Crude Oil

A fossil fuel
Consists of several fractions
A mixture of very wide range of Hydrocarbons
Normally Black in color
Available in plenty in Middle East (Persian Gulf)
Also available in North & western Africa,
Indonesia, South & Central America,
Scandinavia
In India, it is available in Bombay High, KrishnaGodhavari basin, Assam & Rajastan

What is a Refinery?

A refinery is a complex integration

of several process units that work
in a coordinated fashion to make
customized fuels and valuable
petrochemical feed stocks.
It includes Blending.

Over View of a Typical Refinery

The Refining Process

Fractional Distillation
Conversion
Treatment
Blending

Typical refinery Units

Crude Dist Unit & Vac Dist Unit

Hydro treating unit
Fluid Catalytic Cracking unit
Delayed Coker unit
Merox
Sulfur Rec.Unit & ATU
Refinery Tank Farm

Typical Layout of a Refinery

N

g Water Storage
g Buildings
g RTF
g Road/Rail loading
g Sulphur

g CPP / Utilities
g Coker
g PP
g Aromatics
g CDU / VDU

RRT

RRT

RTF

S
F Cr 1
M H Cr 2
A
ETP

CPP

C
A

PP

Material Flow

SPM
2 Nos.

Jetties
4 Nos.

MTF

RTF

Pipeline
despatch
Road
loading
Rail loading

RRTF

Complexity

Increased Complexity
enhances margins
Guwahati

Barauni
Panipat
MRPL

&
l
l
ma

Si

Vizag

x
e
l
p
m
Co

le
p
m

Bongaigon
Digboi

&
e
arg

Reliance

Koyali
BPCL

Mathura
CRL

Haldia

HPCL

MRL

Capacity

Source: Chemsystem

Refinery Block Flow diagram

521/522
H2

H2

234
PSA

C1
221

LPG

HN

TOLUENE

231/232
PLAT

HNUU
331
SAT
LPG
MEROX

H2

251
OX-FR

281
TATORAY
261/262/263
PAREX

271/272/273
ISOMAR

241/242/243
XYL FR

HN

P-XYLENE
LPG
PC NAPHTHA

HN

321/322
SAT
GCU

471
LNUF

LN
341
KERO
MEROX
KERO

311/312
CDU

LAB FEED
KERO / ATF

351/352
DIESEL
UNI.FIN

LPG

415
UNSAT
LPG
MEROX

LPG

GAS OIL

414
UNSAT
GCU

CRUDE

361/362
VGO
UNI.FIN

VGO

VDU

411/412/413
FCC

416
GASOL
MEROX

COKER
LN

371
DCU

LCO

PP
PROPYLENE

180-215
GT FUEL

RFG

TAME

HCGO

CSO
CSO

GAS
PLANT

LCGO
VR

551/552
PP

DIESEL
ETHYLENE

MS

180-215

C5

372

ETYL
REC

422
PROP
REC

HN

LN
311/312

HARN
GT FUEL
O-XYLENE

441
SWS
COKE

431
ARU

431/452/
453
ARU

SULFUR
COKE

CDU/ VDU UNIT

Unit Objectives- CDU/VDU

The objective of the Unit is to separate the

crude oil into various fractions viz:
Off gases or Lean gases
Liquefied Petroleum Gas (LPG)
Full Range Naphtha (FRN)
Light Kerosene (LK)
Heavy Kerosene (HK)
Diesel (AGO or HSD)
Gas Oils (HAGO / LVGO / HVGO)
Vacuum Residue (VR)

CDU Process
Lean Gas

Other streams from

DHT, VGOHT,
LNUU, HNUU

S
G
C

LPG

FRN
LK / ATF

Old Desalters
Crude In

1st Stg.

1st Stg.

Preheat 1

2nd Stg.

2nd Stg.

New Desalters

Water In

Flash
Drun
Preheat 2

Heater

Atm
osp
heri
c
Col.

HK

Diesel

HAGO

Preheat 3

LVGO

Heater
Brine Out

V
a
c.
C
o
l.

