BHARAT PETROLEUM CORPORATION LIMITED (BPCL)

Major Players in Petroleum Sector (India)

BPCL

HPCL
IOCL

RIL
ESSAR SHELL

Introduction
Bharat Petroleum Corporation Limited (BPCL) is one of India's largest PSU companies, with Global Fortune 500 rank of 289 (2009).
Its interests are in petroleum sector. It is involved in the refining and retailing of petroleum co. ltd

BPCL's growth post-nationalization (in 1976) has been phenomenal. It is considered a pioneer in marketing initiatives, and employs Best in Class practices.
On 1 August 1977, it was renamed Bharat Petroleum Corporation Limited.

ABOUT COMPANY

3rd largest oil company in India; Owned by the Government of India; Revenue (2009): $30 billion; Employees: 13600 In 1976, the Burmah Shell Group of Companies was taken over to form Bharat Refineries Limited. Renamed Bharat Petroleum Corporation Limited in 1977 First refinery to process newly found indigenous crude (Bombay High), in the country

Major Achievements in 2009 -2010

Sales turnover at Rs. 133,749.10 crores
Crude throughput at 23.03 MMT Market Sales including exports at 30.76 MMT Net profit at Rs. 1,719.98 crores Oil and Gas discoveries abroad show promise Innovating continuously across the entire value chain

Primary energy consumption of India

USA Total Europe & Eurasia China

Oil Natural Gas 40.4 24.4 32.3 33.8 21.1 2.7

Coal 24.6 18.0 69.6

Nuclear Hydro electric 8.0 2.6 9.6 6.3 0.8 5.8

India
Asia Pacific excl India & China

29.9
45.5 36.4

8.5
19.6 23.5

55.0
23.8 27.8

1.0
7.4 6.0

5.6
3.7 6.3

World

Oil contributes to 30 % of the Primary Energy demand of the country

Sources of crude and oil trade flows

Top World Oil Net Exporters, 2005 (OPEC members in italics) Net Oil Exports (million barrels Country per day) 1) 2) Saudi Arabia Russia

a a a a a a

9.1 6.7

3)
4)

Norway
Iran United Arab Emirates Nigeria Kuwait Venezuela Algeria Mexico

2.7
2.6 2.4 2.3

5)
6)

7) 8)
9)

2.3
2.2 1.8 1.7

10)

BPCL Crude Oil sourcing

Total Crude 22.5

Pipeline
Libya Kuwait
Iraq S Arabia UAE Yemen

9.5
13.0

BPC 12

NRL 2.5

Ships

KRL 8.0 Nigeria

Brunei Malaysia

Crude oil figures in MMTPA

Oil Downstream Sector in India

2005
All India
IOC 6.0 IOC 8.0 IOC (BRPL) 2.4
BONGAIGAON

Imported Crude crude processed Product consumption

94.8 124.2 111.7

IOC 13.7
BHATINDA PANIPAT MATHURA DIGBOI

IOC 0.7 BPC (NRL) 3.0

NUMALIGARH

IOC 6.0
SIKKIM

BARAUNI

GUWAHATI

All figures in MMTPA

Vadinar BINA

IOC 1.0

Reliance 33.0
JAMNAGAR
KOYALI

HALDIA

HPC 5.5

MUMBAI PARADEEP

IOC 6.0
VISHAKHAPATNAM

LEGEND
REFINERY

EXISTING

PROPOSED

BPC 12.0
MRPL 9.7
GOA

HPC 7.5

IOC (CPCL) 9.5

MANGALORE CHENNAI

Region
North
South

14.0 35.2

BPC (KRL) 7.5 IOC (CPCL) 1.0

NARIMANAM

East
COCHIN

19.1
64.2

West

Crude oil to products

Main Products
C5-C10 PETROL C9-C16 KERO C14-C24 HSD >C22 FO Decreasing Boiling Point (deg C) Lt Distillate

C3-C4 LPG

100 200
300 400 500

CRUDE OIL REFINING

Middle Distillate

Heavy ends

Main process - simple distillation

CHEMICAL ENGINEERING (OPERATIONS)

Crude Distillation Unit

Gas
110 C

LPG

2.0 ata

Lt Distillate
Naphtha upto 170 C

Heater
370 C

Distillation column

Kerosine upto 270 C

Middle Distillate

CRUDE

Diesel upto 360 C

360 C
2.2 ata

Atmospheric Residue >360 C

Heavy ends

Crude oil distillation (atmospheric and vacuum)

A simple guide to oil refining

Fluid catalytic cracking

C30 C-C-C + C-C-C-C-C + C-C-C-C + C8 +C 10

Simple Refinery flow chart

(Major units) Crude unit BH +LS crude Train-1 Vacuum unit Cracking unit PRODUCTS
Light distillate LPG Naphtha Petrol Benzene Toluene

CDU-1
Atm residue

HVU

CCU

BH +LS crude Train-2

CDU-2

FPU

FCCU

Middle distillate Kerosene ATF Diesel

Imp HS crude Train-3

CDU-3 VDU

HCR

Various chemicals are added in different units for specific purpose

Heavy ends Furnace oil LSHS Bitumen Sulfur

REFINERY PROCESS FLOW DIAGRAM (COMPLEX)

