Beedy.ca SIM

Oil Re-Refining Simulator — Demo

Vacuum distillation · 60 000 t/y
SIM TIME 00:00:00
Σ Custom build →

Module

This module is under construction for the oil re-refining trainer — it will follow the same format as the wastewater simulator (laboratory bench, Otis assistant, live trends, operator shift station).

The science behind the plant

The knowledge library for used-oil re-refining.

The working reference an operator learns from and an engineer designs from — the science, cited and derived, from feedstock chemistry to base-oil spec, wired to the plant you just ran.

Plant practiceThe live simulator — run it, break it, learn the operating envelope.
School theoryThis library — theory, derivations, data and problems to actually do the work.
Otis · operator advisor

What to do right now

—

Priority actions — fix these first

Optimization — squeeze more from a stable plant

Otis reads the live plant every tick and ranks the corrective and optimization moves, worst first. The reasoning rides along with every action so you learn the why, not just the what.  

DEHYDRATION STRIPPING FRACTIONATION TFE VACUUM RECEIVING UTILITIES TANK FARM ENVIRONMENT 100 · DEHYDRATION⛶ OPEN SCREEN 200 · GASOIL STRIPPING⛶ OPEN SCREEN 300 · FRACTIONATION⛶ OPEN SCREEN 400 · THIN-FILM EVAPORATORS⛶ OPEN SCREEN 500 · VACUUM SYSTEM⛶ OPEN SCREEN C-101 / C-102 OVERHEADS → X-101 VACUUM PACKAGE C-103 OVERHEAD → X-102 4-STAGE VACUUM PACKAGE P-501A/B F-501A/B E-101A/B MX-101 E-103 X-103 · KOH DOSINGV-109 · P-115/116 C-101 · DEHYDRATION · 5 TRAYS 140 °C400 mb P-102A/B MX-102A/B X-104 · CORR. INHIBITOR V-102 · REACTOR C-102 · GASOIL STRIPPER 270 °C70 mb ΔP 9 mb E-104 V-103 · GASOIL DRUM 18.3 t/d gasoil ↓ TK-308 P-105A/B RFX E-105 P-103A/B P-104A/B C-103 · VACUUM FRACTIONATION 10 mb top ΔP 4 mb V-107 · LVGO DRUM P-110A/B E-106 20.5 t/d LVGO ↓ TK-310/311 V-108 · VGO DRUM P-111A/B E-107 92 t/d VGO ↓ TK-301..304 M EV-101 · TFE #1 340 °C 62 A JKT 322·331·338 V-105 P-108A/B M EV-102 · TFE #2 345 °C 58 A 36" / 40" EVAPORATOR VAPOR RETURNS P-109A/B 27 t/d residue ↓ TK-306/309 X-105 BRG LUBE X-106 SEAL FLUSH H-202 · HOT-OIL FURNACE⛶ OPEN SCREEN 346 °C X-102 · 4-STAGE VACUUM (C-103) J-102→J-105 · E-109/110/111 X-101 · 2-STAGE (C-101 / C-102) J-107→E-113→J-106→E-112 J-101 VENT EJECTOR MP STEAM · FI-30/31 · 4.1 t/h V-104 · CONDENSATE DRUM V-101 · WATER/GASOLINE SEP. P-106A/B P-107 gasoline phase gasoline → TK-305 P-112A/B P-114A/B 8.6 t/d water + lights → SWS / gasoline X-102 SUCTION: 10 mb 500 · RECEIVING (CRHU)⛶ OPEN SCREEN 200 · UTILITIES 300 · PRODUCT TANK FARM⛶ OPEN SCREEN 400 · ENVIRONMENT⛶ OPEN SCREEN TRUCK UNLOADING P-1 P-2 P-3 RS-1 · 50 m³ A · MAIN FEED TANK Ø12.5 m LT/TI-500-01 · HH/LL ← slop + off-spec returns 6"-HBD-500-041 · TANK A → P-501A/B B C D E1 