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7/27/2019 Presentation on Oil & Gas
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Petroleum (from Latin petrarock and oleumoil), crude oil,
sometimes colloquially called black gold, is a thick, dark brown or
greenish flammable liquid, which exists in the upper strata of some
areas of the Earth's crust. It consists of a complex mixture of various
hydrocarbons, largely of the alkane series, but may vary much in
appearance, composition, and purity. Petroleum is also the raw
material for many chemical products, including solvents, fertilizers,
pesticides, and plastics.
PETROLEUUM
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HISTORYThe first oil wells were drilled in China in the 4th century or
earlier. The oil was burned to evaporate brine and produce
salt. By the 10th century, extensive bamboo pipelines
connected oil wells with salt springs.The modern history of oil began in 1853, with the discovery
of the process of oil distillation. Crude oil was distilled into
kerosene by Ignacy Lukasiewicz, a Polish Scientist. The first
"rock oil" mine was created inRobrka, near Krosno in
southern Poland in the following year and the first refinery(actually a distillery) was built in Ulaszowice, also by
Lukasiewicz.
PETROLEUUM
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4TH CENTURY --OIL DRILLED IN CHINA AND BURNED TO EVAPORATE
BRINE TO PRODUCE SALT
10TH
CENTURY--TRANSPORTATION OF OIL THROUGH BAMBOOPIELINES
1853----------OIL DISTILLED BY POLISH SCIENTISTIGNANCYLUKASIEWICZ AND IN 1854 FIRST REFINERY WAS SET UP
BY MR LUKASIEWICZ
1859--- ------------OIL DISCOVERED BY COL DRAKE IN PENSYLVANIA, USA
1866-----------------OIL FOUND BY MR GOODENOUGH IN UPPER ASSAM
1889-----------------OIL PRODUCTION STARTED UNDER ASSAM RAILWAY &
TRADINGCORPORATION
1901-----------------500 BARRELS PER DAY REFINERY SET UP IN DIGBOI,
ASSAM
2005------- ABOUT 2135 BILLION BBLS/DAY REFINING CAPACITY
(17 REFINERIES) IN INDIA
ABOUT 81995 BILLION BBLS/DAY REFINING CAPACITY(739 REFINERIES) IN WORLD
A FEW HISTORICAL MILESTONES IN PETROLEUM
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What Is Crude Oil?
Crude Oil is a liquid mixture ofthousandsof organic chemicals found underground. Itis the result of organic matter decaying overthousands of years; hence the namefossilfuel
Crude oil is found all over the world and variestremendously in its density, aromatics, sulfur, andmetals content Crude oil is found all over theworld and varies tremendously in its density,aromatics, sulfur, and metals content
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So, HowDo You Make Good Stuff Out
Of Crude? Separate crude into fractions
Convert low octane components to higher
octane components Convert the very heavy stuff to heavy oils
Convert heavy oils togasoline,diesel,jet fuel
Remove sulfur/nitrogen through reaction Blend intermediate streams together to meet
product specifications
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Crude oil is a finite resource. It is estimated that there is a total of
2,390 billion barrels (380 km) of crude oil on Earth. Estimates ofundiscovered reserves range widely from 275 to 1,469 billion
barrels (44 to 234 km).
Between 1859 and 1968, 200 billion barrels (31 km) of oil were
used, and since then oil production has stabilized at 22 billion
barrels (3.5 km) per year. In 2004, as prices reach record highs,
world consumption is on track to 30 billion barrels per year.
It is believed that about 77% of crude oil has already been
discovered, and 30% of it has been used so far. Current estimates
are that oil reserves will become scarce by the 2050s, although thisdate has been pushed forward many times as new oil wells are
discovered.
