oil_refinery_presentation_v1 sllfmfls.pdf
- 1. Oil Refinery: Complete Process Overview & Environmental Compliance A comprehensive analysis of refinery operations, processes, equipment, and environmental standards for industry professionals August 2, 2025 | Technical Presentation Made with Genspark
- 2. Agenda Presentation Outline 1 Sector Introduction 2 Key Products & Sub-sectors 3 Industry Production Processes 4 Crude Oil Distillation 5 Major Process Units 6 Equipment & Infrastructure 7 Emission Sources & Types 8 CEMS Technology 9 Environmental Compliance 10 Summary & Key Takeaways Oil Refinery: Complete Process Overview & Environmental Compliance Made with Genspark
- 3. Sector Introduction Overview The oil refinery sector involves the process of transforming crude oil into useful products such as gasoline, diesel, kerosene, jet fuel, and various petrochemical feedstock. Refineries also produce by-products such as asphalt and lubricants. This process is essential to meet the growing demand for energy and petroleum-based products globally. Sub-sectors Primary: Petroleum Refining Core processing of crude oil into fuels and basic petroleum products Secondary: Petrochemicals Production of chemicals derived from petroleum, serving as raw materials for plastics, synthetics, and industrial chemicals Secondary: Gas Processing Separation and purification of natural gas components for commercial and industrial use Secondary: Bitumen Production Manufacturing of asphalt and other heavy residual products for construction and infrastructure Industry Importance Essential for transportation fuels Backbone of industrial manufacturing Source for consumer product materials Critical component of global energy security Significant economic driver and employer Oil Refinery: Complete Process Overview & Environmental Compliance Made with Genspark
- 4. Key Products & Sub-sectors Key Products Transportation Fuels Gasoline Diesel Jet Fuel Kerosene Industrial Products Liquefied Petroleum Gas (LPG) Lubricants Fuel Oil Sulphur Petrochemical Feedstock Ethylene Propylene Benzene Naphtha Sub-sectors Petroleum Refining Petrochemicals Gas Processing Bitumen Production Oil Refinery: Complete Process Overview & Environmental Compliance Made with Genspark
- 5. Industry Production Process Overview Oil refining is a complex 10-step process that transforms crude oil into valuable products. The process integrates physical separation, chemical conversion, and quality control to create fuels, petrochemicals, and other petroleum-based products that meet industry standards. Refinery Production Process Flow Oil Refinery: Complete Process Overview & Environmental Compliance 1 Crude Oil Intake Crude oil arrives via ships or pipelines and is tested for quality 2 Distillation Oil is heated and separated into fractions based on boiling points 3 Fractionation Towers Tall towers collect different components like gas, petrol, diesel 4 Conversion Processes Cracking breaks big molecules; Reforming improves petrol quality 5 Treatment Removes harmful substances like sulfur to reduce pollution 6 Blending Different fuels are mixed to meet quality standards 7 Storage Refined products are stored in large tanks before delivery 8 By-Product Handling Manages items like asphalt and petroleum coke responsibly 9 Environmental Controls Uses filters and scrubbers to reduce emissions 10 Continuous Monitoring Computers and sensors track operations for efficiency and safety Made with Genspark
- 6. Crude Oil Distillation Process Distillation Process Overview Crude oil distillation is the primary separation process in a refinery. The process separates crude oil into different fractions based on their boiling points in a distillation tower (column). Heated crude oil enters the tower where components with different boiling points condense at different heights and are collected on trays, resulting in the separation of various petroleum products. Distillation Tower Fractions 20°C TOP Gases & Light Naphtha Petroleum gases (C₁-C₄), used for LPG and petrochemical feedstock 70°C Heavy Naphtha (Gasoline) C₅-C₁₀ hydrocarbons, primary component for gasoline production 170°C Kerosene C₁₁-C₁₃ hydrocarbons, used for jet fuel and heating oil 270°C Diesel/Gas Oil C₁₄-C₂₀ hydrocarbons, used for diesel fuel and heating >340°C BOTTOM Residuum Heavy hydrocarbons used for lubricating oils, waxes, bitumen, and sent to vacuum distillation Distillation Process Steps 1 Crude oil is preheated using recovered heat from other refinery processes 2 Preheated crude enters the furnace where it's heated to 350-400°C 3 Hot crude enters the atmospheric distillation column at flash zone 4 Lighter components rise as vapor while heavier ones fall to the bottom 5 Components condense at different temperatures on trays inside tower 6 Fractions are withdrawn at different heights and sent for further processing Oil Refinery: Complete Process Overview & Environmental Compliance Made with Genspark
