Pakistan Refinery Limited

By.

Engr. Abdul Latif Sanjrani M.S (Environmental Science)

Subject :ENV-701 Advance Environmental Science

Respected Teacher: Dr. S.Adnan Hasan

SINDH MADRESSATUL ISLAM UNIVERSTY, KARACHI, PAKISTAN

Commitment:

Save Environment

ContactsList of Abbreviations ……………………………………………

HSEQ Policy ……………………………………………………..

Satellite View …………………………………………………….

Oil Refineries in Karachi ………………………………………

Famous Oil Refineries …………………………………………..

Introduction of Refinery ………………………………………..

Major Products of Oil Refineries ………………………………

National Refinery Limited (NRL) ………………………………

Pakistan Refinery Limited (PRL) ………………………………

Installed Units in PRL …………………………………………...

Schematic flow diagram of typical Oil Refinery ……………….

Common Process Units ………………………………………….

Waste Management ……………………………………………...

Emission …………………………………………………………

List

of

Ab

bre

viat

ion

sSMIU SINDH MADRESSATUL ISLAM UNIVERSTY

MS Master of Science ENV Environmental

AES Advance Environmental

Science

PRL Pakistan Refinery Limited

NEQS National Environmental

Quality Standards

NRL National Refinery Limited

SEPA Sindh Environmental

Protection Agency

PEPA Pakistan Environmental Protection

Agency

OHSAS Occupational Health & Safety

Advisory Services

QMS Quality Management System

ISO International Organization for

Standardization

HSE Health Safety & Environment

QC Quality Control QA Quality Assurance

CNG Compressed Natural Gas LPG Liquefied Petroleum Gas

API American Petroleum Institute DAF Dissolved Air Flotation

CRU Catalytic Reformer unit BTX Benzene Toluene Xylene

240 48’ 11.85” North

670 07’ 00.14” East

Pakistan

Refinery has

around 200

acres of land

for its Korangi

Creek

premises.

OIL REFINERIES IN KARACHI

Karachi is the largest city in Pakistan.

Karachi is located in the south of Sindh, on the coast of

the Arabian Sea.

The city covers an area of approximately 3,530 square

kilometers (1,363 sq mi).

It is the world's Third largest city proper behind Mumbai

in terms of population, which exceeds 23.5 million.

Cont…

In terms of metropolitan population, it is the twentieth

largest city of the world, and is Pakistan's premier

center of banking, industry, and trade.

Karachi is also the home of Pakistan's largest

corporations that are involved in entertainment, arts,

fashion, advertising, publishing, software development

and medical research.

It also serves as a major hub of higher education in

South Asia, and the wider Islamic World.

The famous oil refineries in Karachi are:

National Refinery Limited (NRL)

Pakistan Refinery Limited (PRL)

BOSICOR (Byco) Petroleum Limited

35,000 barrels per day

expanded capacity of 120,000 barrels per day

OIL REFINERIES IN KARACHI

INTRODUCTION

OIL REFINERY:

An oil refinery is an industrial process plant

where crude oil is processed and refined into more

useful petroleum products.

MAJOR PRODUCTS OF OIL REFINERIES

• Light Distillates: (LPG, Gasoline & Naphtha)

• Middle Distillates: (Kerosene, Diesel)

• Heavy Distillates & Residuum: ( Fuel oil, Lubricating oils,

Wax, & Tar)

National Refinery Limited (NRL)

National Refinery Limited (NRL) is the largest

petroleum refining complex in Pakistan, comprises

of:

Three fuel processing plants

An BTX plant

NRL was incorporated on August 19, 1964 as a

public limited company & nationalized on January 1972

PAKISTAN REFINERY LIMITED (PRL)

Pakistan Refinery Limited (PRL) was built and

commissioned in October 1962 at Karachi.

PRL is a capacity of 50,000 barrels per day.

It is being the first in Pakistan oil industry to achieve

OHSAS 18001:1999 and ISO 14001:1996

certification in November, 2002.

