Presentation

on

FUNDAMENTALS OF

REFINERY PROCESSES
FOR

HPCL CPM 4
 CONTENTS

• GROWTH & DEVELOPMENT OF REFINING INDUSTRY

• CRUDE OIL AND ITS CHARACTERISTICS

• REFINING PROCESSES

• SPECIFICATIONS OF PRODUCTS & RELATED TESTS

• INTEGRATED REFINERY & PETROCHEMICAL PLANTS

• ADVANCES IN PETROLEUM REFINING TECHNOLOGIES

• FUTURE REFINING SCENARIO

• ENERGY CONSERVATION & LOSS MINIMIZATION

• GROSS REFINING MARGIN & REFINERY PROFITABILITY

 Development of Indian Refining Industry

 During the last 70 years after the Independence

Country witnessed remarkable growth in
Crude Oil Refining facilities.

Refineries growing from 1 to 23 in number;

installed Crude processing capacity increasing
from 0.25 MMTPA at the time of independence
to 235 MMTPA as on 1st April’ 2017.

 At present there are 23 Refineries operating in

the country (17 in Public sector, 3 in Joint sector
and 3 in Private Sector)
 Development of Indian Refining Industry

 At the time of Independence, India had only 1

very small capacity Refinery at Digboi. Capacity
0.25 MMTPA.

 First decade of Independence (1947-57) saw the

establishment of 3 Coastal Refineries by
Multinational oil companies operating in India at
that time i.e. Burma Shell, Stanvac and Caltex.
Burmah Shell and Stanvac set up their refineries
in Bombay while Caltex did so at Vizag.

Total Refining capacity in India raised to 4.8

MMTPA
 Development of Indian Refining Industry
 Second decade (1957–67) witnessed the
commissioning of 3 fully owned public sector oil
Refineries – at Barauni, Guwahati & Koyali. These 3
inland Refineries were set-up with co-operation
from Romania & Russia essentially to process the
indigenous crudes.
Total Refining capacity = 12.7 MMTPA
 Next 10 yrs. (1967-77) witnessed establishment of 2
Refineries – one at Chennai with the participation of
American & Iranian companies and other in public sector
(at Haldia) by IOC with the assistance from Romania
and France.
Total Refining Capacity = 22.9 MMTPA
 Development of Indian Refining Industry
 Period (1977-87) saw commissioning of 2 more
Refineries in Public sector, one at Bongaigaon; which was
the first Refinery-cum-Petrochemical Unit in India, and other
at Mathura in 1982 with the assistance of Soviets.
Major expansions of the Coastal Refineries at Mumbai,
Cochin, Madras and Vizag was also completed in that
period. Total Refining capacity = 47 MMTPA

 During the 8th plan period, domestic Refining capacity

has been raised to about 62 MMTPA. The highest priority
has been accorded to low cost expansion of the Refining
capacity and a new Refinery of 3 MMTPA (in Joint Sector) at
Mangalore was commissioned, which underwent major
expansions later on.
 Development of Indian Refining Industry

 Period 1997-2002 saw commissioning of 2 more

Refineries in Public / Joint sector (Panipat and NRL)
and one in Pvt. Sector (RIL, Jamnagar – 33
MMTPA) taking the total Refining capacity to
about 115 MMTPA.
 In 2007, Essar (Pvt. Sector) commissioned its 10.5
MMTPA Refinery at Jamnagar, which was expanded in
stages to 20 MMTPA capacity.
 By April, 2008, India’s total Refining Capacity reached
150 MMTPA.
 In 2009, RPL commissioned its second (SEZ) Refinery
of 27 MMTPA capacity at Jamnagar.
 NEW REFINING PROJECTS

 In July’2011 Bharat Oman’s 6 MMTPA Bina Refinery in

MP and in March’2012, HMEL’s Bhatinda Refinery was
commissioned.
 IOC also commissioned its 15 MMTPA Refinery with
Petrochemical Complex in 2015 at Paradeep (Orissa).
 In addition to these three Grass-root Refineries, many
companies expanded their existing Refineries,
thereby taking the total installed capacity to 234.5
MMTPA as on 01-04-2017.

 By the end of FY 2017-18, total Refining capacity will

go up to 240 MMTPA, when all the expansion Projects
are commissioned.
 Installed Capacity & Crude Processing (MMTPA)
REFINERY Capacity as on April -17 Processing in 2016-17
IOC - Digboi 0.65 0.53
IOC – Guwahati 1.0 0.86
IOC – Bongaigaon 2.35 2.49
IOC – Barauni 6.0 6.53
IOC – Haldia 7.5 7.69
IOC – Mathura 8.0 9.23
IOC – Koyali 13.7 13.99
IOC – Panipat 15.0 15.64
IOC - Paradeep 15.0 8.23
HPCL – Vizag 8.3 9.33
HPCL – Mumbai 7.5 8.51
 Installed Capacity & Crude Processing (MMTPA)
REFINERY Capacity as on April -17 Processing in 2016-17

BPCL – Mumbai 12.0 13.54

BPCL – Kochi 12.4 11.82
BPCL-Bina 6.0 6.36
CPCL – Narimanam 1.5 0.53
CPCL - Chennai 10.5 9.76
NRL – Numaligarh 3.0 2.68
MPRL – Mangalore 15.0 15.96
ESSAR – Jamnagar 20.0 20.92
RIL – Jamnagar (2) 33+27=60 70.17
ONGC – Tatipaka 0.07 0.08
HMEL - Bhatinda 9.00 10.52
Total 23 Refineries 234.5 245.4
PETRO PRODUCTS - PRODUCTION & CONSUMPTION
PRODUCTS 2016-17 2016-17
PRODUCTION CONSUMPTION
LPG 11.25 21.55
MS 36.52 23.76
Naphtha 19.76 13.25
ATF 13.81 7.02
SKO 5.98 5.40
HSD 102.12 76.01
LDO 0.63 0.45
FO/LSHS 12.03 7.19
LUBES 1.03 3.41
BITUMEN 5.18 5.89
PETCOKE 12.92 23.59
OTHERS 21.46 6.69
TOTAL 242.69 194.21
 CRUDE OIL COMPOSITION

 COMPOSTION OF CRUDE OIL:

– LARGE NO. OF DIFFERENT HYDROCARBONS
– IMPURITIES SUCH AS ‘S’, N, O2 METALS, ETC.
– BOTTOM SEDIMENTS & WATER (BS & W)
– SALTS, SUCH AS NACL, MGCL2, ETC.

