In this section we shall talk about: Refinery Configurations MODULE – 1 B Refinery Overview In this section we shall talk about: Why Refining? Products and Specs. Refinery Process Schemes Refinery Configurations Module - 5

The Macro-system GAS PROCESSING OILFIELD PROCESSING PETRO- CHEMICAL NATURAL GAS POWER PLANT C1,C2,C3,C4,C5+ GAS PROCESSING POWER FERTILIZER PLANT GAS UREA,METHANOL NGL WELL FLUID OILFIELD PROCESSING C3,C4 LPG PETRO- CHEMICAL COMPLEX C2/C3 POLYMER PLASTIC RUBBER,FOAM NGL OIL/ GAS WELLS Offshore Or Onshore FIBER & YARN TREATED WATER OIL DETERGENTS CHEMICALS NAPHTHA REINJECTION NGL REFINERY LPG GASOLINE KERO/JET FUEL DIESEL DISPOSAL LUBE OILS FUEL OIL AtoZ Flash Animation Upstream Downstream BITUMEN

History of Petroleum Refining - Automobile Driven Growth Refinery configuration changed with time according to changing market demand. 1861- The first refining unit, produced kerosene for lighting by simple atmospheric distillation. 1900 to 1950: Three significant events transformed refinery technology - The invention of the electric light decreased the demand for kerosene. The invention of the internal combustion engine created a demand for diesel fuel and gasoline. Aero-planes created need for high octane aviation gasoline.

History of Petroleum Refining- Environment Driven Developments 1950-1980: explosion in demand for gasoline and diesel and higher quality requirements resulted in – consolidation & improvement on octane boosting processes, improved technologies for cracking ‘heavies’. 1980 onwards: major impact due to environment related specs on products and effluents. Ban on use of lead, use of MTBE as octane booster and its replacement. Stringent sulfur specifications– deeper Hydrodesulphurization. Limiting benzene in automotive fuel products lead to greater use of other octane boosting processes like Isomerization. Fluctuating oil price and business uncertainties.

From Heavy distillates Refinery Processes Refining comprises of five categories of processes: 2. Conversion Processes To meet Product Spec. 3. Conversion Processes Heavies to lights 5. Treatment Processes Environment related and polishing 1. Primary Separation Distill into Various Cuts 4. Processing for Lubes From Heavy distillates

Atmospheric and Vac. Distillation Refinery Processing Concept Conversion Process Product Up-gradation Catalytic Reforming Isomerization Treatment Processes Hydro-desulfurization Hydro-treatment Crude Oil Product Finishing Merox for gasoline Hydro-finishing Atmospheric and Vac. Distillation Primary Separation Storage and Blending Conversion Process Cracking of ‘Heavies’ Thermal Cracking/ Coking FCC/ Hydro-cracking PRODUCTS Lube Oil Processing Extraction/Hydro-fining De-waxing De-asphalting Finishing Blending Formulation

Refinery Blending Operation Gases Intermediate Components Blending Operations Processing Crude Distillation Processing Crude oil Finished Products Processing

Refinery Processing Primary Separation Conversion Processes <35oC Butane and Lighter Gas Processing (LPG) 35-80oC Light Gasoline Motor Gasoline Blending 80-140oC Naphtha Cat. Reforming Crude Oil Atm. Distillation 140-250oC Kerosene Hydro-desulfurization 250-350oC Light Gas Oil (Diesel) Hydro-treating 350-450oC FCC, Hydro-cracking Vacuum Gas Oil Vac. Distillation 450-550oC Lube Manufacturing Heavy Gas Oil 550+ oC Vac. Residue Cracking (Coking), Bitumen

Atmospheric Process Flow Diagram OVERHEAD ACCUMULATOR CRUDE FEED FUEL GAS OR FLARE STORAGE COOLER NAPTHA STORAGE CRUDE TOWER Y KEROSENE STORAGE RESID STORAGE Heater 270-370 0C DIESEL STORAGE Heat Recovery Train (Preheating to 270 0C) To Reboilers DESALTER From Reboilers

Conversion Processes - Generic Diagram Product C Product D Feed A Feed B Pumps Reactor Heat Exch. Furnace Distillation Column Heat Recovery Reaction System Separation

Conversion Processes for Gasoline Up-gradation Gasoline Up-gradation is required to raise Octane Number levels with higher engine performance requirements. Till the seventies, Catalytic Reforming was the most prevalent process to increase Octane Number. Aromatics generated by Reforming Process and Lead was found to be health hazard. With lead addition eliminated and stricter aromatics spec., use of reformer gasoline as blending stock was reduced. These lead to evolution of new sources of high Octane gasoline # Isomerization # Alkylation # Fluid Catalytic Cracking (FCC)

Catalytic Reforming Process Platinum or Pt-Rh based catalyst, high temp (480-520 0C) and pressure (10-20 bar). Paraffins / naphthenes to aromatics. Products are- High Octane gasoline stock. Feedstock for fiber (Petrochemical). Hydrogen is formed as by-product. Feed Heater Reactor-1 Reactor-2 Pre-heater Cracked Gases Hydrogen High ON Product 500-550 0C Separator Component Vol% in feed Vol% in product Paraffins 45-55 30-45 Aromatics 05-10 45-60 Naphthenes 30-40 Olefins 00-02 00

Conversion of ‘Heavies’ to ‘Light’ – Cracking Processes ‘Cracking’ the molecules of low value heavy cuts and residues to high value light products by heat, pressure and catalyst. The process generates gases and high value white products (gasoline, kerosene, diesel) by cracking. 500 0C =

