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
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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
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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
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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)
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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
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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.
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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
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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
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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
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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.
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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
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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.
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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…
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