GS BEDD

Salalah Methanol Project

BASIC ENGINEERING

DESIGN DATA

(BEDD)

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BASIC ENGINEERING DESIGN DATA

CONTRACTOR JOB NO. : 7S72 PROJECT NAME : Salalah Methanol Project OWNER : Salalah Methanol Company, LLC (FZC) SITE : Salalah, Sultanate of Oman

0 15/06/07 Issued for Approval J. Y. KIM S.W.HONG M.R.LEE

REV. DATE DESCRIPTION PREP’D CHK’D APP’D OWNER


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TABLE OF CONTENTS

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1. GENERAL

1.1 COMMON INFORMATION

1.2 GENERAL SITE COMMON INFORMATION

1.3 UNITS OF MEASUREMENT

2. UTILITIES

2.1 WATER

2.1 STEAM

2.3 COMPRESSED AIR / INERT GAS

2.4 ELECTRICAL POWER

3. SITE CONDITIONS

3.1 TEMPERATURE

3.2 HUMIDITY

3.3 ATMOSPHERIC PRESSURE

3.4 PRECIPITATION

3.5 UNDERGROUND WATER LEVEL

3.6 WIND SPEED AND PREVAILING DIRECTION

3.7 SEISMIC INTENSITY

4. SITE AREA

5. CAPACITY AND PRODUCT SPECIFICATIONS

5.1 METHANOL CAPACITY

5.2 METHANOL SPECIFICATION

5.3 METHANOL LOADING RATES

6. FEEDSTOCK AND FUEL

6.1 NATURAL GAS


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6.2 SUPPLY CONDITIONS

6.3 DESIGN OPERATION CAPACITY

7. DISTILLATION

8. START-UP, IMPORT STEAM AND EXPORT STEAM

9. NOISE

Appendix 1. REFINED METHANOL SPECIFICATIONS

2. SEA WATER ANALYSIS

3. DEMINERALIZED WATER QUALITY

4. UTILITY WATER QUALITY

5. POTABLE WATER QUALITY


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1. GENERAL

1.1 COMMON INFORMATION

1.1.1 PURPOSE

This document defines the Basic Engineering Design Data (BEDD) to be used during the

basic/detail design of the Salalah Methanol Plants and relevant utility/offsite facilities that will

be built in the Salalah Free-Zone, the Sultanate of Oman. The facility includes all offsites

and utilities (OSBL) in addition to the Methanol Plant (ISBL).

1.1.2 SCOPE

1) Unless otherwise specified, this document shall be applied to all equipment, materials

and/or package facilities involved in this Salalah Methanol Plant Project.

2) This document covers location of plant site, geometrical conditions, climatic conditions,

utilities conditions and allowable limits to be applied to the design of equipment,

materials and/or package facilities involved in this Salalah Methanol Plant Project.

3) The Basic Engineering Design Data (BEDD), which is not specified in this document

and which shall be applied to the design of equipment, materials and/or package

facilities, will be defined in requisitions, drawings, data sheets and/or other documents

included in requisitions.

1.1.3 OWNER'S NAME, LOCATION AND PROJECT NAME

The full names and abbreviations are as follows: (The latter are shown in [ ].)

a) Owner's Name Salalah Methanol Co., LLC (FZC)

[ SMC ]

b) Location Salalah, The Sultanate of Oman

[ Salalah ]

c) Project Name Salalah Methanol Project

[ SMP ]

The abbreviations described above will appear on project specification and drawing title

block.

1.1.4 TYPE AND CAPACITY OF THE PLANT

Nominal 3000 MTPD Methanol Plant

1.2 GENERAL SITE COMMON INFORMATION

The site is located approximately 15 km southwest of the city of Salalah, in the southwest of

the Sultanate of Oman (Following Figure 1). The Salalah seaport premises are 200m to the

east of the site. The site is an undeveloped open area with a downward slope towards the


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northeast (Figure 2 shows the location of site). A Port Authority building delimits the plot on

the southeastern corner; rocky outcrops and hills border the plot on the southwestern side.

The site is divided in two by a wadi running east west and diverting towards the north at the

western end.

Geotechnical and Topographical Surveys have been commissioned by SMC. Refer to Part

IV of ITB.

