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3.7.21 Flare Loads and Flare Design 21
3.7.22 Additional Operational Requirements 21
3.8 Utilities 25
3.9 Other Raw Material Requirements 25
4. BATTERY LIMIT CONDITIONS 26
5. SYSTEM SKETCH 28
6. PROCESS GUARANTEES 29

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1. INTRODUCTION
1.1 Unit Processing Objectives
The objective of the Residue Fluidised Catalytic Cracker (RFCC) is to process
hydrotreated atmospheric residue from the Residue Hydro-desulphuriser Unit
(RHDS) to produce propylene as feedstock for the Polypropylene Unit (PPU), light
& heavy FCC gasoline for the gasoline pool, propane, mixed Butane as feedstock
for the Indirect Alkylation Unit (InAlk), light cycle oil as feedstock for the Gas Oil
Desulphurization Unit (GOHDS), and clarified oil.
The unit is also required to process 400-4000 kg/hr of returned purge gas from the
Polypropylene Unit for recovery
The Unit will be designed to operate in maximum propylene and maximum
gasoline modes.
While operating in maximum propylene mode the production of propylene shall be
approximately 48000 kg/hr (net from the RFCC, excluding PPU purge gas
processing). This is intended to match the maximum capacity of a single train
Polypropylene Unit.
1.2 Use of Document
This document shall be used as the design basis for the process design of the
RFCC only.
The design requirements specified in this document are considered to be the
minimum required.
2. UNIT INDEPENDENCE
The RFCC shall be capable of operating as an independent unit subject to the
availability of:
• Feedstocks
• Utilities

The feed to the unit will be the hydrotreated atmospheric residue from the RHDS
Unit.
The RFCC unit will comprise the following unit operations:
• RFCC (including the reactor ,catalyst regeneration, catalyst storage &
handling, main fractionator, strippers, slurry filters, flue gas section
including power recovery based on economic evaluation, CO-Boiler,
scrubber & stack )
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• Gas concentration section (GCU) ( including the wet gas compressor,
stripper, debutanizer, naphtha splitter, primary & secondary absorbers, fuel
gas and amine treater)
• LPG absorber
• Amine regenerator
• LPG depropanizer, deethanizer
• Propylene recovery (including the C3 splitter columns),propylene
purification (including dryers with regeneration facility, guard beds for
arsine, COS etc to remove all impurities as required by the Polypropylene
Unit.

• Steam generation facility including BFW treatment.
3. BASIS OF DESIGN
3.1 Design Objective
The RFCC Unit is designed to process feedstocks from the Residue
Hydrodesulphuriser (RHDS), and a propylene rich purge stream from the
Polypropylene Unit, to produce maximum yields of propylene for the downstream
petrochemical complex and Naphtha for the Gasoline pool.
The Unit produces the following product streams:
• An amine treated LPG stream. This LPG stream will be caustic treated (by
others) to remove Mercaptans. The mercaptan free LPG will be routed
back to the RFCC C
3
/C
4
splitter.
• After mercaptan removal by others, the LPG stream will be split to produce
a propylene stream to the Polypropylene Unit, a mixed butane stream to
Indirect Alkylation Unit , and a propane stream to the LPG pool.
• Light FCC Gasoline (LFG) to the gasoline pool via caustic treating.
• Heavy FCC Gasoline (HFG) to the gasoline pool.
• Light cycle oil (LCO) product to the Gas Oil Hydrodesulphurisation Unit
and/or fuel oil
• Clarified Oil (CLO) product to refinery fuel oil

The unit also produces the following by-products:
• Treated off gas to fuel gas
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• Sour water to sour water treatment
• Flue gas to atmosphere via stack
The unit will be required to process a recycle Propane rich purge stream from the
PPU.
3.2 Design Capacity
The RFCC shall be designed to process 80,000 BPSD of hydrotreated
atmospheric residue as defined under section 3.4.
In addition purge gas (400-4000 kg/hr) from the Aromatics Complex &
Polypropylene Units respectively will be processed.
The unit will be designed with the flexibility to operate in both maximum propylene
and maximum gasoline modes at the 80,000 BPSD capacity.
Material balances and yields shall be developed for both design cases.
3.3 Feed Cases
The unit shall be designed to process desulphurised atmospheric residue from the
RHDS. The design capacity is provided in section 3.2 & the properties of the
feedstock are given in Section 3.4 below.

In addition to the design case, the following capability cases shall be included.

Processing of full range naphtha from the RHDS, KHDS & GOHDS in the GCU
section during the CDU shutdown and the overall refinery operation at a lower

capacity.

Processing of feed from RHDS & storage tanks with modified feed qualities during
contingencies such as catalyst changeovers.



