United States
Environmental Protection
Agency
Office of Air Quality
Planning and Standards
Research Triangle Park NC 27711
EPA-450/3-78-025
June 1978
Air
&EPA
Development of
Petroleum Refinery
Plot Plans
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EPA-450/3-78-025
Development of Petroleum
Refinery Plot Plans
by
D. Powell, P. Peterson, K. Luedtke, and L Levanas
Pacific Environmental Services, Inc.
1930 14th Street
Santa Monica, California 90404
Contract No. 68-02-2606
EPA Project Officer: K.C. Hustvedt
Prepared for
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Air and Waste Management
Office of Air Quality Planning and Standards
Research Triangle Park, North Carolina 27711
June 1978
-------
This report is issued by the Environmental Protection Agency to report
technical data of interest to a limited number of readers. Copies are
available free of charge to Federal employees, current contractors and
grantees, and nonprofit organizations - in limited quantities - from the
Library Services Office (MD-35), U.S. Environmental Protection Agency,
Research Triangle Park, North Carolina 27711; or, for a fee, from the
National Technical Information Service, 5285 Port Royal Road, Springfield,
Virginia 22161.
This report was furnished to the Environmental Protection Agency by
Pacific Environmental Services, Inc. , 1930 14th Street, Santa Monica,
California 90404 in fulfillment of Contract No. 68-02-2606. The contents of this
report are reproduced herein as received from Pacific Environmental Services, Inc.
The opinions, findings, and conclusions expressed are those of the author and
not necessarily those of the Environmental Protection Agency. Mention of company
or product names is not to be considered as an endorsement by the Environmental
Protection Agency.
Publication No. EPA-450/3-78-025
11
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TABLE OF CONTENTS
Page
OBJECTIVES -I
DESCRIPTION OF REFINERY CASES 1
APPROACH FOR DEVELOPING THE REFINERY CASES AND THE LISTING OF
POTENTIAL EMISSION POINTS 3
EMISSION POINT ITEMIZATIONS 5
Pumps and Compressors 5
Valves and Fittings 6
Combustion Devices 7
Structures 7
Tanks 7
STANDARD PROCESS UNITS 8
SMALL CAPACITY EXISTING REFINERY 66
INTERMEDIATE CAPACITY EXISTING REFINERY 84
LARGE CAPACITY EXISTING REFINERY 126
NEW REFINERY 164
APPENDIX A - VAPOR PRESSURES OF VARIOUS STOCKS 178
APPENDIX B - ENGLISH -S.I. UNIT CONVERSIONS 180
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OBJECTIVES
The objectives of this work assignment are to place repre-
sentative process units, tankages, auxiliary equipment, and struc-
tures frequently found in refineries into modules and then to
locate these modules on refinery plot plans for the purpose of
generating hydrocarbon ambient dispersion models. In specific,
to establish a basis for calculating hydrocarbon emissions —
including benzene, information is provided for four hypothetical
refineries. The information required for the calculation con-
sists of:
1. A plot plan of each refinery mapping the location and
area of appropriate modules
2. An estimate of the number and size of potential emission
points in each module including pumps and compressors,
valves and fittings, heaters or boilers, tanks and reser-
voirs, wastewater treatment facilities, cooling towers
and flares
3. A list of tall and wide structures in each module which
could affect airflow and thereby hydrocarbon dispersion
DESCRIPTION OF REFINERY CASES
Four refinery cases are detailed in the report. Each case
corresponds to a refinery category named in the work assignment.
The four cases together span the capacities and ages of presently
operating refineries. Each refinery case includes an aromatics
recovery process. The four cases developed are:
1. A small capacity existing refinery with a crude unit
charge rate of 8,000 m3/day
2. An intermediate capacity existing refinery with a crude
unit charge rate of 32,000 m3/day
3. A large capacity existing refinery with a crude unit
charge rate of 56,000 m3/day
4. A relatively new refinery with a crude unit charge rate
of 40,000 m^/day
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SUMMARY
The following table summarizes the number of points from which
hydrocarbons may be emitted for each refinery case
Pumps - active and
spare in hydrocarbon
service
Small
Existing
Ref i nery
186
Compressors - active and
spare in hydrocarbon
service 17
Pumps and compressors
active and spare in
aqueous service
Control valves
Process valves
Fittings
Relief valves
Samples fittings
Combustion devices
Tanks
Flares
30
228
16,645
54,706
237
323
29
78
2
Intermediate
Existing
Refinery
411
37
43
364
28,240
94,867
429
634
49
416
4
Large
Existing
Refinery
614
61
53
809
48,670
162,996
739
997
91
236
3
i
New
Refinery
315
24
25
352
24,805
83,337
371
495
32
70
2
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APPROACH FOR DEVELOPING THE REFINERY CASES AND THE LISTINGS OF POTENTIAL
EMISSION POINTS
A refinery is conceptualized as an aggregation of modules that
serve as the basis of a dispersion model calculation. Modules are
three-dimensional volumes whose sides are defined by the perimeter
of the module within the refinery and by an average module height.
Three general types of modules appear in the four refineries: pro-
cess modules, tankage modules, and modules with miscellaneous sup-
portive functions.
A process module is the area on which a refinery unit trans-
forms a feedstream to intermediate or final products. For example,
in the catalytic reformer module, the feedstream, naphtha, is trans-
formed into a liquid product, reformate; and gaseous by-products,
butanes and lighter gases. The average module height for all pro-
cess modules is 5 meters and roughly corresponds to the height of
a pipe rack.
Tankage modules consist of land in the refinery on which
storage vessels are placed to contain crude, intermediate products,
or final products. The average module height for these modules is
ground level.
Refining functions taking place in the remaining areas of the
refinery may include bulk loading and unloading, flares, wastewater
treatment facilities, boilers and incinerators, and vacant areas
within the refinery. The average module height of these modules is
ground level.
The hydrocarbon dispersion model predicts hydrocarbon concen-
trations outside the refinery boundary. Two distinct types of in-
formation regarding refinery modules are necessary to make this cal-
culation. The first relates to the area allocated to the module
and to the placement of the module inside the refinery boundaries.
The areas of the modules and the siting of the modules within the
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refinery were obtained from plot plans of operating refineries. To
facilitate modeling, the shapes of the modules and the refineries
were stylized as rectangular.
The second consists of itemizing the possible hydrocarbon
emission points and the significantly large structures within the
modules. For example, emission points in the catalytic reformer module
include the pumps and compressors, valves and fittings, and process
heaters associated with the reformer reactor section and the frac-
tionating section. Tankage modules require a table to provide the
information needed to calculate tank emissions.
To minimize repetition of equipment listings, the report is
organized into five sections. Preceeding the refinery cases,
standard process units were developed for frequently found processes.
When these units appear in any of the refinery modules, the standard
unit is referenced. However, there may be differences between the
throughput listed for the standard unit and that listed for the
^efinery module. The normal operating range of the standard units
may vary from 50 percent to 150 percent of the rated throughput with-
out changing the emission point itemization. If there are signifi-
cant differences between the standard unit and the refinery module,
the correct values will be listed in the refinery module. These
differences are mainly process heater design heat inputs.
Four refinery cases are developed after the standard unit
descriptions in the report. For each refinery, a plot plan; a module
key; and a page listing the crude charge, the product slate, and
the appropriate number of wharf modules provide summary data. Fol-
lowing the summary data are the refinery module descriptions. In-
cluded here are the functional title of the module; the module area
in hectares; a description of the inputs and outputs of the module;
an emission point itemization; and, a large structure listing. A
comparison of the refinery outputs with the crude charges indicates
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a net volumetric increase in each refinery case. This increase is
due to input streams into the refinery which are not crude oil and
to the addition of hydrogen into process streams.
EMISSION POINT ITEMIZATIONS
Equipment itemizations for each standard unit or refinery module
were developed from engineering experience, from discussions with
refiners, from available refinery inspection reports, and from lit-
erature sources such as the refining handbook edition of Hydrocarbon
Processing. The data included in the report for standard units, pro-
cess modules, and some miscellaneous modules are: the number of
active and spare pumps and compressors and a classification of the
Reid vapor pressure of the fluid being pumped; an estimate of the
number of control, process, and relief valves; an estimate of the
number of fittings; an estimate of the number of sampling connec-
tions; the number of process heaters and boilers and an estimate of
the design heat input; and a listing of structures significantly
large enough to affect airflow through the module. For tankage, the
data included are: the material stored in the tank; type of seal on
the tank; tank height and diameter; and the annual throughput of the
tank. Each type of emission point data is discussed in detail below.
Pumps and Compressors
The number of active and spare pumps and compressors was deter-
mined either by counting pumps on actual process flow diagrams or
by estimating the number from the process flow diagrams provided in
the Hydrocarbon Processing refining handbook. The number of spare
pumps was estimated from engineering judgement when the actual
number was not known. In the report, the Reid vapor pressure of
the fluid pumped was listed in one of the following ranges:
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RVP
RVP RANGE
CATEGORY (kPa)
A Greater than 180
B 180 - 34.5
C 34.5 - 3.4
D Less 3.4
Additionally, a pump is designated, C, if the pump is centrifugal
type; R, is the pump is a reciprocating type. The type of pump seal
is indicated by, M, for mechanical seals or by, P, for packed seals.
Valves and Fittings
The number of control valves either was counted on actual pro-
cess flow diagrams or was estimated by comparing similar vessel
types in processes where the actual number of control valves was
known.
The number of process valves was prorated on the number of active
and spare hydrocarbon pumps. Based on recent data provided by the
EPA task manager, the number of process valves equaled 70 times the
number of active and spare pumps. Inspections in Los Angeles area
refineries have shown that 23.6 percent of the total number of these
process valves are in gas service, with 78.8 percent of these gas
service valves being 4cm or greater and 21.2 percent under 4cm. The
remaining 76.4 percent of the process valves were in liquid service
with 44.3 percent of these liquid service valves being 4cm or greater.
The total number of fittings reported in the standard units and
refinery modules include both flanged and screwed fittings. This
figure was derived by multiplying the number of active and spare
pumps handling hydrocarbons by 235. From the Los Angeles Air Pollu-
tion District Joint Report, 60 percent of the total are screwed
fittings and the remaining 40 percent are flanged fittings.
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The number of relief valves were determined in a manner similar
to that used for estimating the number of control valves. Here,
vessels and columns within the module were used as a basis for esti-
mation.
The number of sampling connections in a unit or module was de-
termined by summing the number of pumps, the number of heat ex-
changers, and the number of hydrocarbon streams flowing in and out of
the module.
Combustion Devices
The number of process heaters and boilers, the design heat input
for each device, and stack heights and diameters came from Hydro-
carbon Processing process flow sheets and from several inspection
reports of processing operations.
Structures
Structures and vessels greater than 9m in height or greater
than 9m in diameter were listed for each module. The dimensions of
these structures were estimated from engineering experience.
Tanks
The data recorded for each tank were: the stock held in the
tank; an estimate of the Reid vapor pressure of the stock; notations
for the type of roof - FR for floating roof, XR for fixed roof, P for
pressure; the diameter and height of the tank; and an estimate of the
annual throughput. The annual throughput was estimated at 13 times
the tank capacity if the actual throughput was not known. No pumps
or valve counts were listed with tanks as these emission points
were inventoried in other units or modules.
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STANDARD UNIT KEY
Standard Unit No. Description
XI Distillation and Gas Recovery
X2 Naphtha Hydrotreater
X3 Light Ends Recovery
X4 Catalytic Reformer
X5 Jet Hydrofiner
X6 Hydrotreater
X7 Hydrogen Manufacture
X8 Partial Oxidation-Hydrogen Manufacture
X9 Vacuum Gas Oil Unit
XI0 Benzene Fractionation
Xll Steam Rerun Still
XI2 Crude Distillation
XI3 Catalytic Reformer
XI4 Vacuum Residuum Desulfurizer
XI5 Alkylation
XI6 Propylene Polymer Plant
XI7 LPG Plant
XI8 Heavy Gas Oil Distillates Hydrodesulfizer
XI9 Gas Oil Washer and Brightener
X20 Sulfur Recovery
X21 Absorption Section of Well man-Lord
tail gas clean-up unit
X22 Chemical section of Wellman-Lord
tail gas clean-up unit.
X23 Sulfuric Acid Plant
X24 Catalytic Reformer
X25 Aromatics Extraction
X26 Catalytic Cracking Unit
X27 Para-Xylene Plant
X28 Delayed Coker Plant
X29 SO? Treating Plant
X30 Acid Treating Plant
X31 Gasoline Sweetening
X32 Crude Distillation'
X33 Crude Desalting
X34 Specialty Crude Distillation
X35 Gasoline Fractionating
X36 Loading Rack Facility
X37 Vapor Recovery Plant
X38 Ship and Barge Loading Facility
X39 Gasoline Rectifier Plant
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Standard Unit No. Description
X40 Wastewater Treatment Facility
X41 Sour Water Oxidizer
X42 Solvent Decarbonizer
X43 Thermal Hydrodealkylation
X44 Naphtha Hydrodesulfurizer
X45 Refinery Stock Transfer Center
X46 Acid Gas Treating Plant
X47 Beavon-Stretford Sulfur Recovery Plant
X48 Alkylation
X49 Vacuum Distillation Unit
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STANDARD UNIT NO. XI
DISTILLATION AND GAS RECOVERY UNIT
1.5 x 10° nwday
1. PUMPS AND COMPRESSORS
2
2
2
No. Service
4 Absorption
oil 2x
Propane x
Butane x
Gasoline
product x
Demeth. abs.
btms. x
Deeth. abs.
btms. x
Propane
refrigerant 2x
Propane
reflux 2x
Butane product
Propane pro-
duct
Lean gaso 2x
Compressors x
Spare RVP Class Pump Type Seal Type
2
2
4
2
B
A
A
2. VALVES AND FITTINGS
a. Control Valves - 51
b. Process Valves - 3,220
c. Fittings - 10,800
d. Relief Valves - 56
e. Sample Connections - 63
3. COMBUSTION DEVICES
a. Process Heaters and Boilers
Design Heat Input
No. Type (GJ/hr)
~2~ H 51.7
C
C
C
Stack
Height
(m)
33.5
M
M
M
M
M
M
A
A
A
C
A
C
C
C
C
C
M
M
M
M
P
Stack
Di ameter
(m)
1.8
10
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STANDARD UNIT NO. X2
NAPHTHA HYDROTREATER
2,385 m3/day
1. PUMPS AND COMPRESSORS
No.
1
1
1
1
1
1
1
1
1
1
1
1
Service Spare
Reactor bottoms x
Stripper bottoms x
Product pump x
Product pump
Desulfurizer pump x
Separator pump
Separator pump x
Separator pump
Feed pump x
Feed pump
Compressor x
Compressor
RVP Class
B
B
B
B
B
B
B
B
B
B
A
A
Pump Type
C
C
C
C
C
C
C
C
C
C
R
R
Seal Type
P
M
M
M
M
M
M
M
M
M
P
P
2. VALVES AND FITTINGS
a. Control Valves - 19
b. Process Valves - 1,330
c. Fittings - 4,465
d. Relief Valves - 23
e. Sample Connections - 29
3. COMBUSTION DEVICES
a. Process Heaters and Boilers
Stack Stack
Design Heat Input Height Diameter
No. Type (GJ/hr) (m) (m)
~T~ H 24.0 36.6 ~O4
1 H 25.6 36.6 2.44
11
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STANDARD UNIT NO. X3
LIGHT ENDS RECOVERY UNIT
85,000 m3/day
1. PUMPS AND COMPRESSORS
No.
Service Spare RVP Class
~TT Feed gas
1
1
1
]
1
1
compressor
Propane/Pro-
pylene
Liquid feed
Gasoline to
storage
Butane/Buty-
lene
Stabilizer gas
compressor
Deethanizer
bottoms
X
X
X
X
X
X
X
A
A
B
B
B
A
B
Pump Type
R
R
C
C
C
c
c
Seal Type
P
P
M
M
M
M
M
VALVES AND FITTINGS
a.
b.
c.
d.
e.
Control Valves -
Process Valves -
Fittings - 3,525
Relief Valves -
15
1,050
18
Sample Connections - 19
12
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STANDARD UNIT NO. X4
CATALYTIC REFORMER
4,800 m3/day
1. PUMPS AND COMPRESSORS
o. Service Spare
1 Feed x
1 Bottoms x
1 Reboiler feed x
1 Product x
1 Recycle compressor
1 Booster compressor x
RVP Class
B
B
B
A
A
A
Pump Type
C
C
R
C
C
C
Seal Type
M
M
P
M
M
M
2. VALVES AND FITTINGS
a. Control Valves - 16
b. Process Valves - 770
c. Fittings - 2£85
d. Relief Valves - 12
e. Sample Connections - 18
3. COMBUSTION DEVICES
a. Process Heaters and Boilers
No.
1
1
1
H
H
H
Design Heat Input
(GJ/hr)
81.7
87.0
79.1
15.8
Stack
Height
(m)
27.4
27.4
27.4
27.4
Stack
Diameter
(m)
T7TT
1.13
1.13
1.13
13
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STANDARD UNIT NO. X5
JET HYDBOFINER
500 m3/day
1. PUMPS AND COMPRESSORS
No. Service Spare RVP Class Pump Type Seal Type
T" Feed
1 Reactor
bottoms
1 LP separator
1 Recycle
1 Product
1 Recycle gas
Compressor
^^•••••••••M
X
X
X
X
X
X
c
C
C
C
C
A
C
C
C
R
R
C
M
M
M
P
P
M
2. VALVES AND FITTINGS
a. Control Valves - 12
b. Process Valves - 840
c. Fittings - 2,820
d. Relief Valves - 15
e. Sample Connections - 16
3. COMBUSTION DEVICES
a. Process Heaters and Boilers
Stack Stack
Design Heat Input Height Diameter
Quantity Type (6J/hr) (m) (m)
1 H 177 31.* 1.4
1 H 12. 31.* 1.4
* Heaters share common stack
14
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STANDARD UNIT NO. X6
HYDROTREATER UNIT
8,000 m3/day fr^sh feed
1. PUMPS AND COMPRESSORS
2.
No.
~T~
1
1
1
1
1
1
1
1
1
1
1
1
1
1
*
Service Spare
H2 compressor x
Recycle com-
pressor
Feed
Water injec-
tion
Debut, over-
head
Fract. reflux x
Debut re-
boiler x
Fract. over-
head x
Naphtha x
Kero.
Kero. x
Hvy Distil-
late x
Fract.
Bottoms x
Injection
Regeneration*
Circulating
Intermittent usage
VALVES AND FITTINGS
a.
b.
c.
d.
e.
Control Valves - 64
Process Valves - 1610
Fittings - 5405
Relief Valves - 28
Sample Connections - '
Spare RVP Class Pump Type Seal Type
A
C
A
B
B
A
B
C
C
D
D
C
C
C
C
C
C
C
C
C
R
P
M
M
M
M
M
M
M
M
M
M
P
M
15
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STANDARD UNIT NO. X6
HYDROTREATER UNIT
8,000 m3/day fresh feed
(Concluded)
3. COMBUSTION DEVICES
A. Process Heaters and Boilers
Stack Stack
Design Heat Input Height Diameter
Quantity Type (GJ/hr) (m) (m)
I ~H 71.3 33.5 ~~7TO
1 H 308.1 55.0 3.9
1 H 185.7 40.0 3.1
16
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STANDARD UNIT NO. X7
HYDROGEN MANUFACTURING UNIT
2,800,000 fn3/day
1. PUMPS AND COMPRESSORS
No. Service Spare
1 Hydrogen Compressor x
1 Hydrogen Compressor
1 Carbonate x
1 Feed x
RVP Class
A
A
D
8
Pump Type Seal Type
C M
C M
C M
C M
2. VALVES AND FITTINGS
a. Control Valves - 37
b. Process Valves - 2,430
c. Fittings - 8,225
d. Relief Valves - 34
e. Sample Connections - 46
3. COMBUSTION DEVICES
a. Process Heaters and Boilers
Stack
Design Heat Input Height
No. Type (GJ/hr) (m)
1 (with 2 H 527.7
Stacks)
30.9
30.9
Stack
Diameter
(m)
1.45
2.4
17
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1.
2.
STANDARD UNIT NO. X8
PARTIAL OXIDATION UNIT FOR HYDROGEN MANUFACTURE
85,000 m3/day
PUMPS AND COMPRESSORS
No. Service
T Feed pump
2 Compressors
Spare RVP Class Pump Type
x B C
x A C
Seal Type
M
M
VALVES AND FITTINGS
a. Control Valves
b. Process Valves
- 10
- 350
c. Fittings - 1,175
d. Relief valves - 12
e. Sample Connections - 16
3. COMBUSTION DEVICES
a. Process Heaters and Boilers
Stack
Design Heat Input Height
No.
1
1
1
1
1
Type
H
H
H
B
B
(GJ/hr)
58.6
83.0
285
95.5
74.4
(m)
31.0
40.5*
40.5*
31.0
33.5
Stack
Diameter
(m)
4.1
2.75
2.75
1.5
2.1
*Heaters share common stack
18
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2.
STANDARD UNIT NO. X9
VACUUM GAS OIL UNIT
5,565 m3/day
1. PUMPS AND COMPRESSORS
No.
1
1
1
1
1
3
2
Service Spare
Primary feed x
Secondary feed x
Reactor bottoms
pump x
Naphtha pump x
Gas oil product
pump x
Separator pump 2x
Recycle gas
compressor x
RVP Class
C
C
C
B
C
C
A
Pump Type
C
C
C
C
C
C
C
Seal Type
M
M
M
M
M
M
M
VALVES AND FITTINGS
a.
b.
c.
d.
e.
Control Valves - 20
Process Valves - 1,260
Fittings - 4,230
Relief Valves - 15
Sample Connections - 25
3. COMBUSTION DEVICES
a. Process Heaters and Boilers
Stack Stack
Design Heat Input Height Diameter
(GJ/hr) (m) (m)
86.0 52.0 174
No. Type
~T~ H
1 B 33.7 33.5 1.3
19
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STANDARD UNIT NO. XI0
BENZENE FRACTIONATION
800 m3/day
1. PUMPS AND COMPRESSORS
RVP Pump Seal
No.
1
1
1
1
1
1
Service
Feed to benzene/toluene
col umn
Benzene product
Toluene produce
Feed to xylene column
Xylene product
Heavy aromatic product
Spare
X
X
X
X
X
X
Class
C
C
C
D
D
D
Type
C
C
C
C
C
C
Jyj
M
M
M
M
M
M
2. VALVES AND FITTINGS
a. Control Valves - 10
b. Process Valves - 840
c. Fittings - 2,820
d. Relief Valves - 8
e. Sampling Connections - 12
3. COMBUSTION DEVICES
a. Process Heaters and Boilers
No.
