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Main Products
C3-C4 LPG
Lt Distillate 0
Lt Distillate
Middle
Distillate
Heavy ends
TYPES OF HYDROCARBONS:
– PARAFFINS
– NAPHTENES
– AROMATICS
– OLEFINS
TYPES OF HYDROCARBON
• PARAFFINS :
• NAPHTHENES :
– Saturated Cyclic hydrocarbons.
– High chemical stability.
– General Formula CnH2n.
• OLEFINS :
– Unsaturated open chain hydrocarbons.
– Highly reactive.
– Generally formed during cracking / conversion processes.
TYPES OF HYDROCARBON (Contd…)
• AROMATICS :
– Unsaturated Cyclic hydrocarbons having general formula
CnHn.
– Chemically reactive.
– Aromatics in Gasoline increases Octane number.
– Undesirable in Kerosene because of their tendency to
give smoky flame.
IMPURITIES IN CRUDE OIL
• SULPHUR:
– Major impurity and present in elemental form.
– Sulfides / oxides of sulfur (H2S, Mercaptans, SO2 etc)
generated in refinery processes.
– Present as H2S / Mercaptans in LPG, as Sulfur / Mercaptans in
Gasoline, Kerosene, ATF and as sulfur in HSD & Residues.
– Sweetening Processes (caustic washing, Mercaptan Oxidation)
are used to remove these impurities from products.
IMPURITIES IN CRUDE OIL (Contd..)
• NITROGEN :
– Present in elemental form and also as oxides of Nitrogen.
– Forms Acids and causes corrosion.
– Removal is necessary to get on-grade products and
secondary units feedstocks.
• OXYGEN :
– Present in elemental form and also as compounds of
Oxygen.
– Forms Naphthenic Acids and causes stress corrosion.
IMPURITIES IN CRUDE OIL (Contd..)
• METALS :
– Main metals in Crude oil are - Lead, Nickel, Vanadium & Copper.
– Present in very small quantity (ppm level), in Crude and gets distributed
in various products.
– Poison to catalysts even in very small amount.
• SALTS :
– Are formed during Refining process.
– Main salts - NaCL, MgCL2, KCL.
– Acids formed from these salts attacks plant equipments and corrosion
sets In.
• SEDIMENTS & WATER:
– Sediment: Fine particles of sand clay, volcanic ash,drilling mud, rust, iron
sulphide, metals and scale.
– Damaging Effects Plugging Abrasion and residual product contamination.
– Water causes irregular behaviour in distillation.
Reid Vapour Pressure (RVP) and Light End Analysis
WAX CONTENT
Primary Yields
% wt
Light Distillates 24 14 16 17 16
% wt
Middle Distillates 46 36 36 43 36
% wt
Residue 30 50 48 40 48
YIELD PATTERN OF VARIOUS CRUDES (% WT)
LPG
Naphtha
Petrol
Kerosene
Diesel
Heavy ends
140.0
Yield - %wt on crude,
117.0 120.0 Price - % of crude price
120.0
Avg product price – 104.6 %
100.0
Crude
80.0 70.0
64.1
% 53.4
60.0
20.0
13.9 9.7
0.0
Light distillate Middle distillate Heavy ends
Yield Wt. Avg Price Realization
Naphtha 100
Crude Distillation Unit
CRUDE
CDU
300
Diesel / Gas oil
400
Fuel Oil
(Atmospheric
Residue)
HYDRO SKIMMING REFINERY
Refinery equipped with Atmospheric Distillation, Naphtha reforming and necessary treating
processes. More complex than topping refinery and produces gasoline
LPG LPG 0
Mogas
Mogas
CRU
Crude Distillation Unit
Naphtha 100
Catalytic Reformer
CDU
CRUDE
OIL Jet / Kerosene 200
Fuel Oil
(Atmospheric Residue)
CRACKING REFINERY
Also has Vacuum Distillation and Catalytic Cracking. Adds complexity to the hydro skimming
refinery & converts fuel oil to light and middle distillates
CRUDE
OIL Jet / Kerosene
Vacuum Distillate
(Vacuum Gasoil,
Waxy Distillate)
Vacuum Distillation
Catalytic Cracker
FCCU
VDU
Mogas
CRU
Catalytic Reformer Naphtha
CDU
CRUDE
OIL Jet Jet / Kerosene
Gasoil
Diesel
VLS
Low-sulphur
Desulphuriser Diesel / Gasoil
Vacuum Distillation
Vacuum Distillate
Hydrocracker
HCCU
(Vacuum Gasoil,
VDU
Waxy Distillate)
Coke
Hydrogen
Coker
HYDROCRACKING + RDS REFINERY
Adds further complexity to the hydro cracker cracking refinery by high conversion of
fuel oil into distillates. Also has Residue Desulfuriser. Produces low sulphur fuels
Mogas
CRU
Catalytic Reformer Naphtha 100
CDU
CRUDE
OIL Jet Jet / Kerosene 200
Gasoil
Diesel
VLS
Low-sulphur 300
Desulphuriser Diesel / Gasoil
400
Vacuum Distillation
Vacuum Distillate
Hydrocracker
(Vacuum Gasoil,
HCCU
