Saturated Hydrocarbon Refining Process Units

Light Naphtha

Full Conversion Petroleum Refinery G05 Saturated Gas Plant (SGP)

D-25 99% purity
Isomerization Unit (ISOM)
R-2 & R-3 P
Relief
G10 Hydroprocessing Complex
1300 psig
1600 psig
Header

Refinery Process Flow Diagram 1300 psig 1600 psig 150 psig
(C1-C2)
HP FG
lean
Propane 150 psig C-101
ISOM Reactor
System
350 psig 400 psig
Header
Header

P
Header 95% purity P

Header Header Header Sales 99% purity Header Hydrocracking Unit

(RPFD) amine P
T-1 D-24 (HCU)
T-3 AMNU Hydrogen
C-105 A/B/C Deethanizer Caustic Scrubber/ first stage
rich Plant #1
Makeup T-6 Virgin Naphtha Hydrotreater Distillate Hydrotreater
AGO Mercaptan (H2P #1) R-31 HDT
makeup Compressors D-22 amine Depropanizer (VNHT) makeup (DHT) makeup
LVGO D-21 lean Extractor &
hydrogen D-23 makeup
T-1 LCCO CDU absorbent 99% purity R-32 HDC
light ends R-37
R-35 Reactors
Generic Refinery light ends LCGO F-41
(C1-C4) DHT T-2 steam (nC4 & iC4)
Hydrogen
Plant #2
Reactor
Reactor System
(C1-C4) wild Sponge System
VNHT ALKY (H2P #2) P F System P
Revision 3, 2/2024 FG bleed gas CNHT
naphtha Oil Absorber T-4 (T-1 Relief
F recycle
350 psig HP recycle P Relief
F recycle
hydrogen
1500 psig
makeup hydrogen Fuel Gas bleed gas 1100 psig
(H2 + C1-C2)
hydrogen RFMR Debutanizer caustic Deisobutanizer) Header bleed gas hydrogen Header bleed gas
D-22 Relief G03 Hydrocracking Unit ISOM
(C3-C12) (H2, C1, & C2) (H2,C1, & C2) (H2,C1, & C2)
T-2 R-31 Header
Atmospheric Hydrotreating
(HCU) light ends unstabilized
T-5 lean 84% purity Cat Naphtha Hydrotreater
(CNHT) C-105 A/B/C
second stage
Amine amine Reformer makeup
makeup

1500 psig recycle hydrogen

Crude Tower SWS Reactor (C1-C4) naphtha 3 Stage Makeup Hydrogen Compressors
Contactor AMNU Unit (RFMR) R-33
(C5-C12) R-36 Capacities: 2,500 scfh each
F-42 CDU HDC Reactor
naphtha SGP rich Reactor Loading Steps: System
LPG amine System
(C5-C12) steam P 50%, 60%,70%, 80%, 90%, 100% recycle P
bleed gas T-10 unstabilized (C3-C4) Relief
G01 Crude Distillation Unit T-4 (H2 + C1-C2) Fractionator light naphtha F recycle
P
Relief
F
hydrogen 1500 psig

