarified water in Chlorination compartment of Chlorination/Dechlorination Basin followed by Sodium
Metabisulfite solution injection for Dechlorination in Dechlorination compartment.
For removal of remaining suspended solids, the dechlorinated water is routed to the Continuous Sand
Filter. The unit consists of two continuously regenerated sand filters, each designed for 70 % of total
capacity. The continuous backwash stream from the sand filters is recycled to WW Collection Tank (T-
85001). In case of High TOC in Chlorination Tank, the chlorination tank has to be drained into the Waste
Water Collection Tank (T-85001) via Backwash Effluent Basin.
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The clean effluent from sand filters will flow on gravity into the Filtrate Basin, where the treated effluent
quality is continuously monitored by means of a flow, turbidity, temperature, TOD and pH measurement.
It is expected that sand filter clear water can meet the outfall water quality. However, in case of
hydrocarbon contamination, the effluent can be sent to Activated Carbon Filters for final polishing. The
treated waste water will be sent to the Treated Effluent Tank (T-85003), from where the treated WW is
transferred to MISC (OSBL) by means of Treated Effluent Pump (P-85006A/B).
Chemical Storage, Preparation and Dosing
Nutrient (Urea and Phosphoric Acid) Preparation and Dosing Package (ME-85012)
Urea and phosphoric acid are used as nitrogen and phosphorous supplement for Aeration Tanks and
aerobic Sludge Digester.
Granular urea is dissolved in water with a concentration of about 10 wt% and stored in Urea Solution Tank.
Diluted urea is sent to the users by Urea Solution Dosing Pump.
Concentrated phosphoric acid is supplied in 1 m3 plastic containers. Concentrated phosphoric acid is
diluted with water to a concentration of about 10 wt% in Phosphoric Acid Dosing Vessel and is sent to the
users via Phosphoric Acid Dosing Pumps. The dosing packages are surrounded by a dike wall to isolate
the package from surrounding environment in case of any accidental leakages. The drainage is routed to
Neutralization Pit (Z-85005).
Polymer Preparation and Dosing Package (ME-85013)
Cationic polyelectrolyte is used as coagulant in the following equipment:
WW Dissolved Gas Floatation (DGF) Package (ME-85005)
Secondary Clarifier in Biotreater (ME-85006)
Sludge Dewatering Package (ME-85007)
Induced Air Floatation (IAF) Package (ME-85009)
Storm Water Clarifier (ME-85010)
Solid polyelectrolyte is dissolved in water and injected into influent streams by means of injection pumps.
All chemical dosing packages are surrounded by a dike wall to isolate the package from surrounding
environment in case of any accidental leakages. The drainage is routed to Neutralization Pit (Z-85005).
Caustic Soda Dosing Package (ME-85014)
Caustic soda (20 wt%) is used for pH control within wastewater treatment unit. Caustic soda (20 wt%) is
supplied from Caustic Storage Tank to Caustic Dosing Vessel. The dosing vessel vent/breathing line is
routed to hydraulically sealed neutralization pot.
Caustic Dosing Vessel and Caustic Dosing Pump are surrounded by a dike wall to isolate the package
from surrounding environment in case of any accidental leakages. The drainage is routed to Neutralization
Pit (Z-85005).
Concentrated Sulfuric Acid Dosing Package (ME-85015)
Concentrated sulfuric acid (H2SO4) is used for pH control within waste water treatment unit. Concentrated
sulfuric acid is supplied from Sulfuric Acid Storage Tank to Sulfuric Acid Dosing Vessel. The dosing vessel
vent/breathing line is routed to hydraulically sealed neutralization pot, filled with Limestone.
Sulfuric Acid Dosing Vessel and Sulfuric Acid Dosing Pump are surrounded by a dike wall to isolate the
package from surrounding environment in case of any accidental leakages. The drainage is routed to
Neutralization Pit (Z-85005).
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Hypochlorite and SMBS Dosing Package (ME-85016)
Sodium hypochlorite is used for treated wastewater disinfection and Sodium Metabisulfite (SMBS) is
utilized for dechlorination of treated wastewater in Chlorination/Dechlorination Basin.
Sodium hypochlorite and SMBS will be supplied by bag/container. All required components for preparation,
injection and control of hypochlorite and SMBS into treated waste water will be provided by package (ME-
85016) vendor. The dosing package is surrounded by a dike wall to isolate from surrounding environment
in case of any accidental leakage. The drainage is routed to Neutralization Pit (Z-85005).
7.1.2 Waste Incineration Unit (WIU - 8600)
Vent Gas Incinerator
The vent gases of the following storage tanks have to be routed to a Vent Gas Incinerator as these contain
nitrogen with toxic components or smelly fumes (stream 1):
Raw Pyrolysis Gasoline Storage Tank
C6 – C7 Cut Storage Tank
The vapor flows from the storage tanks are the result of pumping in and thermal out breathing during the
day. Pyrolysis Gasoline Vent Gas Blowers (K-83005A/B) are installed to transfer the vent gases from the
storage tanks to the Vent Gas Incinerator package.
A second stream (2) to be processed is originating from the Waste Water Treatment Unit. Vapors formed
during the thermal out breathing and pumping in are routed to the Vent Gas Incinerator via Vent Gas
Blower (K-85001 A/B). This line is usually active and can contain hydrocarbons in traces.
Benzene / MTBE Contaminated Waste Water Collection Tank
Waste Water Collection Tank
Skimmed Oil Vessel
Oily Sludge Storage Tank
Spent Caustic Storage Tank
Spent Caustic Oxidation Effluent Tank
The third stream (3) to be processed is the spent air stream from the Spent Caustic Oxidation Unit. This air
stream has a continuous flow rate and contains traces of hydrocarbons.
The fourth stream (4) to be processed is the vent gas from Rerun Tower Vacuum Package (J-62011) in
Pygas Hydrotreater Unit, when it is not routed to the Cracking Heaters, containing air with hydrocarbons.
During shut down of the SCU, the PGHYD waste gas flow (stream 4) and the Spent Oxidation Unit 8100
waste gas flow (stream 3) becomes zero, whereas the vapor flow from other sources (streams 1 and 2)
continues. The Incinerator has to be designed for that situation.
This package is an incinerator specially designed for high hydrocarbon conversion efficiency.
Flame Arrestors ME-86001-A01A/B and ME-86001-A02A/B (part of ME-86001) are required to prevent fire
in case of back flow from the incinerators into the vent gas line.
In case the Vent Gas Incinerator ME-86001-F-01 is not available and during the start-up of the blowers, the
vent gases are routed to the atmosphere at safe location via Vent Gas Stack (ME-86001-SK-01).
The flue gas is routed via a stack to the atmosphere. The incinerator is fired by means of fuel gas with
Natural Gas as back-up.
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Liquid and Solid Waste Incinerator
The waste liquid streams and solid wastes from the process and utilities units are collected in Waste Liquid
Hold-up Drum V-86001.
V-86001 is provided with low pressure steam coils in order to keep the fluid at the right temperature to
allow pumping to the incinerator. The vessel is purged with nitrogen to remove any hydrocarbon vapors to
the Wet Flare.
All streams are considered intermittent. Part of the liquid streams is transported by tank car or drums and
partly by pipeline.
The solid waste is transported by means of trucks or by conveyor and is dumped in a Waste Feed Hopper
part of Waste Liquid Hold-up Drum V-86001. A feeder charges the solids into the drum.
To prevent suspend solids settle down the contents are mixed by internal mixer(s) inside of V-86001 which
receives a return stream pumping from P-86001A/B to V-86001. From the Waste Liquid Feed Pump
P-86001 A/B the liquid-solid is routed to incinerator package ME-86002 by level control. One connection to
the tank car is available in case that the liquid/solid incinerator package is not available.
This incinerator is fired with fuel gas with Natural Gas as back-up. The following liquid and solid waste
streams will be handled:
Skimmed Oil from Skimmed Oil Pump P-85010 (Skimmed Oil Vessel V-85001 in WWTU)
Waste Liquid from ME-86001-P-01 (Vent Gas KO Drum part of Vent Gas Incinerator Package)
Dewatered Bio Sludge from ME-85007 (from conveyor in WWTU)
Dewatered Oily Sludge from ME-85007 (from conveyor, same supply as above)
Liquid waste (in barrel) from polymer plants containing up to 15 – 20% Alkyls
Skimmed oil from Amine Unit hydrocarbon drain pump (P-11054)
Hydrocarbon/water mixtures from drain vessels by tank car
Hydrocarbon/water mixtures or Maintenance Waste Oils from drums
Tar from quench water system
The solids are converted into flue gas and solid effluent. This effluent has to be transported to a landfill.
The fly ash shall be removed from the flue gas and shall be stored in silo’s.
7.1.3 Flare Unit (FLRU - 8900)
Main Wet Flare Stack Package ME-89001
The Wet Flare system handles wet vapor relief loads from safety valves and vent gases which are above
0°C at atmospheric pressure or, when the relieved flow contains significant amounts of water vapor. It
consists of a branched header discharging into the Wet Flare K.O. Drum V-89001 which is located near the
Flare Stack.
In addition to wet vapor reliefs, dry/cold reliefs from the Steam Cracker Unit, Refinery Dry Gas Treatment
Unit, NGL Treating and Fractionation Unit and Pressurized Storage for Ethylene, Propylene and NGLE C2+
will have a common Cold Flare K.O. drum (V-83012) handling vapor reliefs and (manual) liquid drain
scenarios. Any liquid in the drum will be vaporized in special type heat exchanger (Armstrong type or
equivalent) to avoid freezing of the heating fluid in such a system.
The Wet and Cold Flare headers will be combined before to route to main wet flare header/stack. In order
to combine the Wet Flare and Cold Flare into one flare header/stack, the cold flare vapors from the Cold
Flare KO drum (V-83012) is heated to a temperature well above the minimum allowable metal temperature
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for Low Temperature Carbon Steel, i.e. above -48°C by means of jacketed pipe. After the temperature has
been raised the combine wet and cold relief’s header is routed to Wet Flare K.O. Drum V-89001.
Any liquid accumulated in the V-89001 is routed by the Flare Knock Out Drum Pump P-89001A/B to the
Quench Water Drain Drum V-10003. Only during shutdown of the SCU; the pumped liquid is routed to the
Waste Water Collection Tank T-85001. The pump is automatically started at high level and stopped at low
level. Both pumps are connected to the emergency power grid. The pump capacities are set to drain the
determining load of liquid hydrocarbons and water in two (2) hours.
The vapors flow through the Wet Flare Seal Drum (ME-89001-V-02) to the Wet Flare Stack (ME-89001-
SK-01). Service Water is supplied to Wet Flare Seal Drum to maintain the water seal level. In addition
Service Water flows continuously through an orifice (parallel to the level controller) into the seal drum to
ensure adequate water seal level. The continuous overflow is sent to the Oily Water Sewer (OWS). The
function of the seal drum is to prevent ingress of air into flare header. Ingress of air is not allowed into the
flare header as it can result in an explosive mixture in the header.
The inlet to the flare stack and the flare sub-headers are purged with fuel gas to ensure a positive flow from
the flare system to the flare stack. Nitrogen is used as back-up for fuel gas purge.
