Future Refinery FCCs Role in Refinery Petrochemical Integration
Refinery TPK
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Transcript of Refinery TPK
TATIPAKA MINI REFINERY
A SUCCESS STORY
11 SUCCESSFUL
YEARS
MINI-REFINERY - CONCEPT
Development of Marginal fields as they have less life-time.
To reduce transportation cost of oil from remote or
Inaccessible locations.
To reduce transportation cost of refined products .
Pay back period is low i.e. 3 to 5 years, instead of normal
refinery average of 15 years.
No dependency on external source for refinery crude.
Transportation hazard is minimized due to proximity of
source and processing facility.
Meets the need of the small consumers locally in the
areas even without big infrastructure support
MINI-REFINERY - Facts
100 Mini-refineries (0.03 to 1.0 MMTPA) around the world (mainly in USA, Australia, Russia)
Only 2 Mini-refineries in India
Re-locatable Skid mounted refinery with Erection time - 6 months to 18 months.
Re-erection time can be as small as 60 days.
Cold re-start in less than one hour and can be put in full operation.
feed mix is possible to vary.
NEED FOR THE REFINERY
To avoid transportation of crude due to strikes or
shutdown in HPCL VKSP refinery.
To ensure uninterrupted supply of gas from Tatipaka
GCS, in case of any interruption in transportation of
oil.
To minimize safety hazards involved in long distance
transportation.
To minimize pilpherages & transit loss of crude oil
involved in long distance transportation
To meet the internal HSD requirements of
Rajahmundry and Karaikal assets.
Advantages in Processing our own crude
Savings of a huge hidden charges towards oil transportation cost up to Yanam, Pumping cost up to the cargo, cost of product insurance, transit losses, wharf age charges at loading & unloading points storage & handling losses at Yanam, cargo and Mumbai.
All the refinery products are being handed over to OMC’s at Refinery gate only which will not attribute to any kind of product loss.
Though Refinery is designed for four products Naptha , SKO, HSD and LSHS , we are producing six products from the those four trays, Naptha, SKO, HSD LSHS, HFHSD and MTO(LAWS). depending on the demand and supply of the products with in-house expertise.
Self sufficiency for the requirement of internal consumption of HSD of all the Assets, RJY, KKL & EOA.
No additional resources required like existing manpower, Air compressors, water source, power supply, Fire services, security and additional land etc. Best Utilization will reduce the operating cost of both the refineries.
TATIPAKA REFINERY
DATE OF COMMISSIONING
3rd Sep 2001
REFINING CAPACITY
NORMAL: 1500 BPD (186 TPD)
MAX : 2000 BPD (250 TPD)
TATIPAKA REFINERY IS CERTIFIED FOR ISO-14001
(ENVIRONMENT) , ISO-9001 (QUALITY) AND OHSAS-18001
(SAFETY) SINCE 2002
OHSAS
18001
ISO
14001
ISO
9001
TATIPAKA
COMPLEX
TATIPAKA
MINI-REFINERY
BASICENGG:
IOGPT,
MUMBAI
COST :
26.5 Crores
CONSLTAN
T: PDIL,
NOIDA
PROJECT
EXEC: NICCO
/ VENTECH PERIOD:
450 DAYS
TATIPAKA REFINERY
REFINERY SCHEMATIC FLOW DIAGRAM
MAJOR EQUIPMENTS DESALTER
HEAT EXCHANGERS SKID
PUMPS SKID
COLUMN SKID
FURNACE
CI / NH3 / DEMULSIFIER TANKS – 1 NO EACH
BOILER – 2 NOS
DM WATER UNIT – 1 NOS
WATER TREATMENT PLANT – 1 NOS
COOLIN TOWER – 2 NOS
STORAGE TANKS – 8 NOS
LOADING GANTRY- 4 BAY
WEIGH BRIDGE – 1 NO
PROCESS DESCRIPTION
Crude oil is heated from 36°C to 135°C in first stage of
preheating (through exchangers E-101, E-102, E-103 A/B) and
then sent to de-salter where the water content from the crude
is totally removed.
Desalted crude at 125°C is the heated up to 220°C in second
stage of preheating (through E-104A/B, E-105 A/B, E-106) and
then heated in a furnace up to 330°C.
The heated crude (partially vapourized) is fed into the
atmospheric distillation column at a pressure of 0.8 atm where
products NAPHTHA (140°C), SKO (180°C), HSD (240°C) and
LSHS (300°C) get separated depending on their individual
boiling points.
