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Lecture 1
Lecture 1
Lecture 1
Introduction: Status of
Petroleum Refinery, Crude Oil
And Natural Gas Origin,
Occurrence, Exploration,
Drilling And Processing, Fuel
Norms
LECTURE 1
INTRODUCTION
Petroleum and derivatives such as asphalt have been known and used for almost 6000 years and
there is evidence of use of asphalt in building more than 600 years ago. Modern petroleum
refining began in 1859 with discovery of petroleum in Pennsylvania and subsequent
commercialization. The exploration of petroleum originated in the latter part of the nineteenth
century [Speight, 1999].
Oil and gas production includes exploration, drilling, extraction, stabilization. The underground
traps of oil and gas are called reservoir. Various types of traps are structural traps, stratigraphic
traps and combination traps Most reservoir contain water also along with oil and gas. Reserves
are classified as proven, probable and possible reserves. Earlier finding of oil and gas was matter
of luck and hit and miss process. Tools used for oil and gas exploration are based and dependent
on gravity change, magnetic field change, time, change and electrical resistance. However it has
become now more challenging and complex. With advent of three dimensional seismic
technology which is based on the sound waves, identify the subsurface formation by reflection of
sound, there has been much improvement in identification of oil and gas traps and reservoirs.
Seismic technology significantly improves the method of estimating the oil and gas deposits.
Next step after exploration is the drilling of exploratory well. Drilling may be vertical drilling or
horizontal drilling. Drilling may be performed on-shore or off-shore. Horizontal drilling and
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hydro-fracturing has resulted in economical and more productive drilling of shale gas which was
not economical with conventional vertical drilling.
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cyclohexane, components of gasoline.
1,2 dimethyl
cyclohexane.
Aromatics 6 carbon atom Benzene, Aromatics are not desirable in
in ring with Toluene, Xylene, kerosene and lubricating oil.
three around Ethyl Benzene, Benzene is carcinogenic and hence
linkage. Cumene, undesirable part of gasoline.
Naphthaline
Non Hydrocarbons
Non-hydrocarbons Compounds Remarks
Sulphur compounds Hydrogen sulphide, Undesirable due to foul odour
Mercaptans 0.5% to 7%
Nitrogen compounds Quinotine, Pyradine, The presence of nitrogen
pyrrole, indole, carbazole compounds in gasoline and
kerosene degrades the colour of
product on exposure to sunlight.
They may cause gum formation
normally less than 0.2.
Oxygen compounds Naphthenic acids, phenols Content traces to 2%. These
acids cause corrosion problem at
various stages of processing and
pollution problem.
Source: Mall,2007
PROCESSING OF PETROLEUM (CRUDE OIL)
Processing of Petroleum from drilling: when petroleum is drilled and brought to the surface, the
pressure drops resulting in separation of gases from the crude oil. Further processing of crude
involves separation of water and oil and salt. Associated natural gas is further processed for
separation of natural gas, condensate, acid gases. Crude oil varies in appearance from brownish
green mobile liquid to black viscous and sometimes semisolid. . Figure M-VI 1.1 illustrates the
process of oil and gas processing [Ravindranath and Habibula, 1992]
.
CRUDE OIL PROCESSED IN INDIA
Both indigenous and imported crude oil are processed in India. Various imported sources of
crude oil is given in Table M-VI 1.2.There has been continuous changes in the crude oil quality.
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Now imp
ported crudee oils are beeing heavierr with higheer sulphur coontent. Channging worlddwide
crude oiil scenario is given in
n Table M-VI 1.3. Inddigenous crrude oil is also varyinng in
characterristics. Rajassthan crude oil contain
ns high sulphhur and maay pose seriious challenge to
Indian petroleum refining indusstry Typicall characterisstics of variious indigennous crude oil is
given in Table M-VI 1.4.
Figure M-VI
M 1.1: Oil and G
Gas Processsing
Sou
urce: Ravindraanath and Haabibula, 1992
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Table M-VI 1.2: Imported Crude Sources
Middle East Kuwait, Dubai, S. Arabia( Arab Mix, Arab medium), Iraq,
Abu Dhabi, UAE(upper Zakum,Murban,UM Shaif)
Iran, Kuwait : Ratawai, Egypt( Suez Mix, Zeit mix),
Mediterranean Libya - Es Sider
West Africa Nigeria-Bonny Light, Eseravos, Forcados, Penington,
Quaiboe)
Angola, -Cabinda, Palanca, Girassol
Eq. Guinea -Ceiba, Zaffiro
Congo -Nikossa, Kitina
Far East Malaysia -Labuan, Miri Light
Australia -Barrow Island, Cooper Basin,Chalis
Brunei -Seria Light
Source: Samanti,R.K. “Refining challenges and Trends” 6th summer School on “Petroleum
refining and petrochemicals” June 6, 2012, Organised by New Delhi
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yield 80-82% (Light distillates 24%, Middle distillate
47%), Wax content 9.9%, total sulphur 0.02%.
North Gujarat Crude 28 oAPI, Sulphur content 0.1%, Pour point +27 0C,
Distillate yield low 33-35%, High organic acidity.
Bombay High Crude 38 oAPI, Sulphur 0.2%, Pour point +30 oC, Distillate
yield 65-70% (Light distillate 24%, Middle distillates
46%), High aromatics.
Narimanam Crude 46 oAPI, Sulphur 0.1%, Pour point 3 oC, Distillate yield
80%.
KG Basin Ravva Crude 36 oAPI, Sulphur 0.1%, Pour point +30 oC, Distillate
yield 61%.