Some observations w.r.t. Crude Reserve and consumption
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Refineries
Refineries are very complicatedchemical
processing plants that use reactions and
separations to convert crude oil into gasoline andother valuable products
The purpose of an oil refinery is to transform
relatively low value crude oil into high value
products as efficiently, profitably and
environmentally sound a way as possible
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Distillation The initial separation takes place
in the distillation Column
The Crude is first heated in a furnaceto 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
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Distillation (Atmospheric and Vacuum)
This is the first stage in the refining for separating crude oil
components at atmospheric pressure by heating, and subsequent
condensing, of the fractions (unfinished petroleum products) by
cooling.
Distillation under reduced pressure (less than atmospheric) i.e.
Vacuum Distillation lowers the boiling temperature of the liquid
being distilled permitting the production of distillates at lowertemperature than would be necessary in atmospheric distillation,
thus avoiding coke formation.
The Jamnagar Refinery has a combined Crude Distillation Unit /
Vacuum Distillation Unit (CDU / VDU) to separate the crude oil into
primarily fractions of LPG, Naphtha, Kerosene, Gasoil, Vacuum Gas
Oil and Vacuum Residue. The combined CDU/VDU maximizes
energy integration to minimize the energy required for primary
separation.
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http://en.wikipedia.org/wiki/Image:ShellMartinez.jpghttp://en.wikipedia.org/wiki/Image:ShellMartinez.jpg7/27/2019 Presentation on Oil & Gas
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Furnace
Distillation Column
Crude
Kerosene
Gases +Tops + Naphtha
Light Gasoil
Heavy Gasoil
Long Residue
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Diesel
Gas Oil
CrudeOil
Bitumen
Roads
Long Chain Molecules
Gas treatmentSulphur
RecoverySulphur
H2S H2S
Waxy Distillate
Butane
De-asphalting
AsphaltFuel oil
De-asphalted oil DAO
Desulphurisation
Kerosine
Shorter Chain Molecules
Hydrogen
ManufacturingUnit
Hyrdr
ocracker
Hydrogen
High Vacuum
Separation
Vacuum Gas Oil
Long Residue
Distillation
Diagram of Refinery Units
Platformer Petrol
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GASOILS32%
JET/ KERO14%
MOGAS30%
FUEL AND LOSS7%
FUEL OILS17%
Approx 7 Barrels to the Tonne
A Typical Crude Barrel
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NATURAL
GAS
C3/C4 (LPG)
NAPHTHA
ETHANE
KEROSENE
CATALYTIC
REFORMING
GAS CRACKER
GAS OIL
FCC
PROPYLENE
BUTANE
METHANESTEAM
REFORMING
HYDROGEN
ETHYLENE GLYCOL
ETHYLENE DICHLORIDE
POLY PROPYLENE
ACRYLONITRILE
TOLUENE
O-XYLENE
P-XYLENE
BUTADIENE
MALEIC ANHYDRIDE
POLYISOBUTYLENE
POLYBUTADIENE
ETHYL BENZENE STYRENE
CUMENE PHENOL
POLY ETHYLENE TEREPHTHALATE
ETHYLENE OXIDE
POLY VINYL CHLORIDEPOLYETHYLENE
METHYLMETHACRYLATE
METHANOLFORMALDEHYDE ACETIC ACID
LINEAR ALPHA OLEFIN
POLYACRYLONITRILE
CARBON FIBRE
RESIDUE
CRU
DE
OIL
NAPHTHA
CRACKER
BENZOIC ACID
PHTHALIC ANHYDRIDE
DETERGENT
CYCLO HEXANE CAPROLACTUM
POLYCARBONATE
SYNTHESIS GAS
BUTYLENE BIS-PHENOL A
BENZENE
OVERVIEW OF REFINERY & PETROCHEMICAL PRODUCTS
ABS
RUBBER
STYRENE
BUTADIE
NE
RUBBER
ACRYLO
NITRILE
BUTADIE
NE
RUBBER
POLY
STYRENE
ETHYLENE
NYLON 6
GASOLINE
HYDROCRACKING
DIESEL
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Major Refinery Products
LPG (Propane/Butane)
GASOLINE (hundreds of blends)
JET FUELS
DIESEL FUELS
HEATING OILS
GREASES
ASPHALTS
COKE (not the kind you drink )
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Top petroleum-producing countriesSource: Energy Statistics from the U.S. Government
(Ordered by amount (barrels per dayproduced in 2004):
Saudi Arabia (OPEC)
RussiaUnited States
Iran (OPEC)
Mexico
China
Norway
Canada
Venezuela (OPEC)
United Arab Emirates (OPEC)
Kuwait (OPEC)
Nigeria (OPEC)
United Kingdom
Iraq
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Ordered by amount exportedin 2003:
Saudi Arabia (OPEC)
Russia
Norway
Iran (OPEC)
United Arab Emirates (OPEC)
Venezuela (OPEC)
Kuwait (OPEC)
Nigeria (OPEC)
Mexico
Algeria (OPEC)
Libya (OPEC)
Note that the USA consumes almost all of its own production.Total world production/consumption (as of 2005) is approximately 84 million
barrels per day.
