Sez - Iii.project Description-Rev IFC

LAB project Environmental Impact Assessment March 2002
Section 3: Project description 1 of 42
SECTION 3
PROJECT DESCRIPTION
Section Summary
3.1 SITE LOCATION 4
3.2 PLANT DESCRIPTION 5
3.2.1 PLANT HISTORY 5

3.2.2 PROCESS DESCRIPTION 6
3.2.2.1 Paraffin Conversion to Olefin (PACOL) 7
3.2.2.2 Linear Detergent Alkylate Process (LAB) 9
3.2.2.3 Treatment of Gases 10
3.2.2.4 Treatment of Liquids 12
3.2.2.5 Treatment of Wastes 13
3.2.3 PLANT UNITS DESCRIPTION 13

3.2.3.1 Process Units Installed in the Process Area 14
3.2.3.2 Facilities installed outside the Process Area 15
3.3.3 MATERIALS, SUBSTANCES AND RESOURCES INPUT / OUTPUT 19
3.3.3.1 Raw materials and resources input 19
3.3.3.2 Products output 21
3.3.4 Emissions to the environment and resources use 22
3.3.4.1 Emissions 22
3.3.4.1 Resources use 27
3.4 YARD PHASE 29
3.5 PROJECT RELIABILITY AND SAFETY SYSTEMS 30
3.6 SAFETY CRITERIA AND SAFETY MEASURES ADOPTED

IN ORDER TO PREVENT INCIDENTS 34
3.7 PLANT MAINTENANCE AND AVAILABILITY 37
3.8 ADVERSE IMPACTS PREVENTION AND MITIGATION AND

MEASURES 38
3.9 EXAMINED ALTERNATIVES 39
3.10 ENVIRONMENTAL INTERFERENCE PARAMETERS

SYNTHESIS 41
ANNEXES TO SECTION 3
III.1 Block diagrams
III.2 General lay-out
III.3 Material Safety Data Sheets
III.4 General lay-out with air emission sources localization
III.5 General lay-out with waste water sewerage
III.6 HAZOP Analysis Report

3.1 Site location
LAB site is located in South-West part of Syria, about 25 km south of Damascus (see
figures 4.1, 4.3), not very far from political borders with Lebanon (about 50 km North-
West), Israel (about 70 km West), Jordan (about 80-90 km South). It has a coastline of
about 183 km in length.
LAB site is located in the Province of Damascus Countryside, in the territory

pertaining to the Municipality of Deir Ali village, which is also the principal inhabited
centre near the site. The area is a plain upland one, about 700m above sea level, with
rocky desert features.
An important road, the highway connecting Damascus to Daraa (near Jordan border)
is present at a minimum distance of about 400 m from LAB site.
For more detail about territorial context and environmental component status refer to
sec.4.
3.2 Plant description
3.2.1 Plant history
The Proponent has purchased an existing LAB plant in Yambol City (Bulgaria) in order
to have it dismantled, reconditioned and re-assembled in Syria. The Plant, described
more in detail in the following, includes the process units and the relevant facilities.
The Plants process units basic design and license were provided by UOP, while the
detailed engineering was originally made in Bulgaria where the previous LAB project
was done. The main equipment, machinery, instrumentation, accessories were
originally manufactured / sourced in Bulgaria and Western Europe.
The Bulgaria plant construction started in 1984 but was never brought to completion,
as works were stopped in 1991 and the plant was therefore never put into operation.
During the dismantling activities, performed between 2000 and 2001, an UOP survey
has been carried out to assess the general conditions of the Bulgarian Plants
equipment (mainly vessel, columns and heat exchangers).
The original Bulgarian Plants engineering documentation, was completely re-ordered,

checked and classified.
All available process area, basic & detail engineering documentation, equipment
drawings, have been collected to the Site from Ballestra offices, properly packed and
marked by Ballestra.
Ballestra has provided the Basic design engineering documents for off sites units
(tank farm and utilities units), which includes the following documents: P&I drawings,
equipment specifications, instrument specifications, lay out.
The detail engineering documents for off sites units (utilities and tank farm units) have
been provided by two third Companies. INCO, a Turkish engineering company,
provided piping and structures detailed documents, while ELTECH, an Italian one,
provided all the electric and instruments specifications and diagrams. The construction
drawings of the new equipment has been provided directly by the relevant
constructors.
During the re-erection works Ballestra is supervising all the activities: a dedicated
Ballestra Site Manager is continuously present at Site in order to give instructions
when necessary, to assist and to report to the Project Manager, issue the project
status reports and to collect all information to all parties in this project.
3.2.2 Process description
The HF Detergent Alkylation Process is a catalytic process to alkylate benzene with

linear olefins to form linear alkylbenzene. The linear alkylbenzenes produced from the
C10-C13 linear olefins are useful detergent intermediates and can be readily sulfonated
to yield linear alkylbenzene sulfonates. These compounds constitute the active
ingredients of many household detergents.
The process is based on two main reactions:
paraffin dehydrogenation and conversion to olefins (PACOL)
benzene alkylation with linear olefins, in order to obtain Linear Alkyl Benzene
(LAB).
The principal raw materials are paraffins and benzene, the principal product is Linear
Alkyl Benzene. By-products are light gases (hydrogen, light hydrocarbons), alkylate
polymers and heavy alkylates.
Catalysts are used in both reactions: Palladium on Alumina pellets in Pacol unit and
Hydrofluoric Acid in the Alkylation unit.
The following flow diagram (Fig.3.1, see also Annex III.1) shows main process blocks:
- Paraffin pre-treatment (Oxygen stripping unit)
- Paraffin conversion to olefins (PACOL unit)
- Benzene alkylation with linear olefins (HF alkylation unit)
- Raw materials, products and by-products storage (Tank farm)
In order to provide heat for reagents (to reach reaction temperature) and for vapor
production in the distillation columns, a Hot oil unit and a specific charge heater in
Pacol unit are present. Fuel oil is the main fuel, but also a low quantity of process by
products from PACOL unit (light ends) and from Lab unit (heavy polymers) are burnt.
In the following sections process and plant units are described in more detail.
.
LAB project -- Environmental Impact Assessment March 2002
AHMAD DAABOUL & SONS Co.
FOR DETERGENTS Section 3: Project description Figure
4175
Oxygen
n-paraffins C10 - C13 stripper unit
175 4175
n-Paraffins
Light-end from PACOL Light ends
50
31325
Paraffin dehydrogenation
Recycle n-paraffins
Pacol unit
Hydrogen
Raw material n-paraffins +
n-olefins 125
& products storage 1675
Tank Farm 35150

Benzene
75
Olefins alkylation
HF alkylation unit Alkyl. Polymers
LAB 5000
Heavy alkylates 425
Hot oil unit
= Flowrate (kg/h)
Fig. 3.1: Global Block Diagram

