igniting minds... energizing lives… haldia refinery presentation on lobs. hirak dutta, general...

Igniting Minds... Energizing Lives…Haldia Refinery

Haldia Refinery

Presentation on LOBS.

Hirak Dutta, General Manager(Technical)

Haldia Refinery


LUBRICANTS

LUBRICANTS = BASE OILS + ADDITIVES

BOTH MINERAL AND SYNTHETIC BASE STOCKS AND THEIR MIXURES ARE USED IN LUBRICANT FORMULATION

MINERAL OILS PRODUCED / REFINED FROM CRUDE OILS ARE SINGLE COMMON SOURCE OF BASE STOCKS.

LUBRICATING PROPERTIES OF BASE STOCKS ARE INFLUENCED BY

CRUDE SOURCE

REFINING PROCESSES


USE OF LUBRICANTS/BASE OILS

ENGINE OILS

GEAR OILS

TRANSMISSION FLUID

INDUSTRIAL APPLICATION

CATALYST CARRIER OILS.

WHITE OIL APPLICATION


FUNCTION OF LUBRICANTS

MINIMISE FRICTION AND WEAR

REMOVAL OF DEBRIS

DISSIPATION OF HEAT

ACT AS ELECTRIC INSULATOR

PREVENTS RUSTING & CORROSION


LUBE BASE OILS

FORMULATION OF LUBRICATING OILS HAS BECOME VERY COMPLEX-

OEM ( ORIGINAL EQUIPMENT MANUFATURER) REQUIREMENT

GOVERNMENT REGULATION EFFICIENT USE ENERGY CONSERVATION ENVIRONMENT CONCERN CHANGING PRODUCT SPECIFICATIONS EXPANDING VAST MARKET.


REQUISITE PROPERTIES

APPROPRIATE VISCOSITY

HIGH VISCOSITY INDEX

LOW POUR POINT

LOW VOLATILITYAND HIGH FLASH POINT

GOOD THERMAL AND OXIDATION STABILITY

HIGH HEAT CAPACITY GOOD THERMAL CONDUCTIVITY

NON CORROSIVE, OILINESS AND WETABILITY


LUBE BASE OILS

ALL BASE OILS DO NOT POSSESS SIMILAR PHYSICO CHEMICAL PROPERTIES OR PROVIDE EQUIVALENT ENGINE OIL PERFORMANCE.

API ( AMERICAN PETROLEUM INSTITUTE) CLASSIFIED ALL BASE STOCKS IN FIVE GROUPS ON THE BASIS OF

SATURATES

VISCOSITY INDEX(VI)

SULFUR CONTENT


API BASE OIL CLASSIFICATION

VI SATURATES

%

SULPHUR

%

GROUP I 80-100 <90 >0.03

GROUP II 80-120 >90 <0.03

GROUP III >120 >90 <0.03

GROUP IV POLY ALFA-OLEFINS (SYNTHETIC ORIGIN)


LUBE BASE OILS

LUBE PROCESSING REQUIREMENT IS A FUNCTION OF

HYDROCARBON STRUCTURE OF

FEED

TARGET PROPERTIES OF

FINISHED BASE OILS


HYDROCARBON STRUCTURE

STRUCTURE V I POUR PT INTEREST

N-PARRAFIN VERY HIGH HIGH LOW

ISO-PARAFFIN HIGH LOW HIGH

NAPHTHENE MEDIUM LOW HIGH

AROMATICS LOW LOW LOW

CONDENSED

/POLAR

VERY LOW -- LOW


Lube Base Oils – PROCESSING:

THREE MAIN STEPS FOR LUBE PROCRSSING:

LIQ-LIQ EXTRN. TO INCREASE VI

DE-WAXING TO REDUCE PP

FINISHING TO IMPROVE

COLOUR AND OXIDATION

STABILITY


Lube ProcessingProperties set by Process Units

Flash points , KV &Noack

VI, Stability &Solvency

Pour Point Color & Stability

Vac

uu

m

Dis

till

atio

n

Sol

ven

t E

xtra

ctio

n

or H

ydro

cra

ckin

g.

Sol

ven

t D

ewax

ing

or

Cat

alyt

ic D

ewax

ing.

Cla

y T

reat

ing

or

Hyd

rofi

nis

hin

g

VGOVacuum

DistillatesWaxy

Raffinates Dewaxed Oils Base Oils

Light Neutral

Medium Neutral

Heavy Neutral

Bright Stock

Vacuum Resid.

AromaticExtracts.

Waxes and Micro waxesPropane

Deasphalting

Asphalts.

Gas

Naptha

Kero / Jet

Diesel

Atomospheric Resid.

Crude Oil

Ato

mos

ph

eric

Dis

till

atio

n


TREATING / REFINING FOR LUBE PROCESSING

SOLVENT EXTRACTION

SOLVENT EXTRACTION

SOLVENT EXTRACTION

SOLVENT EXTRACTION

SOLVENT DEWAXING API GROUP I

HYDRO-FINISHING

HYDRO-FINISHING

WAX

CATALYTIC DEWAXING

API GROUP I IHYDRO-FINISHING

RAFF. HYDRO-TREATING

HYDRO-ISOMERISATION

HYDRO-FINISHING API GROUP II

SOLVENT DEWAXING

WAX ISOMERISATION API GROUP III


Gr I and Gr II Processing - Comparison


Additive Types

DispersantsDetergentsAntiwearFriction ModifiersOxidation InhibitorsRust InhibitorsEmulsifiers / DemulsifiersAntifoamants


BASE OIL PRODUCT QUALITY- KEY REQUIREMENTS

ViscosityVIPour PointColourOxidative StabilityThermal StabilityAnti-Wear PerformanceBetter SolvencyLower Volatility