FEEDS AND PRODUCTS
27% @240-280 C
15% @170–210
C
32% @140 C
26% @300 C
CRUDE OIL @330 C (44th)
CRUDE : CONDENSATE
75:25
KSP(W) GMAA
TPK LINGALA NAPHTHA
(11th)
SKO (22nd)
HSD (35th)
LSHS (49th)
New Product Additions
HF-HSD in 2005
By TEAM REFINERY
HFHSD Production Normal HSD produced up to 2005-2006
Huge demand foreseen for HFHSD due to increased
activity in EOA- Kakinada
Already normal HSD demand met for RJY and
CAUVERY onshore rigs and production installations
Feasibility of HFHSD studied
HF HSD with Flash point above 66°C need to be
produced.
HFHSD - MODIFICATIONS HFHSD (HSD with flash point > 66 ºC) is planned to
produce for meeting the requirement of EOA-KKD.
To cope with increased load of HFHSD production, Additional heat exchanger E-103B is provided in parellel.
New operating parameters Column Operating Parameters
Location Before After Units
Top Temp 102.1 105.1 o C
HN Draw 143.1 146.5 o C
SKO Draw 206.7 185 o C
HSD Draw 283.7 293.9 o C
Feed Temp 291.6 300.5 o C
Top Reflux 5626 5799 Kg/Hr
Kero Pump Around 8727 9196 Kg/Hr
HSD Pump Around 8432 6686 Kg/Hr
Sl.No. Characterisrics Specifications Method Result
1 Density @ 150C 0.820 - 0.860 IP-160/87 0.8415
2 Flash Point(PM), 0C 660C Min. P-21 66
3 Pour Point, 0C
Max.
120C Winter P-10 (+) 18
210C Summer
4 Appearance Visual Light Yellow
colour
5 Kinematic Viscosity,
cst 2.5 - 15.7 P-25 3.75
6 Sulphur, Total %by
wt. max 0.25
ASTM D
5453 0.01765
HFHSD Specifications
Name of Asset Present HSD supply during 2010 (203Days)
Actual
requirement
of HSD
Remarks
Rajahmundry
30 KL/D 30 KL/D 100 % requirement met
Karaikal
21 KL/D 21 KL/D 100 % requirement met
Kakinada-EOA 20 KL/D 215 KL/D
(Based on 6500
KL/month)
195 KL/day
requirement not met.
Total 71 KL/D 266 KL/D
Shortage of HSD/HFHSD (195 KL/D ) is being proposed to meet through
Refinery expansion Project & Existing (95KL/D + 24 KL/D = 119 KL/D).
Requirement HFHSD for internal use
New Product Additions
MTO in 2011
By TEAM REFINERY
Properties of MTO
Low odour solvent
Fast setting power
Good solvency power
No additives required
No additional processing equipments required
No additional manpower or processing shut down required during the change over of the product.
No modification of the existing refinery or column internals required.
No additional financial implications but it is a source of additional revenue.
• By replacing SKO with MTO product i.e. 37 TPD or 12210 Tons/annum
SKO net realization Price = 22374 Rs/MT
MTO net realization Price = 34936 Rs/MT
Difference is 12562 Rs/MT X 12210 = 15.33 Cr
(During previous quarter rates, it was worked out as 17.9 Cr)
To reduce the demand of Naptha & increasing the yield of product MTO will increase the profitability of the refinery.
Launching of New product
Mineral Turpentine Oil (MTO)
MTO - MINERAL TURPENTINE OIL
Change in Market Dynamics after supply of Reliance Gas motivated to diversify product line.
Present SKO production 15% of feed and it can be replaced with MTO to improve the refinery profit margins.
MTO is an intermediate product between SKO & Naphtha.
MTO produced on Experimental basis in July, 2010 and 1st tanker flagged off on 12.04.11
If Need arises, the product MTO can be interchanged with SKO as per market demand without any changes in the plant.
Applications of MTO
Adhesive industries
Paint and resin industries
Thinner industries
Agro-chemicals,households' insecticides, fungicides industries.
