Oil Refinery Process

Oil Refinery Process
Yogyakarta/ 10 November 2012
DIT. PENGOLAHAN PERTAMINA
Tlp : 021-381-5481
Email : [email protected]
1
Materi Presentasi
I.
II.
III.
IV.
V.
VI.
Gambaran umum
Proses – proses utama di kilang
Konfigurasi proses kilang
Feed dan spesifikasi
Product dan spesifikasi
Tantangan ke depan
2
Gambaran umum
3
Marketable
Product
Crude Oil
Pengolahan
(Refining)
SLC
Duri
ALC
Nigeria
dll
LPG
Gasoline
Kerosene / Avtur
ADO
Fuel Oil
C2=, C3=, C4=
Wax, Asphalt,
Aromatic, coke
4
Alur pengolahan minyak (oil)
Downstream
Upstream
Trading
Commercial
Customer
Exploration
• Geophysical
Evaluation &
Design
• Field Development
• Drilling Operations
Retail
Customer
Production
Refining
Primary
Distribution
Terminalling
• Crude Oil & Gas
Production
• Refining of
Crude
• Pipeline
Transportation
• Inventory
Management
• Gathering &
Processing
• Product
Blending
• Barge & Vessel
Transportation
• Product
Blending
• Price Setting
• Truck Dispatch
• Customer Service
• Transportation &
Storage
• Marketing
• Demand Forecast
• Demand
Fulfillment
Typical Crude & product
Distribution
200
HOMC
Import
20
Export
Natural
Gas
Contractor
100
300
LPG
Exchange
Crude
100
Indonesian
Crude Production
200
Export,
Exchange,
Repayment
Fuel Product
- Mogas
: 190
- Kerosene : 150
- Gasoil
: 250
-IDO
:
8
-IFO
:
67
Product
1,000.0
700
Pertamina production &
Government Entlitement
7
: 30
- Aviation
: 33
- Pertamax
:
7
- Pertamax Plus :
3
- Pertadex
0.2
:
600
500
Petrochemical (Excl. LPG )
400
Import Crude
Unit : MBCD
400
- Total
: 41
Miscellineous
- Total
: 120.0
Ref. Fuel & Loss
- Total
: 7.5 % Vol on Crude
6
Kilang Pengolahan Minyak Milik PERTAMINA
I
170
253.5
II
10
VII
132.5
125
V
III
348
Dalam MBPSD
RU I : Pangkalan Brandan
RU II : Dumai
RU III : Plaju
RU IV : Cilacap
RU V : Balikpapan
RU VI : Balongan
RU VII : Kasim
7
Asia pacific major refineries
Refiners
Shell
1,272
Exxon Mobil
Caltex (including
1,047
SK
555
14
11
285
6
1,115
Pertamina
PTT
Number of
refineries
1,801
LG-Caltex)
2
1031
370
6
485
5
782
Nippon Mitsubishi
Idemitsu
670
Cosmo Oil
599
BP
247
Petronas
298
SPC
285
Petron
Influenced**
capacity (KBD)
Controlled* total
capacity (KBD)
180
* Majority controlled and manned by company
** Minority ownership
Source: Facts – EWCI; company website
4
5
285
4
3
3
1
1
Proses – proses utama di kilang
9
Proses – proses utama di Oil Refinery
No
Jenis
Proses
Unit Proses
Tujuan Proses
1
Persiapan
Desalter
Menurunkan water,
menurunkan garam
2
Pemisahan
Pemisahan primer
berdasar titik didih
3
Treating
4
Konversi
5
Perbaikan
Kualitas
Crude Distilling Unit (CDU),
High Vakum Unit (HVU)
Hydrotreating dan demetalisasi
(HDS, ARHDM, DHDT, DHDT),
Amine Absorber,
Hydrocracker, Fluid Catalytic
Cracking (FCC), RFCC, Delayed
Coker, Visbreaker, Platforming,
H2 Plant.
Hydrotreater (HDS)
6
Prosesproses Lain
Polymerisasi, Isomerisasi
Penex,Totaray), MDU
Polymerisasi,
aromatisasi, Filtrasi
Pemurnian
Perengkahan,
pembentukan /
reforming
Perbaikan kualitas
10
Konfigurasi proses kilang
11
Tipikal refinery process flow diagram
12
RU II Dumai
GAS
L.NAP
LPG
L.NAP
LPG
H.NAP
NRU
HCU
212
PL-I
H.NAP
L.NAP
KERO
BTM
TO PREMIUM
NHDT
ADO
HCU
212
HVGO
EXCESS
GAS
HOMC
L.KERO
H.KERO
ADO
S.RES
GAS
TO LSWR
BTM
LPG
SRN
TO PREM.
