Issue 1 | July 2022

Centre For High Technology

Ministry of Petroleum & Natural Gas
Government of India

OIL AND GAS

TECHNICAL JOURNAL

Ministry of Petroleum and Natural Gas

Government of India
 Centre For High Technology
M in is t r y o f P e tro le u m & N atu ral G as
G o v e rn m e n t o f India
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Foreword

It is great pleasure for me to hand out first edition of Oil & Gas
Technical Journal, which will be released henceforth annually by
CHT.

The refining industry is currently passing through a very challenging

phase due to crude oil price volatility and issue of sustainability
in the long term arising from impending shift in demand pattern.
Although, demand of transport liquid fuels may see some declining
trend worldwide due to substitution by EVs, Green Hydrogen, gas
and renewable, demand of petroleum fuels will continue to grow in
India in near future due to rapid urbanisation and industrialisation.
Therefore, refineries need to expand to meet the growing demand as
well as be able to foresee the emerging technologies and act proactively to align with changing
energy landscape. To remain competitive and be able to sustain pressure on margins, refinery
also need to continue to invest in operational improvements, energy efficiency and integrate with
petrochemicals and biorefining. Sustainable economic development requires more than simply
"opening up" and waiting for new technologies to flow in. It demands continuous technological
effort by domestic enterprises, along with supportive government policies.

India at COP 26 held in Glasgow made very significant announcement of achieving target of 500
GW renewable energy by 2030; 50 % of installed capacity of electricity from renewable sources
and reduction of emission intensity by 45% by 2030 over 2005 level and net zero by 2070. India
also aspires to be energy independent by the year 2047. Govt. has also announced the National
Hydrogen Mission and biofuels policy with the ambition to boost growth of green hydrogen
and biofuels in India to work towards being energy independent.

As a prelude to the above pronouncements, India announced the first part of the National
Green Hydrogen policy on 17th February,2022. The policy is pathbreaking and paves the way for
meeting the target of production of 5 million tonnes of Green hydrogen by 2030 and the related
development of renewable energy capacity.

Govt has taken several steps to incentivize promotion of Green fuels. Govt. has targeted
blending of 20% ethanol in Petrol by 2025 and 5% biodiesel in diesel by 2030. In order to augment
availability of biofuels, Govt. is promoting 2G ethanol as well as setting up of 5000 plants for
production of 15 TMT of CBG.

In today's world, knowledge is treated as the key to success. Knowledge might be power, but it is
much more powerful when it is shared. Information is really just the data or details of something,
but knowledge taps into the experience and context of somebody who has understood and
used that data. Some people believe that it is good to share as much information as possible
in scientific research, business and the academic world. Others believe that some information
is too important or too valuable to be shared freely and it is better to keep the information
confidential. Some organizations try to conceal information because they believe they have
invested in resources to research in a specific direction and they should receive the advantage
of their investment.

Oil & Gas Technical Journal -1 3

 In reference to modern data sharing, open science, open data and open access movement are
also steadily growing in recognition. Most people would probably agree without hesitation that
data sharing and the communication of scientific findings, technical expertise and knowledge
has brought humanity where it is now, and still is one of the cornerstones of modern civilization.
Thus, the publication of scientific data is an essential necessity.

With the objective to boost productivity, cut down on repeat mistakes, and to build on other
experience, this is a humble beginning to get the latest technological advancements in the
refining and Petrochemicals field and make it accessible to others.

This edition has been possible due to overwhelming response and contribution by the individuals
and organisations. I hope this journal will help all stakeholders connected with energy sector
both in public and private sector to remain abreast with the latest technological developments
and formulate their strategies and action plans.

(Alok Sharma)
Executive Director

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Editorial Board

Editor in chief & Executive Director

Shri Alok Sharma

Members

Shri Brijesh Kumar

Advisor (Tech.), CHT

Shri Satya Prakash

Advisor (Tech.), CHT

Smt. Renu Raina

Additional Director, CHT

Shri Balayogi Nathi

Joint Director, CHT

Shri Rajan Kumar

Joint Director, CHT

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Email: [email protected] Website: www.cht.gov.in

Note:
No part of this journal shall be reproduced in whole or in part by any means without permission from CHT.
The views expressed by various authors and the information provided by them are solely from their sources.
The publishers and editors are in no way responsible for these views and may not necessarily subscribe to
these views.

Oil & Gas Technical Journal -1 5

 TABLE OF CONTENTS

HT*f=
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Part-1 Petrochemicals
1.1 Propylene Derivative Petrochemical Project 11
Commissioning Experience
- Bharat Petroleum Corporation Limited
1.2 Indian Insight on Crude Oil-to-Chemicals (COTC): 17
Future of Refining
- Indian Oil Corporation Limited
1.3 Refineries of the Future Producing Petrochemicals 29
- Honeywell UOP

Innovations in Refining
2.1 De-bottlenecking of Crude and Vacuum 37
Distillation Unit to improve productivity
- Engineers India Limited
2.2 Reconfiguration of Naphtha Splitters Using 43
Divided Wall Column
- Bharat Petroleum Corporation Limited
2.3 Commercial Demonstration of [HP]2 Catalyst: 49
A Multispecialty Catalyst Formulation for
Maximizing FCC Products Yield
- Hindustan Petroleum Corporation Limited
2.4 HPCL's Pressure drop mitigation technique for 53

O
Naphtha Hydrotreaters
- Hindustan Petroleum Corporation Limited
2.5 Potential Technologies for Benzene Recovery 57
from FCC Gasoline

o Part 3
- Indian Institute o f Petroleum

Energy Efficiency Improvement

3.1 Maximize Fired Heater Efficiency 65
- Engineers India Limited
3.2 Energy efficiency improvement through APC 79
- Bharat Petroleum Corporation Limited
3.3 Energy efficiency Improvement in Crude & 87
Vacuum Distillation unit targeting emissions
- Engineers India Limited
Part-4 Alternate Energy, Carbon
Sequestration & Environment
4.1 C 02 EOR as a Possible Carbon Sequestration 95
Tool in a Matured Reservoir: Pilot Design
based on simulation
- Oil India Lim ited
4.2 GREEN HYDROGEN- The New Energy Vector 107
- IndianOil Corporation Limited
4.3 Review of Rest Available Blue Hydrogen Technologies 115
- Haldor Topsoe
4.4 A Vision for Transforming Carbon & Creating Value 123
- LanzaTech Private Limited

P art-5 Operations - Troubleshooting

5.1 Hazards and Safety of Fired Heater system 131
- Engineers India Limited
5.2 Improvement in pressure control of CDU-4 141
Stabilizer column by in-house developed
Auto-Tuning Method- BPCL Kochi Refinery
- Bharat Petroleum Corporation Limited
5.3 Averting Unplanned Shutdowns during Utility 149
pipeline ruptures- Line Stop technique
application at Refinery
- Mangalore Refinery & Petrochemicals Limited
1
Part-1
Petrochemicals
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1.1 Propylene Derivative Petrochemical Project Commissioning Experience

Authors: Nair Sashi V.C, Velampudi Anuroop, Nishant Choubey, Subbarao Vemuri, Hariprasad K R
BPCL Kochi Refinery

Mr. Nair Sashi V.Chandrashekar is working as Senior Manager in Bharat Petroleum Corporation Ltd-
Kochi Refinery. He is Chemical Engineer & MBA with more than 25 years of experience in Process/
Operations/Projects including commissioning experience in Refining and niche Petrochemicals.

J
r
Mr. Velampudi Anuroop is working as Petchem Manager in Bharat Petroleum Corporation
Ltd- Kochi Refinery. He is Chemical Engineer having 10 years of experience, involved in
Commissioning, operations and stabilization of petrochemical units. Experienced in Ammonia
manufacturing, Ethylene cracker, Acrylic Acid manufacturing and Tank farm operations.

Mr. Nishant Choubey is working as Petchem Manager in Bharat Petroleum Corporation Ltd- Kochi
Refinery. A Chemical Engineer with 9 years of experience in Operations and Commissioning in
refinery and petrochemical. Experienced in Hydrogen, Diesel Hydro Desulphurization unit, Sulphur
Recovery Unit and Oxo Alcohol Unit.

J
r
Mr. Hariprasad K R is working as Petchem Manager in Bharat Petroleum Corporation Ltd- Kochi
Refinery. A Chemical Engineer with 10 years of experience in Operations/ Technical services
and Commissioning departments in fuels refinery and petrochemical divisions of BPCL.
Experienced in Petro-FCCU, Merox, Biturox, Acrylates and Tank farm operations.

Vi

1.1.1 Abstract of Petrochemicals producing both Commodity

and Niche derivatives.
Considering disruption in alternate energy
sources, advent of electric vehicles and BPCL group refinery Kochi Refinery (KR)
change in consumer mobility pattern, a commissioned a Petro FCC (as a part of
substantial reduction in fuels demand growth Integrated Refinery Expansion Project) to
rate is expected. In order to overcome this produce 500 KTA of Propylene which needs
predicted threat, fulfil the BPCL aspirations to be valorized to Petro chemicals. PDPP was
& de-risk its business, BPCL group refineries envisaged to utilize 250 KTA of Propylene to
had undertaken visioning exercises and produce niche petrochemicals Acrylic acid, Oxo
identified key focus area towards production alcohol and Acrylates.

Oil & Gas Technical Journal -1 11

 PDPP project was mechanically completed and as a strategy BPCL group refinery future
commissioning activities were in progress.. expansions are oriented towards production
However, the covid pandemic disruption of Petrochemicals producing both Commodity
affected the project in a major way and affected and Niche derivatives.
the travel of foreign licensors to project site for
supervising the commissioning activities. BPCL 1.1.3 Propylene Derivatives Petrochemical
had to adopt innovative processes to engage the Project (PDPP)
process licensors, who agreed to provide round
the clock remote support if BPCL shares the Prior to PDPP BPCL group refineries produced
DCS screens. BPCL established remote devices Benzene, Toluene & Poly Propylene Feed Stock
such as helmet mounted cameras, intrinsically (as petrochemicals) at its Mumbai & Kochi
safe mobile phones, and web interface for DCS refineries with a typical production of about 243
screen sharing with dedicated Wi-Fi system. kilo tons per annum (KTA). BPCL group refinery
The aforesaid innovative approach with the Kochi Refinery (KR) commissioned a Petro FCC
support of Schneider electric, resulted in safe (as a part of Integrated Refinery Expansion
commissioning of all the three units of PDPP Project) to produce 500 KTA of Propylene which
complex. needs to be valorized to Petro chemicals. PDPP
was envisaged to utilize 250 KTA of Propylene
1.1.2 Introduction to produce niche petrochemicals Acrylic acid,
Oxo alcohol and Acrylates as under:
BPCL group refineries have an installed
crude processing capacity of 38.3 MMTPA Product Saleable Annual
post implementation of approved projects. Quantity (KTA)
Prior to entry into the field of petrochemicals,
Acrylic acid 47
BPCL group refineries configuration was
predominantly skewed towards transportation Butyl Acrylate 180
fuels. However considering disruption in 2 Ethyl Hexyl Acrylate 10
alternate energy sources, advent of electric Normal Butanol 38
vehicles and change in consumer mobility
pattern, a substantial reduction in the growth 2 Ethyl Hexanol 47
rate of fuels demand is expected in the future. Iso Butanol 7
In order to overcome this predicted threat, fulfil
the BPCL aspirations & de-risk its business, The typical end uses of PDPP petrochemical
BPCL group refineries had undertaken visioning products are as below:
exercises and identified key focus area as
diversification into Petrochemicals, in future. Products Typical End Use
Acrylic Acid Detergents, pulp & paper,
World over petrochemicals consumption textiles, surface coatings
is benchmarked in terms of per capita and water treatment
consumption of polymer. India's per capita
Butyl Acrylate Paints and coatings, Resins,
polymer consumption of ~ 8.0 - 10 kg, is
2-Ethyl Hexyl Adhesives, Dispersions,
far below the world average of about 35 kg,
Acrylate Printing inks, Sealants,
USA's 90 kg and China's 46 kg giving enough
Pressure sensitive tapes
indication of potential growth of Petrochemical
industry. Also, a committee constituted by N-Butanol Plasticizers, Solvent, Paints
Ministry on India's Petro Chemical Vision I-Butanol and Coatings, Adhesives
2030 envisages investments to the order of 2-Ethyl Hexanol
USD 40 - 60 billion to meet growing Petro
chemicals demand in India. Based on relatively
1.1.4 Project Details
robust growth rates and current low levels of
consumption, petrochemicals would provide
PDPP was implemented at a project cost
an alternate hedge for Indian Refineries. Hence
of approx. Rs. 6200 crore. Technology was

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sourced from reputed international licensors Challenges encountered during

after a detailed two stage search process implementation:
consisting of Expression of Interest (EOI)
followed by tendering activity. • Unfamiliar nature of Niche/Specialty petrochemical
project for BPCL and EIL (p M c) - First such project
Engineers India Ltd (EIL) were appointed as in India.
the Project Management Consultant (PMC). • Process related aspects related to polymerization
Environmental clearance was accorded to the tendency.
project by Ministry of Environment (MoEF) on
15 May, 2015. Synthesis gas and Hydrogen Procurement related:
feedstock required for the project is being
• Long lead time for delivery of critical items like
supplied on Build Own Operate (BOO) basis by
Acrylic Acid Reactor, Refrigeration System, and
Prod Air products India Ltd.
Incinerator etc.
Acrylic acid and Acrylates unit are the units • Limited number of vendors.
being set up first time in the country. Oxo • Specialized nature/metallurgy of equipment.
alcohol, capacity is world scale catering to
internal Acrylates consumption and merchant 1.15 Alternative to conventional way of
sales. The block diagram of the complex is commissioning
shown below (qty in 1000 tons).
PDPP project was mechanically complete and
Technology characteristics: commissioning activities were in progress
during the Feb-Mar 2020 period. However the
• Closely guarded technology. Covid pandemic disruption affected the project
• Limited number of producers/technology licensors in a major way. Many commissioning experts
(Foreign nationals) from the side of Process
• High capital investment for relatively smaller
licensors and equipment vendors had been
capacity.
mobilized at site during February and March
• Limited number of operating plants for some 2020 and were engaged in commissioning
technologies. activities of equipment and units. During
March 2020, when lockdown was declared,
borders closed and only staff identified as

Oil & Gas Technical Journal -1 13

 essential were allowed to travel and work footage of plant activities with helmet mounted
on-site, others worked remotely, where ever cameras. The "New Normal" conditions also
possible. This sudden change necessitated made categorization of activities by rendering
relook at work-practices concerning working higher priority to core activities necessary for
conditions, employee engagement & training, bringing the new units online safely.
efficiency enhancement and communication,
without compromising on safety. Most of the With the assistance of Schneider electric,
site mobilized licensors left the site during a Secure Gateway was established in the
second half of March 2020 owing to the spread communication server system that acts as
of COVID 19 pandemic across the globe. After a conduit between users in remote locations
several follow ups with ministry, permissions and In Touch applications running on a
were obtained to allow experts at site for communication protocol host in the data
essential activities. However, Licensor were not center. The secure gateway is installed in a
in a position to travel to site under the Covid protection zone to route all In Touch network
situation. Many of the experts had informed data through a SSL based connection.
that they may be able to travel earliest by the This server arrangement enabled the
beginning of September 2020, hoping that commissioning team to avail remote support
the epidemic spread situation will improve. In from licensor 24X7. Being first of its kind in
case it materializes, the experts would have India, BPCL has successfully commissioned
to undergo quarantine as per the COVID SOP PDPP complex by adopting this innovative
established at work site and within the country. technology that consists of remote devices
However due to a surge in Covid infection cases such as helmet mounted cameras (see Image
(second wave), the Licensors deferred travel 1 below), intrinsically safe mobile phones, and
plans again due to their Govt. / organization web interface for DCS screen sharing, social
directives. The Licensor agreed to provide media services, virtual meeting interfaces,
round the clock remote support, if BPCL secure gateway and dedicated Wi-Fi system
agrees to share DCS console screen and video for availing Licensor support.

Image 1:- Use o f helmet mounted ‘REAL WEAR' device for on the spot
two way communication in Acrylic acid unit

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Image 2:- Use o f helmet mounted ‘REAL WEAR' device for on the spot
two way communication in Acrylates unit.

Image 3:- Use o f helmet mounted ‘REAL WEAR' device for on the spot
two way communication in Oxo alcohol unit.

Oil & Gas Technical Journal -1 15

 Image 4:- Use o f helmet mounted ‘REAL WEAR’ device for on the spot
two way communication in Offsites and utilities unit

1.1.6 Innovations adopted in PDPP complex cleaning area and filter cleaning effluent
pits. Installation of pumps at underground
During the commissioning of PDPP project, vessel sump pits. Etc.
BPCL-KR developed innovative schemes to
sustain the plant operation with better safety
1.1.7 Conclusion:
by integrating package items installed in the
The onset of COVID 19 pandemic can be termed
units of PDPP.
as a ‘silver lining' which has enabled opening
up a new and hitherto unexplored concepts,
Some of the innovative schemes developed
thereby leading to a digital transformation in
are:•
commissioning activities of this petrochemical
• Integration of chilled water lines from one project. It has highlighted the importance of
unit's tank farm to other unit's tank farm moving towards digitalization. BPCL is adopting
for cooling of tank inventories. new approaches and techniques are being
• Developed schemes to run package item brainstormed to create data-driven (AI enabled)
equipment individually (Incinerator) which and self-learning systems, concerning safety
resulted in reduced start up time. and efficiency enhancement. The success of
this digitally transformation allowed BPCL to
• Innovative schemes, by which other units
commission first of its kind niche petrochemical
in PDPP can send their effluents without
project. This innovative experience of BPCL can
any hindrance irrespective of the unit run
be taken as a model for other sister companies
condition/shutdown condition.
venturing into challenging projects to enable
• Developed schemes for better effluent growth and increase investor value.
management. Ex: installation of filter

i b * -----------

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1.2 Indian Insight on Crude Oil-to-Chemicals (COTC): Future of Refining

Author: Ekta Powar, Process Manager, Indian Oil Corporation Limited

Ms. Ekta Powar is working as a Process Manager at Panipat Naphtha Cracker in IndianOil
Corporation Limited. She is looking after monitoring of MEG, glycols producing unit, Effluent
Treatment Plant (ETP), N2-O2 BOO plant and MEG Revamp project. She has also worked as
production engineer in Naphtha Cracker Unit, planning and coordination department and NCU/
AU unit monitoring

1.2.1 Abstract transportation fuels i.e. gasoline, diesel, and

fuel oil accounts for over 60% of the products
With the swelling crude oil prices, flattening manufactured [1]. In current times, refinery
demands and plunging margins of margins are continuously shrinking due to
transportation fuels, the likelihood of sustaining plateauing demand for transportation fuels
a standalone refinery operation seems very and perennially changing environmental
difficult in upcoming future. Demand of regulations on these fuels. Refineries are forced
petrochemicals and downstream high value to explore ways to remain profitable in the near
chemicals is continuously increasing globally. In future by improving the yield of high-value
this scenario, possibility to fulfill the increasing products, reducing input costs with measures
market demand by producing petrochemicals like expanding crude oil basket and exploring
from crude oil appears to be a very promising opportunities in downward integration to
strategy. In recent times, refineries are produce petrochemical and higher-margin
exploring ways to integrate petrochemical chemicals in place of transportation fuels.
complexes with the refineries to realize striking
margins in this sector. Further downward Crude Oil-to-Chemicals (COTC) is a powerful
integration of petrochemicals to downstream industry driver and a strong area of interest
chemicals adds even more worth to the value for all integrated refineries and chemicals
chain. This paper intends to provide an insight producers in Asia/Pacific, China, the Middle
on how Crude oil to Chemicals (COTC) fits into East and Eastern Europe. COTC technology
the landscape of Refinery and Petrochemical implementation becomes even more important
integrations, its comparison with traditional considering the facts based on the forecasts
refining configuration, technologies available which predict a slowing of transportation fuels
for COTC and its strategic role in preparedness growth approaching 2040 with market being
of the refineries for battling with ongoing and adequately supplied with hybrids and Electric
upcoming challenges in refining sector. Vehicles, while the growth in chemicals is
expected to go up considering the population
1.2.2 Introduction and middle class wealth continues will rise
increasing in demand for packaging, updating
During the last century, crude oil has played lifestyle and even in automobile sector In recent
a vital role as primary source of energy in times, petrochemical products have become an
transportation, energy and manufacturing integral part of modern societies with products
sector. Oil refineries play a significant role like plastics, fertilisers, packaging, clothing,
in providing the usable products for these digital devices, medical equipment, detergents,
applications by converting crude oil to products vehicle tires etc. Petrochemical products are
via various processes. also used as part of the modern energy system
in wind turbine blades, solar panels, battery
In refineries, share of petroleum derived cells, insulation for buildings, and automobile
parts.

Oil & Gas Technical Journal -1 17

1.2.3 Challenges of a standalone Refinery 58% in 2025 and begin to plateau after 2030[3].
Primary reasons for flattening the petroleum
In refineries, crude oil is processed through products demand will be penetration of
these three processes namely, a) Separation electric vehicles in the market because of its
Process; b) Conversion Process and c) cost effectiveness and being better for the
Treatment Process. environment. As per the forecast for next 25
years, there will be an increased uptake of
In separation process, crude oil is separated alternative drive technologies like hydrogen,
into useful products such as liquefied biofuels etc. for commercial vehicles which
petroleum gas (LPG), Naphtha, Motor Spirit will cause a drop in demand for transportation
(MS), High Speed Diesel (HSD), Aviation Turbine fuels. With this decline in demand, refiners will
fuel (ATF), Fuel oil(FO), Bitumen and pet-coke. face the challenges in operating the refineries
In conversion process, heavy hydrocarbon in an economic manner. Figure-2 below
molecules are converted to lighter molecules illustrates the plateauing of demand in from
adding value to product chain. In final stage of 2035 onwards for conventional fuels.
treatment, products from conversion stage are
further treated to make them usable as final
products complying with desired specifications
and environmental guidelines.

Products from a refinery, their share and end

use are illustrated in figure-1 below.

LPG-4% Cooking fuel, automotive fuel

Naphtha- Blended in Gasoline, Hydrogen

10% generation and pertochemical Figure 2: Demand forecast o f conventional
feedstock refinery fuels

M S -12% Fuel in Automotives With passing time, environmental regulations

on transportation fuels are perennially
ATF-10% Jet fuel becoming stringent and in order to meet these
regulations, refineries are incurring extremely
high expenditures for adding treatment
HSD-45% Fuel in Automotives facilities like hydro treatments for producing
cleaner fuels. These treatment units involve
FO-2% For heating Purpose substantial capital and operating cost for
refineries. The cost of compliance acts as a
Bitumen- In roads paving
deterrent for refinery margins and poses hurdle
2% in the path of refineries planning for capacity
expansions.
Petcoke-4% Electrodes making
Also, with stringent environmental regulations
in place, much cleaner gaseous fuels are
Figure 1: Refinery products share and their end use replacing liquid feeds in refinery units as fuel/
feed. Also, Naphtha stream blending in gasoline
In a traditional way of operating the refinery and use as a feed in hydrogen generation
business, refiners are going to face an unit is restricted because of its high sulphur
array of challenges related to operations, content, making Naphtha a surplus stream
environmental concerns and sales of the from refinery. Due to this, Naphtha is exported
products. Share of the average oil barrel at low prices to sustain refinery operation. On
dedicated to transportation fuel will peak at the other hand, Naphtha is an ideal feedstock

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for petrochemical process. Paraffinic/straight integrated complex provides an opportunity for

chain naphtha is a suitable feed to Naphtha optimal molecule and resources management
Cracker Unit (NCU) and Aromatic Naphtha is for better bottom-line for the company.
apt for Para-Xylene (PX)/Para-Terephthalic Refineries aim to maximize fuels as final
Acid (PTA) Complex as a feed. Naphtha supply products and, in the process, opportunities for
to petrochemical complex results in olefin and extracting higher value is underutilised. For
aromatics production, which are precursor to example, naphtha streams in a refinery are
petrochemicals production. reformed to yield reformate which is used in
gasoline as a blend, and propylene produced
1.2.4 Integration of Petrochemicals with in the FCC is used to produce alkylate that
Refinery again is used as blend in the gasoline pool
or propylene is blended in LPG as a fuel.
Integration of a refinery and petrochemical Preferably, reformate is an appropriate feed
complex implies identifying synergies and to produce aromatics, and the propylene can
optimising them for operational and economic be further processed to produce high-value
gains by exchanging feedstocks, by-products, polypropylene. We illustrate a typical stream
and utilities between both the facilities. The sharing between refinery and petrochemical
complex below in figure-3.

Fig. 3 Typical Refinery and Petrochemical Integration Block Flow Diagram

Some of the stream sharing options for an hydrogenation.

integrated refinery and petrochemical complex 4) Pyrolysis gasoline up-gradation to elude
adds to the bottom-line and provide flexibility negative value products generation
in the business. (Negative value products are those whose
value is lower than the Naphtha feed to
1) Hydrogen sharing between the refinery,
cracker). Some options include:
cracker and aromatics increases flexibility.
• Recovery of di-cyclopentadiene (DCPD)
2) Recovery of ethylene and propylene from
from C5 di-olefins. Alternately, C5 stream
FCC/Coker off gas in Ethylene Recovery
can be hydrogenated and recycled to the
Unit (ERU).
cracker or blended to the gasoline pool as
3) Recovery of 1-3 butadiene/butenes-1/ an octane booster.
butane-2 from C4 Mix stream, recycling
• Recovery of benzene from pyrolysis
to the cracker, or adding to LPG after

Oil & Gas Technical Journal -1 19

 gasoline that contains over 30 wt% are integrated at a single site, allowing exchange of
benzene by extractive distillation return streams/intermediates and taking benefits of
technology. the synergies.
• C7-C8 stream also acts as an excellent
octane booster for gasoline pool. The advantages of a synergic integrated complex are
Alternatively, C7-C8 cut can also be listed below:
routed to PX-PTA for para-xylene (PX)
• Capital cost, operating cost and resource
yield enhancement.
optimization and increasing profitability attributed
• The C9+ cut can be absorbed in the diesel to:
pool.
» Shared infrastructure and utilities.
5) Pyrolysis fuel oil with low viscosity can be
» Lower transportation costs.
blended with refinery fuel oil pool or can
be used as a feed for Carbon Black Feed » Minimization of fixed overheads.
Stock (CBFS) recovery. • Surplus feedstocks availability for petrochemicals.
6) Initiatives like INDMAX, a flagship venture • Very low transportation cost of feedstock/
by IOCL R&D helps refiners to produce intermediates to/from petrochemicals.
higher yields of ethylene, propylene and • Dampened effect of demand/price fluctuations of
LPG along with high octane gasoline type of product on profitability by compensating
from various resid/non-resid feedstocks. with other products margins.
Robust and high performing design of • Olefins command significant price advantage over
INDMAX unit has proven it's commercially transportation fuels.
viability with three already commissioned
• More options exist to for streams routing to respond
and successfully running units. Four
to market demands.
other units of 2-3 MMTPA capacity are at
various stage of design in different Indian • Value enhancement from integrating intermediate/
refineries. return streams.
INDMAX technology employs catalyst Path forward for Petrochemical Industry in
system having higher metal tolerance,
India
higher selectivity towards light olefins and
lower dry gas yield. Petrochemical industry plays a pivotal role in the
Typical light olefins yield on wt% of feed is shown country's economy. The sector serves as the backbone
below: for the development of various other key sectors, such
as agriculture, infrastructure, health care, automobile,
textiles and consumer durables. It is one of the fastest
growing sectors, with demand growing at a CAGR of
8%-plus over the last five years [5]. The penetration
level of petrochemicals in India is, however, far lower
than the global average. As per a report published
by FICCI in year 2014-15, India's per capita polymer
consumption is 11 kg against the world average of 28
Kg/capita showing significant headroom for growth in
the country.

Fig. 4 INDMAX Unit Typical light olefins yield on

wt% o f feed [4]

In the non-integrated scenario, refineries are exporting

naphtha to other autonomous steam crackers and
aromatic complexes. However, several benefits can be
accrued when refinery and petrochemical complexes

Fig 5: India's per capita polymer consumption

comparison, kg/person

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India is developing to be one of the fastest growing furnishings, automobiles parts, household items,
economies in the world. India is the fourth largest toys, cultivation, horticulture, irrigation system and
refiner in the world, with the capacity of 250 MMTPA packaging to medical supplies.
of crude processing. Country's refining capacity aims
to serve national demand of petroleum products and Some relevant projections for the Indian refining and
to supply petroleum products to neighbouring Asian petrochemicals sector are [6]:
countries.
• Domestic refining capacity is projected to reach up
to 553 MMTPA by 2040 to meet domestic growing
In India, a large population and comparatively low
per capita consumption of polymers shows the demand from current capacity of 249 MMTPA.
capacity of high growth margin for the petrochemical • Petrochemical market in India stands at 42.50
products. In today's changing scenario, chemicals and MMTPA presently and is estimated to reach up to
petrochemicals also have a vital role to play in economic 49.62 MMTPA by 2025.
growth for the areas like agriculture, infrastructure, • Additional propylene capacity of 5 MMTPA of
health care, textiles and consumables. Petrochemical polypropylene (PP) capacity is expected to be
products cover the entire range of consumables and added by 2025.
durables, starting from fabrics, housing, construction, • Around 4 MMTPA of high-density polyethylene

AFG H AN ISTAN I N D I A
KASHMIR Location o f
Petrochem ical Indu strie s

HIMACHAlV
PRADESH ;
PAKISTAN
/ PUNJAB) Cl-INA
UTTARAKHAND. (TIBET)
fPanipat

" T ANVoEiHr-
x \
,ura ' i ? n Di£bo,V
v 'V v-0 w&gaian d
UTTAR PRADESH

.. . JHARKHAND /W E S / T R IP l^ ty ., j
BENGAL _ VJ \ r
Jamnagar Vadod. MADHYA PRADESH
^ GUJARATIS MYANMAR

^ y H a z ira
N A G A R P A ^ '^ MAHARASHTRA (ODISHA)
ORISSA
Nagothane
Mumbai# • Ra^ale
\ •Patalganga
AKAKIAN Vishakhapatnam
ANDHRA
PRADESH

ia t a k a :

LEGEN D
International Boundary
— - State Boundary
Petrochemical Industries
Ta m i l n a d i

Map not to Scale

Copyright © 2011 wvAv.mapsotmdia.com
This map is updated as on A p ril 13, 2011
i SRI \
LANKA’ O C EAN

Source: maps o f India

Oil & Gas Technical Journal -1 21

 (HDPE) and low-linear-density polyethylene a strong recovery since the beginning of 2021, with
(LLDPE) capacity is forecast to be added by 2025. demand increasing from the major end markets such
• By 2025, India is forecasted to have a shortfall of as construction and health & safety. This was driven
Purified Terephthalic Acid (PTA) and Para-Xylene partly by a rebound in US GDP, which will likely grow
(PX) of 1.8 MMTPA and 0.6 MMTPA, respectively. between 6.0% and 6.5% during 2021 after declining by
3.5% in 2020 [5].
Considering the facts above, pathway to India’s future
towards petrochemical business holds tremendous 1.2.5 Future of Refining: Crude Oil to
potential of growth.
Chemicals (COTC)
In last two years, Covid-19 had hampered the growth
Currently in most refineries, petrochemicals
momentum of the petrochemical market in India,
are manufactured as side streams, keeping
disrupting the supply chain along with weakening the
a primary focus on transportation fuel
demand. However, the level of impact and the recovery
production. Crude oil-to-chemicals (COTC)
trajectory have been different across the petrochemical
is the technology to directly convert crude oil
value chain. The supply of petrochemical was majorly
to high-value chemical products instead of
been affected owing to labor shortage, logistical
conventional fuels. It enables the production
challenges, low utilization rates, and the reduction in
of chemical feedstock up to 70% to 80% of the
operational expenses.
barrel against ~10-15% in a typical refinery
complex [6].
The petrochemical market witnessed a notable
change in its consumption pattern amid the pandemic.
Petrochemicals products are expected to be
Industries, such as the automotive, construction,
the largest driver of global oil demand growth,
electronics, textiles, and rigid packaging experienced
exceeding the demand of gasoline/diesel 2030
a sudden slump in demand. On the other hand, the
onwards. The global chemicals market is
demand for petrochemicals from flexible packaging,
growing at a fast pace, with chemicals demand
personal care, and healthcare had risen sharply. The
rise forecast of 3-3.5% by 2025-30 compared to
pandemic brought about various changes in the India
1-1.5% for crude oil. In view of this, integrating
petrochemical market, including digitization, increased
petrochemical complex with refineries will
consolidation activities, and a focus on scenario-
be essential to match the gap between local
based planning.
demand and supply of the products. In this
scenario, non-integrated refineries will be
Chemical industries were temporarily hampered due
more susceptible to demand risks. Fig-6 below
to first and second wave of Covid-19 due to disruption
explains the level of integration in refinery and
of supply chain along with weakening the demand.
petrochemical complexes.
On the positive note, chemical industry has witnessed

Crude Oil to Chemical

(COTC)
f1
Refming+Steam W
Cracker+ Paraxylene
Complex r
o
Refining and Steam ► n
Cracker or Refining and
Paraxylene Complex
3
Q
5
H
HH

Fig 6: Typical Refinery and petrochemical integration block diagram

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Crude oil to chemicals adds more value towards petrochemicals to support an investment in India.
downstream chemicals value chains for propylene, Such strategic shifts have been found to increase
ethylene and pyrolysis gasoline. These include margins, while also raising integration, complexity,
cumene/phenol/Isopropyl Alcohol (IPA), propylene and output volumes at a disruptive scale. A typical
oxide (PO)/propylene glycol/polyol and styrene (as configuration of COTC plant is shown below in
a co-product of PO). A substantial demand and fig-7.
growth rate exists for these downstream specialty

Fig 7: Configuration o f a typical COTC plant

COTC continues to garner the attention of integrated U.S., Middle East and China. Major COTC players are
refineries and chemicals producers in Asia Pacific, tabulated below in Table-1. By expanding the usage of
China, the Middle East and Eastern Europe. However, crude oil in the chemical industry, COTC is expected to
despite its growing popularity, only a few well-equipped change and possibly disrupt the market landscape by
integrated oil companies globally are looking to deploy 2025-2030. National and independent oil companies
this technology to make inroads in the petrochemical are expected to invest further in this segment as COTC
industry. These include some large companies in the adoption grows [7].

