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Igniting Minds... Energizing Lives… Haldia Refinery Presentation on LOBS. Hirak Dutta, General Manager(Technical) Haldia Refinery.

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Presentation on theme: "Igniting Minds... Energizing Lives… Haldia Refinery Presentation on LOBS. Hirak Dutta, General Manager(Technical) Haldia Refinery."— Presentation transcript:

1 Igniting Minds... Energizing Lives… Haldia Refinery Presentation on LOBS. Hirak Dutta, General Manager(Technical) Haldia Refinery

2 Igniting Minds... Energizing Lives… Haldia Refinery LUBRICANTS LUBRICANTS = BASE OILS + ADDITIVES BOTH MINERAL AND SYNTHETIC BASE STOCKS AND THEIR MIXURES ARE USED IN LUBRICANT FORMULATION MINERAL OILS PRODUCED / REFINED FROM CRUDE OILS ARE SINGLE COMMON SOURCE OF BASE STOCKS. LUBRICATING PROPERTIES OF BASE STOCKS ARE INFLUENCED BY  CRUDE SOURCE  REFINING PROCESSES

3 Igniting Minds... Energizing Lives… Haldia Refinery USE OF LUBRICANTS/BASE OILS ENGINE OILS GEAR OILS TRANSMISSION FLUID INDUSTRIAL APPLICATION CATALYST CARRIER OILS. WHITE OIL APPLICATION

4 Igniting Minds... Energizing Lives… Haldia Refinery FUNCTION OF LUBRICANTS MINIMISE FRICTION AND WEAR REMOVAL OF DEBRIS DISSIPATION OF HEAT ACT AS ELECTRIC INSULATOR PREVENTS RUSTING & CORROSION

5 Igniting Minds... Energizing Lives… Haldia Refinery LUBE BASE OILS FORMULATION OF LUBRICATING OILS HAS BECOME VERY COMPLEX-  OEM ( ORIGINAL EQUIPMENT MANUFATURER) REQUIREMENT  GOVERNMENT REGULATION  EFFICIENT USE  ENERGY CONSERVATION  ENVIRONMENT CONCERN  CHANGING PRODUCT SPECIFICATIONS  EXPANDING VAST MARKET.

6 Igniting Minds... Energizing Lives… Haldia Refinery REQUISITE PROPERTIES APPROPRIATE VISCOSITY HIGH VISCOSITY INDEX LOW POUR POINT LOW VOLATILITYAND HIGH FLASH POINT GOOD THERMAL AND OXIDATION STABILITY HIGH HEAT CAPACITY GOOD THERMAL CONDUCTIVITY NON CORROSIVE, OILINESS AND WETABILITY

7 Igniting Minds... Energizing Lives… Haldia Refinery LUBE BASE OILS ALL BASE OILS DO NOT POSSESS SIMILAR PHYSICO CHEMICAL PROPERTIES OR PROVIDE EQUIVALENT ENGINE OIL PERFORMANCE. API ( AMERICAN PETROLEUM INSTITUTE) CLASSIFIED ALL BASE STOCKS IN FIVE GROUPS ON THE BASIS OF SATURATES VISCOSITY INDEX(VI) SULFUR CONTENT

8 Igniting Minds... Energizing Lives… Haldia Refinery API BASE OIL CLASSIFICATION VISATURATES % SULPHUR % GROUP I <90>0.03 GROUP II >90<0.03 GROUP III >120>90<0.03 GROUP IV POLY ALFA-OLEFINS (SYNTHETIC ORIGIN) GROUP V NOT INCLUDED IN ABOVE FOUR – VEGETABLE OILS, ESTERS ETC.

9 Igniting Minds... Energizing Lives… Haldia Refinery LUBE BASE OILS LUBE PROCESSING REQUIREMENT IS A FUNCTION OF  HYDROCARBON STRUCTURE OF FEED  TARGET PROPERTIES OF FINISHED BASE OILS

10 Igniting Minds... Energizing Lives… Haldia Refinery HYDROCARBON STRUCTURE STRUCTUREV IPOUR PTINTEREST N-PARRAFINVERY HIGHHIGHLOW ISO-PARAFFINHIGHLOWHIGH NAPHTHENEMEDIUMLOWHIGH AROMATICSLOW CONDENSED /POLAR VERY LOW--LOW

11 Igniting Minds... Energizing Lives… Haldia Refinery Lube Composition and Properties n - Paraffins i - Paraffins mono - Naphthenes di & higher Naphthenes mono - Aromatics di - Aromatics tri & higher- Aromatics Molecular weight KV VI Pour Point VI

12 Igniting Minds... Energizing Lives… Haldia Refinery Lube Base Oils – PROCESSING: THREE MAIN STEPS FOR LUBE PROCRSSING:  LIQ-LIQ EXTRN. TO INCREASE VI  DE-WAXING TO REDUCE PP  FINISHING TO IMPROVE COLOUR AND OXIDATION STABILITY