 TYPES OF HYDROCARBONS:
– PARAFFINS
– NAPHTENES
– AROMATICS
– OLEFINS
 TYPES OF HYDROCARBON
• PARAFFINS :
- Open chain saturated compounds of C & H
having general formula CnH2n+2.
– Have great chemical stability.
– Two types
• n - Paraffins
• Iso - Paraffins.
– N-Paraffins have low Octane No. & high ignition
properties.
– Iso-Paraffins have high Octane No.
 TYPES OF HYDROCARBON (Contd…)

• NAPHTHENES :
– Saturated Cyclic hydrocarbons.
– High chemical stability.
– General Formula CnH2n.
• OLEFINS :
– Unsaturated open chain hydrocarbons.
– Highly reactive.
– Generally formed during cracking / conversion
processes.
 TYPES OF HYDROCARBON (Contd…)

• AROMATICS :
– Unsaturated Cyclic hydrocarbons having general
formula CnHn.
– Chemically reactive.
– Aromatics in Gasoline increases Octane number.
– Undesirable in Kerosene because of their tendency
to give smoky flame.
 IMPURITIES IN CRUDE OIL
• SULPHUR:
– Major impurity and present in elemental form.
– Sulfides / oxides of sulfur (H2S, Mercaptans, SO2 etc)
generated in refinery processes.
– Present as H2S / Mercaptans in LPG, as Sulfur /
Mercaptans in Gasoline, Kerosene, ATF and as sulfur in
HSD & Residues.
– Sweetening Processes (caustic washing, Mercaptan
Oxidation) are used to remove these impurities from
products.
 IMPURITIES IN CRUDE OIL (Contd..)
• NITROGEN :
– Present in elemental form and also as oxides of
Nitrogen.
– Forms Acids and causes corrosion.
– Removal is necessary to get on-grade products and
secondary units feedstocks.

• OXYGEN :
– Present in elemental form and also as compounds of
Oxygen.
– Forms Naphthenic Acids and causes stress corrosion.
 IMPURITIES IN CRUDE OIL (Contd..)
• METALS :
– Main metals in Crude oil are - Lead, Nickel, Vanadium &
Copper.
– Present in very small quantity (ppm level), in Crude and
gets distributed in various products.
– Poison to catalysts even in very small amount.

• SALTS :
– Are formed during Refining process.
– Main salts - NaCL, MgCL2, KCL.
– Acids formed from these salts attacks plant equipments
and corrosion sets in.
 SEDIMENT & WATER (BS & W)

•Sediment: Fine particles of sand clay, volcanic ash,

drilling mud, rust, iron sulphide, metals
and scale.

• Damaging Effects: Plugging/abrasion of Heat Exchanger

Tubes and residual product
contamination.

• Water causes irregular behavior in Distillation process as

it forms Steam.
 DENSITY / API GRAVITY
Density is used for:

•Weight to volume or vice versa calculations

•Checking the consistency of crude supply
•Control of refinery operations
•Used in various correlations
•Also gives a rough indication of type of crude oil
141.5
API GRAVITY= - 131.5
SP.GR.@ 60/60°F
Examples:
Water = 10 API
Kerosene = 45 API
Motor Gasoline = 58 API
Natural Gasoline = 75 API
Crude oils are categorized based on gravity
Light grades : Above 33 degree API
Medium grades: 23-33 degree API
Heavy grades: upto 22 degree API
Reid Vapour Pressure (RVP) and Light End Analysis

RVP indicates relative Percentage of gaseous and

lighter hydrocarbons in crude oil.
POUR POINT

• Indicates relative amount of wax present in Crude oil.

• Is the temperature below which pumping & transportation
problems may be encountered
• Along with viscosity, is used in pumping and design
calculations.

WAX CONTENT

Normal paraffins above C16 are solid at somewhat ambient

temperatures. These hydrocarbons -
• Affect the flow behavior of Crude
• Affect the Product quality of Gas oil, VGO and Asphalt
• Lube manufacture is also dependent on wax content of
the Crude.
COMPARISON OF IND. & ME CRUDES QUALITY
PROPERTIES UNIT BH ANK KUWAIT ARAB IRN IRN
MIX LT. HY.

API Gravity @ 150C --- 38.3 47.4 31.2 30.3 34.0 31.1
0
Pour Point C +30 +18 -17 -15 -12 -6
% wt
Wax Content 14.7 9.9 4.5 5.6 5.7 4.4
% wt
Asphaltenes 0.05 <0.05 1.3 2.7 0.9 2.0
% wt
Total Sulfur 0.2 0.02 2.54 2.65 1.4 1.65

Primary Yields
% wt
Light Distillates 24 33 14 16 17 16
% wt
Middle Distillates 46 47 36 36 43 36
% wt
Residue 30 20 50 48 40 48
YIELD PATTERN OF VARIOUS CRUDES (% WT)

STREAMS BH KUWAIT DUBAI

GAS 0.2 0.3 0.1
LPG 1.1 1.2 2.5
NAPHTHA 23.0 16.0 12.9
KEROSENE 20.5 16.5 15.3
HSD 25.0 18.0 27.2
RCO 30.0 48.0 42.0
LVGO + HVGO 74.0 58.0 52.0
VACUUM DIESEL 3.0 1.0 2.0
VACUUM RESIDUE 23.0 41.0 46.0
 STAGES IN CRUDE OIL REFINING
PRIMARY PROCESSING
– PHYSICAL SEPARATION BY DISTILLATION.

