Presentation on Strategy of Octane Management at IOCL – Mathura ...

IOCL – Mathura Mathura Refinery
Refinery
<strong>Presentation</strong>
on
Strategy of Octane Management at IOCL – Mathura Refinery
New Delhi, 16 th – 17 th April’ 12

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.
Agenda
IOCL – Mathura Refinery 2

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

Base Case:
Importance of RON on Refinery Profitability:
Mass Flow RON Olefins Aromatics Benzene Sulfur
TMT % % % ppm
Light Isomerate 27.62 88.0 0 0.1 0 0
Heavy Isomerate 3.07 80.0 0 0.1 0 0
Heavy Reformate 36.56 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 0.35 57.0 1 8 2 90
TMT/Month 103.8 91.6 16.6 29.9 0.8 32.4
Case-I: RON of Reformate Reduced by 1 Number
Mass Flow RON Olefins Aromatics Benzene Sulfur
TMT % % % ppm
Light Isomerate 27.62 88.0 0 0.1 0 0
Heavy Isomerate 3.07 80.0 0 0.1 0 0
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
SRN 0.35 57.0 1 8 2 90
TMT/Month 102.1 91.6 16.9 30.3 0.8 32.9
IOCL – Mathura Refinery 5
104.0
103.5
103.0
102.5
102.0
101.5
101.0
103.8
102.1
Base Case Case-I
Monthly MS Production (Thousand MT)
Decrease of 1 RON of reformate – Decrease in MS Production by 1.8 TMT.

Base Case:
Importance of RON on Refinery Profitability:
Mass Flow RON Olefins Aromatics Benzene Sulfur
TMT % % % ppm
Light Isomerate 27.62 88.0 0 0.1 0 0
Heavy Isomerate 3.07 80.0 0 0.1 0 0
Heavy Reformate 36.56 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 0.35 57.0 1 8 2 90
TMT/Month 103.8 91.6 16.6 29.9 0.8 32.4
Case-II: RON of FCC Gasoline Reduced by 1 Number
Mass Flow RON Olefins Aromatics Benzene Sulfur
TMT % % % ppm
Light Isomerate 27.62 88.0 0 0.1 0 0
Heavy Isomerate 3.07 80.0 0 0.1 0 0
Heavy Reformate 36.56 99.5 1 80 1.8 0
FCC Gasoline 33.19 89.5 50 12.5 0.5 100
OHCU LN 1.51 70.0 1 8 0.8 5
SRN 0.35 57.0 1 8 2 90
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
104.0
103.5
103.0
102.5
102.0
101.5
103.8
102.3
Base Case Case-II
Monthly MS Production (Thousand MT)

Base Case:
Importance of RON on Refinery Profitability:
Mass Flow RON Olefins Aromatics Benzene Sulfur
TMT % % % ppm
Light Isomerate 27.62 88.0 0 0.1 0 0
Heavy Isomerate 3.07 80.0 0 0.1 0 0
Heavy Reformate 36.56 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 0.35 57.0 1 8 2 90
TMT/Month 103.8 91.6 16.6 29.9 0.8 32.4
Case-II: RON of Isomerate reduced by 1 Number
Mass Flow RON Olefins Aromatics Benzene Sulfur
TMT % % % ppm
Light Isomerate 27.62 87.0 0 0.1 0 0
Heavy Isomerate 3.07 80.0 0 0.1 0 0
Heavy Reformate 36.56 99.5 1 80 1.8 0
FCC Gasoline 33.19 89.5 50 12.5 0.5 100
OHCU LN 1.76 70.0 1 8 0.8 5
SRN 0.35 57.0 1 8 2 90
TMT/Month 102.6 91.6 16.8 30.2 0.8 32.8
Decrease of 1 RON of Isomerate – Decrease in MS Production by 1.3 TMT.
IOCL – Mathura Refinery 7
104.0
103.5
103.0
102.5
102.0
101.5
103.8
102.6
Base Case Case-II
Monthly MS Production (Thousand MT)

Challenge:
Increasing High Sulfur Crude basket.
Decreasing N+2A.
Decreasing RON of Reformate.
Challenges & Opportunity:
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

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

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
Heart Cut
Isomerate
Yield: 87 %
RON: 87
Treated Gasoline
Yield: 99 %
RON: 89-90
MS Pool
IOCL – Mathura Refinery 10