13 Igniting Minds... Energizing Lives… Haldia Refinery TREATING / REFINING FOR LUBE PROCESSING SOLVENT EXTRACTION SOLVENT DEWAXING API GROUP I HYDRO-FINISHING WAX CATALYTIC DEWAXING API GROUP IHYDRO-FINISHING RAFF. HYDRO- CONVERSION SOLVENT DEWAXING HYDRO-FINISHING API GROUP I HYDRO-FINISHING WAX RAFF. HYDRO- TREATING HYDRO- ISOMERISATION HYDRO-FINISHING API GROUP I,II SOLVENT DEWAXING WAX ISOMERISATION API GROUP III

14 Igniting Minds... Energizing Lives… Haldia Refinery TREATING / REFINING FOR LUBE PROCESSING LHDC HYDRO - ISOMERISATION API GROUP II,III HYDRO-FINISHING WAX FHDC SOLVENT DEWAXING API GROUP II HYDRO-FINISHING

15 Igniting Minds... Energizing Lives… Haldia Refinery Gr I and Gr II Processing - Comparison

16 Igniting Minds... Energizing Lives… Haldia Refinery Igniting Minds... Energizing Lives… Haldia Refinery BASE OIL PRODUCT QUALITY- KEY REQUIREMENTS Viscosity VI Pour Point Colour Oxidative Stability Thermal Stability Anti-Wear Performance Minimise Sludging Better Solvency Lower Volatility

17 Igniting Minds... Energizing Lives… Haldia Refinery Igniting Minds... Energizing Lives… Haldia Refinery EFFECT OF MANUFACTURING PROCESS ON PROPERTIES OF BASE OILS

18 Igniting Minds... Energizing Lives… Haldia Refinery API BASE OIL CHARACTERISATION GROUPS Viscosity Index Saturates % wt Sulphur %wt GROUP I <90>0.03 GROUP II >90<0.03 GROUP III >120>90<0.03 GROUP IV Poly Alpha Olefins(Synthetic Oils) GROUP V All other base oils

19 Igniting Minds... Energizing Lives… Haldia Refinery Haldia Gr-I & Gr-II LOBS Comparison GradeKV (cSt)VI (min.)Pour Point (max) GR I 150N28-32 (40oC) N10 (100oC)95-6 HN13.5 (100oC)92-3 BN32 (100oC)92-3 GR II 70N (40oC) N (40oC) N (40oC)95 (105) BS30 (100oC)95-6

20 Igniting Minds... Energizing Lives… Haldia Refinery Igniting Minds... Energizing Lives… Haldia Refinery Gr-I & Gr-II LOBS Processing: Comparison Hydro- finishing Solvent De-waxing Solvent Extraction Hydro Treating Wax Isomeris ation Hydro- finishing Group-IGroup-II VI Pour Point

21 Igniting Minds... Energizing Lives… Haldia Refinery HALDIA LUBE BLOCK

22 Igniting Minds... Energizing Lives… Haldia Refinery Igniting Minds... Energizing Lives… Haldia Refinery Simple Block Flow Diagram of Haldia Refinery

23 Igniting Minds... Energizing Lives… Haldia Refinery Igniting Minds... Energizing Lives… Haldia Refinery Vacuum Distillation Unit Purpose: To Vacuum Distill RCO from Crude Distillation Unit. Vac.Distillate is feed stock for LOBS units or FCCU. Products: GAS OIL ---- Diesel Component. Spindle Oil ---- Diesel Component or H-70 LOBS feed stock. Light Oil N grade LOBS feed stock or FCCU feed. Inter Oil N grade LOBS feed stock or FCCU feed. Heavy Oil N grade LOBS feed stock or FCCU feed. Vac. Residu ---- Feed stock for PDA unit. Quality Monitoring : K. V at 100 0C, Flash Point, Density.

24 Igniting Minds... Energizing Lives… Haldia Refinery Igniting Minds... Energizing Lives… Haldia Refinery Product Quality of Distillate & Short Residue StreamBoiling Range.0C 15 0C Fl. Point 0C C %SCCR wt% Gas Oil at Spindle oil Light oil Inter oil Hy. oil Short Residue

25 Igniting Minds... Energizing Lives… Haldia Refinery Igniting Minds... Energizing Lives… Haldia Refinery Major Operating Conditions RCO feed temp : deg C Preheat Temp : 285 deg C Coil Outlet Temp : 400 deg C Vac Tower Flash Zone Pr mm Hg at 400 dec C Vac Tower Top Temp : 80 deg C Stripping Steam : Mt/hr Furnace recycle : 11 m3/hr Pump around : from 300 deg C to 228 deg C Product Draw off temp : 232, 245, 333 & 370 for SO,LO, IO & HO Bottom Quench : 5 m3/hr

26 Igniting Minds... Energizing Lives… Haldia Refinery PROPANE DE-ASPHALTING UNIT Feed Stock: Vac. Residue from VDU. Product: De- Asphalted Oil. Asphalt for production of Bitumen. Quality Monitoring: DAO ---K.V at 100 o C, Flash Point Asphalt --- Penetration.

