IOCL – Mathura Refinery IOCL – Mathura Refinery IOCL – Mathura Refinery

Presentation

on

Strategy of Octane Management at IOCL – Mathura Refinery

New Delhi, 16th – 17th April’ 12

IOCL – Mathura Refinery 2

Mathura Refinery – Configuration & Major Process Units.

MS Barrel of Mathura Refinery.

Challenges on meeting EURO-IV MS specification.

Octane Management Practice at Mathura Refinery.

Conclusion.

Agenda

IOCL – Mathura Refinery 3

Crude Processing Capacity 8.0 MMTPA

Major Units Atmospheric & Vacuum Unit

FCCU, OHCU

CRU, Isomerisation, FCC Gasoline Treater

DHDT, DHDS

VBU, BBU

Sulfur Recovery Units, Tail Gas Treatment Unit

HGUs, Power Plant,

Raw water & Effluent Treatment Plant

Crude Processed High Sulfur, Nigerian, Bombay High

Crude Mix

Mathura Refinery Configuration:

IOCL – Mathura Refinery 4

MS Barrel of Mathura Refinery:

Treated FCC Gasoline

Isomerate

Reformate

OHCU Light Naphtha

Straight Run Naphtha

Major Streams:

IOCL – Mathura Refinery 5

Importance of RON on Refinery Profitability:

Base Case:

Mass Flow RON Olefins Aromatics Benzene Sulfur

TMT % % % ppm

Light Isomerate 27.62 88.0 0 0.1 0 0

Heavy Isomerate 3.07 80.0 0 0.1 0 0

Heavy Reformate 36.56 99.5 1 80 1.8 0

FCC Gasoline 33.19 90.5 50 12.5 0.5 100

OHCU LN 3.02 70.0 1 8 0.8 5

SRN 0.35 57.0 1 8 2 90

TMT/Month 103.8 91.6 16.6 29.9 0.8 32.4

Mass Flow RON Olefins Aromatics Benzene Sulfur

TMT % % % ppm

Light Isomerate 27.62 88.0 0 0.1 0 0

Heavy Isomerate 3.07 80.0 0 0.1 0 0

Heavy Reformate 36.56 98.5 1 80 1.8 0

FCC Gasoline 33.19 90.5 50 12.5 0.5 100

OHCU LN 1.26 70.0 1 8 0.8 5

SRN 0.35 57.0 1 8 2 90

TMT/Month 102.1 91.6 16.9 30.3 0.8 32.9

Case-I: RON of Reformate Reduced by 1 Number

103.8

102.1

101.0

101.5

102.0

102.5

103.0

103.5

104.0

Base Case Case-I

Monthly MS Production (Thousand MT)

Decrease of 1 RON of reformate – Decrease in MS Production by 1.8 TMT.

IOCL – Mathura Refinery 6

Importance of RON on Refinery Profitability:

Base Case:

Mass Flow RON Olefins Aromatics Benzene Sulfur

TMT % % % ppm

Light Isomerate 27.62 88.0 0 0.1 0 0

Heavy Isomerate 3.07 80.0 0 0.1 0 0

Heavy Reformate 36.56 99.5 1 80 1.8 0

FCC Gasoline 33.19 90.5 50 12.5 0.5 100

OHCU LN 3.02 70.0 1 8 0.8 5

SRN 0.35 57.0 1 8 2 90

TMT/Month 103.8 91.6 16.6 29.9 0.8 32.4

Case-II: RON of FCC Gasoline Reduced by 1 Number

Decrease of 1 RON of FCC Gasoline – Decrease in MS Production by 1.5 TMT.

Mass Flow RON Olefins Aromatics Benzene Sulfur

TMT % % % ppm

Light Isomerate 27.62 88.0 0 0.1 0 0

Heavy Isomerate 3.07 80.0 0 0.1 0 0

Heavy Reformate 36.56 99.5 1 80 1.8 0

FCC Gasoline 33.19 89.5 50 12.5 0.5 100

OHCU LN 1.51 70.0 1 8 0.8 5

SRN 0.35 57.0 1 8 2 90

TMT/Month 102.3 91.6 16.9 30.2 0.8 32.8

103.8

102.3

101.5

102.0

102.5

103.0

103.5

104.0

Base Case Case-II

Monthly MS Production (Thousand MT)

IOCL – Mathura Refinery 7

Importance of RON on Refinery Profitability:

Base Case:

Mass Flow RON Olefins Aromatics Benzene Sulfur

TMT % % % ppm

Light Isomerate 27.62 88.0 0 0.1 0 0

Heavy Isomerate 3.07 80.0 0 0.1 0 0

Heavy Reformate 36.56 99.5 1 80 1.8 0

FCC Gasoline 33.19 90.5 50 12.5 0.5 100

OHCU LN 3.02 70.0 1 8 0.8 5

SRN 0.35 57.0 1 8 2 90

TMT/Month 103.8 91.6 16.6 29.9 0.8 32.4

Case-II: RON of Isomerate reduced by 1 Number

Decrease of 1 RON of Isomerate – Decrease in MS Production by 1.3 TMT.

