Welcome

Refinery Overview & Configuration

Online Summer Internship Programme, IIChE

Abhay Raj Mishra

Dy. General Manager (Technical Services), Gujarat Refinery
 Crude Purchase Crude Storage Refining Product Storage
Transportation
(Tanker/
pipeline)

Retailing (Consumer / Demand Marketing Product Storage Product Transportation/

centre) (Terminal / Port / Depot) Distribution
(Pipeline / Rail / Road)
 WHAT IS A REFINERY ??
PETROLEUM
REFINERY
Crude ‘Marketable’
Oil Products
 What is Oil Refinery?
• The oil refinery or petroleum refinery is an
industrial process plant where the crude oil is
processed and made into more suitable
products such as petroleum naphtha,
gasoline, diesel fuel, asphalt base, heating oil,
kerosene, and liquefied petroleum gases.

• Oil refineries serve as a refining process after

crude oil extraction by oil rigs.
 What is Crude Oil?
 Crude oils are complex mixtures that contain
many different hydrocarbon compounds,
depending on the specific oil field, i.e. the oil in
one area differs in appearance and composition
from that of another region.

 An "average" crude oil contains about 84%

carbon, 14% hydrogen, 1% -3% sulfur and less
than 1% nitrogen, oxygen, metals, and salts.
 Petroleum Refining -History
• The first refinery, started in 1861, produced
kerosene by simple atmospheric distillation
• Gradually Demand for Lighter Products and Middle
Distillates increased after invention of electric power
and IC engine
• Modern technology and Environmental
Considerations called for more and more high
quality and superior products
• Today’s modern refinery employs more than 20
different operations
Indian Refineries
 Indian Refineries
Company No. of Refineries Place Capacity (MMTPA)
Barauni 6
Koyali 13.7
Haldia 7.5
Mathura 8
Panipat 15
Digboi 0.65
Bongaigaon 2.35
IOCL 11 Guwahati 1
CPCL, Manali 10.5

CPCL, Cauvery Basin 1

Sub_Total 65.7
Paradip 15
Total 80.7

Mumbai 6.5
HPCL 3 Visakhapatnam 8.3
HMEL, Bathinda 9
Total 23.8

Mumbai 12
Kochi 9.5
BPCL 4 BORL, Bina 6
Numaligarh 3
Total 30.5
Tatipaka 0.07
ONGC 2 Mangalore 15
Total 15.07
Jamnagar (DTA) 33
RIL 2 Jamnagar (SEZ) 27
Total 60
Essar Oil Limited 1 Vadinar 20
Grand Total 23   230.07
Refinery Configuration
 Products from Refinery
 Fuels : LPG, gasoline, kerosene /
ATF, diesel and residual fuel oil /
furnace oil.
 Non energy products: Lube Oil,
Base Stocks, Waxes, Bitumen
etc.

Specialty Products

Linear Alkaline Benzene

Propylene
Benzene
Toluene
Para-xylene
 Refinery Configuration

GUIDING FACTORS
Crudes to be processed

 Product demand : Present & next 10 years.

 Product quality : Applicable for future.
 Value added products
 Technologies
available
 Energy Conservation
 Refinery Configuration: Process Units
 Crude Distillation Unit
 Vacuum Dist. Unit
 FCCU
 HCU / OHCU
 VBU/DCU
 CRU
 DHDS / KHDS
 MEROX
 OM&S
Captive Power Plant for Steam & Power
 REFINERY PROCESS

These include
•Physical separation processes (Primary processes)
•Chemical / conversion processes (Secondary processes)
 COMPLETE REFINERY OPERATION
Quality Marketing Power &
Control Utilities

OM&S (Product Blending & Finishing Units

Dispatch)

Crude Oil Jetty / Separation Units

Pipeline OM&S OM&S
(Intermediates)

Conversion Units

Waste Welfare /
Treatment Admn.
Round the clock operation
BASIC REFINERY OPERATIONS
Hydrocarbon molecules in crude do NOT meet customer needs

SEPARATION PROCESSES Segregate the molecules

(Primary Processes)

CONVERSION PROCESSES Rearrange the molecules

(Secondary Processes)

FINISHING PROCESSES Remove Contaminants

(Secondary Processes)

MARKETABLE PRODUCTS
 REFINERY SCHEME
Crude Pretreatment Fractionation
• Desalting • Atmospheric & Vacuum
Distillation

Treatment Conversion
• Diesel Hydrodesulphurization • Fluidized-bed Catalytic Cracking