27 Igniting Minds... Energizing Lives… Haldia Refinery ROSE : Residium Oil Supercritical Extraction -- Feed & Product Quality Technology Licensed by M.W. Kellog Technology Co. USA Design : MT/Yr Feed Quality : 15.5 deg C : 1.01/ deg C : 800/2500 Flash Point : 320 min CCR, wt % : 20/23 % S : 4.3/4.5 Product Quality : Sp Gr deg C: 30-35/40-45 CCR wt% : 2.2 max Fl Point, deg C : 320 min

28 Igniting Minds... Energizing Lives… Haldia Refinery Igniting Minds... Energizing Lives… Haldia Refinery Major Operating Parameters- PDA ROSE  Feed Temp : 130 deg C  First & 2 nd Dilution : 0.5:1 by volume of propane in each  Total Dilution : 12: 1 (propane : feed by volume  Extraction top Pr : 38 kg/cm2G  Top/Bot temp : 68/52 deg C  DAO separator : 43.6 kg/cm2 g pr. & 102 deg C temp

29 Igniting Minds... Energizing Lives… Haldia Refinery Extraction Process Best Solvent Property Selective power High Solvent Power Low Lt-Hy selectivity and high group selectivity Boiling point difference with feed Low melting point Good gap in density between oil & solvent Low surface tension high thermal chemical stability Low toxicity, Flammability & corrosivity Low latent heat & sp. Ht low viscosity at working temp High bio degradability

30 Igniting Minds... Energizing Lives… Haldia Refinery SOLVENT EXTRACTION UNIT. FEU/NMPEU Feed stock Vac. Distillate from VDU & DAO from PDA unit. Purpose To extract aromatics from distillates to improve VI of LOBS using Furfural/NMP as solvent. Products: Raffinate for further processing of LOBS & Aromatic extract. Quality Monitoring: Raffinate: K.V at 100 oC, RI, CCR Extract : Density.

31 Igniting Minds... Energizing Lives… Haldia Refinery FEU/NMPEU : Yield, Feed & Product Quality, Major Operating Conditions Operating ConditionsFEUNMPEU Raffinate Yield, %wt Feed Rate, m3/hr Extraction temp. Gradient Solvent:Feed Ratio :11.93/2.22:1 Top Temp, deg C Bottom Temp, deg C Extractor Pr, kg/cm2g Raff/Ext Furnace COT185/225270/290 Extract Flash Col Pr.,kg/cm2g0.5/1.50.6/1.2/1.5 Raffinate/Ext. Vaccum Flash Col. Pr, mmHg 200/220350/300 Water in SolventReduces solvent powerAnti Solvent

32 Igniting Minds... Energizing Lives… Haldia Refinery Solvent De-waxing Unit Feed Stock : Raffinate Ex- FEU. Product : De-waxed Oil & Slack Wax. Quality Monitoring: DWO : Pour Point, Flash Point, KV at 100oC & 40 oC Slack Wax : Flash Point.

33 Igniting Minds... Energizing Lives… Haldia Refinery Solvent Dewaxing Unit Objective To remove paraffinic hydrocarbons to the extend that the Lube based stock produced will have enough low pour point to make it suitable for low temp application The Process Extraction and crystallisation to achieve dewaxing with the addition of SDA followed by filtration & Solvent Recovery Solvent : MEK & Toluene in equal proportions. Toluene is oil solvent & MEK is anti wax solvent. Feed characterised by density, Kin. Visc & RI LOBS Product characterised by density, Pour Pt, VI, Flash Point, CCR,Kin Visc.

34 Igniting Minds... Energizing Lives… Haldia Refinery Solvent Dewaxing Unit Good Qualities of Dewaxing Solvent Blends: High solvent Power for oil & Low Solvent power for wax Low visc. at operating temperature to get low pressure drop & to help in precipitation /crystallization Good Filterability Low Freezing point & temperature effect of Dewaxing High thermal/chemical stability Boiling point much lower than that of feed Low latent heat/specific heat

35 Igniting Minds... Energizing Lives… Haldia Refinery Igniting Minds... Energizing Lives… Haldia Refinery Lube Hydrofinishing Unit Feed Stock : DWO from SDU. Catalyst : HR 348 supplied by Procatalyse.High purity Alumina extrudates impregnated with Nickel and Molybdenum oxides Purpose: To improve color by removing Sulphur,Oxygen & Nitrogen in a reactor with Cobalt / Moly catalyst. Quality Monitoring: Color, K.V at 100 oC, VI.

