TATIPAKA MINI REFINERY A SUCCESS STORY
11 SUCCESSFUL YEARS YEA RS
MINI-REFINERY - CONCEPT
Development of Marginal fields as they have less life-time.
To reduce transportation cost of oil from remote or Inaccessible locations.
To reduce transportation cost of refined products .
Pay back period is low i.e. 3 to 5 years, instead of normal refinery average of 15 years.
No dependency on external source for refinery crude.
Transportation hazard is minimized due to proximity of source and processing facility.
Meets the need of the small consumers locally in the areas even without big infrastructure support
MINI-REFINERY - CONCEPT
Development of Marginal fields as they have less life-time.
To reduce transportation cost of oil from remote or Inaccessible locations.
To reduce transportation cost of refined products .
Pay back period is low i.e. 3 to 5 years, instead of normal refinery average of 15 years.
No dependency on external source for refinery crude.
Transportation hazard is minimized due to proximity of source and processing facility.
Meets the need of the small consumers locally in the areas even without big infrastructure support
MINI-REFINERY - Facts
100 Mini-refineries (0.03 to 1.0 MMTPA) around the world (mainly in USA, Australia, Russia) Only 2 Mini-refineries in India Re-locatable Skid mounted refinery with Erection time - 6 months to 18 months. Re-erection time can be as small as 60 days. Cold re-start re-start in less less than one hour and can be put in full operation. feed mix is possible to vary. vary.
NEED FOR THE REFINERY To avoid transportation of crude due to strikes or shutdown in HPCL VKSP refinery. To ensure uninterrupted supply of gas from Tatipaka GCS, in case of any interruption in transportation of oil. To minimize safety hazards involved in long distance transportation. To minimize pilpherages & transit loss of crude oil involved involv ed in long distance transportation To meet the internal HSD requirements of Rajahmundry and Karaikal assets.
Advantages in Processing our own crude
Savings of a huge hidden charges towards oil transportation cost up to Yanam, Pumping cost up to the cargo, cost of product insurance, transit losses, wharf age charges at loading & unloading points storage & handling losses at Yanam, cargo and Mumbai. All the refinery products are being handed over to OMC’s at Refinery gate only which will not attribute to any kind of product loss. Though Refinery is designed for four products Naptha , SKO, HSD and LSHS , we are producing six products from the those four trays, Naptha, SKO, HSD LSHS, HFHSD and MTO(LAWS). depending on the demand and supply of the products with in-house expertise. Self sufficiency for the requirement of internal consumption of HSD of all the Assets, RJY, KKL & EOA. No additional resources required like existing manpower, Air compressors, water source, power supply, Fire services, security and additional land etc. Best Utilization will reduce the operating cost of both the refineries.
TATIPAKA REFINERY DATE OF COMMISSIONING 3rd Sep 2001
REFINING CAPACITY NORMAL: 1500 BPD (186 TPD) MAX : 2000 BPD (250 TPD)
TATIPAKA REFINERY IS CERTIFIED FOR ISO-14001 (ENVIRONMENT) , ISO-9001 (QUALITY) AND OHSAS-18001 (SAFETY) SINCE 2002
ISO 9001
TATIPAKA COMPLEX
OHSAS 18001
ISO 14001
TATIPAKA REFINERY COST : 26.5 Crores
BASICENGG: IOGPT, MUMBAI
TATIPAKA MINI-REFINERY
PROJECT EXEC: NICCO / VENTECH
CONSLTAN T: PDIL, NOIDA PERIOD: 450 DAYS
REFINERY SCHEMATIC FLOW DIAGRAM
MAJOR EQUIPMENTS
DESALTER
HEAT EXCHANGERS SKID
PUMPS SKID
COLUMN SKID
FURNACE
CI / NH3 / DEMULSIFIER TANKS
BOILER – 2 NOS
DM WATER UNIT – 1 NOS
WATER TREATMENT PLANT – 1 NOS
COOLIN TOWER – 2 NOS
STORAGE TANKS – 8 NOS
LOADING GANTRY- 4 BAY
WEIGH BRIDGE – 1 NO
–
1 NO EACH
PROCESS DESCRIPTION
Crude oil is heated from 36°C to 135°C in first stage of preheating (through exchangers E-101, E-102, E-103 A/B) and then sent to de-salter where the water content from the crude is totally removed.
Desalted crude at 125°C is the heated up to 220°C in second stage of preheating (through E-104A/B, E-105 A/B, E-106) and then heated in a furnace up to 330°C.