No. of sites = 2 (Refinery and Oil Storage Terminal

at Keamari)

1 Barrels = 31.5 Gallons (US)

1Gallons = 3.78541 Litters

• Desalter Unit

• Crude Unit

• Catalytic Hydro-de-sulphuriser Unit

• Plat-former Unit

• Effluent Water Treatment Plant

• LPG Recovery Unit

• Reverse Osmosis Unit

• Water Softening Unit

• Steam Generation Unit

• Electricity Generation Unit

INSTALLED UNITS IN PAKISTAN REFINERY LIMITED

Sche

mat

ic fl

ow d

iagr

am o

f typ

ical

Oil

Refin

ery

Common Process Units Found in Refineries

Desalter unit washes out salt from the crude oil before it enters

the atmospheric distillation unit.

Atmospheric Distillation unit distills crude oil into different

fractions according to the boiling ranges.

Vacuum Distillation unit further distills residual bottoms after

atmospheric distillation.

Naphtha Hydro-treater unit uses hydrogen to desulfurize

naphtha from atmospheric distillation. Than it can be send to a

Catalytic Reformer unit.

Cont…

Catalytic Reformer unit is used to convert the naphtha-boiling

range molecules into higher octane reformat (reformer product).

The reformat has higher content of aromatics and cyclic

hydrocarbons). An important byproduct of a reformer is hydrogen

released during the catalyst reaction. The hydrogen is used either

in the hydro-treaters or the hydro-Cracker.

Distillate Hydro-treater unit desulfurizes distillates (such as

diesel) after atmospheric distillation.

Fluid Catalytic Cracker unit upgrades heavier fractions into

lighter, more valuable products.

Cont…

Hydro cracker unit uses hydrogen to upgrade heavier fractions

into lighter, more valuable products.

Visbreaking unit upgrades heavy residual oils by cracking them

thermally into lighter, more valuable reduced viscosity products.

Merox unit treats LPG, kerosene or jet fuel by oxidizing

mercaptans to organic disulfides.

Coking units (delayed coking, fluid coker, and flexicoker)

process very heavy residual oils into gasoline and diesel fuel,

leaving petroleum coke as a residual product.

Alkylation unit produces high-octane component for gasoline

blending.

Cont…

Dimerization unit converts olefins into higher-octane gasoline

blending components. For example, butanes can be dimerized into

isooctane which may subsequently be hydrogenated to form

isooctane.

Isomerization unit converts linear molecules to higher-octane

branched molecules for blending into gasoline or feed to alkylation

units.

Steam reforming unit produces hydrogen for the hydro-treaters

or hydro-crackers.

Liquefied gas storage units for propane and similar gaseous

fuels at pressure sufficient to maintain it in liquid form. These

units are usually spherical vessels or bullets (horizontal vessels

with rounded ends.

Cont…

Storage tanks for crude oil and finished products, usually

cylindrical, with some sort of vapor emission control and

surrounded by an earthen berm to contain Spills.

Amine gas treater, Claus unit, and tail gas treatment for

converting hydrogen sulfide from hydro-desulphurization into

elemental sulfur.

Utility units such as cooling towers for circulating cooling

water, boiler plants for steam generation, instrument air systems

for pneumatically operated control valves and an electrical

substation.

Cont…

Wastewater collection and treating systems consisting of API

(American Petroleum Institute) separators, Dissolved Air Flotation

(DAF) units and some type of further treatment (such as an

activated sludge bio-treater) to make such water suitable for reuse

or for disposal.

Solvent refining units use solvent such as cresol or furfural to

remove unwanted, mainly asphaltenic materials from lubricating oil

stock (or diesel stock).

Solvent de-waxing units remove the heavy waxy constituents

petrolatum from vacuum distillation products

Hydro Unit Plat former Unit

Steam Generation Unit Electricity Generation Unit

LPG Recovery Unit Desalter Unit

Waste Heat Recovery Unit

Reverse Osmosis Unit Water Softening Unit

Effluent Water Treatment Unit

Waste Management :

Waste at PRL is collected in a very organized manner before

sending to its final disposal /destination determined on the

basis of the type of material. All materials are initially

segregated at source of generation and shifted to the specified

cells of different categories of material (steel structure, damage

instrument, /equipment, aluminum, wood, glass, piping,

electrical fixtures & cables)) setup in scrap yard situated within

the Refinery premises.

Waste

PRL also conducts monthly testing of its all emissions sources such as

Stacks, Boilers & Generators. The graphical representation of the emission

level of different greenhouse gases vs. NEQS limits are given below for the

furnaces stack.

Emission

QUESTIONS or DISCUSSION?