15 Naduhatty Selai Raman

8/10/2019 15 Naduhatty Selai Raman

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Indian Refining ScenarioProcessing of Opportunity Crudes

July 18, 2014

6thIndia-Canada Energy Forum, Calgary, Alberta
http://iocl.com/index.asp


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Corporate Overview

Incorporated in 1964

Indias Highest Ranked Fortune 500

Company at 88

th

of Global Fortune

Listing

Sales Turnover in 2013-14: USD

78.87 Billion

Corporate Office, New Delhi, India


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IndianOil- Birds Eye View

10 Group Refineries accounting for a total refining

capacity of 66.3 MMTPA(1.3 mbpd)

Asias largest marketing network with around 39,000

sales touch points Cross Country pipeline network of 10,909 kms for

transportation of crude and products

Spreading marketing network of Petrochemicalsa

step for forward integration Gas Marketing infrastructure

Renewables, nuclear and upstream ventures

Asia-Pacifics largest downstream R&D set up
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Alternative Energy

-Bioenergy-Hydrogen

-Gasification

Petrochem. &

Polymers

Bio Technology Technical

Services

Refinery Technology-FCC/HD

-Catalyst

-Pipelines (iPIG)

LubricantTechnology

NanotechnologyFuelAdditives

R D Today

IndianOil-R D-A Snapshot

Future EnergySources

-Solar-Shale Oil

-Gas Hydrates


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Primary Energy Consumption:

Current & Future

Coal

52%

Oil27%

NaturalGas10%

NuclearPower

1%Other

10%

2010

Coal41%

Oil30%

NaturalGas8%

NuclearPower

8%

Other13%

2040

Coal28%

Oil34%

NaturalGas22%

Nuclear

Power5% Other

11%

2010

Coal27%

Oil28%

NaturalGas23%

NuclearPower

7%

Other15%

2040

India

World

(24.4 Q Btu) (55 Q Btu)

(819.6 Q Btu)(523.9 Q Btu)

Growth rate: 2.8%

Growth rate: 1.5%

Source: IEO 2013

Q Btu: Quadrillion Btu

Share of Oil Share of Coal

Share of Oil


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Indian Refineries

2012-13

Company No. MMTPAIOC Group 10 66.3BPC Group 4 30.5HPC Group 3 25.5ONGC Group 2 15.066RIL (Pvt.) 2 60.0ESSAR (Pvt.) 1 19.0

Total 22 216.366

Digboi

(0.65)

Numaligarh

(3.0)

Guwahati

(1.0)

Bongaig

aon

(2.35)

Barauni

(6.0)

Mathura

(8.0)

Panipat

(15.0)

Bhatinda

(9.0)

Koyali

(13.7) Haldia

(7.5)

RIL

(60)

EOL

(19)

Paradip

(15.0)

Manali

(11.1)

Nagapattinam

(1.0)

Visakh(9.0)

Tatipaka

(0.066)

Kochi

(9.5)

Mangalore

(15.0)

Mumbai

(BPC:12.0

HPC: 7.5)

Bina

(6.0)

Existing IOC

Subsidiaries of IOC

Other: PSU/JV

Other: Private

New addition

2016-17

Company No. MMTPA

IOC Group 11 95.3BPC Group 4 46.0HPC Group 4 41.2ONGC Group 2 18.1RIL (Pvt.) 2 60.0ESSAR (Pvt.) 1 38.0Nagarjuna 1 15.0

Total 24 313.6
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India: Refinery Capacity

Product Demand (MMTPA)

0

100

200

300

400

2009-10 2010-11 2011-12 2016-17

Refining capacity

Product surplus

Source: MOPNG 2011-12

4349 48

127


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Indian Gasoline Specification

9

S. No. Characteristics Unit BS III BS IV/V*

1 Density 150C Kg/m

3720-775 720-775

2 Distillation

3 Research Octane Number

(RON), Min

91 91

4 Anti Knock Index (AKI)/ MON,Min

81 (MON) 81 (MON)

5 Sulphur, Total , Max mg/Kg 150 50

6 Lead Content(as Pb), Max g/l 0.005 0.005

7 Reid Vapour Pressure (RVP),

Max

Kpa 60 60

8 Benzene, Content, Max % Vol 1 1

9 Olefin content, Max % Vol 21 21

10 Aromatic Content, Max % Vol 42 35

* Reduced gaseous emmission


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Indian Diesel Specification

10

S. No. Characteristics BS III BS IV/V*

1 Density Kg/m3 15 0C 820-845 820-845

2 Sulphur Content, mg/kg (max) 350 50

3 Cetane Number and/or 51 51Cetane Index(min) 46 46

4 PAH 11 11

5 Distillation

95%Vol Reco at 0oC max 360 360

* Reduced gaseous emmission


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Opportunity Crude

Processing

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Opportunity crudes processing:

Constraints

Refinery Design

limitation

Undesired

product

Qualities

High cost of

Treatment

Current Constraints

TAN< 0.5

Salt < 50 ptb, < 20 at some

Long residue < 58-59%

Short residue < 26-28%

S of VGO < 3-3.5%

Total N2& Metals:


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High Pour

(Mangla crude)

High Viscosity

(Maya crude)

Reduction in

Pipeline

Capacity

Remedies adopted

Intermittent heating (costly)

Injection of suitable Drag reducer

Additive

Addition of Pour point

depressants

Blending with normal Crudes

Transportation

Coastal refineries have the advantage of processing Heavy Crudes


Transportation


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Distillation

High Salt

High Residue

yields

Overhead

Corrosion

Upsets

TputLoss

Remedies adopted

Blending with normal Crudes

Efficient Desalter operation

Overhead Corrosion Control

program

CDU / VDU


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Reformer

Lower

Naphtha

yields

Lower feed

stock

availability

Remedies adopted

Increased MS components toReformer by processing Hy.naphtha

Design changes in Pretreater

Use of suitable catalysts in

Pretreater and Reformer

Reformer


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Indmax

CCR upto 4%

LPG Deasphalting

Deasphalted oil

Asphalt for bitumen

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Resid Upgradation

Inhouse Technologies


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High TAN Crude

Processing

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High TAN Crudes

Crude Origin API %'S' TAN

1 Bonga Nigera 29 0.25 0.59

2 Ceiba Eq.Guinea 31.2 0.51 0.8

3 Djeno Congo 27.4 0.27 0.7

4 Escalante Argentina 23.63 0.19 0.78

5 Escravos Nigera 34.3 0.17 0.636 Lavan Iran 35.72 1.44 0.71

7 Saxi Angola 34.97 0.3 0.64

8 Zaffiro Eq.Guinea 29.5 0.26 0.81

9 Marlim Brazil 20.46 0.73 1.13

10 Dalia Angola 22.7 0.496 1.724

11 Dar Blend Sudan 24 0.1 3.8

12 Nowrooz 18.87 4.15 0.983

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Discount available for High TAN crudes


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Factors Affecting NA Corrosion

Temperature

Velocity / Turbulence

Sulfur SpeciesMW of the Naphthenic acid

Metallurgy

Need to understand Crude Quality, Processing

environment & Refinery preparedness before

processing


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Crude Blending

Neutralisation / Mitigation

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High TAN Crude: Processing

Options


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Blending: Corrosion Behavior

TAN Sulfur Corrosion Corrosionrate (P5)

@350oC,

mm/year

High TAN

(>0.5 mgKOH)

Low S

(2wt%) Very High 1.61

Low TAN

(


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Predict Crude software: Joint

Industry Programme (JIP)

Predict-Crude software determines corrosion rates forrefinery materials

Covers all refinery metallurgy

Carbon steel, 5Cr, 9Cr, 12Cr, 304L, and 317L

Input parameters and their rangesTemperature : 235377degC

Naphthenic acid type : high or low MW

Acid content : up to 4.6 mg KOH / g

Active sulfur level: low, medium, high or very highPipe dimensions & flow parameters to calculate wall shear

stress : 1-135 Pa

Software validated utilizing actual refinery data


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Predict Crude S/w


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Predict Crude S/w


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Mitigation:

TAN distribution in Products

0.058

0.417

1.025

1.600

0.033

0.119

0.909

0.500

0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

Kerosene Gasoil VGO VR

TA

N,mgKOH/gmo

fsample

Neat NG Crude NG Crude with Mitigant


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Proposed Mitigant Dosing

Locations

Mitigant

Dosing locations VDU

AU


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Corrosion rate evaluation taking AU data with and without mitigated

condition for high TAN crude & its fractions

Corrosion rate prediction utilizing JIP model for carbon steel, P5, SS316L for

various sizes of piping from 4 to 22 considering the flow rate of AU

respective circuit in the temperature range 235-350oC indicates reduction incorrosion rate significantly

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Effect of mitigant using Predict crude S/w

For Atm Distillation Unit

High TAN Crude Equip. TAN g/mg

KOH

TempoC

Flow rate Wall Shear

Stress

Corrosion

rate

mm/year

Present

Corrosion rate

mm/year

Neat HeaterTube 6 1.8 350 2.54M/S 14.03Pa 0.29 0.30 max

Mitigated HeaterTube 6

0.4 350 2.54M/s 14.03Pa 0.20 --

RCO Pipe 12 2.07 350 1.13M/S 2.35Pa 0.31 0.30 max

RCO from

mitigated crude

Pipe12 0.52 350 1.13M/S 2.35Pa 0.21


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Opportunity crude upgradation

thru Syncrude route

Huge business potential in the

energy sector

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Summary


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Thank you

15 Naduhatty Selai Raman

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