Module - 3

0011 0010 1010 1101 0001 0100 1011

2
ADU / VDU
PRIMARY PROCESSING
1
4
IN REFINERY

Petroleum Ref./Upes/GCT/July-05/Mod-3/01
 OIL REFINERY
 AN ORGANISED AND COORDINATED
0011 0010 1010 1101 0001 0100 1011
ARRANGEMENT OF MANUFACTURING
PROCESSES DESIGNED TO PRODUCE
PHYSICAL AND CHEMICAL CHANGES IN

1
2
CRUDE OIL TO CONVERT INTO EVERYDAY
PRODUCTS LIKE PETROL, DIESEL, LUBES,

4
FUEL OIL AND BITUMEN

 CRUDE OIL FROM THE WELL CONTAINS A

MIXTURE OF HYDROCARBONS AND
RELATIVELY SMALL QUANTITIES OF OTHER
MATERIALS SUCH AS OXGEN, NITROGEN,
SULPHUR, SALT AND WATER
Petroleum Ref./Upes/GCT/July-05/Mod-3/02
  1010
0011 0010 REFINERY REMOVES
1101 0001 0100MOST OF THESE
1011
NON – HYDROCARBON SUBSTANCES AND
THE OIL IS BROKEN DOWN INTO ITS

2
VARIOUS COMPONENTS AND BLENDED

1
INTO USEFUL PRODUCTS

etroleum Ref./Upes/GCT/July-05/Mod-3/03(b)
4
 PETROLEUM HYDROCARBON STRUCTURES
 THREE MAIN HYDROCARBON GROUPS
- PARAFFINS
0011 0010 1010 1101 0001 0100 1011
- NAPHTHENES
- AROMATICS

2
 PARAFFINS

1
- STRAIGHT OR BRANCHED CARBON

4
COMPOUNDS SATURATED WITH
HYDROGEN ATOM
- PARAFFINS ARE VERY STABLE COMPOUNDS

 NAPHTHENES
-CONSIST OF CARBON RIGNS, SOMETIMES
WITH SIDE CHAINS, SATURATED WITH
HYDROGEN ATOMS
- CHEMICALLY STABLE
Petroleum Ref./Upes/GCT/July-05/Mod-3/03
 
AROMATICS
-CONTAIN RING OF SIX CARBON ATOMS WITH
0011 0010 1010 1101 0001 0100 1011
ALTERNATING DOUBLE AND SINGLE BONDS
AND SIX ATTACHED HYDROGEN ATOMS

1
2
- TYPE OF STRUCTURE IS KNOWN AS
BENZENE RING THE MORE ATOMS THE

4
HYDROCARBON MOLECULE HAS, THE
“HEAVIER” IT IS (HIGHER MOLECULAR
WEIGHT) AND THE HIGHER IS ITS BOILING
POINT

SMALL QUANTITIES OF A CRUDE OIL MAY BE

COMPOSED OF COMPUNDS CONTAINING
OXYGEN, NITROGEN, SULPHUR AND METALS
Petroleum Ref./Upes/GCT/July-05/Mod-3/04
 0011 SULPHUR CONTENT
0010 1010 1101 0001 RANGES
0100 1011 FROM
TRACES TO MORE THAN 5%

2
SOUR CRUDE - APPRECIABLE QUANTITIES

1
OF SULPHUR

4
SWEET CRUDE - LITTLE OR NO SULPHUR

Petroleum Ref./Upes/GCT/July-05/Mod-3/05
 REFINING PROCESSING

CRUDE OIL (FEEDSTOCK)

0011•0010 1010 1101 0001 0100 1011

• MIX OF HYDROCARBONS

2
1
• REFINING PROCESS

4
• INVOLVES BREAKING UP OF CRUDE OIL
INTO A NUMBER OF PRODUCTS

• PRODUCTS HAVE VARYING

ARRANGEMENTS OF ATOMS OF
HYDROGEN AND CARBON

Petroleum Ref./Upes/GCT/July-05/Mod-3/06
 REFINING PROCESSING

0011 0010 1010 1101 0001 0100 1011

CAN BE BIFURCATED AS

2
1
 PRIMARY PROCESSING

4
 SECONDARY PROCESSING

Petroleum Ref./Upes/GCT/July-05/Mod-3/07
 PRIMARY PROCESSING
 HEATING CRUDE OIL TO A MAX. OF
0011 0010 1010 1101 0001 0100 1011
ABOUT 4300C & SUBSEQUENT VAPORIZING
OF EACH OF THE COMPONENTS

