1. 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

2. 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

3. 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.

4. History of Petroleum Refining- Environment Driven Developments
: 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.

5. 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

6. 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

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

8. 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 oC
Kerosene
Hydro-desulfurization oC
Light Gas Oil (Diesel)
Hydro-treating oC
FCC, Hydro-cracking
Vacuum Gas Oil
Vac. Distillation oC
Lube Manufacturing
Heavy Gas Oil
550+ oC
Vac. Residue
Cracking (Coking), Bitumen

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

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

11. 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)

12. Catalytic Reforming Process
Platinum or Pt-Rh based catalyst, high temp ( C) 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 C
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

13. 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 =

14. Cracking Processes Contd.
Item
Op. Condition
Severity
Products
Remarks
Thermal Cracking
Fluidized Bed Catalytic Cracking
Hydro-cracking
High temperature, C
no catalyst
High temperature and catalyst C
High temp., High pr., bar, C
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

15. Coker
Cracking Processes (Contd.)

16. 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

17. 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

18. 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.

19. 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.

20. 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

21. 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

22. 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

23. 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

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

25. 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.

26. 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

27. 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

28. 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

29. View of Refinery / Petrochemical Complex

30. Refinery Storage Yard

31. Control Room