Oil & Gas Technical Journal -1 23

 Global Crude Oil to Chemicals Plants
Project Refinery Para- Cracker Estimated Investment Start of
capacity Xylene Capacity Conversion ($ Billion) operation
(MMTPA) Capacity of chemical/
bbl of oil (%)
Hengli Petrochemical 20 4.3 1.5 42 11.4 2018
Zhejian Petroleum and
20 4 1.4 45 12 2019
Chemical (ZPC) Phase-I
Hengyi (Brunei) PMB Refinery-
8 1.5 0.5 >40 3.45 2019
Petrochem
Zhejian Petroleum and
20 4.8 1.2 50 12 2021
Chemical (ZPC) Phase-2
Shenghong refinery and
16 2.8 1.1 60 11 2021
Integrated Petrochem
Amanco/SABIC Jv 20 - 3 45 20 2025
Table-1: Major COTC Plants across the globe [7]

1.2.6 Case Study: COTC vs Non-integrated Combination of feed stock to cracker is

complexes considered as:

• Straight run Naphtha and kerosene.

A case study is prepared to draw a comparison
between COTC configuration vs non-integrated • Off gases from FCC and coker (Rich in
complex. In this case study, following three olefins and ethane/propane).
cases are studied and compared based on • FCC propylene.
their economic value addition to the company
The proposed configuration is equipped with
based on Nov'21 feed and product prices.
these downstream units/facilities:
(Source: spglobal).
• Polypropylene Unit to produce PP
Case-1: Standalone Refinery • Dedicated HDPE unit.
• Swing unit to produce HDPE and LLDPE.
Case-1 represents a standalone refinery with 15
MMTPA of crude processing capacity targeting • Butene-1 unit for internal requirement of
mainly on production of fuels. This refinery co-monomer in PE plants.
is equipped with traditional refining units like • Benzene Extraction Unit for Benzene
CDU/VDU, NHT, FCCU, CCR, isomerization, production from Pyrolysis Gasoline
VGO hydrotreater and Delayed Coker Unit. Stream.
• Hydrogenated C5 and C6 raffinate cut is
This configuration is aims at maximizing diesel recycled back to the cracker.
and gasoline from the refinery and propylene • The C7-C8 stream is routed to the gasoline
produced from FCC is routed to LPG pool. pool and C9+ stream is routed to diesel.

Case-2: Integrated Refinery with Case-3: Integrated Refinery and

steam cracker and aromatics complex Petrochemical Complex along with
downstream chemicals (COTC)
In this case, an integrated refinery and
petrochemical complex with 15 MMTPA of Case-3 represents an integrated refinery and
crude capacity equipped with all refining units petrochemical complex same as Case-2 and
as case-1 and also integrated with aromatics further integrates it with downstream high
and steam cracker complex. value chemicals units like Isopropyl Alcohol

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Table-2 below represents the comparison of unit configuration of cases taken in the case study.

Unit Configuration
Case-1 Case-2 Case-3
CDU/VDU V V V
NHT V V V
FCCU V V V
CCR V V V
Isomerization V V V
VGO-HDT V V V
FCCU V V V
Kerosene Treater V V V
DCU V V V
ERU V V
Aromatics complex V V
Mixed feed cracker V V
PP V V
HDPE/LLDPE (SWING) V V
HDPE V V
MEG V V
Propylene oxide (PO)/Styrene Monomer (SM) V
Polyols V
IPA V
Cumene V
Phenol V
Butadiene V V
Butene-1 V V
Table 2: Unit configuration o f cases into comparison

Based on unit configuration, cases are compared based to the bottom-line of the complex. These details are
on their product pattern, share of fuel products, share given below Table-3.
of petrochemical products and their value addition

Oil & Gas Technical Journal -1 25

 Table 3: Produxt Patten and Economic Analpsis of (Cases
UoM Case-1 Case-2 Case-3
Crude t'put MMTbA 15 15 15
LbG KTbA 600 480 480
Naphtha KTbA 1500 0 0
Gasoline KTbA 1800 1800 1800
ATF KTbA 1500 1500 1480
Diesel KTbA 6750 6000 6000
Total fuel % 81% 65% 65%

bb KTbA -- 600 400

HDbE KTbA -- 300 300
LLDbE/HDbE KTbA -- 350 350
MEG KTbA -- 300 300
Butadiene KTbA -- 200 160
Butene-I KTbA -- 20 60
bTA KTbA -- 580 420
Benzene KTbA -- 20 10
Styrene KTbA -- 0 50
bhenol KTbA -- 0 100
Cumene KTbA -- 0 60
IbA KTbA -- 0 100
bolyols KTbA -- 0 80
betrochemicals% % 0% 16% 16%
Rs./barrel of
GRM 603 1024 1126
crude
*Based on Nov'21 prices. Source: sp globa
Table-3: Product pattern and economic analysis o f cases

From the table-3 above, it is clear that case 3-COTC Further, there are developments in olefin producing
technology garners more gross margins of Rs. 1126/ technology by selecting most appropriate feed of
bbl of crude processed as against Standalone refinery n-paraffins rich naphtha. In C4-C10 cut, n-paraffin
setup (Rs. 603/bbl of crude) and Integrated Refinery feed is separated and used as a feed to steam cracker
& Petrochemical Complex (Rs. 1024/bbl of crude). which gives higher olefins yield, longer run length of
Integration to downstream high value chemicals cracker furnaces, and reduced coking and lesser low
adds value to the system and makes it more robust value products yield. In order to move further in this
and resistant to fluctuations in demand. Crude-to- direction and reducing petroleum production from the
chemicals conversion to be more profitable, avenues complex, design may be adopted to crack kerosene cut
may be explored for competitive crude pricing, (C10-C14) in steam crackers with appropriate design.
export-oriented product pricing, and residue upgrade
investments for heavier crude processing, among On the other hand, there are a few risks associated with
others. COTC technology which may decide for owners for
taking decision on implementation of this technology:

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• COTC being a cost intensive technology needs oil feedstock import (>90%) and with limited
a considerable investment for chemical units' availability of natural gas, implementing crude-
installation. Return on investment on these units to-chemicals technology will be governed by
will depend on region, local demand pattern. capital efficiency of the project and demand for
• In major COTC players, China has the biggest the petrochemicals project in the local region.
capacity installation in the form of two large projects
- Hengli Petrochemicals (42% conversion per barrel 1.2.8 References
of oil) and Zhejiang Petroleum and Chemical (COTC
[1] h ttp s ://w w w .o p e c .o rg /o p e c _ w e b /s ta tic _
phase 1, achieved 45% conversion per barrel of files_project/media/downloads/publications/
oil). Considering this, there is a risk of oversupply WOO_2019.pdf
of petrochemicals and high value chemicals in the [2] h ttp s://w w w .ca ta lystg rp .co m /w p -co n te n t/
market of the Asia-Pacific region. uploads/2018/11/PRES-Oil-to-Chemicals-II-
July2019.pdf
1.2.7 Conclusions [3] https://www.statista.com/statistics / 282774/
global-product-demand-outlook-worldwide/
The paper presented a study of merits of [4] https://iocl.com/uploads/IOCL_R&D_LEAFLETS
Crude Oil to Chemicals technology over / INDMAX_Technology.pdf
non-integrated complexes. In forecasted [5] https://ficci.in/spdocument/20396/knowledge-
challenging times, COTC will emerge as vital paper-ps.pdf
technology to tackle the market dynamics, price [6] https://business.mapsofindia.com/
fluctuations to remain profitable. COTC plants petrochemical/
produce a large volume of chemicals, thereby [7] https://www.futurebridge.com /blog / crude-
disrupting the supply demand dynamics of oil-to-chem icals-future-of-refinery/#:~:text=
end-product chemicals; end-product market Crude%20oil%2Dto%2Dchemicals%20(,a%20
dynamics are likely to play a major role in non%2Dintegrated%20refinery%20complex.
assessing the feasibility of the COTC plant.
The large-scale adoption of COTC provides
opportunities for operational integration in
refineries to align themselves with the emerging
trend of expanding business portfolios into
petrochemicals. However, the type and level of
integration are principally driven by feedstock
availability and pricing that varies from region
to region. For India, which depends on crude

Oil & Gas Technical Journal -1 27

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f ------------------------------------------------------------------------------------------------------
1.3 Refineries of the Future Producing Petrochemicals
Authors: Prateek Gupta, Configuration Specialist & Mr Stan Carp, Senior Manager
Honeywell UOP
r
Mr. Prateek Gupta is Configuration Specialist and at present working with IPS- Configuration
and Process Consultancy, Petrochemical and Refining Technologies (PRT), Honeywell UOP. He
has over 15 Years of international experience. Expert on providing strategic direction to clients
on proper configuration of refinery and petrochemical complex, Crude Oil to Chemicals via
different pathways, Techno-economic evaluation. He is Certified Six Sigma Green Belt Expert.

Mr Stan Carp is working as Senior Manager, Configuration and Process Consultancy with UOP
Honeywell. He is also Certified Six Sigma Green Belt Expert

Domestic transportation fuel demand in India by 2025 this opportunity, many in the industry are turning to
is expected to grow by 50% for gasoline and 17% for petrochemical integration, an adjacent market with
diesel compared to 2019. Indian refiners currently strong growth potential and substantially higher
export 17% of overall fuels production; most of the margins.
exported fuel is diesel. Reduced global demand for
diesel will put downward pressure on these exports. 1.3.1 Demand Growth Forecast
Contributing to the excess diesel is the reduced demand
for kerosene as a fuel. Since the government has been Demand growth forecast (2018-28)
providing LPG to replace kerosene for consumers,
10
refiners have been moving kerosene production into
diesel.

Additionally, export fuel markets that have historically

been supplied by India are now building their own
refineries. With more regions supplying their own fuels,
Indian refiners planning to export to those markets
will be forced to adjust accordingly. With uncertainty
in product demand and global trade dynamics, Indian
refiners are under increasing pressure to chart their path
forward for growth and continued competitiveness. -6 Source: I.H.S. Market, FGE, WoodMAc, UOP Analysis

Figure 1
While global fuels demand is softening, global
petrochemical demand is projected to grow nearly In addition to projected growth in petrochemical
1.5 times GDP, with compound annual growth rates demand, new technologies are enabling both
(CAGRs) of 3-4% from 2018-2028. Similarly, for massive increases in economies of scale and
India, petrochemical demand is anticipated to grow lower cost of production. World-scale refineries
with CAGRs up to 7.0% from 2018-2028. See Figure employing these new technologies are being
1. Consumer demand for more packaging, plastics built in regions with growing fuels demand,
and synthetic fabrics is driving this demand growth off-setting imports, and extending into
both worldwide and in India. To take advantage of petrochemicals to improve their internal rate of

Oil & Gas Technical Journal -1 29

 return (IRR). These new, world-scale integrated xylene production.
plants will be considerably more resilient to • Propane dehydrogenation to allow world-scale
shrinking gasoline and diesel margins. production of propylene.
• Steam cracking to extend into ethylene.
They will be able to service their debt and
remain more competitive than much of the An integration case study has been developed
installed base. to illustrate a potential pathway that profitably
transforms an existing refinery into a Refinery of the
Indian refiners that diversify into petrochemicals Future. The study analyzes a base case with a product
while satisfying local demand for fuels, will slate that is predominantly fuels, and six additional
continue to run at capacity and will benefit cases that incrementally increase production of
from improved profitability. petrochemicals at each step. If an existing refiner
were to use this investment pathway to move from
Creating a Refinery of the Future fuels to petrochemicals, the impact on flexibility,
competitiveness, and profit margin could be immensely
The key to unlocking these opportunities in beneficial. Analysis of each step as a separate case
petrochemicals lies in stepwise investments in allows for the economic benefits to be quantified.
new process technology with advanced molecular
management that may include: The Base Case refinery is configured for processing
20,000 kMTA of Arab Light, producing gasoline and
• Light olefin cracking to increase FCC propylene diesel fuels. The configuration includes a FCC as the
production. main VGO conversion unit and a Delayed Coking unit
• Bottom of the barrel conversion with slurry for vacuum residue conversion. See Figure 2. The
hydrocracking technology to upgrade heavy refinery is configured to produce BS-VI compliant fuels.
oil to fuels or intermediates for petrochemicals. The overall product slate is 35 wt% gasoline, 42 wt%
• Extension into an aromatics complex for para- distillate and 8 wt% LPG on a crude basis. See Table 1
xylene. for production profile and key economic performance
indicators for this case and subsequent cases.
• Distillate hydrocracking to enable world-scale para-

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Case 1 adds the Total Petrochemicals/UOP Olefin the foundation to maximize petrochemical production
Cracking Process (OCP) with propylene recovery to with subsequent investments. Diesel production is
the existing FCC unit, reducing gasoline production increased by 27% over Case 1. Upgrading the vacuum
and allowing the refiner to begin producing ethylene residue from $61/MT to diesel at $700/MT, is the clear
and propylene. Integration of OCP with the FCC unit economic driver. Case 2 results in a NCM increase of
enables refiners to overcome existing constraints that $3/BBL and an incremental IRR of 18% compared to
may prevent additional propylene production. Olefin Case 1.
production from the facility is 5 wt% on a crude basis,
resulting in a net cash margin (NCM) increase of $4/ Case 3 is major step into petrochemicals that integrates
BBL and an incremental internal rate of return (IRR) of an aromatics complex into the refinery, enabling
19% relative to the base case. See Figure 3. the refiner to enter into the para-xylene market.
Reformate for gasoline blending is diverted to the
Case 2 replaces the Delayed Coking unit with a Slurry aromatics complex, reducing production of gasoline
Hydrocracking unit, in this case UOP Uniflex™ MC™ and resulting in 1,600 kMTA of para-xylene production.
technology, which is based on hydrogen addition Gasoline production is decreased by 30% compared
rather than carbon rejection. 98% of the vacuum to Case 2, while the refinery continues to produce a
residue is now converted to distillate, naphtha and BS-VI compliant gasoline product. Increasing overall
LPG. The low-value unconverted product is only petrochemical production to 17 wt% on crude results
2% of the unit's production. The Uniflex MC process in a NCM increase of $3/BBL and an incremental IRR
increases residue conversion to higher value products, of 22% relative to Case 2.
enabling the refiner to increase profit margin and set

Production Profile & Economic Performance

Case Number Base 1 2 3 4 5 6

Product, wt% Crude Processes
Gasoline 35 34 31 22 35 36 25
Distilate 43 43 52 47 16 15 18
LPG 8 3 3 4 9 7 0
PetCoke or Pitch 5 5 1 1 1 1 1
Fuels & Loss 10 10 8 10 11 12 9
Aromatics 0 0 0 11 21 22 23
Others 0 5 5 5 5 8 24
Total Products 100 100 100 100 100 100 100
Total Petrochemicals 0 5 5 17 27 29 47
Economic Performannce Relative to Previous Case
Net Cash Margin (NCM), Base -619 +384 +424 +46 +266 +1555
SMM/year
Net Cash Margin (NCM), Base +4 +3 +3 +1 +2 +11
$/BBL
Incremental IRR, % | Base 19.1 17.7 22.4 5.0 15.9 13.4

Table 1

Case 4 the Kerosene and Diesel Unionfining units are the refinery into world-scale production of para-
replaced with maximum conversion Unicracking units xylene. These two Unicracking technologies could be
designed to produce naphtha. This enables elimination implemented stepwise with the low-cost kerosene
of kerosene, reduction of diesel and maximum hydrocracking option added first, followed by the
production of heavy naphtha for para-xylene, moving diesel hydrocracking option. Employing two naphtha

Oil & Gas Technical Journal -1 31

mode hydrocrackers enables para-xylene production produced propane. Recovery of the Oleflex propylene
to double compared to Case 3, resulting in 3,000 kMTA is integrated into the FCC/OCP propylene recovery
of para-xylene. Distillate production is reduced by system to reduce capital and improve efficiency. This
65% compared to Case 3 and overall petrochemical additional investment increases overall petrochemical
production increases to 27 wt% on a crude basis. production to 29 wt% on a crude basis, and results in a
Combining Cases 3 and 4 in one step enable maximum NCM increase of $2/BBL and incremental IRR of 16%
para-xylene production and result in an incremental relative to Case 4.
IRR of 17% relative to Case 2. Further paraxylene
production could be achieved with the UOP Toluene Case 6 is another key step into petrochemicals that
Methylation Process. Toluene methylation increases integrates a steam cracker with the refinery and
para-xylene by almost 50% from the same amount of aromatics complex, enabling the refiner to enter the
reformate, and benzene production is eliminated. polyethylene market. Light cracked naphtha, light
straight run naphtha, LPG, and off-gases are fed to
Case 5 integrates a world-scale 500 kMTA UOP the 1,500 kMTA steam cracker. Gasoline production
Oleflex™ Process Unit (propane dehydrogenation) into is decreased by 30% compared to Case 5, while the
the refinery to further increase production of propylene refinery continues to produce a BS-VI compliant
from refinery produced propane. The previous cases gasoline product. This configuration increases overall
have increased the production of LPG (5 times petrochemical production to 47 wt% on crude basis,
relative to the base case) enabling implementation and results in a NCM increase of $11/BBL and an
of a world-scale Oleflex unit fed entirely on refinery incremental IRR of 13% relative to Case 5. See Figure 4.

This study demonstrates a potential investment molecular management technologies. As an example,

pathway that, over time, transforms existing assets a refinery currently producing fuels, with a capacity of
into a Refinery of the Future. While each refiner will 100 kBPD, has begun engineering for the first phase
require a solution as unique as their refinery, the study of investments that will allow the refiner to improve
demonstrates a strategy that is being successfully margins by producing 35 wt% petrochemicals while
implemented for existing refineries. Many overseas continuing to make 43 wt% fuels. A number of UOP
refineries are embracing the petrochemical integration technologies, including the Uniflex MC process
model and they are employing these advanced technology for maximum bottom of barrel conversion

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and Unicracking process technology for maximum producing 66 wt% petrochemicals and minimal
conversion of VGO and distillate to naphtha, will form fuels. Overseas refineries are being transformed into
the core of this integrated refinery. UOP also identified Refineries of the Future and Indian refineries can
a pathway to a maximum petrochemical operation replicate this integration model as well.

*The economic results are for exemplary purpose only. Result may vary depending on the final configuration

1.3.2 Summary configurations against efficient benchmarks

to ensure the best possible investment while
As fuels demand declines and global meeting project objectives.
competition increases, diversifying into
petrochemicals will enable Indian refiners to The studies in this paper identified a potential
maintain crude capacity and improve margins. diversification pathway to petrochemicals
For grassroots projects and existing refinery through a series of economically viable
upgrades, a high-value integration strategy investments. Each step of this plan resulted in
will create additional value. Crude capacity a high-quality investment with case-by-case
is maintained while moving into higher value incremental IRR's up to 20%. Following this
petrochemicals, and on-specification gasoline plan, a refiner can unlock new value from crude
and distillate will be co-produced, but at a oil, potentially improving net cash margin by
reduced rate. over $20 /BBL.

Petrochemical integration is complex and Each existing refinery and new complex will
capital-intensive, requiring a strategy that is require a tailored configuration that embodies
definitively quantified to maximize value at the technologies and concepts discussed
each step. Optimization, not maximization, is in this paper. As one of the only companies
the key. Optimization means better molecule that incorporates process technology and
management and improved configurations. configuration expertise, Honeywell UOP
UOP's E6 model enables comparison of fully integrates complexes, achieves optimal

Oil & Gas Technical Journal -1 33

 molecular management and maximizes the goals, enabling maximum asset utilization
value of a barrel of crude. Partnering with and improved reliability. With the right retrofit
Honeywell UOP provides refiners with integrated technology and domain expertise, the Refinery
services and solutions for a connected plant of the Future is now within reach.
to accomplish today's complex operating

34 Oil & Gas Technical Journal -1

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2.1 De-bottlenecking of Crude and Vacuum Distillation Unit to improve

productivity
Authors: Dr. Ashwani Malhotra and Mr. Ameya Dhok, Engineers India Limited, New Delhi

r
Dr. Ashwani Malhotra is serving as Chief General Manager in Engineers India Ltd. He has 35
years of experience in the process design and engineering o f refineries (including Crude &
Vacuum Distillation unit) and onshore/offshore oil and gas facilities and in the Equipment and
R&D divisions of EIL. He also has experience in application of IIOT in Refinery.

Mr, Ameya Dhok works as Senior Manager with Engineers India Ltd. He has experience in Process
simulation & optimization for refinery unit design like Crude distillation, Delayed Coker, and
Naphtha splitter units. His area of interest includes Process engineering and exploring energy
improvement measures.

2.1.1 Abstract careful and systematic approach needs to be

adhered to have an optimum design. The key
The refinery process unit needs to perform highlights of the design include optimized
efficiently to have the maximum profitability light end data to match the existing overhead
and productivity. One of the main reasons for circuit limitation, maximizing the preheat
process units to perform inefficiently can be with minimum modifications, upgrading to
attributable due to variation in feed stream high-capacity tray in stabilizer section to
properties. In a typical refinery, the actual accommodate the increased light end load,
crude basket can be quite exhaustive from hybrid vacuum system for vacuum column
the design cases. Hence any change in crude operation to have reduced OPEX and thereby
composition can have significant impact on making the unit more energy efficient.
the yield and hence energy utilization. The
problem is commonly encountered in crude 2.1.2 Introduction
units wherein the design and actual crude
assay differs especially for lighter crude The processing of crude oil in crude unit is an
wherein the light ends vary significantly leading important aspect and is key to functioning of
to debottlenecking of light end processing the refinery profitability as it provides feedstock
section. In this paper, a typical case study is to downstream unit. The separation of crude oil
discussed wherein the unit is revamped to into the desired streams primarily depends on
address the above issue and also target for the crude oil characteristics. Typically, crude oil
an energy efficient unit design. As the crude is characterized by following properties:
being processed is lighter, the yield from Crude
Column is higher. This leads to higher Crude • API Gravity
heater duty. In order to avoid modification in • Sulfur content
Crude heater and utilize margin in vacuum • Total Acid Number (TAN)
heater a new exchanger service (Crude/RCO)
was added in preheat. The critical aspect in The crude oil assay characterization is critical
debottlenecking with hardware constraint is to while designing crude unit. This becomes
achieve the target with minimum modifications more important when it comes to revamping
and within stipulated turnaround time. A an existing crude unit. The approach is to carry

Oil & Gas Technical Journal -1 37

 out a test run with the intended design crude
in existing unit, this helps in identifying the key
bottlenecks/constraints in existing design.

A typical crude unit consists of crude section

followed by vacuum section. The crude oil is
firstly heated in preheat train exchanger network
wherein the heat is made available through the
hot stream from crude and vacuum column.
After preheat the temperature of desalted
crude is increased to the desired level in crude
heater before it enters the distillation column
(refer Figure-1) where it is separated into 2.1.3 Methodology
desired cuts depending upon its boiling range.
The crude column bottoms, reduced crude oil Revamp of any process units is primarily
(RCO) is further heated in vacuum heater and with objective of capacity enhancement and/
enters the vacuum column operating under or yield and product quality improvement to
vacuum condition and separated into desired be implemented within shutdown period. The
cuts (refer Figure-2). recent trend in revamp projects is to aim for
energy improvement also as an integral part
of the objective. The activities in revamping
and de-bottlenecking are far more complex
which results in complex engineering scope
requirements and hence execution challenges
and significant performance issues. Revamp
or de-bottlenecking projects require special
consideration to the issues that are normally
not present for grassroots designs. The
major considerations are discussed in detail in
following sections.
Figure 1
L ig h t end p ro c e s s in g s e c tio n
This paper focuses on design optimization for
revamp of existing crude unit to process crude
The key aspect in design of crude unit, especially
which is lighter than existing design. Further the the light end section depends on the lighter
implementation of revamp within the stipulated
hydrocarbon composition. The load to crude
time frame of turnaround is challenging. With column overhead circuit increases linearly with
the existing hardware limitation and new crude
increase in light end composition especially
assay, the design is to be optimized to• methane and ethane which governs the fuel
• Minimize the changes in existing unit with loss. Thus, it becomes imperative to finalize
limitations in crude heater. the light ends to be considered in design.
• Design objective to be met i.e. revamp
design to be able to process lighter crude.
• Reduce the energy dependency and make
the design more energy efficient.

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Figure 3

As a case study, comparison of TBP curve • Increase in existing overhead circuit

(Figure-3) for pre and post crude assay shows pressure drop leading to fuel gas
that the revamp crude has higher lighter generation.
content than existing. The TBP cut range (IBP • Stabilizer column limitation.
-125) stream content increased by 25%. Due to
this substantial increase in light end following To address the above key issues to be taken
constraints were identified. care in design with the objective to implement
the changes in short shutdown period, thorough
analysis was done and scheme was finalized.

Table 1:

Option Modification Pressure drop Fuel loss

acceptable
I Additional shell for overhead condenser Yes No
II Single shell operating + lateral air cooler piping No Yes
replacement

To minimize the modification in the overhead was finalized as the existing layout allowed
circuit i.e. replacing overhead main header and for easy placement of this additional shell.
lateral lines and minimizing the losses of fuel, From table 1 above, providing additional
the option of considering an additional parallel shell in overhead condenser leads to total
shell to existing overhead condenser was condensation and the pressure drop is within
envisaged (refer Figure 4). This modification acceptable pressure drop limits.

Oil & Gas Technical Journal -1 39

The increased light end had an impact on the stabilizer for identifying the minimum energy requirement point.
column which separates the LPG and Naptha cut. The key input to pinch analysis is the hot and cold stream
Due to the increased load in existing column, LPG conditions i.e. flow rate and temperature levels. The
specifications could not be met due to increased outcome is that the cold stream outlet temperatures
vapor liquid traffic in existing column. This problem are maximized with minimum exchangers.
was suitably mitigated by replacing the existing
conventional valve trays with high capacity trays. With The revamp objective was to maximize the preheat
this revamp the additional load could be handled and temperature as the existing crude heater was limiting.
the product streams met target specifications. To achieve the target of maximizing the preheat
temperature with minimal changes, potential strategic
Pinch Analysis locations were identified in the existing preheat
network (refer figure 5) so that existing network is
The preheat train configuration is optimized using the utilized without any changes. Two preheat exchangers
Pinch technology which is based on the first principles were added at the start and just before the heater inlet
(refer figure 6).

Figure 5

The crude column bottom stream (RCO) was utilized The crude received at battery limit is heated to an
in the preheat exchanger located upstream of crude optimum value before it enters the existing preheat
heater. This leads to increase in preheat temperature exchanger (wherein the heat is provided by crude
thereby reducing crude heater duty and avoiding major column overhead stream) so as to minimize corrosion
changes in crude heater. The RCO was again heated issue in overhead circuit.
in vacuum heater which was within the design margin
limit.

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From table 2 below it is evident that utilizing the existing 2.1.4 Conclusion
design margin minimizes the changes required.
The crude and vacuum distillation unit being
Table 2 first primary processing unit requires thorough
review for different crude processing. Also,
Sr. Parameter Pre­ Post­
it has the highest processing capacity in a
No. Revamp Revamp
refinery and it is highly energy intensive process
1. Preheat Temperature X X + 12 C and therefore, even a small reduction in Energy
2. Crude Heater Duty X* 0.95 X requirements in this unit leads to substantial
saving for the Refiner.
* Actual plant lower duty envisaged

Hybrid Vacuum system The methodologies adopted shows that

implementing changes in revamp during the
The vacuum column operation is critical w.r.t. to stipulated shutdown period can be met after
desired specification of vacuum column products careful analysis of the constraints. To address
and so is the design configuration of it. The vacuum the issue of handling increased light ends the
is maintained using ejector system which utilizes modifications suggested are optimized w.r.t.
substantial quantity of energy in the form of steam. implementation and fuel loss (in form of gas
The hybrid vacuum system comprises of utilizing generated at low pressure). This fuel loss would
both ejector and Liquid ring vacuum pump (LRVP) to require additional power to compress the gas
maintain the desired level of vacuum. further for sending to fuel gas system. Further
the use of RCO in preheat addressed the issue
For revamp scenarios the last stage of the ejector can of existing crude heater firing limitation which
be replaced with LRVP (Liquid ring vacuum pump). avoided major heater modifications. It is also
For a typical case, Comparison shows that the OPEX observed that envisaging hybrid system by
for hybrid system is low compared to conventional all replacing the last stage ejector with LRVP in
ejector system. vacuum overhead system reduces the energy
Table 3 dependency. A typical case study shows that
implementation of LRVP reduces the operating
Utility Last stage Ejector Hybrid System cost (OPEX) with viable payback period thereby
system making it a more realistic approach for energy
OPEX X 0.25 X efficient design.
(Basis: In house/ vendor data)

Oil & Gas Technical Journal -1 41

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/■--------------------------------------------------------------------------------------------------------------------------------------------------------
2.2 Reconfiguration of Naphtha Splitters Using Divided Wall Column
Technology
Author: Ratheesh S, Mumbai Refinery, Bharat Petroleum Corporation Limited
r ----------------------------------------------------------------------------------------------------
The author, Mr Ratheesh S is currently working as Manager, Process Technology in BPCL
Mumbai Refinery. He holds a Chemical Engineering degree. With over H years of experience,
he has expertise in process design and development, commissioning and technical services for
refineries

v.
2.2.1 Introduction to 6000 tons/day, by means of modification
of column internals. Post revamp, MR is
BPCL Mumbai Refinery is a pioneer in oil & able to operate RFU Splitter I & II in parallel
gas industry, especially in the field of energy configuration, thereby shutting down ISOM
conservation and environment protection by Naphtha Splitter, which is an epitome of energy
means of innovative approaches. Naphtha conservation by means of innovation.
management is crucial for improving the
overall Gross Refining Margin (GRM) of any 2.2.2 Background
refinery. Naphtha can be managed by effective
separation and upgradation and optimizing the Straight Run Naphtha from Stabilizer bottoms
blending strategies, which in turn minimizes of both CDU-3 and CDU-4 is being received
the overall Naphtha production. in Naphtha Splitters. The quantity and quality
of naphtha depends upon the type of crude.
Mumbai Refinery (MR) consists of 2 Crude Typically, Naphtha generated from Bombay
Distillation Units, namely CDU-3 and CDU-4. High (BH) crude contains high amount of
MR was having three Naphtha Splitters namely Benzene; whereas Naphtha generated from
Reformer Feed Preparation Unit (RFU) Splitter Middle East crudes contains relatively lower
I, RFU Splitter II and Isomerization Unit (ISOM) Benzene. For upgradation purpose, Naphtha
Naphtha Splitter, to split 6000 tons/day of has to be separated into ISOM feed (C5 and C6
Stabilized Naphtha from the Crude Distillation with low Benzene content) and CCR feed (C7+).
Units into light and heavy components.
RFU Splitter I & II were operating in series In the pre-revamp scenario, RFU, with series
configuration wherein Splitter I bottoms were configuration of the two Splitters, was
fed to Splitter II. Along with its scheduled processing 4300 tons/day of Stabilized Naphtha
turnaround for maintenance and inspection and ISOM Naphtha Splitter was processing
activities, RFU had also undergone a revamp in 1700 tons/day of Stabilized Naphtha. Details
the month of Sept-Oct 2021 for enhancing its of these columns (pre-revamp) are provided in
feed processing capacity from 4300 tons/day Table 1:

Table 1: Details of Naphtha Splitters (Pre-revamp)

| Sl. No. Equipment Description Outer Diameter, m Height, m Internals

1 RFU Splitter I 3.0 21.75 60 Nos. of Valve trays with tray
spacing of 610 mm
2 RFU Splitter II 3.4 21.75 3 beds (Total 48 layers) of
structured packings
3 ISOM Naphtha Splitter 2.6 43.90 3 beds (Total 51 layers) of
structured packings

Oil & Gas Technical Journal -1 43

 In the pre-revamp scenario of RFU, Top cuts With an objective to improve the performance of
(C5-85oC) from RFU Splitter I as well as these Splitters, our Corporate R&D Centre had
ISOM Naphtha Splitter were getting routed to done a detailed analysis of Naphtha operations
Naphtha Hydrotreating Unit (NHT), where it was in MR, in detail. Based on the analysis of feed
getting hydrotreated to get ISOM feed. Bottom and products data, it was found that:
cut from Splitter I was getting fed to Splitter II.
Mid cut from Splitter I, Top cut from Splitter II • Existing configuration was outdated and
and Mid Cut from ISOM Naphtha Splitter were requires upgradation as per changes in
getting routed to Naphtha product pool. Bottom refinery configuration.
cuts (95-135oC) from r Fu Splitter II as well • Separation efficiency was low and overall
as ISOM Naphtha Splitter were getting routed energy consumption was high.
to Naphtha Hydrotreating Unit (NHT), where • ISOM feed was having low amount of C6
it was getting hydrotreated to get CCR feed. components, which are active reactants in
Pre-revamp configuration RFU is indicated in ISOM Unit for RON improvement.
Figure 1.

Figure 1: Pre-revamp Configuration o f RFU Splitters

In order to address the above issues, different 2.2.3 Objectives of RFU Revamp
schemes were configured and simulated
using Aspen Plus. Stream properties (quality The main objectives of RFU Revamp were as
and quantity) as well as energy consumption follows:
of each configuration was compared with
existing configuration. Based on economical • Increase RFU feed processing capacity
and operational benefits, one of these from 4300 MTPD to 6000 MTPD by
configurations was finalized and proposed for operating Splitter I & II in parallel
implementation. The selected configuration configuration so that ISOM Naphtha
was to convert RFU Splitter II into a Divided Splitter can be shut down. Feed
Wall Column (DWC) so that RFU Splitter I & II distribution to both the Splitters shall
can be operated in parallel and ISOM Naphtha be optimized suitably to minimize the
Splitter can be shut down. quantum of modifications and maximize
the product quality and yield.

