Submitted by:Akhilesh PathakB.Tech(CH)(0906451006)

Mathura Refinery, the sixth refinery of Indian Oil was commissioned in 1982 with a capacity of 6.0 MMTPA to meet the demand of petroleum products in north western region of the country, which includes National Capital Region.

Only company placed at 83rd position among fortune 500 companies.

Mathura Refinery is the first in Asia and third in the world to receive the coveted ISO-14001 certification for Environment Management System in 1996. It is also the first in the World to get OHSMS certification for Safety Management in 1998.

The major secondary processing units provided were Fluidised Catalytic Cracking Unit (FCCU), Vis-breaker Unit (VBU) and Bitumen Blowing Unit (BBU).The original technology for these units was sourced from erstwhile USSR, UOP etc. Soaker drum technology of EIL was implemented in VBU in the year 1993. For production of unleaded Gasoline, Continuous Catalytic Reforming Unit (CCRU) was commissioned in 1998 with technology from Axens, France. A DHDS licensed from Axens, France was commissioned in 1999 for production of HSD with low Sulphur content of 0.25% wt (max). With the commissioning of Once Through Hydrocracker Unit (licensed from Chevron, USA) in July 2000, capacity of Mathura Refinery was increased to 8.0 MMTPA.

An oil refinery separates the crude oil in to different fractions and converts them into usable products .

Maximize Higher value distillates like LPG, , ATF, Kerosene and Diesel.

Produce cleaner products.

Crude oil is a complex mixture of thousands of hydrocarbons. (i.e paraffin, Napthenes & Aromatics)

Brownish black in Color and colloidal in nature

Contains small amounts of non hydrocarbon impurities in the form of organic compounds of sulphur, oxygen, nitrogen, metals, water and salts.

Hydro Carbons > 95%

S.no.Element Percentage(%)1Carbon 83-87 2Hydrogen 11-15 3Sulphur 0-3 4Oxygen0-2 5Nitrogen0-0.6 6Metals0-0.1

1.SulphurCompounds :H2S, Mercaptans, Thiophenes, Benzothiophenes

2.Nitrogen Compounds :Pyrrole, Pyridine, Quinoline, etc.

3.Oxygen Compounds :Naphthenic Acid,Phenol etc.

4.Metallic Derivatives:Derivatives of Organic acids with metals Like Ni, Cu, V, Pb, As.

5.Water and Salt :Along with water, Soluble inorganic compounds like Chlorides, Sulphates of Sodium, Calcium and Magnesium

s.no. ProductKey Quality parameters

1LPGEvaporation Temperature at 95 % Volume =2 deg C, MaxCu Corrosion =not worse than No.1

2Motor SpiritDensity =720-775 Kg/M3Sulphur=150 ppm, MaxBenzene =1 Vol. %, Max

3ATFDensity =775-84 Kg/M3Flash Point = 38 deg c, MinSulphur=0.25 wt %,MaxSmoke Point =20 mm, Min

s.no. ProductKey Quality parameters

4DieselDensity =820-845 Kg/M3Sulphur= 50 ppmCetaneNumber = 51 Min

5Fuel OilSulphur= 4 wt %, MaxAsh = 0.1 wt %, MaxKV@ 50 deg c =125 , Max (Winter)=180 , Max (Summer)

6BitumenFlash Point =175 deg C,MinViscosity at 60 Deg C = 2400 (min) CP Softening Point =45-55 deg C

PhysicalThermalCatalytic

DistillationVisbreakingHydrotreating

Solvent extractionDelayed cokingCatalytic reforming

Propane deasphaltingFlexicokingCatalytic cracking

Solvent dewaxingHydrocracking,Isomerization

BlendingCatalytic dewaxing

PRIMARY PROCESSING UNITS

SECONDARY PROCESSING UNITS

The purpose of Primary unit is to separate the crude in to different fractions by distillation.Known as mother unit of the refinery, consist ofCRUDE DISTILLATION UNIT (CDU)

VACUUM DISTILLATION UNIT (VDU)

Commonly referred as Atmospheric and Vacuum Distillation unit (AVU)

1.The hydrolysis of salts in crude oil at high temperature produces HCL and corrodes the Column Internals and overhead system.

