1. Indian Refineries Overview

2. Contents Indian oil scenario Crude oil sourcing Refining Processes
Refinery overview

3. Refineries in India * MUMBAI 2 Nos. * KOYALI * MATHURA * HALDIA
* VISHAKAHAPATNAM
* CHENNAI
COCHIN *
* MRPL
BARAUNI *
* PANIPAT
JAMNAGAR *
* BONGAIGAON
* DIGBOI
* NUMALIGARH
* GUWAHATI

4. Refining capacities HPCL – Mumbai 5.50 CPCL – Chennai 6.50
HPCL – Visakh CRL – Narimanam 0.50
HPCL – Total CPCL – Total 7.00
IOC – Guwahati NRL – Numaligarh 3.00
IOC – Barauni BPCL – Mumbai 6.90
IOC – Koyali MRPL – Mangalore 9.69
IOC – Haldia RPL – Jamnagar
IOC – Mathura CRL – Cochin 7.50
IOC – Panipat BRPL – Bogaingaon 2.35
IOC – Digboi 0.65
IOC – Total
Total Refining capacity
All Figures are in Million tons per annum

5. Dependence on Crude Oil imports
Refining capacity increased from 52 MMPTA to 121 MMTPA over last decade
Stagnant indigenous production (33 MMTPA) resulted in crude oil imports from 19 MMTPA to 88 TMT during last decade
Indian crude mix shifted from lighter to heavier
Crude sourced from Middle east, Far east, West Africa and South America

6. From net imports to net exports
Petroleum product imports increased from 5.5 MMT during to 25 MMT during
Start up of new refineries and capacity additions to older ones, since resulted in India becoming net exporter of Petroleum products

7. Crude oil sourcing

8. Crude Oil
Crude oils are complex mixtures containing many different hydrocarbon compounds that vary in appearance and composition from one oil field to another. Crude oils range in consistency from water to tar-like solids, and in color from clear to black. An "average" crude oil contains about 84% carbon, 14% hydrogen, 1%-3% sulfur, and less than 1% each of nitrogen, oxygen, metals, and salts.

9. Classification of Crude Oil
Crude oils are generally classified as paraffinic, naphthenic, or aromatic, based on the predominant proportion of similar hydrocarbon molecules. Mixed-base crudes have varying amounts of each type of hydrocarbon. Refinery crude base stocks usually consist of mixtures of two or more different crude oils.
Relatively simple crude oil assays are used to classify crude oils as paraffinic, naphthenic, aromatic, or mixed. One assay method (United States Bureau of Mines) is based on distillation, and another method (UOP "K" factor) is based on gravity and boiling points. More comprehensive crude assays determine the value of the crude (i.e., its yield and quality of useful products) and processing parameters.
Crude oils are usually grouped according to yield structure.

10. Classification of Crude Oil
Crude oils are also defined in terms of API (American Petroleum Institute) gravity.
The higher the API gravity, the lighter is the crude. For example, light crude oils have high API gravities and low specific gravities. Crude oils with low carbon, high hydrogen, and high API gravity are usually rich in paraffins and tend to yield greater proportions of gasoline and light petroleum products; those with high carbon, low hydrogen, and low API gravities are usually rich in aromatics.
Crude oils that contain appreciable quantities of hydrogen sulfide or other reactive sulfur compounds are called "sour." Those with lower sulfur are called "sweet."

11. Common crudes processed in India
High Sulfur Low Sulfur
Arab Light (Saudi Arabia) Bonny Light (Nigeria)
Arab Mix (Saudi Arabia) Cieba (Equ. Guinea)
Basrah (Iraq) Escravos (Nigeria)
Dubai Farcados (Nigeria)
Kuwait Essider (Libya)
Iran Mix Labuan (Malaysia)
Murban (UAE) Masila (Yemen)
Oman Miri Light (Malaysia)
Suez Mix (Egypt) Tapis (Malaysia)
Umm Shaif (UAE) Ravva (KGB India)
Upper Zakum (UAE) Mumbai High

12. Yield Patterns from different Crudes
High Sulfur Low Sulfur
Basrah AXL Mum High Qua Iboe
API
LPG MS
Naphtha
ATF/SKO
HSD
LDO
Lubes
IFO/LSHS
Bitumen
F&L
GRM $/bbl (2.52)

