REFINARY OVERVIEW

Petroleum Refinery Overview

Introduction
Major Facilities in a Refinery are :
❖Crude Oil Receipt & Storage
❖Processing Units
❖Product Storage & Dispatch Facilities
❖Utilities Generation Facilities
❖Effluent Treatment & Flare System

Crude Oil Receipt & Storage
• Crude Oil Receipt
❖ Thru Ships / Marine Tankers for coastal refineries
❖ Thru pipeline for in-land refineries
• Crude Oil Storage
❖ Stored in Floating roof tanks
❖ Storage may be split into coastal & refinery site

Products Storage & Dispatch
• Intermediate & Finished Product Storage
❖ At refinery site & Mktg. Terminal
• Blending Facilities
❖ To produce different grades of products
• Finished Product Dispatch
❖ By Road
❖ By Rail
❖ By Pipeline
❖ By Ships / Marine Tankers
❖ In Drums / Cans

Utilities Generation Facility
• Water System
❖ Raw water receipt, storage & treatment
❖ Service water, Drinking water
❖ Cooling water
❖ DM water
• Steam, Power & Condensate System
• Compressed Air & Nitrogen Generation
• Fuel System
❖ Fuel Oil
❖ Fuel Gas / LPG vaporiser / LNG

Effluent Treatment & Flare
• ETP treats liquid effluents prior to disposal
❖ Treated effluents should meet MINAS standards
❖ No net effluents in case of Zero Discharge refineries
• Gaseous effluents are disposed off
❖ With or w/o treatment
❖ Through flare or directly
• Solid effluents are disposed by
❖ Incineration or
❖ Secured land fill
• Flare is used for disposal of all Hydrocarbon vapors &
acid gases

INTRODUCTION TO CRUDE OIL
• Elemental Composition
Element Wt%
C 84-87
H 11-14
S 0-2
N 0.2
• Degree API = 141.5 - 131.5
Sp Gr
• API Range of Crude Oils = 20 – 40

INTRODUCTION TO CRUDE OIL
• Classification of Crude
Based on API
0
API Crude Type
>= 40 Paraffinic
33 – 40 Intermediate
<= 33 Naphthenic
• Crude Chracterisation
Factor
K = (MABP) 1/3
Sp. Gr
K Crude Type
<= 11.5 Naphthenic
>= 12.1 Paraffinic
11.5 – 12.1 Intermediate

INTRODUCTION TO CRUDE OIL
• Sulphur Content - expressed as Wt% S in Crude
❖ Sour Crude S > 0.5%, Typically Requires Special Processing
❖ Sweet Crude S < 0.5%
• Salt Content - expressed as NaCl present in lb/ ‘000 barrel (ptb)
• Nitrogen Content - High Nitrogen is undesirable, basic nitrogen
destroys active sites of catalyst
• Metal Content - Metals are typ. Ni, V, Cu, Fe etc. Metal content may
vary from few PPM to 1000 PPM.

INTRODUCTION TO CRUDE OIL
• Typical Crude Classification
❖
❖
❖
❖
❖
❖
❖
❖
Light / Medium / Heavy Crudes
Low S / High S Crudes
Paraffinic / Naphthanic / Aromatic Crudes
Lube Bearing / Non Lube Bearing Crudes
Waxy / Non Waxy crudes
High TAN Acidic Crudes
Condensate
Bituminous / Tar Sands / Shale Oil

Refining Operations
Petroleum refining can be grouped into five basic areas:
1. Fractionation (Distillation) is the separation of crude oil into
different fractions based on their B.Pts.
2. Conversion processes change the size &/or structure of
hydrocarbon molecules. These processes include:
❖ Decomposition (dividing) by thermal and catalytic cracking;
❖ Unification (combining) through alkylation and polymerization; and
❖ Alteration (rearranging) with isomerization and catalytic reforming.
3. Treatment processes prepare hydrocarbon streams for additional
processing and to prepare finished products.
4. Formulating and Blending is the process of mixing and combining
hydrocarbon fractions, additives, and other components to produce
finished products with specific performance properties.
5. Other Refining Operations

