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Introduction to Petroleum & Petro - Chemical Products. Description on Unit Process, Production & Business Opportunities In India
CONTENTS
1. The Black Gold 2. About Hydrocarbon Industry 3. A Guide of Refinery Process 4. Table of various process with approximate cost & criticality 5. Crude Distillation Unit 6. Production of Gasoline (Petrol) from Heavy Naphtha 7. Fluid Catalytic Cracking 8. List of Refineries in India and their production capacities 9. Procurement Methods adopted by Indian Refineries 10. Major Refinery Equipment’s
- Part 1 of Presentation
THE BLACK GOLD WhatisCrudeOil?• Anunrefinedpetroleumproductcomposedofhydrocarbondepositsandorganic
compounds.OriginofHydrocarbons
TypesofCrudeOil• SweetCrude(LowH2S&CO2)–MostpreferableforproducDonofgasoline.• SourCrude(HighH2S&CO2)–Crudewithmorethan0.5%sulfurGradesofCrude• Brent(UK),WestTexasIntermediate(US),Daqing(China),BCF-17(Venezuela),
Maga(Mexico),Bonny(Nigeria),Dubai(UAE)Composi<on• 83–87%Carbon• 11-15%Hydrogen• 1–6%Sulfur
AcDonofmicro-organismsonDecayingPlants&
Animals
FormaDonofHydrocarbonsHighPressure&high
Temperature
UnderEarthsSurface
Hydrocarbon Industry – Up Stream Process
Petroleum Exploration • Explora<onTechniques• GeoPhysical
• GravimetricMethod• MagnetometricMethod• SeismicSurvey• RemoteSensingMethod
• GeoChemical• Chemicalanalysisofsurfacesoil
androcks
• GeoTechnical• MechanicalProperDesofrocks
andsurfacearemeasured
Petroleum Production • OilExtrac<on&Recovery• Primaryrecovery
• Oncethecompleterigisset-up,theundergroundpressureintheoilreservoirissufficienttoforcetheoiltothesurface.
• Secondaryrecovery• Supplyofexternalenergyintothe
reservoirintheformofinjecDngfluidstoincreasereservoirpressure,henceincreasingthenaturalreservoirdrivewithanarDficialdrive.(eg.Water,Naturalgas)
• Enhancedrecovery• Thismethodinjectssteamtoheat
upoilthereservoirtoreduceitsviscosityandmakingiteasiertoextract.
Hydrocarbon Industry – Down Stream Process
Refining & Petrochemicals • Refining
• PetroleumrefiningprocessesarethechemicalengineeringprocessestotransformcrudeoilintousefulproductssuchasLiquefiedPetroleumGas(LPG),Gasoline(Petrol),Kerosene,JetFuel,DieselOil&fueloils.
• Petrochemicals
• Chemicalsobtaineddirectlyfromcracking(pyrolysis),orindirectlyfromchemicalprocessingofpetroleumoilornaturalgas.
• Fewexamples,plasDcs,rubbers,fibres,paints,solvents&detergents.
Marketing & Distribution • Marke<ng
• MarkeDngisthefinalstepinthechainthatdeliversusefulpetroleumproductstoend-usercustomers.
• Drivingfactors:• Volume• MarketShare• Margin
• Distribu<on
• DistribuDonlinesofoil&gasmustbemanagedwithhighlevelsofconsistencyandsafety.