SECONDARY PROCESSING
– CHEMICAL SEPARATION AND CONVERSION OF
COMPOUNDS.

 PRODUCT TREATING
– REMOVAL OF UNDESIRED IMPURITIES

 PRODUCT BLENDING
– BLENDING OF DIFFERENT PRODUCT COMPONENTS
TO GET ON GRADE FINISHED PRODUCT.
 PRIMARY PROCESSING
Crude Oil contains large no. of different types of Hydrocarbons.

Separation of crude oil into smaller groups of Hydrocarbons

(useful products) is achieved by using large difference in the
Boiling Points of these Hydrocarbons.

Crude oil is split into a no. of product cuts based on boiling

points.

First separation is carried out in Crude Distillation Unit (CDU).

Further separation of CDU residue is done in Vacuum Distillation

Unit (VDU).

All products from CDU/VDU require further treatment to

remove impurities.
 ATMOSPHERIC DISTILLATION

This is the first stage in the refining for separating crude oil
components by physical separation process at near
atmospheric pressure by heating and subsequent condensing
the fractions by cooling.

Product cuts from CDU Boiling Range (deg C)

- Gas & LPG < 40
- Naphtha 40-140
- ATF / Kerosene 140-270/300
- Light Gas Oil (LGO) 270-320
- Heavy Gas Oil (HGO) 320-370
- Atmospheric Residue (AR) >370

* Naphtha is further split into Light & heavy cuts in Naphtha Splitter Unit
* LGO & HGO are combined to form raw Diesel product.
MAJOR EQUIPMENTS IN ATMOSPHERIC
DISTILLATION UNIT

Desalter

Preheat train

Furnace

Atmospheric column

Stripping columns

Stabilizer

Condensers & coolers

CRUDE OIL
ATMOSPHERIC DISTILLATION UNIT
GAS

WATER
A
T
NAPTHA
M
O S
S T
P R
H I
STEAM
E P
R P
I E
C R
DESALTER
D Kerosene
I
S S
WATER T T
I R
L I
P STEAM
L
A P
T E
I R
Light Gas Oil
O
N
S
C T
O R
L I STEAM
U P
M P
FURNACE N STEAM E
Heavy Gas Oil
R

Reduced Crude Oil

 VACUUM DISTILLATION

• Atmospheric Residue (AR) from CDU is a feed to VDU.

• AR is heated to 410 - 430 deg C & passed into a high vacuum (20-50
mm Hg) column where Vacuum Diesel, Vacuum Gas Oil (VGO), and
Vacuum Residue (VR) are separated.

Product cuts from VDU Boiling Range (deg C)

- Vacuum Diesel (VD) 365-375

- Light Vacuum Gas Oil (LVGO) 375-465
- Heavy Vacuum Gas Oil (HVGO) 465-575
- Raw lube Oil cuts 375-615
- Vacuum Residue (VR) >575

* LVGO & HVGO are again combined as VGO and is a feedstock for
Secondary Processing Units like FCC or Hydro-cracker.
VACCUM DISTILLATION UNIT
STEAM NONCONDENSIBLE
cw cw cw
EJECTIOS GAS

SUMP
cw ONLY
WATER

4100 C LIGHT VAC GAS OIL

REDUCED TO
4300 C
CRUDE STEAM HEAVY VAC GAS OIL
STEAM 25 TO
50 MM
VR

HEATER
VACUUM
TOWER
 SECONDARY PROCESSING

Intermediate Product Streams from CDU/VDU, with or without treatment

are further processed in Secondary Processing Units.

Lt. Naphtha - Isomerization Unit (ISOM)

Hy.Naphtha - Continuous Catalytic Reforming Unit (CCR)

AR - Residue Fluidized Catalytic Cracking Unit (RFCC)

VGO - Fluidized Catalytic Cracker (FCC) / Hydrocracker (HCU)

VR - Delayed Coker Unit (DCU) / Vis-breaker Unit (VBU) / Solvent

De-asphalting Unit (SDA) / Bitumen Blowing Unit (BBU)
 PRODUCT TREATMENT- OBJECTIVES
 Primary separation only physical separation; products need
treatment to meet desired specifications.

 To make petroleum products suitable for use with respect to

performance, corrosivity, suitability of storage, odor etc.

 Treatment of products to render them marketable – e.g.

Hydro-treating of HSD, Merox sweetening of LPG and
Gasoline.

 Recovery of environmentally hazardous materials through

processing e.g. Sulfur Recovery Unit.

 Treatment of intermediate product cuts (e.g. Naphtha, VGO,

VR, etc.) before secondary processing (like reforming,
cracking) helps to protect catalyst, improve yields.
 Major contaminants of Petroleum
distillates and their effects
Contaminants Effects
Hydrogen Sulfide Acidity, corrosion, obnoxious combustion products,
reduced octane no., foul odour
Mercaptans Corrosion, obnoxious combustion products, reduced
octane no., gum deposits, engine deposits, foul odour

Naphthemic Acid Acidity and corrosion

Phenol compounds Engine deposits

Total Sulfur Corrosion, obnoxious combustion products, reduced

octane no.
Nitrogen bases Foul odour, colour formation, possible engine deposits

Traces of Metals Gum formation, Engine deposits

 PRODUCT TREATMENT
Intermediate & Raw Product Streams from CDU/VDU and
Secondary Processing Units like FCC / VBU / DCU are
treated to remove impurities to maintain desired Product
Specifications.

