INTRODUCTION OF DUNG QUAT REFINERY

DUNG QUAT REFINERY

 Site
 12 km in the East of No 1 national
road
 7 km from Chu Lai Airport, 100km
from Da Nang
 38 km from Quang Ngai Town
 The Site is bounded by Dung Quat
Bay to the North and Viet Thanh
Bay to the South
 Quang Ngai
Province
Area: 5,131.51 km2
Population: 1,198,500 (1999)
 DUNG QUAT REFINERY

 Capacity:
 6.5 million tons crude oil/annum (148,000
BPSD)
 Feedstock:
 Sweet case: Bach Ho Crude Oil
 Sour Case: Mix Bach Ho + Dubai (5.5/1)
 Capital investment $3.0 billion.
 DUNG QUAT REFINERY

Main products (meet ASEAN standards):

 LPG
 Polypropylene
 Unleaded Gasoline (RON 83 and 92)
 Jet Fuel (Jet A1)/ Burning Kerosene
 Auto Diesel and Industrial Diesel
 Fuel Oil
 DUNG QUAT REFINERY

 Package 1: Refinery Inside Battery Limit

 Package 2: Crude Tank Farm
 Package 3: Product Tankage, Truck Loading,
Interconnecting Pipeline, Product Export berth
 Package 4: Single Point Mooring (SPM)
 Package 5A: Breakwater
 Package 5B: Jetty
 Package 7: Administration Building
 DUNG QUAT REFINERY

Plot Plant:
36 ha
40 ha
4 ha
27 ha
125 ha
232 ha
(Add. 135 ha for Product
Harbor Service Area)
 DUNG QUAT REFINERY

EPC Package 1 (Refinery Inside Battery Limit)

 Includes: Process Units, Utility and Offsite facilities
 Main Process Units:
 Crude Distillation Unit (CDU)
 Kerosene Treating Unit (KTU)
 Naphtha Hydrotreating Unit (NHT)
 Continuous Catalytic Reforming Unit (CCR)
 Residue Fluid Catalytic Cracking Unit (RFCC)
 LPG Treating Unit (LTU)
 RFCC Naphtha Treating Unit (NTU)
 Propylene Recovery Unit (PRU)
 DUNG QUAT REFINERY

EPC Package 2: Crude Tankage

 Stores Crude Oil imported through SPM
 Includes six floating roof tanks with total
working capacity: 390,000 m3
 Capacity is equal to 11 day's operation at the
design CDU feed rate ( 148,000 BPSD) +
maximum parcel size (110,000 DWT).
 DUNG QUAT REFINERY

EPC package 3: Product Tankage, Truck

Loading, Jetty Topsides, Interconnecting
pipeline
 Stores and exports products
 Includes:
 27 tanks with total working capacity: 397,000 m3 to store and
dispatch products via Jetty Topsides, Truck Loading and Product
Pipeline
 Interconnecting Pipelines: totally 10 km (7km from the Refinery to
the Product Tankage and 3km from the Product Tankage to the
Product Export Berths
 Jetty: Loading arms, MOV valves, slop tanks, drains, etc., as well as
on-shore facilities including custody transfer flowmeters, safety
valves, etc.
 DUNG QUAT REFINERY

EPC Package 4: single point Mooring

(SPM)
 Import Crude Oil from Tanker
 The SPM Unit comprises of
 Single Point Mooring Buoy
 Interconnecting hoses
 PLEM
 submarine pipeline
 The SPM buoy is located approximately 3.2km off-shore in
Viet Thanh bay.
 DUNG QUAT REFINERY

EPC Package 5A: Beak water

 Keep the Loading Operations in good
condition
 The Breakwater of about 1.6km long
 DUNG QUAT REFINERY

EPC Package 5B: Product Export Berths

 Harbour for product export operations
 Includes:
 2 Ocean Tankers Berths (Berths 1 and 2) provide capability for
ocean tankers in the range of 15,000 to 30,000 dead weight
tonnage (DWT) with facility expandable to 50,000 DWT.
 4 Coastal Tankers Berths (Berths 3, 4, 5, 6) provide capability for
coastal tankers in the range of 1,000 to 5,000 dead weight
tonnage (DWT) with facility expandable to 30,000 DWT.
 DUNG QUAT REFINERY

