Introduction to Petroleum &

Petro - Chemical Products.

Description on Unit Process, Production & Business
Opportunities In India
1.  The Black Gold
2.  About Hydrocarbon Industry
3.  A Guide of Refinery Process
4.  Table of various process with approximate cost & criticality
5.  Crude Distillation Unit
6.  Production of Gasoline (Petrol) from Heavy Naphtha
7.  Fluid Catalytic Cracking
8.  List of Refineries in India and their production capacities
9.  Procurement Methods adopted by Indian Refineries
10.  Major Refinery Equipment’s

CONTENTS - Part 1 of Presentation

THE BLACK GOLD
What is Crude Oil ?
•  An unrefined petroleum product composed of hydrocarbon deposits and organic
compounds.
Origin of Hydrocarbons

AcDon of micro-organisms Under Earths Surface FormaDon of
on Decaying Plants &
Animals
High Pressure & high Hydrocarbons
Temperature

Types of Crude Oil
•  Sweet Crude (Low H2S & CO2) – Most preferable for producDon of gasoline.
•  Sour Crude (High H2S & CO2) – Crude with more than 0.5% sulfur
Grades of Crude
•  Brent(UK), West Texas Intermediate(US), Daqing (China), BCF-17(Venezuela),
Maga(Mexico), Bonny(Nigeria), Dubai(UAE)
Composi<on
•  83 – 87% Carbon
•  11 - 15 % Hydrogen
•  1 – 6% Sulfur
Graph Explaining the grades of
crude oil
API = (141.5/S) – 131.5
ABOUT HYDROCARBON INDUSTRY
Upstream, Midstream & Downstream Process
Hydrocarbon Industry – Up Stream Process
Petroleum Exploration Petroleum Production
•  Explora<on Techniques •  Oil Extrac<on & Recovery
•  Geo Physical •  Primary recovery
•  Once the complete rig is set-up, the
•  Gravimetric Method underground pressure in the oil
reservoir is sufficient to force the oil
•  Magnetometric Method to the surface.
•  Seismic Survey •  Secondary recovery
•  Remote Sensing Method •  Supply of external energy into the
reservoir in the form of injecDng
•  Geo Chemical fluids to increase reservoir pressure,
hence increasing the natural
•  Chemical analysis of surface soil reservoir drive with an arDficial
drive. (eg. Water, Natural gas)
and rocks
•  Enhanced recovery
•  Geo Technical •  This method injects steam to heat
•  Mechanical ProperDes of rocks up oil the reservoir to reduce its
viscosity and making it easier to
and surface are measured extract.
VARIOUS TYPES OF RIGS USED FOR PETROLEUM EXTRACTION
On shore Platforms & Off shore Platforms
Hydrocarbon Industry – Down Stream Process
Refining & Petrochemicals Marketing & Distribution
•  Refining •  Marke<ng
•  Petroleum refining processes are •  MarkeDng is the final step in the
the chemical engineering chain that delivers useful
processes to transform crude oil petroleum products to end-user
into useful products such as customers.
Liquefied Petroleum Gas(LPG), •  Driving factors:
Gasoline (Petrol), Kerosene, Jet •  Volume
Fuel, Diesel Oil & fuel oils. •  Market Share
•  Margin
•  Petrochemicals
•  Chemicals obtained directly from •  Distribu<on
cracking(pyrolysis), or indirectly •  DistribuDon lines of oil & gas
from chemical processing of must be managed with high levels
petroleum oil or natural gas. of consistency and safety.
•  Few examples, plasDcs, rubbers,
fibres, paints, solvents & •  DistribuDon is done via,
•  Pipe lines
detergents.
•  Cryogenic tanks
•  On-Site systems
Hydrocarbon Industry – India
Ministry of Petroleum & Natural Gas