2
1
 FRACTIONATING TOWER / CDU

4
 COMPOUNDS NORMALLY FRACTIONATED

 GAS & LPG

 NAPHTHA
 SKO
 HSD

Petroleum Ref./Upes/GCT/July-05/Mod-3/08
 PRIMARY PROCESSING Contd…
 ALL PRODUCTS EXCEPT SKO & HSD WOULD
0011REQUIRE FURTHER
0010 1010 1101 TREATMENT
0001 0100 1011

 UN – VAPORIZED LIQUID FLOWS DOWN AS

2
ATMOSPHERIC RESIDUE
 ATMOSPHERIC RESIDUE HEATED TO 400-

1
4
6000C & PASSED INTO A
 HIGH VACUUM COLUMN
 VGO (VACUUM GAS OIL)
 SR (SHORT RESIDUE)

 VGO IS THE FEED FOR SECONDARY

PROCESSING
SR
Petroleum IS USED FOR FO,
Ref./Upes/GCT/July-05/Mod-3/09 LSHS & BITUMEN
 PRIMARY REFINING STEP
PHYSICAL SEPARATION
0011 0010 1010 1101 0001 0100 1011

SEPARATION OF CRUDE OIL ACHIEVED BY

2
THE COMPOUND OF DIFFERING

1
VOLATILITY.

4
CRUDE OIL SPLIT INTO A NO OF CUTS
DEPENDING ON BOILING POINTS.

SEPARATION TAKES PLACE WITH CRUDE

DISTILLATION UNIT CDU

FURTHER SEPARATION OF CDU RESIDUE IN

A VACUUM DISTILLATION UNIT VDU
Petroleum Ref./Upes/GCT/July-05/Mod-3/10
 0011 0010 1010 1101 0001 0100 1011

2
1
etroleum Ref./Upes/GCT/July-05/Mod-3/11
4
 ATMOSPHERIC DISTILLATION

0011 0010 1010 1101 0001 0100 1011

THIS IS THE FIRST STAGE IN THE
REFINING FOR SEPARATING CRUDE

2
OIL COMPONENTS AT ATMOSPHERIC

1
PRESSURE BY HEATING AND

4
,SUBSEQUENT CONDENSING, OF THE
FRACTIONS (UNFINISHED PETROLEUM
PRODUCTS) BY COOLING.

Petroleum Ref./Upes/GCT/July-05/Mod-3/12
 CDU - OPERATES AT ATMOSPHERIC

PRODUCTS
0011 0010 1010 1101 0001 0100 1011
- GAS
- LPG

2
- NAPHTHA

1
- ATF
- KEROSENE

4
- MTO
- DIESEL
- JUTE BATCHING OIL
- REDUCED CRUDE OIL
VDU - RCO IS THE FEED
PRODUCTS
VGO
RAW LUBE CUTS
Petroleum Ref./Upes/GCT/July-05/Mod-3/13
 RAW STREAMS FROM CDU
 MEROX
 HYDROTREARTMENT
 REFORMING
0011 0010 1010 1101 0001 0100 1011
 ISOMERISATION
 FCC

2
1
VGO IS TREATED IN FCC
 LPG

4
 PROPYLENE
 PETROCHEMICAL FEEDSTOCKS
 MOTOR SPIRITS
 DIESEL
RAW LUBE CUTS
 REMOVAL OF AROMATICS & WAX
 HYDROTREATED
Petroleum Ref./Upes/GCT/July-05/Mod-3/14
 SHORT RESIDUE

 TREATED IN COKER UNIT

0001 0100
0011 0010 1010 1101 ALSO DEASPHALTING UNIT
1011
DAO
- SOLVENT EXTRACTION UNIT

2
- DEWAXING UNIT

1
- HYDROFINISHING UNIT

4
PETROLEUM COKE

 POWER
 CALCINED PETROLEUM COKE
SULPUR ?

HYDROGEN ?

Petroleum Ref./Upes/GCT/July-05/Mod-3/15
MAJOR EQUIPMENTS IN CRUDE OIL
DISTILLATION
0011 DESALTER
0010 1010 1101 0001 0100 1011

PREHEAT TRAIN

2
1
FURNACE

4
ATMOSPHERIC COLUM

STRIPPING COLUMNS

STABILIZER

CONDENSERS & COOLERS

Petroleum Ref./Upes/GCT/July-05/Mod-3/16
 CRUDE OIL
CRUDE OIL DISTILLATION
GAS

WATER
A
NAPTHA
0011 0010 1010 1101 0001 0100 1011 T
M
O S
S T
P R
STEAM

2
H I
E P

1
R P
I E
C R
DESALTER
Kerosene

4
D
I
S S
WATER T T
I R
L I
P STEAM
L
A P
T E
I R
Light Gas Oil
O
N
S
C T
O R
L I STEAM
U P

ADU FURNACE M
N STEAM
P
E
Heavy Gas Oil
R

Petroleum Ref./Upes/GCT/July-05/Mod-3/17
Reduced Crude Oi
 0011 0010 1010 1101 0001 0100 1011

