Download as PDF, PPTX
More Related Content
Similar to Process Engineer Role in oil & gas Refinery
Process Engineer Role in oil & gas Refinery
- 1. Process Design –What Chemical Engineers Should Know 7th June’ 2013 Engineers India Limited- Delivering excellence through people 1
- 2. Out Line Engineers IndiaLimited- Delivering excellence through people Chemical Engineering Overview Role of Process Engineer Issues Facing Refining Industry
- 3. Chemical Engineer Chemical engineersare involved in the design, modification and operation of processes to produce the things we rely on everyday - petrol, chocolate, cosmetics, electricity, cars, aspirin, the list is endless... Engineers India Limited- Delivering excellence through people
- 4. What is ChemicalEngineering ? vChemical engineering is the branch of engineering that applies the physical sciences (e.g., chemistry and physics) and/or life sciences (e.g., biology, microbiology and biochemistry) together with mathematics and economics to processes that convert basic raw materials or chemicals into more useful or valuable forms. vModern Chemical engineering also deals with pioneering valuable materials and related techniques – which are often essential to related fields such as nanotechnology, fuel cells and biomedical engineering. Engineers India Limited- Delivering excellence through people
- 5. What is aChemical Engineer ? vChemical Engineers can be divided into two broad groups • Chemical Process Engineers- This category deals in design, construction and operation of plants and machinery in industrial chemical and related processes • Chemical Product Engineers- are involved in the development of new or adapted substances for products ranging from foods and beverages to cosmetics to cleaners to pharmaceutical ingredients, among many other products Engineers India Limited- Delivering excellence through people
- 6. Section-II : OutLine Engineers India Limited- Delivering excellence through people Role of Process Engineer
- 7. Fields of Operation ProcessEngineers are employed across a variety of sectors including: § Oil and gas § Process plant and equipment § Energy § Chemicals and allied products § Water § Materials § Mining and minerals § Biotechnology § Pharmaceuticals Engineers India Limited- Delivering excellence through people
- 8.
- 9. Process Engineer –Fields of Operation Process Engineer Chemicals Hydrocarbons Fertilisers Nuclear Pharmaceutic als
- 10. What Do ProcessEngineers Do? vConceptualization of processes vInvent new processes vOptimization and control of processes to make them more cost effective, efficient and environmental friendly. vMake optimal designs (e.g pump and compressor power vis-à-vis line size) vPlan and operate facilities vOptimally integrate various systems and facilities vValue Engineering vPlant modeling Engineers India Limited- Delivering excellence through people
- 11. What Do ProcessEngineers Do? vConceptualization of Processes § Definition of the plant – Feed, Products, Capacity § Screening of options to ascertain whether the process is commercially established / proven § Study of alternative processes – comparison of salient features, capex, opex, advantages & limitations § Commercial application – Proven Track Record § Selection of Process Flow Scheme based on specific project requirements Engineers India Limited- Delivering excellence through people
- 12. What Do ProcessEngineers Do? vInvent new processes § Which reaction pathways should be used to make the product? § How to purify the desired product? § How to control the process and ensure it is safe? § How to make the process cost effective? § What should be done with any by-products formed? § How to reduce the amounts of unwanted by-products formed § What to do with unreacted raw materials? § How to recycle energy within process? Engineers India Limited- Delivering excellence through people
- 13. What Do ProcessEngineers Do? vOptimization and control of processes to make them more cost effective, efficient and environmental friendly. § Flow scheme simulation – generation of Heat & Mass Balance § Flow scheme optimisation to minimise Opex § Stream routing optimisation § Energy optimisation § Development of process controls to achieve § Ensure stable operation § Ensure safe operation § Meet start up, shutdown & emergency requirements through process controls & interlocks § Hardware optimisation to minimise Capex Engineers India Limited- Delivering excellence through people
