BASIC OF REFINING

GENERAL
What a Refinery Does

REFINING

CRUDE OIL
REFINERY PRODUCT
“Left Side” Barrel does not provide market what it needs
A refinery maximizes the conversion of crude oil into
desirable products

2
GENERAL
KEY PROPERTIES OF CRUDE

1. API Gravity - Heavy or Light (% of large HC molecules vs. small)

• 33 – 50: Light Crude
• 24 – 33 : Intermediate Crude

• Below 24 : Heavy Crude

2. Sulfur Content - Sour or Sweet (contains high sulfur or low)

• Below 0.5% : Low (Sweet Crude)
• 0.5 ~ 1.5% : Medium
• Above 1.5% : High

Other Properties:
Pour Point, Distillation Range, Carbon Residue, Total Acid Number (corrosive acids present),
Contamination levels (Nitrogen, sodium, metals, chlorides, salts, sediment)

3
GENERAL

Design Crude Blend

Crude Assay

4
GENERAL
CRUDE OIL COMPOSITION

CRUDE OIL

HYDROCARBONS NON-HYDROCARBONS

ALIPHATICS AROMATICS NAPHTHENES SULFURS NITROGENS OXYGENS METALLICS

25% 17% 50% <8% <1% <3% <100PPM

C1 - C60 (C6H5)n O
CYCLOALKANES
SH

N
H COOH
S

5
 OVERALL LAYOUT

§ Process New 20 Unit (Incl. RFCC)

§ Revamp 4 Unit
§ UT&OS New 14 Unit

FEED TANK

CDU
Pre-flash

CDU Revamping

POWER STATION
BOILER PKG & STEAM
GEN.
CCB Modi.
UTILITY CCB
COOLING TOWER
RFCC / LPG
VDU Revamp. Treat./ PRU
Utility Substation

BFW & DEMIN WATER DHT 1 DHT 2 RFCC

STORAGE NHT
Interconnecting Pipe rack Fuel Gas (GSH)
Fuel Oil system system

Spent ISOMERIZATION CCR PL Ⅱ PROCESS COOLING

SWRO PKG
IA/PA/N2 Caustic TOWER
Alkylation
NHT Ⅱ
SGC & LPG Treat. / Amin
Regen./ SWS
WWTP
LPG&PROPYLENE STORAGE
Sea Water Intake SPHERES

Acid FLARE

GASOLINE TANK
Jetty 6A & Modification

6
ISBL UNIT

7
ISBL UNIT
ISBL LINCENSED UNIT

UNIT UNIT/AREA LICENSOR

052 Residual Fluid Catalytic Cracking (RFFCC) AXENS
053 RFCC Naphta Hydro Treating (RFCC NHT) AXENS
054 Diesel Hydrotreater - 1 AXENS
059 Continuous Catalytic Reforming (CCR Platformer) UOP
062 Unsaturated RFCC LPG Treating AXENS
063 Popylene Recovery Unit (PRU) AXENS
065 Alkylation CB&I
066 Wet Gas Sulphuric Acid Haldor - Topsoe
082 Isomerization UOP
083 Diesel Hydrotreater - 2 AXENS
084 Naphta Hydro Treater (NHT) UOP
068 Hydrogen Manufacturing Unit (HMU) Air Liquid (ALEC)
169 Sulphur Recovery Unit (SRU) Kinetic Technology (KT)

AXENS: FRANCH
UOP: US
CB&I: NETHERLANDS
Haldor – Topsoe: DENMARK
8
 BLOCK DIAGRAM OF RDMP PROJECT - ISBL

SGCU
Off Gas
LPG FROM CCR II
LPG Rec SLPGT LPG
5.8 CCR II

NHT II ISOMER
GASOLINE

CDU IV NHT I CCR I

200 / 300 20 20

DHT I
DIESEL
VDU II &
81 JET FUEL
DHT II
CDU V
60 PROPYLENE
VDU III HCU
25 55 /

PRU ALKYLATION
RFCC LPGT

XXXX Unit Name RDS RFCC RFCC NHT

DESIGN / STAGE 1 unit capacity MFO (DCO)

