Crude Oil

A fossil fuel Consists of several fractions A mixture of very wide range of Hydrocarbons Normally Black in color Available in plenty in Middle East (Persian Gulf) Also available in North & western Africa, Indonesia, South & Central America, Scandinavia In India, it is available in Bombay High, KrishnaGodhavari basin, Assam & Rajastan

What is a Refinery?
A refinery is a complex integration of several process units that work in a coordinated fashion to make customized fuels and valuable petrochemical feed stocks. It includes Blending.

Over View of a Typical Refinery

The Refining Process

Fractional Distillation Conversion Treatment Blending

Typical refinery Units

Crude Dist Unit & Vac Dist Unit Hydro treating unit Fluid Catalytic Cracking unit Delayed Coker unit Merox Sulfur Rec.Unit & ATU Refinery Tank Farm

Typical Layout of a Refinery

N
g Water Storage g Buildings g RTF g Road/Rail loading g Sulphur g CPP / Utilities g Coker g PP g Aromatics g CDU / VDU

RRT

RRT

RTF

S F Cr 1 M H Cr 2 A ETP

U C A

CPP

PP

Material Flow

SPM 2 Nos.

Jetties 4 Nos.

MTF

RTF

Pipeline despatch
Road loading Rail loading RRTF

Increased Complexity enhances margins

Complexity
Guwahati Barauni Panipat MRPL

Reliance

L ll & ma
BPCL

& ge ar

lex mp Co

Si

ple m

S
Bongaigon Digboi Haldia Vizag

Koyali Mathura CRL

HPCL

MRL

Capacity

Source: Chemsystem

Refinery Block Flow diagram

H2 521/522 H2 C1 221 HNUU LPG 331 SAT LPG MEROX HN LN 341 KERO MEROX KERO 471 LNUF 234 PSA 231/232 PLAT H2 TOLUENE 281 TATORAY 261/262/263 PAREX HN 241/242/243 XYL FR HARN GT FUEL O-XYLENE

251 OX-FR
271/272/273 ISOMAR

HN

P-XYLENE LPG PC NAPHTHA LAB FEED KERO / ATF

321/322 SAT GCU

351/352 DIESEL UNI.FIN LPG 414 UNSAT GCU LN

LPG

311/312 CDU CRUDE

GAS OIL

415 UNSAT LPG MEROX HN 416 GASOL MEROX

422 PROP REC

ETYL REC 551/552 PP

DIESEL ETHYLENE

PP PROPYLENE MS

311/312 VDU

VGO 372 COKER LN GAS PLANT LCGO VR 371 DCU HCGO

361/362 VGO UNI.FIN

411/412/413 FCC

180-215

LCO

180-215 GT FUEL

C5

TAME CSO

RFG CSO

441 SWS COKE

431 ARU

431/452/ 453 ARU

SULFUR COKE

CDU/ VDU UNIT

Unit Objectives- CDU/VDU

The objective of the Unit is to separate the crude oil into various fractions viz: Off gases or Lean gases Liquefied Petroleum Gas (LPG) Full Range Naphtha (FRN) Light Kerosene (LK) Heavy Kerosene (HK) Diesel (AGO or HSD) Gas Oils (HAGO / LVGO / HVGO) Vacuum Residue (VR)

CDU Process
Other stream from s D T, VGOH H T, LN U H U U, NU

Lean Gas

S G C

LP G

FR N
LK / ATF

Old Desalters
C rude In

1st Stg.

2nd Stg.

1st Stg.

2nd Stg.

Flash Drun
Preheat 2

Heater

Atm osp heri c C ol.

H K

D iesel

Preheat 1

New Desalters

Preheat 3

H AGO
LVGO

Water In

Heater
Brine Out

V a c. C o l.