P:\\01509i\figure\progettuale.cdr
Ballestra
3.2.2.1 Paraffin Conversion to Olefin (PACOL)
Introduction
The UOP Pacol Process (paraffin conversion to olefins) is very similar in flow scheme
and process equipment to many other hydrogen recycle reaction systems which utilize
a fixed catalyst bed (like platforming). In the next figure PACOL flow diagram is shown.
Feed Section
The feed to the Pacol process unit consists of both fresh and recycle paraffin streams.
The recycle paraffin stream comes from the top of the paraffin column of the UOP
Detergent Alkylation process unit (see point A in the Fig.3.2).
The recycle paraffin stream and the fresh paraffin stream are first sent upflow through
two alumina treaters operated in series (B). The purpose of the alumina treaters is to
remove combined fluorides from the recycle paraffin stream coming from the detergent
alkylation unit. Fluorides are a poison to the Pacol catalyst. The alumina treaters are
two carbon steel vessels, which contain activated alumina resting on crushed
limestone support material.
The mixed liquid feed, after the treaters, is sent to the combined feed/effluent
exchanger (C).
Reactor Section
The liquid feed is mixed with recycle hydrogen gas from the recycle gas compressor
after entering the combined feed exchanger. The combined feed is preheated in this
exchanger by exchanging heat with the reactor effluent.
The reactor effluent passes through the exchanger where it is cooled as the combined
feed is preheated. The combined feed is heated to reaction temperature by the charge
heater (D). The Pacol charge heater is designed to operate on either fuel gas and/or
fuel oil. From the charge heater the hot combined feed is sent directly to the Pacol
reactor (E) where the following reaction takes place.
H H H H
R1 C C R1 R1 C C R1
H H
Paraffins from oxygen stripper
Alumina treater
4175
A B
Paraffin purification
31325
35500
Paraffins from alkylation
5217
Paraffin & Hydrogen
C
Heat recovery
40717
Hydrogen
H
Feed fired heater D Compressor
40717
Dehydrogenation E
reactor
40717
40717
5217
F
Paraffin - Olefins
condensation 125
Hydrogen to furnace
35375 50
Light hydrocarbon
stripper
G Light gas to furnace
Light liquid to storage
175
35150
Parffin & oleofin to alkylation
= Flowrate (kg/h)
Fig. 3.2: PACOL Unit Block Diagram
Ballestra
The reactor product flows back to the combined feed exchanger. The Pacol unit is
operated with only one reactor in service at a time, but has two reactor vessels. While
one reactor remains in operation, the other reactor with deactivated catalyst is
unloaded and reloaded with fresh catalyst.
The reactor section also contains a second heater which is provided so that one of the
reactors loaded with fresh catalyst (Pd on alumina pellets) can be heated while the
other reactor is still producing olefins. The heater is a simple all-radiant type with
combination gas and fuel oil burners.
Separator Section
After passing through the combined feed exchanger (C), the reactor product is sent to
the reactor products condenser (F). This condenser is used to condense the vaporized
product stream, which is then separated in the product separator. The purpose of the
product separator is to provide means for the cooled reactor effluent to separate into
the liquid product and the hydrogen-rich recycle gas. If there is an excess of pressure,
it will open the control valve to flare.
The liquid from the product separator is sent to the Pacol stripper (G).
Recycle gas is taken directly off the top of the product separator to the recycle gas
coalescer and then to the suction of the recycle gas compressor (H). Much of the
entrained liquid and condensation mist that could end up in the recycle gas is
designed to be removed by the recycle gas coalescer. The coalescer consists of three
separate compartments and two liquid boots to collect the liquid. The recycle hydrogen
is sent to the inlet of the combined feed/effluent exchanger (C).
Fractionation Section
The stripper column (G) is necessary to remove all of the light ends formed by
cracking reactions in the reactor. Stripper overhead vapors are cooled in the stripper
overhead condenser and separated into a gas and liquid phase in the stripper
receiver. Stripper off-gas is sent to fuel gas or to the flare if the pressure is high.
The column bottoms, paraffins and olefins, are pumped to the detergent alkylation unit
(next unit). As much heat as possible is normally recovered from the bottoms stream
by passing it through a heat exchanger where the recycle paraffin stream is heated on
its way to the paraffin alumina treaters.
3.2.2.2 Linear Detergent Alkylate Process (LAB)
Reactor System
The HF Detergent Alkylation Process is a catalytic process to alkylate benzene with

linear olefins in the presence of an HF acid catalyst, to form linear alkylbenzene
According to the following block diagram (Fig.3.3), the reaction is carried out in a two
stage mixer-settler system (H). The reagents are first mixed and then cooled. The
liquid proceeds upflow in the first stage alkylation mixer and the outlet is sent to the
first stage settler where the acid and hydrocarbon phases separate.
The hydrocarbon phase from the first stage settler enters the second stage alkylation
mixer and the hydrocarbon effluent from the second stage settler goes to the HF
stripper (I). The acid phase is pumped back to the mixer stages.
HF Regenerator
The main purpose of the HF regenerator (L) is to remove the heavy unsaturated
material (alkylate polymers) contained in the hydrofluoric acid. After separation from
the HF and neutralization (M), the polymers go to the fuel oil circuit where they are
mixed with the fuel oil that is burnt in the two heaters, Pacol Charge and Hot oil heater.
HF Stripper
The hydrocarbon phase from the second stage settler (H) is fed onto the top tray of
the HF stripper (I) where the HF dissolved in the hydrocarbon phase is stripped out.
The bottoms liquid leaving the column is virtually free of HF. It does contain organic
fluorides, however, which may decompose and form HF again when exposed to high
temperatures. The HF stripper is heated by means of a hot oil reboiler. If the HF
stripper is ever allowed to cool down because of an emergency, acid that goes to the
bottom of the column can be recirculated to the reboiler so that acid going forward to
the benzene column is minimized.
Benzene from storage 1675
Benzene dryer Q
Paraffins +
olefin from PACOL 35150
15700
50850
3600
HF alkylation: 1st stage
H Liquid HF
47250
HF alkylation: 2nd stage

H
3525
Benzene recycle 50775
L
HF stripper column I HF regeneration
7570
75
43205
6455
Benzene distillation N HF neutralization M
Benzene recycle
36750 75
A 32325
Paraffin distillation O
Recycled paraffins to PACOL Heavy polym. to furnace
LAB + Heavy alkylates 5425
5000
LAB distillation P
LAB to storage
425
Heavy alkylated
to storage
= Flowrate (kg/h)
Fig. 3.3: HF Alkylation Unit Block Diagram
Ballestra
Benzene Column
The HF stripper bottoms are fed to the benzene column (N) where benzene is
separated from the heavier hydrocarbons and recycled to the hydrocarbon feed cooler
inlet. The benzene drag stream leaving the unit from the overhead of the benzene
column is treated with solid KOH in the benzene KOH treater for removal of traces of
free acid that may have been carried through from the HF stripper.
Paraffin Column
The bottoms from the benzene column go to the paraffin column (O). The net n-
paraffins from the overhead accumulator go to the Pacol feed surge drum being
alumina treated in route to remove the combined fluorides.
The bottoms of the paraffin column is pumped to the rerun column.
Alkylate Rerun Column
The final split between detergent range alkylate and heavy alkylate is performed under
vacuum in the alkylate rerun column (P).
The LAB product normally goes to one of the product day tanks. Typically of the feed
to the column 5-10% is taken off as bottoms (heavy alkylate).
Benzene Stripper
The high volatility of water dissolved in hydrocarbons is used in this column (Q) to
obtain water-free benzene in the column bottoms which also removes any dissolved
oxygen or noncondensibles in the benzene or off spec feeds.
3.2.2.3 Treatment of Gases
Non-Acidic Gases
The non-acidic hydrocarbon gases from process vents and relief valves discharge will
be sent to the flare, while all acid vents and relief valves are piped to a separate acid
relief system (see Fig.3.4).
Acid Relief System
Acid relief and vent gases first flow to a liquid knockout drum while the acid
contaminated drain liquid goes to the liquid recovery drum to remove all liquid
possible. The liquid from the knockout drum is educted using the neutralization
NON ACID ACID ACID

GASES GASES DRAIN
Liquid Gases Liquid

Knock-out drum recovery drum
Liquid
Neutralized gases Relief gas
scrubber
Hydro-carbons CAF2 sludge
API Neutralizing Alkylation