F1 SETTLING / RECEIVING TANKS F2 F3 F4 G1 E2 H1 H2 H3 LSH overfill/tank · Protectoseal PV vents · grounding verify STEAM PLANT⛶ OPEN SCREEN H-201 BOILER V-201 DEAERATOR P-201A/B MP 10 barg → EJECTORS/E-105 ↑ · PSV-104 @17.1 · PV-01 MPS→LPS COOLING WATER CT-201 + FA-201 FAN X-208 BASIN P-210A/B X-207 CHEM CWS → E-102/104/107/108 · E-109..113 ↑ TIC-06 · 28 °C AIR SYSTEM K-201A K-201B V-203 X-204 DRY V-209 IA priority: PALL-20 → I-09 closes PV-20 FLUSHING OIL V-206 + E-203 P-208A/B F-201 → residue lines / EV drains TK-301..304 · VGO · 4 × 1055 m³ TK-301 TK-302 TK-303 TK-304 P-301 VFD X-301 + EWP-211LOADING RAIL / TRUCK → TK-308 · GASOIL P-308 TK-305 GASOLINE · FR P-305 TK-310 / TK-311 · LVGO TK-310 TK-311 ASPHALT · ELEC HEAT 172 kW · 181 °C TK-306 · 485 m³ TK-309 · 485 m³ FA-301 VAPOUR P-306 X-303 ARM TK-307 · KOH 92 m³ P-307 → X-103 (U-100) ↑ GASOLINE (P-112) ↓ from V-101 · operator split 166–509 kg/h, total <650 SOUR WATER (V-101/V-104) ↓ C-401 · SWS E-401A/B E-402A/B P-401A/B X-401 POST-TRT TREATED WATER → SEWER EWP-219 · ZEECO T.O. PACKAGE V-401 KO H-401 T.O. QUENCH X-402 SCRUB STACK VENTS → V-401: COV · V-104 · TK V-402 DRAINS P-403 P-418 WATER TREATMENT X-403 SOFTENER MX-401 P-407A/B F-404 SAND pH control 400-AIC-93 · divert/recirc logic · → sewer PIC03TIC08FIC15FIC16FCV 03PCV 03FCV 08FCV 10FCV 11FCV 12FCV 15FCV 18PCV 15
C-103 · VACUUM FRACTIONATION
as-built internals · Sulzer/Koch-Glitsch drawing grammar · live physics
24" OVHD PSV-10 MESH PAD REFLUX BED 1 · LVGO PA RETURN BED 2 · VGO WASH BED SLOP WAX FEED · XV-06 VAPOR HORN 36" EV-102 40" EV-101 LG-55 VORTEX BRKR BOTTOMS → FIC-15 → EV-101 T.L. 54600 MIN PT09 10 mb TI10 — TI11 — TI12 — TI13 — PT11 PSHH-11 → I-08 PDI10 — TI14 — V-107 · LIC-06 —t/d V-108 · LIC-07 —t/d wash: — ΔP — LT-05 55%
LVGO/VGO overlap: — (PA steals reflux from BED 2 — heat recovery vs sharpness)
H-202 · THERMAL-OIL SYSTEM Therminol 72 · duty 2.0 Gcal/h · fired 12.1 MMBTU/h · 17 barg @ 400 °C · as-built J11031 + 2001-200-PID-1070-03/04/11
FIRED HEATER · EWP-202 CIRCULATION · INVENTORY · SEALS DISTRIBUTION · CONSUMERS AI02 TI25 — H-202 · HC2-8.0-D-HF · HELICAL COIL B-20001 · MAXON KINEDIZER LE 8" BL-25001 · M-25001 PSL25 TI12 TI14 FSL27 PSV-27001 @247 psig FUEL TRAIN · J11031 Sh.2 · raw gasoline / fuel gas ← TK-305 PI01 FE/FT PCV @2.5 psi PSL20 S vent S SSOV DBB + POC PSH20 FCV-20000FC pilot DBB train LINE LEGEND HOT SUPPLY 341 °C RETURN 315 °C FUEL GAS INSTRUMENT SIGNAL BMS BIC-20001 · purge ≥4 volumes · TFI 15 s · low-fire start · MODULATE DIKE (note 11) V-205 · EXPANSION · Ø2350 × 4690 N₂ · PCV-12 @4.05 LT07 LALL07 → I-02/I-03 TRIP V-204 · SURGE · Ø1030 P-204 make-up PSV-49 @8.5 FTR RETURN F-202 P-203A/B · 257 m³/h · 100 HP E-204/205 A & B · SEAL POTS PSH29 LSL22 leak det. / pot level → PAH·LAL 8" FTA