refinery overview modification.ppt

8/19/2019 refinery overview modification.ppt

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1

A.Ramasubramanian – Chennai Process Head

CHENNAI / DATE XX/XX/XXXX

REFINING PROCESS - OVERVIEW


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What is Crude Oil ?•Latin name, comes from : Petra (Rock) and Oleum(Oil)

•Petroleum is a fossil fuel which is mainly a mixture of organic compounds called

hydrocarbons made of hydrogen and carbon!

•"ormally #lack in color

•$%ailable in plenty in &iddle 'ast (Persian ulf)$lso a%ailable in "orth western$frica, *ndonesia, +outh entral $merica, +candina%ia

•*n *ndia, it is a%ailable in #ombay -igh, .rishna/odha%ari basin, $ssam Ra0asthan

•.ey properties to classify crude oil

$P* ra%ity (121!34 +p! ra%ity /151!3) and 6iscosity!

•lassi7cation according to sulfur content

+weet crude: +ulfur e8ual or less than 9!3

+our crude: +ulfur more than 9!3


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Need For Refinin ?


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Need For Refinin ?


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Oil isseparated

into itsconstituents

bydistillation,

and some ofthese

componentsare furtherseparated by

chemicalreactions and

di;erentsol%ents!

6arioushydrocarbonsproduced are

thenchemically

altered usingcatalytic

process tomake them

more suitablefor theirintendedpurpose!!

-


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Refinin Histor/

0nention of

0C enines

0ncreasedasoline

and diesel

demand

Need

for hih

octane

and

cetane

fuels

%an on leadusae

4%5 and

other octane

boosters

6O7 and NO7

'imitinbenzene

Fluctuatin oil

#rice 8ailabilit/ of

chea#er

sources oil

sands

Refiner/

marin


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4/#ical Chemical com#osition of Crude

Carbon : ;3 ;9 < H/droen : 1= 1! < 6ul#hur : =*=" . <

Nitroen : =*1 2 <O7/en : =*=" 1*" <etals : = =*1! <


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Classification of Crude

6ul#hur content close to 1< : 6>eet crude

others sour crude

ore than 2*"< : Hihl/ sour crude*

6ul#hur can be inarious forms such as 4hiols 6ul#hides C/clic

sul#hides disul#hides thio#henes etc*

6ul#hur com#ounds #oses enironmental concern**

O7/enic com#ounds @

8lcohols ehers c/clic ether furan carbo7/lic acids na#hthenic acids etc*

No>ada/s increasinl/ hih 48N crudes are bein #rocessed* 0t increases

corrosion #roblems in refiner/*

Nitroen com#ounds @ P/rrole indole carbozole benzocarbozole

#/ridine etc

Nitroen acts as catal/st #oison and #oses nitroen o7ide emission

threats*


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Classification of Crudeetals @ etals #resent as inoranic salts and as #or#h/rins & Ni B

etc) 4hese salts are remoed in dasltin #rocess*Ni B #ro#h/rins act as catal/st #oisons

Characterization of Crude%ased on arious factors @

4radin @ ,ensit/ 8P0 rait/4rans#ortation @ RBP Pour #oint Wa7 ContentContaminants @ 6alt %6WProcessabilit/ @ 6ul#hur Nitroen 48N 8s#haltene CRCrac-in Point @ 864 ,istillationClassification @ Characterisation factor*


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Characterization of Crude 8P0 (rait/

8P0 (rait/ & 1!1*"$6#ecific (rait/ ) 131*" 8P0 D 31 'iht crude oil 8P0 22 31 i7ed %ased 8P0 E 22 Hea/ Crude

&8P0 is a maor Factor for crude #ricin )

6ul#hur @

6ul#hur E =*" >t eet6ul#hur =*" 1 medium sour 6ul#hur D 1 >t 13 ? 5


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Characterization of CrudeTAN

Crudes are termed as high Acid crude if TAN of crude is > 0.5mg KOH/gm Crude Oil

UOP Characterisation actor !K UOP "

# > $%.$ & Paraffinic crude !'er( )a*(& less as+haltic& lo) sul+hur& high +our +oint"

# $%.$ , $$.5 & C(cleic ! Na+hthenic -ase stoc#s& lo) )a*& less as+halt& lo) +our +oint"

K $0 .5 & Aromatic ! more aromatic& high sul+ur& nitrogen"

