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Presented by

Soma ChattopadhyaySenior Manager (TS)

Haldia Refinery, IOCL 22nd December, 2010

BASIC REFINING OPERATIONS & DISTILLATION

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Refineries in India

Digboi

GuwahatiBarauni

Koyali

Haldia RefineryFourth in the chain of 8 operating refineries under Indian Oil, the largest commercial enterprise in the country and one of the Fortune 500 company in India

Mathura

Panipat

NRLBRPL

HPC-V

CPCLCBR

KRL

MRPL

HPC-MBPC

RPL

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Haldia Refinery

PORT

HALDIA TOWNSHIP

FROM CALCUTTAFROM CALCUTTA

NATIONAL HIGHWAY 41

Geonkhali Roychak

R A I L L I N

K

HFC

SHAW WALLACE

H L L

HALDIA PETRO.

Kukrahati

DURGACHAK

CHLORIDE

LOCATION PLAN

Mitsubishi

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Haldia Refinery

7.5 MMTPA Crude capacity*Fuel + Lube combine

refinery500 Acres area

~1600 employees Own township and

hospital at 8Km distance

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Haldia Refinery: Process Units

FOB BLOCK• CDU-I• CDU-II

• NHDT/CRU•KHDS

LOB BLOCK• VDU-I• PDA• FEU• NMP• SDU• LHFU• CDWU• WHFU

DHDS BLOCK• DHDS• HGU• SRU/ARU/SWS• FCCU• MSQ• NGU

OHCU BLOCK• OHCU• HGU• NGU• SRU/ARU/SWS

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Very SimplifiedPetroleum andPetrochemical

Flowchart

OilWell

CrudeOil

Separations

Conv

ersi

ons

Sepa

ratio

nsan

dPu

rific

atio

ns

NaturalGas

Propane &Butane

Naphtha(C5 - C10 )

Fuel

Fuel

Gasoline

Jet Fuel

Fuel

RX Ethylene PolyethyleneRX

RX Polymers (Furnitures7 UP Bottles)

RX

RX Organic ChemicalsMore Polymers

(Aspirin, Hair Spray)(Football Helmet, AstroTurf, Nylon)

Home HeatingOil, LubricatingOil, Wax

Diesel Fuels

Kerosene &

Gas Oils (C 10 +)

Coke(Carbon Material Similar to Coal)

Steel Making

AsphaltRoads Pot Holes

Purifications remove sulfur and heavy metals

RX = Chemical Reactions

Graphite Fibers(Tennis Racquets)

THE REFINERY

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What Is Crude Oil?

•Crude Oil is a liquid mixture of thousands of organic chemicals found underground. It is the result of organic matter decaying over thousands of years; hence the name fossil fuel

•Crude oil is found all over the world and varies in its density, aromatics, sulfur, and metals content

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What Is Crude Oil?

•Crude Oil is a liquid mixture of thousands of organic chemicals found underground. It is the result of organic matter decaying over thousands of years; hence the name fossil fuel

•Crude oil is found all over the world and varies in its density, aromatics, sulfur, and metals content

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CRUDE OIL NA

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CRUDE OIL NATURE & COMPOSITION

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Major Refinery Products

•LPG (Propane/Butane)•GASOLINE•JET FUELS•DIESEL FUELS•HEATING OILS•LUBRICATING OILS•ASPHALTS•COKE (not the kind you drink )

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Gasoline Specifications

Gasoline must meet many criteria which change with the time of year and geographic location. Some critical specifications are:

•Vapor Pressure• Density•Octane No.• Sulfur Content•Benzene ContentGasoline is always a blend of a number of streams in the refinery

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Other Specifications

Other refinery products must meet other specifications such as:

•Cetane number•Density•Pour Point•Flash Point•Viscosity•Viscosity Index•Colour

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So, How You Make Good Stuff Out Of That Gooey Crude ?