13. Crude oil Refining

14. Crude Oil Refining
Refining is a collection of processes necessary to convert low valued crude oil to wide range of high valued products
Refining processes are broadly divided into four types
Fractionation
Conversion
Treating
Blending

15. Fractionation First & most important step in crude refining
Hydrocarbon molecules do not change in structure
No new compounds are formed
Atmospheric Distillation
Separation of crudes into fractions using the principal of boiling point difference i.e. Light ends at the top & Heavy at the bottom
main products are LPG, Naphtha, Kerosene, ATF, HSD, Reduced Crude Oil.
Vacuum Distillation
Re-distillation of Reduced Crude Oil for further separation.
Separation under vacuum to avoid decomposition of reduced crude
Main products are vacuum gas oil, distillates for lubes, FCC feed stock, Bitumen & LSHS

16. Fractionation

17. Conversion Processes
Change in size and structure of the hydrocarbon molecule in order to convert surplus by products from fractionation to high valued marketable products
Decomposition (dividing)
Fluidized catalytic cracking
Hydro cracking
Visbreaking
Delayed Coking
Unification (combining)
Alkylation
Polymerization
Alteration (rearranging)
Isomerization
Catalytic reforming.

18. Decomposition Processes
Fluidized catalytic cracking
Fluidized Catalytic cracking breaks complex hydrocarbons into simpler molecules in order to increase the quality and quantity of lighter, more desirable products and decrease the amount of residuals. This process rearranges the molecular structure of hydrocarbon compounds to convert heavy hydrocarbon feedstock into lighter fractions such as kerosene, gasoline, LPG, heating oil, and petrochemical feedstock
Produces better quality (High Octane) Gasoline by cracking Vacuum Gas oils in presence of a catalyst
Simultaneously produces large amount of LPG

19. Fluidized catalytic Cracking

20. Decomposition Processes
Hydro cracking
A two-stage process combining catalytic cracking and hydrogenation,
Heavier feedstock cracked in the presence of hydrogen to produce more desirable products like Kerosene, Gasoline & Diesel.
Process employs high pressure, high temperature, a catalyst, and hydrogen.
Used for feed stocks that are difficult to process by either catalytic cracking or reforming due to high polycyclic aromatic content and/or high concentrations of catalyst poisons like sulfur and nitrogen compounds.
Atmospheric column residue
Vacuum column residue
Heavy Gas oils from Coker

21. Hydro Cracking

22. Decomposition Processes
Visbreaking
Reduces viscosity of Vacuum residue by thermal process
IFO generation reduces by 30 – 35% due to lower diesel requirement for cutting viscosity
LPG & Naphtha are produced as by-products
Delayed Coking
A severe method of thermal cracking used to upgrade heavy residuals into lighter products or distillates.
Produces straight-run gasoline (coker naphtha) and various middle-distillate fractions used as FCCU feedstock.
The process completely eliminate hydrogen so that the residue is a form of carbon called "coke."

23. Delayed coking

24. Unification Processes
Polymerization
Makes high octane gasoline from olefins and refinery gases using catalyst
Alkylation
Same as polymerization but the end product has better performance in I. C. Engines.
Combines isobutane with light olefins to produce very high quality gasoline (RON >105)

25. Alteration Processes Catalytic reforming
Convert low-octane naphthas into high-octane gasoline blending components called reformates.
Reforming is a mixture of cracking, polymerization, dehydrogenation, and isomerization taking place simultaneously.
Depending on the properties of the naphtha feedstock and catalysts used, reformates can be produced with very high concentrations of toluene, benzene, xylene, and other aromatics useful in gasoline blending and petrochemical processing.
Hydrogen is produced a significant by-product

26. Alteration Processes Isomerization
Isomerization converts n-butane, n-pentane and n-hexane into their respective isoparaffins of substantially higher octane number.
The straight-chain paraffins are converted to their branched-chain counterparts whose component atoms are the same but are arranged in a different geometric structure.
n-butane is converted into isobutane to provide additional feedstock for alkylation units,
N-pentanes and n-hexanes are converted into higher branched isomers for gasoline blending.

