REFINING PROCESSES

A.DATTA

LECT04

DieselDiesel

Gas OilGas Oil

Crude OilCrude Oil

BitumenBitumen

Roads

Long Chain MoleculesLong Chain Molecules

Gas treatmentGas treatmentSulphurSulphur

RecoveryRecovery SulphurSulphur

HH22SS HH22SS

Waxy DistillateWaxy Distillate

Butane Butane De-asphaltingDe-asphalting

AsphaltAsphalt Fuel oilFuel oil

De-asphalted oil DAODe-asphalted oil DAO

DesulphurisationDesulphurisation

KerosineKerosine

Shorter Chain MoleculesShorter Chain Molecules

HydrogenHydrogenManufacturingManufacturing

UnitUnit

Hyr

dro

crac

ker

Hyr

dro

crac

ker

HydrogenHydrogen

High VacuumHigh VacuumSeparationSeparation

Vacuum Gas OilVacuum Gas Oil Long ResidueLong Residue

DistillationDistillation

Diagram of Refinery UnitsDiagram of Refinery Units

PlatformerPlatformer PetrolPetrol

CDU1

CDU2

HVU1BBU

HVU2BDU

HCU

HMU

HDS2

SplitHDT

PlatDePr

HDS1

FuelGas

GasOilBlend

MogasBlend

FuelOilBlend

RG

RGH2RG

H2

RG

H2

RG

H2

RG

Natural Gas

Syngas and Reformates

Condensates and LowSulphur Crudes

High Sulphur Crudes

Imported Residues

High Sulphur Crudes

Low Sulphur Crudes

Imported Residues

Naphtha

Kero

LGO

HGO

Long Residue

Naphtha

Kero

LGOHGO

Long Residue

Sulphur

Refinery Gas

Regular Mogas

Premium Mogas

Kero / Avtur

CO2

Automotive Gasoilsand Marine

Light Fuel Oil

Bunkers

Heavy Fuel Oil

Refinery Fuel

Bitumen 80/100

Bitumen 180/200

Bitumen 45/55

The Process UnitsThe Process Units

GASOILSGASOILS32%32%

JET/ KEROJET/ KERO14%14%

MOGASMOGAS30%30%

FUEL AND LOSSFUEL AND LOSS7%7%

FUEL OILSFUEL OILS17%17%

Approx 7 Barrels to the TonneApprox 7 Barrels to the Tonne

A Typical Crude BarrelA Typical Crude Barrel

Distiller UnitsDistiller Units

Platformer

Hydrocracker

Gasoil Hydrotreater

Kerosine Hydrodesulphuriser

Depropaniser

Hydrogen Manufacturing unit

High Vaccuum Unit

Butane Deasphalting unit

Bitumen Unit

Sulphur Recovery

Product Blending

CrudeCrude

Products outProducts out

The Process UnitsThe Process Units

DistillationDistillation• The initial separation takes place The initial separation takes place

in the distillation Columnin the distillation Column

• The Crude is first heated in a furnaceThe Crude is first heated in a furnaceto a temperature of 360 to a temperature of 360 ooCC

• It enters the column and vapours and It enters the column and vapours and liquids separateliquids separate

• The light vapours rise to the top whilst The light vapours rise to the top whilst the heavier liquids fall to the bottomthe heavier liquids fall to the bottom

FurnaceFurnace

Distillation ColumnDistillation Column

CrudeCrude

KeroseneKerosene

Gases +Tops + NaphthaGases +Tops + Naphtha

Light GasoilLight Gasoil

Heavy GasoilHeavy Gasoil

Long ResidueLong Residue

Crude

Lower BoilingLower Boiling

Higher BoilingHigher Boiling

Distillation ColumnDistillation Column

DesulphurisationDesulphurisation

HydrogenHydrogen

Under Pressure and Heat Under Pressure and Heat Reaction takes place and Reaction takes place and Hydrogen bonds with Hydrogen bonds with Sulphur to form HSulphur to form H22ss

Desulphurisation ProcessDesulphurisation Process

ReactorReactor

CatalystCatalyst

Sour Tops + NaphthaSour Tops + Naphtha

Sour GasoilSour Gasoil

Sour KeroseneSour Kerosene

Desulphurised KeroseneDesulphurised Kerosene

Desulphurised Tops + NaphthaDesulphurised Tops + Naphtha

Desulphurised GasoilDesulphurised Gasoil

H2S H2S

• Increases low Octane Naphtha to Increases low Octane Naphtha to high Octane Platformatehigh Octane Platformate

