CRITICAL MATERIALS REQlJIREMENTS FOR …

1 CRITICALMATERIALSREQlJIREMENTSFORPETROLE UMREFININGAREPORTOFTHENATIONALPETROLEUMC OUNCILMARCH,1966-~~~--------------~--~-- -'IiiNATIONALPETROLEUMCOUNCIL1625 KStreet, ,Washington, , , ,Secretary-TreasurerAnAdvisoryCommitteet otheDEPARTMENTOFTHEINTERIORW ashington, , ,AssistantSecretary, ~ ' ,1966 TABL EoFCONTENT SPARTPARTIIIINTRODUCTION GENERALASSUMPTIONSANDENGINEERINGGROUNDRU LES 16 PARTIIIPROCESSUNITS. 9 Section1-Crudedistillation(includingdesa lting,vacuumandstabilization 10 Section2-Catalyticreformingandfeedprepar ation 22 Section3-Catalyticcracking. 31 Section4-Delayedcoking. 51 Section5-Hydrotreating 61 Section6-Hydrocracking 69 Section7-Hydrogenplant. 79 Section8-Alkylation. 107 Section11-Powerdistribution. 120 Section14-Wastewaterseparatorandemulsion treating.)

2 123 Section15-Instrumentair. 125 Section16-Plantair 128 Section17-Fireprotection 131 LISTSOFDIAGRAMSANDFIGURESP rocessUnits . Off-SiteFacilities. ** , ,PresidentAmericanPetrofina, , , , ,PresidentTheStandardOilCompany(Ohio) (Indiana) ' ** (Ohio) * 'BrienHumbleOil& *ServedasGovernmentCo-ChairmanuntilJune3 0,1965twhentermasRefiningSpecialist, (includingdesalting,vacuumandstabilizati on) ' ' , , :Infulfillingtheresponsibilitiesassigned totheSecretaryoftheInteriorbythePresiden twithrespecttopreparednessplanningforthe petroleumindustry, , , ,theCouncilsubmittedavaluablereport,I~te rialsRequirementsforOilandGasExploration ,DrillingandProduction, , , "- v -PARTIINTRODUCTIONI nfulfillingtheresponsibilitiesassignedto theSecretaryoftheInteriorbythePresidentw ithrespecttopre-parednessplanningforthep etroleumindustry, ,however, ,thepetroleumindustryishighlydependenton certainessentialmaterials,includingcarbo nandalloysteel,copper,aluminum, , , , , ~erallytorepresentcrudethroughputsoffrom 10,000barrelsperstreamdayto150, , (includingdesalting,vacuumandstabilizati on) 2 ( )andheavy( ) , ,actualunitmaterialsrequirementswereused ,modifiedasnecessaryinlinewiththeforegoi nggeneral-3 reactualunitdatawerenotavailable, ,however, (BDSA)

3 , ~lreplacementand/orrepairofadamagedunitw ouldrequireon-siteinspectionandevaluatio n, ,accordingly,noestimatesweremadeforcriti calmaterialsrequirementsfortheproduction oflubricants,petrochemicalprecursors,asp halt, 4 ,becauseoftheirnature, , ,however, ,processchemicalsandcatalystsessentialto sustainingoperationofexistingequipmentwo uldbeofvitalconsiderationintimesofemerge ncy, 5 -PARTIIGENERALASSUMPTIONSANDENGINEERINGG ROUNDRULESF orthepurposeofpreparingtheattachedestima tesofmaterialsrequirementsforprocessesan dauxiliaryfacilities, ,ASA, , ,000voltsprimarywithsecondary13, ,residualsup-plementalfuel, ,1, , 6 , ,unlessotherwisespecified, ,appro-priateallowanceoverandabovethatin dicatedinthisstudymustbemadeforsuchmisce llaneousitemsaswinterizing,blowdown, ,suchaslaboratories,shops, 7 , ,noestimatesinthiscategoryaremadeinthisr eport, ;refinerylocationsandplotplans, , 8 '--~-------------~ (a)3(b)3(c)45678 NUMBER lalb23456a6b78 NUMBER lalb23-a-l3-a-23b3c45678 PARTIIIPROCESSUNITSTABLEOFCONTENTSC rudedistillation(includingdesalting,vacu umandstabilization).

