critical issues when building a new refinery or upgrading...

RBD

Critical Issues when Building a New Refinery or Upgrading an Existing One

Ken Carlson RBD Technologies Inc., USA.

• Capital costs • Operating costs • Crude oil versus operating costs • Processing: Dry Fractionation Degumming/Neutralization Drying Bleaching Hydrogenation Interesterification Deodorization Vacuum Systems Controls Glass Scale Refining Lab • Summary

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TOPICS Critical Issues when Building a New Refinery or Upgrading an Existing One

1000 TPD Refinery $ 50,000,000

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Civil 25%

Tank Farm 12.5 %

Utilities 12.5%

Process HW 23%

Installation 25%

Engineering 2%

100 TPD Refinery $ 10,000,000

Civil 25%

Tank Farm 12.5%

Utilities 12.5%

Process HW 17%

Installation 25%

Engineering 8%

INVESTMENT COSTS Bigger is Less


Depreciation 26%

(10 years, 5%)

Utilities etc. 25%

Labor 5% (20 x $60K/year)

Processing Loss 44%

Processing Loss 25%

Labor 29% (20 x $60K/year)

Depreciation 31% (10 years, 5%)

Utilities etc. 15%

1000 TPD Refinery $ 75/MT

100 TPD Refinery $ 125/MT

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OPERATING COSTS Bigger is Less


1000 TPD Refinery Total: $1,275/MT

100 TPD Refinery Total: $1,325/MT

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Crude oil: $1,200/MT 94%

Operation: $75/MT 6%

Crude oil: $1,200/MT 91%

Operation: $125/MT 9%

OIL VERSUS TOTAL COST Cost of oil is dominant


PROCESSING Chemical or Physical?

Refining Modification

Bi-product

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Chilled Water Tank

Refrig System

Alternating Crystallizers Continuous

Option ?

Cooling Water

Slurry Circulation Pump

Stearin Filter

Stearin Melt Tank

Core Blow Tank

Stearin

Olein

Filter “Squeeze” Pump

Crude oil

Hot Olein Wash Tank

Cold Olein Rinse Tank

Olein Tank Fill Work Filter

Heater

DRY FRACTIONATION Continuous ?

Alternatives: drum filter

or centrifuges


To Drying/ Cooling

Wash water effluent

Wash water Receiver

Separator

Acid Lye

Gums/ Soap

Soapstock Receiver

Heater/ Cooler

Cavitation Mixer ?

Separator

Mixer

Wash Reactor

Cavitation Mixer ?

Enzyme ?

Size/Design of Degumming/ Neutralization

Reactor

Type of Heater

Acid conditioned oil to Bleaching

Degummed or neutralized oil to Bleaching or Washing ?

Water

Feed Oil

Type of pump

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DEG/NEUTRALIZATION Design for degumming and neutralization

Water washing for QA


Degummed or neutralized oil

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DRYING/COOLING Use when sending oil to storage

Heater Cooler Hot well

Vacuum Dryer

Steam

Recycle to cooling tower

Vacuum system

Water from cooling tower

Mechanical Vacuum Pump ?


BLEACHING Basic Design

Bleaching Reactor

Heater

Adsorbent Filters

Precoat/Heel Tank

Filtrate Receiver

HR

Spent Adsorbent

Safety Filters

Hot oil to Deodorizing

To vacuum

Adsorbent Hopper

Dosing System

Cooled oil to Storage

Filter Aid


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Steam mixing ?

Pulse Tube Filters ?

Precoat or recycle ?

Slurry Tank ?

Carbon ?

Optical on-line technology for measuring chlorophyll


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Bleaching Reactor

Trim Heater

Adsorbent Filters (3-cycle operation)

Precoat/Heel Tank

Filtrate Receiver

Spent ads.

To vacuum

Earth Hopper

Earth Feeder

Safety Filters

Silica Feeder

Silica Mix Tank

Silica Hopper

Slurry Tank

To vacuum

Dryer

Heater

Filter Aid

Hot oil to Deodorizing

Vent Vent Water

2nd (earth) Filtration

1st (silica) Filtration

Clean

A B C


BLEACHING Silica pre-treatment and earth re-use for

less earth & oil loss


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Reactor

Catalyst Filter

Precoat Tank

Spent Catalyst

Safety Filter

To vacuum

Filter Aid

Bleached oil

HR

Hydrogen

N2

To Post Bleaching

Drop Tank

Feed Tank

Flash Tank

Catalyst

Vent

HYDROGENATION For hard fats only

otherwise blending and/or IE

Dual Reactors For high capacity

Pulse Tube Filter ?


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Reactor

Adsorbent Filter

Precoat Tank

Spent Adsorbent

Safety Filter

To vacuum

Dosing System

Filter Aid

Sodium Methoxide

Dosing System

Silica Earth

Citric Acid Dosing System

Heater

N2

N2

Interesterified oil

Drop Tank

Blended bleached oils

Pulse Tube Filter ?