EFFECT OF MANUFACTURING PROCESSON

PROPERTIES OF BASE OILS

PROPERTY DEASPHALTING EXTRACTION DEWAXING HYDRO -FINISHING

SP.GR DECREASE DECREASE INCREASE DECREASE

FLASH PT NIL NIL NIL NIL

VISCOSITY DECREASE DECREASE INCREASE NIL

VI INCREASE INCREASE DECREASE NIL


API BASE OIL CHARACTERISATION GROUPS

Viscosity Index

Saturates

% wt

Sulphur

%wt

GROUP I 80-100 <90 >0.03

GROUP II 80-120 >90 <0.03

GROUP III >120 >90 <0.03

GROUP IV Poly Alpha Olefins(Synthetic Oils)


Haldia Gr-I & Gr-II LOBS Comparison

Grade KV (cSt) VI (min.) Pour Point (max)

GR

I

150N 28-32 (40oC) 100 -9

500N 10 (100oC) 95 -6

HN 13.5 (100oC) 92 -3

BN 32 (100oC) 92 -3

GR

II

70N 9.5-15.5 (40oC) 100 -21

150N 28.8-32 (40oC) 105 -15

500N 90-105 (40oC) 95 (105) -15

150BS 30 (100oC) 95 -6



Gr-I & Gr-II LOBS Processing: Comparison

Hydro-finishing

Solvent De-waxing

Solvent Extraction

Solvent Extraction

Hydro Treating

Wax Isomerisation

Hydro-finishing

Group-I Group-IIVI Pour Point



Simple Block Flow Diagram of Haldia Refinery

Crude

CDU

1

CDU

2

Fuel Gas

LPG

SR Naph

Kero Cut

St.Run G.O

JBO

RCO

ATU

Desulphurised Fuel Gas

SRU Sulphur

LPGNaphtha

90 – 140°CCRU MS(Petrol)

C5 – 90°C

KHDS

MTO

RTF/ATF

Kerosene

DHDS O.25% S HSD

O.05% S HSD

HGU

H2

JBO

VDU

1

VDU

2

IFO

GO

SO

LO / IO / HO

SR

PDA

DAO

FEU

NMPSDU HFU

100 N

150 N

500 N

850 N

150 BS

FCCU

Ext.

S.Wax

LO

Asp.

VBU FO

BTUBitumen

Bit Eml.

CBFS

Slack Wax

MCW MCW

CIDW

MERICHEMMERICAT



Vacuum Distillation Unit

Purpose:

To Vacuum Distill RCO from Crude Distillation Unit.

Vac.Distillate is feed stock for LOBS units or FCCU.

Products:

GAS OIL ---- Diesel Component.

Spindle Oil ---- Diesel Component or H-70 LOBS feed stock.

Light Oil ---- 150 N grade LOBS feed stock or FCCU feed.

Inter Oil ---- 500 N grade LOBS feed stock or FCCU feed.

Heavy Oil ---- 850 N grade LOBS feed stock or FCCU feed.

Vac. Residu ---- Feed stock for PDA unit.

Quality Monitoring : K. V at 100 0C, Flash Point, Density.



Product Quality of Distillate & Short Residue

Stream Boiling Range.0C

Den @ 15 0C

Fl. Point

0C

KV @ 98.9 0C

%S CCR wt%

Gas Oil 265-362 0.8591 119 4 at 37.8

1.38

Spindle oil 362-385 0.8992 162 3.54 1.96

Light oil 385-462 0.8950 184 3.84 2.38

Inter oil 462-504 0.9218 242 10.23 2.38

Hy. oil 504-562 0.9354 282 21.06 2.4

Short Residue

542+ 1.013 342 1075 4.33 14.24


Major Operating Conditions

• RCO feed temp : 90-115 deg C • Preheat Temp : 285 deg C• Coil Outlet Temp : 400 deg C •Vac Tower Flash Zone Pr. 120-130 mm Hg at 400 dec C • Vac Tower Top Temp : 80 deg C• Stripping Steam : 6.5-10 Mt/hr• Furnace recycle : 11 m3/hr Pump around : from 300 deg C to 228 deg C• Product Draw off temp : 232 , 245, 333 & 370 for SO,LO, • IO & HO• Bottom Quench : 5 m3/hr


PROPANE DE-ASPHALTING UNIT

Feed Stock:

• Vac. Residue from VDU.

Product:

De- Asphalted Oil.

Asphalt for production of Bitumen.

Quality Monitoring:

DAO ---K.V at 100 o C, Flash Point

Asphalt --- Penetration.


ROSE : Residium Oil Supercritical Extraction -- Feed & Product Quality

Technology Licensed by M.W. Kellog Technology Co. USADesign : 800000 MT/Yr

Feed Quality : Den @ 15.5 deg C : 1.01/1.03

Vis @ 100 deg C : 800/2500 Flash Point : 320 min CCR , wt % : 20/23 % S : 4.3/4.5

Product Quality : Sp Gr. 0.91-0.93

Visc @ 100 deg C: 30-35/40-45 CCR wt% : 2.2 max Fl Point, deg C : 320 min



Major Operating Parameters- PDA ROSE

Feed Temp : 130 deg C First & 2nd Dilution : 0.5:1 by volume of propane in

each Total Dilution : 12: 1 (propane : feed by volume Extraction top Pr : 38 kg/cm2G Top/Bot temp : 68/52 deg C DAO separator : 43.6 kg/cm2 g pr. & 102 deg C

temp


Extraction Process

Best Solvent Property Selective power High Solvent Power Low Lt-Hy selectivity and high group selectivity Boiling point difference with feed Low melting point Good gap in density between oil & solvent Low surface tension high thermal chemical stability Low toxicity , Flammability & corrosivity Low latent heat & sp. Ht low viscosity at working temp High bio degradability


SOLVENT EXTRACTION UNIT.FEU/NMPEU

Feed stock

Vac. Distillate from VDU & DAO from PDA unit.

Purpose

To extract aromatics from distillates to improve VI of LOBS using Furfural/NMP as solvent.

Products:

Raffinate for further processing of LOBS & Aromatic extract.

Quality Monitoring:

Raffinate: K.V at 100 oC , RI, CCR

Extract : Density.


FEU/NMPEU : Yield, Feed & Product Quality, Major Operating Conditions

Operating Conditions FEU NMPEU

Raffinate Yield, %wt 52-65 45-55

Feed Rate, m3/hr 50-73 40-50

Extraction temp. Gradient 40-50 10

Solvent:Feed Ratio 1.2-1.5:1 1.93/2.22:1

Top Temp, deg C 95-130 70-95

Bottom Temp, deg C 45-80 60-85

Extractor Pr, kg/cm2g 2.0 1.5-2.0

Raff/Ext Furnace COT 185/225 270/290

Extract Flash Col Pr.,kg/cm2g 0.5/1.5 0.6/1.2/1.5

Raffinate/Ext. Vaccum Flash Col. Pr, mmHg

200/220 350/300

Water in Solvent Reduces solvent power Anti Solvent


Solvent De-waxing Unit

Feed Stock :

Raffinate Ex- FEU.

Product :

De-waxed Oil & Slack Wax.

Quality Monitoring:

DWO : Pour Point, Flash Point, KV at 100oC & 40 oC

Slack Wax : Flash Point.


Solvent Dewaxing Unit

Objective

To remove paraffinic hydrocarbons to the extend that the Lube based stock produced will have enough low pour point to make it suitable for low temp application

The Process

Extraction and crystallisation to achieve dewaxing with the addition of SDA followed by filtration & Solvent Recovery

Solvent : MEK & Toluene in equal proportions. Toluene is oil solvent & MEK is anti wax solvent.

Feed characterised by density, Kin. Visc & RI

LOBS Product characterised by density, Pour Pt, VI, Flash Point, CCR,Kin Visc.


Solvent Dewaxing Unit

Good Qualities of Dewaxing Solvent Blends:

High solvent Power for oil & Low Solvent power for wax

Low visc. at operating temperature to get low pressure drop & to help in precipitation /crystallization

Good Filterability

Low Freezing point & temperature effect of Dewaxing

High thermal/chemical stability

Boiling point much lower than that of feed

Low latent heat/specific heat



Lube Hydrofinishing Unit

Feed Stock :

DWO from SDU.

Catalyst :

HR 348 supplied by Procatalyse.High purity Alumina extrudates impregnated with Nickel and Molybdenum oxides

Purpose:

To improve color by removing Sulphur,Oxygen & Nitrogen in a reactor with Cobalt / Moly catalyst.

Quality Monitoring:

Color, K.V at 100 oC, VI.


Lube Hydrofinishing Unit

Major reactions : Hydrodesulphurization, Mild hydrodenitrogenation, Olefins hydrogenation, mild aromatic hydrogenation, decomposition of heteromolecules.Sulphur is usually present as mercaptan, sulphides, disulphide and thiophenic sulphur. Sulphur is removed as H2S.Nitrogen is usually present as Ammines and pyrrole, pyridine etc. More difficult reaction and ultimate product is hydrocarbon & ammonia.Olefins are present in low quantity & most of them are saturated during hydro finishing. Normally aromatics are not hydrogenated. Due to liberation of some aromatics rings towards the light compounds are stripped off to reach the required flash point. Thus results in slight VI improvement also.Oxygenated compounds are mostly removed in the solvent extraction step. If any remaining removed as water.As a result, color & color stability improves, mild VI improvement occurs


Hydro finishing Unit :

Main operating Variables :Temperature: optimum to achieve desulphurization. Lower the temp, higher is the product viscosity & yieldsPartial Pressure of Hydrogen : Increase favors the reaction & reduces coke by avoiding polymerization reaction. Can be modified by change in total pressure and recycle ratio. Total pressure kept maximum compatible with the equipmentSpace Velocity : Hourly volume flow rate of feed wrt to the catalyst volume. Lower is the space velocity higher the severity. (0.75-1.3 m3 of feed per m3 of catalyst) Mole ratio of hydrogen/hydrocarbon: Includes quantity needed for hydro finishing + quantity which increases the partial pressure of hydrogenFeed quality: Higher the impurities higher the severity


Hydro finishing Unit Operating Parameters

Reactor inlet temp : 270-340 deg C

Reactor outlet temp : 360

H2 partial pr. At reactor outlet : 45 kg/cm2g

Space velocity : 0.84 to 1.45 m3 of feed per m3 of catalyst

H2 recycle : 153 liters of pure H2 per litre of oil feed at 15 deg C

Absorber (C-1) : 35.5 kg/cm2g/62.5 deg C

Stripper, (C-2) : 0.25 kg/cm2g /250 deg C

Vacuum Drier (C-3): 50 mm of Hg/249 deg C

1st HP Separator (B-2) : 66.5 kg/cm2g/250 deg C

2nd HP Separator (B-3) : 65.5 kg/cm2g/50 deg C

LP Separator (B-4) : 5.0 kg/cm2g/250 deg C


VISCOSITY – VI RELATIONSHIP

Temperature

Visc

osity

Paraffin

Naphthene

Aromatics

TemperatureVi

scos

ity

L

U

H

0 VI

100 VI

Sample


CIDW unit, The process

Hydro treatment of feed

De-Waxing

Hydro finishing

Recovery



Purification of Feed

Removal of S, N

S + H2 H2S + Q

N2 + 3H2 2 NH3 + Q

S, N are poison to De-Waxing Catalyst

Side Reactions:

Cracking

Saturation of Unsaturates



Feed + H2 S, N free feed

+ H2 + HC +H2S +

NH3

R 01

High Temperature,

High Pressure

Exothermic reaction


Hydro treatment Reactor (R 01)

Three catalyst beds

Total catalyst Volume- 40.8 m3

EM-7420 Ni-Mo Hydrogenation Catalyst

Operating Variables:Temperature

Hydrogen circulation and partial pressure

Space velocity


Hydro treatment Reactor (R 01)

Operating ConditionsATTRIBUTE 100 N 150 N 500 N 500 N w/

500 SW500 SW 150 BS

HDT Temp, in/out (deg C)SOREOR

302/318

370/386

302/314

370/382

302/321

370/387

302/321

370/384

302/316

370/384

302/323

370/391

*HDT Pres, (kg/cm2 -A) InletOutlet

143.8138.5

143.8138.5

143.8138.5

143.8138.5

143.8138.5

143.8138.5


How to get rid of H2S, NH3?

H2S absorbed in Lean diethyl amine solution

C 02 Amine absorption Column

NH3 absorbed in water

C 03 Wash Water scrubber

Recycle Treated Gas back to the system using Recycle compressors


De-Waxing

Conversion of N paraffins to Iso Paraffins

N paraffins Waxy in Nature

Iso Paraffins Non – Waxy

Isomerization

Side Raections

Cracking

Saturation of unsaturates


De-Waxing

R 02

Clean feed Ex R 01 + Treated H2

Low pour point product + H2 + HC

High Temperature

High Pressure

Highly Exothermic Reactions


De-Waxing Reactor, R 02Three catalyst bedsTotal catalyst volume = 40.8 m3Bed 1 – Partial Ni- Mo & bal. EM7-7210 Pt/Pd Hydrogenation catalyst for HDS, HDN and aromatic saturation.Bed 2&3 - EM-7300 Pt. Isomerisation CatalystOperating Variables:

TemperatureHydrogen circulation and partial pressureSpace velocity


De-Waxing Reactor, R 02

Operating Conditions


ATTRIBUTE 100 N 150 N 500 N 500 N w/ 500 SW

500 SW 150 BS

MSDW Temp, in/out (deg C)SOREOR

304/311

375/382

304/310 375/381

304/314

375/385

304/315

375/386

304/319 375/390

304/317

375/388

*MSDW Pres, (kg/cm2 -A) InletOutlet

126.8120.5

126.8120.5

126.8120.5

126.8120.5

126.8120.5

126.8120.5


Hydrofinishing

Product stabilization through saturation of poly nuclear aromatics

Improvement in Color


Hydrofinishing Reactor, R 03

Low pour point product + H2 + HC

Hydro finished product + H2 + HC

Low Temperature

High Pressure

Mild Exothermic



Two catalyst Beds

Total catalyst volume = 27.2 m3

EM7-7500 Pt/Pd Aromatic saturation



Operating ConditionsATTRIBUTE 100 N 150 N 500 N 500 N w/

500 SW500 SW 150 BS

HDF Temp, in/out (deg C)SOREOR

247/250

288/291

247/250

288/291

247/250

288/291

247/250

288/291

247/250 288/291

247/250

288/291*HDF Pres,

(kg/cm2 -A) InletOutlet

118.3113.0

118.3113.0

118.3113.0

118.3113.0

118.3113.0

118.3113.0


Control Of Reaction Exotherm

Quench --Cold recycle hydrogen flow to all reactor beds


CATALYTIC DEWAXING:GENERAL FLOWSHEET

Purge

Make Up hydrogen

Product Fractionation

Section

Naphtha

Diesel

Group III LOBS Product

Separator

Hydrotreater Effluent Scrubbing Section

Hydrotreating CDW

Hydrofinishing

Recycle

Feed


HALDIA CDWUHigh Pr. Feed/Reactor Section

Waxy Feed

M/U H2

Vacuum Drier BottomsDewaxed Lube Product

Dewaxed LubeProduct to Storage

Separator Liquidsto HP Stripper

HDT Raffinateto Vac Stabilizer

Amine Cond.

Purge

HDT

MSDW HDF

Haldia HDT/MSDW UnitHigh Pressure Feed/Reactor Section

84-F-01

84-R-01

84-F-02

84-R-02 84-R-03

84-E-03

84-E-06

84-E-02

84-E-11

84-K-01

84-B-07

84-E-04

84-EA-01

84-E-05

84-B-02

84-P-01

84-E-01 84-G-01 84-M-01

84-B-01

84-EA-0684-P-02

84-C-01

84-C-02 84-C-03

84-P-14 84-P-15

84-B-03

84-B-04

84-E-07

84-EA-02

84-E-08

84-B-05

84-B-06

84-K-02

S/U - Internal Liquid Recycle

Carrier Oil S/U

Heavy Diesel(Light Lube)

Separator Liquidsto HP Stripper

NNF S/U Line

S/U Line


HALDIA CDWULow Pressure Recovery Section

MSDW/HDFHTS & LTS Liquid

Haldia HDT/MSDW UnitLow Pressure Recovery Section

84-P-08

Lean Amine84-C-09

84-P-05

84-EA-03

HP Stripper

HT Stripper& LTS Liquid

MPS

Fuel Gas

84-B-1084-E-12

84-P-04

Wild Naphthato Storage

84-C-04

84-F-03

84-C-05

84-J-01

MPS

Lube Productto 84-E-01

84-P-09

Diesel toStorage

84-C-06

Vacuum Stripper/Drier

84-C-07 / 84-C-08

MPS

84-P-07

84-J-02

84-EA-05

Heavy Diesel to Storage

84-B-11

84-P-03

84-E-13

S/U

SWS

84-P-1984-P-20

84-B-17

Gas to84-B-24

84-P-13

From 84-B-26

Gas from84-B-1784-B-19

84-B-24

SWS

Heavy Diesel toLube Product

Stm

84-E-15/16/17

84-J-03/04/05

84-EA-04

84-P-06

84-G-02


HALDIA CDWUOperating Parameters

WART, HDT, degC 310-390

WART, HDW, deg C 310-390

WART, HDF, deg C 210-290

LHSV, sec-1 1-1.5

Operating pr, kg/cm2g 120-145


YIELD PATTERN OF CATALYTIC DEWAXING UNIT HALDIA

ATTRIBUTE 100N 150N 500N 150BS

H2 CONSP 0.91 0.72 1.1 1.23

H2S +NH3 0.75 0.81 1.17 1.73

GAS 1.03 0.76 0.96 1.46

NAPHTHA 1.86 1.57 2.88 3.32

HSD 25.67 13.6 9.19 9.59

LIGHT LUBE 7.19 12.1 16.3 0

LOBS 64.4 71.9 70.58 85.1


Lube Base Oil Product QualitiesGrade KV (cSt) VI (min.) Pour Point

(max)

GR

I

150N 28-32 (40oC) 100 -9

500N 10 (100oC) 95 -6

HN 13.5 (100oC) 92 -3

BN 32 (100oC) 92 -3

GR

II

70N 9.5-15.5 (40oC) 100 -21

150N 28.8-32 (40oC) 105 -15

500N 90-105 (40oC) 95 (105) -15

150BS 30 (100oC) 95 -6


Group I grade LOBSGroup I grade LOBS

Group II grade LOBSGroup II grade LOBS

GROUP – I / GROUP – II LOBS


NEW GENERATION LUBRUCANT WILL REQUIRE

LUBRICANT PERFORMANCE REQUIRED

BASE STOCK PROPERTY NEEDED

ENGINE OILS LOW EMMISSIONS,

LOW OIL CONSUMPTION

FUEL ECONOMY

EXTENDED DRAIN

LOW VOLATILITY AT LOW VISCOSITY

LOW VISCOSITY & HIGH VISCOSITY INDEX

OXIDATION STABILITY

GEAR OILS FILL FOR LIFE

FUEL ECONOMY

OXIDATION STABILITY

HIGH VISCOSITY INDEX(GR-III)

TRANSMISSION FLUID

EXCELLENT FLUIDITY

FUEL ECONOMY

HIGH VISCOSITY INDEX(GR-III)

LOW VISCOSITY, LOW VOLATILITY


THANK YOU


BASE OIL TRENDS

Market share (%)

1980 - 90s 2000

API Gr I 75-85 50-60

API Gr II 10-15 30-40

Others 1-2 5-10

Lesser availability of lube bearing crude

Better fuel economy, improved performance and extended drainage

Impact on environment


ADDITIVES

Required to impart or enhance desired properties of oils.

DispersantsDetergentsOxidation inhibitorsRust and corrosion inhibitorsViscosity Index improversPour Point depressantsFoam InhibitorsAnti-wear Agents/Friction modifiers


LOBS Manufacture by HydroProcessing

Alternative Route-I

Vacu

um d

istilla

tion

Propane De-Asphalting

Gas

NaphthaKeroDiesel

RCO

Vacuum Distillates

Waxy Raffinate

De-waxed oilsVGO

KV, Flash Point VI, CCR Pour Point Colour &

Stability

Lube

Hyd

roTr

eate

r

150N500N150BS

Cat

alyt

ic D

ewax

ing

Uni

t

70N/100NGr-II LOBS

Hydr

oFin

ishin

g Un

it


LOBS Manufacture by HydroProcessing

Alternative Route-II

Vacu

um d

istilla

tion

Propane De-Asphalting

Gas

NaphthaKeroDiesel

RCO

Vacuum Distillates

De-waxed oilsVGO

KV, Flash Point VI, CCR Pour Point Colour &

Stability

Hydr

o Cr

acke

r

150N500N150BS

Cat

alyt

ic D

ewax

ing

Uni

t

70N/100NGr-II LOBS

Hydr

oFin

ishin

g Un

it

Vacuum Distilled HydroCrackate Residue



FUNCTIONS OF LUBRICATING OIL

REDUCE FRICTION &WEAR

PREVENT SCUFFING & SEIZURE OF MOVING PARTS.

REMOVE HEAT FROM CONTACT SURFACE.

PREVENT RUST & CORROSION.

PREVENT EXCESSIVE DEPOSITS & SLUDGE FORMATION

DISPERSION OF GENERATED CONTAMINANTS

MAINTENANCE OF WATER SEPARABILITY & EMULSIBILITY

MAINTENANCE OF SEALING IN CRITICAL PARTS.

MAINTENANCE OF RESISTANCE TO DEGRADATION IN PRESENCE OF OXYGEN & CATALYTIC MATERIALS.



Vacuum Distillation Unit PFD (preheat and product cooling section )

P-1/1R

B-1

E-121

E-1A

E-1B

E-1C

E-1D

E-2AE-2B

E-2C

E-123

E-127

E-14A/B

E-6A

E-6BE-6C

E-4B

E-4A E-122A/B

E-7

E-9

E-11

RCO Ex tanks

LO Ex P-5/5R

GO Ex P-3/3R

SO Ex P-7/7R

PA Ex P-6/6R

IO Ex P-12/12R

HO Ex P-8/7R

SR Ex P-10/10R

H-1A H-1B

DM water

To VB steamheader

CW To TK-761

GO to R/D

GO to top reflux

CWCW

CW

CW

RCO to P-113/113R suction

SO to R/D

E-10

TW

E-125A/B IO to R/D

HO to R/D TW

TW

TW

SR to R/D

E-126A/B

E-124A/B

Pump Around To # 18 of C-1

IO to VBU

FC-20

FC-21LO R/D

To Tar

To VBU

FC-15

FC-19 FC-23A

FC-22FC

-23

To HSD

To Tar

To TK-761

To VBU

FC-25

FC-24

FC-27

FC-26To R/D

To VBU

FC-12FC-28

LC-02

TC-06

Vac slop to PDA

Vac slop Ex P-9/9R

HO Ex P-8/7R

To PDA

To VBU

Bot quench



Vacuum Distillation Unit PFD(furnace and fractionator circuit)

