Slide 1

Conversion of Waste Lube Oil to Gasoline

Dr. John Lau Sie YonAcademic Advisor

Tan Et Kuan Industrial Advisor

Member (Group 6 Year 2015)

Yong Wan Wei Director 16311109

Alan Wong Chiew Wee Chief Environmental Officer 16530807

Colin Wong Lik Long Chief Financial Officer 16530849

Aaron Lim Chee RenChief Executive Officer 15410908

Chan Wai MunChief Safety Officer 16012114

Anavah Oil Corperation

Chemical Engineering Department

1

Presentation Outline

Part 1 Project Background (Chief Executive Officer)ObjectiveMarket SurveyProcess SelectionStorage and Transport RequirementsSite SelectionProject SchedulePart 2 Technical Aspect (Director and Chief Environmental Officer)PFD and Stream TableMaterials and Energy BalanceMajor Utilities SpecificationsProcess Optimization and Energy IntegrationPreliminary Equipment SchedulePreliminary Piping SpecificationsEquipment and Plant LayoutPreliminary Environment Impact AssessmentPart 3 Process Control & Economic Analysis (Chief Safety Officer and Chief Financial Officer)Economic Assumptions and MethodsCost SummaryEconomic AnalysisP&ID and Process Control PhilosophyPlant Commissioning, Startup and Shutdown

2

Introduction

Objectives

Process 1 kilotonne waste lube oil into gasoline

95% purity

High sustainability

Low operational risk

Low environmental impact

Constraints

Maximize gasoline yield

HYSYS Equipment

HYSYS simulation conversion

Market Survey

Target Market: Malaysia

40% of Malaysia energy consumption comes from liquid fuel 1

Average annual growth of gasoline: 6.7% 2

Source: EIA (2014); IndexMundi (n.d.)

0.37 MBD

4

Process Selection

Source: PETDER (2012); SENER (n.d); Paulik (2011); zmen (2015)

Re-refining

Acid/clay Treatment

Solvent Extraction

Hydroprocessing

Cracking

Hydrocracking

Fluid Catalytic Cracking

Fractionation

Product quality dependent of feed

solvent cost

Recoverable solvent

asphalt production

product yield and quality

H2 gas recyclable

operating condition

H2S removal

product yield

clay disposal cost

operating condition

Acid sludge disposal problem

Acid/clay Treatment

Solvent Extraction

Hydroprocessing

Technical Economic Safety & SustainabilityEnvironment

Block Flow Diagram

Process Flow Diagram

Hydrogenation

Fractionation

Catalytic Cracking

gasoline yield

cost due to catalyst price but can be regenerated

Catalyst generable making it cost effective

Stripper used to remove coke and impurities

gasoline yield

cost due to hydrogen price

operating condition

Produces coke and sulphur

Hydrocracking

Fluid Catalytic Cracking

5

Material Storage

Material Transportation

Source: Adenan (2005); Department of Labour (n.d.); OFA (2010)

614-for General Purpose and Special Purpose Oil Systems

620-for operating 17kPa

650-most common (gasoline, oil, chemicals)

6

Waste Lube Oil

API Standard 614

Hydrogen

API Standard 620

Gasoline

API Standard 650

Waste Lube Oil

Avoid dense population and environmentally sensitive route

Hydrogen

Transport medium to include safety valve

Gasoline

Transport through pipeline to comply Petroleum Regulations 1985

Site Selection

Sipitang Oil and Gas Industrial Park

Gebeng

Industrial Park

Pengerang Integrated Petroleum Complex

Pengerang Integrated Petroleum Complex

614-for General Purpose and Special Purpose Oil Systems

620-for operating 17kPa

650-most common (gasoline, oil, chemicals)

7

Site Characteristic

Close to Singapore & Malacca Straits

Tax Incentive

Income tax exemption on statutory income for 15 years in

Facilities & Infrastructure

Deepwater port

Utilities

Labour Market

109.28 acres

Numerous vocational institute and universities

On-site 1300MW power plant

Dedicated sulphur handling facilities

Socio Impact

Relatively unpopulated leading to minimal relocation

Project Schedule

TasksAugSeptOctNovWk 1Wk 2Wk 3Wk 4Wk 5Wk 6Wk 7Wk 8Wk 9Wk 10Wk 11Wk 12Overview research to gather required informationTask distributionCompany formation (logo, name)Project background, constraints, objective, market survey, evaluation of alternative process, construct block flow diagramJustification on process selection, site selection and raw material selectionProduct storage requirement, transportation requirements and memo 1Memo 1 compiling and submissionConstruct process flow diagram, specification of major utilities and process optimisationEquipment schedule, detail, sizing, specification on piping and construct plot planEnvironmental impact assessment, process safety, hazards review and memo 2Memo 2 compiling and submissionEstimation on capital, operating cost and plant process control philosophyKey issues identification, equipment list for major, minor design study and memo 3Memo 3 compiling and submissionDesign Project PresentationVolume 1 compiling and submissionMemo 2 compiling and submissionVolume 2 compiling and submissionFinal report

Design project presentation

614-for General Purpose and Special Purpose Oil Systems

620-for operating 17kPa

650-most common (gasoline, oil, chemicals)

8

Node 1:

Knock-Out Drum, V-101, V-102, V-103

Node 3:

Packed Bed Absorber, T-100 and Fractionator, T-101

Node 2:

Fluidized Bed Reactor, R-100

Initial Process Hazard and Safety Review

Preliminary HAZOP Analysis

- This plant is divided into 3 nodes.

Node 1

NodeParameterGuidewordPossible CausesConsequencesSafeguardAction requiredKnock-Out DrumTemperatureHigh- Poor insulation- Heat tracing- Thermal radiation (Sun)- Overpressurized- Low mechanical strength- Loss of containment (vaporization)- Temperature control system- Thermal relief valve- Mechanical integrity- Temperature alarm system- Regular inspection and maintenance- Tanks coated with reflective paint - Personal protective equipment- Strict adherence to working procedureLevelHigh- Flooding- Carryover- Spillage of gas- Overpressurized- Drain valve- Level indicator and alarm- Alternative pipeline- Ensure instruments are clearly labelled, easy to view and designed to be easily understand- Personal protective equipmentLow- Leakage- Valve/controller failure- Process disruption- Financial loss- Level indicator- Level alarm- Provide clear and correct instructions- Regular inspection and maintenancePressureHigh- Blockage- Faulty of valves- Thermal expansion- Tank rupture- Explosion- Injuries and fatalities- Pressure control system- Pressure relief valve- Vent valve- Pressure alarms- Vacuum break valve- Regular inspection and maintenance- Monitor the indicators frequentlyCorrosion-- Presence of impurities- Lack of cleaning- Deposition- Porosity- Anode installation- Pre-coating- Ensure pipe integrity- Strict adherence to maintenance schedule