SUPPLY PT53 PSV-95 @11.4 → FTR PIC19 PV-19 FO · spill → FTR CONSUMER BRANCHES E-103 · dehydration E-104 · stripper E-105 · reboiler E-106 · frac feed EV-101/102 JACKETS FIC-16→FCV-18 · TCV-24 LIVE · TIC-27002 BULK OUT— FILM— FIRING— FLOW— ΔT LOOP— COKE— BULK T · TREND LIMITS 380 BULK · 400 FILM BURNER LOCKOUT <500 GPM BMS TRIPS · BIC-20001 TIAH-27003/04 coil hi-T TIAH-25001 flue hi-T FSL/FSLL-27001 oil flow PSL/PSH-20001 gas P ZSC-20001/02 main POC BE-20001 flame failure PPS/PSL-25001 comb air ZSC-20004/05 pilot POC LALL-07 expansion LL PSV-27001 @247 psig RAMP 30·10·45·60 °C/h (hold 95–125 °C · water) TITLE THERMAL-OIL SYSTEM DWG № SIM-200-001 · SH 1/1 DESIGN BASIS EWP-202 · NFPA 86 · API RP 556 REV 2 · SCALE NTS
X-101 / X-102 · VACUUM SYSTEM Steam-jet ejectors 4+2 stage · design 7.5 mmHg @ 1.0 DAE · motive MP steam V16 · barometric condensing → V-104 · vents → thermal oxidizer · as-built 2001-100-PID-1070-05 Rev 4
X-102 · 4-STAGE EJECTOR TRAIN · FRACTIONATION VACUUM 3"-V16-100-703 · MOTIVE STEAM · FI-31 METER RUN FI31 ST-10 24"-BF-100-081 · C-103 OVERHEAD COLUMN TOP— mmHg J-102 · 1st STG BOOSTER J-103 · 2nd STG EJ-103 E-109 · 1st INTERCOND. TI75 PI81 X-102 PACKAGE (skid) J-104 · 3rd STG PI82 E-110 · 2nd INTERCOND. J-105 · 4th STG E-111 AFTERCOND PI83 VENT → THERMAL OXIDIZER BAROMETRIC SEAL LEGS · CPO-167/170/171 · ~10 m PROCESS CONDENSING · DEHYDRATION OVERHEAD 8"-BD · C-101 + V-102 OVHD PT14 E-102 · DEHY COND. TI72 TE33 V-101 · WATER / GASOLINE SEPARATOR LIC10 LIC11 P-112A/B · GASOLINE LSLL-24 → I-14 TRIP LCV-10 FC → TK-305 P-114A/B · WATER LSLL-25 → I-15 TRIP LCV-11 FC → SWS J-101 · VENT EJECTOR PIC15 PCV-15 FC · AIR BLEED X-101 · 2-STAGE · STRIPPER VACUUM 4"-EDG · C-102 OVHD ↓ J-107 · 1st STG PI79 E-113 J-106 · 2nd STG PI80 E-112 → TO VENT HDR V-104 · CONDENSATE DRUM · 2-COMPARTMENT LIGHT OIL CONDENSATE LSH12 LSL12 LC13 PI87 P-106A/B → SWS · LCV-13 FC LSLL-28 → I-17 TRIP P-107 · LIGHT OIL LSH/LSL-12 AUTO ST/SP LSLL-20 → I-16 TRIP LIVE · PIC-15 SUCTION— LOAD— MOTIVE— COND FLOOR— MDP MARGIN— STATE— SUCTION · TREND DESIGN 7.5 mmHg @ 1.0 DAE BREAK LATCH · CLEAR <0.92 MDP INTERLOCKS · LEVEL TRIPS I-14 LSLL-24 → P-112A/B I-15 LSLL-25 → P-114A/B I-16 LSLL-20 → P-107 I-17 LSLL-28 → P-106A/B RESET PB-100-02/03 CONTROL PIC-15 air bleed = load ctl all LCV/PCV FAIL CLOSED vents → thermal oxidizer TRAPS ST-01/02/10 on V16 LINE LEGEND PROCESS VAPOR MOTIVE STEAM CW / BAROMETRIC LEG INSTRUMENT SIGNAL TITLE VACUUM / EJECTORS DWG № SIM-100-005 · SH 1/1 DESIGN BASIS HEI EJECTOR STD · GRAHAM CURVES REV 2 · SCALE NTS
H-401 · THERMAL OXIDIZER · ENVIRONMENTAL TRAIN Waste vent gas → K.O. drum → V-seal → oxidizer @ ≥760 °C → weir quench → packed-bed caustic scrubber → stack · dual BMS · as-built 19923-CO101..106
