Bharat Petroleum (BPCL) Refinery 2009 - 2010 Presentation

BHARAT PETROLEUM CORPORATION LIMITED (BPCL)

Major Players in Petroleum Sector (India)

BPCL

HPCL

IOCL

RIL

ESSAR

SHELL

Introduction

Bharat Petroleum Corporation Limited (BPCL) is one of India's largest PSU

companies, with Global Fortune 500 rank of 289 (2009).

Its interests are in petroleum sector.

It is involved in the refining and retailing of petroleum co. ltd

BPCL's growth post-nationalization (in 1976) has been phenomenal. It is considered a

pioneer in marketing initiatives, and employs Best in Class practices.

On 1 August 1977, it was renamed Bharat Petroleum Corporation Limited.

ABOUT COMPANY

3rd largest oil company in India; Owned by the Government of India; Revenue (2009): $30 billion; Employees: 13600

In 1976, the Burmah Shell Group of Companies was taken over to form Bharat Refineries Limited. Renamed Bharat Petroleum

Corporation Limited in 1977

First refinery to process newly found indigenous crude (Bombay High), in the country

Major Achievements in 2009 -2010

Sales turnover at Rs. 133,749.10 crores

Crude throughput at 23.03 MMT

Market Sales including exports at 30.76 MMT

Net profit at Rs. 1,719.98 crores

Oil and Gas discoveries abroad show promise

Innovating continuously across the entire value chain

Primary energy consumption of India

Oil Natural Gas Coal Nuclear Hydro electric

USA 40.4 24.4 24.6 8.0 2.6

Total Europe & Eurasia 32.3 33.8 18.0 9.6 6.3

China 21.1 2.7 69.6 0.8 5.8

India 29.9 8.5 55.0 1.0 5.6

Asia Pacif ic excl India & China 45.5 19.6 23.8 7.4 3.7

World 36.4 23.5 27.8 6.0 6.3

Oil contributes to 30 % of the Primary Energy demand of the country

Sources of crude and oil trade flows

Top World Oil Net Exporters, 2005

(OPEC members in italics)

Country

Net Oil Exports

(million barrels

per day)

1) Saudi Arabia a 9.12) Russia a 6.73) Norway 2.7

4) Iran a 2.6

5) United Arab aEmirates 2.4

6) Nigeria a 2.37) Kuwait a 2.38) Venezuela 2.2

9) Algeria 1.8

10) Mexico 1.7

BPCL Crude Oil sourcing

KuwaitIraq

S Arabia

UAE

Yemen

Libya

Nigeria MalaysiaBrunei

BPC 12NRL 2.5

KRL 8.0

Total Crude 22.5

Pipeline 9.5

Ships 13.0

Crude oil figures in MMTPA

SIKKIM

GOA

MUMBAI

MANGALORE

COCHIN

CHENNAI

VISHAKHAPATNAM

HALDIA

MATHURA

KOYALI

BONGAIGAON

GUWAHATI

DIGBOI

NUMALIGARH

PANIPAT

NARIMANAM

BARAUNI

BHATINDA

JAMNAGAR

Reliance 33.0

BPC 12.0

HPC

5.5

MRPL 9.7

BPC (KRL) 7.5

IOC (CPCL) 9.5

IOC (CPCL) 1.0

HPC 7.5

IOC 6.0

IOC 8.0

IOC 6.0

BPC (NRL)

3.0

IOC

0.7

IOC

1.0

IOC (BRPL)

2.4

IOC 6.0

IOC 13.7

BINA

PARADEEP

REFINERY

EXISTING

North

South

East

West

Region

PROPOSEDLEGEND

Oil Downstream Sector in India2005

Vadinar

All India

Imported Crude 94.8

crude processed 124.2

Product consumption 111.7

All figures in MMTPA

14.0

35.2

19.1

64.2

0100

200

300

400

Dec

reas

ing B

oil

ing P

oin

t (d

eg C

)

CRUDE OIL

REFINING

Main Products

Crude oil to products

LPG

PETROL

KERO

HSD

FO

Main process - simple distillation

C3-C4

C9-C16

C14-C24

>C22

C5-C10

500

Lt Distillate

Middle

Distillate

Heavy ends

CHEMICAL ENGINEERING (OPERATIONS)

Crude Distillation Unit

Distillation

column

Gas

Naphtha

upto 170 C

Kerosine

upto 270 C

Diesel

upto 360 C

Atmospheric Residue

>360 C

CRUDE

LPG

Heater

370 C

360 C

2.2 ata

110 C

2.0 ata Lt Distillate

Middle

Distillate

Heavy ends

Crude oil distillation (atmospheric and vacuum)

A simple guide to oil refining

Fluid catalytic cracking

C30 C-C-C + C-C-C-C-C + C-C-C-C + C8 +C 10

Light distillate

LPG

Naphtha

Petrol

Benzene

Toluene

CDU-1

CDU-2 FPU

HVU CCU

FCCU

Crude unit Cracking unitPRODUCTSVacuum unit

Atm residue

BH +LS crude

Simple Refinery flow chart(Major units)

CDU-3 VDU HCRImp HS crude

Middle distillate

Kerosene

ATF

Diesel

Heavy ends

Furnace oil

LSHS

Bitumen

Sulfur

Train-1

Train-2

Train-3

BH +LS crude

Various chemicals are added in different units for specific purpose

DEAROMATISATION

AMINE

TREATING SULPHUR

RECOVERY

CAUSTIC

TREATER

REFORMER

FEED UNIT

HYDRO

DESULPHURISATION

CATALYTIC

REFORMER

AROMATIC

RECOVERY

PRE FRACTIONATOR

FRACTIONATOR

KEROMEROX

C3/C4

SEPARATION

MTBE

LPG

AMINE/MEROX

GASOLINE

MEROXFCCU2

FCCU1VACUUM

DISTILLATION1

VACUUM

DISTILLATION2

BITUMEN

BLOWING

CRUDE

OIL

METHANOL

REFINERY PROCESS FLOW DIAGRAM (COMPLEX)

LPG

ATF

SKO

HSD

MS

LSHS

BIT.