Vapors from Wet Flare K.O. Drum V-89001 are routed to the Flare Package ME-89001 which mainly
consists of: Wet Flare Seal Drum (ME-89001-V-02), Flare Stack (ME-89001-SK-01), Flare Tip, Flare Fuel
Gas KO Drum (ME-89001-V-01), Flare Ignition System, Molecular Seal and required instrumentation for
control and safe guarding. For details reference is made to Main Wet Flare Package (ME-89001) package
specification.
The stack is equipped with a molecular dry seal as additional protection against air ingress. The relief
gases are ignited by the pilot flames and released to atmosphere. A flame generator is installed to ignite
the pilots. The flare tip pilot temperature switches-on automatically the ignition in case of loss of flame.
Remote ignition from control room is possible in case the automatic re-ignition does not work.
Fuel gas is used as pilot gas and purge gas. Natural gas is used as back-up for fuel gas.
MP steam is routed to the Flare Tip to ensure smokeless flaring at low relief loads and to protect flare
system against flame back. The MP steam flow is controlled by a control valve proportional to the relieved
gas flow rate. To optimize the steam consumption infrared sensors are installed to sense flare
characteristic of the flame and adjust the steam flow rate automatically.
The main equipment connected directly to wet flare header are:
Refinery Dry Gas Treating Unit
o RDG Compressor 1st Stage Suction Drum (V-12001)
o RDG Oxygen Converter (R-12001 A/B)
o RDG Amine / Water Wash Column (C-12001)
o RDG Depropylenizer (C-12005)
NGL Treating and Fractionation Unit
o NGL Amine / Water Wash Column (C-11002)
o C3+ Stripping Hold Up Drum (V-11007)
Steam Cracker Unit
o C3+ Feed Vaporizer (E-20018 A/B)
o Quench Tower (C-21003)
st
o Charge Gas Compressor 1 Stage Suction Drum(V-22001)
rd
o Charge Gas Compressor 3 Stage Suction Drum(V-22004)
o Hydrogen Compressor (K-23001)
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o Fuel Gas KO Drum (V-23005)
o Acetylene Converters (R-22001 A/B/C)
o MAPD Converters (R-24001 A/B)
o Debutanizer Reflux Drum (V-24004)
o Propylene Fractionators (C-24003-04)
o Propylene Refrigeration Compressor (K-25001)
o Binary Refrigerant Compressor (K-26001)
Selective C4 Hydrogenation Unit
st
o SHU 1 Stage Feed Drum (V-28011)
st
o SHU 1 Stage Separator Drum (V-28012)
nd
o SHU 2 Stage Separator Drum (V-28022)
MTBE Unit and Butene-1 Unit
o Water Wash Column (C-60001)
o C4 Feed Surge Drum (V-60001)
o Secondary Reactor (R-60002)
o CD Reaction Column (C-60002)
o CD Reaction Column OVHD Drum (V-60002)
o Methanol Extraction Column (C-60003)
o Methanol Recovery Column OVHD Drum (V-60003)
o Methanol Recovery Column (C-60004)
o Methanol Drain Drum (V-60004)
o B-1 Heavies Column #1 (C-61001)
o B-1 Heavies Column Overhead Drum (V-61001)
o B-1 Lights Column #1 (C-61003)
o B-1 Lights Column Reflux Drum (V-61002)
Pyrolysis Gasoline Hydrogenation Unit
ST
o 1 Stage Feed Surge Drum (V-62001)
o 1st Stage Hydrogenation 1st Reactor (R-62001A/B)
o Cold Separator Drum (V-62003)
o Passivation Drum (V-62004)
o 2nd Stage Separator Drum (V-62032)
o 2nd Stage Feed Surge Drum (V-62031)
o 2nd Stage Hydrogenation Reactor (R-62031)
o Recycle Compressors K.O. Drum (V-62033)
o Recycle Compressors (K-62031 A/B)
ST
o 1 Stage Stabilizer (C-62011)
nd
o 2 Stage Stabilizer (C-62041)
o Depentanizer (C-62042)
o Depentanizer Reflux Drum (V-62042)
o Rerun Tower (C-62012)
o Deheptanizer (C-62043)
o Deheptanizer Reflux Drum (V-62043)
Pressurized storage for Mixed C4, Butene-1, Butene-2 and Hydrogenated C4.
One Hydrocarbon Drain Drum V-89002 is available to drain the liquid from the Main Wet Flare System and
Spare Storage Wet Flare System. The contents are routed to the Quench Tower Drain Drum by the
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Hydrocarbon Drain Pump P-89002. Only during shutdown of the SCU; the pumped liquid is routed to the
Waste Water Collection Tank.
The main equipment connected to wet flare header via cold/dry relief header are:
Refinery Dry Gas Treating Unit
o RDG Demethanizer Reflux Drum (V-12007)
o RDG Deethanizer Reflux Drum (V-12008)
o RDG Depropylenizer Reflux Drum (V-12010)
o NGL Treating and Fractionation Unit
o NGL Deethanizer Reflux Drum (V-11002)
Steam Cracker Unit
o HP Depropanizer Reflux Drum (V-22012)
o LP Depropanizer Reflux Drum (V-22015)
o Demethanizer (C-23001)
o Deethanizer Reflux Drum (V-23004)
o Hydrogen Off gas (ME-23000-E06)
o Methane Off gas (ME-23000-E06)
o Recycle Ethane (ME-23000-E06)
o Ethylene Product (ME-23000-E06)
o Ethylene Fractionator Reflux Drum (V-24002)
o Propylene Fractionator No. 1 and 2 Reflux Drum (V-24003)
o Debutanizer Reflux Drum (V-24004)
st
o Propylene Refrigeration System 1 Stage Suction Drum (V-25001)
nd
o Propylene Refrigeration System 2 Stage Suction Drum (V-25002)
rd
o Propylene Refrigeration System 3 Stage Suction Drum (V-25003)
th
o Propylene Refrigeration System 4 Stage Suction Drum (V-25004)
st
o Binary Refrigeration System1 Stage Suction Drum (V-26001)
o Binary Refrigeration System 2nd Stage Suction Drum (V-26002)
rd
o Binary Refrigeration System 3 Stage Suction Drum (V-26003)
Pressurized storage sphere for NGL C2+.
Pressurized storage spheres for Ethylene and Propylene.
High pressure equipment and piping of Cryogenic Ethylene and Propylene Storage
Spare Storage Wet Flare ME-89003
In case the Main Wet Flare ME-89001 is taken out of operation, all wet storage area vents and relief are
routed to Spare Storage Wet Flare ME-89003.
From the main combined wet and cold flare header the reliefs are routed to the Spare Storage Wet Flare
K.O. Drum V-89004 which is located near the Flare Stack.
Any liquid accumulated in the V-89004 is pumped by the Spare Storage Wet Flare Knock Out Drum Pump
P 89003A/B to the liquid outlet line from the V-89001 to be routed then to the Quench Water Drain Drum
V-10003. Only during shutdown of the SCU; the pumped liquid is routed to the Waste Water Collection
Tank T-85001. The pump is automatically started at high level and stopped at low level. Both pumps are
connected to the emergency power grid. The pump capacities are set to drain the determining load of liquid
hydrocarbons and water in two (2) hours.
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The vapors flow through the Wet Flare Water Seal Drum (ME-89003-V-01) to the Wet Flare Stack ME-
89003-SK-01. Service Water is supplied to Wet Flare Water Seal Drum (ME-89003-V-01) to maintain the
water seal level. In addition Service Water flows continuously through an orifice (parallel to the level
controller) into the seal drum to ensure adequate water seal level. The continuous overflow is sent to the
Oily Water Sewer (OWS). The function of the seal drum is to prevent ingress of air into flare header.
Ingress of air is not allowed into the flare header as it can result in an explosive mixture in the header.
The inlet to the flare stack and the flare sub-headers are purged with fuel gas to ensure a positive flow from
the flare system to the flare stack. Nitrogen is used as back-up for fuel gas purge.
Vapors from Spare Storage Wet Flare K.O. Drum V-89004 are routed to the Flare Package ME-89003
which consists of: Wet Flare Water Seal Drum (ME-89003-V-01), Flare Stack (ME-89003-SK-01), Flare
Tip, Molecular Seal and required instrumentation for control and safe guarding. Ignition system and fuel
gas ko drum will be common with the main wet flare system. For details reference is made to Main Wet
Flare Package (ME-89003) package specification.
The stack is equipped with a molecular dry seal as additional protection against air ingress. The relief
gases are ignited by the pilot flames and released to atmosphere. A flare generator is installed to ignite the
pilots. Fuel gas is used as pilot gas and purge gas. Natural gas is used as back-up for fuel gas. The flare
tip pilot temperature switches-on automatically the ignition in case of loss of flame. Remote ignition from
control room is possible in case the automatic re-ignition does not work.
MP steam is routed to the Flare Tip to ensure smokeless flaring at low relief loads and to protect flare
system against flame back. The MP steam flow is controlled by a control valve proportional to the relieved
gas flow rate. To optimize the steam consumption infrared sensors are installed to sense flare
characteristic of the flame and adjust the steam flow rate automatically.
The main equipment connected to this header is:
Pressurized storage for Mixed C4, Butene-1, Butene-2, Hydrogenated C4, Pressurized storage spheres
for NGL C2+, Ethylene and Propylene including high pressure equipment and piping in Cryogenic
Ethylene and Propylene Storage area.
Acid Gas Flare
The Acid Gas Flare system handles vapor relief loads from safety valves and vent gases with H2S content
higher than 1000 ppm. It consists of a branched header discharging into the Acid Gas Flare K.O. Drum V-
89008 which is located near the Main Wet Flare Stack (ME-89001-SK-01).
Any liquid accumulated in the V-89008 is routed by the Acid Gas Flare KO Drum Pump P-89008 A/B to the
SCU Sour Gas KO Drum (V-10008). The pump is automatically started at high level and stopped at low
level. Both pumps are connected to the emergency power grid. The pump capacities are set to drain the
determining load of liquid hydrocarbons and water in two (2) hours.
Vapors from Acid Gas Flare K.O. Drum V-89001 are routed to acid gas flare riser which is connected to the
combustion zone of Wet Flare Stack (ME-89001-SK-01) upstream of wet flare molecular seal. The inlet to
the flare stack and the flare sub-headers are purged with fuel gas to ensure a positive flow from the flare
system to the flare stack. Ingress of air is not allowed into the flare header as it can result in an explosive
mixture in the header. Nitrogen is used as back-up for fuel gas purge.
The Acid Gas Flare riser is equipped with a molecular dry seal as additional protection against air ingress.
The relief gases are ignited by the wet flare pilot flames and released to atmosphere.
Fuel gas is used as pilot gas and purge gas. Natural gas is used as back-up for fuel gas.
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MP steam is routed to the Flare Tip to ensure smokeless flaring at low relief loads and to protect flare
system against flame back. The MP steam flow is controlled by a control valve proportional to the relieved
gas flow rate. To optimize the steam consumption infrared sensors are installed to sense flare
characteristic of the flame and adjust the steam flow rate automatically.