- 14. What Do ProcessEngineers Do? vOptimal Design requires cost benefit analysis on case to case basis. Few examples are § Pump and Compressor power vis-à-vis line size – HP piping, Pipelines etc § Column number of trays vis-à-vis condenser & reboiler duties § Low level heat recovery § Designing for wide range of feedstocks vis-à-vis capacity compromise § Sparing philosophy for equipment to maintain high on-stream factor Engineers India Limited- Delivering excellence through people
- 15. What Do ProcessEngineers Do? vOptimally integrate various systems and facilities § Stream & energy integration within a process unit or utility system § Stream & energy integration between different process units § Stream & energy integration between process units & utility facilities § Stream & energy integration between process units & offsite facilities § Common facilities for various process units to optimise hardware Engineers India Limited- Delivering excellence through people
- 16. What Do ProcessEngineers Do? vValue Engineering § Implies adding value to an operating asset through either of the following means : § Reduction of capital cost § Reduction of operating cost § Yield improvement § Product quality improvement § Minimise quality give away § Improve on stream factor § Minimise losses, enhance recovery, recycle Engineers India Limited- Delivering excellence through people
- 17. What Do ProcessEngineers Do? vPlant Modeling § Key role in developing an optimum unit equipment layout Ø Equipment sequencing as per flow scheme Ø Layout to optimise cost by minimising high pressure, high alloy piping Ø Ensure that process requirements w.r.t free draining, no pockets etc are met Ø Ensure safe operation by restricting hazardous chemicals & their handling in one area, adequate open space for equipment approach, escape in case of emergency Ø Ensure ease of operation by locating equipment, CV, PSV, status lamps etc at accessible locations for easy monitoring Engineers India Limited- Delivering excellence through people
- 18. What Do ProcessEngineers Do? vPlant modeling § Key role in developing an optimum overall plot plan Ø Units placement in overall plot plan to take care of process requirements taking into account streams being handled Ø Nature of process units (DCU, Sulphur block) Ø Integration requirements between various units, utility generation & offsite facilities Ø Future expansion envisaged, if any Engineers India Limited- Delivering excellence through people
- 19. Process Engineering Process Deliverables –Study reports – Feasibility reports – Detailed feasibility reports – Technology evaluation reports – Basic Engineering Design Packages – Commissioning and Safety / Investigation – Diagnostics and Troubleshooting Engineers India Limited- Delivering excellence through people
- 20. Methodology of ConfigurationStudy and DFR . Delivering excellence through people KICK-OFF MEETING DESIGN BASIS FINALIZATION LP MODEL DEVELOPMENT - BUILD VARIOUS OPTIONS Carry out techno-economic comparison of alternatives based on CAPEX, OPEX, sales realization, etc. SCREENING OF OPTIONS Short list 3-4 options after a broad evaluation of a number of options and carry out a detailed evaluation of these to arrive at the recommended option. Select and finalize the configuration option Evolve Project cost estimates as part of DFR Preparation of DFR MID TERM REVIEW WITH CLIENT BEFORE SHORTLISTING OPTIONS. REVIEW AFTER DEVELOPING SHORT LISTED OPTIONS. (FINALIZE THE CONFIGURATION). FINAL REPORT
- 21. Basic Design &Engineering Package § Basic engineering design basis § Process flow diagrams § Heat & material balance § Process description § Piping & Instrumentation diagrams § Equipment & Instrument Specifications § Catalyst & Chemicals § Utility Summary § Effluent summary § Supervisory Operating Instructions Engineers India Limited- Delivering excellence through people