RCO
VR
S-Block
Simplified Fuel Refinery Configuration
Crude
CDU
LPG
MS
SK / ATF
HSD
VDU
VGO
FCC
CLO
DCU
HCGO
Sour
Water
Rich
Amine
Sulphur
Str. SW
Lean
Amine
Coke

RCO
VR
Simplified Lube Block Configuration
LPG
Crude
CDU
VGO
RAFFINATE
DWO
MS
SK / ATF
HSD
VDU
SEU
SDU HFU LOBS
DAO
SLACK
WAX
DEOILED
WAX
SDA
EXTRACT
TO FO
WDU
WHFU
WAX
Pitch
FOOTS OIL

Refining Operations
Processing Type
Primary Processing
Secondary Processing
Residue Processing
Process Units
Crude & Vacuum Distillation
• Fluid Catalytic Cracking (FCC)
• Hydrocracking (OHCU or HCU)
• Delayed coking (DCU)
• LC Fining
• Visbreaking (VBU)
• Bitumen Blowing (BBU)
Treating Units
• FG Amine Treating ( FG ATU)
• LPG Caustic wash, LPG ATU, LPG Merox
• Naphtha Caustic wash, Merox, Hydrotreating
• MS Selective HDT, ISOM, Bensat
• Kero / ATF Merox, Extraction, HDT

Refining Operations
Processing Type
Treating Units
Process Units
• Diesel Hydrotreating (DHDS, DHDT)
• VGO Hydrotreating (VGO HDT)
• RCO Hydrotreating (ARDS)
• Vac. Residue Hydrotreating (VRDS)
Others
• Sour Water Stripping (SWS)
• Amine Regeneration (ARU)
• Sulphur Recovery (SRU)
Lube Units
• Solvent Extraction (SEU)
• Solvent Deasphalting (SDA)
• Solvent Dewaxing (SDU)
• Wax Deoiling
• Lube / Wax Hydrotreating

Overview of Petroleum Refining Processes
Process Action Method Purpose Feedstock(s) Product(s)
FRACTIONATION PROCESSES
Atmospheric
Distillation
(CDU)
Separation Thermal /
Boiling Point
Separate
fractions
Crude oil
Gas, LPG,
Naphtha,
SK/ATF,
HSD, RCO
Vacuum
Distillation
(VDU)
Separation Thermal /
Boiling Point
Separate
fractions
Atmospheric
tower bottoms
Vac. Gas oil,
Lube stock,
Residue

Overview of Petroleum Refining Processes
Process Action Method Purpose Feedstock(s) Product(s)
CONVERSION PROCESSES – CHAIN CLEVAGE
Fluid Catalytic
Cracking
(FCCU)
Conversion Catalytic Upgrade
Heavy
Oils
VGO, RCO,
VR, Cr. Hvy.
Oils
Gas, LPG,
Gasoline,
Diesel,
Petrochem
feedstock
Hydrocracking
(HCU)
Conversion
Catalytic in
presence of
Hydrogen
Upgrade
Heavy
Oils
VGO, Cr. Hvy.
Oils, Residue
Gas, LPG,
Naphtha,
SK/ATF,
HSD

Overview of Petroleum Refining Processes
Process Action Method Purpose Feedstock(s) Product(s)
CONVERSION PROCESSES – CHAIN CLEVAGE
Delayed Coking
(DCU)
Conversion Thermal Upgrade
Residue
RCO, VR
Gas, LPG,
Naphtha,
Kero,
Diesel
Visbreaking
(VBU)
Conversion Thermal Reduce
Viscosity
RCO, VR
Gas, LPG,
Naphtha,
Fuel Oil
Hydrogen
Steam
Reforming
Conversion Thermal /
Catalytic
Produce
Hydrogen
Gas, LPG,
Desulphurised
naphtha
Hydrogen

