Submitted by: Akhilesh Pathak B.Tech(CH) ( )

 Mathura Refinery, the sixth refinery of Indian Oil was commissioned in 1982 with a capacity of 6.0 MMTPA to meet the demand of petroleum products in north western region of the country, which includes National Capital Region.  Only company placed at 83 rd position among fortune 500 companies.  Mathura Refinery is the first in Asia and third in the world to receive the coveted ISO certification for Environment Management System in It is also the first in the World to get OHSMS certification for Safety Management in 1998.

 The major secondary processing units provided were Fluidised Catalytic Cracking Unit (FCCU), Vis-breaker Unit (VBU) and Bitumen Blowing Unit (BBU).  The original technology for these units was sourced from erstwhile USSR, UOP etc.  Soaker drum technology of EIL was implemented in VBU in the year  For production of unleaded Gasoline, Continuous Catalytic Reforming Unit (CCRU) was commissioned in 1998 with technology from Axens, France.  A DHDS licensed from Axens, France was commissioned in 1999 for production of HSD with low Sulphur content of 0.25% wt (max).  With the commissioning of Once Through Hydrocracker Unit (licensed from Chevron, USA) in July 2000, capacity of Mathura Refinery was increased to 8.0 MMTPA.

 An oil refinery separates the crude oil in to different fractions and converts them into usable products.  Maximize Higher value distillates like LPG,, ATF, Kerosene and Diesel.  Produce cleaner products.

 Crude oil is a complex mixture of thousands of hydrocarbons. (i.e paraffin, Napthenes & Aromatics)  Brownish black in Color and colloidal in nature  Contains small amounts of non hydrocarbon impurities in the form of organic compounds of sulphur, oxygen, nitrogen, metals, water and salts.

Hydro Carbons > 95% S.no.ElementPercentage(%) 1Carbon Hydrogen Sulphur0-3 4Oxygen0-2 5Nitrogen Metals0-0.1

1.SulphurCompounds :H2S, Mercaptans, Thiophenes, Benzothiophenes 2.Nitrogen Compounds :Pyrrole, Pyridine, Quinoline, etc. 3.Oxygen Compounds :Naphthenic Acid,Phenol etc. 4.Metallic Derivatives:Derivatives of Organic acids with metals Like Ni, Cu, V, Pb, As. 5.Water and Salt :Along with water, Soluble inorganic compounds like Chlorides, Sulphates of Sodium, Calcium and Magnesium

s.no.ProductKey Quality parameters 1LPGEvaporation Temperature at 95 % Volume =2 deg C, Max Cu Corrosion =not worse than No.1 2Motor SpiritDensity = Kg/M3 Sulphur=150 ppm, Max Benzene =1 Vol. %, Max 3ATFDensity = Kg/M3 Flash Point = 38 deg c, Min Sulphur=0.25 wt %,Max Smoke Point =20 mm, Min

s.no.ProductKey Quality parameters 4DieselDensity = Kg/M3 Sulphur= 50 ppm CetaneNumber = 51 Min 5Fuel OilSulphur= 4 wt %, Max Ash = 0.1 wt %, Max 50 deg c =125, Max (Winter) =180, Max (Summer) 6BitumenFlash Point =175 deg C,Min Viscosity at 60 Deg C = 2400 (min) CP Softening Point =45-55 deg C

PhysicalThermalCatalytic DistillationVisbreakingHydrotreating Solvent extractionDelayed cokingCatalytic reforming Propane deasphaltingFlexicokingCatalytic cracking Solvent dewaxingHydrocracking, Isomerization BlendingCatalytic dewaxing

 PRIMARY PROCESSING UNITS  SECONDARY PROCESSING UNITS

The purpose of Primary unit is to separate the crude in to different fractions by distillation. Known as mother unit of the refinery, consist of  CRUDE DISTILLATION UNIT (CDU)  VACUUM DISTILLATION UNIT (VDU) Commonly referred as Atmospheric and Vacuum Distillation unit (AVU)