• DistribuDonisdonevia,• Pipelines• Cryogenictanks• On-Sitesystems
Ministry of Petroleum & Natural Gas
Industry Bodies
Petroleum Planning & Analysis Cell
Centre for High Technology Petro Fed Petroleum Conservation
& Research Association
Up Stream Process
Exploration & Production
ONGC OIL
Private companies
like Cairn, RIL etc.,
Down Stream Process
Refining & Marketing
HPCL BPCL IOCL RIL, etc.,
Distribution
GAIL India RIL
Hydrocarbon Industry – India
Src:MinistryofPetroleum&NaturalGas
A GUIDE OF REFINERY PROCESS
CrudeOilStorageTank
Desalter
HeaDng (CDU
)Crude
DisD
llaDo
nUnit/ADU
VD
U(V
acuu
m
DisDllaDo
nUnit)
GasProcessing
NHTU
NHTU
ATF-HDT
DHDT
VGO-HDT
Hydrocracker
DCU
BitumenBlowing
ARU
Merox
SRU Sulphur
LPG(Propane&Butane)
Naptha
Gasolline
JetFuel/Kerosene
DieselFuel
ISOM
CCR
ATFMEROX
FCCU
AlkylaDonUnit
PolyUnit
NeedleCokeUnit
PropylenePRU
LightGas
LightNaphtha
HeavyNaphtha
KeroseneJetFuel
DieselOil
GasOil
DesaltedCrude
ReducedCoke
FuelGas
H2S
RefineryFuel/FuelGas
H2H2
H2S
Diesel
VacuumResiduel
HeavyVacuumGasOil
C3/C4
Propane
Butane
DieselIso-Butane
Gasoline
LightVacuumGasOil
PremierCokeCokerNaphthatoCCRCokerGasoiltoFCCUPetroleumCoke
Bitumen
A GUIDE OF REFINERY PROCESS
CrudeOilStorageTank
Desalter
HeaDng (CDU
)Crude
DisD
llaDo
nUnit/ADU
VD
U(V
acuu
m
DisDllaDo
nUnit)
GasProcessing
NHTU
NHTU
ATF-HDT
DHDT
VGO-HDT
Hydrocracker
DCU
BitumenBlowing
ARU
Merox
SRU Sulphur
LPG(Propane&Butane)
Naptha
Gasolline
JetFuel/Kerosene
DieselFuel
ISOM
CCR
ATFMEROX
FCCU
AlkylaDonUnit
PolyUnit
NeedleCokeUnit
PropylenePRU
LightGas
LightNaphtha
HeavyNaphtha
KeroseneJetFuel
DieselOil
GasOil
DesaltedCrude
ReducedCoke
FuelGas
H2S
RefineryFuel/FuelGas
H2H2
H2S
Diesel
VacuumResiduel
HeavyVacuumGasOil
C3/C4
Propane
Butane
DieselIso-Butane
Gasoline
LightVacuumGasOil
PremierCokeCokerNaphthatoCCRCokerGasoiltoFCCUPetroleumCoke
Bitumen
v
vv
vv
v
Table of Various Unit Process with Approximate cost & criticality
S.No. Unit Name Approximate Cost Criticality
Major Units
1 CDU – Crude Distillation Unit
2 VDU – Vacuum Distillation Unit
Hydro-treating Process
3 ATF HTD - Aviation Turbine Fuel Hydrotreater
4 DHDT – Diesel Hydrotreating
5 NHT – Naphtha Hydro Treater
6 VGO HDT – Vacuum Gas Hydrotreater
Cracking Process
7 FCCU - Fluid Catalalytic Cracking Unit
8 Steam Cracking Unit
9 Hydrocracking Unit
Reforming Process
10 CCR – Continuous Catalytic Reformer
Table of Various Unit Process with Approximate cost & criticality
S.No. Unit Name Approximate Cost Criticality
Isomerization Process
11 Light Naphtha Isomerization Unit
De-Sulfurization / Merox Process & Sulfur Recovery Process
12 ATF Merox – Aviation Turbine Fuel Merox
13 GMU – Gasoline Merox Unit
14 Extraction and removal of mercaptans from LPG
15 SRU – Sulfur Recovery Unit
16 SWS – Sour Water Stripper
Coking Process
17 DCU – Delayed Coker Unit
18 Needle Coker Unit
19 Fluidic Coking Unit
20 Flexi Coking Unit
Table of Various Unit Process with Approximate cost & criticality
S.No. Unit Name Approximate Cost Criticality
Other Units
21 HF Alkylation Unit
22 Vib Breaker Unit
23 Polymerization Unit
24 ARU - Amine Recovery Unit
25 AGS – Air Generation System
26 AGU – Acid Generation Unit
27 De-Salination / De-Mineralization Unit
28 ETP – Effluent Treatment Plant
29 Hydrogen Manufacturing Unit
De-Salting Unit
PreheatedCrudeOil
DMWater
CausDcSoluDon
PowerT.F
DosingPump
FIC
CrudeoilFeedPump
pHC DPC
Salt-Water
CrudeOil ElectrodePlatesOil–WaterInterface
TT PT
FIC