Heater or Design Heat Input
Boiler (GJ/hr)
H
90
Stack
Height
(m)
30.5
Stack
Diameter
(m)
1.8
20
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STANDARD UNIT NO. Xll
STEAM RERUN STILL
2,000 m3/day
1. PUMPS AND COMPRESSORS
No. Service Spare RVP Class Pump Type Seal Type
~T~ FeeHx C R P~
1 Fract. Btms. x D C P
1 Recycle C C M
1 Stripper Btms. D R P
1 Gas Oil Product x D C P
2. VALVES AND FITTINGS
a. Control Valves - 12
b. Process Valves - 560
c. Fittings - 1,904
d. Relief Valves - 12
e. Sample Connections - 17
3. COMBUSTION DEVICES
a. Process Heaters and Boilers
Stack Stack
Design Heat Input Height Diameter
No. Type (GJ/hr) (m) (m)
1 H 46.2 25.5 1.4
21
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STANDARD UNIT NO. XI2
CRUDE DISTILLATION UNIT
23,850 m3/day
1. PUMPS AND COMPRESSORS
No. Service Spare RVP Class Pump Type Seal Type
~T~ Primary feed x C C M
2 Secondary feed x C C M
2 Vacuum heater
charge x D C M
2 Vacuum column
bottoms x D CM
2 Atmos. column
reflux x B C M
2 Vacuum column
reflux x C C M
1 First sidecut B C M
1 Second sidecut C C M
1 Third sidecut C C M
1 Fourth sidecut C C M
1 Fifth sidecut D C M
1 Sixth sidecut D C M
1 Rectifier re-
flux x B C M
1 Rectifier feed x B C M
1 Seventh sidecut D C M
1 Vacuum net
overhead x D C M
1 Light oil
feedback x C R P
1 Heavy oil
feedback x C R P
1 Oil from
vacuum skimmer C R P
1 Rectifier net
overhead x B R P
2. VALVES AND FITTINGS
a. Control Valves - 40
b. Process Valves - 2,660
c. Fittings - 8,930
d. Relief Valves - 39
e. Sample Connections - 57
22
-------
STANDARD UNIT NO. XI2
CRUDE DISTILLATION UNIT
23,850 m3/day
(Concluded)
3. COMBUSTION DEVICES
a. Process Heaters and Boilers
Stack Stack
Design Heat Input Height Diameter
No. Type (GJ/hr) (m) (m)
2 H 2T651.8 4.0*
2 H 69 38.1 1.4*
2 H 52 38.1 1.3*
*Heaters share common stack
23
-------
2.
3.
STANDARD UNIT NO. XI3
CATALYTIC REFORMER
3,200 m3/day
1. PUMPS AND COMPRESSORS
No. Service Spare RVP Class
~T~ Feed x B
1 Bottoms x B
1 LPG A
1 Reboiler feed A
1 Product x B
1 Recycle com-
pressor x A
1 Booster com-
pressor A
VALVES AND FITTINGS
a. Control Valves - 16
b. Process Valves - 770
c. Fittings - 2,585
d. Relief Valves - 12
e. Sample Connections - 16
COMBUSTION DEVICES
a. Process Heaters and Boilers
Design Heat Input
No. Type (GJ/hr)
1 H 82.
1 H 87.
1 H 79.
1 H 16.
Pump Type Seal Type
C M
C M
R P
R P
C M
C M
C M
Stack Stack
Height Diameter
(m) (m)
27.4 1.1
27.4 1.1
27.4 1.1
27.4 1.1
24
-------
STANDARD UNIT NO. XH
VACUUM RESIDUUM DESULFURIZER
4,500 m3/day
1. PUMPS AND COMPRESSORS
No. Service Spare RVP Class
3 Feed x D
1 Product D
2 Separator x C
2 Compressors A
2. VALVES AND FITTINGS
a. Control Valves - 14
b. Process Valves - 770
c. Fittings - 2,585
d. Relief Valves - 13
e. Sample Connections - 18
3. COMBUSTION DEVICES
a. Process Heaters and Boilers
Design Heat Input
No. Type (GJ/hr)
~T~ H 21.1
1 H 15.8
Pump Type
C
C
C
C
Stack
Height
(m)
36.6
37.8
Seal Type
M
M
M
M
Stack
Diameter
w
1.4
1.1
25
-------
STANDARD UNIT NO. XI5
H2S04 ALKYLATION PLANT
800 m3/day
1. PUMPS AND COMPRESSORS
No. Service Spare RVP Class Pump Type Seal Type
3
1
1
1
1
1
1
1
1
1
1
1
2
1
1
Fresh acid x
Butane/buty-
lenes feed
Splitter
Splitter
ref 1 ux x
Splitter
bottoms
Deisobutanizer
feed
Deisobutanizer
ref 1 ux x
Deubutanizer
reflux x
Depropanizer
ref 1 ux
Propane treater
bottoms
Compressor con-
densate
accumulator pump
Cold effluent
pump
Butane/Butyl enes
and isobutane x
Alkylate to
storage x
Compressor x
_
A
A
A
B
A
A
A
A
A
A
B
A
B
A
R
C
C
C
C
C
C
C
C
C
C
C
R
C
C
P
M
M
M
M
M
M
M
M
M
M
M
P
M
M
2. VALVES AND FITTINGS
a. Control Valves - 36
b. Process Valves - 1,750
c. Fittings - 5,875
d. Relief Valves - 16
e. Sample Connections - 30
26
-------
STANDARD UNIT NO. XI5
H2S04 ALKYLATION PLANT
800 m3/day
(Concluded)
3. COMBUSTION DEVICES
A. Process Heaters and Boilers
Stack Stack
Design Heat Input Height Diameter
No. Type (GJ/hr) (m) (m)
H 80.35.0 T77
27
-------
STANDARD UNIT NO. XI6
PROPYLENE POLYMER PLANT
560 m3/day
1. PUMPS AND COMPRESSORS
No.
~T
1
1
1
2
Service
Product to
storage
Stabilizer
feed
Stabilizer
reflux
Fractionator
reflux
Fractionator
feed
Spare
X
X
X
X
X
RVP Class
B
A
A
B
B
Pump Type
C
C
C
C
C
Seal •
M
M
M
M
M
2. VALVES AND FITTINGS
a. Control Valves - 15
b. Process Valves - 840
c. Fittings - 2,820
d. Relief Valves - 12
e. Sample Connections - 19
28
-------
STANDARD UNIT NO. XI7
LP6 PLANT
400 m3/day
1. PUMPS AND COMPRESSORS
No. Service Spare RVP Class Pump Type Seal Type
T~ Debutanizer
OH feed to de-
propanizer
1 Debutanizer
ref 1 ux x
1 Liquid propane
to storage x
1 Deisobutanizer
feed x
1 Deisobutanizer
reflux
1 Deisobutanizer
bottoms to
storage x
A
A
A
A
A
A
C
C
C
C
C
C
M
M
M
M
M
M
2. VALVES AND FITTINGS
a. Control Valves - 10
b. Process Valves - 700
c. Fittings - 2,350
d. Relief Valves - 12
e. Sample Connections - 17
29
-------
2.
STANDARD UNIT NO. XI8
HEAVY GAS OIL DISTILLATES HYDRODESULFURIZER
1,900 m3/day
1. PUMPS AND COMPRESSORS
No.
1
2
2
Service Spare
Feed x
Product x
Separator x
Compressors x
RVP Class
C
D
C
A
Pump Type
C
C
C
R
Seal Type
M
M
M
P
VALVES AND FITTINGS
a.
b.
c.
d.
e.
Control Valves - 10
Process Valves - 700
Fittings - 2,350
Relief Valves - 12
Sample Connections -
16
3. COMBUSTION DEVICES
a. Process Heaters and Boilers
No.
^r
Type
H
Design Heat Input
(GJ/hr)
31.6
Stack
Height
(m)
46.
Stack
Diameter
(m)
1.2
30
-------
STANDARD UNIT NO. XI9
GAS OIL WASHER AND BRIGHTENER
1,500 m3/day
1. PUMPS
No. Service Spare RVP Class Pump Type Seal Type
~T~ Teed*x D C P
1 Water - C P
2. VALVES AND FITTINGS
a. Process Valves - 180
b. Fittings - 470
NOTE: This unit is seldom used. New refineries would very
probably not have a unit of this type. Early versions brightened
with an air stream.
31
-------
STANDARD UNIT NO. X20
SULFUR RECOVERY UNIT (2 STAGE CLAUS UNIT)
272 metric tons/day
1. PUMPS AND COMPRESSORS
No. Service Type
~T~ Sulfur transfer Vertical, submerged
2. VALVES AND FITTINGS
a. Control Valves - 4
b. Process Valves - 150
c. Fittings - 392
3. COMBUSTION DEVICES
a. Process Heaters and Boilers
Design Heat Input Height Diameter
No. Type (GJ/hr) (m) (m)
~T~ H* 65.4 * *~^
2 H* * 34.8 * * *
* Main reactor
* * Auxiliary start-up burners
* * * Gases vented to tail gas clean-up unit,
Standard Units No. X21 and X22
-------
STANDARD UNIT NO. X21
ABSORPTION SECTION OF A WELLMAN-LORD TAIL GAS CLEAN-UP UNIT
1. PUMPS AND COMPRESSORS
No. Service Spare RVP Class Pump Type Seal Type
Recycle quench
water C P
NaHS03 Solution C P
2. VALVES AND'FITTINGS
a. Process Valves - 95
b. Fittings - 264
3. COMBUSTION DEVICES
a. Process Heaters and Boilers
No.
1
1
Type
H
H
Design Heat Input
(GJ/hr)
52.8
44.0
Stack
Height
(m)
45.7
46.0
Stack
Diameter
(m)
1.7
2.5
33
-------
STANDARD UNIT NO. X22
CHEMICAL SECTION OF A WELLMAN-LORD TAIL GAS CLEAN-UP UNIT
1. PUMPS AND COMPRESSORS
No. Service Spare RVP Class Pump Type Seal Type
1 Recycle quench
water x
1 NaHSOa solu-
tion X
1 Na2S03 slurry
pump
1 H20 recycle
pump
1 Compressor x
C
\
C
C
C
C
p
p
p
p
p
2. VALVES AND FITTINGS
A. Control Valves - 8
b. Process Valves - 420
c. Fittings - 1,410
d. Relief Valves - 7
e. Sample Connections - 12
3. COMBUSTION DEVICES
a. Process Heaters and Boilers
Stack Stack
Design Heat Input Height Diameter
Quantity Type (GJ/hr) (m) (m)
1 0* 31.6 45.7 1.7
1 H 26.4 46. 1.7
* Thermal oxidizer
34
-------
STANDARD UNIT NO. X23
SULFURIC ACID PLANT
182 metric tons/day
1. PUMPS AND COMPRESSORS
No.
T"
1
1
1
Service
Spare RVP Class
01 euro x
Sulfur feed
Absorbing acid x
Drying acid
Pump Type
C
C
C
C
Seal Type
P
P
P
P
2. VALVES AND FITTINGS
a. Control Valves - 8
b. Process Valves - 490
c. Fittings - 1,645
d. Relief valves - 8
e. Sample Connections - 15
3. COMBUSTION DEVICES
a. Process Heaters and Boilers
Quantity
1
Stack Stack
Design Heat Input Height Diameter
Type (GJ/hr) (m) (m)
SB* 31.7
1.8 7.0
Sulfur burner
35
-------
STANDARD UNIT NO. X24
CATALYTIC REFORMER
7,200 m3/day
1. PUMPS AND COMPRESSORS
No. Service Spare RVP Class Pump Type Seal Type
TT
1
1
1
2
2
2
Reactor
bottoms
Stripper
bottoms
Product
Feed
Reflux
Separator
Recycle gas
compressors
X
X
X
X
X
X
X
C
C
B
B
B
B
A
C
C
C
C
C
C
C
M
M
M
M
M
M
M
2. VALVES AND FITTINGS
a. Control Valves - 22
b. Process Valves - 1,470
c. Fittings - 4,935
d. Relief Valves - 18
e. Sample Connections - 30
3. COMBUSTION DEVICES
a. Process Heaters and Boilers
Stack Stack
Design Heat Input Height Diameter
-1- Type (GJ/hr)
__
* Heaters share common stack
36
-------
STANDARD UNIT NO. X25
AROMATIC EXTRACTION PLANT (SULFOLANE SOLVENT)
600 m3/day Total Aromatics
1. PUMPS AND COMPRESSORS
No. Service Spare RVP Class Pump Type Seal Type
~T~ Extractor
feed x B C M
1 Extractor
reflux x B C M
1 Raffinate
product B C M
1 Raffinate
water wash
recycle x Aqueous R P
1 Water stripper
tower charge x B C M
1 Bottoms -
solvent
recovery
tower x R P
1 Bottoms water
stripper x R P
1 Raffinate
from water
wash x C C M
1 Extract to
fractionation x C C M
1 Feed to benzene/
toluene column x C C M
1 Benzene product x C C M
1 Toluene product x C C M
1 Feed to xylene
column x D C M
1 Xylene product x D C M
1 Heavy aromatic
product x D C M
2. VALVES AND FITTINGS
a. Control Valves - 29
b. Process Valves - 2,030
c. Fittings - 6,815
d. Relief Valves - 34
e. Sampling Connections - 29
37
-------
STANDARD UNIT NO. X25
AROMATIC EXTRACTION PLANT (SULFOLANE SOLVENT)
600 m3/day Total Aromatics
(Concluded)
3. COMBUSTION DEVICES
a. Process Heaters and Boilers
Stack Stack
Heater or Design Heat Input Height Diamater
No. Boiler (GJ/hr) (m) (m)
1 H 70 30.5 1.8
38
-------
STANDARD UNIT NO. X26
FLUID CATALYTIC-CRACKING UNIT
7,950 m3/day
1. PUMPS AND COMPRESSORS
No.
~r
i
i
i
2
2
1
1
1
1
4
1
1
2
3
1
1
Compressor
Defautanizer overhead
Fractionator top reflux
Fractionator 1st cut
Absorber feed
Absorber lean sponge
Stablizer bottoms
Stablizer reflux
Gasoline overhead
Intermediate reflux
Gas oil circulation
Thick slurry
Clarified oil
Slurry return to feed
Slurry recycle to
fractionator
Hydraulic oil
Gas oil
Spare
X
X
X
X
X
X
X
X
2x
X
X
X
X
VALVES AND FITTINGS
a.
b.
c.
d.
Control Valves - 35
Process Valves - 2,870
Fittings - 9,635
Relief Valves - 18
RVP
Class
A
A
B
B
B
B
B
B
B
C
D
D
D
D
D
D
D
Pump
Type
R
C
C
C
C
C
C
C
C
C
C
C
C
C
C
R
C
Seal
Type
P
M
M
M
M
M
M
M
M
M
M
M
M
M
M
P
M
e. Sample Connections - 67
COMBUSTION DEVICES
Service
Feed preheater*
Regenerator startup
heater*
CO boiler
Design Heat Input
(GJ/hr)
79.1
69.9
614
Stack Stack
Height(m) Diameter(m)
42^6 2.0
42.7
4.3
*Feed preheater and regenerator start-up heater share common
stack
39
-------
STANDARD UNIT NO. X26
FLUID CATALYTIC-CRACKING UNIT
7,950 m3/day
(Concluded)
4. VESSELS Dimensions (m)
On a
structure
with an
overall
No. Service Piameter Height height of
~T~ Reactor 9T7~"~ 14.3 23.4
1 Regenerator 18.1 10.7 30.5
1 Hot catalyst storage
(2 vessels) 10.5 12.2 15.2
40
-------
STANDARD UNIT NO. X27
PARA-XYLENE PLANT
140 Metric Tons/day
1. PUMPS AND COMPRESSORS
No. Service Spare RVP Class Pump Type Seal Type
2 Feed x C C M
1 1st stage melt C C M
1 2nd stage melt C C M
1 Splitter reflx x B C M
1 Make-up Tol-
uene x C C M
2. VALVES AND FITTINGS
a. Control Valves - 9
b. Process Valves - 630
c. Fittings - 2,115
d. Relief Valves - 11
e. Sample Connections - 16
41
-------
STANDARD UNIT NO. X28
DELAYED COKER PLANT
7,950 nrvday
PUMPS AND COMPRESSORS
No. Servi ce
3
3
4
3
1
1
2
Coker feed
Condensate
Gasoline
Stripper bottoms
Ref 1 ux
Reflux
Compressor
jyare
X
X
2x
X
X
X
X
i\yr uiaba
D
C
B
C
C
B
A
rump iype
C
C
C
C
C
C
C
oeai 1
P
M
M
M
M
M
P
VALVES AND FITTINGS
a. Control Valves - 27
b. Process Valves - 1,750
c. Fittings - 5,875
d. Relief Valves - 30
e. Sample Connections - 43
COMBUSTION DEVICES
a. Process Heaters and Boilers
No.
~3~~
Type
H
Design Heat Input
(GJ/hr)
T75
Stack
Height
(m)
53.3
Stack
Diameter
(m)
' 4*
* 2 Stacks
42
-------
STANDARD UNIT NO. X29
S02 TREATING PLANT
1,100 m3/day
1. PUMPS AND COMPRESSORS
No. Service Spare RVP Class Pump Type Seal Type
IT
1
2
2
1
6
1
1
1
1
Feed x
Raffinate x
Caustic
Extract x
Caustic scrubber
S02 3x
S02 reflux x
Extractor feed
Acid
Raffinate
C
C
C
C
A
A
C
C
C
C
C
C
C
R
R
C
C
M
M
R
M
M
P
P
M
M
4 S02 compressor 2x
2. VALVES AND FITTINGS
a. Control Valves - 43
b. Process Valves - 2,170
c. Fittings - 7,285
d. Relief Valves - 38
e. Sample Connections - 46
43
-------
STANDARD UNIT NO. X30
ACID TREATING PLANT
447 m3/day
1. PUMPS AND COMPRESSORS
0.
T
2
1
1
1
1
Service
Kerosene feed
Kerosene Acid
Product
Brightener
Feed
Caustic recycle
Salt Water Feed
Spare
X
X
X
X
X
RVP Class
C
C
C
C
Aq
Aq
Pump Type
R
R
C
C
R
C
Seal Type
P
P
M
M
P
P
2. VALVES AND FITTINGS
a. Control Valves - 12
b. Process Valves - 840
c. Fittings - 2,820
d. Relief Valves - 15
e. Sample Connections - 19
44
-------
STANDARD UNIT NO. X31
GASOLINE SWEETENING UNIT
4,450 m3/day
1. PUMPS AND COMPRESSORS
No. Spare RVP Class Pump Type Seal Type
~T~ Inhibitor transfer x DR P
1 Naphtha charge x B CM
1 Inhibitor solution D CM
1 Inhibitor slurry
recycle x D CM
1 Inhibitor
injection D C P
2. VALVES AND FITTINGS
a. Control Valves - 6
b. Process Valves - 560
c. Fittings - 1,880
d. Relief Valves - 8
e. Sample Connections - 13
45
-------
STANDARD UNIT NO. X32
CRUDE DISTILLATION UNIT
6,360 m3/day
1. PUMPS ANC COMPRESSORS
No. Spare RVP Class Pump Type Seal Type
1 Primary feed x C C M
2 Secondary feed x C CM
2 Vacuum heater
charge x D CM
2 Vacuum column
bottoms x D CM
2 Atmos. column
reflux x B CM
2 Vacuum column
reflux x C CM
1 First sidecut B C M
1 Second sidecut C C M
1 Third sidecut C C M
1 Fourth sidecut C C M
1 Fifth sidecut D C M
1 Sixth sidecut D C M
1 Rectifier reflux x B CM
1 Rectifier feed x B CM
1 Seventh sidecut D C M
1 Vacuum net over-
head x D CM
1 Light oil feedback x C R P
1 Heavy oil feedback x C R P
1 Oil from vacuum
skimmer C R P
1 Rectifier net
overhead x B R P
2. VALVES AND FITTINGS
a. Control Valves - 40
b. Process Valves - 2,590
c. Fittings - 8,695
d. Relief Valves - 45
e. Sample Connections - 56
46
-------
STANDARD UNIT NO. X32
CRUDE DISTILLATION UNIT
6,360 m3/day
(Concluded)
3. COMBUSTION DEVICES
a. Process Heaters and Boilers
Stack Stack
Design Heat Input Height Diameter
No. Type (GJ/hr) (m) (m)
~T~ H W 55 ~~2JO
1 H 47 55 1.4
47
-------
STANDARD UNIT NO. X33
CRUDE DESALTING UNIT
6,400 m3/day
1. PUMPS AND COMPRESSORS
No. Service Spare RVP Class Pump Type Seal Type
Feed x C C M
2. VALVES AND FITTINGS
a. Control Valves - 3
5. Process Valves - 140
c. Fittings - 470
d. Relief Valves - 2
e. Sample Connections - 5
48
-------
STANDARD UNIT NO. X34
SPECIALTY CRUDE UNIT
1,530 m3/day
1. PUMPS AND COMPRESSORS
0.
T~
1
2
1
1
1
1
Servi ce Spare
Primary feed
Secondary feed
Tar x
Top stripper x
Middle stripper
Bottom stripper
Intermediate
reflux x
RVP (
C
C
D
B
C
C
B
RVP Class Pump Type Seal Type
C
C
R
C
C
C
M
M
P
M
M
M
2. VALVES AND FITTINGS
a. Control Valves - 11
b. Process Valves - 770
c. Fittings - 2,585
d. Relief Valves - 13
e. Sample Connections - 18
V
3. COMBUSTION DEVICES
a. Process Heaters and Boilers
No. Type
^~ H
Design Heat Input
(GJ/hr)
Stack
Height
(in)'
24.5
Stack
Di ameter
(m)
~TT5
49
-------
STANDARD UNIT NO. X35
GASOLINE FRACTIONATING UNIT
9,500 m3/day
1. PUMPS AND COMPRESSORS
0.
T
6
6
6
6
2
Service
Ref 1 ux
Feed
Bottoms
1st sidecut
2nd sidecut
Compressors
Spare
3 x
3 x
3 x
2 x
2 x
x
RVP Class
B
B
B
B
B
A
Pump Type
C
C
C
C
C
C
Seal Type
M
M
M
M
M
M
2. VALVES AND FITTINGS
a. Control Valves - 54
b. Process Valves - 3,220
c. Fittings - 10,800
d. Relief Valves - 38
e. Sample Connections - 70
3. COMBUSTION DEVICES
a. Process Heaters and Boilers
Stack Stack
Design Heat Input Height Diameter
Quantity Type (6J/hr) (m) (m)
T~^ H 34.7 "26; 175
50
-------
STANDARD UNIT NO. X36
LOADING RACK FACILITY
A. TANK CAR LOADING RACK FACILITY
There are two long racks and one short rack with tracks on
either side. The rack from which refined products are loaded
is 3.8 m high x 680 m long x 10 m wide. A full spot, 18.3 m is
alternated with a 1/2 spot, 9.1 m to facilitate car spotting.
Groups of 6 to 8 risers are located at each spot, of which
there are 25. Groups of 3 to 5 risers are located at the 1/2
spots, of which there are 24. Stocks over 10.3 kilo-pascals Reid
vapor pressure are loaded with a vapor return to a recovery
system. All other stocks are loaded with a submerged loading
spout. All loading spouts are equipped with quick-closing type
valves.
The rack from which the heavy fuels, furnace and stove oils
and diesel fuels is 3.8 m high x 610 m long x 10 m wide. The
same arrangement of spots and risers holds for these two tracks.
There are 22 spots and 23-1/2 spots.
The short rack is 3.8 m high x 183 m long x 10 m wide. This
is a utility rack with 4 spots for car cleaning, 2 spots for off-
test fuel and gasoline pumpout and 2 spots for xylene and pur-
chased polymer pumpout.
B. TRUCK LOADING RACK FACILITY
This facility has three racks. The long one in the center is
for gasolines and thinners over 10.3 kPa. All loading of this
material is done with a vapor return system to the vapor recovery
plant. It is able to load 3 trucks and trailers on each side.
The rack is 55 m long. The loading platform is 3.8 m above ground
level with a roof to an overall height of 7.62 m and is 7 m wide.
