refinery process
TRANSCRIPT
Crude Oil
A fossil fuelConsists of several fractionsA mixture of very wide range of Hydrocarbons Normally Black in colorAvailable in plenty in Middle East (Persian Gulf)Also available in North & western Africa, Indonesia, South & Central America, ScandinaviaIn India, it is available in Bombay High, Krishna-Godhavari basin, Assam & Rajastan
What is a Refinery?
A refinery is a complex integration of several process units that work in a coordinated fashion to make customized fuels and valuable petrochemical feed stocks.It includes Blending.
Over View of a Typical Refinery
The Refining Process
Fractional DistillationConversionTreatmentBlending
Typical refinery Units
Crude Dist Unit & Vac Dist Unit Hydro treating unitFluid Catalytic Cracking unitDelayed Coker unitMeroxSulfur Rec.Unit & ATURefinery Tank Farm
RTF
F
M H
Cr 1
Cr 2A
C
US
RRT
PP
CPP
RRT
ETP
A
NgWater Storageg Buildingsg RTFg Road/Rail loadingg Sulphur
g CPP / Utilitiesg Cokerg PPg Aromaticsg CDU / VDU
Typical Layout of a Refinery
Material Flow
Jetties4 Nos.
SPM2 Nos.
MTFRTF
RRTFRail loading
Road loading
Pipelinedespatch
Capacity
Koyali
MRL
CRL
MathuraBPCL
Barauni
Guwahati
Small & Simple
Large & Complex
MRPL
Digboi
Bongaigon
Vizag
HPCLHaldia
Panipat
Com
plex
ity
Increased Complexity enhances margins
Source: Chemsystem
Reliance
Refinery Block Flow diagram
311/312CDU
HN
221
HNUU
CRUDE
311/312
VDU
VR371
DCU
372
COKER
GAS
PLANT
234PSA
231/232PLAT
521/522H2 C1H 2
281TATORAY
H2TOLUENE
LPG331SATLPG
MEROX
LN 471LNUF
PC NAPHTHALPG
271/272/273ISOMAR
261/262/263PAREX
241/242/243XYL FR
HARNGT FUELO-XYLENE
P-XYLENE
321/322SATGCU
VGO361/362VGO
UNI.FIN
411/412/413FCC
414UNSAT
GCU
351/352DIESELUNI.FIN
341KERO
MEROX
KERO
KERO / ATF
DIESEL
LAB FEED
415UNSAT
LPGMEROX
LPG
LPG 422PROPREC
ETYLREC
551/552PP
ETHYLENE
PP
PROPYLENE416
GASOLMEROX
TAME
LN
HN
HN
HN
C5
CSOCSO
RFG
MS
180-215GT FUEL
LCO
441SWS
431ARU
431/452/453
ARU
SULFUR
COKELCGO
GAS OIL
LNHCGO
180-215
251OX-FR
COKE
CDU/ VDU UNIT
Unit Objectives- CDU/VDU
The objective of the Unit is to separate the crude oil into various fractions viz:Off gases or Lean gasesLiquefied Petroleum Gas (LPG)Full Range Naphtha (FRN)Light Kerosene (LK)Heavy Kerosene (HK)Diesel (AGO or HSD)Gas Oils (HAGO / LVGO / HVGO)Vacuum Residue (VR)
CDU Process
Crude In 1st Stg. 2nd Stg.
1st Stg. 2nd Stg.
Old Desalters
New Desalters
V a c. C o l.
S G C
Atmospheric
Col.
Other streams fromDHT, VGOHT,LNUU, HNUU
LPG
HK
LK / ATF
FRN
Lean Gas
LVGO
Vacuum Residue
Preheat 1
Water In Brine Out
Preheat 2
Flash Drun
Preheat 3
Heater
Heater
Diesel
HAGO
HVGO
Major Equipment
DesaltersFired HeatersHeat Integration circuitCrude Flash DrumMain FractionatorSide strippersMulti Stage Ejector system
Fluid Catalytic Cracking Unit
Why FCC ?