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• Maximize the quantity of Top cut along along with maximization of Toluene in it.
with minimization of Benzene, C6 This stream will be fed to NHT-CCR Unit.
Naphthenes & C7+ hydrocarbons in it.
This stream will be fed to NHT-ISOM Unit. 2.2.4 Post-Revamp Configuration of RFU
• Minimize the quantity of Mid cut along
Post-revamp RFU Splitter I continues to
with minimization of overlap of it with Top
operate as a conventional side cut column
cut and Bottom Cut. This stream will be
whereas Splitter II has got revamped into a
diverted to Naphtha storage.
middle Divided Wall Column. Post-Revamp
• Maximize the quantity of Bottom cut Configuration of RFU is indicated in Figure 2.

Figure 2: Post-revamp Configuration o f RFU Splitters

With this configuration in place, RFU Splitter I & II heaters. 4 Nos. of new heat exchanger shells
are sufficient to split the entire quantity of Stabilized (by replacing existing 3 Nos. of heat exchanger
Naphtha from Crude Distillation Units. shells) were got added in order to meet the
revised cooling requirement of various process
2.2.5 Major Modifications done in Revamp streams. Further, 7 Nos. of new pumps with LT
motors (by replacing existing 5 Nos. pumps)
No modification was envisaged in Splitter I were also got added. Major modifications done
Reboiler & Splitter II Reboiler, which are fired during the revamp are listed in Table 2.

Oil & Gas Technical Journal -1 45

 Table 2: Details of Major Modifications done during RFU Revamp

Sl. No. Equipment Category Modifications Done

1 Splitter I Packing of Top Bed (10 layers) completely replaced with 13 layers of
new type of packing.
Bed height reduced (from 12 layers to 8 layers) for middle bed.
26 layers of packings reused without any change in bottom bed.
2 Splitter II All beds except bottom bed completely replaced with new structured
packings and bed height reduced (from 27 layers to 13 layers) for bottom
bed in stripping section of the column.
A dividing wall was installed inside the column which runs between top
and bottom beds. The dividing wall section runs approximately middle
1/3rd of the column.
3 New Heat Exchangers MP Steam/RFU Feed Preheater (1 No.)
Splitter I/II Top Cooler (1 Shell)
Splitter I/II Mid Cut Cooler (2 Shells)
Splitter I/II Bottom Cooler (1 Shell)
4 New Vessel RFU Feed Preheater Condensate Pot
5 New Pumps RFU Feed Pumps (2 No.s)
Splitter I Reflux Pumps (2 No.s)
Splitter I Mid Cut Pump (1 No.)
Splitter II Mid Cut Pumps (2 No.s)

Rated capacity of RFU post-revamp is 6600 tons/day with turndown of 40% for Splitter I & Splitter II.

2.2.6 Product Specifications

Post-revamp product specifications are provided in Table 3.

Table 3: Post-revamp Product Specifications

Parameter Top Product Mid Cut Bottom Product

IBP, oC - - > 95
D86 5%V, oC - - > 98
D86 95%V, oC < 80 - -
FBP oC < 85 - -
Benzene, %w <4 - -
C6 Naphthenes, %w < 10 - -
C7 Hydrocarbons, %w <3 - -
Toluene, %w - <2 -

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2.2.7 Divided Wall Column Technology • The new packings in both the columns
are high efficiency packings which are
The revamp of RFU is based on optimized capable of handling high vapor liquid
DWC which maximizes the product yields. traffic.
The added benefit of lower capital investment • Flexibility has been provided to
combined with lower operational cost have operate Splitter I & II columns in series
helped divided wall columns gain in popularity configuration as well.
over conventional columns. When applied to
sequential multi-component separation, DWC
can separate the feed into two or more purified
streams within single tower, thus eliminating
the need of second tower. DWCs offer the
following benefits:

• Suitable for separating multicomponent

mixture into three or more high purity
product streams in a single column.
• Ideal alternative for revamp of side cut
columns when high purity is required from
the three product streams.
• Lower footprint as equipment count is
reduced by half.
• Equipment turnaround time and other
miscellaneous expenditure are reduced. Figure 3: New Dividing Wall inside Splitter II
• Operational and capital expenditure are
reduced by approximately 20-50%. 2.2.8 Conclusion
Following were the salient features of RFU With the latest advances in process simulators
Revamp:• and design methods, DWCs have emerged
as a viable technology over the course of the
• Provision for MP steam preheating: Both
previous two decades. DWCs can also be
the columns were limited in terms of fired
integrated in existing refining technologies,
heater duties. Besides providing high
thereby operating cost can be reduced.
level of product recoveries, MP steam
Naphtha management in refineries can be
preheating provides flexibility to handle
done by effective separation and upgradation
feeds from CDU-3 & CDU-4 at different
strategies, which can minimize the overall
feed temperatures.
Naphtha production. With RFU revamp, BPCL
• Integration between Splitter I & II: The Mumbai Refinery is currently the proud owner
side cut from Splitter I has a substantial of 2 divided wall columns i.e., a middle divided
overlap of C5 components. The side cut wall column in RFU and a top divided wall
from Splitter I is fed to Splitter II on the column, which is a Deisohexanizer, in ISOM
feed side of dividing wall. This leads to a Unit, with huge savings in terms of energy.
considerable reduction in overall side cut
rate from the two columns.

Oil & Gas Technical Journal -1 47

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2.3 Commercial Demonstration of [HP]2 Catalyst: A multispecialty

catalyst formulation for maximizing FCC products yield

Authors: Somanath Kukade and Pramod Kumar

HP Green R&D Centre, Hindustan Petroleum Corporation Limited, Bengaluru, India
r A
Mr Pramod Kumar is working as DGM-FCC in HP Green R&D Centre, Hindustan Petroleum
Corporation Limited, Bengaluru, India. He has vast knowledge in FCC process design, Biomass
to Biofuel research, engineering and technical services in the area o f FCC, visbreaking & delayed
Coking.

J
Mr Somanath Kukade Is working as Senior Manager-FCC in HP Green R&D Centre, Hindustan
Petroleum Corporation Limited, Bengaluru, India. He has experience in Gas-Solid Fluidization,
Cold flow hydrodynamics/CFD, FCC Catalyst Evaluation / Pilot Plant Studies, FCC Process
Design & Process Development, Technical services/troubleshooting for FCC units and Scale-up
of catalyst & additives.

J
2.3.1 Introduction methanol-to-propylene. But due to shift of
naphtha crackers to ethane crackers, the gap
Fluid catalytic cracking (FCC) is one of the for propylene has been on increasing trend.
most important conversion processes used Most of the new steam crackers coming online
in petroleum refineries and has existence of are designed to use ethane as the primary
75+ years. It is widely used to upgrade heavier feedstock, which typically produces less
cuts like vacuum gas oil and residues to more than 2% of propylene compared to ethylene
valuable petroleum products like gasoline and production. Propylene demand has increased
light olefins. It can readily adjust to changes at an average rate of nearly 4-5% per year. In
in feed quality through modifications of India, growth rate for propylene stood at 2.33%
catalyst and operating conditions. Catalysts CAGR and polypropylene (PP) at 3.85% CAGR
and additives play important role with respect for 2020-21. Enhancement of propylene yield
to activity and selectivity in FCC. FCC units from FCC from maximum of 12wt% to 20wt%
typically produce around 4-6wt% propylene but is one of the option to meet growing demand of
can go as high as 12%, depending on feedstock propylene. Refiners are integrating the modern
type, operating conditions such as riser outlet configuration with petrochemical complex and
temperature, reactor pressure, catalyst-to-oil petrochemicals from current average of 7% will
ratio and the type of FCC catalysts/additives. go upto 20%.

The major source of ethylene and propylene Propylene is perhaps the most versatile
is the traditional steam naphtha cracker that building block in the petrochemical industry, in
supplies about 57% of global propylene as a terms of its variety of end-use products and its
by-product to ethylene production. The FCC multitude of production sources. High demand
unit is also an important source of propylene for polypropylene (PP) has been a major driver
producing about 35% of world propylene as for the rapid expansion in propylene production
a by-product to gasoline production. The processes and many polypropylene units are
remaining 8% of world propylene is produced added by refineries. Worldwide, approximately
by ‘on-purpose' processes such as propane two-thirds of propylene is used to make PP.
dehydrogenation, olefin metathesis and

Oil & Gas Technical Journal -1 49

 HP Green R&D Centre (HPGRDC) has developed path to these molecules to transport and crack
a novel catalyst formulation: [HP]2 (Hindustan on mesoporous of active alumina having pore
Petroleum High Propylene) catalyst system size of 12-100 Ao. The upgraded molecules
for maximizing propylene yields. The catalyst viz: LCO range come in contact with Y zeolite
formulation has been patented. The catalyst pores having pore size of 7-8Ao and convert
formulation acts as an additive in conventional to gasoline range molecules using strong
FCC units. The catalyst system can be used in acid sites and the gasoline range olefins are
high severity FCC unit like HPCL patented [HP]2 converted to light olefins (LPG Olefins) through
FCC Technology, DCC (Deep Catalytic Cracking) modified shape selective ZSM-5 having pore
or other high severity FCC for maximization of size of 5-6 Ao. It is important that the catalyst
light olefins. To assess the performance of the have the proper pore size distribution to enable
[HP]2 catalyst field trials of the catalysts were large feed molecules to enter, crack into
carried out at HPCL's FCC units at 10% and lighter products, and diffuse out before being
15% inventory change over and the commercial over-cracked to coke and gas. Therefore, it
demonstration in one of India's DCC unit. FCC is essential to design a catalyst with optimal
Performance of the catalyst formulations as a porosity for effective kinetic conversion. The
catalyst and additive is discussed here. sequential cracking is depicted in Figure-1.
Typical properties are given in Table-1.
2.3.2 [HP]2 Catalyst for Light Olefins: The modified ZSM-5 of the formulation is
having metal function to increase the light
Catalysts and additives play vital role in FCC olefins. The catalytic cracking of alkanes
for enhancing light olefins. The proprietary occurs via bimolecular and monomolecular
tailor made catalyst system has cracking reaction mechanisms. If the monomolecular
functionality to crack feed molecules to mechanism is dominant, the yield of light
gasoline by use of macro-mesoporous and olefins (e.g., ethylene and propylene) is more.
micro-porous functions and increase light Bimolecular reactions are hydrogen transfer
olefins by modified shape selective pentasil reactions, which will saturate the olefins.
zeolite. In [HP]2 catalyst there is upgradation Hydrogen transfer in FCC is a well-known
of larges molecules by physical transport in phenomenon and reduces the gasoline range
macrospores (Lewis acid sites) and primary olefins. The cracking rates of gasoline olefins
cracking mesoporous sites (medium acid on ZSM-5 are higher than those of paraffins
sites) of alumina, which is surface modified and therefore, an increase in hydrogen transfer
to change the strength of the acid sites. The reduces the effectiveness of ZSM-5 additives.
upgraded molecule diffuses into zeolite pores The synergistic alumina and Y-zeolite cracking
to give gasoline, which further cracks to light of feed molecules as explained will provide
olefins in presence of modified shape selective maximum activity and higher gasoline range
ZSM-5 additive incorporated in the [HP]2 olefins for cracking on modified ZSM-5. The
catalyst formulation. The large molecules ratio of monomolecular to bimolecular for the
in the feed prefer to be first precracked on [HP]2 catalyst formulation is higher, indicating
the alumina surface. The feed molecules are monomolecular reactions are dominant in
370+ boiling range consisting of saturates [HP]2 catalyst formulation. The paraffin to
(C14-C34) and heavy aromatics (C14-C60) olefin ratio, which is measure of hydrogen
in the ranges of 40-60% and 35-45%, having transfer reactions is almost 50% less in [HP]2
pore diameter of 12-20Ao and 12-30Ao. These catalyst formulation, indicating the design of
hydrocarbon molecules are too large to fit into the catalyst is selective towards light olefins.
the zeolite pores. The macropores provide free

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M e sop o rou s
Medium Y Zeolite-
acidity Micropores/
Modified
High Acidity
Z S M -5

Figure 1: Sequential cracking o f Hydrocarbon feed to light olefins using [HP]2 catalyst

Table-1: [HP]2 Catalyst properties

Parameter Values
Fresh surface area, m2/gm 150-250
PV, cc/gm 0.35-0.4
APS, micron 75-85
ABD, gm/cc 0.75-0.85
Attrition Index, wt% <6
D ry G as LPG CRN LCG O R e s id C oke C3= RON
2.3.3 Field demonstration of [HP]2 catalyst:
Figure-2: Product yields with 10% [HP]2 catalyst at
The catalyst formulation also acts as an FCCU-A
additive in conventional FCC units. Refinery
trials were taken at three FCC units to assess Field trial at FCCU-B:
the performance of the catalyst as an additive
and commercial demonstration as a catalyst in Trial were conducted at FCCU-B by 15%
one of India's DCC unit. inventory changeover over the period of one
month. Unit throughput was 130 m3/hr with
Field trial at FCCU-A: ROT of 524oC, feed density of 0.918g/cc
sulphur-1.6wt% and CCR-0.62wt% with unit
Trial were conducted by 10% inventory cat/oil of 7.1wt/wt. Monthly average yields
changeover over the period of one and half of before and after addition of [HP]2 catalyst
month. Unit throughput was 100 m3/hr are given in Figure-3. Performance of [HP]2
with ROT of 490oC, feed density of 0.88g/cc catalyst showed 0.32wt% decrease in dry gas,
sulphur-0.3wt% and CCR-0.11wt% with unit 0.50wt% increase in LPG, 0.54 wt% increase
cat/oil of 5.7wt/wt. Test run was conducted in propylene, increase in LCO by 0.62wt% and
to see the performance of [HP]2 catalyst as an reduction in bottoms by 1wt% w.r.t to base
additive at 10% concentration. Performance case.
of [HP]2 catalyst showed 0.6 wt% increase in
LPG, 0.5wt% increase in propylene, increase in
RON by 0.6 units and reduction in bottoms by
0.2wt%. Product yields are given in Figure-2.

Oil & Gas Technical Journal -1 51

 40 100
■ Prior to trial ■ Base Case
35 90
80
30
70
25
60
20 50

15 40

10 30
20
5
10
0 0
Dry Gas LPG CRN LCGO Resid Coke C3= in Dry gas LPG CRN LCO Slurry C3= in RON
LPG
LPG

Figure-3: Monthly average product yields obtained at Figure-4: Product yields with 10% [HP]2 catalyst at
FCCU-B FCCU-C

In both FCC unit field trials, the C3= selectivity in LPG

2.3.4 Commercial Demonstration in FCCU-D:
was seen to increase by 2.5 to 5 vol% from base value
of 34-35 vol%. During, the trial period, there was no
Commercial demonstration as a catalyst was
observation on incremental catalyst loss from the
conducted over the period of 4 months in one of
FCC units, due to the addition of [h P]2 catalyst. Hence,
India's DCC unit. Performance of [HP]2 catalyst
meeting catalyst compatibility with the existing base
showed 0.3wt% increase in propylene (17.7wt%
catalyst.
achieved at 132% of design capacity) and also
increase in propylene selectivity in LPG from
Field trial at FCCU-C: 42.57% to 44.56%. The hydrogen transfer index
for [HP]2 catalyst was 0.3 as compared to base
Trial were conducted by 10% inventory changeover value of 0.4 indicating propylene selectiveness
over the period of 2 months in resid FCC unit. Unit of the catalyst.
throughput was 176-179 m3/hr with ROT of 520-
525oC, feed density of 0.9231 g/cc, sulphur-1.6-2.2wt%
2.3.5 Conclusion:
and CCR-1.3-1.6wt% with unit cat/oil of 7.3-7.5wt/
wt. Test run was conducted to see the performance
Based on the lab study and field trials at FCCU-A,
of [HP]2 catalyst as an additive at 10% concentration.
B & C, [HP]2 catalyst can be used an additive
Performance of [HP]2 catalyst showed 0.42wt%
in existing FCC units to maximize the product
increase in LPG, 0.31wt% increase in propylene,
yields and selectivities and increase the RON
increase in RON by 0.2 units and reduction in bottoms
barrels. In a high olefin FCC unit, the commercial
by 0.25wt%. Product yields are given in Figure-4.
demonstration has proven propylene increase
by 0.3wt%. The demonstration/field trial has
shown it can be used in conventional VGO FCC,
resid FCC and high olefin FCC as an additive
and catalyst.

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2.4 HPCL's Pressure drop mitigation technique for Naphtha Hydrotreaters

Authors: Amit Behera, Kanuparthy Naga Raja
Hindustan Petroleum Corporation Ltd., HP Green R&D Centre, Bangalore

Kanuparthy Naga Raja is working as Chief Manager in HP Green R&D Centre, Hindustan
Petroleum Corporation Ltd. his present reseach area are Hydro-processing, Resid Upgradation,
Hydrogen and Modeling & Simulations

r
J
Mr Amit Behera is working as Assistant manager in HP Green R&D Centre, Hindustan
Petroleum Corporation Ltd. He currently engaged in research in the field of
Hydro-processing; Residue Hydrocracking; Adsorptive desulphurization; Solvent
De-asphalting; Process modelling; CFD

2.4.1 Introduction: inorganic materials such as sediments and

other organic gum forming compounds. In
The total distillate production from Indian addition, any coke formed in the upstream unit
refineries is about 200 MMT per year. With the operations, may also be carried along with the
implementation of BS-VI norms, hydrotreaters process stream and brought into the reactor.
play an important role in fulfilling the These solid materials deposit mainly on the
requirement and demands of BS-VI-compliant top of first bed inside the reactor. Such solid
gasoline and diesel. Hydrotreaters help to deposits, as shown in Figure 1, can reduce the
remove hetero atoms like sulphur, etc., from performance of the process unit by means of
diesel and naphtha fractions for providing blocking the flow of process streams in the
on-spec products for marketing or for further reactor that will lead to pressure drop increase
processing in other secondary conversion across the catalyst bed, reducing the heat
units. transfer and fouling the catalyst bed resulting
in reducing the effectiveness of the catalyst
Hydrotreating Units are fixed bed reactors bed. With the increase in pressure drop across
with single or multiple catalyst beds. While the catalyst bed, the continuous operation
processing diesel or naphtha, the beds of the unit becomes a challenge as the unit
often receive solid materials along with the is designed to operate within the maximum
process fluid. These solid materials are often allowable pressure drop. In addition, the
corroded materials from upstream of reactor, pressure drop increase will increase the overall
energy requirement in the process.

Oil & Gas Technical Journal -1 53

 Figure 1: Solids Inside the Reactor

In refinery, processes such as Naphtha technique is by means of adding the HPCL's

Hydrotreaters, Diesel Hydrotreaters and VGO proprietary product viz., HP-DUCER at
hydrocrackers encounter increased pressure certain intervals based on the severity of the
drop across the first bed due to such solid problem and the type of solid deposits in the
deposits. Though the pressure drop builds up reactor. This product has been successfully
gradually, any unplanned shut down in the unit demonstrated and commercialized in Diesel
suddenly increases the pressure drop across hydro-processing reactors.
the first bed of catalyst. From there on the
operation of the unit becomes a challenge and 2.4.3 HP-DUCER NHT:
force the refiner to limit the unit throughput
to maintain the pressure drop. This pressure HPGRDC has recently developed a new product
drop gradually increases to a level where the viz., HP-DUCER NHT for addressing pressure
continuous operation of the plant will become drop issue in Naphtha Hydrotreaters (NHT).
infeasible. This forces the refiner to shut down The solid deposits in NHT vary from corrosion
the unit to address the pressure drop issue products such as iron sulphides to coke from
before commencing the normal operation. coker naphtha or solids from caustic wash,
etc. The product, HP-DUCER NHT is versatile
It is widely practiced in the refinery, that and robust to handle all types of solid deposits
whenever such issue is encountered, the and also can be customized to suit the unit
operator takes the unit shut down, skims the requirements.
first bed catalyst along with solid deposits,
make up with fresh catalyst and resumes the HP-DUCER-NHT dislodges the solids from the
plant operation. This skimming process has catalyst bed thereby reducing the pressure
shortcomings in terms of production loss, loss drop across the Naphtha Hydrotreating reactor.
of active catalyst, additional cost due to make The working principle is depicted in Fig.2. The
up catalyst, additional manhours for shut use of the HP-DUCER-NHT is an economical
down, catalyst replacement & plant startup approach for maintaining the continuous
following all safety measures, etc. The other operation of the unit without shutting down
ways by which pressure drop issue is handled the unit. The product is a novel material with
are by means of capital-intensive options such great business potential in the downstream as
as Scale Catching internals, graded beds, etc. well as upstream industries. In this article, the
development of HP-DUCER from lab-scale to
2.4.2 HP-DUCER for Hydro-processing Units: the demonstration in NHT reactor has been
described.
HPCL Green R&D Centre (HPGRDC) has
developed a simple technique to address the
pressure drop increase without disturbing
the continuous operation of the plant. This

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for its efficacy in batch scale and pilot scale to

finalize the product formulation and dosage
optimization. It is ensured at the development
stage that HP-DUCER NHT has no effect
on catalyst performance and the product
properties.

2.4.5 Case Study:

One of HPCL's refineries has the issue of

pressure drop increase in the NHT unit. The
unit has been operating at less than 1 barg
pressure drop until a shut down was carried
out. Post unit start up, the pressure drop started
increasing and reached above 2 barg. The unit
throughput had to be reduced to maintain the
pressure drop.

The dosage system has been developed at

refinery site and 10 MT of HP-DUCER NHT
has been produced for commercial use. Based
2.4.4 Research & Development: on the unit performance, feed and product
analysis, the dosage rate has been established
Several product formulations have been to reduce the pressure drop in the NHT reactor.
synthesized at lab scale and tested in various
stages to understand the underlying chemistry The product was slowly dosed to alleviate the
and narrow down properties required for pressure drop and dislodge the solid deposits
different kinds of solid deposits that the on the catalyst bed. Initial response confirmed
product is supposed to encounter in the severe the functionality of the product. Subsequently,
reactor conditions. HP-DUCER NHT was tested the unit responded positively to the minimal
dosage rates.

Oil & Gas Technical Journal -1 55

 Figure 3 shows the field data of the Feed flow The conventional way of skimming or capital­
rate & Delta pressure across the reactor. intensive internals are expensive. HPCL's
HP-DUCER NHT offers an economical and
The red envelopes indicate the injections of flexible technique to overcome this problem.
HP-DUCER-NHT at different intervals. With the The technique is highly safer, requires minimal
first injection of HP-DUCER-NHT, the pressure operational intervention and provide the option
drop of the reactor was reduced below 2 kg/ to the operator to postpone the unit shut
cm2. Subsequent dosage resulted in reduction down as long as the catalyst is active. This
in pressure drop down to 1 kg/cm2. In about can provide enough window to the refiner to
10 days, the flowrates have been brought back plan for the next shutdown for maintenance
to the desired levels with reactor operating at or catalyst replacement activities. From the
lower pressure drop. commercial experience, it is established that
HP-DUCER-NHT is a perfect solution for
2.4.6 Conclusions: reducing the pressure drop while sustaining
the throughput, maintaining the catalyst life
Pressure drop increase in hydro-processing cycle and increasing the service factor of the
fixed bed reactors is a common scenario. unit.

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2.5 Potential Technologies for Benzene Recovery from FCC Gasoline

Authors: Prasenjit Ghosh, Sunil Kumar, Kirtika Kohli

Aromatic Extraction Area, Separation Process Division, CSIR-Indian Institute o f Petroleum, Dehradun, India

Dr. Sunil Kumar is Principal Scientist in CSIR-Indian Institute of Petroleum. He has 12 years of
experience in the refining and chemical industries. His professional interests include- synthesis,
simulation, design, and scale-up of chemical and refining processes, Pinch analysis, Process
integration, development of distillation, extraction and absorption based separation processes.
He received two CSIR Technology Awards, one MoP&NG/ CHT best innovation in R&D award,
two National Technology Development Board (TDB) Awards as a core team member.

r Dr. Kirtika Kohli,is Scientist CSIR-Indian Institute of Petroleum. Her professional interest include
Extraction-based technologies, Desulfurization and dearomatisation, Separation of value-
added chemicals from coal and bio-mass, crude oils to chemicals, Heavy crude oil and vacuum
residue upgradation using slurry bed hydro-cracking process, Deasphalting and de-waxing
of heavy crude oils thermo-chemical conversions of renewable and non-renewable materials
via catalytic process Microwave-assisted pyrolysis of plastics, biomass, and co-pyrolysis of
biomass and plastics, Catalytic CO2 conversion to value-added chemicals. Two U S Granted
Patents; Slurry phase catalyst for residue hydro-cracking and Waste Plastic as a hydrogen
donor for residue upgradation
\

The declining demand for transportation fuels (mainly most widely produced derivative and it is further used to
gasoline) made refiners to focus on upgrading and generate polymers and plastics. Cyclohexane is used in
integrating their refinery operations towards high-value the manufacture of nylon. Cumene is mainly converted
petrochemicals production. In 2016, the petrochemical to phenol for making adhesives and phenolic resins.
feedstocks were reported to be 12% of global crude Benzene is also utilized to produce lubricants, rubbers,
oil demand, and this demand is forecast to reach 18 detergents, dyes, explosives, drugs, and pesticides. In
million barrels per day in the year 2030 . Among the addition, due to health and environmental concerns,
petrochemicals, light olefins and naphtha-based there has been an increasing pressure on refiners to
aromatics are the largest volume basic or intermediate reduce the amount of benzene and other hazardous air
chemicals with a global production capacity of 240 pollutants in the gasoline pool. In 2011, under Mobile
and 85 million tons, respectively, in 2016 . The global Source Air Toxics (MSAT) II regulations, Environmental
production capacity of aromatics is expected to reach Protection Agency (EPA) the United States restricted
133 million tons by 2030. the annual average benzene level in gasoline to 0.62%
vol .
Aromatic hydrocarbons (especially benzene, toluene,
and xylene, BTX) play a pivotal role in the petrochemical In general, hydrogenated pyrolysis gasoline, reformate,
and chemical industries. Benzene is extensively and catalytically cracked gasoline feedstocks are
utilized as a precursor/intermediate to produce various the major contributors of benzene in the refinery
industrial chemicals. Benzene (approx. 80%) is mainly gasoline pool. Because of the increasing demand
used to produce ethylbenzene, cyclohexane, and for petrochemical products, refiners need to develop
cumene. Ethylbenzene, a precursor to styrene, is the technologies using alternative feedstocks.

World Energy Outlook; International Energy Agency (IEA), November 2017, Paris.

Oil & Gas Technical Journal -1 57

2.5.1 Fluid Catalytically Cracked (FCC) to either recovering aromatics or decreasing
Gasoline as an Alternative Feedstock aromatics from the petroleum feedstocks
for Benzene Production such as pyrolysis gasoline, reformate, or
cracked gasoline fractions. As per the author's
In a typical refinery, FCC gasoline comprises knowledge, there is no technology in operation
approximately 10-20% of the gasoline pool. worldwide that can serve the dual purpose of
Because of the increasing demand for light producing benzene lean streams from a cracked
olefins (ethylene and propylene) for the petroleum feedstock like FCC naphtha and
polymer industry, FCCs are predicted to simultaneously recovering high purity benzene.
operate with higher severities, mainly using The most widely used hydroprocessing route
heavier feedstocks (gas oil and residues). High reduces benzene from olefinic feedstocks such
severity FCC operation results in increase in as cracked gasoline. This helps in saturating
production of both olefins as well as aromatics. the olefins, thus lowering the octane of the
For instance, propylene yields can be enhanced cracked gasoline fraction. Olefins present
from 2-5% (conventional FCC) to 16-27%. In in the cracked gasoline fraction contribute
addition, the aromatic content of cracked substantially to the octane in the gasoline pool.
naphtha can reach 50-70%. However, it also Therefore, while using hydroprocessing route
contains a significant amount of olefins and for reducing benzene, results in saturating the
thiophenic sulfur. olefins as well and hence lowering the octane
of the cracked gasoline fraction.
An FCC gasoline (full range) contains 1000­
2000 ppm sulfur and ~15-30% vol. aromatics In hydrocarbon industries, the extraction
(up to 2% vol. benzene). On the contrary, of aromatic hydrocarbons (mainly BTX) is
a narrow C6 fraction (from FCC gasoline) currently performed by liquid-liquid extraction
consists of ~11-19 wt% benzene and ~500 (LLE) or extractive distillation (ED) processes,
ppm sulfur. Therefore, it is essential to develop using solvents such as N-methyl-2-pyrrolidone
technologies to efficiently recover high-value (NMP), sulfolane, N-formyl-morpholine
chemicals like BTX from FCC gasoline. Also, (n Fm ), etc. Patents such as US 3,591,490 ,
technologies are required to make it market- US 3,723,256 , US 5,022,981 , US 7,501,549
ready (with low sulfur and benzene content). describe the processes for the recovery of ethyl
benzene and xylenes, BTX from feedstocks like
The recovery of benzene from FCC gasoline is hydrogenated pyrolysis gasoline, hydrotreated
comparatively less straightforward. The effect pyrolysis naphtha C6-C8 cut, C6-C9 feed
of feedstock properties and reaction process stream, and FCC naphtha, respectively. Another
conditions for the desired product formation patented process, US 8,143,466 disclosed
is a challenging task in an FCC unit. Compared a method for removing benzene from coker
to reformates and hydrogenated pyrolysis naphtha, coker pentane/hexane, reformate
gasoline, cracked gasoline (unprocessed, from FCC gasoline, FCC naphtha, coal oven naphtha,
FCC or thermal crackers) contains olefins pyrolysis gasoline, straight-run gasoline, and
and impurities such as metals, oxygenates, mixtures containing two or more of these
organic peroxides, chlorides, nitrogen, and streams. According to this process, benzene
sulfur compounds. Because of the complex present in feedstocks is catalytically alkylated
nature of cracked gasoline (unprocessed), with alcohol and ethers to higher aromatics.
it is challenging to develop an economically Therefore, the benzene removal is affected by
feasible and reliable benzene recovery process. the alkylation of the benzene rich feedstock.
It has not been practiced in the industry so far. These claimed and proven technologies had
the disadvantages such as higher capital and
Globally, the processes reported are related operating expenditures, significantly lower

2 Long-term sustainability in comm odity petrochemicals; An outlook for olefins and aromatics, presented at Asia Petrochemical
Industry Conference (APIC), May 2017, Sapporo, Japan.
3 Gasoline mobile source air toxics. United States Environmental Protection Agency (EPA) https://www.epa.gov/

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benzene recovery, and loss of octane barrels solvent (water) have been used as a solvent
due to loss of high-octane olefinic compounds. mixture for the ED process. In the process
In addition, technologies related to extracting configuration, four major columns are used,
benzene from FCC light naphtha were not and their details are:
proven commercially. The reason is the rapid
degradation of solvent by polymerization 1. Extractive Distillation Column (EDC) is
in the presence of reactive species such as the heart of the process and comprises a
olefins and di-olefins and impurities like sulfur, mechanism wherein the feedstock enters
nitrogen, oxygenates, and chlorides. the middle section and solvent system
enters the top section below the reflux
In view of these challenges and requirements entry point. ED re-boiler temperature is
for the future petrochemical industries, maintained in the range of 140 to 185°C.
CSIR-IIP has developed extractive distillation From the top of ED column, benzene lean
processes for the recovery low molecular gasoline (raffinate) and from the bottom,
weight aromatics like Benzene and Toluene benzene loaded solvent phase (extract) is
from FCC naphtha. The details of CSIR-IIP's recovered.
two patented technologies for the above 2. Solvent Recovery Column (SRC) column is
purpose are described in the following sections. used to separate solvent from the extract
Both the processes are based on the principle phase to obtain hydrocarbon free solvent
of extractive distillation using NMP solvent system which is recycled and benzene
system and neither of the processes requires with purity > 97 wt%.
any prior feed pre-treatment like selective 3. Extract Section Stripper (ESS) is utilized to
hydrogenation (for di-olefin or sulfur removal) remove benzene/aromatics dissolved in
or any other impurity removal procedure. A the water from the SRC overhead decanter,
C6 rich narrow boiling range cut of full range and the stripped water is used for washing
FCC naphtha is used for both the processes raffinate phase.
with the objective of producing benzene lean 4. Raffinate Section Stripper (RSS) is used to
(< 0.4 wt% Bz.) dearomatized naphtha and high remove the non-aromatic hydrocarbons
purity benzene (purity > 97% in the aromatics dissolved in water from the Ed overhead
rich product). decanter. Hydrocarbon free water from the
RSS bottom is made to enter the steam
2.5.2 CSIR-IIP's NMP based Extractive generator for introducing as stripping
Distillation Technologies steam in the SRC.
Benzene recovery in the final extract product is
1. Aq. NMP based Process
> 99% of the feedstock benzene with a purity >
97 wt%. On the contrary, the benzene content
CSIR-IIP in collaboration with RIL developed
in the raffinate (US Grade Gasoline) is < 0.4
an Aq. NMP based extractive distillation (ED)
wt%. The total hot and cold utility requirement
process scheme to produce benzene lean
(for 70 tph feedstock throughput) is about 24
gasoline along with recovery of high purity
MMKCal/hr and 26 MMKCal/hr, respectively.
benzene from unprocessed cracked gasoline
fraction. The process has been granted Patents
in India and 7 other countries including The 2. Pure NMP based Process
United State of America (US 8,722,952 B2 and
IN 294311). The developed process is reliable Most recently, CSIR-IIP has developed and
to catalytically cracked gasoline fraction with a patented an energy-efficient and cost-effective
boiling range 40-90°C and containing a mixture extractive distillation technology using pure
of olefins, diolefins, naphthenes, paraffins, NMP for the same purpose of recovering high
iso-paraffins, benzene along with impurities purity benzene from C6 rich FCC Naphtha. The
such as metals, chlorides, sulfur, oxygenates, process has been granted patents in India and
nitrogen, and organic peroxides. An aromatic The United States of America (US 10,105,620
selective solvent (NMP) system and a co- B2 and IN 342248). Case studies and examples
highlighted in the patent indicate that it has

Oil & Gas Technical Journal -1 59

 lesser utility requirements along with better • The process does not require any feed
product yields and purity as compared to the purification step or selective hydrogenation
Aq. NMP based process for the same feedstock (to reduce chemically reactive di-olefins
and product requirements. This process is a and sulfur compounds).
vacuum based two-stage extractive distillation • Increase in desired product (benzene)
process using NMP (without any co-solvent) yields and purity as compared to using
which produces benzene lean gasoline Aq. NMP based system.
(benzene < 0.4 wt %) and high purity (> 98 wt
• Improvement in purity of benzene shall
%) benzene from C6 rich cracked gasoline/
help decrease the cost of secondary
naphtha fractions (preferably having a boiling
operations (where benzene is used as a
range of 40-90°C). The advantages of the
precursor or intermediate chemical).
process are:
• Reduction in hot and cold utility
• It is a two-stage vacuum based extractive requirements by > 33 and 31%, respectively
distillation process to produce US Grade as compared to the Aq. NMP based
Gasoline (having benzene < 0.4 wt %) and process.
high purity benzene (> 98 wt %) using pure • There is a considerable reduction in capital
NMP, which is a thermally and chemically investment by eliminating extract and
stable solvent system for impurity laden raffinate sections stripers, and associated
feedstocks such as FCC naphtha. machinery.
The process configuration for the improved process is shown in Figure 1.

