MCR PROJECT

• Project cost was US $ 886 million

• Commissioned in September 2000

• In time completion within budgeted cost

 PROJECT’s MAJOR MILESTONES

 JUN 1995 Agreement between GOP & Abu Dhabi

 AUG 1995 Ground Breaking Ceremony by PM of Pakistan

 NOV 1995 Signing of Contract with UOP (Process

Licensor)

 OCT 1997 Signing of EPC Contract with JGC-Japan

 OCT 1997 Detailed Engineering & Procurement activities

 MAR 1998 Commencement of Construction

 MAR 1999 Marketing Rights to PARCO for LPG

 F.GAS F.G REFINERY
180 TPD
SOUR GAS H2S SULFUR FERTILIZER
AMINE-UNIT SULFUR RECOVERY 80 TPD
G LPG-MEROX
GAS-CON LPG LPG COOKING
N 4,500 BPSD
UNIT 470 TPD BURNERS
G
NAPHTHA+GAS LPG
NAPHTHA
HYDROTRAETOR L.NAPHTHA MS
NAPHTHA 25,000 BPSD 1600 TPD CARS
GASOLIN
HOBC
BLENDS
H.NAPHTHA PLATFORMER & CCR H 610 TPD
16,350 BPSD
CRUDE CRUDE REFORMATE
OIL DISTILLATION
UNIT H.NAPHTHA DEFENCE
JP-8
100,000 BLENDS
JP-8 AIRCRAFTS
BPSD 150 TPD
KEROSENE KERO-MEROX JP1/KERO COMMERCIAL
20,000 BPSD 2000 TPD AIRCRAFTS
HSD
HSD BUSES AND
LVGO 3950 TPD TRUCKS
G HSD/LDO
BLENDS
VACUUM H
DISTILLATION DIESEL-MAX UNIT N
R.CRUDE LDO TUBEWELLS
UNIT CAT/FRAC/THERMAL
42,800 BPSD 150 TPD
SECTIONS
22,450 BPSD DISTILLATE
HVGO VGO

D-MX RESIDUE

VISBREAKER G F.O
15,560 BPSD BLEND F.O POWER
VAC.BTM N 4030 TPD PLANTS

VIS.BTM
 Refinery Products & Uses
Fuel Gas Refinery & Fertilizer
Sulfur Fertilizer
LPG Cooking Burners
Motor Gasoline Bikes & Cars
HSD Buses & Trucks
JP-1 Commercial Air Crafts
JP-8 Defence Air Crafts
LDO Tubewells
Fuel Oil Power Plants
 SHARE IN
REFINING
DHODAK BOSICOR ARL PRL NRL PARCO

1 10
36 13

18
22
Dhodak Refinery Ltd. 2,500 BPSD
Bosicar Refinery Ltd. 30,000 BPSD
Attock Refinery Ltd. 35,000 BPSD
Pakistan Refinery Ltd. 50,000 BPSD
National Refinery Ltd. 62,500 BPSD
Pak Arab Refinery Ltd. 100,000 BPSD
 Crude Oil
 Degassed raw petroleum that has been removed
from the ground.

 Oily, usually dark-colored liquid that occurs

naturally in many parts of the world.

 Containing Gaseous, liquid or solid Elements

 Crude Oil Supply
• PARCO imports crude oil from Middle
East. Some local crude is also processed.
• Crude Oil is transported from Karachi to
MCR site at Qasba Gujrat through a
dedicated 864 km pipeline.
 Crude Oil Pumps
Flow Full Load Current
Capacity (FLC)
Pump
(m3/hr) Amp.

02 Centrifugal 510 135

01 Centrifugal 220 61
 Crude Feed Components / Ratio
1. Arabian Light
2. Upper Zakum
3. Murban
4. Local
5. Condensate
6. HSL
7. LSL
 Crude Feed Tanks

 There are six (06) Crude Feed Tanks of

Storage Capacity = 39260 m3
 Refining Process
The Refinery processes are classified into:

Primary Processing Units

The Crude & Vacuum Distillation Unit is the Primary
Processing Unit in an Oil Refinery wherein Crude Oil is
separated into various products depending on the
relative volatility of the Hydrocarbon components.

Secondary Processing Units

Secondary Processing Units receive their feeds from the
Crude / Vacuum Units and upgrade them into value
added products.
Design Basis for feed & Products

FEED:
The Crude Distillation Unit is designed to process
100,000 BPSD (662.44 m3/hr) for either:

 Arabian Light crude oil (100 %)

 70/30 volumetric blend of Upper Zakum and Murban

crude oils.
 Impurities in Crude Oil
 Two types of crude oil impurities can be defined. Those
impurities that can be removed by electrical desalting are
generally classed as "Oleophobic" (lacking an affinity for oil) and
may be designated as follows:
Oleophobic Impurities General Range
 Salts 10 - 1000 PTB
 Water 0.1 - 2 Vol.%
 Sediment 1 - 500 PTB.
PTB = pounds per thousand barrels of oil.
 Impurities Cont.
 These oleophobic constituents are insoluble in crude oil
and are present as a second phase, being carried as
discrete particles by the oil.

