BMS-CJS EXPANSION

TEAM
William Kelly, Maxy Nwosu, Tuyet Nguyen,
Cole Clabough, Joseph Amoabeng, Sabrina Smith

May 2, 2017
Crude Blend
Our Process
Atm Tower
Desalter

Desalter Atm Tower

Pre-Frac Tower

Pre-Frac Tower
Vac
Tower

Vac Tower
 Aspen Simulation
• Property Method: Grayson

Aspen Technology,Inc. ASPEN PLUS User Guide: ASPEN PLUS Release 9. Cambridge,
Massachussetts: Aspen Technology, 1994. Print.
Why choose a Pre-Frac?

• Reduce Heat Duty of Atmospheric Furnace

• Reduce size of Atmospheric Crude Tower
• No naphtha splitter needed
• Save $$$
 Pre-Fractionation Tower

• 21 stages
• 50 MBBL/D Light Naphtha
• Inlet Temp: 425°F
• Condenser, no reboiler
• Height: 53 ft.
• Diameter: 33 ft.
 Pre-Frac Tower Results

Kaes, Gerald L. Refinery Process Modeling: A Practical Guide to Steady State Modeling of
Petroleum Processes (using Commercial Simulators). Athens, GA: Athens Printing, 2008. Print.
Money Saved is Money Earned
 Atmospheric Column
• 40 Stages
• Inlet Temp: 650°F
• 3 Pumparounds
• 3 Strippers
• Height: 93 ft.
• Diameter: 31 ft.
 Atmospheric Results

http://blog.jazzfactory.in/2010/07/how-to-present-excel-tables-in.html
 Vacuum Tower
• 17 Stages
• Inlet Temp: 760°F
• 2 Pumparounds
• No reboiler or
condenser
• ASTM D1160 95%
• Large vapor volumes
for feed rate
• Height:98 ft.
• Diameter: 39 ft.

http://www3.aiche.org/proceedings/content/Annual-2013/extended-abstracts/P318278.pdf
http://www.koch-glitsch.com/Document%20Library/KGSP.pdf
 Vacuum Tower Results

Kaes, Gerald L. Refinery Process Modeling: A Practical Guide to Steady State Modeling of
Petroleum Processes (using Commercial Simulators). Athens, GA: Athens Printing, 2008. Print.
CONTINUOUS CATALYST
REGENERATION (CCR) REFORMER
WHY CCR????
• Produces higher octane number
• Less shut down time
• Operates at lower pressure
• Uses catalyst with less stability but higher selectivity
and yield
• Produces more reformate with higher aromatic
content
• Steady production of hydrogen with constant purity
 Feed Characteristics

Catalyst Properties: Pt-Sn/Al2O3

Le-Goff, P. Y., and J. Lopez. "Special Report Refining Developments - Axens." Www.axens.net.
Axens, Sept. 2012. Web. 1 May 2017.
 Reactor Specifications

Weight Hourly Space Velocity (WHSV)

http://nptel.ac.in/courses/103107082/module6/lecture6/lecture6.pdf
Reactor Structure

Iranshahi, Davood, Mohsen Karimi, Shahram Amiri, Mitra Jafari, Razieh Rafiei, and Mohammad Reza
Rahimpour. "Modeling of naphtha reforming unit applying detailed description of kinetic in
continuous catalytic regeneration process." Chemical Engineering Research and Design 92.9 (2014):
1704-727. Web.
Why Radial Flow Reactor????
Heat Integration
• Cold Streams • Hot Streams
• Desalter Feed • Pre-Frac Off Gas
• Pre-Fractionation • Wet Gas
Tower Feed • Light Naphtha
• Heavy Naphtha
• Atmospheric Tower
• Kerosene
Feed
• Diesel
• Vacuum Tower Feed • AGO
• Vacuum Tower Off Gas
• Light Vacuum Gas Oil
• Heavy Vacuum Gas Oil
• Vacuum Bottoms
 Limitations & Considerations
• Minimum Approach temperature: 10 deg.
Celsius
• Avoid Temperature Crossing
• Reducing heat duty needed from hot utility
(high pressure steam)
• Mass flow rates & Heat Capacities (m*Cp)
• Utility cost vs. Equipment Cost

Turton, Richard, Richard C. Bailie, and Wallace B. Whiting. Analysis, synthesis, and design of chemical
processes. Upper Saddle River, NJ: Pearson Education International, 2015. Print.
Heat Integration Streams
Temperature Interval Diagram
Composite Curves
Heat Exchanger Calculations
Heat Integration

Desalter Feed Pre-frac Feed

Atmospheric Feed
Vacuum
Feed
Savings From Heat Integration
• Utility Required without Integration:
$153 million per year
• Utility Required with Integration:
$79 million per year
• Savings:
$74 million per year
48.36% utilities saved
SAFETY
•Safety incidents in refineries can be very
costly in terms of human and infrastructure.