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3.4 Feedstock Properties

Hydrodesulphurised Atmospheric Residue From RHDS Unit

Feed Unit
Design
Value
Test
Method
S.G. @ 15ºC 0.9377 ASTM D-1298

API Gravity API 19.4 ASTM D-1298
K Factor 12.01
Sulphur wt% 0.4
ASTM D-1552/
ASTM D-2622/ ASTM D-4294
Nitrogen ppmw 1350 ASTM- 5762
Hydrogen
wt% 12.0 ASTM D-4808
Distillation Vol%

ASTM D-1160
IBP (1%)
o
C 348
5
o
C 386
10
o
C 401
20
o
C


30
o
C 448
50
o

C 493
70
o
C 559
80
o
C


90
o
C
95
o
C
FBP
o
C
Flash Point
o
C > 100
ASTM D-6450/
ASTM- D3828/ ASTM D-56
Pour Point
o
C 36 ASTM D-97
Aniline Point
o
C 99 ASTM D-611
TAN mgKOH/g Nil

CCR wt% 5.0 ASTM D-189
V Content ppmw 9.0 ASTM D-5863
Ni Content ppmw 7.0 ASTM D-5863
Total Ni + V ppmw 16 ASTM D-5863
Asphaltenes wt% 2.1 ASTM D-6560
Viscosity @ 40
cSt 280

.Note: During the tankage switchover sulphur level of 0.42 Wt % and total metals of 17
ppmw expected for a short duration.



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Monomer Purge Gas From the Polypropylene Unit:

Component Unit Design Value

Hydrogen Mole % 8.26
Ethane Mole % 0.93
Propylene Mole % 75.06
Propane Mole % 15.75
Total 100.0




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Intermediate, LPG from caustic treatment


Specification Unit Test Method
Specific Gravity gm/cc Report ASTM D-1657/ASTM D-2598
Composition

Water wt% Report

Nitrogen wt% Report
Oxygen wt% Report
Hydrogen wt% Report
Methane wt% Report
Ethane wt% Report ASTM D-2163
Ethylene wt% Report
Propane wt% Report ASTM D-2163
Propylene wt% Report
n-Butane wt% Report ASTM D-2163
iso-Butane wt% Report ASTM D-2163
1-Butene wt% Report
t-2-Butene wt% Report
c-2-Butene wt% Report
iso-Butene wt% Report
1,2-Butadiene wt% Report
1,3-Butadiene wt% Report
C
5
+ wt% Report ASTM D-2163

Sulphur Dioxide ppmw < 0.5
Carbon Monoxide ppmw Report ASTM D-3416
Carbon Dioxide ppmw Report ASTM D-3416
Hydrogen Sulphide ppmw < 0.5 ASTM D-2420
Methyl Acetylene ppmw Report
Propadiene ppmw Report
Total Mercaptans S ppmw 5 max ASTM D-3227
COS ppmw Report
CS
2,

ppmw Report
Total Sulphur ppm w < 10
Arsine ppbw Report ASTM E-819
Phosphine ppbw Report
NH
3
ppmw Report
Copper strip corrosion (1hr @38
o
C) 1 max ASTM D-1838
Water at operating conditions No free entrained
Caustic in LPG ppmw < 0.5
Amine ppmw To be advised
Note: Relevant properties of LPG from caustic treatment to be confirmed by the licensor of
the Caustic treatment Unit.
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3.5 Product Specifications
For the design feedstocks and flow rate, the RFCC shall meet the following product

specifications.

Intermediate, LPG to caustic treatment

Specification Unit
Value
Test Method
Specific Gravity gm/cc Report ASTM D-1657/ASTM D-2598
Composition

Water wt% Report
Nitrogen wt% Report
Oxygen wt% Report
Hydrogen wt% Report
Methane wt% Report ASTM D-2163
Ethane wt% Report ASTM D-2163
Ethylene wt% Report ASTM D-2163
Propane wt% Report ASTM D-2163
Propylene wt% Report ASTM D-2163
n-Butane wt% Report ASTM D-2163
iso-Butane wt% Report ASTM D-2163
1-Butene wt% Report ASTM D-2163
t-2-Butene wt% Report ASTM D-2163
c-2-Butene wt% Report ASTM D-2163
iso-Butene wt% Report ASTM D-2163
1,2-Butadiene wt% Report ASTM D-2163
1,3-Butadiene wt% Report ASTM D-2163
C
5
+ wt% Report ASTM D-2163


Sulphur Dioxide ppmw Report
Carbon Monoxide ppmw Report ASTM D-3416
Carbon Dioxide ppmw Report ASTM D-3416
Hydrogen Sulphide ppmw <50 ASTM D-2420
Methyl Acetylene ppmw <50
Propadiene ppmw <50
Total Mercaptans S ppmw <57 ASTM D-3227
COS ppmw <15
CS
2,
ppmw Report
Arsine ppbw Report ASTM E-819
Phosphine ppbw Report
NH
3
ppmw Report
Copper strip corrosion (1hr @ 38
o
C) 1 max ASTM D-1838
Amine ppmw Report
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Propylene
Component/property Unit
Specification
Test Method
Specific Gravity gm/cc Report
ASTM D-1657/
ASTM D-2598
Composition