Figure 1. Process configuration for the two-stage vacuum-based extractive distillation for the simultaneous production
o f US Grade Gasoline and high purity benzene from cracked gasoline fraction 10.

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2.5.3 Process Description of columns C-01, C-02, and C-03,

respectively.
A two-stage vacuum-based ED operation is
used for this process. A single solvent system
The major process outcomes are:
having pure NMP is utilized. The solvent to • The total heating duty (17.63 MMKCal/
feedstock weight ratio in the main ED column hr) and cooling duty (19.45 MMKCal/hr)
(C-01) is maintained in the range of 3-4 and requirements are significantly reduced
the reboiler temperature is in the range of 175- compared to the heating duty (23.76
185°C. Referring to Figure 1. MMKCal/hr) and cooling duty (25.73
• The feedstock i.e., catalytically cracked MMKCal/hr) requirement of the Aq.
gasoline fraction (boiling range 40-90°C) NMP based system for the same feed
enters through line 1-A (below the middle throughput composition. The benzene
portion of a multi-stage ED column C-01), purity in the extract product and the
the feedstock is pre-heated in a pre-heater raffinate yield also increases slightly.
E-01, and a circulating solvent is used as a • Another interesting observation is
hot stream 9-B for the pre-heater. when both ED columns C-01 and C-02
are operated in vacuum at -0.285 kg/
• The overhead product from ED column
cm2g and -0.489 kg/cm2g pressures,
C-01 is passed through line 2 and
respectively, in the presence of a side re­
condensed in the cooler E-02 to about
boiler in C-01, the total heating duty and
70°C. Further, the mixed vapor-liquid
cooling duty requirements can be further
overhead steam 2-A is fed to a second ED
decreased (14.16 and 15.99 MMKCal/
column C-02 (middle section). C-02 is a
hr, respectively) due to the utilization of
refluxed ED column, and sufficient reflux
heat from the hot circulating solvent.
in C-02 minimizes any solvent carryover
A substantial amount of heat i.e., 3.5
to the top product section.
MMKCal/hr present in the hot circulating
• ED column C-02 top product is rich in solvent, is used in a side reboiler E-08
olefins and non-aromatic hydrocarbons is (attached with main ED column C-01)
passed through line 4, condensed in cooler which not only decreases the column's
E-03, and is collected in the drum V-01. heat load but also the cooling load of the
A portion of the condensed hydrocarbon circulating solvent cooler.
from V-01 can be returned to the ED
column C-02 as reflux (via line 6-A), While Thus, the pure NMP based process indicates
benzene lean gasoline product can be sent a better performance in terms of product
to gasoline storage and other processing yield and purities. It has a lesser energy/utility
units through line 6. The bottom product requirement in comparison with Aq. NMP
from C-02 is recycled back to the top of based system (reduction in heating up to ~33%
C-01 as a reflux stream. and reduction in cooling duties up to ~31%) for
• Using vacuum, both sequential ED the same feedstock and processing objective.
columns C-01 and C-02 are maintained
at a pressure below atmospheric pressure 2.5.4 Way Ahead
(0.59-0.39 kg/cm2g).
Both the above-described processes
• The solvent from the benzene rich extract
phase (bottom stream 3 from ED column have immense applicability in valorizing
unconventional cracked hydrocarbon streams
C-01) is separated in a Solvent Recovery
Column (SRC) (C-03). Benzene of high like FCC naphtha by recovering high value
aromatics like Benzene and Toluene, especially
purity can be routed to storage through
line 8. now that the focus is more on production of
petrochemicals rather than fuel. Increase in
• Circulating solvent (70-90°C) after severity of FCC units across the world are
exchanging heat is fed to ED column C-01. being for maximizing production of olefin and
• E-04, E-05, and E-07 are the re-boilers aromatics will eventually lead to adoption

Oil & Gas Technical Journal -1 61

 of solvent extraction-based technologies as of light aromatics from other unconventional
described above. The described processes also feedstocks such as reformed bio-derived
have the potential to be extended to recovery naphtha or waste plastic derived naphtha.

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3.1 Maximize Fired Heater Efficiency

(A blueprint for saving energy and reducing carbon footprint)
____________ !_____________ ____ ___________ ____________________________________________

Authors: Navneet Agarwal, Ishita Bhattacharya, Kapil B Batra, Heat Transfer Department
Engineers India Limited
r
Mr Navneet Agarwal is presently working as Deputy General Manager with Engineers India
Limited. Holds a B.Tech degree in Chemical Engineering. He has over 23 years of work experience
in the field o f Fired Heater design, revamp & troubleshooting for the hydrocarbon industry.
Manages a team of engineers working on Fired Heaters and Combustion System. Published
technical papers in reputed journals including Hydrocarbon Processing

r
Ms Ishita Bhattacharya works as Manager with Engineers India Limited. She holds a Bachelor's
degree in Chemical Engineering. Has over 9 years of work experience in design, engineering
and troubleshooting of fired heater and combustion systems. Rich site experience including
Performance Guarantee Test Run for fired heaters. Prominent speaker in webinars conducted
by EIL on Fire heater.

Mr Kapil B Batra holds a Bachelor's degree in Chemical Engineering, working as Deputy Manager
with Engineers India Ltd. He has over 8 years of work experience in thermal design of fired heaters,
process design and field operation. Developing tools for increasing productivity and reliability
though digitization. Published technical papers in reputed journals including Hydrocarbon
Processing

J
India has set an ambitious target of significantly Adoption of latest technologies, provides a framework
reducing its carbon footprint. At the same time, India on building and operating fired heaters at their peak
is also targeting to double its oil refining capacity. A efficiencies.
lot of impetus is on developing options to capture CO2
and integrating renewable power into refinery, but 3.1.1 Design & Conceptualization
these options tend to be much more expensive than
the current energy sources. Hence, making the most of In process fired heaters, fuel oil, fuel gas or
energy that we currently use is even more important. a combination of both are used to heat the
Fired heaters are one of the major energy consumers in process fluids, such as crude oil, residues
any refinery or petrochemical plant. They can account and gas oils and convert them to fuels used
for as much as 70% of CO2 emissions through burning for transportation and other products. In
of hydrocarbon fuels. Hence it makes perfect sense the nascent stage of design itself, correct
to target fired heaters for meeting emission reduction requirement and specifications needs to be
targets through reduced fuel consumption. considered for conceptualization of fired heater
which will result in reliable and energy-efficient
Modern day Fired heaters can generally be designed operation of processes. Critical parameters
for as high as 93% efficiencies using state of the art such as Design Considerations, Waste Heat
technologies, and further reduction in emission can be Recovery System, Heat Integration and Fuel
achieved by using fuels with less carbon content. The selection that need careful consideration
following four sections covering the entire life cycle during conceptualization and design of fired
of fired heaters i.e. Design, Revamp, Operations, and heater, are discussed below:

Oil & Gas Technical Journal -1 65

 Design Considerations

Design Margin: Efficient fired heater design

commences with the optimization of the
heating requirements of process fluid.
Additional design margins are typically
added as an indemnity to meet or exceed the
guarantees provided. However, this can also
result in inefficient heater design and higher
fuel consumption for the actual operating
scenario. Excessive margins can also cause
glitches in design & operation of heaters and
burners to meet emissions at turndown (Arch
temperature lower than 705°C leads to high CO
and VOC emissions). When excessive heater
overdesign is observed, particularly with wide
range of variation in duties for different cases Draft: Draft is Negative pressure (vacuum)
of operation, it should be discussed with the of the air and / or flue gas measured at any
end user/owner and the process licensor to point in the heater. Stack & flue gas systems
ensure that they are aware of the limitations. are designed such that draft at heater arch is
kept at 0.1-inch WC (2.54 mmWC). Excessively
Type of Configuration: There are extensive high draft increases the air delivery of the
design variations of furnace depending on their combustion air fan, which although facilitates
functions, heating service, duty, combustion air complete combustion, but raises stack
delivery and heat recovery systems adopted. temperature, resulting in reduced efficiency.
The preferred type of design configuration Low draft reduces the combustion air delivery
is cylindrical or box-shaped enclosure lined of the burner and can cause smoke. Hence,
with coils carrying process fluid introducing automated draft control needs to be included
from convection section and exiting from in the process fired heater system design for
radiant section, since it utilizes the combustion better control of excess air and draft.
energy from flue gas achieving higher thermal
efficiency and lower fuel consumption (lower Waste Heat Recovery Schemes:
operating costs) as compared with the stand­
alone convection or radiation type furnaces. Efficiency of the fired heater signifies the
amount of fuel required to produce certain
Excess Air: An important parameter for amount of heat; hence it will call for maximum
design consideration in fired heater is at an possible heat extraction from the combustion
optimum excess air level. Operation below gas or flue gas for getting higher fuel efficiency
recommended excess air limits could result of a fired heater. Most of the heaters employ
in higher unburned combustibles, flame designs with various types of heat recovery
instability, and uncontrolled flame patterns, at schemes from flue gases which are worldwide
the same time, operation at higher than design prevalent now-a-days. Refer Table 1.0 for
excess air will increase carbon emissions as features and limitations of various types of
well as reduce the efficiency of the fired heater. waste heat recovery schemes.
Refer Figure 1.0 for the effect of excess air on
emissions and efficiency. Despite few limitations, waste heat recovery
equipment are widely adopted since they
increase fuel efficiency of the heaters to the
maximum in order to reduce fuel consumption
as well as carbon footprint, along with other
detrimental emissions such as SOx, NOx etc.

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Steam air pre-heaters (SAPH) are generally installed efficiency, fuel consumption, and CO2 emission with
with cast air-preheaters to preheat the combustion air different heat recovery schemes based on one of the
in order to maintain minimum tube metal temperature, crude heaters of an executed project. A significant
also leading to additional increase in heater efficiency. reduction in CO2 emissions and increase in fuel
efficiency can be noticed with increasing heat recovery
Figure 2.0 is a good example of the effect on fuel potential.

Table 1.0: Types of Flue gas Waste Heat recovery Schemes

Type Details
Cast Air Preheater (CAPH) Assembly of rectangular cast tubes with integral fins
Increase furnace efficiency by cooling flue gases typically up to 150°C
Prone to sulfur acid corrosion, heat recovery potential depends on the flue
gas acid dew point
Glass Air Preheater (GAPH) Glass tubes resistant to cold end corrosion
Flue gas exit temperature can be kept ~ 20-25°C above flue gas acid dew
point
Target efficiency >90% with both cast & glass APH
Top mounted Air Preheater Used in case heat recovery potential in the existing furnace is low or space
constraint
Tube bundles are installed on convection top of heater to heat combustion
air from flue gases
Steam Generator/ Steam Flue gas residual heat recovered by generating or heating steam in the heater
Superheater (SG/SSH) convection section
Complete steam generation system in a convection section of an all-radiant
process heater can result in ~90% fuel efficiency

100.0%
100.0% 99.4% 100.0%

98.0% 98.0% W Cj
CO O
96.0% 96.o% E
CO

3 ? 94.0% 94.0%
o>
92.5%
£
.92
92.0%
ECD 0°
M 90.0% 90.0% ^
LU 89.5% U
of
"I 8 8 .0 % 88.0% 08 s
LL _ CO
o g
® 86 .0 % 8 6 .0 %
E >
84.0% 82.8% 84.0% 5 t=
co c0)
82.0% 82.0% ^o ^—
q3

80.0% 80.0% ii
without S S H & with S S H & w/o with top-m ounted with S S H & C A P H with S S H , C A P H &
APH APH APH SAPH

Net Efficiency •Fuel Consumption & C 02 emission (%)

Figure 2.0: Impact o f Fuel Efficiency on Fuel Consumption & CO2 Emission with various Heat Recovery Schemes

Oil & Gas Technical Journal -1 67

 Heat Integration: result in emission of harmful pollutants as
well as Green House Gases (GHG) into the
Energy integration of fired heater into the environment. Typically, liquid fuel or fuel oil
process helps to target minimum fuel and contains much more sulphur and carbon than
optimum air preheat temperature prior to the gaseous fuel leading to less energy content
detailed design which eventually reduces the and high amount of undesirable pollutant
carbon footprint. Few approaches for heat emissions. Achievable fuel efficiency with
integration are: fuel oil is also lower than that of fuel gas due
• Multiple lower duty heaters can be to high flue gas acid dew point of flue gases.
combined into a single balanced draft Primarily, for these reasons liquid fuel firing has
heater system wherein collective flue become successively less in use other than
gases from the convection section of the in older refineries. Firing fuel gas and natural
heaters are routed to a single air preheater gas is a recent trend adopted in refineries and
and the preheated combustion air is also petrochemical plants.
fed to all the furnaces thereby increasing
overall fuel efficiency of the combined Impact on fuel efficiency and CO2emission has
system. been analysed for a balanced draft (BD) heater
in Figure 3.0. With standard excess air levels as
• In case of an all-radiant heater along with
per API-560, it is observed that CO2 emission
other radiant-convection fired heater in a
rate can be decreased drastically by ~30% with
single unit, high temperature flue gases
fuel gas or RLNG firing along with increasing
from the all-radiant heater can be routed
fuel efficiency.
below the convection of other heater for
further heat recovery. Thus, overall firing
Refiners are also interested in the new trend
for both of the heater shall be lower
of concepts for assessing hydrogen gas as a
resulting in saving significant amount of
fuel. It can also be observed from Figure 3.0
fuel and reducing overall emission along
that hydrogen rich gas (being less in carbon
with carbon foot print.
content) helps to reduce carbon dioxide
• In certain cases, more than one process emissions significantly by ~70%, thereby also
streams in a unit can be simultaneously reducing carbon footprints. Hydrogen rich
heated in a single heater. This type gas containing ~89% Hydrogen has been
of integration will reduce the required considered here for assessment.
number of fired heaters compared with
each process integrated individually with
standalone fired heater. Several utility
heating can also be considered in a
single furnace. With the heat integration
approach, operating cost and carbon
footprint will reduce along with capital
expenditure.
Feasibility & scope of any heat integration
should be ascertained in the initial stage of
conceptualization and should be carefully
considered for detailed design of the fired
heater system.
Figure 3.0: Net Fuel efficiency (%) & CO2 Emission
Fuel Selection: for firing various Fuels in a Balanced Draft (BD)
heater
Selection of fuel weighs heavily while designing
a fired heater primarily due to the two main
important aspects viz. fuel efficiency and
flue gas emissions. Contaminants in the fuel

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3.1.2 Revamp or Retrofitting (BPSD) refinery in India, even 1% improvement

in Fuel efficiency translates into energy savings
Revamp or retrofitting of a heater entails of almost INR 7 Crore /yr.
significant potential with respect to fuel saving
& carbon footprint reduction. In the event of 3.1.3 Methodology for Performance
facing major challenges due to the fact that Improvement & Revamp Studies:
fired heaters are one of the prime contributors
of the global emission of carbon, refineries, Plant Data Collection: This is the foremost
petrochemicals and many process industries step to understand the inherent and practical
are in overwhelming pressure to reduce conditions of the fired heater intended for
emissions from their existing fired heaters. revamp. Process data and other existing data
requirements are gathered from site along with
However, there should be some concrete site observations of furnace including burner
reasons, why the industries shall revamp the performance. Operating personnel's feedback
fired heaters. Some of the key motives are on furnace operations hold substantial
recognized as follows: importance so that these can be considered
and addressed for performance analysis of the
• Increasing fired heater capacity
heater.
• Decreasing fired heater severity
• Improving thermal efficiency Evaluation of Current Performance: Targeted
• Improving run lengths furnace is simulated based on the operating
• Reducing emissions data collected using furnace rating tools
employing feedback / experience of other
• Reducing utility consumption cases to arrive at the most realistic model.
With the basis of the simulated model, current
Parameter Impact on Efficiency
performance parameters including extent of
19°C reduction in Increases by 1% fouling/ derating are established which are
Stack Flue Gas further used in the next level of evaluation.
Temperature
25°C increase in Air Increases by 1% Evaluation of Performance at Desired Load/
Temperature Efficiency: This step is imperative to predict
10% increase in Decreases by 1% heater performance after revamp and also
Excess Air identify the extent of modifications required to
achievedesired target. Accordingly, assessment
Majority of the above can be resolved of furnace for revamp conditions are done
simultaneously by revamping the heater in one and performance parameters are established
go, enabling enhancement of heater design for the revamp conditions. Detailed check of
duty whenever it is required to add to an Heater components / auxiliaries is carried out
existing unit capacity. In this way, heater can to identify the required modifications for each
operate less severely than the scenario while components/ equipment associated with the
not being revamped and eventually improve heater system.
life & run length of the heater.
Feasible Options: Subsequent to the above
By optimizing the required modifications, evaluation steps, various alternatives are
existing heater can be revamped to achieve studied to target the objective of revamping.
maximum possible efficiency and maximum As required, interactions with equipment
fuel savings that can compensate the suppliers are carried out for adequacy checks
modification costs within a lucrative timespan of different equipment such as burners, fans,
along with helping to reduce carbon footprints. damper, air preheaters etc. within existing
constraints. After detailed feasibility analysis,
It may be noted that for a 120,000-bbl/d list of modifications for each alternative can be

Oil & Gas Technical Journal -1 69

 worked out along with cost benefit analysis for The impact of installing air preheater for
final selection of the desirable option with the achieving maximum efficiency has been
end user/owner. shown in Figure 2.0. Similar benefits are
expected to be achieved for an existing
3.1.4 Options for Fired Heater Revamp and heater revamp also, if other factors or
case studies: deterioration of the existing structure &
components are not considered or as
For revamp, multiple options are available to insignificant.
increase heater efficiency such as:
C. Switchover of firing from fuel oil/
A. Augmentation of convection fuel gas to natural gas
surface area
The primary benefit of converting a Fuel
Convection section heat transfer duty can oil/ gas fired heater to natural gas is to
be boosted by addition of convective heat- gain a more cost-effective, cleaner, more
transfer surface. Additional rows of tubes efficient, and reliable source of heat. This
can be installed in the convection section is a clean energy approach considering
of most heaters without making any stringent environmental stipulations
major changes since most of the heaters across the globe due to the following
generally have a provision for addition of reasons:
few future rows. If space for adding tubes
• Eliminating SOx Emission
has not been provided, convection section
may be extended into the breeching to • Increased Fuel Efficiency
make space. • Better Control & Flexibility in Operation
• Enhanced Life of Furnace & Heat
B. Installation or addition of a new air Transfer Areas
preheater in an existing fired heater
Case Study #1: Emission Reduction &
Installation of outboard air preheating Performance Improvement by switchover to
system into an existing fired heater is NG / RLNG firing
the most effective way of increasing fired
heater efficiency as already discussed This is a case study with reference to detailed study
above. conducted for fired heaters firing conversion to RLNG
for the entire refinery complex. Results of the analysis
Upgrading natural draft heater to a carried out are summarized below:
balanced draft heater with the addition
a) Existing heaters are adequate with NG/RLNG
of an air preheating system results in
without modification in the heat transfer surfaces.
significant hike in heater efficiency and
The flue gas temperature profile across the heater
carbon footprint reduction. In this case,
is marginally higher which increases heat pick-up
existing heater can be re-simulated
in the convection section.
with air preheater to establish revised
operating conditions and plot area b) Marginal increase in flue gas & combustion air
evaluation. Minimum modifications are quantity w.r.t fuel gas firing and reduction in
required to be done in the existing heater quantities w.r.t fuel oil firing are estimated. In case of
system which can reduce the shutdown marginal increase get easily compensated with the
time significantly. The balanced draft auxiliary design margins. Hence, no modification
system also calls for forced draft fans in stack, fan etc. unless operational issues are
which facilitates good mixing and uniform foreseen.
distribution of combustion air and forced c) Resulted in reduction in carbon footprint by ~35%
draft burners that use higher air pressure w.r.t fuel oil firing.
drop favorable for good combustion. d) Burners:

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Heaters with Existing Low NOx •Existing burners adequate, new gas tips based on fuel gas spectrum may be required
Burners •No modification in other components*
•

Heaters with Existing •Retrofit new Low NOx burners

Conventional Burners •Minor floor modification in view of retrofitting, no other modifications

Figure 4.0: Modifications envisaged for burners

Case Study #2: Capacity Augmentation Along It was inferred from the site data that fouling in
with Efficiency Improvement: convection section was possible leading to high
convection exit temperature along with cold end
Adequacy study performed for higher loads as part of corrosion problems due to lower flue gas APH outlet
capacity enhancement project of VDU, for existing: temperature. It was also observed that Stack damper
was in open condition which suggested limitation in
• Heater system ID fan capacity. In view of these concerns, following
• Transfer line & modifications & conclusions had been arrived.
• Associated fuel skid

Performance parameters Current Operating (~80% load) Revamp Condition

Absorbed Duty- HC(Gcal/h) 28 33.5

Temp, In/out, °C 285/404 278/402
BWT, °C 690/825/754 815
Flue Gas exit temperature, °C 377/142 345/160
Stack Temp, °C 230 160
Fuel Efficiency, % ~86 89

Table 3.0: Performance Evaluation for Revamp Case Study #2

Major achievements & minor modifications 3.1.5 Efficient Fired Heater Operating
Strategy
• Capacity enhancement with only addition of two
future rows above existing hydrocarbon coils in
The main objective of an efficient heater
convection sector of heater
operating strategy must be to achieve the
• Heater process fluid inlet terminal modification target coil out temperature (COT) safely
• FD and ID fans' replacement while also reducing the energy, emissions
• Recommended air bypass in case of lower flue gas and maintenance costs. While doing so, the
temperature than as estimated in revamp findings heater should demonstrate stable and robust
performance. All of this requires the heater to
With these minimum modifications, 89% fuel efficiency be operated very close to the constraints.
has been estimated post revamp which is more than
the operating scenario even with several limitations. The energy required for heating process coils
It also reduced the fuel consumption cost and carbon in Fired Heaters is provided by the combustion
footprint substantially. It is also specifically highlighted of fuels, mostly hydrocarbons; and the
that no modification in fuel circuit & transfer line and efficiency of this combustion process greatly
radiant heat transfer had envisaged herein leading to determines the overall efficiency of the fired
minimum shut-down time. heater. Since, it is impossible to operate safely
at stoichiometric oxygen level, fired heaters
are always operated with minimum excess air.
Fired Heaters efficiency, emissions and safety

Oil & Gas Technical Journal -1 71

 will strongly depend on the amount of excess varies from one burner type to another. It also
air volume used for combustion. depends on the fuel type & heater condition.
For new heaters, minimum excess air level
should be specified by the burner vendor and
be verified during burner testing.

In most fired heaters, draft is measured at the

arch or top of the radiant firebox. In natural
draft heaters, this negative pressure creates
the driving force for air to flow into the burners.
Fired heaters are also maintained under slight
negative pressure to ensure that flames stay
within the firebox. However, it is important to
minimize the arch level draft as too much draft
can lead to increased "Tramp Air ingress" i.e.
air passing through any non-burner openings
Figure 5.0: Strategies for Efficient Heater Operation
such as peep doors, header boxes, tube
penetrations etc. into the heater.
Minimizing excess air improves fuel efficiency
by reducing the energy consumed to heat
the additional air. Other factors affecting the
heater efficiency are draft control, tramp air,
burner operation/flame patterns, convection
section tube efficacy etc. Fired heaters operate
under extreme conditions, and hence regular
inspection and asset management should also
form a big part of any strategy in ensuring a
reliable and efficient fired heater operation.

Excess Air & Draft Control

Figure 6.0: Tramp air through tube penetration
The amount of excess air used in combustion
process majorly defines fired heater's efficiency, Tramp air does not take part in combustion
emissions and safety. Minimizing the excess and instead absorbs the heat that should be
air will improve fuel efficiency by reducing transferred to the heater tubes. Tramp air can
the energy consumed to heat the additional also skew O2 readings resulting in inadvertent
air. Figure 7.0 illustrates the relationship sub-stoichiometric burner operation. However,
between excess air, stack temperature and while controlling draft, one must be careful as
fuel efficiency. Typically, presence of carbon too little draft can restrict the airflow through
monoxide (CO) indicates that the fuel is not burners (for natural draft heaters), causing
completely burnt, hence it is important to flame instability, flame impingement, and even
target oxygen levels that does result in no CO in the formation of CO. Figure 8.0 demonstrates
the stack. The optimum amount of excess air a step-by-step procedure to effectively control
excess air and draft in a balanced draft heater.

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Figure 7.0: Fired Heater Efficiency vs. Excess Air

TARGET
DRAFT

Figure 8.0: Balanced Draft Heater excess air and draft control

Oil & Gas Technical Journal -1 73

 Burner Operation/Flame Stability such as shape, size and color. Long and lazy
burner flames are an indication of poor air to
Burner is the heart of a fired heater equipment. fuel mixing. Such abnormal flame conditions
Fired heaters are fitted with multiple burners can lead to inefficient operation consuming
and type of burner is based on the fuel burned, far more fuel than necessary. It also increases
air supply and emission requirements. A good the chances of flame impingement on process
burner operation is indicated by clear firebox, tubes, resulting in higher TMTs and coking.
no smoke, and flames that are compact, steady Table 4.0 lists possible solutions for common
and well-formed. It is important to often visually problems with burner operations.
inspect burner flames for characteristics

Table 4.0: Common Burner Problems & Possible Solutions

Problem Cause Solution

Erratic Flames/Tilting/ Lack of combustion air Reduce firing & adjust air register/
Leaning Flames stack damper
Incorrect burner tip location Correct burner tip location
Furnace Currents CFD modelling to identify & correct
flue gas pattern
Gas flame too long Excessive firing. Reduce firing rates.
Too little primary air (premix only). Increase primary air; decrease
secondary air.
Worn/damaged burner tip. Replace tip
Gas flame too short Tip drilling angle incorrect. Consult burner manufacturer.
Too much primary air (premix only). Increase secondary air, decrease
primary air.
Tip drilling angle incorrect. Consult burner manufacturer.
Flame instability. Flame Lack of oxygen/draft-flooding/ Lower the firing rates. Adjust
liftoff. bogging situation. stack damper or burner register as
needed. When combustion is stable
increase air before increasing fuel.
High fuel pressure. Check/adjust fuel pressure. Clean
tips.
Incorrect fuel composition. Check/correct fuel composition.

3.1.6 Reliability & Asset Management composition etc. Regular visual inspection
concerning flame patterns and condition
Fired Heater operate under extreme conditions. of firebox also plays a major role. Next
It is important that the components such as step involves setting up integrity operating
burners, sight ports, tubes etc. are maintained windows (IOWs) which require determining
in peak condition. Proper asset management the operating limits under which fired heater
can greatly improve reliability and performance, is to be operated. This requires effective data
resulting in cost reduction and a decreased risk collection. The collected data must be analyzed
of unplanned asset failures. An effective asset to identify potential failures & reduce operating
management program involves understanding risks through preventive maintenance.
the conditions of firebox while it is in operation.
This involves monitoring critical operating Fired Heaters must be inspected thoroughly
parameters such as bridge-wall temperature during shutdown and actions must be taken
(BWTs), tube metal temperatures (TMTs), to replace/repair the damaged components.
coil outlet temperatures (COTs), flue gas Standards such as API 530 Annexure A, API

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573 and API 579-1 provides the necessary essential that a reliability strategy is developed
knowledge for assessing the fitness and that addresses the major concerns and
remaining life of fired heaters. Standards potential risks identified in the assessment.
such as API 580 and 581 can also provide Table 5.0 provides a sample reliability
understanding the scenarios for failure. It is management strategy.

Reliability Performance
Regular IR Surveys Clean preheat exchangers when fouled
UT surveys during shutdowns Train operators annually on burner operation
Burner maintenance during shutdown
Selecting optimum metallurgy based on process
composition Using advanced analytics and digitization tools for
Developing effective maintenance philosophy operation improvement
during shutdown.

Table 5.0: Sample Reliability Management Strategy

3.1.7 Emerging Technologies in Fired Heaters processors leading to overall improvement in

performance & asset management. Let us take
With the increasing focus on reducing carbon look at some of these advancements in brief:
emissions, the latest developments in fired
heater technologies are focused on increasing Digital Twins:
the heater efficiency, thereby reducing
emissions. These technologies also help A digital twin is a virtual copy of an actual
improve safety and reliability of fired heaters operating furnace. It is mostly built using the
resulting in reduced unscheduled production first principle model and a physical furnace
downtime. The myriad developments in feeds input data into the model utilizing the
technologies range from advanced analyzers, installed sensors. The pre build model then uses
smart combustion systems, and model based this data, modifies the model, and generates an
process (MPC) control system, new generation accurate digital representation of the operating
air-preheaters, and latest advancements such furnace. Also, a digital twin has full knowledge
as digital twins. The technologies utilize the of the furnace's historical performances, and
latest trends in automation, data analytics and thus it mirrors the actual furnace operation
throughout its lifecycle.

Figure 9.0: Industrial Furnace as Digital Twin

Oil & Gas Technical Journal -1 75

 A digital twin can be utilized for various
scenarios "what-if" scenarios, assessing
the outcomes and impact without the risk of
damaging the physical entity. For example,
a digital twin can be used to set the correct
air-fuel ratio taking into account the burner
properties, fuel composition, and particular
operating conditions instead of the trial-and-
error method that is often used by operators.

A digital twin tracks the fired heater asset

operation over-time and this information can
be used for predictive maintenance, reducing
unscheduled downtime. Hence, an efficiently
utilized digital twin can produce returns on
Figure 10.0: Typical Glass enamelled tube
energy efficiency, reduced emissions and
increased asset life span.
Some advanced plate type air preheaters use
glass coating in the lower sections which is
New Generation Air Preheaters
prone to acid dew point condensation. Glass
enameled tube APH are also recent alternatives
Fired heaters can generally be designed for
of GAPH wherein the carbon steel tubes are
efficiencies as high as 93%. Conventional, fired
typically designed with 2-3 coats of an acid
heaters are designed with metal air preheaters
resistant glass enameling /ceramic coating.
for a minimum flue gas exit temperature of
The tubes are also less prone to breakages
~140-150°C in order to prevent acid dew-point
compared to use of complete glass tubes as
corrosion and subsequent high maintenance
in GAPH.
cost. The exiting flue gases still release ~7%
of available energy to atmosphere. Modern
Another advancement is the use of polymer
air preheaters are designed to maximize the
tube bundles in the lower sections of cast air
heat recovery from flue gases released to
preheaters. The polymeric tubes are resistant
atmosphere.
to acid corrosion. It can also be inferred from
figure 11.0 that the corrosiveness of flue gas
Recent developments include use of a “Plate
is reduced as the temperature of the flue gas
type heat exchangers" instead of cast air-
is reduced beyond the acid dew point. Hence,
preheaters. Plate type air-preheaters are
such air-preheaters offer immense potential to
typically used with very clean fuels having H2S
exploit and recover the available heat from the
content as low as 5 ppmv. Plate APH system
flue gases presently released to atmosphere,
offer very high heat transfer co-efficient,
leading to increased efficiency and reduced
providing superior heat transfer and occupy
emissions. The actual efficiency achievable
less space compared to cast APH system.
will depend on the fuel specifications, service,
operating conditions etc. and need to be
evaluated with the suppliers.

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and near-zero CO emissions over the entire

operating range of the heater. Also, the burner
level insight improves safety of the combustion
systems. Actual efficiency achievable based
on fuel specifications, heater configuration,
service etc. needs detailed evaluation with the
suppliers for specific operating cases.

3.1.8 References
1. API 535, Burners for Fired Heaters in General
Refinery Service, 3rd edition, May 2014.
Figure 11.0: Rate o f Corrosion vs. Surface TMT 2. Engineering Tool Box, (2003). Combustion
Efficiency and Excess Air. https://www.
Smart Combustion Systems: engineeringtoolbox.com/boiler-combustion-
efficiency-d_271.html
Generally, oxygen measurements are taken 3. Malhotra, K., "Rethink Fired Heater Design for
Emissions" Hydrocarbon Processing, December
at radiant arch, as it is a cost-effective way
2019
to ensure there is enough oxygen within the
4. E. Platvoet, "Maximize value and successfully
firebox. However, this location is prone to revamp a fired heater" Hydrocarbon Processing,
issues such as tramp air ingress which can January 2022
skew the measurements. Also, it represents 5. Tim Hill, "Fired heater health monitoring and
the overall situation within the firebox and reliability management in challenging times",
does not represent the condition of individual Inspection Journal, April 2016
burner. Hence, it is difficult to get an accurate 6. Bart Van Den Berg, "Air pre-heater improves
assessment by measuring at one location. energy efficiency", PTQ Q2 2014
Ensuring sufficient oxygen for individual 7. Kevin L. Finnan, "Optimize Combustion Using A
burner is more prominent during turndown Digital Twin", Chemical Processing, July 2021
conditions. The new combustion control 8. A.Garg, "Optimize Fired Heater Operations to
system is targeted to provide the operator Save Money", Hydrocarbon Processing, July
with details on each individual burner, by 1997
utilizing advanced instrumentation hardware 9. Jose Corcega & Tom Korb, "Controlling
Combustion for Fired Heaters", Process Heating,
and data analytics. This improves emission
April 2019
performance and enables single-digit NOX

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3.2 Energy efficiency improvement through APC

Authors: Mr. Rahul V. Kalbande, Senior Manager
Bharat Petroleum Corporation Limited, Kochi Refinery.