51
-------
STANDARD UNIT NO. X36
(Continued)
The racks on either side can accommodate 2 trucks and trailers
on each side. They are 36.6 m long, also with roofs to an over-
all height of 7.62 m and are 7 m wide. One rack loads primarily
heavy fuels and fuel oils. The other loads primarily jet fuels,
kerosene type products and diesel oils.
c. VAPOR RECOVERY PACKAGE UNIT. ABSORPTION TYPE. 1000 Kg / hr.
1 . PUMPS
No.
~T~
1
1
1
AND COMPRESSORS
Servi ce Sj
Vapor compressor
Gasoline Feed to
absorber
Gasoline Feed to
saturation pot
Gasoline to
storage
33 re
X
X
X
X
RVP Class
A
B
B
B
Pump Type
C
C
C
C
Seal Type
M
M
M
M
2. VALVES AND FITTINGS
a. Control Valves - 8
b. Process Valves - 560
c. Fittings - 1,880
d. Relief Valves - 10
e.Sample Connections - 8
3. VESSELS
a. Vapor conservation tank, sphere type, 9 m diameter.
52
-------
STANDARD UNIT NO. X37
VAPOR RECOVERY PLANT
1. PUMPS AND COMPRESSORS
No. Service Spare RVP Class Pump Type Seal Type
3 Compressors x 7TRP
2 Condensate x B R P
1 Rich sponge oil x B R P
1 Lean sponge oil x C R P
2. VALVES AND FITTINGS
a. Control Valves - 12
b. Process Valves - 770
c. Fittings - 2,585
d. Relief Valves - 14
e. Sample Connections - 15
53
-------
STANDARD UNIT NO. X38
SHIP AND BARGE LOADING FACILITY
A. WHARF
A wharf facility for barge and small tanker loading and un-
loading facilities is 20 meters wide x 275 meters long giving an
area of 0.5 hectares. The capacity and input to this module is
8,000 m3/day of products. The output is to off-plot customers.
There is little or no equipment inherent to this module other
than the flexible hose connections between shore loading and dis-
placement lines to those on the ship or barge along with handling
equipment such as gantry cranes, etc.
Vapor recovery lines discharge to central gas recovery unit.
54
-------
STANDARD UNIT NO. X39
GASOLINE RECTIFIER PLANT
1. PUMPS AND COMPRESSORS
No. Service Spare RVP Class Pump Type Seal Type
1 Compressor x A R P
2 Feed x B R P
1 Condensate x B R P
1 Bottoms x B R P
2 Reflux x B R P
2. VALVES AND FITTINGS
a. Control Valves - 14
b. Process Valves - 840
c. Fittings - 2,820
d. Relief Valves - 17
e. Sample Connections - 19
55
-------
STANDARD UNIT NO. X40
WASTE WATER TREATMENT PLANT
20,000 m3/day
The treatment process consists of an equalizing pond, two
parallel air flotation units, an activated sludge tank, two para-
llel primary clarifiers, and a secondary clarifier. No chemical
flocculating agents are used. Effluent from the secondary clarifier
is discharged off-site. Sludge from the primary clarifiers is
cycled back to the activated sludge tank. The organic content of
sludge from the secondary clarifier is reduced in an incinerator.
Ash from the incinerator is disposed off-site.
1. PUMPS AND COMPRESSORS
No. Service
2 Flotation cell feed
2. TREATMENT TANKS AND BASINS
RVP Class
Aqueous
Pump Type
R
Seal Type
P
DIMENSIONS
No.
1
2
1
1
Service
Air flotation cells
Activated sludge cell
Primary clarifiers
Secondary clarifier
Equalizing pond
Diameter
(m)
6.1
24.4
12.2
Height
(m)
6.1
5.0
3.7
6.1
3.7
Width
(m)
78.0
219.5
Length
(m)
78.0
219.5
3. COMBUSTION DEVICES
a. Sludge Incinerator
No.
1
Design Heat Input
Type (GJ/hr)
Multiple
Hearth 20.
Stack
Height
(m)
12.2
Stack
Diameter
(m)
1.0
56
-------
STANDARD UNIT NO. X41
SOUR WATER OXIDIZER
250 m3/day
1. PUMPS AND COMPRESSORS
No. Service Spare RVP Class Pump Type Seal Type
1 Feed x Aq C P
1 Product x Aq C P
1 Air Compressor
2. VALVES AND FITTINGS
a. Control Valves - 3
b. Process Valves - 140
c. Fittings - 470
d. Relief Valves - 5
e. Sample Connections - 4
57
-------
STANDARD UNIT NO. X42
SOLVENT DECARBONIZER
10,000 m3/day
1. PUMPS AND COMPRESSORS
No. Service Spare RVP Class Pump Type Seal Type
2.
3.
2 Reduced crude
feed x D
2 Asphalt x D
2 Propane x A
2 Compressors x A
VALVES AND FITTINGS
a. Control - 12
b. Process - 840
c. Fittings - 2,820
d. Relief Valves - 15
e. Sample Connections - 18
COMBUSTION DEVICES
a. Process Heaters and Boilers
Design Heat Input
Quantity Type (GJ/hr)
1 H 34.
1 H 149.
1 H 25.
R
R
C
C
Stack
Height
(m)
21.
30.*
21.
P
P
M
M
Stack
Diameter
(m)
1.4
1.7*
1.0
*Heater has two stacks, each stack 30.m high and 1.7m in
diameter.
58
-------
2.
3.
STANDARD UNIT NO. X43
THERMAL HYDRODEALKYLATION UNIT
260 m3/day
1. PUMPS AND COMPRESSORS
No.
Service Spare
1 Toluene feed x
1 Stabilizer
ref 1 ux x
1 Benzene reflux x
1 Compressor x
VALVES AND FITTINGS
a. Control Valves - 8
b. Process Valves - 560
c. Fittings - 1 ,880
d. Relief Valves - 9
e. Sample Connections -
COMBUSTION DEVICES
a. Process Heaters and
RVP Class
C
C
C '
A
10
Boilers
Design Heat Input
Quantity Type (GJ/hr)
1 H
21.0
Pump Type
C
C
C
R
Stack
Height
(m)
36.6
Seal Type
M
M
M
P
Stack
Diameter
(m)
1.1
59
-------
STANDARD UNIT NO. X44
NAPHTHA HYDRODESULFURIZER
4,300 m3/day
1. PUMPS AND COMPRESSORS
No.
1
2
1
2
Service Spare
Charge x
Bottoms
Gasoline x
Stabilizer
feed x
Compressors x
RVP Class
B
C
B
B
A
Pump Type
C
C
C
C
C
Seal Type
M
M
M
M
M
2. VALVES AND FITTINGS
a.
b.
c.
d.
e.
Control Valves - 15
Process Valves - 770
Fittings - 2,585
Relief Valves - 14
Sample Connections -
17
3. COMBUSTION DEVICES
a.
Process Heaters and
Boilers
Design Heat Input
Quantity Type (GJ/hr)
1 H
75.0
Stack
Height
(m)
11.8*
Stack
Diameter
(m)
1.1*
*Heater has three stacks, each stack 11.8m high and l.lm
in diameter.
60
-------
STANDARD UNIT NO. X45
REFINERY STOCK TRANSFER CENTER
1. PUMPS AND COMPRESSORS
No. Service Spare RVP Class Pump Type Seal Type
4 Product transfer 2X B R P
4 Product transfer 2X B C M
10 Product transfer 4X C R P
6 Product transfer 3X C C M
4 Product transfer 2X D R P
2 Product transfer X D C M
2. VALVES AND FITTINGS
a. Process Valves - 3,080
b. Fittings - 10,340
Note: The estimated numbers include the valves at the
pump manifolds, intermediate manifolds and those
at the final stock destinations, such as tankage,
within the refinery.
61
-------
STANDARD UNIT NO. X46
ACID GAS TREATING PLANT (METHYLETHANOLAMINE ABSORPTION).
1. PUMPS AND COMPRESSORS
o. Service
1 Water
1 Lean MEA
1 Absorber Bottoms
1 Separator Pump
Sfiare
X
X
X
RVP Class Pump Type
Aqueous
Aqueous
Aqueous
Aqueous
R
R
R
R
Seal Type
P
P
P
P
2. VALVES AND FITTINGS
a. Control Valves - 8
b. Process Valves - 560
c. Fittings - 1,880
d. Relief valves - 10
62
-------
STANDARD UNIT NO. X47
BEAVON-STRETFORD SULFUR RECOVERY PLANT TAIL GAS CLEANUP UNIT
1.5 x 106 m3/day
1. PUMPS AND COMPRESSORS
No. Service Spare RVP Class Pump Type Seal Type
1 Solution circ. ~XAqueous CP
1 Sulfur slurry X Aqueous C P
1 Air blower C P
2. VALVES AND FITTINGS
a. Control Valves - 3
b. Process Valves - 280
c. Fittings - 940
d. Relief Valves - 4
e. Sample Connections- 6
3. VESSELS
a. Oxidizer 12 m diameter x 8 m high
b. Sulfur Slurry Tank 8 m diameter x 7 m high
c. Solution Tank 10 m diameter x 9 m high
63
-------
STANDARD UNIT NO. X48
ALKYLATION UNIT
2,400 m3/day
1. PUMPS AND COMPRESSORS
No. Service Spare RVP Class Pump Type Seal Type
1 Olefin feed x A CM
1 i-butane feed x A C M
1 Fractionator
feed x A CM
1 Bottoms re-
circulation x A C M
1 Reflux x A CM
1 n-butane A R P
1 Stab. Alkylate
to storage x B C M
1 HF from rerun x A C M
2. VALVES AND FITTINGS
a. Control Valves - 15
b. Process Valves - 1,050
c. Fittings - 3,525
d. Relief Valves - 18
e. Sample Connections - 26
3. COMBUSTION DEVICES
a. Process Heaters and Boilers
Stack Stack
Design Heat Input Height Diameter
Quantity Type (GJ/hr) (m) (m)
1H 223. 41.8 279
64
-------
2.
3.
STANDARD UNIT NO. X49
VACUUM UNIT
4,000 m3/day
1. PUMPS AND COMPRESSORS
No. Service Spare RVP Class
2 Feed x D
1 Light Gas Oil x C
1 Heavy Gas Oil x D
2 Bottoms D
VALVES AND FITTINGS
a. Control Valves - 10
b. Process Valves - ^00
c. Fittings - 2,350
d. Relief Valves - 12
e. Sample Connections - 14
COMBUSTION DEVICES
a. Process Heaters and Boilers
Design Heat Input
Quantity Type (GJ/hr)
1 H 106.
Pump Type
C
C
C
C
Stack
Height
(m)
27.0
Seal Type
M
M
M
M
Stack
Diamager
(m)
2.3
65
-------
SMALL CAPACITY EXISTING REFINERY
Scale 1 inch = 120 meters
8
12
14
10
11
13
15
16
17
19
18
20
21
22
23
24
25
26
27
28
66
-------
SMALL CAPACITY EXISTING REFINERY MODULE KEY
Standard Unit
Module No. Description Reference No.
SI Product Storage
S2 Product Storage
S3 Shops and Warehouse
S4 Cooling Towers
S5 Catalytic Reformer X24
S6 Aromatics Extraction X25
S7 Crude Distillation X32, X34, X29
S8 Fluid Catalytic Cracking X26
S9 Feedstock Storage
S10 Wastewater Treatment Plant X40
Sll Feedstock Storage
S12 HF Alkylation/Gasoline Sweetening X48, X31
SI 3 Product Storage
SI4 Gas Concentration/Sulfur Recovery X3, X20
S15 Gasoline Fractionation X10
SI6 Future Expansion
SI7 Boiler House
SI 8 Product Storage
SI9 Crude Oil Storage
S20 Administration Building and Laboratory
S21 Flares
S22 Truck Loading Rack Facility X36
S23 Product Storage
S24 Feedstock Storage
S25 Rail Loading Rack Facility
S26 Crude Oil Storage
S27 Product Storage
S28 Product Storage
67
-------
SMALL CAPACITY EXISTING REFINERY
CRUDE CHARGE RATE 8,000 m3/day
PRODUCT SLATE
PRODUCT PRODUCTION RATE (m3/day)
Gasoline 4,200
Bunker C 1,100
Diesel 1,050
#2 Fuel oil 625
Light Catalytic Cracker Cycle Oil 500
Kerosene 265
Toluene 155
Xylene 100
Benzene 90
Alkylate 75
Heavy Aromatics 40
8,200
NUMBER OF WHARF MODULES 1
68
-------
MODULE NO. SI
PRODUCT STORAGE
Module area =8.2 hectares; 390m x 210m
A. TANKS
No. Stock
2 Kerosene
2 Kerosene
Kerosene
Kerosene
#2 fuel oil
#2 fuel oil
Bunker "C"
2
1
1
1
2
RVP
Estimate
(kPa)
0.21
0.21
0.21
0.21
0.14
0.14
0.0007
Tank
XR
XR
XR
XR
XR
XR
Dia Ht
(m) (m)
lO"T2T
39.9 12.2
41.8 12.2
36.0 12.2
39.9 12.2
29.7 12.2
36.4 12.2
Capacity
(m3)
1,590
15,263
16,716
12,401
15,263
8,430
12,719
Annual
Throughput
(m3)
68,900
206,000
213,050
178,000
116,000
213,600
189,000
MODULE NO. S2
PRODUCT STORAGE
Module area =3.5 hectares; 390m x 90m
A. TANKS
No.
Stock
Xylene
Toluene
Cumene
RVP
Estimate
(kPa)
3.4
7.6
1.4
Tank
*
XR
XR
Dia
(m)
3BT2
36.2
36.0
Ht
12
12
!z
.2
Capacity
(n»3)
12,560
12,560
12,400
Annual
Throughput
(m3)
26,700
49,600
156,000
69
-------
MODULE NO. S3
SHOPS AND WAREHOUSE
Module area =1.6 hectares: 150m x 105m
A. Building
B. Building
C. Building
D I M
Width
(m)
12.
19.
8.
E N S I
Length
(m)
46.
38.
19.
0 N S
Height
(m)
15.
9.
6.
MODULE NO. S4
COOLING TOWERS
Module area =0.2 hectares: 75m x 30m
A. Cooling tower
B. Cooling tower
Width
(m)
15.6
14.6
Length
(m)
91.8
81.6
Height
On)
8.
8.
na LCI r i urr
Rate Capacity
(m3/hr)
20,550
14,000
MODULE NO. S5
CATALYTIC REFORMER
Module area =0.6 hectares: 75m x 75m
Process Input/Output:
The input to the module is naphtha from the first distillation.
The output is gas and condensate to the gas concentration unit
and product to aromatics extraction unit or to gasoline
blending.
70
-------
A. CATALYTIC REFORMER 7,200 m3/day
1. PUMPS AND COMPRESSORS
See Standard Unit No. X24
2. VALVES AND FITTINGS
See Standard Unit No. X24
3. COMBUSTION DEVICES
a. Process Heaters and Boilers
Stack Stack
Design Heat Input Height Diameter
Quantity Type (GJ/hr) (m) (m)
2 H 377"^ 17.4 172
2 H 53. 17.4 1.2
MODULE NO. S6
AROMATICS EXTRACTION
Module area =0.3 hectares: 75m x 45m
Process Input/Output:
The input to this module is reformate from the catalytic
reformer. The output is benzene, toluene, xylene, heavy
aromatics and raffinate to gasoline blending.
A. AROMATICS EXTRACTION 600 m3/day
1. PUMPS AND COMPRESSORS
See Standard Unit No. X25
2. VALVES AND FITTINGS
See Standard Unit No. X25
3. COMBUSTION DEVICES
a. Process Heaters and Boilers
Stack Stack
Design Heat Input Height Diameter
Quantity Type (GJ/hr) (m) (m)
2 ~H~ 55~.16.8 lT5~
1 H 84. 30.1 1.6
71
-------
MODULE NO. S7
CRUDE DISTILLATION
Module area = 1.6 hectares: 150m x 105m
Process Input/Output:
The input to the module is mixed crudes. The output is gas
to the gas concentration unit; gasoline to blending; naphtha
to catalytic reformer; kerosene and fuel oil to product
storage; gas oil to catalytic cracking and reduced crude to
vacuum unit.
A. CRUDE DESALTING UNIT 10,000 m3/day
1. PUMPS AND COMPRESSORS
No. Service Spare RVP Class Pump Type Seal Type
2 Feed x C C M
2. VALVES AND FITTINGS
a. Control Valves - 3
b. Process Valves - 210
c. Fittings - 705
d. Relief Valves - 4
e. Sample Connections - 5
B. CRUDE DISTILLATION UNIT 6,360 m3/day
1. PUMPS AND COMPRESSORS
See Standard Unit No. X32
2. VALVES AND FITTINGS
See Standard Unit No. X32
3. COMBUSTION DEVICES
a. Process Heaters and Boilers
Stack Stack
Design Heat Input Height Diameter
Quantity Type (GJ/hr) (m) (m)
1 H 216. 38.1 2.4
1 H 63. 31.3 1.8
72
-------
C. CRUDE DISTILLATION UNIT 1,530 m3/day
1. PUMPS AND COMPRESSORS
See Standard Unit No. X34
2. VALVES AND FITTINGS
See Standard Unit No. X34
3. COMBUSTION DEVICES
a. Process Heaters and Boilers
Stack Stack
Design Heat Input Height Diameter
Quantity Type (GJ/hr) (m) (m)
T H BIT27.4 ~"T75
D. VACUUM UNIT 4,000 m3/day
See Standard Unit No. X49
MODULE NO. S8
FLUID CATALYTIC CRACKING
Module area =1.4 hectares: 150m x 90m
Process Input/Output:
The input to this module is the gas oils from the crude
distillation. The output is gas and unstabilized gasoline
to the gas concentration unit, light cycle oils to No. 2
fuel and clarified slurry to Bunker "C" fuel.
A. FLUID CATALYTIC CRACKING UNIT 4.800 m3/day
See Standard Unit No. X26
73
-------
MODULE NO. S9
FEEDSTOCK STORAGE
Module area =5.4 hectares: 360m x 150m
A. TANKS
RVP Annual
Estimate Tank Dia Ht Capacity Throughput
No. Stock (kPa) Type (m) (m) .(p3! __Jm3J_
~T" FCC Feed 0.14 XR 36.2 TZTT 12,600 590,530
1 FCC Feed 0.14 XR 39.9 12.2 15,260 18,170
1 Vacuum Feed 0.14 XR 18.2 12.2 3,180 1,419,450
MODULE NO. S10
WASTEWATER TREATMENT PLANT
Module area = 3.2 hectares: 210m x 150m
Process Input/Output:
The input is the skimmed oily water effluent from the
separators. The output is clarified water for disposal
in oceans, rivers, ponds, or by irrigation. Sludge is
disposed by incineration or landfill.
A. WASTEWATER TREATMENT PLANT 20,000 m3/day
See Standard Unit No. X40
MODULE NO. Sll
FEEDSTOCK STORAGE
Module area =4.1 hectares: 270m x 150m
74
-------
A. TANKS
No.
2
2
2
2
RVP
Estimate
Stock (kPa)
Propane
Propylene
n-Butane
ISO-Butane
Alkylation feed
1,303
1,585
352
503
155
Tank Dia H
Type (m) (m
P* 6.7
P* 5.3
P* 14.0
P* 17.9
P* 17.9
Annual
t Capacity Throughput
) (fe) (m3)
160
80
1,430
3,020
3,020
78,200
47,700
130,000
54,500
436,000
Pressure sphere
MODULE NO. S12
HF ALKYLATION/GASOLINE SWEETENING
Module area =0.5 hectares: 75m x 60m
Process Input/Output:
The input to this module is butanes, butylene, propane,
propylene, and gasoline from the gas concentration unit.
Additional gasoline is received from the crude distillation
unit. The output is propane and n-butane to pressure
storage and alkylate and gasoline to gasoline blending.
A. HF ALKYLATION UNIT 1,600 m3/day
See Standard Unit No. 48
B. GASOLINE SWEETENING UNIT 4.300 m3/day
See Standard Unit No. 48
75
-------
MODULE NO. S-13
PRODUCT STORAGE
Module area =1.7 hectares: 225m x 75m
A. TANKS
No. Stock
2 Hvy aromatics
2 Cumene
2 Xylene
1 Hvy aromatics
1 Slop oil
2 Slop oil
1 Slop oil
RVP
Estimate Tank Dia
(kPa) Type (m)
3
1
3
3
3
3
3
.4
.4
.4
.4
.4
.4
.4
XR
XR
XR
XR
XR
XR
XR
8
8
10
18
8
3
5
• £>
.2
.4
.2
.1
.7
.8
Ht
(m)
9.1
9.1
9.1
12.2
6.1
6.1
6.1
Annual
Capacity Throughput
(m?) (m3)
477.
477.
795.
3,180.
312.
64.
160.
6
40
13
7
3
3
2
,800
,800
,355
,650
,700
,400
,135
MODULE NO. S14
GAS CONCENTRATION/SULFUR RECOVERY
Module area =0.5 hectares; 75m x 60m
Process Input/Output:
The input to this module is the gases and gasoline from
the fluid catalytic cracking unit and the gases and light
ends from other units such as the crude distillation units.
The output is acid gas for sulfur recovery, gas to refinery
fuel, gasoline to blending, propane/propylene to cumene or
alkylation feed and butane/butylene to alkylation feed.
A. GAS CONCENTRATION UNIT 85,000 m3/day
See Standard Unit No. X50
B. ACID GAS TREATING PLANT
See Standard Unit No. X46
76
-------
C. SULFUR RECOVERY UNIT 272 metric tons/day
See Standard Unit No. X20
D. TAIL GAS CLEAN-UP UNIT
See Standard Unit No. X21 and X22
MODULE NO. S15
GASOLINE FRACTIONATION
Module area = 0.2 hectares: 75m x 30m
Process Input/Output:
The input to this module is naphtha from the first crude
distillation units. The output is feed stock to the
catalytic reformer, gas concentration unit and gasoline
blending.
A. GASOLINE FRACTIONATING UNIT 2,000 m3/day
1. PUMPS AND COMPRESSORS
No. Service Spare RVP Class Pump Type Seal Type
~2~~ Reflux x B C M
2 Feed x B C M
2 Bottoms x B C M
2 1st Side Cut x B C M
2 2nd Side Cut x B C M
2 Compressors x A C M
2. VALVES AND FITTINGS
a. Control Valves - 20
b. Process Valves - 1,260
c. Fittings - 4,230
d. Relief Valves - 22
e. Sample Connections - 31
77
-------
3. COMBUSTION DEVICES
a. Process Heaters and Boilers
Stack Stack
Design Heat Input Height Diameter
Quantity Type (GJ/hr) (m) (m)
T~^ H 15762& O
MODULE NO. SI6
FUTURE EXPANSION
Module area =0.3 hectares: 75m x 45m
This area is reserved for future expansion,
78
-------
MODULE NO. S-17
BOILER HOUSE
Module area =0.5 hectares: 75m x 60m
A. BOILER HOUSE
1. COMBUSTION DEVICES
a. Process Heaters and Boilers
Stack Stack
Design Heat Input Height Diameter
Quanti ty Type (GJ/hr) (m) (m)
2 B WOT"35".* TT5
*Boilers share common stack
2. BUILDING
15m wide X 36m long X 9m high
MODULE NO. S18
PRODUCT STORAGE
Module area = 1.4 hectares: 150m x 90m
A. TANKS
No.