36 Igniting Minds... Energizing Lives… Haldia Refinery Lube Hydrofinishing Unit Major reactions : Hydrodesulphurization, Mild hydrodenitrogenation, Olefins hydrogenation, mild aromatic hydrogenation, decomposition of heteromolecules. Sulphur is usually present as mercaptan, sulphides, disulphide and thiophenic sulphur. Sulphur is removed as H2S. Nitrogen is usually present as Ammines and pyrrole, pyridine etc. More difficult reaction and ultimate product is hydrocarbon & ammonia. Olefins are present in low quantity & most of them are saturated during hydro finishing. Normally aromatics are not hydrogenated. Due to liberation of some aromatics rings towards the light compounds are stripped off to reach the required flash point. Thus results in slight VI improvement also. Oxygenated compounds are mostly removed in the solvent extraction step. If any remaining removed as water. As a result, color & color stability improves, mild VI improvement occurs

37 Igniting Minds... Energizing Lives… Haldia Refinery Hydro finishing Unit : Main operating Variables : Temperature: optimum to achieve desulphurization. Lower the temp, higher is the product viscosity & yields Partial Pressure of Hydrogen : Increase favors the reaction & reduces coke by avoiding polymerization reaction. Can be modified by change in total pressure and recycle ratio. Total pressure kept maximum compatible with the equipment Space Velocity : Hourly volume flow rate of feed wrt to the catalyst volume. Lower is the space velocity higher the severity. ( m3 of feed per m3 of catalyst) Mole ratio of hydrogen/hydrocarbon: Includes quantity needed for hydro finishing + quantity which increases the partial pressure of hydrogen Feed quality: Higher the impurities higher the severity

38 Igniting Minds... Energizing Lives… Haldia Refinery Hydro finishing Unit Operating Parameters Reactor inlet temp : deg C Reactor outlet temp : 360 H2 partial pr. At reactor outlet : 45 kg/cm2g Space velocity : 0.84 to 1.45 m3 of feed per m3 of catalyst H2 recycle : 153 liters of pure H2 per litre of oil feed at 15 deg C Absorber (C-1) : 35.5 kg/cm2g/62.5 deg C Stripper, (C-2) : 0.25 kg/cm2g /250 deg C Vacuum Drier (C-3): 50 mm of Hg/249 deg C 1 st HP Separator (B-2) : 66.5 kg/cm2g/250 deg C 2 nd HP Separator (B-3) : 65.5 kg/cm2g/50 deg C LP Separator (B-4) : 5.0 kg/cm2g/250 deg C

39 Igniting Minds... Energizing Lives… Haldia Refinery Wax Hydrofinishing Unit Capacity : T/yr Feed & Product Quality : FeedProduct ASTM Colour<7.5<2.0 Sulphur,(wt%) <0.12(Acidity) N(ppm)20-40Nil CCR UV absorbance<0.02 to < 0.15 at various spectra wave length Saponification value<1.0

40 Igniting Minds... Energizing Lives… Haldia Refinery Igniting Minds... Energizing Lives… Haldia Refinery Wax Hydrofinishing Unit Reactor inlet/outlet pr. : 135.5/134 kg/cm2g Reactor inlet/outlet temp : 300 def C Liquid Hourly space velocity : 0.25 hr-1 Hydrogen Partial pressure : 100 kg/cm2g Hydrogen to Hydrocarbon mole ratio : >500 Hot HP separator : 180 deg C/132 kg/cm2g COld HP separator : 40 deg C/131.7 kg/cm2g HP Purge : 36 deg C/66 kg/cm2g LP Seperator : 185 deg C/6.0 kg/cm2g LP Purge : 40deg C/4.4kg/cm2g Liquid in to stripper : 185deg C/0.3 kg/cm2g Liquid MCW ex drier : 180deg C/0.082 kg/cm2g

41 Igniting Minds... Energizing Lives… Haldia Refinery HydroTreatment Reactions Removal of impurities: –Hydro-desulfurization (HDS) –Hydro-denitrification (HDN) –Removal of metals – Ni, V (HDM) Improvement in quality –Hydrogenation of Olefins (HDO) –Hydrogenation of aromatics – mono & poly (HDA) Value addition thru’ increase in H:C ratio; Improvement in CCR(%wt.), VI (in case of lube base stock processing) All these desirable HDT reactions are exothermic

42 Igniting Minds... Energizing Lives… Haldia Refinery HydroTreatment Operating Parameters -Primary H 2 Partial Pressure Temperature LHSV –Secondary Recycle gas rate H 2 S partial pressure

43 Igniting Minds... Energizing Lives… Haldia Refinery Hydro Treatment Operating Parameters Hydrogen Partial Pr. Also called Cold Hydrogen Partial Pressure. Not a direct operating variable; fixed at the time of design Defined as the partial pressure of hydrogen in gas phase at the outlet of last reactor. Under normal operation, depends on : –Total pressure maintained at the HP Separator Controlled by: Intake of fresh make/up hydrogen in balance with hydrogen consumed in reaction and purged from the system to maintain recycle gas purity –Recycle gas purity Depends on non-condensable components generated in rxn. which needs to be purged from recycle gas from Recycle Compressor suction

