refinery process

Crude Oil

A fossil fuelConsists of several fractionsA mixture of very wide range of Hydrocarbons Normally Black in colorAvailable in plenty in Middle East (Persian Gulf)Also available in North & western Africa, Indonesia, South & Central America, ScandinaviaIn India, it is available in Bombay High, Krishna-Godhavari 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 DistillationConversionTreatmentBlending

Typical refinery Units

Crude Dist Unit & Vac Dist Unit Hydro treating unitFluid Catalytic Cracking unitDelayed Coker unitMeroxSulfur Rec.Unit & ATURefinery Tank Farm

RTF

F

M H

Cr 1

Cr 2A

C

US

RRT

PP

CPP

RRT

ETP

A

NgWater Storageg Buildingsg RTFg Road/Rail loadingg Sulphur

g CPP / Utilitiesg Cokerg PPg Aromaticsg CDU / VDU

Typical Layout of a Refinery

Material Flow

Jetties4 Nos.

SPM2 Nos.

MTFRTF

RRTFRail loading

Road loading

Pipelinedespatch

Capacity

Koyali

MRL

CRL

MathuraBPCL

Barauni

Guwahati

Small & Simple

Large & Complex

MRPL

Digboi

Bongaigon

Vizag

HPCLHaldia

Panipat

Com

plex

ity

Increased Complexity enhances margins

Source: Chemsystem

Reliance

Refinery Block Flow diagram

311/312CDU

HN

221

HNUU

CRUDE

311/312

VDU

VR371

DCU

372

COKER

GAS

PLANT

234PSA

231/232PLAT

521/522H2 C1H 2

281TATORAY

H2TOLUENE

LPG331SATLPG

MEROX

LN 471LNUF

PC NAPHTHALPG

271/272/273ISOMAR

261/262/263PAREX

241/242/243XYL FR

HARNGT FUELO-XYLENE

P-XYLENE

321/322SATGCU

VGO361/362VGO

UNI.FIN

411/412/413FCC

414UNSAT

GCU

351/352DIESELUNI.FIN

341KERO

MEROX

KERO

KERO / ATF

DIESEL

LAB FEED

415UNSAT

LPGMEROX

LPG

LPG 422PROPREC

ETYLREC

551/552PP

ETHYLENE

PP

PROPYLENE416

GASOLMEROX

TAME

LN

HN

HN

HN

C5

CSOCSO

RFG

MS

180-215GT FUEL

LCO

441SWS

431ARU

431/452/453

ARU

SULFUR

COKELCGO

GAS OIL

LNHCGO

180-215

251OX-FR

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 gasesLiquefied 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

Crude In 1st Stg. 2nd Stg.

1st Stg. 2nd Stg.

Old Desalters

New Desalters

V a c. C o l.

S G C

Atmospheric

Col.

Other streams fromDHT, VGOHT,LNUU, HNUU

LPG

HK

LK / ATF

FRN

Lean Gas

LVGO

Vacuum Residue

Preheat 1

Water In Brine Out

Preheat 2

Flash Drun

Preheat 3

Heater

Heater

Diesel

HAGO

HVGO

Major Equipment

DesaltersFired HeatersHeat Integration circuitCrude Flash DrumMain FractionatorSide strippersMulti 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 processOffers great flexibility of operation (can be run in LPG, Gasoline or distillate mode)Produces large quantity of Petrochemical feed stocks

Major Equipment

Reactor and RegeneratorPower recovery trains (PRTs)Vortex separators/ CyclonesMain Air Blower/Expander/Motor generators/Steam generatorFlue gas coolerMain Fractionator/ Side StripperWaste Heat Boiler

Typical Gas Con unit

Hp ReceiverStripperDebutanizer, C3C4 splitterAbsorberAmine absorberNaphtha splitterDepentanizer

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 NapthaH2S 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 ReactorCatalyst 300m3 (NiMo CoMo)Fired HeaterStripper

A

REACTORFILTER FUR NA CE

FEED (HIGH S)

REACTOR EFFLUENT

STRIPPERFEED DIESEL

PRE HEAT EX

FiNCOOLER

PROD UCT(LOW S)

Low moisture DIESEL

PROD UCT

SEPARA TOR

NA PHTHA

Drier

VGO HYDROTREATER

VGOHT

A

REACTORFILTER FURNACE

FEED (HIGH S)