DESALTING UNIT

2
1
Petroleum Ref./Upes/GCT/July-05/Mod-3/18
4
 Electrical
Power
Process
Water
0011 0010 1010 1101 0001 0100 1011

2
Alternate Desalted

1
crude

4
Unrefined
GRAVITY
crude
SETTLER

Heater Emulsifier Effluent

DESALTER Water
Petroleum Ref./Upes/GCT/July-05/Mod-3/19
 0011 0010 1010 1101 0001 0100 1011

2
1
troleum Ref./Upes/GCT/July-05/Mod-3/20
4
 NV TRANSFORMER

AC
POWER
0011 0010 1010 1101 0001 0100 1011 SUPPLY

1
2
ELECTRODES
DC DC DC

4
FIELD FIELD FIELD

AC FIELD
WATER

troleum Ref./Upes/GCT/July-05/Mod-3/21
 +
0011 0010 1010 1101 0001 0100 1011
+
+ +

2
1
Droplet movement becomes on
orderly migration towards the
electrode of opposite charge. Small
droplets collide and coalesce into
larger droplets which are removed by
etroleum Ref./Upes/GCT/July-05/Mod-3/22
4
0011 0010 1010 1101 0001 0100 1011

2
1
troleum Ref./Upes/GCT/July-05/Mod-3/23
4
 FUNCTION OF DESALTER
CRUDE OIL CONTAINS SOME SALTS AND
0011 0010 1010 1101 0001 0100 1011
WATER IN FORM OF AN EMULSION. A
DESALTER IS USED TO REMOVE THE

2
SALTS AND WATER PRESENT IN THE

1
CRUDE. THE SALTS PRESENT CAN CAUSE
FOULING IN THE PREHEAT EXCHANGERS,

4
COKING IN THE FURNACE TUBES AND
GETS HYDROLYZED IN COLUMN TO
PRODUCE STRONG ACID HCL, WHICH
CAUSES OVERHEAD SECTION
CORROSION.

etroleum Ref./Upes/GCT/July-05/Mod-3/24
 --------CONTD-------
WASH WATER IS MIXED WITH CRUDE TO
0011 0010 1010 1101 0001 THE
DISSOLVE 0100 1011 SALTS AND OTHER
IMPURITIES. ADJUSTING THE CRUDE / WATER
RATIO BASED ON MIXING VALVE PRESSURE

1
2
DROP CONTROLS MIXING OF CRUDE AND
WATER. WATER CRUDE MIXTURE ENTERS

4
DESALTER VESSEL AND INTRODUCED TO
HIGH VOLTAGE ELECTRIC FIELD, WHICH
CAUSES WATER DROPLETS TO COALESCE
AND PRECIPITATE. THE DESALTED CRUDE
COMES OUT OF THE TOP OF DESALTER AND
WATER SETTLES DOWN.

etroleum Ref./Upes/GCT/July-05/Mod-3/25
 PROCESS VARIABLES

DESALTER
0011 OPERATING
0010 1010 1101 0001 0100 1011VARIABLES

1. PRESSURE DROP (HIGHERTHAN 2 Kg /

2
CM2) ACROSS THE MIXING VALVE.

1
2. WATER INJECTION (2 TO 6%)

4
3. CONDUCTIVITY
4. DESALTER TEMPERATURE (1250 – 1350C)
5. VOLTAGE
6. pH
7. DESALTER PRESSURE

etroleum Ref./Upes/GCT/July-05/Mod-3/26
 VACUUM DISTILLATION UNIT
Gases Naphtha
Light Oil
Kerosene
0011 0010 1010 1101 0001 0100 1011 Diesel Oil
Gas Oil
Primary Flash Column (Flasher)

Atmospheric Distillation
1
2
Crude Light Lube
Oil Medium Oils

Stripper

4
Vacuum Distillation
Heavy
Heater

Heater
Asphalt
Crude oil distillation system, including a primary flash
unit, an atmospheric distillation column, and a vacuum
etroleum Ref./Upes/GCT/July-05/Mod-3/27
• VACUUM DISTILLATION OF REDUCED CRUDE
 Objectives :
To Produce Lube Oils
0011 0010 1010 1101 0001 0100
OR1011
To Produce Vacuum Gas Oil
 Lube Oil Mode :

1
2
Fractions : (i) Heavy Gas Oil HVGO : Overhead
product used for FCC feedstock or

