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
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
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.