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 & Major Process Units. MS Barrel of Mathura Refinery. Challenges on meeting EURO-IV MS specification. Octane Management Practice at Mathura Refinery. Conclusion. 2 IOCL – Mathura Refinery
Mathura Refinery Configuration: 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 3 IOCL – Mathura Refinery
MS Barrel of Mathura Refinery: Major Streams: Treated FCC Gasoline Isomerate Reformate OHCU Light Naphtha Straight Run Naphtha 4 IOCL – Mathura Refinery
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 0.5 100 103.8 104.0 OHCU LN 3.02 70.0 1 8 0.8 5 SRN 0.35 57.0 1 8 2 90 103.5 TMT/Month 103.8 91.6 16.6 29.9 0.8 32.4 103.0 102.5 102.1 102.0 Case-I: RON of Reformate Reduced by 1 Number 101.5 Mass Flow RON Olefins Aromatics Benzene Sulfur 101.0 TMT % % % ppm Base Case Case-I 27.62 88.0 0 0.1 0 0 Light Isomerate 3.07 80.0 0 0.1 0 0 Monthly MS Production (Thousand MT) Heavy Isomerate 36.56 98.5 1 80 1.8 0 Heavy Reformate 33.19 90.5 50 12.5 0.5 100 FCC Gasoline 1.26 70.0 1 8 0.8 5 OHCU LN 0.35 57.0 1 8 2 90 SRN TMT/Month 102.1 91.6 16.9 30.3 0.8 32.9 Decrease of 1 RON of reformate – Decrease in MS Production by 1.8 TMT. 5 IOCL – Mathura Refinery
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 0 104.0 103.8 FCC Gasoline 33.19 90.5 50 12.5 0.5 100 OHCU LN 3.02 70.0 1 8 0.8 5 103.5 SRN 0.35 57.0 1 8 2 90 103.0 TMT/Month 103.8 91.6 16.6 29.9 0.8 32.4 102.3 102.5 102.0 101.5 Case-II: RON of FCC Gasoline Reduced by 1 Number Base Case Case-II Monthly MS Production (Thousand MT) 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 Decrease of 1 RON of FCC Gasoline – Decrease in MS Production by 1.5 TMT. 6 IOCL – Mathura Refinery
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 0 104.0 103.8 FCC Gasoline 33.19 90.5 50 12.5 0.5 100 OHCU LN 3.02 70.0 1 8 0.8 5 103.5 SRN 0.35 57.0 1 8 2 90 103.0 102.6 TMT/Month 103.8 91.6 16.6 29.9 0.8 32.4 102.5 102.0 101.5 Case-II: RON of Isomerate reduced by 1 Number Base Case Case-II Mass Flow RON Olefins Aromatics Benzene Sulfur Monthly MS Production (Thousand MT) 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 Decrease of 1 RON of Isomerate – Decrease in MS Production by 1.3 TMT. 7 IOCL – Mathura Refinery
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. 8 IOCL – Mathura Refinery
Optimization of FCC Gasoline: LCN LPG Isomerization Gasoline Heart Cut to From Isomerisation Unit SHU Isomerate HDS MS Pool HCN Treated FCC Gasoline Gasoline Splitter Unit 9 IOCL – Mathura Refinery
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 Isomerate Yield: 87 % RON: 87 MS Pool Heart Cut Treated Gasoline Yield: 99 % RON: 89-90 10 IOCL – Mathura Refinery
Optimization of FCC Gasoline: Best Practice: • Minimize Heart Cut Yield • Preferential Routing to MS Pool • Isomerisation Gasoline Splitter Unit Constrains: • Benzene in MS Pool LCN • Olefins Gasoline From SHU LPG Isomerization Minimize Heart Direct Routing of Heart Isomerate Cut Yield Cut to MS Pool HDS MS Pool HCN Treated FCC Gasoline 11 IOCL – Mathura Refinery