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In a Complex Refinery with Separation Process and Secondary Conversion Processes………………..

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Very SimplifiedPetroleum andPetrochemical

Flowchart

OilWell

CrudeOil

Separations

Conv

ersi

ons

Sepa

ratio

nsan

dPu

rific

atio

ns

NaturalGas

Propane &Butane

Naphtha(C5 - C10 )

Fuel

Fuel

Gasoline

Jet Fuel

Fuel

RX Ethylene PolyethyleneRX

RX Polymers (Furnitures7 UP Bottles)

RX

RX Organic ChemicalsMore Polymers

(Aspirin, Hair Spray)(Football Helmet, AstroTurf, Nylon)

Home HeatingOil, LubricatingOil, Wax

Diesel Fuels

Kerosene &

Gas Oils (C 10 +)

Coke(Carbon Material Similar to Coal)

Steel Making

AsphaltRoads Pot Holes

Purifications remove sulfur and heavy metals

RX = Chemical Reactions

Graphite Fibers(Tennis Racquets)

THE REFINERY

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REFINERY CONFIGURATION

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Complexity of a RefineryThe combination of refining processes and

operations employed (complexity ) varies from one refinery to another.

Factors deciding the complexity of a refinery• Nature/source of crude oils to be processed• Demand pattern in the markets to be covered• Product quality - current/future• Production of feedstocks for downstream units• Environmental stipulations

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Basic Refining Operations

SEPERATION TECHNIQUES

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Desalting Distillation Extraction Filtration Crystallisation Evaporation Condensation

Basic Refining Operations & Processes

De-Sulphurisation Reforming Cracking Iso-merisation Hydro-cracking Coking

Unit Operations Unit Processes

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Crude Desalting

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•Separate crude into fractions•Convert low octane components to higher octane components

•Convert the very heavy stuff to heavy oils•Convert heavy oils to Gasoline,Diesel,Jet fuel & Lubes

•Remove Sulfur/Nitrogen through reaction•Blend intermediate streams together to meet product specifications

•Blending & Certification•Product Storage & Dispatch

Fractionation Concept

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Distillation - Concept

Distillation is defined as a process in which a liquid or vapour Distillation is defined as a process in which a liquid or vapour mixture of two or more substances is separated into its component mixture of two or more substances is separated into its component fractions of desired purity, by the application and removal of heat. fractions of desired purity, by the application and removal of heat.

Distillation is based on the fact that the vapour of a boiling mixture Distillation is based on the fact that the vapour of a boiling mixture will be richer in the components that have lower boiling points.will be richer in the components that have lower boiling points.

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Types of Distillation Columns

Distillation ColumnsDistillation Columns

BatchBatch ContinuousContinuous

BinaryBinary Multi-ComponentMulti-Component

Two Product & Multi-Product ColumnsTwo Product & Multi-Product ColumnsTray Columns & Packed ColumnsTray Columns & Packed Columns

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Distillation – Basic Operation

The liquid-vapour mixture (feed) is introduced near the middle of the column to a tray The liquid-vapour mixture (feed) is introduced near the middle of the column to a tray known as the feed tray. known as the feed tray. The feed tray divides the column into a top (enriching or rectification section ) and a The feed tray divides the column into a top (enriching or rectification section ) and a bottom (stripping section). bottom (stripping section). The feed flows down the column and collected at the bottom in the reboiler. Heat is The feed flows down the column and collected at the bottom in the reboiler. Heat is supplied to the reboiler to generate vapour using other hot streams or steam.supplied to the reboiler to generate vapour using other hot streams or steam.

The vapour raised in the reboiler is re-introduced into the unit at the bottom of the The vapour raised in the reboiler is re-introduced into the unit at the bottom of the column. column. The liquid removed from the reboiler is known as the bottoms product or simply, The liquid removed from the reboiler is known as the bottoms product or simply, bottoms.bottoms.

