petroleum intro-rev 4

Introduction to Petroleum & Petro - Chemical Products. Description on Unit Process, Production & Business Opportunities In India

CONTENTS

1.  The Black Gold 2.  About Hydrocarbon Industry 3.  A Guide of Refinery Process 4.  Table of various process with approximate cost & criticality 5.  Crude Distillation Unit 6.  Production of Gasoline (Petrol) from Heavy Naphtha 7.  Fluid Catalytic Cracking 8.  List of Refineries in India and their production capacities 9.  Procurement Methods adopted by Indian Refineries 10.  Major Refinery Equipment’s

- Part 1 of Presentation

THE BLACK GOLD WhatisCrudeOil?•  Anunrefinedpetroleumproductcomposedofhydrocarbondepositsandorganic

compounds.OriginofHydrocarbons

TypesofCrudeOil•  SweetCrude(LowH2S&CO2)–MostpreferableforproducDonofgasoline.•  SourCrude(HighH2S&CO2)–Crudewithmorethan0.5%sulfurGradesofCrude•  Brent(UK),WestTexasIntermediate(US),Daqing(China),BCF-17(Venezuela),

Maga(Mexico),Bonny(Nigeria),Dubai(UAE)Composi<on•  83–87%Carbon•  11-15%Hydrogen•  1–6%Sulfur

AcDonofmicro-organismsonDecayingPlants&

Animals

FormaDonofHydrocarbonsHighPressure&high

Temperature

UnderEarthsSurface

Graph Explaining the grades of crude oil

API = (141.5/S) – 131.5

ABOUT HYDROCARBON INDUSTRY Upstream, Midstream & Downstream Process

Hydrocarbon Industry – Up Stream Process

Petroleum Exploration •  Explora<onTechniques•  GeoPhysical

•  GravimetricMethod•  MagnetometricMethod•  SeismicSurvey•  RemoteSensingMethod

•  GeoChemical•  Chemicalanalysisofsurfacesoil

androcks

•  GeoTechnical•  MechanicalProperDesofrocks

andsurfacearemeasured

Petroleum Production •  OilExtrac<on&Recovery•  Primaryrecovery

•  Oncethecompleterigisset-up,theundergroundpressureintheoilreservoirissufficienttoforcetheoiltothesurface.

•  Secondaryrecovery•  Supplyofexternalenergyintothe

reservoirintheformofinjecDngfluidstoincreasereservoirpressure,henceincreasingthenaturalreservoirdrivewithanarDficialdrive.(eg.Water,Naturalgas)

•  Enhancedrecovery•  Thismethodinjectssteamtoheat

upoilthereservoirtoreduceitsviscosityandmakingiteasiertoextract.

VARIOUS TYPES OF RIGS USED FOR PETROLEUM EXTRACTION On shore Platforms & Off shore Platforms

Hydrocarbon Industry – Down Stream Process

Refining & Petrochemicals •  Refining

•  PetroleumrefiningprocessesarethechemicalengineeringprocessestotransformcrudeoilintousefulproductssuchasLiquefiedPetroleumGas(LPG),Gasoline(Petrol),Kerosene,JetFuel,DieselOil&fueloils.

•  Petrochemicals

•  Chemicalsobtaineddirectlyfromcracking(pyrolysis),orindirectlyfromchemicalprocessingofpetroleumoilornaturalgas.

•  Fewexamples,plasDcs,rubbers,fibres,paints,solvents&detergents.

Marketing & Distribution •  Marke<ng

•  MarkeDngisthefinalstepinthechainthatdeliversusefulpetroleumproductstoend-usercustomers.

•  Drivingfactors:•  Volume•  MarketShare•  Margin

•  Distribu<on

•  DistribuDonlinesofoil&gasmustbemanagedwithhighlevelsofconsistencyandsafety.