WASTE GAS · K.O. DRUM · V-SEAL COV HDR (process vents) V-104 · TK vents SWS ovhd TK-305 vapors V-401 · K.O. DRUM · Ø600 insulated + E.T. · dead-leg drain PT52 HH → I-1 LT22 H/HH → I-1 TI24 PSV-57 → COV EJ-411 8" XV-11 FC · ZSO/ZSC · BMS J-401 · EDUCTOR V-SEAL FE-22 venturi seal · anti-flashback LP STEAM · FIC-22/FV-22 TE23 HH → I-1 H-401 · THERMAL OXIDIZER · B-401 + BMS B-401 · WINDBOX 25×16 XMR-01 HEI (BMS) H-401 · Ø2286 × 10 000 · ≥760 °C BE01 BE02 2oo2 LL → I-1 MFT TIC20 — TE21 H = I-3 PERMISSIVE · HH = I-1 FILTER · FA-401 · 18 120 m³/h · EJ-408 PIC55 FE-13 venturi FIC13A SP = calc air (FY-10+FY-11) FD-15 damper FC · PDSL-13 → I-1 60" FLUE QUENCH · V-403A / V-403B V-403A · WEIR QUENCHER Zr → FRP transition · weir + sprays XV-09 FO EMERG WATER · PSLL-59 FT17 LL → I-1 EJ-401B V-403B · QUENCH POT · Ø2438 LIC17 LSLL → I-1 LV-16 FC soft water TE22 P-405A/B · 67 m³/h · 100% STBY DILUTE ACID RECYCLE XV-13 FC acid fwd 32" · EJ-410 SCRUBBER · V-404 · STACK V-404 · PACKED BED · Ø2286 mist eliminator · spray header · EJ-406 PT49 PT50 bed ΔP → BMS H LT18 LSLL → I-1 AIC90 O₂ → AY-90 air trim AE91 CO H alarm P-406A/B · 56 m³/h · 100% STBY FT21 L → BMS AIC93 pH → KOH P-407 · XV-12 FC AE94 cond → blowdown FUEL SKID · 19923-CO101 · BMS 400-LP-BMS-01/02 GASOLINE (TP-112) PI32 XV-01 FC FE-10 CORIOLIS FIC10 FV-10 FC FUEL GAS (TP-107) FE-11 vortex PSL34 XV-02 PSH35 S XV-03 FO vent S XV-04 · DBB FV-12 · ZSL-12 PILOT PCV-36 @0.69 barg · PI-37 S S XV-05/06/07 DBB TO B-401 BURNER FY-10 + FY-11 → calc air required → FIC-13A LIVE · TIC-20 CHAMBER— OUTLET— STACK O₂— STACK CO— QUENCH OUT— SCRUB pH— CHAMBER T · TREND WASTE PERMISSIVE ≥760 °C (I-3) 2oo2 FLAME · MFT = I-1 BMS · MASTER FUEL TRIP I-1 BE-01/02 flame 2oo2 LL TT-20 chamber HH TE-23 V-seal HH PT-52 / LT-22 KO drum HH PSL-34/PSH-35 fuel gas P PSL-39 IAS low PDSL-13 comb air ΔP FT-17 quench recycle LL LSLL-17/18 pot·scrub LL SAFEGUARDS XV-09 emerg water FAIL-OPEN J-401 V-seal anti-flashback purge ≥4 vol · PSL-55 · HEI I-3 waste in only if TE-21 H panels 400-LP-BMS-01/02→DCS LINE LEGEND FLUE GAS WASTE VENT GAS FUEL WATER / DILUTE ACID LP STEAM INSTRUMENT SIGNAL TITLE THERMAL OXIDIZER DWG № SIM-400-001 · SH 1/1 DESIGN BASIS VENDOR PKG · NFPA 86 · CO101-106 REV 2 · SCALE NTS
EV-101 / EV-102 · THIN-FILM EVAPORATORS Wiped-film evaporators · top-entry rotors · hot-oil jackets FTA-674 · vapor → C-103 · residue → V-105 → asphalt storage · as-built 2001-100-PID-1070-04 Rev 6 MOC