- 22. Contents of DetailedFeasibility Report Delivering excellence through people 1. Executive Summary 2. Introduction 3. Market Study (optional) 4. Configuration Study Basis 5. Detailing of Short listed cases 6. Refinery Configuration & Material Balance 7. Description of Project Facilities 8. Process Units Description & Process Flow Schematics 9. Utility Systems 10. Offsite Systems 11. Project Implementation Plan 12. Capital Cost Estimate 13. Financial Analysis 14. Environmental Considerations 15. Over all Plot plan 16. Social & Economic Benefits 17. Energy Conservation Measures 18. Conclusion & Recommendation
- 23. Components of ProjectCost Delivering excellence through people 1. Land 2. Site Development 3. Royalty/Know-how/BDEP fee 4. PMC Supervision 5. Plant & Machinery 6. Catalyst & Chemicals 7. Infrastructure § Roads & Buildings § Effluent Treatment Plant § Railway Siding § Product Dispatch 8. Construction Site Requirements 9. Owner Construction Period Expenses 10. Start-up & Commissioning Expenses 11. Township 12. Contingency 13. Working Capital Margin 14. Interest During Construction
- 24. Thank you Engineers IndiaLimited- Delivering excellence through people
- 25. Section-III : OutLine Engineers India Limited- Delivering excellence through people Issues Facing Refining Industry
- 26. Engineers India Limited-Delivering excellence through people Challenges Facing Refining Industry Shrinking Operating Margins Reducing Differentials Rising Crude Prices Deteriorating Crude Quality Improving Product Quality Stringent Pollution Norms
- 27. Engineers India Limited-Delivering excellence through people Changing Crude Mix Feedstock Shift from Low ‘S’ Light crudes to High Acid Crudes High Sulphur Crudes Heavy Crudes Unconventional Feedstocks
- 28. Regional Crude OilProduction Increasing § Middle East § CIS § Africa § Canada Flat § United States § Latin America § Asia Declining § Europe Engineers India Limited- Delivering excellence through people
- 29. Heavy Sour CrudeProduction Observations : v Total heavy sour crude production is expected to reach 700 MMTPA (14 million B/D ) by Yr. 2020, an increase of over 125 MMTPA over year 2010 production. v The largest increases will come from the Middle East & Canada. Engineers India Limited- Delivering excellence through people
- 30. Conventional & Un-conventionalOil Reserves • Current share of unconventional sources in the total output is about 25%. This is expected to rise to 40% of global oil supply by the year 2015. • Unconventional oil reserves are estimated to be about 6 trillion barrels . • Conventional oil reserves are estimated to be 1.2 trillion barrels. 30% 15% 25% 30% Total World Oil Reserves Conventional Oil Heavy Oil Extra Heavy Oil Oil Sands Bitumen Engineers India Limited- Delivering excellence through people
- 31. Facts About OpportunityCrudes § Opportunity crudes have growing presence in global oil market § Demand is driven by fluctuating oil prices § Processing does pose operating challenges §Careful analysis of crude type is a pre-requisite to establish feasibility & economic justification Engineers India Limited- Delivering excellence through people
- 32. Opportunity Crudes ProcessingPuzzle Engineers India Limited- Delivering excellence through people
- 33. Crude Prices &Spread Engineers India Limited- Delivering excellence through people
- 34. Crude & FuelProduct Price Differentials Engineers India Limited- Delivering excellence through people
- 35. Indian Refineries Configuration EngineersIndia Limited- Delivering excellence through people
- 36. Lt + MiddleDistillate Yield Engineers India Limited- Delivering excellence through people
- 37. Refinery Operating CostSummary Engineers India Limited- Delivering excellence through people
- 38. Upgrade Low ValueStreams § Ethylene Recovery from FCC & DCU Off Gases § Conversion of Propane to Propylene § Residue Upgradation §LCO Upgradation Engineers India Limited- Delivering excellence through people § Sulphur to Sulphuric acid
- 39. Ethylene Potential inOff Gases Engineers India Limited- Delivering excellence through people For a 9 MMTPA refinery, the total ethylene potential in Coker+Petro FCC off gases is 104.5 KTPA.