EPC Package 7: Administration

Building
 Operation Supports
 Consists of:
 Administration Building
 Fire Station/Gas Rescue Station
 Canteen/Shop/ Laundry Building
 First Aid Station
 Maintenance Shop;
 Garage Facilities/Motor Pool Building
 DUNG QUAT REFINERY

Products Balance, tons/year

BMD BMG MMD MMG

Propylene 108,333 157,000 111,000 147,666
LPG 286,000 343,667 276,333 307,000
Gasoline A92 (unlead) 1,407,667 1,952,333 1,534,333 2,081,667
Gasoline A83 (unlead) 534,667 718,000 407,667 515,667
Kerosene/Jet A1 282,333 219,667 219,667 219,667
Auto Diesel 2,084,333 2,115,667 2,225,333 2,321,000
Industrial Diesel 1,327,000 430,000 252,000 30,000
FO 115,667 177,000 1,131,667 466,000
Product Total 6,146,000 6,113,000 6,158,000 6,088,667
Lost and consumed 354,000 386,667 342,000 441,333
Total 6,500,000 6,500,000 6,500,000 6,500,000
 DUNG QUAT REFINERY

PROCESS UNITS
 DUNG QUAT REFINERY

LPG + FG RFCC LPG LTU LPG PRU Propylene

Gas Plant Mix C4
Note C3
Stabiliser

Note LN LPG LPG

Splitter
Treated HN Reformate
HN NHT CCR Mogas 92/83
Treated RFCC
Naphtha
SPM Kerosene
KTU Jet A1
Kerosene
CDU

LGO
Crude
Tankage HGO

RFCC Naphtha
NTU
LCO
Residue
RFCC Auto/Ind. Diesel
DCO
FO
Note : Stabiliser and Naphtha Splitter are parts of CDU
 Crude Distillation Unit (CDU)

 Capacity: 148,000 BPSD (6.5 millions TPA)

 Duty: Split Crude Oil into a number of hydrocarbon
fractions by distillation process
 System:
 Desalter
 Fired Heater
 Main Fractionators & associated Strippers
 Stabilizers and Splitters
 Crude Distillation Unit (CDU)

Product Streams:
 Light Ends: To RFCC Gas Plant
 Light Naphtha: To Mogas Blending
 Heavy Naphtha: To NHT
 Kerosene: To KTU/Kerosene Tankage
 Light Gas Oil: To Diesel Blending
 Heavy Gas Oil: To Diesel/Fuel Oil Blending
 Residue: To RFCC
 Naphtha Hydrotreating Unit
(NHT)
 Capacity: 21,000 BPSD
 Licensed by: UOP
 Duty: Remove sulfur, chlorite, nitrogen,
oxygen, metallic compounds in heavy
naphtha stream taken from CDU process to
protect CCR catalyst by Hydrotreating
 Naphtha Hydrotreating Unit
(NHT)
 A single fixed bed catalyst reactor
 Catalyst: Co + Mo + Al2O3
 Catalyst regeneration cycle life: >2 years
 Treated naphtha: To CCR
 Off-gas: To FG Amine Absorber
at RFCC Gas Plant
 Continuous Catalytic Reformer
(CCR)
 Capacity: 21,000 BPSD
 Licensed by: UOP
 Duty: Reform heavy naphtha straight-run from
NHT to High Octane Mogas Blending
components (Reformat)
 Catalyst: Pt/Al2O3
 Continuous Catalytic Reformer
(CCR)
 Systems:
 4 Reactors (Platformer)
 Continuous Catalyst Regenerator (Cycle Max)
 Combined Exchangers
 Reformat: To Mogas Blending
 Un-stabilized LPG: Blended with Refinery
LPG stream and routed to LPG storage
 Kerosene Treating Unit
(KTU)
 Capacity: 10,000 BPSD
 Licensed by: MERICHEM
 Duty: Treat kerosene stream taken from CDU to
meet Jet A1 specifications
 Technology: FIBER-FILM Contactor
 Kerosene Treating Unit
(KTU)
 System:
 NAPFINING: Naphthenic acid extraction
 MERICAT II: Mercaptan oxidation
 AQUAFINING: Water washing
 Remove Na+
 Salt Dryer: Remove trace of free water and dry
kerosene below saturation
 Clay Filter: Remove remaining solids, moistures, soaps,
emulsions and surfactant
 Kerosene Treating Unit
(KTU)
 Treating reagents: NaOH 200 and 50 Be,
activated carbon, salt, Attapulgus clay
 Catalyst: Cobalt Phthalocyanine (ARI-
100 EXL, ARI-120L), MEA 50%
 Treated kerosene: To Jet A1 Storage
 Spent caustic: To CNU
 Alkaline water: To ETP
 Residue Fluid Catalytic Cracker
(RFCC)