FEED · HIH FROM C-103 BOTTOMS FE-15 venturi FIC15 FCV-15 FC 4"-HIH-100 EV-101 · FIRST EVAPORATOR M MEV-101 · XL IAHH 30" → I-08 TE-18 TE-19 TE-20 TE-21 EV-101 · 4 JACKET ZONES — 36" VAPOR → C-103 FLASH ZONE EJ-104 V-105 · RESIDUE DRUM LT30 LSLL → I-12 TE38 H → I-08 P-108A/B · RESIDUE · I-12 FCV-16 FC · Rev6 MOC bypass TIC24 TCV-24 FC · FTA tracer EV-102 · SECOND EVAPORATOR M MEV-102 · XL IAHH 30" → I-09 TE-26 TE-27 TE-28 TE-29 TE-30 EV-102 · 5 JACKET ZONES 40" VAPOR → C-103 P-109A/B · SC-01/02 · I-13 TSL31 L → I-13 FIC17 PT21 PSLL-21 pump prot ASPHALTIC RESIDUE → TK-306/309 2"-RA-100-127 · SP ← LY-09 chain HOT OIL · BUSS SMS SKIDS 8"-FTA-100-674 ← H-202 · FIC-16 → FCV-18 FIC16 X-105 · BTM BRG LUBE BUSS VD646-PID-002 VGO refill ½" (note 6) pkg → UA-02 common alarm X-106 · SEAL FLUSH BUSS VD646-PID-001 seal flush ¾"-VGO US-01 → UA-01 common alarm LIVE · TIC-24 / FIC-15 FILM T— FEED— ROTOR EV-101— VACUUM— LUBE CUT— RESIDUE— FILM T · TREND DRY-PATCH COKING > 380 °C FILM FOULING → ROTOR AMPS ↑ INTERLOCKS · DETAILS B–E I-08 EV-101 TRIP: IAHH-01 30" · TI-38 H LSHH-08 → XV-06/07/10 I-09 EV-102 TRIP: IAHH-02 30" · LSHH-09 1' I-12 P-108 STOP: LSLL-30 · TI-23 L I-13 P-109 BLOCK: TSL-31 residue cold PSLL-21 residue hdr LL PB-01..05 trip · PB-03 reset rotor amps = fouling gauge LINE LEGEND VAPOR → C-103 PROCESS OIL / RESIDUE HOT OIL FTA TITLE THIN-FILM EVAPS DWG № SIM-100-004 · SH 1/1 DESIGN BASIS WIPED-FILM PKG · 1070-04 REV 6 MOC REV 2 · SCALE NTS
H-201 · STEAM PLANT Softener → feed water drums → deaerator → NG/gasoline boiler → DS-201 conditioning → MPS 10 barg / LPS letdown · as-built 2001-200-PID-1070-01/02/10
WATER MAKEUP · SOFTENER · DRUMS X-201 · SOFTENER 6.5 m³/h EIN MX-201 + LPC LV-02 FC FI07 paces dosing V-207 · FEED WATER DRUM Ø2438 LIC02 LALL → I-01 V-208 · MPC FLASH 3.5 barg PSV-28 @3.45 · PV-09B vent PCV-04 @10 barg ← MPC LV-13 FO · LIC-13 P-202A/B · FEED WATER · I-01 CHEMICAL DOSING · paced by FI-07 X-202ANTISCALE X-203AMINE X-209SULFITE ⅜" SS → injection DEAERATOR · BOILER · DS-201 V-201 · DEAERATOR · EWP-214 PIC09 LIC04 LAHH→I-01 · LALL→I-08 P-201A/B · BFW · I-08 H-201 · STEAM BOILER · NG + RAW GASOLINE NG 503 GASOLINE 019 AI07 O₂ · AI-04 CO · AI-06 HH V-202 · BLOWDOWN TC/TV-25 temper → sewer · vent ATM AE05 ASH-05 auto blowdown DS-201 · DESUPERHEATER BFW spray · FI-11 FI06 MP make HEADERS · MPS 10 barg → LPS 3.4 barg 6"-V16 · MPS HEADER · 10 barg PSV-104 @17.1 · ≤3.6 m (Rev8) EJECTORS E-105 TRACING PIC94 PV-94 FC → SI-201 PIC01 PV-01 FC letdown LPS HEADER · 3.4 barg · TI-01 PSV-02 @6.0 DEAERATOR J-401 SEAL U.S. #1–7 S.S.-100/300/400 condensate returns: MPC → PCV-04 → V-208 · LPC → MX-201 → V-207 INTERLOCKS · PSV I-01 stop P-202: LALL-02·LAHH-04 I-08 stop P-201: LALL-04 PSV-104 17.1 · PSV-02 6.0 PSV-28 3.45 V-208 ASH-05 auto surface blowdown flue AI-04 CO · AI-07 O₂ · AI-06 dosing paced by FI-07 LIVE · PIC-94 MPS PRESS— LPS PRESS— STEAM MAKE— BFW— FIRING— FLUE O₂— STEAM MAKE · TREND LOW MPS → EJECTOR BREAK RISK PIC-94 VENTS EXCESS → SI-201 LINE LEGEND STEAM MPS/LPS WATER / BFW / CONDENSATE FUEL NG / GASOLINE TITLE STEAM PLANT DWG № SIM-200-002 · SH 1/1 DESIGN BASIS 1070-01/02/10 · ASME S1 REV 2 · SCALE NTS
