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A Sunrise Project for a Sunshine Future

PARADEEP REFINERY PROJECT


Faculty
V Suresh
SPNM-CG
Prepared by
Production-CG Team
REFINING
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Distillation, the process by which oil is heated and separated in different
components, is the first stage in refining (primary processing).

Additional processes (secondary processing) ensures the desired products
are produced as per specification.
FRACTIONAL DISTILLATION
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The mixture can be split into simpler fractions by fractional distillation.
CATEGORIES OF END PRODUCTS
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The typical primary end-products are categorised as

Light distillates
Liquid petroleum gas (LPG)
Propylene
Motor Spirit (also known as petrol)
Naphtha

Middle distillates
Kerosene
ATF
HSD (Hi-Speed Diesel)
LDO (Light Diesel Oil)

Heavy distillates
Heavy fuel oils
LSHS

Other Solid Products
Petroleum Coke
Sulphur
CLASSIFICATION OF REFINING PROCESS
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DISTILLATION
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DISTILLATION
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Distillation is based on the fact that the vapour of a boiling mixture will be
richer in the components that have lower boiling points.

When this vapour is cooled and condensed, the condensate will contain
more volatile components. At the same time, the original mixture will
contain more of the less volatile material.
DISTILLATION COLUMN - TYPES
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BATCH COLUMNS

The feed to the column is introduced batch-wise. That is, the column is
charged with a 'batch' and then the distillation process is carried out. When
the desired task is achieved, a next batch of feed is introduced.

CONTINUOUS COLUMNS

Continuous columns process a continuous feed stream. No interruptions
occur unless there is a problem with the column or surrounding process
units.

They are capable of handling high throughputs and are the most common of
the two types
UNSTEADY STATE DISTILLATION
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Previously used at Digboi Refinery
DISTILLATION COLUMN EQUIPMENT
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A typical distillation contains several major components:

a vertical shell where the separation of liquid components is carried out
column internals such as trays/plates and/or packings which are used to
enhance component separations
a reboiler to provide the
necessary vaporisation for the
distillation process
a condenser to cool and
condense the vapour leaving the
top of the column
a reflux drum to hold the
condensed vapour from the top of
the column so that liquid (reflux)
can be recycled back to the column
DISTILLATION PROCESS
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The liquid mixture that is to be processed is known as the feed
Feed is introduced usually somewhere near the middle of the column to
a tray known as the feed tray
The feed tray divides the column into a top (enriching or rectification)
section and a bottom (stripping) section.
The feed flows down the column where it is collected at the bottom in
the reboiler.
INTRODUCTION TO DISTILLATION WITH REFLUX
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1. Feed enters the column somewhere in the
middle of the column.
5. The vapor continues up to the next tray or
stage, where it is again contacted with a
downflowing liquid.
2. Feed is liquid, it flows down to a sieve tray
or stage.
4. The vapor and liquid leaving the tray are
essentially in equilibrium.
In a distillation column the stages (referred to as sieve plates or trays) in a distillation tower are
arranged vertically, as shown schematically in figure below.
3. Vapor enters the tray and bubbles through
the liquid on this tray as the entering liquid
flows across.
6. The concentration of the more volatile
component is being increased in the vapor
form each stage going upward and decreased
in the liquid from each stage going
downwards.
INTRODUCTION TO DISTILLATION WITH REFLUX
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7. The final vapor product coming overhead
is condensed in a condenser and a portion of
the liquid product (distillate) is removed,
which contains a high concentration of A.
9. The liquid leaving the bottom tray enters a
reboilier, where it partially vaporized, and
the remaining liquid, which is lean in A or
rich in B, is withdrawn as liquid product.
In a distillation column the stages (referred to as sieve plates or trays) in a distillation tower are
arranged vertically, as shown schematically in figure below.
8. The remaining liquid from the condenser is
returned (refluxed) as a liquid to the top tray.
10. The vapor from the reboiler is sent back
to the bottom stage or trays is much greater.
DISTILLATION COLUMN
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DISTILLATION TYPES OF LIQUIDS
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LIGHT liquids are composed of ________ molecules.
tend to vaporize ________
have _______ vapor pressures
have _______ boiling points

HEAVY liquids are composed of _________ molecules.
do not tend to vaporize ________
have _______ vapor pressures
have _______ boiling points

Volatility is a term used to refer to ease of vaporization. Hence, a liquid
which tends to vaporize easily has a high ____________.

