mini oil refinery - learning chemical...
TRANSCRIPT
Mini Oil Refinery Review
Rifka Aisyah
1
About Mini Oil Refinery
� Capacity is about 4000 – 30 000 BPD.
� Usually built to fulfill oil demand in remote region.
� Modular mini oil refinery is used because relatively low capital cost and ease and
speed of contruction.
� Petroleum Product Balances in Indonesia (2015)
Demand
(thou. BPD)Share
Production
(thou. BPD)Share
Net export
(thou. BPD)
Product Total 1973 100.0% 1256 100.0% -717
� Current production facilities cannot fullful national petroleum product demand,
therefore more oil refineries need to be developed.
2
Product Total 1973 100.0% 1256 100.0% -717
Gasoline 386 19.6% 352 28.0% -34
Naphta 90 4.6% 18 1.4% -72
Kero/Jet 398 20.2% 130 10.4% -268
Gas Oil 795 40.3% 386 30.7% -409
Heavy Fuel 236 12.0% 318 25.3% 82
Fuel oil total 1905 96.6% 1204 95.9% -701
LPG 53 2.7% 27 2.1% -26
Other products 15 0.8% 25 2.0% 10
Economy of Scale
� Capital cost to refine a litter of crude oil is higher in the case of a mini-refinery.
� Some conditions that make investment in mini oil refinery workable:
o Close access to cheap crude oil
o Near to sizable market – to decrease distribution cost
o An acceptable market for HFO
Project finance on preferential terms for development credit agencieso Project finance on preferential terms for development credit agencies
o Gain government incentives to support regional development
� To minimize capital cost, mini refinery is often supplied only as a simple straight run
atmospheric distilation refinery for diesel and/or kerosene production, with naphta and fuel
oil as by-product
� EXPENSIVE lighter + sweeter crude oil � less facility upgrading � but crude oil source is
limited
� CHEAPER heavier crude oil � more facility upgrading � crude oil source is increasing
3
Recommended Feed Stock Characteristics for
Mini Oil Refinery
� Salt Content
o Maximum salt content 1 kg/1000 barrel
o Pre-treatement required if salt content is more than 1 kg/1000 barrel.
o Additional desalter is still feasible. Fresh water source & waste water disposing
method should be considered.
� Sulphur Content
Crude oil with <1% sulphur will normally refine within the allowable fuel specification
without the need for de-sulphuring process.
� Other Characteristics
o High API
o High natural diesel fraction in its assay
o Low in sulphur, salts, and other contaminant
4
Some Configurations of Mini Oil Refinery
Topping Plant Hydroskimming Cracking Refinery Coking Refinery
Facilities • Crude distilling unit • Crude distilling unit
• Catalytic reformer
(additional)
• HDS
• Crude distilling unit
• Vacuum distilling
unit
• Catalytic cracking
unit
• Crude distilling unit
• FCCU or Hydro-
cracker
Feedstock Condensates/light sweet
crude
Light sweet crude Processed gas oil Processed residual
fuel
� Refinery configuration is influenced by product demand.