Cracking Processes Contd. Item Op. Condition Severity Products Remarks Thermal Cracking Fluidized Bed Catalytic Cracking Hydro-cracking High temperature, 480-530 0C no catalyst High temperature and catalyst 530-570 0C High temp., High pr., 70-150 bar, 400-450 0C Catalyst and Hydrogen Coking process - high reaction time Maximize gasoline or olefins Higher pressure and temperature Coke, gases, white products, cycle oil Gases, olefin, gasoline, cycle oil Mainly white products Minimum cost No residue, products unstable Good for gasoline, LPG. Low Cetane diesel Highest cost, high quality diesel

Coker Cracking Processes (Contd.)

z Hydrocracking Cracking Processes (Contd.) Hydrogen Reactors Compressor Fractionator Naphtha Kerosene Heater Diesel Fuel Gas Cycle Oil Separator z Feed Hydrogen Selection Refinery Process.ppt

Treatment Processes - Hydro-treating The term hydro-treating is used to define treatment processes like- Saturating olefins to paraffins. Removal of sulfur (hydro-desulfurization)HDS.swf H2 Make-up H2 Recycle Compressor Fuel Gas Fuel Gas Light Gasoline Feed De-sulfurized Gasoline Heater Reactor Separator Fractionation

Other Important Processes Petrochemical feedstock generation Propylene, Naphtha, Aromatics are separated or extracted out of the refinery products as feedstock for production of petrochemicals. Formulating and Blending Formulating and blending is the process of mixing and combining hydro-carbon fractions, additives, and other components to produce finished products with specific performance properties.

Current Trend The business environment of the last three decades lead to.... Refineries becoming more complex with different types of processing units. Increased hydrogenation process and hydrogen demand. Increased investment with corresponding price benefit. Adverse impact on refinery margin. Technology to minimize the residual products. Integration of refining and petrochemical industries.

CONVENTIONAL CONFIGURATION OF ‘60s Petroleum Refinery- Simple 60s CONVENTIONAL CONFIGURATION OF ‘60s FUEL GAS LPG NAPHTHA Crude Oil TE Lead HDS REFORMING GASOLINE KEROSENE HDS DIESEL FUEL OIL ATM. DISTL. FCC LUBE PLANT LUBES VAC. DISTL. VISBREAKING RESID./FUEL

Petroleum Refinery- Simple 60s To Complex 90s FUEL GAS Butanes LPG Isomerization C3= NAPHTHA Crude Oil HDS MTBE GASOLINE Reforming KEROSENE HDS DHDS HDS DIESEL FUEL OIL ATM. DISTL. Aromatics Extraction FCC BTX Lube Plant LUBES Hydrocracking Hydro- treatment VAC. DISTL. Coking RESID./FUEL COKE

Refinery Configuration - The Gases Refinery consumption FUEL GAS Butanes LPG Isomerization H2 Crude Oil H2S REFORMING H2S HDS Hydrogen Plant HDS HDS Propylene ATM. DISTL. Aromatics Extraction FCC H2S LUBE PLANT Gas Sweetening H2S Hydrocracking COKING VISBREAKING VAC. DISTL. HDT Sulfur Plant Sulfur

Trend beyond 2000: Integrating Petrochemicals Steam Cracker Polymeri -zation Polythene Poly-propylene Hydrogen Refinery Reformer Naphtha BTX Gas Oil BTX Extraction Reformate Raffinate Propylene Deep Catalytic Cracking LPG Gasoline LCO

Refinery Layout OFFSITE FACILITIES Oil Movement & Storage Flare System Effluent Treatment Plant Steam and Power Cooling Water Safety and Fire Fighting Buildings

The Complexity Factor of a Refinery Nelson Complexity Index is a measure of secondary conversion capacity in comparison to the primary distillation capacity of a refinery. It is an indicator of the investment intensity and value addition potential of a refinery. For calculation of complexity, a value of 1 is assigned to Atmospheric Distillation Unit. All other units are rated in terms of their costs relative to the primary distillation unit. Refineries, with high Nelson Complexity Index have the necessary flexibility in processing a wide variety of crude oils and are capable of achieving higher value addition.

Refinery Complexity Index Unit Older Reports 1998 Reports Distillation Capacity 1.0 Vacuum Distillation 2.0 Thermal Processes 5.0 2.75 Coking   6.0 Catalytic Cracking Catalytic Reforming Catalytic Hydrocracking Catalytic Hydrorefining 3.0 Alkylation / Polymerization 10.0 Aromatics / Isomerisation 15.0 Lubes 60.0 Asphalt 1.5 Hydrogen (Mcfd) Oxygenates Others

Factors Affecting Refinery Configuration and Production Crude oil assay and feedstock mix Product specifications Product demand pattern and targeted product slate Product pricing Utilities and energy cost Process unit configuration Refinery complexity and investment Other cost elements

Application of Linear Programming (LP) Models LP Models are today used for: Optimization of configuration of new refineries For Existing refineries… Planning daily, weekly, monthly and long term operation Effect of change in feed/product composition, quality, price Optimization of operation of individual units Evaluation of crude oils S Process Model Refinery and Crude Data Base Files Refinery Definition Data Input Interface Data Base Access Refinery Structure Specialist System Non-specialist System Output Reports L.P Solver Case

View of Refinery / Petrochemical Complex

Refinery Storage Yard

Control Room