A liquid with a high boiling point has _______ volatility.

A liquid with a high vapor pressure has _______ volatility.
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small
easily
high
low
large
easily
high
low
volatility
low
high
FLOW SCHEME OF MODERN REFINERY
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REFINERY CONFIGURATIONS
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FLOW SCHEME OF PARADIP REFINERY
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VARIOUS UNITS IN THE REFINERY
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1.0 Atmospheric/ Vaccum distillation Unit (AVU) : distills crude oil into various
fractions first at Atmospheric pressure and them under vaccum.
Feed: Crude oil
Products /byproducts
Refinery off gas
LPG
Naphtha
Kerosene
Straight run diesel
Vaccum gas oil
Vaccum residue


VARIOUS UNITS IN THE REFINERY
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2. Naphtha hydrotreater unit (NHTU) uses hydrogen to desulfurize naphtha
from AVU and other units to feed the same to Catalytic Reformer unit
(CCRU).

Process : Feed hydrogen mixture heating reaction ( over catalyst bed)
Separation and recycle of hydrogen stripping of liquid for H2S
product routing.

Feed
Naphtha from AVU
Cracked naphtha from FCCU
Products /byproducts
Fuel gas
Hydrotreated naphtha
VARIOUS UNITS IN THE REFINERY
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3. Continuous Catalytic reformer unit (CCRU) is used to convert the naphtha-
boiling range molecules into higher octane reformate (reformer product).
The reformate has higher content of aromatics. An important byproduct of
a reformer is hydrogen released during the catalyst reaction. The hydrogen
is used for removal of sulhur in hydrotreaters.

Feed
Hydrotreated naphtha
Products /byproducts
Fuel gas - byproduct
Reformate Major component of Petrol
Hydrogen - byproduct
LPG byproduct
VARIOUS UNITS IN THE REFINERY
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4. Distillate/ Diesel hydrotreater (DHDT)unit desulfurizes distillates (such as
diesel) after atmospheric distillation.
Process : Feed hydrogen mixture heating reaction ( over catalyst bed)
Separation and recycle of hydrogen stripping of liquid for H2S
vaccum drying product routing.

Feed
Straight run diesel from AVU
Coker gasoil
FCC light cycle oil
Hydrogen
Products /byproducts
Fuel gas - byproduct
Treated Diesel
Naptha byproduct
VARIOUS UNITS IN THE REFINERY
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5. Vaccum gas oil Hydrotreater unit (VGO-HDT) uses hydrogen to treat the feed
to FCC to remove sulphur and nitrogen compounds.
Process : Feed hydrogen mixture heating reaction ( over catalyst bed)
Separation and recycle of hydrogen stripping of liquid for H2S
Atmospheric distillation for Diesel separation product routing. Diesel is
further hydrotread to meet sulphur specification.
Feed
Vaccum gasoil (VGO) from AVU
Coker Hy gasoil
Hydrogen
Products /byproducts
Fuel gas - byproduct
Treated Diesel
Treated VGO
Naptha byproduct
LPG byproduct
VARIOUS UNITS IN THE REFINERY
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6. Delayed coker Unit (DCU) process very heavy residual oils(vaccum residue)
into gasoline and diesel fuel, leaving petroleum coke as a residual product
by thermal cracking.

Process : Feed heating to high temperature Coking Separation of
distillate and gas. Coke removal and disposal. All products require
further treatment in secondary processing units.

Feed
Vaccum Residue from AVU
Products /byproducts
Fuel gas - byproduct
Coke
Gas oil
Coker naphta
Coker LPG byproduct
VARIOUS UNITS IN THE REFINERY
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7. Fluid catalytic cracker (FCC) is used to convert the high-boiling, high-
molecular weight hydrocarbon fractions of petroleum crude oils to more
valuable gasoline, olefinic gases, and other products.

Process : Feed heating Cracking in presence of catalyst Separation of
distillate and gas.
Spent catalyst regeneration using air and recycle.

Feed
Vaccum Residue from AVU
Products /byproducts
Fuel gas - byproduct
Cracked LPG PRU
Lt Naptha MS blending component
Hy naphtha -
Cycle oils
VARIOUS UNITS IN THE REFINERY
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8. Alkylation unit and Butamer unit : produces high-octane component for
gasoline blending from FCC LPG feed.

