Download as PDF, PPTX
Uploaded byOctovian Cletus
Petroleum Intro-Rev 4
This document provides an overview of the petroleum and petrochemical industry in India. It begins with definitions of crude oil and different types. It then discusses the upstream, midstream, and downstream processes in the hydrocarbon industry including exploration, production, refining, petrochemicals, marketing and distribution. Several key refinery processes are described at a high level like crude distillation, catalytic cracking, and production of gasoline from naphtha. Tables list major Indian refineries and their production capacities. Overall the document serves as an introduction to the petroleum industry supply chain and some important refining technologies.
More Related Content
Petroleum Intro-Rev 4
- 1. Introduction to Petroleum& Petro - Chemical Products. Description on Unit Process, Production & Business Opportunities In India
- 2. CONTENTS 1. The BlackGold 2. About Hydrocarbon Industry 3. A Guide of Refinery Process 4. Table of various process with approximate cost & criticality 5. Crude Distillation Unit 6. Production of Gasoline (Petrol) from Heavy Naphtha 7. Fluid Catalytic Cracking 8. List of Refineries in India and their production capacities 9. Procurement Methods adopted by Indian Refineries 10. Major Refinery Equipment’s - Part 1 of Presentation
- 3. THE BLACK GOLD What is Crude Oil ? • An unrefined petroleum product composed of hydrocarbon deposits and organic compounds. Origin of Hydrocarbons Types of Crude Oil • Sweet Crude (Low H2S & CO2) – Most preferable for producDon of gasoline. • Sour Crude (High H2S & CO2) – Crude with more than 0.5% sulfur Grades of Crude • Brent(UK), West Texas Intermediate(US), Daqing (China), BCF-17(Venezuela), Maga(Mexico), Bonny(Nigeria), Dubai(UAE) Composi<on • 83 – 87% Carbon • 11 - 15 % Hydrogen • 1 – 6% Sulfur AcDon of micro-organisms on Decaying Plants & Animals FormaDon of Hydrocarbons High Pressure & high Temperature Under Earths Surface
- 4. Graph Explaining thegrades of crude oil API = (141.5/S) – 131.5
- 5. ABOUT HYDROCARBON INDUSTRY Upstream,Midstream & Downstream Process
- 6. Hydrocarbon Industry –Up Stream Process Petroleum Exploration • Explora<on Techniques • Geo Physical • Gravimetric Method • Magnetometric Method • Seismic Survey • Remote Sensing Method • Geo Chemical • Chemical analysis of surface soil and rocks • Geo Technical • Mechanical ProperDes of rocks and surface are measured Petroleum Production • Oil Extrac<on & Recovery • Primary recovery • Once the complete rig is set-up, the underground pressure in the oil reservoir is sufficient to force the oil to the surface. • Secondary recovery • Supply of external energy into the reservoir in the form of injecDng fluids to increase reservoir pressure, hence increasing the natural reservoir drive with an arDficial drive. (eg. Water, Natural gas) • Enhanced recovery • This method injects steam to heat up oil the reservoir to reduce its viscosity and making it easier to extract.
