Oil refinery detail's

1. Petroleum Refinery Overview

2. Introduction
Major Facilities in a Refinery are:
Crude Oil Receipt & Storage
Processing Units
Product Storage & Dispatch Facilities
Utilities Generation Facilities
Effluent Treatment & Flare System

3. Crude Oil Receipt & Storage
• Crude Oil Receipt
 Thru Ships / Marine Tankersfor coastal refineries
 Thru pipeline for in-landrefineries
• Crude Oil Storage
 Stored in Floating rooftanks
 Storage may be split into coastal & refinery site

4. Products Storage & Dispatch
• Intermediate & Finished Product Storage
 At refinery site & Mktg. Terminal
• Blending Facilities
 To produce different gradesof products
• Finished Product Dispatch
 By Road
 By Rail
 By Pipeline
 By Ships / Marine Tankers
 In Drums / Cans

5. Utilities Generation Facility
• Water System
 Raw water receipt, storage & treatment
 Servicewater, Drinking water
 Cooling water
 DM water
• Steam, Power & Condensate System
• Compressed Air & Nitrogen Generation
• Fuel System
 Fuel Oil
 Fuel Gas / LPG vaporiser /LNG

6. Effluent Treatment & Flare
• ETP treats liquid effluents prior to disposal
 Treated effluents should meet MINAS standards
 No net effluents in case of Zero Discharge refineries
• Gaseous effluents are disposed off
 With or w/otreatment
 Through flare or directly
• Solid effluents are disposed by
 Incineration or
 Secured landfill
• Flare is used for disposal of all Hydrocarbon vapors &
acid gases

7. INTRODUCTION TO CRUDEOIL
 Elemental Composition
 Degree API = 141.5 - 131.5
Sp Gr
 API Range of Crude Oils = 20 – 40
Element Wt%
C 84-87
H 11-14
S 0-2
N 0.2

8. INTRODUCTION TO CRUDEOIL
 Classification of Crude
Based on API
 Crude Chracterisation
Factor
K = (MABP)1/3
Sp. Gr
0 API Crude Type
>= 40 Paraffinic
33 – 40 Intermediate
<= 33 Naphthenic
K Crude Type
<= 11.5 Naphthenic
>= 12.1 Paraffinic
11.5 – 12.1 Intermediate

9. INTRODUCTION TO CRUDEOIL
 Sulphur Content - expressed as Wt% S inCrude
 Sour Crude S > 0.5%, Typically Requires Special Processing
 Sweet Crude S < 0.5%
 Salt Content - expressed as NaCl present in lb/ ‘000 barrel (ptb)
 Nitrogen Content - High Nitrogen is undesirable, basic nitrogen
destroys active sites of catalyst
 Metal Content - Metals are typ. Ni, V, Cu, Fe etc. Metal content may
vary from few PPM to 1000 PPM.

10. INTRODUCTION TO CRUDEOIL
 Typical Crude Classification
 Light / Medium/ Heavy Crudes
 Low S / High S Crudes
 Paraffinic / Naphthanic / AromaticCrudes
 Lube Bearing / Non Lube Bearing Crudes
 Waxy / Non Waxycrudes
 High TAN Acidic Crudes
 Condensate
 Bituminous / Tar Sands / Shale Oil

11. Refining Operations
Petroleum refining can be grouped into five basic areas:
1. Fractionation (Distillation) is the separation of crude oil into
different fractions based on theirB.Pts.
2. Conversion processes change the size &/or structureof
hydrocarbon molecules. These processes include:
 Decomposition (dividing) by thermal and catalytic cracking;
 Unification (combining) through alkylation and polymerization; and
 Alteration (rearranging) with isomerization and catalytic reforming.
3. Treatment processes prepare hydrocarbon streams for additional
processing and to prepare finishedproducts.
4. Formulating and Blending is the process of mixing and combining
hydrocarbon fractions, additives, and other components to produce
finished products with specific performance properties.
5. Other Refining Operations