Process : Feed Alkylation reaction in-presence of Sulphuric acid catalyst
separation.

Feed
FCC LPG and Straight run LPG ( C4 components)
Products /byproducts
Alkylate
Spent acid
VARIOUS UNITS IN THE REFINERY
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9. Sulphur recovery unit (SRU -Claus unit) and tail gas treatment convert
hydrogen sulfide from hydrodesulfurization into elemental sulfur.


Process : H2S rich gas from Amine regeneration unit Claus reaction
Sulphur separation.

Feed
H2S rich gas from ARU
Products /byproducts
Elemental Sulphur
VARIOUS UNITS IN THE REFINERY
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10. Amine regeneration unit (ARU) recovers /removes hydrogen sulphide from
rich amine and lean amine to sent back to absorbers

Process : Rich amine loaded with H2S from units stripper -> Lean amine
recycle to units and H2S to SRU.

Feed
Rich amine from Hydro treating units
Products /byproducts
H2S rich gas to SRU
Lean amine to units
VARIOUS UNITS IN THE REFINERY
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11. Sour water stripper unit (SWS) strips out ammonia and hydrogen sulphide
from contaminated process water ( especially from Hydro-processing units)
before draining to ETP.

Process : Sour water rich in ammonia and H2S stripper -> Ammonia & H2S
vapours to SRU and stripper sour water to Units and Effluent treatment
plant.

Feed
Sour water From uits
Products /byproducts
Ammonia and H2S rich gas to SRU
Stripped sour water to Units and ETP
VARIOUS UNITS IN THE REFINERY
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12. Other untis