- 7. Major Process Units CDU (Crude Distillation Unit) Separates crude oil into fractions based on boiling points. The primary separation unit of a refinery. Operates at atmospheric pressure Produces naphtha, kerosene, diesel, and heavy residues First major processing unit in refineries VDU (Vacuum Distillation Unit) urther separates heavy residue from CDU under vacuum to prevent thermal cracking. Operates at sub-atmospheric pressure Produces vacuum gas oil and vacuum residue Allows separation without thermal degradation Hydrocracker Breaks down large hydrocarbons into smaller molecules using hydrogen, heat, pressure and catalysts. Produces diesel, jet fuel, and naphtha Uses high pressure (1500-3000 psi) and temperature Converts heavy oil into more valuable lighter products FCC (Fluid Catalytic Cracking) Converts heavy gas oils into lighter, more valuable products using catalysts without hydrogen. Major source of gasoline production in refineries Uses fluidized catalytic beds at high temperatures Produces gasoline, LPG and other light products Oil Refinery: Complete Process Overview & Environmental Compliance Made with Genspark
- 8. Equipment & Infrastructure Common Process Equipment Reactors Hydrocracking, Catalytic Reforming units that convert feedstocks into desired products Columns Distillation, Absorption units that separate different components based on boiling points Heat Exchangers Transfer heat between fluids to optimize energy usage and control process temperatures Compressors Compress gases for various processes and maintain system pressure requirements Storage Tanks Store finished products, intermediates, and raw materials in specialized vessels Furnaces & Heaters Provide heat energy required for distillation, cracking, and other thermal processes Pumps & Valves Transport fluids throughout the refinery and control flow rates and directions Control Systems Monitor and regulate process parameters like temperature, pressure, and flow rates Support Facilities Utilities Steam generation for distillation, cracking, and heat transfer Cooling water systems for condensers and heat exchangers Electricity for pumps, compressors, and control systems Nitrogen supply for purging and inerting operations Emission Control Infrastructure Flares and emission stacks for controlled waste gas disposal Scrubbers and filters to reduce air pollution Continuous Emission Monitoring Systems (CEMS) Oil Refinery: Complete Process Overview & Environmental Compliance Made with Genspark
- 9. Emission Sources & Types Refinery Emission Sources Oil refineries emit various pollutants during operations. These emissions are categorized based on their source points and characteristics, each requiring specific monitoring and control measures. Emission Source Categories Combustion Stacks Boilers, Heaters, Furnaces: These devices burn fuel to generate heat for the refinery, producing emissions primarily from fuel combustion. Process Stacks Distillation Units, Reactors, Hydrotreaters, FCC Units: Emissions arise from the separation or chemical reactions involved in these processes. Fugitive Emissions Crushing, Packing, Equipment Leaks: Emissions occur due to leaks from valves, pumps, and other equipment in the refinery infrastructure. Types of Emissions SOx (Sulfur Oxides) From combustion processes of sulfur- containing fuels NOx (Nitrogen Oxides) From combustion and high-temperature processes CO (Carbon Monoxide) Emitted during incomplete combustion PM (Particulate Matter) From combustion and chemical processes VOC (Volatile Organic Compounds) From fugitive emissions, distillation, and loading Fuel Types Used in Refineries Natural Gas: Primary fuel for combustion processes Fuel Oil: Used in furnaces and heaters Coal: Less common, used in specific processes LPG: Alternative fuel for various units Oil Refinery: Complete Process Overview & Environmental Compliance Made with Genspark