Flare separator pits reactor
Fig. 3.4: Gas Treatment Block Diagram

Ballestra
eductor to the relief gas scrubber hydrocarbon skimming and neutralization section.
Normally, liquid from the pressurized liquid recovery drum is recovered to the reactor
section via the fresh acid pump while the liquid from the liquid knockout drum is sent to
the relief gas scrubber since in the latter case contamination by KOH is considered
possible. The acidic gases from the liquid recovery drum go to the liquid knockout
drum and the acid gases from the liquid knockout drum then pass to the scrubbing
section of the relief gas scrubber (RGS) where they are neutralized by countercurrent
contact with a solution of KOH. The neutralized gases from the overhead of the relief
gas scrubber go to the non-acid relief header and on to the flare. Hydrocarbons
entering the relief gas scrubber overflow the baffle on the hydrocarbon end and
accumulate as indicated by a level instrument and high level alarm. Occasionally it
may be necessary to pump hydrocarbon out of the RGS for which the KOH transfer
pumps are used with the discharge sending the hydrocarbon to the oily water
separator.
The neutralization of HF in the RGS works by the following acid-base reaction:
HF + KOH =============> KF + H2O
The KOH solution is continuously circulated by the KOH circulating pump to the top of
the scrubber. The KOH circulation pumps are set up with the down pump connected to
an uninterruptable power supply with an auto start system such that in the case of low
flow of circulating KOH the spare pump automatically starts to assure continuous
neutralization circulation. The KOH solution is normally maintained between 7 and 10
wt-% KOH and between 0 and 3% KF.
In order to maintain the circulating KOH percent KOH high and percent KF low, a
regeneration system is necessary for the circulating KOH.
The KOH regeneration takes place by the following reaction:
2KF + Ca(OH)2 =========> 2KOH + CaF2
The insoluble calcium fluoride is transferred into one of the neutralizing pits.
Obnoxious Fumes and Odors
The only process area from which potentially fumes could originate would be the unit's
neutralizing basins (see 3.2.2.4). To prevent the discharge of these gases to the
surroundings, the neutralizing basins are tightly covered and equipped with small vent
scrubbers, one for each of the two basins.
3.2.2.4 Treatment of Liquids
Process Waste Water Effluent Sewers
Plant areas (process area, tank farm, utilities excluded nitrogen production, air
compressing, water tanks) are provided with concrete paving in order to collect
possible liquid spills.
Three separate sewer systems are provided:
- one for non acid possibly oily water streams,
- one for possible acid containing water streams
- one for white waters (rain from areas external to possibly contaminated areas,
water discharge from cooling towers and from raw water demineralization unit).
Sanitary waste water from buildings will be collected to a septic tank, from which clean
water will be sent to white water sewerage. Settling tank sludge will be periodically
drained and correctly disposed.
The non-acid possibly oily effluents are directed to the oil separators as they represent
an essentially HF-free stream. Possible HF-containing water streams are directed to
the acid sewers and are collected in the neutralizing basins.
These potential acid containing streams include rainwater runoff from the curbed acid
area, wash water, heavy hydrocarbons, and possibly spent neutralizing media which
may contain HF. In the neutralizing basin, lime is used to convert any HF or traces of
other soluble fluoride compounds in the water to calcium fluoride. Calcium fluoride is
highly inert and has an extremely low solubility in water. Operation of the neutralizing
basin is such that once the calcium fluoride is formed, it is permitted to settle. Once
the level in a chamber has risen, the clear, essentially fluoride-free water is drained
from the neutralizing basin to the sump from which the sump pump pumps it to the
white water sewerage.
Neutralizing Basin
The neutralizing basin consists of two parallel pits. The two parallel pits will be
alternately operated.
Since there are only a few surface drains directed to the pit, inlet flow will normally be
very small, or no flow at all, except when acid equipment is being drained, CBM
(Constant Boiling Mixture, an azeotrope HF-water coming from HF regeneration

column bottom) is being neutralized, or there is a rainstorm. After settling, the effluent
from the first pit is drained by opening the outlet valve to the sump from which it is
pumped away.
3.2.2.5 Treatment of Wastes
Process Treating Waste Solids
These wastes originate when process streams are defluorinated over activated
alumina. Over a period of time, the alumina loses the ability to defluorinate the process
streams. At this time, the alumina is considered "spent" and it is then replaced with
fresh alumina. Spent alumina is recovered by the Suppliers.
Miscellaneous Solid Waste
Porous materials such as wiping cloths, wood, pipe coverings and packings, which
have been suspected of coming into contact with HF, are placed in specially provided
disposal cans for removal. These wastes may originate during normal unit operation or
during a maintenance period and will be disposed in approved landfill.
CaF2 sludge
Calcium fluoride originates from acid liquid neutralization with lime (see 3.2.2.4).
Periodically a vacuum truck will be used to remove calcium fluoride sludge from
neutralization pits for subsequent disposal in an approved landfill. Daaboul is
evaluating the possibility of CaF2 recovery fro industrial use.
3.2.3 Plant units description
The Plants battery limits are marked in the General Lay-Out (Annex III.2) and in the
following Fig.3.5. Plant area is divided into two main parts:
the process area;
the off-site area (outside the process area)
Process units and auxiliary systems are located in the process area. The off-site
facilities (Tank Farm unit and utilities units) are located outside the process area (with
the exception of the Steam boiler unit) and connected to the process units through an
interconnecting system.
With reference to the attached General layout, the overall LAB Plant is composed of:
AUXILIARY PLANTS
FIRE
COMPRESSORS COOLING POWER FLARE
FIGHTING
TOWER UNITS
N2 PRODUCTION
FOR DETERGENTS
CONTROL ROOM/
LABORATORIES
TRUCK
PARKING
PROCESS
OFFICE
AREA
TANK FARM
Fig. 3.5: General lay-out

ENTRANCE
Section 3: Project description
LAB project -- Environmental Impact Assessment
0 25 Metri
Figure
Ballestra
March 2002
Process units installed in the process area .
Other units installed in the process area.
Tank Farm unit located out-side the process area.
Utilities units located out-side the process areas (with the exception of steam
boiler unit).
3.2.3.1 Process Units Installed in the Process Area
PACOL
This unit (marked 01 on the General Layout) is used for the dehydrogenation reaction
of N-paraffins converted to N-olefins.
This process unit includes:
two high working temperature Pacol reactors with relevant heat exchangers;
two large hydrogen compressors;
two process furnaces;
one distillation column;
two alumina treater fixed bed reactors with relevant heat exchangers.
N-paraffin oxygen stripper
This unit is used to remove some oxygenated-dirty compounds from N-paraffins

feedstock, before feeding the n-paraffins to the Pacol Unit. This unit is mainly
composed by one distillation column with relevant ancillaries. The unit is installed near
the Pacol unit.
Alkylation
This unit is used for alkylation of mono-olefins produced in the Pacol unit and includes
also:
HF reaction system using two large alkylation stages in series based mixer-
settlers UOP technology;
the HF unloading system from tankers, to an intermediate storage tank;
a safety guard (marked 06) located close to HF unloading station.
an HF vent scrubber which is used to eliminate the HF vapor present in the

