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PETROLEUM REFINERY DESIGN and engineering

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CHL794
Raghav Agrawal (2008CH70126) Gaurav Yadav (2008CH70114) Neeraj Meena (2008CH10176)

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CRUDE CHARACTERISTICS
Stage 1: Distillation at atmospheric Pressure (748mm Hg) Fraction No. Cut Temp. Sum (C) Percent 1 2 3 4 5 6 7 8 9 10 50 75 100 125 150 175 200 225 250 275 1.9 4.1 9.4 15.6 21.1 26.0 30.1 34.7 39.7 45.4 Stage 2: Distillation continued at 40mm Hg Fraction No. 11 12 13 14 15 Cut Temp. Sum (C) Percent 200 225 250 275 300 48.7 54.4 59.0 63.2 69.2 96.8

Residuum

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CRUDE CHARACTERISTICS

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BLEND: TBP PLOT

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CRUDE CHARACTERISATION
Volume % Distilled 10.00 30.00 50.00 70.00 90.00 TBP (F) 235.94 447.98 627.98 795.92 1063.94

UOP CHARACTERISATION FACTOR, K=11.94

MIXED BASE

Volume % Distilled 10.00

TBP (F) 235.94 10.35 634.35 4.92 1.00 633.35 1093.35 32.50 0.86 11.94

30.00SL VABP ln

MeABP(F) MeABP 50.00API 70.00SG 90.00Kw

Cross Check: API of kerosene : 40 Key fraction No.1 : For Boiling Range of 250C-275C at 1atm API should be in the range 33-40 for a mixed base, so this indicates that the crude is mixed tending towards paraffinic

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CDU PRODUCTS

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VDU PRODUCTS

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Flow Sheet

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CRUDE DESALTING

Salts in the crude oil are mostly in the form of dissolved salts in

fine water droplets emulsified in the crude oil. This is called a water-in-oil emulsion.

Salts are mostly sodium, calcium and Magnesium chlorides

among which Ca and Mg chlorides hydrolize at high T to form HCl.

Causes Fouling in HE, corrosion in equipment and act as catalyst

poison.

Desalting Operation: Water washing ->Heating -> Coalescence ->

Settling

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CRUDE DISTILLATION PROCESS

To distill and separate valuable distillates (naphtha, kerosene,diesel) and atmospheric gas oil (AGO) from the crude feedstock.

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CDU Design Variables

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CDU PRODUCTS

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Material Balance :: CDU

End Temp. Mass [C] Fraction Mass Flow Rate[kg/hr]

Density of crude: 860.67 kg/m3 Crude feed rate: 100,000 bpd or 558277 kg/hr

Product Off Gas Lt Naphtha Naphtha Kerosene Light Diesel

Start temp [C] 10 -15.15 70 10 180 70 180 240 290 340 370 370 816.5 .084 .471 240 290 340 .081 .102 .093 .144 .02 .005

2791.386 11165.54 80391.92 45220.45 56944.27 51919.78 46895.28 262948.6

Destination Power generation Isomerization unit Naphtha reformer Hydrotreater Hydrotreater hydrodesulfuri zation followed by FCCU FCCU vacuum distillation column

Heavy Diesel Atm . Gas Oil

Atm Residue

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Sulfur from ADU

Total Sulfur coming in crude is 0.42%. For M<200
wt%S = 177.448 170.946Ri +0.2258m + 4.054SG

For M>200
wt%S = -58.02 + 38.463Ri - 0.023m +22.4SG Ri =n d/2 m=M(n 1.475)

Ref. :- Fundamentals of Petroleum refining,

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Sulfur coming in Products

n
Off Gas Lt St Run Naphth a Kerosen e Light Diesel Heavy Diesel Atm Gas Oil Residue