•  DistribuDonisdonevia,•  Pipelines•  Cryogenictanks•  On-Sitesystems

Ministry of Petroleum & Natural Gas

Industry Bodies

Petroleum Planning & Analysis Cell

Centre for High Technology Petro Fed Petroleum Conservation

& Research Association

Up Stream Process

Exploration & Production

ONGC OIL

Private companies

like Cairn, RIL etc.,

Down Stream Process

Refining & Marketing

HPCL BPCL IOCL RIL, etc.,

Distribution

GAIL India RIL

Hydrocarbon Industry – India

Src:MinistryofPetroleum&NaturalGas

A GUIDE OF REFINERY PROCESS

CrudeOilStorageTank

Desalter

HeaDng (CDU

)Crude

DisD

llaDo

nUnit/ADU

VD

U(V

acuu

m

DisDllaDo

nUnit)

GasProcessing

NHTU

NHTU

ATF-HDT

DHDT

VGO-HDT

Hydrocracker

DCU

BitumenBlowing

ARU

Merox

SRU Sulphur

LPG(Propane&Butane)

Naptha

Gasolline

JetFuel/Kerosene

DieselFuel

ISOM

CCR

ATFMEROX

FCCU

AlkylaDonUnit

PolyUnit

NeedleCokeUnit

PropylenePRU

LightGas

LightNaphtha

HeavyNaphtha

KeroseneJetFuel

DieselOil

GasOil

DesaltedCrude

ReducedCoke

FuelGas

H2S

RefineryFuel/FuelGas

H2H2

H2S

Diesel

VacuumResiduel

HeavyVacuumGasOil

C3/C4

Propane

Butane

DieselIso-Butane

Gasoline

LightVacuumGasOil

PremierCokeCokerNaphthatoCCRCokerGasoiltoFCCUPetroleumCoke

Bitumen

A GUIDE OF REFINERY PROCESS

CrudeOilStorageTank

Desalter

HeaDng (CDU

)Crude

DisD

llaDo

nUnit/ADU

VD

U(V

acuu

m

DisDllaDo

nUnit)

GasProcessing

NHTU

NHTU

ATF-HDT

DHDT

VGO-HDT

Hydrocracker

DCU

BitumenBlowing

ARU

Merox

SRU Sulphur

LPG(Propane&Butane)

Naptha

Gasolline

JetFuel/Kerosene

DieselFuel

ISOM

CCR

ATFMEROX

FCCU

AlkylaDonUnit

PolyUnit

NeedleCokeUnit

PropylenePRU

LightGas

LightNaphtha

HeavyNaphtha

KeroseneJetFuel

DieselOil

GasOil

DesaltedCrude

ReducedCoke

FuelGas

H2S

RefineryFuel/FuelGas

H2H2

H2S

Diesel

VacuumResiduel

HeavyVacuumGasOil

C3/C4

Propane

Butane

DieselIso-Butane

Gasoline

LightVacuumGasOil

PremierCokeCokerNaphthatoCCRCokerGasoiltoFCCUPetroleumCoke

Bitumen

v

vv

vv

v

VARIOUS UNIT PROCESS IN REFINERY Table of Various Unit Process with Approximate cost & criticality

