Haldia Refinery
Presentation on LOBS.
Hirak Dutta, General Manager(Technical)
Haldia Refinery
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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
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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
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USE OF LUBRICANTS/BASE OILS
ENGINE OILS
GEAR OILS
TRANSMISSION FLUID
INDUSTRIAL APPLICATION
CATALYST CARRIER OILS.
WHITE OIL APPLICATION
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FUNCTION OF LUBRICANTS
MINIMISE FRICTION AND WEAR
REMOVAL OF DEBRIS
DISSIPATION OF HEAT
ACT AS ELECTRIC INSULATOR
PREVENTS RUSTING & CORROSION
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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.
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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
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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
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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)
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LUBE BASE OILS
LUBE PROCESSING REQUIREMENT IS A
FUNCTION OF
HYDROCARBON STRUCTURE OF
FEED
 TARGET PROPERTIES OF
FINISHED BASE OILS
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HYDROCARBON STRUCTURE
STRUCTURE
VI
POUR PT
N-PARRAFIN
VERY HIGH HIGH
LOW
ISO-PARAFFIN
HIGH
LOW
HIGH
NAPHTHENE
MEDIUM
LOW
HIGH
AROMATICS
LOW
LOW
LOW
CONDENSED
/POLAR
VERY LOW --
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INTEREST
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
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Lube Processing
Properties set by Process Units
Kero / Jet
Diesel
Pour Point
Waxy
Raffinates
Atomospheric
Resid.
Aromatic
Extracts.
Base Oils
Dewaxed Oils
Vacuum
Resid.
Propane
Deasphalting
Color &
Stability
Waxes and
Micro waxes
Asphalts.
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Light Neutral
Clay Treating or
Hydrofinishing
Vacuum
Distillates
Solvent Extraction
or Hydro cracking.
VGO
Vacuum
Distillation
Crude
Oil
Atomospheric Distillation
Naptha
VI, Stability &
Solvency
Solvent Dewaxing or
Catalytic Dewaxing.
Flash points ,
KV &Noack
Gas
Medium Neutral
Heavy Neutral
Bright Stock
TREATING / REFINING FOR LUBE PROCESSING
SOLVENT
EXTRACTION
SOLVENT
EXTRACTION
SOLVENT
DEWAXING
CATALYTIC
DEWAXING
SOLVENT
EXTRACTION
RAFF. HYDROTREATING
SOLVENT
EXTRACTION
SOLVENT
DEWAXING
HYDRO-FINISHING
API GROUP I
HYDRO-FINISHING
WAX
HYDRO-FINISHING
API GROUP I I
HYDROISOMERISATION
HYDRO-FINISHING
WAX ISOMERISATION
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API GROUP II
API GROUP III
Gr I and Gr II Processing - Comparison
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Additive Types
Dispersants
Detergents
Antiwear
Friction Modifiers
Oxidation Inhibitors
Rust Inhibitors
Emulsifiers / Demulsifiers
Antifoamants
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BASE OIL PRODUCT QUALITYKEY REQUIREMENTS
Viscosity
VI
Pour Point
Colour
Oxidative Stability
Thermal Stability
Anti-Wear Performance
Better Solvency
Lower Volatility
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EFFECT OF MANUFACTURING PROCESS
ON
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
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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)
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Haldia Gr-I & Gr-II LOBS
Comparison
GR
I
GR
II
Grade
KV (cSt)
VI (min.)
Pour Point
(max)
150N
28-32 (40oC)
100
-9
500N
10 (100oC)
95
-6
HN
13.5 (100oC)
92
-3
BN
32 (100oC)
92
-3
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
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Gr-I & Gr-II LOBS
Processing: Comparison
Solvent
Extraction
Solvent
HydroDe-waxing finishing
Group-I
VI
Solvent
Hydro
Extractio Treating
n
Group-II
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Wax
Isomeris
ation
Hydrofinishing
Pour Point
Simple Block Flow Diagram of Haldia Refinery
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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.
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Product Quality of Distillate & Short Residue
Stream
Boiling
Range.0C
Den
@ 15
0C
Fl.
Point
0C
KV @
98.9 0C
%S
Gas Oil
265-362
0.8591
119
4 at 37.8
1.38
Spindle oil
362-385
0.8992
162
3.54
Light oil
385-462
0.8950
184
3.84
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
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CCR
wt%
1.96
2.38
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
deg C
• Product Draw off temp : 232 , 245, 333 & 370 for SO,LO,
• IO & HO
• Bottom Quench : 5 m3/hr
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228
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.