The main equipment connected directly to wet flare header are:
Amine Regenerator Reflux Drum (V-11052)
Amine Regenerator (C-11051)
RDG Mixed Feed from DCU & RFCC (B/L Interconnecting)
Amine Carbon Filter (V-11051)
Amine Regenerator Reboiler A/B (E-11051A/B)
RDG Amine / Water Wash Column (C-12001)
RDG Compressor First Stage Suction Drum (V-12001)
RDG Compressor Second Stage Suction Drum (V-12002)
RDG Compressor Second Stage (K-12001-2)
RDG Compressor Second Stage Discharge Drum (V-12003)
RDG Amine Oil Degassing Drum (V-12016)
One Sour Water Collection Drum V-89003 is available to drain the liquid from the Acid Gas Flare System.
The contents are routed to the Quench Water Drain Drum (V-10003) by the Sour Water Drain Drum Pump
P-89004.
Sour Water Drain Drum V-89003 is continuously purged with fuel gas and floating on acid gas flare header
pressure.
Cryogenic Low Pressure Flare ME-89002A/B
Reliefs from the Cryogenic Propane / LPG, Ethylene and Propylene Storage Tanks T-81008, T-83003 and
T-83004 respectively are collected in Cryogenic LP Flare KO Drum V-83013 and routed to the Cryogenic
Low Pressure Flare ME-89002 A/B which consists of: Flare Stack (ME-89002-SK-01A/B), Flare Tip, Flare
Ignition System, and Molecular Seal and Fuel Gas KO Drum (ME-89002-V-01): One system is in operation
and one is in stand-by.
MP steam is routed to the Flare Tip to ensure smokeless flaring at low relief load and to protect flare
system against flame back.
Fuel gas is used as pilot gas and purge gas. Natural gas is used as back-up for fuel gas.
The cryogenic flare sub-headers are purged with fuel gas to ensure a positive flow from to the flare stack.
The stack is equipped with a molecular seal as additional protection against air ingress. The relief gases
are ignited by the pilot flames and released to atmosphere. A flare generator is installed to ignite the pilots.
Fuel gas is used as pilot gas and purge gas. Natural gas is used as back-up for fuel gas. The flare tip pilot
temperature switches-on automatically the ignition in case of loss of flame. Remote ignition from control
room is possible in case the automatic re-ignition does not work.
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7.1.4 Monitoring and Control
Waste Water Treatment Unit (8500)
LLOD
The most important controlling variables in this section, is effluent water quality. The effluent water quality
is measured by taking samples from FFB basin. Based on lab result, the operator takes the decision to
send effluent water to proper destination.
If hydrocarbon appears on top of the effluent water collected in FFB (Z-85002) or OCB (Z-85001), operator
will adjust the height of weirs in the basins to collect hydrocarbons. A portable floating type oil skimmer will
be used to skim collected hydrocarbons at the inlet compartment of each basin. The collected hydrocarbon
will be sent to Waste Water Collection Tank (T-85001)
Pressure drop over Bar Screen Packages (ME-85001 and ME-85002) at inlet compartment of FFB and
OCB will be monitored. In case of high pressure drop alarm, bar screens have to be cleaned by operators.
Waste Water Steam Stripper
During normal operation, the feed to the waste water steam stripper is pre-heated. The LLS stripping
steam flow rate to the Stripper is a function of incoming WW flow to the column and the overhead flow to
the condenser. The ratios between feed flow, overhead flow and steam flow are manually adjusted to
satisfy the quality of Stripped WW. The pressure in the column is controlled by the pressure control in V-
85002. Nitrogen will be used in case of a low pressure.
No operator action is required during normal operation of steam stripping unit.
Other Equipment (out of package vendor scope of design and supply)
For process control variables, reference is made to section 5.
7.1.5 Typical Operating Conditions
The below table gives the normal operating setting for the main automatic controls in the Waste Water
Treatment Unit:
LLOD
Design Normal Turndown Trip
Parameter Location Tag Unit Alarm Setting
Value Value Value Setting
200 (H)
TOD FFB(Z-85002)Inlet 850-AI-002 mg/l NA < 10 NA NA
50 (L)
8.5 (H)
pH FFB(Z-85002)Inlet 850-AI-003 - NA 6.5 - 8.5 NA NA
6.5 (L)
Benzene FFB(Z-85002)Inlet 850-AI-001 mg/l NA < 10 NA 20 (H) NA
(-)1750(H)
Level OCB (Z-85001) 850-LI-002A mm Empty Empty Empty (-)5000(L) NA
(-)5200(LL)
(-)1500(HH) (-)1500(HH)
(-)1750(H) (-)1750(H)
Level OCB (Z-85001) 850-LI-032 mm Empty Empty Empty
(-)5000(L) (-)5000(L)
(-)5200(LL) (-)5200(LL)
(-)2500(HH)
(-) 2750(H)
Level FFB (Z-85002) 850-LI-006A mm Empty Empty Empty NA
(-)5000(L)
(-)5200(LL)
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Design Normal Turndown Trip
Parameter Location Tag Unit Alarm Setting
Value Value Value Setting
Level FFB (Z-85002) 850-LI-034 mm Empty Empty Empty (-)5000(L) (-)5000(L)
Level POB (Z-85003) 850-LI-033 mm Empty Empty Empty (-)5000(L) (-)5000(L)
(-) 1750(H) (-)1750(H)
Level OCB(Z-85001)inlet 850-LI-031A mm Empty Empty Empty
(-)5000(L) (-)5000(L)
(-) 2750(H) (-)2750(H)
Level FFB(Z-85002)inlet 850-LI-035A mm Empty Empty Empty
(-)5000(L) (-)5000(L)
Other Equipment (out of package vendor scope of design and supply)
Design Normal Turndown Trip
Parameter Location Tag Unit Alarm Setting
Value Value Value Setting
12 (H)
Pressure T-85001 850-PC-011 mbar-g 8 8 8 NA
4(L)
14600 (HH)
Level T-85001 850-LI-008 mm 7600 7600 7600 600 (LL)
600 (LL)
14400 (H)
Level T-85001 850-LC-009A mm 7600 7600 7600 NA
800 (L)
850-FC-004 /
Flow P-85004A/B m3/h 175 122 73.2 57.75 (L) NA
850-FC-005
K-85001A/B 12 (H)
Pressure 850-PC-015 mbar-g 8 8 8 NA
suction line 4(L)
K-85001AB
Pressure Discharge 850-PI-016 mbar-g 116 116 116 128(H) NA
Line
K-85001A/B
Flow Discharge 850-FC-006 kg/h 2856 2635 1580 (L) NA
Line
o
Temperature T-85002 850-TI-001 C 20 20 20 25 (H) NA
P-85005A/B
o
Temperature Discharge 850-TI-002 C 20 20 20 25 (H) NA
Line
18900(H)
Level T-85002 850-LC-010 mm 9850 9850 9850 NA
800(L)
19100 (HH)
Level T-85002 850-LI-011 mm 9200 9200 9200 600 (LL)
600 (LL)
175.45 (H)
Flow P-85005A/B 850-FC-008 m3/h 159.5 145 87 NA
52.6 (L)
8000(H)
Level T-85005 850-LI-012A mm 4400 4400 4400 NA
800(L)
Level T-85005 850-LI-013 mm 4400 4400 4400 600(LL) 600(LL)
12(H)
Pressure T-85005 850-PC-023 mbar-g 8 8 8 NA
4(L)
6000(H)
Level T-85003 850-LC-014A mm 3400 3400 3400 NA
800(L)
Level T-85003 850-LI-015 mm 3400 3400 3400 600(LL) 600(LL)
P-85006A/B
pH Discharge 850-AI-004 - NA 6.5 - 8.5 NA 8.5 (H) NA
Line
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Design Normal Turndown Trip
Parameter Location Tag Unit Alarm Setting
Value Value Value Setting
P-85006A/B
Turbidity Discharge 850-AI-005 mg/l NA <30 NA 50(H) NA
Line
P-85006A/B
TOC Discharge 850-AI-006 ppmw NA <5 NA 10(H) NA
Line
Level Z-85006 850-LI-016 mm Empty Empty Empty 600(LL) 600(LL)
- 8.5(H)
pH Z-85006 850-AI-007 NA 6.5 – 8.5 NA NA
6.5(L)
o 50 (H)
Temperature V-85001 850-TI-007 C AMB AMB AMB NA
25 (L)
1500 (HH)
1200 (H) 1200 (H)
Level V-85001 850-LI-026 mm 800 800 800
400 (L) 400 (L)
200 (LL)
2000(H)
Level Z-85005 850-LI-028A mm NA NA NA NA
500(L)
Level Z-85005 850-LI-029 mm NA NA NA 200(LL) 200(LL)
8.5 (H)
pH Z-85005 850-AI-014 - NA 6.5 - 8.5 NA NA
6.5 (L)
o
Temperature Z-85005 850-TI-008 C 25 25 25 50 (H) NA
10(H)
TOC WW85010506 850-AI-011 ppmw <5 <5 <5 NA
20(HH)
WW Steam Stripper (C-85001) and Associated Equipment
Design Normal Turndown Trip
Parameter Location Tag Unit Alarm Setting
Value Value Value Setting
Pressure V-85002 850-PC-044 bar-g 1 1 1 0.8 (L) NA
Pressure V-85002 850-PC-045 bar-g 1 1 1 1.2 (H) NA
Pressure C-85001 850-PI-065 bar-g 1.8 1.8 1.8 2.2 (HH) 2.2 (HH)
Pressure S-85001A/B 850-PDI-039 bar 0.2 0.2 0.2 1 (H) NA
12 (H)
Pressure T-85004 850-PC-032 mbar-g 8 8 8 NA
4(L)
3100 (HH)
2900 (H) 3100 (HH)
Level C-85001 850-LI-020 mm 1900 1900 1900
900 (L) 150 (LL)
150 (LL)
2900 (H)
Level C-85001 850-LC-019 mm 1900 1900 1900 NA
900 (L)
1050 (HH)
900 (H) 900 (H)
Level V-85002 850-LI-022 mm 600 600 600
300 (L) 300(L)
150 (LL)
750 (H)
Level V-85002 850-LC-024 mm 525 525 525 NA
300(L)
750 (H)
Level V-85002 850-LI-025A mm 525 525 525 NA
300(L)
16100(H)
Level T-85004 850-LC-017 mm 8700 8700 8700 NA
1300(L)
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Design Normal Turndown Trip
Parameter Location Tag Unit Alarm Setting
Value Value Value Setting
16100(H)
Level T-85004 850-LC-018 mm 8700 8700 8700 600(LL)
600(LL)
Flow C-85001 850-FC-018 kg/hr 1900 1900 1900 2090 (H) NA
Flow P-85009A/B 850-FC-016 m3/hr 38.2 35 21 12.6 (L) NA
8.5 (H)
pH M-85002 850-AC-010 - NA 6.5 - 8.5 NA NA
6.5 (L)
141 (H)
Temperature C-85001 850-TI-006 °C 131 131 131 NA
121 (L)
141 (H)
Temperature C-85001 850-TI-009 °C 131 131 131 NA
121 (L)
141 (H)
Temperature C-85001 850-TI-010 °C 131 131 131 NA
121 (L)
Temperature E-85002 850-TI-005 °C 42 42 42 50(H) NA
Benzene E-85002 850-AI-013 mg/l NA 1 NA 5(H) NA
TOC E-85002 850-AI-012 mg/l NA <5 NA 10(H) NA
7.2 Monitoring Unit Performance
7.2.1 Test Methods and Test Schedule
The following test methods are typically required for performance tests and operation control of the WWT.