Up Stream Process Down Stream Process

Exploration & Refining &

Production Marketing Distribution

ONGC OIL HPCL BPCL IOCL RIL, etc., GAIL India RIL

Private
companies
like Cairn, RIL
etc.,

Industry Bodies

Petroleum Planning & Centre for High

Analysis Cell Technology Petro Fed Petroleum Conservation
& Research Association

Src: Ministry of Petroleum & Natural Gas

 Fuel Gas
ARU Refinery Fuel / Fuel Gas
A GUIDE OF H2S
SRU Sulphur
REFINERY Light Gas Gas
Processing
PROCESS Merox LPG (Propane
& Butane)
H2 H2
Light
Naphtha
NHTU ISOM Naptha
Crude Oil
Storage Tank (CDU) Crude DisDllaDon Unit / ADU
Heavy
Naphtha
NHTU CCR Gasolline

Desalter
Kerosene ATF Jet Fuel /
ATF - HDT
Desalted Jet Fuel MEROX Kerosene
Crude
H2S
Diesel Oil
HeaDng DHDT Diesel Fuel
Diesel
Propane
Gas Oil Poly Unit
Reduced Coke
Butane
PRU AlkylaDon Unit Propylene
DisDllaDon Unit)

Light
VDU (Vacuum

Vacuum VGO-HDT FCCU

C3/C4
Gas Oil
Diesel
Heavy Vacuum Gas Oil Iso-Butane
Hydrocracker Gasoline

Vacuum Coker Naphtha to CCR

Residuel DCU Coker Gas oil to FCCU Needle Coke Unit Premier Coke
Petroleum Coke
Bitumen Blowing Bitumen
 Fuel Gas
ARU Refinery Fuel / Fuel Gas
A GUIDE OF H2S
SRU Sulphur
REFINERY Light Gas Gas
Processing
PROCESS Merox LPG (Propane
& Butane)
H2 H2
Light
Naphtha
NHTU ISOM Naptha
Crude Oil
Storage Tank (CDU) Crude DisDllaDon Unit / ADU

v Heavy
Naphtha
NHTU CCR Gasolline

Desalter
Kerosene ATF Jet Fuel /
ATF - HDT
Desalted Jet Fuel MEROX Kerosene
Crude
H2S
Diesel Oil
HeaDng DHDT Diesel Fuel
Diesel
Propane
Gas Oil Poly Unit
Reduced Coke
Butane
v
PRU AlkylaDon Unit Propylene
v
DisDllaDon Unit)

Light
VDU (Vacuum

Vacuum v
VGO-HDT FCCU
C3/C4
Gas Oil
Diesel
v
Heavy Vacuum Gas Oil Iso-Butane
Hydrocracker Gasoline

Vacuum Coker Naphtha to CCR

Residuel DCU Coker Gas oil to FCCU Needle Coke Unit Premier Coke
Petroleum Coke
v Bitumen Blowing Bitumen
 VARIOUS UNIT PROCESS IN REFINERY
Table of Various Unit Process with Approximate cost & criticality
Table of Various Unit Process with Approximate cost & criticality
S.No. Unit Name Approximate Cost Criticality

Major Units
1 CDU – Crude Distillation Unit
2 VDU – Vacuum Distillation Unit
Hydro-treating Process
3 ATF HTD - Aviation Turbine Fuel Hydrotreater

4 DHDT – Diesel Hydrotreating

5 NHT – Naphtha Hydro Treater
6 VGO HDT – Vacuum Gas Hydrotreater
Cracking Process
7 FCCU - Fluid Catalalytic Cracking Unit
8 Steam Cracking Unit
9 Hydrocracking Unit
Reforming Process
10 CCR – Continuous Catalytic Reformer
Table of Various Unit Process with Approximate cost & criticality
S.No. Unit Name Approximate Cost Criticality

Isomerization Process
11 Light Naphtha Isomerization Unit
De-Sulfurization / Merox Process & Sulfur Recovery Process
12 ATF Merox – Aviation Turbine Fuel Merox
13 GMU – Gasoline Merox Unit
14 Extraction and removal of mercaptans from
LPG
15 SRU – Sulfur Recovery Unit
16 SWS – Sour Water Stripper
Coking Process
17 DCU – Delayed Coker Unit
18 Needle Coker Unit
19 Fluidic Coking Unit
20 Flexi Coking Unit
Table of Various Unit Process with Approximate cost & criticality
S.No. Unit Name Approximate Cost Criticality