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ROSE : Residium Oil Supercritical Extraction
-- Feed & Product Quality
Technology Licensed by M.W. Kellog Technology Co. USA
Design : 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
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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
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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
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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.
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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
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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.
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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.
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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
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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.
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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
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Hydro finishing Unit :
Main operating Variables :
Temperature: optimum to achieve desulphurization. Lower
the temp, higher is the product viscosity & yields
Partial 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
equipment
Space 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 hydrogen
Feed quality: Higher the impurities higher the severity
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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
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Aromatics
Naphthene
L
0 VI
U
H
Paraffin
Viscosity
Viscosity
VISCOSITY – VI RELATIONSHIP
100 VI
Temperature
Temperature
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CIDW unit, The process
Hydro treatment of feed
De-Waxing
Hydro finishing
Recovery
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Hydro treatment of feed
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
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Hydro treatment of feed
Feed + H2
feed
S, N free
R 01
+ H2 + HC
+H2S +reaction
NH3
Exothermic
High Temperature,
High Pressure
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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
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Hydro treatment Reactor (R 01)
Operating Conditions
ATTRIBUTE
HDT Temp,
in/out (deg C)
SOR
EOR
*HDT Pres,
(kg/cm2 -A)
Inlet
Outlet
100 N
150 N
500 N
500 N w/
500 SW
500 SW
302/318
370/386
302/314
370/382
302/321
370/387
302/321
370/384
302/316
370/384
143.8
138.5
143.8
138.5
143.8
138.5
143.8
138.5
143.8
138.5
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150 BS
302/323
370/391
143.8
138.5
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
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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
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De-Waxing
Clean feed
Ex R 01 +
Treated H2
R 02
High Temperature
Low pour point
product + H2 +
HC
Highly Exothermic
Reactions
High Pressure
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De-Waxing Reactor, R 02
Three catalyst beds
Total catalyst volume = 40.8 m3
Bed 1 – Partial Ni- Mo & bal. EM7-7210
Pt/Pd Hydrogenation catalyst for HDS, HDN
and aromatic saturation.
Bed 2&3 - EM-7300 Pt. Isomerisation
Catalyst
Operating Variables:
Temperature
Hydrogen circulation and partial pressure
Space velocity
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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)
SOR
EOR
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)
Inlet
Outlet
126.8
120.5
126.8
120.5
126.8
120.5
126.8
120.5
126.8
120.5
126.8
120.5
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Hydrofinishing
Product stabilization through saturation of
poly nuclear aromatics
Improvement in Color
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Hydrofinishing Reactor, R 03
Low pour
point product
+ H2 + HC
Hydro finished
product + H2 +
HC
Low Temperature
Mild Exothermic
High Pressure
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Hydrofinishing Reactor, R 03
Two catalyst Beds
Total catalyst volume = 27.2 m3
EM7-7500 Pt/Pd Aromatic saturation
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Hydrofinishing Reactor, R 03
Operating Conditions
ATTRIBUTE
HDF Temp,
in/out (deg C)
SOR
EOR
*HDF Pres,
(kg/cm2 -A)
Inlet
Outlet
100 N
150 N
500 N
500 N w/
500 SW
500 SW
150 BS
247/250
288/291
247/250
288/291
247/250
288/291
247/250
288/291
247/250
288/291
247/250
288/291
118.3
113.0
118.3
113.0
118.3
113.0
118.3
113.0
118.3
113.0
118.3
113.0
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Control Of Reaction Exotherm
Quench --Cold recycle hydrogen flow to all
reactor
beds
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CATALYTIC DEWAXING:GENERAL FLOWSHEET
Recycle
Hydrotreating
Purge
CDW
Hydrofinishing
Feed
Separator
Make Up
hydrogen
Naphtha
Hydrotreater Effluent
Scrubbing Section
Diesel
Product
Fractionation
Section
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Group III LOBS
Product
HALDIA CDWU
High Pr. Feed/Reactor Section
Haldia HDT/MSDW Unit
High Pressure Feed/Reactor Section
MSDW
HDF
HDT
84-K-02
84-R-01
84-R-03
84-R-02
Purge
84-B-06
84-F-02
84-B-05
84-F-01
84-E-07
84-E-02
84-E-08
84-E-06
84-EA-02
84-E-03
84-E-11
84-B-04
84-C-02
Amine
M/U H 2
84-C-03
Cond.