12. Simplified Fuel Refinery Configuration
CDU
VDU FCC
DCU
S-Block
Crude
LPG
MS
SK / ATF
HSD
Sulphur
VGO
VR
Coke
RCO
Sour
Water
Rich
Amine
Str. SW
Lean
Amine
CLO
HCGO

13. Simplified Lube Block Configuration
CDU
VDU SEU
SDA
WHFU
Crude
LPG
MS
SK / ATF
HSD
VGO
VR
Pitch
RCO
WAX
SDU HFU LOBS
RAFFINATE DWO
DAO
WDU
SLACK
WAX
FOOTS OIL
DEOILED
WAX
EXTRACT
TO FO

14. Refining Operations
Processing Type Process Units
Primary Processing Crude & Vacuum Distillation
Secondary Processing • Fluid Catalytic Cracking(FCC)
• Hydrocracking (OHCU or HCU)
Residue Processing • Delayed coking(DCU)
• LC Fining
• Visbreaking (VBU)
• Bitumen Blowing (BBU)
Treating Units • FG Amine Treating ( FG ATU)
• LPG Caustic wash, LPG ATU, LPG Merox
• Naphtha Caustic wash, Merox,Hydrotreating
• MS Selective HDT, ISOM, Bensat
• Kero / ATF Merox, Extraction, HDT

15. Refining Operations
Processing Type Process Units
Treating Units • Diesel Hydrotreating (DHDS,DHDT)
• VGO Hydrotreating (VGOHDT)
• RCO Hydrotreating (ARDS)
• Vac. Residue Hydrotreating(VRDS)
Others • Sour Water Stripping(SWS)
• Amine Regeneration(ARU)
• Sulphur Recovery (SRU)
Lube Units • Solvent Extraction(SEU)
• Solvent Deasphalting (SDA)
• Solvent Dewaxing(SDU)
• Wax Deoiling
• Lube / Wax Hydrotreating

16. Overview of Petroleum Refining Processes
Process Action Method Purpose Feedstock(s) Product(s)
FRACTIONATION PROCESSES
Atmospheric
Distillation
(CDU)
Separation Thermal /
Boiling Point
Separate
fractions
Crude oil Gas, LPG,
Naphtha,
SK/ATF,
HSD, RCO
Vacuum
Distillation
(VDU)
Separation Thermal /
Boiling Point
Separate
fractions
Atmospheric
tower bottoms
Vac. Gas oil,
Lube stock,
Residue

17. Overview of Petroleum Refining Processes
Process Action Method Purpose Feedstock(s) Product(s)
CONVERSION PROCESSES – CHAIN CLEVAGE
Fluid Catalytic Conversion Catalytic Upgrade VGO, RCO, Gas, LPG,
Cracking Heavy VR, Cr. Hvy. Gasoline,
(FCCU) Oils Oils Diesel,
Petrochem
feedstock
Hydrocracking
(HCU)
Conversion Catalytic in
presence of
Hydrogen
Upgrade
Heavy
Oils
VGO, Cr. Hvy.
Oils, Residue
Gas, LPG,
Naphtha,
SK/ATF,
HSD

18. Overview of Petroleum Refining Processes
Process Action Method Purpose Feedstock(s) Product(s)
CONVERSION PROCESSES – CHAIN CLEVAGE
Delayed Coking
(DCU)
Conversion Thermal Upgrade
Residue
RCO, VR Gas, LPG,
Naphtha,
Kero,
Diesel
Visbreaking
(VBU)
Conversion Thermal Reduce
Viscosity
RCO, VR Gas, LPG,
Naphtha,
Fuel Oil
Hydrogen
Steam
Reforming
Conversion Thermal /
Catalytic
Produce
Hydrogen
Gas, LPG,
Desulphurised
naphtha
Hydrogen