The heated crude (partially vapourized) is fed into the atmospheric distillation column at a pressure of 0.8 atm where products NAPHTHA (140°C), SKO (180°C), HSD (240°C) and LSHS (300°C) get separated depending on their individual boiling points.
FEEDS AND PRODUCTS KSP(W)
TPK
GMAA
LINGALA 32% @140 C
15% @170 –210 C
CRUDE : CONDENSATE 75:25 CRUDE OIL @330 C (44th)
27% @240-280 C
NAPHTHA (11th)
SKO (22nd)
HSD (35th)
26% @300 C
LSHS (49th)
New Product Additions
HF-HSD
in 2005
By TEAM REFINERY
HFHSD Production
Normal HSD produced up to 2005-2006
Huge demand foreseen for HFHSD due to increased activity in EOA- Kakinada
Already normal HSD demand met for RJY and CAUVERY onshore rigs and production installations
Feasibility of HFHSD studied
HF HSD with Flash point above 66°C need to be produced.
HFHSD - MODIFICATIONS
HFHSD (HSD with flash point > 66 ºC) is planned to produce for meeting the requirement of EOA-KKD.
To cope with increased load of HFHSD production, Additional heat exchanger E-103B is provided in parellel.
New operating parameters Column Operating Parameters Location
Before
After
Units
Top Temp
102.1
105.1
o C
HN Draw
143.1
146.5
o C
SKO Draw
206.7
185
o C
HSD Draw
283.7
293.9
o C
Feed Temp
291.6
300.5
o C
Top Reflux
5626
5799
Kg/Hr
Kero Pump Around
8727
9196
Kg/Hr
HSD Pump Around
8432
6686
Kg/Hr
HFHSD Specifications Sl.No.
Characterisrics
1
Density @ 150C
2
Flash Point(PM), 0C
3
Pour Point, 0C Max.
4
Appearance
5
Kinematic Viscosity, cst
6
Sulphur, Total %by wt. max
Specifications
Method
Result
0.820 - 0.860
IP-160/87
0.8415
660C Min.
P-21
66
P-10
(+) 18
120C Winter
210C Summer Visual
Light Yellow colour
2.5 - 15.7
P-25
3.75
0.25
ASTM D 5453
0.01765
Requirement HFHSD for internal use Name of Asset
Present HSD Actual supply during requirement 2010 (203Days) of HSD
Remarks
Rajahmundry
30 KL/D
30 KL/D
100 % requirement met
Karaikal
21 KL/D
21 KL/D
100 % requirement met
Kakinada-EOA
20 KL/D
215 KL/D
195 KL/day requirement not met.
(Based on 6500 KL/month)
Total
71 KL/D
266 KL/D
Sho rtage o f HSD/HFHSD (195 KL/D ) i s b e i n g p r o p o s e d to m e et t h r o u g h Refinery exp ansio n Projec t & Exis ting (95KL /D + 24 KL/D = 119 KL/D) .
New Product Additions
MTO
in 2011
By TEAM REFINERY
Properties of MTO
Low odour solvent Fast setting power Good solvency power
Launching of New product Mineral Turpentine Oil (MTO)
•
No additives required No additional processing equipments required No additional manpower or processing shut down required during the change over of the product. No modification of the existing refinery or column internals required. No additional financial implications but it is a source of additional revenue. By replacing SKO with MTO product i.e. 37 TPD or 12210 Tons/annum SKO net realization Price = 22374 Rs/MT MTO net realization Price = 34936 Rs/MT Difference is 12562 Rs/MT X 12210 = 15.33 Cr (During previous quarter rates, it was worked out as 17.9 Cr) To reduce the demand of Naptha & increasing the yield of product MTO will increase the profitability of the refinery.
MTO - MINERAL TURPENTINE OIL
Change in Market Dynamics after supply of Reliance Gas motivated to diversify product line.
Present SKO production 15% of feed and it can be replaced with MTO to improve the refinery profit margins.
MTO is an intermediate product between SKO & Naphtha.
MTO produced on Experimental basis in July, 2010 and 1 st tanker flagged off on 12.04.11
If Need arises, the product MTO can be interchanged with SKO as per market demand without any changes in the plant.
