Basic Engineering Package : Basic Engineering Package defines the purpose, content and structure of the basic engineering or design specification, and it is first step in the project development process. Basic Engineering Package emphasizes the importance of carefully maintaining the project's technical direction as defined in the Basic Design Phase and of providing definite direction and sufficient detail to ensure orderly and efficient progression of subsequent detailed engineering, procurement and construction activities.
A Typical Basic Engineering Package for Vegetable Oil Refining
PROCESS DESCRIPTION
General: M/s. Tropical Oil Refining Ltd., intends to set up "Soft and Tropical Oil Refining Project" at Mumbai, in India. This plant will produce 1,000 tons of refined oil from crude oil imported from abroad. Three types of crude oils will be imported, Degummed Soya bean Oil (SBO), Crude Olein (OL) and Crude Palm Oil (PO).
SBO needs chemical refining whereas OL and PO can be treated by physical refining. After refining, all the oils undergo bleaching and deodorizing. Deodorized (RBD) oils are the finished product. These are packed in pouches and tins or sent out in road tankers or rail tankers.
Part of deodorized PO (RBD PO) and bleached SBO (RB SBO) is hydrogenated and deodorized again. Packs of hydrogenated oils are subjected to controlled cooling in cold rooms.
Storage of oils is provided at five stages of the treatment process:
- Crude oil storage
- Refined and bleached oil storage (Intermediate Product)
- Refined bleached and deodorized oils storage (Finished Product)
- Hydrogenated RB oil storage (Intermediate Product)
- Hydrogenated RBD oil storage (Finished Product)
Crude SBO Treatment Process
Stage 1 : Chemical refining of CSBO involves neutralization with caustic soda and washing with water. This is followed by bleaching with clay as adsorbent. Neutralizer and bleacher are the proprietary packages supplied by some companies specialized in this line on turn key basis. The process is continuous.
Oil refining consists of neutralization, bleaching and filtration to remove fatty acids and phosphates from the oils. Bleaching is done to remove the turbidity, which gives undesirable color to the oil. After this oil is deodorized in a tall column under vacuum and high temperature.
Crude SBO is transferred from storage tanks into inlet buffer tank. From here Crude SBO is continuously supplied to the neutralizer package. Neutralized and washed SBO continuously goes to the bleacher. Bleached SBO is received in outlet buffer tank. From here RB SBO is transferred to the storage tank via polishing filter and economizer. Soap stock is generated as by product in neutralizer package. This is taken to storage tank or Crude SBO is sent to acidulation (soap stock splitting) section for further treatment.
Caustic soda and phosphoric acid required in the process are supplied into the respective day tanks using transfer pumps in chemical storage area. Clay bags are manually dumped into the unloading hopper in blender section.
Wastewater generated in neutralizer section is sent to waste water treatment plant using pump. Spent clay from filters is collected in carts and sent out for disposal.
Stage 2 : Deodorizer package is common for SBO, OL, PO and hydrogenated oils. Hence RB SBO oil needs to be stored in intermediate storage tanks, when deodorizer is running on other oils. For starting SBO campaign in deodorizer, all lines and equipment are flushed with steam. Then RBO tank material is supplied continuously to deodorizer package. Deodorized oil is the finished product. Part of SBO is sent for hydrogenation. Deodorized SBO (RBD SBO) is transferred to selected storage tank using pump within package unit.
Stage 3 : Part of RB SBO is hydrogenated in hydrogenator package. RB SBO is sent to hydrogenator in batches. On the way to the reactor, RB SBO exchanges heat with product of previous batch, which is being sent to hydrogenated RB oils storage tank.
Crude OL / PO treatment process
Stage 1 : Physical refining of COL / CPO involves pretreatment with phosphoric acid. This is followed by bleaching with clay as adsorbent. Process for pretreatment and bleaching is proprietary and is supplied as turnkey package. The process is continuous.