organic vents.
the LAB daily storage and off spec storage section with relevant ancillaries.
a series of distillation columns, with relevant ancillaries, used for HF, Benzene,
paraffin and LAB distillation operations.
Other units installed in the Process Area
Hot oil system (marked 02): is used as the heat source for the column reboilers of the
plant. This unit is mainly composed by the Hot oil furnace, hot oil pumping station, hot
oil expansion vessel.
3.2.3.2 Facilities installed outside the Process Area
The off-site facilities include the following systems, each one complete with relevant
piping, control panels, local instrumentation etc.
Compressed and instrument air
This unit (marked 17) is composed of:
N.2 reciprocating compressors (one in stand-by)
one/two air-drying system, heat-less type.
Three plant air storage vessels.
Nitrogen production and storage
This unit (marked 10) is composed by a Nitrogen production package (PSA unit), three
low pressure nitrogen storage vessels, one nitrogen compressor and two high
pressure nitrogen storage cylinders (horizontal vessels).
Steam generation unit
This unit (marked 20) is composed by a package containing the demi water production
unit and the medium pressure steam boiler unit. As above reported, this unit is located
near the hot oil heater, in the process area.
Cooling water system
This unit (marked 16) is composed of:
Cooling towers package (wet cooling type) with relevant chemicals dosing
system
N 3 cooling water feeding pumps (one stand-by) fed from a water concrete
basin.
Main storage tanks
Tanks for raw material, products, by-products and fuel oil will be installed near the
process units.
The tank farm (marked 19) is installed close to the process Plant and is composed of
the following storage tanks:
N-paraffins: n two tanks 2000 m3 each.
LAB: n two tanks 2000 m3 each.
Benzene: n two floating roof 1000 m3 each.
Fuel oil / Diesel oil: n two 500 m3 each.
Light pacol & off spec benzene tank: 100 m3.
KOH solution storage tank: 300 m3.
Heavy alkylate storage tank: 300 m3.
The supply of such products to the factory is made by tank-trucks.
Six nitrogen Tanks was recovered from Bulgaria: these tanks will be reused in Syria as
follow: three tanks for 10 barg plant air storage; three tanks for low pressure nitrogen
storage.
Power production unit
Power distribution (marked 28) includes four diesel units. During the design phase
assumed that the power availability for LAB plant of 100%.
Pumping station
The pumping station (marked 18) is located close to main storage tanks, and
composed of:
Loading / unloading / transfer pumps;
loading/unloading hoses for tank trucks.
Fire fighting water and foam liquid system
This unit (marked 15) is composed of :
One fire fighting water new thank, 2000 m3 of capacity.
N 5 fire-fighting water pumps, installed near the fire fighting water tank.
Liquid foam system composed by two (see par.3.5 for more detail) foam
storage vessels and several foam pumps.
Fire-fighting equipment (Hydrants, detectors, etc.).
Flare
The blow down / flare unit (marked 08) is completed with its accessories (knock out
drum + pump). This unit will be located as far as possible from the process area and
the tank farm area.
Electric power distribution sytem
The electric power distribution system is composed of the following main items:
Medium voltage switchboard 6000 V, to feed the two hot oil pumps (350 kW
each) and the two hydrogen compressors (1050 kW each)
N 3 transformers 6000/400 V. Each transformer can feed the overall plat.
Power center (L.V. switch-gear-for 400 V power distribution)
Motor control centers for all electrical users of the process Plant
Local Power Boards (for utilities/off site facilities pumps and instrument air
production)
Plant control system
The control room and the control cabinets room (marked 09 and 11) based on
commercial DCS or PLC systems is composed of:
DCS or PLC cabinets. The control cabinets are located in two control
buildings: one near the cooling water unit, the second near the control room
Barrier cabinets + Marshalling panels, (for interface with instruments).
N 1 instrument control panel, installed in the control room.
N 1 operator station, located in the control room composed by four operator

console.
N 2 printers.
The software for the whole control system will be developed by the DCS / PLC
provider Company.
Interconnecting System
The interconnecting system for all the above units and systems is realized by pipe
racks which incorporate all pipes (process pipes, utilities pipes) and cable trays for
instruments and electric distribution. The pipe rack structures are organized in the
following system:
Main pipe-rack inside the process area.
The main piping connecting the units in the process area runs on a pipe rack with
3 main branches, where cable trays (for instruments and electric cables) are also
located. All piping and cable trays running on this pipe rack are part of the Plant.
Rack between the tank farm / pumping station and the process area.
This pipe rack supports all lines required for the tank farm unit, the relevant utilities
necessary to the tank farm, the blow-down piping, all cable trays necessary for the
instruments and electric cables.
Connection between flare and process area.
A gas blow down line is installed to connect the process area to the flare unit and it
is complete with relevant piping supports.
Connections between process area and cooling water/fire fighting.
These connections are running underground.

3.3.3 Materials, substances and resources input / output
3.3.3.1 Raw materials and resources input
In the following tables raw material consumption for process units and for utilities is
reported:
Raw materials input in process units
Materials Consumption (Tons/year)

n-Paraffins C10-C13 33.400
Benzene 13.400
Hydrofluoric acid 25
Activated Alumina pellets About 76,200 kg at start-up, periodically recovered
Pacol catalyst 8 m3 at start-up, periodically recovered
Resources input in utilities
Resources Consumption (Tons/year)

Fuel oil 17600
Diesel oil 5600
LPG 250
Water 192000 m3/year
By-products internal recovery
Resources Consumption (Tons/year)

Light ends from Pacol 400
Hydrogen 1000
Alkylate polymers 600
Material flow IN
WHAT FROM WHERE NOTES
Paraffins Iran 5 Trucks/day
Europe (via Latakia/Tartus) Ships / Trucks
HF India 1 Trucks/year
Europe (via Latakia/Tartus) Ships / Trucks
Benzene Europe / USA (via Ships / 2 Trucks/day

Latakia/Tartus)
KOH (Dry) Turkey Trucks
H2 (for start up) SYRIA (around Damascus) Trucks
Pacol catalyst USA (via Latakia/Tartus) Ships / Trucks
Allumina Europe / USA (via Ships / Trucks

Latakia/Tartus)
Fuel oil SIRYA (refineries) 3 Trucks/day
Diesel Oil 1 Trucks/day
LPG SIRYA (refineries) 10 Trucks/year
N2 Self produced ---
Other chemicals SYRIA (near Damascus) Trucks
In Annex III.3 material safety data sheet for substances used in major quantity in the
plant and for more hazardous ones are reported.
3.3.3.2 Products output
In the following table product output from LAB site is reported:
Substance (tons/year)
LAB 40000
Heavy alkylates 3400
Light end from Pacol 1400
Material flow OUT
WHAT TO WHERE NOTES
LAB DAABOUL sulfonation plant located in Trucks

AL KISWAH, south Damascus, 12 km
from LAB plant 8,000 t/y
6 Trucks/day
2 sulfonation plants located around Trucks
Damascus 14,000 t/y
Jordan, Lebanon, Turkey, South Trucks

Arabia 19,000 t/y
Light alkylates Partly burnt in the heater, partly 1 Trucks/week

commercialized
Heavy alkylates Partly burnt in the heater, partly 4 Trucks/week

commercialised (Daaboul is
evaluating a suitable use, a
plant/factory that can use it)
CaF2 sludge Daaboul is evaluating a suitable use 1 Trucks/every 2

for fluorides (a plant/factory that can months
use it)
Exhausted Pacol Sent to UK where platinum is Ships (via

catalyst recovered and sent to USA for Latakia/Tartus) and
producing new catalyst trucks
Exhausted alumina Sent to Europe for regeneration Ships (via

Latakia/Tartus) and
trucks
Waste water In the interim phase, before treatment 15-20 Trucks/day

plant construction, sent to Damascus
waste water plant
3
WATER BALANCE (m /h)
Raw water
from wells
24
16 6 1 1
Cooling Steam Service Buildings

towers generator stations
8 8 3 1 2 1 1
Vapour Vapour Oily Waste water Waste

to to water contaminated organic
atmosphere furnaces with HF water
Blowdown Blowdown Organic Acid

water water sewer sewer
Api Neutralization
separator basin
White
water
sewer
Fig. 3.6: Water Balance

Ballestra
3.3.4 Emissions to the environment and resources use

3.3.4.1 Emissions
Emissions to the environment can be summarized as follows.
AIR EMISSIONS
- Air emissions are due to:
- fuel combustion (mainly fuel oil) in Hot oil unit and Pacol charge heaters;
- fuel combustion (fuel oil) in steam boiler burners;
- fuel combustion (diesel oil) in power generators;
- waste gases and LPG combustion in flare and heater pilots (LPG);
- organic substances evaporation losses from tanks;
- water evaporation losses from cooling tower.
Emission sources localization is shown in the following figure (see also General Lay-
out with air emission sources localization in Annex III.4); significant emission points
and their emission values are listed in the following tables.
SO2 and NOx emission values have been evaluated on the base of 1% sulphur fuel
oil, which will be used in LAB plant, as far as possible considering its availability in
Syria.
Air emissions will be monitored, when the plant will be running. If problems should
arise in NOx emission values respecting, substitution of the existing burners with Low-
NOx ones, will be evaluated.
N Description Characteristic
Frequency Height Diameter Flow rate Concentrations (mg/Nm )