Water mol ppm 2 max
Nitrogen mol ppm Report
Oxygen mol ppm 5 max ASTM D-2233
Hydrogen mol ppm 5 max ASTM D-2504
Methane mol ppm 100 max ASTM D-2712
Ethane mol ppm 200 max ASTM D-2712
Ethylene mol ppm 100 max ASTM D-2712
Propylene mol % 99.6 Min ASTM D-2712
Propane+ Cyclopropane mol % 0.4 max ASTM D-2712
Butane and butenes mol ppm 10 max ASTM D-2712
1,3-Butadiene mol ppm 5 max (1) ASTM D-2712
Saturated C5 mol ppm Report ASTM D-2712
Green Oils (C6-C12) mol ppm Report
Sulphur Dioxide mol ppm Report
Carbon Monoxide mol ppm 0.1 max ASTM D-3416
Carbon Dioxide mol ppm 4 max ASTM D-3416
Hydrogen Sulphide Ppm w Report ASTM D-2420

Acetylene mol ppm 5 max (1) ASTM D-2505
Methyl Acetylene mol ppm 5 max (1) ASTM D-2712
Propadiene mol ppm 5 max (1) ASTM D-2712
Total S Ppmw 1 max as H2S ASTM D-3246
Total Mercaptans S Ppmw Report ASTM D-3227
COS (Carbonyl Sulphide) mol ppm 0.05 max
CS
2,
Ppmw Report
Arsine (ArH3) Ppmw 0.03 max ASTM E-819
Phosphine Ppbw Report
NH
3
Ppmw Report
Oxygenated organic compounds
mol ppm 5 max ASTM D-4864
Copper strip corrosion (1hr @ 38
o
C) 1 max ASTM D-1838
Polymerisation test Good
Amine Ppmw Report
Alcohols Report
Isopropanol Report
1.) The Combined total for 1,3-butadiene, acetylene, methyl acetylene and propadiene is to
be 10 mol ppm max
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Propane
Composition/Property Unit Specification Test Method
Specific Gravity gm/cc Report
ASTM D-1657/
ASTM D-2598
Composition

Water wt% No free water
Nitrogen wt% Report
Oxygen wt% Report ASTM D-2233
Hydrogen wt% Report ASTM D-2504
Methane wt% Report ASTM D-2163
Ethane wt% Report ASTM D-2163
Ethylene wt% Report ASTM D-2163
Propane wt% Report ASTM D-2163
Propylene wt% Report
(2)
ASTM D-2163
n-Butane wt% Report
(1)
ASTM D-2163
iso-Butane wt% Report

(1)
ASTM D-2163
1-Butene wt% Report
(1)
ASTM D-2163
t-2-Butene wt% Report
(1)
ASTM D-2163
c-2-Butene wt% Report
(1)
ASTM D-2163
iso-Butene wt% Report
(1)
ASTM D-2163
1,2-Butadiene wt% Report
(1)
ASTM D-2163
1,3-Butadiene wt% Report
(1)
ASTM D-2163
C
5
+ wt% Report
(1)
ASTM D-2163

Sulphur Dioxide ppmw Report
Carbon Monoxide ppmw Report ASTM D-3416
Carbon Dioxide ppmw Report ASTM D-3416
Hydrogen Sulphide ppmw Nil ASTM D-2420

Methyl Acetylene ppmw Report
Propadiene ppmw Report
Total Mercaptans S ppmw Report ASTM D-3227
COS ppmw Report
CS
2,
ppmw Report
Arsine ppbw Report ASTM E-819
Phosphine ppbw Report
NH
3
ppmw Report
Copper strip corrosion (1hr @
1 max ASTM D-1838
Amine ppmw
Report

1.) Total C
4
+ content to be < 1.68
2.) Propylene Recovery of 99 % min in the Propylene recovery column.
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Mixed Butane/ Butenes
Property /composition Unit Specification Test Method
Specific Gravity Gm/cc Report
ASTM D-1657/
ASTM D-2598
Composition

Water wt%
No Free

Basic Nitrogen
ppm
< 1
Total Oxygen
ppm
w
< 0.5
(1)
ASTM D-2233
Hydrogen wt% Report ASTM D-2504
Methane wt% Report ASTM D-2163
Ethane wt% Report ASTM D-2163
Ethylene wt% Report ASTM D-2163
Propane wt% Report
(2)
ASTM D-2163