Paint catalysts, driers, coating and industries
Textiles, cloth, paper, printing-processing industries
Degreasing and cleaning purpose in machineries, machine spares manufacturing industries
FEEDS AND PRODUCTS
HSD 27% @68T(82KL)
SKO 15% @38T(49KL)
NAPHTHA 32%
@80T(110KL)
LSHS 25% @63T(72KL)
CRUDE OIL @250T(304KL)
CRUDE : CONDENSATE
75:25
KSP(W) /
GOPAVARAM
OIL
TPK CONDENSATE
LINGALA/
MALLESWARAM CONDENSATE
MTO
Fuel&loss (1.5%)
ADVP/PON
CONDENSATE
SKO
NAPHTHA
HSD
PRODUCT Refinery Yield Refinery Yield
(Revised)
Production@
250 TPD
TPD (KL/D)
Remarks
NAPTHA
(0.733)
34% 29% 72 (98) Low marketable
product
SKO/MTO
(0.7828)
15% 15% 37 (47) Low Profitable
product-SKO
HSD / HFHSD (0.825)
22% 31% 78 (95) Highly Profitable
product
LSHS
(0.88)
28% 24% 60 (68) Low marketable
product
TOTAL 99% 99% 247(308) 1 – 1.5% Fuel loss
Although Tatipaka Refinery is designed and constructed for producing four products
Naptha , SKO, HSD and LSHS , Through our in-house expertise we are producing six
products from the those four trays only Naptha, SKO, MTO (LAWS), HSD, HFHSD and
LSHS depending on the demand and supply of the products.
YEILD PATTERN OF THE REFINERY
Performance at a Glance
Year
VAP
Production
(MT)
%Capacity
Utilization
Revenue
Earned
(Cr.)
Profit Earned
(Cr.)
2002 – 03 91464 139 % 97.48 42.36
2003 – 04 90368 137% 95.15 36.20
2004 – 05 91577 139% 130.15 55.22
2005 – 06 92080 140% 164.80 77.61
2006 – 07 92947 141% 156.13 55.94
2007 – 08 61707 94% 121.83 32.28
2008 - 09 82340 125% 186.90 55.28
2009 –10 54442 82.5% 95.41 20.62
2010-11 68789 103% 148.18 62.78
2011-12
(Apr-Sep) 50959 103% 90 36
SPECIFICATIONS FOR NAPHTHA
Sl.No. Characterisrics Specifications
Method of
Test ref.
IS:1448
1 Specific Gravity@60/600F To be reported
2
Distillation
a. IBP, 0C 25 (Min.) P-18
b. FBP, 0C 204(Max.)
3 Reid Vapour Pressure ,Kg/cm2 0.7(Max.) P-39
4 Non Volatile Matter, mg/100ml 5.0(Max.)
5 RCR, % by Mass 0.2(Max.) P-8
6 C/H Ratio(Calculation) To be reported
7 Net Calorific Value,Kcal/Kg To be reported P-7
SPECFICATIONS OF KEROSENE IS:1459-1974
Characteristics Specifications Method Of Test, ref to
(P:) of IS:1448
i) Acidity, Inorganic NIL P:2
ii) BURNING QUALITY:
a) Char Value, mg/kg of oil consumed, Max
b) Bloom on Glass Chimney
20
Not Darker
Than Grey
P:5
iii) Color
a) Saybolt,Min (in case of Undyed Kerosene )
b) Visual (in case of Dyed Kerosene)
10
10
Blue
P:14
P:14
-
iv) Copper Strip Corrosion for 3 hrs. at 500C Not Worse than
No. 1
P:15
v) Distillation:
a) Percent Recovered Below 200 0C, Min
b) Final Boiling Point, degC, Max
20
300
P:18
vi) Flash Point (Abel), degC, Min 35 P:20
vii) Smoke Point, mm, Min 18 P:31
viii) Total Sulfur, Percent by Mass, Max 0.25 P:34
SPECIFICATIONS FOR HSD IS : 1460-2005
Sl. No CHARACTERISTICS SPECIFICATIONS Method of Test ref.