crude fuel
Process Simple distillation Simple distillation with
catalytic reforming &
hydrodesulfurization
Break gas oil using
catalyst at high T & P
into gasoline and
distillates (jet fuel,
kerosene, diesel,
intermediate fuel oil)
Thermally crack
residual fuel into
gasoline and diesel
oil
Products • Diesel and/or kerosene
• Naphta and fuel oil (by
product)
• High octane gasoline • Heavy diesel
(vacuum gas oil)
• Heavy residual oil
• Diesel
• Fuel oil
5
Increasing complexity
Product Yield using “Heavy Crude Oil” at
Different Refinery Configuration
6
Current Mini Oil Refinery in Indonesia (1/2)
PT Tri Wahana Universal (TWU) PT TransPacific Petrochemical Indotama (TPPI)
PT Humpuss Pengolahan Minyak (HPM)
Location Bojonegoro, East Java Tuban, East Java Cepu, Central Java
Year of built 2008 1995
Capacity (bpd) 6000 100 000 10 000
Feed stock source Mobil Cepu Limited (MCL) Pertamina Expected from MCL or from Pertamina-Petrochina (50 km distance)
Characteristics of feedstocks
Light-medium and waxy grade crude with very low sulfur. Very high kerosene, diesel, and VGO cuts but very low naphtha and resid cuts
NA
Feed stock supply method
By 5 km pipeline Expected using 28 km pipeline
Facilities Atmospheric Distillation Column, Vacuum Distillation Unit
Precut column, Condensate Splitter, Distillate Column, Aromatic Plant
Atmospheric Distillation Column, Naphta Hydrotreated, Catalytic Reformer
Products • Naphta/Straight Run Gasoline• Solar/High Speed Diesel• Marine Diesel Oil (MDO)• Residue/Vacuum Tower Bottom
• Naphta• Kerosene• Diesel Oil• Fuel Oil• Aromatics (Ortho-xylene, Para-
xylene, Mixed-xylene, Benzene, Toluene, Reformate)
• Naphta• HSD• IDO• MFO
7
Current Mini Oil Refinery in Indonesia (2/2)
PT Pertamina RU VII PT PatraSK PT Kilang Muba
Location Kasim, Papua Dumai Musi Banyuasin, South Sumatera
Year of built 2008
Capacity (bpd) 10 000 25 000 800
Feed stock source
Walio (60%) + Salawati (40%) Unconverted Oil (UCO) from PT Pertamina RU II Dumai
Characteristics of feedstocksfeedstocks
Feed stock supply method
Facilities Atmospheric Distillation Column,Naphta Hydrotreating Unit,Catalytic Reforming Unit
Crude Distillation Unit,High Vacuum Unit,Hydro Cracking ComplexVacuum Distillation UnitCatalytic Dewaxing Unit
Crude Distillation Unit
Products • Fuel gas (969 bpd)• Premium fuel (1987 bpd)• Kerosene (1831 bpd)• ADO/solar (2439 bpd)• Residue (3390 bpd)
• Lube base oil • Premium• Kerosene
8
Future Plant of Mini Oil Refinery Development
in Indonesia
Company Planned Capacity (BPD)
Remarks
PT Tri Wahana Universal 10 000 Additional
Joint PT Bojonegoro Bangun Sarana &
PT Tierra Energi Perkasa
10 000
PT Chandra Asri Petrochemical 100 000
PT Indo Kilang Prima 2 x 3000 • On going.
• Location: Padang Lawas, North Sumatera
• Expected products: HSD, MFO, kerosene,
naphta
• Start producing in April 2016.
• Total investment USD 54 million.
• Crude supply : PT EMP Tonga, possibly
additional source from PHE Siak, Pacific Oil
PT Indo Kilang Prima 15 000 In Kalimantan and Sumatera
PT Nusantara Energy Resources 25 000 – 30 000 • In Banyuwangi, East Java.
• Feed stock source: Vitol Trader Group
(Netherland)
PT Pertamina RU VII Kasim 50 000 Improve capacity from 10 000 BPD to 50 000
BPD
9
Mini Oil Refinery Facilities
� Atmospheric Distilling Unit (ADU)
Separate different fractions of the crude oil according to boiling range into naphtha, kerosene, diesel, and residuum products. It operates at less than 15 psig.
� Vacuum Distilling Unit (VDU)
Performs the same function as an ADU, but operates at a pressure of less than zero psig. It produces products like marine fuel oil (MFO) and asphalt from the ADU residuum (heavy fuel oil).
� Hydrodesulfurization Unit (HDU)
Removes sulfur and other impurities from naphtha and distillate fuels.
� Catalytic Reformer Unit (CRU)
10
Produces high octane gasoline from naphtha.
� Hydrocracker Unit (HCU)
Produces naphtha, kerosene, and diesel from heavy feedstocks like VDU distillates.
� Desalter
Removes salt from crude oil prior to distillation to prevent fouling and corrosion.
� Splitter/Stabilizer
Separates a feedstock into two products.
� Flare
Combusts any excess vapor released by process equipment.