• Heavier Crudes
• Need for cracking heavy ends
• Heavy demand for lighter fuels
Why FCC
Converts VGO in to Gasoline and lighter products.Cheapest available conversion processOffers great flexibility of operation (can be run in LPG, Gasoline or distillate mode)Produces large quantity of Petrochemical feed stocks
Major Equipment
Reactor and RegeneratorPower recovery trains (PRTs)Vortex separators/ CyclonesMain Air Blower/Expander/Motor generators/Steam generatorFlue gas coolerMain Fractionator/ Side StripperWaste Heat Boiler
Typical Gas Con unit
Hp ReceiverStripperDebutanizer, C3C4 splitterAbsorberAmine absorberNaphtha splitterDepentanizer
Puprose of Gas Con Unit
To separate Close boiling range lighter products like Fuel gas, LPG, Gasoline, Naptha.Acts as partial heat sink for Main fractionator.Stabilizes NapthaH2S removal from gaseous products.
DHT and VGOHT
A Hydro treater/ Union finer is a process unit Where Hydrocarbon Feed is treated with hydrogen in presence of catalyst at high temperature & pressure.Desulfurization(3.2wt% 0.2wt%) 94%Denitrification (1658 ppm 760ppm)Aromatic and Olefin saturation
DIESEL HYDROTREATER
DHT
Major Equipments
Recycle Gas Compressor Fixed Bed Catalytic ReactorCatalyst 300m3 (NiMo CoMo)Fired HeaterStripper
A
REACTORFILTER FUR NA CE
FEED (HIGH S)
REACTOR EFFLUENT
STRIPPERFEED DIESEL
PRE HEAT EX
FiNCOOLER
PROD UCT(LOW S)
Low moisture DIESEL
PROD UCT
SEPARA TOR
NA PHTHA
Drier
VGO HYDROTREATER
VGOHT
A
REACTORFILTER FURNACE
FEED (HIGH S)
REACTOR EFFLUENT
FRACTIONATORFEED VGO
PRE HEAT EX
FAN COOLER
PRODUCT(LOW S)
VGO PRODUCT
SEPARATOR
NAPHTHA
DIESEL
Kerosene
Why VGOHT ?
The Gas Oil product ex. Crude/Coker has high sulfur content. This is to be reduced before sending to FCC for SOX emission control
Hydro-desulphurization of Gas oil is carried out in VGO hydro treating units.
De Nitrification of Gas oil
VGOHT Major Equipments
Recycle Gas Compressor Fixed Bed Catalytic ReactorCatalyst 300m3 (NiMo CoMo)Fired HeaterStripper
Sulfur Complex
Sour Water Stripping Unit (SWS)Amine Treating Unit (ATU)Sulfur Recovery Unit (SRU)-
CBAGranulation Unit
Overview - Sulfur Complex
SWS Unit
Amine UnitTwo absorberFour Strippers
CBA Units GranulationUnit
S -Dispatch
SRU Objective
Main Objective of the unit is to convert H2S in to elemental Sulfur.
Why SRU ?
More Stringent environmental norms of Government / regulatory bodies.
Enables the refinery to process High sulfur crudes.
SRU Process
Acid gas from SWS and ATU stripper is oxidized (burnt) in 2 stages and then treated in catalytic converter. The molten sulfur is transferred to SGU to form Sulfur granules.