1500 psig recycle hydrogen

steam jet Relief FG Header 150 psig Relief 250 psig A
D-22 Header
(CDU) (C3-C12)
(C11-C13) Header (C5-C6) G11a Virgin Naphtha Hydrotreater Header bleed gas
hydrogen bleed gas
(H2,C1, & C2)
(H2,C1, & C2) B
virgin makeup 400 psig (VNHT) 95% purity
R-32 stabilized
distillate JCTU SWS Header off gas C
1st Stage R-33 naphtha CW
(absorbent) T-5 virgin (C1-C2) Relief
Hydrocracking 2nd Stage Regular
T-1
pumparounds distillate
Reactor Hydrocracking
(C5-C12) recycle hydrogen
bleed gas Header
D-1 G12 Light Naphtha Isomerization Unit (ISOM) iC5 product
87 octane
(C13-C20) T-4 (H2 + C1-C2) (90% purity)
Preflash D-23
Reactor jet and diesel steam heavy naphtha F-41 Relief
to hydrogen
Tower pumparounds (C7-C12) (C5-C12) Header SWS
T-6 T-1 circulation (nC5 & iC5; 34% iC5) (H2, C1, & C2) Relief
F-41 lean wild naphtha
T-5 350 psig T-1 Header
overflash Jet FG amine (small flow) T-1 chloride D-22
atmospheric gas oil AMNU T-2 SGP isomerate
steam jet Blender wash Deisopentanizer Caustic High Test
D-21 (AGO) High Pressure (C11-C13) R-37 rich Stripper F-1 (iC5 & iC6)
hot crude oil D-21 D-22 water steam Scrubber 93 octane
Desalter FG (C15-C30) Separators HDT amine
water light ends T-6 T-4 CW caustic
steam diesel Reactor steam CW
condensate steam injection (C1-C4) (nC5, nC6, 300 oF (87 RON
(C13-C17) D-21 WWTP D-41
F-43 light naphtha & iC6) D-21 14 RVP)
wash water P FG
from brine D-23 overflash Diesel
D-23 WWTP pressure (nC5, iC5, nC6, & iC6) SWS
Low Pressure FG steam Blender SWS let down wild naphtha
Separator heavy naphtha
Pipeline
steam Refinery steam
(C7-C12)
CW (small flow)
polynuclear aromatics SGP
Oils Manifold (PNAs) purge flow
heavy diesel
D-11 R-2 R-3 T-4
Docks SWS D-10 T-2 Depentanizer
Relief 350 Isom RX Isom RX
Sulfur Feed
demulsifier Header
G11c Distillate Hydrotreater (DHT) (C20+)
Diesel G14 Hydrogen Plant #1 (H2P #1) Guard Bed Dryers psig
Stabilizer
natural gas (NG)
Blender 600#
1300 psig NG Hydrogen steam steam iC6 product
D-23 off gas Steam D-12 A/B
Hydrogen G15 Jet Caustic Treating Unit (JCTU) super Plant #1 (80% purity)
Slop Oil makeup (C1-C2) Relief D-1 A/B wet wet H2 Makeup
T-7 Header bleed gas heated C-101
System Header D-22 Desulfurizers steam steam Gas Driers (nC5, iC5,nC6 & iC6
Vacuum wash water
H2 + (C1-C2)
D-23 steam makeup Hydrogen
D-21 Water Wash D-9
atmospheric Tower Desalter F-41
recycle H2 HP FG
pressure wild naphtha
dry jet
BFW
Boiler
Feedwater
Compressor G13 Reformer (RFMR) 84% purity 150 psig
residuum light vacuum gas oil D-23 (small flow) fresh water D-24 A/B Hydrogen
let down SWS fuel gas (FG) System recycle hydrogen (H2, C1, & C2)
(C25-C50 +) hydrogen Clay Filters NG Header

Gasoline Blender
(LVGO) (C25-C35) lean SGP
LVGO & HVGO circulation FG BFW
amine T-2 CDU D-21 (C11-C13) FG H2P#2 Reforming Reactors hydrogen off gas Relief
pumparounds heavy vacuum gas oil FG 1100 psig T-1 T-3 Jet Caustic PSA 150 psig F-41 F-42 F-43 F-44
(C30-C50) jet AMNU Stripper
off gas D-2 air S-1 99% purity Hydrogen circulation Header
D-22
(HVGO)

vir
Wash D-23 A/B
virgin distillate rich steam (C11-C13) Blender Jet catalyst Exhaust Header

gi
water/ Salt Driers D-21

n
AGO amine Blender tubes Stack D-8 A-D

je t
F-42 caustic FG FG FG FG wild naphtha
overflash HCGO D-22 dry and clean jet F-52 Pressure Swing
F-42 caustic with purge B-32 (small flow)
HCCO Low Temp (no surfactants) Steam-Methane Adsorber (PSA)
Separator Ultra Low mercaptides regenerated SGP
R-35 Reformer
Sulfur Diesel Caustic caustic PSA T-1
FG HDT (SMR) D-3
steam FG (ULSD) (C13-C17) Diesel Regenerator off gas F-45 Stabilizer
Vacuum Reactor SWS High Temp to R-31 R-32
D-21 40 Cetane Blender (mercaptides CDU R-33
Resid High Temp wash oil to disulfides wash oil Shift Converter D-6 F-52 Reactor Reactor Reactor R-34
Quench (solvent) conversion) D-5 produced Reformate
Separator with Reactor FG
pressure heating oil Heating water (C7-C12)
(C50 +) disulfides
let down production mode Oil Sales (103 RON; 0.6 RVP)
(C13-C20)

