Preliminary Feasibility Report (PFR) for setting up of Petro-Resid Fludizied Catalytic Cracking Unit (PRFCC) at Mumbai Refinery.

Transcription

1 Preliminary Feasibility Report (PFR) for setting up of Petro-Resid Fludizied Catalytic Cracker at Mumbai Refinery. Annexure B Preliminary Feasibility Report (PFR) for setting up of Petro-Resid Fludizied Catalytic Cracking Unit (PRFCC) at Mumbai Refinery. APRIL 2018 Bharat Petroleum Corporation Limited. 1

2 Table of Contents 1. Introduction 2. Objective 3. Scope of Facilities 4. Advantages of the project and technology high lights. 5. Potential Technology Licensors 6. Unit Design 7. Block Flow Diagram 8. Material balance 9. Location of Unit 10. Utility Systems 11. OSBL 12. Finincial Analysis 13. Project Implemenation Schedule 14. Health, Safety & Environment Bharat Petroleum Corporation Limited, Mumbai Refinery Page 2 of 17

3 1 INTRODUCTION Mumbai Refinery (MR) of Bharat Petroleum Corporation Limited (BPCL), has an installed capacity of 12.0 Million Metric Tonnes per Annum (MMTPA) located at Mahul, Mumbai, Maharashtra, India. The refinery was commissioned in 1955 with a crude oil processing capacity of 2.2 MMTPA in a plot area of 450 acres. The refining capacity has been augmented to 12.0 MMTPA through progressive revamps, addition of various process units and incorporating advanced refining technologies. Refinery processes various types of crudes which include Bombay High, East African, Petronas, Kuwait, Arab mix, Arab medium, Basrah, Arab extra light, Murban, Umm Shaif etc. The main products are LPG, Naphtha, MS, Benzene, Toluene, Hexane, SBP, MTO, Kerosene, Jet Fuel, Diesel, Light Diesel Oil, Lubes, Fuel Oil, LSHS and Bitumen. While BPCL has already addressed the quality upgrade for gasoline and diesel fuel products to meet BS-VI standards, BPCL wants to remain competitive, improve refinery profitability further by improving the efficiency of older units and reducing fuel & loss. Feasibility study has been carried out by M/s Flour evaluating various options for profitability improvement. One of the option was to replace existing CCU & FCCU with new state of art, highly energy efficient and petro chemical based Petro Resid Fludized Catalytic Cracker (PR FCC). Existing CCU is of Shell design installed in 1955 and FCCU of UOP design installed in Installation of PRFCC would also enable MR to increase its high Sulphur crude processing capability and target a production of about 450 KTPA of Propylene. This new unit will be installed at Mumbai Refinery (MR) of Bharat Petroleum Corporation Ltd. (BPCL) MR currently has space constraints to accommodate Petro Chemical facilities and hence is in the process of acquiring additional ~400 acres of land at Rasayani, which is located at a distance of about 50 kms from MR. Utilizing this land and leveraging Bharat Petroleum Corporation Limited, Mumbai Refinery Page 3 of 17

4 the Propylene from PRFCC, it is proposed to set up about 450 KTPA of Polypropylene unit with associated facilities at Rasayani. Based on the feasibility report from M/s Flour, M/s Bechtel Engineering And Construction India Pvt Ltd (BECI) has been engaged by BPCL to develop a Detailed Project Feasibility Report (PFR) with +/-20% cost estimate for the addition of PRFCC and PP plants in the Mahul Refinery and Rasayani complex. 2 OBJECTIVE The objective of the project is installation of PRFCC to replace the older units of CCU & FCCU by latest state of the art technology, energy efficient, better yield unit. This unit also provides opportunity for setting up a downstream petrochemical units like Polypropylene based on propylene available from PRFCC). 3 SCOPE OF FACILITIES The scope of the project is to install a Petro Resid Fluidized Catalytic Cracker Unit (PRFCC) along with a Propylene Recovery Unit to provide raw material for downstream petrochemical units and processing of vacuum residues. Major process units proposed under configuration are: Unit Code Name TPD PRFCC Petro Resid Fluid Catalytic Cracker 9000 PRU (Note 1) Propylene Recovery Unit 1073 PRFCC SWS Sour Water Stripper 1300 ARU Amine Regeneration Unit 1440 SRU Sulphur Recovery Unit 165 Note 1. Capacity is amount of Polymer grade Propylene produced. Bharat Petroleum Corporation Limited, Mumbai Refinery Page 4 of 17