Mass Flow RON Olefins Aromatics Benzene Sulfur

TMT % % % ppm

Light Isomerate 27.62 87.0 0 0.1 0 0

Heavy Isomerate 3.07 80.0 0 0.1 0 0

Heavy Reformate 36.56 99.5 1 80 1.8 0

FCC Gasoline 33.19 89.5 50 12.5 0.5 100

OHCU LN 1.76 70.0 1 8 0.8 5

SRN 0.35 57.0 1 8 2 90

TMT/Month 102.6 91.6 16.8 30.2 0.8 32.8

103.8

102.6

101.5

102.0

102.5

103.0

103.5

104.0

Base Case Case-II

Monthly MS Production (Thousand MT)

IOCL – Mathura Refinery 8

Challenges & Opportunity:

Challenge:

Increasing High Sulfur Crude basket.

Decreasing N+2A.

Decreasing RON of Reformate.

Increasing severity of Catalytic Reformer.

Increasing Coke formation.

Throughput limitation with fixed regeneration capability.

Opportunity:

Increasing Isomerate RON.

Decrease RON loss in FCC Gasoline treater by altering yield and routing.

Alternative:

Revamp CCRU.

IOCL – Mathura Refinery 9

HDS

Gasoline Splitter Unit

Heart Cut to

Isomerisation Unit

LCN

HCN

Treated FCC Gasoline

Optimization of FCC Gasoline:

Isomerization

MS Pool

LPG

Isomerate

Gasoline

From

SHU

IOCL – Mathura Refinery 10

Optimization of FCC Gasoline:

Parameters LCN Heart Cut HCN (Treated)

RON 94 - 96 90 - 92 89-90

Sulfur (ppm) < 10 ppm 120 – 130 ppm 120 ppm

Heart Cut

Isomerate

Yield: 87 %

RON: 87

Treated Gasoline

Yield: 99 %

RON: 89-90

MS Pool

IOCL – Mathura Refinery 11

HDS

Gasoline Splitter Unit

Minimize Heart

Cut Yield

LCN

HCN Treated FCC Gasoline

Optimization of FCC Gasoline:

Isomerization

MS Pool

LPG

Isomerate Direct Routing of Heart

Cut to MS Pool

• Minimize Heart Cut Yield

• Preferential Routing to MS Pool

• Isomerisation

Constrains:

• Benzene in MS Pool

• Olefins

Best Practice:

Gasoline

From

SHU

IOCL – Mathura Refinery 12

Optimization of FCC Gasoline: Case Study-I

BASE CASE: All Heart Cut routed to Isomerisation

CASE-I: 75% of Heart Cut routed to Isomerisation Benefits:

• MS Production increase by 2.1 TMT/Month.

Constrains:

• RON of MS Pool.

• Temperature exotherm in HDS Reactor.

Monthly

Production RON Olefins Aromatics Benzene Sulfur

TMT % % % ppm

Light Isomerate 27.62 88.0 0 0.1 0 0

Heavy Isomerate 3.07 80.0 0 0.1 0 0

Heavy Reformate 36.56 99.5 1 80 1.8 0

FCC Gasoline 33.19 90.5 50 12.5 0.5 100

FCC Heart Cut 0.00 92.0 58 4 3.5 130

OHCU LN 3.02 70.0 1 8 0.8 5

SRN 0.35 57.0 1 8 2 90

TMT/Month 103.8 91.6 16.6 29.9 0.8 32.4

Monthly

Production RON Olefins Aromatics Benzene Sulfur

TMT % % % ppm

Light Isomerate 27.62 88.0 0 0.1 0 0

Heavy Isomerate 3.07 80.0 0 0.1 0 0

Heavy Reformate 36.56 99.5 1 80 1.8 0

FCC Gasoline 35.27 90.5 50 12.5 0.7 100

FCC Heart Cut 0.00 92.0 58 4 3.5 130

OHCU LN 3.02 70.0 1 8 0.8 5

SRN 0.30 57.0 1 8 2 90

TMT/Month 105.9 91.6 17.3 29.5 0.8 33.7

103.8

105.9

102.5

103

103.5

104

104.5

105

105.5

106

106.5

Base Case Case-I

Monthly MS Production (Thousand MT)

IOCL – Mathura Refinery 13

Optimization of FCC Gasoline: Case Study-II

BASE CASE: All Heart Cut routed to Isomerisation

CASE-II: 75 % of Heart Cut routed to MS Pool Benefits:

• MS Production increase by 6.2 TMT/Month.