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Crude processed in India are:
1. Indigenous crude oil sources
a. Bombay high and satellite fields
b. North Gujarat and Ankaleshwar crude
c. Assam crudes
d. KG Basin-Rava crude
e. Cauvery Basin crude
All the above crudes are low sulphur =
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2. Imported crudes are sourced mostly from:
a. Gulf Region
b. Nigeria
c. Malaysia
d. Australia
The above crudes are specially selected for production of Bitumen/LOBS/ATF, beside fuel
products.
These crudes are having varying range of sulphur from low of high.
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OIL PRICE DURING 1860 TO 2000
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Country/Region OIL Natural Gas
As on Jan.1 2005 As on Jan.1 2005
Billion barrels % Trillion Cuft. %Middle east 729.341 57.08 2522.125 41.76
East Europe & 88.3 6.91 1964.16 32.52
USSR
Western Europe 16.255 1.27 182.487 3.02
Central & 100.595 7.87 250.52 4.15South America
North America 215.291 16.85 260.494 4.31
(USA) 21.891 1.71 189.046 3.13
(Canada) 178.8 13.99 56.6 0.94
Asea & 36.246 2.84 383.913 6.36Oceania
(India) 5.371 0.42 30.14 0.50
Africa 100.784 7.89 476.509 7.89
WORLD 1277.702 100.00 6040.208 100.00
OIL & NATURAL GAS RESERVE
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Country/Region Number of Crude Catalytic Thermal Reforming
(All capacity Refineries Capacity Cracking Cracking
Billion bbls/day)Middle east 46 6319 372 483 599
East Europe & 88 10128 824 516 1396
USSR
Western Europe 112 15072 2236 1597 2220
Central & 70 6634 1321 452 407
South America
North America 176 20425 6683 2392 4215
(USA) 149 16757 5813 2254 3581
Asea & 202 20205 2720 432 2019Oceania
(India) 17 2135 167 93 42
Africa 45 3213 195 78 387
WORLD 739 81995 14352 5949 11243
REFINING CAPACITY
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REFINING CAPACITY IN INDIA (MMTPA) : AS ON 1.04.2000
FIGS IN MT
1 INSTALLED CAPICITY AS OF DATE PUBLIC JOINT PRIVATE TOTAL
SECTOR SECTOR SECTOR
1. IOC-DIGBOI 0.65 0.65
2. BPCL-BOMBAY 6.90 6.90
3. HPCL-BOMBAY 5.50 5.50
4. HPCL-VIZAG 7.50 7.505. IOC-GAUHATI 1.00 1.00
6. IOC-BARAUNI 4.20 4.20
7. IOC-KOYALI 12.50 12.50
8. IOC-HALDIA 3.75 3.75
9. IOC-MATHURA 7.50 7.50
11 IOC-PANIPAT 6.00 6.00
12 CRL-COCHIN 7.50 7.50
13 CPCL-CHENNAI 6.50 6.50
14 BRPL-ASSAM 2.35 2.3515 MRL-NARIMANAM 0.50 0.50
16 NRL - NUMALIGARH 2.35 2.35
17 RPL - JAMNAGAR 27.00 27.00
18 MRPL-MANGALORE 9.69 9.69
SUB TOTAL 72.35 12.04 27.00 111.39
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2. ADDITIONS IN REFINING CAPACITY
A) PROJECTS APPROVED BY THE GOVT:
Expected
REFINERY EXPANSIONS Commissioning