Configuration of Mini Oil Refinery at
PT Tri Wahana Universal
AOil Feed
Max Density = 781.6 kg/m3 (at 60F)
Max sulfur content = 0.053 %m/m
Max RVP = 5.5 psi (at 100 F)
Kerosene
Overhead Accumulator
Off gas
Naphta
11 BOPD
355 BOPD
530 BOPD
2003 BOPD
ADU
VDU
Atmospheric bottom
High Speed Diesel
Off gas
Vacuum Tower Bottom
Oil Feed Stock
Density = 850.3 kg/m3 (at 60F)
Sulfur content = 0.257 %m/m
Cetane index = 52oC
Max Density = 925 kg/m3 (at 60F)
Max sulfur content = 0.45%m/m
Atmospheric gas oil
11
Banyu Urip
Field
6000 BOPD550 psig140oFAPI 32.8<0.5% BS&W<10 ppm H2S10.5 psia TVP Light vacuum gas oil
Heavy vacuum gas oil
1150 BOPD
1927 BOPD
19 BOPD
600 BOPD
300 BOPD
946 BOPD
Configuration of Mini Oil Refinery at
PT Pertamina RU VII Kasim, Papua
AOil Feed Kerosene
NaphtaHydrotreater
Catalytic Reformer
Heavy naphta
Fuel gas and flare
Sweet naphta
H2
Premium
Light naphta
969 BPD
1987 BPD
ADU
Residue
Oil Feed Stock
Solar
12
10 000 BPDWalio : 60%
Salawati : 40%
(Local Sorong)
Kerosene
1831 BPD
3390 BOPD
2439BPD
Configuration of Mini Oil Refinery at
PT Humpuss Pengolahan Minyak
Crude column accumulator
Off gas
Naphta
To flare
Hydrodesulfurization
Catalytic reforming
High octane gasoline
The facility has been built completely, but not yet commissioned because no crude oil supply.
486 BPD
1285BPD
13
ADU
Atmospheric residue
Diesel
Oil Feed Stock
Kerosene
Plan: Banyu
Urip Crude
10000 BPD
3461 BPD
4764 BPD
Possible Configuration for Mini Oil Refinery
ADU
Naphta Hydrotreater
Catalytic Reformer
Gas
Naphta
Kerosene
Diesel oil
High octane gasoline
Oil Feed Stock
Use for distillation
H2
H2S
DieselHydrotreater
H2
H2
Diesel oil Butene/U
VDU
Atmospheric bottom
Diesel oil
LVGO
Atmospheric gas oil
14
Hydrotreater
H2S
Diesel oil
HVGO
VTB
Off-gas
Hydrocracker Unit
Hydrocracked Gasoline
FCC Naphta
FCC oil
Butene/Pentene
Coker
Coker naphta
Coker gas oil
Petroleum coke
Aspects to be Considered
� Refinery Location
o Steam/water availability
o Wastewater disposing facility
o Required refiniery capacity
o Distance to source oil
o Distance to pipeline
o Distance to sea port
� Quality of Crude Oil
15
� Quality of Crude Oil
o Crude assay
� Product Specification
o Product specification for naphta, diesel, and fuel oil
o Storage capacity
o Average selling price
Indonesian Oil Product SpecificationGasoline
16
Indonesian Oil Product SpecificationIndustrial Diesel Oil (IDO)
17
Indonesian Oil Product SpecificationMarine Fuel Oil (MFO)
18
Example CDU Simulation using Hysys Assumption:
- Capacity = 10 000 BPD
- Oil characteristics = Type C Banyu Urip (using assay characteristics)
- API 32.6 (60oF)
19
Products:
- Naphta = 895 BPD
- Kerosene = 1122 BPD
- Diesel = 3860 BPD
- Atm residue = 4124 BPD
Example Catalytic Reforming Simulation using
Hysys
Atmospheric residue is further processed in Vacuum Distilling Unit to produce LVGO, HVGO, and Vacuum Resid.
20
Products:
- Offgas : 2.94 BPD
- LVGO : 975.3 BPD
- HVGO : 1057 BPD
- Vacuum resid : 2091 BPD