- 7. VARIOUS TYPES OFRIGS USED FOR PETROLEUM EXTRACTION On shore Platforms & Off shore Platforms
- 8. Hydrocarbon Industry –Down Stream Process Refining & Petrochemicals • Refining • Petroleum refining processes are the chemical engineering processes to transform crude oil into useful products such as Liquefied Petroleum Gas(LPG), Gasoline (Petrol), Kerosene, Jet Fuel, Diesel Oil & fuel oils. • Petrochemicals • Chemicals obtained directly from cracking(pyrolysis), or indirectly from chemical processing of petroleum oil or natural gas. • Few examples, plasDcs, rubbers, fibres, paints, solvents & detergents. Marketing & Distribution • Marke<ng • MarkeDng is the final step in the chain that delivers useful petroleum products to end-user customers. • Driving factors: • Volume • Market Share • Margin • Distribu<on • DistribuDon lines of oil & gas must be managed with high levels of consistency and safety. • DistribuDon is done via, • Pipe lines • Cryogenic tanks • On-Site systems
- 9. Ministry of Petroleum& Natural Gas Industry Bodies Petroleum Planning & Analysis Cell Centre for High Technology Petro Fed Petroleum Conservation & Research Association Up Stream Process Exploration & Production ONGC OIL Private companies like Cairn, RIL etc., Down Stream Process Refining & Marketing HPCL BPCL IOCL RIL, etc., Distribution GAIL India RIL Hydrocarbon Industry – India Src: Ministry of Petroleum & Natural Gas
- 10. A GUIDE OF REFINERY PROCESS Crude Oil Storage Tank Desalter HeaDng (CDU) Crude DisDllaDon Unit / ADU VDU (Vacuum DisDllaDon Unit) Gas Processing NHTU NHTU ATF - HDT DHDT VGO-HDT Hydrocracker DCU Bitumen Blowing ARU Merox SRU Sulphur LPG (Propane & Butane) Naptha Gasolline Jet Fuel / Kerosene Diesel Fuel ISOM CCR ATF MEROX FCCU AlkylaDon Unit Poly Unit Needle Coke Unit Propylene PRU Light Gas Light Naphtha Heavy Naphtha Kerosene Jet Fuel Diesel Oil Gas Oil Desalted Crude Reduced Coke Fuel Gas H2S Refinery Fuel / Fuel Gas H2 H2 H2S Diesel Vacuum Residuel Heavy Vacuum Gas Oil C3/C4 Propane Butane Diesel Iso-Butane Gasoline Light Vacuum Gas Oil Premier Coke Coker Naphtha to CCR Coker Gas oil to FCCU Petroleum Coke Bitumen
- 11. A GUIDE OF REFINERY PROCESS Crude Oil Storage Tank Desalter HeaDng (CDU) Crude DisDllaDon Unit / ADU VDU (Vacuum DisDllaDon Unit) Gas Processing NHTU NHTU ATF - HDT DHDT VGO-HDT Hydrocracker DCU Bitumen Blowing ARU Merox SRU Sulphur LPG (Propane & Butane) Naptha Gasolline Jet Fuel / Kerosene Diesel Fuel ISOM CCR ATF MEROX FCCU AlkylaDon Unit Poly Unit Needle Coke Unit Propylene PRU Light Gas Light Naphtha Heavy Naphtha Kerosene Jet Fuel Diesel Oil Gas Oil Desalted Crude Reduced Coke Fuel Gas H2S Refinery Fuel / Fuel Gas H2 H2 H2S Diesel Vacuum Residuel Heavy Vacuum Gas Oil C3/C4 Propane Butane Diesel Iso-Butane Gasoline Light Vacuum Gas Oil Premier Coke Coker Naphtha to CCR Coker Gas oil to FCCU Petroleum Coke Bitumen v v v v v v
- 12. VARIOUS UNIT PROCESSIN REFINERY Table of Various Unit Process with Approximate cost & criticality
- 13. Table of VariousUnit Process with Approximate cost & criticality S.No. Unit Name Approximate Cost Criticality Major Units 1 CDU – Crude Distillation Unit 2 VDU – Vacuum Distillation Unit Hydro-treating Process 3 ATF HTD - Aviation Turbine Fuel Hydrotreater 4 DHDT – Diesel Hydrotreating 5 NHT – Naphtha Hydro Treater 6 VGO HDT – Vacuum Gas Hydrotreater Cracking Process 7 FCCU - Fluid Catalalytic Cracking Unit 8 Steam Cracking Unit 9 Hydrocracking Unit Reforming Process 10 CCR – Continuous Catalytic Reformer