Table of Various Unit Process with Approximate cost & criticality

S.No. Unit Name Approximate Cost Criticality

Major Units

1 CDU – Crude Distillation Unit

2 VDU – Vacuum Distillation Unit

Hydro-treating Process

3 ATF HTD - Aviation Turbine Fuel Hydrotreater

4 DHDT – Diesel Hydrotreating

5 NHT – Naphtha Hydro Treater

6 VGO HDT – Vacuum Gas Hydrotreater

Cracking Process

7 FCCU - Fluid Catalalytic Cracking Unit

8 Steam Cracking Unit

9 Hydrocracking Unit

Reforming Process

10 CCR – Continuous Catalytic Reformer



Isomerization Process

11 Light Naphtha Isomerization Unit

De-Sulfurization / Merox Process & Sulfur Recovery Process

12 ATF Merox – Aviation Turbine Fuel Merox

13 GMU – Gasoline Merox Unit

14 Extraction and removal of mercaptans from LPG

15 SRU – Sulfur Recovery Unit

16 SWS – Sour Water Stripper

Coking Process

17 DCU – Delayed Coker Unit

18 Needle Coker Unit

19 Fluidic Coking Unit

20 Flexi Coking Unit



Other Units

21 HF Alkylation Unit

22 Vib Breaker Unit

23 Polymerization Unit

24 ARU - Amine Recovery Unit

25 AGS – Air Generation System

26 AGU – Acid Generation Unit

27 De-Salination / De-Mineralization Unit

28 ETP – Effluent Treatment Plant

29 Hydrogen Manufacturing Unit

CRUDE DISTILLATION UNIT Atmospheric Distillation Unit & Vacuum Distillation Unit

Atmospheric Distillation Unit (ADU) – Process Flow Diagram

PipeSDllFurnace

SideStripper

De-Salting Unit

PreheatedCrudeOil

DMWater

CausDcSoluDon

PowerT.F

DosingPump

FIC

CrudeoilFeedPump

pHC DPC

Salt-Water

CrudeOil ElectrodePlatesOil–WaterInterface

TT PT

FIC

CrudeBoosterPump

SaltandWatertoDrain

LC

•  FIC-FlowIndicatedControl

•  TT–TemperatureTransmijer

•  PT–PressureTransmijer

•  DPC–DualZonePressureController

•  LC–LevelController

Vacuum Distillation Unit (VDU) – Process Flow Diagram

PRODCUTIONOFGASOLINE(PETROL)FROMHEAVYNAPHTHA Naphtha Hydro Treatment Unit & Reforming Unit

Naphtha HydroTreater - Process Flow Diagram

RawNaphthaStorage

Hyd

roge

n Se

para

tor

Feed Pump

Furnace

Cooler

Make up Hydrogen

Recycle Compressor

Strip

per

Gases to fuel system or sulfur recovery unit

Desulfurised naphtha to storage

Reboiling Furnace

Reactor

Heavy Naphtha Reformer– Process Flow Diagram

DesulfurisedNaphthaStorage

Hyd

roge

n Se

para

tor

FeedPump

Furnace

Cooler

Hydrogentostorage

RecycleCompressor

Debu

taniser

Reactor

Reactor

Furnace

Furnace

Reactor

GasestofuelSystem

ReformatetoStorage

FLUIDISED CATALYTIC CRACKING (FCC) Conversion of VGO(Vacuum Gas Oil) into Gasoline Intermediates using side by side FCC configuration

FLUEGAS

ELECTROSTATICPRECIPITATOR

CATALYSTFINES

SEPARATOR

CATALYSTFINES

COBOILER

FLUEGAS

STEAMAIR

CONDENSATECOMBUSTIONAIR

REGENERATOR

FLUEGAS

FLUEGAS

REACTOR

535DegC1.72barg

CONDENSER

380.56barg

REFLUX

OFFGAS

PHENOLICSOURWATER

REFLUXDRUM

FEEDSTOCK315-430

TOTALFEED

SIDECUTSTRIPPER

CRACKEDNAPHTHA

STEAM

FUELOIL

FUELOIL

SLURRYSETTLER

SLURRYOIL

715DegC2.41barg

DISTILLA

TIONCOLU

MN

STEAM

REACTIONPRODUCTGAS

FLUIDIZED CATALYTIC CRACKING

Fluid Catalytic Cracking

List of Refineries in India and their Production Capacities

Sl.No Sector RefineryName

Loca<on

InvestmentCost(Rs.Incrores)

CommissionedOn

Produc<onCapacity(MMTPA)

PresentProduc<onCapacity(MMTPA)