- 40. Ethylene Recovery FromOff Gases ACID GAS REMOVAL COMPRESSION DRYING & CONTAMINANT REMOVAL ACETYLENE POLISHING DeC1 C2 SPLITTER C2 H4 C2 H6 To Fuel Fuel Gas DeC2 C3+ To PRU Feed From Gas Plant CASCADED REFRIGERATION Engineers India Limited- Delivering excellence through people
- 41. Economics of EthyleneRecovery v About 104.5 KTA of ethylene can be recovered with ERU only which is about MM$104.5 per year based on ethylene price of US$1,000 per ton. v About 44 KTA of additional ethylene can be produced by adding a steam cracking furnace to crack the ethane recovered in the ERU. The additional revenue will be about MM$44 per year less the fuel value of ethane. Engineers India Limited- Delivering excellence through people
- 42. Propylene Supply Demand- Global Engineers India Limited- Delivering excellence through people ü Propylene gap is increasing üSteam crackers shifting to lighter feedstocks which produce less propylene üOn-Purpose Propylene is filling the gap : § High severity FCC (16-20%) § Propane Dehydrogenation (~80%) § MTO / MTP from coal, gas (25-40%) § Olefin Cracking (35-45%) § Metathesis
- 43. Propylene Demand isDriven by Plastics Engineers India Limited- Delivering excellence through people
- 44. Propylene Derivatives Propylene Benzene Cumene Phenolic Resins Phenol Poly Carbonates Epoxy Resins Acetone Other Solvents Acrylates Caprolactum Bisphenol- A Petro FCC Aromatic Complex EngineersIndia Limited- Delivering excellence through people
- 45. Engineers India Limited-Delivering excellence through people Typical LCO Properties High in Aromatics > 80% Nitrogen 100 ~750 wppm Sulphur 0.2~1.5 wt% FCC Diesel Boiling Range T-95 > 3600C Low Cetane 15~25 Gas Oil Clarified Oil Gasoline Light Ends LCO
- 46. Typical Aromatic Distributionin LCO Engineers India Limited- Delivering excellence through people Source : NPRA
- 47. Limited Product UpgradeBy LCO Hydrotreating Engineers India Limited- Delivering excellence through people Source : NPRA
- 48. Engineers India Limited-Delivering excellence through people LCO Disposal Options Aromatics Production Hydrotreating LCO Internal Fuel Firing LCO Cracking Diesel Diesel LN Fuel Oil Diesel LPG Gasoline Benzene Xylenes
- 49. LCO Cracking Economics vTypical conversion achieved = 75% § Conversion to HN = 45%, Benzene = 10%, Xylenes = 20% v Capital cost of a 0.7 MMTPA ISBL unit § Hydrocracking (to HN & HSD) = Rs 450 cr § Hydrocracking (to HN & Aromatics) = Rs 625 cr Engineers India Limited- Delivering excellence through people
- 50. Residue Conversion Options SolventDeasphalting Delayed Coker Deep Hydrocracking Engineers India Limited- Delivering excellence through people
- 51. Deep Hydrocracking Options SlurryTechnology VR conversion ~90% wt High contaminants tolerance Back mixed reactor Iron based catalyst Slurry bottom product is solid product Bottom product disposal issues No commercial reference Ebullated Bed Technology VR conversion levels 70- 80% wt Bottoms is liquid product Back mixed reactor 17 units in operation Semi-continuous catalyst addition / withdrawl Expensive catalyst Catalyst disposal by metal reclamation Engineers India Limited- Delivering excellence through people
- 52. Resid Upgradation TechnologyComparison Parameter SDA DCU Ebullated (LC-Fining/ H-oil) Slurry Hydrocracking Conversion wt% 50 70 70~ 80 80 ~ 90 Capital cost US $/bbl of feed 1120 3300 5150 6911 H2, wt% on FF 0 0 3.0 3.0 Catalyst $/ton of feed 0 0 10 2 Catalyst Make up None None Intermittent Continuous Engineers India Limited- Delivering excellence through people