Crude OL / PO is transferred from storage tanks into inlet buffer tank. From here OL / PO is continuously supplied to the pretreatment and bleaching package. Bleached OL / PO is received in outlet buffer tank. From here RB OL / PO is transferred to the storage tank via polishing filter and economizer.
Phosphoric acid required in the process is supplied into the day tank using transfer pump in chemical storage area. Clay bags are manually dumped into the unloading hopper in blender section.
Waste water generated in neutralizer section is sent to waste water treatment plant using pump. Spent clay from filters is collected in carts and sent out for disposal.
Stage 2 : Deodorizer package is common for SBO, OL, PO and hydrogenated oil. Hence RB OL / PO oil needs to be stored in intermediate storage tanks, when deodorizer is running on other oils. For starting OL / PO campaign in deodorizer, all lines and equipment are flushed with steam. Then RB OL / PO tank is connected to pump and is supplied continuously to deodorizer package. Deodorized OL / PO (RBD OL / PO) is transferred to storage tank using pump within the package unit.
Stage 3 : Part of RBD PO is hydrogenated in hydrogenator package. RB PO is sent to hydrogenator in batches. On the way to the reactor, RB PO exchanges heat with the product of previous batch, which is being sent to hydrogenated RB oils storage tank.
Soap Stock Splitting (Acidulation)
Stage 1 : Soap produced in CSBO neutralizer is partly sold out as soap. The rest is sent to hold tank in soap stock splitting section, which is a proprietary package unit. Soap is treated with sulphuric acid and acid oil is produced as a product. Storage tanks of acid oil and sulphuric acid and their pumps is a part of the package. Waste water produced is sent to waste water treatment plant by pump.
Finished Product Loading and Packing
RBD Oils : Two bays are provided near refinery building for loading RBD oils into road tankers. Operator in the main control room connects the tanker with a hose, selects the RBD oils tank from which oil is to be loaded out, operates appropriate valves and starts the pump from control room. Oil gets filtered and is measured with a mass flow meter. Pump stops after appropriate quantity is loaded.
Rail car loading is done by similar operation.
For packing pouches, RBD oils are transferred by pump to packing line feed tanks in packing hall. Dedicated pumps are provided for feeding SBO, OL, and PO to any of the pouch filling machine. PO is fed to tin filling machines as well.
Hydrogenated RBD Oils : These are not sent out in bulk tankers. Pump is used for transferring these oils from storage tanks to packing line feed tanks. From these tanks, hydrogenated oils are fed to pouch filling machine and tin filling machine using dedicated pumps.
Pouches and tins of hydrogenated oils are taken to cold rooms. Packs of hydrogenated oils are exposed to cold air at –5
oC in the cold rooms for nearly 22 hours. Oils get crystallized in the cold room.
Plant Facilities: Refining, deodorization, hydrogenation and acidulation are carried out in three different plant buildings. The utilities required for the plant are low, medium and high pressure steam, soft water, cooling water, nitrogen, hydrogen and instrument air. All facilities will not be provided from the beginning. Initial work which forms Phase I will include treatment facilities for soft oils (RBD SBO, RBDOL, RBDPO). Hydrogenation section will be introduced later in Phase II. However, BEP should consider both the phases and costs of Phase I and Phase II should be separately indicated.
Plant Capacity: Oil refining and deodorization are continuous processes whereas hydrogenation is a batch process. All the plants shall run continuously for 24 hours a day, 7 days a week and 330 days per year. Plant capacity will be 1,000 tons per day of all oils. The break-up is as follows :
Soya bean oil | 400 TPD |
Palmolein | 300 TPD |
Palm oil | 200 TPD |
Hydrogenated oil | 100 TPD |
Deodorizer is common for all oils and is sized to treat 1,000 tons per day. Pretreatment and blending equipment are common for palmolein and palm oil and are sized for 500 tons per day. Neutralization, bleaching, hydrogenation, deodorization are proprietary oil treatment processes. These will be bought as package on turnkey basis.