UNIT 300 · PRODUCT STORAGE & LOADING VGO · LVGO · gasoil · asphaltic residue (heated, 172 kW) · gasoline/KOH · tank-car + truck loading · as-built 300-series storage P&IDs
VGO · TK-301..304 · 4 × 1055 m³ · E-301..304 HEATERS TK-301 TK-302 TK-303 TK-304 ← t/d VGO from E-107/E-108 rundown · X-301 · EWP-211 P-301 · VFD TANK-CAR LOADING · EWP-211 X-301 arm · grounding verify · LSHH overfill LVGO · TK-310/311 TK-310 TK-311 GASOIL · TK-308 · E-308 TK-308 P-308 · X-304 TRUCK LOADING GASOLINE · ALKALINE · TK-305/307 TK-305 TK-307 · KOH P-305 → fuel skids (TO · H-202 · H-201) · P-307 → X-103 KOH dosing E-307 heater · gasoline from V-101 (P-112) · operator split 166–509 kg/h ASPHALTIC RESIDUE · TK-306/309 · ELEC HEAT 172 kW TK-306 TK-309 E-306A/D · E-309A/D heater banks · FA-301 vapor fan · 178 °C P-306 → X-303 asphalt loading arm · insulated + E.T. ASPHALT TRUCK · X-303 ARM LIVE · RUNDOWN VGO MAKE— GASOIL— RESIDUE— GASOLINE— TK-301 LVL— TK-306 LVL— VGO MAKE · TREND RESIDUE TANKS HELD ≈178 °C GROUNDING VERIFY BEFORE LOAD SAFEGUARDS · LOADING LSHH overfill each tank PV vents · flame protection grounding + bonding verify I-10 (U300) → P-112 motors asphalt lines insulated+E.T. FA-301 vapor fan on residue rail: EWP-211 · X-301 arm truck: X-304 · X-303 arms slop/off-spec → TANK A (CRHU) LINE LEGEND PRODUCT RUNDOWN / LOADING TANK HEATERS (hot oil / electric) TITLE STORAGE & LOADING DWG № SIM-300-001 · SH 1/1 DESIGN BASIS API 650 · 300-SERIES P&IDs REV 2 · SCALE NTS
C-103 · VACUUM FRACTIONATION COLUMN EV vapor returns → flash zone · wash bed · VGO + LVGO packing · BED-2 pumparound · 24" overhead → X-102 · as-built 2001-100-PID-1070-03
C-103 · Ø internals per vendor drawing grammar DEMISTER BED 1 · Mellapak M170.X SK collector → LVGO draw BED 2 · Mellapak M2Y MELLACHEVRON vane BED 3 · Mellapak M170.Y WASH BED · 0 % COKED FLASH ZONE · SUMP BOTTOMS · LT-05 TI10 — norm ≈105 TI11 — norm ≈197 TI12 — norm ≈264 TI13 — norm ≈275 24"-BF-100-081 OVERHEAD — mmHg ⛶ VACUUM PIC15 FIC11 REFLUX · P-110 FCV-11·FO PDI10 PDAH → flooding 36" / 40" EV VAPOR RETURNS · FLASH ZONE ⛶ TFE TI31A TI31B — overflash wets wash bed (HIC-05 / TY-31) FEED · FROM P-103A/B · 3"-HDG-100-228 · 1070-02 FE10 FIC10 SP ← LIC-04 cascade FCV-10·FC S XV-06 ← I-08 trip 8" feed → flash zone BOTTOMS · HIH → EV FEED · FCV-15 LT09 LSHH → FIC-17 SP SIDE DRAWS · RUNDOWN V-107 · LVGO DRUM · 50% LT06 LIC06 P-110A/B · reflux + rundown LCV-06·FC → TK-310/311 — E-106 · PA COOLER PA RETURN · 55 % PA steals internal reflux below (doctrine) V-108 · VGO DRUM · 50% LT07 LIC07 P-111A/B → E-107/E-108 rundown LCV-07·FC → TK-301..304 — ⛶ STORAGE PT09 PCV-15 air bleed → J-107 E-108 reflux cooler TIC14 LVGO REFLUX · 3"-GOH-100-097 (FO) FE11 FIC12 FCV-12·FC · LVGO draw FIC13 FCV-13·FC · VGO REFLUX 