3
Flow rate (tons/year)
a
3
(m) (m) (Nm /h)
SO2 NO2 PTS CO SO2 NO2 PTS CO
1 Hot oil and Pacol Continous 56 2.2 26,800 1,700 460 100 50 365 99 11 21
charge heater-
common stack
2 Start-up heater Discontinous 18 1.2 4,100 1,700 460 100 50 55 15 1.6 3.8
stack
3 Boiler burner Continous 15 1.2 3,500 1,700 460 100 50 48 13 1.4 3
stack
4 Power generator Continous 11 0.45 18,800 29 100 2 25 4 15 4 0.3
units 4 stacks
Total 472 142 18 28
a
Service factor: 8.000 hour/year
Air pollutants emission from storage tanks
Emission source Description Tank Hydrocarbon vapors Mean storage Vapor Total emission / year
identification type released temperature (C) MW (Kilograms)
6A / 6B / 6C LAB Daily storage tanks 450-V28A/B/C CFX Linear Alkyl Benzene 20 242 negligible
7 Heavy alkylate storage tank 103-T6 CFX Heavy alkylates 20 350 negligible
8 Fuel oil tank 103-T3A CFX Light fuel oil 80 - 90 130 170
9 Diesel oil tank 103-T3B CFX Light diesel oil 80 - 90 130 70
10A / 10B Paraffins storage tanks 103-T1A/B CFX n-paraffins C10-C13 20 164 500
11A / 11B Benzene storage tanks 103-T2A/B CFL Benzene 20 78 820
12A / 12B Final LAB storage tanks 103-T5A/B CFX Linear Alkyl Benzene 20 242 negligible
13 Off-spec storage tank 450-V27 CFL Benzene + paraff. 20 > 78 350
Legend CFX = vertical cylindrical with conical fixed roof

CFL = vertical cylindrical with conical fixed roof and internal floating roof
negligible = less than 2 kilograms/year
Section 3: Project description Page 25 of 42
WATER DISCHARGES
- Waste water discharges are due to:
- cooling tower blowdown;

- raw water demineralisation unit blowdown;
- service stations (washing areas where contamination by hydrocarbon or
hydrofluoric acid cannot be excluded);
- building services.
In Annex III.5 a general lay-out with sewage systems is reported.
Site water balance is reported In the following table and in the following Fig.3.6:
3 3
Use Input (m /h) Output (m /h)
Liquid Vapour
Cooling tower losses 16 8 8

(evaporation+liquid blowdown)
Steam generator losses 6 5 1
Potentially contaminated areas 1 1 ---

wash waters
Building services 1 1 ---
Total 24 15 9
Waste water will respect limit values indicated by Syrian guidelines for discharge in
public sewage systems (see also par.2.2.2.1 in Sec.2).
Industrial waste water from companies located around Damascus are typically piped
or trucked to the municipal waste water treatment plant. Daaboul LABs original permit
was based on this. Due to the amounts of waste water to be trucked (up to 15 cubic
meters per hour), the distance of the transport (30-40 Kilometres), as well as relative
low contamination level of the waste water it was in early February 2002 decided to
design and build a full waste water treatment plant on-site. The waste water treated in
the on-site plant will comply with World Bank guidelines and will be used for irrigation
of new green areas within Daabouls own premises, and/or for outside irrigations
projects according to permits obtained.
The design and construction of the waste water treatment plant is delayed according
to the LAB plant implementation schedule and it might, in an interim period during the
commissioning, be necessary to use the municipal waste water treatment system.
WASTE PRODUCTION
- Waste materials production is due to:
- acid waters neutralization in neutralization pits and CaF2 sludge production;

- exhausted Pacol catalyst
- exhausted alumina catalyst.
At the moment Daaboul is evaluating the possibility of CaF2 recovery for industrial
use. Exhausted catalysts will be sent to suppliers for rigeneration/recovery:
WHAT TO WHERE HOW
Exhausted Pacol Sent to UK where, platinum is Ships (via

catalyst recovered and sent to USA for Latakia/Tartus) and
producing new catalyst trucks
Exhausted alumina Sent to Europe for regeneration Ships (via

Latakia/Tartus) and
trucks
Other solid wastes, mainly form maintenance activities, will be disposed in an

approved landfill.
NOISE EMISSION
Noise emission is mainly due to noisy units running (mainly power production units,
compressors, furnaces).
The most noisy units are the power generators, which are located inside a building.
Noise level inside the building is approximately 117 dB(A), outside the building level
the expected noise is approximately 90 dB(A).
For the other noisy units, a value of 85 dB(A) have been considered as noise pressure
level at a distance of 1 m (data assumed also in other studies for similar equipment).
3.3.4.1 Resources use
Resources uses can be summarized as follows.
WATER USE
Water is needed mainly to compensate water discharges and vapor emission (see
previous points in 3.3.3.1). The only available source of water in the area is
underground water. Five wells are present in LAB site.
Water estimated consumption is about 24 m3/hour, approximately equivalent to

190000 m3/year.
FUEL CONSUMPTION
Fuel consumption is necessary in order to guarantee heat supply in different process

steps and electric energy supply to the site.
-Fuel consumption is due to combustion in:

- Hot oil unit and other process heaters (mainly fuel oil);
- Power generation units (Diesel oil)
- flare (LPG and other waste gas).
In order to minimize gaseous emissions (above all SO2 emissions), low sulphur (1%)
fuel oil will be chosen, as far as possible a. Air emissions in 3.3.4.1 have been
calculated considering 1% sulphur fuel oil.
An internal hydrocarbon recovery is performed in different process steps (see previous

process description in section and data in section 3.3.3.1). By products such as:
- Light gaseous ends from Pacol
- Hydrogen
- Alkylate polymers
are recovered in order to be burnt in Hot oil and other process heaters.
Fuel consumption data are reported in previous point 3.3.3.1.
a
In Syria low sulphur distillates are not currently commercialised.
LAND USE
LAB site covers a rectangular area, 160m large x 318m long, of about 50,800m2.
Process area will be paved, in order to avoid soil contamination due to incidental
leakage of hazardous materials.
3.4 Yard phase
Construction works are in progress; INCO International (Sultanate of Oman) has been
encharged to carry on the works; some features of the works in progress are given in
the following:
1- Employed personal for construction activities is 135 totally, 12 of them are technical
staff and 102 are workers. Administration personal are 11.
2- Workers and administrative personal live in different dormitories which are furnished
with similar commodities.
3- A car is used for services between Damascus and site in case of an emergencya
minibus is used for links to Damascus.
4- Two type of machinery are used in the yard

ST
1 ) Construction machines for erection works (like one lifting crane-mobiles, lifting cap
mobile cranes, forklits and so on)
nd
2 ) Supplementary machinery and equipment (like automatic pipe cutting machines,
Flange re-facing machines, Acetylene cutting torches and so on)
5- Transport activities in site for material movements are done by tractors and mobile
cranes. The other vehicle traffic is only for servicing personal to work places, like
measuring & mapping staff and for in coming trucks from outside for supplying
material/and other consumables.
6- Water is supplied from wells. Drinking water is supplied from out of site by filling a
daily tank. Energy supply for work and social life is derived from 350 KVA gen/set
which runs continuously.
7- Waste water comes out only from living places; it is collected by means of a short
sewage system in a waste-water basin (about 150m capacity) periodically drained by
sewage tankers.The distance between basin and dormitory buildings is about 50 m.
8- Waste resulted from working and human activities (for example waste from restaurant)
are collected in barrels which their top are closed. These are taken away by a truck
which collects hard-waste-a company car working under authority of municipality.
9- In the areas and during activities with high noise personnel is provided with ear
protecting head wears and if necessary eyes protection goggles. There are no night
shifts and consequently no noise emission.
In the following Fig.3.7 a program of the building activities and the fraction of realized
ones are reported.
ID Task Name Duration Start Finish % Complete April July October January April July October
1 Mobilization 49 days Fri 15/06/01 Wed 22/08/01 100 % 100 %
3 Daaboul Site Mob. & Warehouse 164 days Mon 18/06/01 Thu 31/01/02 51 % 51 %
5 Project/Warehouse Settlemen 170 days Mon 18/06/01 Fri 08/02/02 19 % 19 %
6
FOR DETERGENTS
7 Project/Design Works 141 days Mon 18/06/01 Mon 31/12/01 35 % 35 %
9 Maintenance & Overhauling W. 185 days Mon 18/06/01 Fri 01/03/02 35 % 35 %