Overview of Petroleum Refining Processes
Process Action Method Purpose Feedstock(s) Product(s)
CONVERSION PROCESSES - UNIFICATION
Alkylation Combining Catalytic Unite olefins
& Isoparaffins
Iso-Butane,
Cracker
olefins
Iso-Octane
(Alkylate)
Grease
Compounding
Combining Thermal Combine
soaps & oil
Lube oil, fatty
acid, alkyl
metal
Lubricating
grease

Overview of Petroleum Refining Processes
Process Action Method Purpose Feedstock(s) Product(s)
CONVERSION PROCESSES – ALTERATION or REARRANGEMENT
Catalytic
Reforming
Alteration Catalytic Upgrade
low-octane
naphtha
SR & Cracked
naphtha
High Octane
Reformate /
Aromatics
Isomerisation Rearrangement Catalytic Convert
straight
chain to
branch
chain
C4 ~ C6
paraffins
Iso-butane /
Iso-pentane /
Iso-hexane

Overview of Petroleum Refining Processes
Process Action Method Purpose Feedstock(s) Product(s)
TREATMENT PROCESSES
Hydro-
Desulphurisation
Conversion Catalytic Reduce
sulphur
High S HC
Streams
Desulphurised
products
Hydrotreating Conversion Catalytic Remove
impurities,
saturate
HC’s
Residual,
Cracked HC’s
Distillates,
Lubes, Wax,
Cracker feed

Overview of Petroleum Refining Processes
Process Action Method Purpose Feedstock(s) Product(s)
TREATMENT PROCESSES
Amine
Treatment
Treatment Absorption Remove
H2S
Sour FG, Sour
LPG
Sweet FG,
LPG
Caustic Wash Treatment Conversion Remove
H2S,
Mercaptans
Sour LPG,
Naphtha, Kero
Sweet LPG,
Naphtha,
Kero

Overview of Petroleum Refining Processes
Process Action Method Purpose Feedstock(s) Product(s)
LUBE PROCESSES
Solvent
Extraction
Extraction Solvent Remove
aromatics
Vacuum gas oil
Raffinate &
Extract
(SEU)
Solvent
Deasphalting
Extraction Solvent Remove
asphaltenes
Vacuum
residue
DAO & Pitch
(SDA)
Solvent
Dewaxing
(SDU)
Relative
Solubility
Solvent
Remove
waxy
components
Raffinate from
SEU
LOBS &
Slack wax
Wax Deoiling
Relative
Solubility
Solvent Remove oil Slack wax from
SDU
Wax & Foots
oil

Refinery Products End Use
• Fuel Gas : Internal fuel firing & blanketing gas
• Liquefied Petroleum Gas (LPG) :
Domestic and industrial fuel & Petrochemical feedstock.
• Gasoline or Motor Spirit : Fuel for automobiles.
• Naphtha : Solvent or Fertiliser & Petrochemical feedstock.
• Aviation Turbine Fuel (ATF) : Aircraft fuel.
• Kerosene : Domestic fuel for stoves, lamps etc.
• High Speed Diesel (HSD) & Light Diesel Oil (LDO) :
Fuel for heavy vehicles. HSD is lighter & cleaner than LDO.
• Lube Oils / Greases : Lubrication of auto & industrial machinery.
• Waxes : Polishes, cosmetics, impregnation etc.
• Bitumen / Asphalt : Laying roads
• Fuel Oil : Fuel for industrial purposes
• Coke : Fuel or as anode grade coke in Aluminum industry

NEED TO UPGRADE QUALITY
• Improved product performance
• Environmental stipulations
• Emissions of toxics
• SOx and NOx Emissions
• Voc emissions
• Emissions of particulates
• Requirement of OEM’s

TARGET PRODUCTS
• Motor Spirit (MS)
• High Speed Diesel (HSD)
• Lubricating Oils
• Fuel Oil
✓ Requirement of environmentalists and original
equipment manufacturers

