IMPROVEMENT OF LUBE OIL UNITS IN DAURA REFINERY BY COOPERATION BETWEEN PRDC & MRC WITH IMPA –

ENGINEERINGPrepared by

Senior chief engineerSALAH MAHDI ALI

الخام النفطCrude Oil

100,000 BPSD

الى االسود النفط Fuel Oil الطاقة

For Power House

المختزل ) ( الخام االسود النفطالدهون Reduced Crude To الى

Lube Plants

هدرجة وحدة HDS النفثا

Naphtha 18,000 BPSD

البنزين تحسين وحدة Catalytic (2رقم )

Reforming 10,000 BPSDتحسين وحدةرقم ) (1البنزين

Power Former 5,000 BPSD

هدرجة وحدةاالبيض النفط

Kerosene HDS 13,000 BPSD

الطائرات وقود Jet Fuel

Blending

المتبقي / االسود / Heavy Fuel OilالنفطResidual

الخفيف الغاز LightزيتGas OilKirkukeكركوك

API 35o/36o Basrah بصرة API 29o/30o Naft Khana خانة نفط API 42o

API 32o

الغاز استخالص وحدة LPG Unit 220 السائل

Ton/D

حدو

تا

يوجال

رطي

قالت

A

tmosp

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istillation U

nits

ا الغاز Heavy Gas لثقيلزيتOil

غاز شبكة الوقود

Fuel Gas Netوحدات الى بروبان Propane To الدهون

Lube Plants

االسود النفط Heavy Fuel Oil

الديزل وقودDiesel Fuel

الغاز زيت Gas الخفيف

Oil

وقود الطائراتJet Fuel

االبيض النفطKerosene

بنزين السياراتGasoline

الغاز السائل

LPG

الشعلة Flare

الخفيفة الزيوت هيئةLight oils corporation

الدهون هيئةLube Oil corporation

عوا

الناةفختل

مةهائي

نن

وهد

D

iffere

nt Ty

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f Fin

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ils

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n U

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ةحد

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صالخست

الاةحد

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رافرفبال

Fu

rfural

Extrac

tion

Un

it

عمش

الةزال

اةحد

وب

مذيبال

So

lven

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ewaxin

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nit حد

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ن هالد

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Oil &

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ydro

finsh

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Un

its

الفراغي الغاز .VزيتG. O.

40 B.O.

60 B.O.

150 B.O.

الشمع الصلب

H. W.

االكستراكت مادةExtract

الممزوج BlendاالسفلتAsphalt

التقطير متبقي.V. Rالفراغي

الرخو .SالشمعW.

1 S. S.

3 S. S.

D. A. O.

االسفلت Base االساس

Asphalt

40 Raff.

60 Raff.

150 Raff.

40 W.F.O.

60 W.F.O.

150 W.F.O.

H. W.

المختزل الخامR. C.

المؤكسد BlownاالسفلتAsphalt

2 S. S.

2 S. S. (Fuel Oil System الوقود منظومة(السائل

االسفلت وحدة Blownالمؤكسد

Asphalt Unit

االسفلتمزج Asphalt Blending

V. R.

بروبان

C3

هواء

Air

مذيب

Solvent

Furfural فرفرال

هيدروجين

H2

جزمال

تدا

حو

Blen

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المضافاتAdditives

Object

Deasphalting Unit No. 2 at Daura Refinery. The unit was designed &constructed by Snamprojetti,Italian company;&it was running from 1968.

Purpose of the work Increasing of the plant capacity on feed. Brief of the technical proposal IMPA Engineering Co. suggests two variants of modernization. Variant No. 1 is aimed at increasing capacity by 10 – 15 %. Variant No. 2 is aimed at maximizing capacity by 30%.

Preliminary unit analysis

Preliminary analysis of existing propane deasphalting unit : 1. Productivity of the unit decreased compared to design values due to inefficient work of furnace and heat exchangers. 2. The rotary disc contactors do not work and it affect the extraction process which will not achieve the design conditions.3. Efficiency of some pumps is reduced due to their mechanical deficiency. 4. Ineffective scheme of solvent recovery in evaporators 02-Т2, 02- Т4.

The original flow diagram of the propane de-asphalting unit with faulty elements

Extractor 02-T1 analysis

The extraction process on propane deasphalting unit was affected due to the improper function of rotary disk contactors which leads to the following: – low efficiency of the extractor because of poor mass transfer of phases. – reduction of plant capacity due to coke deposition on the rotary disk contactors.

Therefore the main task is to upgrade the extractor by using RN-IMPA regular packing as a mass-transfer devices in the extractor. This packing has been specially designed for the process of propane de asphalting as used in Russia.

Regular packing for extraction processes Field of application Realization of mass-exchange process in ‘liquid-liquid’ systems for extraction refining and separation of hydrocarbons.