HVGO

VacuumResidue

Major Equipment

Desalters
Fired Heaters
Heat Integration circuit
Crude Flash Drum
Main Fractionator
Side strippers
Multi Stage Ejector system

Fluid Catalytic Cracking Unit

Why FCC ?
Heavier Crudes
Need for cracking heavy
ends
Heavy demand for lighter
fuels

Why FCC

Converts VGO in to Gasoline and lighter

products.
Cheapest available conversion process
Offers great flexibility of operation (can
be run in LPG, Gasoline or distillate
mode)
Produces large quantity of
Petrochemical feed stocks

Major Equipment

Reactor and Regenerator

Power recovery trains (PRTs)
Vortex separators/ Cyclones
Main Air Blower/Expander/Motor
generators/Steam generator
Flue gas cooler
Main Fractionator/ Side Stripper
Waste Heat Boiler

Typical Gas Con unit

Hp Receiver
Stripper
Debutanizer, C3C4 splitter
Absorber
Amine absorber
Naphtha splitter
Depentanizer

Puprose of Gas Con Unit

To separate Close boiling range

lighter products like Fuel gas,
LPG, Gasoline, Naptha.
Acts as partial heat sink for Main
fractionator.
Stabilizes Naptha
H2S removal from gaseous
products.

DHT and VGOHT

A Hydro treater/ Union finer is a process

unit Where Hydrocarbon Feed is treated
with hydrogen in presence of catalyst at
high temperature & pressure.
Desulfurization(3.2wt% 0.2wt%)
94%
Denitrification (1658 ppm 760ppm)
Aromatic and Olefin saturation

DIESEL HYDROTREATER

DHT

Major Equipments

Recycle Gas Compressor

Fixed Bed Catalytic Reactor
Catalyst 300m3 (NiMo CoMo)
Fired Heater
Stripper

A
NA PHTHA
PR E HEA T EX
FEED
DIES EL

S TRIPPER

FILTER

FUR NA CE

R EA CTOR

Fi N
COOLER

D
r
i
e
r

FEED ( HIGH S)
R EA CTOR EFFLUE NT
PROD UCT(LOW S)

S EPA RA TOR

Lo w
mo isture
DIES EL
PROD UCT

VGO
HYDROTREATER

VGOHT

A
NAPHTHA
PRE HEAT EX
FRACTIONATOR

FEED
VGO
FILTER

FURNACE

REACTOR

Kerosene
DIESEL

FAN
COOLER

FEED (HIGH S)
REACTOR EFFLUENT

VGO
PRODUCT

PRODUCT(LOW S)
SEPARATOR

Why VGOHT ?

The Gas Oil product ex. Crude/Coker has

high sulfur content. This is to be reduced
before sending to FCC for SOX emission
control
Hydro-desulphurization of Gas oil is
carried out in VGO hydro treating units.
De Nitrification of Gas oil

VGOHT Major Equipments

Recycle Gas Compressor

Fixed Bed Catalytic Reactor
Catalyst 300m3 (NiMo CoMo)
Fired Heater
Stripper

Sulfur Complex
Sour Water Stripping Unit
(SWS)
Amine Treating Unit (ATU)
Sulfur Recovery Unit (SRU)CBA
Granulation Unit

Overview - Sulfur Complex

SWS Unit
CBA Units

Granulation
Unit

Amine Unit
Two absorber
Four Strippers

S -Dispatch

SRU Objective

Main Objective of the unit is to

convert H2S in to elemental Sulfur.

Why SRU ?

More Stringent environmental norms of

Government / regulatory bodies.
Enables the refinery to process High
sulfur crudes.

SRU Process

Acid gas from SWS and ATU stripper is

oxidized (burnt) in 2 stages and then
treated in catalytic converter. The
molten sulfur is transferred to SGU to
form Sulfur granules.

Major Equipment

Amine absorber
Flash drum
Stripper
Reaction furnace
Catalytic Reactor
Incinerator
Waste heat boiler

ATU-Simplified Flow Scheme

FG Out

Acid Gas

LA
Absorber
Stripper

FG In

Flash Drum

RA Pump

LA Pump

Lean Amine

CBA-Equipment
Claus Reactor

CBA Reactors

Reaction Furnace
V03
LPG

R01

Steam Drum

R02

R03

C.A

WHB
F02

B01

B02

Vent
Eductor
Sulfur Cooler

Acid Gas

S03

S04

Condensers
S02

Sweep Air Stack

S06

Steam Drum
V04

Rundown Line
Product Chamber

S05

RD Chamber

Sulfur Pit
Incinerator

F03

WHB

Stack

Auto - Fuel quality

trend upto 2010
Gasoline

Sulphur, max.
Benzene, max.