• Uses Heat and Pressure in a Uses Heat and Pressure in a ReactorReactor

• Hydrogen is evolved in the Hydrogen is evolved in the processprocess

• Platinum Catalyst assists the Platinum Catalyst assists the processprocess

PLATFORMINGPLATFORMING

PLATFORMINGPLATFORMING

PlatPlatinum Reinum Reformingforming

High OctaneHigh OctanePlatformatePlatformate

NaphthaNaphthaFrom SplitterFrom Splitter

HydrogenHydrogenRecycleRecycle

HydrogenHydrogenTo UsersTo Users

ReactorReactor

FurnaceFurnace

SeparatorSeparator

50 OCTANE50 OCTANE

100 OCTANE100 OCTANE

520°C520°C18 barg18 barg

515°C515°C

40°C40°C

EE

Platformer UnitPlatformer Unit

Blending TankBlending Tank

High Vacuum High Vacuum &&

Bitumen UnitsBitumen Units

Bitumen Feed TanksBitumen Feed Tanks

Long ResidueLong Residue

High Vacuum Unit - HVU 1High Vacuum Unit - HVU 1

VacuumVacuum

GasesGases

VacuumVacuumGas OilGas Oil

180 Pen180 PenBitumenBitumen

To HydrocrackerTo Hydrocracker for furthur Processingfor furthur Processing

GasesGases

VacuumVacuumGas OilGas Oil

180 Pen180 PenBitumenBitumen

BlowingBlowing ColumnColumn

To Refinery Gas SystemTo Refinery Gas System

Truck Loading and shippingTruck Loading and shipping

45/55 Pen45/55 PenBitumenBitumen

HydrocrackingHydrocracking

What is Hydrocracking ??What is Hydrocracking ??

Production of Production of high quality light productshigh quality light products

from heavy oils,from heavy oils,

in the presence of Hydrogen.in the presence of Hydrogen.

Hydrocracker OverviewHydrocracker Overview

HCU

Long Residue

5500 t/d

HVU VGO

200 t/d

3200 t/dWaxy Distilate

BDUAsphalt

900 t/dAsphalt

10 t/d

70 t/d

Butane

145 t/dPlant gas

Adip gas

Steam1400 t/d

Hydrogen

140 t/d

Tops/Naphtha

Gasoil

Gas120 t/d

1100 t/d

2000 t/d

900 t/dKerosine

Short Residue1900 t/d

DAO1000 t/d

Hydrogen Manufacturing

Unit

HydrocrackerHydrocrackerHigh Vacuum UnitHigh Vacuum Unit

BUTANE DE-ASPHALTING UNITBUTANE DE-ASPHALTING UNIT

Sulphur RecoverySulphur Recovery UnitUnit

Converts HConverts H22S into Sulphur S into Sulphur

For use by Fertiliser CompaniesFor use by Fertiliser Companies

Sulphur PitSulphur Pit

HH22S FeedS Feed Main FurnaceMain Furnace

CoalescerCoalescer

StackStack

Line BurnerLine Burner IncineratorIncineratorReactorReactor

ReactorReactor

Waste Heat Waste Heat BoilerBoiler

Line BurnerLine Burner

Fuel Gas

Fuel Gas

Line BurnerLine Burner

Fuel Gas

Liquid SulphurLiquid Sulphur 59%59%

AA

AA

BB CC

DDCCBB DD

Liquid SulphurLiquid Sulphur

Liquid SulphurLiquid Sulphur

Sulphur Recovery UnitSulphur Recovery Unit

ENVIRONMENTALENVIRONMENTAL

LOWERS EMISSIONSLOWERS EMISSIONS

SCOT UnitSCOT Unit

ReactorReactor

Waste Heat BoilerWaste Heat BoilerUpper Quench ColumnUpper Quench Column

To SWSTo SWS

Quench WaterQuench Water

CoolerCooler

Lower Quench ColumnLower Quench Column

BlowerBlower

KOKO DrumDrum

SCOT Feed GasSCOT Feed Gas

SCOT BurnerSCOT Burner

FGFG

AirAir

SCOT UnitSCOT Unit

Absorber Colum (ADIP)Absorber Colum (ADIP)

To SRUTo SRU

KOKO DrumDrum

Lean ADIPLean ADIP

Semi Rich ADIPSemi Rich ADIP