Node 2

NodeParameterGuidewordPossible CausesConsequencesSafeguardAction requiredFluidized Bed ReactorTemperatureHigh- Faulty of heaters- Presence of impurities- Tube fouling- Defect of control system- Property damage and explosion- Side reaction- Degradation of catalyst- Low purity of product- Temperature control system- Thermal relief valve- Mechanical integrity- Temperature alarm system- Regular inspection and maintenance- Tanks coated with reflective paint - Personal protective equipment- Strict adherence to working procedureLow- Heat loss; vaporization- Tube fouling- Low conversion and production- Wax build up- Temperature control system- Temperature alarm system- Regular inspection and maintenance- Monitor the indicators frequentlyFlowHigh- Reduced back pressure- Controller failure- Valve failures- Pressure deviation- Flooding in the reactor- Spillage- Loss of containment- Financial loss- Hand-operated valve- Alternative pipeline- Shutdown valve- Flow control system- Regular inspection and maintenance- Ensure instruments are clearly labelled, easy to view and designed to be easily understandLow- Pipe leakage- Partial blockage- Sediment; cavitation- Loss of containment- Process disruption- Pipe leak detector- Schedule cleaning routine- Flow control system- Regular inspection and maintenance- Ensure instruments are clearly labelled, easy to view and designed to be easily understandNo- Closed/stuck valve- Human error- No production- Financial loss- Schedule cleaning routine- Flow control system- Regular inspection and maintenance- Ensure sufficient feedstockReverse- Check valve failure- Wrong routing- Poor isolation- Overpressurized- Produce impurities- Process disruption- Drain valve- Alternative check valve- Flow control system- Authorized personnel to perform services- Ensure instruments are clearly labelled, easy to view and designed to be easily understandPressureHigh- Excessive feed supplies- Blockage of pipeline at outlet stream- Valves failure- Pipe rupture- Property damage and explosion- Degradation of catalyst- Side reaction- Pressure control system (pressure gauge/transmitter)- Pressure safety valve- Vent or vacuum break valve- Shutdown valve- Pressure alarm system- Firefighting system in case of emergency - Well insulated reactor to reduce external heat effects- Trip valve to terminate operation at high pressure- Regular inspection and maintenanceLow- Leakage of pipe or vessel- Faulty of pressure control system- Malfunction of pumps- Ineffective conversion and production- Vapour lock- Low purity of product- Install backup pumps- Pressure control and alarm system- Vacuum break valve- Monitor the indicators frequently- Regular inspection and maintenance- Ensure instruments are clearly labelled, easy to view and designed to be easily understand

Node 3

NodeParameterGuidewordPossible CausesConsequencesSafeguardAction requiredPacked Bed Absorber/Fractionator TemperatureHigh- Malfunction of reboiler and condenser- Faulty of temperature control system- Thermal radiation- Flare- High consumption of energy- Product impurities- Inefficient separation- Property damage and explosion- Injuries and fatalities- Loss of containment- Integrated control system- Thermal relief valve- Mechanical integrity- Personal protective equipment- Thorough working procedure- Review the procedure, control system and operating condition- Regular inspection and maintenance- Promote good communication within workers- Provide clear and concise instructionLow- Malfunction of reboiler and condenser- Leakage of pipe or equipment- Heat loss- Poor insulation- Low energy efficiency- Low purity of product- Inefficient separation- Underpressurized- Wax build up- Integrated control system- Thermal alarm system- Mechanical integrity- Personal protective equipment- Monitor the indicators frequently- Ensure instruments are clearly labelled, easy to view and designed to be easily understand- Strict adherence to rules and regulationsFlowHigh- Reduced back pressure- Controller failure- Valve failures- Pressure deviation- Low purity of desired product- Flooding- Spillage- Column damage- Hand-operated valve- Alternative pipeline- Shutdown valve- Flow control system- Regular inspection and maintenance- Ensure instruments are clearly labelled, easy to view and designed to be easily understandLow- Pipe leakage- Partial blockage- Sediment; cavitation- Faulty of pump- Low production- Financial loss- Process disruption- Pipe leak detector- Schedule cleaning routine- Flow control system- Backup pump- Regular inspection and maintenance- Ensure instruments are clearly labelled, easy to view and designed to be easily understandNo- Closed/stuck valve- Pipe leakage/blockage- No production- Financial loss- Schedule cleaning routine- Flow control system- Regular inspection and maintenance- Ensure sufficient feedstockReverse- Check valve failure- Wrong routing- Poor isolation- Pump and column damage - Overpressurized- Produce impurities- Drain valve- Alternative check valve- Flow control system- Authorized personnel to perform services- Regular inspection and maintenancePressureHigh- Excessive feed supplies- Malfunction of condenser- Valves failure- Fouling of pipe- Acceleration of flow- Pipe rupture- Property damage- Vapour cloud explosion- Injuries and fatalities- Pressure control system- Pressure relief valve- Vent valve- Pressure alarms- Vacuum break valve- Mechanical integrity- Regular inspection and maintenance- Ensure good communication between operators- Provide clear, concise and correct instructions- Ensure instruments are clearly labelled, easy to view and designed to be easily understandLow- Possible occurrence of vacuum- Inadequate feedstream- Pipeline rupture/blockage- Process disruption- Inefficient separation- Low production- Financial loss- Pressure control system- Pressure relief valve- Pressure alarm- Vacuum break valve- Regular inspection and maintenance- Provide clear, concise and correct instructions- Ensure instruments are clearly labelled, easy to view and designed to be easily understand

Preliminary Equipment Schedule

EquipmentUnitFunctionOperating condition/capacity/sizeMaterials of constructionFluidized Bed Reactor, R-1001- To react waste lube oil with hydrogen gas to produce H2S which will be removed in treatment process200oC; 27.36L; 4.6 m length, 1.5 m diameter, 0.005m wall thicknessSS-309Packed Bed Absorber, T-100 1- To remove H2S from H2 using water25oC, 10000kPa; 88.36L; 1.5m diameterWater stream: SS-304Column: SS-309Regenerator, FCC-1001- To regenerate used catalyst back into riser710oC, 370kPa; 16370L ; 4.5m height, 7.6m diameterSS-309Riser, FCC-1001- To crack heavy hydrocarbon to lighter hydrocarbon540 oC, 340kPa; 16370L ; 36.5m length, 1m diameterSS-304Fractionator, T-1011- To separate cracked hydrocarbons into separate streams such as light ends, gasoline, diesel and bottoms59-540oC, 330-1000kPaSS-304

There are total of 5 major equipment:

Sources: Petrowiki (2013)

Preliminary Piping Specifications

StreamMaterialCalculated Diameter (mm)Industrial inside diameter, Di (mm)Industrial outside diameter, Do (mm)Nominal Size, (inch)Thickness, tp (mm)Schedule No.No of PipesS1ASME SA 106 Grade B184.04202.74219.1088.18Sch 402S2ASME SA 106 Grade B211.65254.56273.10109.27Sch 402S3SS-304183.77202.74219.1088.18Sch 402S4SS-304135.30154.68168.9067.11Sch 402S5SS-304192.60202.74219.1088.18Sch 402S6SS-304118.63128.20141.3056.55Sch 402S7Alloy 28 (N080208)272.68304.84323.90129.53Sch 401S8Alloy 28 (N080208)140.08154.68168.9067.11Sch 401S9Alloy 28 (N080208)191.98202.74219.1088.18Sch 402S10Alloy 28 (N080208)565.58590.94610.00249.53Sch 402S11Alloy 28 (N080208)411.080.00Sch 402S12SS-316116.69128.20141.3056.55Sch 402S13SS-31653.1762.6873.002.55.16Sch 402S14SS-31660.8162.6873.002.55.16Sch 401S15Alloy 28 (N080208)31.5635.0842.201.253.56Sch 402S16SS-183.48202.74219.1088.18Sch 401S17Alloy 28 (N080208)143.61154.68168.9067.11Sch 401S18SS-304158.95202.74219.1088.18Sch 401S19ASME SA 106 Grade B99.44102.26114.3046.02Sch 401S20Alloy 28 (N080208)161.58202.74219.1088.18Sch 401S21ASME SA 106 Grade B60.0062.6873.002.55.16Sch 401S22ASME SA 106 Grade B60.0062.6873.002.55.16Sch 401S23ASME SA 106 Grade B725.73730.24762.003015.88Sch 301S24ASME SA 106 Grade B116.83128.20141.3056.55Sch 402S25ASME SA 106 Grade B32.4240.9448.301.53.68Sch 402S26ASME SA 106 Grade B12.4215.7621.300.52.77Sch 401S27ASME SA 106 Grade B109.47128.20141.3056.55Sch 402S28ASME SA 106 Grade B29.3235.0842.201.253.56Sch 402

There are total of 28 streams and 44 pipes:

1) The sizing of the piping connected to the major equipment are calculated based on the recommended safety factor of 1.2.

2) The internal pipe diameter ranging from 15 mm to 730 mm.

3) The outer pipe diameter ranging from 21 mm to 762 mm.