The observed surface conditions indicate that medium to high load bearing soils are present

at shallow depths. Shallow foundations are considered appropriate for most structures.

Plant Elevation Datum High Point of Paving = EL+100,000 = MSL+8,500 mm

Marine Environment Yes

Coastal Environment Yes

Subject to dust/s and storms Yes

Site Access No special limitations to be considered

Weight and size limitation No special limitations to be considered

Site subject to Flooding No

Site subject to subsidence No; however base rock is limestone

Figure 1) Figure 2)


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1.3 UNITS OF MEASUREMENT

Measurement Unit Abbreviation

Length

Area

Volume

Volume Flow Liquid

Volume Gases at 1 atm, 0°C

Volume Flow Gas

Velocity

Weight (Mass)

Molecular Mass

Molecular Weight

Density

Mass Flow

Force

Moment of Force

Stress

Polytropic Head

Pressure

Metres

Millimetres

Centimetres

Square metres

Cubic metres

Cubic metres per hour

Cubic metres per second

Normal cubic metres

Normal cubic metres per hour

Meters per second

Kilometres per hour

Kilograms

Tonnes

Kilogram mole

Kilogram/kg mol

Kilograms per cubic decimetre

Kilograms per cubic metre

Kilograms per hour

Tonnes per hour

Tonnes per day

Newton

KiloNewton

Newton metre

KiloNewton metre

Newtons per square Millimetre

KiloJoules per kilogram

Bar

Bar absolute

Bars gauge

Millibar gauge

m

mm

cm

m2 or sq. m

m3 or cu. m

m3/h

m3/s in drainage pipes

Nm3

Nm3/h

m/s

km/h

kg

T or Te

kg mole or kmol

kg/d m3

kg/m3

kg/h

t/h or Te/h

MTPD or t/d

N

kN

Nm

kNm

N/mm2

kJ/kg

bara

barg

mbarg


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Vacuum

Energy

Power

Heat flow

Viscosity

Heat Transfer Coefficient

Temperature

Heat Capacity

Thermal Conductivity

Latent Heat

Current

Voltage

Concentrations

Noise

Revolutions

Time

Bars absolute

Millibar absolute

Millimetres water gauge

KiloJoules

MegaJoules

Kilowatt hour

Kilowatt

Megawatt

Kilowatt

Megawatt

Centipoise

Centistokes

Watts per square meter per

degree Kelvin

Degree Celsius

Kilojoules per kilogram per

degree Kelvin

Watts per metre per degree

Kelvin

Kilojoules per kilogram

Amps

Volts

Parts per million weight

Micrograms per cubic metre

Milligrams per cubic metre

Milligrams per litre

Weight percent

Mole percent

Volume percent

Parts per million volume

Decibel

Revolutions per minute

Second

Hour

Year

bara

mbara

mm H2O

kJ

MJ

kWh

kW

MW

kW

MW

cP

cSt

W/m2K

oC

kJ/kg K

W/m K

kJ/kg

A

V

ppmw

µg/m3

mg/m3

mg/l

wt %

mol %

vol %

ppm vol

dB (A)

RPM

S

h

a or yr


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Moisture

Air Humidity

Piping Nominal Size

Fouling Factor

External Diameter of Tubes

for Heat Exchanger

Surface Tension

Flange Rating

On-stream Factor

weight percent

percent relative humidity

Inches

square metre Degree Kelvin per

watt

Millimetres

dynes per centimetre

Pound

hours/year

wt % H2O

% RH

in (“)

m²K/W

mm

dyne/cm

lb or #


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2. UTILITIES

All Utilities and Services must be provided by the plant, which is to be self-sufficient in

electric power. The only raw materials available are natural gas, sea water, and atmospheric

air.

2.1 WATER

2.1.1 OPERATING & MECHANICAL DESIGN CONDITIONS

System

Temperature (oC) Pressure (barg)

Min. Nor. Max. Mech.

Design Min. Nor. Max.

Mech.

