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Home : A-Process Units
1) Crude Distillation:- Two identical units have been provided each of
60000 bpsd capacity when charging Kuwait crude oil. The units were designed to
process 100% Kuwait crude or mixed crudes containing up to 25% Qatar crude with
over 75% Kuwait crude.
Each unit comprises two stage distillation columns and a stabiliser for
gasoline. The units were upgraded in the sixties up to 75000 bpsd. Products
obtained by straight distillation are Liquified Petroleum Gas (LPG), Light
Gasoline, Naptha, Kerosene, Light gas oil, Heavy gas oil and Residue. Two
caustic washing units, each designed to treat 10,000 bpsd of stablised Gasoline,
Benzine, Naphtha and Kerosine are available.
A common blowdown unit has been provided for Heavy and Light Liquid products
from the two units. Vapors from these products are discharged to atmosphere 125
feet above ground through a stack situated on top of a blow down tank. A
desalter has been also provided to drop the crude salt content to minimum
values. Each unit has two heaters named as primary and secondary heater.
2) De-ethanizer Unit(L.P.G Unit) The unit was designed to process 152,200
lb/hr liquid and gaseous streams coming from crude units and from catalytic
reformer. The de-ethanizer bottoms constitute the feed to crude unit stabilizers
from which the final LPG product and stabilized gasoline are drawn. The unit can
operate on liquid feed only. Lately, the unit was modified to operate also as a
debutanizer, producing LPG and stabilized gasoline.
3) Vacuum Unit:-
The feed flow rate to unit is 10,500 BPSD of long residue from an atmospheric
fractionators, products obtained are:
- Slop oil Diesel Light Vacuum Gas Oil (LVGO) Heavy Vacuum Gas Oil (HVGO)
Slop wax Vacuum bottom Main equipments of the unit are:- - Feed surge drum –
feed preheat exchangers - Feed heater – vacuum column with vacuum system.
- Air cooler for slop wax.
- Medium pressure steam @ 175 psig and 470 °F is generated in the
convection
section of the heater to meet part of the unit requirement.
4) Asphalt Unit:- This unit was constructed in the same area as the
vacuum unit. Product obtained is asphalt with penetration of 60-70 and softening
point (ring of ball) 48-55 °C. The unit consists of feed preheat exchangers.
oxidiser column, air compressors, air cooler for blown asphalt and incinerator
for waste gases from the top of the oxidizer column. The unit was designed to
produce 100,000 tpy paving asphalt. However, this could be exceeded as a
function of the type of feed. Blending of blown asphalt with straight run vacuum
bottoms etc.
5) Drum Making and Filling:- This unit was commissioned in 1987 to
produce drums along with filling facilities to fill these drums with asphalt.
Main unit data:-
1) Drum Making:- Production rate 133 Drums /hr. Drum capacity 220 litre
Drum dimensions i.d. 560 mm ____________hight 950 mm
2) Drum Filling:- Average filling rate 100 drums/hr Auxiliary systems:-
The following important auxiliary systems were provided:-
1) Oxidiser feed tanks.
2) Blown asphalt tanks.
3) Hot oil system.
4) Ram pump.
5) Vacuum heater decoking facility.
Loading arm facility to fill road tankers was also installed and is in
operation.
6) Platformer Unit: The unit was designed for 12,000 BPSD
charging stock 54.5 API Kuwait Naphtha 203 °F / 383 °F. Main unit design data:-
- LHSV --------------------------------------------- 2.0.
- Reactor inlet temp . -------------------------------- 950 °F.
- Separator pressure ---------------------------------450-650 PSIG.
- Recycle Ratio H2: Naphtha -------------------------8 mol / mol
The unit is sem-regenerative type fixed bed catalytic reforming with
prefractionator of naphtha charge, stablisation of the platformate, girbotol
treating of the recycle gas, glycol and amine regeneration system. Also four
clark internal combustion gas engine compressors were installed. Two charge
heater and one intermediate heater were provided to supply the required heat of
the reaction. Three reactors were also included in the unit. The main reactor
charge pump is a turbine driven pump with condensing facilities and no spare
pump. The existing type of catalyst is monometallic R11 catalyst. (U.O.P.)
7) Copper Chloride Unit:- There are four copper chloride units each of
6,000 b/d capacity. The objective of the copper chloride sweetening process is
to produce doctor negative products. The process is an oxidation of mercaptans
to disulphide. The feed to the unit is:-
Light gasoline – Benzine – Benzine naphtha blend and kerosene raffinate.
Soda regeneration system:-
Some of the redundant equipments were utilised to regenerate caustic soda. This
project was initiated and implemented by the Technical Service Department thanks
to the efforts of the late Dr. Omer Salem Zain The system operates successfully
since started in the eighties The effect was not only financial but also
environmental.
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