Presentation. Strategy of Octane Management at IOCL Mathura Refinery

Transcription

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

2 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. IOCL Mathura Refinery 2

3 Mathura Refinery Configuration: Crude Processing Capacity Major Units Crude Processed 8.0 MMTPA 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 High Sulfur, Nigerian, Bombay High Crude Mix IOCL Mathura Refinery 3

4 Major Streams: Treated FCC Gasoline Isomerate Reformate OHCU Light Naphtha Straight Run Naphtha MS Barrel of Mathura Refinery: IOCL Mathura Refinery 4

5 Importance of RON on Refinery Profitability: Base Case: Mass Flow RON Olefins Aromatics Benzene Sulfur FCC Gasoline OHCU LN TMT/Month Case-I: RON of Reformate Reduced by 1 Number Mass Flow RON Olefins Aromatics Benzene Sulfur Heavy Reformate FCC Gasoline OHCU LN Base Case Case-I Monthly MS Production (Thousand MT) TMT/Month Decrease of 1 RON of reformate Decrease in MS Production by 1.8 TMT. IOCL Mathura Refinery 5

6 Importance of RON on Refinery Profitability: Base Case: Mass Flow RON Olefins Aromatics Benzene Sulfur FCC Gasoline OHCU LN TMT/Month Case-II: RON of FCC Gasoline Reduced by 1 Number Base Case Case-II Mass Flow RON Olefins Aromatics Benzene Sulfur FCC Gasoline OHCU LN Monthly MS Production (Thousand MT) TMT/Month Decrease of 1 RON of FCC Gasoline Decrease in MS Production by 1.5 TMT. IOCL Mathura Refinery 6

7 Importance of RON on Refinery Profitability: Base Case: Mass Flow RON Olefins Aromatics Benzene Sulfur FCC Gasoline OHCU LN TMT/Month Case-II: RON of Isomerate reduced by 1 Number Mass Flow RON Olefins Aromatics Benzene Sulfur Light Isomerate FCC Gasoline OHCU LN TMT/Month Base Case Case-II Monthly MS Production (Thousand MT) Decrease of 1 RON of Isomerate Decrease in MS Production by 1.3 TMT. IOCL Mathura Refinery 7

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 8

9 Optimization of FCC Gasoline: LCN Gasoline From SHU Heart Cut to Isomerisation Unit Isomerization LPG Isomerate HCN HDS Treated FCC Gasoline MS Pool Gasoline Splitter Unit IOCL Mathura Refinery 9

10 Optimization of FCC Gasoline: Parameters LCN Heart Cut HCN (Treated) RON Sulfur (ppm) < 10 ppm ppm 120 ppm Isomerate Yield: 87 % RON: 87 Heart Cut MS Pool Treated Gasoline Yield: 99 % RON: IOCL Mathura Refinery 10

11 Optimization of FCC Gasoline: Gasoline From SHU Gasoline Splitter Unit LCN Best Practice: Minimize Heart Cut Yield Preferential Routing to MS Pool Isomerisation Constrains: Benzene in MS Pool Olefins Isomerization LPG Minimize Heart Cut Yield Direct Routing of Heart Cut to MS Pool Isomerate HCN HDS Treated FCC Gasoline MS Pool IOCL Mathura Refinery 11

12 Optimization of FCC Gasoline: Case Study-I BASE CASE: All Heart Cut routed to Isomerisation Monthly Production RON Olefins Aromatics Benzene Sulfur FCC Gasoline FCC Heart Cut OHCU LN TMT/Month CASE-I: 75% of Heart Cut routed to Isomerisation Benefits: Base Case Case-I Monthly MS Production (Thousand MT) Monthly Production RON Olefins Aromatics Benzene Sulfur FCC Gasoline FCC Heart Cut OHCU LN SRN MS Production increase by 2.1 TMT/Month. Constrains: RON of MS Pool. Temperature exotherm in HDS Reactor. TMT/Month IOCL Mathura Refinery 12

13 Optimization of FCC Gasoline: Case Study-II BASE CASE: All Heart Cut routed to Isomerisation Monthly Production RON Olefins Aromatics Benzene Sulfur FCC Gasoline FCC Heart Cut OHCU LN TMT/Month Base Case Case-II Monthly MS Production (Thousand MT) CASE-II: 75 % of Heart Cut routed to MS Pool Benefits: Monthly Production RON Olefins Aromatics Benzene Sulfur FCC Gasoline FCC Heart Cut OHCU LN MS Production increase by 6.2 TMT/Month. Constrains: Benzene in MS Pool. Olefins & Sulfur in MS Pool. TMT/Month IOCL Mathura Refinery 13

14 Isomerisation Unit Isomerisation Reactors Light Isomerate Light Naphtha Heart Cut NHDT DIH Side Cut Recycle Heavy Isomerate Total Isomerate IOCL Mathura Refinery 14

15 Optimization of Isomerate: Light Isomerate: RON: Yield: % of Total Isomerate Heavy Isomerate: RON: Yield: 5-10 % of Total Isomerate Total Isomerate: RON: 87 Heavy Isomerate: Rich in C 6 & C 7 components. Good Reformer Feed. CATALYTIC REFORMER Reformate RON: 82 RON: 98 IOCL Mathura Refinery 15

16 Optimization of Isomerate Case Study BASE CASE: Heavy Isomerate Routed to MS Pool Mass Flow RON Olefins Aromatics Benzene Sulfur FCC Gasoline OHCU LN TMT/Month Base Case Case-I Monthly MS Production (Thousand MT) CASE-I: Heavy Isomerate Routed to Reformate Mass Flow RON Olefins Aromatics Benzene Sulfur Heavy Isomerate Heavy Reformate FCC Gasoline OHCU LN SRN Benefits: MS Production increase by 0.9 TMT/Month. Constrains: Capacity utilization of reformer. Double processing of a single stream. TMT/Month IOCL Mathura Refinery 16

17 Conclusion MS Production can be maximized by: Optimization Heart cut yield in FCC GSU. Optimum routing of Heart cut of GSU. Routing of Isomerate to Reformer feed. Also helps in case of: Meeting demand of high RON MS. (MS-95) Poor RON of Reformate or Isomerate. IOCL Mathura Refinery 17

18 THANK YOU IOCL Mathura Refinery 18