AMINE TREATING

SULPHUR RECOVERY

CAUSTIC TREATER

LPG

REFORMER FEED UNIT

HYDRO DESULPHURISATION

CATALYTIC REFORMER

AROMATIC RECOVERY

CRUDE DISTILLATION FACILITIES

SPECIAL
PRE FRACTIONATOR

PRODUCTS

DEAROMATISATION

FRACTIONATOR

CRUDE

KEROMEROX

ATF SKO HSD

DIESEL HYDRODESULPHURISATION
C3/C4 SEPARATION

OIL

LPG
MS

VACUUM DISTILLATION1

FCCU1

LPG AMINE/MEROX

VACUUM DISTILLATION2

FCCU2

GASOLINE MEROX
METHANOL MTBE

BITUMEN

LSHS
BITUMEN BLOWING

BIT.

Yields are also crude dependent

100% 80% 60% 40% 20% 0% Bombay High

O

Lt Distillate

Middle Distillate

Heavy ends

Bonny Light
33.6 0.18

Arab Light

Kuwait

API

40 0.17

34.2 1.9

31.0

% Sulfur

2.7

Increased crude processing by periodic revamps

14 12 10

Commisioned in 1955 2.2 MMTA

12 8.8 4.8 5.9 6.9 7.5

MMT

8 6 4 2 0 1976 78-83

3.8

83-88

88-93

93-98

98-03

Post RMP

Refined Products
Main Applications
Domestic & Industrial heating,Transport Transport

Key Qualities
Vapour Pressure C2 & C5 content

Demand
LPG

Octane, Sulfur, Vapour Pressure,Benzene

Freezing point, Smoke point, Flash Sulfur, Cetane, Pour point Distillation,Flash point Viscosity, Pour point, Metals, Cal value

PETROL

Aviation, heating, lighting

KERO

Transport, Power

HSD

Industries, Power Sea transport

FO

Modes of Transportation

Road 17%

Rail 5.3%

Ship 8.6% Pipeline 69.1%

Mumbai-Manmad-Mangliya pipeline is the lifeline of the Refinery

Environment Neutral Refinery Operations

9.14
12.0

Crude Processed (MMTPA)

4.2
22

8.9

SOx (MT/D)
15000
13.0

11.8
11.7

Sea water (M3/Hr)

2490

5400

6000

1977

2002

2005

Post RMP

REFINERY PRODUCTS

MECHANICAL ENGINEERING

Process Equipment

Reactors/catalytic converters

Mass Transfer Distillation Absorption

Heat Transfer
Heat Exchangers Air coolers Fired Heaters Air pre heaters Boilers/ steam generators Storage Tanks Air coolers Spheres Bullets

Momentum Transfer
Pumps Compressors Ejectors Eductors

Stripping Extraction
Evaporation

Separation
2 phase (3 phase separators)

Desalters
Degassers Cyclone separators

Pits

API separators
Steam traps

PUMP CLASSIFICATION

PUMPS
KINETIC POSITIVE DISPLACEMENT

SPECIAL

CENTRIFUGAL

ROTARY

RECIPROCATING

AXIAL
FLOW

RADIAL FLOW

MIXED FLOW

GEAR

LOBE DIAPHR. PLUNGER PISTON

CENTRIFUGAL PUMP

SELF PRIMING

VOLUTE CASING

DIFFUSER

NON-SELF PRIMING

SINGLE STAGE

MULTI STAGE

OPEN IMPELLER

CLOSED IMPELLER
SEMI OPEN IMPELLER

SINGLE SUCTION

DOUBLE SUCTION

SINGLE SUCTION

DOUBLE SUCTION

PUMPS NOMENCLATURE

DISCHARGE NOZZLE

STUFFING BOX

THRUST BEARING

SHAFT

CASING

RADIAL BEARING BEARING HOUSING

IMPELLER

SUCTION NOZZLE

CENTRIGFUGAL PUMP FUNCTIONS

liquid
Raise Liquid to Another Level

liquid
Overcome Pipe Friction

Force Liquid into a Pressure Vessel

15 PSIG

30 PSIG

TOTAL HEAD = TH = HD + HS

TYPES OF COMPRESSORS

COMPRESSORS
POSITIVE DISPLACEMENT (COMPRESSING FLUID BY REDUCING VOLUME OF COPRESSION CHAMBER) DYNAMIC TYPE (ACCELERATING AND DECLERATING OF FLUID)

RECIPROCATING

ROTARY TYPE

CENTRIFUGAL COMPRESSORS

AXIAL COMPRESSORS

HELICAL SCREW

SPIRAL AXIAL

STRAIGHT LOBE

SLIDE VANE

HORIZONTAL SPLIT COMPRESSOR 2MCL

HEAT EXCHANGER

GAS TURBINE (CUT VIEW OF GAS TURBINE)

INLET BELLMOUTH

COMPRESSOR

COMBUSTION CHAMBER TURBINE SECTION

ASSEMBLED ROTOR OF A TYPICAL GAS TURBINE

THRUST COLLAR

TURBINE SECTION
COMPRESSOR SECTION

OPERATION CYCLE (BRAYTON CYCLE)

HIGH EFFICIENCY BOILER

Heater

COOLING TOWER