LPG - Caustic Wash / Merox

Naphtha – Hydrodesulfurization (NHDS) / Hydrotreater (NHDT)
ATF/ Kerosene – Kero Merox (KMU) / Kero Hydrotreater (KHDT)
HSD – Hydrodesulfurization (DHDS) / Hydrotreater (DHDT)
VGO – Hydrotreater (VGO-HDT)
AR – Hydrodesulfurization (ARDS)
VR – Hydrodesulfurization (VRDS)
FCC Gasoline – Hydrodesulfurization
Coker Naphtha & Gas Oil – Hydrotreater
Vis-breaker Naphtha & Gas Oil – Hydrotreater
 PRODUCT TREATMENT (Contd.)
De-asphalted Oil (DAO) from SDA - is processed in
- Solvent Extraction Unit and
- De-waxing Unit,
for the removal of aromatics & wax respectively, and Hydrotreated in
- Hydro-finishing Unit,
for the manufacture of Finished Lube Oil Base Stocks (LOBS).

Sulphur is a By-product produced in Product Treatment Units

• Fuel Oil produced from VR, Asphalt produced in SDA & Petroleum Coke
from Coker Unit can be utilized for Power Generation.

• Low Sulfur Petroleum Coke can also be calcined to produce calcined

petroleum coke (CPC).
 PRODUCT BLENDING
OBJECTIVE –

To produce marketable finished product of required quality /

specifications and suitable for a particular application / end
use.

NEED FOR PRODUCT BLENDING –

- Availability of multiple streams of same finished product from

primary / secondary processing units.
- Streams of same finished product needs to be stored
together to reduce product tanks requirements.
- Finished product optimization with respect to quality
giveaway.
- Certain intermediate product stream (ex. VR, LDO) doesnot
meet finished product specifications.
 PRODUCT BLENDING

TYPES OF BLENDING
1. On-line blending – For Products like LPG,
Naphtha, ATF, Kerosene, Diesel, etc.

2. Tank to tank blending – For products like

MS, Furnace oil, LDO, Lube oil base stocks.

* Sometimes ATF is also blended using tank to

tank blending.
 TYPICAL REFINERY UNITS CONFIGURATION
 ATMOSPHERIC/CRUDE DISTILLATION UNIT (ADU/CDU)
 VACUUM DISTILLATION UNIT (VDU)
 NAPHTHA HYDRO-TREATER UNIT (NHT)
 CONTINUOUS CATALYTIC REFORMER UNIT(CCR)
 ISOMERIZATION UNIT (ISOM)
 FLUID CATALYTIC CRACKING UNIT (FCC) OR
HYDROCRACKER UNIT (HCU)
 DELAYED COKIER UNIT (DCU)
 BITUMEN BLOWING UNIT (BBU)
 SULPHUR RECOVERY UNIT (SRU)
 HYDROGEN GENERATION UNIT (HGU)
 DIESEL HYDRO-TREATER UNIT (DHDT)
 OTHER PRODUCTS TREATMENT UNITS
 LUBE OIL PRODUCTION UNITS
 TYPICAL REFINERY BLOCK DIAGRAM

SW EX UNITS
S.W STRIPPER
FG
FG TREATMENT FUEL GAS
(ATU)
GAS SRU SULPHUR
PLANT
LPG LPG
UNSTAB TREATER
NAPHTHA
STAB LT NAP
NAPHTHA
NAP. NAPHTHA
TREATER
OFF
GAS

HYN AP GASOLINE
NSU NHDS CCR BLENDER MS
DISTILLATION
ATMOSPHERIC

Hydrogen
H2

TO HCU
KERO / ATF KERO CAUSTIC
CRUDE WASH KEROSENE
ATF
OIL OFF GAS
GASOILS DHDS DIESEL

VAC
HSD OFF GAS
RCO
LPG
VACUUM LVGO
DISTILLATION HVGO LT NAP
HCU
VR ATF HY NAP.

VR HSD
DAO 150 N
SDA 500 N
BITUMEN IDW BRIGHT STOCK
BLOWING BITUMEN
ASPHALT
CPP
70 MW POWER
 REFINERY PRODUCTS

FUEL PRODUCTS: MIDDLE DISTILLATES

LIGHT DISTILLATES 9. ATF
1. FUEL GAS 10. KEROSENE
2. DOMESTIC LPG 11. HIGH SPEED DIESEL
3. AUTO LPG 12. LIGHT DIESEL OIL
4. REGULAR GASOLINE
5. PREMIUM GASOLINE HEAVY ENDS
6. LOW AROMATIC 13. FUEL OIL (DIFFERENT
NAPHTHA(LAN) GRADES)
7. HIGH AROMATIC 14. LSHS
NAPHTHA(HAN) 15. BITUMEN
8. SPECIAL CUT NAPHTHA 16. PETROLEUM COKE

CONTD..
 REFINERY PRODUCTS
LOBS PRODUCTS: SPECIAL PRODUCTS
1. NEUTRAL OILS 1. FG HEXANE
2. TURBINE OILS 2. MTO
3. INDUSTRIAL
3. INDUSTRIAL OILS
SOLVENTS
4. AXLE OILS 4. BENZENE
5. TRANSFORMER OIL 5. TOLUENE
6. BRIGHT STOCK 6. MIX XYLENES
7. MTBE
BY-PRODUCT 8. LABFS
1. SULPHUR 9. CBFS
10. CALCINED COKE
 Utilities & offsite facilities
 For its operations, Process plant requires utilities such as
fuel gas, power, steam, water, Nitrogen etc.
 (i) Utility Facilities in a typical Refinery would include :
 Power Generation – Captive Power Plant
 Steam Generation– different levels (High pressure,
Medium pressure, low pressure)
 Cooling water system : cooling towers, cooling
water treatment and network systems
 Process water systems
 Fuel gas / fuel oil systems
 Service water system
 Instrument Air system
 Plant Air system
 Water treatment plants including Softening plant,
De-mineralised Water plant
 Nitrogen / Inert gas plant
(ii) Infrastructures/Buildings:
 Control Rooms
 Office Blocks
 Laboratories
 Fire stations & Fire fighting facilities
 Motor control centers
 Workshop - Spares inventory; Machines
 Waste & Effluent Treatment facilities including open
pit incinerators etc.