•BP Texas City Refinery Explosion, 2005.

•Tesoro Refinery Explosion, 2010.

 BP Texas City Refinery
Explosion, 2005
• 15 Fatalities

• 180 Injuries

• $2 Billion

• Poor safety culture

• Mechanical Integrity

http://www.csb.gov/bp-america-refinery-explosion/
Tesoro Refinery Explosion, 2010

• 7 Fatalities

• $40 Million

• Poor Safety Culture

• Lack of Oversight

• Mechanical Integrity

http://www.csb.gov/tesoro-refinery-fatal-explosion-and-fire/
Safety Assurance
How to minimize safety risks ?

•Personal Protective Equipment (PPE)

•Mechanical Integrity

•Chemical and health hazards

•Safety culture.
OBJECTIVE
The following areas will be scrutinized and
examined to ensure proper adherence to safety
in all the refinery expansion units:
•Oversight and Coordination

•Emergency Response and Preparedness

•Safety and Prevention of Hazardous Events

•Community Education and Alerts

 Continuous catalytic
regeneration (CCR) platforming
unit.
•CCR Reactor

•Heat Exchanger

•Furnace
 CCR Reactor
1. Toxic Release
•Gas monitors
•Fire and gas detection system

2. Catalyst Poisoning

3. Combustion Hazards
•Purging
•Burner valves
•Safety control systems
 HEAT EXCHANGERS
1. Fouling
•Regular inspection and cleaning

2. HTHA prevention
•Use of appropriate M.O.C ( low alloy steel
over copper steel)
•Inspection via pyrometer
 FIRED HEATERS
Safety systems to prevent:

1. Fuel accumulation
•Explosions

2. Overheating or Overfiring
•Metallurgical impact

http://www2.emersonprocess.com/en-us/brands/deltav/sis/applications/pages/bms.aspx
Distillation Towers
1. Liquid detection and relief systems
•Prevent overpressure

2. Control systems
•Liquid level detection

3. Corrosion control
•NH3/Alkaline solution injection
 Environmental
• Construction Permitting
• Operating Permitting
• Regulations on Major Emission Sources
 Environmental Permit-
Construction

AIR WASTE

WETLANDS MARINE
 AIR

https://www.tceq.texas.gov/
Environmental Permit- Air

Beaumont – Port Arthur Area

Region 6 for EPA
Region 10 for
Texas Commission of Environmental
Quality
Status : In Attainment
 Environmental Permit- Air
New Construction- Major
New Major Source
In Attainment Status
Review
(NSR) Prevention of Significant
In Attainment Status
Deterioration
(PSD) New Source PerformanceControl
Standards (NSPS)
Greenhouse Gas
Maximum Achievable Best Area Control
(GHG) Control Technology Technology
(MACT) (BACT)
National Emissions
Standards For Hazardous
Pollutants (NESHAPS)
Environmental Permit-Operating

AIR WATER WASTE

EXISTING MAJOR
SOURCE ADDITIONAL WASTE GENERATED WASTE
WATER ROUTED TO SENT OFFSITE FOR
EXISTING TREATEMENT DISPOSAL

TITLE V PERMIT

TPDES PERMIT (Texas

Pollutant Discharge
NO PERMITTING
Elimination System)
NEED PRIOR TO NEEDED
NEEDED BEFORE
CONSTRUCTION DISCHARGE OF WW
 Major Emission Sources
•
 Major Emission Sources
•
 Major Emission Sources
•
 Standards to determine if NSR is
required

https://www.tceq.texas.gov/
 Economics
The light and heavy crude; Algerian Condensate and Dalia were used for this expansion. The
plant was assumed to operate for 330 days out of the year. These crudes were priced using
the WTI index and market data.

Amount
Cost of Crude Total Cost of Raw
Price per BBL Purchased per Days
per year Materials
day (BBL)
Dalia Crude $42.69 226302 330 $3,188,074,685 $5,140,600,079
Algerian
Condensate $55.25 98698 330 $1,799,511,285
 Crude Breakdown
Below is the breakdown of the product produced for the process. 273MBD of our crude
product was produced from the 325MBD of Dalia and Algerian Condensate fed into the
process.