CrudeBoosterPump
SaltandWatertoDrain
LC
• FIC-FlowIndicatedControl
• TT–TemperatureTransmijer
• PT–PressureTransmijer
• DPC–DualZonePressureController
• LC–LevelController
Naphtha HydroTreater - Process Flow Diagram
RawNaphthaStorage
Hyd
roge
n Se
para
tor
Feed Pump
Furnace
Cooler
Make up Hydrogen
Recycle Compressor
Strip
per
Gases to fuel system or sulfur recovery unit
Desulfurised naphtha to storage
Reboiling Furnace
Reactor
Heavy Naphtha Reformer– Process Flow Diagram
DesulfurisedNaphthaStorage
Hyd
roge
n Se
para
tor
FeedPump
Furnace
Cooler
Hydrogentostorage
RecycleCompressor
Debu
taniser
Reactor
Reactor
Furnace
Furnace
Reactor
GasestofuelSystem
ReformatetoStorage
FLUIDISED CATALYTIC CRACKING (FCC) Conversion of VGO(Vacuum Gas Oil) into Gasoline Intermediates using side by side FCC configuration
FLUEGAS
ELECTROSTATICPRECIPITATOR
CATALYSTFINES
SEPARATOR
CATALYSTFINES
COBOILER
FLUEGAS
STEAMAIR
CONDENSATECOMBUSTIONAIR
REGENERATOR
FLUEGAS
FLUEGAS
REACTOR
535DegC1.72barg
CONDENSER
380.56barg
REFLUX
OFFGAS
PHENOLICSOURWATER
REFLUXDRUM
FEEDSTOCK315-430
TOTALFEED
SIDECUTSTRIPPER
CRACKEDNAPHTHA
STEAM
FUELOIL
FUELOIL
SLURRYSETTLER
SLURRYOIL
715DegC2.41barg
DISTILLA
TIONCOLU
MN
STEAM
REACTIONPRODUCTGAS
FLUIDIZED CATALYTIC CRACKING
List of Refineries in India and their Production Capacities
Sl.No Sector RefineryName
Loca<on
InvestmentCost(Rs.Incrores)
CommissionedOn
Produc<onCapacity(MMTPA)
PresentProduc<onCapacity(MMTPA)
1 IOCL GuwahaDRefinery Assam 17.29 1stJanuary1962
0.75 1
2 IOCL BarauniRefinery Bihar 49.4 July1964 3.3 6
3 IOCL KoyaliRefinery Gujarat 26 October1965 2 13.7
4 IOCL HaldiaRefinery WestBengal
January1975 2.5 7.5
5 IOCL MathuraRefinery UjarPradesh
253.92 January1982 6 8
6 IOCL DigboiRefinery Assam 1901/October1981
0.5 0.65
7 IOCL PanipatRefinery Haryana 3868 1998 6 15
8 IOCL BongaigaonRefinery(BRPL)
Assam 50 20thFebruary1974
1 2.35
List of Refineries in India and their Production Capacities
Sl.No Sector RefineryName
Loca<on
InvestmentCost(Rs.Incrores)
CommissionedOn
Produc<onCapacity(MMTPA)
PresentProduc<onCapacity(MMTPA)
9 IOCL ParadipRefinery Orissa 34,555 February7,2016
15
10 HPCL MumbaiRefinery Maharashtra
1954 1.25 6.5
11 HPCL VisakhRefinery AndhraPradesh
1957 0.675 8.3
12 BPCL MumbaiRefinery Maharashtra
1955 2.2 12
13 BPCL KochiRefinery Kerala 27thApril1963 2.5 15.5
14 CPCL(IOCL+NIOC)
ManaliRefinery TamilNadu
43 1965 2.5 10.5
15 CPCL CauveryBasinRefinery
Nagapaonam,TN
1993 0.5 1
16 NRL NumaligarhRefinery Assam October2000 3
List of Refineries in India and their Production Capacities
Sl.No Sector RefineryName
Loca<on
InvestmentCost(Rs.Incrores)
CommissionedOn
Produc<onCapacity(MMTPA)
PresentProduc<onCapacity(MMTPA)
17 MRPL(ONGC)
MangaloreRefinery Karnataka March1996 3.69 15
18 ONGC TaDpakaRefinery AndhraPradesh
27 September2001
0.066 0.132
19 Private JamnagarRefinery(RIL–DTA)
Gujarat 33
20 Private JamnagarRefinery(RIL–SEZ)
Gujarat 37
21 Private EssarOilLimited Vadinar,Gujarat
November2006
10.5 20
22 BORL(BPCL+OOCL)
BinaRefinery MadhyaPradesh
12,200 May,2011 6
23 HMEL(HPCL+Mijal)
GuruGobindSinghRefinery
Bathinda,Punjab
April,2012 9
PROCUREMENT METHODS ADOPTED BY INDIAN REFINERIES Conventional Route & EPC Route
Construction Procurement Engineering
ProcurementmethodadoptedbyIndian
Refineries
Owner(IOCL,BPCL,HPCL,CPCL,NRL,
BORL,BRPL,RIL,ESSAR)
AppoinDngprocesslicensor&consultantforFEEDStudy
(FrontEndEngineeringDesign)
ApprovalfromBoard/Governmentforproject
implicaDons