Test frequency shown is a rough figure and will be optimized with experience in plant operation. Below
mentioned analytical methods can be replaced by Orpic with equivalent methods:
WWT inlet
Sampling position: FFB and OCB
Item Test Method Normal Start-up
TDS APHA 2540C Once/Day Once/Day
TSS APHA 2540D Once/Day Once/Day
pH pH Meter Once/Day Once/Shift
Conductivity Conductivity Meter Once/Day Once/Day
COD ASTM D-1252 Once/Day Once/Day
Total Oil Oil Meter Once/Day Once/Shift
Phenols ASTM D-1783 Once/Day Once/Day
Sulfide SMS 304 Once/Week Once/Day
Total Nitrogen ASTM D-5176 Once/Day Once/Day
Phosphates ASTM D-4327 Once/Day Once/Day
Benzene APHA 6200C Once/Day Once/Day
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Equalized Water
Sampling position: WW Equalization Tank (T-85002) outlet
Item Test Method Normal Start-up
pH pH Meter Once/Week Once/Week
COD ASTM D-1252 Once/Week Once/Week
Total Oil Oil Meter Once/Week Once/Day
Phenols ASTM D-1783 Once/Week Once/Week
Sulfide SMS 304 Once/Day Once/Day
Total Nitrogen ASTM D-5176 Once/Week Once/Week
Phosphates ASTM D-4327 Once/Day Once/Day
DGF outlet
Sampling position: Dissolved Gas Floatation outlet
Item Test Method Normal Start-up
pH pH Meter Once/Week Once/Day
COD ASTM D-1252 Once/Week Once/Week
Total Oil Oil Meter Once/Week Once/Day
Phenols ASTM D-1783 Once/Week Once/Week
Sulfide SMS 304 Once/Day Once/Day
Total Nitrogen ASTM D-5176 Once/Week Once/Week
Phosphate ASTM D-4327 Once/Week Once/Week
Benzene APHA 6200C Once/Week Once/Week
IAF outlet
Sampling position: Induced Air Floatation outlet
Item Test Method Normal Start-up
pH pH Meter Once/Operation Once/Operation
COD ASTM D-1252 Once/Operation Once/Operation
Total Oil Oil Meter Once/Operation Once/Operation
Phenols ASTM D-1783 Once/Operation Once/Operation
Sulfide SMS 304 Once/Operation Once/Operation
Total Nitrogen ASTM D-5176 Once/Operation Once/Operation
Phosphate ASTM D-4327 Once/Operation Once/Operation
Benzene APHA 6200C Once/Operation Once/Operation
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Mixed Liquid
Sampling position: Bioreactor
Item Test Method Normal Start-up
MLSS APHA 2540D Once/Day Once/Day
Dissolved Oxygen DO Meter Once/Week Once/Day
Treated Water
Sampling position: Treated Effluent Tank (T-85003)
Item Test Method Normal Start-up
TDS APHA 2540C Twice/Week Once/Day
TSS APHA 2540D Twice/Week Once/Day
pH pH Meter Twice/Week Once/Day
COD ASTM D-1252 Three times Twice/Week
/Week
BOD BOD Tester Twice/Week Twice/Week
Total Oil Oil Meter Twice/Week Once/Day
Phosphates ASTM D-4327 Twice/Week Twice/Week
Residual Chlorine Residual Chlorine Meter As required Once/Week
Phenols ASTM D-1783 Twice/Week Once/Day
Sulfide SMS 304 Twice/Week Once/Day
Ammonia ASTM D-1426 Twice/Week Twice/Week
Nitrogen
Total Nitrogen ASTM D-5176 Twice/Week Once/Day
Total Coliforms APHA 9221 Twice/Week Once/Day
Cyanide ASTM D-2036 Once/Month Once/Week
Metal Iron ASTM D-1068 Once/Month Once/Week
Chromium ASTM D-1687A Once/Month Once/Day
Hexavalent
Manganese ASTM D-858 Once/Month Once/Day
Copper ASTM D-1688 Once/Month Once/Week
Zinc ASTM D-1691 Once/Month Once/Week
Benzene APHA 6200C Twice/Week Once/Day
Ethyl Benzene APHA 6200C Once/Month Once/Month
Waste Incineration
To be provided by package vendor.
Flare Unit
To be provided by package vendor.
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7.3 Special Areas of Attention and Risks
7.3.1 Waste Water Treatment – LLOD and Collection Section
The operator has to take care for:
All tanks which can receive water that is possibly contaminated with hydrocarbons have to be
filled with clean water before usage (to prevent that oil sticks to the wall).
LLOD Basin is partially filled with clean water and clean (ready to receive water)
LLOD pumps to be checked for proper functioning
LLOD Oily Sludge Pumps (P-85003A/B/C/D) are functioning (normally not in use)
Calibration of analyzers
7.3.2 Waste Water Treatment – Benzene/MTBE Contaminated WW Stripping System
The operator has to take care for:
Benzene/MTBE Contaminated WW Collection Tank (T-85004) which can receive water that is
possibly contaminated with hydrocarbons has to be filled with clean water before usage (to
prevent that oil sticks to the wall).
Verifying dosing of chemicals are still in line with requirements
Replacement / cleaning of filters in bottom outlet of the waste water steam stripper.
7.3.3 Waste Water Treatment – Biological Treatment System
The operator has to take care for:
All tanks which can receive water that is possibly contaminated with hydrocarbons have to be
filled with clean water before usage (to prevent that oil sticks to the wall).
Calibration of oxygen measurement / redox measurement in aeration tank
Calibration of turbidity measurement in clarifier
Sand quality in continuous sand filter
Sludge quality (Dry Solid content and sedimentation properties)
Properties of feed (COD, T, pH)
Required dosing rate of phosphoric acid and urea
7.3.4 Waste Water Treatment – Sludge Treatment System
The operator has to take care for:
Calibration of oxygen measurement / redox measurement in activated sludge holding tank
Verification if batch control settings for sludge holding tank still meets the requirements for a
good settlement of the sludge and to keep the sludge in a good condition
Before using the dewatering unit feed pumps, the pump has to be flushed with Industrial Water,
to avoid that it is running dry.
Prevent sending different sludge with different characteristics to sludge dewatering.
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7.3.5 Caustic and Sulfuric Acid Dosing
The operator has to take care for:
Verifying if liquid seal of the sulfuric acid and caustic vent is still filled.
7.4 Operator Tasks
Operator tasks for these systems are very important for a good performance of the Waste Water Treatment
Unit. The operator has to be aware for strange situations and has to take action. The appropriate action
has to be determined on case to case basis. In all cases, the operator has to check the alarms when
indicated on the DCS.
7.4.1 Waste Water Treatment – LLOD and Collection System
The operator has to take care for:
Emptying of LLOD after receiving (rain) water. Samples have to be taken and analyzed to
determine the right destination (Induced Air Flotation, Waste Water Collection Tank or Waste
Water Steam Stripper).
Flushing of sludge transfer pipes. To protect sludge transfer lines in the FFB and OCB against
plugging, operator is to periodically utilize service water to flush the sludge pipes.
Opening of skimmed oil valve on WW Collection Tank (T-85001) to send skimmed oil to
Skimmed Oil Vessel (V-85001) for about 60 minutes a week.
The operator has to check the alarms when indicated on the DCS.
7.4.2 Waste Water Treatment – Benzene/MTBE Contaminated WW Stripping System
The operator has to take care for:
Dosing rate of sulfuric acid or caustic
Start-up and shut-down of the Waste water Stripper, when required
Daily check Benzene/MTBE Contaminated WW sample at the downstream of Benzene/MTBE
Contaminated WW pH adjustment Mixer (M-85002)
During normal operation, filter (S-85001A/B) steadily gets fouled. The pressure drop over the
filter is an indication for the extent of fouling. The operator should check this pressure drop
regularly. If the pressure drop exceeds the maximum value of 1 bar, manual cleaning of the filter
is required. Meanwhile operation can continue using the spare filter.
Off-spec stripped waste water. In case of off-spec product due to high benzene contamination,
operator is to switch steam stripper effluent to Benzene/MTBE contaminated waste water tank.
If benzene stripper effluent is off-spec not because of benzene contamination but due to high
TOC, then operator has to route the steam stripper effluent to Waste Water Collection Tank (T-
85001) awaiting treating by Dissolved Gas Floatation (DGF) unit.
Sending collected oil in Benzene/MTBE Contaminated WW Collection Tank (T-85004) by
opening skimmed oil valve for about 1 hour a week.
The operator has to check the alarms when indicated on the DCS.
7.4.3 Waste Water Treatment – DGF / IAF
The operator has to take care for:
dosing of chemicals
start-up and shut-down of the DGF/ IAF, when required
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The operator has to check the alarms when indicated on the DCS. Refer the instructions as provided by
Package Vendor.
7.4.4 Waste Water Treatment – Biological Treatment System
The operator has to take care for:
Dosing of chemicals
Oxygen content in aeration tank
Formation of foam on the aeration tank (mainly during start-up)
Performance of the clarifier
Proper functioning of sand filter
Sludge quality (dry solid content and settlement properties)
The operator has to check the alarms when indicated on the DCS. Refer the instructions as provided by
Package Vendor.
7.4.5 Waste Water Treatment – Sludge Treatment System
The operator has to take care for:
Enough settlement time for the sludge in the activated sludge treatment section
Dosing of chemicals
Cleaning of sludge dewatering package after usage
Replacement of sludge container when it is full
The operator has to check the alarms when indicated on the DCS. Refer the instructions as provided by
Package Vendor.
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8.0 NORMAL SHUTDOWN
In the normal operation of plant, the entire shutdown of off-sites facilities is not allowed. However
equipment or sections of line may require temporary shutdown for maintenance or an inspection. In such a
case, only the equipment or the section has to be isolated.
8.1 LLOD
In general, there is no action required for short term shutdown. However in case of maintenance or
inspection requirement, the Last Line Of Defense basins have to be isolated from incoming sewer system
by utilizing blind flanges. The counter flanges are located inside the inlet compartment of LLOD basins and
equipped with blind flanges with lifting lugs for proper isolation of LLOD basins from sewer network. The
inspection and maintenance has to be scheduled for dry seasons.
8.2 Other Equipment (out of package vendor scope of design and supply)
Some general normal shutdown procedures are described below:
8.2.1 Equipment / Section Isolation
The equipment and lines, which should be isolated from in-line equipment completely for safety purpose,
shall be provided with a blind or spacer. Isolation philosophy is as follows:
8.2.2 Isolation for On-stream Maintenance
The equipment, which is expected to be taken out from service during normal operation for maintenance;
such as pumps, blowers, filters and shell & tube exchangers; shall be isolated by permanent spectacle
blinds on the inlet and the outlet. However, no blind is provided on the inlet and the outlet of equipment for
cold low pressure water services (below 65°C).
