Petroleum Refinery Overview

Introduction

Major Facilities in a Refinery are :

❖Crude Oil Receipt & Storage

❖Processing Units
❖Product Storage & Dispatch Facilities
❖Utilities Generation Facilities
❖Effluent Treatment & Flare System
Crude Oil Receipt & Storage

• Crude Oil Receipt

❖ Thru Ships / Marine Tankers for coastal refineries
❖ Thru pipeline for in-land refineries

• Crude Oil Storage

❖ Stored in Floating roof tanks
❖ Storage may be split into coastal & refinery site
Products Storage & Dispatch

• Intermediate & Finished Product Storage

❖ At refinery site & Mktg. Terminal

• Blending Facilities
❖ To produce different grades of products

• Finished Product Dispatch

❖ By Road
❖ By Rail
❖ By Pipeline
❖ By Ships / Marine Tankers
❖ In Drums / Cans
Utilities Generation Facility

• Water System
❖ Raw water receipt, storage & treatment
❖ Service water, Drinking water
❖ Cooling water
❖ DM water

• Steam, Power & Condensate System

• Compressed Air & Nitrogen Generation

• Fuel System
❖ Fuel Oil
❖ Fuel Gas / LPG vaporiser / LNG
Effluent Treatment & Flare

• ETP treats liquid effluents prior to disposal

❖ Treated effluents should meet MINAS standards
❖ No net effluents in case of Zero Discharge refineries

• Gaseous effluents are disposed off

❖ With or w/o treatment
❖ Through flare or directly

• Solid effluents are disposed by

❖ Incineration or
❖ Secured land fill

• Flare is used for disposal of all Hydrocarbon vapors &

acid gases
INTRODUCTION TO CRUDE OIL

▪ Elemental Composition
Element Wt%
C 84-87
H 11-14
S 0-2
N 0.2

▪ Degree API = 141.5 - 131.5

Sp Gr
▪ API Range of Crude Oils = 20 – 40
INTRODUCTION TO CRUDE OIL

▪ Classification of Crude 0 API Crude Type

Based on API >= 40 Paraffinic

33 – 40 Intermediate

<= 33 Naphthenic

K Crude Type
▪ Crude Chracterisation
<= 11.5 Naphthenic
Factor
K = (MABP)1/3 >= 12.1 Paraffinic
Sp. Gr 11.5 – 12.1 Intermediate
INTRODUCTION TO CRUDE OIL

▪ Sulphur Content - expressed as Wt% S in Crude

❖ Sour Crude S > 0.5%, Typically Requires Special Processing

❖ Sweet Crude S < 0.5%

▪ Salt Content - expressed as NaCl present in lb/ ‘000 barrel (ptb)

▪ Nitrogen Content - High Nitrogen is undesirable, basic nitrogen

destroys active sites of catalyst

▪ Metal Content - Metals are typ. Ni, V, Cu, Fe etc. Metal content may
vary from few PPM to 1000 PPM.
INTRODUCTION TO CRUDE OIL

▪ Typical Crude Classification

❖ Light / Medium / Heavy Crudes

❖ Low S / High S Crudes
❖ Paraffinic / Naphthanic / Aromatic Crudes
❖ Lube Bearing / Non Lube Bearing Crudes
❖ Waxy / Non Waxy crudes
❖ High TAN Acidic Crudes
❖ Condensate
❖ Bituminous / Tar Sands / Shale Oil
Refining Operations

Petroleum refining can be grouped into five basic areas:

1. Fractionation (Distillation) is the separation of crude oil into

different fractions based on their B.Pts.

2. Conversion processes change the size &/or structure of

hydrocarbon molecules. These processes include:
❖ Decomposition (dividing) by thermal and catalytic cracking;
❖ Unification (combining) through alkylation and polymerization; and
❖ Alteration (rearranging) with isomerization and catalytic reforming.

3. Treatment processes prepare hydrocarbon streams for additional

processing and to prepare finished products.

4. Formulating and Blending is the process of mixing and combining

hydrocarbon fractions, additives, and other components to produce
finished products with specific performance properties.

5. Other Refining Operations

 Simplified Fuel Refinery Configuration

LPG

CDU MS
Crude SK / ATF
HSD
RCO

VGO
VDU FCC

CLO Sulphur
Sour

S-Block
Water
VR

Str. SW
Rich
Amine Lean
DCU Amine
HCGO

Coke
 Simplified Lube Block Configuration

LPG
MS
CDU
Crude SK / ATF
HSD
VGO RAFFINATE DWO
RCO

VDU SEU SDU HFU LOBS

SLACK DEOILED
DAO WAX WAX
VR

WAX
WDU WHFU
SDA EXTRACT
TO FO
FOOTS OIL
Pitch
Refining Operations

Processing Type Process Units

Primary Processing Crude & Vacuum Distillation

Secondary Processing • Fluid Catalytic Cracking (FCC)

• Hydrocracking (OHCU or HCU)

Residue Processing • Delayed coking (DCU)

• LC Fining
• Visbreaking (VBU)
• Bitumen Blowing (BBU)

Treating Units • FG Amine Treating ( FG ATU)