1
1
2
Stock
Benzene
Benzene
Benzene
Toluene
RVP
Estimate
(kPa)
24
23
7.6
Tank
SP
FR
FR
XR
Dia
(m)
10T5"
15.2
24.4
10.5
Ht
M
•7 •
12.
12.
9.
1
2
2
1
Capacity
(m3)
795
2,230
3,730
795
Annual
Throughput
(m3)
51 !SOO
55,350
29,530
79
-------
MODULE NO.S19
CRUDE OIL STORAGE
Module area =3.2 hectares: 210m x 15Qm
A. TANKS
No. Stock
~T~ Crude
2 Crude
1 Crude
RVP
Estimate
(kPa)
9.3
10.3
9.6
Tank
FR
XR
Dia
(ml
3BT7
59.9
39.7
Ht
(m)
TO
14.6
12.2
Capaci ty
(m3)
15,400
41,150
15,100
Annual
Throughput
(m3)
681 ,380
522,400
125,900
MODULE NO. S20
ADMINISTRATION BUILDING AND LABORATORY
Module area =0.7 hectares: 90m x 75m
A. Administration building
B. Laboratory
D I M
Width
(m)
12.
15.
MODULE S21
FLARES
E N S I 0
Length
(m)
20.
40.
N S
Heiqht
(m)
9.
9.
Module area = 1.8 hectares: 150m x 120m
A. FLARES
Capacity Height
No. Type (m3/hr) (m)
Smokeless with automatic steam control 56,600 35
Smokeless with automatic steam control 40,000 31
80
-------
MODULE NO. S22
TRUCK LOADING RACK FACILITY
Module area =0.9 hectares: 150m x 60m
Process Input/Output:
The input to this module is 100,000 m^/year of various
products to be transported by truck and trailer. Control
strategy includes a vapor recovery system for products
with vapor pressurs of 10 kPa or higher.
A. TRUCK LOADING RACK FACILITY
See Standard Unit no. X36
b. VAPOR RECOVERY PACKAGE UNIT. ABSORPTION TYPE 1,000 kg/hr
See Standard Unit no. X36
MODULE NO. S23
PRODUCT STORAGE
Module area =2.5 hectares: 210m x 120m
A. TANKS
RVP Annual
Estimate Tank Dia Ht. Capacity Throughput
No. Stock (kPa) Type (m) (m) (m3) (nP)
~T~ Natural gasoline 83 FR 1775" TO" 3,657 36,250
1 Raffinate gas. 24 FR 32.5 14.6 12,100 269,000
1 FCC gasoline 63 FR 60.3 14.6 41,650 1,024,520
1 FCC gasoline 63 FR 32.9 14.6 12,400 70,500
81
-------
MODULE NO. S24
FEEDSTOCK STORAGE
Module area =2.9 hectares; 240m x 120m
A. TANKS
RVP Annual
Estimate Tank Dia Ht Capacity Throughput
No. Stock (kPa) Type (m) (m) (m3) (m3)
~T~ Platformer feed 21 FR 3T3" TO" 12,400 227,130
2 Heavy naptha 39 FR 33.3 14.6 12,800 204,400
1 Alkylate 34 FR 36.1 14.6 14.950 366,130
MODULE NO. S25
RAIL LOADING RACK FACILITY
Module area =1.4 hectares: 240m x 60m
Process Input/Output:
The input to this module is toluene and xylene, the only
products to be loaded into rail tank cars. The yearly
combined throughput is 8,000 m3. Control strategy consists
only of submerged fill techniques.
A. TANK CAR LOADING RACK FACILITY
8-spot rack, 10 m wide x 180 m/long x 4 m high
MODULE NO. S26
CRUDE OIL STORAGE
Module area =2.2 hectares: 240m x 90m
Average module height = ground level except as indicated below
A. TANKS
RVP Annual
Estimate Tank Dia Ht Capacity Throughput
No. Stock (kPa) Type (m) (m) (m3) (n»3)
1 Crude" ~~OFR 3677" T4~6~ 15,420 795,760
2 Crude 8.9 XR 35.8 12.2 12,240 591,500
82
-------
MODULE NO. S27
PRODUCT STORAGE
Module area = 5.0 hectares: 240m x 210m
A. TANKS
No. Stock
2
1
1
#2 fuel
#2 fuel
#2 fuel
oil
oil
oil
oil
RVP
Estimate
(kPa)
0.14
0.14
0.14
0.14
Tank
Type
XR
XR
XR
XR
Dia
(m)
TO"
36.2
39.9
10.6
Ht
(m)
T2T
12.2
12.2
9.1
Capacity
(m3)
3,180
12,560
15,260
795
Annual
Throughput
(m3)
261 ,400
181,700
225,700
30,500
MODULE NO. S28
PRODUCT STORAGE
Module area =5.8 hectares: 240m x 240m
A. TANKS
No. Stock
2 Motor gasoline
3 Motor gasoline
1 Motor gasoline
1 Motor gasoline
1 Motor gasoline
RVP
Estimate Tank
(kPa) Type
69
69
69
69
69
FR
FR
FR
FR
FR
Dia
36!7
40.1
45.0
32.5
Ht
&
14.6
14.6
14.6
14.6
Capacity
(m3)
12,400
15,420
19,050
23,200
12,100
Annual
Throughput
(m3)
343,400
440,700
450,250
181,700
227,100
83
-------
INTERMEDIATE CAPACITY EXISTING REFINERY
Scale 1 inch = 240 meters
1
2
3
4
5
6
7
8
9
10
12
13
14
15
16
17
20
18
25
26
28
31
27
29
J&L
32
33
34
35
19
21
22
23
36
37
38
39
40
41
53
56
42
54
55
57
58
59
24
11
60
61
43
45
47
44
46
62
63
49
48
50
51
52
84
-------
INTERMEDIATE CAPACITY EXISTING REFINERY MODULE KEY
Standard Unit
Module No. Description Reference No.
Ml Sourwater Oxidizer X41
M2 Crude Distillation/Crude Desalting X12
M3 Crude Distillation X32
M4 Wastewater Treatment X40
M5 Store House
M6 Boiler Feedwater Treating
M7 Boiler House
M8 Treating Plant
M9 Product Transfer/Wastewater Facilities
M10 Drum Filling
Mil Tank Car and Truck Loading
Ml 2 Flares
Ml3 Solvent Decarbonizer X42
Ml4 Product Handling
Ml 5 Store House
Ml 6 Product Storage
Ml7 Aromatics Extraction X25
Ml8 Thermal Hydrodealkylation X43
Ml9 Future Expansion
M20 Naptha Desulfurizer X44
M21 Naphtha Desulfurizer X44
M22 Product Storage
M23 Product Storage
M24 Product Storage
M25 Water Handling Facilities
M26 Catalytic Cracker X26
M27 Acid-Gas Treating X46
M28 Sulfur Recovery X20, X47
M29 Gasoline Sweetening X31
M30 Fractionating Unit
M31 Catalytic Cracking X26
M32 Fractionating Unit
M33 Hydrogen Manufacture X7
M34 Alkylation X48
M35 Naphtha Hydrotreater X2
M36 Naphtha Hydrotreater X2
M37 Catalytic Reformer X24
M38 Catalytic Reformer X24
M39 Steam Generating Plant
M40 Flares
M41 Product Storage/Truck Loading
M42 Product Storage
85
-------
INTERMEDIATE CAPACITY EXISTING REFINERY MODULE KEY
Standard Unit
Module No. Description Reference No.
M43 Oil-Water Separator
M44 Product Storage
M45 Product Storage
M46 Product Storage
M47 Product Storage
M48 Product Storage
M49 Material Storage
M50 Product Shipment X36
M51 Flare
M52 LPG Tank Loading
M53 Future Expansion
M54 Product Storage
M55 Buildings
M56 Product Storage
M57 Product Storage
M58 Administration Building
M59 Building
M60 Product Storage/Shipping
M61 Truck Loading
M62 Product Storage
M63 Product Storage
The wastewater separator in Module Ml2 treats the aqueous
discharge of Modules Ml, M2, M3, M12, M13, and M14.
The wastewater separator located in Module M25 treats the
aqueous discharge of Modules M4-M6, M15-M21, M25-M38, and
M40 and M41.
The separator in Module M43 treats discharge from Modules M43-
M52 and M62-M63.
The separator in Module M9 treats the discharge from the
remaining modules.
86
-------
INTERMEDIATE CAPACITY EXISTING REFINERY
CRUDE CHARGE RATE 32,000 m3/day
PRODUCT SLATE
PRODUCT PRODUCTION RATE (m3/day)
Gasoline 19,000
Distillate fuel oil 8,000
Asphalt 3,200
Residual fuel oils 2,300
Jet fuel 1,000
Lube oils 900
Mixed olefins 750
Kerosene 600
Benzene 350
Naptha 240
Xylene 60
36,400
NUMBER OF WHARF MODULES
87
-------
MODULE NO. Ml
SOUR WATER OXIDIZER
Module area =1.1 hectares: 180m x 60m
Process Input/Output:
Sour water containing hydrogen sulfide and ammonia is
contacted with air at about 93°C to oxidize the hydrogen
sulfide primarily to thiosulfate. Residual air with
stripped ammonia is sent to a furnace.
A. SOUR WATER OXIDIZER. 950 m3/day
See Standard Unit X41
MODULE NO. M2
CRUDE DISTILLATION UNIT
Module area =1.5 hectares; 180m x 84m
Process Input/Output:
Besides a desalting crude oil feed, there is a crude oil
distillation unit with an associated vacuum unit. Four
fractions from the atmospheric column are charged to four
strippers stacked in one column. Products include light
ends, gasoline, naphtha, furnace oil and light gas oil.
The bottoms are further distilled in a vacuum unit to
provide heavier gas oils and a bottom product for further
processing.
A. CRUDE DESALTING UNIT 31 ,800 m3/day
1 . PUMPS AND COMPRESSORS
2.
No.
~r
VAL
a.
b.
c.
d.
Service SjDare RVP Class
Feed X C
VES AND FITTINGS
Control valves
Process valves
Fittings - 500
Relief valves
- 3
- 100
- 3
Pump Type Seal Type
C M
e. Sample Connections - 3
88
-------
3. STEAM HEATER
B. CRUDE DISTILLATION UNIT 23,850 m3/day
1. PUMPS AND COMPRESSORS
See Standard Unit No. XI2
2. VALVES AND FITTINGS
See Standard Unit No. XI2
3. COMBUSTION DEVICES
a. Process Heaters and Boilers
Stack Stack
Design Heat Input Height Diameter
No. Type (GJ/hr) (m) (m)
~T~ H 39561.0 4.1*
1 H 151 61.0 4.1*
*common stack
C. COOLING TOWER
19.8 m wide x 57.9 m long x 9.1 m high
12,700 m /hr water flow rate
D. COOLING TOWER
12.2 m wide x 18.3 m long x 7.6 m high
2,900 m /hr water flow rate
89
-------
MODULE NO. M3
CRUDE DISTILLATION UNIT
Module area = 1.2 hectares; 180m x 66m
Process Input/Output:
The feed and products are the same as those in Module No. M2
A. CRUDE DISTILLATION UNIT 8,000 m3/day
1. PUMPS AND COMPRESSORS
See Standard Unit No. X32
2. VALVES AND FITTINGS
See Standard Unit No. X32
3. COMBUSTION DEVICES
a. Process Heaters and Boilers
No.
1
Type
H
H
Design Heat Input
(GJ/hr)
125
59
Stack
Height
(m)
55
55
Stack
Diameter
(m)
2.2
1.6
MODULE NO. M4
WASTE WATER TREATMENT PLANT
Module area = 3.8 hectares: 210m x 180m
Process Input/Output:
The input is skimmed oily water effluent from the separators.
The output is clarified water for disposal in oceans, rivers,
ponds or by irrigation. Sludge is disposed by incineration
or landfill.
A. WASTE WATER TREATMENT PLANT 20,000 m3/day
See Standard Unit No. X40
B. SLUDGE INCINERATOR
7.6 m wide x 7.6 m long x 9.2 m high overall
90
-------
B. SLUDGE INCINERATOR (Concluded)
Capacity - 9,100 kg/hr
Equipped with a Venturi scrubber
C. OIL-WATER SEPARATOR
9.2 m wide x 42.7 m long
It is equipped with a floating roof
D. SETTLING BASIN
18.3 m wide x 30.5 m long extending 1.0 m above ground level
E. TANKS .„„,,,,
Rvp Annual
Estimate Tank Dia Ht C*P"1t* Throughput
No. Stock (kPa) Type (m) (m) (m_) (nT)
2 Waste water Aqueous XtT 4277 1377 19,600 254,800
2 Waste water Aqueous XR 38.1 12.2 13,900 180,700
2 Slop oil 0.5 XR 18.3 4.6 1,200 15,600
4 Caustic soda Aqueous XR 11.4 4.6 450 5,850
4 Sulfuric acid Chemical XR 11.4 4.6 450 5,850
MODULE NO. M5
STORE HOUSE
Module area =1.6 hectares: 180m x 90m
This area is essentially a storehouse area for receiving and
dispatching equipment, materials, valves, etc.
A. STOREHOUSE
61.0 m wide x 91.4 m long x 12.2 m high
91
-------
MODULE NO. M6
BOILER FEED WATER TREATING PLANT
Module area = 3.8 hectares: 210m x 180m
Annual
Estimate Tank Dia Ht Capacity Throughput
No. Stock (kPa) Type (m) (m) (m3) (m3)
~B~ Water Aqueous XR T5~T 971 1,650 21,450
2 Chlorine - P 1.2 4.9 900 ka
B. COAGULATION BASIN
54.9 m wide x 61.0 m long
Associated flocculator, precipitator filters and softeners
MODULE NO. M7
BOILER HOUSE
Module area = 4.3 hectares: 240m x 180m
The output is plant steam
A. BOILER HOUSE
1. PUMPS AND COMPRESSORS
No. Service Spare RVP Class Pump Type Seal Type
5 Water X Aqueous C M
4 Fuel oil X D C M
2. COMBUSTION DEVICES
a. Process Heaters and Boilers
No.
~T
1
Type
B
B
Design Heat Input
(GJ/hr)
475 each
633
Stack
Height
(m)
61.0
61.0
Stack
Diameter
(m)
5.8*
5.8*
*Common stack
92
-------
D.
No.
~r
9
2
3
1 Mil NO
Stock
#2
#6
#6
Water
Fuel oil
Fuel oil
Fuel oil
RVP
Estimate
(kPa)
Aqueous
0.1
0.1
0.1
Tank
Type
Open
XR
XR
XR
Di
ft
12
6
4
a
T2~
.2
.1
.6
Ht
7\6
4.6
3.7
Capacity
(m3)
1,650
890
130
60
Annual
Throughput
(m3)
21
n
i
,450
,570
,690
780
C. BUILDING
D. BUILDING
DIMENSIONS
Width
61.0
Length
76.2
Height
15.2
30.5
114.3
10.7
MODULE NO. M8
TREATING PLANT
Module area =4.9 hectares; 270m x 180m
Process Input/Output:
Inputs are solvents, thinners, and kerosene from feedstock
storage. Outputs, stocks treated to improve their color,
go to product storage.
A. TREATING PLANT
1 . PUMPS AND COMPRESSORS
No. Service Spare
4
2
1
3
1
1
Solvents
Thinners
Kerosene
Water
Sulfuric
acid
Caustic
soda
X
X
X
X
X
RVP Class
D
D
D
Aqueous
Aqueous
2. VALVES AND FITTINGS
a. Control Valves - none
b. Process Valves - 700
c. Fittings - 2,350
d. Relief Valves - 4
e. Sample Connections - 12
Pump Type
C
C
C
R
R
R
Seal Type
M
M
M
P
P
P
93
-------
B. SEPARATOR BOX
15.2m wide x 41.1m long
API type with floating roof
SEPARATOR BOX
7.6m wide x 41.1m long
API type with floating roof
MODULE NO. M9
PRODUCT TRANSFER/WASTE WATER FACILITIES
Module area = 3.8 hectares: 210m x 180m
A. PUMP HOUSE
1.
2.
PUMPS AND COMPRESSORS
No. Service Spare RVP
3 Product X
transfer
5 Product
transfer X
3 Product
transfer X
VALVES AND FITTINGS
a. Control Valves - none
b. Process Valves - 490
c. Fittings - 1 ,645
d. Relief Valves - 14
e. Sample Connections - 14
Class
B
C
D
COMBUSTION DEVICES
Pump Type Seal Type
c FT^
c
R
M
P
a. Sludge incinerator
Design
Capacity
Type (Kg/hr)
multiole
hearth
No.
1
910
Stack
Height
(m)
12.2
Stack
Diameter
(m)
1.0
C. OIL WATER SEPARATOR API type
22.9m wide x 42.7m long x 3m high
API type with a floating roof
Capacity 22,800 m3/day
94
-------
D. OIL-WATER SEPARATOR
4.6 m wide x 12.2 m long x 3 m high
CPI type with a fixed roof
Capacity 3,000 m /day
E- MULTIPLE SETTLING BASIN
12.2 m wide x 30.5 m long x 2.6 m deep, 750 m capacity
F. MUD SETTLING POND
30.5 m wide x 51.8 m long x 1.8 m deep
Capacity 2,850 m
G. BUILDING
18.3 m wide x 39.6 m long x 7.6 m high
MODULE NO. M10
DRUM FILLING PLANT
Module area = 5.4 hectares: 300m x 180m
A. DRUM FILLING PLANT
1. PUMPS AND COMPRESSORS
No. Service Spare RVP Class Pump Type Seal Type
T
3
3
Off -test
product
Solvents
Thinners
X
X
X
D
D
D
C
C
C
M
M
M
2. VALVES AND FITTINGS
a. Control Valves - none
b. Process Valves - 230
c. Fittings - 780
d. Relief Valves - 10
e. Sample Connections - 10
95
-------
B. TANKS
No.
1
2
8
9
1
RVP
Estimal
Stock (kPa)
Off-test
thinners 1.0
Thinners 0.7
Solvents 0.7
Thinners 1.4
Off-test
solvents 1.0
Type
XR
XR
XR
XR
XR
D
Dia Ht
(m) (m)
4.3 4.6
12.2 9.1
7.0 6.1
2.4 4.6
9.1 5.5
I M E N S I
Width Length
C.
D.
E.
BUILDING
BUILDING
BUILDING
TANK CAR
21.3
30.5
18.3
MODULE NO
AND TRUCK
Module area = 7.9 hectares: 660m
A.
PUMP HOUSE
41.1
54.9
30.5
. Mil
Capacity
(m3)
65
1,050
235
20
360
0 N S
Height;
9.1
13.7
9.1
ni m uu i
Throughput
(m3)
845
13,650
3,050
260
4,680
LOADING RACKS
x 120m
1 . PUMPS AND COMPRESSORS
No. Service S
3 Diesel
4 Commercial
jet fuel
1 Xylene
1 Benzene
2 Fuel oil
6 Solvents
3 Lube oils
pare RVP Class Pump Type
X
X
X
3X
X
D
D
D
C
D
D
D
C
. C
C
C
R
C
R
Seal Type
M
M
M
M
P
M
P
VALVES AND FITTINGS
a. Control Valves - none
b. Process Valves - 650
96
-------
2. VALVES AND FITTINGS (Concluded)
c. Fittings - 2,030
d. Relief Valves - 27
e. Sample Connections - 27
B. TANKS
No.
~T
9
9
5
1
6
2
3
5
55
3
C.
Stock
Diesel fuel
Comm'l jet fuel
Toluene
Diesel fuel
Benzene
Fuel oil
Solvent
Comm'l jet fuel
Lube oil
Solvent and
components
Lube oil
TANK CAR LOADING
RVP
Estimate
(kPa)
0.
1.
7.
0.
23.
0.
0.
1.
1
4
6
1
1
7
4
below 0.1
0.
7
below 0.1
RACK
Tank Dia
Type (m)
XR
XR
XR
XR
FR
XR
XR
XR
XR
XR
XR
7
9
7
14
14
15
6
7
4
3
4
.3
.4
.0
.6
.6
.2
.7
.9
.3
.7
.9
Ht
r^
7
7
6
6
7
6
7
6
6
6
.6
.6
.1
.1
.6
.1
.6
.1
.1
.1
Capacity
(m3)
250
530
290
1,020
1,020
1,380
210
370
90
60
no
Annual
Throughput
(m3)
3
6
3
13
13
17
2
4
1
1
7250
,890
,770
,260
,260
,940
,730
,810
,170
780
,430
6.1 m wide x 33.5 m long x 5.5 m high
D. SOLVENT AND LUBE OIL TRUCK LOADING RACK
6.1 m wide x 10.7 m long x 4.6 m high
E. BUILDING
12.2 m wide x 33.5 m long x 9.1 m high
97
-------
MODULE NO. Ml2
FLARES
Module area =1.2 hectares: 180m x 66m
A. FLARE
Smokeless type with automatic steam control,
TV-mom* to red
36.6 m high
Capacity 78,000 m3/hr
B. FLARE
Smokeless type with automatic steam control,
TV-moni tored
30.5 m high
Capacity 50,000 m /hr
C. OIL-WATER SEPARATOR
19.8 m wide x 38.1 m long x 3.0 m high
API type with a floating roof
MODULE NO. Ml3
SOLVENT DECARBONIZER
Module area =2.1 hectares: 180m x 114m
Process Input/Output:
Feeds to this unit are reduced crude and propane. Products
are decarbonized oil which can be catalytically cracked and
asphalt which can be blended to make fuel oil. Propane is
recycled.
A. SOLVENT DECARBONIZER 8.000 m3/day
1. PUMPS AND COMPRESSORS
See Standard Unit No. X42
2. VALVES AND FITTINGS
See Standard Unit No. X42
98
-------
3. COMBUSTION DEVICES
a. Process Heaters and Boilers
No.
~r
i
i
Type
H
H
H
Design Heat Input
(GJ/hr)
27
119
20
Stack
Height
(ml
~T\
(two) 30
21
Stack
Diameter
ft
1.5
0.9
MODULE NO. Ml4
PRODUCT HANDLING
Module area =3.2 hectares: 180m x 180m
A. PUMPHOUSE
1. PUMPS AND COMPRESSORS
2.
No.
1
1
1
1
1
1
Service Spare
Propane/propylene X
Cumene
Toluene
Benzene X
Solvent X
Commercial jet fuel X
Fuel oil
RVP Class
A
D
D
C
D
D
D
Pump Type
C
C
C
C
C
C
R
Seal Type
M
M
M
M
M
M
P
VALVES AND FITTINGS
a. Control Valves - none
b. Process Valves - 330
c. Fittings - 1,140
d. Relief Valves - 11
e. Sample Connections - 11
B. TANKS
No.
24~
4
Stock
Solvent
Toluene
RVP
Estimate
(kPa)
0.7
7.6
Tank
Type
XR
XR
Dia Ht
13.7 10.7
Capacity
(m3)
160
1,300
Annual
Throughput
(m3)
2,080
16,900
99
-------
B. TANKS (Concluded)
No.