G02 Delayed Coking Unit

F-42
CO Boiler steam Unsaturated Hydrocarbon Refining Process Units D-24
D-22 system G06 Unsaturated Gas Plant Distillation Section
Coker (DCKU) fuel gas atm
G16 Sulfuric Acid Alkylation Unit D-24
Wet Gas (C1-C2) G04 Fluid Catalytic Cracking Unit Steam Drum
BFW
HP FG (USGP) propylene-rich D-25
Compressor USGP (FCCU) Expander FG
lean
100 ppm H2S (C3= & nC3) (ALKY) T-1 (nC4)
Deaerator absorbent
Turbine lean Chemical Deisobutanizer
D-22 Coker (C1-C2) (naphtha) 0 ppm mercaptans Reaction Section Butane
coker LPG & reactor vapor V-33 S-4 T-3 amine Plant SGP
D-21 Wet Gas C7-C12 C-81 Sales
naphtha Third Stage iC4 refrigerant T-6 (nC4 & iC4) (iC4)
LPG Compressor AMNU regenerated T-8
(C3-C12) Separator T-7 Depropanizer to (90 RON; 52 RVP)
naphtha Refinery D-23 rich caustic Depropanizer D-21
USGP atmos Cat Wet Gas from Mercaptan R-31 Rx
Mud Drum T-2 amine during winter
Oils Manifold Compressor (C1-C2) Reactor feed
SWS air T-9 Extractor Caustic pressure T-2
D-21 Sponge Oil M M M
Regeneration let down Debutanizer
R-31 Cat D-25 Absorber 0 ppm H2S
T-1 System
Coker Main Reactor Fines LPG (iC4 & C4=) Treating Section
T-1
T-2 Column SWS (C3-C4) T-1 D-22 D-23 spent caustic
reactants steam
light cat cycle oil flue FCCU Main caustic
steam naphtha Absorber steam (iC8) alkylate
LCGO & HCGO light coker gas oil (LCCO) gas Column with mercaptides D-22 D-23 (92 RON; 4 RVP)
pumparounds (LCGO) (C13-C20) cat LPG and cat naphtha 100 ppm H2S
D-25 spent acid
heavy cat cycle oil
FCCU
T-2
(C3-C12) lean (nC4, C4= & iC4) from fresh acid condensate
Main Column T-6 amine (60% C4=) Storage fresh
(HCCO) steam Refinery Oils recycle iC4 D-24 caustic
light cracked naphtha (LCN)
(C5-C6)
LCCO & HCCO AMNU
light cat cycle oil Manifold (C3s-C4s)
T-3 heavy coker gas oil (86 RON; 7 RVP)
steam pumparounds (C13-C20) rich
(LCCO) D-21
HCGO
(HCGO)
T-5
amine absorbent to G11b Cracked Naphtha Hydrotreater (CNHT)
T-9 T-2 400 psig
spray (C15-C35) T-3 rich Debutanizer Cracked
Catalyst steam absorbent Naphtha makeup Hydrogen bleed gas off gas Relief
vacuum Circulation T-4 Header (H2 + C1-C2)
cutting water overflash heavy cat cycle oil Stripper steam Splitter Relief Header
residuum Circuit steam recycle hydrogen D-22
R-32 (HCCO) (C15-C35) F-42 Header
atomizing heavy cracked naphtha (HCN) lean
Regenerator
steam (C5-C12) (C7-C12) (80 RON) hydrogen T-8
cold F-41 steam coker LPG & naphtha amine SWS
LVGO circulation wild naphtha
CSO (C3-C12) (C3-C12) AMNU
D-24 HVGO DCKU FG 250 psig (small flow)
D-25 atmos PA rich SGP
hot gas oil combustion amine
Coke Drum Coke Drum wash
feed air T-3
online offline water
CSO
FCCU
coking
operation
decoking
operation
atmos Expander DCKU cat slurry oil (CSO)
Feed (C30+)
sweet hydrogen
sweet fuel gas
G21 Amine Unit (AMNU) recycle H2S
CW
G20 Sulfur Recovery Complex
Steam atmos R-36
pressure
let down steam
Stripper
HCN