5 4 ADVANTAGES OF THE PROJECT AND TECHNOLOGY HIGH LIGHTS. Unit Replaces the old CCU and FCCU unit with a high efficient unit using latest technology. Tighter heat integration with production of high pressure steam from process flue gas heat recovery. A power recovery turbine of around 18 MW during normal operation from the exhaust flue gas from the PRFCC. DeNOX facility to reduce NOx emission using a combination of SCNR and SCR technology along with Low NOx burners. Produce feedstock for downstream petrochemical units to meet the increasing demand for petrochemical products. 5 POTENTIAL TECHNOLOGY LICENSORS The potential licensors for PRFCC and associated units are given below: AXENS CB&I UOP KBR While all the above are potential licensors for PRFCC, some of them may not have the technologies for associated units. However, they can liaison with licensors of associated units with them being the lead licensor. It is recommended that a single licensor design basis be developed for PRFCC and associated units with PRFCC licensor being the single point of contact. 6 UNIT DESIGN The following new process facilities are envisaged as part of the various units under PRFCC complex: Bharat Petroleum Corporation Limited, Mumbai Refinery Page 5 of 17

6 PRFCC Reactor & Regeneration PRFCC Main Fractionator & Unsaturated Gas Plant (USGP) Flue Gas Treatment Facilities Propylene Recovery Unit (PRU) Unsaturated LPG Treating Unit (LTU) RFCC Sour Water Stripping Unit (SWS) Amine Regeneration Unit (ARU) Sulphur Recovery Unit (SRU) The following new / additional Utilities and Offsite facilities are envisaged post PRFCC: New Sea Water Cooling Water System New Condensate Polishing Unit facilities with tankages Additional Instrument & Plant Air generation facilities. Additional BFW generation facilities New Flare System. 6.1 FEED TO THE UNIT The feed stock to the PRFCC complex is a blend of following intermediates from Vacuum Distillation Units and VGO Hydrocracker: Vacuum Residue (VR) 2455 TPD From CDU/VDU-3 & 4 Vacuum Gas Oil (VGO) 6426 TPD From CDU/VDU-3 & 4 Bharat Petroleum Corporation Limited, Mumbai Refinery Page 6 of 17

7 Unconverted Cycle Oil (UCO) 119 TPD From Hydrocracker Blend 9000 TPD To PRFCC Complex The crude processing capacity of the refinery is 12 MMTPA. The refinery is processing a blend of the following crudes: Crude Type Percentage Bombay High 21% Azeri 11% Saharan 11% -Arab Extra Light 29% Murban 14% Arab Mix (65-35) 14% Total 100% 6.2 PRFCC REACTOR AND REGENERATION The purpose of PRFCC unit is to convert a mix feed of Vacuum Residue / Vacuum Gas Oil (VGO) from Vacuum Distillation Unit (VDU) and Unconverted Cycle Oil (UCO) from hydrocracker into Propylene rich light gases and high-octane gasoline. The intent is to maximize Propylene production. Licensor shall configure the design to maximize propylene yields. The PRFCC Reactor & Regeneration shall typically include the following: Reactor Regenerator Bharat Petroleum Corporation Limited, Mumbai Refinery Page 7 of 17

8 Catalyst Cooler (Licensor to confirm requirement) Main Air Blower CO Boiler Power Recovery Turbine Catalyst Storage and Handling Facilities 6.3 MAIN FRACTIONATOR AND UNSATURATED GAS PLANT (USGP) The Main Fractionator and Unsaturated Gas Plant (USGP) shall typically include the following: Main Fractionator and associated systems Wet Gas Compressor Stripper and Absorber System Cracked Naphtha Debutanizer LPG and Off Gas Amine Absorber 6.4 FLUE GAS TREATMENT FACILITIES Flue Gas treatment facilities will be provided as part of PRFCC to scrub the regenerator flue gas and reduce SOx, NOx and particulate emissions. 6.5 UNSATURATED LPG TREATING UNIT The purpose of the Unsaturated LPG Treating Unit (ULTU) is to remove sulfur compounds (mercaptans, H2S and COS) from amine treated LPG received from PRFCC. The Unsaturated LPG Treating Unit ( ULTU) shall typically include the following: Bharat Petroleum Corporation Limited, Mumbai Refinery Page 8 of 17

9 Caustic wash section Water wash section Caustic regeneration section Spent Caustic Degassing 6.6 PROPYLENE RECOVERY UNIT The Propylene Recovery unit separates mix LPG s into polymer grade Propylene, Propane and Mixed C4 s. The Propylene Recovery Unit (PRU) will typically include the following: C3/C4 Splitter Dryer and Contaminant Removal facilities Deethaniser C3 Splitter with Heat Pump Compressor Bharat Petroleum Corporation Limited, Mumbai Refinery Page 9 of 17

10 7 BLOCK FLOW DIAGRAM Bharat Petroleum Corporation Limited, Mumbai Refinery Page 10 of 17