3
2
7
3
2
Stock
Cumene
Commercial
jet fuel
Fuel oil
Benzene
Propane/
RVP
Estimate
JkPaL
1
1
0
23
.4
.4
.14
Tank
Type
XR
XR
XR
FR
Dia
(m)
TIT
9.1
7.3
7.3
Ht
fl-
7.6
6.1
7.6
Capacity
(m3)
1,050
500
250
320
Annual
Throughput
(m3)
13
6
3
4
,650
,500
,250
,160
propylene 1,600 P 3.0 6.1 45 585
C. BUILDING
7.6 m wide x 61.0 m long x 4.6 m high
MODULE NO. Ml5
STOREHOUSE
Module area =3.2 hectares: 180m x 180m
A. STOREHOUSE
45.7 m wide x 91. 4m long x 9.1 m high
MODULE NO. Ml6
PRODUCT STORAGE
Module area = 3.2 hectares: 180m x 180m
A. TANKS
Annual
r *• x Tin- LI* Capacity Throughput
Estimate Tank Dia Ht 3 J 3
No. Stock (kPa) Type (m) (m) (m ) (m )
3 Catalytic
cracking feed 0.1 XR 18.3 6.1 1,600 20,800
3 Alkylate 34. FR 27.4 7.6 4,480 58,240
100
-------
MODULE NO. Ml7
AROMATICS EXTRACTION PLANT
Module area = 2.2 hectares: 240m x 90m
Process Input/Output:
Inputs to this unit are reformates. Benzene, toluene and
xylenes (up to a total of 600 m3) can be produced depending
upon the boiling range of the feed. The toluene can be
charged to a thermal hydrodealkylation unit for manufacture
of additional benzene (Module No. M18). Benzene can be
charged to a cumene unit (Module No. M19).
A. AROMATIC EXTRACTION PLANT 600 m3/day
See Standard Unit No. X25
MODULE NO. Ml8
THERMAL HYDRODEALKYLATION UNIT
Module area =2.2 hectares: 240m x 90m
Process Input/Output:
Toluene is converted in the presence of hydrogen to benzene
with some light gas as a by-product.
A. THERMAL HYDRODEALKYLATION 260 m3/day
See Standard Unit No. X43
MODULE NO. Ml9
FUTURE EXPANSION
Module area = 1.4 hectares: 240m x 60m
This area is reserved for future expansion.
101
-------
RVP
Estimate
(kPa)
10.
0.1
10.
Tank
Type
XR
XR
XR
Dia
(m)
12.2
6.1
18.3
Ht
(m)
7.6
4.6
9.1
Capacity
(m3)
890
135
2,400
Annual
Throughput
(m3)
11,570
1,755
31 ,200
MODULE NO. M20
NAPHTHA DESULFURIZER
Module area = 2.2 hectares: 180m x 120m
Process Input/Output:
Gas oil feed is desulfurized in the presence of hydrogen to
produce feed for a catalytic cracking unit and #2 fuel oil.
Sulfur compounds are converted to hydrogen sulfide with the
production of some light gases.
A. NAPHTHA DESULFURIZER 4,300 m3/day
See Standard Unit No. X44
B. TANKS
No. Stock
10 Hydrotreated
gas oil
3 Diesel fuel
1 Gas oil
MODULE NO. M21
NAPHTHA DESULFURIZER
Module area = 2.2 hectares: 180m x 120m
Process Input/Output:
Gas oil is desulfurized in the presence of hydrogen to produce
feed for a catalytic cracking unit. Sulfur compounds are
converted to hydrogen sulfide with the production of some
light gases.
A. NAPHTHA DESULFURIZER 5,250 m3/day
1. PUMPS AND COMPRESSORS
See Standard Unit No. X44
2. VALVES AND FITTINGS
See Standard Unit No. X44
102
-------
3. COMBUSTION DEVICES
a. Process Heaters and Boilers
Stack Stack
Design Heat Input Height Diameter
B.
No.
10
3
1
No.
TANKS
Stock
Hydro treated
gas oil
Diesel fuel
Gas oil
Module area = 2.9
A.
No.
~T
4
TANKS
Stock
Fuel oil
Type (GJ/hr) (m)
H 92 11.8
nwn
K V r
Estimate Tank Dia Ht Capacity
(kPa) Type (m) (m) (mj)
10 XR 12.2 7.6 890
0.1 XR 6.1 4.6 135
10 XR 18.3 9.1 2,400
MODULE NO. M22
PRODUCT STORAGE
hectares: 240m x 120m
own
Estimate Tank Dia Ht Capacity
(kPa) Type (m) (m) (mj)
0.14 XR 9.1 5.5 360
(m]
1 .2 - three <
Annual
Throughput
o
(m3)
11,570
1,755
31 ,200
Annual
Throughput
o
(m3)
4,680
Straight run
gasoline
Module area =10.
A.
No.
7
3
TANKS
Stock
Commercial
jet fuel
Heavy gas
oil
74. FR 24.4 10.7 5,000
MODULE NO. M23
PRODUCT STORAGE
8 hectares: 360m x 30Qm
m /n
W V P
Estimate Tank Dia Ht Capacity
(kPa) Type (m) (m) (mj)
1.4 XR 35.1 9.1 8,800
0.1 XR 14.6 6.1 1,000
65,000
Annual
Throughput
o
(m3)
114,400
13,000
103
-------
MODULE NO. M24
PRODUCT STORAGE
Module area = 19.2 hectares: 456m x 420m
A. TANKS
No.
1
4
4
1
1
4
Stock
RVP
Estimate
(kPa)
Gasoline 80
Gasoline 80
Fuel oil 0.1
Reformer feed39
Cutter stock 0.1
Commercial
jet fuel 1 .4
Solvents 0.7
Tank
Type
XR
XR
XR
FR
XR
XR
XR
Dia
(m)
35.1
28.0
35.1
28.0
24.4
20.7
12.2
Ht
(m)
9.1
9.8
9.1
9.8
8.0
8.2
5.5
Capacity
8
6
8
6
3
2
,
,
,
,
,
»
800
000
800
000
700
750
550
Annual
Throughput
(m3)
114,400
78,000
114,400
78,000
48,100
35,750
8,450
MODULE NO. M25
WATER HANDLING FACILITIES
Module area =3.1 hectares: 204m x 150m
A pump house, cooling towers, mud settling ponds, primary
separators and a secondary separator are located in the module.
A. PUMPHOUSE
13.7 m wide x 61.0 m long x 10.7 m high
B. COOLING TOWER
15.2 m wide x 91.4 m long x 9.1 m high
17,700 m /hr water flow rate
C. COOLING TOWER
15.2 m wide x 68.6 m long x 9.1 m high
12,200 m /hr water flow rate
D. MUD SETTLING POND
22.9 m wide x 68.6 m long x 3.0 m deep
104
-------
E. MUD SETTLING POND
22.9 m wide x 38.1 m long x 3.0 m deep
F. PRIMARY OIL-WATER SEPARATORS
19.8 m wide x 38.1 m long
Floating roof type
G. SECONDARY OIL-WATER SEPARATOR
38.1 m wide x 61.0 m long
API type with floating roof
MODULE NO. M26
CATALYTIC CRACKING UNIT
Module area = 0.7 hectares; 120m x 60m
Process Input/Output:
The catalytic cracking unit is a typical Kellogg "side-by-side"
type consisting of a reactor, regenerator, electrical precipi-
tator, fractionator and various auxiliary units. The outlet
gas from the precipitator with added gas or oil fuels the CO
boiler.
The unit processes feed stock consisting of heavy gas oil
streams from the vacuum stills or the Hydro-desulfurizer and
decarb oil from the Solvent Decarbonizer. Streams leaving
the main fractionator are a gasoline and lighter overhead
product, a heavier side cut and a bottom gas oil cut part of
which is recycled. The overhead is further processed to
separate gas and gasoline cuts in a three column fractionating
section. Heavier stocks are hydro-treated, cracking and/or
used as blending stock.
A. FLUID CATALYTIC CRACKING UNIT 3,650 m3/day
1. PUMPS AND COMPRESSORS
a. See Standard Unit No. X26
105
-------
2. VALVES AND FITTINGS
a. See Standard Unit No. X26
3. COMBUSTION DEVICES
a. Process Heaters and Boilers
No.
~r
2
1
Heater Design Heat Input
or Boiler (GJ/hr)
H (steam
superheater) 10
H Each 48
B (CO) 263
Stack
Height
(m)
21.3
39.0
42.7
Stack
Diameter
(m)
1.0
2.4*
2.4
*Common stack
B.
4. VESSELS
DIMENSIONS (m)
No.
T~
COOLING
No.
1
Service
Diameter Height
Regenerator 13.0 10.7
TOWER
DIME
Width
N S I 0 N S (m)
Length Height
39.6 6.1
On a structure
with an overall
height of
30.5
Throughput
(metric_tons/hr)
5"79U(5
MODULE NO. M27
ACID GAS TREATING PLANT
Module area =0.4 hectares: 84m x 48m
Process Input/Output:
Acid gas from several locations are treated to remove
hydrogen sulfide
A. ACID GAS TREATING PLANT
See Standard Unit No. X46
106
-------
MODULE NO. M28
SULFUR RECOVERY UNITS
Module area =0.7 hectares: 120m x 54m
Process Input/Output:
HpS is converted to molten sulfur
A. CLAUS SULFUR RECOVERY UNIT 46 metric tons/day
1. PUMPS AND COMPRESSORS
See Standard Unit No. X20
2. VALVES AND FITTINGS
See Standard Unit No. X20
3. COMBUSTION DEVICES
a. Process Heaters and Boilers
Design Heat Input Height Diameter
No. Type (GJ/hr) (m) (m)
~T~ Main reactor 11No stacks
2 Auxiliary start-
up burners 6
B. BEAVON-STRETFORD TAIL GAS CLEANUP UNIT
See Standard Unit No. X47
MODULE NO. M29
GASOLINE SWEETENING UNIT
Module area = 0.5 hectares: 84m x 60m
A. GASOLINE SWEETENING UNIT 4,400 m3/day
1. PUMPS AND COMPRESSORS
a. See Standard Unit No. X31
2. VALVES AND FITTINGS
a. See Standard Unit No. X31
107
-------
MODULE NO. M30
FRACTIONATING UNIT
Module area =0.3 hectares: 84m x 36m
A. FRACTIONATIQN UNIT 800 m3/day
1. PUMPS AND COMPRESSORS
o. Service
T~ Feed to depropanizer
1 Depropanizer reflux/
product
1 Debutanizer feed
1 Debutanizer feed/product
1 Debutanizer bottoms to
storage
Spare
X
X
X
RVP
Class
A
A
A
A
Pump
Type
~T^
C
C
C
C
Seal
^
M
M
M
M
2. VALVES AND FITTINGS
a. Control Valves - 8
b. Process Valves - 560
c. Fittings - 1,880
d. Relief Valves - 10
e. Sample Connections - 10
108
-------
MODULE NO. M31
CATALYTIC CRACKING UNIT
Module area =1.4 hectares: 120m x 120m
Process Input/Output:
The catalytic cracking unit is a typical Kellogg "side-by-
side type consisting of a reactor, regenerator, electrical
precipitator, fractionator and various auxiliary units. The
outlet gas from the precipitation with added gas or oil fuels
the CO boiler.
The unit processes feed stock consisting of heavy gas oil
streams from the vacuum stills and decarb oil from the
Solvent Decarbonizer. Streams leaving the main fractionator
are a gasoline and lighter overhead product, a heavier side
cut and a bottom gas oil cut part of which is recycled.
The overhead is further processed to separate gas and gaso-
line cuts in a three column fractionating section. Heavier
stocks are hydro-treated, cracked and/or used as blending
stock.
A. FLUID CATALYTIC CRACKING UNIT. 7,950 m3/day
1. PUMPS AND COMPRESSORS
a. See Standard Unit No. X26
2. VALVE AND FITTINGS
a. See Standard Unit No. X26
3. COMBUSTION DEVICES
a. Process Heaters and Boilers
Stack Stack
Heater Design Heat Input Height Diameter
No. or Boiler (GJ/hr) (m) (m)
~T~ H (steam
Superheater) 20 21.3 13
2 H 91 39.0 3.4*
1 B(CO) 612 45.9 3.1
*Common stack
109
-------
4. VESSELS
DIMENSIONS
B.
No.
On a structure with
Service Diameter Height an overal height of
1 Reactor 9.7 14.3 9.1
1 Regenerator 18.1 10.7 19.8
2 Hot catalyst
storage 10.5 12.2 3.0
COOLING TOWERS
No.
D I M E N S I 0 N S (m) Throuahout
Width Length Height (metric + 1 hr)
2 13.7 39.6 6.1 5,900
MODULE NO. M32
FRACTIONATING UNIT
Module area =0.4 hectare: 84m x 48m
A. FRACTIONATING UNIT 1 ,600 m3/day
1.
No.
~T
1
1
1
1
PUMPS AND COMPRESSORS
Pump
Service Spare RVP Class Types
Feed tc
depropanizer A C
Depropanizer
reflux/product X A C
Deisobutanizer
feed X A C
Deisobutanizer
reflux/product A C
Deisobutanizer
Seal
Types
M
M
M
M
bottoms to
storage X A CM
2. VALVES AND FITTINGS
a. Control Valves - 8
b. Process Valves - 560
c. Fittings - 1 ,880
d. Relief Valves - 10
e. Single Connections - 10
110
-------
MODULE NO. M33
HYDROGEN MANUFACTURING UNIT
Module area =0.4 hectares: 84m x 48m
Process Input/Output:
Naphtha is used as feed in a steam reforming plant to product
hydrogen
A. HYDROGEN MANUFACTURING UNIT, 1.4 x 106 m3/day
1. PUMPS AND COMPRESSORS
a. See Standard Unit No. X7
2. VALVES AND FITTINGS
a. See Standard Unit No. X7
3. COMBUSTION DEVICES
a. Process Heaters and Boilers
Stack Stack
Design Heat Input Height Diameter
No. Type (GJ/hr) (m) (m)
1 H 264 30.9 1.9
MODULE NO. M34
ALKYLATION UNIT
Module area =2.6 hectares: 174m x 15Qm
Process Input/Output
Feed to the alkylation unit consist of butane butylenes, propane
propylene, isobutane and hydrofluoric acid. The products are the
desired alkylate, propane and butane. The hydrofluoric acid is
recycled.
A ALKYLATION UNIT 2,400 m3/day
1. PUMPS AND COMPRESSORS
a. See Standard Unit No. X48
111
-------
B. TANKS
RVp Annual
Estimate Tank Dia Ht Capacity Throughput
No. Stock (kPa) Type (m) (m) (nT) (nr)
3 AlkyTate 34 FR 18.3 97l 2,400 31,200
2 Alkylate 34 FR 13.7 7.6 1,100 14,300
4 Isobutane 500 P 13.7 1,350 17,550
C. STORM WATER HOLDING BASIN
15.2m wide x 30.5m long x 2.5m deep
MODULE NO. M35
NAPHTHA HYDROTREATER
Module area -1,8 hectares: 180m x 102m
Process Input/Output:
This unit hydrotreats naphtha to provide a suitable
desulfurized feed for a catalytic reformer.
A. NAPHTHA HYDROTREATER, 4,150 m3/day
1. PUMPS AND COMPRESSORS
a. See Standard Unit No. X2
2. VALVUES AND FITTINGS
a. See Standard Unit No. X2
3. COMBUSTION DEVICES
a. Process Heaters and Boilers
Stack Stack
Design Heat Input Height Diameter
No. Type (GJ/hr.) (m) (m)
1 H 42 36.6 3.2
1 H 42 36.6 3.2
112
-------
MODULE NO. M36
NAPHTHA HYDROTREATER
Module area =1.8 heactares: 180m x 102m
Process Input/Output:
This unit hydrotreats naphttia to provide a suitable
desulfurized feed for a catalytic reformer and also
for the hydrogen manufacturing unit.
A. NAPHTHA HYDROTREATER. 4,600 m3/day
1. PUMPS AND COMPRESSOR
a. See Standard Unit No. X2
2. VALVES AND FITTINGS
a. See Standard Unit No. X2
3. COMBUSTION DEVICES
a. Process Heaters and Boilers
No.
1
1
Type
H
H
Design Heat Input
(GJ/hr)
47
50
Stack
Height
36.6
36.6
Stack
Height
3.2
3.2
113
-------
MODULE NO. M37
CATALYTIC REFORMER
Module area =1.7 hectares: 144m x 120m
Process Input/Output:
The feed to the reformer is desulfurized naphtha. The
products in addition to reformate are hydrogen and light
hydrocarbons.
A. CATALYTC REFORMER. 4.150 m3/day
1. PUMPS AND COMPRESSORS
a. See Standard Unit No. X24.
VALVES AND FITTINGS
a. Control Valves - 17
b. Process Valves - 1,190
c. Fittings - 4,000
d. Relief Valves - 17
e. Sample Connections - 30
COMBUSTION DEVICES
a. Process Heaters and Boilers
No.
1
1
1
Type
H
H
H
Design Heat Input
(GJ/hr)
55
133
69
Stack
Height
(m)
36.6
36.6
36.6
Stack
Diameter
(m)
2.3
2.5
2.0
114
-------
MOUDLE NO. M38
CATALYTIC REFORMER
Module area = 2.1 hectares: 144m x 144m
Process Input/Output:
The feed to the reformer is desulfurized naphtha. The products
in addition to reformate are hydrogen and light hydrocarbons.
A. CATALYTIC REFORMER. 4,150 m3/day
1. PUMPS AND COMPRESSORS
a. *ee Standard Unit No. X24
2. VALVES AND FITTINGS
a. Control Valves - 17
b. Process Valves - 1,190
c. Fittings - 4,000
d. Relief Valves - 17
e. Sample Connections - 30
3. COMBUSTION DEVICES
a. Process Heaters and Boilers
No. Type
1 H
1 H
1 H
Design Heat Input
(GJ/hr)
55
133
69
Stack
Height
(m)
36.6
36.6
36.6
Stack
Diameter
(m)
2.3
2.5
2.0
115
-------
MODULE NO. M39
STEAM GENERATING PLANT
Module area = 2.6 hectares: 18Qm x 144m
Process Input/Output:
A boiler house and several tanks are located in this area,
The boiler house accommodates two foilers which have a
common stack. Oil and gas are used as fuels.
A. STEAM GENERATING PLANT
1. COMBUSTION DEVICES
a. Process Heaters and Boilers
B.
No.
2
2
C.
Quanity
2
TANKS
Stock
crude oil
fuel oil
water
BUILDINGS
Heater
or Boiler
3
RVP
Estimate
(kPa)
28
0.1
Design
Heat Input
(GJ/hr)
650 each
Tank Dia Ht
*& £k&
XR 15.2 7.3
XR 18.3 8.2
Stack
Diameter
(m)
5.8
Capacity
(m3)
7,700
1,300
2,150
Stack
Height
(m)
61.0
Annual
Throughput
(m3)
100,000
16,900
27,950
18.3m wide x 30.5m long x 12.2m high
116
-------
Height
(m)
45.7
45.7
Smokeless
Capacity
(m3/hr)
7.9 x 104
4.8 x 104
MODULE NO. M40
FLARES
Module area =3.4 hectares: 186m x 180
Process Input/Output:
The two flares in this area serving the catalytic cracking
units are John Zink smokeless type with automatic steam
control and a TV monitor.
A. FLARES
No.
1
1
MODULE NO. M41
PRODUCT STORAGE/TRUCK LOADING RACK
Module area = 6.7 hectares: 36Qm x 186m
A. PUMPS
RVP Pump Seal
No. Service Spare Class Type Type
1 Transfer ACM
1 Transfer C C M
1 Transfer D C M
B. VALVES AND FITTINGS
a. Control Valves - none
b. Process Valves - 210
c. Fittings - 700
d. Relief Valves - none
e. Sample Connections - 10
117
-------
C. TANKS
RVP
Estimate
(kPa)
0.1
1.4
31
0.1
0.1
0.1
0.1
39
1,440
Tank
Type
XR
XR
FR
XR
XR
XR
XR
FR
P
Dia
(m)
"247?
37.2
37.2
37.2
37.2
21.3
14.6
18.3
3.4
Ht
9.1
12.2
12.2
12.2
12.2
12.2
7.6
9.1
12.2
Capacity
(m5)
4,250
13,250
13,250
13,250
13,250
4,350
1,300
2,400
110
Annual
Throughput
(m3)
55,250
172,250
172,250
172,250
172,250
56,550
16,900
31 ,200
1,430
7.0m side x 30.5m long x 4.6m high
MODULE NO. M42
PRODUCT STORAGE
Module area = 11.3 hectares: 540m x 21Qm
A. PRODUCT TRANSFER
1.
PUMPS AND COMPRESSORS
No. Service
Transfer
Transfer
Transfer
RVP Class Pump Type Seal Type
C CM
D CM
B CM
2.
VALVES AND FITTINGS
a. Control Valves -
b. Process Valves -
c. Fittings -
d. Relief Valves -
none
170
600
none
e. Sample Connections - 10
118
-------
B. TANKS
RVP Annual
Estimate Tank Dia Ht Capacity Throughput
No. Stock (kPa) Type (m) (m) (m3) (m3)
6~~ Crude 21 FR ~3676 1272 12,800 166,400
2 Fuel oil 0.1 XR 36.6 12.2 12,800 166,400
2 Blending stock 50 FR 36.6 12.2 12,800 166,400
1 Commercial jet 1.4 XR 36.6 12.2 12,800 166,400
fuel
C. COOLING TOWER
19.8m wide x 131m long x 9.1m high
17,700 metric ton/hr flow rate
MODULE M43
OIL-WATER SEPARATOR
Module area =2.2 hectares: 180m x 120m
Process Input/Output:
The input to this area is wastewater from a process area. Output is
handled further before final discharge.
A. API TYPE OIL-WATER SEPARATOR
Capacity 14,000 m-Vday
7.6m wide x 34.0m long
It is equipped with a floating roof.
MODULE NO. M44
PRODUCT STORAGE
Module area =6.3 hectares: 300m x 210m
A. TANKS
No.
3
2
Stock
Gasoline
Gasoline
RVP
Estimate
(kPa)
80
80
Tank
Type
XR
FR
Dia Ht.
(m) (m)
36.6 12.2
36.6 12.2
Capacity
(m3)
12,800
12,800
Annual
Throughput
(m3)
265,000
230,000
MODULE NO. M45
PRODUCT STORAGE
Module area = 5.4 hectares: 300m x 18Qm
119
-------
A. TANKS
No. Stock
4Gasoline
2 Gasoline
RVP
Estimate
(kPa)
80
80
Tank
Type (m)
YD •}
-------
MODULE NO. M50
PRODUCT SHIPMENT
Module area = 1.5 hectares: 180m x 84m
A. PRODUCT TRANSFER
1. PUMPS AND COMPRESSORS
B.
No.
T
1
1
1
C.
No.
r~
i
i
TANKS
Stock
Gasoline
Jet fuel
Fuel oil
Kerosene
TANK CAR
Service
Transfer
Transfer
Transfer
RVP
Estimate
(kPa)
80
0.1
below 0.1
0.2
LOADING RACK
Spare
Tank
Type
FR
XR
XR
XR
RVP Pump Seal
Class Type Type
B
D
D
Dia
8.2
5.8
11.6
6.4
Ht.
3.0
7.6
3.0
C
C
D
Capaci ty
290
80
800
95
M
M
M
Annual
Throughput
(m3)
3,770
1,040
10,400
1,235
See Standard Unit No. X36
MODULE NO. M51
FLARE
Module area =2.7 hectares: 180m x 148m
Process Input/Output:
Input to flare is LPG product from storage and loading facilities.
A. FLARE
Height Capacity
No. Type (m) (m/hr)
1 Elevated smokeless 39.6 2,800
MODULE NO. M52
LPG TANK CAR LOADING RACK
Module area =5-4 hectares: 300m x 180m
A. LPG LOADING
1. PUMPS AND COMPRESSORS Rvp Rump ^
No. Service Spare Class Type Type
JT~ Butane ACM
1 Propane X A C M
121
-------
B. TANKS
No. Stock
5 Butarie
0 Propane
C. LPG TANK CAR
3.0m
Module area = 1 .