- 14. Table of VariousUnit Process with Approximate cost & criticality S.No. Unit Name Approximate Cost Criticality Isomerization Process 11 Light Naphtha Isomerization Unit De-Sulfurization / Merox Process & Sulfur Recovery Process 12 ATF Merox – Aviation Turbine Fuel Merox 13 GMU – Gasoline Merox Unit 14 Extraction and removal of mercaptans from LPG 15 SRU – Sulfur Recovery Unit 16 SWS – Sour Water Stripper Coking Process 17 DCU – Delayed Coker Unit 18 Needle Coker Unit 19 Fluidic Coking Unit 20 Flexi Coking Unit
- 15. Table of VariousUnit Process with Approximate cost & criticality S.No. Unit Name Approximate Cost Criticality Other Units 21 HF Alkylation Unit 22 Vib Breaker Unit 23 Polymerization Unit 24 ARU - Amine Recovery Unit 25 AGS – Air Generation System 26 AGU – Acid Generation Unit 27 De-Salination / De-Mineralization Unit 28 ETP – Effluent Treatment Plant 29 Hydrogen Manufacturing Unit
- 16. CRUDE DISTILLATION UNIT AtmosphericDistillation Unit & Vacuum Distillation Unit
- 17. Atmospheric Distillation Unit(ADU) – Process Flow Diagram Pipe SDll Furnace Side Stripper
- 18. De-Salting Unit Preheated Crude Oil DM Water CausDc SoluDon Power T.F Dosing Pump FIC Crude oil Feed Pump pHC DPC Salt - Water Crude Oil Electrode Plates Oil – Water Interface TT PT FIC Crude Booster Pump Salt and Water to Drain LC • FIC - Flow Indicated Control • TT – Temperature Transmijer • PT – Pressure Transmijer • DPC – Dual Zone Pressure Controller • LC – Level Controller
- 19. Vacuum Distillation Unit(VDU) – Process Flow Diagram
- 20. PRODCUTION OF GASOLINE (PETROL) FROM HEAVY NAPHTHA Naphtha Hydro TreatmentUnit & Reforming Unit
- 21. NaphthaHydroTreater - ProcessFlowDiagram Raw Naphtha Storage Hydrogen Separator Feed Pump Furnace Cooler Makeup Hydrogen Recycle Compressor Stripper Gases to fuel system or sulfur recovery unit Desulfurised naphtha to storage Reboiling Furnace Reactor
- 22. Heavy Naphtha Reformer– Process FlowDiagram Desulfurised Naphtha Storage Hydrogen Separator Feed Pump Furnace Cooler Hydrogen to storage Recycle Compressor Debutaniser Reactor Reactor Furnace Furnace Reactor Gases to fuel System Reformate to Storage
- 23. FLUIDISED CATALYTIC CRACKING(FCC) Conversion of VGO(Vacuum Gas Oil) into Gasoline Intermediates using side by side FCC configuration
- 24.
- 25.
- 26. List of Refineriesin India and their Production Capacities Sl.No Sector Refinery Name Loca<on Investment Cost ( Rs. In crores) Commissioned On Produc<on Capacity (MMTPA) Present Produc<on Capacity (MMTPA) 1 IOCL GuwahaD Refinery Assam 17.29 1st January 1962 0.75 1 2 IOCL Barauni Refinery Bihar 49.4 July 1964 3.3 6 3 IOCL Koyali Refinery Gujarat 26 October 1965 2 13.7 4 IOCL Haldia Refinery West Bengal January 1975 2.5 7.5 5 IOCL Mathura Refinery Ujar Pradesh 253.92 January 1982 6 8 6 IOCL Digboi Refinery Assam 1901/October 1981 0.5 0.65 7 IOCL Panipat Refinery Haryana 3868 1998 6 15 8 IOCL Bongaigaon Refinery (BRPL) Assam 50 20th February 1974 1 2.35
