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Forum Title: (Forum 08: New Processing rote to Re-blance
diesel/ gasoline at refineries )
Poster Title: (Increase in Gasoline Production Capacity of oil Refineries)
Author & Coauthors: (Manzar Sattarin, RIPI-NIOC, Iran, Mr. Bayat, Mr
Teymouri, Mr Pasban RIPI-NIOC, Iran)
Block (eg: Block 1: Upstream)
Born in Tehran, Iran, She Studied Chemical Engineering in Sharif University.
she has been working for the RIPI –NIOC since 1990.
Her first posting was at the crude distillation laboratory in crude evaluation department.
Now her posting is as project manager for refining projects.
She is the expert on crude characterization, crude blending and residue upgrading
processes.
She is married with one grownup daughter and a son.

Abstract:
In this work, a pragmatic approach for increasing and other distillate products has been
presented based on gas condensate introduction to visbreaker unit. According to the
proposed method, gas condensate, with final boiling point of about 370°C and mainly
consisting of light naphtha is introduced to the fractionator of visbreaker unit as a part of
column reflux flow. Gasoline from the gas condensate is collected from the top of the column,
and middle distillates are withdrawn as side cuts.
Introducing gas condensate to the reflux line would eliminate the reflux of the fraction of the
main overhead product, i. e. gasoline. As a result, the whole part of the condensed gasoline
in the condensers is withdrawn as product. Although, the quality of the overhead might be
slightly influenced, we found that it is not as pronounced as to spoil the final product
specifications.
In a practical implementation, applied to an oil refinery with the capacity of 125000 bpd crude
oil, 3000 bpd gas condensate was added to the refinery’ s feed stock, leading to the increase
in gasoline, blending naphtha, kerosene and light diesel production up to 6, 10, 2.5 and 2 wt
%, respectively.
Forum Title: Forum 8: New Processing rote to Re- blance diesel/ gasoline at refineries
Poster Title : Increase in Gasoline Production Capacity of oil Refineries )
E

Introduction
• The growth of gasoline consumption in the last few years in Iran, has forced
the National Iranian Oil Products Distribution Co. to increase the domestic
production capacity. Consequently, all the oil refineries are being operated
at full capacity while there is no other conventional approach to increase
gasoline production capacity. Air cooler condensers, in a refinery, are
usually the main bottlenecks.
Forum : New Processing rote to Re-blance diesel/ gasoline at refineries
Posrter Titel: Increase in Gasoline Production Capacity of Oil Refineries
Author : Manzar Sattarin, RIPI-NIOC, Iran

Feed Characterization
Specification S KH Crude oil
API Gravity 36.9 54.6 33.5
Sulphur, wt% 0.27 0.24 1.28
Mercaptan, ppm 30 280 -------
Kin. Vis.
@40°C,cSt
3.810 1.143 6.380
Pour Point, °C +24 <-34 -8
R V P, psi 3.60 1.5 9.65
Acidity, mgKOH/gr 0.4 0.19 0.18

Feed TBP Distillation Data
Boiling Range ,°C S KH Crude oil
IBP-15 2.41 1.01 3.26
IBP-100 13.36 22.24 13.95
IBP-200 31.45 70.55 30.91
IBP-300 50.19 94.35 47.70
IBP-385 67.31 ------ 61.05
385+ 32.69 ------ 38.95

Conditions of Atmospheric Crude Distillation Column
Specification Content
Temperature of feed, °C 348
Top Pressure, Barg 1.86
Bottom Pressure, Barg 2.015
Tray Number 43
Side Stripper Number 3
Pump Around Number 2

Options for adding gas condensate to atmospheric column
• lower Pump around Return
• Upper Pump around Return
• Feed Tray
• Naphtha Stripper Input
• Kerosene Stripper Input
• Diesel Stripper Input
• Reflux line

Products Comparison
Products ,Kg/h Feed* Feed +1500
S
)BPSD(
Feed +2250
KH
)BPSD(
Feed +4500
KH
)BPSD(
Blending Naphtha 33990 35100 36480 38970
Kerosene 105300 106360 107300 109300
Light Diesel 114700 116700 115800 117000

Column flow conditions (flooding)
Section Feed Feed +1500
S
Feed +2250
KH
Feed +4500
KH
Tray 29 83.19 83.95 85.49 88.16
Tray 28 89.30 90.29 91.86 94.56
Tray27 88.25 89.31 90.83 93.55
Tray 26 74.45 75.20 76.58 79.25
Tray 25 73.98 74.74 76.00 78.79
Tray 20 73.34 74.05 75.12 77.96
Tray 18 70.68 71.32 72.51 74.99
Tray 17 78.63 79.97 81.48 83.94
Tray 16 83.97 86.60 88.31 92.25
Tray 15 75.13 78.86 81.09 86.16
Stripping
Zone, Max.
82.43 83.52 83.73 85.25

Duties Comparison (MW)
Air coolers
condensers
Feed Feed+1500
S
Feed+2250
KH
Feed+4500
KH
1 41.13 41.50 42.5 43.86
2 20.40 20.63 21.07 21.75

Disadvantages of adding of gas condensate to the atmospheric column
Directly (Mixing to crude oil)
Consumption energy for separating for second time
Incompatibility for their compositions difference
Indirectly (said options)
Flooding in some trays
Capacity of Air cooler condensers
Products quality

Our Suggestion
A pragmatic approach is gas condensate introduction to fractionator of
visbreaker unit.
According to the proposed method, gas condensate, with final boiling point
of about 370 °C and mainly consisting of light naphtha is introduced to the
fractionator of visbreaker unit as a part of column reflux flow. Gasoline from
the gas condensate is collected from the top of the column, and middle
distillates are withdrawn as side cuts.
Introducing gas condensate to the reflux line would eliminate the reflux of
the fraction of the main overhead product, i.e. gasoline. As a result, the
whole part of the condensed gasoline in the condensers is withdrawn as
product. Although, the quality of the overhead might be slightly influenced,
we found that it is not as pronounced as to spoil the final product
specifications.

Results
• In a practical implementation, applied to an oil refinery with the capacity of
125000 bpd crude oil, 3000 bpd gas condensate was added to the refinery’s
feed stock, leading to the increase in gasoline, blending naphtha, kerosene
and light diesel production up to 6, 10, 2.5 and 2 wt%, respectively.

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