A REPORT

ON
HYDROGEN GENERATION UNIT (HGU)
AND
HYDROTREATING UNIT (HDT)

BY
Name(s) of the ID No(s) Discipline(s)

Student(s)

NITUL KHATANIAR 2008A3PS006P Electrical & Electronics

KAMANASISH BHATTACHARJEE 2008A3PS020P Electrical & Electronics

HARI SAURAV BARUAH 2008C6PS364H Information System

Prepared in partial fulfillment of the

Practice School-I Course

AT

Guwahati Refinery, Guwahati

A Practice School-I station of

BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE, PILANI

(June, 2010)
 A REPORT
ON
HYDROGEN GENERATION UNIT (HGU)
AND
HYDROTREATING UNIT (HDT)

BY
Name(s) of the ID No(s) Discipline(s)

Student(s)

NITUL KHATANIAR 2008A3PS006P Electrical & Electronics

KAMANASISH BHATTACHARJEE 2008A3PS020P Electrical & Electronics

HARI SAURAV BARUAH 2008C6PS364H Information System

AT
GUWAHATI REFINERY, GUWAHATI
A Practice School-I station of

BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE, PILANI

(June, 2010)
 ACKNOWLEDGEMENTS
We acknowledge with thanks the support rendered by B.M. Bansal, chairman of
Guwahati Refinery for inspiring us to write this report. We are extremely grateful to B.P. Das,
General Manager, and Guwahati Refinery for showing his utmost interest towards our report.

We owe a lot to Mr. Mahaveer Surana, a present employee in this refinery and an ex-
Bitsian. He helped us to make the orientation schedule for us and led us through the right path.
We are also thankful to unit chiefs and employees of HGU, HDT and DDCS units for their
cordial interaction with us in spite of their busy schedule.

Inadequate to express our sincere thanks to Dr Sonia Nongmaithem, our PS-I

instructor at Guwahati Refinery, Guwahati centre for her constant support and motivation
without which we would not have been able to complete this report. Her catalytic role has really
inspired us to accomplish this report in a very short span of time.
 BIRLA INSTITUTE OF TECHNOLOGY AND SCIENCE

PILANI (RAJASTHAN)
Practice School Division

Station: GUWAHATI REFINERY Centre: GUWAHATI

Duration: 24th May-16th July, 2010 Date of Start:

Date of Submission: 21st June, 2010

Title of the Project: A Report on Hydrogen Generation Unit (HGU) & Hydrotreating Unit
(HDT)

ID No. /Name(s)/ 2008A3PS006P NITUL KHATANIAR Electrical & Electronics

Discipline(s) of the 2008A3PS020P KAMANASISH BHATTACHARJEE -do-

student(s) : 2008C6PS364H HARI SAURAV BARUAH Information System

Name(s)and

Designation(s) of

the expert(s):

Name(s) of the

PS Faculty: Dr. Sonia Nongmaithem

Key Words: HGU, HDT

Project Area: Hydrogen Generation unit & Hydrotreating unit

Abstract:
This project is all about HGU and HDT unit. In this report, we have tried to explain the main
chemical processes going on inside these two plants based on the data collected from the manual
and illustration by senior engineers. We have also thrown lights on the huge importance of these
two units for the refinery in maintaining the environmental norms regulated by pollution control
board. The main purpose of HGU is to produce hydrogen which is sent to HDT and ISOSIV unit.
Hydrogen is used in reactor for saturating olefins. The main purpose of HDT is to remove
sulphur, nitrogen from finished product as sulphur, nitrogen etc are harmful for environment.
Thus HDT has been installed in Guwahati refinery so as to meet Bharat Stage II specifications of
diesel and produce kerosene of high smoke point. In this report, detailed descriptions of chemical
processes and important equipments (pump, compressor, reactor, valve etc) involved in those
procedures have also been included. Flowcharts of both HGU & HDT have been attached at the
end.

Signature(s) of Student(s): Signature of PS Faculty:

Date:

Date:
 TABLE OF CONTENTS

Page no

1. Introduction 1

2. Design Information On HGU 2

3. Important Facts on HGU in Guwahati refinery 3

4. Equipment list for HGU 3

5. Main systems/function of HGU 5

6. Detailed process description of HGU

6.1. Feed Preheating and hydrogenation 6

6.2. Feed desulphurization and dechlorination 6

6.3. Prereforming 6

6.4. Reforming 7

6.5. HT & LT Shift Conversion 7

6.6. Product Recovery 7

6.7. Heat Recovery

6.7.1. Heat Recovery from flue gas 8

6.7.2. Heat Recovery from process gas 8

6.8. Steam system 9

6.9. Fuel system 9

7. Design Information on HDT 10

8. Important Facts on HDT in Guwahati refinery 10

9. Equipment list for HDT 11

10. Hydrotreater Process Principles 13

11. Hydrotreating Chemistry

 11.1 Sulphur Removal 14

11.2 Nitrogen Removal 15

11.3 Oxygen Removal 16

11.4 Olefin Saturation 16

12. Main Systems/functions of HDT 17

13. Detailed process description of HDT

13.1 Reaction Section 18

13.2 Feed Heating 18

13.3 Reactors 19

13.4 Reactor Effluent Cooling 19

13.5 Reactor Effluent Water Wash 20

13.6 Vapor/ liquid seperator 20

13.7 Recycle Gas System 20

13.8 Make-Up Hydrogen System 21

13.9 Fractionation System

13.9.1 Diesel Mode 22

13.9.2 Kerosene Mode 22

14. Conclusion 23

15. References 24

16. Flowchart

15.1 Flowchart of HGU 25

15.2 Flowchart of HDT 25

 INTRODUCTION
As a part of Practice School-I programme in Guwahati Refinery centre, we have
made this report as mid-term report which is specifically to be based on the organizational unit
itself. Three of us were allotted to make a report on hydrogen generation unit (HGU) and
hydrotreating unit (HDT) by our PS instructor. In this report, we have tried to focus on the basic
chemical processes going on inside these two plants. We have also thrown lights on the huge
importance of these two units for the refinery in maintaining the environmental norms regulated
by pollution control board.

For having a clear-cut idea about the processes we visited HGU first. There at first
the flowchart which was just at the entrance of the unit was illustrated by a senior engineer. Then
he led us to the inside of the plant and gave us ideas about the working principles of various
equipments and their contribution towards the completion of the whole process. For learning
about the controlling and monitoring process, we went to DDCS. There we collected the raw
data about the processes and performance from a manual. The HGU is designed to produce
hydrogen which is sent to hydrotreating and ISOSIV unit. The basic purpose of producing
hydrogen in a refinery is to saturate olefins, to remove sulphur, nitrogen etc from the finished
product.

After completion of HGU, we visited HDT unit. In this case also we followed the
same procedure to understand the processes and to collect the necessary data as in HGU. This
unit is very crucial to maintain the environmental norms. In this unit sulphur, nitrogen etc are
removed from the product. As we know that sulphur is very dangerous to ecosystem, it should be
removed from the fuel. It is removed from product by treating it with hydrogen which is taken
from HGU. In HDT also olefins are saturated. In this unit, we studied the principles of two
reactors for removal of toxic component and three types of compressors for suctioning lighter
gases like hydrogen. They are recycle gas compressor, makeup gas compressor and net gas
compressor. Other equipments were also nicely illustrated.

In this report, we have tried to reflect the interdependence and correlation that
exist in between these two units. The first part of the report is attributed to HGU. In this part, we
at first have provided the design information and some important facts on HGU in Guwahati
refinery followed by equipment list. Then we have discussed the chemical processes of this unit
one by one with necessary operating conditions and chemical reactions. The second part is kept
for HDT unit where the same writing sequence has been maintained. Towards the end of the
report we have given a conclusion based on our study. Flowcharts of both the units have been
attached at the end of this report.

1
DESIGN INFORMATION ABOUT HGU –
1> HGU in Guwahati Refinery has been designed to produce hydrogen at a rate of 1250kg/h
with a minimum purity of 99.985 mol %.

2> Normal operation is based on 0.5T/hr naphtha feed. Generally LRU off gases are not
taken as feed due to diene content.

3> Turn down ratio is 30% of design.

4> On stream days: 360 days/year.

IMPORTANT FACTS ON HGU IN GUWAHATI REFINERY –

OBJECTIVE – To supply hydrogen to hydrotreating unit (HDT) and ISOSIV unit.

CAPACITY - 10,000 TPA

LICENSOR - Technip, BV, Netherlands

FEED - Straight Run Naphtha (SRN)

LRU offgas

PRODUCT - Hydrogen

2
EQUIPMENT LISTS FOR HGU -
EQUIPMENT NUMBER EQUIPMENT NAME
48-V-01 FEED GAS K.O DRUM
48-V-02 NAPTHA FEED SURGE DRUM
48-V-03 STEAM CONDENSATE POT
48-V-04 STEAM DRUM
48-V-05 BLOW DOWN FLASH DRUM
48-V-06 DEGASIFIER
48-V-07 HOT CONDENSATE SEPARATOR
48-V-08 COLD CONDENSATE SEPARATOR
48-V-09 SPILL BACK DRUM
48-V-10 COKER NAPTHA FUEL SURGE DRUM
48-V-11 DISCHARGE DAMPNER VESSEL
48-R-01 HYDROGENATOR
48-R-02 DESULPHERISER
48-R-03 PREREFORMER
48-R-04 HT SHIFT REACTOR
48-R-05 LT SHIFT REACTOR
48-E-01 FEED COMPRESSOR RECYCLE COOLER
48-E-02 FEED PREHEATER/VAPORIZER
48-E-03 HYDROGENATION LOOP COOLER
48-E-04 PROCESS GAS BOILER
48-E-05 STEAM SUPERHEATER
48-E-06 BFW PREHEATER I
48-E-07 BFW PREHEATER II
48-E-08 DEMIN WATER PREHEATER
48-E-09 PROCESS GAS TRIM COOLER
48-E-10 PREREFORMER STARTUP HEATER
48-E-11 COKER NAPTHA FUEL VAPORISER
48-E-12 INDUCT AIR PREWARMWER
48-E-13 COKER NAPTHA COOLER
48-E-20 SHOCK BOILER
48-E-21 REFORMER FEED PREHEATER
48-E-22 PREREFORMER FEED PREHEATER
48-E-23 STEAM SUPERHEATER
48-E-24 FEED PREHEATER
48-E-25 COMBUSTION AIR PREHEATER I
48-E-26 COMBUSTION AIR PREHEATER II
48-E-27 ECONOMIZER
48-AC-01 PROCESS GAS AIR COOLER
48-AC-02 SPILL BACK COOLER/NITROGEN COOLER