Item No. | Description | Capacity in TPD |
1 | CSBO neutralizer package | 400 |
2 | CSBO bleacher package | 400 |
3 | CPO / COL pretreatment and bleaching package | 500 |
4 | Hydrogenation package | 200 |
5 | Deodorizer package | 1000 |
6 | Acidulation package | 70 |
Capacities of various Storage Tanks Basis for oil storage at various stages is as follows:
Materials to be stored | Days |
Crude SBO | 35 |
Crude Olein | 45 |
Crude Palm Oil | 45 |
Refined and Bleached Oils | 3 |
Hydrogenated RB oils | 6 |
Deodorized oils | 3 |
Hydrogenated RBD oils | 6 |
Tank capacities worked out are as follows:
Oil Type | Phase |
I | II |
Crude Oil Storage |
CSBO | 3 X 5,000 MT | - |
COL | 3 X 5,000 MT | - |
CPO | 1 X 5,000 MT | 1 X 5,000 MT |
Intermediate Oil Storage |
RB SBO | 3 X 500 MT | - |
RB OL | 2 X 500 MT | - |
RB PO | 2 X 500 MT | - |
RB HSBO | - | 2 X 200 MT |
RBOH PO | - | 5 X 200 MT |
Finished Product Storage |
RBD SBO | 3 X 500 MT | - |
RBD OL | 2 X 500 MT | - |
RBD PO | 1 X 500 MT | - |
RBHD SBO | - | 2 X 200 MT |
RBDHD PO | - | 5 X 200 MT |
Packing Feed Tanks |
RBD Oils | 3 X 50 MT | 2 X 50 MT |
Hydrogenated RBD Oil | - | 2 x 50 MT |
Basis of storage for by-products and treatment chemicals is as follows:
Material | Storage for Days | Quantity MT |
Soap | 2 | 25 |
Acid oil | 30 | 2 X 250 MT |
Palm fatty acid distillate | 15 | 1 X 250 MT |
Soya fatty acid distillate | 30 | 1 X 50 MT |
Caustic lye (48%) | 30 | 1 X 60 MT |
Phosphoric acid | 30 | 1 X 33 MT |
Sulphuric acid | 15 | 1 X 58 MT |
Citric acid | 60 | 50X500 Liters or 120X200 Liters |
Clay (Imported) | 60 | 11040 X 25 Kg Bags |
Clay (Local) | 30 | 18480 X 25 Kg Bags |
Catalyst | 60 | 300 X 25 Kg Drums |
Hydrogen truck | 3 | 17 X 800 Nm3 |
Packing lines:
Pouches: pack size will be 0.5 liter and 1 liter. Total 10 lines sized for 50 tons per day each should be designed. Out of these only 4 will be put up in Phase I and 6 in Phase II.
Tins: pack size to be considered is 15 kgs. Total 3 lines sized for 50 tons per day each should be designed. All of these will be installed in Phase II.
Bulk loading: 2 bays for tanker loading should be considered, for Phase I which is sufficient for Phase II also. 1 rail car loading station near plant boundary to be considered.
Warehousing: five days storage with respect to packing line capacity should be considered for all types of packs. Storage basis for packaging materials shall be as follows :
Material | Days storage |
Empty tins | 5 |
Empty cartons | 10 |
Pouch reels | 20 |
Cold storage rooms : In Phase II, cold rooms are to be provided for crystallizing hydrogenated RBO SBO and PO in order to produce vanaspati. Pouches and tins of hydrogenated oils will be stacked in cold room and kept in contact with –5
oC air for nearly 32 hours. There will be 4 cold rooms. Each room will hold 75 MT of finished product equivalent to approximately 3 hours output from packing lines. HVAC unit for cold rooms will be based on ammonia and will be located close to cold rooms.
Special design requirements
- All palm oil and palmolein tanks (crude as well as treated) need to be maintained at 55oC.
- Hydrogenated RBD oils need to be stored at 50oC.
- RBD Soya bean oil needs to be stored at 38oC.
- All palmolein and palm oil pipes should be steam traced to prevent solidification of oils in pipe.