Mr. Rahul V. Kalbande is working as Senior Manager in BPCL, Kochi Refinery. Implemented advance
process control in Delayed Coker Unit in Kochi refinery. His area of interest are- technical analysis
of oil market and area of future planning of refineries which include crude oil selections strategies
& Petroleum products import-export strategies, implementing Advance Process Control in refinery.

J
Abstract According to the International Energy Agency
(IEA), improved energy efficiency in buildings,
Process Automation Systems (PAS) are widely known industrial processes and transportation could
to be a crucial element in processing plants worldwide reduce the world's energy needs in 2050 by
which includes oil refining, petrochemical, Chemicals one third, and help control global emissions of
and power generation industries. This paper describes greenhouse gases.
the implementation of Advanced Process Control
in BPCL Kochi Refinery which resulted in optimized Today against a backdrop of rising GHG
process operation thereby improving the energy emissions, oil and gas companies are viewed
efficiency. APC has been implemented in 3 major as crucial segment in mitigating it. Bharat
secondary units of Kochi Refinery (BPCL) in 2021 viz, Petroleum Corporation Limited (BPCL) being
Vacuum Gas Oil Hydro Treatment Unit (VGO HDT), one of the major and integrated oil company
Delayed Coker Unit (DCU) and Petrochemical Fluidized in India continually strive to implement path
Catalytic Cracking Unit (PFCCU). breaking energy saving initiatives and has
always been at the forefront in implementing
projects which yield twin benefit of savings on
energy cost and reduction of Carbon foot print.

Process Automation Systems (PAS) are widely

known to be a crucial element in processing
plants worldwide which includes Chemicals,
petrochemical, oil refining and power generation
industries. In today's VUCA (volatile, uncertain,
complex and ambiguous) environment,
industry leaders employ state of the art PAS to
mitigate complexities with especially Advanced
Process Control (APC) systems specifically
leading to, higher efficiency, less operator
interaction and increased profits.

This paper describes the implementation of

Advanced Process Control in BPCL Kochi
3.2.1 Introduction
Refinery which resulted in optimized process
operation thereby improving the energy
Energy efficiency in its simplest sense stands
efficiency. APC has been implemented in
for efficient energy use. Decreasing energy
3 major secondary units of Kochi Refinery
use reduces energy costs and results in
(BPCL) in 2021 viz, Vacuum Gas Oil Hydro
financial cost saving to consumers. Reducing
Treatment Unit (VGO HDT), Delayed Coker Unit
energy consumption is seen as a solution
(DCU) and Petro Fluidized Catalytic Cracking
to minimizing greenhouse gas emissions.
Unit (PFCCU).

Oil & Gas Technical Journal -1 79

3.2.2 Background in-house resources and without taking the help
of any external implementation partners. The
Advanced process control (APC) applications APC for Crude/Vacuum Distillation and DHDT
have become a norm for refining units in was completed in previous years. The APC
addition to basic regulatory control. Progressing team taken the ambitious target of completing
along the path of regulatory control to advanced the APC implementation in the balance units in
regulatory control (ARC) to conventional APC to the current year itself. As being the tradition of
multivariable predictive control (MVPC), MVPC Kochi Refinery, this also has been planned to
technology has become the main workhorse of execute utilizing own resources and the team
refinery process control and optimization. was able to complete APC implementation in
VGO HDT, DCU and PFCC units by Nov'21.
BPCL-Kochi Refinery is located at
Ambalamugal in Ernakulam Dist. in Kerala 3.2.3 APC Controller Concept
State. The company was incorporated in 1963
as Cochin Refineries Ltd. This Refinery had There are 3 types of variables being considered
an initial refining capacity of 2.5 MMT pA was in controller.
dedicated to the nation on 23rd September
1966. Cochin Refineries Ltd was then renamed 1. Manipulated Variables (MV): A
as Kochi Refineries Ltd (KRL) in May 2000. manipulated variable is a setpoint or valve
Govt. of India had divested its entire holding position moves to control the process. The
in favor of Bharat Petroleum Corporation controller will move these setpoints (or
Ltd (BPCL) and later it was amalgamated valves) in much the same way an operator
with Bharat Petroleum Corporation Ltd in would to meet the control targets that
2006. BPCL-KR, on the growth trajectory has have been set. These variables are also
completed a dream project "Integrated Refinery called independent variables.
Expansion Project", marking a milestone on the 2. Feed Forward Variable (FF): A feed forward
organization's path to progress with refining (disturbance) variable is variable which has
capacity expansion to 15.5 MMTPA . The an impact on the process but one which
project envisages modernization of the refinery the controller cannot move. These referred
to produce auto fuels complying with BS VI to as feed forward variables. Disturbance
specifications. variables are also independent variables.
3. Controlled Variable (CV): A controlled
As part of Integrated Refinery Expansion Project variable is a variable which changes in
(IREP), BPCL has setup a Crude/Vacuum response to a change in a manipulated or
Distillation Unit along with major secondary disturbance variable. These variables are
units i.e. DHDT, VGOHDT, DCU, PFCCU along also called dependent variables. This is
with associated utilities and off-site facilities because their values are dependent on the
values of the independent variables.
Efficient ways of energy usage is a very crucial
factor in profitability of any organization. BPCL The relation between manipulated variables
management always have special focus on and controlled variables can be inferred
energy efficiency improvement. Knowing the (whether it's positively or negatively related)
potential of value addition on implementation and called as the model gain. Each MV will
of APC, the management was keen for be related to one or more CVs. The controller
implementing APC in these units and fully works in two steps:
supportive of the initiative and provided all the
a) Controlling
resources.
b) Optimization
History of APC in Kochi Refinery started way First objective of the controller is to keep all
back in Nineties. The APC in Kochi Refinery has CVs within the given limits. Depending on the
got the peculiarity that the implementation of process requirements high and low limits for
APC in all the units have been completed by the the CVs are to be set from the DCS (Distributed

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Controlled System). To make CVs within limits, • Responding faster to specification

related MVs get adjusted by the controller only changes or disturbances (adoption of
within the low and high limits set for the MVs. change)

Once all related controlled variables are within VGO-HDT Unit

limits, MVs get adjusted to achieve optimization
strategies like minimization or maximization. VGOHDT is Vacuum Gasoil treating unit commissioned
MVs are minimized or maximized based as a part of IREP and having capacity of 3.00 MMTPA.
on controller's economic objectives. It is This unit is designed for hydro treating Vacuum Gas
important to set the variable limits correctly Oil (VGO) and mild hydrocracking of VGO to produce
based on actual requirements since if CV limits lighter products. APC was implemented in VGOHDT
are infeasible or MVs are restricted, economic in Jun'21. The APC in VGOHDT unit consist of the
objectives shall not be met as in such situation following 4 sections.
MVs are adjusted only to control CVs within a) VGOHDT Reactor Controller: This controller is mainly
limits or minimize violation of CV limits. designed to maintain conversion as per demand
and product sulphur within quality specification
Steady State Optimization mandated. Good amount of amine consumption
reduction also achieved.
b) VGOHDT Fractionator Controller: This controller
is mainly designed to maximize Diesel and other
products. Steam consumption reduction was also
achieved.
c) VGOHDT Fractionator Heater Controller: This
controller is mainly designed to minimize flue gas
excess Oxygen and to maximize air preheat.
d) VGOHDT Reactor Heater Controller: This controller
is mainly designed to minimize flue gas excess
Oxygen and to maximize air preheat.

Delayed Coker Unit (DCU)

DCU is Delayed Coker unit commissioned as a part

of IREP with a capacity of 3.80 MMTPA. This unit is
designed for up gradation of Vacuum Residue to value
added products i.e mainly Diesel. APC implemented
3.2.4 APC Implementation in BPCL KR in DCU in Nov'21. DCU consist of 2 controllers. (APC
already implemented in DCU heaters)
Typically APC implementation leads process
unit profitability by• a) DCU Fractionator Section: This controller is mainly
designed to maximize Diesel and MS components.
• Maximizing feed and products (maximum Operator intervention reduction also achieved in
utilization of assets) this controller.
• Minimizing utilities (air, steam etc) b) DCU Gas Concentration Section: This controller is
consumption (For BPCL KR, 1% Change in mainly designed to optimize Wet Gas Compressor
Steam System Size equals =0.9 EII & 1 EII performance. Steam consumption reduction also
reduction is equivalent to cost savings of achieved.
Rs. 31 Cr.)
Challenge Faced during DCU APC
• Pushing to the limit for most profitable
constraints Implementation
• Reducing product quality variations
DCU is a process which involve thermal cracking of
(stretching toward max limits)
vacuum residues. The process involve batch operation

Oil & Gas Technical Journal -1 81

to separate coke by means of drum operation. This LOGIC 2 made it possible to keep APC uptime higher
batch type operation is made continuous by providing by 4-5% during single train operation and by 8-10%
a configuration of a pair of identical Coke Drums during two trains operation on daily basis.
located at the combined process tubing coil outlets of
a Coker Heater. The decoking cycle steps comprise PFCCU
the greatest number of required adjustments to the
DCU process operation. Completing these steps within PFCCU is Petro Fluidized catalytic cracking unit came
the scheduled time intervals is vital to fully utilize the as a part of IREP with a capacity of 2.20 MMTPA.
throughput capacity of the DCU. During this process This unit is designed for converting unconverted
(Coke drum switch over process) which takes place at vacuum gasoil in VGO Hydro treatment units to value
least once in 24 hrs plant get upset due to wide variation added lighter products i.e MS and Propylene. APC
in process parameters. To bring this procedure under implemented in PFCCU in Nov'21. PFCCU consist of
APC umbrella was a big challenge, which otherwise 4 controllers.
reduced APC uptime on daily basis whenever drum
change over process initiated. BPCL KR Team APC a) PFCCU Reactor Regenerator: This controller is
successfully overcome this challenge by introducing mainly designed to maximize value added products
separate mechanism " LOGIC 2" to address process i.e Propylene and MS. Also steam consumption
upset during drum change over process. saving was addressed through this controller.
b) PFCCU Main Column: This controller is mainly
All related MVs & CVs (LCGO Tray Level, LCGO draw off designed to maximize diesel and to maximize feed
temp, HCGO draw off temp) pertaining to drum change preheat.
over activity made faster by assigning different model c) PFCCU Gas Concentration Unit: This controller is
gains. This logic is made in such way that it identifies mainly designed to optimize Wet Gas Compressor
drum switch over process initiation on its own looking performance. Steam consumption reduction also
at some related process parameters and also stops achieved.
actions under LOGIC 2 automatically looking at some
d) PFCCU Propylene Recovery Unit: This controller is
related process parameters.
mainly designed to focus on purity level of different
grades of Propylene.

3.2.5 Post APC Implementation Benefits

Given below some of the process parameters changes after implementation of APC

VGO-HDT:
Amine flow decreased to 256 Mt/Hr (Post APC) from 279 Mt/Hr (Pre APC)

Amine Consumption

Total Fuel gas consumption decreased to 1866 Kg/Hr (Post APC) from 2126 Kg/Hr (Pre APC)

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Reactor! Bed! WABT Standard Deviation decreased to 1.05 (Post APC) from 1.67 (Pre APC)

Reactor Heater excess Oxygen decreased to 2.6% (Post APC) from 3.5% (Pre APC)

Thus VGO HDT total financial benefit estimated to be 14.51 Rs Cr/annum based on Amine consumption reduction
and Fuel gas reduction. Apart from this financial benefit, fractionator diesel draw off flow is being regulated in a
much effective way, looking at draw off temperature which resulted in manual intervention reduction.

DCU:

Given below some of process parameters changes after implementation of APC in DCU.

LCGO draw off temperature increased to 195 deg cel (Post APC) from 191 deg cel (Pre APC) and its Standard
Deviation decreased to 5.2 (Post APC) from 6.2 (Pre APC)

LCGO production increased to 110 Mt/Hr (Post APC) from 100 Mt/Hr (Pre APC)

Oil & Gas Technical Journal -1 83

MP steam in Stripper reboiler decreased to 10.2 Mt/Hr (Post APC) from H .8 Mt/Hr (Pre APC)

Thus DCU total financial benefit estimated to be 48.65 Rs Cr/annum based on majorly product yield variation
(HSD component increase) along with steam and power reduction. Apart from this financial benefit, process
upset during drum change over operation drastically came down because of APC implementation. Also WGC
antisurge opening being regulated in much effective manner looking at deviation which has reduced manual
intervention a lot.

PFCCU:

Given below some of process parameters changes after implementation of APC in PFCCU.

WGC VHP steam decreased to 75 Mt/Hr (Post APC) from 82 Mt/Hr (Pre APC)

Absorber Top Temperature Standard Deviation decreased to 0.43 (Post APC) from 2.39 (Pre APC)

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ABSORBER TOP TEMPERATURE

PRU REBOILER steam decreased to 23.4 Mt/Hr (Post APC) from 25.8 Mt/Hr (Pre APC)

C3 STRIPPER level Standard Deviation decreased to 6.95 (Post APC) from 10.70 (Pre APC)

Thus PFCC total financial benefit estimated Overall improvement was seen in plant
to be 7.93 Rs Cr/annum based on majorly operational efficiency —- increase in target
steam consumption reduction and propylene output, decrease in energy consumption,
giveaway reduction. Apart from this financial and stability of quality indicators. APC
benefit, Fractionator bottom level, LCO tray level implementation resulted into both tangible
and HCO tray level is controlled by manipulating (Product yield, steam consumption, power
LCO product flow which has streamlined level consumption, amine consumption etc) and
controlling in fractionator in much better way. intangible benefits (steady state operation,
Also WGC antisurge opening being regulated standard deviation reduction etc) in BPCL KR.
in much effective manner looking at deviation
Team APC will continue their efforts towards
which has reduced manual intervention a lot.
conceptualizing and implementing means of
energy efficiency improvements through way
3.2.6 Conclusion of APC to reap more benefits for organization.
APC is a great tool for energy optimization
in a process plant. For decades, it has been APC Team Members
contributing to the industry, bringing millions Mr. Jose V Karenthanam, Mr. Manoj Kumar
of dollars benefits all over the world. Advanced M N, Mr. Biju M P Mr. Rahul V. Kalbande, Mr.
process control is an unbeatable combination Jitendra Verma, Ms. Vandana S and Ms. Sonali
of high level technical and business expertise Shetty of Bharat Petroleum Corporation Ltd,
for optimizing plant performance. Kochi Refinery.

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3.3 Energy Efficiency Improvement in Crude & Vacuum Distillation unit

Targeting Emissions
Authors: Dr. Ashwani Malhotra & Mr. Ameya Dhok, Engineers India Limited, New Delhi

\
Dr. Ashwani Malhotra is serving as Chief General Manager in Engineers India Ltd. He has 35 years
of experience in the process design and engineering of refineries (including Crude & Vacuum
Distillation unit) and onshore/offshore oil and gas facilities in the Equipment and R&D divisions of
EIL. He also has experience in application of IIOT in Refinery

c ------------------------------------------------------------------------------------------------------------

Mr. Ameya Dhok works as Senior Manager with Engineers India Ltd. He has experience in
Process simulation & optimization for refinery unit design like Crude distillation, Delayed Coker,
and Naphtha splitter units. His area of interest includes Process engineering and exploring
energy improvement measures.

\ _________________________________________________________________________

3.3.1 Abstract optimum value leads to saving in OPEX. Hybrid

Vacuum system (Ejector + LRVP) design can
Petroleum refining is one of the largest energy prove to be an energy efficient option for both
consuming industrial sectors and is run on grass root and retrofit designs w.r.t. utilities
tight profit margins. Because of ever changing consumed mainly steam and power. For a
market scenarios, crude price dynamics, it typical case, the OPEX for hybrid system in
becomes imperative to realize the optimum case of revamp & grass root designs can be
refining margins. Energy consumption is reduced by 10-25% with viable payback period.
a major operating cost component in any
refinery process unit. Hence reduction in fuel 3.3.2 Introduction
& loss offers great potential and incentive to
improve unit performance as well as overall Crude distillation unit plays a pivotal role in
refinery profitability, thereby, reducing harmful Petroleum refineries as it provides feedstock to
emissions. Typical energy usage accounts downstream secondary processing unit. The
for approximately 50% of refining operating unit is highly energy intensive system which
costs. Crude & Vacuum Distillation Unit requires energy to separate various fractions
(CDU/VDU) the basic processing step in oil of crude oil. Energy consumption in any
refinery is a highly energy-intensive process processing unit constitutes a major operating
representing one of the most important areas cost. Typically about 2 % of crude oil input is
for energy integration. Optimum design shall consumed for the energy requirements of crude
ensure minimization of OPEX by optimizing unit. Mitigation measures to minimize this
operating parameters with suitable provisions energy requirement will result in substantial
for operation flexibility thereby making the unit savings.
energy efficient. Options like Pinch technology
for Heat exchanger network (HEN), increase in Grassroot design of CDU/VDU should be reliable
crude heater efficiency, optimizing operating in such a way that it gives flexibility to process
parameters, use of Hybrid Vacuum system can desired range of crude basket. Unit is required
be approached during design. A typical case to be designed such that it maximizes yield
study for optimization of operating parameters of high value products with minimum energy
like column pressure shows that selecting consumption, optimum product quality and

Oil & Gas Technical Journal -1 87

 flexibility provisions needed to process varying Crude oil is basically a mixture of hydrocarbon (HC)
crudes. Approximately 50% of operating cost in ranging from lighter HC (Methane, ethane) to heavier
refinery is due to energy requirement. Sincere HC (having boiling point more than 600 deg C). Crude
efforts need to be inherited in design to lower oil Distillation is simple separation of crude oil into
the energy requirement. Lowering the energy desired fractions. A typical flow scheme of CDU/
requirements leads to reduction in emissions. VDU is shown in Figure 1. Crude oil is preheated in a
Typically the utilities considered for energy series of preheat exchangers to an optimum desalting
consumption are temperature. After salt removal, the desalted crude
is then pumped to preflash drum where the crude is
• Fuel oil / Fuel Gas flashed and the flashed vapors which are lighter volatile
• Steam material is sent to crude column thereby reducing the
• Power fired heater firing demand.
• Cooling water

The preflashed crude flows through a series of heat Gas oil and Vacuum residue. The different product
exchangers, heated to an optimum temperature streams so obtained from crude & vacuum column
referred as COT (Coil Outlet Temperature) in crude are good heat source and can be suitably used in
heater and finally enters the Crude Column. In crude preheating crude in preheat network making the unit
column products are separated based on their boiling more energy efficient. In certain revamp scenarios the
range and desired specification. Unstabilised Naphtha preflash drum is replaced by a prefractionator which
from crude column overhead is sent to naphtha lowers the load of downstream crude column thereby
stabilizer where LPG and stabilized Naphtha are increasing the throughput.
further separated. Typically Heavy naphtha, Kerosene,
Gas oil (Diesel) is drawn as side cut through dedicated In this paper, an overview on major design approaches
side strippers. The column has typically 2 to 3 pump for energy optimization shall be discussed focusing
arounds located across the column and depends upon typical case studies for design optimization which
the column configuration. shows substantial energy saving.

Reduced crude Oil (RCO) from crude column bottom 3.3.3 Methodology
is sent to vacuum heater and enters the column at
desired temperature. The column has packed beds The key aspect to have an energy efficient
and operates under vacuum condition so that the design is to choose the optimized parameter/
temperature requirement for separation gets lowered equipment. The subsequent section would
i.e. it is based on the fundamental that boiling point give an outline of the major design approaches
and pressure are directly proportional and thus avoids for reducing the energy requirement thereby
thermal cracking to form coke at elevated temperatures. reducing the net emissions.
The RCO is separated into Vacuum Diesel, Vacuum

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Heat exchanger network (HEN) Optimization recovery section, increasing the radiant section area to
increase the heat flux in existing heaters.
Pinch technology uses the first principles basis for
identifying the minimum energy requirement point. It Optimization of operating parameters
mainly depends upon the stream flow rate, temperature
and heat available within. It basically optimizes the The optimization of column operating parameters is
heat integration between hot and cold stream to have case specific i.e. it depends upon the type of crude being
the maximum temperature of the cold stream with processed, new or retrofit design, product specification
minimum heat transfer area and exchangers. The & objective. This aspect of design shall be discussed in
critical factors affecting the final preheat temperature detailed as case study wherein substantial saving in
needs to be taken care in the design. OPEX is reflected.

Crude Heater Design Case Study: Approach to energy improvement

Typically in refinery, the heaters are mostly natural • Optimizing Crude Column Pressure
draft design with process fluid flowing through both A typical case study for carrying out optimization for
the convection & radiant section and the efficiency fixing crude column pressure is done processing a
is around 80% - 82%. Depending upon the existing blend of Arab light & Arab Heavy crude. The design
heater configuration the heater duty can be increased objective is maximization of Diesel stream from
to around 90% - 92% by modifying to balanced draft the column. The crude column overhead circuit
type heater by including an Air Preheater system comprises of two drum system with heat recovery
(APH). The heater efficiency can also be increased by in overhead exchanger as shown in Figure 2 below.
APH augmentation approach, inclusion of waste heat

Crude
Column

Crude Overhead Circuit

Figure 2

A comparison of major operating parameter data at different operating pressure are specified in Table 1 below.

Table 1

Parameter Unit Case-I Case-II Case-III

Column Top Pressure Kg/cm2 a 2.1 2.9 3.2
Heater Duty MMKcal/hr Base 1.15 X Base 1.18 X Base
Fuel Gas generation Yes Nil Nil
The crude heater outlet temperature requires increase from Table 1, there is also fuel gas generation from
with increase in pressure & there is fall in hot rundown overhead naphtha drum at lower operating pressure.
stream temperature with decrease in operating This fuel gas generated will require additional facilities
pressure. However the fall in preheat (~ 5 - 7 deg C) / equipment for further processing. This will lead to
would be compensated by increasing heater firing thus additional power requirement, thereby directionally
increasing the Fuel gas requirement in heater. As seen increasing total energy requirement.

Oil & Gas Technical Journal -1 89

From figure 3, it is seen that the crude heater duty and aspect in design for vacuum column operation. The
crude column pressure are directly proportional to vacuum system can be
each other considering other parameters as same.
• Conventional all ejector system
Hence from Table 1, above the optimum conditions • Hybrid system (Ejector + LRVP)
can be inferred to that corresponding to case II.
Hybrid system can be highly energy efficient option
• Vacuum column overhead configuration - New during design. It can be implemented in new as well
Design as revamp scenarios. A comparison study for OPEX is
done for a hybrid vis a vis ejector system for a typical
Vacuum system configuration is also an important crude unit is given in table 2 below.

Table 2

Utility Ejector system Hybrid system

Steam Consumption Base 0.85 X Base
Operating Cost (steam) Base 0.83 X Base
Power Consumption No Yes
Total Operating Cost Base 0.87 X Base

(Basis: In house/vendor data)

From above it is evident that hybrid system can be Depending on the tradeoff between the cost of steam
highly rewarding in terms of OPEX, thereby reducing vis a vis electricity, it may be economical to replace
the overall energy requirements.• last ejector stage with a LRVP referred to as a Hybrid
system. For a typical case, Comparison between utility
• Vacuum column overhead configuration - Revamp data requirement for following case studies are given
Design below.

Table 3
Utility Ejector system Hybrid System
Steam Consumption Yes No
Power Consumption No Yes
Operating Cost Base 0.25 X Base
(Basis: In house/ vendor data)

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Going further, the capital cost and payback period (using straight line method) evaluation is given below in Table 4.
Table 4

Parameter Value
CAPEX Hybrid (Replacement of Last Stage) Base
OPEX Hybrid (Annual saving for above as per Table 3) 1.25 X Base
Payback period (using straight line method) 0.8 (less than a year)
(Basis: In house/ vendor data)

As the payback period for hybrid system implementation is less than a year, it can be suggested to implement
LRVP

3.3.4 Conclusion lower pressure there would be additional power

requirement to compress the gas further. This
Every design aspect should be thoroughly case study demonstrates reduction in fuel
analyzed and finalized accordingly which firing which leads to reduction in emission.
again depends upon unit design requirements Further it is observed that implementation of
& configuration. Every effort to make the LRVP in vacuum overhead system leads to
design more energy efficient is the need of the significant energy saving. A typical case study
hour. Energy use in general needs a thorough shows that implementation of LRVP in case of
review to ensure that all appropriate costs are grass root design as well as revamps scenario
included. leads to saving in OPEX. in case of revamp
scenarios, the payback period can be less than
The presented case studies demonstrate one year thereby making it a more realistic
substantial energy saving in terms of OPEX. As approach for energy efficient design. This
seen from above, optimizing column pressure case study demonstrates reduction in steam
there is considerable saving in crude heater consumption which leads to reduction in fuel
duty as a result fuel gas requirement will consumption in steam generation system and
come down thereby making the design energy thereby reduction in emission.
efficient. Further in case of gas generation at

Oil & Gas Technical Journal -1 91

1
 Part-4
Alternate Energy,
Carbon Sequestration
& Environment
TM
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4.1 CO2 EOR as a Possible Carbon Sequestration Tool in a Matured

Reservoir: Pilot Design based on simulation
Authors: Akhtar Uddin Ahmed, Pankaj Kumar, Ranjit Dutta and Saloma Yomdo, Oil India Limited

r
Mr Saloma Yomdo Is working as Chief General Manager with Oil India Limited. He is an expert
in the field of Reservoir simulation, field development studies, water flood management, mature
fields revitalization, Enhanced Oil Recovery studies

J
4.1.1 Abstract saturation after miscible CO2 injection reached
~0.13PV.
The role of Carbon Capture, Utilization and
Storage (CCUS) in climate change mitigation A fine scale geological model was built for
has been a topic of debate for over two decades. the entire reservoir and dynamic simulation
India's energy demand has increased multi fold work was performed on the geological model
in recent decades and is likely to propel the without upscaling. The history match of 53-
nation to becoming one of the largest energy year field production and pressure data in the
markets in the future, the transition towards whole reservoir was completed in a commercial
a green economy remains the government's simulator, and various development scenarios
priority in line with various climate change were investigated. Based on the results from
agreements. This work is an endeavor to CO2EOR simulation study, a pilot pattern area of
use CCUS as an effective CO2 mitigation tool ~ 60 acres with one injector and four producers
from the perspective of upstream oil and gas have been identified. The CO2 was injected
companies. into the reservoir at 67 metric ton per day for
5 years and cumulative injection volume is of
The current study summarizes the prospect of the order of around 0.122 million metric ton.
CO2flooding and subsequent CO2sequestration Then the well is proposed to be switched back
from an Indian mature oil field in Assam to water injection afterward.
through laboratory study, reservoir modeling
and pilot design studies. 4.1.2 Introduction

It was confirmed through PVT laboratory The world, and India, can no longer reach Net
studies that CO2 injection can achieve the Zero goals through emission reduction alone.
desired miscibility under reservoir conditions Achieving Net Zero will require widespread
at its Minimum Miscibility Pressure (MMP). adoption of mechanisms to remove carbon
The core-flooding test showed the potential dioxide that is already in the air due to
for significant incremental oil recovery by unavoidable emissions. Geological Carbon
continuous CO2 injection and the residual oil sequestration which includes Carbon Capture,
Utilization, and Storage (CCUS) and Carbon

Oil & Gas Technical Journal -1 95

 Capture and Storage (CCS) will play a vital role residual oil in depleted oil reservoirs with the
in achieving India's ambitious net zero goals, injection of CO2 The oil recovery process can
by 2070. be immiscible or miscible, with the highest oil
recovery expected in miscible displacements
Both CCUS and CCS will need rapid technology [3]. In a miscible process CO2 enhances oil
breakthroughs to sequester carbon at large production by mixing with the residual oil
scale. While CCUS has been around since as a solvent agent at pressures above the
1960's, it is still in experimental stage in India. minimum miscibility pressure (MMP), which is
At its current cost points (above $ 50/t - $ 100/t the minimum pressure at which miscibility is
of CO2abated), carbon capture is too expensive achieved. The reduced viscosity and expansion
for commercial scaling. CCS, on the other of the new CO2 -oil phase decreases flow
hand, is a very new development. The largest resistance toward oil producing wells. The
CCS plant in the world, recently commissioned produced CO2 is separated from the produced
in Iceland, will capture 4 kt CO2/year for storage fluids, re-injected back into the reservoir and
in basalt formations and is reported to cost the process is repeated in a loop. However,
anywhere between US $ 600 - 1,200/tonne of not all the injected CO2 is produced back to
CO2for customers purchasing carbon offsets. the surface, as several mechanisms such
as capillarity, dissolution, and the geologic
4.1.3 Importance of CCUS in Indian Context structure trap a significant percentage (as
much as 50%) of the CO2 injection stream
Current global annual CO2 emission is around within the reservoir.
34.8 billion tons per year, of which India
produces around 2.44 billion tons (as per 2020 Tertiary recovery methods may be employed
data). With over 1.3 billion population, India after waterflood oil recovery declines. Among
is one of the fastest growing major economy the methods commonly used in the United
in the world and it needs sustained sources States is the miscible CO2 EOR.
of energy to fuel its growth and cater to the
aspirations of its huge population. On the other EOR flood was initiated in SACROC project in
hand, looking at the emission front, India, albeit Permian Basin, West Texas. The utilization of
with very less per capita emission, is the third anthropogenic CO2 for enhanced oil recovery
largest CO2 emitter in the world. As per the (EOR) becomes an industry trend, starting from
Nationally Determined Contributions (NDC) of USA to Middle East and now to India. Carbon
Paris Agreement, India has ratified to decrease Capture, Utilization and Storage (CCUS) can
its emission intensity of GDP by 33- 35 percent significantly extend the life-span of an oil field,
by 2030 from 2005 level. In the recently and reduce the atmospheric emission of CO2.
concluded COP-26, India declared to be Net- Figure 1 below shows a strategical field EOR
Zero by year 2070. In this regards CCUS offers development plan, which typically contains the
win-win proposition by curtailing atmospheric following phases:
emissions as well as may potentially be utilized
for enhanced oil recovery (EOR) from mature Phase-1: In this phase, waterflood
oil fields or for production of chemicals & fuels. performance/primary recovery of all the
available brown field is reviewed for identifying
Carbon dioxide-enhanced oil recovery (CO2- probable EOR candidates.
EOR) is a technology which has a dual benefit
of oil production enhancement and at the same Phase-2: After candidate selection, a rapid EOR
time sequestration of CO2 into the Formation. scoping study is recommended by analyzing
CO2-EOR has been applied successfully in the available field data and laboratory test
the USA since the early 1970's. The area with data. A suitable EOR scheme is selected based
the most extensive history of CO2 -EOR is the on key rock and fluid properties like reservoir
Permian Basin in West Texas and eastern heterogeneity, API gravity, viscosity of crude,
New Mexico where more than 50 CO2 -EOR formation thickness, depth, permeability,
projects operate. The technology targets the temperature etc. Geomodeling work is initiated

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followed by a dynamic simulation study. Field development and optimization plan and IOR/ EOR scenarios
will be proposed through simulation studies.