44 Igniting Minds... Energizing Lives… Haldia Refinery Hydro Treatment Operating Parameters LHSV Liquid Hourly Space Velocity: m 3 of fresh feed (at 15°C) per hour per m 3 pf catalyst Significance: –Lower LHSV at design feed rate Allows greater residence time / contacting time of feed in catalyst. Lesser temperature requirement for same extent of reaction. More cycle life Requires higher catalyst & reactor volume – higher initial investment In operation: Will change with change in feed rate For consistent product quality, to be compensated by adjusting reactor temperature Temperature adjustment with change in LHSV as per correlation specified by licensor.

45 Igniting Minds... Energizing Lives… Haldia Refinery HydroTreatment Operating Parameters:Temperature Temperature - main control variable Most sensitive effect on reaction severity Greater variability as compared to other parameters provided by unit design Action on chemical reactions: From a kinetic point of view, when temperature increases, the rate of all the chemical reactions increases, i.e. both the desirable and the undesirable reactions. From a thermodynamic point of view, desirable reactions are exothermic, thus favored by a decrease in temperature Reactions that break carbon-heteroatom bonds (HDS, HDN, HDM) can be complete under appropriate conditions Olefin hydrogenation, though reversible, can also be complete under appropriate conditions Aromatic saturation is reversible and can reach thermodynamic equilibrium Rise in temperature beyond certain point leads to dehydrogenation rate surpassing hydrogenation rate – increase in aromatic concentration Limiting temperature can be shifted to higher level by increasing H2 partial pressure

46 Igniting Minds... Energizing Lives… Haldia Refinery VISCOSITY – VI RELATIONSHIP Temperature Viscosity Paraffin Naphthene Aromatics Temperature Viscosity L U H 0 VI 100 VI Sample

47 Igniting Minds... Energizing Lives… Haldia Refinery HydroTreatment Operating Parameters Temperature Temperature Limit for Hydrogenation of Aromatics % aromatics in HDT product Temperature (°C) Monoaromatics Di aromatics Poly Aromatics (Gas oil – on NiMo/alumina, P H2 =60bar)

48 Igniting Minds... Energizing Lives… Haldia Refinery Igniting Minds... Energizing Lives… Haldia Refinery HydroTreatment Operating Parameters Temperature Interbed Quench T Reactor inlet temp. Fuel T TT Reactor feed Reactor product Reactor temperature control: Factors: Furnace outlet / Reactor inlet temperature Bed delta T Weighted Average Bed Temperature (WABT / WART) Inter-bed quench Rx Heater o/l temp Bed del T

49 Igniting Minds... Energizing Lives… Haldia Refinery Igniting Minds... Energizing Lives… Haldia Refinery HydroTreatment Operating Parameters Temperature Reactor temperature control Weighted Average Bed Temperature (WABT / WART) Convenient single point target parameter

50 Igniting Minds... Energizing Lives… Haldia Refinery Igniting Minds... Energizing Lives… Haldia Refinery HydroTreatment Operating Parameters Temperature Reactor temperature control –WABT / WART controlled by simultaneous control of Reactor inlet temperature Individual bed inlet temperature by regulation of inter bed quench –Additional guidelines: Under normal steady operations, keep the reactor bed outlet temperatures equal for all beds to get better catalyst life. This may require different inlet temperature for different beds; Greater exothermicity in inlet bed – hence lower inlet temp for that bed. Max. allowable delta T across bed specified by designer, normally not more than 20°C

51 Igniting Minds... Energizing Lives… Haldia Refinery Igniting Minds... Energizing Lives… Haldia Refinery HydroTreatment Operating Parameters Catalyst Ageing Catalyst deactivation / aging: –SOR – Start of run & –EOR – End of run temperatures are specified by tech. licensor / catalyst vendor. –Graphical monitoring of progress of reactor temperature on daily basis required to estimate extent of aging of catalyst Actual operating temperatures are normalized for feed quality, t’put and product quality variations and plotted against time Useful for predicting regeneration or catalyst replacement requirement; to know about sudden loss of activity due to process upset

52 Igniting Minds... Energizing Lives… Haldia Refinery Igniting Minds... Energizing Lives… Haldia Refinery HydroTreatment Operating Parameters ReCycle Gas rate Expressed as ratio of Normal cubic meters of hydrogen recycled (excluding quench) to volumetric flow rate of feed in cubic meter at 15°C Significance: –Maintains adequate H 2 partial pressure –Generates turbulence required for proper contacting of feed with catalyst and for better heat transfer in exchangers and heaters –Absorbs reaction heat from exothermic rxns; moderates delta T across cat. bed. Gives better cycle life of catalyst Requirement higher for heavier feeds