84-P-14
84-K-01
84-P-15
84-E-04
84-B-07
Separator Liquids
to HP Stripper
84-E-05
84-B-03
Carrier Oil S/U
84-C-01
84-E-01
84-G-01
84-M-01
84-EA-01
84-B-02
Waxy Feed
Separator Liquids
to HP Stripper
NNF S/U Line
S/U Line
HDT Raffinate
to Vac Stabilizer
84-P-01
84-B-01
84-P-02
Heavy Diesel
(Light Lube)
84-EA-06
Vacuum Drier Bottoms
Dewaxed Lube Product
S/U - Internal Liquid Recycle
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Dewaxed Lube
Product to Storage
HALDIA CDWU
Low Pressure Recovery Section
Haldia HDT/MSDW Unit
Low Pressure Recovery Section
Fuel Gas
84-C-09
Lean Amine
HP Stripper
84-P-13
From 84-B-26
84-B-10
84-E-12
Wild Naphtha
to Storage
MSDW/HDF
HTS & LTS
Liquid
84-J-03/04/05
SWS
S/U
HT Stripper
& LTS Liquid
84-P-04
Vacuum Stripper/Drier
MPS
84-C-04
Gas to
84-B-24
Stm
84-E-15/16/17
84-B-17
84-EA-03
84-C-05
84-P-19
84-B-11
84-P-20
84-G-02
SWS
84-F-03
84-P-09
84-P-03
84-P-08
84-E-13
Gas from
84-B-17
84-B-19
84-J-01
84-C-07 / 84-C-08
Heavy Diesel to
Lube Product
84-J-02
84-B-24
MPS
MPS
84-EA-04
84-P-06
Diesel to
Storage
84-C-06
84-P-07
84-EA-05
Heavy Diesel
to Storage
Lube Product
to 84-E-01
84-P-05
Haldia Refinery
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HALDIA CDWU
Operating 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
Haldia Refinery
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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
Haldia Refinery
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Lube Base Oil Product Qualities
Grade
KV (cSt)
VI (min.)
Pour Point
(max)
28-32 (40oC)
100
-9
10
(100oC)
95
-6
HN
13.5 (100oC)
92
-3
BN
32
92
-3
9.5-15.5 (40oC)
100
-21
28.8-32 (40oC)
105
-15
500N
90-105 (40oC)
95 (105)
-15
150BS
30 (100oC)
95
-6
GR 150N
I
500N
GR 70N
II 150N
(100oC)
Haldia Refinery
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GROUP – I / GROUP – II LOBS
Group I grade
LOBS
Group II grade
LOBS
Haldia Refinery
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NEW GENERATION LUBRUCANT WILL REQUIRE
LUBRICANT PERFORMANCE BASE STOCK
REQUIRED
PROPERTY NEEDED
ENGINE OILS
LOW EMMISSIONS,
LOW OIL CONSUMPTION
FUEL ECONOMY
EXTENDED DRAIN
GEAR OILS
FILL FOR LIFE
FUEL ECONOMY
TRANSMISSION
FLUID
EXCELLENT FLUIDITY
FUEL ECONOMY
LOW VOLATILITY AT LOW
VISCOSITY
LOW VISCOSITY & HIGH
VISCOSITY INDEX
OXIDATION STABILITY
OXIDATION STABILITY
HIGH VISCOSITY INDEX(GR-III)
HIGH VISCOSITY INDEX(GR-III)
LOW VISCOSITY, LOW
VOLATILITY
Haldia Refinery
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THANK YOU
Haldia Refinery
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BASE OIL TRENDS
Market
share (%)
API Gr I
API Gr II
Others
1980 - 90s
2000
75-85
10-15
1-2
50-60
30-40
5-10
Lesser availability of lube bearing crude
Better fuel economy, improved
performance and extended drainage
Impact on environment
Haldia Refinery
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ADDITIVES
Required to impart or enhance desired
properties of oils.
