Crude Oil Refining (Plant Capacity: 83,33,333.334 Ltr./Day)

CRUDE OIL REFINING

[EIRI/EDPR/4606] J.C.: 2823XL

INTRODUCTION

Crude oil, also called petroleum is a complex mixture of carbon and hydrogen (hydrocarbons), which exist as a liquid in the earth's crust. Crude oil has many compositions, some is black, thick and tar like, while other crude oils are lighter in color and thinner. The carbon and hydrogen in crude oil are through to have originated from the remains of microscopic marine organisms that were deposited at the bottom of seas and oceans and was transfored at high temperature and pressure into crude oil and natural gas.

This oil and gas migrates upward through the porous rock, as it is less dense than the water which fills the pores. The oil and gas is trapped by a layer of impermeable rock through which they can't flow. Several different types of oil and gas "traps" exist; a common dome formed by folded sedimentary rocks. Crude oil is obtaned by drilling a hole into the reservoir rock (sandstone, limestone etc.) and pumping it out.

Although all fractions of petroleum find uses, the greatest demand is for gasoline. One barrel of crude petroleum contains only 25-35% gasoline. Transportation demands require that over 50% of the crude oil be converted into gasoline. To meet this demand some petroleum fractions must be converted to gasoline. This may be done by "cracking" breaking down large molecules of heavy heating oil; "reforming" changing molecular structures of low quality gasoline, molecules; or "polymerization"  forming longer molecules from smaller ones. Conversion oil Refining.

Petroleum products are usually grouped into three categories; light distillate (LPG, gasoline, Naphtha), middle distillate (kerosene, diesel), heavy Distillate and residium (heavy fuel oil, lubricating oil, wax, asphalt).

This classification is based on the way crude oil is distilled and separated into fraction (called distillate and residuum).

COST ESTIMATION

Plant Capacity                83,33,333.334 Ltr./Day  

Land & Building (1,00,000 sq.mt.)    Rs. 106.50 Cr    

Plant & Machinery                    Rs. 250.10 Cr 

Working Capital for 3 Months    Rs. 3912.95 Cr 

Total Capital Investment          Rs. 4293.06 Cr 

Rate of Return                          86%

Break Even Point                      15%

CONTENTS

INTRODUCTION

BASICS OF CRUDE OIL

TYPICAL APPROXIMATE CHARACTERISTICS AND PROPERTIES AND GASOLINE POTENTIAL OF VARIOUS CRUDES

PROPERTIES

VISCOCITY

CONDENSATE

PROPERTIES OF CONDENSATE

OIL AND GAS SECTOR IN INDIA

RISING DEMAND OF OIL AND GAS SECTOR IN INDIA:

SITUATION IN INDUSTRY:

OPPORTUNITIES FOR ENTREPRENEURS:

INDUSTRY DEVELOPMENTS:

MARKET OVERVIEW OF PETROLEUM PRODUCTS IN INDIA

MARKET SIZE

INVESTMENTS/RECENT DEVELOPMENTS

GOVERNMENT INITIATIVES

ROAD AHEAD

INDUSTRY SCENARIO OF REFINERY

NATURAL GAS INFRASTRUCTURE:

IMPORT & EXPORT:

PETROLEUM PRODUCTS CONSUMPTION:

UNION BUDGET 2023 HIGHLIGHTS

PRESENT CRUDE OIL REFINING IN INDIA

USES AND APPLICATIONS

B.I.S. SPECIFICATIONS

MANUFACTURING PROCESS OF CRUDE OIL REFINING

PROCESS DETAILS

BASIS STEPS IN CRUDE OIL REFINING

DISTILLATION

CRACKING

TREATING

REFORMING

PRETREATMENT OF CRUDE OIL

DETAILS OF ATMOSPHERIC DISTILLATION

PROCESS FLOW DIAGRAM

SEQUENCES IN CRUDE OIL REFINERY

THE PROCESS OF CRUDE OIL REFINING

CRUDE OIL DISTILLATION

IMPORTANT PROCESSES OF A REFINERY

PREVENTION METHOD OF CORROSION IN CRUDE OIL REFINERIES

ENVIRONMENTAL POLLUTION AND SAFETY CONCERN IN CRUDE OIL REFINERY

PRINCIPLES OF PLANT LAYOUT

STORAGE LAYOUT:

EQUIPMENT LAYOUT:

SAFETY:

PLANT EXPANSION:

FLOOR SPACE:

UTILITIES SERVICING:

BUILDING:

MATERIAL-HANDLING EQUIPMENT:

RAILROADS AND ROADS:

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

1. RAW-MATERIAL SUPPLY:

2. MARKETS:

3. POWER AND FUEL SUPPLY:

4. WATER SUPPLY:

5. CLIMATE:

SPECIFIC FACTORS

6. TRANSPORTATION:

A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES

7. WASTE DISPOSAL:

8. LABOR:

9. REGULATORY LAWS:

10. TAXES:

11. SITE CHARACTERISTICS:

12. COMMUNITY FACTORS:

13. VULNERABILITY TO WARTIME ATTACK:

14. FLOOD AND FIRE CONTROL:

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

1. DEPRECIATION:

2. FIXED ASSETS:

3. WORKING CAPITAL:

4. BREAK-EVEN POINT:

5. OTHER FIXED EXPENSES:

6. MARGIN MONEY:

7. TOTAL LOAD:

8. LAND AREA/MAN POWER RATIO:

PROJECT IMPLEMENTATION SCHEDULES

INTRODUCTION

PROJECT HANDLING

PROJECT SCHEDULING

PROJECT CONSTRUCTION SCHEDULE

TIME SCHEDULE

ADDRESSES OF RAW MATERIALS SUPPLIERS

CRUDE OIL

ADDRESS OF PLANT & MACHINERY SUPPLIERS

STORAGE VESSELS/TANKS

LABORATORY EQUIPMENTS

BOILER

PLANT LAYOUT

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)