F-1

P-113/113R

SR to E-11

RC

O ex F-1/F-2

CWTo Ejectors

VS STEAM

GO as refluxex E-2A/B/C

#1

#4

#5

#8

#12

#16

#19

#22

#26

C-1

F-2

Burners

Fuel gas IFO supplyIFO returnAtomising steam

Fuel gas IFO supplyIFO returnAtomising steam

RCO Ex E-11

P-10/10R

#4

#1

#1

#1

#1#4

#4

#4

P-8/7R

P-12/12R

P-5/5R

P-7/7R

HO draw

IO draw

LO draw

PA draw

SO draw

GO draw

SR draw

P-9/9RVac slop to E-9

Over Flash

HO Ex P-8/7Ras Demister Wash

Bot Quench Ex H-1A/B

Burners

Furnace recycle Ex p-9/9r

VB steam VS steam

VB steam VS steam

Turbulising steam

Turbulising steam

Turbulising steam

Turbulising steam

Combustion airEx APH

Com

bustion airE

x APH

P-6/6R

E-6A/B/C

P-3/3R

E-128A/BGO to E-1A/B/C/D

SO toE-123

VS steam

VS steam

VS steam

VS steam

LO to E-121

IO to E-7

HO to E-9

LC-101

LC-03FC-11

LC-04

LC-05FC-10B

FC-13

FC-12

FC-10AFC-10B

FC-4FC-5

FC-8FC-9

FC-102

PC-06 HV-01

DPC-03

FC-209

FC-216FC-217

FC-201

FC-202

C-105

C-2

C-3

C-4


Vacuum Distillation Unit PFDVacuum System

E-128A

CW

#19

#22#26

E-128B

E-129E-130

31C-1

Cooling Water Inlet Header

Cooling Water Return Header

VM Steam to Ejectors

PEJSEJ

B-2

B-7seal pot

Vent

oil waterBarometric legs

P-101/101R P-102/102R

B-3coaleser

Hot well gas oil to HSD pool

Hot well water to OWS/ DesalterHot well

PC-05

PC-121

VB steam

DM water

P-114A/B/C

E-116A/B/C

E-124A/B/C

E-126A/B

E-125A/B

E-10

Tempered water circuit

B-105SR

HO

IO

Vac Slop

CW

Tempered water

CW CW

CWCW


To vacuum compressor suction via B-12A/B

Feed to DP Chiller Train series -1

Feed to 6 series of parallel DP Chiller Trains.