KTU Kero treater unit for Aviation turbine fuel (ATF) production from
Kerosene.
FCC Light naphtha treating unit for removal of mercaptan suphur
FCC LPG treater - for removal of mercaptan suphur
Sulphuric acid regeneration unit (SARU) for regeneration of spent acid
from Alkylation unit.
ETP effluent treatment unit
Blending station for MS blending
Incinerator for burning sold waste.
Intermediate stream storage tanks
Hydrogen bullet
Flushing oil system
FINISHED PRODUCTS
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Liquefied petroleum gas : propane or butane, is a flammable mixture of hydrocarbon
gases used as a fuel in heating appliances and vehicles.
LPG SPECIFICATIONS (BIS:4576-1999)
LPG DOMESTIC - BULK (ASTM/IP/IS1448)
S no Test method Method Specification
1 Copper Corrosion @38 C 1 Hr D 1838 Not Worse than1
2 Free Water Content VISUAL NOT PRESENT
3 Hydrogen Sulphide D 2420 Passes the TEST
4 Odour P 75 Min. 2.0
5 Total Volatile Sulphur D 2784 Max. 150.0 ppm
6 Volatility (Evapor.Temp 95%V @ 760 mmHg) D 1837 Max. 2.00 CEL
7 Vapour Pressure @40 C D 1267 Max. 1050.0 kPa
FINISHED PRODUCTS
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Motor Spirit (also known as petrol): is a petroleum-derived liquid that is used primarily
as a fuel in internal combustion engines.
BS-IV MS specification (ASTM/IP/IS1448)
S no Test method Specification Method
1 Density @ 15C 720.0 .. 775.0 kg/m3 P 16
2 Recovery upto 70C ( E 70 ) 10.0 .. 45.0 vol% P 18
3 Recovery upto 100C ( E 100 ) 40.0 .. 70.0 vol% P 18
4 Recovery upto 150C ( E 150 ) Min. 75.0 vol% P 18
5 Final Boiling Point ( FBP ) . C Max. 210.0 C P 18
6 Residue Max. 2 vol% P 18
7 Research Octane Number ( RON ) Min. 91.0 P 27
8 Motor Octane Number ( MON ) Min. 81.0 P 26
9 Existent Gum Content ( Solvent washed ) Max. 40.0 mg/dcl P 29
10 Oxidation Stability, minutes Min. 360
11 Sulphur Total Max. 50 mg/kg D 2622
12 Lead Content ( as Pb ) Max. 0.005 g/l
13 Reid Vapour Pressure ( RVP )@38C Max. 60 kPa P 39
14 Vapour Lock Index ( VLI CAL Max. 950
15 Benzene Content Max. 1.0 vol%
16 Cu Strip Corrosion (3hrs @/50P 15 degC) Class 1
17 Olefin Content Max. 21.00 vol% P 23
18 Aromatics Content Max. 35.0 vol% P 23
FINISHED PRODUCTS
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Kerosene: Kerosene is a combustible hydrocarbon liquid. Kerosene lamps are widely
used for lighting in rural areas.
KEROSENE SPECIFICATIONS(IS:1459-1974)
SUPERIOR KEROSENE - (PDS) (ASTM/IP/IS1448)
S no Test method Specification Method
1 Acidity Inorganic in mg.KOH/gm P 2 Max. 0.00
2 Bloom on Glass Chimney P 5 Not Darker than Grey
3 Copper Cor @50C for 3hrs P 15 Not Worse than1
4 Burn Test Char Value P 5 Max. 20.0 mg/kg
5 Colour Saybolt P 14 Min. 10.0
6 Density at 15 C P 16 kg/m3
7 Recovery @ 200 C P 18 (T) 20.00 vol%
8 Dist- FBP P 18 Max. 300.0 CEL
9 Flash Point P 20 Min. 35.0 CEL
10 Smoke Point P 31 Min. 18.00 mm
11 Sulphur Content Total P 34 Max. 0.2500 mass%
FINISHED PRODUCTS
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HSD (high speed Diesel ) : Liquid fuel used in diesel engines (IS:1460-2010)
HSD - BS IV specification (ASTM/IP/IS1448)
S no Test method Specification Method
1 Acidity, inorganic in mg KOH/gm P 2 Max. 0.00
2 Acidity, Total, mg of KOH/g P 2 ---
3 Ash Content Max. % mass P 4 Max. 0.0100 mass%
4 RCR(10% Residue) P 8 Max. 0.30 mass%
5 Cetane number ( CN ) P 9 Min. 51.0
6 Cetane Index ( CI ) D 4737 Min. 46.0
7 Pour Point, Summer C P 10 Max. 15 C
8 Dist. % v/v, Rec @ 360C P 18 Min. 95.0
9 Flash point: ( Abel ) C P 20 Min. 35.0 C
10 Kinematic Viscosity @ 40C P 25 2.000 .. 4.500 cSt
11 Density @ 15C P 16 820.0 .. 845.0 kg/m3
12 Total Sulphur D 2622 Max. 50 mg/kg
13 Water Content Max. 200 mg/kg
14 Cold Filter Plugging point (Summer) P 110 Max. 18 C
15 Total Contaminations EN 12662 Max. 24.0 mg/kg
16 Oxidation stability D 2274 Max. 25 g/m3
17 Polycyclic Aromatic Hydrocarbon( PAH ) IP 391 Max. 11.0 mass%
18 Lubricity, corrected wear scar diameter ISO12156 Max. 460 m
19 Cu Strip Corrosion (3hrs @/50P 15 DegC Class 1
PETROLEUM PROPERTIES
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Reid vapor pressure (RVP) is the absolute pressure exerted by a mixture at
37.7C (100
o
F)
Applicable to LPG, Gasoline

Pour point of a petroleum fraction is the lowest temperature at which the oil will
pour or flow when it is cooled without stirring under standard cooling conditions.
Applicable to ATF , Diesel and fuel oils

Flash point for a hydrocarbon or a fuel is the minimum temperature at which
vapor pressure of the hydrocarbon is sufficient to produce the vapor needed for
spontaneous ignition of the hydrocarbon with the air with the presence of an
external source, i.e., spark or flame.

Flash point is an important parameter for safety considerations, especially during
storage and transportation of volatile petroleum products. The surrounding
temperature around a storage tank should always be less than the flash point of the
fuel to avoid possibility of ignition.
Applicable to ATF , Diesel and Fuel oil.



PETROLEUM PROPERTIES
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Fire point : Flash point should not be mistaken with fire point, which is defined
as the minimum temperature at which the hydrocarbon will continue to burn for at
least 5 seconds after being ignited by a flame.

Auto-ignition temperature is the minimum temperature at which hydrocarbon
vapor when mixed with air can spontaneously ignite without the presence of any
external source. Values of auto-ignition temperature are generally higher than flash
point.