53 Igniting Minds... Energizing Lives… Haldia Refinery Igniting Minds... Energizing Lives… Haldia Refinery HydroTreatment :Other Operating Parameters Wash water injection –H 2 S & NH 3 generated from HDT rxn react to form NH4SH type salts which get deposited in cold parts of recycle loop, especially air cooler tubes –To be washed with water injected at air cooler inlet –Wash water injection at least 5 wt % of feed and ammonium salt conc. In HP separator boot water not to exceed 4% from corrosion consideration Amine absorption Steady amine flow rate and concentration to be maintained for effective control over recycle gas H 2 S content Lower amine temp favors better H 2 S absorption, but may also cause hydrocarbon condensation – which leads to foaming in absorber Optimum amine supply temperature to absorber column = 10°C less than Gas inlet temp. Periodic skimming of accumulated oil in absorber bottom to be done to prevent foaming. Foaming in absorber is indicated by sudden fluctuation in column pressure drop

54 Igniting Minds... Energizing Lives… Haldia Refinery Igniting Minds... Energizing Lives… Haldia Refinery HydroTreatment :Quality Parameters Product compositional characteristics: –Sulfur content –Nitrogen contentFeed to HDW –Metal content –Aromatics content Other characteristics –CCR –Viscosity Index of finished Lube Base Oil

55 Igniting Minds... Energizing Lives… Haldia Refinery CIDW unit, The process Hydro treatment of feed De-Waxing Hydro finishing Recovery Igniting Minds... Energizing Lives… Haldia Refinery

56 Igniting Minds... Energizing Lives… Haldia Refinery Hydro treatment of feed Purification of Feed Removal of S, N S + H2  H2S + Q N2 + 3H2  2 NH3 + Q S, N are poison to De-Waxing Catalyst Side Reactions: Cracking Saturation of Unsaturates Igniting Minds... Energizing Lives… Haldia Refinery

57 Igniting Minds... Energizing Lives… Haldia Refinery Hydro treatment of feed Feed + H2S, N free feed + H2 + HC +H2S + NH3 Igniting Minds... Energizing Lives… Haldia Refinery R 01 High Temperature, High Pressure Exothermic reaction

58 Igniting Minds... Energizing Lives… Haldia Refinery Hydro treatment Reactor (R 01) Three catalyst beds Total catalyst Volume m3 EM-7420 Ni-Mo Hydrogenation Catalyst Operating Variables: Temperature Hydrogen circulation and partial pressure Space velocity Igniting Minds... Energizing Lives… Haldia Refinery

59 Igniting Minds... Energizing Lives… Haldia Refinery Hydro treatment Reactor (R 01) Operating Conditions Igniting Minds... Energizing Lives… Haldia Refinery ATTRIBUTE 100 N150 N500 N500 N w/ 500 SW 500 SW150 BS HDT Temp, in/out (deg C) SOR EOR 302/ / / / / / / / / / / /391 *HDT Pres, (kg/cm 2 -A) Inlet Outlet

60 Igniting Minds... Energizing Lives… Haldia Refinery How to get rid of H2S, NH3? H2S absorbed in Lean diethyl amine solution C 02  Amine absorption Column NH3 absorbed in water C 03  Wash Water scrubber Recycle Treated Gas back to the system using Recycle compressors

61 Igniting Minds... Energizing Lives… Haldia Refinery De-Waxing Conversion of N paraffins to Iso Paraffins N paraffins  Waxy in Nature Iso Paraffins  Non – Waxy Isomerization Side Raections Cracking Saturation of unsaturates

62 Igniting Minds... Energizing Lives… Haldia Refinery De-Waxing R 02 Clean feed Ex R 01 + Treated H2 Low pour point product + H2 + HC High Temperature High Pressure Highly Exothermic Reactions

63 Igniting Minds... Energizing Lives… Haldia Refinery De-Waxing Reactor, R 02 Three catalyst beds Total catalyst volume = 40.8 m3 Bed 1 – EM Pt/Pd Hydrogenation catalyst for HDS, HDN and aromatic saturation. Bed 2&3 - EM-7300 Pt. Isomerisation Catalyst Operating Variables: Temperature Hydrogen circulation and partial pressure Space velocity

64 Igniting Minds... Energizing Lives… Haldia Refinery De-Waxing Reactor, R 02 Operating Conditions Igniting Minds... Energizing Lives… Haldia Refinery ATTRIBUTE 100 N150 N500 N500 N w/ 500 SW 500 SW150 BS MSDW Temp, in/out (deg C) SOR EOR 304/ / / / / / / / / / / /388 *MSDW Pres, (kg/cm 2 -A) Inlet Outlet

65 Igniting Minds... Energizing Lives… Haldia Refinery Hydrofinishing Product stabilization through saturation of poly nuclear aromatics Improvement in Color Igniting Minds... Energizing Lives… Haldia Refinery