(KBPD)
/ STAGE 2
ARU I/II
existing Unit
Revamp - phase 1
Revamp - phase 2
New Unit – phase 1 HMU WSA SWS/RFCC SWS SRU
New Unit – phase 2
9
OSBL UNIT (UTILITY & OFFSET)

• 315 – Fuel Oil and Fuel Gas System

• 319 – Flare System
• 320 – Plant Feed and Product Tankage
• 321 – Interconnecting Piperack
• 323 – New Product Jetty
• 325 – Spent Caustic Treatment & Chemical Preparation
• 331 – Steam & Power Generation System
• 332 – Cooling Water System
• 333 – Fire Water System
• 334 – Waste Water Treatment Plant
• 335 – Air System (IA,PA, and Nitrogen)
• 337 – Sea Water Intake, Desalination & Demineralization System
• 341 – Building

10
 BLOCK DIAGRAM OF RDMP PROJECT - OSBL

OFF GAS FROM ISBL

315
FUEL GAS FUEL OIL/FUEL GAS
FROM SENIPAH

Power to
Distribution

337 331
Steam
SEA WATER WATER TREATMENT POWER & STEAM ISBL UNIT

PRODUCT
FEED CRUDE
332
COOLING WATER

320
PRODUCT 323
FEED & PRODUCT
CRUDE FROM LAWE-LAWE JETTY & METERING
(OTHER PROJECT) TANKAGE

325 333
SPENT CAUSTIC FIRE WATER

335 334 319

AIR SYSTEM WASTEWATER FLARE SYSTEM 11
12
CDU

13
Design Crude Blend

Crude Assay

14
1. Crude pre-heat trains:
• Pre-heating section (existing and new)
• Desalting section (existing and new)
• Fired heaters (existing) and transfer lines
2. Product rundown systems
3. Atmospheric column, side strippers, pumparounds and overhead system
4. Atmospheric column net gas compression and recontacting system
5. Naphtha stabilisation & splitting section
6. Pre-flash column and overhead system (new)
7. Closed drain slop system (tie-in into existing and new)

15
REFINERY PROCESSING

Crude oil is distilled (separation) based on boiling point of the component at the atmospheric condition.

CDU-IV will have 9 primary products :

• Fuel Gas
• LPG
• Light Naphtha
• Heavy Naphtha
• Full Range Naphtha
• Kerosene
• Light Gas Oil (LGO)
• Heavy Gas Oil (HGO)
• Atmospheric Residue (AR)

16
17
 Wild Naphtha to
Recontact Drum (C-1-10)

T = 2740C
CRUDE FROM T = 320C PRE FLASH
STORAGE
DESALTER COLUMN (C-1-101) CRUDE HEATER

Crude/Product Crude/Product
Exchanger Exchanger

Overhead Vapor

Overhead Liquid

Kerosene Side Cut & Product

DISTILLATION
T = 3580C COLUMN

Light Gas Oil (LGO) Side Cut & Product

Heavy Gas Oil Side Cut & Product

AR to VDU & RFCC

18
 Fuel Gas to SGCU

Overhead Crude Column Recontact Stabilizer Stabilizer Column

Vapor Receiver (C-1-09) Drum (C-1-10) (C-1-05) Receiver (C-1-05) LPG to
LPG Recovery Unit
T = 1280C Wild Naphtha from FL & Light Naphtha to
Pre Flash Column
NHT II
Naphtha
Splitter(C-1-06)
Circulating
Naphtha
Crude/Product Exchanger
Heavy Naphtha to
NHT I
Kerosene Side Kerosene
Cut & Product Stripper(C-1-02)

Crude/Product Exchanger
Kerosene to DHT

DISTILLATION
COLUMN
LGO
Light Gas Oil (LGO)
Stripper(C-1-03)
Side Cut & Product
Crude/Product Exchanger
LGO to DHT