REACTOR EFFLUENT

FRACTIONATORFEED VGO

PRE HEAT EX

FAN COOLER

PRODUCT(LOW S)

VGO PRODUCT

SEPARATOR

NAPHTHA

DIESEL

Kerosene

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 ReactorCatalyst 300m3 (NiMo CoMo)Fired HeaterStripper

Sulfur Complex

Sour Water Stripping Unit (SWS)Amine Treating Unit (ATU)Sulfur Recovery Unit (SRU)-

CBAGranulation Unit

Overview - Sulfur Complex

SWS Unit

Amine UnitTwo absorberFour Strippers

CBA Units GranulationUnit

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 absorberFlash drumStripperReaction furnaceCatalytic ReactorIncineratorWaste heat boiler

ATU-Simplified Flow SchemeFG Out

RA Pump

Acid Gas

Flash Drum

LA

FG In

Lean AmineLA Pump

AbsorberStripper

CBA-Equipment

F02 B01 B02

R01 R02 R03

S03

S02

S04

S05 S06

V03

F03

Stack

C.ALPG

Acid Gas

V04RD ChamberProduct Chamber

Rundown Line

Reaction Furnace

WHB

Steam Drum

CBA Reactors

Sulfur Pit

EductorSulfur Cooler

Sweep Air Stack

Vent

IncineratorWHB

Steam Drum

Claus Reactor

Condensers

Auto - Fuel quality trend upto 2010

BIS-2000Bharat stage-

II (Reg/ Prem)

Euro-III Equivalent

(Reg/ Prem)

Euro-IV Equivalent

(Reg/ Prem)

EURO-III (effective

2000 in EU)

EURO-IV (effective

2005 in EU)

Sulphur, max. ppmw 1000 500 150 50 150 10#Benzene, max. % vol 3 metros, 5

rest 3 metros, 5

rest @1 1 1 1

RON, min No. 87 88/93 91/95 91/95 95 95MON, min No. NA NA 81/85 81/85 85 85AKI, min No. 84 84/88 NA NA NA NAAromatics, max. % vol NA NA 42 35 42 35Olefins, max. % vol NA NA 21/18 21/18 18 11**E 70 deg C NA NA 10 / 45 10 / 45 20 / 48 20 / 48E 100 deg C NA NA 40 / 70 40 / 70 46 / 71 46 / 71@ 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.

Gasoline

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

Auto - Fuel quality trend upto 2010

BIS-2000 Bharat stage-II

Euro-III Equivalent

Euro-IV Equivalent

EURO-III (effective

2000 in EU)

EURO-IV (effective

2005 in EU)

Sulphur, max. ppmw 2500 500 350 50 350 10#Cetane Number, min No. 48 48 @ 51 51 51 51**Cetane Index, min No. 46 @ 46 @ 46 48 48 NADistillation T95, max DegC 370 370 360 360 360 360**Poly Aromatics, max. % wt NA NA 11 11 11 11**

Flash point, min. DegC 35 35 35 35 55 55

# 50 ppmw to be supplied from 2005 & 10 ppmw by 2008** to be reviewed by 2005 by European Union.

@ Cetane number 48 or Cetane index 46

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

Diesel Fuels

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 marginNo Fuel oil generationValue added products (LPG, Diesel, Naphtha, Fuel gas and Coke)No Catalyst InvolvedCapable of processing Refinery slop and sludge

Major Equipment- Coking Section

Coke drumFractionatorFired HeaterBlow down systemCoke Cutting system- PLC basedHeat Integration circuitHeading and De heading unitProduct 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.BlendingCorrection of Offspec product.

RTF Work Flow

AROMATICCOMPLEX

INTERMEDITEPRODUCTSTORAGE

RAW MATERIALSSTORAGE

BLENDCOMPONENTS

STORAGE

SLOPSSTORAGE

MTF

RRTF

REFINERYCOMPLEX

HEAVY NAPHTHA

INTERMEDIATE PRODUCTS

FINALPRODUCTSSTORAGE

FINAL PRODUCTS

BLEND HEADER

SLOPS

RAW MATERIALS

FINAL PRODUCTS

RAW MATERIALS

RTF

REFINERY FUELFUEL STORAGE

RFO

FUELCOMPONENTS

Major Equipment

Fixed Roof Storage tanksFloating roof Storage TanksHorton SpheresMixersPumps

Any Questions ?

Thank you