4) Materials chosen for the piping are carbon steel, stainless steel and alloy.

10

Plant Layout

LegendASecurityB1, B2, B3Assembly Point 1, 2, 3C1, C2Car Parking Lot 1, 2D1, D2Bicycle Parking Lot 1, 2EAdmin BuildingFCanteenGMaintenance and WarehouseHR&D BuildingIUtility RoomJControl RoomKFire Prevention StationLBoilerMFire Water TankN1, N2By-product Storage Tank 1, 2O1, O2Product Storage Tank 1, 2PLoading AreaQHydrogen Storage TankRCooling Water Storage TankSWaste Lube Oil Storage TankTPlantUPlant ExpansionVGeneratorWCooling TowerXWaste Storage

Raw Materials

Loading Area

By-product

Product

Waste Storage

Plant Expansion

Equipment Plant

Waste

Product

12m

Equipment Layout

LegendAFluidized Bed ReactorB, C, DKnock-Out DrumEPacked Bed AbsorberFHydrogen Treatment for ReuseGFluid Catalytic CrackingColourPumpCompressorHeat ExchangerCoolerHeater

Waste

Product

Sources: Group (2011), Xaloc (2011)

Preliminary Environmental Impact Assessment (EIA)

Biophysical

Pollution

Social

Commissioning

Interrupt ecosystem of flora and fauna during construction

Emission from plant deteriorate the quality of air

Residents that reside close to construction sites are prone to detrimental health effects

Land Pollution

Conduct vegetation and wildlife habitat assessment

Venting or flaring at the allowable limits

Conduct Human Health and Ecological Risk Assessment

Execute commissioning plan in accordance with rules and regulations

Mitigation Measures

Potential Impacts

Effluent Disposal Plan

EffluentSource Malaysia DOE StandardManagementVapor WastePacked Bed Absorber, T-100H2S for flaring: 5ppmv- Flare to convert H2S to SOx.- Scavenger system is used to convert sulphide species to a more inert state.Aqueous WasteKnock-Out Drum, V-101, V102, V-103- H2S: 5ppmv- NH3: 50ppmvSent to sour water stripper to remove phenol from the water.Solid Waste- Fluid Catalytic Cracking, FCC-100- Fluidized Bed Reactor, R-100- Zeolite: 0.015g/kg- Ni/Mo: 0.001g/kg- Spent zeolite is regenerated.- Ni/MO catalyst is recycled.

Sources: Flora and Fauna (2015), United States Environmental Protection Agency (2015), Prices (2015), MGID (2015), Waycuilis (2000), Li, Zhu and Zhang (2010), Environment (2007),

DOE (2010), Hughes (2011), IPIECA (2010), Varma (2015), Weebly (2015), Bios (2015), K. Caroline (2014)