Propylene wt% Report
(2)
ASTM D-2163
n-Butane wt% Report ASTM D-2163
iso-Butane wt% Report ASTM D-2163
1-Butene wt% Report ASTM D-2163
t-2-Butene wt% Report ASTM D-2163
c-2-Butene wt% Report ASTM D-2163
iso-Butene wt% Report ASTM D-2163
Butadienes wt% 0.6 max ASTM D-2163
C
5
+ wt% 0.5 max ASTM D-2163
Acetonitrile Ppmw 50 max
Acetone
ppm
75 max
Sulphur Dioxide Ppmw Report
Alcohols Ppmw < 10
Caustic Ppmw < 1.0
(1)

Metals ppb w <1
Chlorides & Flurides
ppm
<1
Carbonyl Sulphur
ppm
<1
Sulphur Ppmw < 20.0

(1)

Carbon Monoxide+ Carbon
Ppmw < 1 ASTM D-3416
Hydrogen Sulphide Ppmw < 1.0
(1)
ASTM D-2420
Methyl Acetylene Ppmw Report
Propadiene Ppmw Report
Total Mercaptans S Ppmw Report ASTM D-3227
COS Ppmw Report
CS
2,
Ppmw Report
Arsine Ppbw Report ASTM E-819
Phosphine Ppbw
NH
3
ppmw Report
Copper strip corrosion (1hr @
Report ASTM D-1838
Amine ppmw


1.) To be ensured by Licensor of LPG sweetening unit.
2.) Propane & propylene content to be less than 0.15.
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Light FCC Gasoline (LFG)
Parameters Unit
Specification
(1)

Test method
Cut range
o
C C
5
-90
o
C
(3)


Specific gravity gm/cc Report
ASTM D-1298
Total Sulphur content Ppmw <15 ASTM D-2622/ASTM D-5453
H
2

S Ppmw Report

Mercaptans Sulphur Ppmw <8
ASTM D-3227
Methanethiol Ppmw Report
ASTM D-3227
Ethanethiol Ppmw Report
ASTM D-3227
Propanethiol Ppmw Report
ASTM D-3227
Butanethiol Ppmw Report
ASTM D-3227
CS
2
Ppmw Report
ASTM D-3227
Thiophenes Ppmw <10
ASTM D-3227
RON 96.0/94.8
(4)
ASTM D-2699/ASTM D-2700
MON 80.5/80.1
(4)

ASTM D-2699/ASTM D-2700
Benzene wt% Report
ASTM D-3606/ASTM D-5580
RVP @ 38ºC kPa Report
(2)
ASTM D4953/ASTM D 5191

Copper Corrosion (3hrs @
Report
ASTM D-130
Oxidation stability Minutes Report
(3)

ASTM D-525
Aromatics vol% Report
ASTM D-6293
Olefins vol% Report
ASTM D-6293
Existent gum mg/100ml Report
ASTM D-381
Butane wt% 1.5 max

Distillation, D86, vol%

1 ºC Report
ASTM D-86
5 ºC Report
ASTM D-86
10 ºC Report
ASTM D-86
30 ºC Report
ASTM D-86
50 ºC Report
ASTM D-86
80 ºC Report
ASTM D-86
90 ºC Report

ASTM D-86
95 ºC Report
ASTM D-86
FBP ºC Report
ASTM D-86
1.) Licensor to provide full component breakdown which is to include definition of olefins,
naphthenes, aromatics, paraffins and distribution of sulphur compounds. Octane curve to be
included.
2.) Light cracked gasoline will be routed directly to tankage via treating. RVP to be low enough to
enable this.
3.) Alternate gasoline splitter cut point 70
O
C
4.) Max propylene/max gasoline cases
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Heavy FCC Gasoline (HFG)
Parameters Unit

Specification
(1)
Test method
Cut range
o
C 90 – 210
o
C
Specific gravity Gm/cc Report ASTM D-1298
Total Sulphur content Ppmw <114 ASTM D-2622)/ASTM D-5453
H
2
S Ppmw Report
Mercaptans Sulphur ppmw Report ASTM D-3227
Methanethiol ppmw Report ASTM D-3227
Ethanethiol ppmw Report ASTM D-3227
Propanethiol ppmw Report ASTM D-3227
Butanethiol ppmw Report ASTM D-3227
CS
2
ppmw Report ASTM D-3227
Thiophenes ppmw Report ASTM D-3227
RON 95.7/91.6
(3)
ASTM D-2699/ASTM D-2700
MON 83.5/80.6
(3)
ASTM D-2699/ASTM D-2700
RONC Report
Benzene wt% Report ASTM D-3606/ASTM D-5580

