Detailed Project Report on crude oil refining

CRUDE OIL REFINING
[CODE NO 3458]


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 transformed 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 obtained 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                                           :    25000.00 BARRELS/day      
land & Building (40000 Sq.Mtr)               :    Rs. 32.00 Cr
Plant & Machinery                                      :    Rs. 92.50 Cr
Working Capital for 2 Months                  :    Rs. 753.00 Cr
Total Capital Investment                          :    Rs. 887.00 Cr
Rate of Return                                           :    71%
Break Even Point                                      :    18%


INTRODUCTION    
BASICS OF CRUDE OIL    
TYPICAL APPROXIMATE CHARACTERISTICS AND PROPERTIES AND    
GASOLINE POTENTIAL OF VARIOUS CRUDES    
PROPERTIES    
OVERVIEW OF CRUDE OIL RESERVES    
GLOBAL MARKET POSITION OF CRUDE OIL REFINING    
CRUDE OIL REFINING SCENARIO IN AFGHANISTAN    
USES AND APPLICATIONS    
B.I.S. SPECIFICATION    
SEQUENCES IN CRUDE OIL FEFINING    
REFINING OF PETROLEUM CRUDE OIL    
FRACTIONAL DISTILLATION    
VACUUM DISTILLATION    
CRACKING    
PROCESSING & REFINING CRUDE OIL    
FIGURE: CRUDE OIL DISTILLATION    
FIGURE: IMPORTANT PROCESSES OF A REFINERY    
PRODUCTS MADE FROM A BARREL OF CRUDE OIL (GALLONS)    
FIGURE: PRODUCTS MADE FROM CRUDE OIL    
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    
PREVENTION METHOD OF CORROSION IN CRUDE OIL REFINERIES    
ENVIRONMENTAL POLLUTION AND SAFETY CONCERN IN CRUDE OIL REFINERY    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF PLANT AND MACHINERY    
BOILERS    
COOLING TOWER    
HEAT EXCHANGER    
STORAGE TANKS    
MATERIAL HANDLING EQUIPMENTS    
INSTRUMENTATION & PROCESS CONTROL EQUIPMENTS    
LABORATORY EQUIPMENTS    

                        
APPENDIX – A:

 1.      COST OF PLANT ECONOMICS      
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET