Faculty V Suresh SPNM-CG Prepared by Production-CG Team REFINING PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future 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 PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future The mixture can be split into simpler fractions by fractional distillation. CATEGORIES OF END PRODUCTS PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future The typical primary end-products are categorised as
Light distillates Liquid petroleum gas (LPG) Propylene Motor Spirit (also known as petrol) Naphtha
Other Solid Products Petroleum Coke Sulphur CLASSIFICATION OF REFINING PROCESS PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future DISTILLATION PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future DISTILLATION PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future 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 PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future 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 PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future Previously used at Digboi Refinery DISTILLATION COLUMN EQUIPMENT PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future 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 PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future 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 PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future 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 PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future 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 PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future DISTILLATION TYPES OF LIQUIDS PARADEEP REFINERY PROJECT 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. A Sunrise Project for a Sunshine Future small easily high low large easily high low volatility low high FLOW SCHEME OF MODERN REFINERY PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future REFINERY CONFIGURATIONS PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future FLOW SCHEME OF PARADIP REFINERY PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future VARIOUS UNITS IN THE REFINERY PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future 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 PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future 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 PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future 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 PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future 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 PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future 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 PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future 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 PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future 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 PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future 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 PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future 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 PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future 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 PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future 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 PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future 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 PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future 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 PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future 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 PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future 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 PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future 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 PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future 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 PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future 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 PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future 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 PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future 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) PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future 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 PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future 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) PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future 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 PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future 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 PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future 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 PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future 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 PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future