Conradason Car-on Num-er


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Gield Pattern of Barious Crudes


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Gield Pattern of Barious Crudes


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0m#act of Crudes t/#e on refiner/ desin

Oerall 1efiner( Configuration

Product se+aration

Product Processing

2aterial selection

(ross refiner/ marin

Crude oil selection is im#acts on the oerall Refiner/ 5conomics & both crude

cost and Processin cost)

Refiners need lo> 6ul#hur crudes & and lihter crude) 0m#act is hiher

costs and lo>er #rocessin cost

Refiners #refer lo> acidic crudes


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aor Refiner/ ProductsLP u orrosion @ not more than 1 strip

R6P / 1939 .pa, &ax

&+ Aensity @ B


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Constraints for Refiner/

1) 6#iralin crude cost

2) Current refiner/ confiuration not able to meet clean fuel s#ec for 6 or H6,

3) 'o>er distillate #roduction

!) Need to #roduce alue added #roducts to im#roe refiner/ marin

") Older technoloies & hiher ener/ consum#tion)

.) 5nironmental issues


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Refinin Histor/• Product s#ecifications hae been attractin close attention of enironmentalists as >ell as

eui#ment manufacturers*• Products li-e diesel and asoline are bein s#ecificall/ tareted for ualit/ im#roement*• 'ubricatin oils are also bein loo-ed at >ith a ie> to meetin 8P0 (rade 00$(rade 000

s#ecifications*• 4he main im#lications of the chanes in the #roduct ualit/ are@

0ncreasin use of h/dro conersion to u#rade hea/ stoc-s into alue added #roduct

as >ell as im#roe the ualit/ of distillates*

0nstallation of (as s>eetenin 6ul#hur Recoer/ &AA< min) to meet enironmentalsti#ulations*

• 4hese reuirements hae lead to sinificant inestments but >ithout a corres#ondin #remium

on the #roduct #rices*• 8ccordinl/ refineries hae to loo- at >a/s and means to im#roe their #roduct #attern to• #roduce more alue added #roducts im#roe the ener/ efficienc/ so that total o#eratin

costs can be minimized*• 8ddition of conersion facilities to u#rade hea/ residues >hich >ere bein sold as fuel oil

has also assumed im#ortance*• 4his has necessitated a close e7amination of refiner/ confiurations and almost all the

refineries are ta-in u# studies to criticall/ loo- at facilities >hich >ould be reuired to meet

the future #roduct s#ecifications >hile ensurin that o#erations remain #rofitable*


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Refinin Confiuration• Refiner/ crudes are either liht moderate and hea/ crudes

• 'iht and moderate crudes are tareted for as na#htha diesel

'(O $ H(O fractions

• Hea/ crudes are tareted for co-e and residue #roducts*

•%ased on the crude ualit/ and #roduct reuirements refiner/to#ora#h/ aries*

• %roadl/ the refiner/ confiurations are classified as based on the

#roducts tareted @

:Fuel ma7imization Ber/ #rominent in countries such as 0ndia

: Co-e #roduction

: 'ubricants and lube oil base

: Petrochemicals


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Refinin Confiuration• Refineries can be classified into rou#s of com#arable refineries defined b/ refiner/

com#le7it/

• Com#le7it/ factor denotes the e7tent ca#abilit/ and ca#ital intensit/ of the refiner/* 4he

hiher the com#le7it/ factor the reater the refiner/Is inestment and reater the refiner/Is

abilit/ to add alue to crude oil

• 0n eneral refineries are classified based on com#le7it/ @

4o##in refineries @ Hain onl/ C,J and basic su##ort o#erations* 4he/ cannot control

#roduct sulfur leels* & Com#le7it/ factor E2)

H/dro s-immin refineries include to##in K catal/tic reformin h/dro treatin and #roduct

blendin & com#le7it/ factor 2:.)