- 53. Engineers India Limited-Delivering excellence through people Evolution of Global Refining Industry Hydro skimming Refinery Secondary Processing Complex Refinery Complex Refinery Residue Upgradation Petrochemicals Integration Integrated Refinery- Cum-Petrochemical Complex § Hydrogen § Chemicals § Petrochemicals Gasification
- 54. Engineers India Limited-Delivering excellence through people Refinery Petrochemical Integration § Workable & mutually beneficial solution § Adds value without compromising operations § Enhances cost competitiveness & hence economics § Major savings achieved in transportation, dispatch / receipt facilities, utilities & other expenses § Operational flexibility derived by feedstock optimisation to meet feedstock requirement of petrochemical industry
- 55. Engineers India Limited-Delivering excellence through people Refinery Streams for Petrochemical Integration FCC & Coker Off Gases Fuel Gas FCC LCO FCC & Coker Propylene FCC & Coker Butylenes Kerosene Ethylene / Derivatives MS Pool, Alkylation Propylene, Butylene LPG PP, Cumene / Phenol, Derivatives MEK, MTBE, Secondary Butanols LPG, Alkylation Naphthalene Gasoline, Diesel, IFO Refinery Stream Use in Refinery Petrochemicals SKO / Jet / HSD Pool Ethylene / Derivatives
- 56. Engineers India Limited-Delivering excellence through people Potential Gasification Feeds & Products Chemicals Production Gasification Plant Natural Gas Refinery Gas Vacuum Residue Pitch Coal Pet Coke Bio Mass Fischer Tropsch Reaction Combined Cycle CO2, N2, S Steam Electric Power § H2 § CO § Fertiliser § Chemicals § Methanol § Acetic Acid § Naphtha § Jet § Diesel § Wax Slag for Construction Material & Metal Recovery
- 57. CDU / VDU Delayed Coker Product Treatment Secondary Processing Coke Gasification SynGas Cleaning Methanol Alcohols Acetic Acid Oxo Alcohols Ethylene / Propylene Ketones & Derivatives Poly Olefins Formaldehyde Di-Methyl Ether (DME) Acetate Esters Fuel Distillates Achievable conversion through Methanol route •Methanol to Ethylene = 36% •Methanol to Propylene = 39% •Methanol to Butylene = 5% •Methanol to C1-C4 Alkanes = 20% Coke Gasification to Produce Methanol & Derivatives Engineers India Limited- Delivering excellence through people Indian chemical industry is estimated to grow at 11-15% p.a to reach US$ 224 billion by Yr 2017.
- 58. Pet Coke Gasification EngineersIndia Limited- Delivering excellence through people 100 t/hr Pet Coke Gasification requires 85 t/hr Oxygen to produce 200 t/hr of Syn Gas
- 59. Pet Coke Gasification EngineersIndia Limited- Delivering excellence through people v Typical Syn Gas Composition : § CO = 49.5 % § H2 = 32.5 % § CO2 = 15.5 % § Others = Balance v Capital Cost of a 1 MMTPA Pet Coke gasification plant is Rs 3500 crores § Gasifier = Rs 800 Cr § ASU = Rs 950 Cr § BOP = Rs 250 Cr § Constr., Engg. & indirect costs = Rs 1500 Cr
- 60. Section-IV : OutLine Engineers India Limited- Delivering excellence through people Concluding Remarks
- 61. Conclusion § Refineries arerequired to incorporate unconventional feedstock processing technologies around a core of existing conventional oil refining assets to improve economics & handle future crude quality. § Distillate yield of existing refineries must be enhanced with incorporation of residue upgradation facilities § Low value refinery streams need review for upgradation to value added products § Integration with Petrochemicals is mutually beneficial proposition § Gasification of low value streams provides a window for value addition as well as diversification into Chemicals & Petrochemicals. Engineers India Limited- Delivering excellence through people
- 62. Chemical Engineer -Roles Process Design Research & Development Production Sales
- 63. Sulphuric Acid ProcessFlow Scheme Engineers India Limited- Delivering excellence through people