Dispersants
Detergents
Oxidation inhibitors
Rust and corrosion inhibitors
Viscosity Index improvers
Pour Point depressants
Foam Inhibitors
Anti-wear Agents/Friction modifiers
Haldia Refinery
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LOBS Manufacture by HydroProcessing
Alternative Route-I
VI, CCR
RCO
Waxy
Raffinate
Lube HydroTreater
Vacuum distillation
Naphtha VGO Vacuum
Distillates
Kero
Diesel
Colour &
Stability
Pour Point
Propane
De-Asphalting
De-waxed oils
Haldia Refinery
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HydroFinishing Unit
KV,
Flash Point
Catalytic Dewaxing Unit
Gas
Gr-II LOBS
70N/100N
150N
500N
150BS
LOBS Manufacture by HydroProcessing
Alternative Route-II
VI, CCR
RCO
Hydro Cracker
Vacuum distillation
Naphtha VGO Vacuum
Distillates
Kero
Diesel
Colour &
Stability
Pour Point
Vacuum
Distilled
HydroCrac
kate
Residue
Propane
De-Asphalting
De-waxed oils
Haldia Refinery
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HydroFinishing Unit
KV,
Flash Point
Catalytic Dewaxing Unit
Gas
Gr-II LOBS
70N/100N
150N
500N
150BS
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.
Haldia Refinery
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Vacuum Distillation Unit PFD
(preheat and product cooling section )
LO R/D
B-1
FC-21
E-127
To VBU
CW
RCO Ex tanks
To TK-761
P-1/1R
To Tar
E-121
LO Ex P-5/5R
E-1A
E-1C
GO Ex P-3/3R
E-1B
E-2A
CW
E-1D
SO Ex P-7/7R
E-2B
FC-22
GO to top reflux
To Tar
E-14A/B
TW
E-6C
E-6B
E-4A
IO Ex P-12/12R
E-124A/B
E-4B
FC-12
FC-27
To R/D
FC-26
LC-02
SR to R/D
FC-28
E-11
H-1A
E-10
Vac slop to PDA
To VBU
To PDA
To VBU
Bot quench
H-1B
To VB steam
header
SR Ex P-10/10R
RCO to P-113/113R suction
Pump Around To # 18 of C-1
E-9
TW
IO to VBU
IO to R/D
HO Ex P-8/7R
HO Ex P-8/7R
Vac slop Ex P-9/9R
E-122A/B
FC-25
E-126A/B
HO to R/D TW
TW
E-7
FC-24
SO to R/D
E-125A/B
E-123
TC-06
E-6A
FC-23A To HSD
GO to R/D
CW
E-2C
CW
FC-15
FC-19
CW
PA Ex P-6/6R
To VBU
To TK-761
DM water
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Vacuum Distillation Unit PFD
(furnace and fractionator circuit)
Furnace recycle Ex p-9/9r
FC-10A
FC-5
FC-4
VB steam
F-1
FC-8
Turbulising
steam
Combustion air
Ex APH
FC-10B
VS steam
FC-9
Turbulising
steam
#22
FC-201
F-2
P-113/113R
FC-216
Burners
PA draw
VS steam
FC-11
E-6A/B/C
SO toE-123
P-7/7R
VS steam
#4
#1
LO to E-121
#12
P-6/6R
#8
IO draw
Over Flash
LC-04
#5
P-5/5R
#4
C-3
#1
VS steam
IO to E-7
Combustion air
Ex APH
HO Ex P-8/7R
as Demister Wash
Turbulising steam
FC-217
FC-209
Fuel gas
IFO supply
IFO return
Atomising steam
LC-03
LO draw
C-1
C-105
LC-101
C-2
#16
RCO ex F-1/F-2
Turbulising steam
VB steam
P-3/3R
#4
#1
SO draw
#19
FC-202
VS steam
GO to E-1A/B/C/D
GO draw
#26
Burners
FC-102
Fuel gas
IFO supply
HV-01
PC-06
IFO return
Atomising steam
DPC-03
RCO Ex E-11
To Ejectors
CW E-128A/B
GO as reflux
ex E-2A/B/C
P-9/9R FC-10BHO draw
Vac slop to E-9
FC-13
VS STEAM
Bot Quench Ex H-1A/B
FC-12
#4
#1
SR to E-11
SR draw
P-10/10R
Haldia Refinery
Haldia Refinery
LC-05
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#4
C-4
#1
P-12/12R
VS steam
HO to E-9
P-8/7R
Vacuum Distillation Unit PFD
Vacuum System
Cooling Water Inlet Header
E-128B
E-128A
PC-121