IS:1448
1 Acidity, Inorganic Nil P-2
2 Acidity total, mg KOH/g To be reported, Not limited P-2
3 Ash,% by mass 0.01 Max P-4
4 Carbon Residue(Ramsbottom) on 10% residue, % by
mass 0.3 Max P-8
5 Cetane Number 51 Min P-9
6 Calculated Cetane Index 46 Min ASTM D 4737
7 Pour Point,
C Winter 3 Max P-10
Summer 15 Max
8 Copper strip corrosion, for 3 hrs @ 100
C Not worse than No.1 P-15
9 Distillation, % v/v Recovered
P-18 Recovery at 360
C 95 Min
10 Flash Point-Abel,
C 35 Min P-20
11 Kinematic Viscocity @ 40
C , cSt 2.0 to 4.5 P-25
12 Total Contamination, mg/kg 24 Max EN 12662
13 Density at 15
C, kg/m³ 820-845 P-16
14 Total Sulphur, mg/kg 350 Max ASTM D 4294
15 Water Content, mg/kg 200 Max ISO 12937
16 Cold Filter Plugging Point (CPFF),
C Winter 6 Max P-110
Summer 18 Max
SPECIFICATIONS FOR LSHS IS:1593-1982
CHARACTERISTICS
REQUIREMENTS FOR Method Of
Test, ref to
(P: ) of
IS:1448
Grade
LV
Grade
MV1
Grade
MV2
Grade
HV
i) Acidity, Inorganic Nil Nil Nil Nil P:2
ii) Ash, Percent by mass, Max 0.1 0.1 0.1 0.1 P:4
iii) Gross, Calorific Value Not limited, but to be reported P:6 & P:7
iv) Relative Density at 15/15 degC Not limited, but to be reported P:16 or P:32
v) Flash Point,
[Pensky Martin,(closed)] degC, Min
66degC 66degC 66degC 66degC P:21
vi) Kinematic Viscosity, cSt, at 50degC,
Max
Above
Upto
-
80, max
80
125
125
180
180
370
P:25
vii) Sediment, Percent by mass, Max 0.25 0.25 0.25 0.25 P:30
viii) Sulfur,Total, Percent by Mass,Max 3.5 4.0 4.0 4.5 P:33
ix) Water Content, Percent by volume,
Max
1.0 1.0 1.0 1.0 P:40
SPECIFICATIONS FOR MTO IS:1745-1978
SL.No. CHARACTERISTICS SOLVENT
(125/240)
SOLVENT
(140/205)
METHOD OF
TEST REF 1S:1448
1. COLOUR SAYBOLT, Min. +21 +20 P:14
2. COLOR(ASTM), Max. - - P:12
3. Density at 150C, g/ml To be reported (not limited) P:16
4. FLASH POINT(ABEL), 0C Min. 30 35 P:20
5. DISTILLATION RANGE
a) IBP, 0C Min. 125 145
P:18 b) 50% by vol. recovered at, 0C To be reported (not limited)
c) 95% by vol. recovered at, 0C To be reported (not limited)
d) FBP, 0C Max. 240 205
6. AROMATIC CONTENT, %VOL
Max.
40 40 P:23 OR P:48
7. TOTAL SULPHUR, % Wt. Max. - - P:34 OR P:83
8. Cu STRIP CORROSION
for 3 Hrs. at 500C NOT WORSE THAN No.1 P:15
9. RESIDUE ON EVAPORATION
mg / 100 ml Max. 5 5 P:29(AIR JET)
Naphtha Test Report at Refinery
Sl.No. Characteristics Specifications Method ref
to IS:1448 Results
1 Specific Gravity@60/600F To be reported 0.7268
2
Distillation
a. IBP, 0C 25 (Min.) P-18 42
b. FBP, 0C 204(Max.) 152
3 Reid Vapour Pressure ,
Kg/cm2 0.7(Max.) P-39 0.50
4 Non Volatile Matter,
mg/100ml 5.0(Max.) 2.30
5 RCR, % by Mass 0.2(Max.) P-8 0.070
6 C/H Ratio (Calculation) To be reported 5.62
7 Net Calorific Value, Kcal/Kg To be reported P-7 10529
SKO Test Report at Refinery Sl.No Characterisrics Specification
Manufacturer
spec Method Result
1 Density @ 150C To be reported To be reported IP-160/87 0.7974
2 Flash Point(Abel), 0C 350C Min. 380C Min. IS 1448, P-20 38
3
Distillation
IS 1448, P-18
a. Recovery below
2000C 20 Min. 20 Min. 73
b. IBP, 0C 155
c. FBP, 0C 300 Max. 290 Max. 236
4 Acidity Inorganic,mg
KOH/g Nil Nil IS 1448, P-2 0
5 Smoke Point, mm 18 Min. 19 Min. IS 1448, P-31 22
6 Copper Strip Corrosion@
500C/3Hrs
Not worse than
1
Not worse than
1 IS 1448, P-15 Better than 1a