11 8 MATERIAL BALANCE (MT/D) OFF GAS 655 (7.28%) HCU UCO 119 PR FCC PROPYLENE 1106 (12.28%) PROPANE 137 (1.52%) VGO 6426 (9000 MT/D) LPG 1371 (15.23 %) GASOLINE 2718 (30.2%) TO GTU VR 2455 LCO 1459 (16.21%) TO FO/HSD SLURRY OIL 746 (8.29%) TO FO COKE 808 (8.98 %) 9 LOCATION OF UNIT Location of PR FCC will be well within Refinery permsis. Old units CDU 1 & 2 which have been decommissioned after commissioning of CDU 4 are in the process of dismanteling. As per preliminary assessment, PRFCC can be accommodated within this plot. Exact plot space required and equipment locations will be carried out in detail during DFR. Location of PRFCC plot in MR is shown as below. Bharat Petroleum Corporation Limited, Mumbai Refinery Page 11 of 17

12 10 UTILITY SYSTEMS Existing utility facilities shall be utilized for PRFCC and capacities shall be augmented wherever required. Since PRFCC is replacement for CCU & FCCU, it is expected that most of the utiiltes can be met from exisiting systems. The additional utilites envisaged for PRFCC are as follows: a. Sea Cooling Water Circulation Unit: A dedicated Sea Cooling Water system for PRFCC and associated units will be provided. The new sea cooling water system will be a closed loop circulating system with sea water makeup from the existing sea water intake facilities. The blowdown from the new sea water cooling system will be sent to the existing sea water outfall. The sea cooling water requirements for PRFCC and associated units is estimated to be around 23,000 m3/h. The design circulation capacity is considered to be around 26,000 m3/h. During DFR, adequacy of existing sea cooling water will be checked in lieu of dismanteling of CCU and FCCU. Bharat Petroleum Corporation Limited, Mumbai Refinery Page 12 of 17

13 b. Raw Water/ DM Water & BFW: Requirement of Raw Water, DM water and Boiler Feed water (BFW) is expected to be met from existing facilities since PRFCC is replacement of CCU & FCCU. Exact additional quantity will be worked out during DFR. Raw water is know as DM water after treatement in DM plants. This DM water after treatement in Dearators know as Boiler Feed Water (BFW) is used in three number of boilers, three HRSGs of Gas Turbines GT 1,2 & 3 and in waste heat steam generators in process plants. The DM water & BFW can be met from existing facilities however detailed adequacy check will be done in DFR c. Instrument Air / Plant Air (IA/PA) Unit: Since unit is replacement for CCU & FCCU, it is expected that IA & PA can be met from existing system. The installed Instrument air drying capacity in the refinery is 25,200 Nm3/h of which one dryer capacity of 4500 Nm3/h is considered under maintenance.the current normal and peak Instrument Air consumption in the refinery are 15,409 Nm3/h and 22,575 Nm3/h respectively. For the new PRFCC units, 1897 Nm3/h of Instrument Air (for Instruments) is required. During normal demands, there is adequate capacity in the existing Instrument air dryers for catering to additional demands from PRFCC and associated units. d. Nitrogen System: Nitrogen consumption is expected to be intermittent for PRFCC and associated units usually during start-up and shutdown. Also nitrogen consumption for CCU & FCCU will be saved as PRFCC is replacement for these units. Estimated peak Nitrogen requirement is 7407 Nm3/h. The intermittent requirements are met from existing Liquid Nitrogen storage facilities for existing refinery units which will also apply for the new units. Existing facilities have a liquid Nitrogen storage volume of 660 m3. Approximate liquid Nitrogen volume estimated for PRFCC and associated units is 70 m3 which can be sourced from the existing Liquid Nitrogen facilities. No Nitrogen facility shall be required as nitrogen required for startup and shut down shall be made available by trucks supplying liquid Nitrogen which can be vaporized in the existing set up. Bharat Petroleum Corporation Limited, Mumbai Refinery Page 13 of 17

14 e. Fuel Gas System: PRFCC is net exporter of fuel gas. During normal operation, unit can generate around 17 MT/D of FG and consumption will be around 10 MT/D. Hence 7 MT/D can be exported to Refinery FG system. During start up of unit, RLNG is available as make up to FG system. f. Steam System: Steam generation from refinery process units post addition of PRFCC and associated units is estimated to be 641 TPH. This includes a net steam export of 127 TPH from PRFCC Unit.Steam Consumption in refinery process units post addition of PRFCC and associated units is estimated to be 941 TPH.The net Steam demand of 300 TPH will be met by the existing HEBs and HRSGs. No additional boilers will be required. g. Power: The present refinery power consumption is around 115 MW. The maximum power generation from the Gas Turbines in the existing refinery is 76 MW. The balance power is sourced from the grid. Power requirement in refinery post addition of PRFCC and associated units is estimated to be around 176 MW. Hence an additional power of 61 MW will need to be sourced from the grid. A Power Recovery Turbine(PRT) is envisaged in PRFCC to extract power from Flue gases. During normal operation, Flue Gas Power Recovery Turbine in PRFCC is estimated to generate around 18 MW power, which will reduce the net power demand to 43 MW. 11 OSBL FACILITIES: Hydrocarbon Storage & Movement: The storage requirements can be mostly met from existing tanks as per initial preliminary study. Existing fuel oil tanks 701 & 702 can be used as PRFCC feed tanks, existing propylene bullets V7 & V8 can be used for propylene ex PRFCC also, existing Naphtha tanks 527 & 528 can be used for naphtha storge ex PRFCC, existing tanks 705 & 715 can be used for LCO and 601 & 602 for clarified slurry oil. Required pipelines need to be installed to send the products to existing storage and distribution facility. During DFR, tankage requirement can be worked out in detail. New bullets may be required for Propylene and LPG as the yield is getting increased. Bharat Petroleum Corporation Limited, Mumbai Refinery Page 14 of 17