This vacant
Module area = 2.
A. TANKS
No. Stock
4 Fuel oil
RVP
Estimate
(kPa)
350
1,300
Tank Dia Ht
Type (m) (m)
P 21 .3 sphere
P 3.4 18.9
length
Capacity
(m3)
5,050
170
Annual
Throughput
(m3)
65,650
2,210
LOADING RACK
wide x 30.0m long
0 hectares:
MODULE NO. 53
FUTURE EXPANSION
174m x 60m
area is available for future plant
7 hectares:
RVP
Estimate
(kPa)
below 0.1
Two buildings which are
Module area =2.6 hectares:
Module area = 3.
A. TANKS
No. Stock
1 Light fur-
nace oil
1 hectares:
RVP
Estimate
(kPa)
0.1
MODULE NO. M54
PRODUCT STORAGE
240m x 114m
Tank Dia Ht.
Type (m) (m)
MODULE NO. M55
BUILDINGS
expansion
Capacity
(m3)
12,800
less than 9.0m high are located
240m x 108m
MODULE NO. M56
PRODUCT STORAGE
18Qm x 174m
Tank Dia Ht.
Type (m) (m)
XR 36J5 U72
Capacity
12,800
•
Annual
Throughput
166,400
in this area.
Annual
Throughput
(m3)
166,400
122
-------
RVP
Estimate Tank Dia Ht Capacity
No. Stock (kPa) Type (m) (m) (m3)
2 Hydrotreated 0.1 XR 18.3 7.9 2,050
gas oil
MODULE NO. M57
PRODUCT STORAGE
Module area =4.8 hectares: 396m x 12Qm
A. TANKS
RVP
Estimate Tank Dia Ht. Capacity
No. Stock (kPa) Type (m) (m) (m3)
2 Light gas oil 10 XR 36.6 12.2 12,800
1 Hydrotreated 0.1 XR 36.6 12.2 12,800
furnace oil
1 Light Naphtha 84 FR 36.6 12.2 12,800
MODULE NO. M58
ADMINISTRATION OFFICE
Module area =4.1 hectares: 264m x 156m
A. BUILDING
61.0m long x 10.7m high
MODULE NO. M59
BUILDING
Module area =3.2 hectares: 264m x 120m
A. BUILDING
17.7m wide x 38.1m long x 10.7m high
MODULE NO. M60
PRODUCT STORAGE/SHIPPING
Module area = 4.3 hectares: 360m x 120m
A. PRODUCT SHIPPING
1 PUMPS AND COMPRESSORS
RVP Pump
No. Service Spare Class Type
1 Benzene C C
1 Toluene C C
1 Xylene D C
1 Spare - C
Annual
Throughput
(m3)
26,650
Annual
Throughput
(m3)
166,400
166,400
166,400
Seal
Type
M
M
M
M
123
-------
B. TANKS
No.
r~
2
2
2
RVP
Estimate
Stock (kPa)
Benzene 23
Benzene 23
Toluene 7.6
Toluene 7.6
Tank Dia
Type (m)
R 1377
FR 18.3
XR 18.3
XR 27.4
Annual
Ht. Capacity Throughput
(m) (m3) 7m3)
11 .9 1,750 22,750
14.6 3,800 49,400
14.6 3,800 49,400
12.2 1,750 22,750
MODULE NO. M61
TRUCK LOADING RACK
Module area =5.8 hectares: 480m x 12Qm
A.
B.
No.
T~
1
C.
TRUCK LOADING
1 . PUMPS AND COMPRESSORS
No. Service
3 Gasoline
1 Vapor recovei
compressor
2. VALVES AND FITTINGS
a. Control valves -
b. Process valves -
c. Fittings -
d. Relief valves -
e. Sample Connections -
TANKS
RVP
Estimate
Stock (kPa)
Gasoline 30
Vapor above 300
TRUCK LOADING RACK
Spare
X
*y
none
170
590
5
5
Tank Dia
Type (m)
XR ~9~4
Sphere 6.4
RVP Pump Seal
Class Type Type
B CM
A R P
Annual
Ht. Capacity Throughput
(m) (m3) (m3)
67T 420 5,460
135 1,755
13.7m wide x 70.1m long x 6.1m high
124
-------
MODULE NO. M62
PRODUCT STORAGE
Module area =14.4 hectares: 480m x 300m
A. TANKS
No. Stock
TT~ Heavy naphtha
2 Gas oil
4 Diesel fuel
RVP
Estimate
(kPa)
39
0.1
0.1
Tank
Type
PR
XR
XR
Dia Ht. Capacity
(m) (m) (m3)
"4379 13.7 20,700
43.9 13.7 20,700
43.9 13.7 20,700
Annual
Throughput
"
179,000
1 79 ,000
179,000
MODULE NO. M63
PRODUCT STORAGE
Module area = 14.4 hectares: 480m x 300m
A. TANKS
No. Stock
3 Light naphtha
3 Commercial
jet fuel
RVP
Estimate
(kPa)
84
1.4
Tank Dia Ht. Capacity
Type (m) (m) (m3)
FR 43.9 1377 20,700
XR 43.9 13.7 20,700
Annual
Throughput
(g)
179,000
179,000
125
-------
LARGE CAPACITY EXISTING REFINERY
Scale 1 inch = 300 meters
11
12
8
13
14
15
16
17
18
19
20
10
21
23
24
22
25
26
27
33
36
35
37
38
43
44
28
29
30
31
45
46
49
47
50
32
51
34
48
52
39
41
40
42
53
55
56
58
59
60
68
61
62
6364
54
65
66
69
57
72
67
74
75
70
71
73
76
126
-------
LARGE CAPACITY EXISTING REFINERY MODULE KEY
Standard Unit
Module No. Description Reference No.
LI Buffer Zone
L2 Feedstock Storage
L3 Crude Oil Storage
L4 Feedstock Storage
L5 Feedstock Storage
L6 Crude Oil Storage
L7 Feedstock and Product Storage
L8 Crude, Feedstock, and Product Storage
L9 Crude, Feedstock, and Product Storage
L10 Oil-Water Separator
Lll Product Storage
LI 2 Product Storage
LI3 Distillation and Gas Recovery Unit XI
LI4 Jet Hydrofiner/Catalytic Reformer X4, X5
LI 5 Naphtha Nydrotreater X2
LI 6 Hydrotreater X6
LI7 Hydrogen Manufacturing X7
LI8 Partial Oxidation Unit X8
LI9 Future Expansion
L20 Cooling Tower
L21 Flares
L22 Feedstock and Product Storage
L23 Naphtha Hydrotreater X2
L24 Vacuum Gas Oil Unit X9
L25 Benzene Fractionation XI0
L26 Steam Rerun Stills Xll
L27 Future Expansion
L28 Crude Distillation XI2
L29 Catalytic Reformer XI3
L30 Vacuum Residuum Desulfurizer XI4
L31 Hydrogen Manufacturing X7
L32 Alkylation XI5, XI6, XI7
L33 Distillate Hydrodesulfurization X18, X19, X20, X21,
X22
L34 Sulfur Recovery X20, X21, X22, X23
L35 Tanks/Cooling Towers
L36 Catalytic Reformer X24
L37 Aromatics Extraction X25
L38 Catalytic Cracking X26
L39 Para-Xylene Plant X27
L40 Delayed Coker X28
L41 Barrel Storage
127
-------
LARGE CAPACITY EXISTING REFINERY MODULE KEY
Standard Unit
Module No. Description Reference No.
L42 Barrel Reconditioning
L43 Feedstock Storage
L44 Storm Water Impound Basin
L45 Warehouse
L46 Gas Holder/Slowdown Stack
L47 Gas Holder/Slowdown Stack
L48 Fire Prevention Training Facility
L49 Oil-Water Separator
L50 Asphalt Plant
LSI Solvent Treating Plant/Boiler House
L52 S02 Treating Plant/Tanks X29, X30
L53 Lube Oil Packaging
L54 Coke Storage
L55 Crude Oil Storage
L56 Feedstock Storage
L57 Tanks/Impound Basin
L58 Administration
L59 Oil-Water Separator
L60 Gasoline Sweetener/Crude Distillation XI2, X31
L61 Crude Distillation/Crude Desalter X32, X33
L62 Specialty Crude Distillation X34
L63 Specialty Crude Distillation/Condenser
Box X34
L64 Gasoline Fractionating Unit X35
L65 Tank Loading/Truck Loading/Vapor Recovery X36
L66 Buildings
L67 LPG Storage and Blending
L68 Vapor Recovery/Gasoline~Rectifier/Tanks X37, X39
L69 Main Pump House X45
L70 Product Storage
L71 Wastewater Treatment X40
L72 Building
L73 Product Storage
L74 Shops and Warehouse
L75 Crude Oil Storage
L76 Crude, Feedstock, and Product Storage
The oil/water separator in Module L10 treats aqueous discharge
from Modules L1-L21
The separator located in Module L59 treats aqueous streams
from Modules L58-L60, L68, L70, L71, and L73-L76.
The wastewater separator in Module L49 treats discharges from
the remaining modules.
128
-------
LARGE CAPACITY EXISTING REFINERY
CRUDE CHARGE RATE 40,000 m3/day
BENZENE IMPORTED INTO REFINERY 195 m3/day
PRODUCT SLATE
PRODUCT PRODUCTION RATE m3/day
Gasoline 24,248
Fuel oil 10,934
Jet fuel 7,120
Distillate fuel oil 7,929
Coke 3,427
Naptha 1,364
Toluene and xylene 1,143
Asphalt 722
Mixed olefins 462
Benzene 250
Lube oils 127
Kerosene 64
57,790
NUMBER OF WARF MODULES 8
129
-------
MODULE NO. LI
BUFFER ZONE
Module area = 14.4 hectares: 600m x 240m
A. INTERMEDIATE STORM WATER STORAGE BASIN
66.6 m wide x 122 m long x 4 m deep
MODULE NO. L2
FEEDSTOCK STORAGE
Module area =10.1 hectares: 42Qm x 240m
A. RESERVOIR FOR LIGHT RESIDUUM STORAGE
RVP 0.1 kPa
152.4 m wide x 243.8 m long
It extends 3 m above ground level
It is equipped with a fixed roof
Capacity 153,190m3
MODULE NO. L3
CRUDE OIL STORAGE
Module area = 5.0 hectares; 420m x 120m
A. TANKS
RVP Annual
Estimate Tank Dia Ht Capacity Throughput
No. Stock (kPa) Type (m) (m) (m3) (m3)
~~T Crudi 26.0 FR 357 9~T 6,490 34,350
130
-------
MODULE NO. L4
FEEDSTOCK STORAGE
Module area =12.6 hectares: 420m x 300m
A. RESERVOIR FOR HEAVY RESIDUUM STORAGE
RVP 0.0007 kPa
122 m wide x 289.6 m long
It extends 3 m above ground level
It is equipped with a fixed roof
Capacity 49,500 m3
MODULE NO. L5
FEEDSTOCK STORAGE
Module area = 10.1 hectares: 420m x 240m
A. RESERVOIR FOR LIGHT RESIDUUM STORAGE
RVP 0.1 kPa
91.44 m wide x 152.4 m long
It extends 3 m above ground level
It is equipped with a fixed roof
Capacity 79,500 m3
MODULE NO. L6
CRUDE OIL STORAGE
Module area =10.1 hectares: 420m x 240m
A. TANKS
No. Stock
Crude
RVP
Estimate Tank Dia
(kPa) Type (m)
28. FR 35.
Annual
Ht Capacity Throughput
(m) (m3) (m3)
9.1 6,490 84,350
131
-------
MODULE NO. L7
FEEDSTOCK AND PRODUCT STORAGE
Module area =11.5 hectares: 480m x 240m
A. TANKS
No. Stock
1 Cycle oil
1 Heavy gas oil
1 Heavy gas oil
1 Motor gasoline
1 Cutter stock
3 Heavy gas oil
1 Motor gasoline
1 Cutter stock
1 Heavy residuum
1 Light naphtha
1 Diesel
RVP
Estimate
(kPa)
3.4
0.14
0.14
80.
0.14
0.14
80.
0.14
0.0007
84.
0.14
Tank
Type
FR
XR
XR
FR
XR
XR
FR
XR
XR
FR
XR
Dia
M
41.1
35.
35.
42.
35.
36.6
35.
9.1
34.1
35.
36.6
Ht
(m)
14.6
13.4
13.4
14.6
10.7
12.5
10o7
9.1
11.
10.7
12.5
Capaci ty
(m3)
20,460
10,530
10,285
20,460
10,285
13,215
10,285
8,740
10,310
10,285
13,215
Annual
Throughput
(m3)
266,000
136,920
133,710
265,975
133,710
171,800
133,710
113,610
134,065
134,065
171,800
MODULE NO. L8
CRUDE, FEEDSTOCK, AND PRODUCT STORAGE
Module area =30.2 hectares: 720m x 420m
A. TANKS
to. Stock
~T~ Re formate
1 Commercial jet
fuel
2 Reformate
1 Crude oil
5 Motor gasoline
1 Condensate
2 Light residuum
1 Spent caustic
2 Diesel
1 Reformate
1 Crude oil
1 Crude oil
RVP
Estimate
(kPa)
31.
1.4
31.
28.
80.
22.
0.1
34.5
0.14
31.
28.
28.
Tank
Type
FR
XR
FR
FR
FR
FR
XR
FR
XR
FR
FR
XR
Dia
M
35.
30.5
30.5
54.9
35.
36.6
36.6
29.
36.6
45.7
35.
35.
Annual
Ht Capacity Throughput
(m) (m3) (m3)
9.1
12.2
12.2
13.7
10.7
12.5
12.5
12.2
12.2
13.7
10.7
9.1
8,565
7,460
7,460
23,900
10,285
13,215
13,215
7,625
12,850
15,750
10,285
8,565
111,350
97,000
97,000
310,700
133,700
171,800
171,800
99,135
167,000
204,550
133,700
111,350
132
-------
No. Stock
~T~ Jet fuel
1 Stove oil
1 Automotive diesel
1 Furnace oil
1 Heavy gas oil
RVP
Estimate
(kPa)
17.
0.14
0.14
6.
0.14
Tank
Type
FR
XR
XR
XR
XR
Dia
M
35.
45.7
45.7
45.7
45.7
Ht (
10.7
13.7
13.7
13.7
13.7
3apaci ty
(m3)
10,285
15,730
15,730
15,730
15,730
Annual
Throughput
(m3)
133,700
204,500
204,500
204,500
204,500
MODULE NO. L9
CRUDE, FEEDSTOCK, AND PRODUCT STORAGE
Module area =27.7 hectares; 660m x 420m
A. TANKS
No. Stock
1 Reformate
4 Gasoline
1 Diesel
1 Recycle oil
1 Crude
1 Crude
1 Heavy gas oil
1 Jet fuel
1 Jet fuel
1 Heavy gas oil
1 Commercial jet
fuel
3 Commercial jet
fuel
1 Heavy gas oil
1 Thinner
1 Heavy gas oil
1 Jet fuel
1 Light residuum
1 Alkylate
1 Condensate
1 Commercial jet
fuel
1 Jet fuel
2 Motor gasoline
RVP
Estimate
(kPa)
31.
28.
0.14
3.4
28.
28.
0.14
17.
17.
0.14
1.4
1.4
0.14
1.4
0.14
17.
0.1
34.
22.
1.4
17.
80.
Tank
Type
FR
FR
XR
FR
FR
FR
XR
FR
FR
XR
XR
XR
XR
FR
XR
FR
XR
'FR
FR
XR
FR
FR
Dia
(m)
35.
35.
35.
45.7
45.7
61.
35.
35.
45.7
35.
35.
35.
36.6
33.5
35.
35.
35.
36.6
15.2
35.7
35.
35.
Annual
Ht Capacity Throughput
(m) (m3) (m3)
9.1
9.1
9.1
13.7
13.7
19.2
9.1
9.1
13.7
12.2
10.7
9.1
12.5
T3.7
10.7
9.1
9.1
12.5
14.6
12.8
10.7
9.1
8,565
8,565
8,565
15,700
15,700
53,300
8,565
8,565
15,730
8,860
10,300
8,800
13,200
13,200
10,285
8,565
8,565
13,200
2,660
13,200
10,285
8,565
111,350
111,350
111,350
204,500
204,500
692,900
111,350
111,350
204,530
115,130
133,700
114,400
171,600
171,600
134,065
111,350
111,350
171,600
34,640
171,600
134,065
111,350
133
-------
MODULE NO. L10
OIL-WATER SEPARATOR
Module area = 5.0 hectares: 420m x 120m
Process Input/Output:
The input to this module is the wastewater from a process
area and surrounding area. The output is to Module No. 71,
the wastewater treatment plant.
A. API TYPE OIL-WATER SEPARATOR
Capacity 14,560 m3/day
7.62 m wide x 34 m long
It is equipped with a floating roof
MODULE NO. Lll
PRODUCT STORAGE
Module area =7.2 hectares: 300m x 240m
TANKS
No. Stock
1 Motor gasoline
1 Condensate
2 Motor gasoline
RVP
Estimate
(kPa)
80.
22.
80.
Tank
Type
FR
FR
FR
Dia
M
35.
35.
36.6
Ht.
(m)
9.1
9.1
9.1
Capacity
(m3j
8,850
8,850
15,419
Annual
Throughput
(m3)
115,000
115,000
200,448
MODULE NO. LI2
PRODUCT STORAGE
Module area = 1.8 hectares: 600m x 300m
A. TANKS
No. Stock
Gasoline
RVP
Estimate
(kPa)
74
Tank
Type
FR
Dia
(m)
35.
Ht
(m)
9TT
Capacity
(m3)
8,850
Annual
Throughput
(n»3)
115,000
134
-------
MODULE NO. LI3
DISTILLATION AND GAS RECOVERY UNIT
Module area =2.9 hectares: 240m x 120m
Process Input/Output:
The input to this module is the catalytic cracker process
gas and the stabilizer overhead gas. The output is to fuel
gas, LPG storage and gasoline storage.
A. DISTILLATION AND GAS RECOVERY UNIT 1.5 x 106 m3/day
See Standard Unit No. XI
MODULE NO. L14
JET HYDROFINER/CATALYTIC REFORMER
Module area = 2.2 hectares: 240m x 90m
Process Input/Output:
Input to this module is jet fuel and naphtha. Output is
to product storage.
A. JET HYDROFINER 500 m3/day
See Standard Unit No. X5
B. CATALYTIC REFORMER 4.800 m3/day
See Standard Unit No. X4
MODULE NO. LI5
NAPHTHA HYDROTREATER
Module area =2.2 hectares: 240m x 90m
Process input/Output:
The input to this module is from intermediate naphtha
storage. The output is to catalytic reformers, gasoline
blending, or hydrogen manufacture.
135
-------
A. NAPHTHA HYDROTREATER 2.385 m3/day
See Standard Unit No. X2
B. NH3-H2S RECOVERY PLANT
This is considered to be a chemical plant with few
hydrocarbon emissions.
MODULE NO. LI6
HYDROTREATER UNIT
Module area = 2.9 hectares: 24Qm x 120m
Process Input/Output:
The inputs to this module are from the catalytic cracker
and from the vacuum distillation intermediate storage.
Outputs go to a gas recovery section, to intermediate
storage for further processing, and to gasoline blending.
A. HYDROTREATER UNIT 8.000 m3/day
See Standard Unit No. X6
B. BUILDING
Control House - 9.1 m wide x 18.3 m long x 9.2 m high
MODULE NO. LI7
HYDROGEN MANUFACTURING UNIT
Module area =1.4 hectares: 240m x 60m
Process Input/Output:
The input to this module is from a natural gas source,
refinery gas, propane, butane, and naphtha. The output
is to units requiring hydrogen in the Isomax complex.
A. HYDROGEN MANUFACTURING UNIT 2.800.000 m3/day
See Standard Unit No. X7
136
-------
MODULE NO. LI8
PARTIAL OXIDATION UNIT
Module area =1.4 hectares: 240m x 60m
Process Input/Output:
The input to this unit is fuel oil. The output is hydrogen
to the units in the Isomax complex.
A. PARTIAL OXIDATION UNIT FOR HYDROGEN MANUFACTURE 85.000 m3/day
See Standard Unit No. X8
MODULE NO. LI9
FUTURE EXPANSION
The area of this module is 1.4 hectares. This is vacant area
reserved for future plant expansion. Module dimensions are
240m x 60m.
MODULE NO. L20
COOLING TOWER
Module area = 10.8 hectares: 360m x 300m
Process Input/Output:
The input to this module is warm water from a process
complex. The output is cool water back to the complex.
A. BUILDING
23. m wide x 31. m long x 9. m high
B. COOLING TOWER
15. m wide x 55.1 m long x 6.4 high
10,180 T/hr water flow rate
137
-------
MODULE NO. L21
FLARES
Module area =15.1 hectares: 840m x 180m
Process Input/Output:
The input to this module is waste gas from the coker,
catalytic cracking unit, and a process complex. The
output is (#2 and water vapor to the atmosphere.
A. FLARES
Quantity
1
2
Type
Elevated smokeless
Elevated smokeless
Diameter
(m)
1.22
1.22
Height
(m)
51.0
45.7
Capacity
(kg/hr)
313,000
590,000
MODULE NO. L22
FEEDSTOCK AND PRODUCT STORAGE
Module area = 5.8 hectares: 480m x 120m
A. TANKS
No. Stock
~T~ Light gas oil
2 Isobutane
2 Gasoline
1 Polymers
1 Cumene
2 Gasoline
2 Natural gasoline
2 Recycle oil
1 Cutter stock
2 Benzene
1 Isoparaffin
1 Cumene
RVP
Estimate
(kPa)
10.4
503.
80
70
Io4
80
83
3.4
.14
23.
8.3
1.4
Tank Dia
Type (m)
FR
P
FR
FR
FR
FR
P
FR
XR
FR
FR
FR
23.8
10.4
15.2
7.3
9.1
46.0
9.1
18.3
18.3
10.7
10.7
10.7
Ht Capacity
(m) (m3)
10.7
-
14.6
10.7
9.1
15.9
9.1
9.1
10.7
10.7
10.7
4,750
590
2,650
450
600
26.400
390
2,400
2.400
960
960
960
Annual
Throughput
(m3)
61 ,850
10,150
34,450
5,800
7.700
343,500
5,000
31,100
31,000
12,500
12,500
12,500
138
-------
MODULE NO. L23
NAPHTHA HYDROTREATER
Module area =1.0 hectares: 120m x 84 m
Process Input/Output:
The input to this module is from intermediate naphtha
storage. The output is to catalytic reformers, gasoline
blending, or hydrogen manufacture.
A. NAPHTHA HYDROTREATER. 2,385 m3/day
See Standard Unit No. X2
MODULE NO. L24
VACUUM GAS OIL UNIT
Module area = 1.0 hectares: 120m x 84m
Process Input/Output:
The input to this module is from crude units or storage.
The output is to the fluid catalytic cracking unit or to
diesel fuel.
A. VACUUM GAS OIL UNIT, 5,565 m3/day
See Standard Unit No. X9
MODULE NO. L25
BENZENE FRACTIONATION
Module area =1.3 hectares: 120m x 108m
Process Input/Output:
The input to this module is aromatics imported into the
refinery. Outputs ar£ separated aromatics to storage.