IOC-MATHURA 0.50 0.50 2000-01
MRPL-MANGALORE 6.90 6.00 12.90 2000-01
IOC-KOYALI 3.00 3.00 2000-01
SUB TOTAL 10.40 6.00 16.40
NEW REFINERIES
CENTRAL INDIA (JVC-BPC) 6.00 6.00 2001-02
SUB TOTAL 0.00 6.00 6.00
B) PROJECTS UNDER CONSIDERATION (EXPANSION)IOC-PANIPAT (PSU) 3.00 3.00 2002-03
IOC-BARAUNI 2.70 2.70 1999-02
CRL-COCHIN 3.00 3.00 2002-03
MRL-MADRAS 3.00 3.00 2002-03
SUB TOTAL 11.70 11.70
C) NET CAPACITY ADDITION (A+B) 22.10 12.00 34.10
3. PROPOSED REFINERIES
EAST COAST (JVC-IOC/PVT.PARTY) 12.00 12.00 X PLAN
WEST COAST (JVC-HPC) 6.00 6.00 2002-03UP REFINERY (JVC-BPC/SHELL) 7.00 7.00 X PLAN
PUNJAB REFINERY 6.00 6.00 X PLAN
SUB TOTAL 31.00 31.00
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4. PROPOSED PRIVATE SECTOR REFINERIES:
ESSAR ( UNDER CONSTRUCTION ) 9.00 9.00 X PLAN
ASHOK LEYLAND (GOTCO) 2.00 2.00 X PLAN
SOROS 6.00 6.00 X PLAN
NIPPON DENRO 9.00 9.00 X PLAN
SUB TOTAL 26.00 26.00
5. PROPOSED PRIVATE SECTOR REFINERIES (EOUs) LOI issued onINTERNATIONAL PETROLEUM 5.00 5.00 14.6.92
BLACK GOLD 2.50 2.50 10.6.93
PETRO ENERGY PRODUCTS 4.80 4.80 22.6.94 (FIPB)
JINDAL FERRO 6.00 6.00 22.9.94 (CCFI)
TIDCO 2.00 2.00 17.9.94 (CCFI)
ABAN LLOYD 3.00 3.00 12.1.95 (FFCI)
MOPLACE UDYOG 3.00 3.00 14.3.96
SUB TOTAL 26.30 26.30
6. TOTAL (1+2+3+4+5) 94.45 55.04 79.30 228.79
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Oil Refining Companies in India (As on 31stMarch 2001)
Name of the Oil
company
Principal Shareholders Location of refineries Capacity
(million
tons/year)
Age of refineries
(years)
Indian Oil Government of India (82%) Gujarat 12.5 36
Mathura 7.5 19
Panipat 6.0 3
Barauni 4.2 37
Haldia 3.8 27
Guwahati 1.0 39
Digboi 0.7 100
Reliance Petroleum Reliance Industries, its subsidiaries
and associates (65.8%)
Jamnagar 27.0 2
Hindustan Petroleum Government of India (51%) Vizag 7.5 44
Mahul 5.5 47
Mangalore Refineriesand Petrochemicals
Limited
Hindustan Petroleum (37%)/AdityaBirla Group (37%)
Mangalore 9.6 5
Kochi Refineries Bharat Petroleum (55%) Kochi 7.5 35
Chennai Petroleum Indian Oil Corporation (52%) Chennai 6.5 32
Narimanam 0.5 7
Bharat Petroleum Government of India (66%) Mahul 6.9 46
Bongaigaon Refineries Indian Oil Corporation (75%) Bongaigaon 2.4 22
Numaligarh Refineries Bharat Petroleum (51%) Numaligarh 3.0 2
Total 112.1
Source: Annual Reports &Industry Data
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Oil production & consumption in India (Million tons)
1997 1998 1999 2000 2001
Crude oil production 32.9 33.9 32.7 32 32.5
Crude oil consumption 62.9 65.2 68.5 86 103.5
Deficit (Met by Imports) (33.9) (34.5) (39.8) (54.0) (71.0)
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Growth & Development of Refinerieries in