RVP @ 38ºC kPa Report ASTM D4953/ASTM D 5191
Copper Corrosion (3hrs @
1 max ASTM D-130
Oxidation stability minutes 480 min ASTM D-525
Paraffins Report ASTM D-6293
Aromatics vol% Report ASTM D-6293
Light naphthenes Report ASTM D-6293
Heavy naphthenes Report ASTM D-6293
Olefins vol% Report ASTM D-6293
Existent gum mg/100ml 4 max ASTM D-381
Distillation, D86, vol%
1 ºC Report ASTM D-86
5 ºC Report ASTM D-86
10 ºC Report ASTM D-86
30 ºC Report ASTM D-86
50 ºC Report ASTM D-86
80 ºC Report ASTM D-86
90 ºC 190 max ASTM D-86
95 ºC Report ASTM D-86
FBP ºC 210 max ASTM D-86
1.) Licensor to provide full component breakdown which is to include definition of olefins,
naphthenes, aromatics, and paraffins and distribution of sulphur compounds. Octane curve to
be included.
2.) Alternative gasoline splitter cut points 70-210
o
C
3.) Max propylene/max gasoline cases.

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Light Cycle Oil (LCO)
Properties Unit Specification Test method
Specific gravity Gm/cc Report ASTM D-1298/ASTM D-4052
API Report ASTM D-1298/ASTM D-4052
Sulphur Wt % <0.9 ASTM D-2622/ASTM D-5453
Nitrogen Ppmw Report ASTM D-5762
Silicon Ppmw Report ASTM D-5185
Cetane Index >22 ASTM D-976
Cetane number Report ASTM D-613
Flash point
o
C >90 ASTM D-3828/ASTM D-93
Kinetic Viscosity (@ 40
o
C) cP Report ASTM D-445
CCR (on 10% distillation residue) wt % Report ASTM D-189/ASTM D-4530
Pour point
o
C Report ASTM D-97

Ash wt % Report ASTM D-482
Water mg/kg Report ASTM E-203
Sediment mg/l Report ASTM D-2276
Copper strip corrosion (3hrs @ 50
o
C) Report ASTM D-130
Lubricity
μm
Report ASTM D-6079
Total Aromatics Wt % Report
Mono Aromatics Wt % Report
Di Aromatics Wt % Report
Poly aromatic Wt % Report ASTM D-1319/ASTM D-6379
Colour Report ASTM D-1500
Existent gum mg/100ml Report ASTM D-381
Oxidation stability mg/100ml Report ASTM D-2274
Appearance Report ASTM D-4176
ASTM Distillation (Vol%)
IBP ºC Report ASTM D-86
5 ºC Report ASTM D-86
10 ºC Report ASTM D-86
30 ºC Report ASTM D-86
50 ºC Report ASTM D-86
70 ºC Report ASTM D-86
90 ºC <360 ASTM D-86
95 ºC Report ASTM D-86
FBP ºC Report ASTM D-86

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Clarified Oil (CLO)
Properties Unit Value Test Method
Specific gravity gm/cc Report ASTM D-1298/ASTM D-4052
API Report ASTM D-1298/ASTM D-4052
Kinematic viscosity @ 50
o
C cSt Report ASTM D-445
@ 100
o
C Report
Catalyst fines mg/l < 50
Sulphur Wt % 1.0 max
Pour Point ºC Report
Flash Point ºC Report
Vanadium + Sodium Ppm w Report
Heat of combustion Kcal/kg report
D1160 Distillation (Vol%)
IBP ºC Report ASTM D-86
5 ºC Report ASTM D-86

10 ºC Report ASTM D-86
30 ºC Report ASTM D-86
50 ºC Report ASTM D-86
70 ºC Report ASTM D-86
3.6 By-Product Specifications
Flue Gas
Properties Unit Specification
(1)

NOx mg/Nm³ 450 max
SOx mg/Nm³ 500 max
H
2
S mg/Nm³ 7.5 max
CO mg/Nm³ 1000 max
CO
2
mg/Nm³ Report
O
2
mg/Nm³ Report
H
2
O mg/Nm³ Report
NH
3
mg/Nm³ Report
Particulates mg/Nm³ 40 max
1.) Specifications are point source limits. Lower values are required to meet
the ground level concentration requirements.