Other Units
21 HF Alkylation Unit
22 Vib Breaker Unit
23 Polymerization Unit
24 ARU - Amine Recovery Unit
25 AGS – Air Generation System
26 AGU – Acid Generation Unit
27 De-Salination / De-Mineralization Unit
28 ETP – Effluent Treatment Plant
29 Hydrogen Manufacturing Unit
 CRUDE DISTILLATION UNIT
Atmospheric Distillation Unit & Vacuum Distillation Unit
Atmospheric Distillation Unit (ADU) –
Process Flow Diagram

Pipe SDll Furnace

Side Stripper
 De-Salting Unit TT PT
FIC

Power
•  FIC - Flow Indicated T.F
Control
•  TT – Temperature Crude Booster Pump
Transmijer
•  PT – Pressure
Crude Oil Electrode Plates
Transmijer
Oil – Water
•  DPC – Dual Zone
Interface
Pressure Controller
•  LC – Level Controller

Salt - Water
LC

DPC
pHC

Salt and Water

to Drain

CausDc FIC
SoluDon Dosing
Pump

DM Water

Preheated
Crude Oil Crude oil
Feed Pump
Vacuum Distillation Unit (VDU) –
Process Flow Diagram
PRODCUTION OF GASOLINE (PETROL) FROM HEAVY NAPHTHA
Naphtha Hydro Treatment Unit & Reforming Unit
Naphtha HydroTreater - Process Flow Diagram
Make up
Hydrogen
Gases to
fuel system
or sulfur
recovery
unit
Recycle
Compressor

Separator
Hydrogen

Stripper
Desulfurised
naphtha to
storage

Cooler

Reboiling
Furnace

Furnace
Raw
Naphtha
Storage Reactor

Feed
Pump
 Gases to fuel
System

Recycle Compressor

Separator
Hydrogen

Debutaniser
Hydrogen Reformate
to storage to Storage

Cooler

Desulfurised
Naphtha
Storage Furnace Reactor
Reactor
Furnace
Feed
Pump

Heavy Naphtha
Reformer–
Furnace
Process Flow Diagram Reactor
 FLUIDISED CATALYTIC CRACKING (FCC)
Conversion of VGO(Vacuum Gas Oil) into Gasoline Intermediates using side by side FCC configuration
 FLUIDIZED CATALYTIC CRACKING
FLUE GAS
REACTION
CATALYST FLUE GAS PRODUCT GAS
OFF GAS
FINES
CONDENSER
SEPARATOR
REACTOR
FLUE REFLUX
GAS 38 DRUM
CATALYST 535 Deg C 0.56 barg
FINES 1.72 barg
REFLUX
PHENOLIC
ELECTROSTATIC SOUR WATER
CO

DISTILLATION COLUMN
PRECIPITATOR
BOILER
CRACKED NAPHTHA

SIDECUT
STRIPPER
FLUE STEAM
GAS REGENERATOR
715 Deg C
FUEL OIL
2.41 barg
STEAM
AIR
STEAM FUEL OIL

SLURRY
SETTLER

TOTAL FEED
CONDENSATE
COMBUSTION AIR
SLURRY
FEED STOCK 315-430 OIL
Fluid Catalytic Cracking
List of Refineries in India and their Production Capacities

Investment Present
Commissioned Produc<on
Refinery Name Loca<on Cost Produc<on
Sl.No Sector On Capacity
( Rs. In Capacity
(MMTPA)
crores) (MMTPA)
1 IOCL GuwahaD Refinery Assam 17.29 1st January 0.75 1
1962
2 IOCL Barauni Refinery Bihar 49.4 July 1964 3.3 6