66 Igniting Minds... Energizing Lives… Haldia Refinery Hydrofinishing Reactor, R 03 Low pour point product + H2 + HC Hydro finished product + H2 + HC High Temperature High Pressure Mild Exothermic

67 Igniting Minds... Energizing Lives… Haldia Refinery Hydrofinishing Reactor, R 03 Two catalyst Beds Total catalyst volume = 27.2 m3 EM Pt/Pd Aromatic saturation Igniting Minds... Energizing Lives… Haldia Refinery

68 Igniting Minds... Energizing Lives… Haldia Refinery Hydrofinishing Reactor, R 03 Operating Conditions Igniting Minds... Energizing Lives… Haldia Refinery ATTRIBUTE 100 N150 N500 N500 N w/ 500 SW 500 SW150 BS HDF Temp, in/out (deg C) SOR EOR 247/ / / / / / / / / / / /29 1 *HDF Pres, (kg/cm 2 -A) Inlet Outlet

69 Igniting Minds... Energizing Lives… Haldia Refinery Control Of Reaction Exotherm Quench --Cold recycle hydrogen flow to all reactor beds

70 Igniting Minds... Energizing Lives… Haldia Refinery Igniting Minds... Energizing Lives… Haldia Refinery CATALYTIC DEWAXING:GENERAL FLOWSHEET Purge Make Up hydrogen Product Fractionation Section Naphtha Diesel Group III LOBS Product Separator Hydrotreater Effluent Scrubbing Section Hydrotreating CDW Hydrofinishing Recycle Feed

71 Igniting Minds... Energizing Lives… Haldia Refinery Igniting Minds... Energizing Lives… Haldia Refinery HALDIA CDWU High Pr. Feed/Reactor Section

72 Igniting Minds... Energizing Lives… Haldia Refinery Igniting Minds... Energizing Lives… Haldia Refinery HALDIA CDWU Low Pressure Recovery Section

73 Igniting Minds... Energizing Lives… Haldia Refinery Igniting Minds... Energizing Lives… Haldia Refinery HALDIA CDWU Operating Parameters WART, HDT, degC WART, HDW, deg C WART, HDF, deg C LHSV, sec Operating pr, kg/cm2g

74 Igniting Minds... Energizing Lives… Haldia Refinery Igniting Minds... Energizing Lives… Haldia Refinery YIELD PATTERN OF CATALYTIC DEWAXING UNIT HALDIA

75 Igniting Minds... Energizing Lives… Haldia Refinery Lube Base Oil Product Qualities GradeKV (cSt)VI (min.)Pour Point (max) GR I 150N (40oC) N 10 (100oC)95-6 HN 13.5 (100oC)92-3 BN 32 (100oC)92-3 GR II 70N (40oC) N (40oC) N (40oC)95 (105) BS 30 (100oC)95-6

76 Igniting Minds... Energizing Lives… Haldia Refinery Group I grade LOBS Group II grade LOBS GROUP – I / GROUP – II LOBS

77 Igniting Minds... Energizing Lives… Haldia Refinery

78 Igniting Minds... Energizing Lives… Haldia Refinery NEW GENERATION LUBRUCANT WILL REQUIRE LUBRICANTPERFORMANCE REQUIRED BASE STOCK PROPERTY NEEDED ENGINE OILSLOW EMMISSIONS, LOW OIL CONSUMPTION FUEL ECONOMY EXTENDED DRAIN LOW VOLATILITY AT LOW VISCOSITY LOW VISCOSITY & HIGH VISCOSITY INDEX OXIDATION STABILITY GEAR OILSFILL FOR LIFE FUEL ECONOMY OXIDATION STABILITY HIGH VISCOSITY INDEX(GR-III) TRANSMISSION FLUID EXCELLENT FLUIDITY FUEL ECONOMY HIGH VISCOSITY INDEX(GR-III) LOW VISCOSITY, LOW VOLATILITY

79 Igniting Minds... Energizing Lives… Haldia Refinery THANK YOU

80 Igniting Minds... Energizing Lives… Haldia Refinery BASE OIL TRENDS Market share (%) s2000 API Gr I API Gr II Others Lesser availability of lube bearing crude Better fuel economy, improved performance and extended drainage Impact on environment

81 Igniting Minds... Energizing Lives… Haldia Refinery ADDITIVES Required to impart or enhance desired properties of oils. Dispersants Detergents Oxidation inhibitors Rust and corrosion inhibitors Viscosity Index improvers Pour Point depressants Foam Inhibitors Anti-wear Agents/Friction modifiers

82 Igniting Minds... Energizing Lives… Haldia Refinery LOBS Manufacture by HydroProcessing Alternative Route-I Vacuum distillation Propane De-Asphalting Gas Naphtha Kero Diesel RCO Vacuum Distillates Waxy Raffinate De-waxed oils VGO KV, Flash Point VI, CCR Pour Point Colour & Stability Lube HydroTreater 150N 500N 150BS Catalytic Dewaxing Unit 70N/100N Gr-II LOBS HydroFinishing Unit