27. Isomerization & Reforming process
Light Naphtha
SPLITTER G A S O L I N E P H2
Isomerate
Naphtha
Naphtha Hydrotreater
& Isomerization
LPG H2
CCR
Heavy Naphtha
NHT
Reformate
Make up H2
Hydrotreater
Reformer H2

28. Treating Processes
Intended to prepare hydrocarbon streams for additional processing and to prepare finished products.
Includes the removal or separation of aromatics and naphthenes as well as impurities and undesirable contaminants.
Involves chemical or physical separation such as Dissolving, Absorption, or precipitation using a variety and combination of processes including desalting, drying, hydrodesulfurizing, solvent refining, sweetening, solvent extraction, and solvent dewaxing.
Major Treating process
Solvent Extraction
Solvent Dewaxing
Solvent De-Asphalting
Hydro-desulfurization

29. Solvent Extraction
The purpose of solvent extraction is to prevent corrosion, protect catalyst in subsequent processes, and improve finished products by removing unsaturated, aromatic hydrocarbons from lubricant and grease stocks.
The solvent extraction process separates aromatics, naphthenes, and impurities from the product stream by dissolving or precipitation. The feedstock is first dried and then treated using a continuous countercurrent solvent treatment operation. The feedstock is washed with a liquid in which the substances to be removed are more soluble than in the desired resultant product
The most widely used extraction solvents are phenol, furfural, NMP and cresylic acid

30. Solvent Extraction H2 T 203 RAFF SOLN NMP T-201 TREATER T 202
FEED
DRY DRUM
WET
DRUM T 2 6
EXTRACT
STEAM
EXT FURNACE
RAFF FURNACE
F-202
F-201
T-201
TREATER
EXT. SOLN
RAFF SOLN H2
RAF RECOVERY
EXT STRIPPER
HP SEPERATOR
VAC DRIER LP
S/G COMP
STRIPPPER
T 203
T 202
HYDROFINER
NMP SG

31. Solvent Dewaxing
Solvent dewaxing is used to remove wax from either distillate or Lube oil base stock.
Steps involve in solvent dewaxing are
Mixing the feedstock with a solvent
precipitating the wax from the mixture by chilling
recovering the solvent from the wax and dewaxed oil for recycling by distillation and steam stripping.
The most widely used extraction solvents are Methyl Ethyl Ketone (MEK), Propane & Toluene

32. Solvent Dewaxing

33. Solvent De Asphalting
In this solvent extraction process, propane is used as a solvent
Heavy oil fractions are separated to produce heavy lubricating oil (Bright Stock), catalytic cracking feedstock, and asphalt.
Feedstock and liquid propane are pumped to an extraction tower at precisely controlled mixtures. Separation occurs based on differences in solubility.
The products are then evaporated and steam stripped to recover the propane, which is recycled.

34. Hydro de sulfurization
Hydrotreating for sulfur removal is called hydrodesulfurization
The feedstock is deaerated and mixed with hydrogen, preheated in a fired heater and then charged under pressure through a fixed-bed catalytic reactor.
In the reactor, the sulfur and nitrogen compounds in the feedstock are converted into H2S and NH3.
The liquid stream is sent to a stripping column for removal of H2S and other undesirable components.
H2S is further treated in Amine treating & Sulfur recovery unit to produce sulfur

35. Hydro desulfurization

36. Blending
Blending is the physical mixture of a number of different liquid hydrocarbons streams to produce a finished product with certain desired specifications

37. Why Blending is required ?
Non compliance of individual streams from primary or secondary processing units to any product specification of its own
Non availability of matching secondary processing facilities leading to excess streams available for disposal as valuable products
Disposal problem for by-products from treating units like extract from solvent extraction unit or wax from dewaxing unit
Upgradation of valuable surplus streams due to lack of upliftment of specific product and thus avoiding downgradation to heavy ends
Blending maximizes the Refinery profitability by optimizing the overall production slate to extract maximum value from each barrel of crude processed

38. Blended streams / Products
HSD 3. IFO
Heavy Naphtha VTB
Kerosene JBO
LVGO LVGO
JBO Extract
VGO FCC Residue
X’VGO
LCGO 4. LSHS
LDO - VBO
HVGO LVGO
LVGO FCC Residue
I SS 5. Gasoline
- FCC Cracked Naphtha
- St. run Naphtha