H VGO

VacuumR esidue

Major Equipment
Desalters Fired Heaters Heat Integration circuit Crude Flash Drum Main Fractionator Side strippers Multi Stage Ejector system

Fluid Catalytic Cracking Unit

Why FCC ?
Heavier Crudes Need for cracking heavy ends Heavy demand for lighter fuels

Why FCC
Converts VGO in to Gasoline and lighter products. Cheapest available conversion process Offers great flexibility of operation (can be run in LPG, Gasoline or distillate mode) Produces large quantity of Petrochemical feed stocks

Major Equipment
Reactor and Regenerator Power recovery trains (PRTs) Vortex separators/ Cyclones Main Air Blower/Expander/Motor generators/Steam generator Flue gas cooler Main Fractionator/ Side Stripper Waste Heat Boiler

Typical Gas Con unit

Hp Receiver Stripper Debutanizer, C3C4 splitter Absorber Amine absorber Naphtha splitter Depentanizer

Puprose of Gas Con Unit

To separate Close boiling range lighter products like Fuel gas, LPG, Gasoline, Naptha. Acts as partial heat sink for Main fractionator. Stabilizes Naptha H2S removal from gaseous products.

DHT and VGOHT

A Hydro treater/ Union finer is a process unit Where Hydrocarbon Feed is treated with hydrogen in presence of catalyst at high temperature & pressure. Desulfurization(3.2wt% 0.2wt%) 94% Denitrification (1658 ppm 760ppm) Aromatic and Olefin saturation

DIESEL HYDROTREATER

DHT

Major Equipments
Recycle Gas Compressor Fixed Bed Catalytic Reactor Catalyst 300m3 (NiMo CoMo) Fired Heater Stripper

A
NA PHTHA PR E HEA T EX FEED DIES EL S TRIPPER

FILTER

FUR NA CE

R EA CTOR

Fi N COOLER

D r i e r
Lo w mo isture DIES EL PROD UCT

FEED ( HIGH S) R EA CTOR EFFLUE NT PROD UCT(LOW S) S EPA RA TOR

VGO HYDROTREATER

VGOHT

A
NAPHTHA PRE HEAT EX FEED VGO FILTER FURNACE FRACTIONATOR REACTOR

Kerosene
DIESEL

FAN COOLER

FEED (HIGH S) REACTOR EFFLUENT PRODUCT(LOW S) SEPARATOR VGO PRODUCT

Why VGOHT ?
The Gas Oil product ex. Crude/Coker has high sulfur content. This is to be reduced before sending to FCC for SOX emission control Hydro-desulphurization of Gas oil is carried out in VGO hydro treating units. De Nitrification of Gas oil

VGOHT Major Equipments

Recycle Gas Compressor Fixed Bed Catalytic Reactor Catalyst 300m3 (NiMo CoMo) Fired Heater Stripper

Sulfur Complex
Sour Water Stripping Unit (SWS) Amine Treating Unit (ATU) Sulfur Recovery Unit (SRU)CBA Granulation Unit

Overview - Sulfur Complex

SWS Unit CBA Units Amine Unit
Two absorber Four Strippers

Granulation Unit

S -Dispatch

SRU Objective
Main Objective of the unit is to convert H2S in to elemental Sulfur.

Why SRU ?
More Stringent environmental norms of Government / regulatory bodies. Enables the refinery to process High sulfur crudes.

SRU Process
Acid gas from SWS and ATU stripper is oxidized (burnt) in 2 stages and then treated in catalytic converter. The molten sulfur is transferred to SGU to form Sulfur granules.

Major Equipment
Amine absorber Flash drum Stripper Reaction furnace Catalytic Reactor Incinerator Waste heat boiler