3
 48-F-01 REFORMER
48-X-01 DeNox WINDOW(FOR FUTURE)
48-X-02 STACK
48-X-03 STEAM SILENCER
48-X-04 CHEMICALS DOSING UNIT
48-X-05 PSA UNIT
48-J-01 RECYCLE GAS INJECTOR
48-P-01 NAPTHA FEED PUMP
48-P-02 BFW PUMP
48-P-03 COKER NAPTHA FUEL PUMP
48-P-04 NAPTHA BOOSTER PUMP
48-P-05 COKER NAPTHA BOOSTER PUMP
48-G-01 PSA FILTER
48-K-01 FEED GAS COMPRESSOR
48-K-02 RECYCLE HYDROGEN COMPRESSOR
48-K-03 COMBUSTION AIR FAN
48-K-04 FLUE GAS FAN
48-K-05 PENTHOUSE VANTILATION FAN
48-V-20 to 29 PSA ADSORBER
48-V-30 PSA SURGE DRUM

4
MAIN SYSTEMS/FUNCTIONS:-
1> FEED PREHEATING & HYDROGENATION

2> FEED DESULPHERISATION & DECHLORINATION

3> PREREFORMING

4> REFORMING

5> HT & LT SHIFT CONVERSION

6> PRODUCT RECOVERY

7> HEAT RECOVERY

8> STEAM SYSTEM

9>FUEL SYSTEM

5
 DETAILED PROCESS DESCRIPTION:-

1> FEED PREHEATING & HYDROGENATION-

Feed from B.L is first pumped through the naphtha booster pump 48-P-04 to
feed surge drum 48-V-02.Then it is again pumped through naphtha feed pump 48-P-
01.Its outlet pressure is 36.3 kg/cm²g.The feed is mixed with Hydrogen. To bring the
pressure of Hydrogen at the same as that of feed,48-K-02 recycle hydrogen compressor
is used, the inlet pressure of which is about 20 kg/cm²g.This recycle hydrogen provides
necessary quantity for the conversion of olefins and other unsaturated organic
compounds and ensuring adequate partial pressure of hydrogen for the conversion of
organic sulphur and chlorine in the hydrogenator 48-R-01.
Saturation reaction of olefins in the hydrogenator-
R=R + H₂ RH-RH
Hydrogenation of organic sulphur & chlorine compounds-
RSH + H₂ RH + H₂S
RCl + ½ H₂ RH + HCl
The sulphur content in naphtha is reduced to less than 0.1 ppm here.

2> FEED DESULPHURISATION & DECHLORINATION-

Chlorine & sulphur contents are poisons for the downstream prereformer &
reformer. Therefore they must be removed from the feed. This is done in the desulphuriser
48-R-02.In the desulphuriser, there is a chlorine bed which comprises of sodium
aluminate supported on alumina & a ZnO bed which consists of granulated ZnO with
cement binder. The chlorine bed is located above the ZnO bed. Because then the HCl will be
absorbed on the chlorine bed & that will avoid the formation of zinc chloride which can
cause further problems in the process. The sulphur content in the form of hydrogen
sulphide is removed in the ZnO bed. The reaction is as follows-
ZnO + H₂S ZnS + H₂O
The ZnO bed removes hydrogen sulphide content to less than 0.2 ppmw.
The chlorine & ZnO beds are designed to last up to 6 months for mixed feed. When the
sulphur content will found to be greater than 0.2 ppmw in the outlet of desulphuriser
then it is an indication for the renewal of the beds.

3> PREREFORMING-
Steam reforming of naphtha takes place in the prereformer 48-R-03.The
prereformer operates adiabatically. In prereformer, CRG catalysts converts all heavier
hydrocarbons to hydrogen, carbon monoxide, carbon dioxide & methane. The inlet
temperature of prereformer is 450˚C.The reaction that takes place in the prereformer is
exothermic. Now, temperature increase in the prereformer is directly proportional to the

6
 amount of heavier hydrocarbons present. For mixed feed, the outlet temperature is around
465˚C.But as the amount of heavier hydrocarbons is greater in the pure naphtha, the
outlet temperature reaches around 524˚C for pure naphtha feed.

4> REFORMING-
Steam reforming of naphtha also takes place in the tubular reformer 48-F-01.The
reformer consists of 36 tubes divided into 2 rows,18 each with a heated length of
11.7m.The reformer tubes have an ID of 110 mm & are filled with Ni based catalysts
ICI-25-4 & ICI-57-4G.The superheated gas is distributed into reformer tubes where the
reforming reactions takes place. Here hydrogen is produced from methane & steam. The
reaction is as follows-
CnHm + nH₂O nCO + (½m+n) H₂
This conversion is favoured by high temperature, low pressure & high steam
quantity. The normal reformer outlet temperature is 850˚C.The reforming duty is provided
by purge gas & vaporized coker naphtha or SRN.