Design

Sea water supply

(Note 1) - 28 - 50 - 5 10

Sea water return - 38 - 50 - 5 10

Utility water

(Note 2) - 41 - 80 - 4.5 10

Potable water

(Note 3) - 20 - 41 - 4.5 10

Cooling water

supply - 35 - 70 - 5 10

Cooling water

return 45 70 5 10

Note 1. Seawater is taken from the Arabian Sea adjacent to the plant site. The design

intake temperature is 28°C. The salinity of the Arabian Sea is approximately 9% higher than

standard seawater and has been measured at 37.5 ppt; pH is reported at 8.58, with

dissolved oxygen ranging from 5 to 6.7 mg/l depending on depth of intake.

(Refer to Appendix 2)

Note 2. Refer to Appendix 4.

Note 3. Potable water is Chilled to 20 ℃ (Refer to Appendix 5)


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2.1 STEAM


System




Mech.

Design

HP steam - 520 530 560 - 104 105 110.4

MP steam - 340 342 390 - 26 26.9 35.5 &

F.V

LP steam 180 192 210 315 4 4 4 7.8 &

F.V

2.3 COMPRESSED AIR / INERT GAS


System




Mech.

Design

Instrument air - 40 - 60 - 7 - 10.5

Plant air - 40 - 60 - 8 - 10.5

Nitrogen - 40 - 60 - 7 - 10.5

2.4 ELECTRICAL POWER

Electrical Power is distributed by 11 kV and 50 Hz. Motors greater than 150 kW are

supplied at 3.3kV, 50 Hz, and motors less than 150 kW by 400V, 50 Hz. Small power is

available with 230V and 50 Hz.

Motor < 150 kW: 400 V & 50 Hz

Motor > 150 kW: 3.3 kV & 50 Hz

Small Power: 230 V & 50 Hz


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3. SITE CONDITIONS

Local conditions are severe; the climate is characterised mainly by extreme heat and

humidity. The area is also subject to prolonged mist and precipitation during the monsoon

season from June to September. SMC has commissioned a report on Environmental and

Meteorological Data from PARSONS E&C (Part IV of ITB, Supporting Document Section

Report No. PAR4247/RPT/101 REV.A)

3.1 TEMPERATURE

Maximum Temperature reported (Jun 1994) 44.7oC

Minimum Temperature reported (Feb 1983) 10.8oC

Monthly Mean Temperature 26.3oC

Temperature for Material Balance 27oC

Maximum daily mean Wet Bulb Temperature (1998) 28.5oC

Minimum daily mean Wet Bulb Temperature (1998) 9.7oC

Mean Wet Bulb Temperature (1998) 23oC

Design Dry Bulb Temperature for Air Cooled Heat Exchangers 43oC

Design Temperature for Air Compressor 45oC

3.2 HUMIDITY

Maximum RH (1983-2003) 100%

Minimum reported RH (1983-2003) 1%

Monthly Mean RH (1980-2003) 67.5%

Average Relative Humidity for Material Balance 85% @ 27oC

Relative Humidity (for Air Compressors & Fans) 100% @ 45oC

3.3 ATMOSPHERIC PRESSURE

Average for Material Balance 98.3 kPa

Nominal Atmospheric Pressure (for Air Compressor) 98 kPa

Design Maximum Note 1 kPa

Design Minimum Note 1 kPa

Note 1. SMC to be fill up

3.4 PRECIPITATION

Mean annual rainfall (1943 – 2003) 110 mm

Maximum annual rainfall (1964) 510 mm

Minimum annual rainfall (1974) 21.2 mm

Run Off Rates Refer to Document 60-8579-02/C.02a/0001

Civil, Structural, and Architectural Specification, Section 9


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3.5 UNDERGROUND WATER LEVEL Up to 0.6m above Mean Sea Level (MSL)

(Ground Level is 4.5 to 14.5 m above MSL)

3.6 WIND SPEED AND PREVAILING DIRECTION

Prevailing Direction: from South West to South East (see table below)

Direction W NW N NE E SE S SW

Degrees 247.5- 292.5- 337.5- 22.5- 67.5- 112.5- 157.5- 202.5-

292.5 337.5 22.5 67.5 112.5 157.5 202.5 247.5 Frequency 0% 2.8% 17.5% 2.4% 0% 7.9% 45.2% 24.2%

Mean Wind Speed : 3.0 m/s

Maximum Wind : 33 m/s

Wind Loading for Design : 56 m/s

3.7 SEISMIC INTENSITY

Oman is classified by Uniform Building Code 97 as Seismic Zone 2A. The

Geotechnical survey indicates a soil profile of SA.