Licensor to provide the flue gas composition, including hydrocarbon breakdown,
between each unit operation in the flue gas treatment system.
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Licensor to also provide solids loading and particle size distribution at the outlet of
each unit operation in the flue gas clean up system (DeNOx, DeSOx, Economizer
and Reheat).
Licensor to advise acid gas dew point of flue gas to atmosphere.
Off gas to Fuel Gas
Properties Unit
Molecular weight kg/kmol Report
Hydrogen wt% Report
Methane wt% Report
Ethane wt% Report
Ethylene wt% Report
Propane wt% Report
Propylene wt% Report
Butane wt% Report
Butylene wt% Report

Pentane and above wt% Report
Nitrogen ppmw Report
Oxygen and other
contaminants (including COS
and cyanide)
ppmw Report
H
2
S concentration ppmv 100 max

3.7 Specific Design Requirements
3.7.1 On stream factor
The FCCU shall be designed for minimum on-stream factor of 0.95. This is based
on 8320 hours operation per calendar year. On stream factor is defined as
follows:
On stream Factor = (1)

(1) + (2)

(1) = total duration of productive operation
(2) = total duration for repairs and maintenance including turnaround, catalyst
change-out and typical trip outage.
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3.7.2 Turndown
The unit shall be designed to operate satisfactorily in the range 50% to 100% of
design feed rate for the feed defined in section 3.4 while meeting all product
specifications.
3.7.3 Cycle Length
The unit shall be designed to achieve a 4 year run length between major
turnarounds.
3.7.4 Reactor/regenerator configuration
A single riser configuration meets the required objectives in terms of propylene
yield.
Licensor to maximise propylene recovery in the unsaturated gas plant section
based on an absorber/stripper configuration.
It is envisaged that the configuration will not include catalyst coolers. Licensor to
comment on the benefits and disadvantages of including catalyst coolers in the
configuration to achieve required objectives.
Licensor to provide detailed schematic of the proposed reactor/regenerator
system including the following details:
1. Reactor/regenerator dimensions
2. Number of cyclones
3. Riser dimensions
4. Feed injection details
5. Slide valve arrangement/location
Licensor to provide details of the following operating conditions including:-
1. Cat/Oil ratio
2. Reactor/regenerator temperatures and pressures

3. Catalyst make-up/withdrawal rates and inventory
4. Equilibrium catalyst requirement at start-up
5. Regenerator and purge air requirements
6. Metals level on catalyst
7. Catalyst MAT
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3.7.5 Optimum Reactor Operating Pressure & validation of Coke yields
RFCC licensor to design for operation with a minimum reactor pressure.
3.7.6 Cut Point Flexibility for the Main Fractionator
,Licensor shall provide the following cut point flexibility
Flexibility range
o
C
LFG/HFG 70-90
o
C
HFG/LCO 190-210

o
C
LCO/CLO 360-380
o
C
The LFG/HFG & HFG/LCO cut point flexibility provides a means to control total
sulphur levels in full range cracked gasoline and to control the sulphur compounds
in light cracked gasoline (mercaptans/thiophenes).
LCO/CO cut point flexibility is provided to achieve a CLO viscosity of < 40 cSt @
100 °C. from the main fractionator column.
3.7.7 Facility for steam generation.
The facility for the steam generation in the RFCC unit shall include deaeration &
chemical treatment of the feed demineralised water.
3.7.8 C
3
Splitter and De-Ethaniser
Licensor to include the C
3
splitter in the RFCC scope. Licensor is advised that the
C
3
splitter or the de-ethaniser will include a recycle C
3
purge stream from the PP
unit, capacity to be confirmed prior to final design.
3.7.9 Propylene Recovery
The recovery of propylene is to be 97% min .
3.7.10 Process Efficiency
The Licensor’s design shall optimise the consumption of energy and utilities. It is
expected that Licensor’s design will incorporate a high level of heat integration in

order to provide optimum unit efficiency.
Licensor shall base the inclusion of energy integration processes against a
payback time of 8 years or less.
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Specifically, it is expected that fired heaters shall be specified with air preheat
facilitates using waste heat available from flue gas, unless Licensor
demonstrates the addition of air preheat is uneconomic against an 8 year
payback period.
3.7.11 CLO Filtration
Catalyst fines in CLO shall be reduced by means of filtration to less than 50
ppmw. .
3.7.12 Amine Treatment
The unit design shall incorporate amine absorbers and the associated amine
regeneration for the removal of H
2
S from the reactor loop and from sour offgas
streams. The amine solvent shall be a 40% aqueous solution of MDEA.
In addition to the lean amine tank (specified by Licensor), a water wash tank is