83 Igniting Minds... Energizing Lives… Haldia Refinery LOBS Manufacture by HydroProcessing Alternative Route-II Vacuum distillation Propane De-Asphalting Gas Naphtha Kero Diesel RCO Vacuum Distillates De-waxed oils VGO KV, Flash Point VI, CCR Pour Point Colour & Stability Hydro Cracker 150N 500N 150BS Catalytic Dewaxing Unit 70N/100N Gr-II LOBS HydroFinishing Unit Vacuum Distilled HydroCrac kate Residue

84 Igniting Minds... Energizing Lives… Haldia Refinery Igniting Minds... Energizing Lives… Haldia Refinery FUNCTIONS OF LUBRICATING OIL REDUCE FRICTION &WEAR PREVENT SCUFFING & SEIZURE OF MOVING PARTS. REMOVE HEAT FROM CONTACT SURFACE. PREVENT RUST & CORROSION. PREVENT EXCESSIVE DEPOSITS & SLUDGE FORMATION DISPERSION OF GENERATED CONTAMINANTS MAINTENANCE OF WATER SEPARABILITY & EMULSIBILITY MAINTENANCE OF SEALING IN CRITICAL PARTS. MAINTENANCE OF RESISTANCE TO DEGRADATION IN PRESENCE OF OXYGEN & CATALYTIC MATERIALS.

85 Igniting Minds... Energizing Lives… Haldia Refinery Igniting Minds... Energizing Lives… Haldia Refinery Vacuum Distillation Unit PFD (preheat and product cooling section )

86 Igniting Minds... Energizing Lives… Haldia Refinery Igniting Minds... Energizing Lives… Haldia Refinery Vacuum Distillation Unit PFD (furnace and fractionator circuit)

87 Igniting Minds... Energizing Lives… Haldia Refinery Vacuum Distillation Unit PFD Vacuum System

88 Igniting Minds... Energizing Lives… Haldia Refinery FILTRATION & CHILLING SECTION OF SOLVENT DEWAXING UNIT

89 Igniting Minds... Energizing Lives… Haldia Refinery Igniting Minds... Energizing Lives… Haldia Refinery PAGE:1 of 3 Feed to Unit E-1 E-2 E-2A/B LC-01 C-1 C-2 CW Steam CW Atm J-1 #1 VM steam Ex P-8/8R or P-9/9R To E-13b or E-8 VS steam 33P-1/1R 33P-2/2R E-15 CW #3 To P-3/2R via B-1 To E-4A/B O/L E-3 CW TC-12 E-9 P-6/6R E-8 CW E-10B B-11 Ex P-12B Raffinate Mix Extract Mix to C-5 Via E-10A Furfural Ex C-9 Bot P-11/11R FURFURAL EXTRACTION UNIT Extractor Section

90 Igniting Minds... Energizing Lives… Haldia Refinery Igniting Minds... Energizing Lives… Haldia Refinery FURFURAL EXTRACTION UNIT (U-33) Solvent Drying section

91 Igniting Minds... Energizing Lives… Haldia Refinery Igniting Minds... Energizing Lives… Haldia Refinery

92 Igniting Minds... Energizing Lives… Haldia Refinery Igniting Minds... Energizing Lives… Haldia Refinery

93 Igniting Minds... Energizing Lives… Haldia Refinery SOLVENT RECOVERY SECTION OF SOLVENT DE-WAXING UNIT

94 Igniting Minds... Energizing Lives… Haldia Refinery Igniting Minds... Energizing Lives… Haldia Refinery B T-1 B-16a B-16b inert gas to blanketing header for vessel blanketing in SDU B-12aB-12b B-2 filtrate vessel knock out drums B-13 K-1a K-1b E-19 E-20a E-20b Liq NH3 cw M M I G to Filters Hood I G to B-1 I G to Filters Blowing I G to FEU,SDU for purging Separator Funnel DPIC-01 DICV-04-2 DICV-04-1 To B-2 To B-5 PSA N2 storage vessel N2 Ex PSA INERT GAS GENERATION AND DISTRIBUTION SYSTEM IN SOLVENT DE-WAXING UNIT

95 Igniting Minds... Energizing Lives… Haldia Refinery Igniting Minds... Energizing Lives… Haldia Refinery PROPANE DE-ASPHALTING UNIT

96 Igniting Minds... Energizing Lives… Haldia Refinery

97 Igniting Minds... Energizing Lives… Haldia Refinery Igniting Minds... Energizing Lives… Haldia Refinery FURFURAL EXTRACTION UNIT (U-33) Solvent Recovery

98 Igniting Minds... Energizing Lives… Haldia Refinery


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