A. BENZENE FRACTIONATION. 800 m3/day
See Standard Unit No. XI0
139
-------
MODULE NO. L26
STEAM RERUNSTILLS
Module area =1.3 hectares: 120m x 108m
Process Input/Output:
The input to the module is from gas storage. The output
goes to naphtha and gas oil bright stock storage.
A. STEAM RERUN STILLS. 2 stills, 2,000 m3/day each
See Standard Unit No.
MODULE NO. L27
FUTURE EXPANSION
The area of this module is 1.2 hectares. This vacant area is
available for future plant expansion. Module dimensions are
120m x 96m
MODULE NO. L28
CRUDE DISTILLATION UNIT
Module area = 1.0 hectare: 120m x 84m
Process Input/Output:
The input to this module is from crude storage. The output
is to residuum storage and to intermediate storage for the
various fractions that require further processing.
A. CRUDE DISTILLATION UNIT 23,850 m3/day
See Standard Unit No. XI2
140
-------
MODULE NO. L29
CATALYTIC REFORMER
Module area = 1.0 hectares: 120m x 84m
Process Input/Output:
The input to this module is desulfurized naphtha. The
output is to gasoline blending or an aromatic extraction
unit.
A. CATALYTIC REFORMER. 3,200 m3/day
See Standard Unit No. XI3
MODULE NO. L30
VACUUM RESIDUUM DESULFURIZER
Module area = I.Q hectares; 120m x 84m
Process Input/Output:
The input to this module is residuum from storage. The output
is feed to the catalytic cracking unit.
A. VACUUM RESIDUUM DESULFURIZER 4,500 m3/day
See Standard Unit No. XI4
MODULE NO. L31
HYDROGEN MANUFACTURING UNIT
Module area =1.2 hectares: 120m x 96m
Process Input/Output:
The input to this module is from a natural gas source,
refinery gas, propane, butane, and naphtha. The output
is to units requiring hydrogen.
141
-------
A. HYDROGEN MANUFACTURING UNIT 2,800,000 m3/day
See Standard Unit No. X7
MODULE NO. L32
H2S04 ALKYLATION PLANT
Module area =2.9 hectares: 240m x 120m
Process Input/Output:
Inputs are isobutane, butylenes, and sulfuric acid. Outputs
are alkylate, spent acid and unreactive light hydrocarbons
associated with the reactants.
A. H2S04 ALKYLATION PLANT 800 m3/day
See Standard Unit No. XI5
B. PROPYLENE POLYMER PLANT 560 m3/day
See Standard Unit No. XI6
LANT o no rnVday
See Standard Unit No. XI7
MODULE NO. L33
DISTILLATE HYDRODESULFURIZATION
Module area = 3.6 hectares: 30Qm x 120m
Process Input/Output:
Inputs are gas oil from first distillation crude units and
acid gas from the sour water strippers. Output is to
catalytic cracker feed and diesel fuel storage. Elemental
sulfur is sent to H^SO plant.
142
-------
A. HEAVY GAS OIL DISTILLATES HYDRODESULFURIZER 1,900 m3/day
See Standard Unit No. X18
B. GAS OIL HASHER AND BRIGHTENER 1,500 m3/day
See Standard Unit No. XI9
C. SULFUR RECOVERY UNIT
See Standard Unit No. X20
D. TAIL GAS CLEAN-UP UNIT
See Standard Units No. X21 and No. X22
MODULE NO. L34
SULFUR RECOVERY
Module area = 1.6 hectares: 132m x 120m
Process Input/Output:
Inputs to the module come from processing modules producing
sulfur containing gases. Output is sulfuric acid.
A. SULFUR RECOVERY UNIT 3 units, 136 metric tons/day each
See Standard Unit No. X20
B. TAIL GAS CLEAN-UP UNIT 3 units
See Standard Units No. X21 and No. X22
C. SULFURIC ACID PLANT 182 metric tons/day
See Standard Unit No. X23
143
-------
MODULE NO. L35
TANKS/COOLING TOWERS
Module area = 5.8 hectares: 480m x 12Qm
A. TANKS
Annual
Estimate Tank Dig Ht Capacity Throughput
No. Stock (kPa) Type (m) (m) (m3). (m3)
^T BT feed stock TT^ FR TT77 35VO TOJlO TTTT680 -
2 Aromatics 23 FR 10.0 11.5 954 12,400
B. COOLING TOWER
15 m wide x 73.6 m long x 9 m high
14,000 metric tons/hr water flow rate
C. COOLING TOWER
12.4 m wide x 31 m long x 6.4 m high
4,400 metric tons/hr water flow rate
D. GAS HOLDER
46 m diameter x 18.3 m high
E. SLOWDOWN STACK
1 .83 m diameter x 29.3 m high
MODULE NO. L36
CATALYTIC REFORMER
Module area =1.7 hectares: 144m x 12Qm
Process Input/Output:
The input is desulfurized naphtha. The output is gasoline
for blending and aromatics recovery feedstocks.
A. CATALYTIC REFORMER 7,200 m3/day
See Standard Unit No. X24
144
-------
MODULE NO. L37
AROMATICS EXTRACTION UNIT
Module area =2.0 hectares: 168m x 120m
Process Input/Output:
Benzene, toluene and xylenes (total of 600 m /day) can be
produced depenuing upon the boiling range or tne feed.
Benzene can be charged to a cumene unit.
A. AROMATICS EXTRACTION UNIT 600 m3/day
See Standard Unit No. X25
MODULE NO. L38
FLUID CATALYTIC CRACKING UNIT
Module area =2.0 hectares: 168m x 120m
Process Input/Output:
Input is gas oil from desulfurization units. Output is
catalytically cracked gasoline to refinery gasoline pool,
cycle oils to fuel oil blending, and C4 and lighter hydro-
carbons to gas concentration unit.
A. FLUID CATALYTIC CRACKING UNIT 7,950 m3/day
See Standard Unit No. X26
B. COOLING TOWER
15m wide x 32 m long x 9 m high
6,410 metric tons/hr. water flow rate
C. COOLING TOWER
11.5 m wide x 36 m long x 9.2 m high
5,400 metric tons/hr. water flow rate
145
-------
MODULE NO. L39
PARA-XYLENE PLANT
Module area = 2.3 hectares; 192m x 12Qm
Process Input/Output:
Input is xylene from the aromatics extraction unit.
Output is para-xylene to finished product storage.
A. PARA-XYLENE PLANT 140 metric tons/day
See Standard Unit X27
MODULE NO. L40
DELAYED COKER PLANT
Module area = 3.5 hectares : 288m x 120m
Process Input/Output:
The input to the module is heavy residuum storage. The
output is coke to the storage facility.
A. DELAYED COKER PLANT 7,950 m3/day
See Standard Unit No. X28
MODULE NO. L41
BARREL STORAGE
This module is used for open storage of barrels on a paved surface,
The area of the module is 1.9 hectares. Module dimensions are
264m x 72m.
MODULE NO. L42
BARREL RECONDITIONING
Module area =1.6 hectares: 216m x 72m
146
-------
A. SPRAY BOOTH
2.5 m wide x 3.0 m long x 3.0 m high
Paint usage is 0.02 m of enamel per day
B. CAUSTIC PAINT STRIPPING BATH
2.5 m wide x 3.0 m long x 2.0 m deep
C. BUILDING
19.0 m wide x 46.0 m long x 11.0 m high
MODULE NO. L43
FEEDSTOCK STORAGE
Module area = 14.7 hectares: 408m x 360m
A. RESERVOIR FOR RESIDUUM STORAGE
RVP<0.1
152. m diameter
It extends 3. m above ground level
It is equipped with a fixed roof
Capacity 79,500 m
MODULE NO. L44
STORM WATER IMPOUND BASIN
Module area - 15.6 hectares: 432m x 360m
A. STORM WATER IMPOUND BASIN
145 m diameter at ground level
Capacity 75, 710 m
147
-------
MODULE NO. L45
WAREHOUSE
Module area * 1.4 hectares: 120m x 120m
A. WAREHOUSE BUILDING
23. m wide x 122. m long x 12.2 m high
MODULE NO. L46
GAS HOLDER/SLOWDOWN STACK
Module area = 1.4 hectares: 120m x 120m
Process Input/Output:
The input to this module is gas from the catalytic
reforming operations. The gas is recycled or sent to
refinery make-up gas.
A. GAS HOLDER
46 m diameter x 18.3 m high
B. SLOWDOWN STACK
1.83 m diameter x 29.3 m high
MODULE NO. L47
GAS HOLDER/SLOWDOWN STACK
Module area =1.4 hectares; 120m x 120m
Process Input/Output:
The input to this module is gas from the catalalytic reforming
operations. The gas is recycled or sent to refinery make-up
gas.
148
-------
A. GAS HOLDER
46. m diameter x 18.3 m high
B. SLOWDOWN STACK
1.83 m diameter x 29.3 m high
MODULE NO. L48
FIRE PREVENTION TRAINING FACILITY
Module area =0.6 hectares: 120m x 48m
A. FIRE PREVENTION TRAINING FACILITY
This facility consists of some small vessels, a pipe
trench, and some small LPG sources which may be ignited
and extinguished for practice purposes.
B. BUILDING
30.1 m wide x 30.1 m long x 9.1 m high
MODULE NO. L49
OIL-WATER SEPARATOR
Module area =2.2 hectares: 180m x 120m
Process Input/Output:
The input to this module is the wastewater from a process
area and surrounding area. The output is to Module No. 71,
the wastewater treatment plant.
A. API TYPE OIL-WATER SEPARATOR
Capacity 130,000 m /day
38. m wide x 61. m long extending 3. m above ground level
It is equipped with a floating roof
149
-------
MODULE NO. L50
ASPHALT PLANT
Module area = 2.2 hectares: 180m x 120m
Process Input/Output:
The input to this module is from specialty crude distillation
units. The output is asphalt to product sales.
A. ASPHALT PROCESSING UNIT
1. COMBUSTION DEVICES
a. Fume Incinerator
Stack Stack
Design Heat Input Height Diameter
Quantity (GJ/hr) (m) (m)
1 7.0 31.0 0.8
b. Asphalt Shell Still
Dimensions (m)
Number Service Diameter Height Length
4 Air blowing still* 3.0 10.2 10.0
* Mounted horizontally over a firebox with an
overall height of 6.0 m.
Effluent discharges to fume incinerator
B. ASPHALT TRUCK LOADING RACK
D i m e n s i o n s (m)
Width Length Overall Height
Loading rack
C. TANKS
No. Stock
~T~ aTpTTal t
emulsion
6 asphalt
D. BUILDING
40. m wide x 80. m long x 10. m high
150
RVP
Estimate
(kPa)
0.1
0.1
Tank
Type
XR
XR
3.0
Dia Ht
(m) (m)
6.0 9.
12.2 9.
20.0
Capacity
(m3)
0 250
1 1,050
7.0
Annual
Throughput
(m3)
-
-
-------
MODULE NO. LSI
SOLVENT TREATING PLANT/BOILER HOUSE
Module area =1.4 hectares: 120m x 120m
A. SOLVENT TREATING PLANT
1
PUMPS AND COMPRESSORS
Spare
Service
Transfer
Cresyllc acid
Aliphatic acid
VESSELS
No.
3
2
RVP Class
B
D
D
Pump Type
R
R
R
Seal Type
P
P
P
Dia
Service im)
Agitators 20.0
Agitators 20.0
Ht.
M
10.0
10.0
Open
X
Covered
4.
TANK CAR LOADING RACK
Two loading spots for aliphatic and cresylic acids.
TANKS
No.
2
1
1
B. BOILER HOUSE
Stock
Boiler Water
Cresylicacid
Aliphaticacid
RVP
Estimate
(kPa)
0.1
d 0.1
Tank
Type
Open
XR
XR
Dia
M
2.5
10.0
10.0
Ht
M
3.0
10.0
10.0
Capa-
city
(m3)
15.
800.
800.
Annual
Throughput
(m3)
1. COMBUSTION DEVICES
a. Process Heaters and Boilers
No.
2
1
3
1
Type
B
B
B
B
B
Design
Heat Input
(GJ/hr)
25.
53.
109.
187.
197.
Stack
Height
(m)
55.*
55.*
55.*
55.**
55.**
Stack
Diameter
(m)
3.7
3.7
3.7
3.7
3.7
**
Boilers share common stack
Boilers share common stack
151
-------
2. BUILDING
31.0 m wide x 62.0 m long x 12.0 m high
MODULE NO. L52
S02 TREATING PLANT/TANKS
Module area =1.4 hectares: 120m x 12Qm
Process Input/Output:
The major unit is a treating plant for aromatic removal from
various streams from first distillation by a selective
solvent, SO^. The aromatic product goes to an aromatic
recovery unit or gasoline blending. The raffinates go to
jet fuel, diesel fuel, and thinners.
A. SO? TREATING PLANT 1,300 m3/ day
See Standard Unit No. X29
B. ACID TREATING PLANT 447 m3/day
See Standard Unit No. X30
C. TANKS
No.
2
4
4
3
1
Stock
kerosene
diesel fuel
spray oil
kerosene
extract
RVP
Estimate
(kPa)
0.2
0.1
0.2
0.2
0.5
Tank
Type
XR
XR
XR
XR
XR
Dia
M
9.8
11.0
11.0
14.6
7.3
Ht
M
10.7
10.7
9.1
12.2
9.1
cagjlty
800
1,000
850
2,050
380
Annual
Throughput
(m3)
10,400
13,000
11,050
26,650
4,940
152
-------
MODULE NO. L53
LUBRICATING OIL PACKAGING
Module area =8.1 hectares: 480m x 168m
Dimensions (m)
Width Length Height
A. BUILDING FOR CAN FILLING 15.0 120.0 10.7
B. BUILDING FOR BARREL FILLING 15.0 120.0 10.7
C. WAREHOUSE 25.0 60.0 10.7
D. PACKAGE WAREHOUSE 30.0 140.0 10.7
MODULE NO. L54
COKE STORAGE AND HANDLING
Module area =5.8 hectares; 240m x 240m
Process Input/Output:
The input is coke from the delayed coker.
The output is to loading and shipping
facilities offsite
A. COKE STORAGE BUILDING
30.5 m wide x 30.5 m long x 15.2 m high.
B. STRUCTURE FOR CONVEYING EQUIPMENT FROM THE COKER
Associated with the Coke Storage Building is the structure
for the conveying equipment from the coker. Steel frame
work 6 m wide x 488 m long extending 366 m with a height
of 6 m. The last 122 m rises diagonally to a height of
21.3 m.
153
-------
MODULE NO L55
CRUDE OIL STORAGE
Module area =22.0 hectares: 540m x 408
A. TANKS
RVP Annual
Estimate Tank Dia Ht Capacity Throughput
No. Stock (kPa) Type (m) (m) (M3) (m3)
1 crude 28 FR ~7lT7 19.5 75,350 2.257,000
MODULE NO. L56
FEEDSTOCK STORAGE
Module area = 11.9 hectares : 432m x 276jn
A. RESERVOIR FOR LIGHT RESIDUUM STORAGE
RVP 0.1 kPa
152.4 m wide x 243.8 m long
It extends 3 m above ground level
It is equipped with a fixed roof
capacity 153,190m3
MODULE NO. L57
TANKS/IMPOUND BASIN
Module area = 11.4 hectares; 432m x 264m
A. TANKS
No
RVP
Estimate
Stock (kPa)
crude
light residium
IMPOUND BASIN
28.
0.1
Tank
Type
FR
FR
Dia Ht
(mj. (m)
7972 ~T975
79.2 19.5
Annual
Capacity Throughput
(m3) (m3)
96,100
95,100
2,884,000
2,884,000
B.
22.9 m wide x 305 m long at ground level
154
-------
MODULE NO. L58
ADMINISTRATIVE BUILDING
Modules area =2.9 hectares: 240m x 120m
A. ADMINISTRATIVE BUILDING
30.5 m wide x 96.0 long x 10.7 m high
MODULE NO. L59
OIL-WATER SEPARATOR
Module area = 1.4 hectares: 120m x 120m
Process Input/Output:
The input to this module is the wastewater from a process
area and surrounding area. The output is to Module No. 71,
the wastewater treatment plant.
A. API TYPE OIL-WATER SEPARATOR
Capacity 26,000 m3/day
15.2 m wide x 30.5 m long extending 1.0m above ground level
It is equipped with a floating roof
MODULE NO. L60
GASOLINE SWEETENER/CRUDE DISTILLATION-UNIT
Module area =4.6 hectares: 240m x 192m
Process Input/Output
The input to the module is from crude storage. The
output goes to intermediate and residuum storage.
A. GASOLINE SWEETENER 4.450 m3/day
See Standard Unit No. x31
B. CRUDE DISTILLATION 23,850 m3/day
See Standard Unit No. x!2
155
-------
MODULE NO. L61
CRUDE DISTILLATION UNIT/CRUDE DESALTER
Module area =1.8 hectares: 192m x 96m
Process Input/Output
The input to the module is from crude storage. The output
goes to intermediate storage.
A. CRUDE DISTILLATION UNIT 6,360 m3/day
See Standard Unit X32
B. CRUDE DESALTING UNIT 6,400 m3/day
See Standard Unit X33
MODULE NO. L62
SPECIALTY CRUDE UNIT
Module area =1.4 hectares: 192m x 72m
Process Input/Output
The input to the module is from crude storage. The
output goes to residuum and intermediate storage and
to an asphalt processing module.
A. SPECIALTY CRUDE UNIT 1,530 m3/day
See Standard Unit X34
MODULE NO. L63
SPECIALTY CRUDE UNIT/CONDENSER BOX
Module area =1.2 hectares: 192m x 60m
Process Input/Output
The input to the module is from crude storage. The
output goes to residuum and intermediate storage and to
an asphalt procesing module.
A. SPECIALTY CRUDE UNIT 1,530 m3/day
See Standard Unit No. X34
B. OVERHEAD CONDENSER BOX. 305 m3/day
The box has dimensions of 10 m wide x 20 mlong x 3 m deep
and is mounted on a structure 6 m high giving an overall
height of 9 m.
156
-------
MODULE NO. L64
GASOLINE FRACTIONATING UNIT
Module area =1.2 hectares: 19.2m x 6Qm
Process Input/Output
The input to the module is straight run naphtha from crude
distillation units. The output goes to the catalytic reformer
module, to gasoline blending, and to the refinery gas system.
A. GASOLINE FRACTIONATING UNIT 9,500 m3/day
See Standard Unit No. X35
MODULE NO. L65
TANK LOADING/TRUCK LOADING/VAPOR RECOVERY
Module area =4.3 hectares: 360m x 120m
Process Input/Output
The input to the module come from product storage.
A. TANK CAR LOADING RACK FACILITY
See Standard Unit No.
B. TRUCK LOADING RACK FACILITY
See Standard Unit No.
C. VAPOR RECOVERY PACKAGE UNIT ABSORPTION TYPE
1,000 kg/hr
See Standard Unit No. X36
MODULE NO. L 66
BUILDINGS
Module area =2.6 hectares; 360m x 72m
Dimensions (m)
Width Length Height
A. BUILDING 38.0 61.0 15.2
B BUILDING 22.9 38.0 9.1
157
-------
MODULE NO. L67
LPG STORAGE AND BLENDING
MODULES =2.3 hectares: 192m x 120m
A. TANKS
RVP Annual
Estimate Tank Height Length Capacity Throughput
(kPa) Type (m) (m) (m3) (m3)
No. Stock
9 LPG 828 p* 4.4 36.6 557 723.5
horizontal cylindrical pressure tanks mounted
on saddles 3.66 m high.
B. TANK CAR LOADING FACILITY
The loading rack is 36.6 m long and 3.8 m high. There
are 2 spots on each side.
C. TRUCK LOADING FACILITY
The loading rack is 18.3 m long and 3.8 m high
MODULE NO. L68
VAPOR RECOVERY/GASOLINE RECTIFIER UNIT/TANKS
Module area =4.0 hectares: 24Qm x 168m
Process Input/Output
Input to the vapory recovery unit come from fixed roof
storage tanks; output goes to crude distillation unit.
Input to the gasoline rectifier unit come from the
atmospheric crude distillation; output goes to gasoline
storage and to the gas concentration unit.
A. VAPOR RECOVERY PLANT
See Standard Unit X37
B. GASOLINE RECTIFIER UNIT
See Standard Unit X39
158
-------
TANKS Dimensions (m)
Quantity
1
1
Stock
gasoline
alkylate
RVP
Estimate
69
34
Tank
Type
FR
FR
Diameter
23
23
Height
10.7
10.7
Capacity
4,270
4,270
Annual
throughout
55,460
55,460
MODULE NO. L69
MAIN PUMP HOUSE
Module area =4.8 hectares: 288m x 168m
Process Inputs/Outputs
The input to the module comes from processing or
tankage modules. The output from the module goes
to intermediate or product storage.
A. MAIN PUMP HOUSE
See Standard Unit No.X45
B. TANKS
Capa- Annual
No. Stock Estimate Type Diameter Height city Throughput
1 motor gasoline 69 FR 29 9.1 5740 79,620
2 recycle oil 0.14 FR 18.3 9.1 2390 31,100
2 gas oil 0.14 FR 18.3 9.1 2390 31,100
159
-------
MODULE NO. L70
PRODUCT STORAGE
Module area =25.2
A.
No
2
2
2
1
1
1
3
1
2
1
1
1
1
1
1
TANKS
Stock
JP-4
JP-4
diesel
emulsion
diesel
JP-4
motor gasoline
JP-4
JP-4
pentane
diesel
JP-4
motor gasoline
motor gasoline
water
' hectares :
RVP
Estimate
(kPa)
17.
17.
0.14
-
0.14
17.
69.
17.
17.
108.
0.14
17. '
69.
69.
-
600m
Tank
Type
FR
FR
XR
XR
XR
FR
FR
FR
FR
FR
XR
FR
FR
FR
XR
x 420m
Dia
(m)
36.0
35.0
30.5
27.4
27.4
35.0
18.3
35.0
35.0
30.5
35.1
27.4
35.0
18.3
27.4
Ht
(m)
10.7
9.1
9.1
10.7
10.7
10.7
9.1
9.1
9.7
12.2
10.7
9.1
10.7
9.1
9.1
Capacity
(m )
10,315
8,816
6,768
5,868
5,880
9,462
3.304
8,816
10,286
10,711
10,356
4,840
9,611
3,304
4,840
Annual
Throughout
5
134,090
114,607
87,990
75,777
75,609
123,001
42,948
114,607
133,708
139,232
134,626
62,917
124,935
42,949
62,977
MODULE NO. L71
WASTEWATER TREATMENT PLANT
Module area =10.1 hectares: 420m x 240m
A. WASTEWATER TREATMENT PLANT 20,000 m3/day
See Standard Unit No. X40
MODULE NO. L72
BUILDING
Module area =2.7 hectares: 228m x 120m
A. BUILDING
7.62 m wide x 61. 0 m long x 90 m high
160
-------
MODULE NO. L73
PRODUCT STORAGE
Module area =30.2 hectares: 720m x 420m
A. TANKS
No
T~
2
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
RVP
Estimate
Stock (KPa)
fuel oil
fuel oil
gas oil
fuel oil
recycle oil
cutter stock
residuum
cutter stock
fuel oil
fuel oil
naphtha
fuel oil
motor gasoline
thinner
DEA
line wash
olefin 1,
0.14
0.14
10.4
0.14
10.4
0.7
0.1
0.7
0.14
0.14
84.