Sustainable Development

Resource Utilization

Recovery of unreacted material

Economics

- By-product value

- Lower raw material cost

Social

- Employment opportunities

- Development of area

Environmental

- Hydrocarbon cracking process

HYSYS Flowsheet

Fluid Package: Sour Peng-Robinson

Reaction Type: Heterogeneous Catalytic Reaction

Stream Table

NameS1S2S3S4S5S6S7S8S9S10Vapour Fraction0.00001.00000.00001.00000.00001.00000.40261.00000.00000.7607Temperature [C]37.7865.5638.93421.20200.00200.00200.00200.00200.00250.00Pressure [bar]10.0013.79103.40103.40103.40103.40103.10103.10103.1010.00Molar Flow [kgmole/h]369.41209.20369.41209.20369.41209.20571.47230.08341.39341.39Mass Flow [tonne/d]1000.0010.121000.0010.121000.0010.121010.1227.62982.50982.50Liquid Volume Flow [m3/h]45.056.0445.056.0445.056.0451.006.3244.6844.68Heat Flow [MW]-43.800.07-43.640.67-38.980.30-38.33-2.03-36.30-32.54NameS11S12S13S14S15S16S17S18S19S20Vapour Fraction1.00000.03901.00000.00001.00000.00001.00000.00000.99990.0000Temperature [C]250.0026.0026.0026.00407.52250.00208.1925.0025.1744.21Pressure [bar]10.0010.0010.0010.00103.1010.00103.10103.40103.10103.10Molar Flow [kgmole/h]259.68259.6810.13249.5510.1381.71240.211850.30200.651889.86Mass Flow [tonne/d]112.27112.270.62111.650.62870.2328.24800.009.83818.41Liquid Volume Flow [m3/h]5.005.000.294.710.2939.686.6233.405.7934.22Heat Flow [MW]-16.13-19.740.00-19.730.03-16.40-2.00-147.02-0.01-149.02NameS21S22S23S24S25S26S27S28Vapour Fraction1.00001.00001.00000.00000.00000.00000.00000.0000Temperature [C]200.00200.0051.07175.18321.16408.0330.0030.00Pressure [bar]10.0010.003.303.303.403.503.303.38Molar Flow [kgmole/h]5.555.55409.78113.625.790.70113.625.79Mass Flow [tonne/d]2.402.40441.51314.3724.783.85314.3724.78Liquid Volume Flow [m3/h]0.100.1034.2516.301.050.1416.301.05Heat Flow [MW]-0.36-0.36-7.63-6.75-0.46-0.07-7.89-0.63NameP-101-DutyK-101-DutyE-102-DutyPFR-101-DutyE-103-DutyE-104-DutyK-102-DutyE-105-DutyE-106-DutyE-101-DutyHeat Flow [MW]0.1590.6054.662-0.3563.7643.6050.0321.1450.1690.377NameS1S3S2S4S7S8S9S10S11S16S12S13S14S15S17S18S19S20S5S6S23S24S25S26S27S28S21S22Hydrogen0.0030.0030.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0030.0000.0210.0000.0000.0000.0000.0000.0000.000Nitrogen0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.000CO0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.000Oxygen0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0040.0000.0000.0000.0000.0000.0000.000Methane0.0000.0000.0000.0000.0090.0160.0040.0040.0050.0000.0050.0150.0050.0150.0160.0000.0000.0020.0000.0000.0000.0000.0000.0000.0000.0000.0000.000Ethylene0.0000.0001.0001.0000.3520.8300.0290.0290.0380.0010.0380.9810.0000.9810.8360.0001.0000.0000.0001.0000.0320.0000.0000.0000.0000.0000.0000.000Ethane0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.1710.0000.0000.0000.0000.0000.0000.000CO20.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0730.0000.0000.0000.0000.0000.0000.000H2S0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0630.0000.0000.0000.0000.0000.0000.000Propene0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.1260.0000.0000.0000.0000.0000.0000.000Propane0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.1000.0000.0000.0000.0000.0000.0000.000i-Butane0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0220.0000.0000.0000.0000.0000.0000.000i-Butene0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0850.0000.0000.0000.0000.0000.0000.0001-Butene0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0200.0000.0000.0000.0000.0000.0000.00013-Butadiene0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0270.0000.0000.0000.0000.0000.0000.000n-Butane0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0010.0000.0000.0000.0000.0000.0000.000cis2-Butene0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0310.0000.0000.0000.0000.0000.0000.000tr2-Butene0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0230.0000.0000.0000.0000.0000.0000.000i-Pentane0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0010.0000.0000.0000.0000.0000.0000.0001-Pentene0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0010.0000.0000.0000.0000.0000.0000.0002M-1-butene0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0110.0000.0000.0000.0000.0000.0000.000n-Pentane0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0010.0000.0000.0000.0000.0000.0000.000H2O0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0070.0000.0000.0000.0000.0000.0000.0003M-1-butene0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0330.0000.0000.0000.0000.0000.0000.0002M-2-butene0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0030.0000.0000.0000.0000.0000.0000.0002M-13-C4==0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0070.0000.0000.0000.0000.0000.0000.000tr2-Pentene0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0040.0000.0000.0000.0000.0000.0000.000cis2-Pentene0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0010.0000.0000.0000.0000.0000.0000.000Cyclopentane0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0010.0000.0000.0000.0000.0000.0000.000Cyclopentene0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.00022-Mpropane0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.00033M-1-butene0.7710.7710.0000.0000.4980.1500.7330.7330.9500.0430.9500.0030.9890.0030.1431.0000.0000.9970.7710.0000.0000.0000.0000.0000.0000.0001.0001.000Ammonia0.0000.0000.0000.0000.0040.0040.0030.0030.0040.0000.0040.0000.0050.0000.0040.0000.0000.0010.0000.0000.0000.0000.0000.0000.0000.0000.0000.000S_Liq_2800.0130.0130.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0130.0000.0000.0000.0000.0000.0000.0000.0000.00036-40*0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.00040-50*0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.00050-60*0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0640.0020.0000.0000.0020.0000.0000.00060-70*0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0270.0050.0000.0000.0050.0000.0000.00070-80*0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0210.0280.0000.0000.0280.0000.0000.00080-90*0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0130.0750.0000.0000.0750.0000.0000.00090-100*0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0050.0730.0000.0000.0730.0000.0000.000100-110*0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0020.0790.0000.0000.0790.0000.0000.000110-120*0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0010.0870.0000.0000.0870.0000.0000.000120-130*0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0940.0000.0000.0940.0000.0000.000130-140*0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.1000.0000.0010.1000.0000.0000.000140-150*0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.1030.0000.0010.1030.0000.0000.000150-160*0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0970.0010.0010.0970.0010.0000.000160-170*0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0840.0020.0020.0840.0020.0000.000170-180*0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.1030.0080.0040.1030.0080.0000.000180-190*0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0130.0030.0010.0130.0030.0000.000190-200*0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0130.0080.0010.0130.0080.0000.000200-210*0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0190.0310.0030.0190.0310.0000.000210-220*0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0140.0590.0040.0140.0590.0000.000220-230*0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0050.0550.0030.0050.0550.0000.000230-240*0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0030.0660.0030.0030.0660.0000.000240-250*0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0020.0980.0060.0020.0980.0000.000250-260*0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0020.1120.0100.0020.1120.0000.000260-270*0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0010.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0010.0870.0110.0010.0870.0000.000270-280*0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0010.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0690.0130.0000.0690.0000.000280-290*0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0010.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0620.0180.0000.0620.0000.000290-300*0.0010.0010.0000.0000.0000.0000.0010.0010.0000.0020.0000.0000.0000.0000.0000.0000.0000.0000.0010.0000.0000.0000.0840.0380.0000.0840.0000.000300-310*0.0010.0010.0000.0000.0000.0000.0010.0010.0000.0030.0000.0000.0000.0000.0000.0000.0000.0000.0010.0000.0000.0000.0650.0450.0000.0650.0000.000310-320*0.0010.0010.0000.0000.0010.0000.0010.0010.0000.0040.0000.0000.0000.0000.0000.0000.0000.0000.0010.0000.0000.0000.0580.0630.0000.0580.0000.000320-330*0.0020.0020.0000.0000.0010.0000.0020.0020.0000.0070.0000.0000.0000.0000.0000.0000.0000.0000.0020.0000.0000.0000.0500.0850.0000.0500.0000.000330-340*0.0020.0020.0000.0000.0010.0000.0020.0020.0000.0090.0000.0000.0000.0000.0000.0000.0000.0000.0020.0000.0000.0000.0410.1090.0000.0410.0000.000340-350*0.0030.0030.0000.0000.0020.0000.0030.0030.0000.0110.0000.0000.0000.0000.0000.0000.0000.0000.0030.0000.0000.0000.0290.1240.0000.0290.0000.000350-360*0.0030.0030.0000.0000.0020.0000.0030.0030.0000.0140.0000.0000.0000.0000.0000.0000.0000.0000.0030.0000.0000.0000.0020.0160.0000.0020.0000.000360-370*0.0040.0040.0000.0000.0020.0000.0040.0040.0000.0170.0000.0000.0000.0000.0000.0000.0000.0000.0040.0000.0000.0000.0020.0230.0000.0020.0000.000370-380*0.0040.0040.0000.0000.0030.0000.0050.0050.0000.0200.0000.0000.0000.0000.0000.0000.0000.0000.0040.0000.0000.0000.0020.0280.0000.0020.0000.000380-390*0.0050.0050.0000.0000.0030.0000.0060.0060.0000.0230.0000.0000.0000.0000.0000.0000.0000.0000.0050.0000.0000.0000.0010.0250.0000.0010.0000.000390-400*0.0060.0060.0000.0000.0040.0000.0070.0070.0000.0270.0000.0000.0000.0000.0000.0000.0000.0000.0060.0000.0000.0000.0010.0240.0000.0010.0000.000400-410*0.0070.0070.0000.0000.0040.0000.0070.0070.0000.0310.0000.0000.0000.0000.0000.0000.0000.0000.0070.0000.0000.0000.0010.0240.0000.0010.0000.000410-420*0.0080.0080.0000.0000.0050.0000.0090.0090.0000.0350.0000.0000.0000.0000.0000.0000.0000.0000.0080.0000.0000.0000.0000.0240.0000.0000.0000.000420-430*0.0090.0090.0000.0000.0060.0000.0100.0100.0000.0410.0000.0000.0000.0000.0000.0000.0000.0000.0090.0000.0000.0000.0000.0260.0000.0000.0000.000430-440*0.0100.0100.0000.0000.0070.0000.0110.0110.0000.0460.0000.0000.0000.0000.0000.0000.0000.0000.0100.0000.0000.0000.0000.0290.0000.0000.0000.000440-450*0.0110.0110.0000.0000.0070.0000.0120.0120.0000.0500.0000.0000.0000.0000.0000.0000.0000.0000.0110.0000.0000.0000.0000.0280.0000.0000.0000.000450-460*0.0130.0130.0000.0000.0090.0000.0140.0140.0000.0600.0000.0000.0000.0000.0000.0000.0000.0000.0130.0000.0000.0000.0000.0180.0000.0000.0000.000460-480*0.0290.0290.0000.0000.0190.0000.0320.0320.0000.1320.0000.0000.0000.0000.0000.0000.0000.0000.0290.0000.0000.0000.0000.0840.0000.0000.0000.000480-500*0.0250.0250.0000.0000.0160.0000.0270.0270.0000.1120.0000.0000.0000.0000.0000.0000.0000.0000.0250.0000.0000.0000.0000.0570.0000.0000.0000.000500-520*0.0160.0160.0000.0000.0110.0000.0180.0180.0000.0750.0000.0000.0000.0000.0000.0000.0000.0000.0160.0000.0000.0000.0000.0090.0000.0000.0000.000520-540*0.0160.0160.0000.0000.0100.0000.0170.0170.0000.0710.0000.0000.0000.0000.0000.0000.0000.0000.0160.0000.0000.0000.0000.0070.0000.0000.0000.000540-560*0.0130.0130.0000.0000.0080.0000.0140.0140.0000.0590.0000.0000.0000.0000.0000.0000.0000.0000.0130.0000.0000.0000.0000.0060.0000.0000.0000.000560-580*0.0100.0100.0000.0000.0060.0000.0100.0100.0000.0440.0000.0000.0000.0000.0000.0000.0000.0000.0100.0000.0000.0000.0000.0220.0000.0000.0000.000580-600*0.0060.0060.0000.0000.0040.0000.0070.0070.0000.0280.0000.0000.0000.0000.0000.0000.0000.0000.0060.0000.0000.0000.0000.0030.0000.0000.0000.000600-650*0.0060.0060.0000.0000.0040.0000.0060.0060.0000.0260.0000.0000.0000.0000.0000.0000.0000.0000.0060.0000.0000.0000.0000.0000.0000.0000.0000.000650-700*0.0010.0010.0000.0000.0010.0000.0010.0010.0000.0040.0000.0000.0000.0000.0000.0000.0000.0000.0010.0000.0000.0000.0000.0000.0000.0000.0000.000700+*0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.000