1.5"-VGO-100-090 XV-08 ← I-19 PT11 PSHH-11 → I-08 trip LIVE · PIC-15 / PDI-10 TOP P— COLUMN ΔP— FLASH ZONE— REFLUX— PA DUTY— WASH BED— ΔP · TREND ΔP >8 mb = FLOOD / ENTRAIN WASH-BED COKING IRREVERSIBLE INTERLOCKS · DOCTRINE I-08 trip → XV-06/07/10 shut PDAH-100-10 ΔP H → flood FAL-100-17 lube draw low PIC-15 air bleed = vac ctl keep overflash → bed wet PA up = LVGO up, VGO cut ↓ dry bed cokes in minutes RESET I-08 reset only after gas source killed and vacuum <12 mb restored LINE LEGEND VAPOR LIQUID DRAW / RUNDOWN PUMPAROUND SIGNAL TITLE C-103 FRACTIONATION DWG № SIM-100-003 · SH 1/1 DESIGN BASIS VENDOR INTERNALS · 1070-03 REV 3 · SCALE NTS
100 · DEHYDRATION · C-101 Feed preheat E-101A/B → E-103 hot-oil heater → C-101 flash column (5 trays, 400 mb) · overhead water+lights → E-102/V-101 · KOH X-103 · as-built 1070-01
FEED PREHEAT · CONTROL NARRATIVE TANK A → P-501A/B → F-501 STRAINERS FIC15SP—PV— FCV FC E-101A/B · PREHEAT E-103 · DEHY HEATER · HOT OIL FTA TIC01SP—PV— TCV hot-oil FC C-101 · DEHYDRATION · 5 TRAYS — tray 1 OVERHEAD → E-102 → V-101 · X-101 VACUUM ⛶ VACUUM PIC03SP—PV— PCV air bleed FC P-102A/B → E-101 → C-102 FEED ⛶ STRIPPING X-103 · KOH DOSING V-109 · P-115/116 rate: 0.5–1.5 kg/t vs feed TAN MX-101 static mixer OPERATOR TARGETS TIC-01: 140 °C (95–180) PIC-03: 400 mb flash water in feed ≤ 12 % tray 1 ΔT = water gone LAB · every 4 h: BS&W bottoms < 0.5 % KOH vs TAN titration overhead → SWS quality wet feed slug → foam → carryover: cut feed FIRST, never chase with heat LIVE · TIC-01 / PIC-03 FEED— C-101 TEMP— FLASH P— WATER OVHD— WATER IN FEED— BOTTOMS LVL— C-101 T · TREND SLUG → ACC-2014-06 SAPONIFIED 14 % WATER LOAD · NEVER AGAIN LINE LEGEND FEED / BOTTOMS OVERHEAD VAPOR HOT OIL CONTROL SIGNAL TITLE DEHYDRATION DWG № SIM-100-001 · SH 1/1 DESIGN BASIS FLASH DRYING · 1070-01 REV 1 · SCALE NTS
200 · GASOIL STRIPPING · C-102 V-102 KOH reactor → C-102 vacuum stripper (70 mb) · E-105 reboiler (hot oil) · gasoil → V-103 → TK-308 · X-104 corrosion inhibitor · as-built 1070-02
REACTOR · STRIPPER · CONTROL NARRATIVE C-101 BOTTOMS + KOH (MX-102A/B) V-102 · KOH REACTOR residence + neutralization C-102 · GASOIL STRIPPER · 70 mb E-105 · REBOILER · HOT OIL TIC08SP—PV— TCV hot-oil FC 4"-EDG OVERHEAD → X-101 VACUUM PKG ⛶ VACUUM PIC05SP—PV— V-103 · GASOIL DRUM LIC06SP—PV— P-105A/B RFX · P-103/104 rundown → TK-308 · — ⛶ STORAGE X-104 · CORR. INHIBITOR ppm to overhead · filming amine BOTTOMS → E-101 X-CHG → C-103 FEED ⛶ C-103 OPERATOR TARGETS TIC-08: 270 °C (230–300) vacuum: 70 mb gasoil draw ≤ 16 t/d KOH carryover watch LAB · per shift: gasoil flash ≥ 61 °C color · TAN on bottoms chlorides after reactor high draw = lube slip → FAH-09: ease TIC-08 or deepen vacuum first LIVE · TIC-08 C-102 TEMP— VACUUM— GASOIL DRAW— ΔP STRIPPER— REBOIL DUTY— BOTTOMS LVL— C-102 T · TREND GASOIL SLIP RAISES LUBE LOSS CHASE VACUUM BEFORE HEAT LINE LEGEND PROCESS OIL GASOIL OVERHEAD VAPOR CONTROL SIGNAL TITLE GASOIL STRIPPING DWG № SIM-100-002 · SH 1/1 DESIGN BASIS VACUUM STRIPPING · 1070-02 REV 1 · SCALE NTS