SG

Molecul ar Weight
55.6 71.2 112.4 159.8 200.1 243.2 284.7 434.7

m
-6.61 -6.99 -6.38 -4.60 -2.16 0.38 3.04 22.21

d
0.629 0.675 0.749 0.798 0.827 0.849 0.866 0.907

Ri
1.0412 1.0391 1.0434 1.0467 1.0506 1.0516 1.0524 1.0726

% of S
0.054 0.099 0.069 0.072 0.056 1.02 1.87 2.22

Mass of S(kg/h)
1.507348 11.05389 55.47042 32.55873 31.88879 529.5818 876.9418 5837.458

1.3561 0.635 1.3768

0.68

1.4182 0.754 1.4462 0.803 1.4642 0.831 1.4766 0.854 1.4857 0.870 1.5261 0.960

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VDU PRODUCT DISTRIBUTION

To recover valuable gas oils from reduced crude via vacuum distillation..

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VDU PRODUCTS
Product Mass (kg/h)
PRODUCT

Mass Fraction

Off Gas

0.529

139099.5

LVGO

0.119

31290.52

HVGO

0.210

55218.89

Vac Residue

0.143

37601.27

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LVGO sent to gasoline pool after Hydrotreating.

HVGO sent to FCCU after Hydrotreating.

Vacuum Residue sent to Delayed Coker, thermal cracker.

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Naphtha Reformer MASS BALANCE

Mass Balance Feed Products Heavy Naphtha C5+ Mass flow Rates [kg/hr] 80391 Mass fraction 1 0.829

66644
iC4 .0146

1173
nC4 .0205

1648
C3 .0295

2371
C2 .0192

1543
C1 .0115

924
H2 .0227

1824

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Assumptions
Naphtha splits into 70% of Heavy Naphtha of 13 API and

30% of light Naphtha of 30 API.

Assumed Cyclic Reformer so RONR of product coming out

of it is taken to be 94.
Characterization factor K=11.94

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Reformer Correlations

Ref :-Fundamentals of Petroleum refining, Table-5.3 Rdeformer Correlations, Page no. 108

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Fluid Catalytic cracking Unit(FCCU)

Feed from different units Feed rate (kg/hr) Mass of S(kg/hr)

Atm. Gas Oil

46895

876

vaccum distillation HVGO

55218

543

Total feed

102113

1420

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Typical ARDS Yields

Ref :-Fundamentals of Petroleum refining, Table-7.7 , Page No. 170

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Product coming from HDS

Product s Mass Fraction Mass Flowrate [kg/hr] Acid Gases .038

3880
C1 C4 .02

2042
Naphtha .027

2757
Diesel .186

18993
LSFO .745

76074

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FCC PRODUCTS
Product
coke LCO LV% diesel pool gas wt gasoline n C4 C4-C3 C3--

wt%
9.8 15.78 4.73 57.37 2.59 7.29 2.39 6.44

Product Mass (kg/h)

22133.7 35570.8 10662.22 129321.7 5854.079 16432.9 5387.466 14537.14

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FCC Correlations and Assumptions

Cracked Naphtha is sent to the gasoline pool Unsaturated light ends are going to the alkylation unit LCO goes to the diesel pool Conversion is taken as 75%.

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Delayed Coker FEED Properties

Flow rate of Feed 83005 lb/hr Conradson Carbon Residue - 6.5 % Delayed Coker is Used. Naphtha is sent to the reformer unit Gas oil is sent to FCCU after hydro treating

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DELAYED COKER PRODUCTS

Product(mass) (kg/h)

Product

Weight %

C4- gas

8.73

3284

naptha

13.51

5083

coke

10.4

3910

gas oil

67.34

25322

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Delayed Coker Correlations

Ref:- Fundamentals of Petroleum refining, 6.5.6.- Delayed Coker yield Predictions, Page no. 140

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Final Products
Gasoline coming from ADU reformer , FCCU,

thermal cracker naphtha, alkylation unit, light vacuum gas oil.

Diesel coming from light gas oil of ADU, light

cycle oil from FCCU, light gas oil from delayed Coker.

Kerosene from ADU. Coke from FCCU and thermal cracker.

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THANK YOU