5> HT & LT SHIFT CONVERSION-

The shift conversion is used to convert carbon monoxide to hydrogen. The
reaction is as follows-
CO + H₂O CO₂ + H-H
This reaction takes place in 2 different reactors-the HT shift reactor 48-R-04
& the LT shift reactor 48-R-05.The inlet temperature of HT shift reactor is 340˚C.The
CO content is reduced to 4.15 mol% here. Again the inlet temperature of LT shift
reactor is 200˚C.The CO content is reduced to 0.57 mol%(dry basis) here. The shift
reaction is favoured by low temperature & high steam quantity independent of pressure.

6> PRODUCT RECOVERY-

Hydrogen produced is purified by PSA (Pressure Swing Adsorbtion) technique.PSA
adsorber contains molecular sieves which adsorb the contaminants under pressure and allow
hydrogen to pass. To regenerate sieves the adsorber is depressurized where contaminants are
released. After pressurization, the adsorber is ready for reuse. The contaminants which are
released at low pressure are collected in the purge drum and are used to meet part of the heat
demand of the reformer.
The purge gas releasing from PSA has normal pressure of .33kg/cm²g.Finally
hydrogen is passed through a filter 48-G-01 to remove any finer. A part of pure hydrogen is
recycled through hydrogen recycle compressor 48-K-02 A/B for hydrodesulphurization
and rest is sent to B.L. under pressure control at a pressure of 20kg/cm²g.It is the pressure control
which fixes the operating pressure of reformer.

7
7> HEAT RECOVERY-

HEAT RECOVERY FROM FLUE GAS:-

Heat of flue gases leaving the radiant section is recovered in the convection section by
48-E-20 shock boiler,48-E-21 reformer feed preheater,48-E-22 prereformer feed
preheater,48-E-23 steam superheater,48-E-24 feed preheater & finally combustion air
preheaters 48-E-25 & 48-E-26 with an economizer 48-E-27 in between the air preheaters
to enable an acceptable stack temperature. These APH are being provided with bypass to
take care of flue gas dew point. The flue gas is discharged to the atmosphere via the
flue gas fan 48-K-04 to the stack 48-X-02.The radiant box draft is maintained by the
flue gas fan & is achieved through controlling the motor of 48-K-04. The combustion air
required to burn the fuels is provided by the combustion air fan 48-K-03.

HEAT RECOVERY FROM PROCESS GAS:-

Reformer effluent is cooled to the required inlet temperature of about 340˚C for HT shift
reactor 48-K-04 in the process gas boiler 48-E-04.Boiler water from steam drum 48-V-04
operating at a pressure of 42 kg/cm²g,under natural circulation, serves to remove this heat.
The inlet temperature for shift reactor 48-R-04 is controlled by means of an internal
bypass.

The outlet temperature of the gas at HT shift is about 412˚C.The heat recovery
from this effluent is achieved through steam superheating in 48-E-05 & boiler feed water
preheating in 48-E-07.The inlet temperature to the LT shift reactor 48-R-05 is controlled
by a process gas around 48-E-07.To prevent boiler feed water from boiling in this
exchanger, the outlet boiler feed temperature is controlled by a bypass of process gas
around the second boiler feed water preheater 48-E-06.

After LT shift reaction, the process gas is further cooled to below the dew
point of the process gas in the boiler feed water preheater 48-E-06.The remaining heat is
recovered in the DeMin water preheater 48-E-08.The hot process condensate is separated
from the gas in 48-V-07 & the gas is further cooled to about 40C in the process gas
air cooler 48-E-09.The old condensate is separated in 48-V-08 before the gas enters the
psa unit 48-X-05.

8
8>STEAM SYSTEM:-
The boiler feed water receives water from the following sources-

1>Process condensate from the hot & cold seperators 48-V-07 & 48-V-08.

2>Demineralised water, received at the B.L at a normal operating pressure of 5 kg/cm²g

& temperature of 25C.

Steam system consists of a degasifier 48-V-06 operating at 0.3

kg/cm²g.Steam condensate from the feed preheater & flash blow down are added to
provide the required heat for stripping. The process condensate & demineralised water are
stripped in the degasifier 48-V-06 & collected in its sump.

This water is pumped by the boiler feed water pumps 48P-02 to the
steam drum 48-V-06 operating at 42 kg/cm²g.Before entering the steam drum the water is
preheated in the boiler feed water preheaters to maintain below an acceptable level of
contaminants in the boiler water, a part of the boiler water is continuously blown down.
The blown down from steam drum is flashed in blow down flash drum 48-V-05 to
enhance heat recovery. The liquid portion of this flash is cooled against combustion air
before discharge to sewer.

The generated steam is partly used as process steam for the steam
reforming reactions in the prereformer & reformer. Further steam is used as a heat source
for feed preheating/vaporizing in the naphtha feed vaporizer 48-E-02 & as stripping
steam make-up in the degasifier for boiler feed water degassing. The balance steam is
superheated in steam superheater 48-E-23.This is desuperheated as required by boiler feed
water to comply with HP steam quality requirements & sent as export steam on pressure
control to the B.L.

9>FUEL SYSTEM-
The fuels used to supply the required heat demand for reformer are as follows-
(i) PSA purge gas. This is used as the priority fuel(almost 80% of the
reformer fuel).
(ii) Coker naphtha fuel.
(iii) Straight Run Naphtha (SRN).
(iv) Refinery fuel gas.