Examples of application • extraction columns of lube-oil selective treatment units; • extractors of aromatic hydrocarbons separation sections of catalytic reforming units; • extractors for after treatment of diesel fuel.

Results • improvement of product quality; • increase in target product yield; • reduction of ‘solvent-feed’ ratio; • reduction of power consumption.

Features of the packing • film mode of flow; • the film is double-sided; • turbulent mode of flow; • redistribution of liquid; • higher efficiency.

Note: The actual capacity now is about 70% of the design about 9 m3/h due to limitations of heater & exchanger.Therefore the 1st increment is from actual to design(30%) 2nd increment is from design to 130%

DesignCase 1 Case2

Description of technical proposal for variant № 2-A

Purpose – maximum increase in capacity (preliminary 30 %). Technical proposal: 1) Replacement of internal devices of extractor 02-T1: – using RN-IMPA tower packing; – replacement of heaters at the top of the column. 2)Modernization of fired heater with replacement of furnace coil 02-Н1. 3)Replacement of faulty pumps 02-P1, 02-P2, 02-P3,02-P4 which would allow a capacity increase of 30%. 4)Replacement of faulty heat exchangers or tube bundles. 5) Replacement of the internal devices of columns 02-T3 and 02-T5. 6) Optimization of the process and process parameters of the unit: – changing the operating mode of the column 02-Т1; – installation of a new heat exchanger 02-E6 / 1 AB on the propane cooling and condensation line in series with 02-E6 AB; – installation of an additional heat exchanger in front of the fired heater on asphalt flow. 7) Use of an additional second stage flash tower 02-T2 / 1 for de asphalted oil: – installation of heat exchanger 02-E4/1 on the line of de asphalted oil from 02-T2 to 02-T2/1; – to supply propane from 02-T4 under the liquid level in the new evaporator 02-T2/1.

Rosneft, LLC “Novokuybishevsk lube-oil and additives plant”

1. Deasphalting unit # 36/3 Year of modernization: 2007 2. Deasphalting unit # 36/4 The modernization purpose – increase in feed capacity.

Description: single unit’s feed capacity 900 tons per day, 40 m3/hfeed vacuum residua solvent liquid propane products deasphalted oil, asphalt

Scope of work: •base project; •design of the new extractors;

Results: •increase in feed capacity on 30 %; •increase in deasphalted oil yield by 3 – 5 %•reduction of “solvent-feed” ratio by 20 %•the tower packing works without repair of 5 years.

Flow diagram modernized plant for the variant № 2-А

Description of technical proposal for variant № 2-B/С Purpose – maximum increase in capacity (preliminary 30 %). Technical proposal: 1) Replacement of internal devices of extractor 02-T1: – using RN-IMPA tower packing; – replacement of heaters at the top of the column. 2)Modernization of fired heater with replacement of furnace coil 02-Н1. 3)Replacement of faulty pumps 02-P1, 02-P2, 02-P3,02-P4 which would allow a capacity increase of 30%. 4)Replacement of faulty heat exchangers or tube bundles. 5) Replacement of the internal devices of columns 02-T3 and 02-T5.

6) Optimization of the process and process parameters of the unit: – changing the operating mode of the column 02-Т1; – installation of a new heat exchanger 02-E6 / 1 AB on the propane cooling and condensation line in series with 02-E6 AB; – installation of an additional heat exchanger in front of the fired heater on asphalt flow. 7) For variant 2-В: installation the evaporator 02-Е4/1on the line of mixture DAO with propane from 02-Т1to 02-Е3. For variant 2-С: installation two evaporators 02-E4/1 and 02-E4/2 on the line of mixture DAO with propane from 02-Т1 to 02-T2 and use the column 02-T2 as separator. To supply propane from 02-T4 with the propane from evaporators 02-E4/1 and 02-E4/2 to 02-T2.

Flow diagram modernized plant for the variant № 2-В

Flow diagram modernized plant for the variant № 2-С

Subjects under discussion

1- All materials, mechanical design and manufacturing should be standardized according to international codes which are used in Iraqi refineries ( MRC ).2 - Due to the high sulfur content in Propane ( there is no any sweetening unit in MRC for LPG ) and to avoid the corrosion problem in the existing equipment and the new installed equipment discussion was carried out to install new sweetening unit.3- Ensuring that the increase in capacity should not affect the existing specifications or it will improve to any positive limits .4- Due to increasing in capacity ,the utilities such as : electricity , steam , C.W , F.G , solvents will be increased, it is necessary to fix the difference to prepare the demands and the total consumption / ton product should be less than the original rate as IMPA committed .

Recommendations on process control

- The process of de asphalting is carried out using liquid propane at pressures up to 40 atm. and refers to the high-class explosion and fire facilities.

- For control of units of this class, it is advisable to replace the current automated system to modern one.

- This will also improve the accuracy of received information and the quality of technological parameters control .

THANKS FOR YOU ATTENTION

E- mail: smali562000@yahoo.com