HGO
Heavy Gas Oil Stripper(C-1-04)
Side Cut & Product
Crude/Product Exchanger
HGO to DHT

AR to VDU & RFCC

T = 3510C
Crude/Product Exchanger
19
20
21
22
23
No Tag No. Detail Description No Tag No. Detail Description

COLUMN HEAT EXCHANGER & HEATER

1 C-1-01 Crude Column 1 E-1-01A/B Crude / Circulating Kero Exchanger No.1
2 C-1-02 Kerosene Stripper 2 E-1-02A/B Crude / Circulating Kero Exchanger No.2
3 C-1-03 LGO Stripper 3 E-1-11A/B LGO Stripper Reboiler
4 C-1-04 HGO Stripper 4 E-1-14 Stabilizer Feed Exchanger
5 C-1-05 Stabilizer 5 E-1-19A~D Reduced Crude Cooler
6 C-1-06 Naphtha Splitter
6 E-1-112-A~D Preflashed Crude / AR Exchanger No.3
7 C-1-101 Pre-Flash Column
7 E-1-108 Preflashed Crude / Kero Product Exchanger
8 C-1-01-I Crude Column Internal
8 E-1-109A/B Preflashed Crude / AR Exchanger No.1
9 C-1-02-I Kerosene Stripper Internal
9 E-1-110-A~D Preflashed Crude / AR Exchanger No.2
10 C-1-03-I LGO Stripper Internal
10 E-1-111-A~D Preflashed Crude / HGO Product Exchanger
11 C-1-04-I HGO Stripper Internal
11 E-1-113A/B Naphtha Splitter Reboiler
12 C-1-05-I Stabilizer Internal
12 E-1-116 Naphtha Splitter Trim Cooler
13 C-1-06-I Naphtha Splitter Internal
13 E-1-15C Kerosene Product Trim Cooler
14 C-1-101-I Pre-Flash Column Internal
15 C-1-10 Recontact Drum 14 EA-1-26 Naphtha Splitter Condenser
16 C-1-11 Stabilizer Column Receiver 15 E-1-101A~D Crude / Preflash Column Overheads Exchanger
17 C-1-13 Desalted Water Surge Drum 16 E-1-102A Crude / Light Naphtha Exchanger
18 C-1-102 Preflash Column Overhead Drum 17 E-1-103A/B Crude / Heavy Naphtha Exchanger
19 C-1-105 Preflash Column Flare KO Drum 18 E-1-104A/B Crude / Circulating Naphtha Exchanger
20 C-1-107 Preflash Column Closed Drain Drum 19 E-1-105A~D Crude / Kerosene Product Exchanger
21 C-1-114 Slop Surge Drum 20 E-1-106A/B Desalted Crude / Kero Product Exchanger
22 C-1-106 Steam Condensate Flash Drum 21 E-1-107A/B Desalted Crude / AR Exchanger
23 C-1-113 Desalting Water Surge Drum 22 E-1-131A Preflash Column Overhead Water Condenser
24 C-1-08A/B Crude Desalters (Existing) 23 E-1-132 Desalting Water / Brine Exchanger
25 C-1-108A/B Crude Desalters 24 E-1-133 Desalted Water Exchanger
26 C-1-104 Pre-flash Column Reflux Water Filter / Coalescer 25 E-1-114 Crude / FRN Exchanger
27 C-1-109 Crude Column Reflux Filter / Coalescer 26 F-1-01A/B Crude Heater
28 C-1-110A/B Crude Basket Strainers