VM Steam to Ejectors
PC-05
#26
#22
31C-1
CW
CW
SEJ
PEJ
Cooling Water
Return Header
CW
#19
CW
Vent
E-129
E-130
CW
P-101/101R
B-3
coaleser
oil
water
Barometric legs
B-2
B-7
seal pot
P-102/102R
Hot well
Hot well water to OWS/ Desalter
Hot well gas oil to HSD pool
Tempered water circuit
E-116A/B/C
CW
E-125A/B
DM water
B-105
SR
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VB steam
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Tempered water
IO
E-124A/B/C
HO
E-126A/B
Vac
Slop
E-10
FILTRATION & CHILLING SECTION OF SOLVENT DEWAXING UNIT
Liquid Ammonia
To/From storage
E-3.12
E-3.9
E-3.7A/B/C
To Aux comp suction/
From Discharge
Sub cooler
Sub cooler
K-3A/B/C
M
B-3.10
Liquid Ammonia
B-25
B-24
B-3.8
B-3.11
B-26
E-3.6A/B/C
Drain
from B-3.8
Feed Ex tanks
Vapour Ammonia
VB stm
E-2/I
Primary Dilution solvent
P-1/I
SDA Dosing
P-1/II
Wax injection
Feed to DP Chiller
Train series -1
CW
Feed to 6 series of
parallel DP Chiller
Trains.
E-2/II
E-1/II
CW
LA-1A
LR-1B
LR-1A
Filtrate to DP Exchangers
of Chiller series 2-7
Filtrate Ex DP Exchangers
of Chiller series 2-7
Vapour Ammonia
E-3C
Solvent Ex B-8 / B-9
E-3A/B
E-4A
E-4B
E-4C
Liquid Ammonia
E-1/I
VB stm
LA-1C
LA-1B
Feed Ex parallel
DP chiller
Secondary Dilution solvent
series 2-7
Sec Dil to DP chiller
series 2-7
E-4D
Tertiary
Dil solvent
P-4/5/5R
DWO-Mix to solvent recovery
Liquid Ammonia
from storage
From Aux comp
discharge
Ammonia vapors
to consumers
To Aux comp
suction
E-18
B-15
Drain from chillers
and E-4A-D
P-8/8R
B-7
Purging
solvent
To vacuum compressor
suction via B-12A/B
Blowing
Filtrate
VB Steam
B-3a
E-31
B-2
VM steam
P-2/2R
To B-11
Seal pot
B-20A
VB Steam Hot wash
S-1
Filtrate
Wax-mix to
solvent recovery
Cold wash
solvent
B-1
From S-2
to S-11
To S-2
to S-11
Wax-mix Ex
P-3/II-XI
P-3/I
Haldia Refinery
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FURFURAL EXTRACTION UNIT
Extractor Section
To E-13b
or E-8
E-2
Atm
LC-01
#1
E-1
Feed to Unit
PAGE:1 of 3
Steam
J-1
CW
E-2A/B
VM steam
CW
C-1
Ex P-8/8R
or P-9/9R
VS steam
33P-1/1R
33P-2/2R
To E-4A/B O/L
Raffinate Mix To P-3/2R via B-1
E-15
E-3
CW
C-2
#3
E-9
Extract Mix to C-5
Via E-10A
CW TC-12
Ex P-12B
E-8
B-11
P-11/11R
CW
E-10B
Haldia Refinery
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P-6/6R
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Furfural Ex C-9 Bot
FURFURAL EXTRACTION UNIT (U-33)
Solvent Drying section
PAGE:3 of 3
To seal pot
steam
steam
E-14
CW
Ex C-3
Ex C-7
CW
E-5
CW
B-2
#13
#7
#6
#1
Ex C-5 liquid
Ex C-5 Vap
Ex C-6 liquid
Ex C-6 Vap
CW
Ex C-4
C-9
Ex C-8
E-6
B-3
CW
B-4
Furfural To C-2
P-10/10R
P-11/11R
#18
P-4/4R
C-10
#1
P-12A/10R
VB steam
To C-2
To ETP
Haldia Refinery
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PAGE:1 of 2
NMP EXTRACTION UNIT (U-38)
Extraction and Raffinate-Mix Section
E-2 A/B
V-7
CW
TC-1101
OWS
E -14
#1
44P-101A/B Extract R/D
Ex P-9A/B
V-8
LP steam
HP Steam
Ex C-10 Top
PC-1209
38P-2A/B
E-4
P-4A/B
C-3
#1
E-5A-D
FC-1202 TC-1202
C-2
#20
C-4
#7
#16
E-18
TC-1102
To V-9
#4
F-2
PC-1201
IG
E-13
Reflux Ex P-4A/B
V-1
C-1
VM steam
CW
Inert gas
#10
Feed to Unit
Ex Tanks
E-24
FC-1401B
E-1C
To V-5
CW
FC-1401A
E-1A/B
LC-1101
To V-14
E-7A/B/C
CW
FC-1603
#1
E-6
TC-1201
FC-1101
E-3A/B
#1
CW
CW
P-6A/B
E-17
Water injection
Ex v-4/ v-10
PC-1210
LC 1601
To V-14
Extract-Mix To C-5
FC-1201 V-6
FC-1203
IG
P-10A/B
P-3A/B
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Solvent Ex P-5A/B
Reflux to C-5/6/7/8/9
NMP EXTRACTION UNIT (U-38)
Extract -Mix and Solvent Drying Section
PAGE:2 of 2
MP Steam
Ex C-4 Top
Water Injection to E-17 / V-4
J-001
J-002
To V-8
PC-1805
CW
B
V-9
E-12
A
A
E-15
B
E-22B
V-5
P-13A/B
E-22A
E-21A
38PC-1806
FC-1801
#27
CW
Ex C-3 Top
E-21B
#10
V-10
#7
#5
P-15A/B
P-12A/B
V-4
#1
P-7A/B
HP Steam
C-10
E-16
T-2A/B
Slop Tks
C-7
E-20
CW
P-20
T-1A/B
Solv Tks
E-11
V-14
CBD
E-23
C-5
#4
A/B/C
C-8
#1
E-9A/B
To Solvent Manifold
P-5A/B
#20
E-8
To Slop Manifold
P-21A/B
F-1
C-6
P-18A/B
Extract
recycle
C-9 P-11A/B
E-1A/B
P-8A/B
P-17A/B
P-9A/B
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TW
Extract R/D
E-
Deareator feed Ex 44P-101
SOLVENT RECOVERY SECTION OF SOLVENT DE-WAXING UNIT
#30
DWO-Mix
Ex E-3C
E-5A/B
E-7A/B/C/D
E-15A/B/D
#12
E-13
C-2
CW
C-3
C-8
Foots oil Ex C-104 bot
#7
VM steam
VB Stm
C-4
C-1
VS steam
C-10
#1
VS steam
E-8A/B/C/D
VM steam
E-30
P-6/6R
P-7/7R
B-11
P-21A/B
P-20A/B
DWO R/D
P-11/11R
E-17A/C
Slop
E-16
CW
E-6
CW
E-17D
TK 869/871
CW
E-15C
VB steam
Wax-Mix
Ex P-8/R/RR
E-111
C-105
C-5
E-12
VM steam
E-14
C-6
TK 763
Dry solvent
to re-use
C-7
IFO
P-4/5/5R
E-9
Sl Wax to FCCU
Slop
B-9
CW
VM steam
E-17B
B-8
VS steam
P-109/109R
P-9/9R
Foots oil Ex C-104 bot
P-10/10R
Haldia Refinery
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INERT GAS GENERATION AND DISTRIBUTION SYSTEM IN SOLVENT DE-WAXING UNIT
I G to FEU,SDU for purging
N2 Ex PSA
PSA N2
storage
vessel
I G to Filters Hood
I G to B-1
DICV-04-2
B-14
I G to Filters Blowing
34-T-1
34-T-1
E-20a
cw
B-13
DPIC-01
Liq NH3
E-19
E-20b
To B-5
B-16a
Liq NH3
To B-2
DICV-04-1
cw
M
B-12a
K-1b
B-12b
Separator
cw
knock out
drums
B-16b
M
B-2
filtrate vessel
inert gas to blanketing header for
vessel blanketing in SDU
Funnel
Haldia Refinery
Haldia Refinery
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K-1a
PROPANE DE-ASPHALTING UNIT
Feed to Unit
Ex 44-700 P-1/1R/101
K-1/1R
E-6A/A1-I/I1
&
CW
E106A-C
E-4
VB Steam
VM Steam
P-110A-F
E-114A-C
E-10
P-5
FC
B-1/2
Propane Solvent
C-1A/B/C
MX-3/4
&
C-101
P-102A/B/C
MX-02
C-6
CW
C-7
LC
CW or
ETP Water
LC
C-108
P-4/4R
E-116
VB Steam
TW
Local drain
CW
E-8
C-110
LC
CW
DAO R/d
E-115
To Slop
C-5
C-2
E-117
B-3
E-120A
VM Steam
C-4
E-112A/B
Propane vessel
Flare
CW
MX-01
PC
PAGE:1 of 1
E-107
LC
LC
F-1
LC
LC
P-3/3R
P-103A/B
M
T
E-121A/B
MHP Steam
Asphalt to BTU
Asphalt to TPS FC-16
Haldia Refinery
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E-109
CW
E-9
CW
Asphalt
PC-2Ato VBU
PFD of Hydrofinishing Unit
To fuel gas
Page 1 of 2
PC-01
Make up
gas H2
CW
E-8
Recycle gas H2
B-1
K-1A/B
R/D cooler
E-5
FC-03
Feed
TC-03
TC-01
E-1A/B/C
F-1
B-10
E-6A/B
Ex C-3 bot R/D
R-1
P-1A/B
E-2
C-1
CW
PC-03
B-3
B-2
Off gas to fuel gas
B-9
LC-03
K-2A/B/C
LC-02
LC-05
Rich amine
Lean amine
P-6A/B/106
Haldia Refinery
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To B-4
FURFURAL EXTRACTION UNIT (U-33)
Solvent Recovery
Inert gas
PAGE:2 of 3
To B-2
Raff mix
Ex C-2 top
CW
E-5
B-1