4 Catalyticreformingandfeedpreparationcata lyticcracking. Directfired, .. COboilerforcatalyticcracking.. Delayedcoking ..Hydrogenplant ..Alkylation.. Hydrotreater .. Alloyandstainlesssteelrequirements.. FluidcatalyticcrackingunitsCarbonsteelre quirements .Alloysteelrequirements .. Cokingunit-steelrequirements .. Hydrotreater-carbonandalloysteelrequirem ents Hydrocracking-steelrequirements. Hydrogenplant-carbonsteelrequirements Sulphuricacidalkylationplant-carbonsteel requirements.. -9 -),1022314146516169798812132332536270718 090141524333442475463728191 SECTION1 CRUDEDISTILLATION(INCLUDINGDESALTING,VAC UUMANDSTABILIZATION)SECTION1 CRUDEDISTILLATION(INCLUDINGDESALTING,VAC UUMANDSTABILIZATION) ,oneortwocrudecolumnsdependingonunitsize ,foursidestrippersfornaphtha,kerosene,ga soilandheavygasoilstripping,avacuumcolum n, , ,suchaslayoutandlocation, , , ,thealloymaterialswillbeadirectadditivet othecarbonsteelquantitiessinceliners,etc .

5 , , ,ifsourcrudesaredesignedfor, '~ ' ~ ~ ~CRUDEOIL* ~ ~ ~ ~ ~DEBUTANIZER*Butanesandlightercontentwas increasedconsist <:> <:> <:>MU) (I)c:::>G) :E.~(I)ro:::> '"0ci:::>G)I-Z(.)0:: Q)>G)<:>..G)<:>::::s<:>ODcCi) :Zc ~cu:::>c::(.)<:> <:> <:>.-<:> <:> <:> <:>..<:>CO<:>N39H"H33anH3'aSIa!AI-14--51-MB/SD,CRUDEC HARGE-"",--_~-811',II~~~--:;::C;; ::.enCDg~C)Q;:'Q- ==iQ~====Qf====:Q~====:Q~::::~~~~~~~~:~~ !~:::;~QIStainlessSteelValves,Flangesand FittingsStainlessSteelPipeandTUbingI)::0 Q(")'<~l C81II'"I'j:::sIIIICoC"'"tnJTI-I~~/<?t-I-0~- z,1:>.=..Z."en~$CDCo'Q0q" <.."TI~CDentn 2-I;l1). >~(")0I'l'I~CI'l'I,; : '" :::;-C""'"CDZ3-CD-I"Iaen"81 IIIIII~II"81 IIIIIIIIC>CRUDEDISTILLATION(INCLUDINGDES ALTING,VACUUMANDSTABILIZATION) 'Charge10,00075,000150, (intons)(a)Sheetandplate3001,2002,300(b) Pipeandtubing4008501,300(c)Valves,fittin gsandflanges110230400(d)Structuralandoth er4007601,200(e)TOTAL1,2103,0405, (intons)(a)Sheetandplate(b)Pipeandtubing 170375710(c)Valves,fittingsandflanges601 20185(d)Other------(e) (intons)(a)Sheetandplate60160270(b)Pipea ndtubing102540(c)Valves,fittingsandflang es51015(d)Other---(e)TOTAL75195325-16-UN ITCAPACITYB/SDCrudeCharge10,00075,000150 , (a)Wireandcable(infeet)(i)600V,Singlecon ductor(Size)1270,00088,000100,0001025,00 040,00060,000810,00020,00050,00063,0005, 0007,00045,0008,00015,00024,00010,00018, 0001/05008001,0002/02,0003,0004,0003/01, 0001,8002,0004/02,0003,5004,000250 MCM2,0005,0006,000300 MCM8001,5002,000350 MCM1,5002,7003,000500 MCM100(ii)5KV,Singleconductor(Size)