24
No Tag No. Detail Description No Tag No. Detail Description

PACKAGE & OTHERS PUMP

1 A-1-101 Demulsifier Package 1 G-1-10A/B LGO Product Pump
2 A-1-102 Corrosion Inhibitor Package 2 G-1-13A/B Crude Column Water Pump
3 A-1-103 Caustic Injecton Package 3 G-1-17A/B Naphtha Splitter Bottoms Pump
4 A-1-105 Crude Column Overhead Neutraliser 4 G-1-21C Crude Column Reflux Pump
5 A-1-106 Preflash Column Overhead Neutraliser Dosing Package 5 G-1-101A/B Preflash Column Wild Naphtha Pump
6 A-1-107 Crude Column Corrosion Inhibitor Injection Package 6 G-1-102A/B Preflash Column Reflux Pump
7 A-1-104 CPI Package 7 G-1-105A/B Preflash Column Sour Water Pump
8 K-1-01B/C Crude Overhead Vapour Compressor 8 G-1-106A/B Condensate Flash Drum Pump
9 H-1-101 Desuperheater 9 G-1-107A/B Desalting Water Pump
10 Z-1-005 OWS Oil Skimmer 10 G-1-108A/B Flare KO Drum Pump
11 G-1-109A/B 2nd Stage Desalting Water Pump
12 G-1-110A/B 2nd Stage Desalting Water Pump
13 G-1-127A/B Slop Surge Drum Pump
14 G-1-05A Circulation Kerosene Pump
15 G-1-16A/B Naphtha Splitter Ovhd Pump
16 G-1-103A/B/C Desalted Crude Pump
17 G-1-104A/B/C Preflash Column Bottoms Pump
18 G-1-111A/B Hydrocarbon Closed Drain Drum Pump
19 G-1-121A/B PCS Contaminated Water Pump
20 G-1-123A/B OWS Sump Pump
21 G-1-124A/B OWS Skimmed Oil Sump Pump
22 G-1-125A/B CPI Effluent Transfer Pump
23 G-1-126A/B Slop Oil Transfer Pump
24 A-1-104 CPI Package
25 Z-1-005 OWS Oil Skimmer
26 G-1-03A/B/C Desalted Crude Pump
27 G-1-05D Circulating Kerosene Pump
28 G-1-09A/B Kero Product Pump
29 G-1-14A/B/C Stabilizer Charge Pump
25
 Existing Unit CDU IV

Pre- Flash Section

26
 C-1-01Crude Column EA-1-21: Overhead Air Cooler

C-1-09: Crude Column Receiver E-1-08/E-1-07/E-1-25/E-1-06/E-1-06/E-1-05/

F-1-01: Crude Heater E-1-01/E-1-02: Crude/Kerosene Exchanger
C-1-10: Recontact Drum E-1-04: Crude Product Exchanger

C-1-08A/B Desalter
C-1-02: Kerosene Stripper
C-1-20: Overhead Relief Drum
 EA-1-22/EA-1-25/EA-1-24/28/26/23

C-1-06
Naphtha Splitter

C-1-05 Stabilizer

K-1-01 Overhead
Compressor

E-1-17: Heavy Naphtha Trim Cooler E-1-10: Kerosene Stripper Reboiler

C-1-19 C-1-11: Stabilizer
E-1-15: Kerosene Product Trim Cooler E-1-11: LGO Stripper Reboiler C-1-03/04: LGO/HGOStripper
Flare KO Drum Column Receiver
E-1-19: Reduced Crude Cooler
 C-1-101: Pre Flash Column C-1-113: Desalt Water Surge Drum

E-1-101/E-102: Crude/Pre Flash Exchanger C-1-108: Crude Desalter

E-1-109/111: Crude/AR Exchanger

 C-1-101: Pre Flash Column
C-1-102 Pre Flash Column
Overhead Drum

E-1-108: Crude/Kerosene Exchanger C-1-105: Flare KO Drum

E-1-112A~D: Crude/AR Exchanger E-1-110A/B/C/D: Crude/AR Exchanger
A-001-104: CPI Package
E-1-102~107: Crude/Product Exchanger
32
VDU
II

33
REFINERY PROCESSING

Vacuum distillation is a method of distillation performed under reduced pressure (Vacuum Condition).
A reduced pressure decreases the boiling point of compounds.