Applications of MTO
Adhesive industries Paint and resin industries Thinner industries Agro-chemicals,households' insecticides, fungicides industries. Paint catalysts, driers, coating and industries Textiles, cloth, paper, printing-processing industries Degreasing and cleaning purpose in machineries, machine spares manufacturing industries
FEEDS AND PRODUCTS Fuel&loss (1.5%) KSP(W) / GOPAVARAM OIL
LINGALA/ MALLESWARAM
NAPHTHA
CONDENSATE
NAPHTHA TPK
ADVP/PON CONDENSATE
CONDENSATE
32% @80T(110KL)
SKO
MTO
15% @38T(49KL)
SKO CRUDE : CONDENSATE 75:25 CRUDE OIL @250T(304KL)
HSD 27% @68T(82KL)
HSD
LSHS 25% @63T(72KL)
YEILD PATTERN OF THE REFINERY PRODUCT
Refinery Yield
Refinery Yield (Revised)
Production@ 250 TPD
Remarks
TPD (KL /D)
NAPTHA
34%
29%
72 (98)
Low marketable product
15%
15%
37 (47)
Low Profitable product-SKO
22%
31%
78 (95)
Highly product
28%
24%
60 (68)
Low marketable product
99%
99%
247(308)
(0.733)
SKO/MTO (0.7828)
HSD / HFHSD (0.825)
LSHS (0.88)
TOTAL
Profitable
1 – 1.5% Fuel loss
Although Tatipaka Refinery is designed and constructed for producing four products Naptha , SKO, HSD and LSHS , Through our in-house expertise we are producing six products from the those four trays only Naptha, SKO, MTO (LAWS), HSD, HFHSD and
Performance at a Glance VAP Year
Production (MT)
%Capacity Utilization
Revenue Earned (Cr.)
Profit Earned (Cr.)
2002 – 03
91464
139 %
97.48
42.36
2003 – 04
90368
137%
95.15
36.20
2004 – 05
91577
139%
130.15
55.22
2005 – 06
92080
140%
164.80
77.61
2006 – 07
92947
141%
156.13
55.94
2007 – 08
61707
94%
121.83
32.28
2008 - 09
82340
125%
186.90
55.28
2009 –10
54442
82.5%
95.41
20.62
2010-11
68789
103%
148.18
62.78
50959
103%
90
36
2011-12 (Apr-Sep)
SPECIFICATIONS FOR NAPHTHA Sl.No.
1
Characterisrics
Specific Gravity@60/600F
Specifications
Method of Test ref. IS:1448
To be reported
Distillation 2
a. IBP, 0C
25 (Min.)
b. FBP, 0C
204(Max.)
3
Reid Vapour Pressure ,Kg/cm 2
0.7(Max.)
4
Non Volatile Matter, mg/100ml
5.0(Max.)
5
RCR, % by Mass
0.2(Max.)
6
C/H Ratio(Calculation)
To be reported
7
Net Calorific Value,Kcal/Kg
To be reported
P-18
P-39
P-8
P-7
SPECFICATIONS OF KEROSENE IS:1459-1974 Characteristics i)
Method Of Test, ref to
(P:) of IS:1448
NIL
P:2
ii) BURNING QUALITY: a) Char Value, mg/kg of oil consumed, Max b) Bloom on Glass Chimney
20 Not Darker Than Grey
P:5
iii) Color a) Saybolt,Min (in case of Undyed Kerosene ) b) Visual (in case of Dyed Kerosene)
10 10 Blue
P:14 P:14 -
iv) Copper Strip Corrosion for 3 hrs. at 500C
Not Worse than No. 1
P:15
v)
Acidity, Inorganic
Specifications
Distillation: a) Percent Recovered Below 200 0C, Min b) Final Boiling Point, degC, Max
P:18 20 300
vi) Flash Point (Abel), degC, Min
35
P:20
vii) Smoke Point, mm, Min
18
P:31
viii) Total Sulfur, Percent by Mass, Max
0.25
P:34
SPECIFICATIONS FOR HSD IS : 1460-2005 Sl. No
CHARACTERISTICS
1
Acidity, Inorganic
2
Acidity total, mg KOH/g
3
Ash,% by mass
4
Carbon Residue(Ramsbottom) on 10% residue, % by mass
SPECIFICATIONS
Method of Test ref. IS:1448
Nil
P-2
To be reported, Not limited
P-2
0.01 Max
P-4
0.3 Max
P-8
5
Cetane Number
51 Min
P-9
6
Calculated Cetane Index
46 Min
ASTM D 4737
7 8 9
Pour Point, C
Winter
3 Max
Summer
15 Max
Copper strip corrosion, for 3 hrs @ 100 C