1.The hydrolysis of salts in crude oil at high temperature produces HCL and corrodes the Column Internals and overhead system. 2.The sediments in crude oil fouls the heat exchanger, furnace tubes and erodes the pipelines by abrasive action. 3.Desalting approaches -To reduce soluble salt content -To reduce suspended solids. -To reduce residual water 4.Desalting of crude oil is carried out in a vessel provided with electrodes under High potential field( Volts) 5.DesalterOperating condition: -Temperature range : deg C -System pressure :12-14 kg/cm2g

6. The desalted crude is Preheated to about deg C and fed to Prefractionator column 7. The purpose of prefractionator is to separate the lighter hydrocarbons at relatively lower temperature so as to reduce heat energy requirement across furnace and to reduce the main fractionator overhead vapour load 8. Prefractinator are typically used in revamps for energy conservation and unit capacity enhancement Prefractionator Operating condition Top Temperature range= deg c Pressure= kg/cm2g 9. The Pre-fractionator column bottom is fed to Fractionator column after heating to 360 –370 Deg C in Heat Exchanger train & Furnace.

 The main fractionator separates the pre-topped crude in to different fractions like Naphtha, Heavy Naphtha, Aviation Turbine Fuel, Kerosene, Light Gas Oil, Heavy Gas Oil and Reduced Crude Oil.  Column Operating Condition Top Temperature Range = deg C Pressure= Kg/cm2g

Atmospheric and vaccum distillation unit flow diagram

1.VDU objective is to recover valuable product from RCO relatively at lower temperature. 2.Feed preparation unit for FCC/HCU/VBU/BBU 3.The Operating temp. is about Deg C 4. Vacuum is created by steam ejectors. Column Operating Condition: Top Temperature range : deg C Pressure: mm Hg (a)

 RCO from CDU is "heavy", and the separation of this stream into various fractions would normally require more energy and higher temperatures.  Higher hydrocarbons promotes coking reactions at more than 380 deg c at atmospheric pressure fouls the furnace tubes.  To reduce the amount of energy input required, and to recover the valuable products from RCO without cracking, it is distilled under vacuum.  The vacuum condition reduces the boiling point of the RCO and the fractions are separated relatively at lower temperature led to energy saving and reduces fouling of the furnace tubes

s.noVDU ProductQualityProcessing 1LVGOHigh ‘S’, Low Cetane no.Hydrotreatment (DHDS) for Sulphur and Cetane No., 2LDOHigh ‘S’,Heavy Hydrocarbons Fluid catalytic unit / Hydrocracker unit 3HVGOHigh ‘S’,Heavy Hydrocarbons Fluid catalytic unit / Hydrocracker unit 4Vacuum SlopHeavy Hydrocarbons, Fuel oil Product Visbreaker unit / Coker 5Vacuum ResidueResidueBitumen Blowing Unit / VBU / Coker

 Objective : To meet the Euro –III/IV diesel quality requirement ( 350/50 ppm ‘S’ and Min. 51 Cetane No.)  Feed : Straight run diesel / FCC diesel component/ Coker and Visbreaker diesel components.  Catalyst : Ni-Mo oxides  Chemical reactions: Desulphurisation and Denitrification  C 5 H 10 SH+H 2 C 6 H 12 +H 2 S  Aromatic compound + H2 --> NaptheneCompound

1.Typical Product Yields S.no.ProductsWt%End Users 1.Off Gas2.65Refinery Fuel gas system after Amine Wash 2.Wild Naphtha2.8To Naphtha Pool after stabilisation 3.Diesel96.1To Diesel Pool

2. Operating Conditions : Temperature range : C System Pressure : kg/cm2(g)

Diesel hydro treatment unit

S.no.Characterist ics BS IIIBS-IV 1.CetaneNo., min 51 2.Sulphur, PPM max Flash point66 deg C