• LPG Caustic wash, LPG ATU, LPG Merox
• Naphtha Caustic wash, Merox, Hydrotreating
• MS Selective HDT, ISOM, Bensat
• Kero / ATF Merox, Extraction, HDT
Refining Operations

Processing Type Process Units

Treating Units • Diesel Hydrotreating (DHDS, DHDT)
• VGO Hydrotreating (VGO HDT)
• RCO Hydrotreating (ARDS)
• Vac. Residue Hydrotreating (VRDS)

Others • Sour Water Stripping (SWS)

• Amine Regeneration (ARU)
• Sulphur Recovery (SRU)

Lube Units • Solvent Extraction (SEU)

• Solvent Deasphalting (SDA)
• Solvent Dewaxing (SDU)
• Wax Deoiling
• Lube / Wax Hydrotreating
Overview of Petroleum Refining Processes

Process Action Method Purpose Feedstock(s) Product(s)

FRACTIONATION PROCESSES

Atmospheric Separation Thermal / Separate Crude oil Gas, LPG,

Distillation Boiling Point fractions Naphtha,
(CDU) SK/ATF,
HSD, RCO

Vacuum Separation Thermal / Separate Atmospheric Vac. Gas oil,

Distillation Boiling Point fractions tower bottoms Lube stock,
(VDU) Residue
Overview of Petroleum Refining Processes

Process Action Method Purpose Feedstock(s) Product(s)

CONVERSION PROCESSES – CHAIN CLEVAGE

Fluid Catalytic Conversion Catalytic Upgrade VGO, RCO, Gas, LPG,

Cracking Heavy VR, Cr. Hvy. Gasoline,
(FCCU) Oils Oils Diesel,
Petrochem
feedstock
Hydrocracking Conversion Catalytic in Upgrade VGO, Cr. Hvy. Gas, LPG,
(HCU) presence of Heavy Oils, Residue Naphtha,
Hydrogen Oils SK/ATF,
HSD
Overview of Petroleum Refining Processes

Process Action Method Purpose Feedstock(s) Product(s)

CONVERSION PROCESSES – CHAIN CLEVAGE

Delayed Coking Conversion Thermal Upgrade RCO, VR Gas, LPG,

(DCU) Residue Naphtha,
Kero,
Diesel

Visbreaking Conversion Thermal Reduce RCO, VR Gas, LPG,

(VBU) Viscosity Naphtha,
Fuel Oil

Hydrogen Conversion Thermal / Produce Gas, LPG, Hydrogen

Steam Catalytic Hydrogen Desulphurised
Reforming naphtha
Overview of Petroleum Refining Processes

Process Action Method Purpose Feedstock(s) Product(s)

CONVERSION PROCESSES - UNIFICATION

Alkylation Combining Catalytic Unite olefins Iso-Butane, Iso-Octane

& Iso- Cracker (Alkylate)
paraffins olefins

Grease Combining Thermal Combine Lube oil, fatty Lubricating

Compounding soaps & oil acid, alkyl grease
metal
Overview of Petroleum Refining Processes

Process Action Method Purpose Feedstock(s) Product(s)

CONVERSION PROCESSES – ALTERATION or REARRANGEMENT

Catalytic Alteration Catalytic Upgrade SR & Cracked High Octane

Reforming low-octane naphtha Reformate /
naphtha Aromatics

Isomerisation Rearrangement Catalytic Convert C4 ~ C6 Iso-butane /

straight paraffins Iso-pentane /
chain to Iso-hexane
branch
chain
 Overview of Petroleum Refining Processes

Process Action Method Purpose Feedstock(s) Product(s)

TREATMENT PROCESSES

Hydro- Conversion Catalytic Reduce High S HC Desulphuris-

Desulphurisation sulphur Streams ed products

Hydrotreating Conversion Catalytic Remove Residual, Distillates,

impurities, Cracked HC’s Lubes, Wax,
saturate Cracker feed
HC’s
 Overview of Petroleum Refining Processes

Process Action Method Purpose Feedstock(s) Product(s)

TREATMENT PROCESSES

Amine Treatment Absorption Remove Sour FG, Sour Sweet FG,

Treatment H2S LPG LPG

Caustic Wash Treatment Conversion Remove Sour LPG, Sweet LPG,

H2S, Naphtha, Kero Naphtha,
Mercaptans Kero
Overview of Petroleum Refining Processes

Process Action Method Purpose Feedstock(s) Product(s)

LUBE PROCESSES

Solvent Extraction Solvent Remove Vacuum gas oil Raffinate &

Extraction aromatics Extract
(SEU)

Solvent Extraction Solvent Remove Vacuum DAO & Pitch

Deasphalting asphaltenes residue
(SDA)

Solvent Relative Solvent Remove Raffinate from LOBS &

Dewaxing Solubility waxy SEU Slack wax
(SDU) components

Wax Deoiling Relative Solvent Remove oil Slack wax from Wax & Foots
Solubility SDU oil
Refinery Products End Use