3 IOCL Koyali Refinery Gujarat 26 October 1965 2 13.7

4 IOCL Haldia Refinery West January 1975 2.5 7.5

Bengal
5 IOCL Mathura Refinery Ujar 253.92 January 1982 6 8
Pradesh
6 IOCL Digboi Refinery Assam 1901/October 0.5 0.65
1981
7 IOCL Panipat Refinery Haryana 3868 1998 6 15

8 IOCL Bongaigaon Refinery Assam 50 20th February 1 2.35

(BRPL) 1974
List of Refineries in India and their Production Capacities

Investment Present
Commissioned Produc<on
Refinery Name Loca<on Cost Produc<on
Sl.No Sector On Capacity
( Rs. In Capacity
(MMTPA)
crores) (MMTPA)
9 IOCL Paradip Refinery Orissa 34,555 February 7, 15
2016
10 HPCL Mumbai Refinery Maharash 1954 1.25 6.5
tra
11 HPCL Visakh Refinery Andhra 1957 0.675 8.3
Pradesh
12 BPCL Mumbai Refinery Maharash 1955 2.2 12
tra
13 BPCL Kochi Refinery Kerala 27th April 1963 2.5 15.5

14 CPCL (IOCL Manali Refinery Tamil 43 1965 2.5 10.5

+ NIOC) Nadu
15 CPCL Cauvery Basin Nagapao 1993 0.5 1
Refinery nam, TN
16 NRL Numaligarh Refinery Assam October 2000 3
List of Refineries in India and their Production Capacities

Investment Present
Commissioned Produc<on
Refinery Name Loca<on Cost Produc<on
Sl.No Sector On Capacity
( Rs. In Capacity
(MMTPA)
crores) (MMTPA)
17 MRPL Mangalore Refinery Karnataka March 1996 3.69 15
(ONGC)

18 ONGC TaDpaka Refinery Andhra 27 September 0.066 0.132

Pradesh 2001
19 Private Jamnagar Refinery Gujarat 33
(RIL – DTA)
20 Private Jamnagar Refinery Gujarat 37
(RIL – SEZ)
21 Private Essar Oil Limited Vadinar, November 10.5 20
Gujarat 2006
22 BORL Bina Refinery Madhya 12,200 May, 2011 6
(BPCL + Pradesh
OOCL)

23 HMEL Guru Gobind Singh Bathinda, April, 2012 9

(HPCL + Refinery Punjab
Mijal)
 Engineering Procurement Construction

PROCUREMENT METHODS ADOPTED BY INDIAN REFINERIES

Conventional Route & EPC Route
 Method - 1: CONVENTIONAL ROUTE Method - 2: LSTK / EPC ROUTE

AppoinDng “Process Licenser” (By Owner) AppoinDng “Process Licenser” (By Owner)

Procurement method AppoinDng “EPCM” Consultant (By Owner) AppoinDng “PMC” Consultant (By Owner)

adopted by Indian
Process Design & Sizing of ‘Units” by process Process design basis of “Units” by process
Refineries licenser licenser

Detail Design of units & sizing of “Individual PreparaDon of project specificaDons & minimum InvitaDon for tenders for “Individual
Equipment's” by EPCM consultant design & quality requirements by PMC Equipment's” as per MR’s by LSTK

Owner PreparaDon of MR, SpecificaDons, Data Submission of Techno-Commercial bids by

Sheets & Drawings for “Individual “Bidders (Manufacturers)”
(IOCL, BPCL, HPCL, CPCL, NRL, Equipment” by EPCM
BORL, BRPL, RIL, ESSAR)
Technical & Commercial evaluaDon by DEC &
InvitaDon for tenders for “Individual InvitaDon for tenders for LSTK (EPC) bidding LSTK
Equipment's” as per MR’s by EPCM for “UNITS” by PMC
Approval of bidder by owner / PMC & order
Submission of Techno-Commercial Bids by Submission of Techno-Commercial bids by release by LSTK contractor. All financial
“Bidders (Manufacturers)” LSTK contractors. commitments to bidders are by LSTK
AppoinDng process licensor & contractor.
consultant for FEED Study Technical evaluaDon by PMC & Process
Technical EvaluaDon by EPCM
(Front End Engineering Design) licensor Bidders post order acDviDes like drawings,
procurement, manufacturing and E & C will
Commercial EvaluaDon & RecommendaDon be monitored by LSTK contractor as well as
Commercial evaluaDon and recommendaDon EPCM & owner.
by EPCM
by PMC