1 IOCL GuwahaDRefinery Assam 17.29 1stJanuary1962

0.75 1

2 IOCL BarauniRefinery Bihar 49.4 July1964 3.3 6

3 IOCL KoyaliRefinery Gujarat 26 October1965 2 13.7

4 IOCL HaldiaRefinery WestBengal

January1975 2.5 7.5

5 IOCL MathuraRefinery UjarPradesh

253.92 January1982 6 8

6 IOCL DigboiRefinery Assam 1901/October1981

0.5 0.65

7 IOCL PanipatRefinery Haryana 3868 1998 6 15

8 IOCL BongaigaonRefinery(BRPL)

Assam 50 20thFebruary1974

1 2.35



Loca<on


CommissionedOn



9 IOCL ParadipRefinery Orissa 34,555 February7,2016

15

10 HPCL MumbaiRefinery Maharashtra

1954 1.25 6.5

11 HPCL VisakhRefinery AndhraPradesh

1957 0.675 8.3

12 BPCL MumbaiRefinery Maharashtra

1955 2.2 12

13 BPCL KochiRefinery Kerala 27thApril1963 2.5 15.5

14 CPCL(IOCL+NIOC)

ManaliRefinery TamilNadu

43 1965 2.5 10.5

15 CPCL CauveryBasinRefinery

Nagapaonam,TN

1993 0.5 1

16 NRL NumaligarhRefinery Assam October2000 3



Loca<on


CommissionedOn



17 MRPL(ONGC)

MangaloreRefinery Karnataka March1996 3.69 15

18 ONGC TaDpakaRefinery AndhraPradesh

27 September2001

0.066 0.132

19 Private JamnagarRefinery(RIL–DTA)

Gujarat 33

20 Private JamnagarRefinery(RIL–SEZ)

Gujarat 37

21 Private EssarOilLimited Vadinar,Gujarat

November2006

10.5 20

22 BORL(BPCL+OOCL)

BinaRefinery MadhyaPradesh

12,200 May,2011 6

23 HMEL(HPCL+Mijal)

GuruGobindSinghRefinery

Bathinda,Punjab

April,2012 9

PROCUREMENT METHODS ADOPTED BY INDIAN REFINERIES Conventional Route & EPC Route

Construction Procurement Engineering

ProcurementmethodadoptedbyIndian

Refineries

Owner(IOCL,BPCL,HPCL,CPCL,NRL,

BORL,BRPL,RIL,ESSAR)

AppoinDngprocesslicensor&consultantforFEEDStudy

(FrontEndEngineeringDesign)

ApprovalfromBoard/Governmentforproject

implicaDons

Method-1:CONVENTIONALROUTE Method-2:LSTK/EPCROUTE

AppoinDng“ProcessLicenser”(ByOwner)

AppoinDng“EPCM”Consultant(ByOwner)

ProcessDesign&Sizingof‘Units”byprocesslicenser

DetailDesignofunits&sizingof“IndividualEquipment's”byEPCMconsultant

PreparaDonofMR,SpecificaDons,DataSheets&Drawingsfor“Individual

Equipment”byEPCM

InvitaDonfortendersfor“IndividualEquipment's”asperMR’sbyEPCM

SubmissionofTechno-CommercialBidsby“Bidders(Manufacturers)”

TechnicalEvaluaDonbyEPCM

CommercialEvaluaDon&RecommendaDonbyEPCM

ApprovalOfBidderandorderreleasefor“IndividualEquipment's”byowner.Allfinancial

commitmentstobiddersisbyowner

BidderspostorderacDviDeslikedrawings,procurement,manufacturing&E&Cwillbe

monitoredbyEPCM&Owner

CompleDonofproject&commissioningofplantismonitoredbyEPCM

AppoinDng“ProcessLicenser”(ByOwner)

AppoinDng“PMC”Consultant(ByOwner)

Processdesignbasisof“Units”byprocesslicenser

PreparaDonofprojectspecificaDons&minimumdesign&qualityrequirementsbyPMC

InvitaDonfortendersforLSTK(EPC)biddingfor“UNITS”byPMC

SubmissionofTechno-CommercialbidsbyLSTKcontractors.