10
11 Process Area Erection Works 195 days Mon 02/07/01 Fri 29/03/02 52 % 52 %
12
13 Sleel Structure Mod. & Erection 163 days Tue 19/05/01 Thu 31/01/02 83 % 83 %
14
15 Piping Works 195 days Mon 03/09/01 Fri 31/05/02 10 % 10 %
16
17 Erection of Tank farm 130 days Mon 01/10/01 Fri 29/03/02 5% 5%
18
19 Electrical & Instrumentation Works 216 days Mon 03/12/01 Mon 30/09/02 0% 0%
20
21 Tesling of Pipes 304 days Mon 03/09/01 Thu 31/10/02 5% 5%

Section 3: Project description
22
23 Insulation Works 128 days Wed 01/05/02 Fri 25/10/02 0% 0%
Fig. 3.7: Project Calendar with percent of realized activities

24
LAB project -- Environmental Impact Assessment
25 Palnting Works 348 days Wed 01/08/02 Fri 29/11/02 20 % 20 %
26
27 Fire alarm System Installation 64 days Thu 01/06/02 Tue 29/10/02 0% 0%
28
Figure
Ballestra
March 2002
29 Pre-Commissioning 22 days Tue 01/10/02 Wed 30/10/02 0% 0%

3.5 Project reliability and safety systems
PROJECT RELIABILITY
The adopted technology is very well known and several large industrial plants are in
operation since many years in different countries. The HF technology is still the most
applied to produce LAB (almost 80% of the total LAB worldwide produced).
The biggest plant of this type in the world is now operating in Augusta, Sicily (Italy),
with 150,000 tons/year LAB production capacity.
FIRE FIGHTING SYSTEM
The LAB production plant site is protected against accidental fire with a series of
properly sized equipment which are able first to detect possible inflammable gas
mixture presence or fire presence and then to guarantee water sprinkling/distribution
for at least 2 hours in the area involved.
The system is composed of the following equipment:
1. A LEL (lower explosive level) monitoring network for main flammable

hydrocarbons, generating an alarm in control room in case of limit exceeding;
2. A UV (Ultra Violet type) flame detectors network, which is able to generate an

alarm in control room;
3. A sprinkler based cooling system for critical equipment, activated from remote
position (control room);
4. A fire fighting water storage tank 200T1, having an operating capacity of 2000 m3;
5. Four lead pumps (200 P10 / P11 / P12 / P13) having a capacity of 180 m3/h;
6. One jockey-pressure maintenance pump (200 P14), having a capacity of 20 m3/h;
7. Two foaming agent storage vessels, each one having a capacity of 40 m3;
8. Four foam pumps (200 P21 / P22 / P23 / P24);
9. One foam jockey pump (200 P25);
10. A piping network to deliver fire water, divided into three main loops;
11. A piping network to deliver foaming liquid, divided into three main loops;
12. A series of local hydrant;
13. A series of swinging monitor, located both at ground level and above steel
structure;
14. A foam distribution network for storage tanks containing flammable liquids;
Each equipment or particular device will be further described in the following part of
this document.
Concerning monitoring system, refers to the distribution lay-out in which location of

detection points is indicated, dwg. Nr. 3A65.85.014 (2 sheets):
a) LEL detectors have been installed around and inside the process area
(PACOL unit, Hot oil generation and HF Alkylation) to identify possible leaks of
flammable liquids or gases. These detectors are of catalytic type and are able
to generate an alarm in case hydrocarbons concentration, in mixture with
ambient air, exceeds 50 % of the lower explosive level. In this way operators
are timely advised in order to proceed in eliminating leak cause and prevent
dangerous behaviours from safety point of view. All these points are marked
on the lay-out as MX-sensor.
b) In case an explosion or a fire potential source cannot be avoided, UV flame

detectors allow fire source identification and start up of the appropriate
emergency procedure. These detectors respond to flaming fires emitting light
in the ultraviolet portion of the spectrum. UV detectors can respond to a fire
condition in less than 10 milliseconds.
The monitoring system described may be defined as a preventive measure

against potential damages due to fire events.
A further measure to limit fire events or damages is represented by the

sprinkler cooling system. For this system, refers to the lay-out drawing Nr.
3A65.60.002.
c) 15 deluge valves have been installed to feed a sprinkler system for an equal
number of critical equipment or group of them. These valves can be operated
from a remote control room. An effective cooling may result in an additional
safety measure. Actually, fluids circulating through them, due to particular
temperature or pressure conditions, may generate dangerous mixture in case
of external release. Another reason for protecting these equipment is that
keeping them cool, even in case of a fire event, it is always possible to have
the availability of their cooling power or blanketing action. The 15 groups are
resumed here below :
1. Oxygen stripper bottom pumps 390 P2 A/B
2. Fuel oil circulating pumps 900 P3 A/B
3. Reactor product condenser 350 E2

4. Stripper Condenser 350 E4
5. Reactor charge pumps 350 P1 A/B, Stripper overhead receiver pumps 350
P4 A/B and Stripper bottom pumps 350 P5 A/B
6. Oxygen stripper overhead condenser 390 E8
7. (void)
8. Benzene make-up pumps 450 P2 A/B
9. Benzene stripper overhead pumps 450 P3 A/B and Benzene column
overhead pumps 450 P8 A/B
10. Benzene column condenser 450 E12
11. Rerun column overhead and bottom pumps 450 P12 A/B, 450 P13 A/B
12. Flush pumps 450 P11 A/B
13. Paraffin column overhead and bottom pumps 450 P10 A/B, 450 P9 A/B
14. Paraffin column overhead cooler 450 E16
15. Off spec transfer pumps 450 P16 A/B
16. Nitrogen high pressure buffer tanks, 200 V106 / V107
An external cooling with sprayed water is also guaranteed for the Benzene
stripper column 450 V2, the Benzene column 450 V12, the Paraffin column
450 V15 and the HF acid storage drum 450 V18.
Moreover all the storage tanks for flammable hydrocarbons are provided with
toric cooling water distributors, to ensure walls cooling in case of external fire.
Water could also be used to maintain mild wall temperature during summer
and consequently avoid massive hydrocarbons evaporation.
d) Fire fighting water and foam distribution network are indicated in the lay-out
drawings Nr. 3A65.60.003 (for process area) and 3A65.60.004 (for tank farm).
A storage tank for fire fighting water with a capacity of 2000 m3, 200 T1 has
been foreseen to guarantee a sufficient supply during a fire emergency
involving most critical hydrocarbons hold-up release. In case of flame
detection, after first attempt to limit fire extension, the lead pumps (200 P10 /
P11 / P12 / P13) are automatically and in sequence started up according to
user (hydrants or monitors) requirement. A jockey pump is used to maintain
the pressure in the network, in order to guarantee water instantaneous
availability on demand. An adequate pressure level in the network represents
also a necessary condition for safe working of sprinkler and foaming systems.
Fire fighting distribution network has been laid underground and divided into
three main loops: Pacol and Hot oil process area, HF alkylation process area
and tank farm.
Every point of the network has the same the pressure level. Each loop may be
blocked to satisfy water greater demand in the area interested by fire
emergency.
Isolating pits have been provided on loop borders; a blocking manual valve for
water and foaming agent may be operated in every pit.
A pit with gate valves for water and foaming agent is also present where
hydrant or monitors have been placed.
Swinging monitors have been distributed around and inside the process area,
at ground level and mounted on steel structure. Each monitor can be operated
from remote and safe position (according to wind prevailing directions) by
means of joystick control panels.
A particular foam distribution system allows to mix air, fire water and foaming
agent and feed produced foam inside every storage tank containing
flammable liquids. Foaming agent is stored into two vessels, 200 T2 / T3
having a capacity of 40 m3 each one. Foaming agent is then pumped into the
distribution network according to the same logic system as fire water (4 main
load pump + 1 jockey pump that maintain pressure level).
Foam is poured on liquid surface to prevent air/hydrocarbons contact and

