Indian Refineries Overview

Contents

Indian oil scenario

Crude oil sourcing
Refining Processes
Refinery overview

Refineries in India

* PANIPAT
* MATHURA
BARAUNI *
JAMNAGAR *

*
HALDIA

* GUWAHATI
* DIGBOI
* BONGAIGAON
* NUMALIGARH

* KOYALI
* MUMBAI 2 Nos.

* VISHAKAHAPATNAM

* MRPL

COCHIN *

* CHENNAI

Refining capacities
HPCL Mumbai
HPCL Visakh
HPCL Total

5.50
7.50
13.00

CPCL Chennai
CRL Narimanam
CPCL Total

6.50
0.50
7.00

IOC Guwahati
IOC Barauni
IOC Koyali
IOC Haldia
IOC Mathura
IOC Panipat
IOC Digboi
IOC Total

1.00
4.20
12.50
3.75
7.50
6.00
0.65
35.60

NRL Numaligarh
BPCL Mumbai
MRPL Mangalore
RPL Jamnagar
CRL Cochin
BRPL Bogaingaon

3.00
6.90
9.69
27.00
7.50
2.35

Total Refining capacity

112.04
All Figures are in Million tons per annum

Dependence on Crude Oil imports

Indigenous Vs Imports

100%
80%
60%
40%

Supply

Dem and

Indigenous

'0 3 -0 4

'0 2 -0 3

'0 1 -0 2

0 0 -0 1

9 9 -0 0

9 8 -9 9

9 7 -9 8

1 9 9 5 -9 6

'03-04

'02-03

'01-02

00-01

99-00

98-99

97-98

0%

1 9 9 0 -9 1

20%

1995-96

140
120
100
80
60
40
20
0

1990-91

M illion tons

Indigenous crude supply Vs Demand

Import

Refining capacity increased from 52 MMPTA to 121 MMTPA over last

decade
Stagnant indigenous production (33 MMTPA) resulted in crude oil
imports from 19 MMTPA to 88 TMT during last decade
Indian crude mix shifted from lighter to heavier
Crude sourced from Middle east, Far east, West Africa and South
America

From net imports to net exports

Petroleum product imports increased from 5.5 MMT during 1990-91 to

25 MMT during 1998-99.

Start up of new refineries and capacity additions to older ones, since

2001 resulted in India becoming net exporter of Petroleum products

Crude oil sourcing

Crude Oil

Crude oils are complex mixtures containing many different hydrocarbon

compounds that vary in appearance and composition from one oil field
to another. Crude oils range in consistency from water to tar-like solids,
and in color from clear to black. An "average" crude oil contains about
84% carbon, 14% hydrogen, 1%-3% sulfur, and less than 1% each of
nitrogen, oxygen, metals, and salts.

Classification of Crude Oil

Crude oils are generally classified as paraffinic, naphthenic, or
aromatic, based on the predominant proportion of similar hydrocarbon
molecules. Mixed-base crudes have varying amounts of each type of
hydrocarbon. Refinery crude base stocks usually consist of mixtures of
two or more different crude oils.
Relatively simple crude oil assays are used to classify crude oils as
paraffinic, naphthenic, aromatic, or mixed. One assay method (United
States Bureau of Mines) is based on distillation, and another method
(UOP "K" factor) is based on gravity and boiling points. More
comprehensive crude assays determine the value of the crude (i.e., its
yield and quality of useful products) and processing parameters.
Crude oils are usually grouped according to yield structure.

Classification of Crude Oil

Crude oils are also defined in terms of API (American Petroleum
Institute) gravity.
The higher the API gravity, the lighter is the crude. For example, light
crude oils have high API gravities and low specific gravities. Crude oils
with low carbon, high hydrogen, and high API gravity are usually rich in
paraffins and tend to yield greater proportions of gasoline and light
petroleum products; those with high carbon, low hydrogen, and low API
gravities are usually rich in aromatics.
Crude oils that contain appreciable quantities of hydrogen sulfide or
other reactive sulfur compounds are called "sour." Those with lower
sulfur are called "sweet."

Common crudes processed in India

High Sulfur

Low Sulfur

Arab Light (Saudi Arabia)

Bonny Light (Nigeria)

Arab Mix

(Saudi Arabia)

Cieba

(Equ. Guinea)

Basrah

(Iraq)

Escravos

(Nigeria)

Dubai

Farcados

(Nigeria)

Kuwait

Essider

(Libya)

Iran Mix

Labuan

(Malaysia)

Masila

(Yemen)

Miri Light

(Malaysia)

(Egypt)

Tapis

(Malaysia)

(UAE)

Ravva

(KGB India)

Murban

(UAE)

Oman
Suez Mix
Umm Shaif

Upper Zakum (UAE)

Mumbai High

Yield Patterns from different Crudes

API
LPG
MS
Naphtha
ATF/SKO
HSD
LDO
Lubes
IFO/LSHS
Bitumen
F&L
GRM $/bbl

High Sulfur
Basrah
AXL
33.2
37.9
1.6
1.8
1.8
2.3
9.6
10.4
15.2
9.3
15.7
38.4
8.6
6.5
8.0
8.0
24.2
8.0
7.5
7.5
7.5
7.5
4.91
3.14

Low Sulfur
Mum High
Qua Iboe
40.5
37.2
4.2
4.2
12.9
14.0
15.6
12.1
11.5
11.5
41.5
30.6
8.3
21.6
6.0
6.0
6.04
(2.52)

Crude oil Refining

13

Crude Oil Refining

Refining is a collection of processes necessary to convert low valued
crude oil to wide range of high valued products
Refining processes are broadly divided into four types
Fractionation
Conversion
Treating
Blending

Fractionation
First & most important step in crude refining
Hydrocarbon molecules do not change in structure
No new compounds are formed
Atmospheric Distillation
Separation of crudes into fractions using the principal of boiling point
difference i.e. Light ends at the top & Heavy at the bottom
main products are LPG, Naphtha, Kerosene, ATF, HSD, Reduced Crude
Oil.
Vacuum Distillation
Re-distillation of Reduced Crude Oil for further separation.
Separation under vacuum to avoid decomposition of reduced crude
Main products are vacuum gas oil, distillates for lubes, FCC feed stock, Bitumen
& LSHS

Fractionation

Conversion Processes
Change in size and structure of
convert surplus by products
marketable products
1. Decomposition (dividing)
Fluidized catalytic cracking
Hydro cracking
Visbreaking
Delayed Coking
2. Unification (combining)
Alkylation
Polymerization
3. Alteration (rearranging)
Isomerization
Catalytic reforming.

the hydrocarbon molecule in order to

from fractionation to high valued

Decomposition Processes
Fluidized catalytic cracking

Fluidized Catalytic cracking breaks complex hydrocarbons into simpler

molecules in order to increase the quality and quantity of lighter, more
desirable products and decrease the amount of residuals. This process
rearranges the molecular structure of hydrocarbon compounds to
convert heavy hydrocarbon feedstock into lighter fractions such as
kerosene, gasoline, LPG, heating oil, and petrochemical feedstock

Produces better quality (High Octane) Gasoline by cracking Vacuum Gas

oils in presence of a catalyst

Simultaneously produces large amount of LPG

Fluidized catalytic Cracking

Decomposition Processes
Hydro cracking
A two-stage process combining catalytic cracking and hydrogenation,

Heavier feedstock cracked in the presence of hydrogen to produce more

desirable products like Kerosene, Gasoline & Diesel.

Process employs high pressure, high temperature, a catalyst, and

hydrogen.

Used for feed stocks that are difficult to process by either catalytic
cracking or reforming due to high polycyclic aromatic content and/or
high concentrations of catalyst poisons like sulfur and nitrogen
compounds.
Atmospheric column residue
Vacuum column residue
Heavy Gas oils from Coker

Hydro Cracking

Decomposition Processes
Visbreaking
Reduces viscosity of Vacuum residue by thermal process

IFO generation reduces by 30 35% due to lower diesel requirement for

cutting viscosity

LPG & Naphtha are produced as by-products

Delayed Coking
A severe method of thermal cracking used to upgrade heavy residuals
into lighter products or distillates.
Produces straight-run gasoline (coker naphtha) and various middledistillate fractions used as FCCU feedstock.
The process completely eliminate hydrogen so that the residue is a form
of carbon called "coke."

Delayed coking

Unification Processes
Polymerization

Makes high octane gasoline from olefins and refinery gases using
catalyst

Alkylation

Same as polymerization but the end product has better performance in I.

C. Engines.

Combines isobutane with light olefins to produce very high quality

gasoline (RON >105)

Alteration Processes
Catalytic reforming

Convert low-octane naphthas into high-octane gasoline blending

components called reformates.

Reforming is a mixture of cracking, polymerization, dehydrogenation,

and isomerization taking place simultaneously.

Depending on the properties of the naphtha feedstock and catalysts

used, reformates can be produced with very high concentrations of
toluene, benzene, xylene, and other aromatics useful in gasoline
blending and petrochemical processing.

Hydrogen is produced a significant by-product

Alteration Processes
Isomerization

Isomerization converts n-butane, n-pentane and n-hexane into their

respective isoparaffins of substantially higher octane number.

The straight-chain paraffins are converted to their branched-chain

counterparts whose component atoms are the same but are arranged in
a different geometric structure.

n-butane is converted into isobutane to provide additional feedstock for

alkylation units,

N-pentanes and n-hexanes are converted into higher branched isomers

for gasoline blending.

Isomerization & Reforming process

Naphtha

S
P
L
I
T
T
E
R

Light Naphtha
H2

I
S
O
M

Isomerate

Naphtha Hydrotreater
& Isomerization
H2
Heavy Naphtha
Make up H2

NHT

Hydrotreater

H2

LPG
C
C
R
Reformer

Reformate

G
A
S
O
L
I
N
E
P
O
O
L

Treating Processes

Intended to prepare hydrocarbon streams for additional processing and

to prepare finished products.

Includes the removal or separation of aromatics and naphthenes as well

as impurities and undesirable contaminants.

Involves chemical or physical separation such as Dissolving,

Absorption, or precipitation using a variety and combination of
processes including desalting, drying, hydrodesulfurizing, solvent
refining, sweetening, solvent extraction, and solvent dewaxing.

Major Treating process

Solvent Extraction
Solvent Dewaxing
Solvent De-Asphalting
Hydro-desulfurization

Solvent Extraction

The purpose of solvent extraction is to prevent corrosion, protect

catalyst in subsequent processes, and improve finished products by
removing unsaturated, aromatic hydrocarbons from lubricant and
grease stocks.

The solvent extraction process separates aromatics, naphthenes, and

impurities from the product stream by dissolving or precipitation. The
feedstock is first dried and then treated using a continuous
countercurrent solvent treatment operation. The feedstock is washed
with a liquid in which the substances to be removed are more soluble
than in the desired resultant product

The most widely used extraction solvents are phenol, furfural, NMP and
cresylic acid

Solvent Extraction
H2

HYDROFINER
RAFF
FURNACE

RAFF SOLN

T 203

F-202

NMP

RAF RECOVERY

S/G
COMP
WET
DRUM

DRY DRUM

EXT FURNACE

EXT. SOLN
FEED

F-201

SG

STRIPPP
ER

T-201
TREATER

SG

LP

STEAM

VAC

DRIER

HP

SEPERATOR

T 202

T
2 EXT STRIPPER
0
STEAM
6
EXTRACT

Solvent Dewaxing

Solvent dewaxing is used to remove wax from either distillate or Lube

oil base stock.

Steps involve in solvent dewaxing are

Mixing the feedstock with a solvent
precipitating the wax from the mixture by chilling
recovering the solvent from the wax and dewaxed oil for recycling by
distillation and steam stripping.

The most widely used extraction solvents are Methyl Ethyl Ketone
(MEK), Propane & Toluene

Solvent Dewaxing

Solvent De Asphalting

In this solvent extraction process, propane is used as a solvent

Heavy oil fractions are separated to produce heavy lubricating oil (Bright
Stock), catalytic cracking feedstock, and asphalt.

Feedstock and liquid propane are pumped to an extraction tower at

precisely controlled mixtures. Separation occurs based on differences in
solubility.

The products are then evaporated and steam stripped to recover the
propane, which is recycled.

Hydro de sulfurization

Hydrotreating for sulfur removal is called hydrodesulfurization

The feedstock is deaerated and mixed with hydrogen, preheated in a

fired heater and then charged under pressure through a fixed-bed
catalytic reactor.

In the reactor, the sulfur and nitrogen compounds in the feedstock are
converted into H2S and NH3.

The liquid stream is sent to a stripping column for removal of H2S and
other undesirable components.

H2S is further treated in Amine treating & Sulfur recovery unit to

produce sulfur

Hydro desulfurization

Blending

Blending is the physical mixture of a number of

different liquid hydrocarbons streams to produce a
finished product with certain desired specifications

Why Blending is required ?

Non compliance of individual streams from primary or secondary

processing units to any product specification of its own

Non availability of matching secondary processing facilities leading to

excess streams available for disposal as valuable products

Disposal problem for by-products from treating units like extract from
solvent extraction unit or wax from dewaxing unit

Upgradation of valuable surplus streams due to lack of upliftment of

specific product and thus avoiding downgradation to heavy ends
Blending maximizes the Refinery profitability by optimizing the overall
production slate to extract maximum value from each barrel of crude
processed

Blended streams / Products

1.