8.2.3 General Isolation
Column and Reactor
An 8" nozzle size and larger with nozzle rating of 150# shall have a permanent spectacle blind/spade and
spacer to enable maintenance of a column. For a smaller nozzle, a temporary blind shall be provided at a
warehouse to be used for maintenance, although a blind for such a nozzle is not shown in P&IDs. However,
a permanent spectacle blind shall be installed on a nozzle connected to a flare header or utility stream,
regardless of a nozzle size.
Drums
For drum, the isolation philosophy is the same as that of column mentioned above. However, in case
that there are blinds on the downstream or upstream equipment nozzles connected to a nozzle via
piping, no blind is required on such a nozzle.
8.2.4 Vent and Depressurizing for Pressurized Equipment
Open vent lines to flare header
Pressurize the section or equipment to 1.2bar-g with nitrogen and again depressurize to the
flare
Drain the equipment or section content to:
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OCB in case of low hydrocarbon (VOC) pollution
Waste Water Collection Tank (T-85001) in case of high hydrocarbon (VOC)
Benzene/MTBE Contaminated WW Collection Tank (T-85004) in case of benzene
contamination
8.3 Waste Water Steam Stripper
The following sequence has to be used for shut-down:
Stop feeding Waste Water Steam Stripper
Set the ratio control to manual mode and close the steam supply to the column
Set the pressure control to manual mode, de-pressurize system by opening the vent valve to
wet flare and close the nitrogen supply valve
Empty hydrocarbon compartment of Steam Stripper Overhead Reflux Drum.
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9.0 EMERGENCY SHUTDOWN
9.1 General
An Emergency Shutdown (ESD) is not applicable for WWTU. However unplanned shutdown of WWTU
may be required due to fire, mechanical failure, partial or complete failure of one of the utilities.
The nature of the unplanned shutdown can be such that unit operation can be maintained at a reduced rate
or it may necessitate a complete shutdown.
In the following section, information is provided on how to operate in certain emergency cases. Following
cases are covered:
Fire
Power Failure
Instrument Air Failure
Steam failure
Cooling Water Failure
Release of Toxic Gases
Although the procedures cover most types of cases, keep in mind that in some cases the actual procedure
will be dictated by the circumstances. In general, in case of any emergency, action must be taken to make
the unit safe as quickly as possible.
9.2 Fire
Consequence
If a fire occurs in the plant, that section of equipment in which the fire has occurred must be isolated to
confine fire and depressurized to eliminate the source of combustible material. Unless the fire is small and
can be handled quickly the plant will be shutdown. Operation supervisor on duty will advise on shutdown,
based on plant procedures in place.
Actions
Follow operation supervisor’s orders on shutdown and firefighting procedures.
Block in influent and effluent streams.
Isolate section or area where fire is occurring, to remove combustion source.
Depressurize section to flare.
Shutdown remaining portions of plant as time and circumstances permit or require.
9.3 Power Failure
When an electrical power failure occurs, the WWTU has to be survived by putting some critical equipment
on emergency power system.
Consequence
No consequence due to critical equipment will be fed by emergency power system.
Actions
Feed aerobic basins by emergency plant air available at plant battery limit
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Feed OC Water Pump (P-85001A/B) from different power sources
Follow the preceding action with an orderly shutdown using the normal shutdown procedures
described in Section 9.0.
9.4 Instrument Air Failure
Consequence
When an instrument air failure occurs the unit will be shutdown. The unit is designed to fail safe when
instruments air is lost.
Actions
Follow the preceding action with an orderly shutdown using the normal shutdown procedure
described in Section 9.0.
9.5 Steam Failure
Consequence
When a steam failure occurs, the waste water stripping section will be shut-down. No other consequences
are detected as steam failure does not affect the normal operation of rest of WWTU.
Stop feeding the steam stripper,
Follow the preceding action with an orderly shutdown using the normal shutdown procedure
described in Section 9.0 for steam stripping section.
9.6 Cooling Water Failure
When a cooling water failure occurs, the plant operation conditions must be adjusted.
Consequences
Cooling for the air blowers and other rotary equipment will be lost.
Actions
If possible, reduce the influent rate to biological section. Await instructions from operation
supervisor.
Failure of the cooling water to the Steam Stripper OVHD Condenser (E-85003) causes the
Steam Stripper (C-85001) pressure to rise. On High-high pressure in Column overhead, steam
and FEED supply to WW Steam Stripper will be tripped automatically. Follow the preceding
action with an orderly shutdown using the normal shutdown procedure described in Section 8.0
for steam stripping section.
9.7 Release of Combustible Gases
Consequence
If a release of combustible gases occurs in the plant, that section of equipment in which the release has
occurred must be isolated to confine fire and depressurized to eliminate the source of toxic material.
Unless the release is small and can be handled quickly the plant will be shutdown. Operation supervisor on
duty will advise on shutdown, based on plant procedures in place.
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Actions
Follow operation supervisor’s orders on shutdown.
Block in influent streams.
Isolate section or area where fire is occurring, to remove combustion source.
Depressurize system to flare or safe location
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10.0 SAFETY AND SAFEGUARDING
This section contains the outline of the safety and safeguarding connected with the operation and
maintenance of the Utility Facilities.
10.1 General
It is the responsibility of all personnel to make themselves familiar with the hazardous nature of the
materials handled by the unit, the safety precautions and regulations of the unit and the safety equipment
available within the unit.
The following general safety precautions should be followed at all times:
Unit fire protection equipment shall be available and in working order at all times and at the right
place (e.g. fire hoses). It is the responsibility of the unit supervisor to see that this equipment is
regularly inspected and serviced.
Operators finding extinguishers that have been emptied, damaged or otherwise misused should
report them immediately to the plant Fire Department for replacement.
Smoking shall not be permitted within the unit.
Eye wash facilities and safety showers should be inspected regularly and maintained to be
functional.
Self-contained breathing apparatus should be readily available and properly stored on the unit. It
is operator's responsibility to be familiar with the operation and use of this equipment. Again the
unit supervisor should see that the equipment is regularly inspected and serviced by the proper
department.
All guards and shields shall be fitted to moving machinery and to equipment that can spray a
hazardous chemical on personnel.
Personnel safety equipment shall be used as follows:
Hard hats, safety shoes and clothing shall be worn at all times. Shoes and clothing shall
be kept clean and free of oils or chemicals, and in a good state of repair.
Operators will wear chemical type gloves and aprons, face shields and/or chemical safety
goggles when handling chemicals in powder or solution form.
Personnel, who is sprayed or splashed by a chemical, will follow the procedure required
for that chemical.
Operations Department will ensure that all lines/equipment have been rendered safe and
thoroughly cleaned before permitting maintenance to work on equipment.
10.2 Fire Fighting Equipment
The fire-fighting equipment for the unit (fire water hydrants, fixed monitors and water spray systems) is
supplied as per the refinery fire regulations. Follow the refinery fire regulations as to use of fire equipment.
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Suitable fire extinguisher must be readily available. The area around an extinguisher or hydrant must be
clear so that equipment is readily accessible in case of emergency
10.3 Self-Contained Breathing Apparatus
When personnel have to work in an atmosphere hazardous to life at a distance from a source of fresh air,
self-contained breathing apparatus or airline and face mask should be used.
The type of equipment normally used consists of a high-pressure air cylinder, a cylinder valve, a demand
regulator and a face mask and tube assembly fitted with an exhalation valve. The need to have a face
mask that fits properly must be stressed; this means that people who wear glasses or a beard cannot
properly wear self-contained breathing apparatus, as these make it difficult to form a seal between the
mask and the wearers face.
Note: Prior to use personnel must receive adequate training on the use of this equipment as improper
use in a hazardous atmosphere may result in injury or death.
10.4 Chemical Hazards
10.4.1 General
For personnel protection it is necessary to be aware of the hazardous nature of the materials handled in
the unit. Combustible hydrocarbons and streams containing hazardous substances are found throughout
the unit. It is highly recommended to follow package vendor instructions in the regard.
10.4.2 Hydrocarbons
Light hydrocarbons in Fuel Gas Mixed Drum can be released to air (partly) and the vapor/air mixture can
be ignited by a spark (including from static electricity) or flames.
10.4.3 Nitrogen
Nitrogen is an inert gas used for purging equipment or maintaining a positive pressure inert gas blanket on
a vessel.
Nitrogen is neither poisonous nor flammable, but it is an asphyxiant. Consequently care must be exercised
when working inside equipment that has been N2 purged. Adequate ventilation must be provided and
appropriate breathing devices worn. To breathe an atmosphere high in N2 could result in suffocation.
Before entering vessels that have been purged with N2, a check must be made for proper oxygen content
prior to entry. Rapid vaporization of liquid nitrogen can cause severe burns on contact with the skin.
10.4.4 Ammonia
Ammonia is a colorless gas with an extremely pungent odor. Exposure to ammonia may cause varying
degrees of irritation to the eyes, skin, or mucous membranes.
Ammonia exposure for short term and under 100 wt ppm causes nose and throat irritation. Over 500 wt
ppm exposure for approximately 30 minutes causes upper respiratory irritation, tearing, increased pulse
rate and blood pressure. High level exposures can cause long term respiratory problems and/or death.
Sometimes symptoms do not appear for several hours after the exposure has occurred.
Where ammonia concentrations exist in concentrations above standard, respiratory, eye, and skin
protection should be provided. Full face gas masks with ammonia canister or supplied air respirators, both
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with full face pieces, afford good protection. In areas where exposure to liquid ammonia exists, goggles or
face shields, as well as protective clothing impervious to ammonia and including gloves, aprons, and boots
should be required.
In heavy concentrations of ammonia gas, workers should be outfitted with complete self-contained
protective suits impervious to ammonia, with supplied air source, and full headpiece and face piece.
10.5 Opening Lines and Equipment
10.5.1 General
It is recommended that lines which are used incidentally (e.g. for start-up) are spaded-off after use, flushed
(if necessary) and drained.
For opening lines or equipment for repair or inspection, some suggestions are given below (it is not
intended that they should supersede local plant practice and regulations, they should supplement them).
Maintenance crews should be cautioned when working on equipment or lines containing flammable
material.
Release of hydrocarbon vapor to the air in large amounts should be avoided due to the health and fire
hazards. When it is necessary to release gas to the atmosphere, especially at ground level, it should be
done under a blanket of steam; this will assist on dispersing the gas and displace air from the vicinity of the
release.
Equipment or lines should be steamed out or flushed, before starting repair work. Equipment containing
residue has to be flushed first with hot flushing oil prior to be flushed with cold flushing oil. A direct flush
with cold flushing oil could result in a cooling of residue without proper dilution and the resulting high
viscosity may prevent emptying of the equipment. Residue containing lines do not need a hot flush step
since the residue can easily be replaced by cold flushing oil.
Turning of spectacle blinds shall be performed in strict adherence to the refinery standards and
procedures.
Use of spark proof tools or tools dipped in oil is recommended.
All steam hoses should be provided with an approved ground connection to avoid the possibility of the
steam jet generating static electricity.