ATU-Simplified Flow Scheme

FG Out LA
Absorber Stripper

Acid Gas

FG In

Flash Drum

RA Pump

LA Pump

Lean Amine

CBA-Equipment
Claus Reactor Reaction Furnace
V03
LPG C.A

CBA Reactors
R02 R03

Steam Drum

R01

WHB
F02
Acid Gas

B01

B02
S03 S04 S05 S06

Vent Eductor Sulfur Cooler

S02
Rundown Line
Product Chamber RD Chamber

Condensers Sweep Air Stack

Steam Drum
V04
Stack

Sulfur Pit Incinerator

F03

WHB

Auto - Fuel quality trend upto 2010

Gasoline
BIS-2000 Bharat stage- Euro-III Euro-IV EURO-III II (Reg/ Equivalent Equivalent (effective Prem) (Reg/ Prem) (Reg/ Prem) 2000 in EU) 500 3 metros, 5 rest @ 88/93 NA 84/88 NA NA NA NA 150 1 91/95 81/85 NA 42 21/18 10 / 45 40 / 70 50 1 91/95 81/85 NA 35 21/18 10 / 45 40 / 70 150 1 95 85 NA 42 18 20 / 48 46 / 71 EURO-IV (effective 2005 in EU) 10# 1 95 85 NA 35 11** 20 / 48 46 / 71

Sulphur, max. Benzene, max. RON, min MON, min AKI, min Aromatics, max. Olefins, max. E 70 E 100

ppmw % vol No. No. No. % vol % vol deg C deg C

1000 3 metros, 5 rest 87 NA 84 NA NA NA NA

@ The Benzene content will be progressively reduced to 1 vol% by Apr 2005 in 7 mega cities. The rest of the country would have a maximum limit of 3 vol% from Apr 2005. # 50 ppmw to be supplied from 2005 & 10 ppmw by 2008 ** to be reviewed by 2005 by European Union.

Sulfur in Gasoline to go down to 50 ppm by 2010 and benzene to less than 1%

Auto - Fuel quality trend upto 2010

Diesel Fuels
BIS-2000 Sulphur, max. Cetane Number, min Cetane Index, min Distillation T95, max Poly Aromatics, max. Flash point, min. ppmw No. No. DegC % wt DegC 2500 48 46 @ 370 NA 35 Bharat stage- Euro-III II Equivalent 500 48 @ 46 @ 370 NA 35 350 51 46 360 11 35 EURO-III EURO-IV Euro-IV (effective (effective Equivalent 2000 in EU) 2005 in EU) 50 51 48 360 11 35 350 51 48 360 11 55 10# 51** NA 360** 11** 55

@ Cetane number 48 or Cetane index 46 # 50 ppmw to be supplied from 2005 & 10 ppmw by 2008 ** to be reviewed by 2005 by European Union.

Sulfur in Diesel to go down to 50 ppm by 2010 and Cetane Number will be above 51

Delayed Coker Unit

A thermal cracking and successive polymerization process-rapid heating of vacuum residue ( ex VDU) above cracking temperature to form mixture of distillates and coke. The process of formation of coke is delayed in the furnace by way of maintaining higher velocities using HP steam/ BFW

Why DCU ?
High margin No Fuel oil generation Value added products (LPG, Diesel, Naphtha, Fuel gas and Coke) No Catalyst Involved Capable of processing Refinery slop and sludge

Major Equipment- Coking Section

Coke drum Fractionator Fired Heater Blow down system Coke Cutting system- PLC based Heat Integration circuit Heading and De heading unit Product Filter-PLC based

RTF Overview

Functions of RTF
Ensure uninterrupted supply of Crude Oil and other feed/intermediates to Various Units. Receive intermediates, products and blending components from various units. Supply of RFO & slop for reprocessing. Blending Correction of Offspec product.

RTF Work Flow

FINAL PRODUCTS

AROMATIC COMPLEX

FUEL COMPONENTS

REFINERY FUEL FUEL STORAGE

HEAVY NAPHTHA
INTERMEDITE PRODUCT STORAGE

MTF
FINAL PRODUCTS STORAGE

INTERMEDIATE PRODUCTS

FINAL PRODUCTS
BLEND COMPONENTS STORAGE

RFO
REFINERY COMPLEX

BLEND HEADER

RAW MATERIALS
RAW MATERIALS STORAGE

RAW MATERIALS

RRTF

SLOPS

SLOPS STORAGE

RTF

Major Equipment
Fixed Roof Storage tanks Floating roof Storage Tanks Horton Spheres Mixers Pumps

Any Questions ?

Thank you