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 Shutdown2
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 & SustainabilityEnvironmentBlock 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 reportDesign 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 scheduleNode 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 understandNode 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 understandPreliminary 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-304There 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 402There 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 StorageRaw 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 ExchangerCoolerHeaterWaste
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+*0.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.0000.000Waimun 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 (%)17.32Source: 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% Error0.900.76Major 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)--2.120.161.71172.40-54.768.1018.02Waimun 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)5.3290.61888.41SUMMARY
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 facilities28.27Indirect Cost
ParametersRM (Million)Engineering and Supervision14.14Construction expenses16.02Extra Cost
ParametersRM (Million)Legal expenses2.94Contractors fee5.27Contingency29.39Direct 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)1,417.66Economic 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)1,417.662,149.86581.44By 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%1,050.76Venture 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
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D
P
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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
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