● 22 MBD Gasoline
● 26 MBD Diesel
● 41 MBD Kerosene
● 17 MBD Atmospheric Gas Oil
● 31 MBD Heavy Naphtha
● 16 MBD Heavy Vacuum Gas Oil
● 32 MBD Heavy Naphtha
● 50 MBD Light Naphtha
● 69 MBD Light Vacuum Gas Oil
● 51 MBD Vacuum Resid
 Revenue Breakdown
Amount Produced per Estimated Sell
Products Day Days Operating Price Profit per day Profit per year
Gasoline 22014 330 $61.54 $1,354,742 $447,064,715
Diesel 26195 330 $62.93 $1,648,432 $543,982,715
Kerosene 41696 330 $65.10 $2,714,377 $895,744,427
AGO 16747 330 $60.76 $1,017,542 $335,788,743
Heavy
Naphtha 31915 330 $54.25 $1,731,389 $571,358,288
Light Naphtha 50000 330 $48.83 $2,441,500 $805,695,000
HVGO 16000 330 $58.59 $937,440 $309,355,200
LVGO 68506 330 $58.59 $4,013,767 $1,324,542,958
Vac Resid 50936 330 $28.21 $1,436,905 $474,178,505

Total Profit per day $17,296,093

Total Profit per year $5,707,710,550

 Energy Savings
• Assuming HP Steam for Utility

• Utility Cost without heat integration

$237,789,977 USD

• Utility Cost with the use of heat integration and the addition of
the pre-frac
$177,536 861 USD

• Savings per year of Utility Costs

$84,775,869 USD
• Percent Savings
35% Savings
 Energy Savings
Heat Duty Cost of Utility
Unit Flow lb/hr Temp In Temp Out Total Cost
GJ/hr ($/GJ)
E-101 98.30 2020150 66.74 173.15 14.05 $10,938,628
E-102 4.56 2020150 66.74 71.68 14.05 $507,672
E-103 67.23 2020150 71.68 143.73 14.05 $7,480,652
E-104 120.86 2020150 66.74 197.57 14.05 $13,449,310
E-105 83.46 2020150 143.73 225.00 14.05 $9,287,429
E-106 29.78 2020150 197.57 225.00 14.05 $3,313,523
E-107 98.65 4035960 26.73 84.32 14.05 $10,977,288
E-108 59.67 4035960 84.32 115.04 14.05 $6,640,271
E-109 44.17 4035960 115.04 136.84 14.05 $4,914,794
E-110 597.50 4035960 136.84 425.00 14.05 $66,487,006
E-111 125.45 3330520 375.95 436.31 14.05 $13,960,051
E-112 29.72 3330520 436.31 450.01 14.05 $3,307,062
E-113 16.89 1894950 632.68 645.07 14.05 $1,879,230
Atm Furnace 560.11 14.20 $62,992,712
No PreFrac
655.44 14.20 $73,713,621
Furnace
Vac Furnace 218.05 14.20 $24,522,753
 Utility Costs Per Unit
Unit Cost Per Day Cost per Year
E-105 $28,143.72 $9,287,429
E-106 $10,040.98 $3,313,523
E-110 $201,476 $66,487,006
Atm Furnace $190,887 $62,992,712
Vac Furnace $74,311 $24,522,753
Pre Frac Tower $13,246 $4,371,295
Atm Tower $13,246 $4,371,295
Vac Tower $6,442 $2,126,013
Frac Pump $196 $64,835

Total Cost per Day $537,990

Total Cost per Year $177,536,861
 Profit Per Year
Cost of Raw Materials: $5,140,600,079

Cost of Utility: $177,536,861

Equipment Cost: $457,693,000

Profit Per Year: $389,573,610

 Capital Costs
Payback Period
$1.00 $0.89
$0.90 $0.81
$0.80 $0.73
$0.70 $0.64
Cash Flow in Billions USD

$0.60 $0.54
$0.50 $0.43
$0.40 $0.30
$0.30
$0.20 $0.15
$0.10
$-
$(0.10) 0 1 2 3 $(0.01)
4 5 6 7 8 9 10 11 12
$(0.20) $(0.15)
$(0.30) $(0.21)
$(0.40) $(0.29)
$(0.50) $(0.42)
$(0.60)
$(0.70)
$(0.80)
$(0.90)
$(1.00)
Year
Thank
You!