Anyone entering a vessel, which may contain an inert or contaminated atmosphere, must follow safety
precautions and rules which apply. The vessels may contain H2S or other toxic material in addition to
hydrocarbons.
Therefore, the following precautions should be included in the standard procedure.
The vessels should be isolated by positive action, such as blinding, to exclude all sources of hydrocarbon,
fuel gas, steam, air, etc.
The refinery safety officer and supervisory personnel will give their permission for vessel entry after they
have made the appropriate tests.
Install an air mover outside the vessel to sweep away any vapors. The man entering the vessel must be
equipped with a fresh air mask in proper working condition. If the condition of vessel is not enough to enter,
use a compressed air self-contained breathing apparatus.
There should be available and ready for immediate use and transfer to the man in the vessel, a separate
air supply which is independent of electrical power.
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The man entering the vessel should wear a safety harness with properly attached safety line.
If the work involves a large distance above the floor of the vessel, scaffolding or support flooring must be
built to prevent dangerous falls.
There should be a spare fresh air mask complete with its own separate air supply, to allow a second man
to enter the equipment quickly in case of an emergency. This spare equipment must be compact enough to
allow the second man to enter through the manway while entering the equipment.
The API publication “Guide for Inspection of Refinery Equipment” or the NIOSH publication No. 87-113; “A
Guide to Safety in Confined Spaces” can be referred to for additional information on safety procedures for
vessel entry and accident prevention measures.
10.5.2 Opening Large Vessels
When large vessels such as columns or drums are to be opened, the following precautions are
recommended:
All lines leading to and from the equipment are to be blinded off as soon as the process vapors
have been eliminated.
The vessels must be ventilated preferably by mechanical means during the whole time
maintenance or inspection crews are inside the vessel.
After maintenance is complete, and before the vessel is returned to service, air must be displaced
with steam or purged with inert gas.
It is recommended that any man working in a vessel, which has an inert or contaminated atmosphere, not
be permitted to move too far away or into any tight areas, such as through a crude column tray manway.
The reason for this precaution is that should the man develop some difficulty while below a tray, for
example, to a point where he could not function properly or lost consciousness, it would be extremely
difficult for the surveillance team outside the vessel to pull the man up through the small tray manway by
use of the safety line.
Any one working in the bottom of the column or vessel should be aware of the hazard of falling objects.
Hard hats should be worn, but these will not provide total protection against heavy objects. The workmen
should be warned to pay attention, to look, and listen. The maintenance supervisor should be careful when
scheduling work, to avoid having people in the bottom of the vessel when there is heavy work going on in
the top of the column or vessels.
A communication system should be provided for the manway watch so that they can quickly call for help in
the event that the personnel inside the vessel encounter difficulty. A radio, telephone, or public address
system is necessary for that purpose.
Before entering a vessel, the refinery’s safety precautions should be observed. These usually include the
following: sampling the vessel for toxic vapors and oxygen concentration, wearing a safety harness, and
having an attendant outside the vessel.
An unattended vessel should never be entered.
10.5.3 Gas Detection
These are various types of gas detectors used in refinery/petrochemical plants. Most plants will have:
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An explosion meter, to monitor amounts of flammable or explosive gas/air mixtures resulting from
leaks or other releases.
An oxygen analyzer, used mainly to monitor oxygen levels when purging equipment.
A type of chemical gas detector for detecting and identifying chemical gasses. One of the most
commonly used detectors of this type works on a color change of crystals sensitive to the gas to
be analyzed.
10.6 Block Valves around Pressure Relief Valves
Pressure relief valves have been provided with block valves. These block valves are provided with locks to
prevent inadvertent closing during operation. For certain relief cases, two relief valves are shown. A spare
relief valve allows taking out one relief valve for testing or maintenance, while the other valve remains in
service. To switch the service from one valve to the other one, a certain system is provided which prevents
that during the switch-over both relief valves are out of service simultaneously.
In the below scheme the upstream block valves , block valve “B” and “C” are provided with double locks
and the downstream block valves, block valve “A” and block valve “D” are provided with single locks.
Relief valve ‘A” is in operation and relief valve “B” is spare. Valve “A” and “D”, which are provided with
single locks, can only be locked in the open position.
The key which is required to unlock valve B and make closing of valve B possible is trapped in the locking
device of valve C and can only be released after valve C is locked in the open position. The key to lock
valve C in the open position is stored in the key cabinet in the control room.
The situation before changeover is as follows:
Block valves A, B and D is locked open.
Block valve C is locked closed.
Key 1 is in the control room.
Key 2 is trapped in the locking device of block valve C.
Key 3 is trapped in the locking device of block valve D.
Key 4 is trapped in the locking device of block valve A.
Key 5 is trapped in the locking device of block valve B.
Key 1 only fits on the locks of valve C and D.
Key 5 only fits on the locks of valve A and B.
Actions for changeover:
Key 1 obtained from the control room is inserted in the locking device of Block valve C.
This block valve is unlocked now.
Block valve C is opened and key 1 is trapped now.
Key 2 is removed and block valve C is locked open now.
Key 2 is inserted in the locking device of block valve B. Block valve B is unlocked now.
Block valve B is closed and key 2 is trapped now.
Key 5 is removed and block valve B is locked closed now.
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Key 5 is inserted in the locking device of block valve A. Block valve A is unlocked now.
Block valve A is closed and key 5 is now trapped, key 4 is released.
Key 4 is taken to the control room.
Safety valve A can be removed for maintenance.
Situation after change:
Block valves C and D are locked open.
Block valve B is locked closed.
Block valve A is locked closed.
Key 5 is trapped in the locking device of block valve A.
Key 4 is in the control room.
Key 2 is trapped in the locking device of block valve B.
Key 3 is trapped in the locking device of block valve D.
Key 1 is trapped in the locking device of block valve C.
FLARE
OR BACK TO SYSTEM
OR TO CLOSED
SYSTEM
LO LO
VALVE A VALVE D
Size: ..... Size: .....
Set at: ..... Barg Set at: ..... Barg
PSV PSV
....A ....B
3/4"D 3/4"D
LO(LC) LC (LO)
VALVE B VALVE C
PROCESS LINE
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Petrochemical Plant Sohar Environmental Impact Assessment Report
Orpic and CB&I HMR #3817
Attachment 16: Process description and BAT for Spent Caustic Selection Process
G-S000-5240-003 HMR Consultants
June 2015 W
Liwa Plastics Project
CB&I ORPIC
Document Title: Process Description - SCOU 6300
Document No: S-S630-5223-002
CB&I Contract No: 189709
Issued for FEED 0 10-Mar-2015 Peter.Pilgrim SNAZARI JL
Revision Descriptions Rev Date Originator Checker Approver
Page 1 of 7
"THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY (CB&I). IT MAY CONTAIN INFORMATION
DESCRIBING TECHNOLOGY OWNED BY CB&I AND DEEMED TO BE COMMERCIALLY SENSITIVE. IT IS TO BE USED ONLY IN
CONNECTION WITH WORK PERFORMED BY CB&I. REPRODUCTION IN WHOLE OR IN PART FOR ANY PURPOSE OTHER THAN
WORK PERFORMED BY CB&I IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN PERMISSION OF CB&I. IT IS TO BE SAFEGUARDED
AGAINST BOTH DELIBERATE AND INADVERTENT DISCLOSURE TO ANY THIRD PARTY."
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description for Spent Caustic Oxidation Unit S-S630-5223-002 0
INPUTS / REFERENCE DOCUMENTS
Document Number Title Status
S-S000-5222-001 Project Basis of Design – LPP Facilities
S-S000-5223-003 Process Design Basis for Off-Site Facilities
S-S000-5223-001 Process Design Basis for Storage
S-S630-535A-101 Duty Specification for Spent Caustic Oxidation Package ME-63001
S-S630-535A-102 Duty Specification for SCO Unit Crystallizer ME-63002
D-S220-5223-104 PFD Steam Cracker Unit - Spent Caustic Treatment
D-S630-5223-101 UFD Spent Caustic Oxidation Feed and Effluent Storage
D-S630-5223-102 UFD Spent Caustic Oxidation Package
D-S630-5223-103 UFD Spent Caustic Oxidation Unit Mass Balance
REVISION NOTES AND HOLDS
Revision Description of Changes & Holds
HOLDS Description of Holds Rev Date
1 Selected Process for SCO and Crystallizer Package
2 Spent Caustic Dain Cooler (E-63001) requirement
3 Destination of Purge Stream
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Document Title: Document No. Rev:
Process Description for Spent Caustic Oxidation Unit S-S630-5223-002 0
Table of Contents
Contents Page
1.0 INTRODUCTION..................................................................................................................................4
2.0 DEFINITIONS ......................................................................................................................................4
3.0 SPENT CAUSTIC OXIDATION UNIT ...................................................................................................4
3.1 Spent Caustic Storage .............................................................................................................5
3.2 Spent Caustic Oxidation Package ...........................................................................................6
3.3 Crystallizer Package ................................................................................................................7
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Process Description for Spent Caustic Oxidation Unit S-S630-5223-002 0
1.0 INTRODUCTION
Oman Oil Refineries and Petroleum Industries Company (ORPIC) is planning the installation of a new
Petrochemical Complex to be called Liwa Plastics Project (LPP) adjacent to Sohar Refinery Improvement
Project (SRIP) that will include a Steam Cracker Unit (SCU) designed to produce 863 kilo tons per annum
(KTA) of polymer grade ethylene and 300 KTA of polymer grade propylene, Refinery Dry Gas Unit, NGL
Treating and Fractionation Unit, Selective C4 Hydrogenation Unit, MTBE Unit, Butene-1 Recovery Unit,
Pygas Hydrotreating Unit, High Density Polyethylene (HDPE) Plant, Linear Low Density Polyethylene Plant
(LLDPE), new Polypropylene Plant (PP), and associated utility and offsite facilities. The new petrochemical
plant will be integrated with the Sohar Refinery, Sohar Aromatics Plant (AP) and Sohar Polypropylene
Plant (PP) plant.
ORPIC is also planning the installation of a new NGL Extraction plant located in Fahud, Central Oman. The
NGL (C2+) extracted from the natural gas will be transported to the petrochemical complex by pipeline and
used as feedstock to LPP. The new NGL Extraction plant will have independent utility and offsite facilities.
Additional feedstock to LPP are mixed LPG (produced in the Sohar Refinery and Sohar AP), refinery dry
gas produced in the RFCC unit and new Delayed Coking unit (included in SRIP), light naphtha condensate
from OLNG by marine tanker.
This document covers the process description for the Spent Caustic Oxidation Unit 6300 of the new Liwa
Plastics Project in Oman.