Feed Ex parallel DP chiller series 2-7

Sec Dil to DP chiller series 2-7

Filtrate to DP Exchangers of Chiller series 2-7Filtrate Ex DP Exchangers

of Chiller series 2-7SDA Dosing

Wax injection

P-1/I

P-1/II

B-1

B-2

S-1

B-3a

P-3/I

VB Steam

Secondary Dilution solvent

Tertiary Dil solvent

Cold washsolvent

Hot washsolvent

Feed Ex tanks

M

Solvent Ex B-8 / B-9

E-1/I

E-1/II

E-2/I

E-2/II LR-1A LR-1B LA-1B LA-1A LA-1C

E-4A E-4B E-4C E-4DE-3A/BE-3C

E-18

To S-2 to S-11

From S-2 to S-11

Wax-mix ExP-3/II-XI P-2/2R

E-31

VM steam

B-7Wax-mix to solvent recovery

P-8/8RTo B-11

Purging

Blowing

Seal pot

B-20A

Filtrate

VB stm

VB stm CW

CW

Filtrate

DWO-Mix to solvent recoveryP-4/5/5R

Pri

mar

y D

ilut

ion

solv

ent

K-3A/B/C B-24 B-25

B-3.11

B-3.8

E-3.6A/B/C

E-3.7A/B/CE-3.9 E-3.12

Sub coolerSub cooler

B-3.10 Liquid A

mm

onia B-26

Liquid Ammonia To/From storage

Drain from B-3.8

To Aux comp suction/From Discharge

Drain from chillers and E-4A-D

Liquid Ammonia from storage

To Aux comp suction

B-15From Aux comp discharge

Ammonia vapors to consumers

Liquid A

mm

onia

Vapour Ammonia

Vapour Ammonia

VB Steam

FILTRATION & CHILLING SECTION OF SOLVENT DEWAXING UNIT



PAGE:1 of 3

Feed to Unit

E-1

E-2

E-2A/B

LC-01

C-1

C-2

CW

Steam

CW

Atm

J-1#1

VM steam Ex P-8/8Ror P-9/9R

To E-13bor E-8

VS steam

33P-1/1R

33P-2/2R

E-15CW

#3

To P-3/2R via B-1

To E-4A/B O/L

E-3

CW TC-12

E-9

P-6/6R

E-8

CW

E-10B

B-11

Ex P-12B

Raffinate Mix

Extract Mix to C-5Via E-10A

Furfural Ex C-9 Bot

P-11/11R

FURFURAL EXTRACTION UNIT Extractor Section



FURFURAL EXTRACTION UNIT (U-33)Solvent Drying section

PAGE:3 of 3

P-10/10R

VB steamP-12A/10R

P-4/4R

P-11/11R

B-3

B-2

B-4

E-5

E-6

E-14

CW

CW

CW

CW

CW

C-9

C-10

To C-2

Furfural To C-2

Ex C-5 liquid

Ex C-6 liquidEx C-5 Vap

Ex C-6 Vap

#13

#7#6

#1

#18

#1

Ex C-3

Ex C-7

Ex C-4

Ex C-8

steam

steam

To seal pot

To ETP



Solvent Ex P-5A/B

NMP EXTRACTION UNIT (U-38)Extraction and Raffinate-Mix Section

PAGE:1 of 2

Feed to UnitEx Tanks

E-1A/BE-1CLC-1101

C-2

CW

VM steamExtract R/DEx P-9A/B

44P-101A/B

38P-2A/B

P-10A/B

E-17CW

V-7

E-7A/B/CE-18

V-6

P-3A/B

CW

E-3A/B

C-1

#10

#1

TC-1102 FC-1101

TC-1202FC-1202

FC-1201

TC-1201

To V-14PC-1210

Reflux to C-5/6/7/8/9

FC-1203 IG

PC-1201PC-1209

TC-1101

E-2 A/B

LP steamV-8

Ex C-10 Top

IG

Water injectionEx v-4/ v-10

Inert gas

V-1

CW

i.e C-10 Bottom

To V-14

F-2

P-4A/B

P-6A/B

E-4

E-24

E-6CW

To V-5

E-5A-D

MP steam

C-3

C-4

E-13CW

To V-9

Raffinate R/D

FC

-140

1B

#1

#20

#16

#1

Reflux Ex P-4A/B

LC 1601

FC-1603

# 4

OWS

#1

#7

FC

-140

1A

E -14

HP Steam

Extract-Mix To C-5



NMP EXTRACTION UNIT (U-38)Extract -Mix and Solvent Drying Section

C-8

C-9

F-1

P-9A/BP-8A/B

VS steam

CW

TW

E-11

Deareator feed Ex 44P-101

E-8

E-9A/B

Extract R/D

C-5

C-6

C-7

E-20

P-18A/B E-1A/B

E-

To C-1Extract recycle

P-11A/B

E-23A/B/C

P-12A/B

V-9

J-002

V-5

PAGE:2 of 2

P-7A/B

V-4

E-15

C-10

#27

#10

#7

#5

#1

38PC-1806Ex C-3 Top

Ex C-4 Top

J-001

AB A B

E-22AE-22B E-21A E-21B

CW

MP Steam

V-10

P-15A/B

Water Injection to E-17 / V-4

P-13A/B

E-16

HP Steam

T-2A/BSlop Tks

To Solvent Manifold

To Slop Manifold

V-14CBD P-17A/B

P-20

P-5A/B#20

#1

#4

HP

stea

m

Extract-MixFrom C-2 Bot

To V-8PC-1805

FC-1801

T-1A/BSolv Tks

P-21A/B

CW

E-12


E-5A/B

E-7A/B/C/D

DWO-Mix Ex E-3C

Wax-Mix Ex P-8/R/RR

C-5

C-1

C-2 C-3

C-4

C-10

#30

#12

#7

#1

C-8

B-11

E-15A/B/D

E-17A/C

VS steam

VS steam

E-30

VB

steam

VS steam

C-6

C-7

C-105

E-12E-9E-14

E-111

E-17B

E-16 E-6CW

DWO R/D

Sl Wax to FCCU

VM steam

VM

steam

E-17D

E-15CB-8 B-9

P-4/5/5R

Dry solvent to re-use

P-11/11RP-20A/BP-21A/BP-7/7R

P-109/109RP-9/9R

P-10/10R

CW

CW

CW

CW

E-8A/B/C/D

E-13

VM steam

VM steam

P-6/6R

VB Stm

IFOSlop

TK 763

Slop

TK 869/871

Foo

ts o

il E

x C

-104

bot

Foots oil Ex C-104 bot

SOLVENT RECOVERY SECTION OF SOLVENT DE-WAXING UNIT



B-14

34-T-134-T-1

B-16a

B-16b

inert gas to blanketing header for vessel blanketing in SDU

B-12a B-12b

B-2

filtrate vessel

knock out drums

B-13

K-1a

K-1b

E-19

E-20a

E-20b

Liq NH3

Liq NH3

cw

cw

cw

M

M

I G to Filters Hood

I G to B-1

I G to Filters Blowing

I G to FEU,SDU for purging

Separator

Funnel

DPIC-01

DICV-04-2

DICV-04-1

To B-2To B-5

PSA N2storagevesselN2 Ex PSA

INERT GAS GENERATION AND DISTRIBUTION SYSTEM IN SOLVENT DE-WAXING UNIT



PROPANE DE-ASPHALTING UNIT

PAGE:1 of 1Feed to UnitEx 44-700 P-1/1R/101

C-1A/B/C &C-101

F-1

E-112A/B

C-110

C-108

E-121A/BT M

MX-01

MX-3/4MX-02

FC

E-10VB

Ste

am

P-5

P-110A-F

B-1/2Propane vessel

K-1/1R

B-3

C-7

C-6C-4

C-5C-2

P-3/3R

P-103A/B

DAO R/dP-4/4R

E-6A/A1-I/I1&

E106A-C

E-107

E-114A-C

TW

VB

Ste

am

E-119

VM

Ste

am

E - 8

E - 4VB Steam

CW

E-120A

CW

CW orETP Water

Local drain

E-115CW

To Slop

VS

ste

am

VM

Ste

am

Flare

VS steam

E-9

E-109

CW

CW

PC-2AAsphalt to VBU

Asphalt to TPS

Asphalt to BTU

FC-16

MHP SteamP-102A/B/C

E-1

16

E-117CW

PC

CW

LC

LC

LC

LCLC

LCLC

Pro

pane

Sol

vent

E-1

22

E-5A/B


B-10Feed

P-1A/B

E-6A/BEx C-3 bot R/D

R/D cooler E-5

FC-03

TC-03

TC-01

E-1A/B/CF-1

R-1

B-2 B-3

C-1E-2

CW

B-9

LC-02LC-05

LC-03

PC-03 Off gas to fuel gas

K-2A/B/C

Rich amine

P-6A/B/106To B-4

Page 1 of 2

Recycle gas H2Make up gas H2

K-1A/B

B-1

E-8CW

To fuel gas

PC-01

PFD of Hydrofinishing Unit

Lean amine



FURFURAL EXTRACTION UNIT (U-33)Solvent Recovery

PAGE:2 of 3

VS steam

C-3

C-4

C-5

C-6

C-7

C-8

F-1

F-2

P-3/2R

P-5/5R

P-9/9R

P-7/7R

B-1

VS steam

E-4A/B

E-5

E-6A/B

E-7CW

CW

CW

CW

CW

CW

E-6A/B

E-5

DM water

Steam to F-1/F-2

E-10A

E-11

E-12

To C-9

To C-9

To C-9

Extract R/D

To B-2

To B-3

To B-2

To B-3

Raffinate R/D

Raff mix Ex C-2 top

Inert gas

Extract MixEx C-2 bot Via E-9

PC-3


B-4

E-7

B-8

B-5

B-6

C-2

C-3

P-2A/B E-6A/B E-5Feed Ex P-1A/B

To E-1A/B/C s/s

CW

Stripping steam

E-4

CW

E-3

CW

VM steam

PC-04 To fuel gas

LC-06

LC-08

LC-11 LC-18

To drain

drain to Sour Water

Product R/D

LC-09

Page 2 of 2

To F-1

#15

#1

CW

From B-2 / B-3 bottom

Lube Hydrofinishing unit


HydroTreatment Reactions

• Removal of impurities:– Hydro-desulfurization (HDS)

– Hydro-denitrification (HDN)

– Removal of metals – Ni, V (HDM)

• Improvement in quality– Hydrogenation of Olefins (HDO)

– Hydrogenation of aromatics – mono & poly (HDA)• Value addition thru’ increase in H:C ratio; Improvement in

CCR(%wt.), VI (in case of lube base stock processing)

• All these desirable HDT reactions are exothermic


HydroTreatment Operating Parameters

-Primary• H2 Partial Pressure

• Temperature

• LHSV

– Secondary• Recycle gas rate

• H2S partial pressure


Hydro Treatment Operating ParametersHydrogen Partial Pr.