• Diesel Hydrotreatment • Hydrocracking

• Solvent Extraction ( e.g. FEU) • Delayed Coking

• Catalytic Reforming • Visbreaking /Coking

Formulation & Blending

Other Refinery Processes

a. Sour Water Stripping b. Sulphur Recovery c. Cooling Water Treatment
 FEED : Crude Oil: Characterization
By Gravity:

o
API SG
Light >35 <0.85
Medium 26-35 0.85-0.8984
Heavy 10-26 0.8984-1.00
Extra Heavy <10 >1.00
By Sulphur (%wt.):
Sweet <0.5

Medium sour 0.5-1.0

Sour >1.0
 Crude Oil Characterization

4 types of crude oils available to refiners

around the world:
o
API Sulphur (% wt.)
Light Sweet 30-40 <0.5
Light Sour 30-40 0.5-1.5
Heavy Sour 15-30 1.5-3
Extra Heavy <15 >3

High Acid Crudes (HACs)

 TAN (Total Acid Number) > 0.5mg KOH/gm Crude Oil
PROFITABLE CRUDE

TYPE OF CRUDE
TO BE USED

Crude Availability
Crude Cost
Desired Product Yield
Refinery Complexity
Environmental Constraints
PRODUCTS
 Critical Quality Parameters of Products

Sl.no Product Key Quality parameters

1. LPG Evaporation Temperature at 95 % Volume =2 deg C, Max
Cu Corrosion =not worse than No.1
RVP =1050 KPa, Max
2. Motor Spirit Density =720-775 Kg/M3
RON =91 Min
Sulphur =50 ppm, Max
Benzene =1 Vol. %, Max
3. ATF Density =775-840 Kg/M3
Flash Point = 38 deg c, Min
Sulphur =0.25 wt %,Max
Smoke Point =20 mm, Min
4. SKO Density =790-820 Kg/M3
Flash Point =35 deg c, Min
Sulphur = 0.25 wt %, Max
Smoke point = 18 mm, Min
 Critical Quality Parameters of Products

Sl.no Product Key Quality parameters

5. Diesel Density =820-845 Kg/M3
Sulphur = 50 ppm
Cetane Number = 51 Min
Recovery at 360 deg C =95 Min
6. Fuel Oil Kinematic Viscosity@ 50 deg c =125 , Max (Winter)
=180 , Max (Summer)
Sulphur = 4 wt %, Max
Ash = 0.1 wt %, Max
7. Bitumen Penetration at 25 deg c =60 (1/10mm) , Min
Flash Point =175 deg C,Min
Softening Point =45-55 deg C
 REFINERY
PROCESSES
 Basic Refinery Processes

• Planning,Scheduling,Receipt & storage of crude oil

• Separation Processes
• Conversion Processes
• Treatment Processes
• Blending & Certification Processes
• Product storage & Despatch operations
• Other refinery processes & Operations
 Complexity of a Refinery
The combination of refining processes and operations
employed (complexity) varies from one refinery to
another.
Factors deciding the complexity of a refinery
• Nature/source of crude oils to be processed
• Demand pattern in the markets to be covered
• Product quality – current / future
• Production of feed stocks for downstream units
• Inter-fuel substitution
• Environmental stipulations
 Refinery Operations

• PRIMARY PROCESSING UNITS

• SECONDARY PROCESSING UNITS

 PRIMARY PROCESSING UNIT

The purpose of Primary unit is to separate the crude

in to different fractions by distillation.

Known as mother unit of the refinery, consist of

• CRUDE DISTILLATION UNIT (CDU)

• VACUUM DISTILLATION UNIT (VDU)

Commonly referred as Atmospheric and Vacuum Distillation

unit (AVU)
 Classification of Secondary Processing Units

Secondary Processing Units

Treatment Process Cracking Process Quality Other units

Upgradation

Caustic
Wash Merox Diesel / Hydrogen
Generation
Naphtha/Kero. Cat. unit
Isomerisation
Hydrotreating Reforming unit
unit unit
Sulphur
BBU Recovery
unit

LUBES
Visbreaker Delayed Fluid Catalytic Hydro
Unit Coking Cracking cracking
 Major Units
 AUs/CDUs (Atmospheric Units / Crude Distillation Units)

 VDUs (Vacuum Distillation Units)

 CRU (Catalytic Reforming Units)

 DHDS/DHDT (Diesel Hydro-Treating)

 HCU (Hydrocracking Unit)

 FCCU (Fluidized Bed Catalytic Cracking Unit)

 DCU (Delayed Coker Unit)

Atmospheric & Vacuum Distillation Unit Flow Diagram

S
LPG
T
A Pr= 40-60 mm Hg a
B Stabilized Naphtha To Steam Ejector
Pre-topping

T=200 Deg C Unstabilised

Naphtha Light Naphtha
LVGO

Heavy Naphtha
LDO
ATF

Vacuum
Heavy Kero HVGO
Atmospheric
LGO
Desalter Vac Slop
HGO
Furnace
FURNACE
T=130-140
T= 370 Deg C
Deg C