Figure 1: development stages o f a typical EOR Project

Phase-3: After proving the technical and economic Core flood experiment was designed to verify
success through static/dynamic simulation work, the the miscibility of CO2 with live fluid in the
pilot design is completed with a field implementation reservoir rock, and the residual oil saturation
plan. Surface facilities upgrading and subsurface after miscible flood (Sorm). The experiment
monitoring and surveillance plan are designed and was performed on a 24 inch long reservoir
implemented. Then gas injection pilot test is executed core (composite) which was established to
by a multi-disciplinary team effort. initial water saturation level and conditioned
with regard to its initial wettability by an aging
Phase-4: When the pilot test completes, the field process. The experiment was performed at
data including production and pressure data will be 3,250 psi (228.5 Ksc) and 178°F (81°C).
interpreted. Reservoir model will be tuned continuously
by feeding with more and more new pilot testing results. A stack of eight (8) core samples selected from
If the pilot test shows a technically and economically the same rock type, representing good quality
favorable result, the field-wise EOR injection will be sandstone, were placed in the core holder,
deployed. forming a 2-ft composite. The composite was
constructed using Huppler's ordering criterion
This paper mainly presents the results of CO2flooding (Huppler, 1969). The initial water saturation of
in a matured reservoir through laboratory studies, this composite was 42.2% in average, which
reservoir modeling and dynamic simulation work. was carefully brought to irreducible water
saturation using dead crude oil by core-flood
4.1.4 Materials and Methodology and porous plate desaturation methods. The
wettability of the core composite was restored
EOR Core-flood Tests dynamically by aging with dead crude oil

Oil & Gas Technical Journal -1 97

 for around 4 weeks time. Once the reservoir Well wise monthly pressure-production data
conditions equilibrated, the synthetic live oil for all the wells have been used as input for
displaced the dead oil, and a dispersion test history matching in the commercial simulator
(fully miscible) was performed to measure from June 1967 to March 2020. Well wise oil
hydrocarbon pore volume (HCPV). The density rate, gas rate, water rate and the static pressure
of the effluent was measured downstream measurements have been used as history
using an in-line densitometer. matching parameters. Some key parameters
like relative permeability curves, vertical
It is to be noted that all the core flood permeability and aquifer size are tuned to
experiments were conducted at reservoir achieve the desired history match. Both static
conditions of 80°C and 3300 psi (232 Ksc), geological data, petrophysical and dynamic
which is 300 psi (21 Ksc) above the pure CO2- data analysis indicated the presence of three
live oil MMP value. The net confining stress (3) major facies (sand, shaly sand, shale) and a
used in the coreflood was set as 3650 psi (257 lack of hydraulic connectivity in some regions
Ksc), reflecting the average net overburden between these facies. Reasonable rate and
pressure encountered in the actual reservoir. pressure matches were obtained on both well
and field level.
PVT Experiments
Todd-Longstaff Model for Misicble
Multiple PVT experiments were conducted, Flood
including Constant Composition Expansion
The Todd-Longstaff (TL) concept was used to
(CCE), Differential Liberation (DL) and Swelling
model the effects of miscible gas injection in
Tests. Slim tube studies were conducted
the commercial simulator. TL model captures
to determine the MMP between multiple
the key effects of gas injection in several
injectants with recombined live oil. This study
aspects:
provided the minimum pressure at which the
fluid is expected to develop multi-contact 1. The injected gas and in situ oil are assumed
miscibility with pure CO2 or CO2 stream to be first contact miscible above the MMP.
with impurities and helped to establish the 2. The value of represents the size of the
suitability of miscible gas flooding and the dispersed zone in each grid block i.e. a small
reservoir operating pressure. Solubility swelling value indicates that the dispersed zone is
experiments were carried out on reservoir negligible and a large value indicates that
oil to study how the reservoir fluid reacted to the dispersed zone is potentially larger
gas injection. The saturation pressure of the than the grid block size. Typical values
reservoir fluid was determined by carrying out a range from 0.3 to 0.7; in this simulation,
full or partial Constant Composition Expansion the oil recovery is not significantly affected
(CCE) experiment. by the value of and a value of 0.5 is used.
3. The effects of mixing of oil and gas
Static and Dynamic Modelling on viscosity are captured by a mixing
equation. The mixture viscosity is a
A fine scale geological model was constructed function of oil and gas viscosities and
integrating geophysical, geological, saturations.
petrophysical and engineering information 4. The relative permeabilityvalues are
using a commercial software. Review of well entered for a hydrocarbon phase (krn (Sn))
logs, core data and well test data is being carried and a water phase (krw). The oil and gas
out for facies and rock type determination. The relative permeabilitys are then calculated
reservoir static model is bounded by faults as a weighted saturation function. In this
with 0.7 million cells (107 x 50 x 132). The simulation, the oil relative permeability
simulation study was performed on the fine curves from the history match case
scale geological model without going through are used for hydrocarbon relative
the upscaling process. permeabilities, and the water relative
permeabilities are kept the same.

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4.1.5 Results and Discussion shown that the reservoir pressure has declined
to a level of below 100 Ksc during the year of
Reservoir Fluid Analysis 1985-2008 (Figure 2). When the solution gas
was liberated and left the reservoir oil, the gas
Laboratory studies were carried out in order production and GOR increased significantly.
to obtain some critical input parameters for The free gas production during 53-year
reservoir simulation study. CO2 behaves like a production history is just like an immiscible
fluid under reservoir with liquid like density and lean gas flood taking place in the reservoir for
gas like viscosity under reservoir conditions in decades. Therefore, the reservoir fluid under
super critical state. the current reservoir conditions is completely
different from the original live oil at 1960s.
Review of 53 years production history have

Figure 2: Recombined Live Oil Preparation and Validation

MMP Determination The slim tube test using CO2 with some
impurities were also investigated. Gas
Minimal miscibility pressure (MMP) is the composition containing 95% CO2 and 5%
single most important parameter in the design impurity (4.5% C1+0.5% C2) showed the MMP
of a miscible gas EOR. The MMP of CO2-live of 211-232 ksc (i.e., 3000-3300 psi). The gas
oil system in well N079 was determined using composition containing 90% CO2 and 10%
the classical slim tube displacement test. As impurity (9.0%C1+1.0%C2) showed the MMP
shown in Figure 3, the MMP of pure CO2-live oil above 232 ksc (i.e., 3300 psi). These test result
is 211 ksc (3000 psi), which is achievable in the support the robustness of CO2 miscibility due
area of interest of N79 block. to the slightly trapped gas saturation near
production wells in N079 reservoir.

Oil & Gas Technical Journal -1 99

 S lim T u b e M M P D c t iT m im it K m

1 (Kl

j* ' M M P — 2 1 1 lis c
■

o r 3 0 0 0 p it

znon 2200 3 4 110 2600 2 boo jooo in m .14110

P R E 9 S IIR K (P $ I)

Figure 3: MMP determination through slim tube test.

Table 1: Summary of Live oil swelling test at 80 degC

iH H il D n d lj FVJ S a l a r i e s G i t m l K a rin S M - ft liie

I m a k * -») IT J 'I*) C M P *! Ifir O Ifn r r P s .1') l\r| 1Bl 1niJ inJ
PI PI

0.00 2051 F li 14.15 0.77 00 1.137 I.2 2 S S 3 7 1 .2 3 66.12 I.0 0 M -

2 1 .7 2 iSOO Fb 1 T .M tu n 1 .3 .'?7 6 :1 .8 0 110. 1 W tT
34.51 1 870 Fb 10.78 i.+ n : S41.01 lio .s * 11 S «
43.61 3 4 4 1 Pb 3S.T5 o .t g f i » < !l i s*ss im t : 117.66 I is o :
60.38 45<H Fb :e .« #-713 i to ? = 1 *7 0 l,« J 7

111 B a ir r lt ( C u b ic lu e f lo v o-f f lu id ar m d icaled l jiif ^ u n c .iud f« n i|w ra liu e per b a n e l Cc u I mc uiieler ■ o f re*, id u .il oil (i 6 0 F { 2 8 $ .7 K>
l- l 5-m c U ilse l> d c flu c d a-> Eli? v o lim ie o f flu id .iE -..lli.uiCioai prcvtiurc ilrv i J e d b y l he v o lu m e a f i c w n x m m l iE m i l u l -sihn nlLou p ic t u r e
Pb - Ddbthptoi Frasure
PJ - DcupoiiiQ F n a a »
T m A w u d u a u m . 6 0 F (2 B S r K h i j ] 3 p m ■ 0 .0 9 M iP a i: S c r a l a ii l c u m to ia m : 60 F I ZS-3.~ K ■ r_! I -I 6 9 6 p a a 10. 1 0 1 1 2 * M P a I.

Swelling Test bubble disappears, the new cell mixture

(Oil + injected CO2) is at its saturation
Solubility swelling test were carried out on point.
reservoir oil mixtures to study how the reservoir • The pressure and the swollen volume
fluid will interact with the gas injection. The are recorded. Other key fluid properties,
typical procedure applied to swelling tests is including fluid density and viscosity, FVF,
listed as follows: swelling factor, GOR etc. are determined.
• A swelling test starts with a known volume • More CO2 is injected, and the pressure
of reservoir oil at its saturation point in a increased until all CO2 is in solution in the
PVT cell kept at the reservoir temperature oil. This process is repeated for a number
(80°C). of stages. The summary of the swelling
test data is presented Table 1.
• Certain percentage volume of CO2 is
transferred into the PVT cell. The gas and Coreflood Experiment
oil phase are well mixed.
• The pressure is increased, maintaining a The key parameters of rock and fluid properties
constant temperature until all the CO2 has and core-flood results are summarized in
been dissolved. When the last CO2 gas Table 2 and 3.

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Table 2: Fluid and rock properties of Core flood sample

COMPOSITE STACK PARAMETERS

Sample Length (cm) 58.17
Sample Diameter (cm) 3.76
Average Pore Volume (cc) 130.82
Average Porosity (%) 20.29
Harmonic Air Permeability (mD) 28.8
FLUID PARAMETERS @ RESERVOIR CONDITIONS
Reservoir Temp (°C) 80
Reservoir Pressure (Pore Pressure) (psi) 3300
Reservoir Brine Viscosity (cP) 0.45
Reservoir Oil Viscosity (cP) 1.14

Table 3: Coreflood results

Injection CO2Viscosity (cP) 0.05

COREFLOOD RECOVERY DATA
Harmonic Water Permeability, kw (mD) 9.2
Live Oil Phase Permeability@ Swi (mD) 5.37
Initial Water Saturation - Swi (%PV) 42.2
Initial Oil Saturation -S o (%PV) 57.8
Hydrocarbon Pore Volume: (cc) 75.6
Water Injection Rate (cc/min) 0.4
Residual Oil Saturation after waterflood - Sorw (%PV) 28.4
Oil Recovery after Waterflood (%OOIP) 50.9
Residual Oil Saturation - Sorm (%PV) 13.3
Incremental Oil Recovery by CO2 (%OOIP) 26.2

After restoring the wettability and establishing initial After the initial water flood, continuous injection of CO2
oil saturation in the core composite, a waterflood started at a rate of around 0.4 cc/min, with the flow
was performed by injecting formation brine for five direction being the same as the preceding water flood.
pore volume using injection rate of 0.4 cc/min. The oil The incremental oil recovery was produced mainly in
recovery by water injection is 50.9% OOIP and residual the first half pore volume of CO2injection. After ~ 8 pore
oil saturation after the waterflood is around 0.284 PV. volumes of CO2 injection, the incremental oil recovery
Figure 4 shows the pressure drop across the sample, beyond water flood is 26.2% OOIP At the end of CO2
injection rate, and oil recovery versus pore volume injection, the remaining oil saturation was 13.3% PV.
injected.

Oil & Gas Technical Journal -1 101

 CoroFtoodTcit

Figure 4: CO2 EOR Flood Pressure drop Flow Rate Figure 5: Coreflood Results
and oil recovery

Simulation study implementation of CO2 EOR (Figure 7). Both

the pilot areas required drilling of an injector
The main objectives of the simulation study well at the center. Further, it has been observed
were to during the study that Pattern 1 does not merit
implementation as the incremental oil recovery
1. Carry out screening and identify suitable is too low to justify high Capex involvement.
areas of leftover saturation for a CO2 Hence Pattern 2 (P2) has been finally selected
injection pilot for CO2 EOR implementation.
2. Optimize the pilot design through
sensitivity in injection volume and The Pilot area is located in the far eastern
associated CAPEX involvement part of the Country with only few sources of
3. Assess incremental oil recoveries CO2. CO2 supply was likely to be sourced from
associated with pilot CO2 injection. nearby Digboi oil refinery. Due to scarcity of CO2
source in the vicinity of the Pilot area and high
A reasonable good history match is achieved CO2 cost, injection schemes were investigated
for oil, water and gas rates, both at the field to have an optimized injection to production
and well level along with pressure (Figure 6). ratio. Alternating gas and water injection
By computing and visualizing an oil saturation scheme is found to be the most profitable with
index, the CO2 pilot area was selected based improved CO2 sweep as well as increased oil
on remaining oil saturation, sand thickness, recovery. The Injection scheme for the selected
heterogeneity and continuity of sand. The pattern is given below in Table: 4
south-west part of the field had the highest
remaining oil saturations with reasonable Another design consideration is the presence
sand thickness and continuity. Furthermore, of free gas saturation and depletion. The
the sand package here was clearly overlain history matched model indicated that the
by a thick contiguous shale zone, providing gas saturations were between 8-15% in the
containment. Two inverted 5-spot patterns main zone of interest. The presence of free
have been investigated using simulation for gas saturation in the reservoir introduced

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Figure 6: Field Level History Match

Figure 7: Identified Inverted 5 spot Pattern

Oil & Gas Technical Journal -1 103

 an additional element of uncertainty. There revealed that the presence of hydrocarbon
were two possible options - to continue gas saturations less than 10% had a minimal
waterflooding the reservoir for several years impact on CO2 miscibility and did not have a
to resaturate the free gas or to commence significant effect on the flood effectiveness.
CO2 flood with the presence of the free gas, This is supported by PVT studies indicating that
effectively making the flood a mixed CO2- the presence of hydrocarbon gas components
hydrocarbon flood. It is felt that the current does not significantly alter the miscibility of
water flooding will continue for 5 years to CO2. It was recommended that field operations
increase the reservoir pressure and dissolve maintain a voidage replacement ratio of 1.1 till
the free gas in the zone. Simulation work CO2flood commenced.

Table-4: Pilot Area 2 (Case-4) injection strategy

Water Injection CO2 Inj ection Water Injection

Surface Rate Period Surface Rate Period Surface Rate Period
(m3/d) (sm3/d ) (m3/d)
200 5 years 38,000 5 years 200 13 years
(2022-27) (67 tons/d) (2027-32) (2032-45)

The optimum CO2 injection rate in the selected As per the available literature around 90% of
pattern is about 67 tons per day. This translates the purchased CO2 is trapped in the geologic
to approximately 5% hydrocarbon pore volume Formation (Melzer et.al, 2012). As TL model
injected annually. In total, it is estimated that is used to simulate miscible gas injection,
nearly 1,20,000 tons of CO2 will be captured the exact value of CO2 retention could not be
and injected during the 5-year pilot phase. calculated. However, since CO2 injection is
carried out near MMP, a considerable volume
of CO2 retention is expected.

Figure 8: Remaining oil saturation after history match

When CO2-EOR is performed, some of the CO2

is retained in the reservoir. CO2 injection into
a reservoir can be implemented in miscible Figure 9: Incremental Oil over base case
and immiscible conditions, and the distinction
between the two is defined by the minimum Several other key results were obtained from
miscibility pressure. If the conditions are the CO2-EOR simulation study:
miscible, CO2 increases the oil mobility as it is
• The oil recovery from the CO2 injection
dissolved in oil between the injector and the
case was approximately 5.41 MMSKL
producer, and if the conditions are immiscible,
over 25 years. This represents a recovery
there is no CO2 dissolution in oil, which means
factor of 37.9% for the block.
that CO2 flows much faster than oil toward
the producers, causing lower oil recovery and • The incremental produced oil over
higher production of previously injected CO2. the waterflood case is approximately

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0.27 MMSKL (Figure 9). This gives an Energy Fuels 2013,27,4183-4189.

incremental recovery of around 11% 2. Verma, M.K. Fundamentals of Carbon Dioxide-
within the pattern area OOIP or 3% of Enhanced Oil Recovery (CO2-EOR)-A Supporting
the OOIP within the general south-west Document of the Assessment Methodology
for z Recovery Using CO2-EOR Associated with
area of the field (the south-west area has
Carbon Sequestration; Series No. 2015-1071;
approximately 5.0 MMSKL OOIP). U.S. Geological Survey Open-File Report; US
• The decline rate for the CO2 case is Geological Survey: Tucson, AZ, USA, 2015.
approximately 18% per year. This is more 3. Mungan, N. Carbon Dioxide Flooding as an
severe than the waterflood decline of 11%; Enhanced Oil Recovery Process. J. Can. Pet.
the CO2 flood recovers a larger quantity Technol. 1992, 31.
of oil earlier and then has a more rapid 4. Hosseininoosheri, P; Hosseini, S.A.; Nunez-
Lopez, V.; Lake, L.W. Impact of field development
decline.
strategies on CO2 trapping mechanisms in a CO2
• The CO2 utilization ratio is around 6.0 -EOR field: A case study in the Permian Basin
Mscf/bbl within the pattern area (SACROC unit). Int. J. Greenh. Gas Control 2018,
72.
• CO2 is effective at mobilizing residual
oil; the effects of the CO2 flood are seen 5. Langston M V, Hoadley S F, Young D N, "Definitive
CO2 flooding response in the SACROC unit", SPE
beyond the CO2 injection period as the
17321, 1988.
mobilized oil is swept by the injected
6. Al-Otaibi F.M., Al-Mutairi, S.M., Kokal S.L., et
water. al. "Best Practice for Conducting CO2-EOR Lab
Study", SPE-151126-MS, paper presented at the
4.1.6 Conclusion SPE EOR Conference at Oil and Gas West Asia in
Muscat, Oman, April 16-18,2012.
CCUS is vital for combating adverse effects 7. Duchenne, S., Puyou G., Cordelier, P., et al.,
of climate change globally and for India in "Laboratory Investigation o f Miscible CO2 WAG
particular. Success of CCUS in India will not Injection Effiency in Carbonate", SPE-169658-
only increase domestic oil production through MS, paper presented at SPE EOR conference at
CO2 EOR, but also help in reducing carbon Oil and Gas West Asia held in Muscat, Oman,
April 2014.
footprint. The current Study for Implementation
of CO2 EOR in one of its Field is an endeavor 8. F.M. Orr Jr, M.K. Silva, "Effect of Oil Composition
on Minimum Miscibility Pressure - Part 2:
of Oil India Limited to align its objective in
Correlation", SPE Reservoir Engineering, SPE-
line with the vision of Government of India to 14150, November 1987.
reduce carbon foot-print by 2030. Based on 9. Jafari, M., Badakhshan, A., Taghikhani, K., et al.,
the study, the CCUS project shows substantial "Experimental Study and Simulation of Different
potential for recovery enhancement while at EOR Techniques in a Non-Fractured Carbonate
the same time resulting in sequestration of Core from an Iranian Offshore Oil Reservoir",
CO2 in the candidate reservoir. Successful Iran. J. Chem., Chem. Eng., 27 (2), 2008
implementation of the project will pave the way 10. Lei, H., Yang, S.L., Zu, L.H., "Oil Recovery
for implementation of the technology in other Performance and CO2 Storage Potential of
CO2 Water-Alternating-Gas Injection after
similar fields of the Company.
Continuous CO2 Injection in a Multilayer
Formation", Energy Fuel, 2016, 30, 8922-8931.
Acknowledgments
11. Negabhan, S., Pederson K.S., Baisoni, M.A., et al.,
The authors are grateful to Oil India Limited "An EOS Model for a Middle East Reservoir Fluid
(OIL) for granting permission to publish this with an Extensive EOR PVT Data Material", WPE-
136530-MS, paper presented at ADIPEC in Abu
work. The interpretations expressed in this
Dhabi, UAE, Nov. 2010.
paper are solely those of authors and not
12. Seyyedsar S.M., Farzaneh S.A., and Sohrabi M.,
necessarily that of the organization. "Investigation of Low-density CO2 Injection for
Enhanced Oil Recovery", Ind. Eng. Chem. Res.
References 2017, 56, 5443-5454.
13. Srivastava R.K., Huang S.S., Dong, M., "Laboratory
1. Godec, M.L.; Kuuskraa, V.A.; Dipietro, P
Investigation o f Weyburn CO2Miscible Flooding",
Opportunities for Using Anthropogenic CO2
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for Enhanced Oil Recovery and CO2 Storage.
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14. Sunil Kokal, Modiu Sanni, Almohannard 16. Chen P, Selvendran A. et al. “CO2-EOR and
Alhashboul, "Design and Implementation of the Carbon Storage in Indian Oilfields: From
First CO2 EOR Demonstration Project in Saudi Laboratory Study to Pilot Design". SPE-195378-
Arabia", SPE-181729-MS, presented at SPE MS, paper presented at SPE Western Regional
ATCE held in Dubai, Sep 2016. Meeting held in San Jose, California, USA, April
15. OPINION: Carbon Capture and Sequestration: 2019
Enabling a Green New Deal for a Net Zero India.
https://energy.economictimes.indiatimes.com/
news/renewable.
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4.2 GREEN HYDROGEN- The New Energy Vector

Author: Shiva Shukla- Assistant Manager, Panipat Naphtha Cracker
Indian Oil Corporation Limited
4.2.1 Abstract scientist Henry Cavendish in 1766. In 1874
Jules Verne, in his book the Mysterious Island,
Currently, the greatest global problem is "water will one day be employed as fuel,
environmental pollution. To avoid climate projected his vision for the use of hydrogen
catastrophe, spiking words around the world as a zero-carbon fuel. Despite long-known
are being heard at different platforms raising opportunity for hydrogen to be isolated from
pressing pollution concern. The striking water and produce only water when combusted
demand for carbon neutrality with increasing as fuel, techno-economic challenges hindered
energy dependency finds renewable energy as its widespread adoption as a clean fuel during
a one of the solution. Green Hydrogen has been the 19th and 20th centuries.
put at the heart of Worlds Energy security and
climate change. Green hydrogen is hydrogen Currently, hydrogen is mostly used in oil refining,
that is produced using renewable energy production of fertilizers and is responsible for
through electrolysis emitting no hazardous 830 MtCO2 of annual CO2 emissions. However,
gases. Green hydrogen has been labelled as for it to make a significant contribution to clean
the "Fuel of Future". This study addresses the energy transitions, it also needs to be adopted
green hydrogen production, hydrogen storage, in sectors where it is almost completely absent
hydrogen safety as a technological issue and at the moment, such as transport, building and
possible hydrogen economy. India's green power generation.
hydrogen market is currently in the nascent
stages of development. Thus, this study In 21st century hydrogen has become
reviews the solar energy-based hydrogen particularly attractive source of energy due to
production potential in India. The total hydrogen important component for achieving ambitious
production potential of India is estimated climate targets, synergy with the existing
on potential renewable energy production industries and rising demand of Industrial
possible, based on the available governmental decarbonisation.
data. A focus on on-going investment & steps
globally has also been compared & discussed. 4.2.3 Spectrum of Hydrogen

Keywords: Green Hydrogen, Solar Potential Hydrogen is a colourless gas, however

depending on production methods, it can be
4.2.2 Introduction can be grey, blue or green - and sometimes
even pink, yellow, turquoise or white.
Hydrogen is the lightest element in periodic
table. It is colourless, odourless, tasteless, Following are description of different types of
non-toxic, and highly combustible. Most of hydrogen:-
the hydrogen in Earth exists in molecular form
as water or organic compounds. Hydrogen Green hydrogen is defined as hydrogen
can be produced using a number of different produced by splitting water into hydrogen
processes. The majority of hydrogen (95%) is and oxygen using renewable electricity. Most
produced from fossil fuels by steam reforming of the methods for the production of green
(SMR) of natural gas (Ch 4) and other light hydrogen consider obtaining hydrogen either
hydrocarbons, partial oxidation of heavier through water splitting reactions (e.g. water
hydrocarbons & coal gasification. electrolysis, water thermolysis, photocatalytic
water splitting, and thermochemical water
The story of hydrogen is not new, Hydrogen splitting) or via dehydrogenation of hydrogen
was first recognized as a distinct element by carrier molecules.

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 Blue hydrogen is produced using a process into hydrogen gas and carbon using simple
called steam reforming. This involves bringing pyrolysis process.
together natural gas and water (in the form of
steam) to produce hydrogen gas and carbon Yellow hydrogen is a relatively new phrase
dioxide as a by-product. referring to the method of inducing electrolysis
through photoelectric-chemical reaction by
Grey hydrogen is created from natural gas using solar power
or methane. It uses the steam methane
reformation process but without capturing the White hydrogen is the naturally occurring
generated greenhouse gases in the process. hydrogen gas found under the earth in
underground deposits created through
Pink hydrogen is generated through the fracking. Presently, there are no procedures to
electrolysis of water using nuclear power. Pink exploit this resource.
hydrogen produced using nuclear energy can
also be referred to as purple hydrogen or red Above all, the only 100% sustainable &
hydrogen. commercial viable hydrogen is Green hydrogen.
Green hydrogen is gaining momentum due
Turquoise hydrogen is a new entry in the to generation of energy through electrolysis
hydrogen colour chart, and its production is yet process without generating any kind of
to be proven at large scales. Creating turquoise hazardous waste for the environment.
hydrogen begins by converting methane

Figure-1:- Hydrogen Production Origin-Colour Code - *Note-SMR- Steam Methane Reforming

4.2.4 Fact for the Green choice decade 2010-2019, India's generation in a
business-as-usual scenario will be 4.48 Gt in
Global CO2 emission has reached a record high 2030.
of 36.7 Gt. India is the third largest emitter of
carbon dioxide (CO2) after China (10.6 Gt) and In COP-26 held in 2021, India has promised
the US (4.7 Gt) and thus is vital in the fight for a more ambitious target of reducing the
against climate change currently focused on emissions intensity of its economy by 45%
reaching zero emissions by the mid century or than the previous goal of 33-35% cut (in COP-
earlier. 21 held in 2015). According to new target, India
will cut its carbon emission by (1 Gt) annually
India's current CO2 emissions are 2.88 Gt. and therefore, the emissions in 2030 shall be
According to the Centre for Science and 3.48 Gt.
Environment (CSE)'s projections based on
the median annual rate of change in the past Energy sector contributes 68.7% percent of GHG

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emissions in India. The environmental concern capacity and represents ~38% of the overall
associated with booming industrialisation installed power capacity i.e utilizing ~ 10 % of
is growing due to its persistent impact on air the available potential.
quality, depletion of ozone layer, rising earth
temperature, resulting in global warming. The Government of India is aiming to achieve
227 GW of renewable energy capacity by 2022,
According to a report of TERI in 2020, India's much ahead of its target 175 GW as per the Paris
hydrogen demand stood at 6 million Tons (MT) Agreement. Also, the target is kept ambitious to
per year (70MT globally). This can increase 500 GW of electric power generation through
to around 28 Mt by 2050 and to meet the renewable energy sources by 2030.
zealous ambition of net zero this needs to be
decarbonised.

Use of hydrogen is currently dominated by oil

refining (45%), ammonia production, primarily
for fertilizer(40%), methanol production (10%)
and steel production (5%).

Currently, the large share of hydrogen (approx.

95%) is produced by Steam Methane Reforming
(SMR). Only a small proportion of hydrogen is
produced from renewable sources. The high
cost of renewable sources is the main reasons
for this low level of production.

With renewable energy technologies reaching Figure-2:- Installed Renewable Energy

to a level of maturity allows a significant Distribution (MW) -India
potential for emissions reductions from clean
hydrogen. Top 10 countries (Installed Capacity MW)

Emissions from green hydrogen production

using electrolysis is 43 gCO2e/kg of H2
compared to 9.3 kgCO2e/kg of H2 produced
using steam reforming process without carbon
capture.

Adopting green hydrogen as an admired

fuel will be the most competitive route for
hydrogen production by around 2030. Many
experts believe a new energy era of hydrogen is
dawning and that the age of oil is drawing to a
close. New technologies are required to replace
fossil fuels dependency aiming towards a net
carbon neutral economy at the earliest. Figure-3:- Global Renewable Capacity Installed -
Top 10 countries (IRENA-2020)
4.2.5 India's Potential
As per (IRENA, 2020) India ranked at 5th position
Indian has more than 1000+GW renewable among the top 10 countries with renewable
energy generation potential. As of September energy installed capacity in 2020. Apart from
2021, India had 101.53 GW of renewable energy installation, the largest cost reduction in the

Oil & Gas Technical Journal -1 109

 utility-scale sector has been observed by India, Freshwater scarcity is already a persisting
where between 2010 and 2020, costs declined issue worldwide; 1 kg of hydrogen production
by 85%, to reach USD 0.038/kWh - a value 33% will require 9kg of water (50-55kWh of
lower than the global weighted average for that electricity). The excess water requirement for
year. green hydrogen production can be resolved by
seawater utilisation; however usage of same
The same projection has been made by TERI in hydrogen production is associated with
in one of publications stating "The projected challenges such as the corrosion of chloride
cost of wind & solar by 2030, will be between ions in seawater to the anode metal.
Rs. 2.3-2.6 & Rs. 1.9-2.3 per kWH respectively
which will be among the world's best. No doubt Another main component in this simple process
this shall provide economical practicability for of electrolysis is the electrodes. Low electricity
the production of green hydrogen in India at a cost is not enough by itself for competitive
competitive rate. green hydrogen production.

India's energy transition to clean fuels, Commercially operated electrolysers are

adoption of green hydrogen would bring in Alkaline Electrolysers (AE), Polymer Electrolyte
significant benefits. By leveraging low-cost Membrane (PEM), with Solid Oxide Electrolyser
domestic renewable electricity produced at (SOE) and Anion Exchange membrane (AEM).
scale, India could become a regional hub Alkaline and PEM electrolysers' well advanced
for exporting green hydrogen at competitive & well known technology. Alkaline electrolysers
prices and command a reasonable share in have the lowest installed cost, while PEM
the global hydrogen demand of 200 million electrolysers have a much smaller footprint,
tonnes by 2030. However, achieving a low cost combined with higher current density and
of hydrogen production crucially hinges on output pressure. Meanwhile, SOE & AEM
policy support and strategic research priorities having the highest electrical efficiency are still
as well. To avoid missing out on the future in developing stage.
benefits of the energy transition, India needs to
be proactive in creating a productive innovation Table 1:- Comparison of different type of
ecosystem for the development, deployment Electrolysers
and diffusion of technologies.
Type of Efficiency Opr.Temp
Advances and challenges Electrolysis (OC)
(%)
1. AE 70 60-80
2. PEM 58 20-80
3. SOE 99.99 500-850
4. AEM 99.99 50-60

CAPEX requirement for AE is in range of

USD500-1400kWe, for PEM is USD 1100-1800/
kWe & 2800-5600/kWe for SOE [iea furture of
hydrogen]. Gaps in cost and performance are
expected to narrow over time as innovation
and mass deployment of different electrolysis
technologies drive convergence towards
similar costs.
Figure-4:- Electrolysis Process for
Green Hydrogen Generation The areas that need further investigation are
hydrogen transportation & hydrogen storage
The peculiar advantage of green hydrogen is, it facility. The perceived high risk associated with
can be produced wherever there is water and hydrogen by society is an also an important
electricity. challenge.

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Hydrogen's ability to embrittle materials wide used as transport fuel. Around 400+ hydrogen
flammability range and the limited amount fuelling station have already been set up
of energy needed to ignite are few of listed globally.[40] India's 1st hydrogen refuelling
challenges for storage & transportation of station was setup at IOC Faridabad in 2005.
hydrogen on large scale. At present among [41] India's first hydrogen fuelling train fuel is
the several options proposed, metal hydride- also set up to cover its first distance of 89km
based solid-state storage systems have been from Sonipat to Jind. Alstom Coradia iLint is
recognized as one of the most viable solutions the world's first hydrogen passenger train in
for storing hydrogen in hydrogen-powered Poland.
systems. Japan has been on forefront of
development of hydrogen technologies, it Hydrogen Fuel Cell Vehicle (HFCV) - HFCV
claims to breakthrough in hydrogen storage are already commercial in terms of material
by creation of a simple-structured interstitial handling applications. India's first H2 fuel cell
aluminium alloy. was introduced by IOC & Tata Tata Motors in
2018, 15 such buses will soon be launched in
India''s OMC-IOCL is owner and operator of Nations Capital. HFCV in Light Vehicle Category
the 1st high pressure hydrogen storage and has already set a record selling of 3341 units
dispensing terminal in India, with the refuelling in 2021 in US. Many countries depict HFCEV
station located in Delhi. This refuelling station to be alternative Electrical Vehicles (EV) in
uses a PEM electrolyser, outputting hydrogen upcoming future. (Currently the cost of HCEV is
at 30Nm3/hr at a purity of 99.999%, which is twice to EV). HCEV have higher efficiency than
required for fuel cell vehicles. gasoline-based vehicles, long driving range,
and no emissions, thus offering a potential
Apart from the hydrogen resources, the solution for future sustainable transportation.
catalysts, production efficiency, and hydrolysis
rate are aspects to explore during generation. Hydrogen Pipelines- With skyrocketing price
Moreover, fuel cell systems are becoming of natural gaseous one option which seems
increasingly important in both small-scale and possible in future is conversion of natural gas
large-scale hydrogen generation building the pipelines (3 million km worldwide, 17k km
confidence in hydrogen as a safe, clean and India) for hydrogen transportation to refineries
renewable fuel for the future. & fertilizers. Recent studies in Netherland
have suggested that it could be possible with
4.2.6 Commercialization of Green Hydrogen small modifications. Commercialization and
deployment of green hydrogen on a large-
As discussed earlier, hydrogen holds long term scale faces significant challenges. Following
promises in many sectors i.e transportation, are a few barriers to be knocked down before
buildings & power. Hydrogen is already the commercial aspect of green hydrogen is
established in commercial market. More advanced.
than 23,000 Fuel cell powered forklifts are in
• Overall high costs of the hydrogen
operation worldwide.
system including capital, operational,
maintenance, and running costs.
Fuel Electric Cell vehicle have potential to
attract the competitiveness of Electric vehicle. • Integration with other energy vectors
hydrogen based liquid fuel provide potentially using information and communication
attractive options for aviation & shipping. infrastructure.
• Low social awareness and user
Long term prospects in hydrogen usage acceptance.
for heating of buildings could include direct • Supply chain development across all the
hydrogen in hydrogen boilers. H2 & NH3 can be world is still in its incipient phase.
flexible options used in GTs.
• Need for legal and administrative
adherence, policy for different components
Hydrogen Refuelling Station: Hydrogen can be
of the system.

Oil & Gas Technical Journal -1 111

4.2.7 The Green World world's lowest cost green hydrogen producer
by 2030. 6 new projects of 3.96GW constituting
In this global energy scenario, hydrogen is of Enel Green Power for 240MW,
experiencing an unprecedented historical
moment for its future key role. In fact a great Air Liquide of 80MW, Engie 26MW,GNL Quintero
and widespread enthusiasm is growing for 10MW, CAP 20MW & Linde for 20MWhas
up towards it, as indicated by the current proposed a strategy exclusively dedicated to
worldwide economic and political strategies, the green hydrogen for producing 45,000 tons
which endorse the net-zero greenhouse gas of green hydrogen per year by 2027
emissions and the access to clean energy.
China is leading renewable energy technology
It can be clearly noticed how, in the last period producer & exporter. With Sinopec alkaline
(2020-2021), several countries have already electrolyser facility of 260MW in Xinjiang, be
mature strategy proposal. completed in mid-2023,[52] will lead the new
record beating 150MW Baofeng project.[53]
Exhibit 1: Global hydrogen projects and investment across the value chain
The record had been previously held by Air
Liquide's 20MW Becancour facility in Quebec,
Canada.

