Presented by: Amar Karam Chandani(091405) Ankit Shrivastava(091407) Himanshu Jha(091411) Aman Chaturvedi(091440)

Cost estimation is a specialised subject and a profession in its own right. The design Engineer, however, needs to be able to make quick, rough, cost estimates to decide between alternative designs and for project evaluation. Chemical plants are built to make a prot, and an estimate of the investment required and the cost of production are needed before the protability of a project can be assessed.

ESTIMATION AT IOCL
Preliminary cost estimate at IOCL is done manually using excel, where all the data is fed into the excel sheet and a X-Y scatter plot is generated then all the points which are distorting the curve heavily are neglected as they will decrease the accuracy of the estimation. After generation of the plot a equation is obtained on excel and the preliminary new cost is estimated using the obtained equation. To this cost various factors are added and the final cost is obtained. Problems with approach are following: Arranging the massive amount of data present is a tedious job. Huge input of time is required. Wastage of valuable time is there and if the cost is required immediately it will mean a lot of work.

Working steps of the program are following: Takes input data from the user like size of heat exchanger, tag number etc. Then the program connects to the database and searches for all available data points. After obtaining the required data like base cost, base area. Then using the six tenth formulae it does capacity correction and brings all the data into the required area. Then upgrades it to current time by using CEPCI index. The obtained cost is then multiplied with factors to take into account MOC.

Bharat Oman Refineries has set up 6 million tonne per annum capacity grass root refinery at Bina, Madhya Pradesh. It is divided into 3 major facilities as given below: Crude Import and Handling facility Crude transfer and receiving facility through cross country pipelines and terminals Refining and related facilities. A 935 km pipeline from dispatch terminal of COT Vadinar, Gujarat brings crude to the Receipt Terminal at Bina.

1.Primary Processing facilities:

Crude Distillation Unit(CDU) Vacuum Distillation Unit(VDU)

2. Secondary Processing Facilities.

Motor Spirit Block(MSB) Hydrocracker Unit(HCU) Delayed Coker Unit(DCU)

3. Treating Units:
LPG Treating unit ATF Merox Diesel Hydrotreater

4.Sulphur Recovery Block(SRB) 5.Hydrogen Generation Unit(HGU) 6.Captive Power Plant(CPP) 7.Utilities systems:
Raw Water intake system Raw water treatment plant Cooling Tower and Cooling water treatment plant Reverse Osmosis based Demineralization (RODM) Nitrogen plant and Effluent Water Treatment Plant(ETP)

Fuel Gas Liquefied Petroleum Gas(LPG) Naphtha Euro III Motor Spirit (MS) Euro IV Motor Spirit (MS) Aviation Turbine Fuel(ATF) Euro III HSD Euro IV HSD Sulphur Pet Coke

The Delayed Coker Unit (DCU) is designed to process 1,360,000 MT of Vacuum Residue based on Arab Mix Crude This Unit is based on CB&I Lummus technology. Delayed Coking Process is a thermal cracking process for upgrading heavy petroleum residues into lighter gaseous & liquid products and solid Coke . The thermal cracking reaction starts in heater coils and provided residence time or Delayed for an extended period in the Coke Drum for Polymerisation and Cracking reactions to take place

For heating feed from 170oC to 200oC, we require a Shell & Tube Heat Exchanger of overall heat transfer area of 1.77 m2

Coker gas LPG Coker Naphtha (C5-140C) Light Coker Gas Oil(140C-370C) Heavy Coker Gas Oil(370C plus) Coker Fuel Oil Pet Coke

Coker Gas LPG (CDU)

Vacuum Residue from CDU/VDU or Storage Tanks

Coker Naphtha (HCU/DHT)

DELAYED COKER UNIT (1.36 MMTPA)

Light Coker Gas Oil (HCU/DHT)

Heavy Coker Gas Oil (HCU/DHT)

Pet Coke to CPP

DCU HEATER(14-FF-00-101 A/B) CONFIGURATION Balanced Draft, Twin Cell, Cabin Type, Horizontal Tubes Double Fired. Heat Absorption :- 17.2 MMKcal/Hr No of Tubes in Radiation Zone:- Total-64 (32 / Cell) No of Tubes in Convection Zone:-56 No of Soot Blowers:-16/heater No of Burners:-32/heater

The following measurements are to be made for doing the energy balance in oil fired reheating furnaces (e.g. Heating Furnace) i) Weight of stock / Number of billets heated ii) Temperature of furnace walls, roof etc iii) Flue gas temperature iv) Flue gas analysis v) Fuel Oil consumption

USING APPROXIMATE METHOD: 1.) WITH AIR PREHEATER: 2.) WITHOUT AIR PREHEATER: B.)USING INDIRECT METHOD: 1.) SENSIBLE HEAT LOSS DUE TO FLUE GAS: 2.)LOSSES DUE TO SKIN TEMPERATURE AND RADIATION: OVERALL EFFICIENCY OF THE FURNACE:

89.55% 82.05% 6.45% 3.01% 90.5251%

KCFL began its operation in 1987 at Nimrani near Indore, West Madhya Pradesh and has earned cash profits each and every year, since its inception, even though SSP Industry has gone through tumultuous times. Today KCFL has earned the distinction of being the largest manufacturer of SSP in India SSP manufactured and sold by Khaitan Chemicals & Fertilizers Limited under the brand name "Khaitan Khad is amongst the most sought after brands in Western Madhya Pradesh and surrounding areas. Being a straight fertilizer with easy application, low cost per bag and unique 12% sulphur content makes it very popular with the farmers. It is extensively used in crops like Oil Seeds, Groundnut, Potato etc. SSP is also manufactured in granulated form called GSSP

The Wet Gas compressor is a steam turbine driven, 2-stage centrifugal compressor with vertically split casing supplied by M/s BHEL, Hyderabad. The wet gas compressor boosts the pressure of Coker fractionator column overhead receiver gas from 1.13 Kg/cm2 and is delivered to the absorber at a pressure of 15.92 Kg/cm2. The function of the Wet Gas Compressor is to compress Coker Fractionator overhead gases to a higher pressure for enhancing C3, C4 recovery.

The major components of WGC are: 1. Casing 2. Diaphragm 3. Rotor 4. Balancing Drum 5. Bearings 6. Internal Seal

n/(n-1) = EFp. k/(k-1) 0.695 x 1.4 /(1.4-1) = 2.432

With number of impeller = 8 and 2 dim Shrouded impeller, uncorrected efficiency = 0.72 Corrected efficiency become EFp = 0.72 x Co = 0.72 x 0.915 = 0.66 or 66% .