4
after suitable treatment as
Light Lube Oil.
(ii) 3 fractions of Lube Oil : Light,
Intermediate & Heavy.
(iii) Pitch or Residuum –The Bottom
product : Produces Pitch/ Asphalt
 VGO Mode :
Heavy gas oil and lube fractions are
blended
etroleum and used as FCC Feedstock.
Ref./Upes/GCT/July-05/Mod-3/28
 VACCUM DISTILLATION
STEAM NONCONDENSIBLE
cw cw cw
EJECTIOS GAS

0011 0010 1010 1101 0001 0100 1011

SUMP

2
cw ONLY
WATER

1
4
7300 F LIGHT VAC GAS OIL
TOPPED TO
8500F
CRUDE STEAM HEAVY VAC GAS OIL
STEAM 25 TO
30 MM
ASHALT

HEATER
VACUUM
TOWER
etroleum Ref./Upes/GCT/July-05/Mod-3/29
 CRUDE DISTILLATION UNIT PRODUCTS
In the order of increasing boiling points, the main
0011 0010 1010 1101 0001 0100 1011
products from a typical crude distillation unit are :

 Fuel gas : Mainly methane and ethane. In some

1
2
refineries. Propane in excess is also referred to as “dry
gas”.

4
 Wet gas : The wet gas stream contains propane and
butanes as well as methane and ethane. The propane
and butanes are separated to be used for LPG and, in
the case of butanes, for gasoline blending and
alkylation unit feed.

 LSR naphtha : The stabilized LSR naphtha (or LSR

gasoline)
etroleum stream is desulfurzed and used in gasoline
Ref./Upes/GCT/July-05/Mod-3/30
  HSR naphtha or HSR gasoline : The naphtha
cuts are generally used as catalytic reformer feed to
produce high – octane reformate for gasoline
0011 0010 1010and
blending 1101 aromatics.
0001 0100 1011

 Gas oils : The light, atmospheric, and vacuum gas

1
2
oil arm processed in a hydro cracker or catalytic
cracker to produce gasoline, jet and diesel fuels. The

4
heavier vacuum gas oils can also be used as
feedstock for lubricating oil processing units.

 Residuum : The vacuum still bottoms can be

processed in a visbreaker, coker or deasphalting unit
to produce heavy fuel oil or cracking and/or lube base
stocks. For asphalt crudes, the residuum can be
processed to produce road and/or roofing asphalts.
etroleum Ref./Upes/GCT/July-05/Mod-3/31
• TYPICAL OUTPUT FROM ADU / VDU
% of Crude Cut range 0

input C
Fuel
0011 0010 1010 gas
1101 0.01
0001 0100 1011 % - 0.03 % < C25
LPG 1.0 – 1.5 % C3 – C4

2
FRN 11 – 14 % C5 – C16

1
(FULL RANGE (1650 C)
NAPHTHA)

4
LK / ATF 10 – 11 % 1650 - 2270 C
HK 6–7% 2270 - 270 C
Diesel 16 – 17 % 2700 - 3700 C
HAGO 2.5 – 3.0 % 3700 - 3920 C
R.C.O < 3920 C
(Atm. Residue)
LVGO 2.5 – 3.5 %
HVGO 21 – 22 %
etroleum Ref./Upes/GCT/July-05/Mod-3/32
• SATURATED GAS CONCENTRATION UNIT
(SGCU)
0011 0010 1010 1101 0001 0100 1011
 In Atmospheric Distillation column ; fractions below
1650 C are withdrawn as column overheads and sent to

2
SGCU.

1
 SGCU helps in separating gases, LPG and FRN.
 (Also in SGCU ; gases from reformer and

4
Hydrotreaters are processed)
 Fractions produced from SGCU :-
 Gases (C1 + C2) for burning into furnaces or as
petrochemicals feedstock after removal of H2S via
ATU (Anemic Treating Unit)
 LPG (C3 + C4) after removal of mercoptans in
MEROX UNIT.
 Naphtha (C 5 – 165
etroleum Ref./Upes/GCT/July-05/Mod-3/33
0
C) for sending to fertilizer or
 Lean Gas
Other streams
from other units LPG to Marox
S
G
C Naphtha to
0011 0010 1010 1101 0001 0100 1011 Hydrotreater

2
LK / ATF

1
F At
u

4
m HK
Desolater r
Crude os
in
Flash n ph
Drum a LVGO
eri
Water Brine c c Diesel
Preheat 1 in Preheat 3
Out Preheat 2 e Co
l. HVGO
JBO V TO FCC
Lube
a distillates
c.
ADU, VDU & SGCU Furnace
C
o
Vacuum
residue to
l. Belayed Coker/
Biturnen
etroleum Ref./Upes/GCT/July-05/Mod-3/34