ESSAR OIL AND GAS LIMITED,VADINAR

PRESENTED BY :-

KETHAVATH MAHENDER KUMAR HIMANSHU GARG

16JE002638 16JE001880
 INTRODUCTION

• The Essar Oil Ltd grass roots refinery in Gujarat, India (started in 1996) was
completed and commissioned in 2006 (commissioned in third quarter).

• The refinery is the second largest in India after the Reliance Jamnagar
refinery on an adjacent site which can produce over 20MTPA.

• Essar Oil focuses on producing middle distillates such as high-grade kerosene

oil and low sulphur high-speed diesel, which form over 60% of India’s
domestic consumer demand.

• The refinery refines crude oil to produce diesel, gasoline, jet fuel, kerosene,
fuel oil and bitumen to suit market requirements.
Essar Refinery Process Flow

ISOM

Blending

CDU

Ultra Heavy
Crude
VGO MHC
CDU 2 DHDT
Mangala CN

DCU

HMU - I ARU/ Sulfur

SRU
HMU-2
Process Units

• CDU - Crude Distillation Unit

• SGU - Saturated Gas Unit
• VGU MHC - Vacuum Gas Oil Mild Hydrocracking
• DCU - Delayed Coking Unit
• FCCU - Fluid Catalytic Cracking Unit
• ISOM - Isomerization
• DHDS - Diesel Hydrodesulfurization
• DHDT - Diesel Hydrotreating
• HMU - Hydrogen Manufacturing Unit
• NHT - Naphtha Hydrotreating Unit
• CCR - Continuous Catalytic Reforming
• ARU - Amine Regeneration Unit
• SRU - Sulphur Recovery Unit
UNIQUE DESIGN FEATURES
CDU – 18 MTPA CPP (Captive power plant)
• Tallest crude column (90 metres • First refinery to use Coal fired Boilers
height, 76 trays) for meeting Steam and power
VDU demands of the refinery
• Low pressure steam ejectors & FCCU- 3.9 MTPA
vacuum
• 2 Stage Regenerators
CDU-II- 2 MTPA • Running on Maximizing Middle
Distillate Mode
• Capable to process ultra heavy crude NHT/CCR- 1.5/0.9 MTPA
on standalone basis.
• Producing Reformate with 101 RON
DHDT- 4.0 MTPA
• Very high pressure hydro treatment ISOM Unit- 0.7 MTPA
• Capable of producing Euro V diesel • Capable to processing feed with 5%
Benzene and 10% C7+
DCU- 7.5 MTPA
• 6 Coker drums VGO-MHC- 6.5 MTPA
• One of the largest Coker unit in the • Converted to Mild Hydrocracker in
world Sept’2015 Turnaround Shutdown
Vadinar Refinery Process Flow

ISOM

Blending

CDU

Ultra Heavy
Crude
VGO MHC
CDU 2 DHDT
Mangala CN

DCU

HMU - I ARU/ Sulfur

SRU
HMU-2
ADU (Atmospheric Distillation Unit)

VDU (Vacuum Distillation Unit)

Vadinar Refinery Process Flow

ISOM

Blending

CDU

Ultra Heavy
Crude
VGO MHC
CDU 2 DHDT
Mangala CN

DCU

HMU - I ARU/ Sulfur

SRU
HMU-2
DCU (Delayed Coking Unit)

60”

48” 48”

36” 36” HPS

Main KOD
Fractio WGC
nator

60”

Coke drum vapours OVHD

Receiver
Vadinar Refinery Process Flow

ISOM

Blending

CDU

Ultra Heavy
Crude
VGO MHC
CDU 2 DHDT
Mangala CN

DCU

HMU - I ARU/ Sulfur

SRU
HMU-2
FCCU (Fluid Catalytic Cracking Unit)
Vadinar Refinery Process Flow

ISOM

Blending

CDU

Ultra Heavy
Crude
VGO MHC
CDU 2 DHDT
Mangala CN

DCU

HMU - I ARU/ Sulfur

SRU
HMU-2
 ISOM (Isomerization)

LPG
iC5 – iso Pentane

Fuel Gas
DIP
Column
LPG
Stripper

LPG
PENEX
170 M3/Hr Reactor
140 M3/Hr Stabilizer DIH
Feed Column
Light
Treater
Naphtha Isomerate
From NHT
Products of Essar Oil

Product Application
• LPG Domestic Fuel
• Superior Kerosene Oil Domestic Fuel
• Aviation Turbine Fuel Commercial Airlines, Defense
• Furnace Oil DG set, boiler, Furnace, marine
• Bitumen Grade VG30 Process industrial
• Petcoke Industrial fuel
• Sulphur Chemicals industry
• Petrol Automotive Fuel
• Diesel Automotive Fuel
BEST PRACTICES IMPLEMENTED ON
ENERGY FRONT
Promoting culture for continuous EnCon idea generation/ out of the box/
innovation quest for energy optimization at each unit level.
APC module implemented to optimize the operation in various unit.
Indirect losses on slop processing, yield loss and product quality give away
minimized by diligent Operation.
Minimizing power consumption through optimum selection/loading of
drives.
Low grade heat utilization.
Outsourcing steam traps management to minimize steam losses.