Conersion or crac-in refineries include h/dro s-immin and h/drocrac-in K catal/tic

crac-in >hich can transform hea/ crude to liht and middle distillates & .:12)

,ee# conersion or co-in include Conersion K co-in >hich can destro/ heaiest crude

fraction into lihter streams*& com#le7it/ factor D12)


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Refinin Confiuration

8 R!,in!r* )#n,iura(i#n refers to rou# and t/#e of #rocess units in

the refiner/ >ith their ca#acities*Refiner/ confiuration is arried at based on t/#e of crude #rocesseddesired #roduct ualit/ and uantit/ and mar-et demand

0in!ar Pr#rammin #ac-aes are enerall/ used to arrie at ano#timum confiuration ma7imizin the #rofit and minimizin the

inestment*

Pr#"u)( %a((!rn is based on refiner/ confiuration and the crude#rocessed*

ore com#le7 confiuration ies more alue addition to the #roducts

but it has to be seen >hether the inestment is commensurate >ith thebenefits*


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R!,in!r* Pr#)!ssin $#)1s – C$ass!s#, R!,inin %r#)!ss


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(86O'0N5 %'5N,0N(

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Gasoline Specifcation in India

+erial"o! Characteristics Unit

BharatStage II

BharatStage III

BharatStage IV

BharatStage V

1 Proposed year


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REFINERY OVER VIEWPur#ose of (asoline J#radin

1) 6ul#hur Reduction in (asoline #ool

: ain Contribution is from FCC Na#htha

: Reducin FCC na#htha either b/ F55, h/dro treatment or FCC Na#htha feed h/dro treatment2) %enzene Reduction

: 8oid %enzene Production

: Conert or destro/ %enzene

: Recoer %enzene for #etrochemical #roduction

3) 8romatics Reduction : decreases octane

: 57tract aromatics for #etrochemicals

: Reduce seerit/ of o#eration in reformer

!) Olefins anaement in asoline #ool

: ain contributor is FCC asoline

: FCC Na#htha treatin can be im#lemented but >ill decrease octane

: 5therification ho>eer o7/enates future is uncertain

") Octane anaement in (asoline #ool

: 'iht na#htha isomerization ood effect on olefin less sulfur aromatic and olefins ho>eer additional ca#ital

inestment and hiher RBP

: 5therification

: 8l-/lation ood in terms of sulfur aromatics and olefins RBP etc* Handlin of acid safet/ concern

: Reformin @ main constituent of 6 #ool for octane im#roement ho>eer hih aromatic content hence use is

limited

REFINERY OVER VIEW OCTANE C i


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REFINERY OVER VIEW – OCTANE C#m%aris#n

REFINERY OVER VIEW :S S(r!am


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REFINERY OVER VIEW – :S S(r!am

CRNCRN 933*!933*! A3A3 ;=*.;=*. 2!==2!==

'iht 0somerate'iht 0somerate .!3*9.!3*9 ;;*A;;*A ;;*2;;*2 ==

ReformateReformate ;3!;3! 1=31=3 A1A1 ==

'iht FCC (asoline'iht FCC (asoline ..;..; A!*.A!*. ;1*;;1*; 2"=2"=

Hea/ FCC (asolineHea/ FCC (asoline 9A29A2 ;1*3;1*3 9.*39.*3 1=1=

S(r!amS(r!am !n?!n!' #$@!n?!n!' #$@ Ar#ma(i)s'Ar#ma(i)s'

#$@#$@

O$!,ins' #$O$!,ins' #$@@

RVP' 1PaRVP' 1Pa

CRNCRN 1*;1*; 2!*32!*3 3"*"3"*" ""*1"""*1"

'iht 0somerate'iht 0somerate == == == 1=9*11=9*1

ReformateReformate =*A;=*A; ;3*=9;3*=9 1*21*2 1!*91!*9

'iht FCC (asoline'iht FCC (asoline =*9=*9 =*A=*A ."*9."*9 1==1==

Hea/ FCC (asolineHea/ FCC (asoline =*=;=*=; 2.*.2.*. =*9"=*9" ;;

REFINERY OVER VIEW :S S(r!am


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REFINERY OVER VIEW – :S S(r!am ,ensit/

Nil Olefin $6ulfurNil Olefin $6ulfur$%enzene$8romatics$%enzene$8romatics

Hih RBPHih RBP

ReformateReformate Hih RONHih RONNil 6ulfur$'o> OlefinsNil 6ulfur$'o> Olefins

Hih ,ensit/$8romaticsHih ,ensit/$8romatics

'iht FCC'iht FCC(asoline(asoline

Hih RON$'o> ,ensit/Hih RON$'o> ,ensit/ Hih 6ulfur$Olefins$ RBPHih 6ulfur$Olefins$ RBP