 Capacity: 69,700 BPSD

 Licensed by: IFP
 Duty: Converts heavy compounds of
CDU residue into value products (lighter
compounds) by catalytic cracking
process
 Catalyst: Zeolite
 Residue Fluid Catalytic Cracker
(RFCC)

 Operation mode:
 Max Gasoline
 Max Distillate
 System:
 Reactor and 2-stage catalyst regenerator
 Main Fractionator
 Gas Recovery Section (Gas Plant)
 RFCC Gas Plant

 Process the following streams:

 CDU Stabilizer Off-gas
 CDU LPG rich stream
 NHT Off-gas
 Wet gas from RFCC Fractionator
 Duty:
 Recovers C3/C4
 Removes H2S, CO2 from LPG and fuel gas by DEA
absorbers
 Residue Fluid Catalytic Cracker
(RFCC)
 Product streams:
 Unsaturated off-gas: To Refinery Fuel gas
 Mix C3/C4: To LTU
 Naphtha: To NTU
 Light Cycle Oil (LCO): To Diesel Blending
 Decant Oil (DCO): To Fuel Oil Blending
 Other streams:
 Sour water: To SWS
 Rich amine: To ARU
 LPG Treating Unit (LTU)

 Capacity: 21,000 BPSD

 Licensed by: MERICHEM
 Duty: Remove Mercaptan, COS, H2S from
LPG stream of RFCC Gas Plant
 Technology: FIBER-FILM Contactor
 2-stage THIOLEX extraction system
 LPG Treating Unit (LTU)

 Treating reagents: NaOH 200 Be

 Catalyst: MEA 50%wt
 Treated LPG: To PRU/Storage
 Spent caustic: To CNU
 RFCC Naphtha Treating Unit
(NTU)
 Capacity: 45,000 BPSD
 Licensed by: MERICHEM
 Duty: Remove H2S, Mercaptan and other acidic
compounds in Naphtha stream of RFCC Unit
 Technology: FIBER-FILM Contactor
 1-stage MERICAT caustic treating system
 RFCC Naphtha Treating Unit
(NTU)
 Catalyst: Cobalt Phthalocyanine
 Treating reagents: NaOH 200 Be
 Treated naphtha: To Mogas Blending
 Spent caustic: To CNU
 Sour Water Stripper (SWS)

 Duty: Strip NH3 and H2S dissolved in sour

water collected from CDU, NHT and RFCC
Unit
 Surge drum + a single stripping column
 Sour gases: To SRU
 Stripped water: To ETP/CDU Desalter
 Amine Regeneration Unit
(ARU)
 Duty: Skim hydrocarbon and strip sour gas
(H2S) from rich amine stream of RFCC Unit
 Feed surge drum + a regeneration column
 Skimmed oil: To Light slops
 Sour gases: To SRU
 Stripped lean amine: To H2S absorber on
RFCC
 Spent Caustic Neutralization Unit
(CNU)
 Capacity: 1.5 m3/h mixed caustic stream
 Licensed by: MERICHEM
 Duty: Neutralize and remove phenolic and
naphthenic oils from various spent caustic streams
(KTU, LTU, NTU caustic; ETP Water; NHT alkaline
water)
 Technology: FIBER-FILM Contactor
 Spent Caustic Neutralisation Unit
(CNU)
 Caustic Deep Neutralization:
 Neutralize by sulphuric acid 96% and remove acid gases,
naphthenic, phenolic acids from the brine
 Neutralization and Phenol Extraction:
 Neutralize to pH=7 and extract phenol from acidic brine by
solvent (Kerosene)
 Treating reagents: H2SO4 96%, NaOH 50Be,
 Neutralized brine: To ETP
 Off-gas: To SRU
 Acid Oils/Kerosene: To Fuel Oil Blending
 Propylene Recovery Unit
(PRU)
 Capacity: 21.000 BPSD
 Duty: Separate and purify propylene
from the mixed C3/C4 stream of LTU to
polymer grade (99.6 wt%) specification
 Product stream:
 Propylene: To Propylene Tankage/PP
Plant
 C3/C4: To LPG Blending
 Propylene Recovery Unit
(PRU)
 System:
 C3/C4 Splitter: Remove C4’s from LPG
 Propane/propylene splitting facility:
 De-ethaniser: Release product lighter than propylene
 Propane/Propylene splitting column
 Propylene purification:
 Carbonyl sulfide removal
 Arsenic, phosphorous and antimony removal
 Sulfur Recovery Unit (SRU)