4. SITE AREA

All equipment is located within the Salalah Methanol Plant fence, with the exception of the

sea water intake system (located on the adjacent coastline), sea water discharge point

(located in the wadi to the NE of the site) and methanol loading facilities (located at Salalah

Port Berth 31).

The sea water inlet line, the sea water discharge line, the methanol product line, and

services for the jetty area, cross the fence to their respective locations.


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5. CAPACITY AND PRODUCT SPECIFICATIONS

5.1 METHANOL CAPACITY

A nominal 3000 tonnes/d of methanol to the specification in 5.2

5.2 METHANOL SPECIFICATION

The product methanol will meet the requirements of IMPCA 99 and US Federal Grade

AA (US Federal Specification O_M_232K Methanol (Methyl Alcohol) 6810 GS, dated 14

October 1998). Details of these specifications are given in Appendix 1.

In addition, the product methanol will have the following specifications:

Permanganate Fading Time 60 minutes, minimum

Total Alkalinity (ASTM D1614-03) 1 ppm wt as ammonia, maximum

5.3 METHANOL LOADING RATES

The nominal ship loading rate is 3000 t/h. Loading facilities are to be sufficiently flexible

to load ships of capacities ranging from 10000 – 50000 DWT

6. FEEDSTOCK AND FUEL

6.1 NATURAL GAS

The natural gas available at the plant will have a composition in the range given in the

table below. An upstream treatment unit will normally remove the heavy components, but

in the event that this is not in operation, the rich gas feed will be supplied.

Component Rich Gas

Mol % dry Extreme Lean Gas

Mol % Dry Guarantee Gas

Mol % Dry Methane 82 to 88.3 95 max 95.0 Ethane 4.5 to 7.5 0.32 max 0.32 Propane 1.7 to 3.0 - - Butanes 1.1 to 1.85 - - Pentanes 0.35 min - - Pentanes + 0.76 max - - BTX 0.1 max - - He 0.05 max - - Nitrogen 5.0 max 7.5 max 4.68 Carbon Dioxide 1.2 max 3.5 max 0.0 A 75 ppm vol max 75 ppm vol max 75 ppm vol max O2 25 ppm vol max 25 ppm vol max 25 ppm vol max H2S 5 ppm vol max 5 ppm vol max 5 ppm vol max Mercaptan Sulphur 5 ppm vol max 5 ppm vol max 5 ppm vol max Total Sulphur 5 ppm vol max 5 ppm vol max 5 ppm vol max Mercury Note 2 Note 2 Note 2 GHV (Btu/SCF)1 1040 to 1110 946 min 951

Note 1 1 MJ = 947.817 Btu

1 Sm3 = 35.383 SCF


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Water Content = 95 mg/std m³ October through April

160 mg/std m³ May through September

Note 2 Mercury contents to be conformed by SMC. (Refer to 38G and 126G of the

qualifications and clarifications on FEED)

6.2 SUPPLY CONDITIONS

Supply Conditions Minimum Maximum

Supply Pressure, barg, (Downstream of

Gas Company Metering Skid) 32 32

Supply Temperature, oC 5°C above

Hydrocarbon Dew Point

45

Design pressure, barg - 43

Design Temp, oC

- 82

6.3 DESIGN OPERATION CAPACITY

The plant must make the full guaranteed capacity of 3125 tpd of methanol and product

specifications at any composition within the above natural gas composition range during the

Performance Test and must be designed to operate safely under these conditions.

7. DISTILLATION

The design margin for the distillation unit will be 15% total margin on whole unit above

flowsheet conditions including the steam reboiler.

8. START-UP, IMPORT STEAM AND EXPORT STEAM

There are NO external facilities available. All steam is to be produced by the methanol plant

and its offsites.

9. NOISE

The maximum sound pressure level of any equipment shall not exceed 85 dBA in semi-

reverberant acoustic environment. Generally, the sound pressure level requirement must be

met at 1 m from the surface of any equipment. For air cooled exchangers, this requirement

must be met at ear level on the nearest walkway or maintenance platform.