consequently flames development.
3.6 Safety criteria and safety measures adopted in order to

prevent incidents
HazOp analysis for the Daaboul LAB plant (see complete report in Annex III.6)
allowed the definition of a set of recommendations for the improvement of plant safety.
Descriptions and details of all recommendation are included in Attachment #1 to
Annex III.6.
Following a short summary with indication of main issues is provided.
ISOLATION AND PUMPING OUT
Isolation and pumping out of acid circuit of alkylation unit was not foreseen in original
U.O.P. project. The new project has introduced on/off valves and procedures to pump
out the acid mixture in case of emergency. This will allow reducing duration of an
accidental release. On/off remotely activated valves will to be designed as failure hold,
so that in case of lack of energy or instrumental air, they will keep the position. In the
event of emergency a dedicated logic circuit will operate the valves in order to close
main acid circuit and open the lines to the storage vessel.
A reliable trip logic system that foresees feed pumps stop before on/off valves shut
down will be installed.
HF LEAKAGE DETECTION
Video cameras have been selected as means for HF leakage detection.
The installation of a suitable number of video cameras (at least 4) will cover the entire
acid area in all possible directions.
FLAMMABLE GAS DETECTION
A review of flammable gas detectors location will be done, so that they will cover not
only pumps but also areas in which hot flammable fluids are processed and therefore
might be released, particularly in correspondence of flanged joints. Besides, they will
be placed in order to detect the possible cloud directed towards potential ignition
sources (furnaces, hot oil heat exchangers).
FIRE DETECTORS
Review of fire detectors location is required.
They should cover mainly pumps and equipment that process liquids above their
autoignition point (with particular regards to paraffines). For other areas, positioning
should take into consideration the slope of the paved area that might force the pool to
pool.
FIRE PROOFING
Fire proofing of skirts and saddles will be done in PACOL unit and in distillation and
purification section of alkylation unit.
Light fire proofing application along the horizontal metallic structures will be realized,
especially for the areas subjected to a higher fire risk (PACOL unit and distillation and
purification section of alkylation unit).
FIRE FIGHTING
The benzene stripper, V2, the benzene column, V12 and paraffine column V15 are
protected with water sprinklers. Reference for dimensioning will be international
standards (such as NFPA 15). Position of water sprinklers will be optimized.
PAVING AND SEWER SYSTEM
All the equipment containing HF are located on a paved area; leakages and rainfalls in
the area will be collected to Acid sewer and to the neutralization pits.
All equipment containing hydrocarbons are located on a paved area connected to oily
sewer and to the oily separator.
The paved area of alkylation unit will be divided form the rest of the acid section in
order to separate fire risk from toxic risk. In this sense a curb between heat exchanger
E7 and E9, directed N-S, will be built.
Paved area of the distillation and purification section of PACOL unit (positioned
immediately North of PACOL process area main pipe rack) will be adequately sloped
in order to collect the leakages (and potential fire) far from process pipe rack.
The paved areas of the Hydrocarbon processing plant sections will be divided into
smaller areas with a suitable slope towards the wells, in order to collect potential
leakages.
TANK FARM
Storage tank containment dikes will be dimensioned to contain the hold up of the
largest tank. Each benzene storage tank will be positioned in a single dike.
CONTROL ROOM
Control room will be pressurized. Toxic gas detectors will be put in the air intake duct
with alarm in control room; air re-circulation inside control room must be provided.
WIND DIRECTION MONITORING
Wind direction is fundamental for emergency management due to toxic gas release.
Wind cones visible from all parts of the plant will be provided. An anemometric station
in control room is also foreseen.
CONTROL SYSTEMS
Redundancy in control and alarm systems in critical equipment will be realized.

Minimum set of measures that will be implemented is following detailed:
Redundancy of the minimum flow trip of the paraffine flush for acid and
benzene pumps seals.
Redundancies of minimum flow trip for caustic solution recycle in the
neutralization section of alkylation unit.
Installation of high temperature trip on the outlet line of the furnace, with shut-
off of the furnace in the PACOL unit.
DRAINAGE
A spring loaded (dead man type) valve as second manual valve on draining lines, in
order to avoid liquid spills during drainage operations, will be installed.
SHUT-OFF VALVES
Installation of on/off valve, fire safe type, on the bottom line of the vessels containing
large hold up of hot flammable substances, is in project., as a minimum, for vessel 350
V1A/B and 350 V2.
FIREDAMP STEAM
Toroidal vapour ejectors will be installed in correspondence to flanged joints of the

furnaces heat exchangers in the PACOL unit.
LOADING/UNLOADING
A nitrogen system to recover the pressure in the mobile tanker during unloading
operations will be provided.
Volumetric counters for the indication of total amount loaded into the mobile tanker
(with particular concern to LAB, heavy hydrocarbons and light pacolate) will be
installed.
Availability of a earthing plier in each of the loading/unloading bay is required; to be

associated to the consent of relevant pump start up. For LPG station, the logic consent
will be directed also to the opening of an independent on/off valve on the inlet line of
the storage vessel.
3.7 Plant maintenance and availability
On the base of previous experiences, a general stop of the plant for maintenance is
foreseen every 2-3 years.
The actual maintenance frequency will depend on the results of the implementation of
an inspection program, whose contents are to be developed and defined in detail
before plant starting.
Inspection program will describe the typology and frequency of controls, with particular
attention to control of lines and equipment containing acid liquid or gases, in order to
verify possible corrosion effects reducing material thickness.
In Operating Manuals a list of critical lines and equipment and detailed procedures for
their control will be present.
The general maintenance will be committed to specialized external companies,

managed by the internal responsible for maintenance.
Everyday maintenance interventions (like catalysts substitutions, instrument cleaning

and so on) for which actual plant stop is not required, will be made by internal
maintenance staff.
3.8 Adverse impacts prevention and mitigation and measures
In the previous paragraphs a series of prevention and mitigation measures (mainly

technical measures), have been described. In section 5, other prevention measures
(mainly management measures) will be described, concerning safety and environment
management system. Hereafter a short synthesis is reported.
SAFETY
The project has been analysed with HazOp methodology and main issues outcoming
from analysis has been identified and described in par.3.6. HazOp recommendations
are finalized to increase plant reliability and to reduce the potential consequences of
an incident.
Daaboul Lab will implement all recommendations from HazOp, and will use the
HazOp results for accident probability and consequence calculations. All accidents
with probability higher than 10-6 will be included in the emergency Response Plan.
For hygiene and safety operation a training program for personnel is in elaboration
(see also sec.6). All the necessary personal protective equipment will be available for
operative personnel, who will be trained on its use.
ENVIRONMENT
Soil contamination is prevented by the presence of pavements in process areas (see