 Licensed unit
 Capacity:
 Sweet case: 3 tons/day
 Sour case: 36 tons/day
 Duty: Recover Sulfur in Refinery off-gas to
meet environment protection requirements
(SO2 concentration)
 Product: Sulfur Powder
 Polypropylene (PP) Plant

 Licensed unit
 Capacity: 150,000 tons PP/annum
 Duty: Produce PP from Propylene product of
the Refinery by polymerization process
 Product: Unpainted heat and light stabilized
Polypropylene pellets
 Detailed Feasibility Study (DFS) completion
 Water System

 Duty: Produce and distribute various grade of

water to users within Refinery and Product Tank
Farm (PTF) as follows:
 Service water to users at Refinery and PTF
 Make-up supply to freshwater cooling system
 Make-up supply to Refinery potable water system
 Make-up supply to dematerialized water system
 Make-up supply to Refinery fire water system
 Steam and Condensate

Provides:
 HP, MP, LP Steam to and subsequent distribution
within Refinery
 Collection, storage and treatment of Refinery steam
condensate for reuse as HP & MP boiler feedwater
(BFW) in Process Steam Generators
 Collection, storage and treatment of Power Generation
Plant steam condensate for reuse as HHP BFW in
Power Generation Plant
 Steam and Condensate

 Comprise of:
 Steam producing equipment
 Distribution Pipework
 HP to MP and MP to LP letdown stations
 Condensate collection and treatment facilities
 Dearators
 Associated chemical dosing package
 Cooling Water

 Duty: Supply cooling water to all users in

process and utility units (except the condensers
in Power Station)
 A closed fresh water system, cooled by once-
through sea water
 Cooling Water

 Comprise of:
 Cooling Water Circulation Pumps
 Plate Heat Exchanger
 Expansion Tank
 Expansion Tank Oil Skimmer
 Chemical Dosing Package
 Sea Water Intake

Provides:
 Seawater to Power Station for once-through cooling in
Vacuum Condensers
 Seawater to seawater/freshwater exchanger for cooling
the closed loop cooling water system
 Sea Water Intake

 Consists of:
 Seawater Intake box (located offshore)
 Seawater Intake Basin Inlet Line
 Seawater Intake Basin (located onshore)
 Seawater circulation pumps
 Hypochlorite dosing
 Discharge facilities
 Hypochlorite for seawater chlorination is generated
on site by electrolysis of seawater
 Plant and Instrument Air

 Duty: Provides Plant and Instrument Air

for demand of Refinery
 System:
 3 Air Compressors
 Wet Air Receivers: Remove condensed
water
 2 refrigeration-type dryers
 2 Instrument Air Receivers
 Nitrogen System

 Provides:
 Gaseous nitrogen to process users in normal operation
 Liquid nitrogen for storage and subsequent
vaporisation to meet peak loads and startup demands
 Dedicated liquid nitrogen for storage and subsequent
vaporisation for use in CCR Regeneration Section
 Independent high pressure system for leak testing of
process equipment/pipelines
 Nitrogen System

 Comprises of:
 Nitrogen Generation Package
 Liquid Nitrogen Storage
 Vaporisation Package
 Method of generation:
 Cryogenic Air Separation
 Nitrogen purity: 96% volume
 Fuel Gas

 Duty: Provide Fuel Gas to process unit fired

heaters and HHP Boilers at Power Station
 Major users of fuel gas:
 CDU charge heater
 RFCC process heaters
 NHT charge heater
 CCR process heaters
 Power Station Boilers
 Fuel Gas