2.0 DEFINITIONS
The following terms and abbreviations have been used in this document:
Term Definition
ASL Atmospheric Safe Location
LPP Liwa Plastic Project
ORPIC Oman Refineries and Petroleum Industries Company
OSC Oxidized Spent Caustic
PFD Process Flow Diagram
RDG Refinery Dry Gas Treating Unit
SCOP Spent Caustic Oxidation Package
SCU Steam Cracker Unit
UFD Utility Flow Diagram
WWTU Waste Water Treatment Unit
WAO Wet Air Oxidation
3.0 SPENT CAUSTIC OXIDATION UNIT
The Spent Caustic Oxidation Unit is divided into the following sections:
Spent Caustic Feed Storage (Feed, Effluent and drainage)
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Process Description for Spent Caustic Oxidation Unit S-S630-5223-002 0
Spent Caustic Oxidation Package which includes:
Oxidation section to convert sulfides
Neutralization section for pH adjustment
For graphical representation of the Spent Caustic Oxidation Unit, reference is made to the UFD Spent
Caustic Oxidation Feed and Effluent Storage (Document No. D-S630-5223-101) and UFD Spent Caustic
Oxidation Package (Document No. D-S630-5223-102)
3.1 Spent Caustic Storage
The main objectives of the Spent Caustic Storage system are:
Storage of Spent Caustic prior to routing it to the Spent Caustic Oxidation Package
Storage of Oxidized Spent Caustic prior to routing it for final treatment
Collection of the Spent Caustic drains for reprocessing
Spent Caustic waste stream from the Caustic/Water Wash Tower (C-22001) is combined with Spent
Caustic from the Caustic/Water Wash Tower (C-12002) of the RDG, and routed to Spent Caustic
Coalescer (V-22008) followed by Spent Gasoline Coalescer (V-22009) as a pretreatment step. Wash
Gasoline from Quench Water Settler is added to Spent Caustic and routed to V-22008. Gasoline wash is
done in order to remove entrained oils and some dissolved organic compounds from the Spent Caustic.
The Spent Caustic Coalescer (V-22008) effluent is sent to Spent Gasoline Coalescer (V-22009) where the
spent caustic and spent gasoline is separated. Then spent caustic is sent to Spent Caustic Storage Tank
(T-63001).
The tank operates at ambient temperature and slightly above atmosphere. The Spent Caustic may contain
red oil precursors. These components will continue to polymerize in the tank and form more red oil.
Oxygen at ambient temperature can promote these reactions, therefore the tank is nitrogen blanketed in
order to avoid oxygen ingress. T-63001 has a pressure control system. If the pressure is low, nitrogen is
introduced in the tank and in case of high pressure; vapors from the tank are routed to Vent Gas
Incinerator Unit.
Spent Caustic from T-63001 is pumped to the Spent Caustic Oxidation Package (ME-63001) by Spent
Caustic Oxidation Feed Pump (P-63001A/B) on flow control.
The Oxidized Spent Caustic (OSC) is neutralized with 98 wt% sulfuric acid prior to being routed to the
Spent Caustic Oxidation Effluent Tank (T-63002). The tank operates at ambient temperature and slightly
above atmospheric condition. T-63002 is pressure controlled and equipped with nitrogen blanketing system
in order avoid oxygen ingress into the tank. In case of high pressure, vapors from the tank are routed to
Vent Gas Incinerator Unit.
Treated Spent Caustic is then pumped to the Waste Water Equalization Tank (HOLD 1) in the WWTP by
Spent Caustic Oxidation Effluent Pump (P-63002A/B) on flow control. The flow controller is cascaded to
T-63002 level controller.
T-63001 and T-63002 have skimming connections to allow manual removal of any separated
hydrocarbons. Skimmed Oil from T-63001 and T-63002 is collected and routed to WWTU Skimmed Oil
Vessel (V-85001).
Spent Caustic drains from different points of the Spent Caustic Oxidation Unit are routed to the Spent
Caustic Area Sump (Z-63001). Spent Caustic Dain Cooler (E-63001) (HOLD 2) is provided to cool down
the drains from Spent Caustic Oxidation Unit prior to sending those to Z-63001.
Spent Caustic from Z-63001 is sent to T-63001 by Spent Caustic Area Sump Pump (P-63004) for
reprocessing.
Page 5 of 7
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description for Spent Caustic Oxidation Unit S-S630-5223-002 0
3.2 Spent Caustic Oxidation Package
Spent Caustic is considered as hazardous waste due to its high pH and due to its composition. Spent
Caustic wastes contain high COD, TDS, sulfides, mercaptides, free caustic, polymeric organic compounds
and other aromatics. The high COD due to high sulfide content and high pH are detrimental to the
downstream oily water and biological treatment (high sulfide concentration will poison the micro-organisms)
systems. Therefore spent caustic streams shall be separately collected, gasoline washed, treated in a Wet
Air Oxidation (WAO) process and neutralized before sending for further treatment to the Crystallizer
Package.
In WAO process, air is brought into close contact with an aqueous solution and dispersion of organic
material at an elevated temperature and pressure is performed. During oxidation, the organic compounds
convert to CO2 plus water or organic acids and the sulfides to thiosulfates or sulfates. Oxidation of sulfides
to thiosulfates and sulfates happens according to the following exothermic reactions:
Na2S + O2 + ½ H2O ½ Na2S2O3 + NaOH + Heat
½ Na2S2O3 + O2 + NaOH Na2SO4 + ½ H2O + Heat
The oxidized Spent Caustic is neutralized with concentrated Sulfuric Acid. The neutralization reactions are
given below:
NaOH + ½ H2SO4 ½ Na2SO4 + H2O
Na2CO3 + H2SO4 CO2 (g) + H2O (l) + Na2SO4 (aq)
The Spent Caustic Oxidation Package (ME-63001), abbreviated as SCOP, will be designed to treat the
Spent Caustic stream in a WAO process. The package will be designed for a turndown of 50 % of the
process design flow rate. The oxidized Spent Caustic is neutralized to a pH in the range of 7 to 9 with
concentrated Sulfuric Acid. The net neutralized Spent Caustic is sent to the SCO Effluent Tank T-63002
where after homogenization, it will be sent to the Crystallizer Package (ME-63002) via Spent Caustic
Oxidation Effluent Pump (P-63002A/B).
The unit’s drain system will collect all spent caustic in to the Spent Caustic Area Sump (Z-63001). The
sump is equipped with a submerged pump, Spent Caustic Area Sump Pump (P-63004). The spent caustic
is pumped from the Spent Caustic Area Sump back to the Spent Caustic Feed Storage Tank (T-63001).
The vent gas from storage tanks T-63001/2 and SCOP waste gas are sent to the Vent Gas Incinerator
Unit. This way stripped hydrocarbons from the Spent Caustic feed and any occasional Hydrogen Sulfide
are disposed safely.
All facilities required for neutralization of the oxidized Spent Caustic are included in the Spent Caustic
Oxidation Package and shall be provided by the package vendor.
Operating and design conditions and the WAO process configuration are set by the package vendor based
on the effluent quality requirements. PFDs and the Process Description of the SCOP shall be provided by
vendor as per vendor process configuration.
Page 6 of 7
Liwa Plastics Project
Document Title: Document No. Rev:
Process Description for Spent Caustic Oxidation Unit S-S630-5223-002 0
3.3 Crystallizer Package
The purpose of installing a Crystallizer Package (ME-63002) is to separate the solids in the fully oxidized
spent Caustic (SCO) effluent by means of an Evaporation System. The Evaporation System consists of a
Steam Driven Forced Circulation Crystallizer System with Centrifuge. The solid crystals are to be sent for
landfill. The distillate stream can be sent to WWTU for further treatment and the purge stream which mainly
contains dissolved non-organic solids needs to be treated by an oxidizing chemical agent and sent as brine
to outfall (Hold 3).
Page 7 of 7
Spent Caustic Treatment and Disposal
Spent caustic needs treatment prior to disposal. The waste stream contains different inorganic and
organic acidic components originated from contact with components such as carbon dioxide,
sulfides, carbonates, benzene and phenolics. Because of their acidity, corrosiveness and toxicity
these components must be removed. Several treatment methods can be used to manage spent
caustic, but their suitability is driven by quantity, composition and disposal limits to be achieved.
The main treatment method selected for the LPP complex is Wet Air Oxidation (WAO), a liquid‐phase
hydrothermal oxidation using dissolved oxygen at elevated temperatures. Oxidation efficiency
increases with temperature, while partial pressure of the oxygen governs the oxidation depth to be
achieved. If needed, a chemical oxidation step can be added in the form of for example hydrogen
peroxide injection to achieve low BOD and COD limits.
Due to its high treatment efficiencies, no‐sludge generation and minimal air pollution, this method is
most widely used. It is one of the European Union and US Environmental Protection Agency’s best
available techniques (BATs).
The alternative for a Wet Air Oxidation treatment would be Spent Caustic Incineration.
This is a gas‐phase oxidation process at much higher temperatures (900‐1000°C), converting
inorganic constituents into molten forms and decomposing organic compounds into most stable
states. It could achieve ultimate oxidation levels. However, the spent caustic stream from the LPP
complex does or hardly provides any calorific value and therefore requires firing of natural gas to
vaporize the spent caustic stream and for sustaining the high‐temperature needs. Eutectic solid
crystals formation in the quench section is crucial. Handling and disposal of this crystalline material is
on an intermittent but frequent basis. Flue gas scrubbing will be required to control NOx and SOx
emission. Still waste water effluent contains high concentrations of dissolved salts (sulphates and
carbonates).
High OPEX (operational cost) due to high maintenance (associated with refractory repairs), high fuel
requirements and high cooling/quenching requirements) make this option environmentally less
attractive compared to the WAO process.
The treated effluent from the WAO process (or from the Incinerator process) can be disposed off
with desalination unit reject (brine) towards the seawater return channel or routed to a
crystallization unit to reduce TDS (mainly material already present in fresh seawater as well) of the
effluent stream. However, this crystalline material will have to be handled as landfill.
1) The FEED package includes a Wet Air Oxidation (WAO) unit for spent caustic treatment with
an additional Spent Caustic Oxidation Effluent Crystallization unit.
a. Final effluent from crystallization unit is free of salts and can be disposed off in normal manner.
b. Solid waste at a rate of 24 t/d salts will have to be disposed.
2) Orpic requested to investigate the installation of a Spent Caustic Effluent Incinerator.
a. Currently no or hardly any market response on our requisition; any detailed information is not
expected within another couple of weeks, if any.
b. Incinerator will reduce COD/BOD, but does not address TDS. All salts will end up in waste
water from the incinerator unit, similar to the WAO effluent (without crystallizer), consequently TDS is
similar to WAO option without crystallization.
c. Incinerator has high energy demand to evaporate all water in the effluent, incinerate any
material at 900-1000°C and quench/condense all flue gasses. Since the spent caustic stream only
contains traces of hydrocarbons, the energy has to be provided by natural gas firing.
d. Additional precautions have to be taken to avoid emission of NOx and SOx.
3) Direct disposal of the WAO effluent (or as applicable Incinerator effluent) with the Desalination
Unit Reject (brine), as already indicated in our earlier correspondence (December 2014), still can be
considered to avoid the installation of a crystallizer unit.
a. Routing 2,150 m3/h of Desalination Unit Reject (brine) with the seawater cooling return (58,000
m3/h) increases the seawater TDS content by 0.29%. Adding WAO effluent (9.7 m3/h) to this mixed
stream adds an additional 0.027% to the TDS by only. This means 12 mg/l out of 43,138 mg/l TDS in
final seawater return is attributable to the WAO effluent.
b. In the seawater return channel, the LPP stream is further diluted with the seawater return from
SRIP. Specifications for the stream from SRIP are not available, but it is assumed that this stream
meets criteria and is comparable with the LPP seawater return. The anticipated contribution of the
WAO effluent on TDS of the combined seawater return stream is even further reduced to 0.016%.
c. Spent Caustic WAO effluent contribution to TDS is mainly in the form of sodium and sulphate
ions. Concentration of these components in seawater outfall is therefore similar of concentrations at
seawater intake.
d. BOD and COD are slightly above natural seawater BOD and COD levels. However, these can
be further reduced chemical injection. Components like benzene have been removed from the effluent
stream already.