 The second class of impurity is known as "Oleophillic"

impurity (having a strong affinity
for oil). Typical constituents of this type may be listed as
follows:
 Impurities Cont.
Oleophillic Impurities General Range
 Sulfur Compounds 0.1 - 5 Wt.% as sulfur
 Organo-Metallic Compounds 5 - 400 ppm as the metal
(Nickel, Vanadium, Iron, Arsenic, etc.)
 Naphthenic Acids 0.03 - 0.4 Vol.%
 Nitrogen Compounds 0.06 - 15 Vol.%
 Non-Acidic Oxygen 0 - 2 Wt.% as oxygen
Compounds
 (Resin, Cresols, etc.)
 These Oleophillic impurities are soluble in crude oil and cannot be
effectively removed by electrical desalting methods.
 Crude Assay
“A procedure for determining the general
distillation and quality characteristics of
crude oil.”
Metals (PPM)
API Sp. Sulfur Nitrogen C.C.R Ash Water Salt Wax TAN (mg
Crude
Gravity Gravity (wt.%) (wt.%) (wt.%) (wt.%) (wt.%) (wt.%) (wt.%) KOH/gm)

Ni Va Fe Na

Arabian
33.1 0.8592 1.82 0.08 4.19 0.01 0 6 3.2 0.04 4 14 0 1
Light

Upper
33.62 0.8569 1.92 0.08 5.061 0.01 0.05 5 3.8 0.04 10 10 2 1
Zakum

Murban 40 0.8256 0.78 0.004 1.86 0 0.05 3 3.9 0.02 2 2 0 0

Ref: UOP Crude Assay

Process:
Crude Distillation Unit converts the raw crude oil
into valuable products by distillation i.e.,
Separation of products at their boiling points.

Products:
 18,300 BPSD un-stabilized Naphtha
 15,400 BPSD Kerosene
 23,500 BPSD straight run Diesel and
 42,800 BPSD Reduced Crude.
 Plant Duty of Crude Distillation Unit

 Crude charge and preheat section

 Crude desalter section
 Crude charge heater section
 Crude column and sidecut product section
 Reduced crude section
 Diesel section
 Kerosene section
 Naphtha pumparound section
 Crude column overhead section
 CRUDE DISTILLATION
UNIT 109/115 oC
0.91 Kg/cm2g
DISTILLATION OVHD
COLUMN SYSTEM
Crude Distillation Unit converts the
crude oil into valuable products by
NET GASES
distillation i.e., Separation of products
TO GCU
at their boiling points.
NAPHTHA
TO GCU
The design processing capacity of Crude
KEROSENE
Distillation Unit is 100,000 BPSD
CRUDE TO KMU
(15,900 m3/day).
STRAIGHT RUN
DIESEL TO
HEATER DHDS

363/371 oC

REDUCED
CRUDE TO VDU
 Draw Off Temperature
From Column

Temp. (C) UZ/MU AL

 Unstabilized Naphtha 127

133
 Kerosene 180 179
 SR. Diesel 263 260
 Reduced Crude 339
350
 Products Route
 Overhead Gases to GCU Unit
 Unstabilized Naphtha to GCU Unit
 Kerosene to Kero Merox Unit
 Atmospheric Diesel to DOB/LDO/FOB/DHDS Unit
 Atmospheric Residue to VDU
 Chemicals Used at CDU
 Anhydrous Ammonia (Neutralizer)
 Antifoulant
 Demulsifier
 Corrosion Inhibitor
 Phosphate is used to control:
1. pH
2. Chloride
3. Silica
4. Conductivity &
5. Phosphate of the boiler water
 Major Equipments of CDU
 Pumps (Centrifugal & P.D)
 Steam Turbines
 Exchangers
 Vessels
 P.D Compressor
(Suction P = 0.91 Kg/cm2) & (Discharge P = 4.0 Kg/cm2)
 Desalters (Inlet 129 C)
 Flash Drum (Inlet 190 C)
 Heater (Inlet 255/265 & Outlet 363/371 C)
 Crude Distillation Column (Inlet 363/371 C)
 Strippers (Kerosene & SR. Diesel)
 Coalescers (Kerosene & SR. Diesel)
 Salt Dryer (SR. Diesel)
 PLANT NNF STRIPPED
WATER WATER
DESALTED
CRUDE

MIXING ELECTRODES MIXING ELECTRODES

VALVE VALVE

PDC PDC

LC LC

1ST STAGE 2ND STAGE

RAW CRUDE BRINE

Process Variables of Desalters

1. Pressure drop across the mixing valve

2. Quantity of water injected
3. Temperature
4. Conductivity
5. Voltage
6. Pressure
Process Variables of Desalters
1. Pressure drop across the mixing valve

 The greater the pressure drop across the mixing valve,

the greater will be the mixing action. The greater the
pressure drop, the smaller the particle size and the
tighter or more stable the emulsion.

 Emulsion
Emulsification is that process of size reduction in which
two or more immiscible liquids are intimately mixed.