- 27. List of Refineriesin India and their Production Capacities Sl.No Sector Refinery Name Loca<on Investment Cost ( Rs. In crores) Commissioned On Produc<on Capacity (MMTPA) Present Produc<on Capacity (MMTPA) 9 IOCL Paradip Refinery Orissa 34,555 February 7, 2016 15 10 HPCL Mumbai Refinery Maharash tra 1954 1.25 6.5 11 HPCL Visakh Refinery Andhra Pradesh 1957 0.675 8.3 12 BPCL Mumbai Refinery Maharash tra 1955 2.2 12 13 BPCL Kochi Refinery Kerala 27th April 1963 2.5 15.5 14 CPCL (IOCL + NIOC) Manali Refinery Tamil Nadu 43 1965 2.5 10.5 15 CPCL Cauvery Basin Refinery Nagapao nam, TN 1993 0.5 1 16 NRL Numaligarh Refinery Assam October 2000 3
- 28. List of Refineriesin India and their Production Capacities Sl.No Sector Refinery Name Loca<on Investment Cost ( Rs. In crores) Commissioned On Produc<on Capacity (MMTPA) Present Produc<on Capacity (MMTPA) 17 MRPL (ONGC) Mangalore Refinery Karnataka March 1996 3.69 15 18 ONGC TaDpaka Refinery Andhra Pradesh 27 September 2001 0.066 0.132 19 Private Jamnagar Refinery (RIL – DTA) Gujarat 33 20 Private Jamnagar Refinery (RIL – SEZ) Gujarat 37 21 Private Essar Oil Limited Vadinar, Gujarat November 2006 10.5 20 22 BORL (BPCL + OOCL) Bina Refinery Madhya Pradesh 12,200 May, 2011 6 23 HMEL (HPCL + Mijal) Guru Gobind Singh Refinery Bathinda, Punjab April, 2012 9
- 29. PROCUREMENT METHODS ADOPTEDBY INDIAN REFINERIES Conventional Route & EPC Route ConstructionProcurementEngineering
- 30.
- 31. Major Refinery Equipment’s • Pressure vessels • Heat exchangers • Shell & Tube Heat Exchangers • Plate & Frame Heat exchangers • Air cooled heat exchanger • Double Pipe exchanger • Process Vessels • Drums • Gravity Separators • Column • Reactor • Storage Tanks • Fixed-roof tanks • External floating roof tanks • Internal floating roof tanks • Domed external floating roof tanks • Horizontal tanks • Pressure tanks • Variable vapor space tanks • LNG (Liquefied Natural Gas) tanks • Fired heaters / Furnace • Piping system & Valves • Pumps • Centrifugal Pumps • Positive Displacement pumps • Reciprocating pumps • Rotary Pumps • Compressors • Reciprocating • Rotary Screw • Rotary Centrifugal • Cooling Towers
- 32. Heat Exchangers Shell &Tube Heat Exchanger Plate & Frame Heat Exchanger
- 33. Heat Exchangers Air CooledHeat Exchanger Double Pipe Heat Exchanger
- 34. Process Vessels Drums GravitySeparators
- 35.
- 36.
- 37.
- 38. Storage Tanks Fixed RookTank External Floating roof tank
- 39. Storage Tanks Internal Floatingroof tank Doomed External floating roof tank
- 40. Storage Tanks Horizontal tankPressure Tank
- 41. Storage Tanks Variable vaporspace tank LNG Tanks
- 42. Fired Heaters /Furnace
- 43.
- 44. Reference 1. The Black Gold • Fundamentals of petroleum & Petrochemical Engg – Ujam Ray Chaudhuri • hjps://en.wikipedia.org/wiki/Benchmark_(crude_oil) • hjp://www.markeDndex.com.au/crude-oil 2. About Hydrocarbon Industry • Fundamentals of petroleum & Petrochemical Engg – Ujam Ray Chaudhuri 3. A Guide of Refinery Process • Chemical Engineering Process – An AICHE PublicaDons • Essar presentaDon 4. Table of various process with approximate cost & criDcality 5. Crude DisDllaDon Unit • Fundamentals of petroleum & Petrochemical Engg – Ujam Ray Chaudhuri 6. ProducDon of Gasoline (Petrol) from Heavy Naphtha • Fundamentals of petroleum & Petrochemical Engg – Ujam Ray Chaudhuri • Chemical Engineering Process – An AICHE PublicaDons 7. Fluid CatalyDc Cracking • hjps://en.wikipedia.org/wiki/Fluid_catalyDc_cracking • Chemical Engineering Process – An AICHE PublicaDons 8. List of Refineries in India and their producDon capaciDes • Ministry of Petroleum & Natural Gas India