(iii) Safety Related:

 Flare system
 Fire water system including Fire water network,
Hydrants layout
 Medical center
 Water Sprinklers, deluge systems
Rail Siding Typical Refinery Layout Emergency
flare
Fire STN.
Tank Farm
Plant
Area Work shop

STORES
Expansion

Laboratory

Maintenance shop

Plant Plant
ROAD
Area Utilities
Canteen

ROAD Change
Room
Captive Cooling
Power Unit Towers Admn Office

ROAD
CRITERIAS FOR PRODUCT SPECIFICATIONS

1) End Use and Applications

2) Safety in Handling & Storage

3) Environmental Protection

4) Equipment Corrosion

5) Flow Properties
 PRODUCT PROPERTIES

• FLASH POINT : Lowest temperature at which vapors from the oil

ignite instantaneously.

• POUR POINT : Lowest temperature at which no oil flows.

• FREEZING POINT : Constant temperature at which oil solidifies.

• VISCOSITY : A measure of resistance to flow of oil.

• RECOVERY(%) : Percent of oil Distilled at 370 deg. C.

• OCTANE NO. : Determines the anti-knock property of Gasoline.

Higher the octane, better the anti-knock property.

• VISCOSITY INDEX : Determines temperature stability of lube oil with

respect to viscosity.
 PRODUCT SPECIFICATIONS
 Important specifications for main Refinery Products

Refinery Product Specification

L.P.G. Vapor. Pressure, H2S.

Gasoline Octane No., Boiling Range, Sulfur,
Aromatic / Olefins content
Naphtha Boiling Range, Sulfur
Kerosene Smoke point, Flash Pt. Sulfur content
Jet Fuel Freezing point, Flash point,
Boiling point
Diesel Oil Cetane no., Carbon Residue
Pour point, Flash Point.
Lubricating Oil Viscosity, Viscosity Index,
 PRODUCT QUALITY TESTS &
THEIR SIGNIFICANCE
TEST - DISTILLATION

Significance - Significance varies from Product to

Product.

- For Crude oil, ASTM Distillation gives

idea about the quantum of various
fractions.

- TBP Distillation reveals characteristics

useful for the design of the Refinery.

- 10% vol. of Distillation for MS is the

indication of ease of Engine start.
 PRODUCT QUALITY TESTS &
THEIR SIGNIFICANCE

TEST - VAPOUR PRESSURE

- Pressure exerted by vapors when it is in equilibrium

with the liquid.

- Vapor pressure of volatile, non-viscous products is

determined by Reid Method.

Significance

- Test is important with respect to safety in transport,

vapor lock in the gasoline engines, types and design of
storage tanks employed.

- High vapor pressure entails loss of product during

storage and transportation.
 PRODUCT QUALITY TESTS &
THEIR SIGNIFICANCE

TEST - OCTANE NUMBER

- Test for rating the antiknock of motor fuels

- O.N. is defined as the % volume of Iso-Octane in a

Mixture of Iso-Octane and n-Heptane that gives the
same knocking as the fuel.

- Octane requirements of Gasoline Engines depend on

their compression ratio.
Significance

- O.N. signifies the ignition quality of Gasoline in

automobile engines.
- For optimum delivery of power to the engine, fuel-air
mixture injected into the engine should ignite at the right
time.

- Due to heat of compression, the temp. in the cylinder

goes high and there could be mistimed ignition. A high
octane Gasoline is better for ignition. Mistimed ignition
produce knocking in the Engine.

- Knocking in an Engine may result in loss of energy and

may cause severe damage
-Minimum required octane ensures trouble free operation.
 • The different hydrocarbon in Gasoline :
 Straight chains paraffin
 ISO –paraffin
 Naphthenes
 Aromatics
• For the same Carbon No; straight chain paraffin have
lowest octane No.

• Branched chain paraffin (isomers), Naphthenes have

higher octane No.

• Olefins also have high O.N. but they cause gum

deposits in the fuel tank and are not desirable.

• Aromatic have highest O.N. but their content is being

restricted due to their carcinogenic nature.
 PRODUCT QUALITY TESTS &
THEIR SIGNIFICANCE

TEST - FLASH POINT

- Lowest temp. at which application of test flame causes

vapor above the sample to ignite.

- Flash point below 500C - Abel apparatus

- Flash point above 500C - Pensky / Martenes.

Significance

- Low flash products are potential to fire hazards.

 PRODUCT QUALITY TESTS &
THEIR SIGNIFICANCE

TEST - CETANE NUMBER

- Determined in a single cylinder CFR Engine.

- Compares ignition delay characteristics of fuel with

reference blend of known Cetane number.

- Reference fuel used are n-Cetane (100 c.n.) and alpha-

methyl-naphthalene (0 c.n.).

Significance
- Indication of ignition quality of fuel
- High Cetane number facilitate easy starting of
compression ignition engines and lessen engine
roughness.
 PRODUCT QUALITY TESTS &
THEIR SIGNIFICANCE

TEST - SMOKE POINT

- Maximum flame height in mm at which fuel will burn

without smoking when determined in a smoke point
apparatus under specified conditions.
Significance
- Important test for kerosene evaluating their ability to
burn without producing smoke.

- Higher the smoke point, better it is for domestic use.

- Serves as a guide to assess the aromatic content of

kerosene.
 PRODUCT QUALITY TESTS &
THEIR SIGNIFICANCE

TEST - FREEZING POINT

- Temperature at which crystals of hydrocarbons formed

on cooling, disappear.

Significance

- Detection of separated solids in aviation engine fuels at

temperatures likely to be encountered during flight.
 PRODUCT QUALITY TESTS &
THEIR SIGNIFICANCE

TEST - POUR POINT

- Lowest temperature at which oil is observed to flow

when cooled and examined under prescribed
conditions.