TechnicalevaluaDonbyPMC&Processlicensor

CommercialevaluaDonandrecommendaDonbyPMC

ApprovalofLSTKcontractorandorderreleasefor‘Units”byowner.Allfinancialcommitments

toLSTKcontractorsarebyowner

LSTKwilldevelopprocessdesign,P&ID’s&equipmentdatasheets&MR’sfor“IndividualEquipment's”.MayappointDEC&inspecDon

agency,ifrequired.

InvitaDonfortendersfor“IndividualEquipment's”asperMR’sbyLSTK

SubmissionofTechno-Commercialbidsby“Bidders(Manufacturers)”

Technical&CommercialevaluaDonbyDEC&LSTK

Approvalofbidderbyowner/PMC&orderreleasebyLSTKcontractor.AllfinancialcommitmentstobiddersarebyLSTK

contractor.

BidderspostorderacDviDeslikedrawings,procurement,manufacturingandE&CwillbemonitoredbyLSTKcontractoraswellas

EPCM&owner.

CompleDonofproject&commissioningofplantisdonebyLSTKcontractor&approvedbyPMC/

Licensor/Owner

Major Refinery Equipment’s •  Pressure vessels

•  Heat exchangers •  Shell & Tube Heat Exchangers •  Plate & Frame Heat exchangers •  Air cooled heat exchanger •  Double Pipe exchanger

•  Process Vessels •  Drums •  Gravity Separators •  Column •  Reactor

•  Storage Tanks •  Fixed-roof tanks •  External floating roof tanks •  Internal floating roof tanks •  Domed external floating roof tanks •  Horizontal tanks •  Pressure tanks •  Variable vapor space tanks •  LNG (Liquefied Natural Gas) tanks

•  Fired heaters / Furnace •  Piping system & Valves •  Pumps

•  Centrifugal Pumps •  Positive Displacement pumps

•  Reciprocating pumps •  Rotary Pumps

•  Compressors •  Reciprocating •  Rotary Screw •  Rotary Centrifugal

•  Cooling Towers

Heat Exchangers

Shell & Tube Heat Exchanger Plate & Frame Heat Exchanger

Heat Exchangers

Air Cooled Heat Exchanger Double Pipe Heat Exchanger

Process Vessels

Drums Gravity Separators

Process Vessels

Drums Drums

Process Vessels

Separators Separtors

Process Vessels

Column Reactor

Storage Tanks

Fixed Rook Tank External Floating roof tank

Storage Tanks

Internal Floating roof tank Doomed External floating roof tank

Storage Tanks

Horizontal tank Pressure Tank

Storage Tanks

Variable vapor space tank LNG Tanks

Fired Heaters / Furnace

Cooling Towers

Reference

1.  TheBlackGold•  Fundamentalsofpetroleum&PetrochemicalEngg–UjamRayChaudhuri•  hjps://en.wikipedia.org/wiki/Benchmark_(crude_oil)•  hjp://www.markeDndex.com.au/crude-oil

2.  AboutHydrocarbonIndustry•  Fundamentalsofpetroleum&PetrochemicalEngg–UjamRayChaudhuri

3.  AGuideofRefineryProcess•  ChemicalEngineeringProcess–AnAICHEPublicaDons•  EssarpresentaDon

4.  Tableofvariousprocesswithapproximatecost&criDcality5.  CrudeDisDllaDonUnit

•  Fundamentalsofpetroleum&PetrochemicalEngg–UjamRayChaudhuri6.  ProducDonofGasoline(Petrol)fromHeavyNaphtha

•  Fundamentalsofpetroleum&PetrochemicalEngg–UjamRayChaudhuri•  ChemicalEngineeringProcess–AnAICHEPublicaDons

7.  FluidCatalyDcCracking•  hjps://en.wikipedia.org/wiki/Fluid_catalyDc_cracking•  ChemicalEngineeringProcess–AnAICHEPublicaDons

8.  ListofRefineriesinIndiaandtheirproducDoncapaciDes•  MinistryofPetroleum&NaturalGasIndia

petroleum intro-rev 4

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