7 Colour saybolt +10 +10 IS 1448, P-14 +10
8 Sulphur , total, % by Wt 0.25 0.25 ASTM D 5453 0.0072
9 BURNING QUALITY
IS 1448, P-5
A) Char value, mg/Kg Max 20 Max 20 14.80
B) Bloom on Chimney, Not darker than
grey
Predominating colour Not darker
than grey
Not darker than
grey
MTO Test Report at Refinery
Sl.No. Characterisrics MTO 125/240 METHOD OF
TEST RESULT
1 COLOUR (SAYBOLT) Min (+)21 P:14 (+)21
2 DENSITY AT 15 0 C,g/ml TO BE
REPORTED,NOT
LIMITED P:16 0.7909
3 FLASH POINT (ABEL),0 C Min 30 P:20 38
4 DISTILLATION RANGE
5 a) IBP,Min 125
P:18
149
6 b) 50% by vol recovered at,0C TO BE
REPORTED,NOT
LIMITED 175
7 c) 95% by vol recovered at,0C TO BE
REPORTED,NOT
LIMITED 208
8 d) FBP, Max,0C 240 222
9 TOTAL SULPHUR, Max %Wt ASTM D 5453 0.0036
10 Cu S.C.FOR 3 Hrs AT 50 0C NOT WORSE
THAN 1 P:15 No.1
11 ROE,mg/100 ml,Max 5 P:29 (AIR JET) 0.8
LSHS Test Report at Refinery
Sl.No
. Characterisrics Specifications Method Result
1 Density @ 150C To be reported IP-160/87 0.8864
2 Flash Point(PM), 0C 66 Min. P-21 68
3 Pour Point, 0C 60 Max. P-10 42
4 Water Content, % V/V 1.0 Max. P-40 <0.05
5 Gross Calorific Value,
Kcal/Kg To be reported P-7 10750
Dynamic Feed Mix Change
Poor upliftment of Naphtha and LSHS forced experiment various crude mix
Originally designed to process Crude condensate mix (Kesanapalli)
Availability of various crudes like Gopavaram and Lingala allowed to make changes in the feed mix therby producting products as per usage.
FEED MIX PRODUCT MIX
MARKETING
TIE UPs
TATIPAKA REFINERY
NAPHTHA
NAPHTHA
APCL, VIZAG
PRICE @ RTP per MT
EMERALD PETROCHEM LTD
Nagpur
LSHS
LSHS
PRICE @ RTP
MoU SIGNED FOR 2 YEARS
ESSAR STEEL, VIZAG
ITC, BANGALORE
HSD
HSD
HUGE SAVINGS TO ONGC AS TOTAL HSD
REQUIREMENT FOR KG AND KKL ONSHORE
& PARTIAL KKD REQUIREMENT MET
KG ONSHORE
KKL ONSHORE
KKD OFFSHORE HFHSD
GOKAVARAM TERMINAL
SKO / MTO
SKO
PDS KEROSENE
MTO Solvents / Paint industry
Naptha Upliftment of M/s. HPCl from
Tatipaka Refinery
Rejuvenation of Refinery Operations During 2011, RJY Asset has made efforts to improve the
upliftment of Naphtha. At this juncture HPCL has agreed to lift
sufficient quantity of Naphtha and LSHS on day to day basis and
requested ONGC, to purchase of lubes from M/s HPCL. RJY
Asset had agreed and accordingly a proposal was sent to Head
quarters on “win-win situation” strategy. This effort has resulted
in achieving VAP production targets and efficiency of the plant
is increased from 82.5%(2010) to 102.7% (2011)
Later to improve the profitability of Refinery though the VAP
upliftment reduced by M/s HPCL MTO is being produced in place
of the SKO.
During the less off take of the Naptha crude from Gopavaram is
processed and less off take of the LSHS more KSP crude is
processed.
Awards and Accolades
GREEN TECH SAFETY – SILVER 2003-04
& 2004-05
GREEN TECH ENVIRONMENT EXCELLENCE
SILVER 2003-04 & 2004-05
GREEN TECH ENVIRONMENT EXCELLENCE
- GOLD 2006, 2011
BEST FIRE SUB-STATION 2011-12
(All over ONGC)
BEST ONSHORE INSTALLATION AWARD 2011
(All over ONGC)
GROUP AWARD FROM DIRECTOR(ONSHORE) FOR
COMMISIONING REFINERY- 2002
CERTIFICATE OF APPRECIATION FROM NATIONAL
SAFETY COUNCIL, AP CHAPTER - 2005
C&MD INNOVATION GROUP AWARD FOR NEW
PRODUCT MTO 2011
THE HIGH TECHNICAL AUDIT RATED AWARD FROM
DIRECTOR (T&FS) 2008-09
THANK YOU