required (to be detailed by Contractor)
3.7.13 Design Guidelines for Process and Equipment
Guidelines for the design of process and equipment are listed in Doc. No. 3550-
8110-PD-0007. The guidelines are used to achieve a consistent design approach
across the project. These are not intended to supersede the Licensor’s design
requirements, or any criteria which may impact the Licensor’s guarantees.
3.7.14 Catalyst type
The RFCC Licensor to advise catalyst type utilized in the RFCC, equivalent
catalyst types and additives. Licensor to advise recommended catalyst
supplier(s).
3.7.15 Catalyst Handling
All permanent facilities required for storage, loading and unloading of the catalyst
shall be included.
The RFCC Licensor to include facilities for storage and handling of fresh,
equilibrium/spent catalyst. Licensor to also include catalyst feeders in its design.
3.7.16 Chemicals
Facilities for the storage and preparation of chemicals (if any) required for the
normal operation of the unit, or required to facilitate unit shutdown and
maintenance shall be included.
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3.7.17 Effluents and Emissions
The RFCC Licensor shall identify all effluent streams (gaseous, liquid and solid)
arising from the process during normal operation and significant abnormal
operations. Estimated rates and compositions shall be provided for each stream,
together with facilities for safe treatment and disposal.
3.7.18 Purging and flushing
The RFCC Licensor shall provide any special facilities required for the purging
and flushing of equipment and instruments.
3.7.19 Start-up and shutdown
The RFCC Licensor shall provide any special facilities required to facilitate
smooth and safe start-up of the unit, and unit shutdown.
3.7.20 Process Control, Safety and Shutdown Systems
The unit design shall incorporate the use of modern state-of-the-art process
control systems and shutdown logic systems. The RFCC Licensor shall specify
all necessary process control systems and safety shutdown logic systems
required to support the safe operation and maintenance of the complex.
3.7.21 Flare Loads and Flare Design
The RFCC Licensor shall specify all safety/pressure relief valves required to
protect plant and equipment within the unit. Licensor shall also quantify the relief
loads arising from controlling and significant relief scenarios for each
safety/pressure relief valve (e.g. utility failure, blocked-in, external fire, etc) in
accordance with API 520 and API 521.
An on-plot Flare Knock-out Drum is required.
3.7.22 Additional Operational Requirements
The following requirements reflect Employer’s experience and will be addressed
as a part of Licensor’s design. Contractor to follow up as required.
1) Regenerator – Due to erosion issues, Licensor to comment on the
following technologies/proposals as alternatives to catalyst coolers:

• High performance feed nozzle
• Increased efficiency of stripping between oil and catalyst
• Shortening of catalytic cracking time
• Prevention of back mixing in riser
• Increased catalyst circulation
• Decreasing of system pressure
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2) Excessive coke formation in reactor - Licensor to advise new technologies
and features to minimise coking. Licensor to comment on reducing of
regenerator temperature in order to do this.
3) Excessive coking at the top of the Disengager – Licensor to comment on
installation of anti-coking steam for the top dead space of Disengager.
4) Vapour line coking by polymerisation – Licensor to comment on the
following design criteria for vapour line design and minimizing of ensuing
pressure drops:
• High velocity
• Adequate refractory insulation
• Minimising of lengths

5) Reactor maintenance – Licensor to comment on what allowances are to be
made for adequate maintenance access inside the reactor.
6) Reactor isolation - Licensor to advise what isolation features are
incorporated so as to ensure easy and safe maintenance work.
7) Poor fluidization characteristics in the reactor – Licensor to comment on
how proper fluidization and hence catalyst circulation, is achieved within
the reactor.
8) Catalyst losses from regenerator – Licensor to comment on what features
are available to minimise catalyst losses, maintaining catalyst activity and
minimising downstream fouling. Licensor to comment on inclusion of
second cyclone to achieve this.
9) Cyclone operational issues – Licensor to advise what design criteria is
applied to minimise erosion of cyclones, and also minimising catalyst
losses.
10) Refractory issues – Licensor to supply information on refractory vendors
and relevant information on actual refractory to be applied.
11) Sticking of plug valve and lift pipe sleeve for catalyst – Licensor to advise
on means of minimising.
12) Regenerator air blower – Licensor to comment on technical feasibility of
installation of a single air blower in light of simplicity and being economical.
13) Erosion of ring air nozzle by catalyst – Licensor to comment on protecting
of the ring air nozzle by covering with refractory.
14) Plugging of slide valves – Licensor to comment on minimising sticking of
slide valves due to coke and refractory chunks.
15) Flue gas slide valve - Licensor to comment on ways to prevent the slide
valve on the regenerator flue gas line from sticking due to molten catalyst.
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16) Mechanical issues around catalyst feed and withdrawal line – Licensor to
comment on the following proposals in order to mitigate erosion problems
associated with the catalyst feed handling system:
• Installation of spare catalyst feeder, catalyst feed line, and nozzle.
• Constructing piping out of short, replaceable, spool pieces
17) Catalyst feed handling system – Licensor to comment on optimising
catalyst feed handling system for maximising polypropylene and gasoline
production.
18) Flue gas boiler - Licensor to comment on installing a combined boiler
system (CO- B and WHB) in light of minimising costs and simplifying
operation. Licensor to comment on any safety aspects associated with
such a configuration. Licensor to take into consideration possible CO
explosion, especially at start-up.
19) Boiler tube fouling – Licensor to comment on installation of sand blast
system on the CO-B.
20) Aluminium ammonium sulphate fouling in the flue gas – Licensor to advise
on the suitability of the following proposals in order to minimise fouling in
the Economizer by aluminium ammonium sulphate:
• Installation of DeNOx system downstream of the CO-B.
• Preheating of gas and controlling the economiser outlet temperature
above 230