Not worse than No.1
Distillation, % v/v Recovered
P-10 P-15 P-18
Recovery at 360 C
95 Min
10
Flash Point-Abel, C
35 Min
P-20
11
Kinematic Viscocity @ 40 C , cSt
2.0 to 4.5
P-25
12
Total Contamination, mg/kg
24 Max
EN 12662
13
Density at 15 C, kg/m³
820-845
P-16
14
Total Sulphur, mg/kg
350 Max
ASTM D 4294
15
Water Content, mg/kg
200 Max
ISO 12937
16
Cold Filter Plugging Point (CPFF), C
Winter
6 Max
Summer
18 Max
P-110
SPECIFICATIONS FOR LSHS IS:1593-1982 REQUIREMENTS FOR
CHARACTERISTICS
Method Of
Grade LV
Grade MV1
Grade MV2
Grade HV
Test, ref to (P: ) of IS:1448
Nil
Nil
Nil
Nil
P:2
ii) Ash, Percent by mass, Max
0.1
0.1
0.1
0.1
P:4
iii) Gross, Calorific Value
Not limited, but to be reported
P:6 & P:7
iv) Relative Density at 15/15 degC
Not limited, but to be reported
P:16 or P:32
v) Flash Point, [Pensky Martin,(closed)] degC, Min
66degC
66degC
66degC
66degC
P:21
vi) Kinematic Viscosity, cSt, at 50degC, Max Above Upto
80, max
80 125
125 180
180 370
P:25
vii) Sediment, Percent by mass, Max
0.25
0.25
0.25
0.25
P:30
viii) Sulfur,Total, Percent by Mass,Max
3.5
4.0
4.0
4.5
P:33
ix) Water Content, Percent by volume, Max
1.0
1.0
1.0
1.0
P:40
i)
Acidity, Inorganic
SPECIFICATIONS FOR MTO IS:1745-1978 SL.No.
CHARACTERISTICS
1.
COLOUR SAYBOLT, Min.
2.
COLOR(ASTM), Max.
3.
Density at 150C, g/ml
4.
FLASH POINT(ABEL), 0C Min.
5.
DISTILLATION RANGE a) IBP, 0C Min.
6.
SOLVENT
SOLVENT
METHOD OF
(125/240)
(140/205)
TEST REF 1S:1448
+21
+20
P:14
-
-
P:12
To be reported (not limited) 30
35
125
145
b) 50% by vol. recovered at, 0C
To be reported (not limited)
c) 95% by vol. recovered at, 0C
To be reported (not limited)
P:16 P:20
P:18
d) FBP, 0C Max.
240
205
AROMATIC CONTENT, %VOL
40
40
P:23 OR P:48
-
-
P:34 OR P:83
Max. 7.
TOTAL SULPHUR, % Wt. Max.
8.
Cu STRIP CORROSION
for 3 Hrs. at 500C 9.
NOT WORSE THAN No.1
P:15
RESIDUE ON EVAPORATION mg / 100 ml Max.
5
5
P:29(AIR JET)
Naphtha Test Report at Refinery Sl.No. 1
Characteristics Specific Gravity@60/600F
Specifications
Method ref to IS:1448
Results 0.7268
To be reported
Distillation 2
a. IBP, 0C
25 (Min.)
b. FBP, 0C
204(Max.)
3
Reid Vapour Pressure , Kg/cm2
0.7(Max.)
4
Non Volatile Matter, mg/100ml
5.0(Max.)
5
RCR, % by Mass
0.2(Max.)
6
C/H Ratio (Calculation)
7
Net Calorific Value, Kcal/Kg To be reported
P-18
42 152
P-39
0.50
2.30
P-8
To be reported
0.070 5.62
P-7
10529
SKO Test Report at Refinery Sl.No
Characterisrics
1
Density @ 150C
2
Flash Point(Abel), 0C
Manufacturer spec
Method
Result
To be reported To be reported
IP-160/87
0.7974
IS 1448, P-20
38
Specification 350C Min.
380C Min.
20 Min.
20 Min.
Distillation 3
a. Recovery below 2000C
IS 1448, P-18
b. IBP, 0C
4 5 6
c. FBP, 0C Acidity Inorganic,mg KOH/g
73 155
300 Max.
290 Max.
Nil
Nil
Smoke Point, mm 18 Min. 19 Min. Copper Strip Corrosion@ Not worse than Not worse than 500C/3Hrs 1 1
236
IS 1448, P-2
0
IS 1448, P-31
22
IS 1448, P-15
Better than 1a
7
Colour saybolt
+10
+10
IS 1448, P-14
+10
8
Sulphur , total, % by Wt
0.25
0.25
ASTM D 5453
0.0072
9
BURNING QUALITY Max 20
Max 20
A) Char value, mg/Kg
IS 1448, P-5
B) Bloom on Chimney, Predominating colour
14.80
Not darker than grey
Not darker than grey
Not darker than grey
MTO Test Report at Refinery Sl.No.