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Distillation – Basic Operation

The vapour moves up the column, and as it exits the top of the unit, it is cooled by a The vapour moves up the column, and as it exits the top of the unit, it is cooled by a condenser. condenser.

The condensed liquid is stored in a holding vessel known as the reflux drum. The condensed liquid is stored in a holding vessel known as the reflux drum.

Some of this liquid is recycled back to the top of the column and this is called the Some of this liquid is recycled back to the top of the column and this is called the reflux.reflux.

The condensed liquid that is removed from the system is known as the distillate or top The condensed liquid that is removed from the system is known as the distillate or top product.product.

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SEPARATIONS -CRUDE/VACUUM FRACTIONATION: MOTHER UNITS

•DISTILLATION COLUMNS ATMOSPHERIC DISTILLATION

Light (LPG, Naphtha & MS), Middle Distillate ( SKO /ATF & HSD ) components and Heavier portion of the crude is separated by heating up to 370 – 380 oC and fractionation at a pressure of 2.0 – 2.8 Kg/cm2g.

VACUUM DISTILLATIONHeavier Distillate ( Heavy Diesel , VGO ) is separated from

Reduced Crude Oil (RCO) by heating up to 410 – 420 oC and fractionation under vacuum ( 20-60 mm Hg abs ) condition

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SEPARATIONS CRUDE/VACUUM FRACTIONATION: MOTHER UNITSTypical Products from CDU•Gas/LPG•Naphtha•SKO/ATF•HSD•RCO•Vacuum Distillation of RCO produces VGO (or LOBS cuts) and VR

•All products need further treatment/processing.

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SEPARATIONS -CRUDE/VACUUM FRACTIONATION: MOTHER UNITS

Typical Products from VDU•Vacuum Gas Oil•DHDS Feed Stream•FCCU Feed Streams•LOBS Feed Streams•Vacuum Residue

All products need further treatment/processing.

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REACTIONS

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REACTIONS

Almost all the reactions in the refinery use special catalysts that increase the rate and selectivity of the reaction. This improves efficiency and reduces unwanted byproducts.

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Reactions to Make Higher Octane

ISOMERIZATIONC-C-C-C-C-C --> C C nC6 C-C-C-C iC6

REFORMINGC-C-C-C-C-C-C --> C nC7 C C-CH3 C C toluene C

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Reactions To Make Higher Octane

ALKYLATION

C CC=C-C + C-C-C --> C-C-C-C-C Cpropylene isobutane isoheptane (2,2,dmp)

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Conversion : Cracking and rearranging molecules to add value

•Need : To increase the production of distillates by converting residues, for value addition

•Major Conversion ProcessesThermal conversion : Visbreaking, Delayed Coking

Catalytic conversion : FCC, Hydrocracking•Technological Factors

Heavier Hydro-Carbon molecules are cracked under severe operating conditions of Temp. ( 500 – 510 oC ) and pressure ( 1.4 - 2.2 kg/cm2) to get Lighter Hydro-Carbons like LPG , MS & HSD components. Strict operating conditions are maintained to get on-specs. products

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Reactions To Convert Heavy Oils

HYDROCRACKING H2 + heavy oil --> gasoline + diesel 290 C 150 C 232 C

use boiling point to describe oils

CAT CRACKING heavy oil --> gasoline + propylene, butane,

other “light ends” 290 C 150 C

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Reactions To Convert ResidResid is the “bottom of the barrel” - the material that is left in

the bottom of the crude/vacuum distillation towers

COKING resid + heat --> coke + heavy oil + Lighter Products> 482 C solid 290 C

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Reactions To Remove SulfurHYDRODESULFURIZATION

2 R-SH + H2 --> 2 R + 2 H2S Mercaptan hydrocarbon

SULFUR RECOVERYconvert H2S to elemental sulfur:

2 H2S + 2 O2 --> SO2 + S + 2 H2O2 H2S + SO2 --> 3S + 2 H2O

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THANK YOU