CR

UD

E D

IST

ILL

AT

ION

F

AC

ILIT

IES

DIESEL HYDRODESULPHURISATION

SPECIAL

PRODUCTS

LPG

BITUMEN

Yields are also crude dependent

0%

20%

40%

60%

80%

100%

Bombay

High

Bonny

Light

Arab Light Kuwait

Lt Distillate

Middle

Distillate

Heavy ends

0.17 0.18 1.9 2.7

O API 40 33.6 34.2 31.0

% Sulfur

8.8

12

5.94.8

3.8

7.56.9

0

2

4

6

8

10

12

14

1976 78-83 83-88 88-93 93-98 98-03 Post RMP

MM

T

Increased crude processingby periodic revamps

Commisioned in 1955 2.2 MMTA

Refined Products

Demand Key Qualities

Octane, Sulfur,

Vapour Pressure,Benzene

Vapour Pressure

C2 & C5 content

Sulfur, Cetane, Pour point

Distillation,Flash point

Viscosity, Pour point,

Metals, Cal value

Main Applications

Domestic & Industrial

heating,Transport

Transport

Aviation, heating,

lighting

Transport, Power

Industries, Power

Sea transport

LPG

PETROL

KERO

HSD

FO

Freezing point,

Smoke point, Flash

Rail

5.3%

Pipeline

69.1%

Ship

8.6%

Road

17%

Modes of Transportation

Mumbai-Manmad-Mangliya pipeline is the lifeline of the Refinery

Environment Neutral Refinery Operations

1977 2002

Crude Processed (MMTPA)

4.2

8.9

Sea water (M3/Hr)

SOx (MT/D)

2490

1500013.0

22

2005

12.0

11.8

60005400

11.7

9.14

Post

RMP

REFINERY PRODUCTS

MECHANICAL ENGINEERING

Process Equipment Reactors/catalytic converters

Mass Transfer Momentum Transfer

PumpsDistillation

Absorption

Stripping

Extraction

Evaporation

Heat Transfer

Heat Exchangers

Fired Heaters

Air coolers

Air pre heaters

Boilers/ steam generators

Compressors

Ejectors

Eductors

Storage

Tanks

Spheres

Air coolers

Bullets

Pits

Separation

2 phase (3 phase separators)

Desalters

Cyclone separators

API separators

Degassers

Steam traps

PUMP CLASSIFICATION

PUMPS

KINETIC POSITIVE DISPLACEMENT

SPECIAL CENTRIFUGAL ROTARY RECIPROCATING

RADIAL

FLOW

AXIAL

FLOW

MIXED

FLOW

GEAR LOBE

DIAPHR. PLUNGER PISTON

CENTRIFUGAL PUMP

SELF

PRIMING

NON-SELF

PRIMING

SINGLE

STAGE

MULTI

STAGE

SINGLE

SUCTION

SINGLE

SUCTION

DOUBLE

SUCTION

DOUBLE

SUCTION

OPEN

IMPELLER

SEMI

OPEN

IMPELLER

CLOSED

IMPELLER

VOLUTE

CASINGDIFFUSER

PUMPS NOMENCLATURE

IMPELLER

BEARING

HOUSING

RADIAL

BEARING

SHAFT

THRUST

BEARING

STUFFING

BOX

DISCHARGE

NOZZLE

CASING

SUCTION

NOZZLE

liquid

liquid

30 PSIG

15 PSIG

CENTRIGFUGAL PUMP FUNCTIONS

Raise Liquid to

Another Level

Overcome Pipe

Friction

Force Liquid into

a Pressure Vessel

TOTAL HEAD = TH = HD + HS

TYPES OF COMPRESSORS

COMPRESSORS

POSITIVE DISPLACEMENT

(COMPRESSING FLUID BY REDUCING

VOLUME OF COPRESSION CHAMBER)

DYNAMIC TYPE

(ACCELERATING AND

DECLERATING OF FLUID)

RECIPROCATING ROTARY TYPECENTRIFUGAL

COMPRESSORS

AXIAL

COMPRESSORS

HELICAL

SCREW

SPIRAL

AXIAL

STRAIGHT

LOBE

SLIDE

VANE

HORIZONTAL SPLIT COMPRESSOR 2MCL

HEAT EXCHANGER

GAS TURBINE (CUT VIEW OF GAS TURBINE)

INLET

BELLMOUTH

COMPRESSOR COMBUSTION

CHAMBERTURBINE

SECTION

ASSEMBLED ROTOR OF A TYPICAL GAS TURBINE

COMPRESSOR SECTION

THRUST COLLAR

TURBINE SECTION

OPERATION CYCLE (BRAYTON CYCLE)

HIGH EFFICIENCY BOILER

Heater

COOLING TOWER