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

Optimization of FCC Gasoline: Case Study-I
BASE CASE: All Heart Cut routed to Isomerisation
Monthly
Production RON Olefins Aromatics Benzene Sulfur
TMT % % % ppm
Light Isomerate 27.62 88.0 0 0.1 0 0
Heavy Isomerate 3.07 80.0 0 0.1 0 0
Heavy Reformate 36.56 99.5 1 80 1.8 0
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
SRN 0.35 57.0 1 8 2 90
TMT/Month 103.8 91.6 16.6 29.9 0.8 32.4
CASE-I: 75% of Heart Cut routed to Isomerisation Benefits:
Monthly
Production RON Olefins Aromatics Benzene Sulfur
TMT % % % ppm
Light Isomerate 27.62 88.0 0 0.1 0 0
Heavy Isomerate 3.07 80.0 0 0.1 0 0
Heavy Reformate 36.56 99.5 1 80 1.8 0
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
TMT/Month 105.9 91.6 17.3 29.5 0.8 33.7
• MS Production increase by 2.1 TMT/Month.
Constrains:
• RON of MS Pool.
• Temperature exotherm in HDS Reactor.
IOCL – Mathura Refinery 12
106.5
106
105.5
105
104.5
104
103.5
103
102.5
103.8
105.9
Base Case Case-I
Monthly MS Production (Thousand MT)

Optimization of FCC Gasoline: Case Study-II
BASE CASE: All Heart Cut routed to Isomerisation
Monthly
Production RON Olefins Aromatics Benzene Sulfur
TMT % % % ppm
Light Isomerate 27.62 88.0 0 0.1 0 0
Heavy Isomerate 3.07 80.0 0 0.1 0 0
Heavy Reformate 36.56 99.5 1 80 1.8 0
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
SRN 0.35 57.0 1 8 2 90
TMT/Month 103.8 91.6 16.6 29.9 0.8 32.4
CASE-II: 75 % of Heart Cut routed to MS Pool Benefits:
Monthly
Production RON Olefins Aromatics Benzene Sulfur
TMT % % % ppm
Light Isomerate 27.62 88.0 0 0.1 0 0
Heavy Isomerate 3.07 80.0 0 0.1 0 0
Heavy Reformate 36.56 99.5 1 80 1.8 0
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
SRN 0.35 57.0 1 8 2 90
TMT/Month 110.0 91.6 19.0 28.9 0.9 37.9
• MS Production increase by 6.2 TMT/Month.
Constrains:
• Benzene in MS Pool.
• Olefins & Sulfur in MS Pool.
IOCL – Mathura Refinery 13
112
110
108
106
104
102
100
103.8
110.0
Base Case Case-II
Monthly MS Production (Thousand MT)

Light
Naphtha
Heart Cut
NHDT
Isomerisation Unit
Isomerisation Reactors
Light Isomerate
IOCL – Mathura Refinery 14
DIH
Side Cut
Recycle
Heavy Isomerate
Total 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
Optimization of Isomerate:
Heavy Isomerate:
Rich in C 6 & C 7 components.
Good Reformer Feed.
CATALYTIC REFORMER
Total Isomerate:
RON: 87
RON: 82 RON: 98
Reformate
IOCL – Mathura Refinery 15

Optimization of Isomerate – Case Study
BASE CASE: Heavy Isomerate Routed to MS Pool
Mass Flow RON Olefins Aromatics Benzene Sulfur
TMT % % % ppm
Light Isomerate 27.62 88.0 0 0.1 0 0
Heavy Isomerate 3.07 80.0 0 0.1 0 0
Heavy Reformate 36.56 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 0.35 57.0 1 8 2 90
TMT/Month 103.8 91.6 16.6 29.9 0.8 32.4
CASE-I: Heavy Isomerate Routed to Reformate
Mass Flow RON Olefins Aromatics Benzene Sulfur
TMT % % % ppm
Light Isomerate 27.62 88.0 0 0.1 0 0
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
TMT/Month 104.7 91.6 16.6 31.6 0.8 33.3
Benefits:
• MS Production increase by 0.9 TMT/Month.
Constrains:
• Capacity utilization of reformer.
• Double processing of a single stream.
IOCL – Mathura Refinery 16
105
104.5
104
103.5
103
103.8
104.7
Base Case Case-I
Monthly MS Production (Thousand MT)

MS Production can be maximized by:
Conclusion
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

THANK YOU
IOCL – Mathura Refinery 18