19. Overview of Petroleum Refining Processes
Process Action Method Purpose Feedstock(s) Product(s)
CONVERSION PROCESSES - UNIFICATION
Alkylation Combining Catalytic Unite olefins
& Iso-
paraffins
Iso-Butane,
Cracker
olefins
Iso-Octane
(Alkylate)
Grease
Compounding
Combining Thermal Combine
soaps & oil
Lube oil, fatty
acid, alkyl
metal
Lubricating
grease

20. Overview of Petroleum Refining Processes
Process Action Method Purpose Feedstock(s) Product(s)
CONVERSION PROCESSES – ALTERATION orREARRANGEMENT
Catalytic
Reforming
Alteration Catalytic Upgrade
low-octane
naphtha
SR & Cracked
naphtha
High Octane
Reformate /
Aromatics
Isomerisation Rearrangement Catalytic Convert
straight
chain to
branch
chain
C4 ~ C6
paraffins
Iso-butane /
Iso-pentane /
Iso-hexane

21. Overview of Petroleum Refining Processes
Process Action Method Purpose Feedstock(s) Product(s)
TREATMENT PROCESSES
Hydro-
Desulphurisation
Conversion Catalytic Reduce
sulphur
High S HC
Streams
Desulphuris-
ed products
Hydrotreating Conversion Catalytic Remove
impurities,
saturate
HC’s
Residual,
Cracked HC’s
Distillates,
Lubes, Wax,
Cracker feed

22. Overview of Petroleum Refining Processes
Process Action Method Purpose Feedstock(s) Product(s)
TREATMENT PROCESSES
Amine
Treatment
Treatment Absorption Remove
H2S
Sour FG, Sour
LPG
Sweet FG,
LPG
Caustic Wash Treatment Conversion Remove
H2S,
Mercaptans
Sour LPG,
Naphtha, Kero
Sweet LPG,
Naphtha,
Kero

23. Overview of Petroleum Refining Processes
Process Action Method Purpose Feedstock(s) Product(s)
LUBE PROCESSES
Solvent
Extraction
(SEU)
Extraction Solvent Remove
aromatics
Vacuum gas oil Raffinate &
Extract
Solvent
Deasphalting
(SDA)
Extraction Solvent Remove
asphaltenes
Vacuum
residue
DAO & Pitch
Solvent
Dewaxing
(SDU)
Relative
Solubility
Solvent Remove
waxy
components
Raffinate from
SEU
LOBS &
Slack wax
Wax Deoiling Relative
Solubility
Solvent Remove oil Slack waxfrom
SDU
Wax &Foots
oil

24. Refinery Products End Use
• Fuel Gas : Internal fuel firing & blanketing gas
• Liquefied Petroleum Gas (LPG) :
Domestic and industrial fuel & Petrochemical feedstock.
• Gasoline or Motor Spirit : Fuel for automobiles.
• Naphtha : Solvent or Fertiliser & Petrochemical feedstock.
• Aviation Turbine Fuel (ATF) : Aircraft fuel.
• Kerosene : Domestic fuel for stoves, lamps etc.
• High Speed Diesel (HSD) & Light Diesel Oil (LDO) :
Fuel for heavy vehicles. HSD is lighter & cleaner than LDO.
• Lube Oils / Greases : Lubrication of auto & industrial machinery.
• Waxes : Polishes, cosmetics, impregnation etc.
• Bitumen / Asphalt : Laying roads
• Fuel Oil : Fuel for industrial purposes
• Coke : Fuel or as anode grade coke in Aluminum industry

25. NEED TO UPGRADE QUALITY
• Improved product performance
• Environmental stipulations
• Emissions oftoxics
• SOx and NOx Emissions
• Voc emissions
• Emissions ofparticulates
• Requirement ofOEM’s

26. TARGET PRODUCTS
• Motor Spirit (MS)
• High Speed Diesel (HSD)
• Lubricating Oils
• Fuel Oil
 Requirement of environmentalists and original
equipment manufacturers