o
C to prevent fouling.
• Square arrangement tubes
• Not installing finned tubes
• Installation of retractable soot blower
21) Tube fouling in the WHB – Licensor to advise on reducing fouling in the
WHB.
22) Plugging of EP - Licensor to comment on reducing of plugging by catalyst
in the EP bottom conveyor section.
23) Terminal flue gas – Licensor to advise acid gas dew point.
24) DeSOx – Licensor to comment on reducing erosion and plugging by
solvent and FCC catalyst.
25) Duct plugging – Licensor to advise how to minimise accumulation of
catalyst in the duct and ensuing plugging.
26) Hydrocarbon contamination in CO gas – Licensor to advise on ways to
minimise hydrocarbon contamination of CO gas.
27) Raw oil feed – Licensor to comment on installation of a surge drum and
automatic filter to minimise introduction of water and sludge from tankage.
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28) Coking at the Main Fractionator inlet line – Licensor to comment on
methods to prevent oil back mixing with feed to the Main Fractionator and
coking at the inlet nozzle.
29) Maximising of aromatics – Licensor to advise what adjustments to the Main
Fractionator design can be made to maximise aromatics production.
30) Excessive coking in the bottom pumparound exchangers – Licensor to
comment on the following proposals to minimise coking in the bottom
pumparound:
• Shortening of residence time and advise the maximum pumparound
rate.
• Maintaining the bottoms temperature at the bottom of the
Fractionator at a maximum of 320
o
C.
If the excessive coking in the bottoms exchangers can be reduced with the
proposals outlined in nr 30 above, Licensor to comment on whether the
fouling factor for the Bottoms Exchanger can be lowered.
31) Coke and catalyst from the Main Fractionator – Licensor to comment on
installation of an automatic filter on the Main Fractionator bottoms pump
suction.
32) Corrosion and deposits (Cl, NH
3
, H
2
S…) within the main column – Licensor
to comment on installation of water withdrawal system at the Top
Pumparound or top tray, and suitable metallurgy or cladding for the Main
Fractionator.
33) To limit water accumulation in the Main Fractionator, Licensor to comment

on normal operation without cold reflux.
34) Corrosion in the Main Fractionator by HCN, H
2
S and CO
2
– Licensor to
comment on suitable metallurgy, chemical additives, and stress relaxation
in order to limit excessive corrosion in Main Fractionator.
35) High catalyst content in the CLO – Licensor to comment on installation of
suitable means of catalyst separation for the CLO stream.
36) Severe HCN corrosion in the two phase flow in the Gas Concentration Unit
Intercooler, Aftercooler and Absorber – Licensor to advise suitable
metallurgy between the Wet Gas Compressor and the High Pressure
Separator, and also comment on the use of alloys.
37) Insufficient reboiling duty during start-up – Licensor to advise criteria used
when sizing reboilers for Gas Concentration Unit Stripper, Debutanizer,
Depropaniser, and Deethaniser , especially during start-up. Licensor to
comment on design of the columns with separate start-up reboilers.
38) Coking in the Debutanizer reboiler – Licensor to advise suitable
Debutanizer reboiler temperature so as to prevent coking by
polymerization.
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39) NH
3
and H
2
S corrosion in the Debutaniser Overhead Condenser - Licensor
to comment on suitable metallurgy for Overhead Condenser to limit
corrosion.
40) Corrosion in the Amine Regenerator – Licensor to advise suitable
metallurgy in the Amine Regeneration Section. Licensor to comment on
use of high grade materials.
41) Entrainment of Amine and Sodium in the LPG from the Amine Contactor –
Licensor to comment on the requirement of a water wash system
downstream of caustic wash.
3.8 Utilities
Design data for available utility supplies are given in the Basic Engineering
Design Data (BEDD) document, 3550-8820-SP-0001.
Licensor shall identify all utility consumption requirements and provide estimated
rates of consumption for normal operation and for significant abnormal
operations.
Licensor to provide steam balance around unit operations in the flue gas clean
up system (DeNOx, DeSOx, Economizer and Reheat) for start-up, normal,
shutdown, and emergency operation.
Licensor to also provide instrument air, Nitrogen, and plant air requirements.
3.9 Other Raw Material Requirements
Licensor shall specify all other raw materials required for the unit in addition to
the feedstock, catalysts, chemicals and utilities. This typically includes, but is not

limited, to corrosion inhibitors. This specification shall include materials, hazard
data, method of use, frequency of use and consumption. The design shall
include all specialised equipment required for their use.