Source: Mishra & Unnikrishnan, 1996, p.22
REFINERY PROCESSES
Refining of crude oils or petroleum essentially consists of primary separation processes and
secondary conversion processes. The petroleum refining process is the separation of the different
hydrocarbons present in the crude oil into useful fractions and the conversion of some of the
hydrocarbons into products having higher quality performance. Atmospheric and vacuum
distillation of crude oils is the main primary separation processes producing various straight run
products, e.g., gasoline to lube oils/vacuum gas oils (VGO). These products, particularly the light
and middle distillates, i.e., gasoline, kerosene and diesel are more in demand than their direct
availability from crude oils, all over the world. The typical refinery operation involves separation
processes, conversion processes, finishing processes, environmental protection processes.
Typical refinery process diagram is shown in Figure M-VI 1.2.
SEPARATION PROCESSES
Distillation
Absorption
Extraction
Crystallisation
Adsorption
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Gasolines or naphtha (light/heavy)
Kerosene, lamp oil jet fuel
Diesel oil and domestic heating oils
Heavy Industrial fuels
CONVERSION PROCESSES
Process for Improvement of Properties
Catalytic reforming
Isomerisation
Alkylation
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Figure M-VI 1.2: Typical Refinery Processes and Products
Thermal processes:
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Visbreaking
Coking
Catalytic Processes
Catalytic cracking(FCC)
Hydrocracking
Steam reforming
Hydroconversion
FINISHING PROCESSES
Hydrotreatment/hydrogenation
Sweetening
SECONDARY PROCESSES: Processing residues from primary processes and upgrading them
to distillates e.g. FCCU, HCU
REFINING CAPACITY
Global oil consumption and refining capacity, World Refining Capacity Country wise 2009 are
given in Table M-VI 1.5 and Figure M-VI 1.3. Present refining capacity in India is million tones
per annum. The present import of crude in India is around 180 million tones per annum. It is
expected that the import of crude oil has to exceed 240 million tones per annum in the next five
years, if GDP growth of around 6 to 7percent were to be sustained [Venkat, 2012].
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Table M-VI 1.5: Global Oil Consumption and Refining Capacity 2009
million barrel/d
Region Oil consumption Refining Remarks
capacity
Asia Pacific 25.99 26.81 Just matching
North america 22.83 21.13 Deficit
Europe and 19.37 24.92 Surplus
Eurasia
S & cent 5.65 6.69 Surplus
.America
Middle east 7.15 7.86 Surplus
Africa 3.08 3.26 Surplus
Total 84.04 90.66 Surplus
Source: Samanti,R.K. “Refining challenges and Trends.6th Summer School on “ Petroleum refining and
petrochemicals” June 6,2011, Organised by New Delhi
RUSSIAN
FED., 6% JAPAN, 5%
CHINA, 10% S. KOREA,
3%
INDIA, 4%
ITALY, 3%
USA, 19%
S. ARABIA,
2%
OTHERS , GERMANY,
45% 3%
Figure M-VI 1.3: World Refining Capacity Country wise 2009
Total: 90.7 mbpd (4533 MMTPA)
Sources: Mr. R.K. Samtani, DGM (Exploration & Production) IOC ltd. 6th June 2011
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Changing Scenario in Gasoline and Diesel Specifications
Major Parameters of Gasoline Specifications [Table M-VI 1.6]
• Lead phase out
• Lower RVP
• Lower benzene & aromatics
• Lower olefin content
• Limited Oxygen content
• Lower Sulfur content
Major Parameters of Diesel Specifications [Table M-VI 1.7]
• Low sulfur
• Low aromatics
• High cetane number
• Lower density
• Lower distillation end point
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number(min)
Distillation 370 370 360 360
99% Vol (oC
max)
Polycyclic No spec. No spec 11 11
aromatics
hydrocarbons
(PAH),%
massmax
Source: Rajgopal, S. “Refining challenges and Trends.6th summer School on “Petroleum refining
and petrochemicals” June 6,2012, Organised by New Delhi
187
REFERENCE
1. Garg, M. O., Invited talk 23 rd National Convention of Chemical Engineers IIT Roorkee, 5 –
7 October 2007
2. Mishra, A.K, Unnikrishnan, A., “Overview of the quality of crude oils processed in India”
1996, p.22 Challenges in crude oil evaluation: edt. Nagpal, J.M., New Delhi, Tata McGraw-
Hill Publishing Company Ltd, 1996, p. 1.
3. Mukhulyonov, I.U., Kuznetsov, D., Averbukh, A., Tumarkina, E., Furmer “Chemical
Technology” Mir Publishers Moscow,1974
4. Rajgopal, S., “Petroleum refining and petrochemicals” Refining challenges and Trends 6th
summer School on June 6,2012, Organised by New Delhi
5. Ravindranath,K., Habubula,M. “Hydro carbon condensate Fractionation in oil and gas
processing complex”, Chemical Engineering world, Vol 27, No.10, 1992, p.43
6. Samanti,R.K., “Refining challenges and Trends” 6th summer School on “ Petroleum refining
and petrochemicals” June 6,2012, Organised by New Delhi
7. Samtani R.K., DGM (Exploration & Production) IOC ltd. 6th June 2011
8. Singh, S., Vaidya,S.M., “The benefits from refinery and petrochemical Integration”
Chemical Industry digest August 2012,p67
9. Speight J.G. “The chemistry and technology of Petroleum”, Marccel Decker, Inc, New York,
1999.
10. Venkatraman, N.S., “Algae biofuel could be India’s savior” chemical News July, 2012, p.40
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