India
1866 Oil discovery at Nahorpung, Assam.
1889 Oil Production started at Digboi, Assam.
1893 First Refinery started at Margharita, Assam.
1899 Assam Oil Company was formed.
1901
Digboi Refinery was commissioned
supplanting the earlier refinery at Margarita.
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Year Incident
1947-1957
Setting up of three coastal refineries by
Multi National Oil Companies (MNCs)
2 at Mumbai (Esso & Burmah Shell)
1 at Vizag (Caltex)
The MNCs were already marketing
petroleum products in India by then.
1954
Indian Oil exploration with the help of
Russian Geologists.
1956
Formation of Oil and Natural GasCommission for exploration and
production of crude oil and gas.
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Year Incident
1958
Indian Refineries Ltd (IRL) was formed in
the public sector to install refineries and
pipelines in India.Oil India Ltd (OIL) was formed as a joint
venture company between Government
of India and Burmah Oil Co.
1959
Indian Oil Company formed for
marketing petroleum products.
1962
The first refinery in the public sector
commissioned at Guwahati (0.75
MMTPA) under IRL.
1963
Indian Oil Blending Ltd. -A JV between
Indian Oil Co. and Mobil Petroleum Co.
Inc. was formed for manufacture of lube
oils and greases.
1964
IRL was dissolved and merged withIndian Oil Co. Ltd, to form Indian Oil
Corporation Ltd. (IOCL)
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Year Incident
1974 IOBL became part of IOCL.
1981
Assets of erstwhile Assam Oil Co. were
taken over and vested in IOC as Assam
Oil Division (AOD).
1998 Panipat Refinery of IOC commissioned.
1999
Reliance Petroleum Refinery at
Jamnagar, commissioned.
2000 Numaligarh refinery commisssioned.
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Year Incident Total Refining Capacity
MMTPA
2002-03 135
Barauni Expansion
Haldia Expansion
HPCL, Mumbai ExpansionCPCL, Nagapatinam
RPL Expansion
Future Outlook (as per 2025 vision document)
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Year Incident Total Refining Capacity
MMTPA
2003-04 170
Koyali Expansion
Panipat Expansion
BPCL Expansion
CPCL ExpansionBRPL Expansion
Paradip
Essar Oil Expansion
Nagarjuna Oil
Future Outlook (as per 2025 vision document)
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Year Incident Total Refining Capacity
MMTPA
2004-05 176
Kochi Refinery Expansion
2005-06 214
Essar Oil Expansion
RPL Expansion
Bhatinda
2006-07 BRPL Expansion 221
Bina
Future Outlook (as per 2025 vision document)
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Strategies for Indian Refineries
Residue upgradation technologies for heavy crudes
Technologies for producing lighter fuels.
Process technologies to improve quality with
respect to :
- performance parameters- eco-friendly products
Value addition to refinery streams
Increased emphasis on Process Control/
Automation
Evolutionary/innovative technological changes
expected rather than evolutionary ones.
Refineries to be integrated, compact and flexible
with respect to crude/ product mix.
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Future Technological Challenges
Meeting higher demand of petroleum
products (viz. distillates)
Meeting higher standards of product
qualities.
More emphasis on environment
Value addition to refineries
Technologies to improve margins
Zero emission refinery
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DISTILLATION RANGE IMPROVEMENT
New residue conversion technologies like FCC,
Hydrocracker, RDS-RFCC
Advanced controls and optimisation
Advanced catalysts
Continuous simulation of plants/product mix through
computer models
Prudent selection of technologies and proper
integration of secondary units/ plants.
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REFINING CAPACITY IN INDIA AS IN THE YEAR 2002
No Refineries MMTPA
Year of
Commissioning
1 Indian Oil Corporation Limited, Digboi 0.65 1901
2 Indian Oil Corporation Limited, Guwahati 1.00 1962
3 Indian Oil Corporation Limited, Barauni 3.30 (6.0) 1964
4 Indian Oil Corporation Limited, Koyali 13.5 (18) 1965
5 Indian Oil Corporation Limited, Haldia 3.75 (7.5) 1974
6 Indian Oil Corporation Limited, Mathura 7.50 1982
7 Hindustan Petroleum Corporation Limited, Vizag 7.50 1975
8 Hindustan Petroleum Corporation Limited, Mumbai 5.50 1954
9 Bharat Petroleum Corporation Limited, Mumbai 8.90 1955
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No Refineries MMTPA
Year of
Commissioning
10
Cochin Refineries Limited, Cochin
7.50 (10.5)
1966
11Chennai Petroleum Corporation Limited, Chennia
6.50 (9.5)1969
12 Bongaigaon Refineries Limited, Bongaigaon 2.35 1972
13
Madras Refineries Limited (CBR), Nagapatinam
0.50
1994
14 Mangalore Refineries & Petrochemicals Ltd.,
Mangalore6.00 (9.0)
1995
15 Indian Oil Corporation Limited, Panipat 6.00 1998
16 Reliance Petroleum Limited, Jamnagar 27.00 1999
17 Numaligarh Refineries Ltd., Numaligarh 3.00 2000
Total Capacity
112.45
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ADVANCES IN PETROLEUM REFINING
Various issues faced by the refining industry have
led to many major developments in this area. The
challenges are:
1. Crude oil is becoming heavier and higher in
sulphur and metal content.
2. Reduced growth in fuel oil demand.
3. Rapid growth in light/middle distillates.
4. Stringent environmental regulation for cleaner
products/processes and demand for quality
products.
5. Declining refining margins
6. Improved engine design/automobiles need better
quality fuel and lubricating oils.
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Advances in refining technology can bebroadly divided into the following
categories.
Improved and integrated refining
Production of better quality products
Processing of residues/heavier ends
Management of power and utilitues.
Value addition through optimisation of refineryconfiguration
Petrochemicals production
Better quality and increased lube oil production
Power generation from heavier petroleumproducts.
Specialty chemicals production.
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Improvements are taking place in many
areas. Some of them are listed below
Distillation
Fluid Catalytic Cracking (FCC), Resid Fluid
Catalytic cracking (RFCC).
Delayed coking Needle coke manufacturing,
Visbreaker-Soaker Technology.
Hydro processing
Hydro treatment of various streams including
residues.
Hydro cracking
Super Oil Cracking (SOC) of heavy distillates
to get 90% conversion to distillates.
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Improvements are taking place in many areas. Some of
them are listed below
Mobile Distillate De-Waxing (MDDW) to upgrade heavy
fuel oil to high quality distillate and gas yield of 93-95%.
Isomerisation
Catalytic Reforming
Alkylation
Etherification
Power generation by petroleum residue and coke by using
Gasification Combined Cycle (GCC) technology.
In this process along with power, steam and H2 can be
produced which are required in the refinery.
More and more use of information technology.
Modeling simulation
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Refinery integration and value addition strategies
Small an Medium Refineries Integration with Specialty Chemical
Production Units for Value addition
Anode Grade Coke Needle Coke
Production Microcrystalline Wax Production
Alpha-Olefins Production
Larger Refineries
Petrochemicals and Specialty Products
Integration of Refining and Power Generation Integration of Fuels and Lube Production
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Thank you
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