 Sufficient pressure drop through the mixing valve must

be maintained to create a good emulsion, but at the
same time a maximum pressure will make very strong
emulsion (e.g: as high as 4.6 kg/cm2)
 Process Variables of Cont.
 As ΔP increases, B, S & W will gradually increases.
 Operation Range = 0.35 – 1.75 kg/cm2
 Normal Range = 0.49 – 0.79 kg/cm2
 It can as high as 4.6 kg/cm2

 Particle size of most common emulsions is approximately

1 – 10 microns in dia.

 Such particles are not visible to the eye but are easily
resolved under a microscope.
 FIGURE 2-1

TYPICAL CURVES FOR A PARTICULAR CRUDE

B.S. & W AND SALT CONTENT
V.S.
MIXING VALVE P
(APPROXIMATE ONLY)
60

55

50

45
Salt Content of Effluent Crude - PTB.

40

35

30

25
Vol %
20 Salt Content 2.0

15 B.S. & W 1.5

10 1.0

5 0.5

0 0
0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0
ΔP Across Mixing Valve - kg/cm2
 Process Variables of Cont.
2. Quantity of water injected
 Water injection Range = 3 - 8 vol. % of current crude feed
rate.

 If less quantity is used, then desalting efficiency will reduce

due to the inability to contact all of the brine droplets.
 If too much quantity is used, then desalter may short out
or current flow will rise to the point where operation
becomes expensive.

 In this plant, the water injection rate for each desalter is

designed at approx. 5 vol. % on current crude feed rate.
 Process Variables of Cont.
3. Temperature
 As temperature increases, then conductivity will also
increases. Therefore, from this stand point, a lower
temperature is desirable but for good emulsion, viscosity
of crude must be kept below approximately 9 cst.

 Design Range = 129 ºC

 Operation Range = 105 – 130 ºC
 It can as high as 150 ºC
 Process Variables of Cont.
4. Conductivity
 As temp. increases, then conductivity will increases.
 As water injection increase, then conductivity will increases
until it reaches where desalter may short out.
 Conductivity becomes acceptable between pH of 6.5 – 8.5.
 The optimum pH is normally 7.0-7.5, but varies depending
upon the crude oil.

 Caustic (NaOH) is added as pH controller. In the high pH

ranges, the sodium naphthenates formed by the reaction of
caustic and naphthenic acids in the crude act as emulsion
stabilizers and the emulsion becomes very hard to break.
 Process Variables of Cont.
5. Voltage (A.C Supply)

 For good desalting, approximately 3000 volts per inch

of distance between electrodes is required.
 Voltage tapping for both Desalters = 12, 16 & 20 KV
 Normal 20 KV (20,000 volts) is tapped.
 If voltage is above 3000 volts per inch, then desalter
may short out or current flow will rise to the point
where operation becomes expensive.
 If voltage is below 3000 volts per inch, then
demulsification becomes poor.
 If conductivity increases, then it will also increase the
voltage.
 Process Variables of Cont.

6. Pressure

 Pressure should be high enough to prevent

vaporization within the desalter.

 An operating pressure of 1.4 - 3.5 kg/cm2 above the

vaporization pressure at a given temperature is normal.
Effective operation of Desalters

For the effective operation of desalters, we have

following facilities:

 Demulsifier with 3.0 ppm of crude feed rate is injected

at the start of crude pre-heat section & at the inlet of
2nd stage desalter.

 Mud washing facility is also provided for each deslater.

 Desalting Benefits
Effective desalting can provide following
benefits:

1. Longer runs.
2. Running at maximum capacity.
3. Less water quantity will be used.
4. Less cost for labor.
5. Less frequent turnarounds.
 Desalting Benefits
6. Less down time for maintenance.
7. Less corrosion, fouling, plugging, scaling,
coking and slugging of exchangers &
furnaces tube hot spots.
8. Less erosion by solids in control valves,
exchangers, pumps, and furnaces.
9. Less salt and solids in residual fuel.
10. Products will be improved by better
operational control.
 Major Equipments Cont.
 Flash Drum (Inlet 190 C)
 Heater (Inlet 255/265 & Outlet 363/371 C)
 Crude Distillation Column (Inlet 363/371 C)
 Strippers (Kerosene & SR. Diesel)
 Coalescers (Kerosene & SR. Diesel)
 Salt Dryer (SR. Diesel)
 Utilities Used at CDU
 Power
 Nitrogen
 BFW
 Demin Water
 LS, MS & HS Steam
 Instrument/ Plant Air
 Plant Water
 Cooling Water
 Fuel Oil / Fuel Gas
 Emergency Equipments
 Safety Valves & Flare System
 Car Sealed Valves
 Remote Operating Valve
 Instrument Alarms & Trips
 Emergency Shutdown Systems
 Safety Equipments
 Fire Fighting & Protective Equipments
 Emergency Booth
 Safety Showers & Eye Washers
 Fire Extinguishers & Foam Trolley
 Fire Hydrants & Monitors
 Deluge & Sprinkler System
 Fire Alarm System
 MAC points
 UV & IR Detectors
 HC & H2S Detectors