From a BREF/BAT point of view, also spent caustic WAO will be the preferred route over spent
caustic Incineration. This also will have to be addressed in the EIA report.
Considering the above, CB&I recommends not to pursue the Incinerator option any further and keep
the configuration as currently provided in the FEED package, i.e. WAO. + crystallization unit. Whether
a crystallization unit will indeed be required will depend on the whether the very small contribution of
the WAO effluent on the total TDS concentration is acceptable or not.
Petrochemical Plant Sohar Environmental Impact Assessment Report
Orpic and CB&I HMR #3817
Attachment 17: Tie-ins and Interconnecting lines
G-S000-5240-003 HMR Consultants
June 2015 X
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
P80018201-4"-HOLD-N (BUTENE-2 FROM P83020A/B TO INALK UNIT 2900)
NOTES
P10010407-3"-A1A1E-N (OLNG CONDENSATE FROM OOT P-97505A/B)
P80020201-3"-A2A1-N (C8-C10 CUT FROM P-83025A/B TO BLENDING (TP-S620015))
MA800A-6"-A1A1-N (METHANOL FROM T-6107A TO T-810003A/B (TP-610001))
P80017301-4"-A2A1-N (MTBE FROM P-83018A/B TO T-6231A/B)
FOR CONT. SEE D-S975-5225-003 N-1093.000
No.10 ROAD(P) N: 1093.000
000
P80010609-6"-T4A1-N (PG PROPYLENE TO T83002A/B FROM TP-S620001)
1 UNIT 1100 UNIT 1300 PLANT
2000.
EXISTING
P97510402-6"-T2A1-N (MIXED LPG FROM EXIST. TANKAGE)
AREA FOR HVAC
33
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1950.
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WIND
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7M
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NOTES
2
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90
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HS70011408-10"-MS13-IH (HP STEAM FROM SCU)
PROPANE/LPG VAPOR RETURN FROM K-81004 TO JETTY
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)
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88GH13
9
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No.13 ROAD(S) N:617.000
106M PIPE SLEEPER 002-1
EL 99150
CRUDE RECEIVING 24"
T-A9105 FACILITIES
000
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(BY ORC)
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C
EL 99150 N: 544200
F FIRE N:535.000 F
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SPOSAL AREA DI
(
UTM COORDINATES N:495.000
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P-6504B
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UTM COORDINATES
TANK SLUDGE
N: 2707536.733
)
N: 2707552.017 E: 460586.481 AB
TP-S620015)
)
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E: 460576.972 MIN.EL 98600
Z-6555
NO.3 L.S FOR SY Z-6504 P-6555A/B
L TO T-6213 AT SOHAR REF.(
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NO.2 L.S FOR CWS TREATMENT
L ROAD(
BUTENE-1 FROM SCU TO HDPE/LLDPE)
HEXENE-1 FROM JETTY TO STORAGE)
NE TO JETTY)
Z-6527 (WWT)
NG)
P-6527
ES)
Z-6528 (REF. TO V-215A-301-A-033)
BUTENE-2 FROM P83020A/B TO I
NTERCONNECTI
TI
P-6528
S/S
LI
NG)
ETHYLENE VAPOR TO PPA)
LLP CONDENSATE TO UTI
002-3
Z-5207
CE WATER FROM I
NTERCONNECTI
WW FROM PE TO SCU)
No.15 ROAD(P) N:404.000
HP STEAM FROM SCU)
SOPENTANE VAPOR LI
WWT REUSE
UTM COORDINATES
L / WASH OI
S FUEL OI
SUBSTATION WATER TANK
E
HP BFW FROM I
DMW FROM SCU)
TRUCK YARD 2nd SULFUR STORAGE AREA EL 99500 (SS-22) (BY OTHER)
N: 2707539.357 (FUTURE) (FUTURE)
PUMPS
(BY OTHER)
PE SLEEPER
REUSE
LABORATORY
E: 460556.583 EQUIPMENT
PYROLYSI
FG FROM I
(12)
SHELTER
HYDRO BLAST
FLUX OI
SERVI
(BY OTHERS) No.16 ROAD(S) N:363.000
LPG FROM)
JETTING CLEANING
AREA AREA
P-6524A/B/C/D
PI
000
H(
1-PP (
01-6"-N1A1-N (
H(
04-6"-MS01-N (
CHEMICAL
0"-MS01-N (
I
NG92010204-2"-A1A1-N (
P80019701-3"-A2A1E-N (
-ST (
P920XXYY-6"-HOLD-N (
-N (
208-3"-A1A1-N (
I
448.
P97010102-10"-A1A1-N (
BWF70011508-3"-MS13-I
P80020201-3"-A2A1-N (
NO.4 L.S
P92010202-2"-A2A1-N (
P80018201-4"-HOLD-N (
0104-4"-A1A1-N (
STORAGE
-N (
P80012801-6"-T2A1-N (
P92010201-3"-A2A1-N (
3-I
Z-5208-2
Z-6524A/B
FOR SY (SPACE ONLY) BUILDING
H H
05-12"-A4A1
AB
1508-6"-MS1
0"-MS1
P92010206-2"- -N (
P80015201-4"-A2A1
Z-5209
1
7701-3"-A2A1
P)E:
OPEN YARD
000
SHUTDOWN WAREHOUSE T-6301 T-6302 ME-6302
Z-6522
C ROAD(
1750.
CONTRACTOR AREA
1108-1
1408-1
P-6522A/B
DMW920101
EL 99500
WW920101
PIPE SLEEPER PIPE SLEEPER
P)E:
LLC7001
FG70011
P920101
68" CLEAN SEA WATER RETURN
PW7001
HS7001
P9201
P1001
FIRE EL 99500
F ROAD(
STATION
(8)
61
80"
P-3801
M
V-3801 ME-3801
A/B/C T-3801
WAITING AREA WAITING AREA
GASOLINE 1
WARE HOUSE
FOR CONT.SEE D-S975-5225-004
FOR CONT.SEE D-S975-5225-001
GAS OIL
CATALYST
STORAGE LOADING AREA 1 LEGEND
MAINT. BUILDING LPG
OFFICE MAINTENANCE LOADING AREA
(6)
WORKSHOP
BUILDING 1 2 3 4
61M
MEDICAL ME-6301
J CENTER
FUTURE
LPG WEIGH SCALE J
EL 99700
(20)
80"
(10) SULFUR GRANULATION &
EL 99500 1st SULFUR STORAGE AREA
NON-RESERVATION
4))
TRUCK WAITING AREA
3/1
No.18 ROAD(S) N:200.000
ETHYLENE VAPOR TO/FROM M-83002/K-83008 FROM JETTY)
No.17 ROAD(P) N:200.000
2/1
TRUCK LOADING
PROPYLENE VAPOR RETURN FROM JETTY TO/FROM V-83019)
Z-5206
TP-S6201
TRUCK LOADING SATELLITE OFFICE
)
GUARD HOUSE
5)
)
1)
TP-S910004)
TRUCK YARD BUILDING
0001/2/3)
BUTANE-1 VAPOR RETURN FROM JETTY TO T-83008A/B
TP-S62001
FOR MAIN ENTRY
OLNG CONDENSATE FROM OOT P-97505A/B)TO V-2001
(W/SS-23 & SIH-6)
ON FROM JETTY TO V-83004)
)
TP-610001)
004 TO JETTY
PG PROPYLENE TO/FROM JETTY TO/FROM T-83004)
GUARD HOUSE
ON FROM JETTY TO V-83009)
TREATED OFFGAS TO V-12001 FROM TP-S220001)
3 AT SOHAR REF.(
PG PROPYLENE TO T83002A/B FROM TP-S620001)
T 2900)
PG ETHYLENE TO/FROM JETTY TO T-83003)
TP-S91
NG (
BUTANE-1 TO/FROM JETTY TO T-830008A/B)
03 (
000
009A/B TO JETTY
SECURITY OFFICE
NG)
07A TO T-810003A/B (
NALK UNI
88"
88"
448.
0 CUT FROM P-83025A/B TO BLENDI
PROPANE/LPG FROM JETTY TO V-81008)
PROPYLENE FROM P-83013A/B TO PE/PP)
LP NATURAL GAS FROM SCU TO PE/PP)
C6-C7 CUT FROM P-83024A/B TO T-A91
HEXENE-1 TO/FROM STORAGE TO PE/PP)
8A/B TO T-6231A/B)
002 (
SOPENTANE FROM STORAGE TO PE/PP)
NTERCONNECTI
SOPENTANE FROM JETTY TO STORAGE)
K K
PROPANE/LPG VAPOR RETURN FROM K-81
N WATER TO PE/PP FROM SCU)
BUTENE-1 FROM SCU TO HDPE/LLDPE)
1
HEXENE-1 FROM JETTY TO STORAGE)
E:
NE TO JETTY)
500
NG)
ST.TANKAGE)
001/21
ES)
2060.
BUTENE-2 FROM P83020A/B TO I
NTERCONNECTI
L TO T-621
LITI
L TO T-21
E:
HYDROGEN FROM ME-23001)
NG)
ETHYLENE VAPOR TO PPA)
LLP CONDENSATE TO UTI
PROPANE/LPG FROM P-81
CE WATER FROM I
RCULATI
NTERCONNECTI
WW FROM PE TO SCU)
HP STEAM FROM SCU)
VENT GAS TO V-22002)
SOPENTANE VAPOR LI
RCULATI
KEY PLAN
XED LPG FROM EXI
S FUEL OI
METHANOL FROM T-61
MTBE FROM P-8301
L/WASH OI
HP BFW FROM I
ETHYLENE CI
P/S C
9/K-83009)
BREAKWAT
PROPYLENE CI
ER
OFCC PHASE 1
FG FROM I
PYROLYSI
)
ETHYLENE VAPOR TO/FROM JETTY TO/FROM M-83002/K-83008)
4)
FLUX OI
SERVI
LPG FROM)
DEMI
3/1
ETTY
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I
MAJSJ
SUBSTATION
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H
C(
RT
C(
BE
C(
PROPYLENE VAPOR RETURN TO/FROM JETTY TO/FROM V-8301
TP-S62012/1
H(
1-PP (
09-16"-A1A1E-ST (
H(
2B
MI
608-10"-K2A0CCX-I
606-12"-K2A0CCX-I
01-6"-N1A1-N (
-C
0104-6"-MS01-N (
RTH
108-10"-MS01-N (
BE
609-4"-K2A0CCX-I
NG92010204-2"-A1A1-N (
B
HY92010108-2"-B2A1-N (
-
C(
TH
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