Waimun help me to include the Composition Table please TQ

13

jon chan (jc) -

Mass Balance

Source: HimmeIblau and Riggs (2012), Mapior (2009), Towler and Sinnott (2012), Balabin, Syunyaev and Karpov (2007), Antos and Aitani (2004), Toolbox (2015), ChemTeam (2015),

Dutta (2007), Fahim, Al-Sahhaf and (Elkilan 2009)

Energy Balance

Summary of Mass Balance

EquipmentP-101K-101E-102E-101V-101E-103V-102E-104V-103K-102Mix-101T-100FCC-100E-105E-106StreamS3S4S5S6S9S10S16S12S14_Sour Water_1S15S17S20_Sour Water_2Reactor EffluentS27_Gasoline ProductS28_Diesel ProductHYSYS (kg/s)11.570.1211.570.1211.3711.3710.071.301.290.010.339.479.483.630.29Manual (kg/s)11.570.1211.570.1211.3711.3710.071.301.290.010.339.4710.073.630.29Error (%)0.000.000.000.000.000.000.000.000.000.000.000.006.230.000.00ReactionHydrodesulfurization in R-100Hydrodenitrogenation in R-100HYSYS (%) Conversion116.80105.90Literature (%) Conversion98.0095.00Error (%)16.1010.29EquipmentFCC-100, Stream S16HYSYS (%) Yield36.08Literature (%) Yield42.33Error (%)17.32

Source: Beltramone et al. (2008), Ferdous, Dalai and Adjaye (2003), Ahsan (2015)

Summary of Energy Balance

EquipmentP-101K-101K-102E-101E-102E-103E-104E-105E-106T-101Duty StreamP-101-DutyK-101-DutyK-102-DutyE-101-DutyE-102-DutyE-103-DutyE-104-DutyE-105-DutyE-106-DutyQ-CondenserManual (MJ/h)571.702216.09115.351369.7414726.075650.172204.754834.60763.2720144.73HYSYS (MJ/h)571.682179.02113.471357.0116784.9113550.2712978.844117.99608.7324543.80% Error0.001.701.660.9412.2758.3083.0117.4025.3917.92EquipmentMIX-101R-100StreamS-17S-7Manual (C)210.06201.52HYSYS (C)208.19200.00% Error0.900.76

Major Utilities Specifications

Utilities Used:

Electricity

LP Steam

Cooling Water

Duty NameP-101-DutyK-101-DutyE-102-DutyPFR-101-DutyE-103-DutyE-104-DutyK-102-DutyE-105-DutyE-106-DutyE-101-DutyEquipmentP-101K-101E-102R-100E-103E-104K-102E-105E-106E-101Heat Flow (kJ/h)5.72E+052.18E+061.68E+07-1.28E+061.36E+071.30E+071.14E+054.12E+066.10E+051.36E+06Utility TypeElectricityElectricityLP SteamLP SteamLP SteamCooling WaterElectricityCooling WaterCooling WaterCooling WaterMass Flow (kg/s)--2.120.161.71172.40-54.768.1018.02

Waimun help me to include the Composition Table please TQ

14

Process Optimisation

Three Optimisation Methods:

Change the route and equipment for removal of H2S from waste lube oil

Process screening for optimum amount of zeolite in FCC

Use HYSYS Optimser

Before

After

Three Optimisation Methods:

Change the route and equipment for removal of H2S from waste lube oil

Process screening for optimum amount of zeolite in FCC

Use HYSYS Optimiser

Optimum

point

Three Optimisation Methods:

Change the route and equipment for removal of H2S from waste lube oil

Process screening for optimum amount of zeolite in FCC

Use HYSYS Optimiser

CategoryStream NameUnit PriceTotal AmountPrice (RM/day)Difference (%)Before OptimizationAfter OptimizationBefore OptimizationAfter OptimizationUtilities (Cost)SteamS-31, S-32, E-102-Duty, E-103-DutyRM 70.10/ton18607.20 ton/day350.27ton/day18607.2024552.64+31.95ElectricityK-101-Duty, K-102-Duty, P-101-DutyRM 5.904/kW12805.77 kW/day795.60 kW/day12805.774697.25-63.32Cooling waterPFR-100-Duty,T-101-Condenser Duty,E-104-Duty, E-105-Duty, E-106 DutyRM 2.96/ton88309.88 ton/day23124.63 ton/day88309.8868448.91-22.49Raw Materials (Cost)Waste lube oilS-1_Waste Lube OilRM 0.055/kg1000000.00 kg/day1000000.00 kg/day54992.4654992.460.00HydrogenS-2_Hydrogen GasRM 5.95/kg24320.00 kg/day10121.89 kg/day144704.0060225.26-58.38Process waterS-11_H2O-1, S-19_H2O-2RM 2.96/kg6000.00 ton/day800.00 ton/day17760.002368.00-86.67CatalystCatalyst (Zeolite) in FCC-100RM 255.50/kg270.00 kg/day400.00 kg/day68987.70102204.00+48.15CatalystCatalyst (Ni/Mo) in R-100RM 10.63/kg18.60 kg/day18.60 kg/day197.57197.570.00Product (Profit)GasolineS-37RM 1935/m3348.64 m3/day396.40 m3/day674632.10766963.02+13.69DieselS-38RM 1845/m354.70 m3/day25.41 m3/day100929.2146872.99-53.56Total Profit (Gasoline)268267.47449276.92+67.47Total Profit (Gasoline and Diesel)369196.68496149.91+34.39

+67.47 %

Energy Integration

Pinch Temperature

Minimum Hot Utility

Minimum Cold Utility

Energy integration BeforeAfterSavings (%)Hot utility (MW)8.5513.84055.09Cold utility (MW)5.3290.61888.41

SUMMARY

4 Heat Exchangers

3 Coolers

2 Heaters

Objective: Minimise Utility Usage

Targeting Tool: Problem Table Algorithm (PTA)

Tmin:10C

15

Profit vs Zeolite Loading

Net Profit270290310330350370390400410391993.334633953406788.941372731415419.81561648002424884.15701870801434750.38046756299444323.42858143803448655.34536799998449276.92349589401440065.54235223Catalyst cost27029031033035037039040041068987.774097.89999999999479208.10000000000684318.29999999998889428.594538.799648.9102204104759.1

Zeolite loading (kg/day)

Profit (RM/day)

Catalyst Cost (RM/day)

Process & Instrumentation Diagram (P&ID)

Fractionator Distillation Column

Fluidized Catalytic Cracking Unit

One control valves per process line

Placement of valves follow API RP 553

Design of control instrumentation based on API RP 14C and API RP 554

Degree of Freedom = 33

16

Control Philosophy

Fractionation

Distillation Column

Pressure Control: Maintain vessel pressure by controlling amount of excess gas to flaring

Level Control: Maintain liquid level in condenser tank by controlling reflux rate

Flowrate Control: Control the flowrate of each product stream

Temperature Control: Control the amount of top and bottom steam to maintain vessel temperature

Emergency Safeguard: Temperature and Pressure Trips and Shutdown Valve

Fluidized Catalytic Cracking

Pressure Control: Maintain reactor pressure by controlling amount of gas to flaring

Model Predictive Control: Optimize the system and simultaneously control the temperature and liquid level

Composition Analyzer: Monitor the composition of product using Gas Chromatography

Pressure Relief Valve: Startup / Pressure control fails

Emergency Safeguard: Level, Pressure and Temperature Trips, Blowdown Valve and Shutdown Valve

17

Control Logic Diagram for FCC unit

Supervisory Control and Data Acquisition (SCADA)

Sources: Aronson (2013), Dreamstime (2015), Gibson (2008), Goh (2015), Liptak (2005), VividCortex (2015)

Plant Pre-Startup, Commissioning and Startup

Preparation and Planning

Mechanical Completion and Integrity Checking

Pre-Commissioning and Operational Testing

Startup and Initial Operation

Performance and Acceptance Testing

Post Commissioning

Plant Shutdown

Sources: AcornStairlift (2015), Allcheck (2015), Boultton (2013), Coelho (2007), Kleiman (2011), Wave Control (2015)

19

Process Shutdown

Normal Shutdown

Extended Shutdown

Emergency Shutdown

Economic Analysis

Assumptions

1 USD= RM 4.25

Linear Depreciation

Construction Period: 2 Years

25 Years of Project Life

No Additives Added in the Gasoline Produced. Thus, 10% Margin of Actual Petrol Price (RON 95) is taken.