- 10. CEMS (Continuous Emission Monitoring System) Technology What is CEMS? CEMS (Continuous Emission Monitoring System) is the integrated system used to measure flow, dust, concentration of air pollutants, and other parameters in industrial exhaust gases. It's a critical technology for environmental compliance, providing real- time data for regulatory reporting and process optimization. CEMS Types Extractive CEMS Samples flue gases from emission stacks and analyzes them in a laboratory-style system. Technologies: NDIR (Non- Dispersive Infrared), UV Fluorescence, Electrochemical Sensors In-Situ CEMS Measures gases directly in the stack without sampling, providing real- time measurement. Technologies: DOAS (Differential Optical Absorption), Tunable Diode Laser, FTIR Dilution-Based CEMS Gases are diluted before analysis, often used for higher-volume emissions and complex gas mixtures. Technologies: Dilution probes, Multi-gas analyzers, Heated sample lines Measurable Parameters SO₂ (Sulfur Dioxide) NOx (Nitrogen Oxides) CO (Carbon Monoxide) CO₂ (Carbon Dioxide) O₂ (Oxygen) PM (Particulate Matter) Temperature Flow Rate Technology Providers E Emerson A ABB S Siemens H Horiba T Thermo Fisher Scientific F Fuji Electric Data Transmission & Validation CEMS data is transmitted to regulatory bodies such as the Central Pollution Control Board (CPCB) or State Pollution Control Boards (SPCB) via secure data links. The data undergoes validation using standard reference methods and is integrated into environmental monitoring portals for compliance verification and reporting. Oil Refinery: Complete Process Overview & Environmental Compliance Made with Genspark
- 11. Environmental Compliance Standards Regulatory Overview Oil refineries in India must comply with strict environmental standards set by the Central Pollution Control Board (CPCB) and state-level authorities like Gujarat Pollution Control Board (GPCB). These regulations enforce specific thresholds for emissions to control air pollution. Pollution Control Technologies Scrubbers Remove SO₂ and particulate matter from flue gases Catalytic Converters Reduce NOx emissions through chemical reactions CEMS Implementation Required for continuous monitoring and reporting Note: Refineries must implement pollution control technologies and use CEMS to ensure they meet regulatory requirements. Data must be transmitted to CPCB/SPCB via secure data links. Emission Standards Comparison Pollutant Fuel Type CPCB Limit (mg/Nm³) GPCB Limit SO₂ Gas 50 50 SO₂ Liquid 850-1700 850 NOx Gas 250-350 150 ppm @15% O₂ NOx Liquid 350-450 150 ppm @15% O₂ CO All types 150 100 PM All types 50 50 Compliance Documentation CPCB comprehensive industry document on refineries (1980s) CPCB 2008 emission limits for refineries Effluent discharge norms & load-based standards CPCB directions for Oil Refineries and OCEMS Oil Refinery: Complete Process Overview & Environmental Compliance Made with Genspark
- 12. Summary & Key Takeaways Key Takeaways Refinery Process Flow The 10-step process from crude intake to final products forms the backbone of refinery operations, with distillation being the critical primary separation process. Key Process Units CDU, VDU, Hydrocracker, and FCC units are fundamental to converting heavy crude fractions into valuable lighter products through specialized processes. Equipment & Infrastructure Refineries rely on specialized equipment including reactors, columns, heat exchangers, and compressors, all arranged in a strategic plant layout for optimal process flow. Emissions Management Refineries monitor and control SOx, NOx, CO, PM, and VOCs from various emission sources using advanced CEMS technologies and environmental controls. Prepare for Q&A Production Efficiency Environmental Impact Compliance Standards Process Technology Equipment Reliability Emission Control Monitoring Systems Future Trends Modern oil refineries balance efficient production processes with stringent environmental controls to meet global energy demands while minimizing environmental impact. Oil Refinery: Complete Process Overview & Environmental Compliance Made with Genspark