Method-1:CONVENTIONALROUTE Method-2:LSTK/EPCROUTE
AppoinDng“ProcessLicenser”(ByOwner)
AppoinDng“EPCM”Consultant(ByOwner)
ProcessDesign&Sizingof‘Units”byprocesslicenser
DetailDesignofunits&sizingof“IndividualEquipment's”byEPCMconsultant
PreparaDonofMR,SpecificaDons,DataSheets&Drawingsfor“Individual
Equipment”byEPCM
InvitaDonfortendersfor“IndividualEquipment's”asperMR’sbyEPCM
SubmissionofTechno-CommercialBidsby“Bidders(Manufacturers)”
TechnicalEvaluaDonbyEPCM
CommercialEvaluaDon&RecommendaDonbyEPCM
ApprovalOfBidderandorderreleasefor“IndividualEquipment's”byowner.Allfinancial
commitmentstobiddersisbyowner
BidderspostorderacDviDeslikedrawings,procurement,manufacturing&E&Cwillbe
monitoredbyEPCM&Owner
CompleDonofproject&commissioningofplantismonitoredbyEPCM
AppoinDng“ProcessLicenser”(ByOwner)
AppoinDng“PMC”Consultant(ByOwner)
Processdesignbasisof“Units”byprocesslicenser
PreparaDonofprojectspecificaDons&minimumdesign&qualityrequirementsbyPMC
InvitaDonfortendersforLSTK(EPC)biddingfor“UNITS”byPMC
SubmissionofTechno-CommercialbidsbyLSTKcontractors.
TechnicalevaluaDonbyPMC&Processlicensor
CommercialevaluaDonandrecommendaDonbyPMC
ApprovalofLSTKcontractorandorderreleasefor‘Units”byowner.Allfinancialcommitments
toLSTKcontractorsarebyowner
LSTKwilldevelopprocessdesign,P&ID’s&equipmentdatasheets&MR’sfor“IndividualEquipment's”.MayappointDEC&inspecDon
agency,ifrequired.
InvitaDonfortendersfor“IndividualEquipment's”asperMR’sbyLSTK
SubmissionofTechno-Commercialbidsby“Bidders(Manufacturers)”
Technical&CommercialevaluaDonbyDEC&LSTK
Approvalofbidderbyowner/PMC&orderreleasebyLSTKcontractor.AllfinancialcommitmentstobiddersarebyLSTK
contractor.
BidderspostorderacDviDeslikedrawings,procurement,manufacturingandE&CwillbemonitoredbyLSTKcontractoraswellas
EPCM&owner.
CompleDonofproject&commissioningofplantisdonebyLSTKcontractor&approvedbyPMC/
Licensor/Owner
Major Refinery Equipment’s • Pressure vessels
• Heat exchangers • Shell & Tube Heat Exchangers • Plate & Frame Heat exchangers • Air cooled heat exchanger • Double Pipe exchanger
• Process Vessels • Drums • Gravity Separators • Column • Reactor
• Storage Tanks • Fixed-roof tanks • External floating roof tanks • Internal floating roof tanks • Domed external floating roof tanks • Horizontal tanks • Pressure tanks • Variable vapor space tanks • LNG (Liquefied Natural Gas) tanks
• Fired heaters / Furnace • Piping system & Valves • Pumps
• Centrifugal Pumps • Positive Displacement pumps
• Reciprocating pumps • Rotary Pumps
• Compressors • Reciprocating • Rotary Screw • Rotary Centrifugal
• Cooling Towers
Reference
1. TheBlackGold• Fundamentalsofpetroleum&PetrochemicalEngg–UjamRayChaudhuri• hjps://en.wikipedia.org/wiki/Benchmark_(crude_oil)• hjp://www.markeDndex.com.au/crude-oil
2. AboutHydrocarbonIndustry• Fundamentalsofpetroleum&PetrochemicalEngg–UjamRayChaudhuri
3. AGuideofRefineryProcess• ChemicalEngineeringProcess–AnAICHEPublicaDons• EssarpresentaDon
4. Tableofvariousprocesswithapproximatecost&criDcality5. CrudeDisDllaDonUnit
• Fundamentalsofpetroleum&PetrochemicalEngg–UjamRayChaudhuri6. ProducDonofGasoline(Petrol)fromHeavyNaphtha
• Fundamentalsofpetroleum&PetrochemicalEngg–UjamRayChaudhuri• ChemicalEngineeringProcess–AnAICHEPublicaDons
7. FluidCatalyDcCracking• hjps://en.wikipedia.org/wiki/Fluid_catalyDc_cracking• ChemicalEngineeringProcess–AnAICHEPublicaDons
8. ListofRefineriesinIndiaandtheirproducDoncapaciDes• MinistryofPetroleum&NaturalGasIndia