Source: Peters and Timmerhaus (1991), McMahon (2015)

Method Used

Percentage of Purchased Eqpt. Cost

Literature Review;

CEPCI

Gasoline Price and Utilities Cost are based in Malaysia

Total Capital Cost

Direct Cost

Extra Cost

Indirect Cost

ParametersRM (Million)Land123.77Purchased Equipment47.12Process Instrumentation and Control3.30Purchased Equipment Installation11.78Piping (include installation)21.21Electrical Equipment and Materials4.71Buildings (including services)18.85Yard Improvement4.71Service facilities28.27

Indirect Cost

ParametersRM (Million)Engineering and Supervision14.14Construction expenses16.02

Extra Cost

ParametersRM (Million)Legal expenses2.94Contractors fee5.27Contingency29.39

Direct Cost

+

+

Fixed Capital Cost

RM 351.38 Million

Ratio Factor of Fluid Plant

Total Capital Cost

RM 413.94 Million

+

Working Capital

RM 41.39 Million

Cumulative Capital Cost

RM 455.34 Million

Inclusive 6% GST

Total Production Cost

Manufacturing Cost

General Expenses

ParametersRM (Million)Raw Material61.63Operating Labor1.83Utilities34.87Direct Supervisory0.18Maintenance & Repairs7.03Operating Supplies1.05Laboratory charges0.18Patents and Royalties2.28Catalyst and solvents22.83Insurance3.51ParametersRM (Million)Administrative0.27Distribution & marketing3.04Research & Development6.32Financing12.42Contingency2.28

+

Cumulative Production Cost

RM 159.75 Million

Break-even Graph

104 ktonne/year of Gasoline Produced by Anavah

Linear Approximation

Cumulative Cash Flow Diagram

USD 333.57 Million = RM 1,417.66 Million

ParametersBaseTotal Annual Revenue, RM (Million)253.10Gross profit, RM (Million)93.35Corporate tax rate (%)24Salvage, RM (Million)41.39Total depreciable cost, RM (Million)413.94Average depreciation, RM (Million)16.56Turnover ratio0.72Annual net profit, RM (Million)58.36Net cash flow, RM (Million)74.92Return on Investment, %14.10Acceptable Rate of Return, %8Payback/payout period (years)6.08Reference Payback period0.74Venture profit, RM (Million)21.94Discounted factor, DF0.15Asset/book value, RM (Million)41.39Present Worth Factor10.67Present worth, RM (Million)829.92Net Present Worth, RM (Million)374.58Internal rate of return29%Cumulative cash position, RM (Million)1,417.66

Economic Analysis

Scenario Analysis

Manipulated

Variables

Corporate Tax

Base

24%

Best

7%

Base

30%

Gasoline Price After 10% Margin

Base

RM 1.94/liter

Best

RM 2.07/liter

Base

RM 1.62/liter

10 Years of

Historical Petrol Price

Summary of Base, Best & Worst

ParametersBaseBestWorstTotal Annual Revenue, RM (Million)253.10270.76211.90Gross profit, RM (Million)93.35111.0152.15Corporate tax rate (%)24730Salvage, RM (Million)41.3941.3941.39Total depreciable cost, RM (Million)413.94413.94413.94Average depreciation, RM (Million)16.5616.5616.56Turnover ratio0.720.770.60Annual net profit, RM (Million)58.3687.6524.91Net cash flow, RM (Million)74.92104.2141.47Return on Investment, %14.1021.176.02Acceptable Rate of Return, %888Payback/payout period (years)6.084.3710.98Reference Payback period0.740.740.74Venture profit, RM (Million)21.9451.22(11.51)Discounted factor, DF0.150.150.15Asset/book value, RM (Million)41.3941.3941.39Present Worth Factor10.6710.6710.67Present worth, RM (Million)829.921,142.56472.86Net Present Worth, RM (Million)374.58687.2217.52Internal rate of return29%34%24%Cumulative cash position, RM (Million)1,417.662,149.86581.44

By Selling

Gasoline Only

Base Case

Best Case

Worst Case

Annual

Net

Profit

RM 58.36 Million

RM 87.65 Million

RM 24.91 Million

+ 50 %

- 57 %

Base, Best & Worst Case

Payback

Period

6 Years

4 Years

11 Years

Cumulative

Cash

RM 1,417.66 Million

RM 2,149.86 Million

RM 581.44 Million

+ 52 %

- 59 %

Worst Case Scenario

ParametersWorst(Gasoline Only)Total Annual Revenue, RM (Million)211.90Gross profit, RM (Million)52.15Corporate tax rate (%)30Salvage, RM (Million)41.39Total depreciable cost, RM (Million)413.94Average depreciation, RM (Million)16.56Turnover ratio0.60Annual net profit, RM (Million)24.91Net cash flow, RM (Million)41.47Return on Investment, %6.02Acceptable Rate of Return, %8Payback/payout period (years)10.98Reference Payback period0.74Venture profit, RM (Million)(11.51)Discounted factor, DF0.15Asset/book value, RM (Million)41.39Present Worth Factor10.67Present worth, RM (Million)472.86Net Present Worth, RM (Million)17.52Internal rate of return24%Cumulative cash position, RM (Million)581.44Worst(Gasoline & All By-products)238.7178.973041.39413.9416.560.6843.6960.2410.5587.560.747.260.1541.3910.67673.25217.9127%1,050.76

Venture profit, RM (Million)

(11.51)

7.26

Payback/payout period (years)

10.98

7.56

Cumulative cash position, RM (Million)

581.44

1050.76

Source: Crystal Graphics (2015), Cohen (2013)

Conclusion

Hydroprocessing & Fluid Catalytic Cracking

Mass and Energy Balance

HAZOP, SCADA and Logic Control

95% Purity of Gasoline

RM 58 Million of Annual Net Profit; 6 Years of Payback Period

Source: Crystal Graphics (2015), Cohen (2013)

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Q & A

Waste Lube OilP-101AK-101AHydrogen GasS-3S-4S-5S-1S-2H2OS-18S-19 H2 Further Treatmentfor ReuseS-20Sour WaterS-9S-16Light EndsGasolineDieselBottomsLCO SteamBottoms SteamE-106AE-105AE-102AE-104ATT-101ATT-102AS-27S-281000 kPa37.78 C1379 kPa65.56 C 10340 kPa38.93 C10340 kPa421.2 C10340 kPa200 C10310 kPa200 C330 kPa30 C338 kPa30 CMIX-101K-102AS-13S-15S-21S-22S-26S-25S-24S-23 kPa C10340 kPa25 C10310 kPa25.17 C10310 kPa44.21 C10310 kPa407.52 C1000 kPa250 C1000 kPa200 C1000 kPa200 C330 kPa51.05 C330 kPa175.18C340 kPa321.15 C kPa CP-101BK-101BE-102BE-104BS-6E-101A10340 kPa200 CE-101BV-101S-710310 kPa200 CE-103AE-103BS-101000 kPa250 CV-102S-111000 kPa250 CV-103S-121000 kPa26 CK-102BS-810310 kPa200 CS-1710310 kPa208.19 CT-100FCC-100R-100RegeneratorT-101E-105BE-106BTT-101BTT-102BSour WaterS-141000 kPa26 C