Approval Of Bidder and order release for CompleDon of project & commissioning of plant
Approval of LSTK contractor and order release is done by LSTK contractor & approved by PMC /
“Individual Equipment's” by owner. All financial
Approval from Board/ for ‘Units” by owner. All financial commitments Licensor / Owner
commitments to bidders is by owner
Government for project to LSTK contractors are by owner
implicaDons Bidders post order acDviDes like drawings,
procurement, manufacturing & E&C will be
LSTK will develop process design, P&ID’s &
monitored by EPCM & Owner
equipment data sheets & MR’s for “Individual
Equipment's”. May appoint DEC & inspecDon
agency, if required.
CompleDon of project & commissioning of
plant is monitored by EPCM
Major Refinery Equipment’s
•  Pressure vessels •  Fired heaters / Furnace   
•  Heat exchangers •  Piping system & Valves
•  Shell & Tube Heat Exchangers •  Pumps
•  Plate & Frame Heat exchangers •  Centrifugal Pumps
•  Air cooled heat exchanger •  Positive Displacement pumps
•  Double Pipe exchanger •  Reciprocating pumps
•  Process Vessels •  Rotary Pumps
•  Drums •  Compressors
•  Gravity Separators •  Reciprocating
•  Column •  Rotary Screw
•  Reactor •  Rotary Centrifugal
•  Storage Tanks •  Cooling Towers
•  Fixed-roof tanks
•  External floating roof tanks
•  Internal floating roof tanks
•  Domed external floating roof tanks
•  Horizontal tanks
•  Pressure tanks
•  Variable vapor space tanks
•  LNG (Liquefied Natural Gas) tanks
Heat Exchangers

Shell & Tube Heat Exchanger Plate & Frame Heat Exchanger
Heat Exchangers

Air Cooled Heat Exchanger Double Pipe Heat Exchanger

Process Vessels

Drums Gravity Separators

Process Vessels

Drums Drums
Process Vessels

Separators Separtors
Process Vessels

Column Reactor
Storage Tanks

Fixed Rook Tank External Floating roof tank

Storage Tanks

Internal Floating roof tank Doomed External floating roof tank

Storage Tanks

Horizontal tank Pressure Tank

Storage Tanks

Variable vapor space tank LNG Tanks

Fired Heaters / Furnace
Cooling Towers
Reference

1.  The Black Gold

•  Fundamentals of petroleum & Petrochemical Engg – Ujam Ray Chaudhuri
•  hjps://en.wikipedia.org/wiki/Benchmark_(crude_oil)
•  hjp://www.markeDndex.com.au/crude-oil
2.  About Hydrocarbon Industry
•  Fundamentals of petroleum & Petrochemical Engg – Ujam Ray Chaudhuri
3.  A Guide of Refinery Process
•  Chemical Engineering Process – An AICHE PublicaDons
•  Essar presentaDon
4.  Table of various process with approximate cost & criDcality
5.  Crude DisDllaDon Unit
•  Fundamentals of petroleum & Petrochemical Engg – Ujam Ray Chaudhuri
6.  ProducDon of Gasoline (Petrol) from Heavy Naphtha
•  Fundamentals of petroleum & Petrochemical Engg – Ujam Ray Chaudhuri
•  Chemical Engineering Process – An AICHE PublicaDons
7.  Fluid CatalyDc Cracking
•  hjps://en.wikipedia.org/wiki/Fluid_catalyDc_cracking
•  Chemical Engineering Process – An AICHE PublicaDons
8.  List of Refineries in India and their producDon capaciDes
•  Ministry of Petroleum & Natural Gas India