Optimization of FCC Gasoline: Case Study-I BASE CASE: All Heart Cut routed to Isomerisation 106.5 105.9 Monthly 106 Production RON Olefins Aromatics Benzene Sulfur 105.5 TMT % % % ppm 105 Light Isomerate 27.62 88.0 0 0.1 0 0 104.5 Heavy Isomerate 3.07 80.0 0 0.1 0 0 103.8 104 Heavy Reformate 36.56 99.5 1 80 1.8 0 103.5 FCC Gasoline 33.19 90.5 50 12.5 0.5 100 FCC Heart Cut 0.00 92.0 58 4 3.5 130 103 OHCU LN 3.02 70.0 1 8 0.8 5 102.5 SRN 0.35 57.0 1 8 2 90 Base Case Case-I Monthly MS Production (Thousand MT) TMT/Month 103.8 91.6 16.6 29.9 0.8 32.4 CASE-I: 75% of Heart Cut routed to Isomerisation Benefits: Monthly • MS Production increase by 2.1 TMT/Month. 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 Constrains: FCC Gasoline 35.27 90.5 50 12.5 0.7 100 • RON of MS Pool. FCC Heart Cut 0.00 92.0 58 4 3.5 130 OHCU LN 3.02 70.0 1 8 0.8 5 • Temperature exotherm in HDS Reactor. SRN 0.30 57.0 1 8 2 90 TMT/Month 105.9 91.6 17.3 29.5 0.8 33.7 12 IOCL – Mathura Refinery
Optimization of FCC Gasoline: Case Study-II BASE CASE: All Heart Cut routed to Isomerisation 112 Monthly 110.0 Production RON Olefins Aromatics Benzene Sulfur 110 TMT % % % ppm 108 Light Isomerate 27.62 88.0 0 0.1 0 0 Heavy Isomerate 3.07 80.0 0 0.1 0 0 106 103.8 Heavy Reformate 36.56 99.5 1 80 1.8 0 104 FCC Gasoline 33.19 90.5 50 12.5 0.5 100 102 FCC Heart Cut 0.00 92.0 58 4 3.5 130 OHCU LN 3.02 70.0 1 8 0.8 5 100 SRN 0.35 57.0 1 8 2 90 Base Case Case-II Monthly MS Production (Thousand MT) TMT/Month 103.8 91.6 16.6 29.9 0.8 32.4 CASE-II: 75 % of Heart Cut routed to MS Pool Benefits: Monthly • MS Production increase by 6.2 TMT/Month. 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 Constrains: FCC Gasoline 33.19 90.5 50 12.5 0.5 100 • Benzene in MS Pool. FCC Heart Cut 6.22 92.0 58 4 3.5 130 OHCU LN 3.02 70.0 1 8 0.8 5 • Olefins & Sulfur in MS Pool. SRN 0.35 57.0 1 8 2 90 TMT/Month 110.0 91.6 19.0 28.9 0.9 37.9 13 IOCL – Mathura Refinery
Isomerisation Unit Light Isomerate Isomerisation Reactors DIH Light Naphtha NHDT Side Cut Recycle Heart Cut Heavy Isomerate Total Isomerate 14 IOCL – Mathura Refinery
Optimization of Isomerate: Light Isomerate: RON: 88.0 – 89.0 Yield: 90-95 % of Total Isomerate Total Isomerate: RON: 87 Heavy Isomerate: RON: 80.0 – 82.0 Yield: 5-10 % of Total Isomerate Heavy Isomerate: Rich in C 6 & C 7 components. Good Reformer Feed. CATALYTIC REFORMER Reformate RON: 82 RON: 98 15 IOCL – Mathura Refinery
Optimization of Isomerate – Case Study BASE CASE: Heavy Isomerate Routed to MS Pool 105 Mass Flow RON Olefins Aromatics Benzene Sulfur 104.7 TMT % % % ppm Light Isomerate 27.62 88.0 0 0.1 0 0 104.5 Heavy Isomerate 3.07 80.0 0 0.1 0 0 Heavy Reformate 36.56 99.5 1 80 1.8 0 104 103.8 FCC Gasoline 33.19 90.5 50 12.5 0.5 100 OHCU LN 3.02 70.0 1 8 0.8 5 103.5 SRN 0.35 57.0 1 8 2 90 103 TMT/Month 103.8 91.6 16.6 29.9 0.8 32.4 Base Case Case-I Monthly MS Production (Thousand MT) Benefits: CASE-I: Heavy Isomerate Routed to Reformate • MS Production increase by 0.9 TMT/Month. Mass Flow RON Olefins Aromatics Benzene Sulfur TMT % % % ppm Light Isomerate 27.62 88.0 0 0.1 0 0 Constrains: Heavy Isomerate 0.00 80.0 0 0.1 0 0 • Capacity utilization of reformer. Heavy Reformate 39.16 99.5 1 80 1.8 0 FCC Gasoline 33.19 90.5 50 12.5 0.5 100 • Double processing of a single stream. 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 16 IOCL – Mathura Refinery
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