Hea/ FCCHea/ FCC(asoline(asoline

'o> 6ulfur $%enzene'o> 6ulfur $%enzeneolefins$RBPolefins$RBP

Hih 8romatics$Hih 8romatics$

'o> RON'o> RON

REFINERY OVER VIEW im%a)( #, S V #n


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LPG

H2

ISOMERATE

TREATED HEAVY

FCC GASOLINE

TREATED LIGHT

FCC GASOLINE

NAPHTHA

SPLITTER UNIT

NHT/CCR

M

S

P

O

O

L

SELECTIVE HYDROGENATION

& SPLITTER SECTION

PRIME G+ UNIT

NAPHTHA HYDROTRTEATER &

ISOMERISATION

MAKE UP H2

PURGE GAS

H2 MAKE UP FROM CCR

FG

REFORMATE

SR FULL RANGE

NAPHTHA

FCC NAPHTHA

MAKE UP H2

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Refinin Histor/

(86 O0' %'5N,0N(

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Refinin Histor/ 4echnoloical o#tions for %ottoms of %arrel J# radation

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Refinin Histor/Diesel Specification in India

S. No Characteristic BSII BSIII BSIV BSV

1 Densit K!/"# 1$ %C 2'('' 2')*$ 2')*$

2 S,-. C0ntent "!/! "3 $'' #$' $' 1'

#45Cetne N"6e "ini"" n7 /0

* $1 $1

#465 Cetne In7e3 0 n7 n7

*8 *8 *8

*P0,99,i9 A0"ti9H70960n

( 11 11

$ Disti,,ti0n

45 Re90: Min: At #$' %C $ ( (

465 Re90: Min: At #;' %C


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Refinin Histor/ ,iesel Pool1) 6ul#hur Reduction in ,iesel

: lo> sul#hur crudes limitiation of hih #rice

: H/drotreatin of arious diesel streams

: 0nstall $ ream# ,H,6 $ ,H,4 units in e7istin refiner/

2)8romatics Reduction

: Choosin hih #araffinic crudes

: choose lo> aromatic diesel blend stoc- & diert hih aromatic diesel to fuel oil affects in oerall refiner/ #rofitabilit/

and diesel olume)

3) 6eere H/drotreatin usin Nio catal/st& for seere aromatic saturation noble metal catal/st reuired) hiher

inestment

!) Cetane im#roement

: H/drocrac-in and aromatics saturation

: Jsae of cetane im#roement addities

") ,ensit/ Reduction

: can be achieed durin dee# h/drodesul#hurization and de#ends u#on feedstoc- sulfur remoal saturation of di $

tri aromatic com#ounds

.) A"< distillation #oint

: adust the dra>s of C,J results in reduction of diesel olume reduction in hea/ aromatics densit/ reduction

im#roement in cold flo> #ro#erties

: ild h/drocrac-in

REFINERY OVER VIEWRefinin Histor/ 0m#act of %6 B ,iesel on 0ndian Refineries


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Refinin Histor/ 0m#act of %6 B ,iesel on 0ndian Refineries

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ORefinin Histor/ 4echnoloical o#tions for %ottoms of %arrel J#

radationN!!" ,#r H!a* En"s Pr#)!ssin

1)Crude 6late has become heaier

2)Concentration of sulfur and other contaminants has been increasin

3)6ulfur s#ecification becomin more strinent

!),emand for Fuel oil is declinin

")Cost of 'iht crude relatie to hea/ crude is increasin

T># T*%!s #, (!)&n#$#i!s ar! aai$ab$!

1)Remoal of Carbon

: Bisbrea-in ,ela/ed Co-er 6olent ,eas#haltin Resid FCC

2)8ddition of H2

: Catal/tic H/drocrac-in #rocess

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Refinin Histor/

• Refineries becomin more com#le7 >ith different t/#es of #rocessin

units

• 0ncreased h/droenation #rocess and hiher h/droen demand

• 4his results in aderse im#act on refiner/ marin alon >ith oil and

#roduct #rice

• 4echnolo/ to minimize the residual #roducts and usae of

unconentional oil sources

• 0nteration of refinin and #etrochemical industries


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CR5DE DISTI00ATION

R!,in!r* Pr#)!ssin –


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* CR5DE DISTI00ATION

R!,in!r* Pr#)!ssin – F!!" Pr!&!a(


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* an" D!sa$(in



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* (*%i)a$ F!!" Pr!&!a(

R!,in!r* Pr#)!ssin - CD5


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• 6e#arates crude oil into arious