F-1
E-4A/B
To C-9
C-3
CW
To B-3
E-6A/B
PC-3
To C-9
P-3/2R
CW
C-4
E-7
P-5/5R
E-12
C-6
E-11
To B-2
E-10A
C-5
E-5
C-7
CW
F-2
To C-9
To B-3
E-6A/B
C-8
Extract Mix
Ex C-2 bot
Via E-9
CW
Steam to F-1/F-2
P-7/7R
Extract R/D
P-9/9R
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Haldia Refinery
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DM water
CW
Lube Hydrofinishing unit
PC-04
Page 2 of 2
To fuel gas
E-7
VM steam
CW
From B-2 / B-3
bottom
B-8
B-4
To F-1
E-4
E-3
CW
CW
B-6
LC-06
B-5
#15
LC-11
C-2
Stripping steam
LC-18
#1
LC-08
To drain
C-3
drain to Sour Water
LC-09
To E-1A/B/C s/s
Product R/D
P-2A/B
E-6A/B
Feed Ex P-1A/B
E-5
CW
Haldia Refinery
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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
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HydroTreatment Operating
Parameters
-Primary
• H2 Partial Pressure
• Temperature
• LHSV
– Secondary
• Recycle gas rate
• H2S partial pressure
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Hydro Treatment Operating Parameters
Hydrogen 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
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Hydro Treatment Operating Parameters
LHSV
• 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.
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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
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HydroTreatment Operating Parameters
Temperature
Temperature Limit for Hydrogenation of Aromatics
% aromatics in HDT product
Monoaromatics
Di aromatics
Poly Aromatics
250
300
400
350
(Gas oil – on NiMo/alumina, PH2=60bar)
Temperature (°C)
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HydroTreatment Operating Parameters
Temperature
Reactor inlet temp.
T
T
Bed
del T
T
Interbed
Quench
T
Rx Heater
o/l temp
Fuel
Reactor feed
Reactor product
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Reactor temperature
control: Factors:
Furnace outlet /
Reactor inlet
temperature
Bed delta T
Weighted
Average Bed
Temperature
(WABT / WART)
Inter-bed quench
HydroTreatment Operating Parameters
Temperature
Reactor temperature control
Weighted Average Bed Temperature (WABT / WART)
Convenient single point target parameter
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HydroTreatment Operating Parameters
Temperature
• 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
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HydroTreatment Operating Parameters
Catalyst 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
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HydroTreatment Operating Parameters
ReCycle 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
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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
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HydroTreatment :Quality
Parameters
• Product compositional characteristics:
–
–
–
–
Sulfur content
Nitrogen content
Metal content
Aromatics content
Feed to HDW
• Other characteristics
– CCR
– Viscosity Index of finished Lube Base Oil
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