27. TECHNOLOGIES WITH EIL (REFINERIES)
CRUDE
DISTILLA
TION
VACUUM
DISTILLA
TION
AMINE TREATING SULPHUR RECOVERY
SULPHUR
TREATING
LPG
TREATING
HYDROTREATING
REFORMER
NAPHTHA
GASOLINE
GAS
LPG
NAPHTHA
KERO/JET HYDROTREATING KEROSENE /ATF
SO2 EXTRACTION
CAUSTIC WASH
HYDROTREATING
DIESEL
FCC /
HCU
LUBE WAX BLOCK
EXTR’N/DEWAXING/DEOILING
COKING/VISBREAKING
SOLVENT DEASPHALTING
HFU
LOBS
WAX
BITUMEN BLOWING
COKE
FUEL OIL
ASPHALT
BITUMEN
GAS

28. Crude Mix High
Sulphur
Low
Sulphur
- India 52% 48%
- Reliance 95% 5%
Status of Indian Refineries

29. Is Indian Refining IndustryCompetitive?
Average yield of light and middle distillates :
USA 90% (Approx.)
India 72.5%
Reliance 90% (Approx.)

30. Is Indian Refining IndustryCompetitive?
 GRMs for India presently around $6 – $7/bbl
GRMs for the World around $6 - $7/ bbl
With 72.5 % distillates, Indian refining is still
competitive with the World
Should distillates touch 88% – 90%, our
GRMs would increase phenomenonly

31. Performance ofRefineries
Refinery Imported HS
Crude %
2005-06
Light Ends
%
2005-06
Middle
Distillates %
2005-06
Heavy
Ends %
2005-06
HPCL(M)
HPCL(V)
BPCL
KRL
IOCL(J)
IOCL(M)
IOCL(H)
CPCL
MRPL
74
44.5
31.7
43.8
25.9
54.6
72.8
69.8
69.0
18.1
27.3
27.7
23.4
15.9
18.9
17.1
18.7
20.1
42.4
46.8
45.1
49.3
47.9
52.2
43.7
48.3
53.3
30.7
18.8
20.6
16.9
29.7
23.7
29.4
23.1
20.3

32. Typical Fuel & Loss Break-Up of Refinery
Basis : 100% HS Crude Processing & Captive PowerGeneration
A. Fuel & Loss (wt% on crude)
• Fuel gas 1.5 – 2.0%
• Losses 0.5 – 1.0%
• Fuel Oil 6.0 – 8.0%
Total Fuel & Loss 8.0 – 11.0%
B. SOx Emission
Sulphur in IFO, wt% 1.0
Estimated SOx Emission, Tons/hr 1.25*
* Typical Sox Emission from Refineries is less than 1t/hr

33. Petroleum Refining Capacity of India
L O C AT I O N R E F I N E R Y C AP AC I T Y , M M T P A
E X I S TI NG Y E AR 2 0 0 7
I O C L
Digboi 0.65 0.65
Guwahati 1.0 1.0
Barauni 4.2 6.0
Koyali 12.5 12.5
Haldia 3.75 3.75
Mathura 8.0 8.0
Panipat 6.0 12.0
Paradip 0.0 9.0
Sub-Total 36.1 52.9
H P C L
M u m b a i 5.5 5.5
Visakh 7.5 7.5
Punjab 0.0 9.0
M R P L 9.6 9.6
Sub-Total 22.6 31.6
B P C L
M u m b a i 6.9 12.0
Bina 0.0 6.0
Sub-Total 6.9 12.0
C P C L
Chennai 6.5 9.5
N a r i m a n a m 0.5 0.5
Sub-Total 7.0 10.0
K R L Kochi 7.5 13.5*
B R P L Bo n gaigaon 2.35 2.35
N R L Numaligarh 3.0 3.0
R P L Ja m n a gar 27.0 27.0
E s s ar Ja m n a gar 0.0 10.5
Na ga rjuna Cuddalore 0.0 6.0
Total 112.45 174.85
Notes : 1. Year 2 0 0 7 is e n d of X plan.
2. * B a se d o n 6.0 M M T PA expansion planned for K RL .
3. Future Refineries.