Waxy Distillate)
VDU
Hydrogen
AR/VRDS
REFINERY CONFIGURATION
Refinery Processes
• Crude Distillation
LPG
110 C
2.0 ata Lt Distillate
Naphtha
upto 170 C
Heater Kerosine
Distillation
column upto 270 C
370 C
Middle
Distillate
CRUDE Diesel
upto 360 C
360 C
2.2 ata
Vacuum Diesel
Atmospheric VDU
10-20
LVGO
Residue mmHg abs
400-405 HVGO Heavy vacuum
gas oil
Deg C
Slops
Vacuum
Residue
Typical Product Pattern
Reformate
Typical Yield
Cracked LPG
Vacuum
Gas Oil Gasoline
FCC Light Cycle Oil
Heavy Cycle Oil
Clarified Oil
Slurry Recycle
Fluid Catalytic Cracking unit
P-2.0 bar T-495 to 515 C
Vapors to fractionator
P-1.7-2.1 bar
T-700 C
Stripper
Catalyst
Regenerator T-685 C
Riser
Reaction
C30 C-C-C + C-C-C-C-C + C-C-C-C
Air Steam
+ C8 +C 10
VGO
Typical Product Pattern
LPG
Vacuum
Gas Oil HCU Light Naphtha
170-180
Kg/cm2g Heavy Naphtha
380-390 C
350-360 C Kerosene / ATF
HSD
Unconverted Oil
Residue Upgradation Process
Fuel gas
Coke
/ Unconverted Oil
PRODUCT TREATMENT- OBJECTIVES
Primary separation only physical separation; products need
treatment to meet desired specifications.
Contaminants Effects
Hydrogen Sulfide Acidity, corrosion, obnoxious combustion products,
reduced octane no., foul odour
Mereaptans Corrosion, obnoxious combustion products, reduced
octane no., gum deposits, engine deposits, foul odour
• Fuel Oil produced from VR, Asphalt produced in SDA & Petroleum Coke from
Coker Unit can be utilized for Power Generation.
• Petroleum Coke can also be calcined to produce calcined petroleum coke (CPC).
PRODUCT BLENDING
• OBJECTIVE –
• TYPES OF BLENDING
1. On-line blending – For products like LPG,
Naphtha, MS, ATF, Kerosene, Diesel, etc.
3) Environmental Protection
4) Equipment Corrosion
5) Flow Properties
PRODUCT PROPERTIES
TEST - DISTILLATION
- Significance varies from Product to Product.
- For Crude oil, ASTM Distillation gives idea about the quantum of various
fractions.
Refinery.
Significance
- Test is important with respect to safety in transport, vapor lock in the gasoline engines,
types and design of storage tanks employed.
- High vapor pressure entails loss of product during storage and transportation.
PRODUCT QUALITY TESTS &
THEIR SIGNIFICANCE
Significance
- Due to heat of compression, the temp. in the cylinder goes high and there could be
mistimed ignition. A high octane gasoline is better for ignition. Mistimed ignition
produce knocking in the engine.
- Knocking in an engine may result in loss of energy and may cause severe damage
-Minimum required octane ensures trouble free operation.
• The different hydrocarbon in gasoline :
₋ For the same Carbon No; straight chain paraffin have lowest octane No.
₋ Olefins also have high O.N. but they cause gum deposits in the fuel tank
and are not desirable.
₋ Aromatic have high O.N. but their content is being restricted due to their
carcinogenic nature.
PRODUCT QUALITY TESTS &
THEIR SIGNIFICANCE
- Lowest temp. at which application of test flame causes vapor above the sample
to ignite.
Significance
- Reference fuel used are normal Cetane (100 c.n.) and alpha-methyl-
naphthalene (0 c.n.).
Significance
Significance
Significance
Distillation :
@ rec. up to 700C,% vol. 10 – 45 10 – 45 10 – 45
@ rec. up to 1000C,% vol. 40 – 70 40 – 70 40 – 70
@ rec. up to 1800C,% vol. 90 75, min. 75, min.
Final BP, 00 C, max. 215 210 210
Residue, % vol., max. 2 2 2
RON, min. 88 91 91
MON, min. - 81 81
Diesel Specifications
Characteristics Bharat Stage II Euro III Euro IV
Equivalent Equivalent
Poly-cyclic Aromatics HC - 11 11
(PAH), % mass, max.
BLENDING
BH +LS crude LPG / C3
CDU-1 HVU VGO CCU Naphtha
Train-1 Atm residue MS
Benzene
LPG C3-C4/MTBE Toluene
NHDS CRU ARU
Naphtha Hexane
Blending streams – 110 GASOLINE SBP
Acid gas
CCR To make 32 different grade products
ATU / SRU SPLITTER
Middle distillate
MTO
2.0 mmta
BH +LS crude Crude & product tanks – >100 Kerosene
ATF
VGO
CDU-2 FPU FCCU
Train-2 HSD
Atm residue LOBS
LDO
GO
HGU1
Naphtha
VGO
DHDS Heavy ends
Furnace oil
6.0 mmta HGU2
LSHS
Imp HS crude HCU Bitumen
CDU-3 VDU
Train-3 Sulfur
BBU LOBS