🛢️ BTX — Aromatics Complex (Benzene/Toluene/Xylene)

Модуль #300. План КазМунайГаз — Атырау Aromatics Complex (на базе Атырауского НПЗ) для extraction BTX из reformate стрима. Reference: Aramco Yanbu (Saudi) 1.5 Mt/yr, Reliance Jamnagar India 1.8 Mt/yr, CNPC Dushanzi 1.0 Mt/yr. UOP Sulfolane / Tatoray / Parex / Isomar licensed processes. Output — para-xylene 70%, benzene 25%, toluene 5% (after extraction). Para-xylene → PTA (Purified Terephthalic Acid) → PET resin для пластик. бутылок и текстиль. Atyrau target 500 000 т PX/год = ~1.2 Mt BTX feed. EU IED BAT Refining + API RP 581 + СН РК 4.04-15.

1. Состав BTX Complex 1.2 Mt/yr

Naphtha hydrotreater: H2 + NiMo catalyst @ 320 °C × 50 бар, удаляет S/N до <0.5 ppm (защита Pt reformer катализатора);
Catalytic Reformer CCR Platforming UOP: 4-reactor cascade + continuous catalyst regeneration, Pt-Sn/Al2O3 catalyst, 500 °C × 5 бар, H2 produced 80-100 Nm³/m³ feed;
Reformate fractionation: distillation column в depentanizer + extractive distillation, separates C6-C9 для BTX downstream;
UOP Sulfolane extraction: liquid-liquid extraction с sulfolane solvent (3,3-thiolane-1,1-dioxide), high-selectivity для aromatics over paraffins/naphthenes, recovery 99.5%;
Tatoray process: conversion toluene + heavy aromatics → mixed xylenes + benzene (transalkylation), zeolite catalyst @ 350-450 °C × 30 бар;
Parex (UOP) PX separation: simulated moving bed SMB chromatography с zeolite Y, output PX purity 99.7-99.9%;
Isomar isomerization: remaining ortho-xylene + meta-xylene + ethylbenzene → equilibrium mixture, recycle обратно в Parex;
Heat integration network: 50+ shell-and-tube heat exchangers, energy savings 35-40% vs standalone;
Steam system: own ТЭЦ 50 МВт + boilers для HP/MP/LP steam grid;
Storage: 12 spheres × 1000 м³ для feedstock + 8 atmospheric tanks для PX/benzene/toluene storage 30 000-50 000 т каждый;
Loading + offloading: railcar gantry для PX export к PET plant (рыночный leader China) + truck loading для domestic chemical industry;
Flare: 80-100 м elevated flare для emergency vapors + tip steam-assisted smokeless;
Wastewater treatment: sour water stripper + bio-treatment + COD removal до <100 mg/L per EU IED BAT;
Distributed Control System DCS: Honeywell Experion / Yokogawa CENTUM VP, 5000+ tags, ESD layer per IEC 61511;
Benzene exposure controls: OSHA PEL 1 ppm 8-h TWA, area monitors каждые 5-10 м, personal samplers для operators 50-100 чел.

Упражнение 1 — Process для PX 500 кт/год

Только хроматография без reformerТолько distillation column из reformateТолько cumene processIntegrated UOP BTX Complex Reformer→Sulfolane→Tatoray→Parex→Isomar: (1) naphtha 70-110 °C feed hydrotreated сера<0.5 ppm, (2) CCR Platforming Pt-Sn catalyst converts naphthenes → aromatics @ 500 °C × 5 бар, продукт reformate aromatic content 65-72%, (3) Sulfolane extractive distillation separates BTX from paraffins recovery 99.5%, (4) Tatoray transalkylation toluene→benzene+xylenes equilibrium catalyst ZSM-5, (5) Parex SMB simulated moving bed separates PX 99.7% from mixed C8 aromatics, (6) Isomar isomerizes remaining ortho/meta/EB back to equilibrium, (7) recycle loops Parex+Isomar+Tatoray для 95% PX selectivity на total BTX feed. UOP licensed since 1971 most common worldwide for >50 BTX plants. EU IED BAT Refining + API RP 581 + СН РК 4.04-15

Упражнение 2 — Feed naphtha rate

Выпуск 500 000 т PX/год. Reformate aromatic content 70%, PX selectivity на aromatics 60%. Расход naphtha (т/год)?

Упражнение 3 — Капекс BTX Complex 500 кт PX/год

CCR Platforming UOP licensed под ключ = 280 млрд
Naphtha hydrotreater + H2 plant SMR = 95 млрд
Sulfolane extraction columns + solvent inventory = 65 млрд
Tatoray + Parex SMB + Isomar = 220 млрд
Heat integration network 50+ HE + steam loop = 75 млрд
ТЭЦ 50 МВт + boilers HP/MP/LP = 85 млрд
Storage 12× 1000 м³ spheres + 8× tanks PX/B/T = 50 млрд
Flare 80 м + DCS + safety + EU IED BAT compliance + проект 4% + ПИР + СП + PNR = 80 млрд

Упражнение 4 — Benzene exposure control

Никаких мер — операторы привыклиТолько годовой осмотрComprehensive benzene exposure program per OSHA 29 CFR 1910.1028 + ECHA REACH SVHC: (1) PEL 1 ppm 8-h TWA, Action Level 0.5 ppm, STEL 5 ppm; (2) area monitors fixed Drager Polytron 8200 каждые 5-10 м + personal samplers Casella 3M 3520 для operators; (3) medical surveillance — annual benzene-specific blood (CBC complete blood count) + hematology + monthly urinary trans,trans-muconic acid biomarker; (4) PPE — supplied air respirator SAR Drager PSS 5000 (no half-face cartridge — benzene absorbed through skin); (5) closed-loop sample systems no open-air vapor; (6) leak detection LDAR EPA Method 21 portable FID каждый месяц all flange/valve; (7) cancer warning labels + restricted access + 40-hr training initial + 8-hr annual refresher; (8) IARC Group 1 carcinogen → REACH SVHC restricted + EU CMR substances; OSHA 29 CFR 1910.1028 + ECHA REACH + EU IED BAT + IARC Monograph 100F + СН РК 4.04-15Только respirator polymask

Нормативная база

EU IED BAT Reference Refining (REF BREF) 2015
API RP 581 — Risk-Based Inspection Methodology
API RP 538 — Industrial Fired Boilers
OSHA 29 CFR 1910.1028 — Benzene Standard
IARC Monograph 100F — Chemical Agents (benzene Group 1 carcinogen)
ECHA REACH Regulation 1907/2006
IEC 61511 — Safety Instrumented Systems
СН РК 4.04-15 — Цветная и нефтехимическая металлургия
OPEC Refinery Standards
UOP Process Licensors Documentation