Presentation on Strategy of Octane Management at IOCL Mathura - - PowerPoint PPT Presentation

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Presentation on Strategy of Octane Management at IOCL Mathura - - PowerPoint PPT Presentation

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Presentation on Strategy of Octane Management at IOCL Mathura Refinery New Delhi, 16 th 17 th April 12 IOCL Mathura Refinery IOCL Mathura Refinery IOCL Mathura Refinery Agenda Mathura Refinery Configuration &

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SLIDE 1

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

Presentation

  • n

Strategy of Octane Management at IOCL – Mathura Refinery

New Delhi, 16th – 17th April’ 12

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SLIDE 2

IOCL – Mathura Refinery

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  • 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

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IOCL – Mathura Refinery

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  • 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:

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SLIDE 4

IOCL – Mathura Refinery

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MS Barrel of Mathura Refinery:

  • Treated FCC Gasoline
  • Isomerate
  • Reformate
  • OHCU Light Naphtha
  • Straight Run Naphtha

Major Streams:

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SLIDE 5

IOCL – Mathura Refinery

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Importance of RON on Refinery Profitability:

Base Case:

Mass Flow RON Olefins Aromatics Benzene Sulfur TMT % % % ppm Light Isomerate 27.62 88.0 0.1 Heavy Isomerate 3.07 80.0 0.1 Heavy Reformate 36.56 99.5 1 80 1.8 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 0.1

Heavy Isomerate

3.07 80.0 0.1

Heavy Reformate

36.56 98.5 1 80 1.8

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.
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IOCL – Mathura Refinery

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Importance of RON on Refinery Profitability:

Base Case:

Mass Flow RON Olefins Aromatics Benzene Sulfur TMT % % % ppm Light Isomerate 27.62 88.0 0.1 Heavy Isomerate 3.07 80.0 0.1 Heavy Reformate 36.56 99.5 1 80 1.8 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 0.1 Heavy Isomerate 3.07 80.0 0.1 Heavy Reformate 36.56 99.5 1 80 1.8 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)

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SLIDE 7

IOCL – Mathura Refinery

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Importance of RON on Refinery Profitability:

Base Case:

Mass Flow RON Olefins Aromatics Benzene Sulfur TMT % % % ppm Light Isomerate 27.62 88.0 0.1 Heavy Isomerate 3.07 80.0 0.1 Heavy Reformate 36.56 99.5 1 80 1.8 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 0.1 Heavy Isomerate 3.07 80.0 0.1 Heavy Reformate 36.56 99.5 1 80 1.8 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)

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SLIDE 8

IOCL – Mathura Refinery

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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.
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SLIDE 9

IOCL – Mathura Refinery

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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

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IOCL – Mathura Refinery

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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

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IOCL – Mathura Refinery

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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

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IOCL – Mathura Refinery

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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 0.1 Heavy Isomerate 3.07 80.0 0.1 Heavy Reformate 36.56 99.5 1 80 1.8 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 0.1 Heavy Isomerate 3.07 80.0 0.1 Heavy Reformate 36.56 99.5 1 80 1.8 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)

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IOCL – Mathura Refinery

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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 0.1 Heavy Isomerate 3.07 80.0 0.1 Heavy Reformate 36.56 99.5 1 80 1.8 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 0.1 Heavy Isomerate 3.07 80.0 0.1 Heavy Reformate 36.56 99.5 1 80 1.8 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)

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IOCL – Mathura Refinery

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Isomerisation Unit

NHDT DIH Isomerisation Reactors Light Naphtha Heart Cut Light Isomerate Heavy Isomerate Total Isomerate Side Cut Recycle

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IOCL – Mathura Refinery

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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

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IOCL – Mathura Refinery

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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 0.1 Heavy Isomerate 3.07 80.0 0.1 Heavy Reformate 36.56 99.5 1 80 1.8 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 0.1 Heavy Isomerate 0.00 80.0 0.1 Heavy Reformate 39.16 99.5 1 80 1.8 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)

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IOCL – Mathura Refinery

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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.
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IOCL – Mathura Refinery

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THANK YOU