6 41,2002,0002,50022,0003,0003,50011/02/02 ,2003/01,0001,4004/0250 MCM800-17-UNITCAPACITYB/SDCrudeCharge(a) Wireandcable(cont'd.)(iii)12KV,3conducto r(Size)1/02/04/0(b)Other(intons) (intons) ,Compressors,etc.(numberofunits)(a)Pumps andmotors(HP)0-2021-10012515020025035040 0(b)Pumpsandturbines(HP)5006001,20010,00 05001215191475,0008001540710115122150,00 02001,200207013-931211121(c)Miscellaneou sdrivers(HP)Fansandmotors0-2021-100-18-2 214142622 UNITCAPACITYB/SDCrudeCharge10,00075,0001 50, (numberandtype)(a)Transformers13,800/480 Vl-l,OOOKVA3-1,000 KVA4-1,000 KVA13,800/4160V1-l,500 KVA1-3,750 KVA480/120Vl-lOKVA2-30 KVA3-30 KVA(b)Switchgear(cubicles)13,800V46(c)Mo torcontrolcenters480V134 (number)10,00075,000150,000(a)(b)(c)(d)( e)(f)(g)(h)(i)(j)(k)Temperaturetransmitt ersPressureindicatorsFlowtransmittersLev elinstrumentsLocalcontrollersTemperature elementsPressureelementsFlowelementsLeve lgaugesSolenoidvalvesControlvalves-19-91 2172155701515131720025012515012123030101 360(1~-3")80(2-6")1523741521300175123015 90(3-10")UNITCAPACITYB/SDCrudeCharge10,0 0075,000150, (contId.)

7 (1)Reliefvalves588(m)Multipointtemperatu rerecorders244(n)Receivercontrollers5580 85(0)Receiverrecorders405055(p)Receiveri ndicators589(q)Alarmswitches203040-20-CR UDEDISTILLATION(INCLUDINGDESALTING,VACUU MANDSTABILIZATION) ,00075,000150, (KVA)4653,5007, (SCFH)52,000390,000780, (GPM)6705,00010, (lbs.(hour)9,60072,000144, (CFM)(a)Instrumentair100200300(b)Plantai r2004005 ,000to40,000B/SDofstraightrun,catalytic, (338oF -3800 FASTM endpoint),andstabilizedheavyreformate(41 0oF-430oFASTM endpoint).Thisestimate,asprepared, ,ifacontrolledfeedstockcanbeassured,orif on-streamefficiencycanbesacrificed, ~DEBUTANIZERTOMSABSORBERFUELGAS)S RNAPHTHASTRIPPEDBOT_ ) APIl'VW-VG-JVIB/SDFRESHFEED(NAPHTHA) >Cl"'"..Q'iii,carho/}Steelp_IlJi/}'e"a/} et'hlIh'i]g-C'(")Q"l'OC 0"..C"U't'lQn19~/:::JU' ~~:::Ji!<"QlC."0-~~:J>-<."-IQlt~-IciQ"0Q-cZ'< (1)0."Cl(1)mClCl-"'T1 Nen-II;:c0I'T1(1):::tJI' :3 (1):::tJ.,>.39":(1)~:::JCJ-'6(I)~~~NgIIII, ,00020,00040, (intons)(a)Sheetandplate2406251,100(b)Pi peandtubing120280520(c)Valves,fittingsan dflanges3273130(d)Structuralandothers-l& .

8 187330(e)TOTAL4681,1652, (intons)(a)Sheetandplate(b)Pipeandtubing 49126220(c)Valves,fittingsandflanges5142 0(d)Other------(e) (a)Wireandcable(infeet)(i)600V,Singlecon ductor(Size)1210864-25-50,00015,0006,000 2,0003,00080,00025,00010,0002,5004,00090 ,00028,00013,0003,0005,000 UNITCAPACITYB/SDFreshFeed5,00020,00040,0 00(a)Wireandcable(cont'd.)(i)600V,Single conductor(Size)(contId.)23,5005,0006,000 1/03,0004,0004,5002/02,0002,5003,0003/01 ,0001,2001,5004/08001,5001,500250 MCM1,8002,3002,300300 MCM500500500400 MCM1,0001,3001,300(ii)5KV,Singleconducto r(Size)41,0001,2001,20011,0001,2001,2003 /01,0001,2001,200(iii)15KV,3conductor(Si ze)350 MCM5001,0001,000(b)Other(intons) ,Compressors,etc.(numberofunits)(a)Pumps andmotors(HP)0-2021-100125-200250-500-26 -9921895210844 UNITCAPACITYB/SDFreshFeed(b)Compressorsa nddrivers(HP)Turbines2,000-3,0003,000-3, 5005,000120,000140,0001 UNITCAPACITYB/SD5,00020,00040, (number)(a)Temperatureelements75130170(b )Pressureelements100370480(c)Flowelement s344360(d)Levelinstruments162835-27-UNIT CAPACITYB/SDFreshFeed5,00020,00040, (contId.)