9
DESIGN INFORMATION ABOUT HDT –
1> Turn down ratio is 40% of design.

2> On stream hours: 8000 hours

IMPORTANT FACTS ON HGU IN GUWAHATI REFINERY –

OBJECTIVE – Bharat Stage II specifications of diesel and produce kerosene of high

smoke point

CAPACITY - 0.6 mmtpa

LICENSOR - UOP LIC, USA

FEED- Diesel mode

state run kero-II,
state run gas oil
coker kerosene
coker gas oil

Kerosene mode
state run kero-I

state run kero-II

PRODUCT -

 High Speed Diesel

 ATF
 State Run Kerosene Oil

10
EQUIPMENT NUMBER EQUIPMENT NAME
49-V-01 FEED COALESCER
49-V-02 FEED SURGE DRUM
49-V-03 WASH WATER BREAK TANK
49-V-04 HIGH PRESSURE SEPERATOR
49-V-05 FIRST STAGE SUCTION DRUM
49-V-06 PRODUCT COALESCER
49-V-07 CAUSTIC WASH TOWER
49-V-08 SAND FILTER
49-V-09 STRIPPER RECIEVER
49-V-10 FUEL GAS KNOCKOUT DRUM
49-V-12 SULPHIDE STORAGE DRUM
49-V-13 SULPHIDE METERING DRUM
49-V-14 NET GAS KNOCKOUT DRUM
49-V-15 SALT DRIER
49-V-16 SECOND STAGE SUCTION DRUM
49-V-17 STRIPPER OFF GAS KNOCKOUT DRUM
49-V-18 ANTISTATIC MIXING TANK
49-V-19 CLOSED BLOW DOWN DRUM
10-B-V FLARE KNOCKOUT DRUM
49-T-01 NEUTRALISATION STORAGE TANK
49-T-02 CAUSTIC HOLDING TANK
49-C-01 RECYCLE GAS COMPRESSOR KOD
49-C-02 STRIPPER
49-R-01 REACTOR-1
49-R-02 REACTOR-2
49-R-03 REACTOR-3(FOR FUTURE)
49-F-01 COMBINED FEED HEATER
49-E-01 FEED PREHEAT EXCHANGER
49-E-02 COLD COMBINED FEED EXCHANGER
49-E-03 HOT COMBINED FEED EXCHANGER
49-E-04 FIRST STAGE DISCHARGE COOLER
49-E-05 SPILLBACK COOLER
49-E-06 PRODUCT COOLER
49-E-07 STRIPPER FEED BOTTOMS EXCHANGER
49-E-08 REACTOR EFFLUENT STRIPPER FEED
49-E-09 STRIPPER TRIM CONDENSER
49-E-10 NET GAS COOLER
49-AC-01(A-D) REACTOR EFFLUENT CONDENSER
49-AC02(A-C) STRIPPER CONDENSER
49-P-01 DIESEL/KEROSENE TRANSFER PUMP

11
49-P-02 ATF TRANSFER PUMP
49-P-03 SURGE PUMP
49-P-04 WASH WATER PUMP
49-P-05 STRIPPER BOTTOMS PUMP
49-P-06 STRIPPER OVERHEAD PUMP
49-P-07 CAUSTIC MAKE-UP PUMP
49-P-08 CAUSTIC CIRCULATION PUMP
49-P-09 SULPHIDE INJECTION PUMP
49-P-10 NEUTRALISATION FEELING PUMP
49-P-11 NEUTRALISATION RETURN PUMP
49-P-12 INHIBITOR INJECTION PUMP
49-P-13 ANTISTATIC AGENT INJECTION PUMP
49-P-14 CLOSED BLOW DOWN PUMP
10B-P-01 FLARE KOD BLOW DOWN PUMP
07-P-01 BACK BLENDING PUMP
49-K-01 RECYCLE GAS COMPRESSOR
49-K-02 NET GAS COMPRESSOR
49-K-03 MAKE-UP GAS COMPRESSOR
49-J-01 EJECTOR
49-G-01 FEED FILTER
49-MX-01 NEUTRALISATION STORAGE TANK MIXER
49-M-01 CONSERVATION VENT

12
Hydrotreater (HDT) Unit
The Unionfining process involves removal of contaminants like organic sulphur, nitrogen and
metal compounds. These contaminants contribute to air pollution, equipment corrosion and
cause difficulties in further processing of material. The Unionfining process is a proprietary,
fixed-bed catalytic process developed by UOP for hydrotreating a wide range of feedstock. The
process uses a catalytic hydrogenation method to upgrade the quantity of petroleum distillate
fraction by decomposing the contaminants with a negligible effect on the boiling range of the
feed. This process is designed to remove sulphur and nitrogen, increase cetane number (48.5
min) and processing kerosene to better smoke point (21min) by saturating olefin and aromatic
compounds while reducing carbon and removing other contaminants such as organometallic
compounds.

Process principles
Unionfining process is carried out at elevated temperature and pressures in a hydrogen
atmosphere. The pressure and temperature may range up to 80-93 kg/cm² c and 350-428˚C
respectively.

