REFINING

PROCESSES

A.DATTA

LECT04
 Diagram of Refinery Units
Sulphur
Crude Oil Gas treatment Recovery Sulphur

H 2S H2S

Shorter Chain Molecules

Desulphurisation Platformer Petrol

Kerosine
Gas Oil

Diesel
Vacuum Gas Oil

Long Residue
High Vacuum
Distillation

Hyrdrocracker
Separation

Long Chain Molecules Hydrogen

Waxy Distillate Manufacturing
Hydrogen Unit
Butane
Bitumen De-asphalting
De-asphalted oil DAO

Roads Asphalt Fuel oil

 The Process Units
Refinery Gas
Natural Gas
Fuel
Gas Sulphur
DePr RG
Syngas and Reformates
Plat
Naphtha
HDT Split RG H2
RG Regular Mogas
Condensates and Low Mogas
Sulphur Crudes Kero Blend Premium Mogas
High Sulphur Crudes
CDU1 RG
LGO
Imported Residues
HDS2 Kero / Avtur
HGO H2
CO2
Long Residue

Automotive Gasoils
GasOil and Marine
Naphtha Blend
RG
HDS1 HMU
Low Sulphur Crudes Kero H2
H2
LGO
HCU Light Fuel Oil
High Sulphur Crudes CDU2 HGO RG FuelOil Heavy Fuel Oil
Blend
Bunkers
Imported Residues
HVU2 Refinery Fuel
HVU1 BDU
Long Residue Bitumen 80/100
BBU Bitumen 180/200
Bitumen 45/55
 Approx 7 Barrels to the Tonne

7% FUEL AND LOSS

30% MOGAS

14% JET/ KERO

32% GASOILS

17% FUEL OILS

A Typical Crude Barrel

 Crude The Process Units

High Vaccuum Unit

Distiller Units Bitumen Unit

Platformer Gasoil Hydrotreater Depropaniser

Hydrocracker Kerosine Hydrodesulphuriser

Butane Deasphalting unit

Hydrogen Manufacturing unit Sulphur Recovery

Product Blending Products out

•
Distillation
The initial separation takes place
in the distillation Column

• The Crude is first heated in a furnace

to a temperature of 360 oC

• It enters the column and vapours and

liquids separate

• The light vapours rise to the top whilst

the heavier liquids fall to the bottom
 Gases +Tops + Naphtha

Kerosene

Crude Light Gasoil

Heavy Gasoil

Furnace

Long Residue

Distillation Column
 Lower Boiling

Crude

Higher Boiling

Distillation Column
Desulphurisation
 Under Pressure and Heat
Sour Tops + Naphtha
Reaction takes place and
Hydrogen bonds with
Sour Kerosene Sulphur to form H2s
Sour Gasoil
Hydrogen

H2S

Desulphurised Tops + Naphtha

Reactor
Catalyst Desulphurised Kerosene

Desulphurised Gasoil

Desulphurisation Process
 PLATFORMING
• Increases low Octane Naphtha to
high Octane Platformate
• Uses Heat and Pressure in a
Reactor
• Hydrogen is evolved in the
process
• Platinum Catalyst assists the
process
PLATFORMING

Platinum Reforming
Platformer Unit
50 OCTANE

Naphtha 520°C
From Splitter 18 barg
Furnace

Hydrogen
Recycle
Hydrogen
To Users

40°C

High Octane
Platformate
E 515°C
Reactor
Blending Tank Separator

100 OCTANE
High Vacuum
&
Bitumen Units
 Vacuum
Gases

Bitumen Feed Tanks Vacuum

Gas Oil

Long Residue

180 Pen
High Vacuum Unit - HVU 1 Bitumen
 Gases To Refinery Gas System

Vacuum To Hydrocracker
Gas Oil for furthur Processing

Truck Loading and shipping

180 Pen
Bitumen

Blowing
Column 45/55 Pen
Bitumen
Hydrocracking
 What is Hydrocracking ??

Production of high quality light products

from heavy oils,
in the presence of Hydrogen.
 Hydrocracker Overview
145 t/d Hydrogen
Plant gas Hydrogen
70 t/d Manufacturing 140 t/d 120 t/d Gas
Adip gas Unit
10 t/d
Butane 1100 t/d
1400 t/d Tops/Naphtha
Steam Waxy Distilate 3200 t/d
HCU 900 t/d
Kerosine
High Vacuum Unit Hydrocracker
Gasoil
5500 t/d DAO 2000 t/d
HVU VGO 1000 t/d
Long Residue 200 t/d

BUTANE DE-ASPHALTING UNIT

BDU
Short Residue Asphalt
900 t/d
1900 t/d
Sulphur Recovery
Unit
Converts H2S into Sulphur
For use by Fertiliser Companies
 Sulphur Recovery Unit

A
H2S Feed Main Furnace
Liquid Sulphur 59%

Fuel Gas

Reactor
Line Burner
Waste Heat
Fuel Gas Boiler

Line Burner
B C
Liquid Sulphur

Stack

Fuel
Gas
A B C D
Incinerator Line Burner D
Coalescer
Sulphur Pit Reactor Liquid Sulphur
 SCOT Unit

ENVIRONMENTAL
LOWERS EMISSIONS
 SCOT Feed Gas SCOT Unit

Air

FG

SCOT Burner
To SRU Reactor

KO Drum
Upper Quench Column Waste Heat Boiler

Blower

Quench Water
Lean ADIP
KO Drum
Cooler

Semi Rich ADIP Lower Quench Column

To SWS
Absorber Colum (ADIP)