Significance

- Serves as a guide to its pump-ability.

- Indicates waxy nature of the oil.

 Gasoline Specification
Characteristics Bharat Euro III Euro IV
Stage II Equivalent Equivalent
Sulfur, % mass, total, max. 0.05 150 (mg/Kg) 50 (mg/Kg)

RVP, kPa, max. 35 – 60 60 60

Benzene,% vol., max. 3 1 1

Aromatics, %vol., max. - 42 35

Olefins %, vol., max. - 21 21

Distillation :
@ rec. up to 700C,% vol. 10 – 45 10 – 45 10 – 45
@ rec. up to 1000C,% vol. 40 – 70 40 – 70 40 – 70
@ rec. up to 1800C,% vol. 90 75, min. 75, min.
Final BP, 00 C, max. 215 210 210
Residue, % vol., max. 2 2 2
RON, min. 88 91 91
MON, min. - 81 81
 Diesel Specifications
Characteristics Bharat Euro III Euro IV
Stage II Equivalent Equivalent

Sulfur, % mass, 0.05 350 (mg/kg) 50 (mg/kg)

total, max.

Cetane No., min. 48 51 51

45 (for Assam 48 (for Assam 48 (for Assam
crude) Crude) Crude)

Poly-cyclic - 11 11
Aromatics HC
(PAH), % mass,
max.
Distillation : 85 min. @ 3600 C 3600 C
95% vol. Recovery 3500C & 95
@ 0 C, max. min. @ 3700 C
 INTEGRATED
REFINERY AND
PETROCHEMICAL
PLANTS
 Major Petrochemicals Feed-stocks
from Refineries

Refinery Stream Petrochemicals

Naphtha Olefins (Steam cracking), Aromatics
(Reforming, Isomerization)
Kerosene Linear Alkyl Benzene (LAB)
FCC LPG C3 Petrochemicals
C4 Petrochemicals
FCC off-gases Olefins
Heavier fractions Olefins (Steam cracking)
Naphtha
Basic building blocks of Petrochemicals viz. Ethylene, Propylene
and Butylene are produced by Steam cracking of light naphtha
(C5-75 deg C).
For Steam cracking, Naphtha or Ethane/Propane (from Natural
gas) are major feed-stocks.
While Naphtha cracking gives Ethylene and Propylene in the
ratio of 2:1, Gas cracking gives a ratio of approximately 10:1,
thus hardly any Propylene is produced in Gas cracking.
Since Propylene is a very important building block particularly
in view of the high growth rate seen for Polypropylene among
the commodity Polymers, a proper balance has to be struck
between Naphtha and Ethane/Propane feed-stocks for Steam
cracking.
 Naphtha To Petrochemicals
ETHYLENE POLYTHENE, PVC EP
PROCESSING

PROPYLENE
PROCESSING POLYPROPYLENE, ACETONE

BUTULENE MEK
PROCESSING

NAPHTHA NAPHTHA ISOBUTYLENE

PROCESSING MTBE, POLYBUTENES , BUTANOL MEK
CRACKER BUTADIENE

BENZENE PROCESSING CAPROLACTUM, NYLON

XYLENE
REFORMING AROMATICS
SEPARATION PROCESSING POLYESTER

PROCESSING POLYESTER
ETHYLBENZENE
Aromatics
Aromatics such as Benzene, Toluene and Xylenes are
produced by reforming heavy naphtha (75-100 deg C).
Benzene is a versatile feedstock from which a number of
Petrochemicals such as Styrene, Phenol, etc. are produced.
Para-xylene is the feedstock for Terphthalic acid and DMT
which in turn are the raw materials for the Polyester
industry.
Alternatively, this Reformats is used in the Gasoline pool. As we
move towards more cleaner Automotive fuels, demand
for Reformate within the Refinery operations is increasing.
Reformer can be designed either to produce Reformate for
Gasoline blending or to maximize the production of Aromatics
or to produce both in suitable proportion.
 C5-
C6-C7 Raffinate
Benzene

Toulene
Light Ends column
C4 / C5 Benzene
column
C6 /C7
Aromatics

Naphtha Catalytic
(C4-C9) Reforming Aromatics
extraction

Xylene
Isomerization
Paraxylene
Orthoxylene
Reformate
splitter O/m xylene

OX
Xylene tower
splitter
C9+ C7+

Reforming and BTX Production Process

Kerosene
Linear Alkyl Benzene (LAB), an important detergent base
material, is produced by alkylation of n-paraffins using
Benzene. N-paraffins are extracted from kerosene.
Kerosene fraction containing about 15% n-paraffins and
low in aromatics content would be an ideal LAB feedstock.
However, about 85-90% of the kerosene drawn by LAB
plant is returned back to the refinery after n-paraffin
extraction. Impact of its blending in the kerosene pool in
terms of smoke point, needs careful checking before action
can be taken on blending of returned fraction in kerosene.
Propylene from FCC LPG
C3 cut from FCC LPG contain 40-50% Propylene. Normally a
propylene fractionator with feed preparation unit is required
to recover this Propylene from C3 cut stream. The propylene
so recovered from a large refinery (cap > 20 MMTPA) is
considerable and matches that required for an economics
size PP plant (100,000 TPA) or 70,000 TPA ACN plant. For
small Refineries, propylene from 2 or 3 refineries can be
clubbed together at one location to consider an economic
size PP or ACN plant.
 Petrochemicals based on Refinery streams
IOCL Guwahati Naphtha Aromatics
BRPL Bongaigaaon Naphtha Aromatics
IOCL Koyali Naphtha Aromatics Olefins
FCC gases Polypropylene
Kerosene LAB
IOCL Haldia Lub extract (CBFS) Carbon Block

BPCL Bombay Naphtha Aromatics

FCC C3 Stream Polypropylene
FCC C4 Stream MTBE
HPCL Bombay Naphtha Olefins
Lube Extract Carbon Block
(CBFS)
HPCL Vizag FCC C3 Stream Oxo-alcohols
CRL Cochin FCC C3 Stream Phenol
FCC C4 Stream) + Poly-isobutenes
Benzene
CPCL Madras FCC C3 Stream Po/PG/Polyols
FCC C3 Stream MEK
Kerosene LAB
Lube extract (CBFS) Carbon black

RIL Jamnagar Naphtha Olefins (At

Naphtha Reforming Hazira)
FCC: C3 Stream Aromatics
Polypropylene

IOCL Panipat Kerosene LAB

Aromatics
 ADVANCES IN

REFINING

TECHNOLOGIES
• Advanced Refining Technologies required for -

 Primary separation only physical separation; products

need treatment to meet desired specifications.