fractions or straiht:run cuts*• Crude boilin rane is bet>een 3=

to ."= =C*• 4he tem#erature of crude is to be

-e#t belo> 3;= =C to aoid

thermal crac-in*• 4he desalted crude is #reheated

usin recoered #rocess heat and

direct fired heater*• C,J or atmos#heric distillation

unit is o#erated slihtl/ aboe

atmos#heric #ressure*

R!,in!r* Pr#)!ssin - VD5


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• ,istillation of atmos#heric

residue under acuum to boil offheaier cuts• 6u#erheated steam is inected

>ith the feed and in the to>er

bottom to reduce h/drocarbon

#artial #ressure

• 4he #rinci#les resembles thoseof fractional distillation e7ce#t

that larer diameter columns are

used to maintain com#arable

a#or elocities at the reduced

#ressures*

R!,in!r* Pr#)!ssin - VD5


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• 0nternal desins of some acuum column are different from

atmos#heric column Random #ac-in and demister #ads are used

instead of tra/s*• Bacuum column is o#erated to meet t>o t/#es of obecties@

4o enerate feed for FCC$ H/drocrac-er for crac-in

4o enerate ra> lube cuts for lube oil manufacture*• Bacuum column o#eration is also of t>o t/#es

,r/ acuum for FCC$ HC feed andWet acuum for lubes*• 'ube cuts need ood se#aration* 0t uses more of steam hence

called Wet Bacuum*• For FCC$ HC feed aim is to distil out to a ma7 cut tem#erature and

se#aration bet>een the cuts is not im#ortant*

6o dr/ acuum o#eration is at lo>est #ressure >ith minimum ofstri##in steam*



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T*%i)a$ Cu( P#in(B "!,ini(i#ns



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Cu( %#in(' O!r $a% an" Tai$s



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Cu( %#in(' O!r $a% an" Tai$s



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(*%i)a$ *i!$"s


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HYDROPROCESSING

HYDROPROCESSING


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HYDROPROCESSING - Pur%#s!


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HYDROPROCESSING –C&ara)(!ris(i)s #, Pr#"u)(s


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C&ara)(!ris(i)s #, Pr#"u)(s

HYDROPROCESSING –C&ara)(!ris(i)s #, Pr#"u)(s


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C&ara)(!ris(i)s #, Pr#"u)(s

HYDROPROCESSING – Tr!n"s


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HYDROPROCESSING – Ca(a$*s(s


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HYDROPROCESSING – HDS


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HYDROPROCESSING – T*% %r#)!ss%aram!(!rs


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%aram!(!rs

HYDROPROCESSING –Na%&(&a H*"r#(r!a(in


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% *

Pr#"u)( Fra)(i#na(i#n• Pentane $ he7ane oerhead either to blendin or isomerization

• %ottoms to reformer

HYDROPROCESSING –Dis(i$$a(! H*"r#(r!a(in


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• 0n eneral all liuid distillate streams contain sulfur com#ounds that must be

remoed

• 6aturate olefins in diesel to im#roe the cetane number

• H/droenation at hih #ressure #roduces small amounts of na#htha due to

h/drocrac-in

• O#eratin conditions de#end on feedstoc- & et or diesel)

HYDROPROCESSING –Gas#i$ H*"r#(r!a(in


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HYDROPROCESSING –H*"r#)ra)1in


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HYDROPROCESSING –H*"r#)ra)1!r F!!"s


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HYDROPROCESSING –H*"r#)ra)1!r Pr#"u)(s


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R!,in!r* Pr#)!ssin – H*"r#)ra)1!r 5ni(


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Di,,!r!n( C#n,iura(i#ns

•6inle:stae once throuh@ For mild h/drocrac-in or >hen a sinificant uantit/ of

unconerted oil is reuired for FCC lubes or eth/lene units*

•6inle:stae rec/cle@ For lo>er ca#acit/ units >hen economical*

•4>o:stae rec/cle #rocesses*

A (>#-s(a! &*"r#)ra)1!r >i(& in(!rm!"ia(! "is(i$$a(i#n r!%r!s!n(s (&! m#s(

)#mm#n %r#)!ss )#n,iura(i#n ,#r maimi?in mi""$! "is(i$$a(!s.