NAPHTHA
CDU
SPK
KERO
DCU
ADO
PL -II
H.NAP
LVGO
HVU
H.NAP
LPG
L.NAP
H2P
701/702
LPG
GAS
CRUDE
LPG
HOMC
TO LOMC
CDU
DMI
H.KERO
ADO
SRN
CRUDE
L.KERO
NAPHTHA
LCGO
HCGO
COKE
DHDT
L.KERO
H.KERO
L.RES
TO LSWR
13
TO LOMC
RU III Plaju
14
RU IV Cilacap
15
RU V Balikpapan
16
RU VI Balongan
17
RU VII Kasim
18
PERBANDINGAN YIELD KILANG UNTUK MENGHASILKAN
PRODUK BERNILAI JUAL TINGGI DAN KOMPETISI
Nelson Complexity Index - Yield indicator
(higher number, high value yields)
Refinery comparison
Production capacity, kbpd
RU IV Cilacap
RU V Balikpapan
RU II Dumai
RU III Plaju / Musi
RU VI Balongan
RU VII Kasim
348
3.5
3.3
260
170
118
125
7.9
4.9
10.6
10
1.0
Indonesia average
International
competitors
South Korea avg
Taiwan average
UK average
Japan average
India average
US average
China average
Reliance India**
4.7
430
305
170
152
132
128
83
5.0
5.9
9.0
7.7
3.8
10.7
3.6
580
14.0
KILANG DENGAN KOMPLEKSITAS TINGGI AKAN MENGHASILKAN
FRAKSI RINGAN LEBIH BESAR DAN PRODUCT VALUE LEBIH TINGGI
Simple /
Hydroskimming
Gas plant
Distillation
Reformer
Crude
oil
Refinery
configuration type
Fuel Gas
LPG /
Propane
Gasoline
Kerosene / Avtur
Solar / Diesel
Fraksi
Ringan
Units
present
Topping
30
Hydroskimming
50
FCC
70
FCC/alky
75
Coking
85
Source:
Actual yield is also dependent on the crude type/quality
McKinsey
Simple (%v)
Coker
Gas/ LPG
Alky
Yields
FCC
Complex /
Cracking
Reformer
Distillation
Residual fuel
*
Typical light
product yield*
% volume
Complex
(%v)
2.11
9.56
Gasoline
16.51
44.58
Kerosene / Avtur
20.22
8.95
Solar / Diesel
21.32
20.44
Residue
39.84
16.47
100.00
100.00
Total
Feed dan Spesifikasi
21
Crude Oil ( minyak bumi) :
 Terdiri atas senyawa C (1 - 40an ) dan H
 Didefinisikan dengan crude assay (boiling point cut, sifat
fisik)
 Mengandung impurities (S, N, metals)
 Dikategorikan sebagai : parafinik, naphthenik, aromatik.
22
Komposisi desain feed (crude) RU’s
RU
UNIT
OPERASI
JENIS CRUDE
KOMPOSISI
CRUDE ( % V)
DUMAI
SLC
DURI
80%
20%
RU II
SUNGAI PAKNING
SLC
LIRIK
90%
10%
RU III
CDU I - VII
SLC
RAMBA
RU IV
CDU I
ALC
100%
CDU II
ARJUNA
ATTAKA
50%
50%
CDU IV
HANDIL
BEKAPAI
60%
40%
CDU V
SLC
WIDURI
70%
30%
RU VI
CDU
SLC
DURI
20%
80%
RU VII
CDU
WALIO
100%
RU V
TABEL. SPESIFIKASI FEED
PRIMARY PROCESSING
NO
PARAMETER
UNIT
UP II
SPK
1
SALT CONTENT
ptb
2
SULFUR
% WT
3
N + 2A
% vol
4
Asphalthenes
% wt
5
Vanadium
ppm wt
max 0.5
6
Nickel
ppm wt
max 20
7
Mercury
ppb
8
TAN
mgKOH/mg
max 0.1
UP III
UP IV
UP V
UP VI
max 7
max 8.7
max 7.8
max 10
max 0.1
max 0.1
max 0.1
max 0.1
max 0.71
max 0.45
min 80
max 25
max 25
max 25
max 0.7
max 0.62
Produk dan Spesifikasi
25
Marketable products :
Produk
No. Atom C
Spesifikasi kritis
LPG
C3 – C4
Kadar C3&C4, RVP, bau, C2, korisifitas
Gasoline
C4 – C12
ON, distilasi/EP, RVP, S, aromat, korisifitas
Jet Fuel / Kero
C8 – C12
Freezing point, smoke point, flash point
ADO/Solar
C12-C18
Cetane Index, distilasi/EP, S, korosifitas
Fuel Oil / Residu > C25
Viskositas, Sg
26
Spesifikasi produk LPG
NO.
ANALISA
METODA
1.
Specific Gravity at 60 / 60 °F
ASTM D - 1657
2.
Komposisi :
ASTM D - 2163
MIN
MAX
To Be Reported
C2
% vol
-
0.8
C3 + C4
% vol
97.0
-
C5 + ( C5 and heavier )
% vol
-
2.0
3.
R.V.P at 100 ° F
psig
ASTM D - 1267
-
145
4.
Weathering Test at 36 °F
% vol
ASTM D - 1837
95
-
5.
Total Sulphur
grains/100
cuft
ASTM D - 2784
-
15 +)
6.
Copper Corrosion 1 hours/100 °F
ASTM D - 1838
-
No. 1
7.
Ethyl or Buthyl Mercaptan Added
8.