 Treatment of products to render them marketable – e.g.

Catalytic Reforming, Amine Treatment Unit, Hydro–
treating Unit.

 Recovery of environmentally hazardous materials through

processing e.g. Sulfur Recovery unit.

 Conversion to change heavy residual products into light

and high value products e.g. Gasoline and Diesel.
Advanced Conversion Processes.
 Processing for up-gradation of product quality e.g.
Hydro-treating of Kerosene & Diesel, Merox sweetening
of LPG and Gasoline.

 Petrochemicals Feedstock Generation.

 Residue / crude gasification

 Gas to liquids (GTL) conversion

 Fuel cells / Hydrogen Management

 New Technologies :

 Integration of Refining and Power generation -

IGCC (Integrated Gasification Combined cycle).

 Integration of Hydrocracker with Diesel

Hydro-treater.

 Lube & fuel Integration (Integration of

Hydrocracker with Iso-dewaxer).

 Petrochemicals integration and Specialty

Products.
 Future Challenges for Refiners
The challenges for the future are :
1. Crude oil is becoming heavier and higher in sulphur
and metal content.

2. Reduced growth in fuel oil demand.

3. Rapid growth in demand for light/middle distillates.

4. Stringent Environmental regulations for cleaner products/

processes and demand for quality product.

5. Declining Refining Margins.

6. Improved Engine/Automobiles designs need better quality

fuel and lubricating oils.
• The complex requirements will require management of
the following:

 Improved and Integrated Refining :

 Production of better quality products

 Better management of residue/ heavy ends:
New Technologies.
 Value addition :
 Petrochemicals production
 Better quality and increased lube oil
production.
 Power generation from heavy Petroleum
products.
 Specific chemicals production
• Future Refining will need to take following actions:

 Distillates yield improvement

 Energy optimization

 Production of high value products

 Hydrocarbon losses minimization

 Product quality up-gradation

 Inventory management.
• Future Refining will have:

 Quality related Units -

 Facilities for Benzene Management in Gasoline

 Diesel Hydro-desulphurization facility

 Fuel oil Hydro-desulphurization facility

 Hydro-treatment of other Products

 Environment Management related Units -

 High efficiency Sulphur Recovery Units & Tail gas

treatment

 Bottom of the barrel up-gradation related unit

 Computerized integrated refinery

 Energy efficient processes

 Diversified and integrated refinery with power

plants, petrochemicals and fertilizers.
 Synergy in Power and Fertilizer co-production -

 Efficient utilization of low value refinery residue for

production of power. Power plant supplies power
and steam required for refinery.

 Co-production of value added fertilizer.

 No additional raw material handling and common

fire fighting facilities.

 Overall economics considerably enhanced

 Already under way in the USA, the Netherlands and

Italy.
Energy Conservation

And

Loss Minimization
 Energy Conservation in Refineries
• World Oil Consumption is currently around 92 Million
Barrels per Day
• World Consumption growth is expected to be around 1.5
Million Barrel per day every year.
• World spare capacity of Oil is just around 3 Million
Barrels.
• So High Oil Prices are here to stay in the medium term
till additional oil finds are developed.
• Conserving Oil in all forms not only makes economic
sense and improves environment, it is our duty for
future generations.
Energy Use Depends on Refinery Configuration

Relative capital cost (per MMT)

1.0 2.1 3.6 4.3 6.7
100%

LPG
75%
NAPHTHA

50%
PETROL

25% KERO

0% DIESEL
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 Energy Conservation in Refineries
• Energy Conservation in Project Stage has the biggest
impact during the life of the Refinery / Unit
– Unit Capacities. Larger Units have better economics
– Inter Unit Energy exchange by routing Hot Streams
– Adopting latest energy saving measures, additional
instrumentation, Analyzers etc. Additional Project
Cost gets easily paid off.
– Choose the correct Steam Generation pressures so
that let down can generate Power
– Project cost Vs Energy savings, an Eternal Dilemma
 Energy Conservation in Refineries
• Energy Conservation in Existing Refinery Units is a
function of
– Design Basis of each Unit and when it was built.
– What could have been an uneconomical energy
saving add on project cost at that time would be
money saver now.
– Performing Pinch Analysis for individual units to
identify additional heat recovery and utility savings.
– Performing Refinery Wide Pinch Analysis to identify
additional heat recovery and utility savings for inter
unit heat exchange
 Energy Management
Why Important?
• Largest Operating Expense (>60%)
• Affects Industrial Productivity
• Serves Environmental Protection
• Reduces Global Warming
• National Energy Strategy
Better Energy Management & more efficient use
of Energy make sound Business sense
 Energy Consumption

• As direct Fuel in the form of Fuel oil or Fuel Gas in

Process Heaters / Furnaces
• Fuel for generating Steam in Boilers
• Fuel Gas / Naphtha in Gas Turbines for generating
Power
• Light Naphtha in the production of Hydrogen
Typical Energy Consumption Pattern in Refinery