Waste Lube OilP-101AK-101AHydrogen GasS-3S-4S-5S-1S-2H2OS-18S-19H2 Further Treatmentfor ReuseS-20Sour WaterS-9S-16Light EndsGasolineDieselBottomsLCO SteamBottoms SteamE-106AE-105AE-102AE-104ATT-101ATT-102AS-27S-281000 kPa37.78 C1379 kPa65.56 C10340 kPa38.93 C10340 kPa421.2 C10340 kPa200 C10310 kPa200 C330 kPa30 C338 kPa30 CMIX-101K-102AS-13S-15S-21S-22S-26S-25S-24S-23kPaC10340 kPa25 C10310 kPa25.17 C10310 kPa44.21 C10310 kPa407.52 C1000 kPa250 C1000 kPa200 C1000 kPa200 C330 kPa51.05 C330 kPa175.18C340 kPa321.15 CkPaCP-101BK-101BE-102BE-104BP-363P-366S-6P-367E-101A10340 kPa200 CE-101BP-377V-101S-710310 kPa200 CE-103AE-103BS-101000 kPa250 CV-102S-111000 kPa250 CV-103S-121000 kPa26 CK-102BS-810310 kPa200 CS-1710310 kPa208.19 CT-100FCC-100R-100RegeneratorT-101P-363P-415E-105BE-106BTT-101BTT-102BSour WaterS-141000 kPa26 CP-431

Waste Lube OilP-101AK-101AHydrogen GasS-3S-4S-5S-1S-2H2OS-18S-19H2 Further Treatmentfor ReuseS-20Sour WaterS-9S-16Light EndsGasolineDieselBottomsLCO SteamBottoms SteamE-106AE-105AE-102AE-104ATT-101ATT-102AS-27S-281000 kPa37.78 C1379 kPa65.56 C10340 kPa38.93 C10340 kPa421.2 C10340 kPa200 C10310 kPa200 C330 kPa30 C338 kPa30 CMIX-101K-102AS-13S-15S-21S-22S-26S-25S-24S-23kPaC10340 kPa25 C10310 kPa25.17 C10310 kPa44.21 C10310 kPa407.52 C1000 kPa250 C1000 kPa200 C1000 kPa200 C330 kPa51.05 C330 kPa175.18C340 kPa321.15 CkPaCP-101BK-101BE-102BE-104BP-363P-366S-6P-367E-101A10340 kPa200 CE-101BP-377V-101S-710310 kPa200 CE-103AE-103BS-101000 kPa250 CV-102S-111000 kPa250 CV-103S-121000 kPa26 CK-102BS-810310 kPa200 CS-1710310 kPa208.19 CT-100FCC-100R-100RegeneratorT-101P-363P-415E-105BE-106BTT-101BTT-102BSour WaterS-141000 kPa26 CP-431

Truck-old-heavyduty-enginenoise

2014

Blues

4153.477

T* (C)T* (C)CP

H

-CP

C

H (MW)

Surplus/

Deficit

Infeasible

Heat

Cascade

(MW)

Feasible

Heat

Cascade

(MW)

416.2000.00003.8402

316.10100.100.001700.1706Surplus0.17064.0108

255.0061.100.002280.1396Surplus0.31024.1504

245.0010.00-0.07300-0.7300Deficit-0.41983.4204

205.0040.00-0.05718-2.2870Deficit-2.70681.1334

195.0010.00-0.01162-0.1162Deficit-2.82301.0173

170.2024.80-0.01332-0.3303Deficit-3.15330.6869

43.93126.27-0.00544-0.6869Deficit-3.84020.0000

25.0018.930.024280.4596Surplus-3.38060.4596

15.0010.000.015820.1582Surplus-3.22240.6178

CP=0.02972MW/CCP=0.01582MW/CCP=0.07528 MW/CCP=0.007879MW/CCP=0.0005807MW/CCP=0.001704MW/C

FCC-100P-101AR-100S-3S-1H2OS-18S-19 H2 Further Treatmentfor ReuseS-20Sour WaterT-101S-16Light EndsGasolineDieselBottomsE-102ATT-101AS-21S-22S-26S-25S-23P-101BE-102BCondenserMMFSV-1FSV-2 MIAmoistureASCPTFTASVPICASDV SDV1PZAHHLLSISS-4S-2MMFSV-3FSV-4 MIAmoistureASCPTFTASVPICASDV SDVPZAHHLLSISK-101AK-101BHLHLPCVPRVSet@ 113.8 barSet@ 103.1 bar BDVSISSISTZAHHTETTTICALHQATZAHHLLTZAHHLLPDIATTSISTEFTPTTZAHHLLPZAHHLLMHPGTEMPCPGV-101 SDVSIS SDVSIS SDVSISPICAHLPCVPRVSet@ 113.8 barSet@ 103.1 bar BDVSISPTHHLLPZALGLTLICAHLLCVVDHHLLLZA SDV9SISTZAHHLLV-102PICAHLPCVSet@ 10 barPTHHLLPZALGLTLICAHLLCVVDHHLLLZA SDVSISSDVSIS SDVSISE-104AE-104BTTTICAHLTZAHHLLV-1035PICAHLPCVSet@ 10 barPTHHLLPZALGLTLICAHLLCVVDHHLLLZA SDVSIS SDVSISSDVSISWaste Lube OilHydrogenMMFSV-5FSV-6MIAmoistureASCFTASVK-102AK-102BPTPICAHLPTPTPTT-100PICAHLPCVPRVSet@ 113.8 barSet@ 103.1 bar BDVSISPT SDVSISQALTHLLCVVDHHLLLZAHHLLPZA SDVSISPGPGTETESDVSISFCVFICARegeneratorPDTLTTTMPCPGPGPZAHHLLPZAHHLLPGTETETETE PGLGVDHHLLLZAPDIATZAHHLLTZAHHLLTTTICALHPTPICAHLPCVPRVSet@ 113.8 barSet@ 103.1 bar BDVSIS SDVSISPICAHLPCVPTCondenser TankLTLICAHLLCVTTHLTICAMHMHMHMHLICALGLE-105AE-105BTTTICAHLTZAHHLLTT-102AE-106AE-106BTTTICAHLTZAHHLLS-28PGPGS-5S-6S-7S-8S-9S-11S-12S-16S-13S-17Sour WaterTTHLTICATCVTTHLTICAPZAHHLLPZAHHLLPZAHHLLPGPGPGTETETETZAHHLLTZAHHLLTZAHHLL SDVSIS SDVSISS-27 SDVS-24FCVHLFICAFTFCVHLFICAFT 111111133TCV11115222224212111224FCV136FCV212134232531763222111115102222257431134TCV461233333136843946103314S-144444445437131186442171855528756756121107558987981398LCV5LCV61975TCV71099101011111011121112868TCV10FCVHLFICAFT65710823876432654119TCV112214131297TCV92112SIS SDV20SISMHMHMHMHMHFlaringFlaringFlaringFlaringFlaringFlaringFlaringFlaringFlaringFlaringFlaringPICAHLPCVPRVSet@ 113.8 barSet@ 103.1 bar BDVSIS533FlaringFlaringFlaringS-15 SDVSIS8E-103AE-103BTTTICAHLTCV323FlaringFlaringFlaringFT5HLS-10TCV271516TCV5644TCV6TT-101BPG15TT-102BPG13HotHotHotHotHotHotHotHotHotHotHotHotHotHotHotColdColdColdColdColdColdColdColdColdColdColdColdColdColdColdColdE-109BHotE-109AE-108BE-108AE-110AE-110BE-107AE-107B11PICAHLPCVSet@ 3.3 barPT149FlaringVLG6DLG4VDLG7VDLG8VDLG9VD

