Crude ToppingCommissioned & Operating
150 KLPD Batch Crude-Oil Distillation Plant India
PROJECT SNAPSHOT
LOCATION
India
CAPACITY
150 KLPD
TECHNOLOGY
Crude Topping
PLANT STATUS
Commissioned & Operating
BALAJI CONSULTANTS’ ROLE
Process Design • FEED • Detailed Engineering • Equipment Supply • Plant Integration • Commissioning
THE CHALLENGE
The client required a 150 KLPD crude-oil distillation plant in India capable of recovering naphtha, kerosene, diesel and heavier hydrocarbon fractions from crude oil, with the flexibility to adjust product cut points according to crude assay and production requirements.
OUR SOLUTION
Balaji Consultants developed the process configuration from crude-assay evaluation through Front-End Engineering Design (FEED). The batch atmospheric-then-vacuum sequence applied in the same distillation system was selected to maximise product flexibility and distillate recovery, matched to the feedstock characteristics and the client's operating requirements.
PROCESS CONFIGURATION
Crude Receipt & PreheatingAtmospheric Distillation Naphtha, Kerosene, Diesel RecoveryVacuum Applied to Same SystemHeavier Distillate RecoveryFinal Heavy Residue Discharge
The crude feed is first processed under atmospheric conditions. Lighter fractions naphtha, kerosene and diesel-range products are progressively vaporised and recovered through the fractionation and condensation system as the batch proceeds. After completion of the atmospheric stage, vacuum is applied to the same distillation system. The reduced pressure lowers the effective boiling temperature of heavier hydrocarbons, permitting recovery of additional distillate fractions at lower effective boiling temperatures and thereby reducing the risk of thermal cracking. The final heavy residue is discharged after completion of the vacuum stage. Product cut points, heating rates and reflux conditions are adjusted according to the crude assay and production requirements. The plant incorporates integrated instrumentation and batch-process control with alarms, interlocks and emergency shutdown provisions.
PROJECT OUTCOME
- 150 KLPD batch crude-oil distillation plant commissioned and in commercial operation
- Naphtha, kerosene and diesel fractions recovered under atmospheric conditions
- Heavier distillate fractions recovered under vacuum in the same distillation system
- Flexible product cut points confirmed during commissioning
- Integrated instrumentation and batch-process control operational
- Performance testing and capacity demonstration completed
SCOPE OF WORK
- Crude-assay evaluation, process design & Front-End Engineering Design (FEED)
- Heat and material balance, equipment sizing & P&IDs
- Multidiscipline detailed engineering mechanical, piping, civil, structural, electrical & instrumentation
- Hazardous-area classification, HAZOP coordination & safety-system engineering
- Equipment procurement, fabrication supervision & supply
- Site construction, erection & installation
- Atmospheric & vacuum commissioning, product-cut optimisation, performance testing & operator training
RELATED TECHNOLOGY
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