Flammability range :
To have a combustion, three elements are required: fuel (hydrocarbon vapor),
oxygen (i.e., air), and a spark to initiate the combustion.
One important parameter to have a good combustion is the ratio of air to
hydrocarbon fuel.
The combustion does not occur if there is too much air (little fuel) or too little air
(too much fuel).
This suggests that combustion occurs when hydrocarbon concentration in the air
is within a certain range.
This range is called flammability range and is usually expressed in terms of lower
and upper volume percent in the mixture of hydrocarbon vapor and air.



PETROLEUM PROPERTIES
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Octane number is a parameter defined to characterize antiknock
characteristic of a fuel (gasoline and jet fuel) for spark ignition engines.
Octane number is a measure of fuel's ability to resist auto-ignition during
compression and prior to ignition. Higher octane number fuels have better
engine performance.

The octane number of a fuel is measured based on two reference
hydrocarbons of n-heptane with an assigned octane number of zero and
isooctane (2,2,4-trimethylpentane) with assigned octane number of 100.
PETROLEUM PROPERTIES
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Motor octane number (MON) and research octane number (RON) :
are two methods of measuring octane number of a fuel in the
laboratory.

The MON is indicative of high-speed performance (900 rpm) and is
measured under heavy road conditions.

The RON is indicative of normal road performance under low engine
speed (600 rpm) city driving conditions.

Isoparaffins and aromatics have high octane numbers while n-paraffins
and olefins have low octane numbers.

In some countries average of the RON and the MON is called Pump
Octane Number (PON) or Anti-Knock Index (AKI)
PETROLEUM PROPERTIES (octane number)
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Generally there are three kinds of gasoline: regular, intermediate, and
premium with PON of 87, 90, and 93, respectively.
Improving the octane number of fuel would result in reducing power loss of
the engine, improving fuel economy, and a reduction in environmental
pollutants and engine damage.
There are a number of additives that can improve octane number of
gasoline.
These additives are tetra-ethyl lead (TEL) not in use, alcohols, and ethers.
PETROLEUM PROPERTIES
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Cetane number (CN) :
For diesel engines, the fuel must have a characteristic that favors auto-
ignition.

The ignition delay period can be evaluated by the fuel characterization
factor called cetane number (CN).

The shorter the ignition delay period the higher CN value.

The cetane number is defined as:
CN = vol% n-cetane + 0.15(vo1% HMN)
Where n-cetane (n-C
16
H
34
) has a CN of 100, and heptamethylnonane
(HMN) has a CN of 15.
PETROLEUM PROPERTIES (cetane number)
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Higher Cetane number fuels reduce combustion noise and permit improved
control of combustion resulting in increased engine efficiency and power
output.

Higher Cetane number fuels tend to result in easier starting and faster
warm-up in cold weather and can cause reduction in air pollution.

Cetane number of diesel fuels can be improved by adding additives such as
2-ethyl-hexyl nitrate or other types of alkyl nitrates.
PETROLEUM PROPERTIES
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Smoke Point (SP)
is a maximum flame height at which a fuel can be burned in a standard
wick-fed lamp without smoking.

It is expressed in millimeters and a high smoke point indicates a fuel with
low smoke-producing tendency.

Smoke point is a characteristic of aviation turbine fuels and kerosenes and
indicates the tendency of a fuel to burn with a smoky flame.

Higher amount of aromatics in a fuel causes a smoky characteristic for the
flame and energy loss due to thermal radiation.

PETROLEUM PROPERTIES
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Carbon residue (CR):
When a petroleum fraction is vaporized in the absence of air at atmospheric
pressure, the nonvolatile compounds have a carbonaceous residue known as
carbon residue (CR).

Therefore, heavier fractions with more aromatic contents have higher carbon
residues while volatile and light fractions such as naphthas and gasolines have
no carbon residues.

There are three different test methods to measure carbon residues,
Ramsbottom (ASTM D 524), the Conradson (ASTM D 189) and microcarbon
(ASTM D 4530). In most cases carbon residues are reported in wt%.
RECAP
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What is the primary process in refining?
What are all called secondary process? Why secondary processing?
What are straight run products?
What are all finished products from refinery?
Properties of Kerosene?
Properties of Diesel?
Properties of Gasoline?
QUERIES
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PARADEEP REFINERY PROJECT
A Sunrise Project for a Sunshine Future

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