Refinery TPK

44
TATIPAKA MINI REFINERY A SUCCESS STORY 11 SUCCESSFUL YEARS

description

TPK Refinery and Crude distillation unit details of the plant including operating parameters and design

Transcript of Refinery TPK

Page 1: Refinery TPK

TATIPAKA MINI REFINERY

A SUCCESS STORY

11 SUCCESSFUL

YEARS

Page 2: Refinery TPK

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

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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.

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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.

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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.

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TATIPAKA REFINERY

DATE OF COMMISSIONING

3rd Sep 2001

REFINING CAPACITY

NORMAL: 1500 BPD (186 TPD)

MAX : 2000 BPD (250 TPD)

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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

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TATIPAKA

MINI-REFINERY

BASICENGG:

IOGPT,

MUMBAI

COST :

26.5 Crores

CONSLTAN

T: PDIL,

NOIDA

PROJECT

EXEC: NICCO

/ VENTECH PERIOD:

450 DAYS

TATIPAKA REFINERY

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REFINERY SCHEMATIC FLOW DIAGRAM

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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

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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.

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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)

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New Product Additions

HF-HSD in 2005

By TEAM REFINERY

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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.

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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

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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

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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

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New Product Additions

MTO in 2011

By TEAM REFINERY

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Properties of MTO

Low odour solvent

Fast setting power

Good solvency power

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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)

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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.

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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

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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

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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

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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

Page 26: Refinery TPK

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

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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

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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

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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

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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)

Page 31: Refinery TPK

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

Page 32: Refinery TPK

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

Page 33: Refinery TPK

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

Page 34: Refinery TPK

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

Page 35: Refinery TPK

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

Page 36: Refinery TPK

MARKETING

TIE UPs

TATIPAKA REFINERY

Page 37: Refinery TPK

NAPHTHA

NAPHTHA

APCL, VIZAG

PRICE @ RTP per MT

EMERALD PETROCHEM LTD

Nagpur

Page 38: Refinery TPK

LSHS

LSHS

PRICE @ RTP

MoU SIGNED FOR 2 YEARS

ESSAR STEEL, VIZAG

ITC, BANGALORE

Page 39: Refinery TPK

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

Page 40: Refinery TPK

SKO / MTO

SKO

PDS KEROSENE

MTO Solvents / Paint industry

Page 41: Refinery TPK

Naptha Upliftment of M/s. HPCl from

Tatipaka Refinery

Page 42: Refinery TPK

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.

Page 43: Refinery TPK

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

Page 44: Refinery TPK

THANK YOU