Presentation on Strategy of Octane Management at IOCL Mathura Refinery New Delhi, 16 th 17 th April 12 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. IOCL Mathura Refinery 2
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
Major Streams: Treated FCC Gasoline Isomerate Reformate OHCU Light Naphtha Straight Run Naphtha MS Barrel of Mathura Refinery: IOCL Mathura Refinery 4
Importance of RON on Refinery Profitability: Base Case: Mass Flow RON Olefins Aromatics Benzene Sulfur FCC Gasoline 33.19 90.5 50 12.5 0.5 100 OHCU LN 3.02 70.0 1 8 0.8 5 TMT/Month 103.8 91.6 16.6 29.9 0.8 32.4 104.0 103.5 103.0 103.8 Case-I: RON of Reformate Reduced by 1 Number Mass Flow RON Olefins Aromatics Benzene Sulfur Heavy Reformate 36.56 98.5 1 80 1.8 0 FCC Gasoline 33.19 90.5 50 12.5 0.5 100 OHCU LN 1.26 70.0 1 8 0.8 5 102.5 102.0 101.5 101.0 102.1 Base Case Case-I Monthly MS Production (Thousand MT) 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. IOCL Mathura Refinery 5
Importance of RON on Refinery Profitability: Base Case: Mass Flow RON Olefins Aromatics Benzene Sulfur FCC Gasoline 33.19 90.5 50 12.5 0.5 100 OHCU LN 3.02 70.0 1 8 0.8 5 104.0 103.5 103.8 TMT/Month 103.8 91.6 16.6 29.9 0.8 32.4 103.0 102.5 102.3 102.0 Case-II: RON of FCC Gasoline Reduced by 1 Number 101.5 Base Case Case-II Mass Flow RON Olefins Aromatics Benzene Sulfur FCC Gasoline 33.19 89.5 50 12.5 0.5 100 OHCU LN 1.51 70.0 1 8 0.8 5 Monthly MS Production (Thousand MT) 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. IOCL Mathura Refinery 6
Importance of RON on Refinery Profitability: Base Case: Mass Flow RON Olefins Aromatics Benzene Sulfur FCC Gasoline 33.19 90.5 50 12.5 0.5 100 OHCU LN 3.02 70.0 1 8 0.8 5 TMT/Month 103.8 91.6 16.6 29.9 0.8 32.4 104.0 103.5 103.0 102.5 103.8 102.6 102.0 Case-II: RON of Isomerate reduced by 1 Number Mass Flow RON Olefins Aromatics Benzene Sulfur Light Isomerate 27.62 87.0 0 0.1 0 0 FCC Gasoline 33.19 89.5 50 12.5 0.5 100 OHCU LN 1.76 70.0 1 8 0.8 5 TMT/Month 102.6 91.6 16.8 30.2 0.8 32.8 101.5 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
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
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
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 Heart Cut MS Pool Treated Gasoline Yield: 99 % RON: 89-90 IOCL Mathura Refinery 10
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
Optimization of FCC Gasoline: Case Study-I BASE CASE: All Heart Cut routed to Isomerisation Monthly Production RON Olefins Aromatics Benzene Sulfur 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 TMT/Month 103.8 91.6 16.6 29.9 0.8 32.4 CASE-I: 75% of Heart Cut routed to Isomerisation 106.5 106 105.5 105 104.5 104 103.5 103 102.5 Benefits: 105.9 103.8 Base Case Case-I Monthly MS Production (Thousand MT) Monthly Production RON Olefins Aromatics Benzene Sulfur 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 MS Production increase by 2.1 TMT/Month. Constrains: RON of MS Pool. Temperature exotherm in HDS Reactor. TMT/Month 105.9 91.6 17.3 29.5 0.8 33.7 IOCL Mathura Refinery 12
Optimization of FCC Gasoline: Case Study-II BASE CASE: All Heart Cut routed to Isomerisation Monthly Production RON Olefins Aromatics Benzene Sulfur 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 TMT/Month 103.8 91.6 16.6 29.9 0.8 32.4 112 110 108 106 104 102 100 110.0 103.8 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 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 MS Production increase by 6.2 TMT/Month. Constrains: Benzene in MS Pool. Olefins & Sulfur in MS Pool. TMT/Month 110.0 91.6 19.0 28.9 0.9 37.9 IOCL Mathura Refinery 13
Isomerisation Unit Isomerisation Reactors Light Isomerate Light Naphtha Heart Cut NHDT DIH Side Cut Recycle Heavy Isomerate Total Isomerate IOCL Mathura Refinery 14
Optimization of Isomerate: 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 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
Optimization of Isomerate Case Study BASE CASE: Heavy Isomerate Routed to MS Pool Mass Flow RON Olefins Aromatics Benzene Sulfur FCC Gasoline 33.19 90.5 50 12.5 0.5 100 OHCU LN 3.02 70.0 1 8 0.8 5 TMT/Month 103.8 91.6 16.6 29.9 0.8 32.4 105 104.5 104 103.5 103 104.7 103.8 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 0.00 80.0 0 0.1 0 0 Heavy Reformate 39.16 99.5 1 80 1.8 0 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 Benefits: MS Production increase by 0.9 TMT/Month. Constrains: Capacity utilization of reformer. Double processing of a single stream. TMT/Month 104.7 91.6 16.6 31.6 0.8 33.3 IOCL Mathura Refinery 16
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
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