HYDROPROCESSING – T!)&n#$#i!s


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H*"r#(r!a(in

H*"r#)ra)1in

HYDROPROCESSING –H*"r#!n )#nsum%(i#n


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HYDROPROCESSING –H*"r#!n s#ur)!s


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GASO0INE 5PGRADING

GASO0INE 5PGRADING


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R!,in!r* Pr#)!ssin – Ca(a$*(i) R!,#rm!r R!,#rm!r is us!" (# %r#"u)! &i& O)(an! as#$in! #r ar#ma(i)s.


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%

• Feed ON "= Product ON A=:1="

• Reformer asoline re#resents u# to "=< asoline #ool

• H/droen is a aluable side #roduct

I(s )a%a)i(* is ,i!" bas!" #n

• asoline demand or

• aromatics #roduction taret or both*

R!a)(i#ns ar! C#n!rsi#n #, %ara,,in an" na%&(&!n!s (# ar#ma(i)s a( &i& (!m%!ra(ur! +9-

84 C' %r!ssur! +-4 bar an" )a(a$*s( P$a(inum #r P(-R& bas!".

F!!" mus( b! %r!(r!a(!" (# r!m#! %#is#ns S' N' m!(a$s' O$!,ins

H!a* Na%&(&a )u( (# b! us!" as ,!!"s(#)1 in r!,#rmin n!!" (# b! (ai$#r!" b* na%&(&a

,ra)(i#na(i#n as

• .= :A= =C for %enzene e7traction

• A= :11= =C for 4oluene e7traction

• 11= :1!= =C for M/lene e7traction

• Preferabl/ A= :1.= =C for asoline ma-in*

• 'icensor @ JOP$ 87ens $

R!,in!r* Pr#)!ssin – Ca(a$*(i) R!,#rm!r


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R!,in!r* Pr#)!ssin – A$1*$a(i#n 5ni((# b! )#!r!" in A$1*$a(i#n m#"u$!

• A%%$i)a(i#n Pro#/lene but/lenes and sometimes #ent/lenes &also -no>n as


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am/lenes) are catal/ticall/ combined >ith iso:butane to form iso:octane*

• Pr#"u)( 8l-/late #roduced hae hih octane and lo> a#or #ressure

characteristics*

• I( )#n(ains n# #$!,ins' ar#ma(i)s #r su$,ur.

• A$1*$a(! &as an #)(an! ar#un" 8 R:/4

• 0#> a%#r %r!ssur! ma1in i( a a$uab$! as#$in! b$!n"in )#m%#n!n(

%ar(i)u$ar$* ,#r %r!mium ra"! %r#"u)(s.

• A$1*$a(i#n is )arri!" in (&! %r!s!n)! #, a s(r#n a)i" )a(a$*s( !i(&!r

&*"r#,$u#ri) HF #r su$,uri) a)i"

6ulfuric 8cid 8l-/lation runs at 3":.=F &2:1"C) to minimize

#ol/merization reactions

HF 8l-/lation >hich is less sensitie to #ol/merization reactions runs at

9=:1==F &2=:3;C)*

R!,in!r* Pr#)!ssin – A$1*$a(i#n 5ni((# b! )#!r!" in A$1*$a(i#n m#"u$!


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• Chillin or refrieration is reuired to remoe heat of reaction*

• 8l-/lation #roducts are distilled to remoe #ro#ane iso:butaneand al-/late*• 6ulfuric acid slude must be remoed and reenerated*• HF is neutralized >ith OH >hich ma/ be reenerated and

returned to the #rocess• 'icensors @ JOP $

6tratco $Conoco#hili#s$577

on$0FP$Jhde

R!,in!r* Pr#)!ssin – FCC 5ni(

• Obectie @ 4o Conert Hea/ Bacuum (as Oil to aluable distillates li-e


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• Obectie @ 4o Conert Hea/ Bacuum (as Oil to aluable distillates li-e

'P( (asoline ,iesel

• Feed @ B(O $ RCO $ BR $ H/drocrac-er %ottom• Catal/st @ 6ilica 8lumina Leolite• Products @ Product reuire further #rocessin* (asoline from FCC >ill

hae hih 6ulfur content* H/dro #rocessin ma/ be reuired

Olefins ma/ be sent to al-/lation unit to #roduce al-/late hain hih

octane numbers



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• FCC technolo/ is the oldest secondar/ #rocess and still continues to be


