REFINERY PROCESS

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REFINERY PROCESS
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WHAT IS CRUDE OIL ?

• COMPLEX MIXTURE OF HYDROCARBONS
• COMPONENTS RANGE FROM METHANE TO LARGE HEAVY
  MOLECULES(C70)
• CAN BE SAID TO CONSIST OF FRACTIONS ie
  LPG,NAPHTHA,KEROSENE,DIESEL,GAS OILS ETC
• RARELY USABLE DIRECTLY
• AIM OF REFINING
• TO PROCESS CRUDE OIL INTO A VARIETY OF USEFUL
  SALEABLE PRODUCTS
• REFINING CONSISTS OF PRIMARY SECONDARY
  PROCESSING
• PRIMARY PROCESSING
• SIMPLE SEPARATION OF CRUDE OIL INTO COMPONENT
  FRACTIONS
• SEPARATION IS ACHIEVED BY MEANS OF DISTILLATION
  OF CRUDE

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AVALABILITY OF CRUDE OIL
INDIGENOUS
IMPORTED
NORTH EAST GULF REGIONS BOMBAY
HIGH AUSTRALIA GUJARAT CIS CAU.BASIN AFRIC
A JVCS FAR EAST
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ATMOSPHERIC DISTILLATION

• FIRST STEP IN THE REFINING OF ANY CRUDE OIL
• CRUDE OIL IS HEATED TO APPROX 370-380 DEG C
• THIS CAUSES THE CRUDE TO VAPOURISE UPTO SLIGHTLY
  MORE THAN DIESEL FRACTION.HEAVIER FRACTION
  REMAINS LIQUID
• VAPOUR-LIQUID MIXTURE OF CRUDE IS FED INTO THE
  DISTILLATION COLUMN
• THE DISTILLATION COLUMN CONSISTS OF A SERIES OF
  TRAYS WHERE CRUDE VAPOUR LIQUID ARE
  CONTINUOUSLY CONTACTED
• THIS CAUSES THE CRUDE OIL TO SEPARATE OUT INTO
  VARIOUS DESIRED FRACTIONS WHICH ARE REMOVED AS
  SIDESTREAMS.
• PRODUCTS OBTAINED ARE
• BOILING RANGE,DEG C
• LPG lt50
• NAPHTHA 50-140
• DIESEL
• HEAVYDIESEL 240-370
• ATMOS RESIDUE 370

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REFINERY FLOW CHART
FOR MOTOR OIL OPERATION
FORINDUSTRIAL OIL OPERATION
TOBS EXTRACT
NMP HF
TOBS 150N 500N 1300N
VPS
IO-100 IO-1600
RCO
150 RAFFINATE
500 N RAFFINATE
1300 N RAFFINATE
HYDROFINER
IO 100 BASE STOCK
HYDROGEN
VTB
PDU
150N BASE STOCK

• EXTRACT
• RPO/CBFS
• RAILEX
• 50EXTRACT
• 40VTB
• 10 150N

LPG
500 N BASE STOCK
PDA
H2 GAS
TOBS
ASPHALT
STEAM
1300 N BASE STOCK
IO 1600 BASE STOCK
150 BS
NMP
IO - 100 (HYDROFINED) IO - 1600 (HYDROFINED)
DAO
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VACCUM DISTILLATION
R C O CONTAINS LOT OF VALUABLE DISTILLATES WHICH
REQUIRES VERY HIGH TEMPERATURE TO DISTILL AT
ATMOSPHERE PRESSURE WHICH WILL RESULT IN
CRACKING THE RESIDUE. TO OVERCOME THIS PROBLEM
DISTILLATION IS CARRIED OUT UNDER VACUUM WHICH
REQUIRES LOWER TEMPERATURES.
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VACCUM DISTILLATION UNIT
OBJECTIVES
A) PRODUCTION OF LUBE CUTS B) PREPARATION OF
HEAVY DISTILLATE FEED STOCKS FOR - THERMAL
CRACKERS. - FLUID CATALYTIC CRACKERS. - HYDROC
RACKERS. C) PRODUCTION OF HEAVY RESIDUE SUITABLE
FOR BITUMEN MANUFACTURE (NOT COMMON NOW A
DAYS)
OBJECTIVE DEPENDS ON - TYPE OF CRUDE
OIL - TYPE OF REFINERY. - DOWNSTREAM
PROCESSING CAPABILITIES. - ANTICIPATED DEMAND /
SALES OF PRODUCTS.
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SOLVENT EXTRACTION-NMP
SOLVENT EXTRACTION IS A PHYSICAL PROCESS OF
REMOVING UNDESIRABLE, AROMATIC COMPONENTS
FROM THE DESIRABLE, PARAFFINIC AND NAPTHENIC
COMPONENTS OF LUBE FEED STOCKS. THE REMOVAL OF
THESE COMPONENTS IMPROVES VISCOSITY INDEX,COLOUR,
OXIDATION AND THERMAL STABILITY OF BASE
OILS. THIS COMPONENT SEPERATION IS ACCOMPLISHED
BY THE PREFERENTIAL SOLUBILITY OF THE UNDESIRABLE
AROMATIC COMPONENTS IN THE HEAVIER SOLVENT RICH
PHASE (EXTRACT). THE LIGHTER PHASE (RAFFINATE)
CONTAINS THE REMAINING PARAFFINIC AND NAPTHENIC
COMPONENTS ALONG WITH SOME DISSOLVED SOLVENT.
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SOLVENT EXTRACTION HYDROFINING
H2
RAFF.SOLUTION
RAFFINATE RECOVERY
HYDROFINER
HYDROFINED RAFFINATE PRODUCT
TREATER TOWER
SOLVENT STRIP GAS RECOVERY
FEED
SOLVENT
EXTRACT RECOVERY
EXTRACT PRODUCT
EXTR. SOLUTION
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PROPANE DEWAXING
IN PROPANE DEWAXING UNIT(PDU),WAX IS REMOVED TO
LOWER DOWN THE POUR POINT OF BASE STOCK WHICH
PERMITS THE LUBRICANTS TO BE USED AT LOWER
TEMPERATURES .IN PDU,PROPANE IS USED AS DILUENT
AND ALSO AS THE REFRIGERATING AGENT TO CHILL THE
FEED STOCK SO THAT THE WAX CAN CRYSTALLIZE
OUT. RAFFINATE FROM NMPs AND INDUSTRIAL OIL FROM
IOH ARE CHARGED TO PDU WITH 0.05 TO 0.12 OF
DEWAXING AID.TEMPERATURE IS RAISED 60C AND
PROPANE IS ADDED.AFTER CHIILING WAX CRYSTALS ARE
REMOVED BY FILTERATION AND PROPANE IS
RECOVERED
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PROPANE DEWAXING UNIT
1) FEED PREPARATION SECTION. 2) CHILLING
SECTION. 3) FILTERATION. 4) D W O
RECOVERY. 5) W A X RECOVERY. 6) PROPANE
CIRCULATION SYSTEM.