TECHNOLOGIES WITH EIL (REFINERIES)
GAS
CRUDE
DISTILLA
TION
GAS
AMINE TREATING
SULPHUR RECOVERY
LPG
SULPHUR
TREATING
NAPHTHA
NAPHTHA
LPG
TREATING
HYDROTREATING
GASOLINE
REFORMER
KERO/JET HYDROTREATING KEROSENE /ATF
VACUUM
DISTILLA
TION
FCC /
HCU
SO2 EXTRACTION
CAUSTIC WASH
HYDROTREATING
LUBE \ WAX BLOCK
EXTR’N/DEWAXING/DEOILING
HFU
DIESEL
LOBS
WAX
COKING/VISBREAKING
BITUMEN BLOWING
SOLVENT DEASPHALTING
FUEL OIL
COKE
ASPHALT
BITUMEN

Status of Indian Refineries
Crude Mix High Low
Sulphur
Sulphur
- India 52% 48%
- Reliance 95% 5%

Is Indian Refining Industry Competitive?
Average yield of light and middle distillates :
USA
90% (Approx.)
India 72.5%
Reliance
90% (Approx.)

Is Indian Refining Industry Competitive?
❖- GRMs for India presently around $6 – $7/bbl
GRMs for the World around $6 - $7/ bbl
With 72.5 % distillates, Indian refining is still
competitive with the World
Should distillates touch 88% – 90%, our
GRMs would increase phenomenonly

Performance of Refineries
Refinery
HPCL(M)
HPCL(V)
Imported HS
Crude %
2005-06
74
44.5
Light Ends
%
2005-06
18.1
27.3
Middle
Distillates %
2005-06
42.4
46.8
Heavy
Ends %
2005-06
30.7
18.8
BPCL
31.7
27.7
45.1
20.6
KRL
43.8
23.4
49.3
16.9
IOCL(J)
25.9
15.9
47.9
29.7
IOCL(M)
54.6
18.9
52.2
23.7
IOCL(H)
72.8
17.1
43.7
29.4
CPCL
69.8
18.7
48.3
23.1
MRPL
69.0
20.1
53.3
20.3

Typical Fuel & Loss Break-Up of Refinery
Basis : 100% HS Crude Processing & Captive Power Generation
A. Fuel & Loss (wt% on crude)
• Fuel gas 1.5 – 2.0 %
• Losses 0.5 – 1.0 %
• Fuel Oil 6.0 – 8.0 %
Total Fuel & Loss 8.0 – 11.0%
B. SOx Emission
Sulphur in IFO, wt% 1.0
Estimated SOx Emission, Tons/hr 1.25*
* Typical Sox Emission from Refineries is less than 1t/hr

Petroleum Refining Capacity of India
LOCATION
REFINERY CAPACITY, MMTPA
EXISTING YEAR 2007
Digboi 0.65 0.65
Guwahati 1.0 1.0
Barauni 4.2 6.0
IOCL
Koyali 12.5 12.5
Haldia 3.75 3.75
Mathura 8.0 8.0
Panipat 6.0 12.0
Paradip 0.0 9.0
Sub-Total 36.1 52.9
Mumbai 5.5 5.5
Visakh 7.5 7.5
HPCL Punjab 0.0 9.0
MRPL 9.6 9.6
Sub-Total 22.6 31.6
Mumbai 6.9 12.0
BPCL Bina 0.0 6.0
Sub-Total 6.9 12.0
Chennai 6.5 9.5
CPCL Narimanam 0.5 0.5
Sub-Total 7.0 10.0
KRL Kochi 7.5 13.5*
BRPL Bongaigaon 2.35 2.35
NRL Numaligarh 3.0 3.0
RPL Jamnagar 27.0 27.0
Essar Jamnagar 0.0 10.5
Nagarjuna Cuddalore 0.0 6.0
Total 112.45 174.85
Notes : 1. Year 2007 is end of X plan.
2. * Based on 6.0 MMTPA expansion planned for KRL.
3. Future Refineries.