3 Coke Drum Modules A/B/C,

CW
H2S
G24 Tail Gas Unit (TGU) System HDT Reactor
(C7-C12)
(70 RON; 3 RVP)
F-41 sweet LPG CO2 & inerts D-26
Each module consists of Fuel Gas System D-11 rich amine B-9
Fuel Tk-1 incinerator
charge pump, heater, and
pair of drums. G31 Fuel Gas and Flare High Pressure Fuel natural gas
(C1)
Gas CW rich D-13
T-3
Amine
Tk-2 Incinerator
outlet gas API Separator Bays
sulfidic Inline
FG Gas Collection Header Users amine NG process Tk-121
Module A is shown here. Coke Pit
Systems high Fuel Gas
Lean
Amine
T-1
Amine
Regenerator
steam T-8
E-91 Refinery wastewater
M
caustic Mixer
M M M
Equalization

air
pressure Gas LPG Waste Heat Boiler Process Diversion
Distribution Regenerator amine acid gas Amine S-91 oil Tank
Header
Author: Warren P. Averill fuel gas D-24 Header
Plants
FG Absorber Incinerator
Sewers Sump Skim
Crude sludge
producers Fuel Gas FGRU D-10 (AAG) H2S, CO2
Tk-120 M M M sewer
waverill@vispersol.com steam lean amine Stack Pit
Mix Drum (94% H2S) & inerts Slop Tank Offsite
HDTs Storm Water TK-115 Tk-114
Fuel Gas Recovery Unit (FGRU) hydrogen Rich Retention Tank Sludge Tank Disposal
©Copyright 2023 slop oil lean amine B-4 Slop Tank
C-81
T-1 22 lean system Refinery Amine Amine 1/3 2/3 G23 Sulfur Recovery Unit Tail Gas Burner Tk-123
Visual Performance Solutions, Inc. FGRU Compressor slop oil Tk-121 Lagoons w/ Aerators filter
(liquid ring compressor) Fuel Gas Amine amine Absorbers and Contactors Header system of AAG of AAG Steam SMR CO2, H2, H2S, Backwash Tank backwash
www.VisPerSol.com from pressure Claus Reactors
CO2, CH4, H2S, Equalization (biological oxidation) TOC/BOD
condensate Absorber AMNU System SO2, H2O & inerts reaction SO2, H2O,
Permit
relief valves (C1-C2) 1 natural gas
G22 Sour Water Stripper Unit (SWS) E-51 reheater R-31B R-31C & inerts T-6 Tank
M M M
M M M M M Clarifier M foam Post Biox Monitoring
rich pilot sour water acid gas (SWAG) R-31A combustion air Quench
D-23 Waste Heat Filters (PBFs)
Feel free to distribute this diagram on paper or FGRU amine
steam
Refinery Sour CW (NH3 & H2S) Boiler
R-3 Tower
Station
bleed gas from S-2 Tail Gas PBF
electronically within your organization and/or hydroprocessing KO Drum
Refinery
Water Sources
F-41 2H2S + SO2 NG
Reactor Sump outfall river
CW refinery slop D-21
technology network. Please do not employ this complex seal Refinery Flare System Flare sour
Reaction waste activated sludge (WAS)
Offsite
molten

oil system
combustion air

sulfur

water E-21 P-81 Furnace CO2, H2S, H2O, Dissolved Air

in any for-profit endeavor without permission off gas from SWS water T-2 Sulfer
Condensers & inerts
coagulant
Flotation Tank
M Disposal
foam polymer
sulfur

auger
sulfur

sulfur
Sour Water
from Mr Averill. process units D-22 D-20
Stripper (SWS) ball valve Recycle M
D-21 Liquid Seal atm SWS
Refinery Relief KO Drum liquid seal steam H2O purge recycle activated sludge (RAS) Sump
Drum
Header slop oil gravity flow plant air
steam stripped
(low pressure) P-82 system water slop oil
water condensate
G32 Wastewater Treatment Plant air
system WWTP D-39 Sulfur Pit (WWTP) air-saturated water