 Other users:
 Refinery Flare System
 Product Tankage (Flare system, steam regenerators)
 Comprises of:
 Fuel Gas Mix Drums
 Vaporiser Package
 Vaporise LPG/Propylene for use at Startup,disposal of
LPG/Propylene off-spec., low FG pressure or emergency event
 Fuel Gas collection/distribution pipework
 Refinery Fuel Oil

 Duty: Supply Fuel Oil to all consumers

within Refinery
 Comprises of:
 2 Refinery Fuel Oil Storage Tanks
 Fuel Oil Pumps
 Fuel Oil Heater
 Supply and return pipework
 Refinery Fuel Oil

 Source of Refinery Fuel Oil:

 In normal operation: Decant Oil (DCO) from
RFCC
 For Refinery Startup: Imported via SPM
 Outages of RFCC: Heavy Gas Oil (HGO) and/or
CDU residue from CDU
 Caustic Supply

 Duty: Make up and provide caustic (NaOH)

solution to all consumers within Refinery
 Comprises of:
 Dissolving Sump: dilutes solid caustic
pellets
 Storage Tanks

 Pumping Facilities
 Caustic Supply

 Concentrations of NaOH solution are made up,

stored and distributed on site:
 500 Be (49.5 wt%)
 Made up by dissolving solid caustic in demin. water
 200 Be (14.4 wt%)
 Made up by diluting 500 Be caustic in demin. water
 50 Be (3.4 wt%)
 Made up by diluting 500 Be caustic in demin. water
 Power Generation &
Distribution
 Provide:
 Electrical Power to Refinery and all associated
facilities
 Steam and condensate to Refinery
 4  15 MW Steam Turbine Turbo-
Generators
 Ability to import/export power from/to
EVN grid
 Refinery Tankage

 Duty: Stores and handles the intermediates and

finished products of the Refinery:
 1 Off-spec Propylene Sphere  1 Light Naphtha Tank
 1 RFCC Feed Tank  2 Mix C4’s Spheres
 2 NHT Feed Tanks  1 HGO Tank
 1 Off-spec RFCC Naphtha Tank  2 LCO Tanks
 1 Reformate Tank
 Product Blending

 Consists of a number of separate systems

and associated components for blending the
final products of Refinery:
 92 RON Mogas
 83 RON Mogas
 Auto Diesel
 Industrial Diesel
 Fuel Oil
 Flushing Oil

 Unit number: 055

 Provides:
 Flushing Oil for process units and Offsite pipework
 Contains catalyst fines
 Pour point is higher than minimum daily ambient temp.
 Flushing Oil for SPM loop
 Consists of:
 Facilities for flushing process units
 Separated facilities for flushing SPM loop
 Flushing Oil

 Source of Flushing Oil:

 For Process units and Offsite pipework:
 LCO from LCO Intermediate Storage Tank
 For SPM loop:
 LGO from SPM Flushing Oil Tank as a slip stream from CDU
rundown
 SPM loop is flushed immediately before and after
each transfer operation
 Slops

 Duty: Collects, Stores light and heavy slops

from Refinery process units and Offsite
areas for subsequent reprocessing in CDU
or RFCC
 Oily Water: To Refinery ETP for further
treatment
 Alternative disposal route for heavy slops:
Refinery Fuel Oil System
 Flare System

 Consists of:
 Refinery Flare System
 Product Tank Farm Flare System
 Each Flare System comprises of:
 Main Flare Stack
 Sour Gas Flare Riser (handle all discharges
containing H2S at levels higher than 10%
vol.)
 Effluent Treatment Plant
(ETP)
 Duty: Treat effluent streams to meet
environment protection requirements
 Consists of:
 Refinery ETP
 Primary, secondary and tertiary treatment
facilities to remove oils, solids and organics
 Product Tankage ETP
 Primary treatment for removing oil and solids
 Effluent Treatment Plant
(ETP)
 “Products” stream:
 Treated effluent: discharged to the sea
 Recovered slop oil: pumped to Refinery Heavy
Slops tank for re-processing
 Digested biological sludge: Buried in Dedicated
Area
 De-watered, de-oiled refinery sludge: To other
facilities for special treatment
 Fire Water System

 Duty: Supply water for firefighting

 Comprises of 2 separate firewater systems:
 Refinery and nearby facilities
 Product Tank Farm, Truck Loading and Jetty
Topsides
 Firewater was taken from the sea at Jetty