FCC-100P-101AR-100S-3S-1H2OS-18S-19H2 Further Treatmentfor ReuseS-20Sour WaterT-101S-16Light EndsGasolineDieselBottomsE-102ATT-101AS-21S-22S-26S-25S-23P-101BE-102BCondenserP-363MMFSV-1FSV-2P-369MIAmoistureASCPTFTASVP-392PICASDVSDVP-3941PZAHHLLP-395P-394SISP-409S-4S-2MMFSV-3FSV-4P-487P-467P-477P-462MIAmoistureASCPTFTASVP-458PICASDVSDVP-455PZAHHLLP-479P-455SISP-465P-454P-460P-398K-101AK-101BP-498P-499P-500HLHLPCVPRVSet@ 113.8 barSet@ 103.1 barBDVSISSISTZAHHP-508TEP-511P-516TTTICALHP-525QATZAHHLLP-526TZAHHLLP-528PDIAP-533TTSISP-536P-537TEP-539FTP-540PTTZAHHLLPZAHHLLMHP-547PGP-550TEMPCP-556PGV-101SDVSISSDVSISSDVSISPICAHLPCVPRVSet@ 113.8 barSet@ 103.1 barBDVSISPTHHLLPZAP-573P-574LGLTLICAHLLCVVDHHLLLZASDV9SISTZAHHLLP-590V-102PICAHLPCVSet@ 10 barPTHHLLPZAP-621P-622P-625LGLTLICAHLLCVVDHHLLLZASDVSISSDVSISSDVSISE-104AE-104BP-659P-650P-654P-661P-665TTTICAHLTZAHHLLP-666V-1035PICAHLPCVSet@ 10 barPTHHLLPZAP-671P-679P-678LGLTLICAHLLCVP-682VDHHLLLZASDVSISSDVSISSDVSISP-668Waste Lube OilHydrogenP-693MMFSV-5FSV-6P-732MIAmoistureASCFTASVK-102AK-102BP-747P-668PTP-749PICAHLP-753P-754PTS-19PTS-20PTP-765T-100PICAHLPCVPRVSet@ 113.8 barSet@ 103.1 barBDVSISPTSDVSISP-789QAP-793P-796P-791LTHLLCVVDHHLLLZAHHLLPZASDVSISPGPGTETESDVSISFCVFICARegeneratorPDTLTTTMPCP-819PGP-820PGPZAHHLLPZAHHLLP-823PGP-825TEP-826TETEP-828TEP-831PGLGVDHHLLLZAP-842P-843P-837P-827PDIATZAHHLLTZAHHLLTTTICALHP-856PTPICAHLPCVPRVSet@ 113.8 barSet@ 103.1 barBDVSISSDVSISPICAHLPCVP-866PTCondenser TankLTLICAHLLCVTTHLTICAP-879P-884MHMHMHMHP-897LICALGP-904P-907LP-914P-918P-919P-920E-105AE-105BP-659P-650P-654P-665TTTICAHLTZAP-666HHLLTT-102AP-919E-106AE-106BP-659P-650P-654P-665TTTICAHLTZAP-666HHLLP-966S-28PGS-22PGS-5S-6P-398P-969S-7S-8S-9S-11S-12S-16S-13S-17Sour WaterTTHLTICATCVTTHLTICAPZAHHLLPZAHHLLPZAHHLLP-981PGP-982PGP-983PGP-984TEP-985TEP-986TETZAHHLLTZAHHLLTZAHHLLSDVSISSDVSISS-27SDVS-24FCVHLFICAFTFCVHLFICAFT111111133TCV11115222224212111224FCV136FCV212134232531763222111115102222257431134TCV461233333136843946103314S-144444445437131186442171855528756756121107558987981398LCV5LCV61975TCV71099101011111011121112868TCV10FCVHLFICAFT65710823876432654119TCV112214131297TCV92112SISSDV20SISMHMHMHMHMHP-837P-1030P-1035P-1036FlaringFlaringFlaringFlaringFlaringFlaringFlaringFlaringFlaringFlaringFlaringP-1040PICAHLPCVPRVSet@ 113.8 barSet@ 103.1 barBDVSIS533FlaringFlaringFlaringP-745P-1047S-15P-1050P-1052SDVSIS8P-458P-1055P-1056P-1057P-1058P-1059P-1060P-1061P-1062P-1063P-1064P-1065P-1066P-1067P-1069P-1070P-1071P-1072P-1073P-1074P-1077P-1078E-103AE-103BP-1085TTTICAHLTCV323P-1100FlaringFlaringFlaringFT5HLS-10TCV271516TCV5644TCV6TT-101BPGS-2415TT-102BPGS-2513HotHotHotHotHotHotHotHotHotHotHotHotHotHotHotColdColdColdColdColdColdColdColdColdColdColdColdColdColdColdColdE-109BHotE-109AE-108BE-108AE-110AE-110BE-107AE-107BP-661P-1135P-1136S-2611PICAHLPCVSet@ 3.3 barPT149FlaringP-1143P-1144P-1148P-1149VLGP-11506P-1152DP-1148P-1148P-1171P-1173P-1172LGP-11684P-1174P-1148P-1148VDP-1182P-1186P-1183LGP-11857P-1184VDP-1189P-1190P-1188LGP-11878P-1191VDP-1193P-1192P-1194LGP-11959P-1196VD

T-101Light EndsGasolineDieselBottomsS-21S-22S-26S-25S-23CondenserCondenser TankLTLICAHLLCVTTHLTICATTHLTICATCVTTHLTICAPZAHHLLPZAHHLLPZAHHLLPGPGPGTETETETZAHHLLTZAHHLLTZAHHLL SDVSISFCVHLFICAFTFCVHLFICAFT75TCV71099101011111011121112868TCV10FCVHLFICAFT65710823876432654 SDV20SISMHMHMHHot11PICAHLPCVSet@ 3.3 barPT149Flaring

FCC-100S-16SDVSISRegeneratorPDTLTTTMPCPGPGPZAHHLLPZAHHLLPGTETETETE PGLGVDHHLLLZAPDIATZAHHLLTZAHHLLTTTICALHPTPICAHLPCVPRVSet@ 113.8 bar BDVSIS SDVSISPICAHLPCVPT1855528756756121107558987981398LCV5LCV619MHMHFlaringFlaringFlaringTCV564TCV6

QA2

FCC-100 Temperature high TCV5Valve closeMore steam entersFCC-100 Temperature low TCV5Valve openLess steam entersAAORFCC-100 Pressure high PCV7Valve closeLess gas to flaringFCC-100 Pressure low PCV7Valve openMore gas to flaringAAORFCC-100 Liquid level high LCV5Valve openMore liquid leaves FCC to RegeneratorAAORLCV6Valve closeLess liquid enters FCC from RegeneratorFCC-100 Liquid level low LCV5Valve openLess liquid leaves FCC to RegeneratorLCV6Valve closeMore liquid enters FCC from RegeneratorORFCC cyclone on autoFCC cyclone on AOROperate FCCLGreen LightInitiate Unit Shutdown for FCCLORPZAHHLL8Pressure Trip activatedTZAHHLL7Temperature Trip activatedLZAHHLL5Level Trip activatedPressure too high or too lowTemperature too high or too lowLevel too high or too lowFCC cyclone offFCC cyclone overloadSDV18Initiate Shutdown Valve for FCC inletSDV19Initiate Shutdown Valve for FCC outletBDV5Initiate Blowdown Valve Prevent product outlet to next operationExcess trapped gas will be sent to flaringPrevent product inlet to FCCRed LightA

Area 1

Raw Materials

Area 2

Hydrogenating

Area 3

Separating

Area 4

Absorbing

Area 5

Cracking

Plant

Areas

Area 6

Process Utilities

Area 7

Product Storage

P

I

D

P

I

D

P

I

D

P

I

D

P

I

D

P

I

D

P

I

D

Remote

I/O

Main

PLC-1

Main

PLC-2

Backup

PLC-1

Backup

PLC-2

Operator

Terminal

Supervisor

Terminal

Supervisory

Computer

Computer

Terminal

Host

Computer

Spare

PLC-1

Industrial

Terminal

LDT

Terminal

Engineering

Terminal

System Control Room

Central Control Room Plant