The catalyst is formulated by composting varying amounts of nickel or cobalt with molybdenum
oxides on an alumina base. The specific catalyst system and unit design parameters are
evaluated on an economic basis for each unit. Each design is based on feed quality, desired
product property, ease of operation, desired cycle length, operating flexibility, construction
schedule and operating costs.

13
Hydrotreating chemistry

Sulphur removal
Feedstock contains simple mercaptans, sulphides, disulphides which are converted to H₂S

Mercaptan

C-C-C-C-SH-H C-C-C-C + H₂S

Sulphide

C-C-S-C-C + 2H 2C-C +H₂S

Disulphide

C-C-S-S-C + 3H₂ 2C-C + 2H₂S

Cyclic sulphide

C C +H₂ C-C-C-C + H₂S

C C

Thiophenic

C C +4H₂ C-C-C-C + H₂S

C C

14
Nitrogen removal
It is more difficult then desulphurization. The side reactions may yield nitrogen compounds
which are more difficult to hydrogenate than the original reactant.

Pyridine

C + 5H₂ C-C-C-C + NH₃

C C

C C

Quinone

C C + H₂ C-C-C-C + NH₃

C C C

C C C

C N

Pyrrole

C C + 4H₂ C-C-C-C + NH₃

C C

15
Oxygen Removal
Organically combined oxygen removal by hydrogenation of carbon –hydroxyl bond (C-OH)
forming water and corresponding hydrocarbon.

Phenol

C OH + H₂ C + H₂O

C C C C

C C C C

C C

Olefin Saturation

It proceeds rapidly and has a high degree of reaction

a) Linear olefin C-C=C-C-C-C + H₂ C-C-C-C-C-C

b) Cyclic olefin

C + H₂ C

C C C C

C C C C

C C

Aromatic

These are the most difficult of all. Unit design parameters consider the desired degree of
saturation for each specific unit. The saturation reaction is very exothermic.

C + H₂ C

C C C C

C C C C

C C

16
MAIN SYSTEMS/FUNCTIONS:-
1> REACTION SECTION

2> FEED HEATING

3> REACTORS

4> REACTOR EFFLUENT COOLING

5> REACTOR EFFLUENT WATERWASH

6> VAPOR/LIQUID SEPERATOR

7> RECYCLE GAS SYSTEM

8> MAKE-UP HYDROGEN GAS SYSTEM

9> FRACTIONATION SECTION

17
PROCESS FLOW

The diesel hydrotreating unit consists of two sections – high pressure reactor and low pressure
fractionation section

1) REACTION SECTION

Feed from the blanketed storage in offsite is passed to the diesel/ kerosene transfer pumps 49-P-
01 A/B. the pump raises feed pressure to 8.4 kg /cm² g.

The ATF feed passes on to a separate SR Kero-I (ATF feed transfer pump 49-P-02) which raise
the pressure to 77kg/ cm² g.

The pumped feed passes on to Feed Coalescer (49-V-01) where water is coalesced from the feed.
The Feed Coalescer is provided with water boat where water coming along with the feed gets
separated. The water is drained automatically from the water boat by LIC-0702.The feed passes
from the Feed Coalescer onto the Feed Surge Drum (49-V-02) via Feed Filter (49-G-01). The
Feed Filter is a back wash type filter. It retains particles of size more than 25 microns.

2) FEED HEATING

The filtered feed from 49-G-01 passes through the shell side of Feed Preheat Exchanger 49-E-01
where it gets heated by Stripper Feed bottoms Exchanger ( 49-E-07 A/B/C) tube side effluent.
The outlet temperature is around 68 to 70˚C to avoid vaporization of feed.The preheated feed
passes to the Feed Surge Drum (49-V-02) and then to the Charge Pumps (49-P-03A/B) where the
pressure is around 120.9 77kg/ cm² g.An interlock to shutdown oil fat in case of low flow of
Diesel/Kerosene or ATF is provided. This is accomplished by closing the shutdown valves FV-
1402 and TV-1401 located in main line and bypass of the exchanger.

The feed passes from the Charge Pumps to the shell side of Cold Combined Feed Exchangers 49-
E-02 and the shell of Hot Combined Feed Exchanger 49-E-03 A/B. the outlet temperature is
controlled by bypassing part of liquid feed across 49-E-02A/B/C and 49-E-03A/B.The combined
gas-liquid feed is preheated in 49-E-02A/B/C and the reactor effluents. The combined feed flows
down on the shell side whereas the reactor effluents flow on the tube side. 49-E-02 has 3 shells
arranged in series, whereas 49-E-03 has two shells stacked on top of other in series. 49-E-03
preheats the combined feed with reactor effluents coming from Stripper Feed/ Reactor Effluents
Exchanger 49-E-08A/B.The feed passes from the exchangers to the Charge Heater 49-F-01.

The recycle gas from the Recycle Gas Compressor (49-K-01) goes upstream of 49-E-02. Part of
the recycle gas goes to two parts – Reactor no.1 and Reactor no. 2 catalysts for quenching the
bed.

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The combined feed leaves the preheat train of 49-E-02 and 49-E-03 at a temperature range of
326-356˚C for Diesel and 306-315˚C for Kerosene.