CDU-IV will have 3 primary products

• Light Vacuum Gas Oil (LVGO)
• Heavy Vacuum Gas Oil (HVGO)
• Vacuum Residue

34
35
 No Tag No. Detail Description
No Tag No. Detail Description
HEAT EXCHANGER, AIR COOLER & HEATER
COLUMN 1 E-2-01 A/B HVGO-Total Feed Exchanger
1 C-2-01 Vacuum Column 2 E-2-02A~D Hot Bottom Total Feed Exchanger
2 C-2-01-I Vacuum Column Internal 3 E-2-03A/B LVGO Pump Around Trim Cooler
3 C-2-02 Charge Surge Drum 4 E-2-04 A-F HVGO Circulating Water Exchanger
5 E-2-05 A/B HVGO BFW Heater
4 C-2-07 Vent Gas KO Drum
6 E-2-06 A/B/C HVGO Product Trim Cooler
5 C-2-03 Ejector Condensate Drum 7 E-2-07 A/B Bottom Circulating Water Exchanger
6 C-2-04 Steam Disengaging Drum 8 E-2-08 A/B/C Cold Bottoms Long Residue Exchanger
7 C-2-05 Intermittent Blowdown Drum 9 E-2-09 1st Stage Intercondenser
8 C-2-06 Continuous Blowdown Drum 10 E-2-10 2nd Stage Intercondenser
9 C-2-09 Steam Air Decoke Quench Drum 11 E-2-11 After Condenser
12 E-2-13 A/B HVGO Cooler
10 C-2-10 Vacuum Unit Relief And Blowdown Drum
13 E-2-101A/B Vacuum Residue / Boiler Feed Water Exchanger
11 C-2-101 Off Gas Interstage KO Drum 14 E-2-102A~C Vacuum Residue / Circulating Water Exchanger
15 E-2-103 Off Gas Interstage Cooler
16 F-2-01A/B Vacuum Unit Charge Heater
17 EA-2-12 LVGO Cooler

No Tag No. Detail Description No Tag No. Detail Description

PUMP MISCELLANEOUS
1 G-2-08A/B Slop Wax Recycle Pump 1 F-2-01A/B Vacuum Unit Charge Heater Revamp
2 G-2-08C Slop Wax Recycle Pump
2 H-2-01A/B Vacuum Ejector
3 G-2-01 A/B Vacuum Charge Pump
3 H-2-02A/B Vacuum Ejector
4 G-2-02 A/B LVGO Pump
4 H-2-03A/B Vacuum Ejector
5 G-2-03 A/B/C HVGO Pump
6 G-2-04 Slop Wax Wash Pump
7 G-2-05 A/B/C Vacuum Bottom Pump
8 G-2-06 Ejector Slop Oil
9 G-2-07 A/B Ejector Condensate Pump
10 G-2-08 A/B/C Slop Wax Recycle Pump
11 G-2-09 A/B Hot HVGO Wash Pump
12 G-2-10 A/B Circulating Water Pump
13 G-2-13 A/B Relief and Blowdown Pump
14 G-2-11 RAM Oil Pump
15 G-1-03 D/E Crude Oil Pump 36
37
 C-2-02: Charge Surge Drum

C-2-04: Steam
Disengaging Drum

E-2-02A~D: Hot Bottom/Feed Exchanger

E-2-03A/B: LVGO/Pumparound Trim Cooler
K-2-101: Off Gas Compressor
E-2-01A/B: HVGO/Feed Exchanger
C-2-101: Offgas Interstage KO Drum
 C-2-01 Vacuum Column
EA-2-12
C-2-02

F-2-01 Vacuum Heater

 E-2-13A/B: HVGO Cooler
E-2-101A/B: VR/BFW Exchanger E-2-04A~F: HVGO/Cir. Water Exchanger
E-2-102A/B/C: VR/Cir. Water Exchanger E-2-06A/B/C: HVGO
E-2-07A/B: VR/Cir. Water Exchanger Product Trim Cooler

E-2-08A/B/C: Cold VR/Residue Exchanger E-2-05A/B:HVGO/BFW Exchanger

One Team! One Spirit! Go Together!