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FCC technolo/ is the oldest secondar/ #rocess and still continues to be

the most ersatile*

• 8##lication @ Conersion of >ide rane of hea/ oils to useful #roducts*Feeds include straiht:run atmos#heric as oils acuum as oils certainatmos#heric residues and hea/ stoc-s

• Products@Hih:octane asoline liht fuel oils and olefin:rich liht ases li-e #ro#/lene for

#etrochemical use and butenes needed for the al-/lation #rocess *

• Present da/ FCC units are used to ma7imize both asoline and#ro#/lene etrochemical feedstoc-)*

• Present FCC units are also e7#ected to hae a continuous run lenths of

oer 3 /ears*• Ber/ fine catal/st flo> li-e liuid in fluidized bed*

• Catal/st &silica:alumina t/#e) im#roed from amor#hous to zeolite t/#eand further throuh use of addities li-e L6*• Faored at hih tem#eratures &"1= ""= C) lo> #ressures &1:2 bar)*


O#eration fle7ibilit/ as #er #roduct and mar-et demand*


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'icensor @

6hell$ 577on$ 87ens $6W$ JOP $ %R$ 'ummus


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OTTO: OF ARRE0 PROCESSING

R!,in!r* Pr#)!ssin – Visbr!a1in


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R!,in!r* Pr#)!ssin – Visbr!a1in• Bisbrea-in is mild and controlled thermal crac-in*

• Biscosit/ reduction hel#s in reducin cutter stoc-s used for dilution*


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/ #

• Pour Point reduction hel#s in flo> #ro#erties*

• Crac- lon #araffin chains off aromatic com#ounds*

• No co-in reactions*

• 4>o t/#es of Bisbrea-in #rocess@

Coil Bisbrea-in

6oa-er Bisbrea-in

• 4radeoff bet>een furnace tem#erature and residence time for isbrea-in

o#erations*

• 'oner residence time leads to lo>er furnace outlet tem#eratures* 4em#erature

bet>een ;==:A3=F &!2":"==C)*

• Pressure ranes bet>een 3==:9"= #si&2=:"= bar)*

• 'icensor @ FW $ JOP $'ummus

R!,in!r* Pr#)!ssin – D!$a*!" C#1in


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R!,in!r* Pr#)!ssin – D!$a*!" C#1in


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R!,in!r* Pr#)!ssin – 0ub! Oi$ P$an(

• 8 conentional lube #lant >ill com#rise of " units as ien in the flo> chart


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• 8 conentional lube #lant >ill com#rise of " units as ien in the flo> chart*• 4he Bacuum unit and the P,8 unit are the mother units for eneratin ra>

cuts of reuired iscosit/*• 4he other three units are meant for meetin ualit/ needs*• 4he first t>o units o#erate on continuous basis >hile other o#erate on a

c/clic mode ta-in feed from storae*

R!,in!r* Pr#)!ssin – 0ub! Oi$ P$an(

• Pur#ose of the P,8 unit is to enerate ,8O or de:as#halted oil to ma-e the


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heaiest t/#es of lube stoc-s &called %riht 6toc-) used to ma-e ear oils*

• 0t uses #ro#ane solent to e7tract ,8O from residue*

• 8s#halt causes carbon de#osits and need to be remoed*

• 4he ne7t unit namel/ e7traction unit im#roes B0 of the oil b/ e7tractin

aromatics b/ use of solents li-e #henol or furfural or NP*

• H/drocrac-er bottom also #roides material for ma-in er/ hih B0 lubes and

this is considered as a su##lementar/ unit to solent e7traction*

• Na#hthenic com#onents ie best ualit/* 8romatics hae lo> B0*

• 4he #ur#ose of de>a7in is to remoe >a7es so that oils do not coneal and it

is also achieed b/ usin solent li-e 5 K 4oluene

• H/drofinishin hel#s to im#roe the color of final lube base oils*

R!,in!r* Pr#)!ssin – :!r# 5ni((# b! %r!s!n(!" in "!(ai$ "urin in"ii"ua$ s!ssi#n

• ero7 #rocess is used to remoe erca#tans b/ e7traction &from lihter


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com#onents li-e 'P() and b/ conersion to disulfides for heaier

com#onents*

• Feed ma/ include 'P( na#htha asoline -erosene et fuel and heatin oils*

• 4he reactions that are res#onsible for remoal of erca#tans ta-e #lace in

#resence of ero7 catal/st and aueous caustic solution are@

R6H K1$! O2 QR66R K QH2O

R6H K NaOH Na6RK H2O

Na6RK 1$! O2 K QH2O NaOHK QR66R

• 4/#ical #roduct merca#tan leels can be controlled to less than 1= >##m*

R!,in!r* Pr#)!ssin –Su%%#r( Pr#)!ss!s


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R!,in!r* Pr#)!ssin –H*"r#!n an" H4S %a(& >a*