Major Equipment
Amine absorberFlash drumStripperReaction furnaceCatalytic ReactorIncineratorWaste heat boiler
ATU-Simplified Flow SchemeFG Out
RA Pump
Acid Gas
Flash Drum
LA
FG In
Lean AmineLA Pump
AbsorberStripper
CBA-Equipment
F02 B01 B02
R01 R02 R03
S03
S02
S04
S05 S06
V03
F03
Stack
C.ALPG
Acid Gas
V04RD ChamberProduct Chamber
Rundown Line
Reaction Furnace
WHB
Steam Drum
CBA Reactors
Sulfur Pit
EductorSulfur Cooler
Sweep Air Stack
Vent
IncineratorWHB
Steam Drum
Claus Reactor
Condensers
Auto - Fuel quality trend upto 2010
BIS-2000Bharat stage-
II (Reg/ Prem)
Euro-III Equivalent
(Reg/ Prem)
Euro-IV Equivalent
(Reg/ Prem)
EURO-III (effective
2000 in EU)
EURO-IV (effective
2005 in EU)
Sulphur, max. ppmw 1000 500 150 50 150 10#Benzene, max. % vol 3 metros, 5
rest 3 metros, 5
rest @1 1 1 1
RON, min No. 87 88/93 91/95 91/95 95 95MON, min No. NA NA 81/85 81/85 85 85AKI, min No. 84 84/88 NA NA NA NAAromatics, max. % vol NA NA 42 35 42 35Olefins, max. % vol NA NA 21/18 21/18 18 11**E 70 deg C NA NA 10 / 45 10 / 45 20 / 48 20 / 48E 100 deg C NA NA 40 / 70 40 / 70 46 / 71 46 / 71@ The Benzene content will be progressively reduced to 1 vol% by Apr 2005 in 7 mega cities. The rest of the country would have a maximum limit of 3 vol% from Apr 2005. # 50 ppmw to be supplied from 2005 & 10 ppmw by 2008** to be reviewed by 2005 by European Union.
Gasoline
Sulfur in Gasoline to go down to 50 ppm by 2010 and benzene to less than 1%
Auto - Fuel quality trend upto 2010
BIS-2000 Bharat stage-II
Euro-III Equivalent
Euro-IV Equivalent
EURO-III (effective
2000 in EU)
EURO-IV (effective
2005 in EU)
Sulphur, max. ppmw 2500 500 350 50 350 10#Cetane Number, min No. 48 48 @ 51 51 51 51**Cetane Index, min No. 46 @ 46 @ 46 48 48 NADistillation T95, max DegC 370 370 360 360 360 360**Poly Aromatics, max. % wt NA NA 11 11 11 11**
Flash point, min. DegC 35 35 35 35 55 55
# 50 ppmw to be supplied from 2005 & 10 ppmw by 2008** to be reviewed by 2005 by European Union.
@ Cetane number 48 or Cetane index 46
Sulfur in Diesel to go down to 50 ppm by 2010 and Cetane Number will be above 51
Diesel Fuels
Delayed Coker Unit
A thermal cracking and successive polymerization process-rapid heating of vacuum residue ( ex VDU) above cracking temperature to form mixture of distillates and coke.The process of formation of coke is delayed in the furnace by way of maintaining higher velocities using HP steam/ BFW
Why DCU ?
High marginNo Fuel oil generationValue added products (LPG, Diesel, Naphtha, Fuel gas and Coke)No Catalyst InvolvedCapable of processing Refinery slop and sludge
Major Equipment- Coking Section
Coke drumFractionatorFired HeaterBlow down systemCoke Cutting system- PLC basedHeat Integration circuitHeading and De heading unitProduct Filter-PLC based
RTF Overview
Functions of RTF
Ensure uninterrupted supply of Crude Oil and other feed/intermediates to Various Units.Receive intermediates, products and blending components from various units. Supply of RFO & slop for reprocessing.BlendingCorrection of Offspec product.
RTF Work Flow
AROMATICCOMPLEX
INTERMEDITEPRODUCTSTORAGE
RAW MATERIALSSTORAGE
BLENDCOMPONENTS
STORAGE
SLOPSSTORAGE
MTF
RRTF
REFINERYCOMPLEX
HEAVY NAPHTHA
INTERMEDIATE PRODUCTS
FINALPRODUCTSSTORAGE
FINAL PRODUCTS
BLEND HEADER
SLOPS
RAW MATERIALS
FINAL PRODUCTS
RAW MATERIALS
RTF
REFINERY FUELFUEL STORAGE
RFO
FUELCOMPONENTS
Major Equipment
Fixed Roof Storage tanksFloating roof Storage TanksHorton SpheresMixersPumps
Any Questions ?
Thank you