The following specifications for Noise shall be followed:

7S72-EVS-00-001 Plant Noise Control

60-8579-02/N02a/0003 Equipment Noise Control


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APPENDIX 1 REFINED METHANOL SPECIFICATIONS

Federal Specification O-M-232K Methanol (Methyl Alcohol) 6810 GS 14-Oct-1998 and IMPCA 1999

Characteristic Federal Grade AA

IMPCA 1999

Method note1

Acetone (%w/w) Carbonylic compounds Note 3

0.002note2 Max 30

mg/kg note2

ASTM E 346-94note2

Acidity (% w/w as acetic acid) 0.003 Max 30 mg/kg

ASTM E 346-94note4

ASTM D 1613-96

Appearance

Free of opalescence,

suspended matter and sediment

Clear and free of suspended

matter

Visual

IMPCA 03-98

Carbonisable impurities colour, Pt-Co scale, maximum

No.30 ASTM E 346-94

Colour, Pt-Co scale, maximum No.5 ASTM D 1209-93

Distillation range at 760 mm Hg Range 1ºC, and shall include the

temp of 64.6ºC ± 0.1º

ASTM E 346-94

ASTM D 1078-97

Ethanol (% w/w) 0.001 50mg/kg ASTM E 346-94 or

IMPCA 001-98

Non-volatile matter 10 mg/100 ml Max

8 mg/kg ASTM D 1353-96

Odour Characteristic with no

residual ASTM D 1296-93

Permanganate time no discharge of colour in (mins)

60 ASTM D 1363-94

Specific gravity at 20ºC/20ºC 0.791 to 0.793 ASTM E 346-94 ASTM

D 891-95

Water (% w/w) 0.1 Max 0.1 ASTM E 346-94 ASTM

E 1064-92

Purity (% w/w) - Min 99.85 IMPCA 001-98

Chloride (ppm w/w) - Max 0.5 IMPCA 002-98

Sulphur (ppm w/w) - Max 0.5 ASTM D 3961-89

Hydrocarbons - pass test ASTM D 1722-90

Total iron (ppm w/w) - Max

0.1mg/kg ASTM E 394-94


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Notes

Note1. The figures after the hyphen in the ASTM standard number are the year of last

revision/update. Always check the current issue for the last update.

Note 2. This is a miscibility test with water, for AA grade use 1.5ml of sample and 3.5ml of water.

Note 3 Strictly in the IMPCA spec this is ‘carbonilic (or carbonyl) compounds’ Test ASTM E 346-94.

This uses Nessler's reagent, which is made using 13.6 g of mercuric chloride in 500ml of

water. Mercuric compounds have been banned or phased out in many countries and

laboratory methods because of environmental pollution restrictions.

A different wet chemistry method is available which is published as British Standard BS 506

part 2 1984 this is also ISO 506 revalidated 1992.

The method relies on the production of a red colour in alkaline conditions with 2.4 –

dinitrophenylhydrazine, which is measured spectrophotometrically at 445nm. The carbonyl

compounds are reported as formaldehyde within a range of 0.0002 to 0.01%w/w in the

methanol.

The theoretical equivalent to the 0.003 weight %(30 mg/kg) carbonyl compounds as acetone

of the pass/fail in ASTM D 1612 and ASTM E346 would be BS 507 result multiplied by a

factor MW acetone / MW formaldehyde 58.08/30.03.= 1.934 or pass fail at .00 155 weight %

formaldehyde.

However different individual carbonyl compounds will respond differently to the different

reagents and one test cannot be said to be exactly the same as the other. This BS test is

used by Johnson Matthey labs.

In view of the environmental constraints upon mercuric chloride reagent used in this test, it is

likely that the test method will be changed by IMPCA to an equivalent of the BS 507 test.

Note 4 The expected TMA content measured by ASTM Method E346-99 with the Extreme Lean Gas

feed is approximately 10 ppb.


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APPENDIX 2 SEA WATER ANALYSIS

WATER ANALYSIS SHEET

Submitted by: SMC Address Co.

FOR OFFICE USE ONLY: Location Water Co.

Submitted by: SMC Address Co

for office use only:

location water co.