- After bleaching, oils should not come in contact with atmospheric oxygen. Hence all storage tanks of RB oils should be blanketed by nitrogen. During change over, lines should be flushed with nitrogen and not with air.
- Oil lines in packing area, down stream of packing line feed tank, should be of SS304.
- Good hygienic practice code should be followed for product ware house.
- Plant should be automated to maximum extent so that manual operations are kept minimum.
Calculation of requirement of Utilities
Major utilities required are
- Raw water: Pressure 3 kg/cm2g, temperature ambient,
- Nitrogen: Pressure 5 kg/cm2g, temperature 40oC, purity 99.9%
- Soft water: Pressure 3 kg/cm2g, temperature 30oC, hardness < 5 ppm
- Dirty cooling water: Pressure 3 kg/cm2g, temperature 32oC, wet temperature 28oC,
- LP steam: Pressure 3 kg/cm2g, temperature 138oC,
- MP steam: Pressure 9 kg/cm2g, temperature 180oC, steam generation Pressure 10.5 kg/cm2g
- Cooling water: Pressure 3 kg/cm2g, temperature 32oC, wet bulb temperature 28oC,
- Instrument air: Pressure 7 kg/cm2g, outlet temperature 40oC max after dryer, dew point @ 1 atm = (-)40oC,
These are required in different plants, for different equipment. The requirement for each equipment, for each utility should be calculated in the form of table below in different sheets. These are then added for the individual plants. When requirement for each plant is worked out it is added to get the total requirement.
Degumming
Equipment | Average flow | Peak flow | Heat load |
Feed pump | | | |
Preheater | | | |
Phosphoric acid tank | | | |
Phosphoric acid pump | | | |
Mixing tank | | | |
Settler | | | |
Discharge pump | | | |
Separators | | | |
Neutralization
Equipment | Average flow | Peak flow | Heat load |
Caustic lye storage tank | | | |
Caustic pumps | | | |
Feed tank | | | |
Pumps | | | |
Preheater | | | |
Feed pumps | | | |
Mixers | | | |
Separators | | | |
Water Washing
Equipment | Average flow | Peak flow | Heat load |
Heater | | | |
Feed pumps | | | |
Mixers | | | |
separators | | | |
Pretreatment
Equipment | Average flow | Peak flow | Heat load |
Feed pump | | | |
Heater | | | |
Mixer | | | |
Settler | | | |
Phosphoric acid tank | | | |
Phosphoric acid pumps | | | |
Bleacher
Equipment | Average flow | Peak flow | Heat load |
Bleaching earth tank | | | |
Activated carbon tank | | | |
Tank pumps | | | |
Bleacher | | | |
Bleacher output pumps | | | |
Filtration
Equipment | Average flow | Peak flow | Heat load |
Leaf filters | | | |
Cyclone separators | | | |
Secondary filters | | | |
Bleached oil tank | | | |
Recycle tank | | | |
Recycle pump | | | |
Vacuum unit | | | |
Recovered oil tank | | | |
Bleached oil pump | | | |
Soft Column Deodorizer
Equipment | Average flow | Peak flow | Heat load |
Filters | | | |
Preheaters | | | |
Deaerator | | | |
Economizer | | | |
Final heater | | | |
Deodorizer | | | |
Fatty acid receiver | | | |
Fatty acid cooler | | | |
Fatty acid pumps | | | |
Exchanger pump | | | |
Vacuum unit | | | |
filters | | | |
These are then summarized as follows for each utility:
Plant | Average flow | Peak flow | Heat load |
Degumming | | | |
Neutralization | | | |
Water Washing | | | |
Pretreatment | | | |
Bleacher | | | |
Filtration | | | |
Soft Column Deodorizer | | | |
Total for all plants | | | |
Documents prepared:
- Process description
- Plant capacity
- Plant facilities required
- Utilities summary sheets
- Data sheets for all the equipment.
- Process flow diagrams
- Piping and instrumentation diagrams