0.14
69.
1.4
34.
34.
585.
Tank
Type
XR
XR
FR
XR
FR
XR
XR
XR
XR
XR
FR
XR
FR
XR
FR
FR
P*
Dia
(m)
3BT6
35.0
35.0
35.0
35.0
35.0
27.4
27.4
30.5
42.7
12.2
36.6
13.7
8.2
8.2
8.2
2.44
Annual
Ht Capacity Throughput
(m) (m3) (m3)
12.8
9.1
10.7
10.7
10.7
10.7
6.0
6.0
12.2
14.6
7.62
14.0
12.2
4.6
4.6
4.6
—
16,638
8,565
10,286
10,020
10,286
10,020
1,225
1,225
10,665
21 ,020
800
13,440
1,070
180
180
180
53.5
216,304
111,345
133,720
130,258
133,720
130,258
15,920
15,920
138,645
271 ,780
10,400
174,710
13,910
2,335
2,335
2,335
695
*Spherical pressure tank
Module area
A. BUILDING
B. BUILDING
MODULE NO. L74
SHOPS AND WAREHOUSE
30.2 hectares: 600m x 504m
D i m e n s i o n (m)
Width Length Height
~38~7T
30.5
7672
91.4
12.2
12.2
161
-------
MODULE NO. L75
CRUDE OIL STORAGE
Module area = 34.6 hectares: 600m x 576m
A. TANKS
No.
3
1
1
2
Stock
crude
crude
crude
crude
RVP
Estimate
(kPa)
28.
28.
28.
28.
Tank
Type
FR
FR
FR
FR
Dia.
(m)
70.1
73.8
67.
69.2
Ht.
(m)
19.5
19.5
14.6
18.3
Capacity
73,288
81,135
49,871
66,927
Annual
Throughput
(m )
219,864
243,404
149,613
200,780
MODULE NO. L76
CRUDE, FEEDSTOCK AND PRODUCT STORAGE
Module area = 38.9 hectares: 1080m x 360m
A. TANKS
No. Stock
1 fuel oil
3 fuel oil
1 crude
6 motor gasoline
1 aromatics
3 crude
1 gas oil
5 motor gasoline
1 pentane
1 motor gasoline
1 JP-4
1 toluene
1 polymers
1 benzene
1 motor gasoline
1 pentane
1 motor gasoline
1 solvent
1 thinner
1 cumene
1 motor gasoline
RVP
Estimate
(kPa)
0.14
0.14
28.
69.
11.
28.
10.4
69.
108.
69.
17.
7.6
70.
23.
69.
108.
69.
0.7
1.2
1.4
69.
Tank
Type
XR
XR
FR
FR
FR
FR
FR
FR
FR
FR
FR
FR
FR
FR
FR
FR
XR
XR
FR
FR
Dia
(m)
61.
61.
30.5
45.7
30.5
47.2
33.5
33.5
20.4
27.4
27.4
20.4
20.4
20.4
27.4
17.4
27.4
27.4
27.4
24.3
24.3
Ht
(m)
14.6
18.3
14.6
13.7
17.0
14.6
14.0
14.0
14.6
14.6
14.6
14.6
14.6
14.6
14.6
14.0
14.6
14.6
14.6
14.6
14.6
Capacity
(m3)
42,663
53,329
9,999
22,472
12,444
25,625
12,906
12,906
4,788
8,639
6,826
4,788
4,788
4,788
6,826
2,356
8,640
8.640
8,640
6,812
6,812
Annual
Throughput
(m3)
554,619
693,273
129,987
292,137
161,764
25,625
167,773
167,773
62,242
112,311
88,743
62,242
62,242
62,242
88,743
30,629
112,310
112,310
112,310
88,554
88,554
162
-------
163
-------
NEW REFINERY
Scale 1 inch = 240 meters
26
27
9
10
8
13
16
17
28
6
12
11
18
"ifiT
20
21
22
23
29
14
30
15
24
25
31
164
-------
NEW REFINERY MODULE KEY
Standard Unit
Module No. Description Reference No.
Nl Future Expansion
N2 Product Storage
N3 Product Storage
N4 Tank Car Loading/Vapor Recovery X36
N5 Feedstock Storage
N6 Delayed Coker/Coke Storage X28
N7 Flares
N8 Gasoline Sweetening X31
N9 Pumping Station
N10 Future Expansion
Nil Sour water/Oxidizer/Acid-gas X41,X46, X20
treating/Sulfur recovery
N12 Catalytic Cracking X26
N13 Alkylation X26
N14 Truckloading/Vapor Recovery X36
N15 Cooling Towers
N16 Catalytic Reformer X24
N17 Aromatics Extraction X25
N18 Thermal Hydro Dealkylation X43
N19 Heavy Gas Oil Desulfurizer XI8
N20 Naptha Desulfurizer X44
N21 Gas Oil Hydro Desulfurizer X9
N22 Distillation/Gas Recovery XI
N23 Crude Distillation/Crude Desalting
N24 Maintenance Shops
N25 Wastewater Treatment X40
N26 Product Storage
N27 Future Expansion
N28 Crude Oil Storage
N29 Feedstock Storage
N30 Administration
N31 Future Expansion
165
-------
NEW REFINERY
CRUDE CHARGE RATE 40,000 m3/day
PRODUCT SLATE PRODUCTION RATE (m3/day)
PRODUCT
Gasoline 22,340
#2 Fuel Oil 12,201
Jet fuel 2,882
Gas oil 2,165
Benzene 760
Xylene 610
Carbon black feed stock 590
Natural gasoline 253
Naptha 135
Toluene 64
42,000
NUMBER OF WHARF MODULES
166
-------
MODULE NO. Nl
FUTURE EXPANSION
Module area = 7.4 hectares; 564m x 132m
This area is reserved for future expansion.
MODULE NO. N2
PRODUCT STORAGE
Module area =2.7 hectares: 564m x 48Qm
No.
1
1
3
2
2
Stock
Diesel fuel
Kerosene
#2 fuel oil
#2 fuel oil
#6 fuel oil
JP-4
RVP
Estimate
(kPa)
0.14
0.21
0.14
0.14
0.0007
17.
Tank
XR
XR
XR
XR
FR
Dia
51 '.8
51.8
64.0
51.8
51.8
Ht
TO"
14.6
14.6
14.6
14.6
14.6
Capacity
(m3)
7,692
30,787
30,787
46,968
31 ,002
31 ,002
Annual
Throughput
100,000
400,231
400,231
610,584
403,026
418,374
MODULE NO. N3
PRODUCT STORAGE
Module area = 12.1 hectares: 420m x 288m
No.
~r
2
1
1
2
Stock
Benzene
Benzene
Toluene
Xylene
Xylene
RVP
Estimate
(kPa)
23.
23.
7.6
3.4
3.4
Tank
Type
FR
FR
FR
FR
FR
Dia
$T
JO . 1
12.2
25.9
25.9
12.2
Ht
fe
12.2
14.6
14.6
12.2
Capacity
(m3)
16,646
1,427
7,692
7,692
1,427
Annual
Throughput
(m3)
216,398
158,200
29,730
100,000
90,272
MODULE NO. N4
TANK CAR LOADING/VAPOR RECOVERY PACKAGE UNIT
Module area = 3.5 hectares: 420m x 84m
Process Input/Output:
The input to the module is from product storage.
167
-------
A. TANK CAR LOADING FACILITY
See Standard Unit No. X36
B. VAPOR RECOVERY PACKAGE UNIT - ABSORPTION TYPE 1000 Kg/hr
See Standard Unit No. X36
MODULE NO. N5
FEEDSTOCK STORAGE
Module area = 16.7 hectares: 456m x 366m
No. Stock
~T~ Coker gas oil
1 Coker gas oil
1 Coker feedstock
1 Coker feedstock
2 Alky late
3 Alkylation feed
1
9
4
Propane
Iso-butane
Butane
RVP
Estimate
(kPa)
0.7
0.7
k 0.7
k 0.7
34.
: 310.
1303.
503.
352.
Tank
Type
XR
XR
XR
XR
FR
P*
P*
P*
P*
Dia
fo
51.8
38.1
32.0
38.1
16.6
14.5
14.5
16.6
Ht
®7
1 t • b
14.6
14.6
14.6
14.6
Capacity
(m3)
'3,757
30,769
11,742
30,769
16,646
2,400
1,600
1,600
2,400
Annual
Throughput
(m3)
48,841
400 ,000
152,646
400,000
216,398
31 ,200
20,800
20,800
31 ,200
*Spherical pressure vessels
MODULE NO. N6
DELAYED COKER/COKE STORAGE
Module area - 6.6 hectares: 366m x 180m
Process Input/Output:
The input to the module is from intermediate storage.
output, which is petroleum coke, leaves the refinery.
A. DELAYED COKER PLANT 7950 m3/day
See Standard Unit No. X28
B. COKE STORAGE BUILDING
This building is 30m wide x 30m long x 15m high.
The
168
-------
MODULE NO. N7
FLARES
Module area =19.8 hectares: 540m x 366m
Process Input/Output:
The input to the module is from the refinery blowdown
and emergency gas system.
A. ELEVATED FLARES
Stack
Design Heat Input Height
Quantity Type (GJ/hr) (m)
1 SmokelFss 650 38.1
1 Smokeless 345 47.3
MODULE NO. N8
GASOLINE SWEETENING UNIT
Module area =5.2 hectares: 480m x 180m
Process Input/Output:
The input to the module is sulfur-containing gasoline.
The output goes to gasoline blending.
A. GASOLINE SWEETENING UNIT 4.450 m3/day
See Standard Unit No. X31
MODULE NO. N9
PUMPING STATION
Module area = 0.4 hectares: 60m x 60m
Process Input/Output:
The input to the module comes from processing modules
The output goes to intermediate and product storage.
169
-------
A. PUMPING STATION
1. PUMPS AND COMPRESSORS
No. Service
3 product transfer
4 product transfer
2 product transfer
4 product transfer
2 product transfer
3 product transfer
2. VALVES AND FITTINGS
a. Process Valves - 1,260
b. Fittings - 4,230
c. Relief Valves - 18
d. Sample Connections - 18
MODULE NO. N10
FUTURE EXPANSION
Module area = 14.9 hectares: 480m x 312m
This module area is reserved for future refinery expansion.
MODULE NO. Nil
SOUR WATER OXIDIZER/ACID GAS TREATING/
SULFUR RECOVERY UNITS
Module area =4.3 hectares: 240m x 180m
Process Input/Output:
The inputs to the sourwater oxidizer come from aqueous
streams from the processing units; output is discharged
to crude desalter. The inputs to the acid gas and
sulfur recovery units are the refinery gas system;
outputs are treated gas back to the refinery gas system
and elemental sulfur to storage.
A. SOUR WATER OXIDIZER 950 m3/day
See Standard Unit No. X41
170
-------
B. ACID GAS TREATING PLANT
See Standard Unit No. X46
C. TWO SULFUR RECOVERY UNITS (2 STAGE GLAUS)
150 metric tons/day each
See Standard Unit No. X20
MODULE NO. N12
FLUID CATALYTIC CRACKING
Module area = 5.8 hectares: 240m x 24Qm
Process Input/Output:
The inputs to the module come from the delayed coker,
crude distillation, and catalytic hydrodesulfurization
units. Output is to the refinery fuel system and to
product blending and storage.
A. FLUID CATALYTIC CRACKING UNIT 12.000 m3/day
See Standard Unit X26.
MODULE NO. N13
HF ALKYLATION
Module area =5.8 hectares: 240m x 24Qm
Process Input/Output:
The inputs to the module are iso-butane and mixed
olefins. The output, alkylate, goes to gasoline
blending.
A. ALKYLATION UNIT. HYDROFLUORIC ACID 5,000 m3/day
See Standard Unit No. X48
MODULE NO. N14
TRUCK LOADING/VAPOR RECOVERY
Module area =4.8 hectares: 396m x 12Qm
Process Input/Output:
The input comes from product storage.
171
-------
A. TRUCK LOADING FACILITY
See Standard Unit No. X36
B. VAPOR RECOVERY PACKAGE SYSTEM - ABSORPTION TYPE 1.000 Kg/hr
See Standard Unit No. X36
MODULE NO. N15
COOLING TOWERS
Module area = 2.9 hectares; 24Qm x 120m
Process Input/Output:
The input to the module is cooling water.
A. TWO COOLING TOWERS
Each 14.6m wide x 76.6m long x 9.0m high
Each 14,000 m3/hr - water flow rate
B. COOLING TOWER
14.6m wide x 32.5m long x 9.0m high
5,200 m3/hr - water flow rate
MODULE NO. N16
CATALYTIC REFORMER
Module area =3.0 hectares: 240m x 126m
Process Input/Output:
The input to the module is desulfurized naphtha from
intermediate storage. The output goes to gasoline
blending and to intermediate storage for feed to the
aromatics recovery unit.
A. CATALYTIC REFORMER 6,000 m3/day
See Standard Unit No. X24
MODULE NO. N17
AROMATICS EXTRACTION
Module area =2.2 hectares; 240m x 90m
172
-------
Process Input/Output:
The input to this module comes from intermediate storage
. of catalytic reformate. The outputs, benzene, toluene,
and xylene go to product storage.
A. AROMATICS EXTRACTION UNIT 1,800 m3/day
1. PUMPS AND COMPRESSORS
See Standard Unit No. X25
2. VALVES AND FITTINGS
See Standard Unit No. X25
3. COMBUSTION DEVICES
a. Process Heaters and Boilers
Stack Stack
Design Heat Input Height Diameter
Quantity Type (GJ/hr) (m) [m]
1 H 210
1^, I Ui I *« L/ I Ullfw 1
(m) (m)
41.7 3.5
MODULE NO. N18
THERMAL HYDRODEALKYLATION
Module area =1.4 hectares: 240m x 60m
Process Input/Output:
The input to the module is toluene from storage. The
output is benzene which is sent to storage.
A. THERMAL HYDRODEALKYLATION 570 m3/day
See Standard Unit No. X43; Design Heat Input is 46.0 (GJ/hr)
MODULE NO. N19
HEAVY GAS OIL DESULFURIZATION
Module area =1.4 hectares: 240m x 60m
Process Input/Output:
The input to the module comes from the delayed coker
and crude distillation units. The output goes to the
catalytic cracking unit.
A. HEAVY GAS OIL DESULFURIZER 1,900 m3/day
See Standard Module No. XI8
173
-------
MODULE NO. N.20
NAPHTHA HYDRODESULFURIZER
Module area = 1.4 hectares: 240m x 60m
Process Input/Output:
The inputs to the module are sulfur-containing naphthas.
The output goes to gasoline blending and to the catalytic
reformer unit.
A. NAPHTHA HYDRODESULFURIZER 4,300 m3/day
See Standard Unit No. X44
MODULE NO. N21
GAS OIL HYDRODESULFURIZER
Module area =1.4 hectares: 240m x 60m
Process Input/Output:
The inputs are light gas oils, kerosene and jet fuels,
Output is to product storage.
A. GAS OIL HYDRODESULFURIZER 5,565 m3/day
See Standard Module No. X9
MODULE NO. N22
DISTILLATION/GAS RECOVERY UNIT
Module area - 1.4 hectares : 240m x 60m
Process Input/Output:
The input to the module is light ends from processing
units. The outputs are sent to the refinery gas
system and to product storage.
A. DISTILLATION AND GAS RECOVERY UNIT 1.5 x 106 m3/day
See Standard Module No. XI
MODULE NO. N23
CRUDE DISTILLATION UNITS/CRUDE DESALTING UNITS
Module area * 2.9 hectares: 240m x 120m
174
-------
Process Input/Output:
Input to the module is from crude intermediate storage.
Outputs go to gas recovery, naphtha, kerosene, gas oil,
and residuum processing units.
A. CRUDE DISTILLATION UNIT 23,850 m3/day
See Standard Unit No. XI2
B. CRUDE DISTILLATION UNIT 6,360 m3/day
See Standard Unit No. X32
C. TWO CRUDE DESALTING UNITS 6,400 m3/day
See Standard Unit No. X33
MODULE NO. N24
MAINTENANCE SHOPS AND STOREHOUSE
Module area = 4.8 hectares: 396m x 120m
A. BUILDING
61m wide x 61m long x llm high
MODULE NO. N25
WASTEWATER TREATMENT
Module area =26.7 hectares: 636m x 420m
Process Input/Output:
Inputs to the module come from refinery sewer system.
Output is discharged to receiving waters.
A. WASTEWATER TREATMENT PLANT 20,000 m3/day
See Standard Unit No. X40
MODULE NO. N26
PRODUCT STORAGE
Module area = 29.8 hectares: 564m x 528m
175
-------
Rvp Annual
Estimate Tank Dia Ht Capacity Throughput
No. Stock (kPa) Type (m) (m) (nT)
T" motor gasoline 69 FR 7672" TO" 66,581
3 motor gasoline 69 FR 51.8 14.6 30,787
836,015
350,920
MODULE NO. N27
FUTURE EXPANSION
Module area = 12.9 hectares: 564m x 228M
This area is reserved for future refinery expansion.
MODULE NO. N28
CRUDE OIL STORAGE
Module area = 21.7 hectares: 516m x 42Qm
No. Stock
9 crude oil
RVP
Estimate Tank Dia Ht
(kPa) Type (m) (m)
28 FR TO" 14.6
Annual
Capacity Throughput
rn3) (m3)
758T~ 1,288,800
MODULE NO. N29
FEEDSTOCK STORAGE
Module area = 20.4 hectares: 516m x 396m
No.
T
1
1
2
1
1
1
1
1
2
1
Stock
" SI urry oil
Slurry oil
FCC feed
FCC gasoline
RVP
Estimate
(kPa)
0.14
0.14
0.14
63.
Nat'l gasoline83.
Reformer feed
Reformer feed
Re formate
Naphtha.
Slop oil
Raffinate
39.
39
31.
39.
0.7
69.
Tank
Type
XR
XR
XR
FR
FR
FR
FR
FR
FR
XR
FR
Dia
30"
51
51
51
32
51
25
25
51
19
51
.8
.8
.8
.0
.8
.9
.9
.8
.8
.8
Ht
14'
14
14
14
14
14
14
14
12
14
.6
.6
.6
.6
.6
.6
.6
.6
.2
.6
Capacity
(m3)
11.
30,
30,
30,
11,
30,
7,
7,
30,
3,
30,
742
787
787
787
742
787
692
692
787
757
769
Annual
Throughput
(m3)
152
400
400
400
73
400
100
100
400
48
400
,646
,231
,231
,231
,293
,231
,000
,000
,231
,841
,231
176
-------
MODULE NO. N30
ADMINISTRATION CENTER
Module area = 7.6 hectares: 636m x 120m
A. BUILDING
125m wide x 125m long x 18m high
MODULE NO. N31
FUTURE EXPANSION
Module area = 19.4 hectares: 540m x 360m
The area is reserved for future refinery expansion,
177
-------
APPENDIX A
VAPOR PRESSURES OF VARIOUS STOCKS
RVP 9 37.8°C
Material psia kPa
Propylene 230 1,585
Propane 189 1,303
Iso-butane 73 503
Normal butane 51 352
Iso-pentane 20.5 141
Normal pentane 15.6 108
Motor gasoline (winter) 13.0 90
Light naphtha 12.2 84
Natural gasoline 12 83
Straight-run gasoline 10.8 74
Motor gasoline (summer) 10 69
Polymers 10 69
Cat gasoline 9.2 63
Aviation gasoline 6 42
Reformer feed stock 5.7 39
Heavy naphtha 5.7 39
Hexane 5.0 34
Alky!ate 5.0 34
Spent caustic 5.0 34
Reformate 4.5 31
B-T feed 4.5 31
178
-------
RVP @ 37.8°C
Material psla kPa
Crude 2-6 (4avg.) 14-42 (28 avg.)
Benzene 3.3 23
Process Condensate 3.0 22
Jet fuel, JP-4 2.5 17
Light gas oil 1.5 10.4
Iso-Paraffin 1.2 8.3
Toluene 1.1 7.6
Furnace oil 0.9 6
Cycle oil 0.5 3.4
Xylene 0.5 3.4
Cumene 0.2 1.4
Jet fuel, commercial 0.2 1.4
Spray or weed oil 0.2 1.4
Thinner 0.2 1.4
Solvent 0.1 0.7
Kerosene 0.03 0.21
Distillate fuel oil 0.02 0.14
Diesel fuel 0.02 0.14
Heavy gas oil 0.02 0.14
Automotive diesel 0.02 0.14
Cutter stock 0.02 0.14
Light residuum 0.015 0.1
Lube oil 0.007 0.05
Heavy residuum 0.0001 0.0007
Residual fuel oil 0.0001 0.0007
179
-------
APPENDIX B
ENGLISH -S.I. UNIT CONVERSIONS
SI Unit
1 Kilogram (Kg)
1 Metric ton
1 Gigajoule (GJ)
1 Hectare
1 Meter (m)
1 Cubic meter (m3)
1 Cubic meter (m3)
1 Kilo pascal (kPa)
English Equivalent
2.2 Pounds
2,200 pounds
1055 x 106 BTU
2.47 acres
3.28 feet
264 gallons
6.29 barrels
6.145 psia
180
-------
TECHNICAL REPORT DATA
{.''tease redd fnstnicna.-is «; r/it Wc.r?t.' h'sor? c
j' EPAV-T450/3-78-025
M. TITLE A.NO SUBTITLE
ACCESSION N
_L
I
'5. REPORT OATS
i May, 1978
Development of Petroleum Refinery Plot Plans
5. PER<-OR.-.«(MG ORGANIZATION CODS
t
i~7. AUTHORISE
D. Powell
K. Luedtke
P. Peterson
L. Levanas
3. P5RFOa.'-.!!NG ORGANISATION REPORT NO. '
9. PERFORMING ORGANIZATION NAMS AND ADDRESS
Pacific Environmental Services, Inc.
1930 14th Street
Santa Monica, California 90404
[10. PROGRAM ?L = -V£NT NO.
.11. CONTRACT. HRANT .MO.
68-02-2506 Task 10
. SPONSORING AGENCY NAME AND ADDRESS
U.S. Environmental Protection Agency
Office of Air Quality Planning and Standards
Emission Standards and Engineering Division
Research Triangle Park. N.C. 27711 _
13. TYPE OF REPORT AND PERIOD CQVttE
Final, iTov., 77 to f-tay, 73
M4. SPONSORING AGENCY CODE
15. SUPPLEiME.NTARY NOTSS
EPA Project Officer: Kent C. Hustvedt
18. ABSTRACT
This study provides information on. four hypothetical refineries for the
purpose of modeling ambient benzene dispersion. Information givan for each
refinery is: z plot plan mapping the location of modules; an estimate of the
number and size of potential emission points in each module including pumps
and compressors, valves and fittings, heaters or boilers, tanks, wastewater
treatment facilities, cooling towers, and flares; and a list of significantly
tall or wide structures in each module. The hypothetical refineries span
the range of operating capacities of refineries found in the United States.
17.
KSY WORDS AND DOCUMENT ANALYSIS
:=3CRI?TORS
•:. COSATI
I Pabrolai;;" P.ef'ning Flanges
: Hydrocarbons Heaters and
j Dispersion Modeling Boilers
; Benzene Storage Tanks |
! Purrio anc Compressor Seals j
; Valves !
Pressure "i.ief Valves i
Air Pollution Control
i Stationary Sources
13H
C7C
UN CLASS IFI-"
"'".'in
i ou
------- |