No. mean max min design design

Note 1 ** ANALYSIS Date:

pH Value 8.3 to 8.5

Suspended Solids mg/l

Electrical Conductivity µS/cm @ 20°C 56446

Total Dissolved Solids as mg/l 37520

Temperature of Supply °C 28 16

Note 3 Alkalinity to pp as mg/l CO3 3.3

Alkalinity to m.o. as mg/l HCO3 191

Sulphate as mg/lSO4 2894

Chloride as mg/l C1 22524

Nitrate as mg/l NO3

Silica as received molybdate reactive. as mg/l SiO2

Phosphate as mg/l PO4

Fluoride as mg/l F

Sulphite as mg/l SO3

Total Anions (excluding silica) as mg/l CaCO3

Total Hardness as mg/l CaCO3

Calcium as mg/l Ca 2894

Magnesium as mg/l Mg 1442

*Sodium as mg/l Na 12785

*Potassium as mg/l K 359

Iron as mg/l Fe

Manganese as mg/l Mn

Free and Saline Ammonia as mg/l NH3

Total Cations as mg/l CaCO3

Free Dissolved CO2 as mg/l CO2

Dissolved O2 as mg/l O 6

Colour Hazen Units

Note 4 +Turbidity Formazin Units FTU APHA

Lead as mg/l Pb

Copper as mg/l Cu

Residual Chlorine as mg/l CI2 0.2 to 1.0


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WATER ANALYSIS SHEET

Submitted by: SMC Address Co.

FOR OFFICE USE ONLY:

Location Water Co.

Submitted by: SMC Address Co

for office use only:

location water co.

* *

Note 1 ANALYSIS

Sample No.

mean

Date 2000

Albuminoid Ammonia as mg/l NH3

Nitrous Nitrogen as mg/l N

Nitric Nitrogen as mg/l N

Note 3 Oxygen absorbed from Acidic N//80 KMn04 4hours @ 20°C as mg/l 0 <0.25

C.O.D. (Dichromate Value N/10) as mg/l 0

Total Organic Carbon as mg/l C 0.86

Oil (including grease and fats) as mg/l

Residue after heating to 500°C as mg/l

Note 4 B.O.D5 Nitrification Suppressed as mg/l

Anionic Synthetic Detergents as mg/l

Non-Ionic Detergents as mg/l

Cationic Detergents as mg/l

Silt Density Index

Notes: 1. ** - tick if item definitely to be included in analysis 2. State if units other than milligrams per litre, or if different conditions of test, are used 3. These are UK test conditions for water sample. Other European countries use

different test conditions (eg N/80 30 min @100°C). Effluents may be analysed by N/80 3 min @ 27°C or N/8 4 h. @ 27°C. Results from these different conditions are NOT interchangeable - conditions MUST be stated.. The test is sometimes called the PV or permanganate value, also results may be given as mg/l KMn04. Please specify accurately. A test reported as organic matter must state best method.

4. By addition of 0.5 mg allylthiourea per 1l of sample


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APPENDIX 3 DEMINERALIZED WATER QUALITY

1) Silica max.0.02 mg/kg 2) Na plus K max.0.01 mg/kg 3) Fe +Cu +Ni max.0.02 mg/kg 4) Electrical conductivity limit max.0.2 microsiemens/cm @25 deg C 5) Total Hardness detectable (below 0.05mg/l CaCO3 by micro titration test) 6) Particulate iron 0.1 mg/l SS max


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APPENDIX 4 UTILITY WATER QUALITY

No. Description Unit Condition

Minimum Maximum

1 Sodium as Na mg/ℓ - 30

2 Calcium as Ca mg/ℓ 13 40

3 Chloride as Cl mg/ℓ - 40

4 Bicarbonate as

HCO3 mg/ℓ 20 40

5 Langelier Index - +0.2 +0.4


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APPENDIX 5 POTABLE WATER QUALITY

No. Description Unit Condition

Minimum Maximum

1 Sodium as Na mg/ℓ - 30

2 Calcium as Ca mg/ℓ 13 40

3 Chloride as Cl mg/ℓ - 40

4 Bicarbonate as

HCO3 mg/ℓ 20 40

5 Langelier Index - +0.2 +0.4

6 Total Coliform most probable number per 100㎖ nil

7 E.Coli colony forming units per 100㎖ nil

SAMPLE

SAMPLE

GS BEDD

Documents

wet bulb temperature

cubic metre

package facilities

fuel natural

salalah methanol

natural gas

product methanol

carbonyl compounds