Secondary Oil Refining - Metaforming Processing Plants

Turn-key EPC Contracting for
High Octane Gasoline
Production Plants

General Information

  • IMMA Global Group develops technological installations of secondary refining of hydrocarbons obtained through the direct distillation of crude oil, namely the straight-run gasoline (fraction 85-180 0C).
  • In order to process straight-run gasoline, it is offer to use the process of “Metaforming”, the aim of which is to increase the octane number of the crude, followed by the production of motor fuels of Euro 3 and Euro 4 standards (trade marks of AI92 or AI95).
  • Installation has been developed in the form of packagedunit and designed to operate on a wide range of fractional composition of the feed stock.

Brief Characteristics of the Project

Production of high-octane gasoline by method of catalytic cracking (aromatisation, isomerisation) of low-octane gasoline.

  • As feed stock, low-octane gasoline, stable gas condensate or straight-run gasoline (naphtha) are used.
  • As a result of catalytic cracking, the followings are produced:
    • High-octane gasoline of AI-92 or AI-95 with Euro 3 and Euro 4 standards
    • LPG (propane – butane)

Catalytic Isomerisation and Aromatisation of Low-Octane Gasoline

Production by way of catalytic isomerisation and aromatisation of lowoctane gasoline (stable gas condensate) is comprised of the following stages:

  • Fractionation of stable gas condensate (low-octane gasoline) and release of fraction of 30-80°С and 80-200°С
  • Catalytic isomerisation and aromatisation of fractions 80-200°С and release of unstable catalyst
  • Stabilization of unstable catalyst and producing of LPG and stable catalyst
  • Fractionation of stable catalyst and release of target gasoline product (with end boiling point up to 215°С) and removal of heavy residue
  • Mixing (compounding) of gasoline fraction (with end boiling point up  to 215°С) with the fraction of stable gas condensate of 30-80°С and producing high-octane gasoline

Production of winter type diesel is carried out on the installation, but under milder condition.

Catalytic Isomerisation and Aromatisation of Low-Octane Gasoline

Baku Plant General View

Technology & Know-how

  • In the process of production of gasoline, the reaction of catalytic aromotisation and isomerisation of hydrocarbon fractions (80-2000С) takes place in the presence of catalyzer.
  • Hydrocarbon fractions of 80-200°С are heated from its initial temperature being within 90°С – 110°С up to the temperature of catalytic aromatisation reaction i.e. 340°С – 450°С in heat exchangers- recuperators and in furnace for feed stock heating.
  • The reaction of catalytic aromatisation and isomerisation occurs in tubular reactors in the presence of a catalyst; the pressure of the reaction is within 0,7 – 1,0 МPа, the space velocity of raw material in the reactor 2 hour-1 , which is constant for the entire cycle.
  • After cooling, seperation, stabilisation and rectification of products of the reaction, stable catalyst is released, which is compounded with 30-80°С fraction of gas condensate to produce high-octane motor gasoline.
  • In the process of aromatisation, the catalyst loses its activity. To restore the activity of the catalyst oxidative regeneration is used. Technical nitrogen is used as oxygen-containing gas.
  • To prevent significant coke-sedimentation, reactors are to be stopped for regeneration after every 300 hours of operation.

Principal Scheme of High-Octane Gasoline Production

Inlet: 56 Octane Nafta
Outlet: 92 or 95 Octane Gasoline & LPG
Capacities: 50-100-200-500 mtons/day

Stock Balance of Naphtha to Gasoline

100% Naphtha –> 75% AI-95 Octane Gasoline + 20% LPG

Installation & Process Management System

  • The installation is equipped with sensors for pressure, temperature, level, flow meters with telemetry output that allows to organize a centralized process control from an operator station by using a computer.
  • Power supply for the installation is to be AC 380/220 V, 50 Hz. As part of the equipment for the installation, an uninterruptible power supply unit is to be  provided with a purpose to manage the installation in the cases of emergency or termination of power supply.

Distinctive Features

Designing of the installation is based on the following criteria:

  • Optimisation of technological process with an aim to minimise capital and operational expenditures
  • Modular design ensuring minimum costs during installation
  • Simplicity in management and maintenance
  • Autonomy of the work of installation
  • Possibility for flexible correction of technological parameters
  • Compliance with safety, fire safety, environmental protection requirements

Plant Layout

Requirements for Plant

Installation place – Territory of any refinery, as well as, a land plot with industrial infrastructure (automobile or rail roads, power, gas, water supply etc.).

Power supply – The supply of AC electrical energy from the available power grid is envisaged.

Compressed air supply – To produce compressed air, two compressors with capacity of 300 m³/h is to beconsidered. Each shall be with a fully automated drying
nod. Compressed air is stored in a tank for compressed air with volume of 50m³. The pressure of the air to be supplied to the processing station is to be 5 kg/cm2

Natural gas supply – Natural gas is to be supplied from the available gas pipeline. In the case of absence, the alternative for heating of the installation can be considered.