SHELL SIDE

Diesel/Kerosene 49-E-02(C B A) E-03 (B A)

ATF 49-E-02(C B A) E-03 (A B)

TUBE SIDE (Reactor Effluent Fluid)

Diesel/Kerosene E-03 (A B) E-08(A B) 49-E-02(C B A)

ATF E-08 (A B) E-03(B A) 49-E-02(C B A)

The feed is passed onto the Charge Heater 49-F-01 for further heating to proper reactor inlet
temperature. The charger is a vertical cylindrical heater with atop mounted convection section.
Feed passes through convection section and leave through radiant section. Heater effluent goes to
Reactor No. 1 (49-R-01). The combined feed leaves 49-F-01 with temperature of 354-365˚C for
Diesel, 334-343˚C for Kerosene and 334-348˚C for ATF.

3) REACTORS

The feed passes on to the reactors for reaction over the catalyst bed. Various exothermic
reactions occur and the temperature of the flowing steam increases. Depending upon the
anticipated temperature rise, arrangement for intermediate quenching of flowing steam with
recycle gas is provided.

49-R-01 has its catalyst divided into two beds with recycle gas quench steam in between. The
outlet of the bottom bed is directed to 49-R-02. The effluents from 49-R-01 is quenched with
recycle gas and passed to 49-R-02. During the course of an operating cycle, the temperature
required to obtain the desired product quality will increase as a result of catalyst deactivation.
The gradual loss in catalyst activity can be compensated for by increasing the reactor
temperature to 385˚C for 49-R-01 and 415˚C for 49-R-02. Above this temperature coke
formation is rapid and performance improvement is slow.

4) REACTOR EFFLUENT COOLING

Diesel mode
49-R-02 effluent passes through 49-E-03 A/B tube side where it exchanges heat with the reactor
feed. After that it goes to the tube side of Stripper Feed/ Reactor Effluent Exchanger 49-E-08
where it exchanges heat with the stripper feed. From 49-E-08 it goes to 49-E-02 where it
exchanges heat with reactor feed.
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ATF mode
49-R-02 effluent passes through 49-E-08 A/B tube side where it exchanges heat with the stripper
feed. From 49-E-08 it goes to tube side of 49-E-03 where it exchanges heat with reactor feed. 49-
E-03A/B effluents are directed to 49-E-02 where it exchanges heat with reactor feed.

5) REACTOR EFFLUENT WATER WASH

Final cooling of reactor effluent steam is performed in an air Finn cooler i.e. the Reactor Effluent
Condensor 49-AC-01. In the reactor, sulphur is converted to H₂S and nitrogen to NH₃. These
combine in vapor phase to from vaporized ammonium salts which can solidify and precipitate as
reactor effluents are cooled. Wash water injected into the steam before it enters condenser in
order to prevent deposition of the salts that may corrode the cooler. Wash water can be cold
clean condensate or a combination of stripped water from sour water stripping unit and cold
clean condensate. Cooled effluent from 49-AC-01 is passed to High Pressure Separator 49-V-04.

6) VAPOR/LIQUID SEPERATOR
Vapor, liquid and sour water separated in High Pressure Seperator 49-V-04. It is a horizontal
vessel with water boot on its underside. Mesh blanket has been provided to act as coalesce and to
separate free water from hydrocarbon. The Hydrocarbon phase leaves from the bottom of 49-V-
04 to Stripper Feed / Bottoms Exchanger 49-E-07.

The sour water collected in the boat of 49-V-04 is sent to interface level control to 49-V-09 via
49-P-06 A/B minimum circulation line. Sour water collected in Stripper Receiver boot is sent to
Sour Water Treating unit located in Sulphur Block. As this water contains large quantities of
toxic H₂S and NH₃, it is advisable not to drain it to OWS for any length of time.

7) RECYCLE GAS SYSTEM

The overhead gas goes to the Recycle Gas Compressor Suction K.O. Drum 49-C-01 for
entrained liquid removal before going to Recycle Gas Compressor 49-K-01 A/B. the overhead
from 49-C-01 goes to the Recycle Gas Compressor 49-K-01. The bottom from 49-C-01 is
drained to CBD. Alternatively, it can also be drained to OWS.

Hydrogen from Make-up Gas Compressor 49-K-03 is mixed with recycle gas going to 49-K-01
A/B. lubrication for 49-K-01 A/B is achieved through forced lube oil circulation. For this, a lube
oil circulation circuit is provided consisting of lube oil tank, lube oil pumps, lube oil filters etc.
lube oil circulation should be maintained at all times and only shut off when the compressor is
reqd. for maintenance.
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49-K-01 A/B discharge line supplies recycle gas to

a) Combined feed exchangers inlet

b) In between two beds of catalyst in 49-R-01

c) 49-R-02 inlet

8) MAKE-UP HYDROGEN SYSTEM

The Make-Up hydrogen obtained from hydrogen unit at a pressure of about 19.5 kg/ cm² g. since
the hydrogen injection pressure in the reactor section is much higher, the make-up gas needs to
be compressed before injection into the DHDT circuit.