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R!,in!r* Pr#)!ssin – H*"r#!n!n!ra(in uni("is)uss!" in s%!)i,i) s!ssi#n

• Consum#tion in h/drotreater sand h/drocrac-er unit*


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• Feed@ 'iht h/drocarbons Nic-el catal/st in ertical tubes situated in the radiant furnace of

the reformer 6team methane reformin &6R) #lants hae continued to be the leadin

technolo/ for eneration of h/droen in refinin and #etrochemical com#le7es*

• 4hese #lants consist of four basic sections@

4he first is feedstoc- treatment >here sul#hur and other contaminants are remoed

4he second is the steam methane reformer >hich conerts feedstoc- and steam tos/nas at hih tem#erature and moderate #ressure

4he third section is the s/nas heat recoer/ and incor#orates CO shift reactor$s to

increase the h/droen /ield

4he final section is ra> h/droen #urification in >hich #ressure s>in adsor#tion &P68)

unit remoes CO CO2and CH!ases to achiee the final #roduct #urit/*

0n addition to the core #rocess sections com#ression is often needed to raise the

feedstoc- and #roduct h/droen #ressures*

R!,in!r* Pr#)!ssin –0i


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R!,in!r* Pr#)!ssin – :!r# 5ni(

• ero7 #rocess utilizes a hih efficienc/ as:liuid contactin desin to e7tract

lo> molecular >eiht merca#tans from a refiner/ as stream usin a stron


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lo> molecular >eiht merca#tans from a refiner/ as stream usin a stron

aueous caustic solution*• 4he merca#tide : rich solent >hich contains the ero7 catal/st is sent to the

reeneration section >here air is inected and the merca#tides #resent are

o7idized to disulfides*

• 4he disulfides are subseuentl/ se#arated from the solent and the

reenerated lean caustic solent is rec/cled bac- to the ero7 57tractor*

R!,in!r* Pr#)!ssin – O,,si(! an"5(i$i(i!s

• Coolin >ater s/stem


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• ,e:mineralized >ater unit 4o #roduce %FW for #o>er and

steam eneration

• Plant 8ir and 0nstrumentation 8ir

• Nitroen s/stem

• Product 6torae and 4an- Farm

• Flare 6/stem

• 5ffluent 4reatment Plant

• Fire Water 6/stem

• Product loadin and unloadin facilities

• Coeneration #o>er #lants

R!,in!r* Pr#)!ssin – Pr#"u)( $!n"s(#)1

• %lendin of refiner/ streams of arious #ro#ortion to meet the reuired #roduct


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#ro#erties and #erformance characteristics

• %lendin is reuired because

• Refineries does not #roduce sinle blend com#onent in sufficient olume to

meet demand

• an/ streams hae #ro#erties that satisf/ one or fe> characteristics but

not all*

• Cost minimization dictates that refined #roducts are blended to meet rather

than e7ceed the s#ecifications*

• (asoline blendin is the most com#le7 and hihl/ automated blendin

o#eration*

R!,in!r* Pr#)!ssin – Pr#"u)($!n"s(#)1


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R!,in!r* Pr#)!ssin –Pr#"u)( $##"s(#)1


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R!,in!r* P!(r#)&!mi)a$ In(!ra(i#n


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R!,in!r* P!(r#)&!mi)a$ In(!r,a)!


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R!,in!r* P!(r#)&!mi)a$ in(!ra(i#n- C4/C2 #$!,ins )#m%$!


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R!,in!r* P!(r#)&!mi)a$ in(!ra(i#n- :i!" C+ In(!ra(i#n


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R!,in!r* P!(r#)&!mi)a$ in(!ra(i#n- Ar#ma(i)s C#n,iura(i#n


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R!,in!r* P!(r#)&!mi)a$ in(!ra(i#n- Summar*


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T&an1 *#u


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>>>.(!)&ni%.)#m

refinery overview modification.ppt

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