3.6), that will collect eventual leakage. Storage tank containment dikes will be
dimensioned in order to contain the hold up of the largest tank.
Air emissions are mainly due to fuel oil combustion in furnaces. Air pollutant emission
will be limited by choice of low sulphur (1%) fuel oil, as far as possible considering its
availability in Syria.
Benzene emissions from storage tanks is limited adopting an internal floating roof with
external fixed roof. Benzene concentration monitoring in different points inside the
plant and at its fence is foreseen (see also section 6).
Particular care will be given in the management system to water use and saving.
In waste water sewerage, separation between possibly acid contaminated liquids and
possibly oily contaminated liquids is foreseen. Two different treatments are provided: a
neutralization treatment, for acid liquids, and an oil separation, for oily liquids.
As already evidenced (3.3.4.1 page 25) a full waste water treatment will be built, so
that waste water will be usable for irrigation purposes.
Noise emissions from power generators (which are the most noisy equipments) is
limited by a closed building.
PREPAREDNESS AND RESPONSE TO EMERGENCY
In par.3.5 fire fighting system has been described.
An emergency plan will be defined before plant start up. A group of internal operator
will be trained for fire fighting and first aid. Appropriate training for emergency
behaviour will be provided for all personnel (see section 6).
3.9 Examined Alternatives
SITE ALTERNATIVES
LAB localization in present site was identified after examining and eliminating another
site choice. The previous site is situated next to existing Daaboul Sulfonation plant
(final destination of LAB). The advantages of this site was the good integration
between the existing and the new plant.
However, the previous choice was not good for two main reasons, evidenced by
Ballestra technicians:
the site was too near to inhabited centres and next to a big supermarket;
the site morphology was not good for a chemical plant (it was not perfectly
plain, giving rise to a much more complex project and to difficulties in trucks
access and movements).
LAB site final choice is good for:
distance from towns (Deir Ali is 1.5 km distant)
the almost desertic features of the area.
PROJECT ALTERNATIVES
As already mentioned, HF technology, adopted in Syria plant, is very well known and
several large industrial plants are in operation since many years in different countries.
The HF technology is still the most applied to produce LAB (almost 80% of the total
LAB worldwide produced).
Two other different technologies are currently available in order to produce LAB:
-AlCl3 technology
-Detal process technology.
AlCl3 technology is very similar to HF technology. AlCl3 is much less hazardous than
HF, but, being used in aqueous solution, is highly corrosive, giving rise to many
maintenance problems; moreover a recovery of the catalyst used is not possible and
large quantities of Aluminum Hydroxide are produced (it could be used as flocculant
agent, after appropriate treatment).
Detal process technology is a state of the art process for the manufacture of detergent
alkylate that uses a solid heterogeneous catalyst to produce Linear Alkylbenzene by
the direct alkylation of benzene and Linear olefins. This technology has the
fundamental advantage of eliminating HF or AlCl3 corrosive liquids.
The choice of HF technology for Syria plant was essentially due to the chance of
recovering an existing not operating plant with a high production capacity. This choice
permits to completely satisfy Daaboul sulfonation plant LAB needs and to provide
more LAB in the Arabic market, substituting a significant quantity (about 20,000
tons/year) currently purchased from external far Countries.
3.10 Environmental interference parameters synthesis
Environmental Main Project Interference with Note

Factor/ Environment
Component
Air Air emissions from fuel oil combustion. Principal emissions concernes :
(Hot oil unit, Pacol charge heaters, SO2 472 tons/year
steam boiler burners, power 1,700 mg/Nm
3
generators).
Nox 142 tons/year
Minor contributions due LPG and waste 3
gases combustion in flare. 460 mg/Nm
Minor contributions from traffic from CO 28 tons/year

3 (*)
and towards the site (about 15-20 50 mg/Nm
trucks/day).
PTS 18 tons/year
3 (**).
100 mg/Nm
Organic substances evaporation losses Fuel oil 170 kg/year

from tanks
Diesel oil 70 kg/year
Paraffins 500 kg/year
Benzene 820 kg/year
Off-specific 350 kg/year
3 3
Water Groundwater use mainly for cooling 24 m /hour - 190,000 m /year
towers and demineralisation operations
(evaporation and blowdown losses).
3 3
Appropriate waste water treatment will 15 m /hour - 120,000 m /year
be performed in the site, in order to
recover water for irrigation (in an Treated waste water will comply to
interim period it might be necessary to WorldBank reference values and
use the municipal waste water plant). will be use for irrigation.
3
Waste Calcium Fluoride sludge production 10 35 m /month
production (from neutralization basins). It could be
recovered in external factories.
Exhausted catalysts can be completely
recovered by the Suppliers.
Noise Noise emissions from some Higher emission values (pressure
equipments (compressors, furnaces, levels at 1 m distance):
power generators).
90 dB(A) for power generators
Minor contributions from traffic from (outside their closed building)
and towards the site (about 15-20
trucks/day). 85 dB(A) for the other equipments.
(*) (**)
: 25 mg/Nm3 for power generators : 2 mg/Nm3 for power generators
Environmental Main Project Interference with Note

Factor/ Environment
Component
2
Land use Occupation of about 50,800 m . ---
Soil and Incidental leakages are collected by
Subsoil pavements and sewer networks in
process area.
In tankfarm, paved dikes and curbs are
provided for incidental leakages
containment.
Landscape The plant is a greenfield one. Highest elevation is 56 meters
(stack).
Flora and The site area is a rocky debris one. No ---
Fauna, vegetal associations or fauna species
Ecosystems are present.

Sez - Iii.project Description-Rev IFC

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LAB project Environmental Impact Assessment March 2002

Section 3: Project description 1 of 42

Section 3: Project description 2 of 42

3.1 SITE LOCATION 4

3.2 PLANT DESCRIPTION 5

3.2.1 PLANT HISTORY 5

3.2.3 PLANT UNITS DESCRIPTION 13

3.5 PROJECT RELIABILITY AND SAFETY SYSTEMS 30

3.6 SAFETY CRITERIA AND SAFETY MEASURES ADOPTED

3.7 PLANT MAINTENANCE AND AVAILABILITY 37

3.8 ADVERSE IMPACTS PREVENTION AND MITIGATION AND

Section 3: Project description 3 of 42

3.9 EXAMINED ALTERNATIVES 39

3.10 ENVIRONMENTAL INTERFERENCE PARAMETERS

III.1 Block diagrams

III.2 General lay-out

III.3 Material Safety Data Sheets

III.4 General lay-out with air emission sources localization

III.5 General lay-out with waste water sewerage

III.6 HAZOP Analysis Report

Section 3: Project description 4 of 42

3.1 Site location

LAB site is located in the Province of Damascus Countryside, in the territory

Section 3: Project description 5 of 42

3.2 Plant description

3.2.1 Plant history

The original Bulgarian Plants engineering documentation, was completely re-ordered,

Section 3: Project description 6 of 42

3.2.2 Process description

The HF Detergent Alkylation Process is a catalytic process to alkylate benzene with

The process is based on two main reactions:

paraffin dehydrogenation and conversion to olefins (PACOL)

- Paraffin pre-treatment (Oxygen stripping unit)

- Paraffin conversion to olefins (PACOL unit)

- Benzene alkylation with linear olefins (HF alkylation unit)

- Raw materials, products and by-products storage (Tank farm)

Tank Farm 35150

Heavy alkylates 425

Hot oil unit

Fig. 3.1: Global Block Diagram

Section 3: Project description 7 of 42

3.2.2.1 Paraffin Conversion to Olefin (PACOL)

Paraffins from oxygen stripper

Light liquid to storage

Parffin & oleofin to alkylation

Fig. 3.2: PACOL Unit Block Diagram

Section 3: Project description 8 of 42

Section 3: Project description 9 of 42

3.2.2.2 Linear Detergent Alkylate Process (LAB)

The HF Detergent Alkylation Process is a catalytic process to alkylate benzene with

Benzene from storage 1675

HF alkylation: 2nd stage

LAB + Heavy alkylates 5425

Fig. 3.3: HF Alkylation Unit Block Diagram

Section 3: Project description 10 of 42

The bottoms of the paraffin column is pumped to the rerun column.

Alkylate Rerun Column

3.2.2.3 Treatment of Gases

Acid Relief System

NON ACID ACID ACID

Liquid Gases Liquid

Hydro-carbons CAF2 sludge

API Neutralizing Alkylation