The make-up gas from the hydrogen unit is mixed with cooled makeup gas compressor spillback
and then to Make-Up Gas Compressor First Stage Drum 49-V-05. 49-V-05 is provided with
mesh blanket to avoid liquid entrainment with vapor. The overheads from 49-V-05 passes to the
Make-Up Gas Compressor 49-K-03 A/B. two reciprocating Make-UP Gas Compressor 49-K-03
A/B have been provided for raising the pressure of make-up gas. The discharge from 49-K-03
A/B is sent to mix with recycle gas at the inlet 49-AC-01. A part of compressed gases from 49-
K-03 A/B second stage discharge is sent to Make-Up Gas Spillback Cooler 49-E-05 from where
they are sent to 49-V-05.

9) FRACTIONATION SECTION

The fractionation section is used for separating sour gas and naphtha from hydrodesulphurized
Diesel/Kerosene/ATF product. The hydrocarbon liquid from 49-V-09 is sent to Stripper 49-C-02
through 49-E-07 A/B/C and 49-E-08 A/B. the feed is preheated by exchanging heat in 49-E-07
and reactor effluents in 49-E-08.

49-C-02 has a total of 38 trays. Vapors leaving top tray are directed to air cooled Stripper
Overheads Condensor 49-AC-02 followed by Stripper Overhead Trim Condensor 49-E-09. To
reduce corrosion in downstream lines and equipment, corrosion injection in Stripper Overhead
Trim Condensor 49-E-09. From here it goes to Stripper Receiver 49-V-09 where separation of
vapor, liquid and water takes place. The water collected in water boot along with sour water sent
from High Pressure Seperator is sent to Sour Water Stripper Unit.

The vapors from 49-V-09 are sent to Stripper Off Gas Knock Out Drum 49-V-17 which is
provided with mesh blanket to separate liquid droplets entrained along with vapors. The
overheads from 49-V-17 pass on to Net Gas Compressor 49-V-09.

The hydrocarbon liquids from 49-V-09 pass on to Stripper Overhead Pumps 49-P-06. The
discharge from 49-P-06 is sent to 49-C-02. Part of discharge from 49-P-06 A/B is drained and
sent to CDU/DCU as unstabilized overhead liquid product. The bottoms of 49-C-02 pass on to
Stripper Bottom Pumps 49-P-05 A/B. The discharge from 49-P-05 A/B is sent to 49-E-07, 49-E-
01 and 49-E-06 which is followed by Diesel Product Coalescer 49-V-06. It is a horizontal vessel
provided with a coalescing element and water boat to separate water from hydrocarbons.

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Diesel mode:

The outlet of 49-V-06 passes on to Salt drier 49-V-15 keeping Caustic Wash Tower (49-V-07)
and Sand Filter (49-V-08) bypasses, for final removal of water. The Salt Drier 49-V-15 is packed
vessel filled with rock salt. When the level of rock salt in the drier falls. It is replaced with a
fresh load.

Kero/ATF mode

The outlet of 49-V-06 passes on to 49-V-07 to remove any residual H2S from product steam and
then through Sand Filter 49-V-08 to remove and entrain caustic. The product is sent to the
location:

a. On-spee hydrotreated product to product storage.

b. Off-spee hydrotreated product to slops

There are provision for anti-static agent in ATF product through anti-static mixing tank and anti-
static pump.

Overhead from Stripper Off Gas KOD passes on to Net Gas Compressor Suction. The net gas
from the compressor discharges to Net Gas Knockout Drum via Net Gas Cooler. The final
product is obtained from Net Gas Knockout Drum. The final product is

 High Speed Diesel

 ATF
 State Run Kerosene Oil
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 CONCLUSION
In today’s industrial era, it is very important to have sharp eye on environment as
it is crucial for the survival of ecosystem. Industries like oil refinery discharge a huge amount of
wastes that are harmful to environment, so they have to be treated before discharge. In Guwahati
Refinery, we have studied hydrogen generation unit(HGU) and hydrotreating unit(HDT).We
have made this report on the importance of these two units in maintaining the environmental
norms regulated by pollution control board. For violation of these norms, an industry may
confront with penalty.

The basic purpose of HGU is to produce hydrogen which is sent to HDT and
ISOSIV unit. Hydrogen is used to saturate olefins. In HGU we have studied the main chemical
processes and the essential equipments. The two types of reactors-adiabatic pre-reformer and
tubular reformer were also studied. For purification of hydrogen, PSA adsorber is used and the
purge gas coming out of this is utilized as the reformer fuel.

The HDT unit in Guwahati Refinery has been installed as to meet Bharat Stage II
specifications of diesel and produce kerosene of high smoke point. In this unit, toxic components
like sulphur, nitrogen are removed from the finished product. We studied the main processes
going inside this plant. Various important equipments like pump, compressor, reactors, cooler,
and heat exchanger have also been studied and included in this report. Three types of
compressors-Recycle gas compressor, Makeup gas compressor and Net gas compressor take
important role in the whole process.

Thus we can conclude that HGU and HDT units are the integral parts of any oil
industry as they are acting as the friend of environment by removing the toxic components from
the finished product.

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 REFERENCES
1. Operating manual of HGU

2. Operating manual of HDT

3.http://www.interstatetraveler.us/Reference-Bibliography/Bellona-HydrogenReport.html

4.http://en.wikipedia.org/wiki/Hydrodesulphurization

5.http://www.business-standard.com/india/news/ioc-hydrgen-generation-unitgoesstream/226364/

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