The European Union has fixed both short and

long term targets. Among them, Germany plans
to deploy up to 5GW of hydrogen generation
capacity using water electrolysers by 2030
with an investment of $900mln. France sets
the most ambitious absolute target for 2030
with a capacity of 6.5 GW.

GW GWh

Figure-5:- Global hydrogen projects & investment-

Hydrogen Council [4]

The world's largest green hydrogen project

is currently Air Liquide's 20MW Becancour
facility in Quebec, Canada, which uses a PEM
electrolyser, supplied by US-based Cummins
and is powered by local hydroelectricity.

Australia-As per latest report of Nov'21

Australia may lead green hydrogen pack with National capacity targets 2030 (GW)
69GW project pipeline. This includes 28GW • Projected consumption potentials 2030 (GWh)
Western Green Energy Hub, 14GW Asian
Renewable Energy Hub, 8GW HyEnergy Zero Figure-6:- European Union Renewable Energy
Carbon Hydrogen 5GW Murchison Renewable Target/Projected
Hydrogen 3.6GW Pacific Solar Hydrogen, 3GW
Gladstone projects in Queensland, 2.8GW Tiwi Japan imports almost 90% of the energy it
Hydrogen Project in the Northern Territory. uses, and has limited room to build out solar
or wind arrays. [58] Still it has opened the
Chile- has set goal having 5GW of electrolysis largest green hydrogen plant, with a 20 MW
capacity under development by 2025, being the solar array feeding a 10 MW electrolyser plant

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(RECHARGE,2020). The Japanese government 4.2.8 Conclusion

more than doubled its hydrogen-related R & D
budget to nearly $300 million in the two years At the end it all land up to high cost. That
to 2019. Japan strategy on Net Zero is different means much more green hydrogen should be
as it is planning to import ammonia. Japanese produced as production technologies become
utilities could first secure ammonia made from more and more mature with more competitive
fossil fuels and find ways to capture or offset costs. In conclusion, the main actions to
the carbon dioxide emitted during that process. accelerate decarbonisation between now and
They could switch to "green" ammonia as 2030 are
demand grows and prices come down.
1. Electrification with renewables
U.S. has already released its hydrogen 2. Acceleration in renewable power
roadmap critically important hydrogen is to generation
achieve a lower-carbon energy mix, concludes 3. Carbon Capture Technology, Scaling up
to strengthen economy by generating $140 Bioenergy-to produce green fuel that
billion per year in revenue and 700,000 jobs by absorbs CO2
2030, and $750 billion per year in revenue and
4. Manufacturing of electrolyser on larger
3.4 million jobs by 2050," as stated by Fuel Cell
scale- to bring reduction in prices.
and Hydrogen Energy Association (FCHEA).
The U.S. is already heavily engaged in the 5. New technology that can convert the
hydrogen economy with hundreds of millions greenhouse gas carbon dioxide (CO2) into
of dollars of public and private investment per fuel by using solar-powered to be explored.
year, and boasting more than half the world's 6. Making green hydrogen competitive and
fuel cell vehicles, 25,000 fuel cell material ready for a further scale up in the 2030s,
handling vehicles, more than 8,000 small scale towards the objective of reaching net zero
fuel systems in 40 states, and more than 550 emissions by 2050.
MW of large-scale fuel cell power installed or
planned.
Reference
1. "Hydrogen". Encyclopedia Britannica.
India's Union Budget for 2021-22 has 2. Hydrogen Fuel and technology, IEA Report 2020
announced a National Hydrogen Energy 3. Global Emissions by Gas- EPA, US Environmental
Mission (NHM) that will draw road map for Protection Agency
using hydrogen as an energy source. India's 4. Greenhouse Gas Emission India-USAID
ambitious goal of 175 GW by 2022 got an 5. The Potential Role of Hydrogen in India-TERI
impetus in the 2021-22 budget which allocated 6. Greenhouse Gas Emission by country-World
Rs. 1500 crore ($200mln) for renewable energy Population Review
development and NHM. Across Indian industry, 7. Hydrogen Resources-Energy Efficiency &
there are considerable efforts to establish Renewable Energy (EERE)
a hydrogen economy in India, not least, the 8. Hydrogen Production Natural Gas Reforming-
work being taken forward by Indian Oil. IOCL (EERE)
is owner and operator of the 1st high pressure 9. Ministry of New And Renewable Energy-Official
hydrogen storage and dispensing terminal in Site
India, with the refuelling station located in Delhi. 10. IRENA-2020
This refuelling station uses a PEM electrolyser, 11. Renewable Power Pathway-TERI 2020
outputting hydrogen at 30Nm3 / hr at purity of 12. Global Hydrogen Demand by Sector in the Net
99.99%, which is required for fuel cell vehicles. Zero Scenario-IEA
13. Future of Hydrogen-IEA
India's plan to lead the green hydrogen industry 14. Make Hydrogen in India-TERI
still needs a much clearer picture.

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4.3 Review of Best Available Blue Hydrogen Technologies

Authors: Yassir Ghiyati, Director o f Hydrogen Business Line, Topsoe &
Nitesh Bansal, Proposal Manager, Expert, Hydrogen, Topsoe

Mr. Yassir Ghiyati is Hydrogen Business Line Director, Topsoe. Having experience in Process
Engineering & Commercial Management activities within P-T-X, hydrogen, syngas, ammonia,
methanol and refining.

V* J
r

Mr. Nitesh Bansal, Proposal Segment Manager, Expert, Hydrogen Topsoe. He is having
experience in process/ design engineering & Techno-commercial activities within hydrogen
and syngas. Developed technology solutions with hydrogen/ syngas area and applied for the IP

Carbon dioxide (CO2) emissions must be reduced is much higher as it can decarbonize other sectors
to tackle global warming. Several governments as well by becoming a preferred energy carrier, either
have therefore already adopted relevant regulatory in pure form or by being converted into ammonia.
frameworks, such as emission trading schemes Hydrogen Council estimates that H2 production will
or carbon taxation, with the aim of reducing CO2 increase 8-10 times by 2050 emphasizing the need for
emissions. decarbonizing H2 production.

As just one example, the European Union (EU) Emission Hydrogen is traditionally produced by steam methane
Trading System (ETS) directive drives CO2 reductions reforming using fossil-based feedstocks such as
by setting a cap on the total CO2 emission allowance natural gas, LPG or naphtha. Hydrogen production
for each company and by reducing this cap figure over from fossil sources without CO2 capture is termed
time. Companies can sell their surplus quotas of CO2 "grey hydrogen".
emission and are thus incentivized to invest in the
most efficient technologies with least CO2 formation One promising way of decarbonizing hydrogen
and to capture, utilize and/or sequester the formed production is by steam electrolysis fueled by
CO2. renewable energy. The hydrogen thus produced is
completely green and leaves no CO2footprint, whether
Since its introduction in 2005, the EU ETS directive has from production or use. Companies such as Haldor
passed through several phases. It is now in its fourth Topsoe have commercialized electrolysis solutions,
phase, in which the pace of annual cap reduction is set that are easy to use as standalone hydrogen unit or
to increase significantly. The EU commission expects in hybrid setups in combinations with traditional
the directive to drive faster adaptation of both "blue" hydrogen production. However, one of the main
and "green" technologies that are essential for EU's current limitations of green hydrogen deployment at
journey towards climate neutrality by 2050. mega scale lies in the insufficient availability of green
power capacity.
According to IEA, the annual hydrogen production
accounts for 830 million tons or 3% of global CO2 To unlock the full potential of hydrogen in the energy
emissions. As such, there is a need to decarbonize transition aimed at reducing CO2 emissions, it is
hydrogen production. However, the potential role that therefore necessary to supplement green hydrogen
hydrogen can play in the net zero carbon economy with other clean hydrogen sources with a low carbon

Oil & Gas Technical Journal -1 115

footprint (known as "blue hydrogen"). Such hydrogen it is necessary to review the main methods used to
can be formed by combining traditional production produce hydrogen in greater detail.
methods with clean technology innovations. Blue
hydrogen can thus be produced either by revamping 4.3.1 Hydrogen Production Technologies
an existing grey hydrogen plant or by constructing a
grassroot blue hydrogen plant. Steam methane reforming
The definition of blue hydrogen is yet not completely Steam methane reforming (SMR) is currently
agreed, but many key industry stakeholders correlate the technology most widely used to produce
blue hydrogen with >90-95 % CO2 recovery. One hydrogen. The main reforming process occurs
weakness of this definition, however, is that it disregards over nickel-based catalysts inside tubes placed
the inherent carbon intensity of the different hydrogen in a hot reformer chamber.
production methods. To discuss this important point,

Figure 1: Traditional steam methane reforming

The steam reforming of hydrocarbons can be described This is cooled in a waste heat boiler generating utility
by the following reactions: steam before it is sent to the shift section where CO
reacts with process steam to create more hydrogen
CnHm + n H2O n CO + [n+^m] H2 - heat (1) and CO2.

CH4 + H2O CO + 3 H2 - heat (2) The effluent from the shift reactor is normally sent to a
pressure swing absorption (PSA) unit to separate pure
CO + h 2o CO2 + H2 +heat (3) hydrogen from the offgas, which is sent to the reformer
as fuel. In low hydrogen purity applications, the PSA
Reformer heat is generated by burning fuel gas, which unit can be avoided or replaced with a methanator.
is usually a combination of natural gas and PSA off-gas
but can also include other off-gas streams imported In a blue hydrogen scenario, the CO2 in the process gas
into the hydrogen plant. Waste heat from the flue gas from the shift section is recovered in a CO2removal unit
is recovered by preheating the feedstock and by steam before being sent to the PSA/methanator. Depending
generation, before the CO2 rich flue gas is vented on the reduction targets for CO2 emissions, it may also
into the atmosphere. The hot process gas exiting the be necessary to add a flue gas CO2 capture unit.
reformer contains a mixture of steam, H2, CO and CO2.

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Heat exchange reforming Convection reforming

In some cases, steam generation in the For hydrogen production capacities below
hydrogen plant is not a viable solution, due 30 kNm3/hour, convection reforming (HTCR)
to plant economics or CO2 footprint. In such is normally a better option than SMR. In
cases, the surplus energy can be utilized to convection reforming, the reformer design is
drive additional reforming by either adding an different since the tubes are bundled in a much
HTER reactor downstream of the SMR or by smaller chamber and the heat required for the
modifying the design and operation of the SMR process is generated by a single burner. The
itself. Both options have been successfully tubes are in contact with the flue gas generated
used in industry. by the burner flame in a convection section.

In both HTER and SMR-B, the steam export Such HTCR design provide heat integration
is significantly lower than traditional SMR with no steam export and is therefore favored
technology, hence the fuel consumption is in cases where steam is not a desired product
lower per hydrogen yield, resulting in lower CO2 or is less valuable than hydrogen.
footprint.
The compact design of the HTCR unit favors
In a HTER layout, a portion of the feedstock modularization and has thus been the preferred
bypasses the SMR and is instead fed into the choice for small scale hydrogen production for
HTER reactor, where it is heat exchanged with decades.
the hot effluent from the SMR. The reforming
taking place in the HTER reactor results in an SynCORTM Reforming
additional 25-30% more hydrogen production
and is therefore also a good option for adding SynCORTM reforming is an advanced
capacity to an existing hydrogen plant. autothermal reforming (A-ATR) process, which
is fundamentally different from the tubular
As mentioned above, another option is to alter steam reforming processes described above
the SMR design, using advanced bayonet in the sense that the main reforming process
catalyst tubes to capture heat from the effluent takes place inside one SynCORTM reactor. It is
before it leaves the SMR. This bayonet design also significantly different than any other ATR
is referred to as SMR-B. process, since it operates at much lower steam
to carbon ratio. The SynCORTM reactor has a
compact design consisting of a refractory-
lined pressure vessel with a burner, combustion
chamber and a catalyst bed.

The process gas enters the SynCORTM reactor

and is mixed with oxygen and additional steam
resulting in a combination of partial combustion
and steam reforming.

Figure 2. SMR-B reformer sketch

At high capacities, conventional SMR design

is limited by the economical size of the
reformer. Heat exchange reforming has been
successfully deployed to extend the single train
capacity limit up to 207 kNm3 per hour.

Oil & Gas Technical Journal -1 117

 The partial oxidation reaction occurs when
a sub-stoichiometric fuel-oxygen mixture
is partially combusted in a series of partial
oxidation reactors. This chemical reaction
takes the general form:

CnHm+ n/' 2
2 O2
2 ^ n CO + m/ 2
2 H2
2

The POx technology has certain well-known

limitations, including:

1. Continuous formation of soot, which must

be removed frequently
2. Relatively high CAPEX due to the need
of multiple reactor design, large air
Figure 3: SynCOR™ reformer separation unit (ASU) & soot removal unit
3. High consumption of oxygen and power
Among blue hydrogen technologies, the 4. Very high operating temperatures (1300-
SynCOR™ process has the lowest OPEX since 1400°C), which significantly limits the
the reactor operates at a steam to carbon ratio service life of the burners
of 0.6, which is 3-5 times less than SMR or less
5. Complicated water-cooled oxygen burner
developed ATR's. The lower steam throughput
also has the benefit of reduced equipment Electrified steam methane reforming
and piping sizing - A benefit that is most (eSMR)
pronounces at large scale since the equipment
and piping are kept within standard sizes even A new hydrogen production method is
at very large single line capacities. electrified steam methane reforming (eSMR).
In this method the main reforming reactions
SynCOR™ technology has a proven track take place inside a catalytic reactor with
record from more than 80 years of industrial reaction heat being generated by an electrical
operation. The largest SynCOR™ reactor in current. This means no hydrocarbon fuel is
operation today has a hydrogen production used in the reformer, which in turn means there
capacity of 500 kNm3/hour, and the economical is no reformer flue-gas. The energy density
limit for single train capacity is 825 kNm3/ of an eSMR results in a reactor size, that is a
hour. SynCOR™ is therefore likely to remain the fraction of an SMR unit.
dominant technology for large-scale hydrogen
production because of its favorable economics. Furthermore, practically all the CO2in the shifted
process gas can be recovered at low cost in a
In SynCOR™, the external fuel demand is CO2 removal unit making this process a very
extremely low, hence a very high carbon good candidate for blue hydrogen production
recovery (>99%) can be obtained without in cases where electricity prices are favorable.
needing to capture the carbon in the flue gas. It
is therefore very well suited for blue hydrogen. The eSMR process has been successfully
tested at pilot scale and will soon be tested in a
Partial Oxidation (POx) demonstration plant.

Hydrogen can also be produced by partial Comparing layouts

oxidation (POx). It is a non-catalytic process
where a fuel-oxygen mixture is partially All the technologies mentioned above can be
combusted resulting in a hydrogen rich syngas, used to produce blue hydrogen. Selecting the
which is then shifted before being sent to technology best suited for any project will
product purification. depend on multiple parameters, including

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capacity, yield and carbon intensity as well as A technology comparison of the main
the levelized cost of hydrogen (LCOH). parameters is presented below starting with
production capacity in Figure 4.

Comparison of Blue Hydrogen Technologies

Syncor™ is the only technology capable of mega scale production in a single line

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Hydrogen production technology

Figure 4: Optimal single line hydrogen production capacity with different reforming technology layouts

At small capacities, HTCR and e-SMR are most The ‘hydrogen yield per consumed natural gas
suitable technologies due to their compact design, feedstock' is very high in eSMR due to its fundamentally
whereas SynCORTM is the preferable choice at higher different design with electrically heated reformer, see
capacities because of low capex. Its single reactor Figure 5. Among other technologies, SynCORTM and
layout and very low steam-to-carbon ratio operation, SMR-B have the highest yields. For Sm R design, this
enables the SynCORTM design to benefit more from is lower due to steam export, which is sometimes
economy of scale. necessary to balance steam requirement outside the
hydrogen plant.

Oil & Gas Technical Journal -1 119

 Comparison of Topsoe Blue Hydrogen Technologies
Yield of Hydrogen

0,45 ------------------------------------------------------------------------------------------------

_ 0,40
TJ
V
E
3
0}

II I I I I I
H2bridge™ SMR SMR-B SMR+HTER ATR Pox SynCOR™
Reform ing Technology Layout

Figure 5: Hydrogen yield for different hydrogen production technologies

Figure 6: Carbon intensity o f different blue hydrogen technologies.

Carbon intensity (CI) is now widely considered the and higher fuel consumption, converting waste energy
most effective way to measure the success of a blue to high levels of steam export. SMR-B has the lowest
hydrogen technology in terms of reductions in CO2 inherent CI among conventional technologies, since
emissions. In Figure 6, CI is shown as the mass of it has no steam export, whereas e-SMR CI is a step
CO2 emitted per unit of hydrogen produced. The grey change better due to the nature of electrified reforming.
columns, which show CI with no carbon capture, are
highest for the SMR design due to its lower efficiency CI can also be reduced by capturing CO2 from the

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process gas. This is more economical than capturing the removal of CO2from the flue gas. This is most cost
CO2 from flue gas and is therefore normally the first effectively done in SynCORTM, due to lower levels of
step in CO2 capture. In Figure 3, this is shown as light flue gas relative to Hydrogen yield. It is not a necessary
blue columns. For SynCORTMand POx, which are both step for eSMR, since there is no flue gas in an eSMR
oxygen fired processes, as well as for e-SMR, achieving plant.
very low CI's is fully feasible by removing the CO2
formed in the process gas only. This feature makes The final choice of the technology ultimately depends
these processes ideal for blue hydrogen production. on achieving a certain target as cost effectively as
possible. Figure 7 shows the relative differences in
Going from light blue to deep blue hydrogen requires LCOH for each technology.

Figure 7: Levelized cost o f hydrogen for different reforming technologies.

Main assumptions:

Natural gas: EUR 4/ MMBTU

Power: EUR 50/ MWh (Power cost is varied from 15-50 EUR/MWh for eSMR to demonstrate cost sensitivity)

CO2credit: EUR 25/Ton

lower OPEX. This is the main reason why

4.3.2 Conclusion SynCORTMhas become the preferred choice for
large scale blue hydrogen production. However,
At the same operational targets and conditions,
eSMR is envisioned to be a better technology
the hydrogen produced in SynCORTM has choice in niche conditions with low electricity
the lowest levelized cost, mainly due the
prices and at small to medium production
combination of high yields, lower CAPEX and capacities.

f t * -----------

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««*)a ^WcT

4.4 A Vision for Transforming Carbon & Creating Value

Mr Sangeet Jain & Dr. Preeti Jain, LanzaTech Private Limited

Mr Sangeet Jain , Country Head (India) & Director working with LanzaTech Pvt Ltd. He is
Chemical Engineer and management professional having led teams in Chemical Plant start up
& commissioning /project implementation/operations /Business development. Area of interest
includes Green chemicals & Biofuels

J
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Dr. Preeti jain Director Business Development & Government Relations working with LanzaTech
Pvt Ltd. She is Member USISPF Biofuels Task Force, CII Bioenergy Committee, ICC NR Executive
Committee. Member National Task Force on Sustainable Aviation Fuels. She is Recognized
as Winner Women Leaders In Oil & Gas by FIPI. Area of interest includes Energy transition,
Low carbon technologies & Circular Economy, Renewables (with focus on advanced biofuels),
Petrochemicals, Sustainability, Climate Change

Vi

The time is now. made from petroleum. The low carbon ethanol can
be transformed into high-value products, including
Fossil carbon is in nearly everything we use in our daily sustainable aviation fuels (SAF), cleaners, fabrics, and
lives. It is not just in fuels or used to generate power, but packaging used in every facet of our lives.
fossil carbon is in fibers, coatings, and materials used
in our clothes, cosmetics, toys, and household goods. The 3rd largest energy consumer in the world, India
Both fuels and materials originate in refineries fed by is seeking solutions to diversify its energy basket,
petroleum or natural gas. Perpetuating virgin fossil reduce reliance on imports, and harness domestic
carbon use in these products is not sustainable given resources to address climate risks. CCT technologies
the current understanding of the impact of extracted, like LanzaTech are expected to increasingly be applied
emitted, and waste carbon on our environment, climate, across economic sectors such as agriculture, industry,
and vulnerable populations. If we are to achieve climate and waste management, as an important strategy to
goals and avoid catastrophic climate and pollution reduce greenhouse gas (GHG) emissions and meet the
disasters, there must be a large scale, strong, rapid, and nation's objective to reduce its reliance on imported
sustained effort to re-tool our entire carbon economy. oil and natural gas. India's commitment at COP 21
To align with a "Net Zero Path” economies today are is indeed a laudable step, however, going forward,
investing in innovative technologies that enable a meeting this commitment will require judicious use of
closed loop, circular carbon economy where carbon carbon resources in the future.
is reused rather than wasted. In India, LanzaTech
is a prime example of how advanced technologies, India is a global leader in biofuels. As we step forward,
such as Carbon Capture and Transformation (CCT), CCT technologies like LanzaTech's can address
can help achieve decarbonization and biofuel goals sustainability needs across the country by reducing
by changing the way the world procures, uses, and air pollution, recycling waste, providing clean jobs,
disposes of carbon. LanzaTech's commercial gas generating cleaner burning fuels, and producing low-
fermentation platform makes low carbon fuel (ethanol) carbon materials. This article provides an overview
and chemicals from waste carbon (such as industrial of LanzaTech's technology and our vision to support
off-gases, agricultural residues, municipal waste, India in its transition to a clean energy future.
waste plastics) with the intent to displace products

Oil & Gas Technical Journal -1 123

4.4.1 LanzaTech's Gas Fermentation Process solid waste, agricultural residue or organic
industrial waste or even landfill and manure
LanzaTech paves a way towards a sustainable digester gas) . Capturing and recycling
future by recycling and reusing waste carbon. waste carbon streams before they enter the
Waste carbon is simply carbon that's already atmosphere or environment offers routes to
seen a primary use, such as the emissions sustainable domestic fuels, carbon-negative
created during the steel making process or the manufacturing, and a circular economy.
carbon found in solid waste streams.
The inherent flexibility of biology allows
The LanzaTech gas fermentation platform LanzaTech's technology to create value using
(Figure 1) is a commercially proven, first- a variety of different waste streams readily
of-a-kind process which uses a biocatalyst available in India (as shown in Figure 1).
(microorganism) to convert gas containing Industrial waste gas, biogas/landfill gas, and
carbon monoxide (CO), hydrogen (H2), and solid wastes are high volume and point sourced
carbon dioxide (CO2) into ethanol, providing feeds which have low value and can be used for
industries an economical, sustainable, and fuel and chemical production without adversely
flexible means of creating value from residues affecting food or land security. LanzaTech's
and off-gas through conversion into products. ethanol produced from these wastes can have
Gas fermentation is an alternative to sugar substantial savings in emissions compared
fermentation. In this approach, instead of to fossil ethanol and is competitive with
breaking down glucose, microbes build up plant-based ethanol without impacting land
products from carbon oxides (CO or CO2), use. Beyond ethanol, LanzaTech's synthetic
which are found in waste gases from heavy biology platform has allowed LanzaTech to
industry (for example, steel mills, processing produce novel biocatalyst strains capable of
plants or refineries), or syngas generated producing other chemical intermediates, such
from solid wastes (including, for example, as isopropanol and acetone, with more in the
unsorted and non-recyclable municipal pipeline, supporting India's strategic expansion
into sustainable chemicals.

Figure 1: LanzaTech gas fermentation process

4.4.2 Capturing and Transforming Carbon using industrial off-gases from Steel (Figure
around the World 2) and Ferro-Alloy plants. They have produced
over 115 million litres of ethanol, avoiding the
LanzaTech's first two commercial scale gas equivalent of over 180,000 metric tons of CO2
fermentation plants are operating in China released into the atmosphere.

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In Europe, ArcelorMittal (Ghent, Belgium) is in the LanzaTech's extensive network of customers and
advanced stages of construction for a facility that partners have committed approximately USD800
will produce ethanol from blast furnace and basic million to the development of new facilities using
oxygen furnace emissions. In India, LanzaTech's LanzaTech's CCT technology. The new facilities are
strategic partner, IndianOil, is building the world's first expected to bring on significant new production
of its kind refinery off-gases to ethanol plant, which is capacity in the future and serve as a major validation
expected to come online this year. In all, seven facilities to potential future customers as our roster of these
implementing LanzaTech's technology are under notable partners continues to grow.
construction in different parts of world. A summary of
LanzaTech's global projects is shown in Figure 3.

Figure 2: The LanzaTech-Shougang 1st commercial scale plant recycling steel m ill offgases (China, 2018)

Figure 3: Global deployment o f LanzaTech technology

Oil & Gas Technical Journal -1 125

4.4.3 Transforming Emissions, Transforming brands, consumers, and sustainability­
the Market conscious governments like India desire
products that are more sustainable than what
The total addressable market for LanzaTech is currently available in the marketplace. Over
technology is over USD1.0 trillion. The pathway the past year, LanzaTech has completed
enables India to invest in a sustainable supply- campaigns with several major brands who
chain solution that will allow companies to have partnered with us to bring to market
advance their own sustainability objectives, products made from industrial emissions.
as well as efforts to meet decarbonization
mandates across the globe. LanzaTech ethanol from industrial emissions
has been the feedstock for a diverse array of
One exciting market segment created by consumer products, most on the shelves today.
LanzaTech's process is ‘CarbonSmartTM Ethanol produced from waste carbon can be
Products'. When choosing paper or plastic converted to ethylene, which can be further
bags, Fairtrade coffee, organic milk or recycled transformed into biopolymers, surfactants,
paper, consumers are given the choice of or polyester fiber. LanzaTech is working with
what sort of footprint they are leaving on the companies like Unilever, Mibelle, L'Oreal, and
planet. LanzaTech envisions a world where a COTY to make packaging, perfume, laundry
consumer can also choose where the carbon detergent and household cleaners (as in Figure
in their products comes from. This is the 4) from our ethanol. India Glycols Limited
inspiration behind CarbonSmart. has converted LanzaTech ethanol into MEG
(monoethylene glycol), a key component of
LanzaTech is finding manufacturers, major PET plastics.

Figure 4: LanzaTech CarbonSmart products

These products can have reduced GHG emissions petrochemical products which contribute ~2% of
by over 70% when compared to equivalent products global GHG emissions. Innovative pathways like
derived from fresh fossil resources. Around the LanzaTech's that produce sustainable chemicals from
world, countries including India are developing low waste streams could be game changers, reducing
carbon growth trajectories to meet the demand for emissions while promoting circularity.

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4.4.4 The Future of Flight: Sustainable LanzaTech, in partnership with the U.S.
Aviation Fuel Department of Energy (US DOE) Pacific
Northwest National Lab and with US DOE
In October of 2021, the International Air support, has developed an innovative Alcohol-
Transport Association (IATA) announced that to-Jet (ATJ) platform to produce SAF from
it had "approved a resolution for the global air ethanol. The ethanol can come from any
transport industry to achieve net-zero carbon environmentally, economically, and socially
emissions by 2050", termed Fly Net Zero. sustainable feedstocks. To accelerate global
IATA also urged the International Civil Aviation commercialization of this SAF technology,
Organization (ICAO) to adopt a comparable LanzaTech spun out a new company, LanzaJet,
commitment, well beyond that currently in 2020. The ethanol-based ATJ technology is
codified in the ICAO Carbon Offset and particularly well-suited to the Indian market
Reduction Scheme for International Aviation due to India's strong ethanol industry.
(CORSIA) which comes into full effect in 2027.
The use of sustainable aviation fuel (SAF) is a In the LanzaJet™ ATJ process, ethanol is
key element of Fly Net Zero and IATA laid out a chemically converted to synthetic paraffinic
scenario in which the global demand for SAF is kerosene (SPK) via the four steps defined
17% of total aviation fuel by 2035 (~91 billion in ASTM D7566 Annex A5: dehydration,
litres). To meet that demand, the capacity for oligomerization, hydrogenation, and
SAF production must grow rapidly. fractionation. Key advantages to the LanzaJet
ATJ process are its unprecedented product
India recognizes decarbonization is essential, flexibility and selectivity. The process can
not just for road transport and industry, but produce a product slate that is 90% SAF
also for aviation. As India is the 3rd largest and 10% renewable diesel or 25% SAF and
domestic aviation market , this creates real 75% renewable diesel with only operational
urgency in creating a domestic SAF supply changes. This flexibility allows the operator
using sustainable feedstocks that are available to respond to demand swings effectively. The
today. SAF from the process is qualified for use in
commercial aviation in blends of up to 50%
with conventional jet.

Figure 5: Ethanol-based A lcohol-to-Jet (ATJ) creates flexibility for global deployment

Oil & Gas Technical Journal -1 127

 Abundant, available waste carbon-based and economic benefits for rural economies and
ethanol coupled with the LanzaJet ATJ process urban communities as well as reduce industrial
can play a key role in deploying SAF production emissions.
across India and the world. The combination
of LanzaTech's gas fermentation technology 4.4.6 Policy: Enabling the change we need
with ethanol-based ATJ technology (as shown Simply put, CCT technologies like LanzaTech's
in Figure 5) enables end-to-end conversion can increase production of domestic ethanol
of waste into SAF without impacting the food and create an indigenous SAF manufacturing
chain, land use, or water supplies. sector in India. At time when industry is looking
to reduce its carbon footprint, this technology
4.4.5 India: An Opportunity for Energy can be leveraged to create jobs and to replace
Security & Decarbonization & Circular fuels and other products currently made from
oil and natural gas with recycled carbon. A
Economy
supportive policy framework will be central
The Energy Transition Roadmap is at the to creating a circular carbon economy with a
forefront of policy considerations in India. foundation on CCT technologies.
Sustainable fuels like biofuels are being seen
as an important pillar in the Roadmap. While The future of sustainable fuels and chemicals
India has made great strides toward blending of can only be assured by technology-neutral
1st generation ethanol into gasoline, advanced policies that incentivize the early adoption
biofuels, made from agricultural, municipal of innovative technologies. A clear roadmap
and industrial wastes, will be very important of supportive policies will be a great enabler
to accelerate India's progress toward energy to attract investment into the first few plants
security and decarbonization of both road implementing a new technology. Such
transport and aviation. Advanced biofuels intervention is needed to reduce the cost of
from CCT pathways offer the opportunity to deploying CCT technologies at a scale that
reduce carbon emissions, improve air quality will subsequently bring down production costs
and provide economic benefits in the sectors in future plants. To fast-track sustainable
where the waste feedstocks originate. ethanol and chemicals projects built on
abundant available waste feedstocks in the
India's ‘National Policy on Biofuels' (NPB) 2018 country, industry needs policy interventions
envisioned developing sustainable domestic such as sustainable feedstock supply chain
feedstocks to promote biofuel production. development, mandates and differential pricing
This policy enabled India to reach 9% ethanol for advanced biofuels and products, subsidies
blending in gasoline in 2021. Moving ahead, for renewable power used in production, as well
advanced biofuels from waste feedstocks as direct financial and fiscal incentives. The role
can play a vital role in expanding the ethanol of Government technical arms like CHT (Centre
production pool in the country and building for High Technology) has been exemplary
circular economy, as part of India's ambitious in recent years; their continued guidance to
plan to achieve 20% blending by 2023 (requiring advance innovative pathways for production
about 12 billion litres of ethanol) . of sustainable fuels as well as chemicals from
The overall ethanol feedstock potential in waste carbon would be of great value.
India from industrial off-gas and other waste Stepping back to look at the bigger picture,
resources is estimated at 30 billion litres per it is clear to that India can play a pivotal role
year. When used as feedstock for ATJ, this in moving the global economy away from
in turn could produce over 17 billion litres fresh fossil carbon and into a circular model
per year of hydrocarbon fuels, of which up to that addresses both fuels and products. This
90% can be SAF. This sustainable ethanol can should be seen as strategic opportunity for
also serve as a building block to produce low India, in which a pragmatic approach to develop
carbon chemicals and materials that today are waste-agrarian-industrial value chains for
made from petroleum. In addition to carbon sustainable fuels and chemicals will cement
benefits, these advanced biofuels, sustainable India's leadership position in a new circular
chemicals, and materials will offer employment carbon economy.

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Operations -
Troubleshooting
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5.1 Hazards and Safety of Fired Heater system

Re-ascertain your fired heater safeguards for better reliability and availability
Shilpa Singh, Rupam Mukherjee, Ankur Saini, Akhil Gobind, Engineers India Limited

Ms Shilpa Singh holds a B.Tech degree in Chemical Engineering and is working as General
Manager in Engineers India Limited's Heat Transfer department. She leads a team of chemical
engineers involved in grassroot designs, revamp studies, capacity and efficiency improvement
projects for fired heater systems. she has over 24 years of experience in this field.

J
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Mr Rupam Mukherjee is Sr. Manager in Engineers India Limited's Heat Transfer department.
He has over 13 years of experience in design, engineering and troubleshooting of fired heater
systems. He holds a post-graduate degree in Energy and Environment Management.

V*

Mr. Ankur Saini is serving as Manager in EIL's heat Transfer Department. His active area of work
includes revamping and troubleshooting of oil refinery fired heaters and furnaces. He holds a
Bachelors degree in Chemical Engineering.

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Mr.Akhil Gobind is Fired Heater Engineer in EIL. He has rich experience in design and revamping
of fired heaters. He holds a B.Tech degree in Chemical Engineering.