2.The sediments in crude oil fouls the heat exchanger, furnace tubes and erodes the pipelines by abrasive action.

3.Desalting approaches-To reduce soluble salt content-To reduce suspended solids.-To reduce residual water

4.Desalting of crude oil is carried out in a vessel provided with electrodes under High potential field(15000-18000 Volts)

5.DesalterOperating condition:-Temperature range :130-140 deg C-System pressure :12-14 kg/cm2g

6. The desalted crude is Preheated to about 180-200 deg C and fed to Prefractionator column

7. The purpose of prefractionator is to separate the lighter hydrocarbons at relatively lower temperature so as to reduce heat energy requirement across furnace and to reduce the main fractionator overhead vapour load

8. Prefractinator are typically used in revamps for energy conservation and unit capacity enhancement

Prefractionator Operating conditionTop Temperature range= 120-130 deg cPressure= 1.5-3.0 kg/cm2g

9. The Pre-fractionator column bottom is fed to Fractionator column after heating to 360 370 Deg C in Heat Exchanger train & Furnace.

The main fractionator separates the pre-topped crude in to different fractions like Naphtha, Heavy Naphtha, Aviation Turbine Fuel, Kerosene, Light Gas Oil, Heavy Gas Oil and Reduced Crude Oil.

Column Operating ConditionTop Temperature Range =120-135 deg CPressure=1.0-2.5 Kg/cm2g

1.VDU objective is to recover valuable product from RCO relatively at lower temperature.

2.Feed preparation unit for FCC/HCU/VBU/BBU

3.The Operating temp. is about 410-420 Deg C

4. Vacuum is created by steam ejectors. Column Operating Condition:Top Temperature range : 50-65 deg CPressure: 25-60 mm Hg (a)

RCO from CDU is "heavy", and the separation of this stream into various fractions would normally require more energy and higher temperatures.

Higher hydrocarbons promotes coking reactions at more than 380 deg c at atmospheric pressure fouls the furnace tubes.

To reduce the amount of energy input required, and to recover the valuable products from RCO without cracking, it is distilled under vacuum.

The vacuum condition reduces the boiling point of the RCO and the fractions are separated relatively at lower temperature led to energy saving and reduces fouling of the furnace tubes

s.noVDU Product Quality Processing 1LVGO High S, Low Cetane no. Hydrotreatment (DHDS) for Sulphur and Cetane No., 2LDO High S,Heavy Hydrocarbons Fluid catalytic unit / Hydrocracker unit 3HVGO High S,Heavy Hydrocarbons Fluid catalytic unit / Hydrocracker unit 4Vacuum Slop Heavy Hydrocarbons , Fuel oil Product Visbreaker unit / Coker 5Vacuum Residue Residue Bitumen Blowing Unit / VBU / Coker

Objective : To meet the Euro III/IV diesel quality requirement ( 350/50 ppm S and Min. 51 Cetane No.)

Feed : Straight run diesel / FCC diesel component/ Coker and Visbreaker diesel components.

Catalyst : Ni-Mo oxides

Chemical reactions: Desulphurisation and DenitrificationC5H10SH+H2 C6H12+H2SAromatic compound + H2 --> NaptheneCompound

1.Typical Product Yields

S.no.ProductsWt%End Users

1.Off Gas2.65Refinery Fuel gas system after Amine Wash

2.Wild Naphtha2.8To Naphtha Pool after stabilisation

3.Diesel96.1To Diesel Pool

2. Operating Conditions :Temperature range : 320-380 CSystem Pressure : 100-105 kg/cm2(g)

S.no.CharacteristicsBS IIIBS-IV

1.CetaneNo., min51512.Sulphur, PPM max350503.Flash point 66 deg C66 deg C