500 · RECEIVING (CRHU) · USED-OIL INTAKE Truck unloading → RS-1 receiver → settling tanks → TANK A main feed Ø12.5 m → P-501 to unit 100 · sample EVERY load · as-built 1070-05x
TRUCK UNLOADING · 3 BAYS + SPARE grounding + bonding BEFORE hose NO SAMPLE = NO UNLOAD P-1/2/3 + PX · STR-strainers RS-1 · RECEIVER 50 m³ A · MAIN FEED TANK · Ø12.5 m LT01SP—PV— HH stop unload · LL stop P-501 — SETTLING / RECEIVING TANKS · B..H B · C · D · E1 · F1 (+G1, H1–H3) settle ≥ 24 h · decant free water low point → SWS P-501A/B · 6"-HBD-500-041 → UNIT 100 FEED · — ⛶ DEHY ← slop + off-spec returns to TANK A ACCEPTANCE · RE-LAB sample EVERY load: · BS&W / water % · density @15 °C · flash point screen · chlorides (Beilstein) · PCB screen if suspect reject: solvents, water >15 %, glycol, PCB high-water load → blend down via settling tanks, never straight to TANK A wet slug = C-101 foam trip (ACC-2014-06) LIVE · TANK A LEVEL— FEED OUT— WATER IN FEED— DAYS OF FEED— TANK A LVL · TREND HH STOPS UNLOADING PUMPS LL STOPS P-501 (UNIT FEED) LINE LEGEND USED OIL SIGNAL / RETURNS TITLE RECEIVING (CRHU) DWG № SIM-500-001 · SH 1/1 DESIGN BASIS INTAKE + SETTLING · 1070-05x REV 1 · SCALE NTS
LABORATORY · SHIFT BENCH university-level bench: run the quick test, then open the FULL EXPERIMENT — theory, ASTM method, live worked calculation, interpretation, quiz
SAMPLE POINTS · RUN A TEST specs per acceptance + product book · results trace to YOUR operating choices
THEORY LIBRARY → NOW IN THE ACADEMY the full theory library moved to its own home — deeper, cited, and cross-linked to these plant screens
The Academy — 13 in-depth chaptersfeedstock chemistry · separation & distillation · vacuum & thermal systems · control & safety · laboratory · re-refining routes & product
THE TRAINING STACK: this bench + scored crisis scenarios (wet load · EV fouling · vacuum break · H-202 cold start) + Otis the assistant + operator rounds — the simulator is one part of a complete operator-training product. Lab results here are honest physics: a cold stripper really does fail the gasoil flash spec, a dry wash bed really does turn the VGO black.
LIVE PHYSICS11 SYSTEM SCREENSLABORATORYCRISIS SCENARIOSOPERATOR TRAINING

OIL RE-REFINING
PLANT SIMULATOR

A complete used-oil vacuum-distillation plant — dehydration to thermal oxidizer — transcribed from as-built P&IDs and driven by real process physics. Explore every system, run the lab, break things safely. This is what Beedy builds for YOUR plant.

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