15 a. Flare: The existing refinery flare has three independent demountable type flare stacks and KOD s located adjacent to each other. The stacks are designed to normally operate in 2 operating and 1 standby mode of taking care of all possible hydrocarbon loads from the refinery complex. Existing flare system is fully utilized hence new flare is expected to be installed to cater PRFCC to safely dispose of the relieving materials during any upset scenarios and to allow safe venting of the equipment/process systems. However during DFR, adequacy check up of exising flare system will be carried out with different mitigitation measures to avoid new flare system. Also flare load due to CCU & FCCU will be nil post commissioning of PRFCCU.. b. Effluent Processing: The effluent generation ex PRFCC can be processed in existing WWTP. The WWTP has surplus capacity of 50 M3/hr. WWTP needs to be evaluated once exact quality and quantity of effluent ex PRFCC is known. No new effluent storage tank is envisaged as per preliminary study. c. Sour Water Processig: The sour water generated ex Fractionator overhead and unsaturated gas plant has to be treated for H2S and NH3. The treated water can be sent to desalter of CDUs. One new two stage SWS of approximate capacity 1300 TPD is envisaged. Sour water generation ex CCU & FCCU will be nil as these plants will be decommissioned after PRFCC commissioning. d. Fire Water Network: Fire water requirement needs to be worked out and fire water network analysis needs to be carried out. It is expected that existing fire water system will be adequate since fire water requirement for CCU & FCCU will be nil. e. Civil Jobs: Requirements for buildings like substations, control rooms, process operator cabins, warehouse, fire & safety building and mechanical workshop needs to be studied for adequacy. f. Analysis: Requirement of enhancement of existing laboratory needs to be further explored. Bharat Petroleum Corporation Limited, Mumbai Refinery Page 15 of 17

16 12 FININCIAL ANALYSIS As per the preliminary estimates, the total project cost including all associated facilities is expected to be in the range of Rs 7500 to 8500 Crores. Estimate with +/- 20% will be known during DFR. Considering the current cost of crude & products and approximate yield from PRFCC, the approximate return on investment (ROI) is expected to be 15%. 13 PROJECT IMPLEMENTATION SCHEDULE An EPCM mode of construction is envisaged for the project.. Total project implementation schedule after getting Environmental clearance, other statutory approvals and final investment approval is expected to be around 36 Months. 14 HEALTH SAFETY & ENVIRONMENT The unit shall be designed in accordance with local regulations, international industry standards and codes.during DFR, priority will be given to maximize heat recovery by means of heat integration with process streams which will reduce cooling water and fan power consumption in rundown coolers. It will be ensured that the addition of PRFCC and associated facilities shall not exceed the SOx Emission rates beyond the current stipulated value of 10.4 TPD. A flue gas scrubber will be provided to reduce the SOx and particulate emissions from flue gases to local emissions stipulations. Combination of SCNR and SCR technologies along with low NOx burners will be explored for use in CO incinerators to reduce NOx emissions. Water used for scrubbing will be sourced from stripped water coming out of existingnonphenolic sour water stripper units thereby avoiding additional raw water consumption. The purge water after treatment to remove solids will be sent to ETP. Stripped water from new Sour water stripper will be routed to existing CDU desalters due to presence of phenols and cyanides. This will also not be used in flue gas scrubbers due to the contaminants mentioned. Bharat Petroleum Corporation Limited, Mumbai Refinery Page 16 of 17

17 Sea water blowdown from sea water cooling towers will be sent to existing sea water outfall. Steam Condensate blowdowns will be cooled and sent to existing ETP. Solid wastes primarily comprise of catalysts collected in Third and Fourth Stage Separators and Flue Gas scrubber. Additionally, spent catalysts are periodically withdrawn. These solid wastes are usually used for landfilling or in cement industries. Bharat Petroleum Corporation Limited, Mumbai Refinery Page 17 of 17