Power
Generation,
12%

Process
Heaters,
68% Steam
generation ,
20%
 Factors Affecting Energy Consumption
Type & Quantity of crude oil processed
– Capacity of the Refinery
– Type of Crude Oil, Light / Heavy
Refinery Configuration
– Directly proportional to the number and type of
secondary processing units
Severity of Operation
• Affected by the operating parameters when stretched
above normal to cater to market demand with Respect
to Yield & Quality
• Fixed Bed Catalytic Units, Start of Run / End Of Run
 Fuel & Loss

• Expressed as % weight on crude oil

• Energy indicator, cannot be used for
comparison
• Performance dependent on
• Configuration
• Complexity
• Type of crude
• Product slate
• Generated or purchased utility
 Major Areas Of Energy Optimization

• Efficiency improvement : Furnaces / Boilers,

Columns, Rotary equipment etc.
• Heat recovery: Maximum recovery of heat from
products to feed, waste heat recovery etc.
• Conservation of utilities like steam, water, instrument
air etc.
• Operating conditions / philosophy
• Advanced control strategies
 Typical En-con Projects -1
• Replace existing low efficiency Boilers with new high
efficiency boilers
• Process Units : Increase in surface area by installing
additional Heat Exchangers
• Reformer Unit : Consider replacing existing Reactor Feed
Effluent exchanger with Packinox exchanger
– Lower pressure drop (Lower feed pump and RGC Power)
– High area for heat exchange ( Lower Furnace )
• Replacement of GRP / Aluminum blades with hollow
FRP in cooling towers : 30-35 % savings in power
• Condensate Recovery Systems
• Flare Gas Recovery Unit
 Typical En-con Projects - 2
• Replace Distillation Column internals with higher
efficiency trays/random packing / Structured packing
• Catalyst changes to improve reaction and selectivity at
lower energy
– FCCU : Change from dense bed to riser bed
– FCCU : Coke selective Catalyst
– Reformer : Mono Metallic Catalyst to Bimetallic
Catalyst
– DHDS / HCU : Higher active catalyst
• Auto Tank gauging, Tank vapor recovery, Tank lorry/
wagon vapor Recovery
• Hot Oil system concept for Reboiler heating at various
locations
 Typical En-con Projects - 3
• FCCU Regenerator Flue Gas power recovery turbines
instead of loosing energy in Orifice Chamber
• Main fractionators of Crude unit Overhead vapor Vs
Crude exchanger to improve heat Recovery.
• Combined Heat and Power generation. High Pressure
Steam for Power while let down steam is for Process
• Gas Turbine / Heat Recovery Steam Generation Systems
 GRM AND

REFINERY

PROFITABILITY
 REFINING COST ELEMENTS

Crude Cost Elements Refining Cost Elements

• FOB Crude Cost • Chemicals and catalysts
• Freight • Fuels and Utilities
• Customs duty • Consumables
• Insurance • Salaries and wages
• Ocean loss • Repairs and maintenance
• Wharfage • Overheads
• Landed Cost of Crude
Definition of Key Terms

GPW – GROSS PRODUCT WORTH

Value of yield of products from a particular crude based on the prevailing
product prices
REFINERY GATE VALUE
Gross Product Worth less variable Refining Cost such as Energy costs
NET BACK VALUE
Refinery Gate Value less freight costs or worth of products “Netted Back”
to crude loading terminal.
GROSS REFINING MARGIN (GRM)
Net Back Value less Crude Price
 GROSS PRODUCT WORTH (GPW)

• Based on the crude oil assay and/or actual

operating experience, the refinery configuration,
etc., it is possible to estimate the yield of different
products that are obtained on processing any
particular crude oil.

• The Gross Product Worth (GPW) of crude oil is

the price of each petroleum product multiplied by
its yield from the crude oil.
GPW =  yi pI where yI is the yield of the individual
product and pI s the price of each product.
 GPW - Example
Dubai Crude100 MT
• Products MT Prices[$/MT] Realization($)
• LPG 4 323 1292
• Naphtha 7 302 2114
• MS 10 331 3310
• SK/ATF 18 277 4986
• HSD 35 261 9135
• FO 16 167 2672
• BITUMEN 10 162 1620

Gross Product Worth: 25129

A. Gross Product Worth (Value of Products) $ 25129
B. Energy Cost at 8% Fuel $ 1336
Consumption [B x FO Price]
C. Refinery Gate Value [A-B] $ 23793
D. Crude Freight Cost @ 0.5 $ / BBL
or $ 3.7 / Tons for 100 Tons $ 370
E. Refinery Gate Value [C-D] $ 23423
F. Crude Cost @ $ 28 / BBL
or $207.2 /MT and for 100 Tons $ 20720
G. Net Back Margin or GRM [E-F] $ 2703
$ / MT $ 27.03
$ / BBL $ 3.65

(Note: 1 MT = 7.4 BBL)

 Type & Quality of Crude
 Refinery Type, Hardware & Complexity
 Efficiency of utilization of the given
hardware
 Energy efficiency of Refining Operation
 Prevailing Crude & Product prices
 Crude Freight Cost
• Benchmark for Profitability of Refining Operations
• Guide for incentive to refine more Crude into
Products, thereby determining optimum level of
Capacity utilization
• Used for optimum selection of Crude for Refineries
vis-à-vis Refinery Hardware
• Trigger for future investment decisions for Capex,
Yield Optimization, Bottoms Up-gradation, Energy
Optimization, Product Quality Improvements etc.
for enhancing bottom line
• Used as performance indicator for comparing
relative performance for various refineries
 ENHANCING REFINERY PROFITABILITY

a) Optimizing Existing Operations, including proper

selection of Crude mix, scheduling and
blending, planning in line with product slate
b) Technological Up-gradations
c) Planning for Economies of Scale
d) Optimization of Refinery Configuration
e) Forward & Backward Integration
f) Human Resource up-gradation & Manpower
Empowerment
THANK YOU FOR YOUR

ACTIVE PARTICIPATION

& PATIENT HEARING