V.
5.1.1 Background Hazards and safety in a process plant is
assessed through HAZOP or Hazard and
Fired Heater systems are complex as well as operability studies which are quintessential
critically important to overall plant operation. features of any new project either at design
At the same time, these equipment demand for phase or at construction phase. However, there
a high level of safety within refinery operating are number of units still operating worldwide
conditions as they inherently bear the source which were built decades ago. Many of these
of ignition. Furnace or fired heater safety has are undergoing expansive debottlenecking
been of utmost priority over many decades and revamping exercise in order to improve
with each decade bringing forth more stricter profitability. Re-Hazop of the fired heater in
and stringent standards and guidelines. such old units is required to re-ascertain the

Oil & Gas Technical Journal -1 131

 safety of the equipment post implementation An important aspect to note is that the Hazop
of the de-bottlenecking project. study is a qualitative analysis of possible
scenarios. To properly gauge this qualitative
HAZOP of a fired heater system demands in­ aspect, a multi-disciplinary team is generally
depth knowledge of the heater design and their employed to properly conduct a fired heater
expected behaviour when put into operation. Hazop. Since fired heater system comprises of
Neither building too much safeguards, nor various sub-systems and auxiliaries like Burner,
being too confident serves the purpose. Air-preheaters, control valves and other safety
Whereas on one front, building too much instrumented function, presence of experts
safeguards causes the system to be sluggish from multiple disciplines like Thermal designer,
and costly, being complacent on the other hand Rotary specialist, Instrument specialist and
can lead to mishaps leading to loss of property safety expert helps in better appreciation of the
and even life. To strike the perfect balance, the Hazards as well as their safeguards. In fact,
HAZOP team is expected to allocate proper some of these safeguards may even fall into
weightage to the safety instrumented system the category of basic design features such as
and the safeguards incorporating the in-built design pressure and temperature considered
design considerations. for equipment design, for which the original
designer may be better placed to guide the
5.1.2 Objective of Fired Heater Hazop outcome.

Hazop study is conducted to effectively analyse The inherent nature of a fired heater system
and estimate the possible failure scenarios and with elaborate air preheat system is to have
their safeguards. Another critical aspect of this simultaneous, parallel and synchronised
study is to properly evaluate the maintainability working of various circuits in tandem. These
and operability aspect of any process non-interlinked circuits are:
equipment facility, including fired heater. Key
• Fuel Circuit
objectives of the Hazop study can be shown as
below: • Process Charge Circuit
• Combustion Air circuit
• Flue gas Circuit
f \ f \
Interestingly enough, each of the above circuit
presents its own set of failure scenarios and
2. Critically analyse
1. Identify Hazards hazards. Although, in many of the cases,
the consequences of multiple scenarios may lead to similar outcome
and Operability Issues
the Hazards of consequence or similar safeguards, a

V J V J holistic approach is adopted to identify each

and every scenario and evaluate its potency
for dire consequences. The article addresses
X f \ these scenarios targeting a balanced draft
type of fired heater system, although majority
4. Identify in-built 3. Adequacy of existing
of the inferences can be extended to Natural
margins, safeguards and engineering safeguards
draft fired heaters also which are less complex
instrumentation that in place and recommend
compared to balanced draft systems.
will prevent the new safeguards if
likelyhood of occurance existing are inadequate
V ________ J \_________ /
5.1.3 Methodology of Hazop

In general, each of the above circuit is taken up

and evaluated on the following pathway:
Fig.l

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*------------------------------------------------------ ' r------------------------------------------------------ ' f------------------------------------------------------ '

Selecting gu id e w ord
Definition of the
circuit (defining as a
node)
L__________________________________________ d
and define deviation
(such as stop p age of
fuel flow)
t __________________________________________ d
♦ Identify all possible
causes (including
inadvertant actions)
L__________________________________________ d

Identify existing
If safeguards are not
adequate, p rop ose
reco m m e n d atio n s
t __________________________________________ j
safeguards and
evaluate their
ad eq uacy
♦ Identify and define
co nse q u en ces

t __________________________________________ d

Notwithstanding above proven systematic or tube leakage is taken up for evaluation to

approach, there are certain assumptions estimate their impact.
which are well noted and recorded which sets
the tone for a fired heater Hazop. For example, For the brevity of this article and for easier
it is assumed that the fired heater is in a understanding of the fired heater Hazop
workable and well maintained condition. It is process, four very common and debated safety
assumed that mechanical protection devices concerns are elaborated below. The examples
shall function when necessitated. Also, certain have been chosen in a fashion to encompass
causes such as sabotage, natural calamity the major nodes and circuits and to highlight
or simultaneous occurrence of two unrelated the most critical safeguards. Additionally, an
events are not considered applicable. To the extra-ordinary cause is also included for better
extent possible and felt necessary, certain appreciation of the Hazop objective.
extra-ordinary cause such as Tube rupture

Oil & Gas Technical Journal -1 133

 Flue Gas

Hvl
2oo3 PALI

Combustion Air

APH

Feed In

Feed Out

2oo3
(tia) < ^ ^ c)
PAHH ID Fan
-<S>J
2oo3 TAHH Si

FALL & PALL FD Fans

2oo3
----- [ m ] -------I FIC I--------[ m ] -----

Legends:
2oo3 PALL
P: Pressure Transmitter
T: Temperature Transmitter
F: Flow Transmitter
Fuel Gas Line Pilot Gas Line HV: Damper
SL: Speed Low
F IR E D H E A T E R W IT H A P H S Y S T E M AY: 02 Analyzer
Exp.Door: Explosion Door
M: Fan Motor

Fig.3

Fig.3 illustrates a typical fired heater with outboard air flames due to any process reasons or due to inadvertent
preheating system. Basic Instrumentation and controls instrument failures may lead to accumulation of large
have been shown in the figure. Relevant references to quantities of unburnt combustibles in the furnace, if the
the tag numbers of instruments in this figure have fuel gas flow continues unabated. Possible re-ignition
been included in parentheses at appropriate locations of the large quantity of potentially explosive air-fuel
in tables exemplifying the common deviations. mixture may result in major explosion leading to loss
of life and property. As safeguards, generally there are
Hazard-1: Sudden loss of fuel and possible low pressure trips provided on the fuel gas line which
re-ignition leading to explosion gets activated as soon as the flow ceases. This low
pressure activated trip leads to complete closure of
Sudden loss of flame is a potential critical hazard in fired the fuel system through actuation of shutdown valves
heater operation. Unsolicited extinguishing of burner in block-and-bleed arrangement. A typical HAZOP
sheet for this cause may look like:

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Probable Cause Consequence Possible Safeguards

Inadvertent fuel loss due to 1. Potential flame extinguish in all 1. Low pressure override (Case
Temperature controller on coil burners. specific)
outlet malfunctions and closes the 2. Fall in furnace draft 2. Low flow alarm on fuel flow
fuel gas control to complete closure meter.
3. Potential flammable mixture
or less than that required
build-up inside firebox. 3. 2 out of 3 (2oo3) tripping of fuel
4. Loss of process fluid heating. to furnace on fuel pressure low-
low which will turn the shutdown
valves to close position (P1A/
P1B/P1C reading Low-low)

Upstream process upset leading to In addition to above consequences, 1. Pilot flame detection through
shutdown of fuel gas contributing this cause will also lead to loss ionization rod or flame scanner.
units of pilot flame leading to potential 2. 2oo3 PALL on pilot gas line
incombustible mixture in firebox activates and initiates shutdown.
(P4A/P4B/P4C reading low-low)

The above two causes are commonly experienced loss of complete flame. This will ensure any residual
or perceived, however, there can be a multitude of combustibles are flushed out safely even when all
other causes for this deviation. Inadvertent closure interlock worked reliably.
of the control valve, malfunction of the air fuel ratio
control block and other causes can also lead to similar Hazard-2: Loss or less flow of combustion air
consequences. However, with presence of above similar leading to fuel rich mixture in firebox
safeguards, the consequences can be well covered. In
some installations or in some countries, use of main Combustion air is driven into the firebox by means of
flame scanner may be a mandatory requirement and mechanical equipment like forced draft fans in any
credit for fail signal of the same can also be accounted. balanced draft system. As is the case with all rotary
Furthermore, in certain cases, dedicated Burner equipment, they have their probability of failure. In
Management System (BMS) is provided which initiates such case of fan failure, the combustion air flow to
a systematic start-up of the fired heater through a pre­ the system will cease which may lead to a fuel rich
determined purging sequence with preset time logic. mixture inside the firebox. To evade this hazardous
Going a step further, some of the installations may situation, numbers of safeguards are adopted. For
also have complete heater trip linked to Main and pilot example, a low flow trip is generally provided on the
burner flame detection systems. combustion air line which can be combined with low
pressure induced trip for higher reliability. This trip
In continuation to above, the trip setting for the 2oo3 leads to closure of fuel to the furnace ensuring that
tripping logic on fuel pressure low-low should be fuel rich conditions are avoided. Similarly, alarms are
selected with care so that the instruments actually provided on fan running as well as on flue gas oxygen
detect the loss of fuel. Nonetheless, gas freeing or analyser that will alert the operator of any discrepancy
steam purging of the firebox is to be mandatorily to normal operating conditions. A typical HAZOP sheet
adopted whenever burners are being reignited after for this cause may look like:

Oil & Gas Technical Journal -1 135

 Probable Cause Consequence Possible Safeguards
Trip of both FD Fans or trip of one 1. Potential flameout in burners 1. Flow low-low (FALL) tripping
FD Fan 2. Accumulation of incombustibles of the heater on combustion
in firebox. air circuit (sometimes in
combination with Pressure
3. Firebox pressure will fall due to
low-low PALL to ensure more
loss of firing
robustness). (P2 + F2 reading
low-low)
2. Loss of running signal of the fan
leading to failure alarm which
will alert the operator.(SL1 and/
or SL2)
3. Oxygen analyser at arch (AY) set
with low alarm for alerting the
operator.
4. Tripping of one FD Fan will lead
to the second FD Fan being
ramped up to take full process
load.

Loss of both FD fans is quite unlikely in refinery Fired gas line or in vicinity of the burners. This is one specific
Heaters, however, this cause presents a wider picture example with intricate knowledge of individual heater
for better evaluation of safeguards. Moreover, even auxiliary comes handy.
with one fan tripping and other fan ramping to full
load; a dearth in combustion air is expected during the Hazard-3: Pressurization of firebox leading to
ramping up period. However, with the safeguards as hot flue gas exposure
mentioned above, the consequences can be negotiated
well. In addition to above safeguards, Hydrocarbon/ Process fired furnaces are maintained under slight
Combustible analyser is provided in firebox in some vacuum conditions to ensure safe operation and to
cases for additional protection. Albeit, this comes at prevent personnel injury. This slight vacuum is created
an additional premium. by the stack in a natural draft furnace or by Induced
draft (ID) fan in balanced draft furnace. This possible
A very notable argument in majority of Hazop reviews hazard is generally nullified by adoption of high firebox
arises on the status of pilot flame on loss of FD Fans. pressure trip. Even before this trip condition arises,
In general, the inspirator for pilot air is located outside there are number of alarms provided which alert the
the burner windbox and does not rely on the FD fans operator on tripping of the ID fan or even upon reaching
for pilot air requirement. Thus, even with failure of the high pressure level in the firebox. Explosion doors
FD fans, pilots should remain inline. Pilots are safety are sometimes provided which serve as a mechanical
devices and are preferably kept inline which helps in protection in case of firebox pressurization. A typical
combusting any minor residual fuel gas left in the main HAZOP sheet for this cause may look like

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Probable Cause Consequence Possible Safeguards

ID Fan trips due to mechanical 1. Firebox pressure increases 1. Loss of ID Fan running signal (SL3)
or electrical failure / Inadvertent reaching to positive pressure leading to stop alarm. In case
closure of stack damper in levels. of Natural draft furnace, a high
Natural draft heater 2. Potential flame instability issues arch pressure alarm will sound
leading to incombustible gas immediately.
accumulation. 2. ID fan trip signal or arch pressure
PIC in case of Natural draft furnace
will lead to opening of main stack
damper (HV-1) which releases the
pressure build-up inside the firebox.
3. The stack is adequate sized to take
care of 100% heater design duty
even without ID fan circuit being
inline.
4. High-High Firebox pressure (P3A/
P3B/P3C reading High-High)
triggering heater trip which will
immediately stop firing.
5. Explosion door provided in many
cases.

Considering stack as an additional safeguard is again Hazard-4: Low or total loss of process feed to
an example of how the presence of the original heater furnace pass leading to coking inside the coil
designer can lend more credibility to the Hazop study.
One more critical point here is the opening time of the Loss of feed to the furnace is again a hazard that may
stack damper. The time of opening and sensitivity to lead to overheating and mechanical damage of the
be devised so that pressure build-up inside the furnace coil, if firing continues unabated. Even, partial loss of
is prevented. Use of relief devices which can operate feed may lead to overheating of the feedstock leading
of minimal positive pressure and their location must to coking inside the coil. To avoid such occurrences,
be ensured as per code requirements. All these help in generally low flow trip is provided on the fluid passes as
crediting the safeguards for this deviation. well as high coil temperature trip is provided. Actuation
of these trips shuts down the fuel to the furnaces
leading to safe situation. A typical hazop table for this
cause may look like:

Probable Cause Consequence Possible Safeguards

Charge feed pump trips / 1. Overheating of heater coils 1. FALL or charge flow low-low
Inadvertent closure of control valve leading to potential mechanical (F1A/F1B/F1C) triggered trip of
on individual pass damage to coils. furnace which will shut down
2. Potential coking in coils due to firing.
low velocity and high coil outlet 2. TAHH (T1A/T1B/T1C) on
temperature. individual pass outlet will trip the
heater shutting down fuels.

Failure of charge pump is a common cause for furnace cracking of the hydrocarbon remaining inside the coil
trip. Even with the above safeguards in line, it is advised and formation of coke. However, purging medium
that the residual process fluid remaining inside the should be decided based on equipment downstream
coils should be swept out as quickly as possible by a and Licensor recommendations.
suitable purging medium. This will help in preventing

Oil & Gas Technical Journal -1 137

Hazard-5: Extra-ordinary cause- Coil rupture/ and may lead to medium to major degree of explosion.
Leakage Coil leakage can result out of prolonged operation of
the tube or operating the heater outside its design limit.
Coil leakage or, in the worst case a coil rupture, may lead The safeguards in this case are induced judgements
to large quantity of combustible being spewed into an only like higher firebox temperature, pressure or higher
ignition source. This is indeed a dangerous situation tube metal temperature reading. A typical hazop sheet
for this cause may look like:

Probable Cause Consequence Possible Safeguards

Coil leakage due to aging of tube or 1. Potential uncontrolled fire due to 1. Arch temperature provided with
due to flame impingement spillage of combustible material. high alarm which will detect
sudden rise.
2. Higher heat release in firebox
will lead to higher coil outlet
temperature leading to coil
outlet high alarm.
3. Tube skin thermocouples will
read high temperature alarm.
4. Oxygen analyser at arch will
have low alarm.
5. Explosion door provided in many
installations
A very important point to note here
is that all of the above safeguards
shall only help in preventing a major
consequence but they cannot
prevent the cause.

Coil leakage is emergency. Adequate protection for re-Hazop to further evaluate their protection
measures and methodology to deal with this status. That exercise, if performed by an expert
situation should be governed by specific company safety audit team, will be of immense help to
guidelines and in some case, certain licensor the refiner in ascertaining and crediting the
guidelines. Safeguards listed against this cause are safety of the fired heater and ensure safety
just indications which will alert the operator about of their employees and the asset for years to
possible tube leakage and help in preventing a possible come. This is especially important in view
‘major' consequence. Necessary immediate actions of the ongoing capacity expansion of many
should then be initiated by authorised company hydrocarbon processing units which were built
personnel in compliance to SOPs. There can be certain decades ago.
other practices like providing high stack temperature
trip which automatically shuts the fuel; however, this Another advantage of such detail Hazop review
should be discussed on case-to-case basis. of existing assets is to ensure and upgrade
the equipment for the latest technological
5.1.4 Key Takeaways and code advancements in the field of fired
heaters, which can enhance their reliability
The benefits and advantages of detail Hazop and availability as well as comply with local
review of fired heater system are known to all statutory guidelines. This is one more critical
as this review is not a luxury, but a ‘necessity' aspect while debottlenecking an existing
nowadays for upcoming installations. However, unit. This Re-Hazop exercise will in fact add
there are numbers of very old installations still immense value to the debottlenecking project
in operation worldwide which can be taken up in terms of enhancing the safety of the unit as
well as to operate the furnace within its Safe

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Operating Window (IOW). supervisor. A detail Hazop study can only re­
verify possible scenarios, however, actions
Added to Hazop review, another critical and SOPs during an emergency very much
tool which forms an integral part of Hazop still depend on adaptability and expertise of
study is to evaluate the safety integrity level specialised operators. The article highlights
(SIL). This SIL study helps in identifying the only a handful of common scenarios and is
interlocks, instruments and control elements not intended to elucidate a complete fired
to be provided with higher reliability that should heater Hazop. In fact, readers are advised to
perform when in demand. The SIL level is consult specialized safety and hazard analysis
accorded to the instruments and components professional organizations like Engineers India
based on the degree of safety it shall provide Limited (EIL) to define and properly evaluate
against loss of life, environment and asset. their specific fired heater system which would
Higher the SIL level, higher is the cost and surely lend value to their asset and add on to
higher is the protection. Thus a competent the integrity of these critical equipment. Also, as
authority or agency will always be better placed highlighted in this article, presence of a multi­
in assisting the end-user in optimising the plant disciplinary team including representatives
machinery and instrumentation cost balancing from end-user during the Hazop and safety
the benefits against the risk. study will help in ensuring a complete 360°
degree review of the fired heater setup and
Finally, nothing can substitute the expertise of ensure better preparedness and emergency
a well trained fired heater operator and shift action plans.

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5.2 Improvement in pressure control of CDU-4 Stabilizer column by in­

house developed Auto-Tuning Method

Mr Susanta Sadhukhan, Senior Manager (Process Engg)

Bharat Petroleum Corporation Limited, Kochi Refinery

5.2.1 Introduction: than 0.38 Kg/cm2 g, the tuning parameters

change automatically as per the logics.
Auto-Tuning of the DCS PID controller has
been incorporated for the first time in Refinery 5.2.2 Background:
thru in-house idea and efforts by APC Team.
Because of disturbance like crude changeover, Feed to Stabilizer column comes from
water carry over, high stabilizer feed rates overhead system of atmosphere column .The
CDU-4 Stabilizer column pressure fluctuates, condensed Atmospheric Column overhead
leading to unsteady operation and off-spec hydrocarbons from overhead naphtha
product which has been observed on many accumulator are pumped to the Naphtha
occasions in past. Stabilizer. Stabilizer column has 48 trays with
feed entering on the #24th tray. Necessary
To mitigate this problem, experience of manual heat to re-boiler is provided by LGO CR to
tuning gained during such instances was the thermo syphon re-boiler. The overhead
consolidated and converted into mathematical products are totally condensed in the stabilizer
logic for changing the controller tuning overhead condenser before routing to stabilizer
parameters (Proportional Band and Integral Reflux Drum. Stabilizer pressure is controlled
Time) automatically. Thru this logic, whenever by the pressure controller (DPC270) situated at
the stabilizer column pressure swings more overhead line.

Oil & Gas Technical Journal -1 141

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Fig 1: CDU-4 Naphtha Stabilizer Column System

5.2.3 Fluctuation in Column Pressure: 5.2.4 Analysis to solve the Problem:

Frequent pressure fluctuation in the range of 7
to 9 kg/cm2g in naphtha Stabilizer Column is Data for all the important parameters were
recorded since 2019 after addition of new high collected to see the relation with stabilizer top
efficiency trays into the column and increasing pressure and identify the actual reason for
LPG processing. The pressure fluctuation pressure fluctuation.
problem resulting in disturbance in the overall
column and downstream units. It has been observed that, when feed
composition changes it results in high LPG
Every time manual tuning has to be done production. It has been observed that, if LPG
whenever pressure fluctuation is recorded is more than 500 MTPD in the feed, pressure
in the column which results in a temporary swing will start. From IP21, we see the variation
solution for the issue. of top pressure with LPG production as shown
in fig. 2 below.

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Fig.2: Top pressure swing with change in LPG production.

As discussed with operation, water carry and fluctuation in top pressure was observed
over in feed leads to pressure fluctuation as with it. This water might be coming from the
indicated in water boot level in overhead reflux overhead system of crude column. Provision to
drum. From IP.21, as water level in boot of reflux control the water entering with feed is not yet
drum at stabilizer column overhead shows available. The relation between top pressure
unsteady behavior over a certain period of time and reflux drum boot level is shown by variation
in trends in fig. 3.

Fig 3: Reflux drum Boot level vs. column top pressure.

When pressure of stabilizer column decreases Increase in reflux flow increases the column
because of some aforesaid reason, hot vapor pressure suddenly which actually suppress the
from bottom section comes to top and increases upcoming hot vapor and results in reduction of
the top temperature. Since top temperature top temperature suddenly. It starts the reverse
controller is in cascade with the reflux flow cycle of earlier action of pressure, temperature
controller, it increases the reflux flow. But effect and reflux controllers. This interactive action
of reflux flow in column pressure is very high. actually provides resonance in fluctuation.

Oil & Gas Technical Journal -1 143

 Fig. 4: Interactive fluctuation in top pressure, top temperature, reflux flow

Pressure fluctuation problem not only comes pressure controller DP270 (i.e. DPC270.OP =
only when LPG production is high, another 0). That time efficiency of pressure controller
main reason of pressure fluctuation is very low DPC270 reduces significantly because around
LPG generation which leads to fully closing of 50% time of pressure fluctuation cycle, it
remains fully closed.

Fig 5: Pressure controller output (DPC270.OP) vs Pressure Value (DPC270.PV)

5.2.5 Highlights and findings: 5.2.6 Actions taken:

• Liquid and Vapor loading of the Stabilizer Frequent tuning of PID controllers (DPC270) has
column is observed near to 133% loading been done to handle the pressure fluctuation
of BH case during operation of high LPG issue. But it became a regular work to do the
and Naphtha feed. tuning of DPC270 controller to stabilize the
• Increasing the loads by 5-10% causes fluctuation.
percent jet flood beyond tolerable limit of
85%. Process tech. have extended stabilizer
• It is suspected that beyond this operating adequacy study to check frequent stabilizer
case load, the top section trays might pressure swing issue, also involved M/s Sulzer
start to flood resulting into pressure tray supplier to study and advice action plan
fluctuations. as it is expected to process high API crudes on
• It is suspected one of the major contributor continuous basis.
for pressure swing is continuous
processing of high API crude which may Many journals and articles have been studied
led to flooding in upper trays. to find out similar case and it solution.

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5.2.7 Introduction of Auto-Tuning of PID Following are the features of Auto-tuning logics:
controller:
• Auto-tuning logics run on every 2 minutes to check
for fluctuation in DPC270.
Basically in practical implementation of a PID
controller and tuning its control parameter, • If fluctuation is more than 0.38 kg/cm2g, tuning
there is a possibility that due to external happens.
disturbances, the process is not tuned to obtain • Once auto-tuning done, it waits for 2 hours for
optimum control. Hence auto-tune method stabilization. During this period no further tuning
serves a masterpiece as it automatically tunes happens even if fluctuation is more than 0.38 kg/
the parameters (which in other case have cm2g.
to be tuned manually and frequently). Many • Auto-tuning makes the DPC270 slow and fast in
products are available from different vendors consecutive cycle to break the cyclic fluctuation
for automatically tuning the PID controllers, effect.
but they are very expensive. An in-house • Automatically tuning never happens if there is no
developed Auto-Tuning of PID controller has fluctuation of DPC270 (less than 0.38 kg/cm2g).
been developed and implemented for tuning
of DPC270 pressure controller whenever is Below are the some cases of process disturbances in
required. Some logics have been written using before and after the implementation of Auto-Tuning
APC software to automatically calculate and methodology, to understand the benefit of this in­
incorporate the value of proportional gain (P house developed method.
of PID controller) automatically in DCS as per
different process conditions and disturbances. On 2nd Feb'21 night stabilizer pressure fluctuation
started and at 5:00 hrs. fluctuation increased to more
than allowable limit and Auto-tuning of DPC270
happened (blue line in the trend). The pressure
fluctuation stopped immediately.

5.2.8 Before implementation of Auto-Tuning:

LPG production was increased on 21st Jan'20 and stabilizer pressure fluctuation was started and
continued for more than 8 days.

Oil & Gas Technical Journal -1 145

LPG production was increased on 10th May'20 and stabilizer pressure fluctuation was started and continued for
more than 20 days.

LPG production was increased on 14th Dec'20 and stabilizer pressure fluctuation was started and continued for
more than 15 days.

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5.2.9 After implementation of Auto-Tuning: because of high LPG make more than 60 times
fluctuation started and auto-tuning happened.
Below trends are for after the implementation Pressure fluctuation has reduced immediately
of Auto-tuning. LPG production has increased or within few hours. The Magnitude of Max
on 4th Feb'20 and subsequently stabilizer and Average fluctuation are also smaller than
pressure fluctuation has started. Green pen earlier.
is for tuning parameter P Till today from then,

Effects on products (Stabilization o f Naphtha RVP):

Since lighter carryover in product naphtha due to pressure fluctuation has reduced, Flaring from RFU FSD has
reduced significantly.

Oil & Gas Technical Journal -1 147

5.3.0 Conclusion because of continuous changing requirement
of behavior/speed of control system to reject
A description and case study of an unstable the disturbances. The only option to stabilize
process has been provided in this paper. The these systems is frequent adjustment of
procedure and thought behind the in-house controller speed to synchronize it with process
developed method to make the system stable requirement. Software which are available for
by taking continuous actions automatically, automatically tuning the PID controllers are
also has been summarized in the theoretical expensive. An in-house developed Auto-Tuning
part of this paper. On experiment basis this of PID controller has been developed and
method was implemented for CDU stabilizer implemented in BPCL refinery for tuning these
column. But in any refinery, this type of many type of controllers automatically whenever is
unstable process are available. The process required. The practical application and benefits
becomes unstable may be because of bad achieved from this work has been explained in
performance of control system or may be the this paper

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5.3 Averting Unplanned Shutdowns during Utility pipeline ruptures- Line

Stop technique application at Refinery-Experience at MRPL
k__________________________________________________________________________________________ }
Mr. Subramanya Prabhu (CM- PE), Mr. Dinesh M (GM- M/M), Mr. Sudesh Kamath (GM- PE), Mr. Sudheer Pai
(CGM-PE) Mangalore Refinery & Petrochemicals Lts

Mr. Subramanya Prabhu Mr. Dinesh M is Mr. Sudesh Kamath Mr. Sudheer Pai
is working as Chief engaged as General is working as General M is working as
Manager (Process Manager (Mechanical Manager (Process Chief General
Engineering) Maintenance) Engineering) Manager (Process
Engineering)

5.3.1 Introduction: losses. During Pandemic, there has been

shutdown of several units due to lack of
To stay competitive and thrive in today's demand of products and in case systems are
uncertain and volatile energy market that is not preserved adequately during such time,
characterized by major shifts in supply and can also lead to failures. Among all utilities,
demand dynamics, refiners must find ways circulating cooling water system is highly
to increase operational efficiencies, maximize prone for corrosion and failures. In a modern
productivity and produce refined products refinery, where treated effluent to recycled back
at lower costs. A major consideration for to cooling towers, there can be often leakages
boosting a refinery's profitability and improving and even failures of the pipeline. Keeping
operational safety is to keep operating units pipelines at their best operating condition is
running and available for service. Further any every refiner's objective, however, it's not as
unplanned shutdowns are not desirable as easy as it sounds due to various constraints
such interruptions can have a profound impact
on the company production planning activities Mangalore Refinery and Petrochemicals Ltd.,
as well as integrity of equipment's which operates a 2.20 MMTPA Petro-FCC unit
undergo mechanical shock. Vigilance in (PFCC), produces propylene which is feedstock
operating rigor, quickly determining or even for valuable Poly-Propylene product. Any
predicting negative impacts, and being able interruptions can seriously hamper the
to efficiently correct deviations from the profitability of the company. The scenarios can
operating process plan are keys to maintaining be severe, as the refining industry wakes up on
high equipment reliability. Wisely investing setting of Pandemic with increased product
in monitoring tools, training, catalyst and demand. It was observed that there was a
chemical treatment programs is a proven rupture of cooling water pipeline supplying
strategy for consistent top performance. to a critical exchanger in the PFCC Unit. Line
stop/Flow stop technique method is method
Utility supply systems in a refinery are the of plugging which is used to isolate system
lifelines for units to operate. Any interruptions components for repair or replacement and
in utilities such as steam, cooling water, boiler provides a shut-off option for pressurized
feed water or DM water can have potential to pipes and vessels. And this is normally
bring the unit down causing serious production planned on long distance transfer pipe lines

Oil & Gas Technical Journal -1 149

 with well in advanced plans and executed Unit (PRU) within the PFCC unit sheared while
accordingly. However, this paper shall discuss leak attending was attempted. The cooling
the experience of using this technique for water return header operates at 4 kg/cm2
emergency scenario of arresting Cooling water pressure, and due to higher spray of cooling
leak online within short duration of time and water, the approach towards the leak for
avoiding the unplanned shutdown of Propylene arresting was not possible. The entire area was
fluid catalytic cracker at Mangalore refinery flooded with water making it unsafe to do any
&Petrochemicals limited. This paper shall repair work. Due to leakage from the header, the
definitely help and guide other Indian refineries water makeup in the cooling tower increased
also to venture and check into the feasibility by around 400 m3/hr. considering the criticality
of opting this method during emergency leak of the situation, an emergency meeting and a
scenarios especially in the main header utility brainstorming discussion was carried out to
lines which if unattended could lead to specific avoid the shutdown of the Plant.
unit or complex shutdowns.
Among the various options "Line Stop/Flow
5.3.2 Experience of Cooling water leak at Stop" technique was chosen and execution
Propylene Fluid catalytic cracker unit at process was started for the same. Line plugging
is used to isolate system components for
MRPL
repair or replacement and provides a shut-off
option for pressurized pipes and vessels. The
PFCC unit at MRPL is a major margin driver for
plugging of a pipeline is accomplished by first
the refinery as it produces valuable products
performing a hot tap and then using a special
such as Propylene, LPG and Motor Spirit.
plugging machine. By inserting a line-plugging
Therefore, any production interruptions to PFCC
head into the line flow and using a special
can result in a significant impact on refinery
sealing element attached to the plugging head,
profitability. It was observed, the cooling water
the flow is stopped.
return header line of the Propylene Recovery

Fig 1: Representative schematic o f "Line stop" Operation

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Line pressure was optimized by taking additional cells 3. Hot tapping operation: Hot Tapping Operation was
in the cooling tower. Further all necessary measures done on all Line stop points, pressure equalization
were in place to ensure a large amount of water leak points & drain points
would not overload ETP The vendors were quickly 4. Installation of line stop assembly: pre-fabricated 8"
approached the line tapping & plugging vendors and bypass line was fitted on to the line stop housing
arranged the related requirements on an emergency to divert the flow & One line stop assembly which
basis. The site was prepared with necessary consists of line stop head with 8" sealing element,
scaffoldings, tools and tackles for carrying out the actuating hydraulic cylinder and the line stop
hot tapping, followed by a line stop. Pre-mobilization housing was fitted on 8" sandwich valve on each
and post-mobilization (i.e. all Hot Tap and line stop side.
Equipment along with its related accessories were 5. Line stop operation: After ensuring leak proof
tested prior to mobilization at work base and on site joint in all flange connections, the pressure in 8"
prior to commencing operations) checks & function stopple housing was equalized with the pressure
tests were carried out to ensure that the equipment in header pipeline and After confirming the
supplied is suitable for the work scope. Equipment pressure equalization on top and bottom side
were calibrated and fully certified before the usage of the 8" sandwich valve, it was then opened at
at site. The entire process was carried out safely with both upstream and downstream side and 8" line
all required PPE's usage and all priority given to work stop head was inserted by actuating the line stop
site safety and procedures. During the procedure cylinder on both the side. After both the upstream
the surrounding area around off point access was and downstream line stop heads were in place,
restricted by use of barricade. product from the isolated section was drained from
Drain Point.
On a brief procedure following points were followed for 6. Line modification work: After the draining was
attending the leak complete and 100% stopple seal ensuring, Water
was purged into the isolated section using the
1. Welding of 8" Line stop fitting and ancillary fittings: vent plug opening from 2" TOR fitting. And the line
8" Line stop tees were welded on the main 8 inch modification works were completed.
line.( one on the upstream and other downstream) 7. Line stop equipment retrieval: After the completion
Along with these 2" fittings were provided for of line modification works, the line was
pressure equalization and Product draining. recommissioned by using 2" pressure equalization
2. Installation of sandwich valve: 8" Sandwich valves connection and both Line Stop heads on upstream
were fitted on 8" line stop fittings which serves the and downstream location was retrieved and 8"
purpose as a control valve throughout the operation Sandwich valve was closed followed by depressurize
and 2" Ball Valve were fitted on the pressure the product from the Line Stop assembly and
equalization fittings and on drain fittings and the retrieving line stop assembly.
valves were made sure for 100% open

PROFILE CHECK OF 8 INCH STOPPLE TEE PROFILE CHECK OF 4 INCH PAD GAS BAG FITTING

DIMENSION CHECK
DIMENSION CHECK

Oil & Gas Technical Journal -1 151

The above jobs were swiftly & continuously carried process was successfully done without shutting down
out with clock-work precision and the heavy cooling the Propylene fluid catalytic cracker which was very
water leak on the return was arrested within short critical for the refinery operations.
duration and the system was restored . The entire

Figure 3: Before Leak Arresting Figure 4: After Leak Arresting with Line

5.3.3 Conclusion and Future uses: executions and very rarely during emergency
short duration scenarios.
Keeping pipelines at their best operating
condition is always the refiner's objective, Mangalore refinery and petrochemicals limited
however, it's not as easy as it sounds due has successfully demonstrated that Line stop/
to various constraints within the complex flow stop method can be effectively executed
refineries where all the units & utility sections within short duration for emergency scenarios
are also interrelated. Line stop/Flow stop is of attending heavy utility cooling water line
safe and cost-effective approach for such utility leaks and avoid unplanned shutdown of critical
leaks and can be important part of the overall units.
"pipeline intervention system" for keeping a
refinery processing system up and running Reference
sustained operations. Line stop technique has
1. “Plant-Tech project method statements":
been predominantly used/applied in the long­
Courtesy: Plant tech Industrial
distance transfer lines with thoroughly planned services. Mangalore. (https://www.youtube.
com/watch?v=5uj5Ky9YhA0- Plant Tech power)

ft*

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Note
Note
Ministry of Petroleum and Natural Gas
Government of India