• Also called Cold Hydrogen Partial Pressure. Not a direct operating variable; fixed at the time of design

• Defined as the partial pressure of hydrogen in gas phase at the outlet of last reactor.

• Under normal operation, depends on: – Total pressure maintained at the HP Separator

• Controlled by: Intake of fresh make/up hydrogen in balance with hydrogen consumed in reaction and purged from the system to maintain recycle gas purity

– Recycle gas purity• Depends on non-condensable components generated in rxn. which

needs to be purged from recycle gas from Recycle Compressor suction


Hydro Treatment Operating ParametersLHSV

• Liquid Hourly Space Velocity: m3 of fresh feed (at 15°C) per hour per m3 pf catalyst

• Significance:

– Lower LHSV at design feed rate

• Allows greater residence time / contacting time of feed in catalyst. Lesser temperature requirement for same extent of reaction. More cycle life

• Requires higher catalyst & reactor volume – higher initial investment

• In operation:• Will change with change in feed rate• For consistent product quality, to be compensated by adjusting

reactor temperature• Temperature adjustment with change in LHSV as per correlation

specified by licensor.


HydroTreatment Operating Parameters:Temperature

• Temperature - main control variable

• Most sensitive effect on reaction severity

• Greater variability as compared to other parameters provided by unit design

• Action on chemical reactions:

• From a kinetic point of view, when temperature increases, the rate of all the chemical reactions increases, i.e. both the desirable and the undesirable reactions.

• From a thermodynamic point of view, desirable reactions are exothermic, thus favored by a decrease in temperature

• Reactions that break carbon-heteroatom bonds (HDS, HDN, HDM) can be complete under appropriate conditions

• Olefin hydrogenation, though reversible, can also be complete under appropriate conditions

• Aromatic saturation is reversible and can reach thermodynamic equilibrium

• Rise in temperature beyond certain point leads to dehydrogenation rate surpassing hydrogenation rate – increase in aromatic concentration

• Limiting temperature can be shifted to higher level by increasing H2 partial pressure


HydroTreatment Operating ParametersTemperature

Temperature Limit for Hydrogenation of Aromatics

250 300 350 400

% a

rom

atic

s in

HD

T pr

oduc

t

Temperature (°C)

Monoaromatics

Di aromatics

Poly Aromatics

(Gas oil – on NiMo/alumina, PH2=60bar)




Interbed Quench

T

Reactor inlet temp.

Fuel

T

T

T

Reactor feed

Reactor product

Reactor temperature control: Factors:

Furnace outlet / Reactor inlet temperature

Bed delta T

Weighted Average Bed Temperature (WABT / WART)

Inter-bed quenchRx Heater o/l temp

Bed del T




Reactor temperature control

Weighted Average Bed Temperature (WABT / WART)

Convenient single point target parameter




• Reactor temperature control– WABT / WART controlled by simultaneous control of

• Reactor inlet temperature• Individual bed inlet temperature by regulation of inter bed

quench– Additional guidelines:

• Under normal steady operations, keep the reactor bed outlet temperatures equal for all beds to get better catalyst life.

• This may require different inlet temperature for different beds; Greater exothermicity in inlet bed – hence lower inlet temp for that bed.

• Max. allowable delta T across bed specified by designer, normally not more than 20°C



HydroTreatment Operating ParametersCatalyst Ageing

• Catalyst deactivation / aging:– SOR – Start of run & – EOR – End of run temperatures are specified by tech. licensor /

catalyst vendor.– Graphical monitoring of progress of reactor temperature on daily

basis required to estimate extent of aging of catalyst• Actual operating temperatures are normalized for feed

quality, t’put and product quality variations and plotted against time

• Useful for predicting regeneration or catalyst replacement requirement; to know about sudden loss of activity due to process upset



HydroTreatment Operating ParametersReCycle Gas rate

• Expressed as ratio of Normal cubic meters of hydrogen recycled (excluding quench) to volumetric flow rate of feed in cubic meter at 15°C

• Significance:

– Maintains adequate H2 partial pressure

– Generates turbulence required for proper contacting of feed with catalyst and for better heat transfer in exchangers and heaters

– Absorbs reaction heat from exothermic rxns; moderates delta T across cat. bed. Gives better cycle life of catalyst

• Requirement higher for heavier feeds



HydroTreatment :Other Operating Parameters

• Wash water injection

– H2S & NH3 generated from HDT rxn react to form NH4SH type salts which get deposited in cold parts of recycle loop, especially air cooler tubes

– To be washed with water injected at air cooler inlet

– Wash water injection at least 5 wt % of feed and ammonium salt conc. In HP separator boot water not to exceed 4% from corrosion consideration

• Amine absorption• Steady amine flow rate and concentration to be maintained for effective control over

recycle gas H2S content

• Lower amine temp favors better H2S absorption, but may also cause hydrocarbon condensation – which leads to foaming in absorber

• Optimum amine supply temperature to absorber column = 10°C less than Gas inlet temp.

• Periodic skimming of accumulated oil in absorber bottom to be done to prevent foaming. Foaming in absorber is indicated by sudden fluctuation in column pressure drop



HydroTreatment :Quality Parameters

• Product compositional characteristics:– Sulfur content– Nitrogen content Feed to HDW– Metal content– Aromatics content

• Other characteristics– CCR – Viscosity Index of finished Lube Base Oil

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