9 (e)Temperaturetransmitters4912(f)Flowtra nsmitters304060(g)Pressurecontrollers471 0(h)Localcontrollers446(i)Controllers536 890(j)Multipointtemperaturerecorders368( k)Recorders446(1)Indicators446(m)Alarmsw itches162030(n)Levelgauges183155(0)Contr olvalves405575(p)Solenoidvalves246(q) ,00020,00040, (KVA)1,4002,3002, (SCFH)85,000310,000610, (GPM)2,6009,90019, ( )2,3008,00015, (CFM)(a)Instrumentair90120150(b) ,00020,00040, :Cobalt-Molybdenum(cubicfeet)4101,8603, :Platinum(cubicfeet)5752,5504,800-30-SEC TION3 CATALYTICCRACKINGSECTION3(a) ,materialsrequirementsareshownforfluidty peofcatalyticcrackingunitsofcapacityof10 ,000,35,000and60, , ,someof'thealloymaterialcouldbereplacedw ithheaviercarbonsteelconsistentwithcorro sivecharacteristicsoffeedstock, ~ ( ~ ~ (EQUIVALENT)~SPONGEABSORBERDEBUTANIZERDE PROPANIZERGASOLINECAUSTICWASHFOULWATERST RIPPERFUELGASPROPANE-PROPYLENEBUTANE-BUT YLENEGASOLINELIGHTFURNACEOILCLARIFIEDSLU RRYCOKE ooooM-33-a33~HS3H~aSIawoIt>oCD00/c5lc5l0 It>"0'Votn~~..V-/~Z~~ :I--G)en.

10 0I"-co<':; ::C"ZciUG)0c:::0z0I-0 UMQ)-G)..G):::l-00> :..J<c:t}.Je/< }t}/<"-RIS" ~.. ;)nJ1S00 ,-----------,gcoI------+------+------+------+--~""o;;;;;:=__-+_----____I C>C> ~C>C>C!JCI)"""z~..I/c51c51 IS ,I-uG)'/fyU)Nc::e.!::/~~>I'?(ro0:::=0, ("t')C>..IciuO::C>c:eCO)ZLL.~j::Cii0::l> ~U) )Zi:i:c::e>. ::e=u<CC>C>NC-~.. >It) ~----~:__---~:_---~C>oaQ=-0~MN,..C>CDa33 ~HS3H~ !SDFreshFeed10,00035,00060, (intons)(a)Sheetandplate1,0602,3153,625( b)Pipeandtubing3687501,085(c)Valves,fitt ingsandflanges187350550(d)Structuralando thers4801,1001,726(e)TOTAL2,0954,5156, (intons)(a)Sheetandplate80193306(b)Pipea ndtubing164880(c)Valves,fittingsandflang es51015(d)Other123150(e) (intons)(a)Sheetandplate95192290(b)Pipea ndtubing(c)Valves,fittingsandflanges(d)O ther(e)TOTAL95192290-35-UNITCAPACITYB/sD FreshFeed10,00035,00060, (a)Wireandcable(infeet)(i)600V,Singlecon ductor(Size)1275,80066,20065,200103,6001 ,200812,0001,2002,400612,0001,200410,800 32,40027,2002,40004,80010,8002,4003/08,7 503,6004,0004/09,6006,000300 MCM2,4008,400(ii)6KV,Singleconductor(Siz e)89,60010,80064,8006,000429,600(iii)Ins trumentcontrolcablea) (singlewire)200,000200,000200,000b)Therm ocoupleleadwire-I/C30,00030,00030,000(b) Other(intons)54100145-36-UNITCAPACITYB/S DFreshFeed10,00035,00060, ,Compressors,etc.