39. Examples of blend optimization
Possible routing of High ‘S’ I SS is 150N, LDO & IFO
Value of I ss realized in 150 N Rs / T
Value realized in LDO Rs / T
Value realized in IFO Rs / T
Possible routing of VTB
Value realized in Bitumen Rs 8400 / T
Value realized in IFO Rs 4420 / T

40. Contents Refinery growth Refinery location & layout Crude processed
Products
Crude receiving and product dispatching facilities
Refinery process units
Refinery Block diagrams
Physical performance
Commitment to Environment
Major Projects under implementation

41. Total Products = 29 Fuel Products = 13 Propane LPG Motor Gasoline
Low Aromatic Naphtha
High Aromatic Naphtha
Special Cut Naphtha
Aviation Turbo Fuel
Superior Kerosene Oil
Special cut Kerosene
High Speed Diesel (3 Grades)
Light Diesel Oil
Fuel Oil ( 2 grades)
LSHS
Lube Products = 9
Neutral Oils = 3
Turbine Oils = 2
Industrial Oils = 2
Spindle Oil
Bright Stock
Specialties = 7
Hexane
Solvent 1425
MTO
CBFS
RPO
Bitumen (3 Grades)
Sulfur

42. Product Mix

43. Crude receiving and Product shipment facilities
Mahul
Terminal
SAHAR / SANTACRUZ
JAWAHER
DWEEP
LPG
Nap./IFO/SKO/LSHS/HSD
A T F
Hex/Sol/MTO/RPO/CBFS
42”
LSHS
24”
PRIPAU
MANIFOLD
Vashi / Loni / Sewri /Wadala
Mazagaon
MS/HSD/SKO/LDO
36”
IFO / Lubes
Naphtha
RCF
24”
ONGC URAN
Bitumen
BH Gas
HP REFINERY
BPCL

44. Refinery Process Units
Fuels Block
Crude Distillation - 2
Vacuum Distillation - 2
Naphtha stabilizers - 2
Fluidized Catalytic Cracking
Diesel Hydro De Sulfurization
Hexane
Propane
Lube Block
Vacuum Distillation
Solvent Extraction
Propane De-waxing
Propane De-Asphalting
Industrial Oil Hydrofiner
Utilities
Captive Power Plant - 5 GTG’s
Effluent Treatment Plants - 2
Boiler House
Cooling Towers
Instrument/utility air system
Tankage

45. Mumbai Refinery Process units
LPG
HMU
Hexane /Solvent
Stabilizer
Naphtha FR
CDU
Treating
ATF HS
SKO/MTO
HSD
DHDS
Sulfur
LDO
VDUs
SEUs
Spindle Oil
150 N
PDU
500 N
1300 N
Bright Stock
PDA
IOH
IO-100
IO-1600 FR E
CDU
Bitumen LS
IFO
FCC
VDU
Gasoline
LSHS

46. Commitment to Environment Protection
Major environmental projects
Implemented over past 2 decades : Rs 935 Cr. (208 Million USD)
Under implementation (GFECP ): Rs 1152 Cr. ( 256 Million USD)
Refinery meets stipulations set by MPCB & CPCB
Extensive green cover in the Refinery & residential complex.
Initiated Tank sludge treatment process to recovery oil from sludge

47. Green Fuels & Emission Control Project
Objectives
To meet EURO-III specifications for MS
Augmentation of crude processing capacity to 7.9 MMTPA
Project Cost: Rs 1852 Crores (411 Mill. USD)
New Units
Naphtha Splitter
Naphtha Hydrotreater
Catalytic Reforming Unit
Isomerization unit
FCC Gasoline Hydrotreater (Prime G+)
Flue Gas Desulfurization Unit
De NOx Facilities

48. Green Fuels & Emission Control Project
ISOM G A S O L I N E P
Light Naphtha
SPLITTER H2
Isomerate
Naphtha
Naphtha Hydrotreater
& Isomerization
LPG H2
CCR
Heavy Naphtha
NHT
Reformate
Make up H2
Hydrotreater
Reformer
FCCU Cracked
Naphtha
Light FCC Gasoline S H U H2
PRIME G+
Selective Hydrogenation
& Splitter
Heavy FCC Gasoline