ppmw
% vol

RON, min
MON, min
AKI, min
Aromatics, max.
Olefins, max.
E 70
E 100

No.
No.
No.
% vol
% vol
deg C
deg C

BIS-2000

Bharat stage- Euro-III

Euro-IV
EURO-III
II (Reg/
Equivalent Equivalent
(effective
Prem)
(Reg/ Prem) (Reg/ Prem) 2000 in EU)

1000
3 metros, 5
rest
87
NA
84
NA
NA
NA
NA

500
3 metros, 5
rest @
88/93
NA
84/88
NA
NA
NA
NA

EURO-IV
(effective
2005 in EU)

150
1

50
1

150
1

10#
1

91/95
81/85
NA
42
21/18
10 / 45
40 / 70

91/95
81/85
NA
35
21/18
10 / 45
40 / 70

95
85
NA
42
18
20 / 48
46 / 71

95
85
NA
35
11**
20 / 48
46 / 71

@ The Benzene content will be progressively reduced to 1 vol% by Apr 2005 in 7 mega cities. The rest of the country would
have a maximum limit of 3 vol% from Apr 2005.
# 50 ppmw to be supplied from 2005 & 10 ppmw by 2008
** to be reviewed by 2005 by European Union.

Sulfur in Gasoline to go down to 50 ppm by 2010 and benzene to less than 1%

Auto - Fuel quality trend upto 2010

Diesel Fuels
Bharat stage- Euro-III
BIS-2000
II
Equivalent

Euro-IV
Equivalent

EURO-III
EURO-IV
(effective
(effective
2000 in EU) 2005 in EU)

Sulphur, max.
Cetane Number, min
Cetane Index, min
Distillation T95, max
Poly Aromatics, max.

ppmw
No.
No.
DegC
% wt

2500
48
46 @
370
NA

500
48 @
46 @
370
NA

350
51
46
360
11

50
51
48
360
11

350
51
48
360
11

10#
51**
NA
360**
11**

Flash point, min.

DegC

35

35

35

35

55

55

@ Cetane number 48 or Cetane index 46

# 50 ppmw to be supplied from 2005 & 10 ppmw by 2008
** to be reviewed by 2005 by European Union.

Sulfur in Diesel to go down to 50 ppm by 2010 and Cetane

Number will be above 51

Delayed Coker Unit

A thermal cracking and successive

polymerization process-rapid heating of
vacuum residue ( ex VDU) above cracking
temperature to form mixture of distillates
and coke.
The process of formation of coke is delayed
in the furnace by way of maintaining higher
velocities using HP steam/ BFW

Why DCU ?

High margin
No Fuel oil generation
Value added products (LPG, Diesel,
Naphtha, Fuel gas and Coke)
No Catalyst Involved
Capable of processing Refinery
slop and sludge

Major Equipment- Coking Section

Coke drum
Fractionator
Fired Heater
Blow down system
Coke Cutting system- PLC based
Heat Integration circuit
Heading and De heading unit
Product Filter-PLC based

RTF Overview

Functions of RTF

Ensure uninterrupted supply of Crude Oil

and other feed/intermediates to Various
Units.
Receive intermediates, products and
blending components from various units.
Supply of RFO & slop for reprocessing.
Blending
Correction of Offspec product.

RTF Work Flow

FINAL PRODUCTS

AROMATIC
COMPLEX

FUEL
COMPONENTS

REFINERY FUEL
FUEL STORAGE

MTF

HEAVY NAPHTHA

INTERMEDIATE PRODUCTS

FINAL
PRODUCTS
STORAGE

INTERMEDITE
PRODUCT
STORAGE

FINAL PRODUCTS

RFO

BLEND
COMPONENTS
STORAGE

BLEND HEADER

REFINERY
COMPLEX

RAW MATERIALS
RAW MATERIALS
STORAGE

SLOPS

SLOPS
STORAGE

RTF

RAW MATERIALS

RRTF

Major Equipment

Fixed Roof Storage tanks

Floating roof Storage Tanks
Horton Spheres
Mixers
Pumps

Any Questions ?

Thank you