• Fuel Gas : Internal fuel firing & blanketing gas

• Liquefied Petroleum Gas (LPG) :
Domestic and industrial fuel & Petrochemical feedstock.
• Gasoline or Motor Spirit : Fuel for automobiles.
• Naphtha : Solvent or Fertiliser & Petrochemical feedstock.
• Aviation Turbine Fuel (ATF) : Aircraft fuel.
• Kerosene : Domestic fuel for stoves, lamps etc.
• High Speed Diesel (HSD) & Light Diesel Oil (LDO) :
Fuel for heavy vehicles. HSD is lighter & cleaner than LDO.
• Lube Oils / Greases : Lubrication of auto & industrial machinery.
• Waxes : Polishes, cosmetics, impregnation etc.
• Bitumen / Asphalt : Laying roads
• Fuel Oil : Fuel for industrial purposes
• Coke : Fuel or as anode grade coke in Aluminum industry
NEED TO UPGRADE QUALITY

• Improved product performance

• Environmental stipulations
• Emissions of toxics
• SOx and NOx Emissions
• Voc emissions
• Emissions of particulates
• Requirement of OEM’s
TARGET PRODUCTS

• Motor Spirit (MS)

• High Speed Diesel (HSD)

• Lubricating Oils

• Fuel Oil

✓ Requirement of environmentalists and original

equipment manufacturers
TECHNOLOGIES WITH EIL (REFINERIES) GAS

GAS
AMINE TREATING SULPHUR RECOVERY
LPG SULPHUR
TREATING
NAPHTHA NAPHTHA LPG
CRUDE TREATING
DISTILLA GASOLINE
TION HYDROTREATING
REFORMER
KERO/JET HYDROTREATING KEROSENE /ATF

SO2 EXTRACTION
CAUSTIC WASH DIESEL
HYDROTREATING
VACUUM
DISTILLA FCC / LOBS
TION HCU
LUBE \ WAX BLOCK HFU
EXTR’N/DEWAXING/DEOILING WAX

COKING/VISBREAKING
FUEL OIL

COKE
SOLVENT DEASPHALTING
ASPHALT
BITUMEN BLOWING BITUMEN
Status of Indian Refineries

Crude Mix High Low

Sulphur Sulphur

- India 52% 48%

- Reliance 95% 5%
 Is Indian Refining Industry Competitive?

Average yield of light and middle distillates :

USA 90% (Approx.)

India 72.5%

Reliance 90% (Approx.)

Is Indian Refining Industry Competitive ?

❖- GRMs for India presently around $6 – $7/bbl

GRMs for the World around $6 - $7/ bbl

With 72.5 % distillates, Indian refining is still

competitive with the World

Should distillates touch 88% – 90%, our

GRMs would increase phenomenonly
Performance of Refineries
Refinery Imported HS Light Ends Middle Heavy
Crude % % Distillates % Ends %
2005-06 2005-06 2005-06 2005-06
HPCL(M) 74 18.1 42.4 30.7
HPCL(V) 44.5 27.3 46.8 18.8

BPCL 31.7 27.7 45.1 20.6

KRL 43.8 23.4 49.3 16.9

IOCL(J) 25.9 15.9 47.9 29.7

IOCL(M) 54.6 18.9 52.2 23.7
IOCL(H) 72.8 17.1 43.7 29.4

CPCL 69.8 18.7 48.3 23.1

MRPL 69.0 20.1 53.3 20.3

 Typical Fuel & Loss Break-Up of Refinery

Basis : 100% HS Crude Processing & Captive Power Generation

A. Fuel & Loss (wt% on crude)

• Fuel gas 1.5 – 2.0 %
• Losses 0.5 – 1.0 %
• Fuel Oil 6.0 – 8.0 %
Total Fuel & Loss 8.0 – 11.0%
B. SOx Emission
Sulphur in IFO, wt% 1.0
Estimated SOx Emission, Tons/hr 1.25*

* Typical Sox Emission from Refineries is less than 1t/hr

Petroleum Refining Capacity of India
LOCATION REFINERY CAPACITY, MMTPA
EXISTING YEAR 2007
Digboi 0.65 0.65
Guwahati 1.0 1.0
Barauni 4.2 6.0
Koyali 12.5 12.5
IOCL Haldia 3.75 3.75
Mathura 8.0 8.0
Panipat 6.0 12.0
Paradip 0.0 9.0
Sub-Total 36.1 52.9
Mumbai 5.5 5.5
Visakh 7.5 7.5
HPCL Punjab 0.0 9.0
MRPL 9.6 9.6
Sub-Total 22.6 31.6
Mumbai 6.9 12.0
BPCL Bina 0.0 6.0
Sub-Total 6.9 12.0
Chennai 6.5 9.5
CPCL Narimanam 0.5 0.5
Sub-Total 7.0 10.0
KRL Kochi 7.5 13.5*
BRPL Bongaigaon 2.35 2.35
NRL Numaligarh 3.0 3.0
RPL Jamnagar 27.0 27.0
Essar Jamnagar 0.0 10.5
Nagarjuna Cuddalore 0.0 6.0

Total 112.45 174.85

Notes : 1. Year 2007 is end of X plan.
2. * Based on 6.0 MMTPA expansion planned for KRL.
3. Future Refineries.