HSD
3. IFO
Heavy Naphtha
Kerosene
- JBO

LVGO
- LVGO
JBO
- Extract
VGO
- FCC Residue
XVGO
LCGO
4. LSHS
2. LDO
- VBO
HVGO
- LVGO
LVGO
- FCC Residue
XVGO
I SS
5. Gasoline
- FCC Cracked Naphtha
- St. run Naphtha

- VTB

Examples of blend optimization

Possible routing of High S I SS is 150N, LDO & IFO

Value of I ss realized in 150 N
Rs 16850 / T
Value realized in LDO
Rs 15525 / T
Value realized in IFO
Rs 10060 / T

Possible routing of VTB

Value realized in Bitumen
Value realized in IFO

Rs 8400 / T
Rs 4420 / T

Contents

Refinery growth
Refinery location & layout
Crude processed
Products
Crude receiving and product dispatching facilities
Refinery process units
Refinery Block diagrams
Physical performance
Commitment to Environment
Major Projects under implementation

Total Products = 29
Fuel Products = 13
1. Propane
2. LPG
3. Motor Gasoline
4. Low Aromatic Naphtha
5. High Aromatic Naphtha
6. Special Cut Naphtha
7. Aviation Turbo Fuel
8. Superior Kerosene Oil
9. Special cut Kerosene
10. High Speed Diesel (3 Grades)
11. Light Diesel Oil
12. Fuel Oil ( 2 grades)
13. LSHS

Lube Products = 9
1. Neutral Oils = 3
2. Turbine Oils = 2
3. Industrial Oils = 2
4. Spindle Oil
5. Bright Stock
Specialties = 7
1. Hexane
2. Solvent 1425
3. MTO
4. CBFS
5. RPO
6. Bitumen (3 Grades)
7. Sulfur

Product Mix

Crude receiving and Product shipment

facilities
Mahul
Terminal

SAHAR / SANTACRUZ
Nap./IFO/SKO/LSHS/HSD

LPG
A
F T

JAWAHER
DWEEP

x
He
S

42

PRIPAU
MANIFOLD

/M
ol
S
/

/
TO

RP

C
O/

BF

S
LSH

24
MS/HSD/SKO/LDO

36

IFO / Lubes

Vashi / Loni /
Sewri
/Wadala
Mazagaon

Naphtha
RCF

ONGC URAN

24
BH Gas

Bitum
e
n

HP REFINERY

BPCL

Refinery Process Units

Fuels Block
Crude Distillation
-2
Vacuum Distillation
-2
Naphtha stabilizers
-2
Fluidized Catalytic Cracking
Diesel Hydro De Sulfurization
Hexane
Propane

Lube Block
Vacuum Distillation
Solvent Extraction Propane De-waxing
Propane De-Asphalting
Industrial Oil Hydrofiner

Utilities
Captive Power Plant - 5 GTGs
Effluent Treatment Plants - 2
Boiler House
Cooling Towers
Instrument/utility air system
Tankage

Mumbai Refinery Process units

Stabiliz
er

F
R

HS

Treating

C
D
U

DHDS

S
E
U
s

V
D
U
s

LS

HMU

P
D
A

F
R
E
C
D
U

P
D
U
I
O
H

LP
G
Hexane
Naphth
/Solvent
a
ATF
SKO/MT
HSD
O
Sulfur
LDO
Spindle Oil
150 N
500 N
1300 N
Bright
Stock
IO-100
IO-1600
Bitumen
IFO

V
D
U

F
C
C

Gasoline
LSHS

Commitment to Environment Protection

Major environmental projects
Implemented over past 2 decades : Rs 935 Cr. (208 Million USD)
Under implementation (GFECP ): Rs 1152 Cr. ( 256 Million USD)

Refinery meets stipulations set by MPCB & CPCB

Extensive green cover in the Refinery & residential complex.

Initiated Tank sludge treatment process to recovery oil from sludge

Green Fuels & Emission Control Project

Objectives
To meet EURO-III specifications for MS
Augmentation of crude processing capacity to 7.9 MMTPA
Project Cost:

Rs 1852 Crores (411 Mill. USD)

New Units
Naphtha Splitter
Naphtha Hydrotreater
Catalytic Reforming Unit
Isomerization unit
FCC Gasoline Hydrotreater (Prime G+)
Flue Gas Desulfurization Unit
De NOx Facilities

Green Fuels & Emission Control Project

Naphtha

S
P
L
I
T
T
E
R

Light Naphtha
H2

I
S
O
M

Isomerate

Naphtha Hydrotreater
& Isomerization
H2
Heavy Naphtha
Make up H2

NHT

Hydrotreater
FCCU
Cracked
Naphtha

S
H
U

LPG
C
C
R

Reformate

Reformer
Light FCC Gasoline

H2

Selective Hydrogenation
& Splitter

PRIME G+

Heavy FCC Gasoline

G
A
S
O
L
I
N
E
P
O
O
L