Characterisrics
1
COLOUR (SAYBOLT) Min
2
DENSITY AT 15 0 C,g/ml
3
FLASH POINT (ABEL),0 C Min
4 5
DISTILLATION RANGE a) IBP,Min
6
b) 50% by vol recovered at, 0C
7
c) 95% by vol recovered at, 0C 0
8
d) FBP, Max, C
9
TOTAL SULPHUR, Max %Wt
10
Cu S.C.FOR 3 Hrs AT 50 0C
11
ROE,mg/100 ml,Max
METHOD OF TEST
RESULT
(+)21 TO BE REPORTED,NOT LIMITED
P:14
(+)21
P:16
0.7909
30
P:20
38
MTO 125/240
125 TO BE REPORTED,NOT LIMITED TO BE REPORTED,NOT LIMITED 240
149
P:18
175
208 222
ASTM D 5453
0.0036
NOT WORSE THAN 1
P:15
No.1
5
P:29 (AIR JET)
0.8
LSHS Test Report at Refinery Sl.No .
Characterisrics
Specifications
Method
Result
1
Density @ 150C
2
Flash Point(PM), 0C
66 Min.
P-21
68
3
Pour Point, 0C
60 Max.
P-10
42
4
Water Content, % V/V
1.0 Max.
P-40
<0.05
5
Gross Calorific Value, To be reported Kcal/Kg
P-7
10750
To be reported IP-160/87
0.8864
Dynamic Feed Mix Change
Poor upliftment of Naphtha and LSHS forced experiment various crude mix
Originally designed to process Crude condensate mix (Kesanapalli)
Availability of various crudes like Gopavaram and Lingala allowed to make changes in the feed mix therby producting products as per usage. FEED MIX
PRODUCT MIX
TATIPAKA REFINERY MARKETING TIE UPs
NAPHTHA APCL, VIZAG
NAPHTHA
EMERALD PETROCHEM LTD Nagpur
PRICE @ RTP per MT
LSHS ESSAR STEEL, VIZAG
LSHS
ITC, BANGALORE
PRICE @ RTP MoU SIGNED FOR 2 YEARS
HSD KG ONSHORE KKL ONSHORE
HSD GOKAVARAM TERMINAL
HFHSD
KKD OFFSHORE
HUGE SAVINGS TO ONGC AS TOTAL HSD REQUIREMENT FOR KG AND KKL ONSHORE & PARTIAL KKD REQUIREMENT MET
SKO / MTO
SKO PDS KEROSENE
MTO
Solvents / Paint industry
Naptha Upliftment of M/s. HPCl from Tatipaka Refinery
Rejuvenation of Refinery Operations
During 2011, RJY Asset has made efforts to improve the upliftment of Naphtha. At this juncture HPCL has agreed to lift sufficient quantity of Naphtha and LSHS on day to day basis and requested ONGC, to purchase of lubes from M/s HPCL. RJY Asset had agreed and accordingly a proposal was sent to Head quarters on “win-win situation ” strategy. This effort has resulted in achieving VAP production targets and efficiency of the plant is increased from 82.5%(2010) to 102.7% (2011)
Later to improve the profitability of Refinery though the VAP upliftment reduced by M/s HPCL MTO is being produced in place of the SKO.
During the less off take of the Naptha crude from Gopavaram is processed and less off take of the LSHS more KSP crude is processed.
Awards and Accolades GROUP AWARD FROM DIRECTOR(ONSHORE) FOR COMMISIONING REFINERY- 2002 GREEN TECH ENVIRONMENT EXCELLENCE SILVER 2003-04 & 2004-05 GREEN TECH SAFETY – SILVER 2003-04 & 2004-05 CERTIFICATE OF APPRECIATION FROM NATIONAL SAFETY COUNCIL, AP CHAPTER - 2005 THE HIGH TECHNICAL AUDIT RATED AWARD FROM DIRECTOR (T&FS) 2008-09 C&MD INNOVATION GROUP AWARD FOR NEW PRODUCT MTO 2011 GREEN TECH ENVIRONMENT EXCELLENCE - GOLD 2006, 2011 BEST ONSHORE INSTALLATION AWARD 2011 (All over ONGC) BEST FIRE SUB-STATION 2011-12