The document describes various refining processes used in an oil refinery to separate and convert crude oil into useful products. Key processes include distillation to separate crude oil into fractions like gasoline and diesel; desulfurization to remove sulfur from fuels; platforming to increase gasoline octane; hydrocracking heavier fractions into lighter products; bitumen processing; and sulfur recovery from sulfur-containing gases. The overall refining process allows crude oil to be converted into a variety of high value fuels, lubricants, and petrochemical feedstocks.

1. REFINING
PROCESSES
A.DATTA
LECT04

2. Diesel
Gas Oil
Crude Oil
Bitumen
Roads
Long Chain Molecules
Gas treatment
Sulphur
Recovery Sulphur
H2S H2S
Waxy Distillate
Butane
De-asphalting
Asphalt Fuel oil
De-asphalted oil DAO
Desulphurisation
Kerosine
Shorter Chain Molecules
Hydrogen
Manufacturing
Unit
Hyrdrocracker
Hydrogen
High Vacuum
Separation
Vacuum Gas Oil
Long Residue
Distillation
Diagram of Refinery Units
Platformer Petrol

3. CDU1
CDU2
HVU1
BBU
HVU2
BDU
HCU
HMU
HDS2
Split
HDT
Plat
DePr
HDS1
Fuel
Gas
GasOil
Blend
Mogas
Blend
FuelOil
Blend
RG
RG
H2
RG
H2
RG
H2
RG
H2
RG
Natural Gas
Syngas and Reformates
Condensates and Low
Sulphur Crudes
High Sulphur Crudes
Imported Residues
High Sulphur Crudes
Low Sulphur Crudes
Imported Residues
Naphtha
Kero
LGO
HGO
Long Residue
Naphtha
Kero
LGO
HGO
Long Residue
Sulphur
Refinery Gas
Regular Mogas
Premium Mogas
Kero / Avtur
CO2
Automotive Gasoils
and Marine
Light Fuel Oil
Bunkers
Heavy Fuel Oil
Refinery Fuel
Bitumen 80/100
Bitumen 180/200
Bitumen 45/55
The Process Units

4. GASOILS
32%
JET/ KERO
14%
MOGAS
30%
FUELAND LOSS
7%
FUEL OILS
17%
Approx 7 Barrels to the Tonne
A Typical Crude Barrel

5. Distiller Units
Platformer
Hydrocracker
Gasoil Hydrotreater
Kerosine Hydrodesulphuriser
Depropaniser
Hydrogen Manufacturing unit
High Vaccuum Unit
Butane Deasphalting unit
Bitumen Unit
Sulphur Recovery
Product Blending
Crude
Products out
The Process Units

6. Distillation
• The initial separation takes place
in the distillation Column
• The Crude is first heated in a furnace
to a temperature of 360 oC
• It enters the column and vapours and
liquids separate
• The light vapours rise to the top whilst
the heavier liquids fall to the bottom

7. Furnace
Distillation Column
Crude
Kerosene
Gases +Tops + Naphtha
Light Gasoil
Heavy Gasoil
Long Residue

8. Crude
Lower Boiling
Higher Boiling
Distillation Column

9. Desulphurisation

10. Hydrogen
Under Pressure and Heat
Reaction takes place and
Hydrogen bonds with
Sulphur to form H2s
Desulphurisation Process
Reactor
Catalyst
Sour Tops + Naphtha
Sour Gasoil
Sour Kerosene
Desulphurised Kerosene
Desulphurised Tops + Naphtha
Desulphurised Gasoil
H2S

11. • Increases low Octane Naphtha to
high Octane Platformate
• Uses Heat and Pressure in a
Reactor
• Hydrogen is evolved in the
process
• Platinum Catalyst assists the
process
PLATFORMING

12. PLATFORMING
Platinum Reforming

13. High Octane
Platformate
Naphtha
From Splitter
Hydrogen
Recycle
Hydrogen
To Users
Reactor
Furnace
Separator
50 OCTANE
100 OCTANE
520°C
18 barg
515°C
40°C
E
Platformer Unit
Blending Tank

14. High Vacuum
&
Bitumen Units

15. Bitumen Feed Tanks
Long Residue
High Vacuum Unit - HVU 1
Vacuum
Gases
Vacuum
Gas Oil
180 Pen
Bitumen

16. To Hydrocracker
for furthur Processing
Gases
Vacuum
Gas Oil
180 Pen
Bitumen
Blowing
Column
To Refinery Gas System
Truck Loading and shipping
45/55 Pen
Bitumen

17. Hydrocracking

18. What is Hydrocracking ??
Production of high quality light products
from heavy oils,
in the presence of Hydrogen.

19. Hydrocracker Overview
HCU
Long Residue
5500 t/d
HVU VGO
200 t/d
3200 t/d
Waxy Distilate
BDU
Asphalt
900 t/d
Asphalt
10 t/d
70 t/d
Butane
145 t/d
Plant gas
Adip gas
Steam
1400 t/d
Hydrogen
140 t/d
Tops/Naphtha
Gasoil
Gas
120 t/d
1100 t/d
2000 t/d
900 t/d
Kerosine
Short Residue
1900 t/d
DAO
1000 t/d
Hydrogen
Manufacturing
Unit
Hydrocracker
High Vacuum Unit
BUTANE DE-ASPHALTING UNIT

20. Sulphur Recovery
Unit
Converts H2S into Sulphur
For use by Fertiliser Companies

21. Sulphur Pit
H2S Feed Main Furnace
Coalescer
Stack
Line Burner
Incinerator
Reactor
Reactor
Waste Heat
Boiler
Line Burner
Fuel Gas
Fuel
Gas
Line Burner
Fuel Gas
Liquid Sulphur 59%
A
A
B C
D
C
B D
Liquid Sulphur
Liquid Sulphur
Sulphur Recovery Unit

22. ENVIRONMENTAL
LOWERS EMISSIONS
SCOT Unit

23. Reactor
Waste Heat Boiler
Upper Quench Column
To SWS
Quench Water
Cooler
Lower Quench Column
Blower
KO Drum
SCOT Feed Gas
SCOT Burner
FG
Air
SCOT Unit
Absorber Colum (ADIP)
To SRU
KO Drum
Lean ADIP
Semi Rich ADIP