Water Content
mL / 1000 AG
50 *)
Visual
No free water
+) Sebelum ditambah ethyl atau buthyl mercaptan
*) Tidak dilakukan di Laboratorium
Ref. Dirjen Migas no. No. 26525.K/10/DJM.S/2009
27
Spesifikasi produk premium (hal 1 dari 2)
NO.
ANALISA
1.
Research Octane Number
2.
Colour
3.
Dyes content
4.
Cu. Strip Corrosion 3 hrs / 50 oC
5.
Distillation :
METODA
MIN
MAX
ASTM D-2699
88.0
-
Visual
gr/100 L
Yellow
-
0.13
ASTM D-130
-
No. 1
ASTM D-86
-
-
10 % Vol. recovery
oC
-
74
50 % Vol. recovery
oC
75
125
90 % Vol. recovery
oC
-
180
End Point
oC
-
215
Residue
% vol
-
2.0
IP-130
-
Negative
6.
Doctor Test or No. 9
7.
Existent Gum
mg/100 mL
ASTM D-381
-
4.0
8.
Induction Period
Minutes
ASTM D-525
240
-
9.
Mercaptan Sulphur
% wt
ASTM D-3227
-
0.0020
10.
Density at 15 oC
Kg/m3
ASTM D-4052
715,0
780,0
11.
Oksigenat content
% vol
Mixing
-
11
12.
R.V.P at 100 oF
kPa
ASTM D-323
-
69
13.
Lead Content
g/L
ASTM D-5059
-
0.013
14.
Total Sulphur
% wt
ASTM D-2622
-
0.10
28
Spesifikasi produk Solar
NO.
ANALISA
METODA
Visual
MIN
MAX
1.
Appearance
2.
Density 15 °C
kg / m³
ASTM D - 1298
815
870
3.
Strong Acid Number
mg KOH/g
ASTM D - 664
-
NIL
4.
Total Acid Number
mg KOH/g
ASTM D - 664
-
0.6
5.
Ash Content
% wt
ASTM D - 482
-
0.01
6.
Cetane Index
ASTM D - 4737
48
-
7.
Colour ASTM
ASTM D - 1500
-
3.0
8.
Cu. Strip Corrosion 3 hrs / 100 °C
ASTM D - 130
-
No. 1
9.
Distillation, T90
°C
ASTM D - 86
-
370
10.
Pour Point
°C
ASTM D - 97
-
18
11.
Sediment
% wt
ASTM D - 473
-
0.01
12.
Visc. Kinematic at 40 °C
cSt
ASTM D - 445
2.000
5.000
13.
Water Content
mg / kg
ASTM D - 1744
-
500
14.
Flash Point PMcc
°C
ASTM D - 93
55
-
15.
Total Sulphur *
% wt
ASTM D - 2622
-
0.35
-
0.1
No. ASTM
Clear & Bright
OR
ASTM D - 1552
16.
Conradson Carbon Residue
% wt
ASTM D - 4530
*) Ref. : SK Dirjen Migas No. 3675 K/24/DJM/2006.
Surat dari Dir. Jen. Migas No. : 5312/14/DJM.T/2008.
Surat dari Dir. Jen. Migas No. : 1470/04/DJM.0/2009.
29
Spesifikasi produk Kerosene
NO.
ANALISA
METODA
MIN
MAX
1.
Density 15 °C
kg / m ³
ASTM D - 1298
-
835
2.
Burning Test ( Dry Char )
mg / kg
IP - 10
-
40
3.
Cu. Strip Corrosion 3 hrs / 50 °C
Class
ASTM D - 130
-
No. 1
4.
Distilation :
-
310
18
-
38.0
-
ASTM D - 86
End Point
°C
Recovery at 200 °C
% vol
°C
5.
Flash Point Abel
IP - 170
6.
Odour & Colour
7.
Smoke Point
mm
ASTM D -1322
15
-
8.
Total Sulphur
% wt
ASTM D -1266
-
0.20
-
Marketable
Ref. : Dirjen Migas No. 17K/72/DDJM/1999 Tgl. 16 April 1999
30
Tantangan ke depan
31
Tantangan ke depan
Lingkungan yang berubah :
1.
2.
3.
4.
Harga crude yang cenderung tinggi.
Tuntutan kinerja standart global.
Regulasi produk yang berubah.
Tuntutan lindungan lingkungan yang semakin ketat.
Tuntutan terhadap Pengolahan :
1.
2.
3.
4.
5.
Menaikkan kehandalan kilang.
Mengurangi losses dan refinery fuel.
Mengoptimalkan produksi.
Memenuhi regulasi pemerintah.
Menurunkan biaya-biaya.
32
Tipikal Struktur Biaya Bidang Pengolahan
Biaya Pengolahan;
2.4%
Biaya Angkutan;
0.9%
Biaya Refinery
Fuel; 3.6%
Biaya Depresiasi;
0.9%
Biaya Interest;
0.1%
Bahan Baku;
92.1%
Trend Karakteristik Bisnis Pengolahan Oil & Gas
Terima kasih atas perhatiannya…
36