Constrains:

• Benzene in MS Pool.

• Olefins & Sulfur in MS Pool.

Monthly

Production RON Olefins Aromatics Benzene Sulfur

TMT % % % ppm

Light Isomerate 27.62 88.0 0 0.1 0 0

Heavy Isomerate 3.07 80.0 0 0.1 0 0

Heavy Reformate 36.56 99.5 1 80 1.8 0

FCC Gasoline 33.19 90.5 50 12.5 0.5 100

FCC Heart Cut 0.00 92.0 58 4 3.5 130

OHCU LN 3.02 70.0 1 8 0.8 5

SRN 0.35 57.0 1 8 2 90

TMT/Month 103.8 91.6 16.6 29.9 0.8 32.4

Monthly

Production RON Olefins Aromatics Benzene Sulfur

TMT % % % ppm

Light Isomerate 27.62 88.0 0 0.1 0 0

Heavy Isomerate 3.07 80.0 0 0.1 0 0

Heavy Reformate 36.56 99.5 1 80 1.8 0

FCC Gasoline 33.19 90.5 50 12.5 0.5 100

FCC Heart Cut 6.22 92.0 58 4 3.5 130

OHCU LN 3.02 70.0 1 8 0.8 5

SRN 0.35 57.0 1 8 2 90

TMT/Month 110.0 91.6 19.0 28.9 0.9 37.9

103.8

110.0

100

102

104

106

108

110

112

Base Case Case-II

Monthly MS Production (Thousand MT)

IOCL – Mathura Refinery 14

Isomerisation Unit

NHDT

DIH

Isomerisation Reactors

Light

Naphtha

Heart Cut

Light Isomerate

Heavy Isomerate

Total Isomerate

Side Cut

Recycle

IOCL – Mathura Refinery 15

Optimization of Isomerate:

Total Isomerate:

RON: 87

Light Isomerate:

RON: 88.0 – 89.0

Yield: 90-95 % of Total Isomerate

Heavy Isomerate:

RON: 80.0 – 82.0

Yield: 5-10 % of Total Isomerate

Heavy Isomerate:

Rich in C6 & C7 components.

Good Reformer Feed.

CATALYTIC REFORMER

RON: 82 RON: 98

Reformate

IOCL – Mathura Refinery 16

BASE CASE: Heavy Isomerate Routed to MS Pool

CASE-I: Heavy Isomerate Routed to Reformate Benefits:

• MS Production increase by 0.9 TMT/Month.

Constrains:

• Capacity utilization of reformer.

• Double processing of a single stream.

Optimization of Isomerate – Case Study

Mass Flow RON Olefins Aromatics Benzene Sulfur

TMT % % % ppm

Light Isomerate 27.62 88.0 0 0.1 0 0

Heavy Isomerate 3.07 80.0 0 0.1 0 0

Heavy Reformate 36.56 99.5 1 80 1.8 0

FCC Gasoline 33.19 90.5 50 12.5 0.5 100

OHCU LN 3.02 70.0 1 8 0.8 5

SRN 0.35 57.0 1 8 2 90

TMT/Month 103.8 91.6 16.6 29.9 0.8 32.4

Mass Flow RON Olefins Aromatics Benzene Sulfur

TMT % % % ppm

Light Isomerate 27.62 88.0 0 0.1 0 0

Heavy Isomerate 0.00 80.0 0 0.1 0 0

Heavy Reformate 39.16 99.5 1 80 1.8 0

FCC Gasoline 33.19 90.5 50 12.5 0.5 100

OHCU LN 3.02 70.0 1 8 0.8 5

SRN 1.70 57.0 1 8 2 90

TMT/Month 104.7 91.6 16.6 31.6 0.8 33.3

103.8

104.7

103

103.5

104

104.5

105

Base Case Case-I

Monthly MS Production (Thousand MT)

IOCL – Mathura Refinery 17

Conclusion

Optimization Heart cut yield in FCC GSU.

Optimum routing of Heart cut of GSU.

Routing of Isomerate to Reformer feed.

MS Production can be maximized by:

Also helps in case of:

Meeting demand of high RON MS. (MS-95)

Poor RON of Reformate or Isomerate.

IOCL – Mathura Refinery 18

THANK YOU