INTERESTERIFICATION Batch Chemical:

For frequently changing recipes

Toxic


INTERESTERIFICATION Continuous Enzymatic:

Lower operating cost, higher quality, non toxic

Courtesy of DeSmet Ballestra

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Blended RBD oils

Vacuum Dryer Buffer Tank

Heater Cooler

Enzyme Preparation

Tank

To vacuum

To vacuum

To vacuum

To vacuum

Enzyme

Product Tank

Cooler

Safety Filters

Interesterified oils

4 –

6 In

tere

ster

ifica

tion

Reac

tors


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BFW Cooler Filters Heater

Polish Filters

Cooler

Distillate

HR Cooler

Anti-ox System

High Pressure Steam Generator

Scrubber

To Vacuum

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To Vacuum

Pre-heated Boiler Feed Water ?

Nitrogen

Steam

Product Cooler

Boiler Feed Water

BFW Surge Tank

Double Thermo siphon

Loops ?

Bleached oil

DEODORIZATION Semi-Continuous and

heating/cooling under vacuum for multiple stock changes


HR Filters Heater

Polish Filters

Spar

ge S

team

N

itrog

en

Cooler

Distillate

Product Cooler

Alternating HR units ?

Heat-bleaching Section

Post Deodorizer

Anti-ox System

Distillate Receiver

Deaerator

Stripping Section

Double Shell?

High Pressure Steam Generator

Back-up Heater

Final Heater

Scrubber

Cooler

To Vacuum

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Bleached oil

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Electric ?

DEODORIZATION Continuous PC and heating/cooling under

pressure for minimum energy consumption


Cooler

High FFA Fraction

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Toco/Sterol Fraction

To Vacuum

Lo Temp Section

High Temp Section

Cooler

Vapor from Deodorizer

DEODORIZATION Two-stage scrubber for

max distillate value


Steam

Cooling Water

Vapor from Deodorization


Greasy Cooling Water

“Greasy” System “Clean” System

Clean water to Cooling Tower

Greasy water to Cooling Tower Effluent

Greasy water Cooler

Caustic

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VACUUM SYSTEMS Greasy or clean?

Barometric or surface

condensers ?

Steam

Hot Well Water Chiller


Cooling Water

Hot Well Effluent

Steam Ammonia to Chiller

Ammonia from Chiller

Start-up jet

Muffler

In use Melting Hot

ammonia


Ejectors

Melted fat

Ice Condensers Surface

Condensers

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VACUUM SYSTEMS Ice Condensation:

Optimum for large plants


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CONTROLS From hardwire to fieldbus

Some common terms:

RTU Remote Terminal Unit (converts sensor to digital data) PLC Programmable Logic Controller SCADA Supervisory Control Automation Data Acquisition HMI Human Machine Interface (PC) LAN Local Area Network WLAN Wireless Local Area Network

Traditional control technology: Hard wired with 4 - 20 mA analog field instruments Trends: • Fieldbus that allows multiple units per wire set as well as two-way communication with digital HART type instruments with EDDL • Wireless instruments for remote locations • Handheld communicators for linking with SCADA system • Special apps for smart phones ?

Some common terms:

Fieldbus Digital two-way data transfer (6 – 8 devices/cable) Ethernet Standard communications protocol for building LANs HART Highway Addressable Remote Transducer (communication protocol for smart hosts and devices) EDDL Electronic Device Description Language (for accessing instrument manuals in SCADA system)


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CONTROLS Typical components of complete refinery

Item Deg/Neu Bleach Deo Tanks Other Total I/O’s 33 113 89 190 50 475 FIC/LIC 7 6 6 - 3 22 TIC 3 4 7 - 4 18 FT/LT/TT 3 16 32 35 4 90 LS/PS/TS 4 18 8 24 10 64


Ice Condenser

Deodorizer with heating mantle and temperature control Gum/soap separator – 900 G

100 ml centrifuge tubes with conical bottom

High Shear Mixers

Filtration Funnel

Distillate Receiver

Titration Device

Hot Plate with

Stirrer

Bleached Oil

Receiver

Scales

Digital Vacuum Gauge

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LABORATORY Glass Scale Refining for QA


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SUMMARY Key Points

• Plant size: Think big and/or specialized • Product vs operating cost: Oil price over 90% of total operating cost • Physical or chemical refining: Design for chemical • Dry Fractionation: Continuous under development (DeSmet) • Deg/Neutralization: Design for neutralization for QA Consider enzymatic degumming for yield gain Consider water washing for QA Consider cavitation mixing for less reagents • Bleaching: Consider earth re-use (green oils) • Hydrogenation: For making hard fats only • Interesterification: Consider enzymatic • Deodorization: SC for multi stocks, continuous PC for bulk Two stage scrubber for higher distillate value • Vacuum Systems: Consider “clean” or ice condensing designs

• Controls: Consider fieldbus & HART instruments


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THANKS FOR YOUR ATTENTION !


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