Crude Oil SR
Furnace
FURNACE
T= 415 Deg C
RCO
 Continuous Catalytic Reforming

• Platforming Process
– Produces high octane reformate (gasoline) or
aromatics raw material for further processing
downstream
– By-products are H2 and LPG
– Accomplished in hydrogen atmosphere at elevated
temperature and pressure across a platinum
containing catalyst

35 UOP 3089a-2
 CCRU
Catalyst In (from Regenerator)

Reactor No. 1 Feed

Reactor No. 1 Effluent

Catalyst Transfer Pipes
Reactor No. 1

Reactor No. 2 Feed

Reactor No. 2 Effluent

Centerpipe Reactor No. 2

Last Reactor Feed

Last Reactor Effluent

Scallops Last Reactor

Catalyst Out (To Regenerator)

 DHDS / DHDT

Off. gas
Fuel gas
H2 Recycle
Recycle Compressor
H2 Make A
bs Lean
Up or COL OVHD
Temp. 350 Amine
b RECEIVER
Deg C er
S
T
Rich
Amine R
I
Wild
P
naphtha
P
Pr. 35-40
kg/cm2g E
R Steam

Feed

Furnace
Treated Diesel
Reactor-1 Reactor-2
DHDS Product Yields & Operating
Conditions
1. Typical Product Yields
Sl.no. Products Wt% End Users
1. Off Gas 1.36 Refinery Fuel gas
system after Amine
Wash
2. Wild Naphtha 1.34 To Naphtha Pool after
stabilisation
3. Diesel 98.0 To Euro II Diesel Pool

2. Operating Conditions :
Temperature range : 320-380 DEG C
System Pressure : 35-40 kg/cm2(g)
 DHDS & DHDT Product Yields & Operating
Conditions

DHDS DHDT
Products Wt% Products Wt%
Off Gas 1.36 Off Gas 2.5
Wild Naphtha 1.34 Wild Naphtha 2.8
Diesel 98.0 Diesel 96.0

Operating Conditions Operating Conditions

Temperature range : 320-380 DEG C Temperature range : 320-380 DEG C
System Pressure : 40 kg/cm2(g) System Pressure : 115 kg/cm2(g)
 Hydrocracker Unit

Makeup Recycle Gas

H2 Gases
Fresh Feed Recycle
R Gas Heavy
E Naphtha
A RGC
C RGC Kerosene
T
O
Diesel
R

First stage
separator separator
Product Unconverted Oil

Second stage Product

 ISOMERIZATION

• Rearrangement of straight chain hydrocarbons to branched

chain

• The more branched chain , the higher is the Octane.

 Fluid Catalytic Cracking Flow Diagram

FLUE GAS COL OVHD

M RECEIVER
A
R I HN
E N
S Regene FG
T A
rator C
A C O LCO
C T L
K O U
ORIFICE R M HCO LPG
CHAMBER N Recyc WGC GAS CON
le UNIT

FCCG

MAB
CLO
AIR
SLURRY
FEED SETTLER
CO BOILER
Furnace
FURNACE

Slurry Recycle
 Product Yield Pattern of FCCU
Product Yield % Routing
Dry gas (with
2.15 Refinery FG header
inerts)
LPG 13.78 FCCU LPG Merox

Gasoline 38.88 MS Pool

Hy naptha 14.14
LCO 19.72 DHDS/DHDT

CLO 7.13 DCU / FO

Coke 4.2 Combustion in Regenerator

DCU (Delayed Coker Unit)
Product Yield Pattern of DCU
Product Typical Yield %

Gas 2

LPG 3

LCN (Light Coker Naphtha) 7

HCN (Hy. Coker Naphtha) 6

LCGO (Light Coker Gas Oil) 29

HCGO (Hy.Coker Gas Oil) 30

Coke 22
 Other Process Units

• Hydrogen Generation Unit

• Bitumen Blowing Unit
• Sulphur Recovery Unit
 Hydrogen Generation Unit Flow Diagram

FEED
HYDROGEN
Hydrogenator SAT. STEAM
Pre-Reformer
Steam DM
Desulphuriser Reformer Drum water

Shift De- aerator PSA

Reactor
PSV

HP STEAM
Export

condensate
FLUE
GAS
OFF GAS as FUEL
AIR
 Bitumen Blowing Unit Flow Diagram

Air
Off gasTo
Bitumen Incenerator
reactor

S
E
P
A
R

Furnace A
Furnace T
FEED O
R

Bitumen to R/D
FLO
after Cooling
 Sulphur Recovery Unit

• Objective : To Reduce the SO2 emission from the Refinery

by recovering Sulphur from Amine Acid and Sour Gases
produced during various Hydrotreating Process.

• Feed : Amine Acid gases and Sour acid gases

Thank you